Documente Academic
Documente Profesional
Documente Cultură
: KM-178E
Vol. No. : TT178E-03
200·225·230·270 class
Technical Manual
(Troubleshooting)
Excavator
200 class
200•200LC•210H•210LCH•210•210LC•210N•240
225 class
Excavator
Service Manual (Manual No. KM-178E) consists of the following three separate volumes;
Technical Manual (Operational Principle) : Vol. No. TO178E
Technical Manual (Troubleshooting) : Vol. No. TT178E
Workshop Manual : Vol. No. W178E
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redelivery and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
IN-01
INTRODUCTION
PAGE NUMBER
Example : T 1-3-5
This is the safety alert symbol. When you see this • IMPORTANT:
symbol, be alert to the potential for personal injury. Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights. • NOTE:
To avoid injury and damage, be sure to use appropri- Indicates supplementary technical information or
ate lifting techniques and equipment when lifting know-how.
heavy parts.
IN-02
INTRODUCTION
UNITS USED
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-03
INTRODUCTION
IN-04
SAFETY
RECOGNIZE SAFETY INFORMATION
001-E01A-0688
SA-688
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
SA-2
SAFETY
PREPARE FOR EMERGENCIES
004-E01A-0437
005-E01A-0438
SA-3
SAFETY
PROTECT AGAINST NOISE
006-E01A-0434
SA-434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by
walking around it before you start it to avoid
personal injury.
• In the walk-around inspection be sure to cover all
points described in the “PRE-START
INSPECTION” chapter in the operator’s manual.
S007-E01A-0435
SA-435
SA-4
SAFETY
GENERAL PRECAUTIONS FOR CAB
SA-5
SAFETY
USE HANDHOLDS AND STEPS
008-E01B-0439
009-E01A-0378
SA-6
SAFETY
FASTEN YOUR SEAT BELT
010-E01A-0237
011-E01A-0426
SA-7
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may
cause the machine to runaway, possibly resulting in
serious injury or death.
• Start the engine only when seated in the
operator's seat.
• NEVER start the engine while standing on the
track or on ground.
• Do not start engine by shorting across starter
terminals.
• Before starting the engine, confirm that all control SA-444
012-E01B-0444
JUMP STARTING
machine.
S013-E01A-0032
SA-8
SAFETY
KEEP RIDERS OFF MACHINE
014-E01B-0379
SA-379
018-E01A-0481
SA-481
017-E01A-0491
SA-491
SA-9
SAFETY
DRIVE MACHINE SAFELY
SA-387
SA-388
019-E01D-0492
SA-590
SA-10
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
• Death or serious injury may result if you attempt to
mount or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle / acceleration seleclter and the SA-391
020-E08A-0493
SA-11
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.
equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP
IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a
signal person.
• No machine motions shall be made unless
signals are clearly understood by both signalman SA-384
and operator.
• Learn the meanings of all flags, signs, and
markings used on the job and confirm who has
the responsibility for signaling.
• Keep windows, mirrors, and lights clean and in
good condition.
• Dust, heavy rain, fog, etc., can reduce visibility.
As visibility decreases, reduce speed and use
proper lighting.
• Read and understand all operating instructions in
the operator’s manual.
S021-E01A-0494
SA-12
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF
TIPPING MACHINE---SERIOUS OR FATAL
CRUSHING INJURIES WILL RESULT
injury or death.
To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.
• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or
slipping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is SA-440
unavoidable.
• Reduce swing speed as necessary when
swinging loads.
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to
become soft and make ground travel unstable.
S025-E01B-0495
SA-13
SAFETY
AVOID POWER LINES
029-E01A-0381
OBJECT HANDLING
032-E01A-0014
SA-14
SAFETY
PROTECT AGAINST FLYING DEBRIS
031-E01A-0432
SA-432
033-E09B-0390
SA-15
SAFETY
HANDLE FLUIDS SAFELY-AVOID FIRES
034-E01A-0496
SA-019
SA-16
SAFETY
SAFETY TRANSPORTING
S035-E08A-0395
SA-17
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
SA-18
SAFETY
• If a maintenance procedure must be performed
with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or
replace as necessary. Refer to the section
discussing that part in the “MAINTENANCE”
chapter in the operator’s manual.
• Keep all parts in good condition and properly
installed.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
• When cleaning parts, always use nonflammable
SA-028
detergent oil. Never use highly frammable oil
such as fuel oil and gasoline to clean parts or
surfaces.
• Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
• Illuminate your work area adequately but safely.
• Use a portable safety light for working inside or
under the machine.
• Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• Sufficiently illuminate the work site. Use a
maintence work light when working under or SA-527
S500-E02B-0497
SA-037
SA-19
SAFETY
WARN OTHERS OF SERVICE WORK
SS2045102
502-E01A-0026
SA-026
SA-20
SAFETY
PREVENT PARTS FROM FLYING
503-E01B-0344
504-E01A-0034 SA-034
SA-040
S522-E01A-0040
SA-21
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under
pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
• To avoid possible injury from hot spraying water.
DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the
stop. Allow all pressure to be released before
removing the cap. SA-039
505-E01B-0498 SA-225
S506-E01A-0019
SA-22
SAFETY
AVOID HIGH-PRESSURE FLUIDS
SA-292
507-E03A-0499
SA-044
SA-23
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to
fires.
• Check for oil leaks due to missing or loose
clamps, kinked hoses, lines or hoses that rub
against each other, damage to the oil-cooler, and
loose oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or SA-019
hoses.
Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.
• Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
SA-24
SAFETY
Check Key Switch:
• If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
• Always check key switch function before
operating the machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to
confirm that the engine stops.
• If any abnormalities are found, be sure to repair
them before operating the machine.
S508-E02B-0019
SA-25
SAFETY
EVACUATING IN CASE OF FIRE
518-E02B-0393
SS-1510
509-E01A-0016
SA-016
SA-26
SAFETY
PRECAUTIONS FOR WELDING AND
GRINDING
• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated
and prepared area. Store flammable objects in a
safe place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
• Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before
starting grinding.
• After finishing welding and grinding, recheck that SA-818
SA-27
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
• Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated
area. Dispose of paint and solvent properly.
511-E01A-0029
512-E01C-0032
SA-28
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
• If spilled onto skin, refrigerant may cause a cold
contact burn.
• Refer to the freon container for proper use when
servicing the air conditioning system.
• Use a recovery and recycling system to avoid
venting freon into the atmosphere.
• Never let the freon stream make contact with the
skin.
SA-405
513-E01A-0405
S515-E01A-0309
SA-29
SAFETY
DISPOSE OF WASTE PROPERLY
S516-E01A-0226
S517-E01A-0435 SA-435
SA-30
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction Group 4 Excavator Test
Operational Performance Tests................. T4-1-1 Travel Speed .............................................T4-4-1
Preparation for Performance Tests............ T4-1-2 Track Revolution Speed ............................T4-4-2
Mistrack Check..........................................T4-4-3
Group 2 Standard Travel Parking Function Check .................T4-4-4
Operational Performance Standard Table Swing Speed .............................................T4-4-5
ZX200 class ............................................ T4-2-1 Swing Function Drift Check .......................T4-4-6
ZAXIS225USR ........................................ T4-2-5 Swing Motor Leakage................................T4-4-8
ZAXIS225US........................................... T4-2-9 Maximum Swingable Slant Angle ............T4-4-10
ZX230 class .......................................... T4-2-13 Swing Bearing Play .................................T4-4-12
ZX270 class .......................................... T4-2-17 Hydraulic Cylinder Cycle Time ................T4-4-14
Main Pump P-Q Diagram ........................ T4-2-22 Dig Function Drift Check .........................T4-4-16
Injection Pump ........................................ T4-2-24 Control Lever Operating Force ................T4-4-18
Dr.ZX Monitor Indicating Values Control Lever Stroke ...............................T4-4-20
ZX200 class .......................................... T4-2-28 Combined Boom Raise/Swing
ZAXIS225USR ...................................... T4-2-32 Function Check .....................................T4-4-22
ZAXIS225US......................................... T4-2-36 Boom Raise and Arm Roll-In
ZX230 class .......................................... T4-2-40 Combined Operation ...........................T4-4-24
ZX270 class .......................................... T4-2-44
Sensor Activating Range ....................... T4-2-48
178T-4-1
Group 5 Component Test
Primary Pilot Pressure .............................. T4-5-1
Secondary Pilot Pressure ......................... T4-5-4
Solenoid Valve Set Pressure..................... T4-5-6
Main Pump Delivery Pressure................... T4-5-9
Main Relief Valve Set Pressure............... T4-5-10
Relief Pressure (When relieving
Swing) ................................................. T4-5-14
Relief Pressure (When relieving
Travel) ................................................. T4-5-16
Overload Relief Valve Set Pressure ........ T4-5-18
Main Pump Flow Rate Measurement ...... T4-5-22
Swing Motor Drainage ............................ T4-5-29
Travel Motor Drainage ............................ T4-5-32
Group 6 Adjustment
Engine Speed Adjustment and
Engine Learning .................................... T4-6-1
Govenor Lever and Fuel
Cut Lever Position ................................. T4-6-4
178T-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedure to quan- The machine performance does not always deterio-
titatively check all system and functions on the ma- rate as the working hours increase. However, the
chine. machine performance is normally considered to re-
duce in proportion to the increase of the operation
Purpose of Performance Tests hours. Accordingly, restoring the machine perform-
1. To comprehensively evaluate each operational ance by repair, adjustment, or replacement shall con-
function by comparing the performance test data sider the number of the machine’s working hours.
with the standard values.
2. According to the evaluation results, repair, adjust, Definition of “Performance Standard”
or replace parts or components as necessary to 1. Operation speed values and dimensions of the
restore the machine’s performance to the desired new machine.
standard. 2. Operational performance of new components
3. To economically operate the machine under op- adjusted to specifications. Allowable errors will be
timal conditions. indicated as necessary.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the op-
erational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to evalu-
ate the performance test data.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out
performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to
run straight more than 20 m (65 ft 7 in), and to
make a full swing with the front attachment ex-
tended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork-
ers. Once the test is started, be sure to commu-
nicate with each other using these signals, and to
follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid acci-
dents due to landslides or contact with
high-voltage power lines. Always confirm that
there is sufficient space for full swings.
4. Avoid polluting the machine and the ground with T105-06-01-003
T105-06-01-004
T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard
ZX200 CLASS OPERATIONAL
PERFORMANCE STANDARD TABLE
The standard Performance values are listed in the Engine Control Dial : Fast Idle
table below. Refer to the Group T4-3 to T4-5 for Power Mode Switch : P Mode
performance test procedures. Values indicated in Auto-Idle/Acceleration Selector : OFF
parentheses are reference values. Work Mode Switch : Digging Mode
Hydraulic Oil Temperature : 50±5 °C (122±9 °F)
The following switch positions shall be selected and
the hydraulic oil temperature shall be maintained as
indicated below as the preconditions of performance
tests unless otherwise instructed in each performance
test procedure:
NOTE: 1 mm=0.03937 in
ZX200 class
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
ENGINE SPEED min
-1
T4-3-1
Slow Idle Speed 900+150-100 Value indicated on Dr. ZX.
Fast Idle Speed (Normal) 1950+65-50 ↑
Fast Idle Speed (Wirh ECO deactivated) 2050+65-50 ↑
Extend the boom cylinder to
relieve the boom raise
Fast Idle Speed (Relief Operation) 1900+65-50
circuit.Value indicated on Dr.
ZX.
Fast Idle Speed (E mode) 1800+90-70 Value indicated on Dr. ZX.
Extend the boom and arm
cylinder to relieve the boom
Fast Idle Speed (HP mode) 2000 to 2250
raise and arm roll-in circuit.
Value indicated on Dr. ZX.
Auto-Idle Speed 1300+135-100 Value indicated on Dr. ZX.
Auto-Acceleration Speed 1650+125-100 ↑
Warming Up Speed 1400+140-100 ↑
ENGINE COMPRESSION PRESSURE After engine warm-up T4-3-4
3.04 (31, 440)
(After engine warm-up) 2
MPa (kgf/cm , psi)
VALVE CLEARANCE (IN, EX) 0.4 With the engine cold T4-3-6
NOZZLE INJECTION PRESSURE T4-3-8
2 18.1 (185, 2630)
MPa (kgf/cm , psi)
NOZZLE INJECTION PRESSURE T4-3-8
2 18.1 (185, 2630)
MPa (kgf/cm , psi)
INJECTION TIMING T4-3-10
10°
(Degrees before TDC) deg.
LUBRICANT CONSUMPTION Hour meter: 2000 hours or T4-3-12
50 or less
(Rated output) mL/h less
T4-2-1
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZX200 class
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
TRAVEL SPEED sec/20 m T4-4-1
Travel speed isn’t shifted to
Fast Speed 13.0±1.2 fast speed mode one side-
track is jacked up.
Slow Speed 20.0±2.0
TRACK REVOLUTION SPEED sec/3 rev T4-4-2
Fast Speed 17.2±1.0 LC: 18.3±1.0
Slow Speed 26.2±2.0 LC: 27.9±2.0
MISTRACK mm/20 m T4-4-3
200 or less
(With fast and slow travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0 T4-4-4
SWING SPEED sec/3 rev 13.5±1.0 Bucket empty T4-4-5
SWING FUNCTION DRIFT CHECK T4-4-6
1254 or less Bucket empty
mm /180°
SWING MOTOR LEAKAGE mm/5 min 0 Bucket loaded T4-4-8
MAXIMUM SWINGABLE SLANT ANGLE 22° or possibly Bucket loaded T4-4-10
deg. more
SWING BEARING PLAY mm 0.2 to 1.25 Allowable limit: 2.0 to 3.05 T4-4-12
HYDRAULIC CYLINDER CYCLE TIME 2.91 m arm T4-4-14
sec 0.8 m3 (PCSA heaped)
bucket, bucket empty
Boom Raise 3.1±0.3
Boom Lower 2.3±0.3
Arm Roll-In 3.8±0.3
Arm Roll-Out 2.8±0.3
Bucket Roll-In 3.4±0.3
Bucket Roll-Out 2.3±0.3
DIG FUNCTION DRIFT CHECK mm/5 min 2.91m arm T4-4-16
0.8 m3 (PCSA heaped) bucket
Boom Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 5 or less Bucket empty
Arm Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 15 or less Bucket empty
Bucket Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 10 or less Bucket empty
Bucket Bottom
(Maximum Reach Position) 150 or less Bucket loaded
(Arm Roll-In position) 110 or less Bucket empty
T4-2-2
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZX200 class
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
CONTROL LEVER OPERATING FORCE HITACHI lever pattern T4-4-18
N (kgf, lbf・ft)
Boom Lever 18 (1.8, 13) or less
Arm Lever 15 (1.5, 10.8) or
(ISO Lever Pattern: Swing Lever) less
Bucket Lever 15 (1.5, 10.8) or
less
Swing Lever 18 (1.8, 13) or less
(ISO Lever Pattern: Arm Lever)
Travel Lever 28 (2.8, 20.3) or
less
CONTROL LEVER STROKE mm HITACHI lever pattern T4-4-20
Boom Lever 105±10
Arm Lever
84±10
(ISO Lever Pattern: Swing Lever)
Bucket Lever 84±10
Swing Lever 105±10
(ISO Lever Pattern: Arm Lever)
Travel Lever 120±10
BOOM RAISE/SWING sec 2.91 m arm T4-4-22
3.6±0.3 0.8 m3 (PCSA heaped)
bucket, bucket empty
(Bucket Teeth Height: H) mm 6700 or more
BOOM RAISE/ARM ROLL-IN sec 2.91 m arm T4-4-24
4.5±0.5 0.8 m3 (PCSA heaped)
bucket, bucket empty
PRIMARY PILOT PRESSURE T4-5-1
2
MPa (kgf/cm , psi)
Engine: Fast Idle 4.0+1.0-0.5
(41+10-5, 580+142-71)
Engine: Slow Idle 3.5+1.0-0
(35 -0, 500+142-0)
+10
T4-2-3
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZX200 class Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks Page
Standard)
MAIN RELIEF VALVE SET PRESSURE T4-5-10
2
MPa (kgf/cm , psi)
Boom, Arm, and Bucket 34.3+2.0-0.5 Value indicated on Dr. ZX
(350+20-5,
4980+284-71)
Power Boost 36.3+2.0-1.0 Value indicated on Dr. ZX
(370+20-10,
5260+284-142)
RELIEF PRESSURE 31.9+2.3-0 Value indicated on Dr. ZX T4-5-14
2
MPa (kgf/cm , psi)
(When relieving Swing) (325+25-0,
4620+356-0)
RELIEF PRESSURE 34.3+2.0-0.5 Value indicated on Dr. ZX T4-5-16
2
MPa (kgf/cm , psi)
(When relieving Travel) (350+20-5,
4980+284-71)
OVERLOAD RELIEF VALVE SET PRES- (Reference values T4-5-18
SURE MPa (kgf/cm , psi) at 50 L/min)
2
T4-2-4
OPERATIONAL PERFORMANCE TEST / Standard
ZAXIS225USR OPERATIONAL
PERFORMANCE STANDARD TABLE
The standard Performance values are listed in the Engine Control Dial : Fast Idle
table below. Refer to the Group T4-3 to T4-5 for Power Mode Switch : P Mode
performance test procedures. Values indicated in Auto-Idle/Acceleration Selector : OFF
parentheses are reference values. Work Mode Switch : Digging Mode
Hydraulic Oil Temperature : 50±5 °C (122±9 °F)
The following switch positions shall be selected and
the hydraulic oil temperature shall be maintained as
indicated below as the preconditions of performance
tests unless otherwise instructed in each performance
test procedure:
NOTE: 1 mm=0.03937 in
ZAXIS225USR
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
ENGINE SPEED min
-1
T4-3-1
Slow Idle Speed 950±100 Value indicated on Dr. ZX.
Fast Idle Speed (Normal) 1965±50 ↑
Fast Idle Speed (Wirh ECO deactivated) 2060±50 ↑
Extend the boom cylinder to
relieve the boom raise
Fast Idle Speed (Relief Operation) 1915±50
circuit.Value indicated on Dr.
ZX.
Fast Idle Speed (E mode) 1820±70 Value indicated on Dr. ZX.
Extend the boom and arm
cylinder to relieve the boom
Fast Idle Speed (HP mode) 2000 to 2250
raise and arm roll-in circuit.
Value indicated on Dr. ZX.
Auto-Idle Speed 1335±100 Value indicated on Dr. ZX.
Auto-Acceleration Speed 1675±100 ↑
Warming Up Speed 1400+140-100 ↑
ENGINE COMPRESSION PRESSURE After engine warm-up T4-3-4
3.04 (31, 440)
(After engine warm-up) 2
MPa (kgf/cm , psi)
VALVE CLEARANCE (IN, EX) 0.4 With the engine cold T4-3-6
NOZZLE INJECTION PRESSURE T4-3-8
2 18.1 (185, 2630)
MPa (kgf/cm , psi)
INJECTION TIMING T4-3-10
10°
(Degrees before TDC) deg.
LUBRICANT CONSUMPTION Hour meter: 2000 hours or T4-3-12
50 or less
(Rated output) mL/h less
T4-2-5
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZAXIS225USR
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
TRAVEL SPEED sec/20 m T4-4-1
Travel speed isn’t shifted to
Fast Speed 13.6±1.2 fast speed mode one side-
track is jacked up.
Slow Speed 21.8±2.0
TRACK REVOLUTION SPEED sec/3 rev T4-4-2
17.8±1.0 LC: 18.9±1.0
Fast Speed
28.2±2.0 LC: 30.1±2.0
Slow Speed
MISTRACK mm/20 m T4-4-3
200 or less
(With fast and slow travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0 T4-4-4
SWING SPEED sec/3 rev 13.5±1.0 Bucket empty T4-4-5
SWING FUNCTION DRIFT CHECK T4-4-6
1254 or less Bucket empty
mm /180°
SWING MOTOR LEAKAGE mm/5 min 0 Bucket loaded T4-4-8
MAXIMUM SWINGABLE SLANT ANGLE 20° or possibly Bucket loaded T4-4-10
deg. more
SWING BEARING PLAY mm 0.2 to 1.25 Allowable limit: 2.0 to 3.05 T4-4-12
HYDRAULIC CYLINDER CYCLE TIME 2.91 m arm T4-4-14
sec 0.8 m3 (PCSA heaped)
bucket, bucket empty
Boom Raise 3.1±0.3
Boom Lower 2.3±0.3
Arm Roll-In 3.8±0.3
Arm Roll-Out 2.8±0.3
Bucket Roll-In 3.4±0.3
Bucket Roll-Out 2.3±0.3
DIG FUNCTION DRIFT CHECK mm/5 min 2.91m arm T4-4-16
0.8 m3 (PCSA heaped) bucket
Boom Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 5 or less Bucket empty
Arm Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 15 or less Bucket empty
Bucket Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 10 or less Bucket empty
Bucket Bottom
(Maximum Reach Position) 150 or less Bucket loaded
(Arm Roll-In position) 110 or less Bucket empty
T4-2-6
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZAXIS225USR
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
CONTROL LEVER OPERATING FORCE HITACHI lever pattern T4-4-18
N (kgf, lbf・ft)
Boom Lever 18 (1.8, 13) or less
Arm Lever 15 (1.5, 10.8) or
(ISO Lever Pattern: Swing Lever) less
Bucket Lever 15 (1.5, 10.8) or
less
Swing Lever 18 (1.8, 13) or less
(ISO Lever Pattern: Arm Lever)
Travel Lever 28 (2.8, 20.3) or
less
CONTROL LEVER STROKE mm HITACHI lever pattern T4-4-20
Boom Lever 105±10
Arm Lever
84±10
(ISO Lever Pattern: Swing Lever)
Bucket Lever 84±10
Swing Lever 105±10
(ISO Lever Pattern: Arm Lever)
Travel Lever 120±10
BOOM RAISE/SWING sec 2.91 m arm T4-4-22
3.6±0.3 0.8 m3 (PCSA heaped)
bucket, bucket empty
(Bucket Teeth Height: H) mm 6500 or more
BOOM RAISE/ARM ROLL-IN sec 2.91 m arm T4-4-24
4.5±0.5 0.8 m3 (PCSA heaped)
bucket, bucket empty
PRIMARY PILOT PRESSURE T4-5-1
2
MPa (kgf/cm , psi)
Engine: Fast Idle 4.0+1.0-0.5
(41+10-5, 580+142-71)
Engine: Slow Idle 3.5+1.0-0
(35 -0, 500+142-0)
+10
T4-2-7
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZAXIS225USR Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks Page
Standard)
MAIN RELIEF VALVE SET PRESSURE T4-5-10
2
MPa (kgf/cm , psi)
Boom, Arm, and Bucket 34.3+2.0-0.5 Value indicated on Dr. ZX
(350+20-5,
4980+284-71)
Power Boost 36.3+2.0-1.0 Value indicated on Dr. ZX
(370+20-10,
5260+284-142)
RELIEF PRESSURE 31.9+2.3-0 Value indicated on Dr. ZX T4-5-14
2
MPa (kgf/cm , psi)
(When relieving Swing) (325+25-0,
4620+356-0)
RELIEF PRESSURE 34.3+2.0-0.5 Value indicated on Dr. ZX T4-5-16
2
MPa (kgf/cm , psi)
(When relieving Travel) (350+20-5,
4980+284-71)
OVERLOAD RELIEF VALVE SET PRES- (Reference values T4-5-18
SURE MPa (kgf/cm , psi) at 50 L/min)
2
T4-2-8
OPERATIONAL PERFORMANCE TEST / Standard
ZAXIS225US OPERATIONAL
PERFORMANCE STANDARD TABLE
The standard Performance values are listed in the Engine Control Dial : Fast Idle
table below. Refer to the Group T4-3 to T4-5 for Power Mode Switch : P Mode
performance test procedures. Values indicated in Auto-Idle/Acceleration Selector : OFF
parentheses are reference values. Work Mode Switch : Digging Mode
Hydraulic Oil Temperature : 50±5 °C (122±9 °F)
The following switch positions shall be selected and
the hydraulic oil temperature shall be maintained as
indicated below as the preconditions of performance
tests unless otherwise instructed in each performance
test procedure:
NOTE: 1 mm=0.03937 in
ZAXIS225US
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
ENGINE SPEED min
-1
T4-3-1
Slow Idle Speed 950±100 Value indicated on Dr. ZX.
Fast Idle Speed (Normal) 1965±50 ↑
Fast Idle Speed (Wirh ECO deactivated) 2065±50 ↑
Extend the boom cylinder to
relieve the boom raise
Fast Idle Speed (Relief Operation) 1915±50
circuit.Value indicated on Dr.
ZX.
Fast Idle Speed (E mode) 1820±70 Value indicated on Dr. ZX.
Extend the boom and arm
cylinder to relieve the boom
Fast Idle Speed (HP mode) 2000 to 2250
raise and arm roll-in circuit.
Value indicated on Dr. ZX.
Auto-Idle Speed 1335±100 Value indicated on Dr. ZX.
Auto-Acceleration Speed 1675±100 ↑
Warming Up Speed 1400+140-100 ↑
ENGINE COMPRESSION PRESSURE After engine warm-up T4-3-4
3.04 (31, 440)
(After engine warm-up) 2
MPa (kgf/cm , psi)
VALVE CLEARANCE (IN, EX) 0.4 With the engine cold T4-3-6
NOZZLE INJECTION PRESSURE T4-3-8
2 18.1 (185, 2630)
MPa (kgf/cm , psi)
INJECTION TIMING T4-3-10
10°
(Degrees before TDC) deg.
LUBRICANT CONSUMPTION Hour meter: 2000 hours or T4-3-12
50 or less
(Rated output) mL/h less
T4-2-9
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZAXIS225US
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
TRAVEL SPEED sec/20 m T4-4-1
Travel speed isn’t shifted to
Fast Speed 13.6±1.2 fast speed mode one side-
track is jacked up.
Slow Speed 21.8±2.0
TRACK REVOLUTION SPEED sec/3 rev T4-4-2
17.8±1.0 LC: 18.9±1.0
Fast Speed
28.2±2.0 LC: 30.1±2.0
Slow Speed
MISTRACK mm/20 m T4-4-3
200 or less
(With fast and slow travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0 T4-4-4
SWING SPEED sec/3 rev 13.5±1.0 Bucket empty T4-4-5
SWING FUNCTION DRIFT CHECK T4-4-6
1254 or less Bucket empty
mm /180°
SWING MOTOR LEAKAGE mm/5 min 0 Bucket loaded T4-4-8
MAXIMUM SWINGABLE SLANT ANGLE 20° or possibly Bucket loaded T4-4-10
deg. more
SWING BEARING PLAY mm 0.2 to 1.25 Allowable limit: 2.0 to 3.05 T4-4-12
HYDRAULIC CYLINDER CYCLE TIME 2.91 m arm T4-4-14
sec 0.8 m3 (PCSA heaped)
bucket, bucket empty
Boom Raise 3.8±0.3
Boom Lower 3.0±0.3
Arm Roll-In 3.8±0.3
Arm Roll-Out 2.8±0.3
Bucket Roll-In 3.4±0.3
Bucket Roll-Out 2.3±0.3
DIG FUNCTION DRIFT CHECK mm/5 min 2.91m arm T4-4-16
0.8 m3 (PCSA heaped) bucket
Boom Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 5 or less Bucket empty
Arm Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 15 or less Bucket empty
Bucket Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 10 or less Bucket empty
Bucket Bottom
(Maximum Reach Position) 150 or less Bucket loaded
(Arm Roll-In position) 110 or less Bucket empty
T4-2-10
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZAXIS225US
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
CONTROL LEVER OPERATING FORCE HITACHI lever pattern T4-4-18
N (kgf, lbf・ft)
Boom Lever 18 (1.8, 13) or less
Arm Lever 15 (1.5, 10.8) or
(ISO Lever Pattern: Swing Lever) less
Bucket Lever 15 (1.5, 10.8) or
less
Swing Lever 18 (1.8, 13) or less
(ISO Lever Pattern: Arm Lever)
Travel Lever 28 (2.8, 20.3) or
less
CONTROL LEVER STROKE mm HITACHI lever pattern T4-4-20
Boom Lever 105±10
Arm Lever
84±10
(ISO Lever Pattern: Swing Lever)
Bucket Lever 84±10
Swing Lever 105±10
(ISO Lever Pattern: Arm Lever)
Travel Lever 120±10
BOOM RAISE/SWING sec 2.91 m arm T4-4-22
3.5±0.3 0.8 m3 (PCSA heaped)
bucket, bucket empty
(Bucket Teeth Height: H) mm 6800 or more
BOOM RAISE/ARM ROLL-IN sec 2.91 m arm T4-4-24
4.5±0.5 0.8 m3 (PCSA heaped)
bucket, bucket empty
PRIMARY PILOT PRESSURE T4-5-1
2
MPa (kgf/cm , psi)
Engine: Fast Idle 4.0+1.0-0.5
(41+10-5, 580+142-71)
Engine: Slow Idle 3.5+1.0-0
(35 -0, 500+142-0)
+10
T4-2-11
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZAXIS225US Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks Page
Standard)
MAIN RELIEF VALVE SET PRESSURE T4-5-10
2
MPa (kgf/cm , psi)
Boom, Arm, and Bucket 34.3+2.0-0.5 Value indicated on Dr. ZX
(350+20-5,
4980+284-71)
Power Boost 36.3+2.0-1.0 Value indicated on Dr. ZX
(370+20-10,
5260+284-142)
RELIEF PRESSURE 31.9+2.3-0 Value indicated on Dr. ZX T4-5-14
2
MPa (kgf/cm , psi)
(When relieving Swing) (325+25-0,
4620+356-0)
RELIEF PRESSURE 34.3+2.0-0.5 Value indicated on Dr. ZX T4-5-16
2
MPa (kgf/cm , psi)
(When relieving Travel) (350+20-5,
4980+284-71)
OVERLOAD RELIEF VALVE SET PRES- (Reference values T4-5-18
SURE MPa (kgf/cm , psi) at 50 L/min)
2
T4-2-12
OPERATIONAL PERFORMANCE TEST / Standard
ZX230 CLASS OPERATIONAL
PERFORMANCE STANDARD TABLE
The standard Performance values are listed in the Engine Control Dial : Fast Idle
table below. Refer to the Group T4-3 to T4-5 for Power Mode Switch : P Mode
performance test procedures. Values indicated in Auto-Idle/Acceleration Selector : OFF
parentheses are reference values. Work Mode Switch : Digging Mode
Hydraulic Oil Temperature : 50±5 °C (122±9 °F)
The following switch positions shall be selected and
the hydraulic oil temperature shall be maintained as
indicated below as the preconditions of performance
tests unless otherwise instructed in each performance
test procedure:
NOTE: 1 mm=0.03937 in
ZX230 class
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
ENGINE SPEED min
-1
T4-3-1
Slow Idle Speed 900+150-100 Value indicated on Dr. ZX.
Fast Idle Speed (Normal) 2050+65-50 ↑
Fast Idle Speed (Wirh ECO deactivated) 2180+65-50 ↑
Extend the boom cylinder to
relieve the boom raise
Fast Idle Speed (Relief Operation) 2000+65-50
circuit.Value indicated on Dr.
ZX.
Fast Idle Speed (E mode) 1980+90-70 Value indicated on Dr. ZX.
Extend the boom and arm
cylinder to relieve the boom
Fast Idle Speed (HP mode) 2000 to 2250
raise and arm roll-in circuit.
Value indicated on Dr. ZX.
Auto-Idle Speed 1300+135-100 Value indicated on Dr. ZX.
Auto-Acceleration Speed 1750+125-100 ↑
Warming Up Speed 1400+140-100 ↑
ENGINE COMPRESSION PRESSURE After engine warm-up T4-3-4
3.04 (31, 440)
(After engine warm-up) 2
MPa (kgf/cm , psi)
VALVE CLEARANCE (IN, EX) 0.4 With the engine cold T4-3-6
NOZZLE INJECTION PRESSURE T4-3-8
2 18.1 (185, 2630)
MPa (kgf/cm , psi)
INJECTION TIMING T4-3-10
10°
(Degrees before TDC) deg.
LUBRICANT CONSUMPTION Hour meter: 2000 hours or T4-3-12
60 or less
(Rated output) mL/h less
T4-2-13
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZX230 class
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
TRAVEL SPEED sec/20 m T4-4-1
Travel speed isn’t shifted to
Fast Speed 12.9±1.0 fast speed mode one side-
track is jacked up.
Slow Speed 21.0±2.0
TRACK REVOLUTION SPEED sec/3 rev T4-4-2
Fast Speed 17.1±1.0 LC: 18.7±1.0
Slow Speed 28.2±2.0 LC: 30.0±2.0
MISTRACK mm/20 m T4-4-3
200 or less
(With fast and slow travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0 T4-4-4
SWING SPEED sec/3 rev 14.3±1.0 Bucket empty T4-4-5
SWING FUNCTION DRIFT CHECK T4-4-6
1730 or less Bucket empty
mm /180°
SWING MOTOR LEAKAGE mm/5 min 0 Bucket loaded T4-4-8
MAXIMUM SWINGABLE SLANT ANGLE 20° or possibly Bucket loaded T4-4-10
deg. more
SWING BEARING PLAY mm 0.2 to 1.25 Allowable limit: 2.0 to 3.05 T4-4-12
HYDRAULIC CYLINDER CYCLE TIME 2.96 m arm T4-4-14
sec 1.0 m3 (PCSA heaped)
bucket, bucket empty
Boom Raise 3.3±0.3
Boom Lower 2.5±0.3
Arm Roll-In 4.1±0.3
Arm Roll-Out 2.9±0.3
Bucket Roll-In 4.1±0.3
Bucket Roll-Out 2.5±0.3
DIG FUNCTION DRIFT CHECK mm/5 min 2.96 m arm T4-4-16
1.0 m3 (PCSA heaped) bucket
Boom Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 5 or less Bucket empty
Arm Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 15 or less Bucket empty
Bucket Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 10 or less Bucket empty
Bucket Bottom
(Maximum Reach Position) 150 or less Bucket loaded
(Arm Roll-In position) 110 or less Bucket empty
T4-2-14
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZX230 class
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
CONTROL LEVER OPERATING FORCE HITACHI lever pattern T4-4-18
N (kgf, lbf・ft)
Boom Lever 18 (1.8, 13) or less
Arm Lever 15 (1.5, 10.8) or
(ISO Lever Pattern: Swing Lever) less
Bucket Lever 15 (1.5, 10.8) or
less
Swing Lever 18 (1.8, 13) or less
(ISO Lever Pattern: Arm Lever)
Travel Lever 28 (2.8, 20.3) or
less
CONTROL LEVER STROKE mm HITACHI lever pattern T4-4-20
Boom Lever 105±10
Arm Lever
84±10
(ISO Lever Pattern: Swing Lever)
Bucket Lever 84±10
Swing Lever 105±10
(ISO Lever Pattern: Arm Lever)
Travel Lever 120±10
BOOM RAISE/SWING sec 2.96 m arm T4-4-22
3.8±0.3 1.0 m3 (PCSA heaped)
bucket, bucket empty
(Bucket Teeth Height: H) mm 6550 or more
BOOM RAISE/ARM ROLL-IN sec 2.96 m arm T4-4-24
5.0±0.5 1.0 m3 (PCSA heaped)
bucket, bucket empty
PRIMARY PILOT PRESSURE T4-5-1
2
MPa (kgf/cm , psi)
Engine: Fast Idle 4.0+1.0-0.5 Value indicated on Dr. ZX
(41+10-5, 580+142-71)
Engine: Slow Idle 3.5+1.0-0 Value indicated on Dr. ZX
(35 -0, 500+142-0)
+10
T4-2-15
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZX230 class Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks Page
Standard)
MAIN RELIEF VALVE SET PRESSURE T4-5-10
2
MPa (kgf/cm , psi)
Boom, Arm, and Bucket 34.3+2.0-0.5 Value indicated on Dr. ZX
(350+20-5,
4980+284-71)
Power Boost 36.3+2.0-1.0 Value indicated on Dr. ZX
(370+20-10,
5260+284-142)
RELIEF PRESSURE 30.9+2.20-0.5 Value indicated on Dr. ZX T4-5-14
2
MPa (kgf/cm , psi)
(When relieving Swing) (315+23-5,
4479+327-71)
RELIEF PRESSURE 34.3+2.0-0.5 Value indicated on Dr. ZX T4-5-16
2
MPa (kgf/cm , psi)
(When relieving Travel) (350+20-5,
4980+284-71)
OVERLOAD RELIEF VALVE SET PRES- (Reference values T4-5-18
SURE MPa (kgf/cm , psi) at 50 L/min)
2
T4-2-16
OPERATIONAL PERFORMANCE TEST / Standard
ZX270 CLASS OPERATIONAL
PERFORMANCE STANDARD TABLE
The standard Performance values are listed in the Engine Control Dial : Fast Idle
table below. Refer to the Group T4-3 to T4-5 for Power Mode Switch : P Mode
performance test procedures. Values indicated in Auto-Idle/Acceleration Selector : OFF
parentheses are reference values. Work Mode Switch : Digging Mode
Hydraulic Oil Temperature : 50±5 °C (122±9 °F)
The following switch positions shall be selected and
the hydraulic oil temperature shall be maintained as
indicated below as the preconditions of performance
tests unless otherwise instructed in each performance
test procedure:
NOTE: 1 mm=0.03937 in
ZX270 class
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
ENGINE SPEED min
-1
T4-3-1
Slow Idle Speed 900+150-100 Value indicated on Dr. ZX.
Fast Idle Speed (Normal) 2100+65-50 ↑
Fast Idle Speed (Wirh ECO deactivated) 2230+65-50 ↑
Extend the boom cylinder to
relieve the boom raise
Fast Idle Speed (Relief Operation) 2050+65-50
circuit.Value indicated on Dr.
ZX.
Fast Idle Speed (E mode) 2030+90-70 Value indicated on Dr. ZX.
Extend the boom and arm
cylinder to relieve the boom
Fast Idle Speed (HP mode) 2050 to 2300
raise and arm roll-in circuit.
Value indicated on Dr. ZX.
Auto-Idle Speed 1300+135-100 Value indicated on Dr. ZX.
Auto-Acceleration Speed 1800+125-100 ↑
Warming Up Speed 1400+140-100 ↑
ENGINE COMPRESSION PRESSURE After engine warm-up T4-3-4
3.04 (31, 440)
(After engine warm-up) 2
MPa (kgf/cm , psi)
VALVE CLEARANCE (IN, EX) 0.4 With the engine cold T4-3-6
NOZZLE INJECTION PRESSURE T4-3-8
2 18.1 (185, 2630)
MPa (kgf/cm , psi)
INJECTION TIMING T4-3-10
10°
(Degrees before TDC) deg.
LUBRICANT CONSUMPTION Hour meter: 2000 hours or T4-3-12
60 or less
(Rated output) mL/h less
T4-2-17
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZX270 class
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
TRAVEL SPEED sec/20 m T4-4-1
Travel speed isn’t shifted to
Fast Speed 14.7±1.2 fast speed mode one side-
track is jacked up.
Slow Speed 24.8±2.0
TRACK REVOLUTION SPEED sec/3 rev T4-4-2
34.6±2.0 LC: 36.1±2.0
Fast Speed
34.6±2.0 LC: 36.1±2.0
Slow Speed
MISTRACK mm/20 m T4-4-3
200 or less
(With fast and slow travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0 T4-4-4
SWING SPEED sec/3 rev 14.9±1.0 Bucket empty T4-4-5
SWING FUNCTION DRIFT CHECK T4-4-6
1483 or less Bucket empty
mm /180°
SWING MOTOR LEAKAGE mm/5 min 0 Bucket loaded T4-4-8
MAXIMUM SWINGABLE SLANT ANGLE 19° or possibly Bucket loaded T4-4-10
deg. more
SWING BEARING PLAY mm 0.2 to 1.25 Allowable limit: 2.0 to 3.05 T4-4-12
HYDRAULIC CYLINDER CYCLE TIME 3.10 m arm T4-4-14
sec 1.1 m3 (PCSA heaped)
bucket, bucket empty
Boom Raise 3.6±0.3
Boom Lower 2.6±0.3
Arm Roll-In 3.9±0.3
Arm Roll-Out 3.0±0.3
Bucket Roll-In 4.3±0.3
Bucket Roll-Out 2.5±0.3
DIG FUNCTION DRIFT CHECK mm/5 min 3.10m arm T4-4-16
1.1 m3 (PCSA heaped) bucket
Boom Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 5 or less Bucket empty
Arm Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 15 or less Bucket empty
Bucket Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 10 or less Bucket empty
Bucket Bottom
(Maximum Reach Position) 150 or less Bucket loaded
(Arm Roll-In position) 110 or less Bucket empty
T4-2-18
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZX270 class
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
CONTROL LEVER OPERATING FORCE HITACHI lever pattern T4-4-18
N (kgf, lbf・ft)
Boom Lever 18 (1.8, 13) or less
Arm Lever 15 (1.5, 10.8) or
(ISO Lever Pattern: Swing Lever) less
Bucket Lever 15 (1.5, 10.8) or
less
Swing Lever 18 (1.8, 13) or less
(ISO Lever Pattern: Arm Lever)
Travel Lever 28 (2.8, 20.3) or
less
CONTROL LEVER STROKE mm HITACHI lever pattern T4-4-20
Boom Lever 105±10
Arm Lever
84±10
(ISO Lever Pattern: Swing Lever)
Bucket Lever 84±10
Swing Lever 105±10
(ISO Lever Pattern: Arm Lever)
Travel Lever 120±10
BOOM RAISE/SWING sec 3.10 m arm T4-4-22
3.9±0.4 1.1 m3 (PCSA heaped)
bucket, bucket empty
(Bucket Teeth Height: H) mm 6600 or more
BOOM RAISE/ARM ROLL-IN sec 3.10 m arm T4-4-24
5.2±0.5 1.1 m3 (PCSA heaped)
bucket, bucket empty
PRIMARY PILOT PRESSURE T4-5-1
2
MPa (kgf/cm , psi)
Engine: Fast Idle 4.0+1.0-0.5 Value indicated on Dr. ZX
(41+10-5, 580+142-71)
Engine: Slow Idle 3.5+1.0-0 Value indicated on Dr. ZX
(35 -0, 500+142-0)
+10
T4-2-19
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZX270 class Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks Page
Standard)
MAIN RELIEF VALVE SET PRESSURE T4-5-10
2
MPa (kgf/cm , psi)
Boom, Arm, and Bucket 34.3+2.0-0.5 Value indicated on Dr. ZX
(350+20-5,
4980+284-71)
Power Boost 36.3+2.0-1.0 Value indicated on Dr. ZX
(370+20-10,
5260+284-142)
RELIEF PRESSURE 31.4+2.3-0.5 Value indicated on Dr. ZX T4-5-15
2
MPa (kgf/cm , psi)
(When relieving Swing) (320+23-5,
4550+327-71)
RELIEF PRESSURE 34.3+2.0-0.5 Value indicated on Dr. ZX T4-5-17
2
MPa (kgf/cm , psi)
(When relieving Travel) (350+20-5,
4980+284-71)
OVERLOAD RELIEF VALVE SET PRES- (Reference values T4-5-18
SURE MPa (kgf/cm , psi) at 50 L/min)
2
T4-2-20
OPERATIONAL PERFORMANCE TEST / Standard
(Blank)
T4-2-21
OPERATIONAL PERFORMANCE TEST / Standard
MAIN PUMP P-Q DIAGRAM
• ZX230 class Points on P-Q Line • ZX270 class Points on P-Q Line
Delivery Pressure Flow Rate Delivery Pressure Flow Rate
MPa (kgf/cm2) L/min MPa (kgf/cm2) L/min
A 3.9 (40) 204±3 A 3.9 (40) 209±3
B 12.7 (130) 202+3-6 B 14.7 (150) 207±3
C 15.6 (159) [202] C 16.5 (168) [207]
D 17.6 (180) 178±6 D 18.6 (190) 182±6
E 21.0 (214) [141] E 21.1 (215) [153]
F 27.1 (277) 115±6 F 27.4 (280) 126±6
The valve indicated in parentheses is only a reference The valve indicated in parentheses is only a reference
valve. valve.
L/min A
B
Flow D
Rate
T4-2-22
OPERATIONAL PERFORMANCE TEST / Standard
• P-Q Control by Pump Control Pilot Pressure Signal
L/min
C
Flow
Rate
MPa (kgf/cm2)
Pump Control Pressure
T178-04-05-004
T4-2-23
OPERATIONAL PERFORMANCE TEST / Standard
INJECTION PUMP
ZX200 class, 225 class
Test Conditions:
1. Injection pump: PES6AD 101061-8830 8. Transfer pump pressure:
2. Governor: EP/RSV 105419-1660 157 kPa (1.6 kgf/cm2, 23 psi)
3. Nozzle and nozzle holder assembly: 9. Injection pipe: Inner Dia. 2 mm×Outer Dia. 6
105780-8140 (Bosch No. EF8511/9A) mm-Length 600 mm (0.079×0.236-23.6 in)
4. Nozzle: 105780-0000 (Bosch No. DN12SD12T) 10. Fuel temperature: 40+5 °C (104+9 °F)
5. Nozzle holder: 105780-2080 (Bosch No. 11. Overflow valve opening pressure: 127 kPa (1.3
EF8511/9) kgf/cm2, 18.5 psi)
6. Nozzle opening pressure:
17.2 MPa (175 kgf/cm2, 2490 psi) NOTE: The nozzle test injection pressure is 17.2
7. Test fuel: ISO 4113 or SAE J967d MPa (175 kgf/cm2, 2490 psi). However,
actual machine injection pressure is 18.1
MPa (185 kgf/cm2, 2630 psi).
Governor adjustment
Above 14.0
Rack limit
D Idle-sub spring setting
11.0
Governor spring setting
10.9±0.1
A
10.3
Rack Position
(mm) 9.8±0.1
8.0
7.5 C
10.2-0.5
7.3±0.3
0 240 450
1075 1200
350 (500) (1110) 1125
T178-04-05-003
-1
Pump Speed min (rpm)
T4-2-24
OPERATIONAL PERFORMANCE TEST / Standard
ZX230 class
Test Conditions:
1. Injection pump: PES6AD 101605-0090 8. Transfer pump pressure:
2. Governor: EP/RSV 105411-2300 255 kPa (2.6 kgf/cm2, 37 psi)
3. Nozzle and nozzle holder assembly: 9. Injection pipe: Inner Dia. 2 mm×Outer Dia. 6
105780-8140 (Bosch No. EF8511/9A) mm-Length 600 mm (0.079×0.236-23.6 in)
4. Nozzle: 105780-0000 (Bosch No. DN12SD12T) 10. Fuel temperature: 40+5 °C (104+9 °F)
5. Nozzle holder: 105780-2080 (Bosch No. 11. Overflow valve opening pressure: 255 kPa (2.6
EF8511/9) kgf/cm2, 37 psi)
6. Nozzle opening pressure:
17.2 MPa (175 kgf/cm2, 2490 psi) NOTE: The nozzle test injection pressure is 17.2
7. Test fuel: ISO 4113 or SAE J967d MPa (175 kgf/cm2, 2490 psi). However,
actual machine injection pressure is 18.1
MPa (185 kgf/cm2, 2630 psi).
Governor adjustment
Rack limit
Above Idle-sub spring setting
Governor spring setting
Rack Position
(mm)
-1
Pump Speed min (rpm) T1HD-04-05-001
T4-2-25
OPERATIONAL PERFORMANCE TEST / Standard
ZX270 class
Test Conditions:
1. Injection pump: PES6AD 101605-0100 8. Transfer pump pressure:
2. Governor: EP/RSV 105411-2300 255 kPa (2.6 kgf/cm2, 37 psi)
3. Nozzle and nozzle holder assembly: 9. Injection pipe: Inner Dia. 2 mm×Outer Dia. 6
105780-8140 (Bosch No. EF8511/9A) mm-Length 600 mm (0.079×0.236-23.6 in)
4. Nozzle: 105780-0000 (Bosch No. DN12SD12T) 10. Fuel temperature: 40+5 °C (104+9 °F)
5. Nozzle holder: 105780-2080 (Bosch No. 11. Overflow valve opening pressure: 255 kPa (2.6
EF8511/9) kgf/cm2, 37 psi)
6. Nozzle opening pressure:
17.2 MPa (175 kgf/cm2, 2490 psi) NOTE: The nozzle test injection pressure is 17.2
7. Test fuel: ISO 4113 or SAE J967d MPa (175 kgf/cm2, 2490 psi). However,
actual machine injection pressure is 18.1
MPa (185 kgf/cm2, 2630 psi).
Governor adjustment
Rack limit
Above Idle-sub spring setting
Boost compensation: 0.3±0.1mm
Governor spring setting
-1
Pump Speed min (rpm)
T1HG-04-05-001
T4-2-26
OPERATIONAL PERFORMANCE TEST / Standard
(Blank)
T4-2-27
OPERATIONAL PERFORMANCE TEST / Standard
ZX200 CLASS DR. ZX MONITOR INDI-
CATING VALUES
Unless specified, test under the following conditions. ∗
NOTE: Items marked ( ) are measurable with the
Engine Speed: Fast Idle built-in diagnosing system.
Work Mode Switch: Digging Mode ∗∗
Items marked ( ) are measurable with the
Power Mode Switch: P mode
built-in diagnosing system. However, it
Auto-Idle/Acceleration Selector: OFF
may be difficult to read the measured value
while operating the machine.
T4-2-28
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-29
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-30
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-31
OPERATIONAL PERFORMANCE TEST / Standard
ZAXIS225USR
DR. ZX MONITOR INDICATING VALUES
Unless specified, test under the following conditions. ∗
NOTE: Items marked ( ) are measurable with the
Engine Speed: Fast Idle built-in diagnosing system.
Work Mode Switch: Digging Mode ∗∗
Items marked ( ) are measurable with the
Power Mode Switch: P mode
built-in diagnosing system. However, it
Auto-Idle/Acceleration Selector: OFF
may be difficult to read the measured value
while operating the machine.
T4-2-32
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-33
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-34
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-35
OPERATIONAL PERFORMANCE TEST / Standard
ZAXIS225US
DR. ZX MONITOR INDICATING VALUES
Unless specified, test under the following conditions. ∗
NOTE: Items marked ( ) are measurable with the
Engine Speed: Fast Idle built-in diagnosing system.
Work Mode Switch: Digging Mode ∗∗
Items marked ( ) are measurable with the
Power Mode Switch: P mode
built-in diagnosing system. However, it
Auto-Idle/Acceleration Selector: OFF
may be difficult to read the measured value
while operating the machine.
T4-2-36
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-37
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-38
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-39
OPERATIONAL PERFORMANCE TEST / Standard
ZX230 CLASS DR. ZX MONITOR INDI-
CATING VALUES
Unless specified, test under the following conditions. ∗
NOTE: Items marked ( ) are measurable with the
Engine Speed: Fast Idle built-in diagnosing system.
Work Mode Switch: Digging Mode ∗∗
Items marked ( ) are measurable with the
Power Mode Switch: P mode
built-in diagnosing system. However, it
Auto-Idle/Acceleration Selector: OFF
may be difficult to read the measured value
while operating the machine.
T4-2-40
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-41
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-42
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-43
OPERATIONAL PERFORMANCE TEST / Standard
ZX270 CLASS DR. ZX MONITOR INDI-
CATING VALUES
Unless specified, test under the following conditions. ∗
NOTE: Items marked ( ) are measurable with the
Engine Speed: Fast Idle built-in diagnosing system.
Work Mode Switch: Digging Mode ∗∗
Items marked ( ) are measurable with the
Power Mode Switch: P mode
built-in diagnosing system. However, it
Auto-Idle/Acceleration Selector: OFF
may be difficult to read the measured value
while operating the machine.
T4-2-44
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-45
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-46
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-47
OPERATIONAL PERFORMANCE TEST / Standard
SENSOR ACTIVATING RANGE
1. Checking Method
T4-2-48
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary
1. Measure the engine speed using the built-in di- 2
agnosing system or Dr. ZX. If the built-in diag-
nosing system or Dr. ZX is not available, use an 1
engine speed meter or a pulse counter. (Refer to
the TROUBLESHOOTING / General group.)
2. Measure the engine speeds in each mode.
Preparation: 3
1. Select the monitor function of the built-in diag-
nosing system (In case of Dr. ZX, connect it first).
When using an engine speed meter, install speed
pickup (2) to injection pipe (1).
When using a pulse counter, disconnect the
N-sensor connector.
2. Warm up the machine until the engine coolant
temperature reaches 50 °C (122 °F) or more, and
hydraulic oil is 50±5 °C (122±9 °F).
T4-3-1
OPERATIONAL PERFORMANCE TEST / Engine Test
Measurement: Evaluation:
1. Check engine speeds for auto-warm up (when Refer to T4-2 Operational Performance Standard.
starting the engine), auto-idle, slow idle, fast idle
(when normal), fast idle (when the ECO is deac- Remedy:
tivated), fast idle (in the E mode), and fast idle (in Refer to T5-4 Troubleshooting B.
the HP mode).
2. Select the switch positions and the test condi- NOTE: ECO stands for the auto engine speed re-
tions corresponding to the engine speed to be duction system by 200 min-1.
measured as shown in the table below.
3. When using the pulse counter, read the pulse
counter. Calculate the engine speed using the
following formula:
Engine Speed (min-1) =
Pulse Numbers (Hz) × 60 / 34
Engine Power Auto-Idle/ Auto- Work
Control Mode Acceleration Mode Test Conditions
Dial Switch Selector Switch
Digging
Slow Idle Min. Speed P OFF
Mode
Fast Idle Digging
Max. Speed P OFF
(Normal) Mode
Fast Idle Check in the Dr. ZX special
Digging
(With ECO deac- Max. Speed P OFF functions with ECO deacti-
Mode
tivated) vated.
Fast Idle Digging Check the engine speed while
Max. Speed P OFF
(Relief operation) Mode relieving the boom raise circuit.
Fast Idle Digging
Max. Speed E Mode OFF
(E mode) Mode
Fast Idle Digging Check the engine speed while
Max. Speed HP Mode OFF
(HP mode) Mode relieving the boom raise circuit.
Check engine speed 4 seconds
Digging
Auto-Idle Max. Speed P Auto-Idle after returning all control levers
Mode
to neutral.
Check reduced engine speed
Digging
Auto-Acceleration Max. Speed P Auto-Acceleration within 3 seconds after returning
Mode
all control levers to neutral.
Digging Check only when oil tempera-
Warming Up Max. Speed P OFF
Mode ture is lower than 0 °C (32 °F).
T4-3-2
OPERATIONAL PERFORMANCE TEST / Engine Test
Monitor Panel Switch Panel
Engine Con-
trol Dial
Auto-Idle/Acceleration
Selector
Power Mode
Switch
Work Mode
Switch
T178-01-01-003
T178-01-01-004
T4-3-3
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders
to check for a decline in engine power.
2. Check exhaust gas color. Keep track of engine oil
consumption.
3. Check for abnormalities in the intake system, in-
cluding the air filter.
Preparation:
1. Confirm that valve clearances are correct.
2. Confirm that the batteries are charged properly.
3. Run the engine until the coolant temperature
gauge reaches the operating range.
4. Stop the engine. Remove glow plugs from each
cylinder.
Measurement:
1. Turn the starter to crank the engine. Record the
compression pressure of each cylinder.
2. Repeat measurement three times for each cylin-
der and calculate the mean values.
Evaluation:
Refer to T4-2 Operational Performance Standard.
Remedy:
Refer to engine shop manual.
T4-3-4
OPERATIONAL PERFORMANCE TEST / Engine Test
(Blank)
T4-3-5
OPERATIONAL PERFORMANCE TEST / Engine Test
VALVE CLEARANCE ADJUSTMENT
Summary:
1. Perform the measurement when the engine is
cold.
2. Before starting work, clean the head cover
mounting area to avoid contamination in the en-
gine.
Preparation:
1. Locate the top dead center (TDC) in the com-
pression stroke. Top Mark
Align the TDC mark on the crank pulley with the
pointer located on the timing gear case as illus-
TDC Mark
trated. Piston No.1 (or piston No.6) is now posi-
tioned at the TDC in its compression stroke.
Timing Gear
Case
NOTE: When rotating the crank pulley, remove the
fan guard. Then, rotate the fan while hold- Crank Pulley
ing the fan belt. If it is difficult to rotate,
remove all glow plugs to release the com-
pression pressure.
T157-05-02-002
2. Remove the head cover.
3. Move push rods for the intake and exhaust
valves on the No.1 cylinder up and down by hand.
If any clearances on the both ends of the push
rods are found, piston No.1 is positioned at TDC
in the compression stroke. (If the exhaust valve
of cylinder No.1 is pushed down, piston No.6 is
positioned at TDC in the compression stroke.
Start measurement from the cylinder (No.1 or
No.6) positioned at TDC in the compression
stroke.
T4-3-6
OPERATIONAL PERFORMANCE TEST / Engine Test
Measurement:
1. Insert a thickness gauge into the clearance be-
tween the rocker arm and the valve stem end to
measure the valve clearance.
Evaluation:
Refer to T4-2 Operational Performance Standard.
Adjustment:
If the measurement results are out of specification,
adjust the valve clearance in the same order of
measurement.
T4-3-7
OPERATIONAL PERFORMANCE TEST / Engine Test
NOZZLE CHECK
Summary:
1. Check the injection pressure and the spray pat-
tern with a nozzle tester.
2. Before starting work, clean the nozzle holder
mounting area to avoid contamination in the en-
gine.
Preparation:
1. Remove the nozzle holders.
Remove all nozzle holders and fuel injection pip-
ings from the engine.
2. Attach a nozzle holder to the nozzle tester.
Measurement:
CAUTION: Never touch spray directly. The
fuel spray from the nozzle may penetrate the
skin, resulting in serious injury. If fuel pene-
trates into the blood stream, it may cause
blood toxication.
1. Injection pressure
After attaching the nozzle holder to the nozzle
tester, strongly make several strokes of the tester
to inject fuel. Then, while operating the tester at T107-06-02-006
approx. 60 time strokes a minute, measure the
fuel injection pressure.
If adjustment is required, loosen the lock nuts
and adjust the adjusting screws. Turn clockwise
to increase the pressure, and counterclockwise
to decrease the pressure.
2. Spray pattern
For this test, turn the pressure tester knob to by-
pass the pressure gauge. Attach the nozzle
holder to the nozzle tester. Strongly make several
strokes of the tester and check the fuel spray pat-
tern.
3. Oil tight condition
Keep the pressure slightly below the injection
pressure. Check for fuel leak from around the
nozzle tip.
T4-3-8
OPERATIONAL PERFORMANCE TEST / Engine Test
Evaluation:
1. Standard Injection Pressure:
Normal
Refer to T4-2 Operational Performance Standard.
2. Spray Pattern
• Large-size spray should not be visible to the na-
ked eye.
• No stray sideways sprays should be seen.
• During initial injection stage, spray size should be
fine and injected intermittently.
• There should be no drips found.
• Injection spray angle must be normal.
3. Oil Tight Condition
No fuel leaks.
T102-02-11-005
Abnormal
Adjustment:
1. To adjust the injection pressure, loosen the lock
nuts. Adjust the adjusting screw. T102-02-11-006
T107-06-02-007
T4-3-9
OPERATIONAL PERFORMANCE TEST / Engine Test
INJECTION TIMING
Timing Mark
Inspection:
1. Position No.1 piston to the top dead center. Turn Top Mark
the crank pulley in the direction of rotation (clock-
wise as seen from the front of the engine) to set a
TDC Mark
“TDC” mark on the crank pulley under the “Top
mark”, located on the timing gear case.
Timing Gear
Case
NOTE: When rotating the crank pulley, remove the
fan guard. Then, rotate the fan while hold- Crank Pulley
ing the fan belt. If it is difficult to rotate,
remove all glow plugs to release the com-
pression pressure.
T157-05-02-002
2. Remove the timing check hole cover on the front
section of the fuel injection pump. Gear Case
Projection
When the mark on the injection pump is set un-
der the projection of the gear case, No.1 piston is
positioned at the top dead center. If the mark is
not set under the projection, keep turning to ad-
just. Check
Hole
4. Remove the delivery valve holder for No.1 cylin- Gear Case
der from the injection pump to pull the delivery Projection
valve and the spring out. Reinstall the delivery
valve holder.
: 39 to 44 N⋅m
(4 to 4.5 kgf⋅m, 28.9 to 32.6 lbf⋅ft)
Injection Pump
Alignment Mark T107-02-12-008
T4-3-10
OPERATIONAL PERFORMANCE TEST / Engine Test
5. Turn the crank pulley at approx. 30 degrees
counterclockwise.
6. While supplying fuel with the feed pump, turn the
crank pulley slowly clockwise just until fuel can-
not be seen from the top of the delivery valve
hole. This is the position where the injection
starts.
7. Check the “TDC” mark, located on the crank pul-
ley for what degrees the “TDC” mark indicates.
Adjustment:
1. Turn the crank pulley so that the “TDC” mark
comes just above the correct timing position on
the timing gear case.
2. Loosen the mounting nuts of the injection pump.
3. When advancing timing, tilt the injection pump
outward against the cylinder block. T107-02-12-009
T4-3-11
OPERATIONAL PERFORMANCE TEST / Engine Test
LUBRICANT CONSUMPTION
Measuring Method
1. Place the machine on level firm ground, and
leave it for at least one hour to let the lubricant
lower to the oil pan.
At this time, confirm that the machine is level,
using a leveler.
2. Record the read-out A (unit: hour) of the hour
meter.
3. Replenish the lubricant up to the high-level
gauge.
4. Operate the machine for at least 100 hours or un-
til the oil level lowers to the low-level gauge.
Evaluation:
Refer to T4-2 Operational Performance Standard.
T4-3-12
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary: Measurement:
Measure the time required for the excavator to travel 1. Measure both the slow and fast speeds of the
a 20 m (65.6 ft) test track. machine.
2. Select the following switch positions:
Preparation: Travel Engine Power Work Auto-Idle/
1. Adjust the track sag on both sidetracks equally. Mode Control Mode Mode Acceleration
2. Prepare a flat and solid test track 20 m (65.6 ft) in Switch Dial Switch Switch Selector
length with extra length of 3 to 5 m (9.8 to 16 ft) Slow Digging
on both ends for machine acceleration and Fast Idle P Mode OFF
Mode Mode
deceleration. Fast Digging
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above Fast Idle P Mode OFF
Mode Mode
the ground with the arm and bucket rolled in.
4. Maintain hydraulic oil temperature at 50±5 °C 3. Start traveling the machine in the acceleration
(122±9 °F). zone with the travel levers to full stroke.
4. Measure the time required to travel 20 m (65.6
ft).
5. After measuring the forward travel speed, turn
the upperstructure 180° and measure the reverse
Arm Rolled-In, Bucket Rolled-In travel speed.
End 6. Repeat steps 4. to 5. three times in each direc-
Bucket Height: 0.3 to 0.5 m tion and calculate the average values.
Start
20 m Deceleration
Evaluation:
Zone Refer to the Operational Performance Standard in
3 to 5 m Group T4-2.
Acceleration
Zone
3 to 5 m Remedy:
Refer to the Troubleshooting B in Group T5-4.
T105-06-03-001
T4-4-1
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRACK REVOLUTION SPEED
Summary: Measurement:
Measure the track revolution cycle time with the 1. Measure both the slow and fast travel speeds of
track raised off ground. the machine.
2. Select the following switch positions:
Preparation: Travel Engine Power Work Auto-Idle/
1. Adjust the track sag of both side tracks to be Mode Control Mode Mode Acceleration
equal. Switch Dial Switch Switch Selector
2. On the track to be measured, mark one shoe with Slow Digging
Fast Idle P Mode OFF
chalk. Mode Mode
3. Swing the upperstructure 90° and lower the Fast Digging
Fast Idle P Mode OFF
bucket to raise the track off ground. Keep the Mode Mode
boom-arm angle between 90 to 110° as shown. 3. Operate the travel control lever of the raised
Place blocks under the machine frame. track to full stroke.
4. Measure the time required for 3 revolutions in
both directions after a constant track revolution
speed is obtained.
5. Raise the other side and repeat the above
procedures.
90 to 110° 6. Repeat steps 3. to 5. three times and calculate
the average values.
Evaluation:
Refer to the Operational Performance Standard
M104-07-067 Table in Group T4-2.
Mark
CAUTION: Securely support the raised track NOTE: The measurement data obtained through
using wooden blocks. the raised track revolution test may have
wide variations. Therefore, the evaluation
4. Maintain the hydraulic oil temperature at 50±5 °C based on the results obtained from the 20
(122±9 °F). m travel speed check described before is
more recommendable.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-2
OPERATIONAL PERFORMANCE TEST / Excavator Test
MISTRACK CHECK
Summary: Measurement:
1. Allow the machine to travel 20 m (65.6 ft). 1. Measure the amount of mistracking in both fast,
Measure the maximum tread deviation from the and slow travel speeds.
tread chord line drawn between the travel start 2. Select the following switch positions:
and end points to check the performance Travel Engine Power Work Auto-Idle/
equilibrium between both sides of the travel Mode Control Mode Mode Acceleration
device systems (from the main pump to the travel Switch Dial Switch Switch Selector
motor). Slow Digging
2. If measured on a concrete surface, the tread Fast Idle P Mode OFF
Mode Mode
deviation has a trend to decrease. Fast Digging
Fast Idle P Mode OFF
Mode Mode
Preparation:
1. Adjust the track sag of both tracks to be equal. 3. Start traveling the machine in the acceleration
2. Provide a flat, solid test yard 20 m (65.6 ft) in zone with the travel levers at full stroke.
length, with extra length of 3 to 5 m (9.8 to 16 ft) 4. Measure the maximum distance between a
on both ends for machine acceleration and straight 20 m (65.6 ft) tread chord line and the
deceleration. tread made by the machine.
5. After measuring the tracking in forward travel,
turn the upperstructure 180° and measure in
Maximum Distance reverse travel.
6. Repeat steps 3. to 5. three times and calculate
the average values.
Acceleration
Zone: Evaluation:
3 to 5 m
20 m Refer to the Operational Performance Standard
Table in Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T105-06-03-022
T4-4-3
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL PARKING LEAKAGE
Summary:
To measure the parking brake function on a speci-
fied slope.
Preparation:
1. The surface of the test slope shall be even with a
gradient of 20 % (11.31°).
0.2 to 0.3 m
2. Mark a white line on the travel device cover.
3. Hold the bucket 0.2 to 0.3 m (8 to 12 in) above
the ground with the arm and bucket fully rolled in.
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T105-06-03-004
Measurement:
1. Measure the travel parking brake slip amount
while parked.
2. Climb the slope and place the travel levers in
neutral.
3. Stop the engine.
4. After the machine stops, put alignment marks on
a track link or shoe, and the track side frame.
5. After 5 minutes, measure the distance between
the marks on the track link or shoe and the track
side frame.
Evaluation:
Refer to the Operational Performance Standard
Table in Group T4-2.
Alignment marks on the trackside
frame and shoe when the machine
comes to a stop.
Displacement measured
after 5 minutes.
T105-06-03-006
T4-4-4
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING SPEED
Summary:
Measure the time required to swing three complete CAUTION: Prevent personal injury. Always
turns. make sure that the area is clear and that
co-workers are out of the swing area before
Preparation: starting the measurement.
1. Check the lubrication of the swing gear and
swing bearing. Measurement:
2. Place the machine on flat, solid ground with 1. Select the following switch positions:
ample space for swinging. Do not conduct this Auto-Idle/
Engine Con- Power Mode Work Mode
test on slopes. Acceleration
trol Dial Switch Switch
3. With the arm rolled out and bucket rolled in, hold Selector
the bucket so that the height of the bucket pin is Digging
Fast Idle P Mode OFF
the same as the boom foot pin. The bucket must Mode
be empty.
2. Operate swing control lever fully.
3. Measure the time required to swing 3 turns in
one direction.
4. Operate swing control lever fully in the opposite
direction and measure the time required for 3
turns.
The same height as the
5. Repeat steps 2. to 4. three times and calculate
boom foot pin height the average values.
T105-06-03-013 Evaluation:
Refer to the Operational Performance Standard in
NOTE: In case a sufficient space for the meas- Group T4-2.
urement is difficult to find, carry out the
measurement with the boom fully raised Remedy:
and the arm fully rolled-in. Refer to the Troubleshooting B in Group T5-4.
T178-04-03-001
T4-4-5
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING FUNCTION DRIFT CHECK
Summary:
Measure the swing drift on the bearing outer
circumference when stopping after a 180° full-speed
swing.
Preparation:
1. Check the lubrication of the swing gear and
swing bearing.
2. Place the machine on flat, solid ground with
ample space for swinging. Do not conduct this Two Check Marks
test on a slope.
T105-06-03-008
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. The bucket must
be empty.
4. Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
5. Swing the upperstructure 180°.
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T4-4-6
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Select the following switch positions:
Auto-Idle/
Engine Con- Power Mode Work Mode
Acceleration
trol Dial Switch Switch
Selector
Measure Difference Between Marks
Digging
Fast Idle P Mode OFF
Mode
Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-7
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING MOTOR LEAKAGE
Summary:
Check for upperstructure drift while suspending a
load on a slope.
Preparation:
1. Check the lubrication of the swing gear and
swing bearing.
2. Park the machine on a smooth slope with a
gradient of 26.8 % (15°).
3. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
ZX200 class, 225 class: W=1050 kg (2320 lb)
ZX230 class: W=1350 kg (2980 lb)
ZX270 class: W=1500 kg (3310 lb)
4. With the arm rolled out, and bucket rolled in,
position the arm top pin height to be level with the
boom foot pin.
5. Swing the upperstructure to position it 90° to the T105-06-03-011
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as
illustrated.
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T4-4-8
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Select the following switch position:
Auto-Idle/
Power Mode Work Mode
Acceleration
Switch Switch
Selector
Measure Difference Between Marks
P Mode Digging Mode OFF
Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-9
OPERATIONAL PERFORMANCE TEST / Excavator Test
MAXIMUM SWINGABLE SLANT ANGLE
Summary: Measurement:
With the upperstructure swung 90° to the slope, 1. Select the following switch positions:
check the maximum slant angle on which the upper- Engine Auto-Idle/
Power Mode Work Mode
structure can swing to the uphill side. Control Acceleration
Switch Switch
Dial Selector
Preparation: Fast Idle P Mode Digging Mode OFF
1. Check that the swing gear and bearing are well
lubricated.
2. Load bucket fully. In lieu of loading the bucket, 2. Operate the swing lever to full stroke to swing the
weight (W) of the following specification can be upperstructure to the uphill side.
used. 3. If the machine can swing, measure the cab floor
ZX200 class, 225 class: W=1050 kg (2320 lb) slant angle.
ZX230 class: W=1350 kg (2980 lb) 4. Increase the slope angle and repeat steps 2. and
ZX270 class: W=1500 kg (3310 lb) 3. Check both clockwise and counterclockwise.
3. With the arm cylinder fully retracted and the 5. Perform the measurement three times.
bucket cylinder fully extended, hold the arm top
pin to the position flush with the boom foot pin Evaluation:
height. Refer to the Operational Performance Standard in
4. Climb a slope and swing the upperstructure 90° Group T4-2.
to the slope.
5. Maintain the hydraulic oil temperature at 50±5 °C Remedy:
(122±9 °F). Refer to the Troubleshooting B in Group T5-4.
T105-06-03-011
T4-4-10
OPERATIONAL PERFORMANCE TEST / Excavator Test
(Blank)
T4-4-11
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING BEARING PLAY
Summary:
Measure the swing bearing play using a dial gauge
to check the wear of bearing races and balls.
Preparation:
1. Check swing bearing mounting bolts for loose-
ness.
2. Check the lubrication of the swing bearing. Con-
firm that bearing rotation is smooth and without
noise.
3. Install a dial gauge on the track frame as shown, Magnetic Dial
using a magnetic base. Base Gauge
T105-06-03-014
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the front
idlers.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race.
6. Bucket should be empty.
T4-4-12
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. With the arm rolled out and bucket rolled in, hold
Measurement: (h1)
the bucket so that the height of the bucket pin is
the same as the boom foot pin. Record the dial
gauge reading (h1).
2. Lower the bucket to the ground and use it to
raise the front idler 0.5 m (20 in). Record the dial
gauge reading (h2).
3. Calculate bearing play (H) from this data (h1 and The same height
as the boom foot
h2) as follows: pin height
H=h2-h1
Evaluation: T105-06-03-007
T105-06-03-017
T4-4-13
OPERATIONAL PERFORMANCE TEST / Excavator Test
HYDRAULIC CYLINDER CYCLE TIME
Measure the cycle time of the boom, arm, and bucket
cylinders.
Preparation:
1. Be sure to measure at the position as follows.
• To measure the cycle time of the boom cylinders:
With the arm rolled out and the empty bucket
rolled in, lower the bucket to the ground, as
shown.
• To measure the cycle time of the arm cylinder: T105-06-03-018
T105-06-03-020
T4-4-14
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Select the following switch positions:
Engine Auto-Idle/
Power Mode Work Mode
Control Acceleration
Switch Switch
Dial Selector
Fast Idle P Mode Digging Mode OFF
Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-15
OPERATIONAL PERFORMANCE TEST / Excavator Test
DIG FUNCTION DRIFT CHECK
Summary:
Measure dig function drift, which can be caused by
oil leakage in the control valve and boom, arm, and
bucket cylinders, with the loaded bucket.
in) extended from the fully retracted position. Arm Cylinder Extension
3. Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position.
4. With the arm rolled out and the bucket rolled in,
hold the bucket so that the height of the bucket
pin is the same as the boom foot pin.
Mark
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the bucket, as well as the boom, arm and T110-06-03-001
Evalution:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T110-06-03-002
T4-4-16
OPERATIONAL PERFORMANCE TEST / Excavator Test
• Arm Roll-In Position
Summary:
Measure dig function drift, which can be caused by
oil leakage in the control valve and boom, arm, and
bucket cylinders.
Preparation:
1. The bucket must be empty.
2. Position the arm cylinder with the rod 50 mm (2
in) retracted from the fully extended position.
3. Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position.
4. With the arm rolled in and the bucket rolled in.
1m
Lower the boom until the arm tip is 1 m (40 in)
above the ground.
5. Maintain the hydraulic oil temperature at 50±5 °C T173-04-03-001
(122±9 °F).
Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the arm tip, as well as the boom, arm and
bucket cylinders. Cylinder Retraction
3. Repeat step 2. three times and calculate the
average values. Mark Mark
Evalution:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T110-06-03-002
T4-4-17
OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER OPERATING FORCE
Summary:
1. Use a spring scale to measure the maximum
resistance of each control lever as illustrated.
2. Measure the maximum operating force of the
front attachment control lever.
3. Measure the operating force at the grip center of
each control lever.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T107-06-03-004
T4-4-18
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Measure each control lever.
2. Select the following switch positions:
Engine Auto-Idle/
Power Mode Work Mode
Control Acceleration
Switch Switch
Dial Selector
Fast Idle P Mode Digging Mode OFF
Evalution:
Refer to the Orerational Performance Standard in
Group T4-2.
T4-4-19
OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER STROKE
Summary:
1. Measure each lever stroke at the lever top using
a ruler.
2. Measure the lever stroke at the grip center of
each control lever.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both
side lever strokes.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement: T107-06-03-005
Evalution:
Refer to the Orerational Performance Standard in
Group T4-2.
T4-4-20
OPERATIONAL PERFORMANCE TEST / Excavator Test
(Blank)
T4-4-21
OPERATIONAL PERFORMANCE TEST / Excavator Test
COMBINED BOOM RAISE/SWING
FUNCTION CHECK
Summary:
1. Check boom raise and swing movement and
speeds while operating both functions
simultaneously.
2. Make sure that the cylinders don’t hesitate while
operating the cylinder with the engine running at
fast idle.
Preparation:
1. With the arm fully rolled out and bucket fully
rolled in, lower the bucket to the ground. The
bucket must be empty.
2. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T4-4-22
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Select the following switch positions:
Engine Auto-Idle/
Power Mode Work Mode
Control Acceleration
Switch Switch
Dial Selector
Fast Idle P Mode Digging Mode OFF
Evalution:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
H
T107-06-03-011
T4-4-23
OPERATIONAL PERFORMANCE TEST / Excavator Test
BOOM RAISE/ARM ROLL-IN COMBINED
OPERATION
Summary:
1. Performance of boom raise and arm roll-in com-
bined operation is checked.
2. Make sure that the cylinders don’t hesitate while
operating the cylinder with the engine running at
fast idle.
Preparation:
1. Fully retract the arm cylinder and fully extend the
bucket cylinder. Adjust the boom cylinder so that
the bucket tooth tip height is 0.5 m (1 ft 8 in)
above the ground. (Empty the bucket.)
2. Maintain the hydraulic oil temperature at 50 ± 5
°C (122±9 °F). 0.5 m
Measurement: T107-06-03-006
Evaluation:
Refer to T4-2 Operational Performance Standard.
Remedy:
Refer to T5-4 Troubleshooting B.
T107-06-03-008
T4-4-24
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove the plug from the pilot filter. Install
adapter (ST 6069) and pressure gauge (ST
6942) to the removed plug hole (pressure check
port).
: 14 mm
Plug
Measurement:
1. Select the following switch positions:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Digging
Fast Idle P Mode OFF
Mode
Digging
Slow Idle P Mode OFF
Mode
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-5-1
OPERATIONAL PERFORMANCE TEST / Component Test
Primary Pilot Pressure Adjustment Procedure
Adjustment:
Adjust the relief valve set-pressure as necessary.
: 41 mm
Relief Valve
T4-5-2
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)
T4-5-3
OPERATIONAL PERFORMANCE TEST / Component Test
SECONDARY PILOT PRESSURE
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
Signal Control Valve
oil tank to release any remaining pressure.
3. Measure the pressure by either of the following
methods.
NOTE: When disconnecting the pilot lines from the
Control
signal control valve, use tool (SNAP-ON Valve
GAN850812B: size 19.05 mm) to easily
disconnect the lines.
T157-05-04-011
T4-5-4
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Digging
Fast Idle P Mode OFF
Mode
Digging
Slow Idle P Mode OFF
Mode
2. Measure the pilot pressure in each specified set-
ting above with the corresponding control lever
operated full stroke.
3. Repeat the measurement three times and calcu-
late the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-5-5
OPERATIONAL PERFORMANCE TEST / Component Test
SOLENOID VALVE SET PRESSURE
Solenoid Valve Unit
Measure solenoid valve set pressure with both the Serial No.104679 and up (ZX200 class and 225 class)
Dr.ZX and the pressure gauge. Serial No.010327 and up (ZX230 class)
Serial No.020043 and up (ZX270 class)
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Disconnect line (1) from the solenoid valve to be
measured. Install hose (Parts Number: 4216453),
tee (ST 6451), adapter (ST 6461), and pressure
gauge (ST 6942) to the disconnected end at the
solenoid valve side, as illustrated.
: 17 mm, 19 mm, 22 mm
6 7 8 9 T178-01-02-003
Solenoid Valve
Pressure Gauge
T4-5-6
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Digging
Fast Idle P Mode OFF
Mode
Digging
Slow Idle P Mode OFF
Mode
Evaluation:
Refer to the performance Standard Table in Group
T4-2.
T4-5-7
OPERATIONAL PERFORMANCE TEST / Component Test
Solenoid Valve Set Pressure Adjustment Proce-
dure 7
7 8
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-8
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN PUMP DELIVERY PRESSURE
The main pump delivery pressure can also be meas-
ured with Dr.ZX.
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install adapter (ST 6069), hose (ST 6943)
and pressure gauge (ST 6941) on the port.
: 6 mm
Measurement:
1. Select the following switch positions:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch T157-05-04-005
Selector
Digging
Fast Idle P Mode OFF
Mode
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-5-9
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN RELIEF VALVE SET PRESSURE
The main relief pressure can also be measured with
Dr.ZX.
Summary:
Measure the main relief valve setting pressure at the
main pump delivery port.
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install adapter (ST 6069), hose (ST 6943)
and pressure gauge (ST 6941) on the port.
: 6 mm
T157-05-04-005
T4-5-10
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Digging
Fast Idle P Mode OFF
Mode
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-5-11
OPERATIONAL PERFORMANCE TEST / Component Test
Main Relief Pressure Setting Adjustment Proce-
dure Main Relief
Valve
Adjustment:
Adjust the pressure setting of the main relief valve
using plug (3) (for the low-side relief pressure set-
ting) and plug (5) (for the high-side relief pressure
setting).
2. Loosen lock nut (4). Turn plug (5) to adjust the M178-05-003
4
2
T157-05-04-009
Plug (5, 3)
Pressure Pressure
Increase Decrease
W107-02-05-127
T4-5-12
OPERATIONAL PERFORMANCE TEST / Component Test
• Low-Side Relief Pressure Setting Adjustment
Procedure
1. Loosen lock nut (1). Turn plug (3) counter clock-
wisely until the specified value is obtained refer-
ring to the table below. Retighten lock nut (1).
: 27 mm
: Lock Nut (1):
59 to 68 N⋅m
(6 to 7 kgf⋅m, 43 to 51 lbf⋅ft)
T4-5-13
OPERATIONAL PERFORMANCE TEST / Component Test
RELIEF PRESSURE (When relieving
Swing)
ZX200 class, 225 class, 230 class
Adjust pressure by changing the number of shims
(2).
T4-5-14
OPERATIONAL PERFORMANCE TEST / Component Test
ZX270 class Swing Relief
Valve
Adjustment
Loosen lock nut (2) to release adjusting screw (1).
T107-02-04-020
Up to serial No.20037
Adjusting Screw Up to serial No.20037
1/4 1/2 3/4 1
Turns 1 2
Change MPa 2.9 5.8 8.7 11.7
in (kgf/cm2) (30) (59.5) (89) (119)
Pressure (psi) (430) (850) (1270) (1690)
T157-02-04-006
Pressure Pressure
Increase Decrease
T157-05-04-023
T4-5-15
OPERATIONAL PERFORMANCE TEST / Component Test
RELIEF PRESSURE (When relieving
Travel)
ZX200 , 225 class, 230 class
1. Remove the travel relief valve.
: 36 mm
3. Install shims (5) between poppet (3) and spring Travel Relief
guide (4) to adjust the set-pressure. Valve
3 4
T135-06-04-001
T4-5-16
OPERATIONAL PERFORMANCE TEST / Component Test
ZX270 class
Adjustment
Loosen lock nut (2) to adjust adjusting screw (1).
: 19 mm
: 6 mm
T157-05-04-008
2 1
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-17
OPERATIONAL PERFORMANCE TEST / Component Test
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary:
1. The circuit pressure must be increased by apply- 3. If the overload relief valve performance must be
ing an external force while blocking the return cir- checked on the machine, however, measure the
cuit from the control valve. This measuring main relief pressure while releasing each front
method is hazardous and the results obtained function respective to the measuring overload re-
with this method are unreliable. lief valve. And, assume that the overload relief
2. The oil flow rate used to set the overload relief valve is functioning correctly if the obtained main
pressure is far less than that used to set the main relief pressure is within the specified value range.
relief pressure. Therefore, measuring the over- Measure the main pressure of the front functions
load pressure in the main circuit by increasing as follows:
the main relief set-pressure more than the over-
load valve set-pressure is not a proper method. Preparation:
In addition, in case a main relief valve designed 1. Properly shut down the engine.
to leak a small quantity of oil before reliving is 2. Press the air release valve on top of the hydraulic
used, its pre-leaking start pressure must be in- oil tank to release any remaining pressure.
creased more than the overload relief valve 3. Remove the plug from the main pump delivery
set-pressure. However, the pre-leaking start port. Install adapter (ST 6069), hose (ST 6943)
pressure is not always increased more than the and pressure gauge (ST 6941) on the port.
overload relief valve set-pressure as the adjust- : 6 mm
able upper limit of the main relief valve
set-pressure is provided. Accordingly, the over- 4. Connect Dr.ZX to the machine for main pump de-
load relief valve assembly should be removed livery pressure monitoring.
from the machine and checked on a specified Start the engine. Confirm that no oil leakage is
test stand at a correct oil flow rate. Some over- observed at the pressure gauge connection.
load relief valves come in contact with the control
valve body to block the oil passage. When this 5. Maintain the hydraulic oil temperature at 50±5 °C
type of overload relief valve is checked, the con- (122±9 °F).
trol valve body must be precisely finished as the
test unit. Provide one control valve other than
that on the machine as a test kit.
T4-5-18
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Digging
Fast Idle P Mode OFF
Mode
Evaluation:
1. Performance of the overload relief valves are
normal if the measured main relief pressures are T157-05-04-005
T4-5-19
OPERATIONAL PERFORMANCE TEST / Component Test
Overload Relief Valve Set Pressure Adjusting
Procedure
Adjustment:
Adjust the pressure setting of the overload relief
valve using adjusting screw (2) after loosening lock 1
nut (1).
W107-02-05-129
T4-5-20
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)
T4-5-21
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN PUMP FLOW RATE MEASUREMENT
• P-Q Control (Torque Control) 5. Install a pressure gauge to the main pump to be
Summary: measured. (Refer to T4-5-9 Main Pump Delivery
Main pump performance is checked by measuring Pressure.)
the pump flow rate with a hydraulic tester installed at : 6 mm
the main pump delivery port (one side) to be meas- 6. Disconnect pipe (13) from the regulator. Connect
ured. Use Dr. ZX and a pressure gauge at the same plug (PF 1/4) to the disconnected pipe.
time. : 17 mm
7. Disconnect the N sensor connector. Connect the
IMPORTANT: This measurement procedure is a pulse counter to the N sensor.
simple method. The measured data 8. Disconnect the vacuum pump. Loosen plug (12)
will be lower by approx. 5 % than on top of the pump casing to bleed air from the
the accurately measured value. To main pump until oil only comes out of the plug
measure accurately, disconnect the clearance.
return circuit from the control valve 9. Fully open the loading valve of the hydraulic
and connect it to the hydraulic oil tester.
tank. 10. Start the engine. Check the pressure gauge con-
nection for any oil leaks. Install Dr. ZX and select
Preparation: the monitor function.
1. Stop the engine. Push the air bleed valve to
bleed air. Connect a vacuum pump to the oil filler Measurement:
port. 1. Maintain the hydraulic oil temperature at 50±5 °C
NOTE: Operate the vacuum pump while connect- (122±9 °F).
ing the pump flow rate test line. 2. Measure the maximum flow rate.
2. Disconnect the delivery hose from the main 3. Select each switch position as follows:
pump (one side) to be measured. Connect pipe Auto-Idle /
Engine Power Mode Work Mode
(1 or 2) to the pump delivery port using the split Acceleration
Control Dial Switch Switch
flanges and bolts which were used to connect the Selector
disconnected delivery hose. Digging
Fast Idle P Mode OFF
: 41 mm : 10 mm Mode
3. Connect hose (1 or 2) to hydraulic tester (5) us-
ing test hose (3) and adapter (4). Connect 4. Adjust the main relief valve set-pressure in the
adapter (6), joint (7), test hose (8) and flange (9) control valve to each pressure point specified
to hydraulic tester (5). along the main pump P-Q curve. (Refer to
: 41 mm : 10 mm T4-2-22) Slowly close the loading valve of the
4. Connect the delivery hose to flange (9) with split hydraulic tester while relieving the pressure in the
flanges (10) and bolts (11). arm roll-in circuit. Measure the flow rates and en-
: 10 mm gine speeds at the pressure points specified in
the P-Q curve.
5. Repeat each measurement three times and cal-
culate the average values.
T4-5-22
OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified pump speed using the following formu- Refer to T4-2 Operational Performance Standard.
las: NOTE: When actually measuring, install pipe (1 or
2) only to the pump to be measured.
Qc = (Ns × Q) ⁄ Ne
1, 2 3 4 5 6 7 8 9 10 11
T173-04-04-002
13
N Sensor
T178-03-01-001
12
1 - Pipe E (ST 6144) 5 - Hydraulic Tester (ST 6299) 8- Test Hose (ST 6320) 11 - Bolt (ST 6409) (4 used)
2 - Pipe B (ST 6143) 6 - Adapter PF1 × UNF1-7/8 9- Flange (ST 6118) 12 - Plug
(ST 6146)
3 - Test Hose (ST 6145) 7 - Joint (ST 6330) 10 - Split Flange (ST 6130) 13 - Pipe
4 - Adapter PF1 × UNF1-7/8
(ST 6146)
T4-5-23
OPERATIONAL PERFORMANCE TEST / Component Test
•Pilot Characteristics
Summary:
Main pump performance is checked by measuring 5. Connect hose (19) to port T on reducing valve
the pump flow rate with a hydraulic tester installed at (16). Connect adapter (20) to the other end of
the main pump delivery port (one side) to be meas- hose (19). Remove plug L from the return pipe.
ured. Use Dr. ZX and a pressure gauge at the same Connect hose (19) to the plug L port.
time. : 19 mm, 22 mm
6. Disconnect pipe (21) from the regulator. Connect
IMPORTANT: This measurement procedure is a plug (PF 1/4) to the disconnected pipe.
simple method. The measured data : 17 mm
will be lower by approx. 5 % than 7. Disconnect the N sensor connector. Connect the
the accurately measured value. To pulse counter to the N sensor.
measure accurately, disconnect the 8. Disconnect the vacuum pump. Loosen the plug
return circuit from the control valve from the top of the pump casing. Bleed air from
and connect it to the hydraulic oil the casing until oil only comes out of the plug
tank. clearance.
9. Fully open the loading valve of the hydraulic
Preparation: tester.
1. Referring to steps 1 to 4 on page T4-5-22, con- 10.Start the engine. Check the line connections for
nect a hydraulic tester to the main pump to be any oil leaks.
measured.
2. Disconnect the hose from regulator port Pi of the
pump to be measured. Connect plug (ST 6213)
to the disconnected hose.
: 6 mm, 19 mm
3. Install adapters (15) (3 used) to reducing valve
(16). Remove plug M from the pilot filter. Then,
install adapter (13) and hose (14) to the pilot filter.
Connect the other end of hose (14) to regulator
port P1 on reducing valve (16).
: 19 mm
4. Install tee (17) to port P2 on reducing valve (16).
Connect pressure gauge (18) and hose (14) to
tee (17). Connect hose (14) to the regulator.
: 19 mm
T4-5-24
OPERATIONAL PERFORMANCE TEST / Component Test
1, 2 3 4 5 6 7 8 9 10 11
T173-04-04-002
21 Port Pi
Plug M
N Sensor
12 T178-03-07-001
T178-03-01-001
T L
20
18
P1 P2 19
15
14 17 15 16 15 14 13
T178-04-04-004
1 - Pipe E (ST 6144) 7 - Joint (ST6330) 12 - Plug M 17 - Tee UNF7/16 × UNF7/16×
PF1/4
(ST 6451)
2 - Pipe B (ST 6143) 8 - Test Hose (ST 6320) 13 - Adapter UNF7/16 × PF1/4 18 - Pressure Gauge
(ST 6069) (ST 6931)
3 - Test Hose (ST 6145) 9 - Flange (ST 6118) 14 - Hose U UF7/16 × UNF7/16 19 - Hose UNF7/16 × UNF7/16
(4334309) (4334309)
4 - Adapter PF1 × UNF1-7/8 10 - Split Flange (ST 6130) 15 - Adapter PF3/8 × UNF7/16 20 - Adapter PF3/8 × UNF7/16
(ST 6146) (4200465) (4200465)
5 - Hydraulic Tester (ST 6299) 11 - Bolt (ST 6409) (4 used) 16 - Reducing Valve (4325439) 21 - Pipe
6 - Adapter PF1 × UNF1-7/8
(ST 6146)
T4-5-25
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Maintain the hydraulic oil temperature at 50±5 °C Evaluation:
(122±9 °F) 1. Convert the measured flow rates to those at the
2. The pump flow rate in response to the external specified pump speed using the following for-
command pilot pressure is measured. mulas:
3. Select each switch position as follows:
Auto-Idle / Qc = (Ns × Q) ⁄ Ne
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector Qc : Converted Flow Rate
Digging Q : Measured Flow Rate
Fast Idle P Mode OFF Ns : Specified Pump Speed
Mode
4. Adjust the reducing valve set-pressure to each (ZX200 class, 225 class: 1900 min-1)
pressure point specified along the main pump (ZX230 class: 2000 min-1)
P-Q curve. (Pilot Characteristics) (Refer to (ZX270 class: 2050 min-1)
T4-2-23.) Measure the flow rates and engine Ne : Measured Engine Speed
speeds at the pressure points specified in the Pulse Numbers (Hz)×60/34
P-Q curve.
5. Repeat each measurement three times and cal- 2. Standard Flow Rate
culate the average values. Refer to T4-2 Operational Performance Stan-
dard.
NOTE: Both pipes (1 and 2) are illustrated as if
they are installed. When actually measur-
ing, install pipe (1 or 2) only to the pump to
be measured.
T4-5-26
OPERATIONAL PERFORMANCE TEST / Component Test
Regulator Adjustment
6 5 1 2
10
4 3
7 8
T178-03-01-006
1 - Lock Nut (For Minimum 4 - Adjusting Screw (For 7 - Lock Nut 9 - Lock Nut
Flow Adjustment) Maximum Flow Adjust- (For P-Q Line Adjustment) (For P-Q Line Adjustment)
ment)
2 - Adjusting Screw (For 5 - Lock Nut 8 - Adjusting Screw 10 - Adjusting Screw
Minimum Flow Adjustment) (For Pilot Pressure Char- (For P-Q Line Adjustment) (For P-Q Line Adjustment)
acteristic Adjustment)
3 - Lock Nut (For Maximum 6 - Adjusting Screw
Flow Adjustment) (For Pilot Pressure Char-
acteristic Adjustment)
Pi
2. Maximum Flow Rate Loosen lock nut (3) and turn 1) Do not turn the adjusting screw
adjusting screw (4). more than two turns.
Q Rotating adjusting screw (4) 1/4 2) Do not increase the maximum flow
a turn clockwise decreases the rate.
maximum pump flow rate by In other words, do not turn the ad-
7.14 cm3/rev. (0.44 in3/rev). justing screw counterclockwise. In-
: 13 mm creasing the maximum flow rate
: 9.8 N⋅m (turning the adjusting screw coun-
(1 kgf⋅m, 7.2 lbf⋅ft) terclockwise), however, will be re-
quired after adjusting the pilot pres-
sure characteristics.
3) Securely retighten lock nut (3) after
Pd the adjustment.
T4-5-27
OPERATIONAL PERFORMANCE TEST / Component Test
4. P-Q Control A: Loosen lock nut (7) and turn 1) Do not turn the adjusting screws
(Torque Adjustment) adjusting screw (8). more than one turn.
Rotating adjusting screw (8) 2) Rotate the adjusting screws watch-
Q 1/4 a turn clockwise increases ing the engine performance.
the maximum pump flow rate 3) Securely retighten lock nut (7) or (9)
A by 13.43 cm3/rev. after the adjustment.
(0.82 in3/rev.).
B: Loosen lock nut (9) and turn
adjusting screw (10).
Rotating adjusting screw (10)
1/4 a turn clockwise increases
Pd the maximum pump flow rate
by 2.36 cm3/rev. (0.14 in3/rev).
Q
Pd
T4-5-28
OPERATIONAL PERFORMANCE TEST / Component Test
SWING MOTOR DRAINAGE
Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while
swinging the upperstructure.
1
CAUTION: Prevent personal injury. Always
make sure that the area is clear and that
co-workers are out of the swing area before
starting the measurement.
Also, take care not to fall off the machine
while the measurement.
Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F). Rotate the swing motor to warm the
inside of the motor.
T157-05-04-014
2. Properly shut down the engine. Press the air re-
lease valve (1) on top of the hydraulic oil tank to
release any remaining pressure.
2
3. Disconnect the swing motor drain hose (2) at the
hydraulic oil tank end. Install plug (ST 6213) to
the disconnected end on the hydraulic oil tank.
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
T178-04-04-005
T4-5-29
OPERATIONAL PERFORMANCE TEST / Component Test
Preconditions for Measurement:
1. Select the following switch positions:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Digging
Fast Idle P Mode OFF
Mode
Measurement:
1. Amount of Oil Drained While Swinging the Up- The same height as
perstructure boom foot pin height
(1) Fully retract the arm cylinder. Fully extend the
T105-06-03-013
bucket cylinder. Raise the boom so that the
arm tip pin height is the same as the boom
foot pin height. Be sure that the bucket is
empty.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start draining oil measure-
ment after the swing speed reaches a con-
stant maximum speed. The measuring time
should be more than 45 seconds.
(3) Repeat the measurement at least three times
in both clockwise and counterclockwise direc-
tions, and calculate the average values.
T4-5-30
OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
∆Q = 60 × q / t
Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L) T107-06-05-008
T4-5-31
OPERATIONAL PERFORMANCE TEST / Component Test
TRAVEL MOTOR DRAINAGE
Summary:
To check travel motor performance, measure the
amount of oil draining from the travel motor while
rotating the travel motor with the measuring side
track jacked up.
Preparation:
1. Main hydraulic oil temperature at 50±5 °C
(122±9 °F). Rotate the travel motor to warm the
inside of the motor.
T157-05-04-010
T4-5-32
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Amount of Oil Drained While Rotating Travel
Motor
(1) Start the engine. Jack up the measuring side
track using the front attachment, as illus-
trated. 90 to 110°
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
∆Q = 60 × q / t
Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-33
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)
T4-5-34
OPERATIONAL PERFORMANCE TEST / Adjustment
ENGINE SPEED ADJUSTMENT AND
ENGINE LEARNING
After removing and/or replacing the components as
described below for repair and/or inspection, or if error
in engine speed is found, readjust engine speed and
perform engine learning.
5. Loosen the bolt holding the control lever to the EC Holding Bolt
motor output shaft.
Control Lever T157-07-04-015
6. While monitoring the actual engine speed with Dr.
ZX or the engine speed meter, adjust the control
lever so that the minimum speed (slow idle)
matches the specification.
Specification: Refer to T4-2 OPERATIONAL PER
FORMANCE TEST.
T4-6-1
OPERATIONAL PERFORMANCE TEST / Adjustment
Engine Learning:
1. Turn the key switch OFF
Learning
NOTE: In case the engine doesn’t stop when the Switch
key switch is turned OFF, pull the handle
located under the seat to stop the engine.
Dr.ZX
2. Disconnect Dr. ZX. Wait for 5 seconds. Connector
to MC
3. Turn the learning switch ON.
225 class
(ZAXIS225US)
T1SM-01-02-006
Learning Switch Dr.ZX Connector
to MC
Learning Switch is
Turned to Stamp E
Learning Switch
Stamp
T1CC-05-01-001
T4-6-2
OPERATIONAL PERFORMANCE TEST / Adjustment
(Blank)
T4-6-3
OPERATIONAL PERFORMANCE TEST / Adjustment
GOVERNOR LEVER AND FUEL CUT
LEVER POSITION
1 2 3 4
T105-07-04-003
1 - Governor Cable (From EC Motor)
2 - Fuel Cut-Off Cable
(Fuel Cut-Off Handle)
3 - Fuel Cut Lever
4 - Governor Lever
T4-6-4
OPERATIONAL PERFORMANCE TEST / Adjustment
• Governor Lever Position
A B
STOP FULL
FULL
T105-07-04-003
STOP
A
B
T105-07-04-003
T4-6-5
OPERATIONAL PERFORMANCE TEST / Adjustment
(Blank)
T4-6-6
SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 General Group 3 Troubleshooting A
Introduction ............................................... T5-1-1 Troubleshooting A Procedure ....................T5-3-1
Diagnosing Procedure .............................. T5-1-2 Fault Code List ..........................................T5-3-2
Built-In Diagnosing System Operation ...... T5-1-6 Fault Code 01, 02, 03................................T5-3-3
Built-In Diagnosing Function Display List .. T5-1-7 Fault Code 04............................................T5-3-3
Dr. ZX Operation ....................................... T5-1-8 Fault Code 06............................................T5-3-4
Dr. ZX Fault Code List............................. T5-1-10 Fault Code 07............................................T5-3-5
Dr. ZX Monitoring Item List ..................... T5-1-12 Fault Code 08............................................T5-3-6
Dr. ZX Special Function .......................... T5-1-14 Fault Code 10, 11 ......................................T5-3-7
Dr. ZX Service Mode............................... T5-1-15 Fault Code 12, 13......................................T5-3-8
Adjustment Data List............................... T5-1-25 Fault Code 14, 15, 16, 18..........................T5-3-9
Initial Setting of Boom Electronic Fault Code 19..........................................T5-3-10
Cushion................................................. T5-1-27
Group 4 Troubleshooting B
Group 2 Component Layout Troubleshooting B Procedure ....................T5-4-1
Main Component Layout ........................... T5-2-1 Relationship between Machine Trouble
Electrical Component Layout (Overview) .. T5-2-4 Symptoms and Related Parts ..................T5-4-2
Electrical System Correlation between Trouble
(Relays and Related Equipment) ............ T5-2-7 Symptoms and Part Failures .................T5-4-24
Electrical System Engine System Troubleshooting ..............T5-4-37
(Monitors and Switches).......................... T5-2-9 All Actuator System Troubleshooting .......T5-4-58
Pump Device .......................................... T5-2-10 Front Attachment System
Swing Device .......................................... T5-2-10 Troubleshooting.....................................T5-4-67
Control Valve .......................................... T5-2-11 Swing System Troubleshooting ...............T5-4-82
Signal Control Valve................................ T5-2-11 Travel System Troubleshooting ...............T5-4-87
Solenoid Valve Unit................................. T5-2-11 Other System Troubleshooting ................T5-4-94
Travel Device .......................................... T5-2-12 Exchange Inspection ............................. T5-4-114
Positioning Control Valve ........................ T5-2-12 Emergency Boom Lowering
Components in Control Valve.................. T5-2-14 Procedure............................................ T5-4-116
Signal Control Valve
Port Location......................................... T5-2-26
178T-5-1
Group 5 Troubleshooting C Group 7 ICX
Troubleshooting C Procedure ................... T5-5-1 Outline ......................................................T5-7-1
Malfunction of Coolant ICX Fault Code List ...................................T5-7-8
Temperature Gauge ................................ T5-5-2 Satellite Terminal Fault Code List ..............T5-7-8
Malfunction of Fuel Gauge ........................ T5-5-4 Fault Code 1 to 4 and 6.............................T5-7-9
Malfunction of Indicator Light Fault Code 7 to 10.....................................T5-7-9
Check System ......................................... T5-5-6 Some Parts of Data in Daily Report,
Malfunction of Preheat Indicator ............... T5-5-7 Frequency Distribution, Cumulative
Malfunction of Engine Oil Level Operation Hours are not Recorded........T5-7-10
Indicator .................................................. T5-5-8
Malfunction of Coolant Level
Indicator ................................................ T5-5-10
Malfunction of Alternator Indicator .......... T5-5-12
Malfunction of Engine Oil Pressure
Indicator ................................................ T5-5-14
Malfunction of Overheat Indicator ........... T5-5-16
Malfunction of Air Filter Restriction
Indicator ................................................ T5-5-18
Malfunction of Buzzer ............................. T5-5-20
Malfunction of LCD ................................. T5-5-22
Malfunction of Hour Meter....................... T5-5-23
Malfunction of Hydraulic Oil Filter
Indicator (Optional) ............................... T5-5-24
178T-5-2
TROUBLESHOOTING / General
INTRODUCTION
Refer to the inspection and troubleshooting proce- • Troubleshooting B (base machine diagnosis start-
dures after any machine trouble has occurred. The ing with inspection of abnormal operational
inspection and troubleshooting procedures are pre- status)
sented in an orderly fashion in this section to quickly Refer to these procedures when no fault codes
find the cause of the machine trouble and solution. are displayed after diagnosing the machine with
Dr. ZX (or the built-in diagnosing system). Trace
The troubleshooting section in this manual consists of the cause of trouble based on the inspected re-
7 groups; General, Component Layout, Troubleshoot- sult of the abnormal symptom.
ing A (base machine diagnosis using fault codes),
Troubleshooting B (base machine diagnosis starting Example: Even if the engine control dial is oper-
with inspection of abnormal operational status), Trou- ated, engine speed remains unchanged.
bleshooting C (monitor diagnosis), Electrical System
Inspection, and ICX. • Troubleshooting C (monitor diagnosis)
Refer to these procedures when gauges and/or
• General indicators are malfunctioning.
T5-1-1
TROUBLESHOOTING / General
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient
troubleshooting:
T5-1-2
TROUBLESHOOTING / General
3. Inspect the machine
Before starting the troubleshooting procedure,
check the machine’s daily maintenance points, as
shown in the operator's manual.
T5-1-3
TROUBLESHOOTING / General
5. Perform troubleshooting
CAUTION: Never attempt to disconnect
harnesses or hydraulic lines while the engine
is running. The machine may malfunction or
pressurized oil may spout, possibly resulting
in personal injury. Be sure to stop the engine
before disconnecting harnesses or hydraulic
lines.
T5-1-4
TROUBLESHOOTING / General
(Blank)
T5-1-5
TROUBLESHOOTING / General
BUILT-IN DIAGNOSING SYSTEM OPERA-
TION
IMPORTANT: This system is to be operated by the
HITACHI Dealer Only. Don’t explain
this system function to the cus-
tomer.
T5-1-6
TROUBLESHOOTING / General
BUILT-IN DIAGNOSING FUNCTION DISPLAY LIST
Display
Description Monitored Result Unit Remarks
Order
1 Hour Meter {{{{{ h Standard Mode
2 Trip 1 {{{{{ h Standard Mode (Subtraction)
3 Trip 2 {{{{{ h Standard Mode (Subtraction)
-1
4 Engine Actual Speed n {{{{ min User Mode (Required to set
in the Dr. ZX service mode)
5 Hydraulic Oil Tempera- {{{ °C User Mode (Required to set
ture in the Dr. ZX service mode)
6 L1 {{{ - Display Purpose Only
7 Overload Alarm L2 {{{ % European Spec. Only
8 Fault Code* 0 {{ - Possible to display
9 ML Switch** 1 {{ 0: Switch OFF Possible to display
1: Switch ON
10 Pump 1 Delivery Pres- 2 {{ MPa Possible to display
sure
11 Pump 2 Delivery Pres- 3 {{ MPa Possible to display
sure
12 Pump 1 Pump (Flow) 4 {{ MPa Possible to display
Control Pressure
13 Pump 2 Pump (Flow) 5 {{ MPa Possible to display
Control Pressure
-1
14 Engine Target Speed 6 {{ min Possible to display
15 EC Angle 7 {{ V Possible to display
16 Dial Angle 8 {{ V Possible to display
17 Boom Raise Pilot Pres- 9 {{ MPa Possible to display
sure
18 Arm Roll-In Pilot Pres- A {{ MPa Possible to display
sure
19 Swing Control Pilot b {{ MPa Possible to display
Pressure
20 Travel Control Pilot c {{ MPa Possible to display
Pressure
21 Front Att. Operation d {{ 0: Not Operating Possible to display
1: Operating
22 Att. Control Pressure E {{ MPa Possible to display
23 Work Mode F {{ 0: Digging Possible to display
1: Breaker
2: Secondary
Crusher
(Demolisher)
3: Crusher
4: Vibro-Hammer
T5-1-7
TROUBLESHOOTING / General
Dr. ZX OPERATION Except ZAXIS225US:
Rear Console
Dr. ZX is a troubleshooting tool to diagnose the elec- Fuse Box
tronic control system including the MC (main Control-
ler) and ICX (Information Controller). When Dr. ZX is Dr. ZX
connected to either the MC or the ICX, it displays Connector
whether the controllers and sensors operate normally (MC)
in the form of fault codes (Self-Diagnosing Result Dis-
play Function).
In addition, Dr. ZX can display the inputs from sensors
and switches to the MC and/or the outputs to actua-
tors such as solenoid valves from the MC in real time
while operating the machine (Monitor Display Func-
tion).
ZAXIS225US:
Fuse Box
Dr. ZX
Dr. ZX Connector Connector
(ICX) (MC)
(Located at Back-
side of Sheet) T1SM-01-02-006
Palm
(Dr. ZX)
Battery Box
Cable
T178-05-01-167
T5-1-8
TROUBLESHOOTING / General
Operation
1. Connect palm (Dr. ZX) to the diagnosis connec-
tors (MC and ICX) located in the cab, using Hot Start
Sync cable and battery box cable.
Self-diagnostic
Result by control- Enter model
ler is displayed Record
code and serial
No.
Retry B
Select data to
be monitored
Self-diagnostic
Result is displayed Monitored data
is displayed
T5-1-9
TROUBLESHOOTING / General
DR. ZX FAULT CODE LIST
T5-1-10
TROUBLESHOOTING / General
(Blank)
T5-1-11
TROUBLESHOOTING / General
DR. ZX MONITORING ITEM LIST
DR. ZX displays the input signals from the switches
and sensors to the MC and the control signals to the
actuators from the MC.
T5-1-12
TROUBLESHOOTING / General
Optional
Item Data Unit
Optional Pump 3 Delivery Pressure Input signal from pump 3 delivery pressure sen- MPa
sor
Boom Cylinder Bottom Pressure MPa
Boom Cylinder Rod Pressure MPa
Arm Roll-Out Pilot Pressure Input signal from pressure sensor (arm roll-out) MPa
ATT. Control Pressure Input signal from pressure sensor (auxiliary) MPa
Boom Angle V
Arm Angle V
Pump 1 Max. Displacement cm3
*Boom Dampener Switch OFF, SOFT, HARD
Pump 1 Proportional Solenoid Valve Control signal to pump 1 flow rate control sole- MPa
Output noid valve
ATT. Proportional Solenoid Valve MPa
Output
*Boom Dampener Proportional Valve MPa
Output
Travel/Swing/Load Alarm Tr, Sw, Load
Initial **ML Setting Unf, Done, Abrt,
Und
Initial Boom-Angle Setting Unf, Done, Abrt,
Und
NOTE: ML specification is only available in Japa- NOTE: *** Available for ZAXIS225US
nese domestic market. (Up to serial No. 104908).
* Available for only ZX200 class and **** Available for ZX200, 225 class
ZAXIS225USR. (Up to serial No.104678) and
** Initial boom electronic cushion setting is ZX230 class (Up to serial No. 010326)
also possible in this item for and ZX270 class (Up to Serial
ZAXIS225US (Up to serial No. 104908). No 020042).
T5-1-13
TROUBLESHOOTING / General
Dr. ZX SPECIAL FUNCTION
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS200.
T178-05-01-013 T178-05-01-168
Fig. A Fig. B
Select ESC to return
to Fig. A.
Special function
Execute Execute
T5-1-14
TROUBLESHOOTING / General
Dr. ZX SERVICE MODE
Except ZAXIS225US
Dr. ZX has three (3) modes, learning value display, Engine
parameter change, and monitor display information Learning
Switch
setting.
Stamped
Mark E
T1CC-05-01-001
T5-1-15
TROUBLESHOOTING / General
Item Data
Learning Data Display
EC Motor Stop Position Display of the engine stop value in engine learning
EC Motor Maximum Speed Position Display of max. engine speed valve in engine learning
Boom Angle Sensor Correction Value Display of boom angle sensor correction value
Arm Angle Sensor Correction Value Display of arm angle sensor correction value
Parameter Change
Li Speed Adjustment Adjustment of minimum engine speed
WU Speed Adjustment Adjustment of warming up engine speed
AI Speed Adjustment Adjustment of auto-idle engine speed
E Speed Adjustment Adjustment of E-mode engine speed
P Speed Adjustment Adjustment of P-mode engine speed
Breaker Engine Speed Adjustment Adjustment of breaker operation engine speed
Secondary Crusher (Demolisher) Engine Adjustment of secondary crusher (demolisher) operation
Speed Adjustment engine speed
Crusher Engine Speed Adjustment Adjustment of crusher operation engine speed
Vibro-Hammer Speed Adjustment Adjustment of vibratory hammer operation engine speed
Hyd. Breaker P1 Max Swash Angle Adjustment of lowest pump 1 max. flow rate in breaker
Adjustment operation
Secondary Crusher (Demolisher) P1 Max Adjustment of lowest pump 1 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P1 Max Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in crusher
operation
Vibro P1 Max Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in vibratory
hammer operation
Hyd. Breaker P2 Max Swash Angle Adjustment of lowest pump 2 max. flow rate in breaker
Adjustment operation
Secondary Crusher (Demolisher) P2 Max Adjustment of lowest pump 2 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P2 Max Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in crusher
operation
Vibro P2 Max Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in vibratory
hammer operation
Pump PQ Base Torque Correction Adjustment of pump P-Q curve
ATT Proportional Solenoid Valve Adjustment Adjustment of optional solenoid valve
T5-1-16
TROUBLESHOOTING / General
Item Data
Boom Lower Dampener Proportional Adjustment of solenoid valve
Solenoid Valve Adjustment
ATT Speed Increase Down Waiting Time Setting of time required for engine speed increase
**ATT Torque Down ON/OFF ON/OFF of torque down control, when a front attachment is
operated.
*ML Crane Front Code Change Setting of front att. code for ML models
*ML Crane Bucket Code Change Setting of bucket code for ML models
Max. *ML Crane Speed Adjustment Setting of engine speed in crane mode
*ML Crane Bucket Weight Adjustment
Min, Boom CYL. Bottom Pressure Over
Balance
Monitor Display Change
Engine Actual Speed Display/Non-display Monitor setting of display/no-display of actual engine speed
Hydraulic Oil Temperature Display/No-display Monitor setting of display/no-display of hydraulic oil
temperature
Hydraulic Oil Filter LED Display/No-display Monitor setting of ON/OFF of hydraulic oil filter LED.
NOTE: * ML specification is only available in Japanese domestic market.
** Available for ZX200 class and ZX225 class.
T5-1-17
TROUBLESHOOTING / General
Displaying Engine Learning Data and Angle Sensor Correction Valve
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS200.
T5-1-18
TROUBLESHOOTING / General
EC Motor stop position EC Motor Maximum Boom angle sensor Arm angle sensor correction
engine speed position correction value value
T5-1-19
TROUBLESHOOTING / General
Changing Parameters In The Controller
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS200.
Start the service mode on the condition that the engine learning switch is turned on.
To change the parameter, it is necessary to enter the password. To change the password, refer to the “Changing the password”
section.
The menu will be displayed. Enter the password to change Select the item you want to change. The
Select Parameter Change from the parameter. up- and down-arrow buttons can be
the menu. used to scroll through the item list.
Fig. F
Fig. E T178-05-01-042
T178-05-01-043
Fig. G
Select ESC to return T178-05-01-044
Select ESC to return to Fig. E. Select ESC to return
to Fig. D. to Fig. E.
T5-1-20
TROUBLESHOOTING / General
Enter the new value Confirm the new value Parameter adjustment
result
Enter the new value in the The new value will be displayed
The adjusted value will be
Adjustment space, and press in the Adjustment space. Select
displayed.
Execution. Execute to change to this value.
T5-1-21
TROUBLESHOOTING / General
Changing The User Mode Display on The Monitor Panel
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS200.
Start the service mode on the condition that the engine learning switch is turned on.
T5-1-22
TROUBLESHOOTING / General
T5-1-23
TROUBLESHOOTING / General
T5-1-24
TROUBLESHOOTING / General
ADJUSTMENT DATA LIST
T5-1-25
TROUBLESHOOTING / General
T5-1-26
TROUBLESHOOTING / General
INITIAL SETTING OF BOOM ELECTRONIC
CUSHION
(Available on the ZAXIS225US (Serial No.104908
and earlier).) Monitor:
displayed on LCD.
6. Turn the learning switch to neutral. Engine Learning Switch:
If the initial setting is completed, L2 84 is
displayed on LCD.
7. Turn the key switch OFF.
NOTE: If fault code as the table in next page is
displayed, be sure to perform the initial
setting of the boom electronic cushion
again after curing the problem.
Initial Setting
of Boom
Electronic
Cushion Side
T1SM-01-02-006
Engine
Learning
Switch
T5-1-27
TROUBLESHOOTING / General
T5-1-28
TROUBLESHOOTING / Component Layout
MAIN COMPONENT LAYOUT
ZX200 class, 230 class, 270 class
1
3
4
5
6
7
8
9
21
10
11
12
20 13
14
15
19 16
18
17 T178-01-02-001
1- Bucket Cylinder 7- Fuel Tank 13- Intercooler 19- Pilot Shut-Off Valve
2- Arm Cylinder 8- Hydraulic Oil Tank 14- Radiator 20- Travel Pilot Valve
3- Boom Cylinder 9- Control Valve 15- Oil Cooler 21- Front Attachment/Swing
Pilot Valve
4- Center Joint 10- Pilot Filter and Pilot Relief Valve 16- Battery
5- Swing Bearing 11- Pump Device 17- Travel Device
6- Swing Device 12- Engine 18- Signal Control Valve
T5-2-1
TROUBLESHOOTING / Component Layout
ZAXIS225US
3
4
5
6
7
8
9
21
18
20
19
10
18
11
17
16 12
13
15 14 T1GF-01-02-001
1 - Bucket Cylinder 7 - Hydraulic Oil Tank 13 - Oil Cooler 19 - Pilot Shut-Off Valve
2 - Arm Cylinder 8 - Swing Device 14 - Intercooler 20 - Travel Pilot Valve
3 - Boom Cylinder 9 - Pump Device 15 - Battery 21 - Boom Electronic Cushion
Solenoid Valve*
4 - Signal Control Valve 10 - Pilot Filter and Pilot Relief 16 - Fuel Tank
Valve
5 - Control Valve 11 - Engine 17 - Center Joint
6 - Solenoid Valve Unit 12 - Radiator 18 - Front Attachment/Swing
Pilot Valve
T5-2-2
TROUBLESHOOTING / Component Layout
ZAXIS225USR
1
2
3
4
5
6
7
8
20
9
10
11
19
18 12
17 13
14 T1GD-01-02-001
16
15
1 - Bucket Cylinder 6 - Solenoid Valve Unit 11 - Pilot Filter and Pilot Relief 16 - Battery
Valve
2- Arm Cylinder 7- Fuel Tank 12 - Engine 17 - Center Joint
3- Boom Cylinder 8- Hydraulic Oil Tank 13 - Radiator 18 - Pilot Shut-Off Valve
4- Signal Control Valve 9- Swing Device 14 - Oil Cooler 19 - Travel Pilot Valve
5- Control Valve 10 - Pump Device 15 - Inter Cooler 20 - Front Attachment/Swing
Pilot Valve
T5-2-3
TROUBLESHOOTING / Component Layout
ELECTRICAL COMPONENT LAYOUT
(Overview)
18
17
16
15
14
10
13
T5-2-4
TROUBLESHOOTING / Component Layout
ZAXIS225US
• Pump 1 and 2 Delivery Pressure Sensor
• Pump 1 and 2 Control Pressure Sensor
• N Sensor 1 2 3 4 5 6
• Torque Control Solenoid Valve
• Pump 2 Flow Rate Control Solenoid Valve
Refer to the Pump Device group.
9
10
11
12
19
18
17
16
15
13 T1GF-01-02-002
14
• Pressure Sensor (Boom Raise) • Pressure Sensor (Travel) • Pressure Sensor (Front Attachment)
• Pressure Sensor (Arm Roll-In) • Pressure Sensor (Swing) Refer to the Swing Device group.
Refer to the Control Valve group. Refer to the Signal Control
Valve group.
1 - Overheat Switch 6 - Air Cleaner Restriction 11 - Wiper Motor 16 - Hydraulic Oil Temperature
Switch sensor
2 - Coolant Temperature Sen- 7 - Fuel Sensor 12 - Boom Angle Sensor 17 - Engine Oil Level Switch*
sor
3 - Battery Relay 8 - Coolant Level Switch* 13 - Horn 18 - EC Motor and EC Sensor
4 - Glow Relay 9 - Starter Relay 14 - Boom Electronic Cushion
Solenoid Valve
5 - Fusible Link 10 - Battery 15 - Solenoid Valve Unit
T5-2-5
TROUBLESHOOTING / Component Layout
ZAXIS225USR
• Pump 1 and 2 Delivery Pressure Sensor
• Pump 1 and 2 Control Pressure Sensor
• N Sensor 1 2 3 4 5
• Torque Control Solenoid Valve
• Pump 2 Flow Rate Control Solenoid Valve
Refer to the Pump Device group.
6
17
8
9
10
16
15
14
13
12
T1GD-01-02-002
11
• Pressure Sensor (Boom Raise) • Pressure Sensor (Travel) • Pressure Sensor (Front Attachment)
• Pressure Sensor (Arm Roll-In) • Pressure Sensor (Swing) Refer to the Swing Device group.
Refer to the Control Valve group. Refer to the Signal Control
Valve group.
T5-2-6
TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM (Relays and Related Equipment)
Except ZAXIS225US
5
4
Rear Deck 3 6
2
8
9
10
T178-01-02-006
15
14
18 13
17 12
16 11
T178-01-02-007
1- Satellite Terminal ON/OFF 6- Fuse Box 11- Load Damp Relay (R1) 16- Wiper Relay A (R6)
Switch (Satellite Navigation
System Equipped Machines
only)
2- QOS Controller 7- Learning Switch 12- Washer Relay (R2) 17- Wiper Relay B (R7)
3- ICX (Information Controller) 8- Dr. ZX Connector to MC 13- Work Light Relay 2 (R3) 18- Wiper Relay C (R8)
4- MC (Main Controller) 9- Download Connector (Not connected in 14- Work Light Relay 1 (R4)
Satellite Terminal equipped machines)
5- Satellite Terminal (Optional) 10- Dr. ZX Connector to ICX 15- Horn Relay (R5)
T5-2-7
TROUBLESHOOTING / Component Layout
ZAXIS225US
15
4
16
14
17
13
12
11 5
10
T1GF-01-02-003
1, 2 3
6
9 8 7
T1SM-01-02-006
1 - ICX (Information Controller) 6 - Fuse Box 11 - Work Light Relay 1 (R4) 16 - Wiper Relay B (R7)
2 - MC (Main Controller) 7 - Dr. ZX Connector to MC 12 - Work Light Relay 2 (R3) 17 - Wiper Relay C (R8)
3 - Satellite Terminal (Op- 8 - Dr. ZX Connector to ICX 13 - Washer Relay (R2)
tional)
4 - Download Connector 9 - * Learning Switch 14 - Load Dump Relay (R1)
5 - Diode D1, D2, D3, D4 10 - Horn Relay (R5) 15 - Wiper Relay A (R6)
T5-2-8
TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM (Monitors and
Switches)
1 2
20
19
21
18
3
17
22
16 4
15
23
5
14 24
6
13 7
12 8
25
11
9
10
T178-01-02-008
T178-01-01-004
1- Coolant Temperature Gauge 8- Alternator Indicator 15- Digging Mode Indicator 22- Power Mode Switch
2- Fuel Gauge 9- Hydraulic Oil Filter Indicator 16- Attachment Mode Indicator 23- Travel Mode Switch
(Optional)
3- Display Selection Switch 10- Coolant Level Indicator * 17- Liquid Crystal Display 24- Work Light Switch
4- SET Switch 11- Engine Oil Level Indicator * 18- Auto-Idle Indicator 25- Wiper/Washer Switch
5- Work Mode Switch 12- Engine Oil Pressure Indica- 19- Auto-Acceleration Indicator
tor
6- Fuel Level Indicator 13- Preheat Indicator 20- Engine Control Dial
7- Air Filter Restriction Switch 14- Overheat Indicator 21- Auto-Idle/Acceleration Se-
lector
T5-2-9
TROUBLESHOOTING / Component Layout
PUMP DEVICE
9
3 2 1
6
7
8
10
T178-03-01-001
5 4 T178-03-01-003
SWING DEVICE
ZX200 class, 225 class, 230 class ZX270 class 11
11
12
12
T178-03-02-001 T1HG-03-02-003
1- Pump 1 4- Pump 1 Delivery Pressure 7- Torque Control Solenoid Valve 10- N Sensor
Sensor
2- Pump 2 5- Pump 2 Delivery Pressure 8- Pump 1 Control Pressure Sensor 11- Swing Relief Valve
Sensor
3- Pilot Pump 6- Pump 2 Flow Rate Control 9- Pump 2 Control Pressure Sensor 12- Pressure Sensor
Solenoid Valve (Front Attachment)
T5-2-10
GENERAL / Component Layout
CONTROL VALVE SOLENOID VALVE UNIT
2
1 Serial No.104679 and up (ZX200 class and 225 class)
Serial No.010327 and up (ZX230 class)
Serial No.020043 and up (ZX270 class)
T178-03-07-005
7 8 9
3
T178-03-03-001
SIGNAL CONTROL VALVE Up to serial No.104678 (ZX200 class and 225 class)
Up to serial No.010326 (ZX230 class)
Up to serial No.020042 (ZX270 class)
6 7 8 9 T178-01-02-003
T178-03-06-015
1 - Main Relief Valve 4 - Pressure Sensor (Swing) 7 - Solenoid Valve Unit (SC) 10 - Solenoid Valve Unit (SG)
2 - Pressure Sensor (Arm 5 - Pressure Sensor (Travel) 8 - Solenoid Valve Unit (SI)
Roll-in)
3 - Pressure Sensor (Boom 6 - Solenoid Valve Unit (SE)*
Raise)
T5-2-11
GENERAL / Component Layout
TRAVEL DEVICE POSITIONING CONTROL VALVE
(2-piece Boom Only)
ZX200 class, 225 class and 230 class ZX200 class
T178-03-03-071
1
T1HD-01-02-001
2
1
3
T178-03-03-068
T1HG-01-02-002
T5-2-12
TROUBLESHOOTING / Component Layout
(Blank)
T5-2-13
TROUBLESHOOTING / Component Layout
COMPONENTS IN CONTROL VALVE
1 2 3 4 5 6 7 8 9 10
36
35
34
33
11
12
13
32 14
31 15
30
16
17
29
28
18
19
20
21
27 22
26
25 24 23
T178-03-03-016
1 - Load Check Valve (Travel 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
Parallel Circuit) Valve (Poppet Valve) (Switch Valve) (Arm: Bottom Side)
2 - Check Valve 11 - Bucket Regenerative Valve 20 - Load Check Valve (Arm 29 - Overload Relief Valve
(Main Relief Circuit) Tandem Circuit) (Arm: Rod Side)
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) (4-Spool Side Parallel Cir- Valve)
cuit)
4 - Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve (Switch
(Main Relief Circuit) (Bucket: Bottom Side) Valve)
5 - Check Valve 14 - Load Check Valve (Boom 1 23 - Arm Flow Rate Control 32 - Load Check Valve (Boom 2
(Flow Combiner Valve Parallel Circuit) Valve (Poppet Valve) Parallel Circuit)
Circuit)
6 - Flow Combiner Valve 15 - Boom Regenerative Valve 24 - Arm Flow Rate Control 33 - Auxiliary Flow Rate Control
Valve (Switch Valve) Valve (Switch Valve)
7 - Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve (Swing 34 - Auxiliary Flow Rate Control
Valve (Boom: Bottom Side) Circuit) Valve (Poppet Valve)
8 - Check Valve 17 - Overload Relief Valve 26 - Check Valve 35 - Load Check Valve (Travel
(Aux. Flow Combiner (Boom: Rod Side) (Arm Regenerative Circuit) Tandem Circuit)
Valve Circuit)
9 - Bucket Flow Rate Control 18 - Boom Anti-Drift Valve 27 - Arm Regenerative Valve 36 - Load Check Valve (Orifice)
Valve (Switch Valve) (Check Valve) (Bucket)
T5-2-14
TROUBLESHOOTING / Component Layout
Front
19
ZX225 class
12
29
3
18
22
35
2
20
14 4
9, 10
Front
ZX200 class
ZX230 class
36 ZX270 class
W178-02-05-017
1 - Load Check Valve (Travel 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
Parallel Circuit) Valve (Poppet Valve) (Switch Valve) (Arm: Bottom Side)
2 - Check Valve 11 - Bucket Regenerative Valve 20 - Load Check Valve (Arm 29 - Overload Relief Valve
(Main Relief Circuit) Tandem Circuit) (Arm: Rod Side)
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) (4-Spool Side Parallel Cir- Valve)
cuit)
4 - Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve (Switch
(Main Relief Circuit) (Bucket: Bottom Side) Valve)
5 - Check Valve 14 - Load Check Valve (Boom 1 23 - Arm Flow Rate Control 32 - Load Check Valve (Boom 2
(Flow Combiner Valve Parallel Circuit) Valve (Poppet Valve) Parallel Circuit)
Circuit)
6 - Flow Combiner Valve 15 - Boom Regenerative Valve 24 - Arm Flow Rate Control 33 - Auxiliary Flow Rate Control
Valve (Switch Valve) Valve (Switch Valve)
7 - Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve (Swing 34 - Auxiliary Flow Rate Control
Valve (Boom: Bottom Side) Circuit) Valve (Poppet Valve)
8 - Check Valve 17 - Overload Relief Valve 26 - Check Valve 35 - Load Check Valve (Travel
(Aux. Flow Combiner (Boom: Rod Side) (Arm Regenerative Circuit) Tandem Circuit)
Valve Circuit)
9 - Bucket Flow Rate Control 18 - Boom Anti-Drift Valve 27 - Arm Regenerative Valve 36 - Load Check Valve (Orifice)
Valve (Switch Valve) (Check Valve) (Bucket)
T5-2-15
TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7 8 9 10
36
35
34
33
11
12
13
32 14
31 15
30
16
17
29
28
18
19
20
21
27 22
26
25 24 23
T178-03-03-016
T5-2-16
TROUBLESHOOTING / Component Layout
Front
ZX225 class
25
31
16
30
23, 24
32
33, 34
26
Front 28
17
ZX200 class
ZX230 class 13
ZX270 class W178-02-05-018
6
1 - Load Check Valve (Travel 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
Parallel Circuit) Valve (Poppet Valve) (Switch Valve) (Arm: Bottom Side)
2 - Check Valve 11 - Bucket Regenerative Valve 20 - Load Check Valve (Arm 29 - Overload Relief Valve
(Main Relief Circuit) Tandem Circuit) (Arm: Rod Side)
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) (4-Spool Side Parallel Cir- Valve)
cuit)
4 - Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve (Switch
(Main Relief Circuit) (Bucket: Bottom Side) Valve)
5 - Check Valve 14 - Load Check Valve (Boom 1 23 - Arm Flow Rate Control 32 - Load Check Valve (Boom 2
(Flow Combiner Valve Parallel Circuit) Valve (Poppet Valve) Parallel Circuit)
Circuit)
6 - Flow Combiner Valve 15 - Boom Regenerative Valve 24 - Arm Flow Rate Control 33 - Auxiliary Flow Rate Control
Valve (Switch Valve) Valve (Switch Valve)
7 - Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve (Swing 34 - Auxiliary Flow Rate Control
Valve (Boom: Bottom Side) Circuit) Valve (Poppet Valve)
8 - Check Valve 17 - Overload Relief Valve 26 - Check Valve 35 - Load Check Valve (Travel
(Aux. Flow Combiner (Boom: Rod Side) (Arm Regenerative Circuit) Tandem Circuit)
Valve Circuit)
9 - Bucket Flow Rate Control 18 - Boom Anti-Drift Valve 27 - Arm Regenerative Valve 36 - Load Check Valve (Orifice)
Valve (Switch Valve) (Check Valve) (Bucket)
T5-2-17
TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7 8 9 10
36
35
34
33
11
12
13
32 14
31 15
30
16
17
29
28
18
19
20
21
27 22
26
25 24 23
T178-03-03-016
H A Cross Section C
B Auxiliary Bucket
I C
D
E
F 12
View K
G
10
J 34
33 9
11
13
M178-05-003
T178-03-03-005
T5-2-18
TROUBLESHOOTING / Component Layout
Cross Section A Cross Section a
5
3
T178-03-03-047
1
Cross Section J
7 6 T178-03-03-044
T178-03-03-003
1 - Load Check Valve (Travel 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
Parallel Circuit) Valve (Poppet Valve) (Switch Valve) (Arm: Bottom Side)
2 - Check Valve 11 - Bucket Regenerative Valve 20 - Load Check Valve (Arm 29 - Overload Relief Valve
(Main Relief Circuit) Tandem Circuit) (Arm: Rod Side)
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) (4-Spool Side Parallel Cir- Valve)
cuit)
4 - Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve (Switch
(Main Relief Circuit) (Bucket: Bottom Side) Valve)
5 - Check Valve 14 - Load Check Valve (Boom 1 23 - Arm Flow Rate Control 32 - Load Check Valve (Boom 2
(Flow Combiner Valve Parallel Circuit) Valve (Poppet Valve) Parallel Circuit)
Circuit)
6 - Flow Combiner Valve 15 - Boom Regenerative Valve 24 - Arm Flow Rate Control 33 - Auxiliary Flow Rate Control
Valve (Switch Valve) Valve (Switch Valve)
7 - Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve (Swing 34 - Auxiliary Flow Rate Control
Valve (Boom: Bottom Side) Circuit) Valve (Poppet Valve)
8 - Check Valve 17 - Overload Relief Valve 26 - Check Valve 35 - Load Check Valve (Travel
(Aux. Flow Combiner (Boom: Rod Side) (Arm Regenerative Circuit) Tandem Circuit)
Valve Circuit)
9 - Bucket Flow Rate Control 18 - Boom Anti-Drift Valve 27 - Arm Regenerative Valve 36 - Load Check Valve (Orifice)
Valve (Switch Valve) (Check Valve) (Bucket)
T5-2-19
TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7 8 9 10
36
35
34
33
11
12
13
32 14
31 15
30
16
17
29
28
18
19
20
21
27 22
26
25 24 23
T178-03-03-016
29 19
27
18
32 25
14
15
26
17
T178-03-03-008
T178-03-03-006
T5-2-20
TROUBLESHOOTING / Component Layout
22
31 16
30
23
20
T178-03-03-009
24
28
T178-03-03-007
1 - Load Check Valve (Travel 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
Parallel Circuit) Valve (Poppet Valve) (Switch Valve) (Arm: Bottom Side)
2 - Check Valve 11 - Bucket Regenerative Valve 20 - Load Check Valve (Arm 29 - Overload Relief Valve
(Main Relief Circuit) Tandem Circuit) (Arm: Rod Side)
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) (4-Spool Side Parallel Cir- Valve)
cuit)
4 - Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve (Switch
(Main Relief Circuit) (Bucket: Bottom Side) Valve)
5 - Check Valve 14 - Load Check Valve (Boom 1 23 - Arm Flow Rate Control 32 - Load Check Valve (Boom 2
(Flow Combiner Valve Parallel Circuit) Valve (Poppet Valve) Parallel Circuit)
Circuit)
6 - Flow Combiner Valve 15 - Boom Regenerative Valve 24 - Arm Flow Rate Control 33 - Auxiliary Flow Rate Control
Valve (Switch Valve) Valve (Switch Valve)
7 - Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve (Swing 34 - Auxiliary Flow Rate Control
Valve (Boom: Bottom Side) Circuit) Valve (Poppet Valve)
8 - Check Valve 17 - Overload Relief Valve 26 - Check Valve 35 - Load Check Valve (Travel
(Aux. Flow Combiner (Boom: Rod Side) (Arm Regenerative Circuit) Tandem Circuit)
Valve Circuit)
9 - Bucket Flow Rate Control 18 - Boom Anti-Drift Valve 27 - Arm Regenerative Valve 36 - Load Check Valve (Orifice)
Valve (Switch Valve) (Check Valve) (Bucket)
T5-2-21
TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7 8 9 10
36
35
34
33
11
12
13
32 14
31 15
30
16
17
29
28
18
19
20
21
27 22
26
25 24 23
T178-03-03-016
21
4
2
T178-03-03-042 T178-03-03-041
T5-2-22
TROUBLESHOOTING / Component Layout
T178-03-03-045
M Cross Section M
35
T178-03-03-046
T178-03-03-048
1 - Load Check Valve (Travel 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
Parallel Circuit) Valve (Poppet Valve) (Switch Valve) (Arm: Bottom Side)
2 - Check Valve 11 - Bucket Regenerative Valve 20 - Load Check Valve (Arm 29 - Overload Relief Valve
(Main Relief Circuit) Tandem Circuit) (Arm: Rod Side)
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) (4-Spool Side Parallel Cir- Valve)
cuit)
4 - Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve (Switch
(Main Relief Circuit) (Bucket: Bottom Side) Valve)
5 - Check Valve 14 - Load Check Valve (Boom 1 23 - Arm Flow Rate Control 32 - Load Check Valve (Boom 2
(Flow Combiner Valve Parallel Circuit) Valve (Poppet Valve) Parallel Circuit)
Circuit)
6 - Flow Combiner Valve 15 - Boom Regenerative Valve 24 - Arm Flow Rate Control 33 - Auxiliary Flow Rate Control
Valve (Switch Valve) Valve (Switch Valve)
7 - Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve (Swing 34 - Auxiliary Flow Rate Control
Valve (Boom: Bottom Side) Circuit) Valve (Poppet Valve)
8 - Check Valve 17 - Overload Relief Valve 26 - Check Valve 35 - Load Check Valve (Travel
(Aux. Flow Combiner (Boom: Rod Side) (Arm Regenerative Circuit) Tandem Circuit)
Valve Circuit)
9 - Bucket Flow Rate Control 18 - Boom Anti-Drift Valve 27 - Arm Regenerative Valve 36 - Load Check Valve (Orifice)
Valve (Switch Valve) (Check Valve) (Bucket)
T5-2-23
TROUBLESHOOTING / Component Layout
2-piece Boom (Optional)
4
T178-03-03-064
3
1 - Load Check Valve 2- Overload Relief Valve 3- Overload Relief Valve 4- Load Check Valve
(Positioning Circuit) (Positioning: Rod Side) (Positioning: Bottom Side) (Positioning Parallel Circuit)
T5-2-24
TROUBLESHOOTING / Component Layout
ZX200 class
X
2
X
3 1 - Section X-X T198-03-03-003
T198-03-03-002
4 D
Section D-D
1 3
T178-03-03-067
T178-03-03-066
T5-2-25
TROUBLESHOOTING / Component Layout
SIGNAL CONTROL VALVE PORT LOCA-
TION
T5-2-26
TROUBLESHOOTING / Component Layout
E
M
D
H
B
F
SB
PI G
K N
I
SH
J
DF
SA L
T178-03-06-016
1 5
13
2 4
SK
SE
14
Control Valve Side
7
9
6
10
SN
SL
11
T5-2-27
TROUBLESHOOTING / Component Layout
T5-2-28
TROUBLESHOOTING / Component Layout
Pilot Valve Side
PH
C
A
E
M
D
H
B
F
SB
PI G
K N
I
SH
J
DF
SA L
T178-03-06-016
1 5
13
2 4
SK
SE
14
Control Valve Side
7
9
6
10
SN
SL
11
T5-2-29
TROUBLESHOOTING / Component Layout
(Blank)
T5-2-30
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault
codes are displayed after diagnosing the main con-
troller (MC) using Dr. ZX (or the built-in diagnosing
system).
YES(OK)
(2)
(1) After completing the checking and/or measuring procedures in box
・ (1) (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
(3)
NO(NOT OK)
・ Refer to “Electrical System Inspection” Group (Group 6) for descriptions in the dotted-line
box.
・ Use Dr. ZX (or the built-in diagnosing system) for descriptions in the double-line box.
・ Causes of machine problems are stated in the thick-line box. Scanning quickly through the
thick-line boxes allows you to estimate the possible causes before actually following the
flow chart.
Harness
Open End
Side
Harness End Connector
T158-05-03-001
T5-3-1
TROUBLESHOOTING / Troubleshooting A
FAULT CODE LIST
Fault code Problem Cause
01 Abnormal EEPROM • Faulty MC
02 Abnormal RAM
03 Abnormal A/D Conversion
04 Abnormal Sensor Voltage • Faulty MC
• Faulty Harness
• Faulty Sensor
06 Abnormal EC Sensor • Faulty MC
• Faulty Harness
• Faulty EC Sensor
07 Abnormal Engine Control Dial Angle • Faulty MC
• Faulty Harness
• Faulty Engine Control Dial
08 Abnormal Boom Angle Sensor • Faulty MC
• Faulty Harness
• Faulty Boom Angle Sensor
10 Abnormal Pump 1 Delivery Pressure • Faulty MC
11 Abnormal Pump 2 Delivery Pressure • Faulty Harness
• Faulty Pump Delivery Pressure Sensor
12 Abnormal Pump1 Pump Control Pressure • Faulty MC
13 Abnormal Pump2 Pump Control Pressure • Faulty Harness
• Faulty Pump Control Pressure Sensor
14 Abnormal Swing Lever Stroke • Faulty MC
15 Abnormal Boom Raise Lever Stroke • Faulty Harness
16 Abnormal Arm Roll-In Lever Stroke • Faulty Pilot Pressure Sensor
18 Abnormal Travel Lever Stroke
19 Abnormal Oil Temperature • Faulty MC
• Faulty Harness
• Faulty Oil Temperature Sensor
T5-3-2
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 01 (ABNORMAL EEPROM)
FAULT CODE 02 (ABNORMAL RAM)
FAULT CODE 03
(ABNORMAL A/D CONVERSION)
Faulty MC.
NO
· Refer to T4-6-1.
* Even if any fault codes are still displayed after re-
trying, as long as the engine and machine operate
normally, the machine can be operated as it is.
FAULT CODE 04
(ABNORMAL SENSOR VOLTAGE)
T5-3-3
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 06
(ABNORMAL EC SENSOR)
C23 C31
#18
EC Sensor
1 2 3
T5-3-4
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 07
(ABNORMAL ENGINE CONTROL DIAL
ANGLE)
Engine Control Dial Specification Connector (Harness End Connector Viewed from the
Minimum Speed 0.3 to 1.0 V Open End Side)
Maximum Speed 4.0 to 4.7 V
MC Connector C
#6
C1 C10
C23 C31
Switch Panel
#4 #3 #2
T5-3-5
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 08
(ABNORMAL BOOM ANGLE SENSOR)
(Up to serial No.104908 (ZAXIS225US))
YES
Check harness be-
tween MC connector C Faulty harness be-
Disconnect boom an- (31 P) harness end tween MC and boom
gle sensor. Check if YES terminal #17 and boom angle sensor.
voltage between har- angle sensor terminal
ness end connector #2 for breakage or
YES short circuit.
terminals #1 and #3 is
5 ±0.5 V. Faulty MC.
NO
Disconnect boom angle
· Refer to T4-6-1.
sensor. Check if resis-
tance between harness
· Key switch: ON Broken harness be-
end connector terminals YES tween MC and boom
#1 and #3 is 5 ±0.5 kΩ. Check if voltage be-
tween boom angle angle sensor terminal
NO sensor harness end #3.
connector terminal #2
and vehicle frame is 5
±0.5 V.
Broken harness be-
tween MC and boom
angle sensor terminal
· Key switch: ON
NO #1.
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
C1 C10
C23 C31
#17
1 2
3
T5-3-6
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 10
(ABNORMAL PUMP 1 DELIVERY PRES-
SURE)
FAULT CODE 11
(ABNORMAL PUMP 2 DELIVERY PRES-
SURE)
Checking Instruction
• Both pump 1 and pump 2 delivery pressure sen-
sors seldom fail at the same time. Accordingly, if
both fault codes 10 and 11 are displayed simulta- Faulty harness be-
neously, faulty harness may be the cause of this Check harness be- tween MC and pump
problem. tween MC connector C delivery pressure
(31P) harness end ter-
YES sensor.
minal #1 (pump 1) or
#4 (pump 2) and pump
YES delivery pressure sen-
sor terminal #2 for
breakage or short cir-
Faulty MC.
cuit.
Disconnect pump de- NO
livery pressure sensor.
Check if voltage be- · Refer to T4-6-1.
tween harness end
NO connector terminals #1 Broken harness be-
and #3 is 5±0.5 V. tween MC and pump
Check if voltage be- delivery pressure
Check if fault codes are tween pump delivery YES sensor terminal #3.
switched after switching pressure sensor har-
pump 1 delivery pressure ness end connector
· Key switch: ON
sensor with pump 2 de- terminal #1 and vehicle
livery pressure sensor frame matches speci-
NO Broken harness be-
and retrying. fication. tween MC and pump
delivery pressure
NO sensor terminal #1.
· Key switch: ON
· Specification: 5±0.5 V Faulty pump delivery
pressure sensor.
YES
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#1 #4
C1 C10
C23 C31
3 2 1
T5-3-7
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 12
(ABNORMAL PUMP 1 CONTROL PRES-
SURE)
FAULT CODE 13
(ABNORMAL PUMP 2 CONTROL PRES-
SURE)
Checking Instruction
• Both pump 1 and pump 2 control pressure sen-
sors seldom fail at the same time. Accordingly, if
both fault codes 12 and 13 are displayed simul-
taneously, faulty harness may be the cause of Check harness be- Faulty harness be-
this problem. tween MC connector C tween MC and pump
(31P) harness end ter- control pressure sen-
minal #7 (pump 1) or
YES sor.
#13 (pump 2) and
pump control pressure
YES sensor terminal #2 for
breakage or short cir-
cuit.
· Key switch: ON
· Specification: 5±0.5 V
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#13 #7
C1 C10
C23 C31
1 2 3
T5-3-8
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 14
(ABNORMAL SWING PILOT PRESSURE)
FAULT CODE 15
(ABNORMAL BOOM RAISE PILOT
PRESSURE)
FAULT CODE 16
(ABNORMAL ARM ROLL-IN PILOT Check harness be-
Faulty harness be-
PRESSURE) tween MC connector C
(31P) harness end tween MC and
FAULT CODE 18 each corresponding
YES pressure sensor.
(ABNORMAL TRAVEL PILOT PRESSURE) terminal and pressure
YES sensor terminal #2 for
Checking Instruction breakage or short cir-
• All pressure sensors seldom fail at the same time. cuit. Faulty MC.
Accordingly, if fault codes 14, 15, 16, and 18 are NO
displayed simultaneously, faulty harness may be · Refer to T4-6-1.
the cause of this problem.
Connector C Terminal:
Disconnect pressure #14: Pressure Sensor (Swing)
sensor. Check if volt- #2: Pressure Sensor
NO age between harness (Boom Raise)
end connector termi- #5: Pressure Sensor
nals #1 and #3 is 5±0.5 (Arm Roll-In)
V. #3: Pressure Sensor
(Travel)
Check if fault code dis-
Broken harness be-
appears after switching
· Key switch: ON tween MC and
pressure sensor with an-
pressure sensor ter-
other pressure sensor Check if voltage be- minal #3.
and retrying. tween pressure YES
sensor harness end
connector terminal #1
and vehicle frame
NO matches specification. Broken harness be-
tween MC and
Fault Code: pressure sensor ter-
14: Pressure Sensor (Swing) NO
minal #1.
15: Pressure Sensor
(Boom Raise) · Key switch: ON
16: Pressure Sensor · Specification: 5±0.5 V
(Arm Roll-In)
18: Pressure Sensor Faulty pressure sen-
(Travel) sor.
YES
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#2 #3 #5
C1 C10
C23 C31
#14
1 2 3
T5-3-9
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 19
(ABNORMAL OIL TEMPERATURE)
· Specification: Refer to
the table below.
Faulty oil temperature
sensor.
NO
Oil Temperature Specification Connector (Harness End Connector Viewed from the Open End Side)
Oil Temperature Resistance
(°C) (kΩ) MC Connector B
−20 16.2±1.6 B8
B1
0 (5.88)
20 2.45±0.24
40 (1.14)
60 (0.534) B19 B25
80 0.322 #22
MC Connector C
C1 C10
C23 C31
#24
1 2
T5-3-10
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code
is displayed on the Dr.ZX (or the built-in diagnosing
system) although the machine’s operation is
abnormal.
On the front section pages of this group T5-4, are
tables indicating the relationship between machine
trouble symptoms and related parts which may cause
such trouble if failed.
Start the troubleshooting with more probable causes
selected by referring to these tables.
YES(OK)
(2)
• After checking or measuring item (1), select either YES (OK) or
・ (1) NO (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO(NOT OK)
・ • Special instructions or reference item are indicated in the spaces under the box.
Incorrect measuring or checking methods will render troubleshooting impossible,
· Key switch: ON and may damage components as well.
• Explanation of how to use test harness kit required. Refer to “Electrical System
・
Inspection” Group (Group 6) in this section.
・ • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
T5-4-1
TROUBLESHOOTING / Troubleshooting B
RELATIONSHIP BETWEEN MACHINE
TROUBLE SYMPTOMS AND RELATED
PARTS
This table indicates the relationship between machine
trouble symptoms and the potential problem parts,
which may cause trouble if failed, and the evaluation
methods of these components.
Parts
EC Motor EC Sensor
• Moves governor. • Detects minimum governor speed position
(2.5 V) only when key switch is turned ON.
• Detects minimum and maximum speed posi-
tion when engine learning is conducted.
Function
• Governor lever doesn’t move. • Engine speed is controlled based on idle posi-
tion set when key switch is turned ON. There-
fore, engine speed is always controlled with
Symptoms in control sys- error in idle position setting if set incorrectly.
tem when trouble occurs.
• Even if engine control dial is turned, engine • Error in setting will seldom occur so that
speed doesn’t increase from slow idle speed. change in machine operation will not be no-
• Engine start may be difficult though starter ticed.
rotates. • In case error is set on lower side, engine
• Engine will stall if discontinuity occurs in EC speed changes but runs slower than normal
motor while engine is running at more than a through the full range when engine control dial
specified speed. is turned. (Note: In case error is set on upper
• Engine will become uncontrollable if disconti- side, EC motor is driven so that it runs faster
nuity occurs in EC motor while engine is run- than the control range. However, motor, a
ning at lower than a specified speed. Engine worm gear type, holds governor lever at
cannot be stopped with key switch. maximum constant position, preventing en-
Symptoms in machine gine stall. When engine control dial is turned
operation when trouble to minimum speed position, governor lever is
returned to idle position.)
occurs. • When starting engine, engine speed fluctu-
ates.
• Starting engine is occasionally difficult.
Others
• Engine is stopped by EC motor. (Engine stop • If EC sensor is faulty, engine learning is not
motor is not provided.) performed.
NOTE Fuel cut-off cable is provided.
T5-4-2
TROUBLESHOOTING / Troubleshooting B
Engine Control Dial Pump Control Pressure Sensor Pump 1 Delivery Pressure Sensor
• Indicates governor lever position (engine • Monitors pump control pressure to con- • Monitors pump delivery pressure to con-
target speed). trol auto-acceleration system and travel trol HP mode, auto-acceleration, slow
motor swash angle controls. speed torque increase, auto power lift
and travel motor swash angle controls.
• Engine speed doesn’t change even if • No signals arrive to MC • If pump delivery pressure sensor output
engine control dial is turned. is 0 or 5 V, following symptoms will be
• If discontinuity or short circuit occurs in presented by back-up mode function.
engine control dial, target speed of 1400
-1
min is used as back-up value.
• Engine speed is kept unchanged from • Auto-acceleration control is inoperable • HP mode is inoperable.
-1
1400 min . (Auto-idle system functions. (but not noticeable). • Auto-acceleration control is inoperable.
Engine can be stopped by key switch.) • Travel speed is kept in slow mode, not • Machine mistakes occasionally when
allowing to automatically change to fast traveling at slow idle speed.
mode. • Boom raise power is weak during dig-
ging operation.
• Travel speed is kept in slow mode, not
allowing to automatically change to fast
mode.
Fault code 07 is displayed. Fault codes 12 and 13 are displayed. Fault codes 10 is displayed.
Monitor Item: Engine Target Speed, Dial Monitor Item: Pump 1 and 2 pump control Monitor Item: Pump 1 delivery pressure
Angle (Displayed by built-in diagnosing pressure (Displayed by built-in diagnostic (Displayed by built-in diagnostic system)
system) system)
• Evaluation by Dr. ZX
Broken Circuit: 0.25 V or less
Short Circuit: 0.75 V or more
T5-4-3
TROUBLESHOOTING / Troubleshooting B
• If pump delivery pressure sensor output is 0 or • Engine stalls if pump torque is increased.
Symptoms in control sys- 5 V, following symptoms will be presented by
back-up mode function.
tem when trouble occurs.
• HP mode is inoperable. • Engine stalls if pump torque is increased.
• Auto-acceleration control is inoperable.
• Machine mistakes occasionally when traveling
at slow idle speed.
• Swing power is weak during a combined op-
eration.
• During short circuited, swing is given priority.
• Arm is slow when arm roll-in and swing com-
bined operation is made.
• Travel speed is kept in slow mode, not allow-
Symptoms in machine op- ing to automatically change to fast mode.
eration when trouble oc-
curs.
Using Test
Harness
Others
NOTE
T5-4-4
TROUBLESHOOTING / Troubleshooting B
Pressure Sensor
Pressure Sensor (Travel) Pressure Sensor (Swing)
(Front Attachment)
• Monitors travel pilot pressure to control • Monitors front attachment pilot pressure • Monitors swing pilot pressure to control
auto-idle, auto-acceleration, idle to control auto-idle, and idle speed-up, arm flow rate and arm regenerative sys-
speed-up, engine speed automatic in- and engine speed automatic increase at tems.
crease at travel (ZX270 class only), slow travel (ZX270 class only).
speed torque increase, and travel motor
swash angle controls.
• Engine speed doesn’t increase even if • Engine speed doesn’t increase even if • Since arm regenerative function is inop-
auto-idle/auto-acceleration selector is any front attachment actuator is operated erable, when swing/arm roll-in combined
auto-idle position. with auto-idle/auto-acceleration selector operation is made, initial arm moving
• Engine speed doesn’t increase even if is auto-idle position. speed is slow. (Not remarkable)
auto-idle/auto-acceleration selector is • Occasionally, engine speed hunts while • During arm level crowding operation, arm
auto-acceleration position. operating front attachment at slow idle. speed is slightly slow.
• Occasionally, engine speed hunts while • ZX270 class only:
traveling at slow idle. Travel speed isn’t increased.
• If there is a difference in delivery flow (Not remarkable)
rate between pumps 1 and 2, machine
may mistrack when traveling at minimum
speed. (Not remarkable)
• Fast travel mode cannot be selected
even if travel mode switch is turned to
the FAST position. (Not remarkable)
• ZX270 class only:
Travel speed isn’t increased.
(Not remarkable)
• Judge if pressure sensor is faulty or port • Judge if pressure sensor is faulty or port • Judge if pressure sensor is faulty or port
is clogged by switching pressure sensor is clogged by switching pressure sensor is clogged by switching pressure sensor
with another pressure sensor. with another pressure sensor. with another pressure sensor.
T5-4-5
TROUBLESHOOTING / Troubleshooting B
Function
• Even if boom is raised with HP mode switch ON, • Even if arm is rolled-in with HP mode
engine speed doesn’t increase. switch ON, engine speed doesn’t in-
• Even if boom is raised with crease.
auto-idle/auto-acceleration selector is • Even if arm is rolled-in with
auto-acceleration position, engine speed doesn’t auto-idle/auto-acceleration selector is
increase. auto-acceleration position, engine speed
• Arm roll-in speed becomes slightly slower than doesn’t increase.
normal in boom raise and arm roll-in combined • Arm roll-in and swing speeds become
Symptoms in machine op- operation as arm regenerative system doesn’t slightly slower in swing and arm roll-in
work. (Not remarkable) combined operation as arm flow rate con-
eration when trouble occurs. • Arm roll-in and boom raise speeds become trol doesn’t work. (Not remarkable)
slightly slower at the beginning stage of arm level • Arm speed is slow in arm level crowd op-
crowd operation. eration.
• Boom raise power is weak. (Not remarkable)
By Monitor Monitor Item: Boom Raise Pilot Pressure (displayed Monitor Item: Arm Roll-In Pilot Pressure
built-in diagnosing system). (displayed built-in diagnosing system).
Function Monitor pressure change while raising boom. Monitor pressure change while rolling arm
in.
Evaluation
Others
• Judge if pressure sensor is faulty or port is • Judge if pressure sensor is faulty or port
clogged by switching pressure sensor with an- is clogged by switching pressure sensor
other pressure sensor. with another pressure sensor.
NOTE
T5-4-6
TROUBLESHOOTING / Troubleshooting B
Pressure Sensor
Torque Control Solenoid Valve Solenoid Valve Unit (SG)
(Auxiliary) (Optional)
• Monitors attachment pilot pressure when • Supplies control pressure to pumps 1 • Temporarily increases main relief valve
attachment is installed to control at- and 2 to control speed sensing and slow set-pressure when operating machine
tachment operation speed increase, speed torque increase controls. either in power digging and auto-power
pump 1 and pump 2 flow rate limit, and lift mode.
auxiliary flow rate controls.
• No signals arrive to MC • If torque control solenoid valve is not • In case solenoid valve unit (SG) is not
activated, output pressure from solenoid activated, pressure at port SG becomes
2 2
valve is 0 MPa (0 kgf/cm ). 0 MPa (0 kgf/cm ).
• Engine speed doesn’t increase when • Even if speed sensing system doesn’t Solenoid valve unit (SG) is closed:
attachment is operated. work, upper limit power is restricted so • Relief pressure stays at normal 34 MPa
• When attachment is operated, operation that machine is operable.
2
(350 kfg/cm ). Even if power digging
speed increases. • Machine may occasionally mistrack switch is pressed, relief pressure doesn’t
when traveling at slow idle speed. increase. Power doesn’t increase.
Solenoid valve unit (SG) is open:
• The pressure always increases.
Every operation makes the force in-
crease.
Monitor Item: ATT Control Pressure (dis- Monitor Item: Pump Torque Proportional Monitor Item: Power Boost Control Pres-
played built-in diagnosing system). Solenoid Valve Output sure
Monitor pressure change while operating
attachment.
• Judge if pressure sensor is faulty or port • Proportional solenoid valve is used as
is clogged by switching pressure sensor an ON/OFF valve. Therefore, even if
with another pressure sensor. power digging switch is pressed or re-
leased, lamp will come ON when nor-
mal. In case lamp goes OFF, it may be
due to broken harness.
T5-4-7
TROUBLESHOOTING / Troubleshooting B
Parts
Solenoid Valve Unit (SE)* Solenoid Valve Unit (SC)
• Changes oil flow restriction at arm flow rate • Routes return oil from arm cylinder rod side to
control valve in 5-spool control valve to shift bottom side when rolling arm in to increase
arm 1 and swing spool circuits from parallel arm speed.
circuit to tandem circuit.
Function • This is to secure sufficient swing force.
• In case solenoid valve unit (SE) is not acti- • In case solenoid valve unit (SC) is not acti-
vated, pressure at port SE becomes 0 MPa (0 vated, pressure at port SC becomes 0 MPa (0
2 2
kgf/cm ). kgf/cm ). Arm regenerative valve will not oper-
Symptoms in control sys- ate at this time.
tem when trouble occurs.
Solenoid valve unit (SE) is closed: Solenoid valve unit (SC) is closed:
• Actuator which is operated earlier is given pri- • Arm speed is slow in arm level crowd opera-
ority to operate in arm roll-in and swing com- tion.
bined operation. Solenoid valve unit (SC) is open:
• Swing becomes slow when pump 2 delivery • Arm speed is fast as the arm regeneration is
pressure is high. always operated.
Solenoid valve unit (SE) is open:
• Arm speed becomes slow as the parallel cir-
cuit in arm 1 spool is restricted.
By Fault Code
Monitor Item: Arm Regenerative Proportional Sol. Monitor Item: Arm Flow Rate Proportional Sol.
By Monitor Valve Output Valve Output
Evaluation Function
Using Test • Install lamp harness (ST 7226) to check out- • Install lamp harness (ST 7226) to check out-
put signals from MC and harness condition. put signals from MC and harness condition.
Harness
Others
NOTE
T2-1 T2-1
Descriptions of Control
(Operational Principle Sec-
tion in T/M)
NOTE:* Up to serial No.104678 (ZX200 class and 225 class)
Up to serial No.010326 (ZX230 class)
Up to serial No.020042 (ZX270 class)
T5-4-8
TROUBLESHOOTING / Troubleshooting B
Max. Pump 1 Flow Rate Limit So- Max. Pump 2 Flow Rate
Solenoid Valve Unit (SI) lenoid Valve (Optional) Limit Solenoid Valve
• When pump delivery pressure is low in • When operating attachment, limits • When operating attachment, limits
fast travel mode, travel motor swash an- maximum pump 1 flow rate. maximum pump 2 flow rate.
gle is reduced to increase travel speed.
• Fast travel mode cannot be selected. • In case max. pump 1 flow rate limit so- • In case max. pump 2 flow rate limit so-
lenoid valve is not activated, pressure at lenoid valve is not activated, pressure at
2 2
output port becomes 0 MPa (0 kgf/cm ). output port becomes 0 MPa (0 kgf/cm ).
Solenoid valve unit (SI) is closed: Max. pump 1 flow rate limit solenoid valve Max. pump 2 flow late limit solenoid valve
• Even if travel mode switch is turned to is closed: is closed:
FAST position, fast travel mode cannot • When operating attachment, operating • When operating attachment, operating
be selected. speed doesn’t decrease. speed doesn’t decrease.
Solenoid valve unit (SI) is open: Max. pump 1 flow rate limit solenoid valve Max. pump 2 flow rate limit solenoid valve
• Travel speed is always fast. is open: is open:
• Right travel, bucket, arm and boom • Left travel, arm, boom and swing speeds
speeds are slow as maximum flow rate are slow as maximum flow rate of pump
of pump 1 decreases. 2 decreases.
• Machine mistracks to the right when • Machine mistracks to the left when trav-
traveling. eling.
• Install lamp harness (ST 7226) to check
output signals from MC and harness
condition.
T5-4-9
TROUBLESHOOTING / Troubleshooting B
• Boom electronic cushion isn’t performed. • In case auxiliary flow rate control sole-
noid valve is not activated, pressure at
2
output port becomes 0 MPa (0 kgf/cm ).
By Fault Code
Monitor item: Bu Damper Proportional Sole-
By Monitor Function noid Valve Output
Evaluation
NOTE
T5-4-10
TROUBLESHOOTING / Troubleshooting B
• Speed sensing control is inoperable. • If circuit breakage occurs, system oper- • Engine learning is not performed.
ates as if hydraulic oil temperature is 40 • The initial setting of the boom electronic
°C (Dr. ZX or monitor will not indicate 40 cushion* can’t be performed.
°C in diagnosis operation).
• Engine stalls under adverse operating • Even if oil temperature is lower than 0 Engine learning:
conditions such as at high altitude. °C, auto-warming up control doesn’t op- • Machine will operate normally problem is
erate so that engine runs at idle speed caused by broken circuit or discontinuity
when engine is started. of switch. (Only learning cannot be per-
• When oil temperature is lower than 10 formed.)
°C, arm regenerative control is inoper- • If short circuit occurs, learning mode
able. operation starts when key switch is
turned ON. Therefore, engine will stall at
2 second or 20 seconds after engine
starts.
Monitor Item: Actual engine speed (If N Monitor Item: Engine Learning Control
sensor fails, engine speed is not meas-
ured.)
• Even if signals from N sensor are not
delivered due to broken circuit or poor
sensor installation, few changes in op-
erational performance occur, making
troubleshooting difficult. Use monitor
function.
T5-4-11
TROUBLESHOOTING / Troubleshooting B
Parts
Power Digging Switch Travel Mode Selector
• Activates power digging control. • Changes travel mode.
ON: 0V→Increasing Pressure Fast Mode: 0V
OFF: 5V→ Not Increasing Pressure Slow Mode: 5V
Function
• Broken Circuit: Pressure doesn’t increase. • Broken Circuit in Switch: Travel speed re-
• Short Circuit: Pressure increases for 8 sec- mains unchanged in slow mode (5V).
onds after turning key switch and stops in- • Short circuit in Switch: Travel speed remains
Symptoms in control sys- creasing. unchanged in fast mode (0 V).
tem when trouble occurs.
• Power digging control doesn’t operate if bro- • Even if travel mode selector is turned to the
ken circuit or short circuit occurs. FAST position, fast travel mode cannot be se-
lected.
• Even if travel mode selector is turned to the
SLOW position, travel mode is turned to the
Symptoms in machine op- FAST position.
eration when trouble oc-
curs.
By Fault Code
By Monitor Monitor Item: Power Digging (Boost) Switch Monitor Item: Travel Mode
Evaluation Function
Using Test
Harness
Others
NOTE
T5-4-12
TROUBLESHOOTING / Troubleshooting B
Auto-Idle/Auto-Acceleration Selec-
Boom Angle Sensor* MC tor (Auto-Idle)
• Monitors boom angle to perform the • Controls engine, pump, and valve op- • Activates auto-idle control.
boom electronic cushion control. eration. ON: 0 V → Auto-idle is operable.
OFF: 5 V → Inoperable.
• MC makes the boom electronic cushion • Depending on trouble situations, control • Broken Circuit: Auto-idle system is inop-
solenoid valve perform even with a bro- system malfunction may differ. (The fol- erable.
ken or short circuit. lowing symptoms in machine operation • Short Circuit: Even if
indicates that MC logic circuit has auto-idle/auto-acceleration selector is
failed.) OFF, auto-idle control is always per-
formed.
• Boom speed becomes slow as the boom • Even if key switch is turned ON, step • Same as described above.
raise pilot circuit is reduced by the boom motor will not move to the START posi-
electronic cushion solenoid valve even tion so that engine cannot start. Even
with a broken or short circuit. though engine starts, speed stays slow.
• Since pump displacement is held at
minimum, all actuator speeds are slow.
Fault Code 08 is displayed. Fault codes 01, 02, and 03 are displayed.
Other fault codes may be displayed.
Monitor item: Boom Angle Monitor Item: Auto-Idle/Auto-Accel Switch
• Before suspecting a failure in MC, be
sure to check the fuses in control sys-
tem. If any sensor in 5 V system is
short-circuited, all sensor fault codes will
be displayed.
T5-4-13
TROUBLESHOOTING / Troubleshooting B
Symptoms in control
system when trouble oc-
curs.
Symptoms in machine
operation when trouble
occurs.
By Fault
By Monitor Monitor Item: Auto-Idle/Auto-Accel Switch Monitor Item: E/P/HP Mode Switch
Function
Evaluation
Using Test
Harness
Others
NOTE
T5-4-14
TROUBLESHOOTING / Troubleshooting B
Monitor Item: E/P/HP Mode Switch Monitor Item: Work Mode Switch Monitor Item: Work Mode Switch
T5-4-15
TROUBLESHOOTING / Troubleshooting B
• In response to operation of the auxiliary valve, • During combined operation of travel and
engine speed related to the attachment is front/swing, insufficient oil is supplied to
controlled. left travel spool.
• Even if auxiliary valve is operated, engine • While traveling, when front/swing lever is
speed doesn’t increase. operated, machine mistracks to the left.
• Even if attachment mode is selected, maxi-
mum engine speed doesn’t decrease.
By Fault Code
By Monitor
Function
Evaluation
Using Test Har-
ness
Others
NOTE
T5-4-16
TROUBLESHOOTING / Troubleshooting B
• If spool is bound or spring is broken, • If switch valve is bound with valve activated, • If spool is bound or spring is broken, ori-
orifice doesn’t vary. bucket circuit is always restricted. fice doesn’t vary.
• If fully opened: Swing power is weak. • If poppet valve is bound at fully closed posi- • If bound at fully closed position, attach-
• If fully closed: Arm speed is slow tion or if switch valve is bound when poppet ment speed becomes slow.
during arm level crowd operation. valve is fully closed, bucket speed becomes • If bound at fully opened position, boom
slow. doesn’t move during 3-combined opera-
• If poppet valve is bound at fully opened po- tion of swing, arm roll-in, and boom raise.
sition or if switch valve is bound when pop-
pet valve is fully opened, boom doesn’t
move during 3-combined operation of
bucket, arm roll-in, and boom raise.
T5-4-17
TROUBLESHOOTING / Troubleshooting B
Parts
Boom Regenerative Valve Arm Regenerative Valve
• Prevents boom cylinder hesitation by routing • To be shifted by pilot pressure from sole-
return oil from boom cylinder bottom side to noid valve unit (SC).
rod side. • Increases arm speed by routing return oil
from arm cylinder rod side to bottom side.
Function
• If check valve is kept closed, boom is not • Arm regenerative function is inoperable.
smoothly lowered.
• If check valve is kept open, machine cannot
be raised off ground with front attachment.
By Fault Code
By Monitor
Function
Evaluation
Using Test Har-
ness
Others
NOTE
T5-4-18
TROUBLESHOOTING / Troubleshooting B
• If check valve is kept closed, bucket • If switch valve is bound, check valve doesn’t • If switch valve is bound, check valve
is not smoothly rolled in. open. doesn’t open.
• If check valve is kept open, bucket
power is weak.
• Same as described above. • If check valve is kept closed, arm roll-in • If check valve is kept closed, boom
speed becomes slow. doesn’t lower.
• If check valve is kept open, front attachment • If check valve is kept open, front attach-
drift increases due to oil leaks in control ment drift increases due to oil leaks in
valve. control valve.
• Arm moves jerky or arm speed becomes • Boom moves jerky or arm speed becomes
slow depending on valve bound conditions. slow depending on valve bound condi-
tions.
T5-4-19
TROUBLESHOOTING / Troubleshooting B
Parts
Auxiliary Flow Combiner Valve Bypass Cut Valve
• Supplies pressure oil from pump 1 to auxiliary • Supplies pressure oil from pump 1 to aux-
spool when auxiliary spool is operated. iliary spool when auxiliary spool is oper-
ated.
Function
• If control valve is kept closed, operating speed • If spool is bound in the fully open position,
doesn’t increase in single auxiliary operation. single attachment operation speed be-
comes slow.
• If spool is bound in the fully closed posi-
tion, main relief valve continues to relieve
with all control levers positioned in neutral.
• If spool is bound in opened position, when
all control levers are in neutral, pump 1
pressure is higher than pump 2 pressure.
By Fault Code
By Monitor
Function
Evaluation
Using Test Har-
ness
Others
NOTE
T5-4-20
TROUBLESHOOTING / Troubleshooting B
• If spool is bound in the fully open position, • If spool is bound in the fully open position, • If spool is bound in the fully open po-
even if control lever is in neutral, pump 1 even if control lever is in neutral, pump 2 sition, when boom, arm, bucket, or
swash angle is tilted to maximum. (When swash angle is tilted to maximum. (When swing is operated, flow combiner
traveling with travel levers held in half way traveling with travel levers held in half way valve is shifted.
stroke, machine mistracks to the left.) stroke, machine mistracks to the right.) • If spool is bound in the fully closed
• If spool is bound in the fully open position, • If spool is bound in the fully open position, position, when travel and front/swing
pump 1 control pressure sensor monitors pump 2 control pressure sensor monitors combined operation is made, ma-
the maximum pressure. the maximum pressure. chine mistracks to the left. (left travel
• If spool is bound in the fully closed posi- • If spool is bound in the fully closed position, speed is slow.)
tion, even if control lever is operated, pump even if control lever is operated, pump 2
1 swash angle is held to minimum. (Right swash angle is held to minimum. (Left travel
travel is inoperable in single travel opera- is inoperable in single travel operation.
tion. Bucket speed is very slow.) Swing speed is very slow.)
• If spool is bound in the fully open position, • If spool is bound in the fully open position,
pump 1 control pressure sensor can’t pump 2 control pressure sensor can’t moni-
monitor the pump control pressure. tor the pump control pressure.
(Right travel doesn’t run fast with right track (Left travel doesn’t run fast with left track
jacked-up.) jacked-up.)
T5-4-21
TROUBLESHOOTING / Troubleshooting B
• If spool is bound in the fully open position, • If spool is bound in the fully open position,
swing parking brake is kept released. (Ma- bucket speed becomes slow when boom
chine vibrates while traveling.) raise and bucket combined operation is
• If spool is bound in the fully open position, the made. (Bucket flow rate control is inoper-
pressure sensor (front) is always turned into able.)
ON. • If spool is bound in the fully closed posi-
Thus, engine speed doesn’t decrease when tion, boom doesn’t move during
the control lever is in neutral during 3-combined operation of bucket, arm
auto-idle/acceleration control. roll-in, and boom raise.
• If spool is bound in the fully closed position,
swing parking brake is kept applied. (Dragging
is felt.)
Symptoms in control system • If spool is bound in the fully closed position,
when trouble occurs. the pressure sensor (front) is always turned
into OFF.
Thus, engine speed doesn’t increase when
the control lever is operated during
auto-idle/acceleration control.
By Fault Code
By Monitor
Function
Evaluation
Using Test Har-
ness
Others
NOTE
T5-4-22
TROUBLESHOOTING / Troubleshooting B
T3-6
T5-4-23
TROUBLESHOOTING / Troubleshooting B
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine z : Related, required to check
{ : Related. However, in case this component fails, other trouble
troubles and parts contributing to the cause of the symptom will be more noticeable so that this component will not
trouble if failed. be the direct cause of the trouble concerned.
Parts
MC (Main Controller) z z
EC Motor z
EC Sensor { z
Pump 1 Delivery Pressure Sensor
Key Switch z
Engine Control Dial
Auto-Idle/Acceleration Selector
Engine Unit z z
Governor z z
Check batteries. Check fuel system Check fuel cut-off handle and engine control
(filters and piping). cable. Be sure to perform engine learning after
Remarks replacing engine.
T5-4-24
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
z z z { z z
z { {
{ {
z {
z
z { z
z {
z {
T5-4-25
TROUBLESHOOTING / Troubleshooting B
z : Related, required to check
{ : Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will not
be the direct cause of the trouble concerned.
Parts
MC (Main Controller) z z z
QOS Controller
Torque Control Solenoid Valve
N Sensor
Hyd. Oil Temperature Sensor
Key Switch
Engine Control Dial
Auto-Idle/Acceleration Selector
z
Engine Unit z
Pump Regulator
Remarks
T5-4-26
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
z z
z
z
z
z
z
{
Check fuel system for Check batteries.
clogging.
T5-4-27
TROUBLESHOOTING / Troubleshooting B
Parts
MC (Main Controller) z
Torque Control Solenoid Valve {
Solenoid Valve Unit (SE)*
Pump 2 Delivery Pressure
Sensor
Pressure Sensor (Swing)
Pressure Sensor (Arm Roll-In)
N Sensor {
Spool
Main Relief Valve {
Arm Flow Rate Control Valve
Main Pump z z z
Regulator { z z
Pilot Pump z
Pilot Valve
Pilot Relief Valve z
Pump 1 Flow Rate Control
z
Valve
Pump 2 Flow Rate Control
z
Valve
Arm Flow Rate Control Valve
Spool**
Remarks
NOTE: The trouble symptoms in this table are de- z : Related, required to check
scribed provided that each trouble occurs { : Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will not
independently. In case more than one trou- be the direct cause of the trouble concerned.
ble occurs at the same time, find out all
faulty components while checking all sus-
pected components in each trouble symp-
tom.
T5-4-28
TROUBLESHOOTING / Troubleshooting B
z
{
z {
T5-4-29
TROUBLESHOOTING / Troubleshooting B
Parts
MC (Main Controller) z z* z
Solenoid Valve Unit (SG) z
Solenoid Valve Unit (SE)* z
Solenoid Valve Unit (SC) z
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor {
Pressure Sensor (Swing) {
Pressure Sensor (Boom Raise) {
Pressure Sensor (Arm Roll-In) {
Oil Temperature Sensor
Power Digging Switch z
Spool z
Main Relief Valve z z
Overload Relief Valve z z
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve z
Bucket Regenerative Valve
Arm Flow Rate Control Valve z
Bucket Flow Rate Control Valve
Boom Anti-Drift Valve
Arm Anti-Drift Valve
Emergency Valve
Shockless Valve (Signal Control Valve) z
Shuttle Valve (Signal Control Valve) z
Remarks
T5-4-30
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
z
z
z
z
z
z z
z z
T5-4-31
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
Front Attachment System Troubleshooting
F-9∗ F-10
The shock is lar- Front attachment
Trouble ger at the full drifts remarkably.
Symptom stroke of boom
raise.
MC (Main Controller) z
Solenoid Valve Unit (SG)
Solenoid Valve Unit (SE)*
Solenoid Valve Unit (SC)
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pressure Sensor (Swing)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Oil Temperature Sensor
Power Digging Switch
Spool z z
Main Relief Valve
Overload Relief Valve z z
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve
Bucket Regenerative Valve
Arm Flow Rate Control Valve
Bucket Flow Rate Control Valve
Boom Anti-Drift Valve z z
Arm Anti-Drift Valve z z
Emergency Valve
Shockless Valve (Signal Control Valve)
Shuttle Valve (Signal Control Valve)
Remarks
T5-4-32
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-33
TROUBLESHOOTING / Troubleshooting B
Parts
MC (Main Controller) z
Torque Control Solenoid Valve
Solenoid Valve Unit (SE)* z
Solenoid Valve Unit (SC)
Solenoid Valve Unit (SI)
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor {
Pump 1 Control Pressure Sensor
Pump 2 Control Pressure Sensor
Pressure Sensor (Travel)
Pressure Sensor (Swing) {
Pressure Sensor (Arm Roll-In) {
Travel Mode Switch
Pump Device
Spool
Load Check Valve
Arm Flow Rate Control Valve z
Flow Combiner Valve
Swing Parking Brake Release Spool
z
(Signal Control Valve)
Pump 1 Flow Control Valve
(Signal Control Valve)
Pump 2 Flow Control Valve
z
(Signal Control Valve)
Flow Combiner Control Spool
(Signal Control Valve)
Arm Flow Rate Control Valve Control Spool
z
(Signal Control Valve)**
Shuttle Valve (Signal Control Valve) { z
Swing Device z
Travel Device
Center Joint
Pilot Valve z
Also, refer to T-5.
Remarks
T5-4-34
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
T-2 T-3 T-4 T-5 Q-1
One side track doesn’t Machine mistracks dur- Occasionally, machine Fast travel is inoperable. Wiper is inoperable or
rotate or rotates slowly. ing travel and front at- mistracks when traveling Travel mode does not not retracted.
Machine mistracks. tachment combined with engine running at change from slow mode
operation. slow speed. to fast mode.
z
z
z
{ {
{ {
{
{
{ {
z
z
z
z
{
z
z
z
z
In case either bucket or
swing is also slow, refer
to A-2 or A-3.
T5-4-35
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
Q-2
Air Conditioner Malfunc-
Trouble tion
Symptom
Parts
MC (Main Controller)
Torque Control Solenoid Valve
Solenoid Valve Unit (SE)*
Solenoid Valve Unit (SC)
Solenoid Valve Unit (SI)
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pump 1 Control Pressure Sensor
Pump 2 Control Pressure Sensor
Pressure Sensor (Travel)
Pressure Sensor (Swing)
Pressure Sensor (Arm Roll-In)
Travel Mode Switch
Pump Device
Spool
Load Check Valve
Arm Flow Rate Control Valve
Flow Combiner Valve
Swing Parking Brake Release Spool
(Signal Control Valve)
Pump 1 Flow Control Valve
(Signal Control Valve)
Pump 2 Flow Control Valve
(Signal Control Valve)
Flow Combiner Control Spool
(Signal Control Valve)
Arm Flow Rate Control Valve Control Spool
(Signal Control Valve)**
Shuttle Valve (Signal Control Valve)
Swing Device
Travel Device
Center Joint
Pilot Valve
Remarks
T5-4-36
TROUBLESHOOTING / Troubleshooting B
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter doesn’t rotate.
NO
· Voltage: More than 24 V
Density: More than 1.26 Faulty battery or fusible
link.
NO
T178-05-04-001
T105-07-04-002
T5-4-37
TROUBLESHOOTING / Troubleshooting B
E-2 Although starter rotates, engine doesn’t
start.
Faulty engine.
YES
· Refer to engine shop manual.
Check if governor lever
moves to the START position
when key switch is turned ON.
YES Faulty EC motor.
1 2 3 4
T105-07-04-003
1 - Governor Cable (From EC Mo-
tor)
2 - Fuel Cut-Off Cable
(Fuel Cut-Off Handle)
3 - Fuel Cut Lever
4 - Governor Lever
T5-4-38
TROUBLESHOOTING / Troubleshooting B
• Governor Lever Position
A B
STOP FULL
FULL
T105-07-04-003
STOP
A
B
T105-07-04-003
T5-4-39
TROUBLESHOOTING / Troubleshooting B
E-3 When engine control dial is fully rotated,
engine stalls.
Occasionally engine stalls during operation
with engine control dial fully rotated and
auto-idle ON.
Engine speed is slower than specification in
all operating ranges.
Idle speed is faster or slower than specifica-
tion.
• In case engine learning has not been performed • Refer to pages for Engine Learning in the SYS-
or engine learning has been incorrectly per- TEM/Control System group in the T/M (Opera-
formed, engine speed becomes slower than tional Principle).
specification across the operating range. • Check for loose harness connections before-
• In case the EC sensor is faulty, engine speed is hand.
controlled based on the governor lever position,
which is judged as the idle position when the key
switch is turned ON. Accordingly, discrepancies
in engine speed from specification will result.
Depending on where the governor lever is posi-
tioned when the key switch is turned ON, dis-
crepancy will differ, causing this trouble to be not
reproducible.
NO Monitor engine
· Refer to T4-6-1 for learning status.
engine learning
procedures.
· Monitor item: En-
gine learning con-
trol
T5-4-40
TROUBLESHOOTING / Troubleshooting B
· Refer to T4-6-1.
T5-4-41
TROUBLESHOOTING / Troubleshooting B
E-4 Even if engine control dial is rotated, engine
speed remains unchanged.
· Refer to T4-6-1.
T5-4-42
TROUBLESHOOTING / Troubleshooting B
E-5 Engine speed doesn’t increase after engine
is started.
More than 0 °C
when starting Normal.
T5-4-43
TROUBLESHOOTING / Troubleshooting B
E-6 Faulty HP mode
• Sensors detect the conditions necessary to oper- • Refer to the pages for HP Mode Control in the
ate the HP mode. Therefore, if any of these sen- SYSTEM / Control System group in the T/M (Op-
sor fails, the HP mode becomes inoperable. erational Principle).
• Pressure sensors (arm roll-in and boom raise) • Check for loose harness connections before-
and pump 1 and 2 delivery pressure sensors are hand.
also engaged in the HP mode control. However, if
these sensors fail, other operating functions will
be also affected. (Refer to the relationship be-
tween machine trouble symptoms and related
parts on page T5-4-2.)
Faulty power mode
switch or broken
harness between
NO power mode switch
and MC.
Monitor power mode
switch. Check if indica-
tion HP is highlighted
when power mode
NO switch is turned to “HP Check if governor
mode”. lever comes in contact YES Faulty engine.
with full-side stopper
while relieving boom
raise circuit pressure.
YES
Check if any fault Faulty MC.
codes are displayed. · Monitor item: E/P/HP
mode switch NO
· Refer to T4-6-1.
Faulty corresponding
sensor or broken
harness between
sensor and MC.
YES
· Fault codes:
Pump 1 delivery pressure sensor: 10
Pump 2 delivery pressure sensor: 11
Pilot pressure sensor (boom raise): 15
Pilot pressure sensor (arm roll-in): 16
T5-4-44
TROUBLESHOOTING / Troubleshooting B
• Although the power mode switch isn’t turned to the
HP mode position, HP mode is operable.
T5-4-45
TROUBLESHOOTING / Troubleshooting B
E-7 Even if key switch is turned OFF, engine
doesn’t stop. (In case the engine doesn’t
stop, stop the engine by pulling the engine
stop handle located under the seat stand.
Then, begin inspection.)
T5-4-46
TROUBLESHOOTING / Troubleshooting B
E-8 Faulty auto-idle system
• In case trouble symptoms E1 to E7 are recog- • Refer to the pages for Auto-Idle Control in the
nized, perform the troubleshooting of these trou- SYSTEM / Control System group in the T/M (Op-
bles beforehand. erational Principle).
• Although the failure in pressure sensors (travel • Check for loose harness connections before-
and front attachment) will have relevance to mal- hand.
function of the auto-idle control. However, if these
sensors fail, other operating functions will also be
affected. (Refer to the relationship between ma- Normal (Turn power
chine trouble symptoms and related parts on mode switch to a posi-
page T5-4-2.) YES tion other than the E
mode.)
Faulty MC.
· Monitor item: Auto-idle / NO
auto-accel switch
· Auto-idle /
auto-acceleration selec-
tor: OFF
T5-4-47
TROUBLESHOOTING / Troubleshooting B
E-9 Faulty E mode
Faulty MC.
YES
· Monitor item: · Refer to T4-6-1.
E/P/HP mode switch
Faulty MC.
· Monitor item: E/P/HP switch NO
· Power mode switch: P mode
· Refer to T4-6-1.
T5-4-48
TROUBLESHOOTING / Troubleshooting B
E-10 Faulty auto-acceleration system
Related Fault Code: 10, 11, 12, 13, 14, 15, 16, and
18
• In case trouble symptoms E-1 to E-9 are recog- • Refer to the pages for Auto-Acceleration Control
nized, perform the troubleshooting of these trou- in the SYSTEM / Control System group in the
bles beforehand. T/M (Operational Principle).
• Although the failure in pressure sensors (travel,
swing, boom raise, and arm roll-in), pump 1 and
2 delivery pressure sensors, and pump 1 and 2
control pressure sensors will have relevance to
malfunction of the auto-acceleration control.
However, if these sensors fail, other operating
functions will also be affected. (Refer to the rela-
tionship between machine trouble symptoms and
related parts on page T5-4-2.) Faulty auto-idle /
auto-acceleration selector or
broken harness between
Monitor auto-idle / auto-acceleration switch and MC.
NO
auto-acceleration selector.
Check if displayed “AA” is
turned OFF or ON in response
to auto-acceleration switch
operation.
Faulty MC.
YES
· Refer to T4-6-1.
· Monitor item:
Auto-idle/auto-accel
switch
Faulty MC.
· Monitor item: Auto-idle / NO
auto-accel switch
· Auto-idle / auto-acceleration se- · Refer to T4-6-1.
lector:
Auto-idle position
T5-4-49
TROUBLESHOOTING / Troubleshooting B
E-11 When traveling or operating front attach-
ment with engine running at slow idle, en-
gine hunts.
Faulty MC.
· Monitor item: NO
Engine target speed
· Possible to display with built-in · Refer to T4-6-1.
diagnosing system
T5-4-50
TROUBLESHOOTING / Troubleshooting B
E-12 Engine speed doesn’t increase even if at-
tachment is operated in attachment mode.
• In case trouble symptoms E-1 to E-11 are recog- • Refer to the pages for Attachment Operation
nized, perform the troubleshooting of these trou- Speed Increase Control in the SYSTEM / Control
bles beforehand. System group in the T/M (Operational Principle).
• Although the failure in pressure sensor (auxiliary) • Check for loose harness connections before-
and power mode switch will have relevance to hand.
the malfunction of the attachment operation
speed increase control. However, if these sensor
and switches fail, other operating functions will
also be affected. (Refer to the relationship be-
tween machine trouble symptoms and related
parts on page T5-4-2.)
Normal (Set to “In-
NO crease (+)”.)
Check if attachment
speed adjustment
has been set to “In-
NO crease (+)” in Dr. ZX Monitor attachment
service mode. pilot pressure. Check YES
if pressure varies in To A
response to lever
Check if P speed ad-
stroke.
justment has been YES
set to “Decrease” in Faulty auxiliary pres-
Dr. ZX service mode. sure sensor.
NO
T5-4-51
TROUBLESHOOTING / Troubleshooting B
E-13 When attachment mode is selected, engine
speed doesn’t decrease.
T5-4-52
TROUBLESHOOTING / Troubleshooting B
E-14 Engine stalls within several seconds after
engine has started.
T5-4-53
TROUBLESHOOTING / Troubleshooting B
E-15 Engine stalls during operation under ad-
verse condition such as at high altitude.
Disassemble to check
regulator.
YES
Monitor actual engine
speed. Check if engine
speed is abnormal. · Monitor item: Pump torque
proportional solenoid valve
output
· Refer to the Operational Per-
· Monitor item: formance Test section.
Engine actual speed Faulty N sensor, or faulty
harness between N
sensor and MC.
YES
A
Broken harness be-
tween torque control so-
lenoid valve and MC.
NO
T5-4-54
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-55
TROUBLESHOOTING / Troubleshooting B
E-16 Engine is difficult to start at low tempera-
ture. (During cold weather or in cold dis-
tricts, the engine is difficult to start or
doesn’t start although pre-heated.)
• Check if electricity is routed to the glow plugs. • Check battery at the same time.
Check the glow plugs for any abnormality. • Check for loose harness connections before-
• The pre-heat system operates only when coolant hand.
temperature is below 10 °C (50 °F). When cool-
ant temperature is higher than 10 °C (50 °F), the
pre-heat system doesn’t operate.
Remove
the
copper
plate.
Specification: 20 to 24 V
Specification: Below 10 Ω
T105-07-04-006
T105-07-04-007
T5-4-56
TROUBLESHOOTING / Troubleshooting B
T5-4-57
TROUBLESHOOTING / Troubleshooting B
ALL ACTUATOR SYSTEM TROUBLE-
SHOOTING
A-1 All actuator speeds are slow.
• Reduction in pump 1 and 2 flow rate due to • Although speed is satisfactory, in case power is
some reasons or faulty pilot system may cause weak, refer to the troubleshooting for faulty relief
this trouble. valve (F-1).
• Also, check for fuse of the torque control sole- • Check for loose harness connections before-
noid valve. hand.
Check if primary
pilot pressure is Faulty N sensor or
normal. broken harness in N
YES sensor circuit.
· Monitor item:
Pump torque NO
proportional solenoid
valve output
· Refer to the opera-
tional performance
Test section
T5-4-58
TROUBLESHOOTING / Troubleshooting B
Pressure Gauge
Mounting Port
Solenoid Valve
Faulty MC.
· Refer to T4-6-6.
T5-4-59
TROUBLESHOOTING / Troubleshooting B
A-2 Left travel is inoperable during single travel
operation. Single swing operation speed is
slow. Arm is slightly slow during arm level
crowding. (All problems occur at the same
time.)
T5-4-60
TROUBLESHOOTING / Troubleshooting B
A-3 Right travel is inoperable during single
travel operation. Single bucket operation
speed is slow. Boom is not raised properly
during arm level crowding. (All problems
occur at the same time.)
T5-4-61
TROUBLESHOOTING / Troubleshooting B
A-4 Actuator doesn’t stop even if control lever
is returned to neutral.
NO
· Although pilot pressure is not
routed to spool end in control
valve, spool is kept opened
due to binding of spool.
T5-4-62
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-63
TROUBLESHOOTING / Troubleshooting B
A-5 Occasionally, swing or arm roll-in speed
becomes slow during swing and arm roll-in
combined operation.
Faulty corresponding
sensor or faulty MC, or
YES
broken harness be-
tween MC and sensor.
T5-4-64
TROUBLESHOOTING / Troubleshooting B
Serial No.104679 and up
(ZX200 class and 225 class)
Serial No.010327 and up (ZX230 class) NOTE: The arm flow rate control valve control
Serial No.020043 and up (ZX270 class) spool in the signal control valve is provided,
• Faulty arm flow rate control valve may cause this instead of the solenoid valve SE.
trouble.
• Refer to the COMPONENT OPERATION / Con-
trol Valve group in the T/M (Operational Princi-
ple).
Install pressure gauge to hose
SE connecting signal control
valve to arm flow rate control
valve in control valve. Check if YES Faulty arm flow rate control
relief pressure is approx. 3.9 valve.
MPa (40 kgf/cm2) while per-
forming 2-function combined
NO operation of arm roll-in, and
swing.
Bound arm flow rate control
valve control spool in signal
. Check if any fault control valve.
codes are displayed. NO
T178-03-06-015
W178-02-05-018
Front Side
ZXS200 class, 230 class, 270 class
T5-4-65
TROUBLESHOOTING / Troubleshooting B
A-6 Actuator speed is faster than normal
Machine mistracks when travel lever is op-
erated at half stroke. Precise control cannot
be performed.
T5-4-66
TROUBLESHOOTING / Troubleshooting B
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
F-1 All front attachment actuator power is weak.
T5-4-67
TROUBLESHOOTING / Troubleshooting B
T5-4-68
TROUBLESHOOTING / Troubleshooting B
Disconnect solenoid
valve unit (SG). Con-
nect test harness (ST Faulty solenoid valve unit
7226) between sole- YES (SG).
noid valve unit and
harness. Check if test
harness lamp comes
ON. Faulty harness between so-
lenoid valve unit (SG) and
NO MC.
T5-4-69
TROUBLESHOOTING / Troubleshooting B
F-3 Some cylinders are inoperable or speeds
are slow.
T5-4-70
TROUBLESHOOTING / Troubleshooting B
• Boom speed is slow. (Up to serial No.104908
(ZAXIS225US))
• Refer to F-7.
• If the initial setting of the boom electronic cushion
fails or the related sensors are faulty, the boom
electronic cushion solenoid valve restricts the
boom raise pilot circuit.
NOTE: The boom cushion solenoid valve is pro-
vided on up to serial No.104908.
T5-4-71
TROUBLESHOOTING / Troubleshooting B
F-4 Arm speed is slow in a combined operation.
Arm speed is slow during arm level crowd-
ing.
T5-4-72
TROUBLESHOOTING / Troubleshooting B
Disconnect solenoid
valve unit (SE).
Connect test har-
ness (ST 7226) Faulty solenoid
between solenoid valve unit (SE).
valve unit (SE) and YES
harness. Check if
test harness lamp
NO comes ON. Broken harness
between solenoid
valve unit (SE) and
NO MC.
· Perform swing and
arm roll-in combined
operation. YES Faulty arm regen-
erative valve.
T5-4-73
TROUBLESHOOTING / Troubleshooting B
T5-4-74
TROUBLESHOOTING / Troubleshooting B
Control Valve
Front Side Signal Control Valve
ZX225 class (Control Valve Side)
Hose SE
Front Side
W178-02-05-018
ZX200 class, 230 class, 270 class
T178-03-06-015
T5-4-75
TROUBLESHOOTING / Troubleshooting B
F-5 Bucket is slow in bucket roll-in single op-
eration. Bucket doesn’t move smoothly in
bucket roll-in single operation.
Hose (SK)
Bucket Flow
Rate Control
Valve
T178-05-04-002
T5-4-76
TROUBLESHOOTING / Troubleshooting B
F-6 When starting to move in combined opera-
tion, arm doesn’t smoothly move. Arm starts
to move slightly slow in arm roll-in single
operation. These troubles often occur when
oil temperature is low.
T5-4-77
TROUBLESHOOTING / Troubleshooting B
F-8 When boom raise or arm roll-out is operated,
boom or arm starts to move after moving
slightly downward.
· Disassemble / Visual
Inspection Faulty load check valve.
NO
T5-4-78
TROUBLESHOOTING / Troubleshooting B
F-9 The shock is larger at the full stroke of
boom raise
Up to serial No.104908 (ZAXIS225US)
T1GF-02-01-001
T5-4-79
TROUBLESHOOTING / Troubleshooting B
F-10 Front attachment drifts remarkably.
Normal
YES
Correctly adjust
emergency valve and
Check if each front lock it up.
attachment cylin- NO
der drift is within Check if emergency
specification. valve at boom 1 sec-
NO tion in control valve Check if symptom is
4-spool block is cor- deleted when overload
rectly adjusted. relief valve is tempo-
Check if cylinder drift YES rarily switched with
is reduced when pilot another overload relief
NO shut-off valve is valve.
closed.
T5-4-80
TROUBLESHOOTING / Troubleshooting B
Emergency
Valve
Scored control 1
valve spool, broken
NO spring, or loose
spool end. 2
NO Check if oil
leaks in cylin-
ders. Faulty cylinder.
(Replace seal kit.)
YES
T178-05-04-003
Faulty overload
relief valve. Adjustment Procedure:
YES Loosen (1) and tighten (2).
Tightening Torque:
(1)- 13 N⋅m (1.3 kgf⋅m)
(2)- 7 N⋅m (0.7 kgf⋅m)
T5-4-81
TROUBLESHOOTING / Troubleshooting B
SWING SYSTEM TROUBLESHOOTING
S-1 Swing is slow or unmoving.
T5-4-82
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-83
TROUBLESHOOTING / Troubleshooting B
S-2 Swing is slow (weak in power) in swing and
arm roll-in combined operation.
Swing doesn’t start smoothly.
Swing power is weak.
T5-4-84
TROUBLESHOOTING / Troubleshooting B
Control Valve
Front Side Signal Control Valve
ZX225 class (Control Valve Side)
Hose SE
Front Side
W178-02-05-018
ZX200 class, 230 class, 270 class
T178-03-06-015
T5-4-85
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-86
TROUBLESHOOTING / Troubleshooting B
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Both right and left tracks do not rotate or
rotate slowly.
T5-4-87
TROUBLESHOOTING / Troubleshooting B
T-2 One side track doesn’t rotate or rotates
slowly. Machine mistracks.
• Check that both side track sags are equally ad- • In one side track only doesn’t rotate, the pilot
justed. valve, control valve, travel motor, or center joint
• Faulty pump control will cause the machine to may be faulty.
mistrack. In this case, other trouble symptoms
such as slow bucket or swing single operation
speed, or slow arm roll-in and boom raise speed
in level crowd operation will occur at the same
time. If both mistrack and other symptoms as
described above occurs at the same time, refer Check if travel motor
to A-2 and A-3. drain oil amount is
YES
normal. To A
Faulty counterbalance
NO valve.
T5-4-88
TROUBLESHOOTING / Troubleshooting B
B
Faulty travel relief
valve.
YES
External Oil ←
7 Leak
5 4
W157-03-03-003
T5-4-89
TROUBLESHOOTING / Troubleshooting B
T-3 Machine mistracks during travel and front
attachment combined operation.
Hose (SL)
Flow
Combiner
Valve
T178-05-04-002
T5-4-90
TROUBLESHOOTING / Troubleshooting B
T-4 Occasionally, machine mistracks when
traveling with engine running at slow speed.
· Monitor item:
Pump torque proportional
solenoid valve output
· Engine:
Running at slow idle
speed
T5-4-91
TROUBLESHOOTING / Troubleshooting B
T-5 Fast travel is inoperable.
Travel mode doesn’t change from slow
mode to fast mode.
· Monitor item:
Travel motor swash angle
control pressure
· Travel mode: Fast
· Measurement: Refer to Op-
erational Performance Test
Section.
· Fault codes:
10: Pump 1 delivery pressure sensor
11: Pump 2 delivery pressure sensor
12: Pump 1 control pressure sensor
13: Pump 2 control pressure sensor
T5-4-92
TROUBLESHOOTING / Troubleshooting B
NO
T5-4-93
TROUBLESHOOTING / Troubleshooting B
OTHER SYSTEM TROUBLESHOOTING
O-1 Wiper is inoperable or not retracted.
Checking Instructions
• The wiper is driven by electric power routed via • If the front window is open, the wiper won’t oper-
the relay circuit controlled by the monitor assem- ate. Check that the front window is securely
bly. In case the wiper is inoperable, first check closed.
the wiper motor and links for any abnormality us-
ing an auxiliary electric power and the test har-
ness. Faulty front window
open/close switch or
short-circuited harness
between front window
YES open/close switch and
monitor.
T5-4-94
TROUBLESHOOTING / Troubleshooting B
Lamp S
M B S
L E
Ground
T178-05-04-004
Retracted Position
Operating Range
T178-05-04-005
Lamp S
T157-07-04-004
T5-4-95
TROUBLESHOOTING / Troubleshooting B
O-2 Air Conditioner Malfunction
Normal Operation
Press lower side fan switch. Press upper side fan switch.
Keep pressing OFF switch STEP 1
for more than 3 seconds. Display Function Con-
firmation
Press lower side fan switch. Press upper side fan switch.
Keep pressing OFF switch STEP 2
for more than 3 seconds. Present Trouble
Diagnosing
Press lower side fan switch. Press upper side fan switch.
Press lower side fan switch. Press upper side fan switch.
Keep pressing OFF switch
for more than 3 seconds. STEP 4
Sensing Temperature
Display
Press lower side fan switch. Press upper side fan switch.
Keep pressing OFF switch
for more than 3 seconds. STEP 5
Component Operation Check
Press AUTO switch and Press AUTO Press A/C Press A/C switch and
lower side fan switch. Switch and switch and upper side fan switch.
upper side lower side
fan switch. fan switch.
Keep pressing OFF switch STEP 6-1 STEP 6-2
for more than 3 seconds. Correction of the Set Selection of Celsius and Fahrenheit
Temperature Temperature Indication
Keep pressing OFF switch
for more than 3 seconds.
Self-Diagnosis
T5-4-96
TROUBLESHOOTING / Troubleshooting B
Self-Diagnostic System Activation
Fan Switch LCD Air Conditioner Switch
Turn the key switch ON while pressing the air condi-
tioner switch and mode switch on air conditioner
control panel.
T5-4-97
TROUBLESHOOTING / Troubleshooting B
STEP 2 Present Trouble Diagnosing
The LCD indicates the fault codes for present ab-
Fan Switch LCD
normalities of the mix door, mode encoder, and/or
sensors.
T5-4-98
TROUBLESHOOTING / Troubleshooting B
STEP 3 Past Trouble Diagnosing
The LCD indicates the fault codes for past abnor-
Fan Switch LCD Air Conditioner Switch
malities of the mix door, mode encoder, and/or sen-
sors.
The past stored fault codes are deleted.
T5-4-99
TROUBLESHOOTING / Troubleshooting B
STEP 4 Sensing Temperature Display Fan Mark
The LCD indicates the sensing temperature detected
Fan Switch LCD Air Conditioner Switch
by each temperature sensor (excluding the insulation
sensor).
NOTE: The coolant temperature sensor indicates Fresh Air Vent Switch OFF Switch
“H” when coolant temperature is more than
21 °C (70 °F) and “L” when coolant tem-
perature is less than 21 °C (70 °F).
• Sensing temperature detected by each sensor is
automatically displayed on the LCD and is cycled at
an interval of 3 seconds with the timer. The timer is
turned ON or OFF by operating the fresh air vent
switch.
• Referring to the fan mark can check which sensing
temperature is displayed.
• Select the next step to be performed by operating
the switches as follows:
• Press the upper side of the fan switch: To pro-
ceed to “STEP 5.”
• Press the lower side of the fan switch: To return
to “STEP 3.”
• Keep pressing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed)
T5-4-100
TROUBLESHOOTING / Troubleshooting B
STEP 5 Component Operation Check Air Conditioner
Fan Switch LCD Switch AUTO Switch
Each component operation is checked by performing
pattern operation.
Table 1
Component Indication Operation Pattern Remarks
on LCD
Air Mix Damper 51 Controls opening extent of air mix 0%, 50%, 100%: “C”, “5”, and “H” are
damper: 0% (fully closed) → indicated next to the decimal point
50%*→ 100% (fully opened) respectively.
Fan 52 Controls air flow volume: Lo → Indicators corresponding to air flow vol-
M(Lo) → M(Hi) → Hi ume light.
Air Vent Loca- 53 Selects air vent: Front*→ Indicator corresponding to selected air
tion Front/Rear → Front/Foot → Foot vent lights.
Fresh/Circula-tio 54 Select Ventilation Mode: Circula- Indicator corresponding to selected
n Air Vent Selec- tion* → Fresh mode light.
tion
Air Conditioner 55 Turns air conditioner switch: ON* ON: Indicator lights.
→ OFF OFF: Indicator is extinguished.
T5-4-101
TROUBLESHOOTING / Troubleshooting B
STEP 6-1 Correction of the Set Temperature
Fine correction of the set temperature. Temperature
Fan Switch LCD Control Switch AUTO Switch
25°C (77 °F) and set temperature correction is -1°C OFF Switch
(-34 °F), the actually controlled temperature be-
comes 24°C (75 °F).
• Select the next step to be performed by operating
the switches as follows:
• Press the AUTO switch and lower side of the fan
switch: To return to “STEP 5.”
• Keep pressing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed)
T5-4-102
TROUBLESHOOTING / Troubleshooting B
STEP 6-2 Selection of Celsius and Fahrenheit
Temperature Indication
Fan Switch LCD Air Conditioner Switch
Selection of Celsius and Fahrenheit Temperature In-
dication.
• Each time when the fresh air vent switch is pressed,
Celsius or Fahrenheit temperature may be dis-
played alternately.
• Temperature is displayed at the top of the LCD
window as follows.
(C: Celsius, F: Fahrenheit) T178-05-08-001
T5-4-103
TROUBLESHOOTING / Troubleshooting B
※ Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to Hitachi Tsuchiura Works Quality Assurance Dept. after
experiencing a problem with your machine’s air conditioning system.
< AIR CONDITIONER TROUBLE REPORT > File No.
(1) What Checked by:
Model (Serial No. )
Operation Type Manual Semi-Auto Full-Auto
Delivery Date Year Month
(2) When
Date Year Month Day Operating Hour ( h)
Time Morning Daytime Evening Night
Frequency Every Day Once a Week Once a Month Times per
(3) Where
Job Site Address State County Town
Access Road Condition Paved Not Paved (Gravel Sand Soil)
(4) How (Operating Conditions)
Weather Fine Cloudy Rain Snow
Atmospheric Temperature Very Hot Hot Cold Very Cold
Operating Conditions Parking Traveling Working
Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when
full-auto operation
A/C ON OFF
Control Air Induction Re-Circulation Fresh Air Circulation
Panel AUTO ON OFF Not Available
Fill following items when operated in manual mode or when manual control type unit is used.
Vent Position Front Front / Rear Foot Front / Rear and Foot
Fan First Second Third Fourth Fifth Sixth
(5) How (Problem Symptom)
Abnormal Compressor Operation
Symptom Not turned ON <Check Result>
Not turned OFF (1) Is problem reproducible ?
Others Reproducible
Uncontrollable air temperature Not reproducible
(2) Pressure (To be measured at gauge manifold)
Symptom No cool air
Low Pressure
No warm air
High Pressure
Others
(3) Which parts have been replaced ?
Uncontrollable air volume
1
Symptom Air flows in Hi mode only
No air flows
2
Small air volume
Others
Uncontrollable vent hole
∗ Before replacing the control amplifier, be sure to
check that the connectors are correctly connected
Symptom Vent hole isn’t selected
while repeatedly disconnecting and reconnecting
Others connectors.
Abnormal panel indication
Faulty Indicator Vent Hole
A/C
AUTO
Fresh Air Circulation
Fan OFF
Fan (Lo • •• Hi)
Temperature Control
Symptom Stays OFF
Stays ON
Blinks
Others
T5-4-104
TROUBLESHOOTING / Troubleshooting B
ZAXIS225US:
Refrigerant Quantity ....................... 900±50 g
Compressor Oil Quantity................ 210 cm3
T5-4-105
TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Refrigerant pressure Bubbles can be seen in sight Piping and/or parts are stained with oil,
in both high and glass. respond to gas detector.
low-pressure sides is
low.
No oil stain is found or gas detector
doesn’t respond. Refrigerant has not
been refilled for longer than one sea-
son.
No bubbles are seen in sight
glass.
Refrigerant pressure
in low-pressure side Bubbles can be seen in sight Compressor cylinder is extremely hot,
Insuffi- is high. glass. emitting a smell.
cient
Cooling
Power
Refrigerant pressure in Compressor cylinder is extremely hot,
high-pressure side is low. emitting a smell.
Refrigerant pressure
in high-pressure side Bubbles can be seen in sight Refrigerant pressure in low-pressure
is high. glass. side is low.
Even if condenser is sprayed with water, few bubbles appear. Receiver dryer tem-
perature is low.
Thermistor cools.
T5-4-106
TROUBLESHOOTING / Troubleshooting B
Gas leaks from pipe joints and/or parts. Re-tighten or replace parts.
Frozen expansion valve or water in circuit. After evacuation, refill refrigerant and/or replace re-
ceiver dryer.
Gas leaks from case. Seal gaps using vinyl tape or packing compound.
Poor contact of expansion valve temperature sensing cylinder. Make good contact. Replace temperature sensing
stay.
Clogged high-pressure circuit before receiver dryer. Remove clog, or replace parts.
Clean Condenser.
Gas leaks from case. Seal gaps using vinyl tape or packing compound.
Even if function and performance are normal, when Instruct user on correct air-conditioner operation.
air-conditioner is kept operated for a long time with thermistor (Reset thermistor to either minimum or middle cooling
in max. cooling position and air flow in M or L mode, frost may position or increase air flow.)
form.
T5-4-107
TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Gas blowing sound (roaring). Gas vibration noise (compressor discharge and/or
suction gas noise).
Expansion valve connection, whistle Abnormal noise from expansion valve (Expansion
Noise sound, gas blowing sound. valve is normally functioning.).
Noisy compressor.
Compressor rotating sound.
Vibration and/or loose screws due to excessive drive
belt looseness.
T5-4-108
TROUBLESHOOTING / Troubleshooting B
Repair or replace.
Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.
Replace.
Repair or replace.
Replace.
Clean.
Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in
L mode for more than 10 minutes, flush smell out by condensed water.
T5-4-109
TROUBLESHOOTING / Troubleshooting B
Compressor
Inoperable
cooling Clutch terminal voltage is low.
system.
T5-4-110
TROUBLESHOOTING / Troubleshooting B
Oil and refrigerant leaks from front housing, and/or cylinder block joint. Replace.
No leaks (normal).
Replace.
Blown gasket (See NOTE 3 on page T5-4-113.)
T5-4-111
TROUBLESHOOTING / Troubleshooting B
Compressor
Trouble other than compressor. Refer to the Cooling Circuit Troubleshooting Ta-
ble on page T5-4-106.
Abnormal
noise
T5-4-112
TROUBLESHOOTING / Troubleshooting B
Loose screws.
Broken valve.
Replace.
Blown gasket.
NOTE:
1. Don’t quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A
slight oil seepage will appear due to the seal construction. However, this oil seepage will not
cause malfunction. Be sure to accurately check whether oil is leaking or seeping only.
2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose sur-
face may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
high-pressure side and low-pressure side is 0.49 MPa (5 kgf/cm2) or less. When the clutch is
turned OFF, the pressure difference between high-pressure side and low-pressure side will dis-
appear within about 10 seconds.
T5-4-113
TROUBLESHOOTING / Troubleshooting B
EXCHANGE INSPECTION
Exchange inspection method is a troubleshooting
method to find the trouble location by exchanging the
suspected part / component with another part
/component having identical characteristics.
Pump 2 Pump 1
Many sensors and solenoid valves used on this ma- (5-Spool (4-Spool
chine are identical. Therefore, using this switch-check Section) Section)
method, faulty part /component, and/or harness can
be easily found.
PP2 PP1
Example: Abnormal pump 1 delivery pressure (Fault
code: 10)
Check Method:
1. Switch two delivery pressure sensors located as
Figure A
shown in figure A to figure B.
2. Retry troubleshooting. T157-07-04-006
Result:
In case the pump 2 delivery pressure is abnormal
(fault code 11), the pump 1 delivery pressure sensor
is considered to be faulty.
Pump 2 Pump 1
In case the pump 1 delivery pressure is abnormal (4-Spool
(5-Spool
(fault code 10), the pump 1 delivery pressure sensor Section) Section)
harness is considered to be faulty.
PP1 PP2
Figure B T157-07-04-006
T5-4-114
TROUBLESHOOTING / Troubleshooting B
T5-4-115
TROUBLESHOOTING / Troubleshooting B
EMERGENCY BOOM LOWERING PRO-
CEDURE
Front Attachment Side
CAUTION: Prevent personal injury. Confirm
that no one is under the front attachment 2
before starting the procedure below.
Screw (2) 2
Tool : 4 mm (Hexagonal wrench)
Torque : 6.9 N⋅m (0.7 kgf⋅m, 5.0 lbf⋅ft)
T5-4-116
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C (TROUBLE-
SHOOTING FOR MONITOR) PROCEDURE
Use troubleshooting C when any monitors, such as
gauges or indicators malfunction.
YES (OK)
(2)
After completing the checking and/or measuring procedures in box
・ (1) (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
・ Causes of machine problems are stated in the thick-line box. Scanning quickly through
the thick-line boxes, allows you to estimate the possible causes before actually following
the flow chart.
Open End
Side
Harness End Connector
T158-05-03-001
T5-5-1
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF COOLANT TEM-
PERATURE GAUGE
• Check for loose harness connections beforehand.
Disconnect coolant
temperature sensor. Faulty coolant temperature
YES sensor.
Ground harness end
Gauge pointer terminal to vehicle
keeps moving frame, Check if pointer
unstably. swings and is stabi-
lized to (H) side.
Faulty monitor.
NO
· Key switch: ON
T5-5-2
TROUBLESHOOTING / Troubleshooting C
105 ゚ C
(95 ゚
70 ゚ C
T157-07-05-001
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-3
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF FUEL GAUGE
Faulty monitor.
NO
· Key switch: ON
T5-5-4
TROUBLESHOOTING / Troubleshooting C
Fuel Sensor
Float
FULL
R381.9 mm
257 mm 3/4
93 mm
70.5 mm
1/2
204 mm
1/4
338 mm
EMPTY
T178-05-05-001
NOTE: 1 mm = 0.03937 in
10 9 8 7 6 5 4 3 2 1
1 2
20 19 18 17 16 15 14 13 12 11
T5-5-5
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF INDICATOR LIGHT
CHECK SYSTEM
• Check for loose harness connections beforehand.
Burnt fuse or faulty monitor.
Disconnect monitor con- YES
nector C. Check if there is
continuity between harness
YES end connector terminal
#1(power input) and fuse
Indicator doesn’t box terminal #5(switch box). Broken harness between
light when indicator Check if all in- fuse and monitor.
light check operation dicators don’t
is performed. light. NO
Conduct troubleshooting of
each indicator, which does
NO not light.
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-6
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF PREHEAT INDICATOR
• The preheat system operates only when coolant • In case the preheat system malfunctions, refer to
temperature is below 10 °C (50 °F), lighting the the troubleshooting B for E-16 Engine is difficult to
preheat indicator for 8 seconds. (Refer to the start at low temperature.
SYSTEM /Electrical Circuit group.) • Check for loose harness connections beforehand.
Remove connector
(with black and Faulty coolant tem-
white cables) from YES perature switch.
Preheat indicator
coolant tempera-
lights even though
ture switch. Check
preheat system
if indicator goes Faulty QOS con-
doesn’t operate YES
OFF by grounding troller.
(coolant tempera-
harness end con-
ture is more than
nector to vehicle Without connecting
10 °C (50 °F)).
frame. Disconnect QOS QOS controller, re-
move connector B Short-circuited har-
controller. Check if
(20P) from monitor. ness between QOS
indicator goes YES
Check for continuity controller and moni-
OFF.
NO between monitor tor.
harness end con-
NO nector terminal #20
and vehicle frame.
· Key switch: ON
· Key switch: ON Faulty monitor.
NO
10 9 8 7 6 5 4 3 2 1 1 2 3
20 19 18 17 16 15 14 13 12 11 4 5 6
T5-5-7
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE OIL LEVEL
INDICATOR
(Up to serial No.104679 (ZX200 class and 225
class), Up to serial No.010322 (ZX230 class), Up
to serial No.020040 (ZX270 class))
Without connecting
connector to engine oil Short-circuited harness be-
level switch, remove tween engine oil level switch
YES and monitor.
connector B (20P) from
monitor. Check for con-
Check if indicator NO tinuity between monitor
lights by removing harness end connector
connector (with terminal #8 and vehicle
Indicator doesn’t frame. Faulty monitor.
light even if engine black and white ca-
ble) from engine oil NO
oil level is lower
than specification. level switch.
Without connecting
connector to engine oil
level switch, remove
connector B (20P) from
monitor. Check for con-
Remove connector tinuity between monitor
(with black and white NO harness end connector To A
cables) from engine oil terminal #8 and engine
Lower than 3.5 mm level switch. Check if oil level switch connec-
below LOW level mark indicator goes OFF by tor.
on oil level gauge grounding harness
end connector to vehi-
cle frame.
Indicator comes ON
even if engine oil
level matches Check oil level with
specification. oil level gauge. Faulty engine oil level switch.
YES
A
Broken harness between en-
gine oil level switch and moni-
NO tor.
T5-5-8
TROUBLESHOOTING / Troubleshooting C
ON
H A (Indicator ON)
L
(Indicator OFF)
OFF
A: 3.5 mm
T107-04-03-010
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-9
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF COOLANT LEVEL IN-
DICATOR
(Up to serial No.104679 (ZX200 class and 225
class), Up to serial No.010322 (ZX230 class), Up
to serial No.020040 (ZX270 class))
Without connecting
connector to coolant
level switch, remove
connector B (20P) from
monitor. Check for con-
tinuity between monitor
Remove connector NO harness end connector
(with gray cables) from terminal #9 and coolant To A
coolant level switch. level switch connector.
Check if indicator goes
OFF by grounding
harness end connec-
NO tor terminal #1 to vehi-
cle frame.
A
Broken harness between
coolant level switch and moni-
NO tor.
T5-5-10
TROUBLESHOOTING / Troubleshooting C
Reserve Tank
ON
FULL
LOW
Radiator OFF
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 1 2
T5-5-11
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ALTERNATOR INDI-
CATOR
• Check for loose harness connections beforehand. NOTE: *Regulator terminals L are water-resistant
type connectors so that it is not practical to
measure voltage at these terminals.
Measure voltage at starter relay terminal R
instead. Check for continuity between
starter relay terminal R and regulator
terminal L beforehand.
Between 13 V
and 33.5 V Faulty monitor.
Measure voltage at
Between 13 V monitor connector A
and 33.5 V (16P) terminal #2.
Broken harness between
Alternator indicator regulator terminal L and
stays ON after en- Measure voltage at monitor.
· Engine: Running
gine is started. regulator terminal L.* Less than 13 V or
higher than 33.5 V
Between 10 V
and 33.5 V Faulty monitor.
Measure voltage at
YES regulator terminal L.*
Although alternator
output is low, alter- Check if indicator Faulty regulator.
nator indicator lights when key · Key switch: ON
· Engine: Stopped Less than 10 V or
doesn’t light. switch is turned ON. higher than 33.5 V
E
8 7 6 5 4 3 2 1
S R 16 15 14 13 12 11 10 9
T5-5-12
TROUBLESHOOTING / Troubleshooting C
(Blank)
T5-5-13
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE OIL PRES-
SURE INDICATOR
• Check for loose harness connections beforehand. NOTE: During one or two minutes after the engine
is stopped, engine oil pressure may still
exist. When the engine is restarted under
this condition, the indicator may not light.
Faulty monitor.
NO
T5-5-14
TROUBLESHOOTING / Troubleshooting C
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-15
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF OVERHEAT INDICA-
TOR
• Check for loose harness connections beforehand.
Faulty monitor.
NO
Check if indicator
Indicator lights even
goes OFF when
if coolant tempera-
overheat switch is Disconnect overheat
ture is low.
disconnected. switch. Remove con- Short-circuited harness be-
YES tween monitor and overheat
nector B (20P) from
monitor. Check for con- switch.
· Key switch: ON tinuity between connec-
· Engine: Stopped tor terminal #6 and vehi-
NO cle frame.
Faulty monitor.
NO
T5-5-16
TROUBLESHOOTING / Troubleshooting C
Overheat Switch
Coolant Temperature Operation
Lower than 105 °C OFF
(221 °F)
105 °C (221 °F) or ON
higher
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-17
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF AIR FILTER RESTRIC-
TION INDICATOR
• Check for loose harness connections beforehand.
· Key switch: ON
Burned indicator light.
NO
A
Broken harness between
monitor and air filter restriction
switch.
NO
T5-5-18
TROUBLESHOOTING / Troubleshooting C
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-19
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF BUZZER
• Check for loose harness connections beforehand. NOTE: *Regulator terminals L are water-resistant
type connectors so that it is not practical to
measure voltage at these terminals.
Measure voltage at starter relay terminal R
instead. Check for continuity between
starter relay terminal R and regulator ter-
minal L beforehand.
-1
· Engine speed: 900 min
(rpm) or faster.
T5-5-20
TROUBLESHOOTING / Troubleshooting C
8 7 6 5 4 3 2 1 E
16 15 14 13 12 11 10 9 S R
Lower than 13 V or
more than 33.5 V Faulty regulator and alterna-
tor.
T5-5-21
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF LCD
Display
Description Cause of Trouble
Order
1 Hour Meter Refer to the next page.
2 Trip 1 Faulty Monitor.
3 Trip 2
4 Actual Engine Speed In case Dr. ZX can display data, monitor is abnormal or communication
5 Hydraulic Oil Tempera- between monitor and MC is interrupted. In case Dr. ZX doesn’t display
ture data, corresponding signal sensor is faulty. (The machine must have
any abnormality in the control system. Refer to Troubleshooting B.)
6 Faulty monitor or interrupted communication between ML controller and
7 Load Alarm monitor.
8 Hydraulic Oil Filter Faulty monitor or interrupted communication between ICX controller
and monitor.
9 Fault Code In case Dr. ZX can display data, monitor is abnormal or communication
10 ML Switch between monitor and MC is interrupted. In case Dr. ZX doesn’t display
11 Pump 1 Delivery Pres- data, corresponding signal sensor is faulty. (The machine must have
sure any abnormality in the control system. Refer to Troubleshooting B.)
12 Pump 2 Delivery Pres-
sure
13 Pump 1 Control Pres-
sure
14 Pump 2 Control Pres-
sure
15 Target Engine Speed
16 EC Angle
17 Dial Angle
18 Boom Raise Lever
Stroke
19 Arm Roll-In Lever Stroke
20 Swing Lever Stroke
21 Travel Lever Stroke
22 Front Attachment Lever
Stroke
23 Attachment Lever Stroke
24 Work Mode
T5-5-22
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HOUR METER
8 7 6 5 4 3 2 1 E
16 15 14 13 12 11 10 9 S R
T5-5-23
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HYDRAULIC OIL FIL-
TER INDICATOR (Optional)
A
Faulty monitor.
NO
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
T5-5-24
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.
Be sure to remove the negative terminals from
the batteries first when taking wire harnesses
and connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses, and fusible links and, in some
cases, cause fire due to short circuiting.
2. Color coding of wire harnesses. Code Color Code Color
The color codes of the wire harnesses in the R Red W White
electrical system are shown in the table on the L Blue G Green
right. Or Orange Lg Light
In cases on the design sheet where two colors green
are indicated for one wire, the left initial stands Y Yellow B Black
for the base color, while the right initial stands for Br Brown P Pink
the marking color.
Gr Gray V Violet
T5-6-1
TROUBLESHOOTING / Electrical System Inspection
3. Precautions for connecting and disconnecting
terminal connectors.
1) When disconnecting harnesses, grasp them
Right Wrong
by their connectors. Do not pull on the wire
itself. Be sure to release the lock first before
attempting to separate connectors, if a lock
is provided. (Refer to “Instructions for
Disconnecting Connector” on page T5-6-3.)
2) Water-resistant connectors keep water out T107-07-06-001
T5-6-2
TROUBLESHOOTING / Electrical System Inspection
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
• Push to Unlock and Separate Type
T107-04-05-003
T5-6-3
TROUBLESHOOTING / Electrical System Inspection
FUSE INSPECTION
Cracks in a fuse are so fine that it is very difficult or NOTE: All terminals located along the lengthwise
impossible to find by visual inspection. Use a tester to centerline of the fuse box are connected to
correctly inspect fuse continuity by following the in- the power source, while terminals located
structions described below. away from the center of the fuse box are
connected to loads (accessories). There-
1. Turn Key Switch ON fore, test all fuses in the same method ex-
When the key switch is turned ON, current from cept for the glow plug relay circuit fuse.
key switch terminal M activates the battery relay Check the glow plug relay circuit fuse with
so that electric power is supplied to all circuits the key switch turned to the ON position
except the glow plug relay circuit. (Refer to the then follow the procedure in step 3.
circuit diagram.)
2. Remove the fuse box cover. Set the tester volt-
age to meet the circuit specification to be meas-
ured. (Measurement Range: 0 to 30 V) 10 20
3. Ground the negative probe of the tester to the 9 19
vehicle frame. Touch the terminals located away
from the center of the fuse box with the positive 8 18
probe of the tester one at a time. When normal 7 17
continuity of a fuse is intact, the tester will indi-
cate 20 to 25 V (battery voltage). 6 16
5 15
4 14
3 13
2 12
1 11
M178-07-034
Fuse Fuse
Capacity Connected to Capacity Connected to
No. No.
1 5A Radio, Monitor ICX (Backup 11 20 A Work Light Relays 1 and 2
Power)
2 5A MC (Main Power) 12 10 A Wiper Relays A, B, and C,
Wiper Motor, Washer Relay
3 10 A MC (EC Motor Power) 13 20 A Heater (Air Conditioner Unit)
4 10 A MC (Solenoid Valve Power) 14 10 A Horn Relay
5 5A Monitor 15 5A Radio
6 5A MC, ICX (Power ON Signal) 16 10 A Cigarette Lighter
7 5A Air Conditioner Unit 17 5A Room Light
8 5A Optional 1 18 10 A Auxiliary
9 10 A Optional 2 19 5A QOS Controller, Glow Plug
Relay
10 5A Optional 3 20 − Empty
T5-6-4
TROUBLESHOOTING / Electrical System Inspection
FUSIBLE LINK INSPECTION Battery Relay
Inspection
Replacement
battery relay.
3. Open the upper and bottom side covers of the
fusible link box. Remove screws M6 (2 used).
4. Take out the fusible link to replace it. Battery
Relay
5. Retighten screws M6 (2 used). Bolt M8
6. Install the fusible link box and the cable to the
battery relay.
7. Reconnect the negative cable to the battery.
Cable Screw M6
T107-04-05-008
T5-6-5
TROUBLESHOOTING / Electrical System Inspection
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between
the battery positive terminal and the vehicle
frame.
Normal Voltage: 24 V
Normal Voltage: 26 to 28 V
T157-07-06-007
T5-6-6
TROUBLESHOOTING / Electrical System Inspection
HOW TO TROUBLESHOOT ALTERNATOR
MALFUNCTIONS
In general, the alternator indicator remains off when
the alternator is generating power.
If the alternator indicator comes on while the engine is
running, the alternator might be defective.
T5-6-7
TROUBLESHOOTING / Electrical System Inspection
CONTINUITY CHECK
Harness
Single-line continuity check A a
Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity
Ω
T5-6-8
TROUBLESHOOTING / Electrical System Inspection
Multi-line continuity check
Disconnect both end connectors of the harness, First short-circuit
and short-circuit two terminals, (A) and (B), at one
end connector, as illustrated. Then, check continuity
A a
between terminals (a) and (b) at the other connector. B b
If the ohm-meter reading is ∞ Ω, either line (A) - (a), C c
or (B) - (b) is in discontinuity. To find out which line
is discontinued, conduct the single line continuity Second short-circuit
check on both lines individually, or, after changing
the short-circuit terminals from (A) - (B) to (A) - (C),
check continuity once more between terminals (a)
Ω
and (c).
A a
×
B b
C c
T107-07-05-005
T5-6-9
TROUBLESHOOTING / Electrical System Inspection
(Blank)
T5-6-10
TROUBLESHOOTING / Electrical System Inspection
VOLTAGE AND CURRENT MEASURE-
MENT
Turn key switch ON so that the specified voltage (cur-
rent) is supplied to the location to be measured.
Judge if the circuit is normal by evaluating whether
the measured voltage (current) matches the specifica-
tion.
24-Volt Circuit
Start checking the circuit in order up to the loca-
tion to be measured from either power source or
actuator side. Thereby, the faulty location in the
circuit will be found.
Black Probe (Minus) of Tester : To ground to the vehi-
cle frame
Red Probe (Plus) of Tester : To touch the location
to be measured
T5-6-11
TROUBLESHOOTING / Electrical System Inspection
T5-6-12
TROUBLESHOOTING / Electrical System Inspection
Key Switch
Battery
6 8
1 2 3 5 4 9
15
Battery Relay
Fuse
10 Box
Starter
18 Load
Damp
Relay
11
12 23 22 21 20 19 17
13 Monitor
Starter Relay
16
Alternator
Glow
Plug
Relay
14
Glow Plug
T178-05-06-001
T5-6-13
TROUBLESHOOTING / Electrical System Inspection
5 Voltage Circuit
Power Signal or
• Voltage between terminal #1 and the vehicle Two Polarities Source Ground
frame (ground) 1 2
With the key switch turned OFF, disconnect the
sensor connector.
Measure the voltage between terminal #1 on the
machine harness side connector and the vehicle
(ground) under the following conditions.
V
• Key switch position: ON
• Tester black terminal (negative):
Connected to the vehicle (ground)
• Tester red terminal (positive):
T107-07-05-006
Connected to terminal #1
Power
Three Polarities
Source Signal Ground
Evaluation: 1 2 3
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal #1 is normal.
terminal
With the key switch turned OFF, disconnect the Two Polarities
1 2
sensor connector.
Measure the voltage between terminal #1 on the
machine harness side connector and the ground
terminal (terminal #2 for two polarities, or terminal
#3 for three polarities) under the following V
conditions.
T107-07-05-009
T5-6-14
TROUBLESHOOTING / Electrical System Inspection
CHECK BY FALSE SIGNAL
Two Polarities
Turn the key switch OFF. After disconnecting the sen- (Oil Temperature)
sor connector, turn the key switch ON. Then, connect (N Sensor)
1 2
machine side harness end connector terminal #1
(power) to terminal #2 (signal). (Power voltage is used
as a false signal.) Check the controller using Dr. ZX
monitor function under this condition. When the
maximum value is displayed, the MC and the circuit
up to the machine side harness end connector are
normal. When the pressure switch circuits are normal, Connect
Dr. ZX displays “ON”.
Connect
T107-07-05-011
T5-6-15
TROUBLESHOOTING / Electrical System Inspection
TEST HARNESS
With a test harness installed between connectors, the
circuit condition is checked depending on whether the
test harness lamp lights or extinguishes during opera-
tion.
T107-07-06-015
Parts Number (ST 7226)
T5-6-16
TROUBLESHOOTING / Electrical System Inspection
Parts Number 4284347 (ST 7129)
Use to measure the EC sensor circuit signal line
voltage (between terminals #2 and #3).
(Red)
(Refer to T5-3-4.)
(Black)
T5-6-17
TROUBLESHOOTING / Electrical System Inspection
(Blank)
T5-6-18
TROUBLESHOOTING / ICX
OUTLINE
The ICX (information controller) stores signals from
various kinds of sensors and switches provided on the
machine as data. The various input signals are
grouped into “Daily Report Data List”, “Frequency Dis-
tribution Data List”, “Cumulative Operation Hour List”,
“Alarm List”, and “Trouble List” and are recorded in
the ICX.
T5-7-1
TROUBLESHOOTING / ICX
Daily Report Data List
Data Details
1 Key Switch ON Time Time when key switch is first turned ON during daily operation
(Time is recorded by key switch ON signal.)
2 Key Switch OFF Time Time when key switch is last turned OFF during daily operation
(Time is recorded by key switch ON signal.)
3 Engine Start Time Time when engine is first started during daily operation
(Time is recorded by alternator output signal.)
4 Engine Stop Time Time when engine is last stopped during daily operation
(Time is recorded by alternator output signal.)
6 Fuel Level The value of the final remained fuel during a day
(Value is recorded by fuel sensor signal from monitor.)
7 Engine Operating Hours Total engine operating hours during daily operation
(Hours are recorded by alternator output signal.)
8 Swing Operating Hours Total swing operating hours during daily operation
(Hours are recorded by signals from swing pressure sensor.)
9 Travel Operating Hours Total travel operating hours during daily operation
(Hours are recorded by signals from travel pressure sensor.)
10 Front Attachment Operat- Total front attachment operating hours during daily operation
ing Hours (Hours are recorded by signals from front attachment pressure sensor.)
11 Breaker Operating Hours Total breaker operating hours during daily operation
(Hours are recorded by signals from auxiliary pressure sensor and attach-
ment mode switch.)
12 Auxiliary Attachment Ex- Total auxiliary attachment except for breaker operating hours during daily
cept for Breaker Operating operation
Hours (Hours are recorded by signals from auxiliary pressure sensor and attach-
ment mode switch.)
T5-7-2
TROUBLESHOOTING / ICX
Data Details
13 *ML Operating Hours Total *ML crane operating hours during daily operation
(Hours are recorded by signals from crane mode switch.)
14 Engine Operating Hour Engine operating hour distribution during daily operation
Distribution (Operating hours are recorded only when alternator output signal is con-
tinuously delivered for more than 10 minutes.)
NOTE: The daily operation in this table is equiva- *ML specification is only available in Japa-
lent to the hours between 0:00 and nese domestic market.
23:59:59 counted by the ICX built-in clock.
In case the engine is kept operated be-
yond 0:00, such data are recorded as
those for the following day.
Data Details
1 Engine Speeds Frequency distribution of engine speeds
(Speeds are recorded by signals from N sensor.)
4 Average Pump Deliv- Frequency distribution of average delivery pressure from pumps 1 and 2
ery Pressure (Average pressures are recorded by signals from delivery pressure sensors of
pumps 1 and 2.)
5 Average Pump Deliv- Frequency distribution of average delivery pressure from pumps during digging
ery Pressure in Dig- operation
ging Operation (Average pressures are recorded by signals from arm roll-in pressure sensor.)
6 Average Pump Deliv- Frequency distribution of average delivery pressure from pumps during travel
ery Pressure in Travel operation
Operation (Average pressures are recorded by signals from travel pressure sensor.)
T5-7-3
TROUBLESHOOTING / ICX
Cumulative Operation Hour List
Data Details
1 Engine Operation Hour Cumulative engine operation hours
(Hours are recorded by alternator output signal.)
6 Auxiliary Attachment Cumulative attachment operation hours except for breaker operation hours
Except for Breaker (Hours are recorded by signals from auxiliary pressure sensor and auxiliary
Operation Hour mode switch.)
T5-7-4
TROUBLESHOOTING / ICX
Alarm List
85 Coolant in Radiator Date and time when coolant level indicator lighted are recorded by
signals from coolant level switch.
86 Hydraulic Oil Filter Date and time when hydraulic oil filter indicator lighted are recorded
by signals from hydraulic oil filter restriction switch.
89 Overheat Date and time when overheat indicator lighted are recorded by sig-
nals from overheat switch.
90 Engine Oil Pressure Date and time when engine oil pressure indicator lighted are re-
corded by signals from engine oil pressure switch.
93 Air Filter Restriction Date and time when air filter restriction indicator lighted are re-
corded by signals from air filter restriction switch.
94 Alternator Indicator Date and time when alternator indicator lighted are recorded by sig-
nals from monitor controller.
T5-7-5
TROUBLESHOOTING / ICX
Trouble List
Fault
Trouble Details
Code
01 Abnormal EEPROM Occurrence time and date of fault code 01
07 Abnormal Engine Control Dial Occurrence time and date of fault code 07
10 Abnormal Pump 1 Delivery Pressure Occurrence time and date of fault code 10
11 Abnormal Pump 2 Delivery Pressure Occurrence time and date of fault code 11
12 Abnormal Pump 1 Control Pressure Occurrence time and date of fault code 12
13 Abnormal Pump 2 Control Pressure Occurrence time and date of fault code 13
14 Abnormal Swing Lever Stroke Occurrence time and date of fault code 14
15 Abnormal Boom Raise Lever Stroke Occurrence time and date of fault code 15
16 Abnormal Arm Roll-In Lever Stroke Occurrence time and date of fault code 16
18 Abnormal Travel Lever Stroke Occurrence time and date of fault code 18
19 Abnormal Oil Temperature Sensor Occurrence time and date of fault code 19
65 Monitor Communication Error Time and date when communication error between
monitor and ICX occurred.
66 Satellite Terminal Communication Error Time and date when communication error between sat-
ellite terminal and ICX occurred.
T5-7-6
TROUBLESHOOTING / ICX
(Blank)
T5-7-7
TROUBLESHOOTING / ICX
ICX FAULT CODE LIST
Fault
Trouble Remarks
Code
1 Abnormal Internal RAM In case of SAM error
7 MC Communication Timeout (For ZAXIS) In case MC communication didn’t last for more than 7
seconds.
8 Monitor Communication Timeout In case monitor communication didn’t last for more than
24 seconds.
9* MC Communication Timeout (For EX5) In case MC communication didn’t last for more than 20
seconds.
10 Satellite Terminal Communication Timeout In case satellite communication didn’t last for more than
1 minute.
Fault
Trouble Remarks
Code
101 Satellite Terminal: Internal Error Abnormal EEPROM
104 Satellite Terminal: Communication Error In case satellite communication cannot be accom-
plished.
105 Satellite Terminal: Internal Error In case sending retry over occurred or local loop back
test failed with power ON.
106 Satellite Terminal: Communication Error In case sending retry over occurred.
107 Satellite Terminal: Abnormal Harness In case reception data doesn’t match sending data.
T5-7-8
TROUBLESHOOTING / ICX
FAULT CODE 1 TO 4 AND 6
Faulty ICX.
NO
FAULT CODE 7 TO 10
T5-7-9
TROUBLESHOOTING / ICX
SOME PARTS OF DATA IN DAILY REPORT,
FREQUENCY DISTRIBUTION, CUMULA-
TIVE OPERATION HOURS ARE NOT RE-
CORDED
• All necessary data signals may not be input into
the ICX. Individual signals are utilized to record
more than one data. While referring to the table
below, check the corresponding system for any
abnormality.
Engine start and stop time, Engine operating hours (Daily report and cumulative Alternator
operation hour), Engine operating hour distribution
Travel operating hours (Daily report and cumulative operation hour), Average Travel pressure sensor
pump delivery pressure distribution in travel operation
Front attachment operating hours (Daily report and cumulative operation hour) Front attachment pressure
sensor
Swing operating hours (Daily report and cumulative operation hour) Swing pressure sensor
Average pump delivery pressure distribution in digging operation Arm roll-in pressure sen-
sor
Breaker operating hours (Daily report and cumulative operation hour), Auxiliary Auxiliary pressure sensor
attachment except for breaker operating hours (Daily report and cumulative op-
eration hour)
Distribution of average pump delivery pressure, average pump delivery pressure Pump 1 delivery pressure
in digging operation and travel operation sensor
Distribution of average pump delivery pressure, average pump delivery pressure Pump 2 delivery pressure
in digging operation and travel operation sensor
Breaker operating hours (Daily report and cumulative operation hour) Attachment mode switch
Auxiliary attachment except for breaker operating hours (Daily report and cumula- Auxiliary mode switch
tive operation hour)
*ML operating hours (Daily report and cumulative operation hour) Crane mode switch
T5-7-10
TROUBLESHOOTING / ICX
Check harness between ICX terminal B1 and monitor In case hour meter malfunctions, refer to trouble-
terminal B3. shooting C.
Check harness between ICX terminal B1 and monitor In case coolant temperature gauge malfunctions, refer
terminal B3. to troubleshooting C.
Check harness between ICX terminal B1 and monitor In case fuel gauge malfunctions, refer to troubleshoot-
terminal B3. ing C.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
T5-7-11
TROUBLESHOOTING / ICX
(Blank)
T5-7-12
Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162
REPLY: