Technical Manual: (Troubleshooting)

Technical Manual
(Troubleshooting)
Vol No.: TT178E-03
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INTRODUCTION
TO THE READER
This manual is written for an experienced technician If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using Service Manual
Revision Request Form at the end of this man-
Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition Operation Manual of the Engine
to this manual. Parts Catalog of the Engine
Hitachi Training Material
The Operators Manual
The Parts Catalog
MANUAL COMPOSITION
This manual consists of three portions: the Techni- Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
Information included in the Technical Manual Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redelivery and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
IN-01

INTRODUCTION
PAGE NUMBER
Each page has a number, located on the center
lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual
SAFETY ALERT SYMBOL AND HEADLINE

NOTATIONS
CAUTION:
In this manual, the following safety alert symbol and Indicated potentially hazardous situation which
signal words are used to alert the reader to the could, if not avoided, result in personal injury or
potential for personal injury of machine damage. death.
This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury. Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights. NOTE:
To avoid injury and damage, be sure to use appropri- Indicates supplementary technical information or
know-how.
ate lifting techniques and equipment when lifting
heavy parts.
IN-02

INTRODUCTION
UNITS USED
2
SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature C F C 1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque Nm kgf m 1.0197 mL/rev cc/rev 1.0
Nm lbf ft 0.7375
IN-03

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

shown in the table below. When referring to the texts and/or illustrations
indicated with the applicable machine class names in this manual,
check that the machine models concerned are included using this ta-
ble.
Class
ZX200 Class ZAXIS200, 200LC, 210H, 210LCH, 210, 210LC, 210N, 240
ZX225 Class ZAXIS225USR, 225USRLC, 225US, 225USLC
ZX230 Class ZAXIS230, 230LC, 240H, 240LCH, 250, 250LC, 250LCN
ZX270 Class ZAXIS270, 270LC, 280LC, 280LCN
Model
Std. Model 200, 200LC, 210, 210LC, 210H, 210LCH, 210N, 225USR, 225USRLC,
225US, 225USLC, 230, 230LC, 240, 240H, 240LCH, 250, 250LC, 250LCN, 270,
270LC, 280LC, 280LCN
IN-04

SAFETY
RECOGNIZE SAFETY INFORMATION
This is the SAFETY ALERT SYMBOL.
When you see this symbol on your machine or in
this manual, be alert to the potential for personal
injury.
Follow recommended precautions and safe
operating practices.
001-E01A-0688
SA-688
UNDERSTAND SIGNAL WORDS
On machine safety signs, signal words designating

the degree or level of hazard - DANGER,
WARNING, or CAUTION - are used with the safety
alert symbol.
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
DANGER or WARNING safety signs are
located near specific hazards. General
precautions are listed on CAUTION safety
signs.
Some safety signs dont use any of the
designated signal words above after the safety
alert symbol are occasionally used on this
machine. SA-1223
CAUTION also calls attention to safety messages in

this manual.
To avoid confusing machine protection with
personal safety messages, a signal word
IMPORTANT indicates a situation which, if not
avoided, could result in damage to the machine.
NOTE indicates an additional explanation for an

element of information.
002-E01C-1223
SA-1

SAFETY
FOLLOW SAFETY INSTRUCTIONS
Carefully read and follow all safety signs on the
machine and all safety messages in this manual.
Safety signs should be installed, maintained and
replaced when necessary.
If a safety sign or this manual is damaged or
missing, order a replacement from your author-
ized dealer in the same way you order other
replacement parts (be sure to state machine
model and serial number when ordering).
Learn how to operate the machine and its controls
correctly and safely.
Allow only trained, qualified, authorized personnel SA-003
to operate the machine.

Keep your machine in proper working condition.
Unauthorized modifications of the machine may
impair its function and/or safety and affect ma-
chine life.
The safety messages in this SAFETY chapter are
intended to illustrate basic safety procedures of
machines. However it is impossible for these safety
messages to cover every hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your au-
thorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003
SA-2

SAFETY
PREPARE FOR EMERGENCIES
Be prepared if a fire starts or if an accident occurs.
Keep a first aid kit and fire extinguisher on hand.
Thoroughly read and understand the label at-
tached on the fire extinguisher to use it properly.
To ensure that a fire-extinguisher can be always
used when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
Establish emergency procedure guidelines to
cope with fires and accidents.
Keep emergency numbers for doctors, ambu-
lance service, hospital, and fire department SA-437
posted near your telephone.
004-E01A-0437
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment

appropriate to the job.
You may need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask. SA-438
Be sure to wear the correct equipment and clothing

for the job. Do not take any chances.
Avoid wearing loose clothing, jewelry, or other
items that can catch on control levers or other
parts of the machine.
Operating equipment safely requires the full
attention of the operator. Do not wear radio or
music headphones while operating the machine.
005-E01A-0438
SA-3

SAFETY
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause
impairment or loss of hearing.
Wear a suitable hearing protective device such
as earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.
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 operators manual.
S007-E01A-0435
SA-435
SA-4

SAFETY
GENERAL PRECAUTIONS FOR CAB
Before entering the cab, thoroughly remove all
dirt and/or oil from the soles of your work boots. If
any controls such as a pedal is operated while
with dirt and/or oil on the soles of the operators
work boots the operators foot may slip off the
pedal, possibly resulting in a personal accident.
Dont leave parts and/or tools lying around the
operators seat. Store them in their specified lo-
cations.
Avoid storing transparent bottles in the cab. Dont
attach any transparent type window decorations
on the windowpanes as they may focus sunlight,
possibly starting a fire.
Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab
while operating the machine.
Keep all flammable objects and/or explosives
away from the machine.
After using the ashtray, always cover it to extin-
guish the match and/or tobacco.
Dont leave cigarette lighters in the cab. When
the temperature in the cab increases, the lighter
may explode.
524-E01A-0000
SA-5

SAFETY
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal injury.
When you mounting and dismounting the ma-
chine, always face the machine and maintain a
three-point contact with the steps and handrails.
Do not use any controls as hand-holds.
Never jump on or off the machine. Never mount
or dismount a moving machine.
Be careful of slippery conditions on platforms,
steps, and handrails when mounting and dis-
mounting the machine.
SA-439
008-E01B-0439
ADJUST THE OPERATOR'S SEAT

A poorly adjusted seat for either the operator or for
the work at hand may quickly fatigue the operator
leading to misoperations.
The seat should be adjusted whenever changing
the operator for the machine.
The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
If not, move the seat forward or backward, and
check again.
SA-378
009-E01A-0378
SA-6

SAFETY
FASTEN YOUR SEAT BELT
If the machine should overturn, the operator may
become injured and/or thrown from the cab.
Additionally the operator may be crushed by the
overturning machine, resulting in serious injury or
death.
Prior to operating the machine, thoroughly
examine webbing, buckle and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine.
Be sure to remain seated with the seat belt SA-237
securely fastened at all times when the machine

is in operation to minimize the chance of injury
from an accident.
We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.
010-E01A-0237
MOVE AND OPERATE MACHINE SAFELY

Bystanders can be run over.
Take extra care not to run over bystanders.
Confirm the location of bystanders before moving,
swinging, or operating the machine.
Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the
machine. SA-426
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
levers are in neutral.
012-E01B-0444
JUMP STARTING
Battery gas can explode, resulting in serious injury.
If the engine must be jump started, be sure to
follow the instructions shown in the OPERATING
THE ENGINE chapter in the operators manual.
The operator must be in the operators seat so
that the machine will be under control when the
engine starts. Jump starting is a two-person
operation.
Never use a frozen battery.
Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway SA-032
machine.
S013-E01A-0032
SA-8

SAFETY
KEEP RIDERS OFF MACHINE
Riders on machine are subject to injury such as
being struck by foreign objects and being thrown off
the machine.
Only the operator should be on the machine.
Keep riders off.
Riders also obstruct the operators view, resulting
in the machine being operated in an unsafe
manner.
014-E01B-0379
SA-379
PROVIDE SIGNALS FOR FOBS INVOLV-

ING MULTIPLE NUMBERS OF MACHINES
For jobs involving multiple numbers of machines,

provide signals commonly known by all personnel
involved. Also, appoint a signal person to coordi-
nate the job site. Make sure that all personnel obey
the signal persons directions.
018-E01A-0481
SA-481
CONFIRM DIRECTION OF MACHINE TO

BE DRIVEN
Incorrect travel pedal/lever operation may result in

serious injury death.
Before driving the machine, confirm the position
of the undercarriage in relation to the operators
position. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.
017-E01A-0491
SA-491
SA-9

SAFETY
DRIVE MACHINE SAFELY
Before driving the machine, always confirm that the
travel levers/pedals direction corresponds to the
direction you wish to drive.
Be sure to detour around any obstructions.
Avoid traveling over obstructions. Soil, fragments
of rocks, and/or metal pieces may scatter around
the machine. Dont allow personnel to stay
around the machine while traveling.
SA-387
Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or
death.
When driving up or down a slope, keep the
bucket facing the direction of travel, approxi-
mately 200 to 300 mm (A) above the ground.
If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop traveling.
SA-388
Driving across the face of a slope or steering on SA-441
a slope may cause the machine to skid or turn-

over. If the direction must be changed, move the
WRONG
machine to level ground, then, change the direc-
tion to ensure sage operation.
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
H/P mode switch off.

Run the engine at slow idle speed without load
for 5 minutes to cool down the engine.
Stop the engine and remove the key from the key
switch.
Pull the pilot control shut-off lever to LOCK
position.
Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
Position the machine to prevent rolling.
Park a reasonable distance from other machines.
SA-392
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.
To avoid back-over and swing accidents:

Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
Keep the travel alarm in working condition (if SA-383
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 operators 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
MACHINE WILL TIP OVER FASTER THAN YOU

CAN JUMP FREE
FASTEN YOUR SEAT BELT
The danger of tipping is always present when

operating on a grade, possibly resulting in serious SA-012
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
Serious injury or death can result if the machine or
front attachments are not kept a safe distance from
electric lines.
When operating near an electric line, NEVER
move any part of the machine or load closer than
3 m (10 ft) plus twice the line insulator length.
Check and comply with any local regulations that
may apply.
Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site.
SA-381
029-E01A-0381
OBJECT HANDLING
If a lifted load should fall, any person nearby may
be struck by the falling load or may be crushed
underneath it, resulting in serious injury or death.
When using the machine for craning operations,
be sure to comply with all local regulations.
Do not use damaged chains or frayed cables,
sables, slings, or ropes.
Before craning, position the upperstructure with
the travel motors at the rear.
Move the load slowly and carefully. Never move it
suddenly.
Keep all persons well away from the load.
Never move a load over a person's head.
Do not allow anyone to approach the load until it
is safely and securely situated on supporting
SA-014
blocks or on the ground.
Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.
032-E01A-0014
SA-14

SAFETY
PROTECT AGAINST FLYING DEBRIS
If flying debris hit eyes or any other part of the body,
serious injury may result.
Guard against injury from flying pieces of metal
or debris; wear goggles or safety glasses.
Keep bystanders away from the working area
before striking any object.
031-E01A-0432
SA-432
PARK MACHINE SAFELY

To avoid accidents:
Park machine on a firm, level surface.
Lower bucket to the ground.
Turn auto-idle / acceleration selector and H/P
mode switch off.
Run engine at slow idle speed without load for 5
minutes.
Turn key switch to OFF to stop engine.
Remove the key from the key switch.
Pull the pilot control shut-off lever to the LOCK
position. SA-390
Close windows, roof vent, and cab door.

Lock all access doors and compartments.
033-E09B-0390
SA-15

SAFETY
HANDLE FLUIDS SAFELY AVOID FIRES
Handle fuel with care; it is highly flammable. If fuel
ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.
Do not refuel the machine while smoking or when
near open flame or sparks.
Always stop the engine before refueling the
machine.
Fill the fuel tank outdoors.
All fuels, most lubricants, and some coolants are

flammable. SA-018
Store flammable fluids well away from fire

hazards.
Do not incinerate or puncture pressurized
containers.
Do not store oily rags; they can ignite and burn
spontaneously.
Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
SA-16

SAFETY
SAFETY TRANSPORTING
The danger of tipping is present when
loading/unloading the machine onto/from a truck or
trailer bed.
Be sure to observe local regulations when
transporting the machine on public roads.
Provide an appropriate truck or trailer for
transporting the machine.
Take the following precautions when loading /

unloading the machine:
1) Select firm level ground. SA-395
2) Be sure to use a loading dock or ramp.

3) Be sure to have a signal person when
loading/unloading the machine.
4) Always turn the auto-idle / acceleration selector
and the H/P mode switch OFF when loading or
unloading the machine, to avoid unexpected
speed increase due to unintentional operation
of a control lever.
5) Always select the slow speed mode with the
travel mode switches. In the high speed mode,
travel speed may automatically increase.
6) Avoid steering while driving up or down the
ramp as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify traveling direction, and begin to
drive again.
7) Do not operate any levers besides the travel
levers when driving up or down the ramp.
8) The top end of the ramp where it meets the
flatbed is a sudden bump. Take care when
traveling over it.
9) Prevent possible injury from machine tipping
while the upperstructure is rotating.
10) Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11) Securely fasten chain or cables to the machine
frame. Refer to "transporting" chapter in the
operator's manual for details.
S035-E08A-0395
SA-17

SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
Understand service procedures before doing

work.
Keep work area clean and dry.
Do not spray water or steam inside cab.
Never lubricate or service the machine while it is
moving.
Keep hands, feet and clothing away from
power-driven parts.
Before servicing the machine:

1) Park the machine on a level surface.
2) Lower the bucket to the ground.
3) Turn the auto-idle / acceleration selecltor off.
4) Run the engine at slow idle speed without load
for 5 minutes.
5) Turn the key switch to OFF to stop engine.
6) Relieve the pressure in the hydraulic system by
moving the control levers several times.
7) Remove the key from the switch.
8) Attach a Do Not Operate tag on the control
lever.
9) Pull the pilot control shut-off lever to the LOCK
position.
10) Allow the engine to cool.
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 operators 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
inside the machine.

Always use a work light protected with a guard.
In case the light bulb is broken, spilled fuel, oil
antifreeze fluid, or window washer fluid may
catch fire.
S500-E02B-0497
SA-037
SA-19

SAFETY
WARN OTHERS OF SERVICE WORK
Unexpected machine movement can cause serious
injury.
Before performing any work on the machine, at-
tach a Do Not Operate tag on the control lever.
This tag is available from your authorized dealer.
SS2045102
SUPPORT MACHINE PROPERLY

Never attempt to work on the machine without
securing the machine first.
Always lower the attachment to the ground
before you work on the machine.
If you must work on a lifted machine or
attachment, securely support the machine or
attachment. Do not support the machine on
cinder blocks, hollow tires, or props that may
crumble under continuous load. Do not work
under a machine that is supported solely by a
SA-527
jack.
519-E01A-0527
STAY CLEAR OF MOVING PARTS

Entanglement in moving parts can cause serious
injury.
To prevent accidents, care should be taken to
ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working around
rotating parts.
502-E01A-0026
SA-026
SA-20

SAFETY
PREVENT PARTS FROM FLYING
Grease in the track adjuster is under high pressure.
Failure to follow the precautions below may result in
serious injury, blindness, or death.
Do not attempt to remove GREASE FITTING or
VALVE ASSEMBLY.
As pieces may fly off, be sure to keep body and
face away from valve.
Travel reduction gears are under pressure.
As pieces may fly off, be sure to keep body and
face away from AIR RELEASE PLUG to avoid
injury. GEAR OIL is hot. SA-344
Wait for GEAR OIL to cool, then gradually loosen

AIR RELEASE PLUG to release pressure.
503-E01B-0344
STORE ATTACHMENTS SAFELY

Stored attachments such as buckets, hydraulic
hammers, and blades can fall and cause serious
injury or death.
Securely store attachments and implements to
prevent falling. Keep children and bystanders
away from storage areas.
504-E01A-0034 SA-034
USE TOOLS PROPERLY

Use tools appropriate for the work to be done.
Makeshift tools, parts, and procedures can create
safety hazards.
For loosening and tightening hardware, use the
correct size tools to avoid injury caused by
slipping wrenches.
Use only recommended replacement parts.
(See the parts catalog.)
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
The hydraulic oil tank is pressurized. Again, be

sure to release all pressure before removing the
cap.
Hot fluids and surfaces:

Engine oil, gear oil and hydraulic oil also become
hot during operation.
The engine, hoses, lines and other parts become
hot as well.
Wait for the oil and components to cool before
starting any maintenance or inspection work.
505-E01B-0498 SA-225
REPLACE RUBBER HOSES

PERIODICALLY
Rubber hoses that contain flammable fluids under

pressure may break due to aging, fatigue, and
abrasion. It is very difficult to gauge the extent of
deterioration due to aging, fatigue, and abrasion of
rubber hoses by inspection alone.
Periodically replace the rubber hoses. (See the
page of Periodic replacement of parts in the
operators manual.)
Failure to periodically replace rubber hoses may
cause a fire, fluid injection into skin, or the front SA-019
attachment to fall on a person nearby, which may

result in severe burns, gangrene, or otherwise
serious injury or death.
S506-E01A-0019
SA-22

SAFETY
AVOID HIGH-PRESSURE FLUIDS
Fluids such as diesel fuel or hydraulic oil under
pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
Tighten all connections before applying pressure.
Search for leaks with a piece of cardboard; take
care to protect hands and body from
high-pressure fluids. Wear a face shield or SA-031
goggles for eye protection.

If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.
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.
Check for Shorts:

Short circuits can cause fires.
Clean and tighten all electrical connections.
Check before starting work for loose, kinked,
hardened or frayed electrical cables and wires.
Check before starting work for missing or
damaged terminal caps.
DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
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.
Check Emergency Engine Stop Switch:

If a fire breaks out, failure to release pressurized air
inside the hydraulic tank will escalate fire, hamper-
ing fire fighting.
Check the emergency engine stop switch func-
tion every 250 hours:
1) Start the engine and run it at slow Idle.
2) Turn the emergency engine stop switch to the
EMERG. STOP position.
3) Confirm that both engines stop and that
pressurized air inside the hydraulic oil tank is
released (a hissing sound should be heard).
If any abnormalities are found, be sure to repair
them before operating the machine.
Check Heat Shields:

Damaged or missing heat shields may lead to fires.
Damaged or missing heat shields must be
repaired or replaced before operating the
machine.
S508-E02B-0019
SA-25

SAFETY
EVACUATING IN CASE OF FIRE
If a fire breaks out, evacuate the machine in the
following way:
Stop the engine by turning the key switch to the
OFF position if there is time.
Use a fire extinguisher if there is time.
Exit the machine.
In an emergency, if the cab door and/or the front SA-393
window cannot be opened, break the front or rear

window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on EMERGENCY
EXIT in Operators Manual.
518-E02B-0393
SS-1510
BEWARE OF EXHAUST FUMES

Prevent asphyxiation. Engine exhaust fumes can
cause sickness or death.
If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.
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
there are no abnormalities such as the area sur-

rounding the welded area still smoldering.
523-E01A-0818
AVOID HEATING NEAR PRESSURIZED

FLUID LINES
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
Do not heat by welding, soldering, or using a
torch near pressurized fluid lines or other
flammable materials.
Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area.
Install temporary fire-resistant guards to protect
hoses or other materials before engaging in
welding, soldering, etc.. SA-030
AVOID APPLYING HEAT TO LINES

CONTAINING FLAMMABLE FLUIDS
Do not weld or flame cut pipes or tubes that
contain flammable fluids.
Clean them thoroughly with nonflammable
solvent before welding or flame cutting them.
510-E01B-0030
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.
Remove paint before welding or heating:

1) If you sand or grind paint, avoid breathing the
dust. SA-029
Wear an approved respirator.

2) If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.
511-E01A-0029
PREVENT BATTERY EXPLOSIONS
Battery gas can explode.

Keep sparks, lighted matches, and flame away
from the top of battery.
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or hy-
drometer.
Do not charge a frozen battery; it may explode.
Warm the battery to 16 C ( 60 F ) first.
Do not continue to use or charge the battery
when electrolyte level is lower than specified. Ex-
plosion of the battery may result. SA-032
Loose terminals may produce sparks. Securely

tighten all terminals.
Battery electrolyte is poisonous. If the battery
should explode battery electrolyte may be splashed
into eyes, possibly resulting in blindness.
Be sure to wear eye protection when checking
electrolyte specific gravity.
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
HANDLE CHEMICAL PRODUCTS SAFELY

Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals
used with your machine include such items as
lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides
specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know
exactly what the risks are and how to do the job SA-309
safely. Then follow procedures and use

recommended equipment.
S515-E01A-0309
SA-29

SAFETY
DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids.
Do not use food or beverage containers that may
mislead someone into drinking from them.
Do not pour waste onto the ground, down a drain,
or into any water source.
Air conditioning refrigerants escaping into the air
can damage the Earths atmosphere. SA-226
Government regulations may require a certified

air conditioning service center to recover and
recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center.
S516-E01A-0226
BEFORE RETURNING THE MACHINE TO

THE CUSTOMER
After maintenance or repair work is complete,
confirm that:
The machine is functioning properly, especially
the safety systems.
Worn or damaged parts have been repaired or
replaced
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
Group 3 Engine Test

Engine Speed ........................................... T4-3-1
Engine Compression Pressure ................. T4-3-4
Valve Clearance Adjustment ..................... T4-3-6
Nozzle Check............................................ T4-3-8
Injection Timing....................................... T4-3-10
Lubricant Consumption ......................... T4-3-12
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 machines 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 machines 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.
Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
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
leaking oil. Use oil pans to catch escaping oil.

Pay special attention to this when removing hy-
draulic pipings.
MAKE PRECISE MEASUREMENT

1. Accurately calibrate test instruments in advance
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
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
+65 relieve the boom raise
Fast Idle Speed (Relief Operation) 1900 -50
circuit.Value indicated on Dr.
ZX.
+90
Fast Idle Speed (E mode) 1800 -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) MPa (kgf/cm2, 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)
18.1 (185, 2630)
MPa (kgf/cm2, 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

NOTE: 1 mm=0.03937 in
ZX200 class
Reference
Page
Standard)
TRAVEL SPEED sec/20 m T4-4-1
Travel speed isnt 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
Bucket Cylinder
Bucket Bottom
T4-2-2

NOTE: 1 mm=0.03937 in
ZX200 class
Reference
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
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 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)
PRIMARY PILOT PRESSURE T4-5-1
MPa (kgf/cm2, psi)
Engine: Fast Idle 4.0+1.0-0.5
+10 +142
(41 -5, 580 -71)
+1.0
Engine: Slow Idle 3.5 -0
(35+10-0, 500+142-0)
SECONDARY PILOT PRESSURE) 3.4 to 4.0 Value indicated on Dr. ZX T4-5-4
(Engine: Fast Idle and Slow Idle) (34 to 40, 483 to (Lever: Full stroke)
MPa (kgf/cm2, psi) 570)
SOLENOID VALVE SET PRESSURE Value Indicated On T4-5-6
MPa (kgf/cm2, psi) Dr. ZX 0.2 (2, 28)
MAIN PUMP DELIVERY PRESSURE 0.7+1.0-0.5 Value indicated on Dr. ZX T4-5-9
MPa (kgf/cm2, psi) (7 -5, 100+142-71)
+10
T4-2-3

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,
+284
4980 -71)
Power Boost 36.3+2.0-1.0 Value indicated on Dr. ZX
+20
(370 -10,
+284
5260 -142)
RELIEF PRESSURE MPa (kgf/cm2, psi) +2.3
31.9 -0 Value indicated on Dr. ZX T4-5-14
(When relieving Swing) (325+25-0,
+356
4620 -0)
34.3 -0.5 Value indicated on Dr. ZX T4-5-16
(When relieving Travel) (350+20-5,
+284
4980 -71)
OVERLOAD RELIEF VALVE SET PRES- (Reference values T4-5-18
SURE MPa (kgf/cm2, psi) at 50 L/min)
Boom (Raise/Lower), Arm Roll-In, and 37.3+1.0-0
Bucket Roll-In +10
(380 -0,
5400+142-0)
Arm Roll-Out, Bucket Roll-Out 39.2+1.0-0
+10
(400 -0,
+142
5690 -0)
MAIN PUMP FLOW TEST (L/min) - Refer to page T4-2-22, 23. T4-5-22
SWING MOTOR DRAINAGE (L/min) T4-5-29
With constant maximum speed 0.2 to 0.3
With the motor relieved (2 to 5)
TRAVEL MOTOR DRAINAGE (L/min) T4-5-32
With the track jacked up 1.4 to 2.1 Allowable limit: 2.6
With the motor relieved 1.4 to 4.0 Allowable limit: 5.0
T4-2-4

ZAXIS225USR OPERATIONAL
test procedure:
NOTE: 1 mm=0.03937 in
ZAXIS225USR
Reference
Page
Standard)
Slow Idle Speed 950 100 Value indicated on Dr. ZX.
Fast Idle Speed (Normal) 1965 50
Fast Idle Speed (Wirh ECO deactivated) 2060 50
relieve the boom raise
Fast Idle Speed (Relief Operation) 1915 50
ZX.
Fast Idle Speed (E mode) 1820 70 Value indicated on Dr. ZX.
Auto-Idle Speed 1335 100 Value indicated on Dr. ZX.
Auto-Acceleration Speed 1675 100
3.04 (31, 440)
2 18.1 (185, 2630)
MPa (kgf/cm , psi)
10
50 or less
T4-2-5

NOTE: 1 mm=0.03937 in
ZAXIS225USR
Reference
Page
Standard)
track is jacked up.
Slow Speed 21.8 2.0
17.8 1.0 LC: 18.9 1.0
Fast Speed
28.2 2.0 LC: 30.1 2.0
Slow Speed
200 or less
mm /180
deg. more
3
sec 0.8 m (PCSA heaped)
Boom Raise 3.1 0.3
Boom Lower 2.3 0.3
Arm Roll-In 3.8 0.3
Boom Cylinder
Arm Cylinder
Bucket Cylinder
Bucket Bottom
T4-2-6

NOTE: 1 mm=0.03937 in
ZAXIS225USR
Reference
Page
Standard)
N (kgf, lbf ft)
Arm Lever 15 (1.5, 10.8) or
less
less
Boom Lever 105 10
Arm Lever
84 10
Bucket Lever 84 10
Swing Lever 105 10
Travel Lever 120 10
3.6 0.3 0.8 m3 (PCSA heaped)
4.5 0.5 0.8 m3 (PCSA heaped)
MPa (kgf/cm2, psi)
+10 +142
(41 -5, 580 -71)
+1.0
(35+10-0, 500+142-0)
MPa (kgf/cm2, psi) Dr. ZX 0.2 (2,28)
MPa (kgf/cm2, psi) (7 -5, 100+142-71)
+10
T4-2-7

NOTE: 1 mm=0.03937 in
ZAXIS225USR Reference
Standard)
2
MPa (kgf/cm , psi)
(350+20-5,
+284
4980 -71)
+20
(370 -10,
+284
5260 -142)
+356
4620 -0)
+284
4980 -71)
Bucket Roll-In +10
(380 -0,
5400+142-0)
+10
(400 -0,
+142
5690 -0)
T4-2-8

ZAXIS225US OPERATIONAL
test procedure:
NOTE: 1 mm=0.03937 in
ZAXIS225US
Reference
Page
Standard)
Slow Idle Speed 950 100 Value indicated on Dr. ZX.
Fast Idle Speed (Normal) 1965 50
Fast Idle Speed (Wirh ECO deactivated) 2065 50
relieve the boom raise
Fast Idle Speed (Relief Operation) 1915 50
ZX.
Fast Idle Speed (E mode) 1820 70 Value indicated on Dr. ZX.
Auto-Idle Speed 1335 100 Value indicated on Dr. ZX.
Auto-Acceleration Speed 1675 100
3.04 (31, 440)
2 18.1 (185, 2630)
MPa (kgf/cm , psi)
10
50 or less
T4-2-9

NOTE: 1 mm=0.03937 in
ZAXIS225US
Reference
Page
Standard)
track is jacked up.
Slow Speed 21.8 2.0
17.8 1.0 LC: 18.9 1.0
Fast Speed
28.2 2.0 LC: 30.1 2.0
Slow Speed
200 or less
mm /180
deg. more
3
Boom Raise 3.8 0.3
Boom Lower 3.0 0.3
Arm Roll-In 3.8 0.3
Boom Cylinder
Arm Cylinder
Bucket Cylinder
Bucket Bottom
T4-2-10

NOTE: 1 mm=0.03937 in
ZAXIS225US
Reference
Page
Standard)
N (kgf, lbf ft)
Arm Lever 15 (1.5, 10.8) or
less
less
Boom Lever 105 10
Arm Lever
84 10
Bucket Lever 84 10
Swing Lever 105 10
Travel Lever 120 10
3.5 0.3 0.8 m3 (PCSA heaped)
4.5 0.5 0.8 m3 (PCSA heaped)
MPa (kgf/cm2, psi)
+10 +142
(41 -5, 580 -71)
+1.0
(35+10-0, 500+142-0)
MPa (kgf/cm2, psi) Dr. ZX 0.2 (2.28)
MPa (kgf/cm2, psi) (7 -5, 100+142-71)
+10
T4-2-11

NOTE: 1 mm=0.03937 in
ZAXIS225US Reference
Standard)
2
MPa (kgf/cm , psi)
(350+20-5,
+284
4980 -71)
+20
(370 -10,
+284
5260 -142)
+356
4620 -0)
+284
4980 -71)
Bucket Roll-In +10
(380 -0,
5400+142-0)
+10
(400 -0,
+142
5690 -0)
T4-2-12

test procedure:
NOTE: 1 mm=0.03937 in
ZX230 class
Reference
Page
Standard)
ZX.
+90
3.04 (31, 440)
2 18.1 (185, 2630)
MPa (kgf/cm , psi)
10
60 or less
T4-2-13

NOTE: 1 mm=0.03937 in
ZX230 class
Reference
Page
Standard)
track is jacked up.
Slow Speed 21.0 2.0
Fast Speed 17.1 1.0 LC: 18.7 1.0
Slow Speed 28.2 2.0 LC: 30.0 2.0
200 or less
mm /180
deg. more
sec 1.0 m3 (PCSA heaped)
Boom Raise 3.3 0.3
Boom Lower 2.5 0.3
Arm Roll-In 4.1 0.3
DIG FUNCTION DRIFT CHECK mm/5 min 2.96 m arm T4-4-16
Boom Cylinder
Arm Cylinder
Bucket Cylinder
Bucket Bottom
T4-2-14

NOTE: 1 mm=0.03937 in
ZX230 class
Reference
Page
Standard)
N (kgf, lbf ft)
Arm Lever 15 (1.5, 10.8) or
less
less
Boom Lever 105 10
Arm Lever
84 10
Bucket Lever 84 10
Swing Lever 105 10
Travel Lever 120 10
3.8 0.3 1.0 m3 (PCSA heaped)
5.0 0.5 1.0 m3 (PCSA heaped)
MPa (kgf/cm2, psi)
Engine: Fast Idle 4.0+1.0-0.5 Value indicated on Dr. ZX
+10 +142
(41 -5, 580 -71)
+1.0
Engine: Slow Idle 3.5 -0 Value indicated on Dr. ZX
(35+10-0, 500+142-0)
MPa (kgf/cm2, psi) (8 -5, 114+171-71)
+12
T4-2-15

NOTE: 1 mm=0.03937 in
Standard)
2
MPa (kgf/cm , psi)
(350+20-5,
+284
4980 -71)
+20
(370 -10,
+284
5260 -142)
RELIEF PRESSURE MPa (kgf/cm2, psi) 30.9
+2.20
-0.5 Value indicated on Dr. ZX T4-5-14
+327
4479 -71)
+284
4980 -71)
Bucket Roll-In +10
(379 -0,
5389+142-0)
+10
(400 -0,
+142
5690 -0)
T4-2-16

test procedure:
NOTE: 1 mm=0.03937 in
ZX270 class
Reference
Page
Standard)
ZX.
+90
3.04 (31, 440)
2 18.1 (185, 2630)
MPa (kgf/cm , psi)
10
60 or less
T4-2-17

NOTE: 1 mm=0.03937 in
ZX270 class
Reference
Page
Standard)
track is jacked up.
Slow Speed 24.8 2.0
34.6 2.0 LC: 36.1 2.0
Fast Speed
34.6 2.0 LC: 36.1 2.0
Slow Speed
200 or less
mm /180
deg. more
3
Boom Raise 3.6 0.3
Boom Lower 2.6 0.3
Arm Roll-In 3.9 0.3
Boom Cylinder
Arm Cylinder
Bucket Cylinder
Bucket Bottom
T4-2-18

NOTE: 1 mm=0.03937 in
ZX270 class
Reference
Page
Standard)
N (kgf, lbf ft)
Arm Lever 15 (1.5, 10.8) or
less
less
Boom Lever 105 10
Arm Lever
84 10
Bucket Lever 84 10
Swing Lever 105 10
Travel Lever 120 10
3.9 0.4 1.1 m3 (PCSA heaped)
5.2 0.5 1.1 m3 (PCSA heaped)
MPa (kgf/cm2, psi)
Engine: Fast Idle 4.0+1.0-0.5 Value indicated on Dr. ZX
+10 +142
(41 -5, 580 -71)
+1.0
Engine: Slow Idle 3.5 -0 Value indicated on Dr. ZX
(35+10-0, 500+142-0)
MPa (kgf/cm2, psi) (8 -5, 114+171-71)
+12
T4-2-19

NOTE: 1 mm=0.03937 in
Standard)
2
MPa (kgf/cm , psi)
(350+20-5,
+284
4980 -71)
+20
(370 -10,
+284
5260 -142)
+327
4550 -71)
+284
4980 -71)
Bucket Roll-In +10
(379 -0,
5389+142-0)
+10
(400 -0,
+142
5690 -0)
With the track jacked up 3.0 Allowable limit: 5 or more
With the motor relieved 6.0
T4-2-20

(Blank)
T4-2-21

MAIN PUMP P-Q DIAGRAM
Hydraulic P-Q Control (Torque Control)
ZX200 class, 225 class Points on P-Q Line
(REFERENCE: Measured at Test Stand) Delivery Pressure Flow Rate
MPa (kgf/cm2, psi) L/min (gpm)
Rated Pump Speed: A 3.9 (40, 570) 194 3 (51.2 0.8)
-1
ZX200, 225 class: 1900 min (rpm) B 13.9 (142, 2020) [192] ([50.7])
ZX230 class: 2000 10 min-1 (rpm) C 16.7 (170, 2420) 163 6 (43.1 1.6)
ZX270 class: 2050 10 min-1 (rpm) D 20.5 (209, 2970) [123] ([32.5])
Hydraulic Oil Temperature: 50 5 C (122 9 F) E 26.9 (274, 3900) 99 6 (26.2 1.6)
F 34.3 (350, 4980) 72 6 (19.0 1.6)
NOTE: Refer to T4-5-22. The value indicated in parentheses is only a reference
value.
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
Delivery Pressure MPa (kgf/cm2)

T178-04-05-001
T4-2-22

P-Q Control by Pump Control Pilot Pressure Signal
(REFERENCE: Measured at Test Stand) ZX200 class, 225 class

Points on P-Q Line
Rated Pump Speed: Pump Control Pressure Flow Rate
ZX200 class, 225 class: 1900 min-1 (rpm) MPa (kgf/cm2, psi) L/min (gpm)
-1
ZX230 class: 2000 10 min (rpm) 1.7 0.05
-1
ZX270 class: 2050 10 min (rpm) A 67 2 (17.7 0.5)
Hydraulic Oil Temperature: 50 5 C (122 9 F) (17 0.5, 242 7)
B 2.0 (20, 284) [92] ([243])
NOTE: Refer to T4-5-24. 9 0.05
0.3
C 0.5 7 194 3 (51.2 0.8)
(30 3, 427 43)
The value indicated in parentheses is only a reference
ZX230 class Points on P-Q Line value.
Pump Control Pressure Flow Rate
2
MPa (kgf/cm , psi) L/min (gpm) ZX270 class Points on P-Q Line
A 6 Pump Control Pressure Flow Rate
62 0
MPa (kgf/cm2, psi) L/min (gpm)
B 1.7 0.05 (17 0.5) 71 2 A 6
75 0
C 2.9 0.05
(30 0.5
3) 204 3 B
0.29 1.8 0.05 (18.5 0.5) 88 2
C 2.9
0.05
0.29 (30
0.5
3) 209 3
L/min
C
Flow
Rate
MPa (kgf/cm2)
Pump Control Pressure
T178-04-05-004
T4-2-23

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).
Injection rate adjustment

Average Injection Maximum Variance
Adjusting Pump Speed Rack Position
Strokes Rate Between Cylinders Fixed Remarks
Point (mm-1) (mm)
(cm3/1000 Stroke) (%)
A 1075 10.3 89 1.5 2 Lever Basic
C 450 Approx. 7.4 9 1.3 14 Rack
D 100 - 150 5 - Lever Rack limit
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

ZX230 class
Test Conditions:
EF8511/9) kgf/cm2, 37 psi)
2
MPa (185 kgf/cm , 2630 psi).

Adjusting Pump Speed Rack Position
Strokes Rate Between Cylinders Fixed Remarks
Point (mm-1) (mm)
(cm3/1000 Stroke) (%)
A 1050 10.4 95 1.5 2 Lever Basic
C 450 Approx. 7.3 12 1.3 14 Rack
D 100 - 105 5 - Lever Rack limit
Governor adjustment
Rack limit
Above Idle-sub spring setting
Rack Position
(mm)
Pump Speed min-1 (rpm) T1HD-04-05-001
T4-2-25

ZX270 class
Test Conditions:
EF8511/9) kgf/cm2, 37 psi)
2
MPa (185 kgf/cm , 2630 psi).

Adjusting Pump Speed Rack Position Boost
Rate Between Cylinders Fixed Remarks
Point (mm-1) (mm) (kPa)
(cm3/1000 Stroke) (%)
A 1075 10.3 110.5 1.5 2 Lever 109
C 450 Approx. 7.3 12 1.3 14 Rack 0
D 100 - 105 5 - Lever 0 Rack limit
Governor adjustment
Rack limit
Above Idle-sub spring setting
Boost compensation: 0.3 0.1mm
Pump Speed min-1 (rpm)

T1HG-04-05-001
T4-2-26

(Blank)
T4-2-27

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
Reference Measured Value

Item Remarks
Value First Second Third Average
PUMP 1 PRESSURE (MPa)
Control Lever in Neutral 0.5
Boom Raise 23.3 When relieving
Boom Lower -
Arm Roll-in 35.0 When relieving
Arm Roll-Out 35.0 When relieving
Bucket Roll-Out 35.3 When relieving
Bucket Roll-In* 35.5 When relieving
Boom Raise + Arm Roll-In
+ Bucket Roll-In Combined 34.8 When relieving
Operation
Boom Lower -
Bucket Roll-In 0.8 When relieving
Operation
T4-2-28


Item Remarks
PUMP 1 PUMP CONTROL
PRESSURE (MPa)
Boom Lower -
Operation
PUMP 2 PUMP CONTROL
PRESSURE (MPa)
Boom Lower -
Boom Raise + Arm Roll-In +
Bucket Roll-In Combined 3.87 When relieving
Operation
T4-2-29


Item Remarks
TARGET ENGINE SPEED (min-1)
Fast Idle 1800
Fast Idle
1900
(When operating a control lever)
Fast Idle (HP Mode) 2100
Fast Idle (E Mode) 1650
Auto-Idle 1150
Slow Idle 750
ACTUAL ENGINE SPEED (min-1)
Fast Idle 2010
Fast Idle
1920
Auto-Idle 1330
Slow Idle 920
ENGINE SPEED DEVIATION
(min-1)
Fast Idle 208
Fast Idle
22
Auto-Idle 186
Slow Idle 174
EC ANGLE (Volt)
Minimum 2.53
Maximum 3.20
DIAL ANGLE (Volt)
Minimum 0.54
Maximum 4.33
T4-2-30


Item Remarks
BOOM RAISE PILOT
4.15 When relieving
CONTROL PRESSURE (MPa)
ARM ROLL-IN PILOT
4.07 When relieving
SWING PILOT CONTROL
-
PRESSURE (MPa)
TRAVEL PILOT CONTROL
4.05
PRESSURE (MPa)
FRONT ATTACHMENT ON-OFF is dis-
-
CONTROL PRESSURE (MPa) played
PUMP 2 PROPORTIONAL
3.92
VALVE OUTPUT
MAIN PUMP TORQUE PRO- Engine Slow Idle +
1.45
PORTIONAL BALVE OUTPUT Travel
ARM FLOW RATE PROPOR-
TIONAL VALVE OUTPUT
(MPa)
Lever in Neutral 1.16
Swing and Arm Roll-In
1.13
Combined Operation
ARM REGENERATIVE PRO-
PORTIONAL VALVE OUTPUT
(MPa)
Swing, Arm Roll-In, and Boom
2.72
Raise Combined Operation
POWER DIGGING CONTROL
PRESSURE (MPa)
During Operation 2.92
When Relieving Boom Raise
2.92
Circuit
TRAVEL MOTOR CONTROL Traveling, Travel
2.92
PRESSURE (MPa) Mode Switch: Fast
EC MOTOR POSITION (Step) When relieving arm
376
roll-in circuit
NOTE: Up to serial No.104678
T4-2-31

ZAXIS225USR
DR. ZX MONITOR INDICATING VALUES

Item Remarks
Boom Lower -
Operation
Boom Lower -
Operation
T4-2-32


Item Remarks
PUMP 1 PUMP CONTROL
PRESSURE (MPa)
Boom Lower -
Operation
PUMP 2 PUMP CONTROL
PRESSURE (MPa)
Boom Lower -
Operation
T4-2-33


Item Remarks
Fast Idle 1800
Fast Idle
1900
Auto-Idle 1150
Slow Idle 750
Fast Idle 1980
Fast Idle
1910
Auto-Idle 1360
Slow Idle 990
(min-1)
Fast Idle 178
Fast Idle
20
Auto-Idle 216
Slow Idle 246
EC ANGLE (Volt)
Minimum 2.49
Maximum 3.16
Maximum (HP Mode) 3.49
Maximum (E Mode) 3.08
DIAL ANGLE (Volt)
Minimum 0.46
Maximum 4.39
T4-2-34


Item Remarks
BOOM RAISE PILOT
3.88 When relieving
ARM ROLL-IN PILOT
3.67 When relieving
SWING PILOT CONTROL
-
PRESSURE (MPa)
4.00
PRESSURE (MPa)
-
PUMP 2 PROPORTIONAL
3.92
VALVE OUTPUT
1.33
TIONAL VALVE OUTPUT (MPa)
1.02
Combined Operation
PORTIONAL VALVE OUT-
PUT (MPa)
2.72
PRESSURE (MPa)
When Relieving Boom Raise Auto-Power
2.92
Circuit Lift Control
2.92
EC MOTOR POSITION (Step)
Minimum 0
Maximum 304
Maximum (Arm Roll-in Relief) 336
NOTE: *** Up to serial No.104678
T4-2-35

ZAXIS225US
DR. ZX MONITOR INDICATING VALUES

Item Remarks
Boom Lower -
Operation
Boom Lower -
Operation
T4-2-36


Item Remarks
PUMP 1 PUMP CONTROL
PRESSURE (MPa)
Boom Lower -
Operation
PUMP 2 PUMP CONTROL
PRESSURE (MPa)
Boom Lower -
Operation
T4-2-37


Item Remarks
Fast Idle 1800
Fast Idle
1900
Fast Idle (HP Mode) 2100 Arm Roll-In
Relief
Auto-Idle 1150
Slow Idle 750
Fast Idle 2010
Fast Idle
1860
Relief
Auto-Idle 1350
Slow Idle 940
(min-1)
Fast Idle 216
Fast Idle
36
Relief
Auto-Idle 198
Slow Idle 198
EC ANGLE (Volt)
Minimum 2.51
Maximum 3.20
DIAL ANGLE (Volt)
Minimum 0.44
Maximum 4.19
T4-2-38


Item Remarks
BOOM RAISE PILOT
When Relieving 1.46
ARM ROLL-IN PILOT
3.81 When relieving
SWING PILOT CONTROL
-
PRESSURE (MPa)
3.88
PRESSURE (MPa)
-
PUMP 2 PROPORTIONAL
3.92
VALVE OUTPUT
1.57
1.54
Combined Operation
PUT (MPa)
1.36
PRESSURE (MPa)
2.92
Circuit
2.92
EC MOTOR POSITION (Step)
Minimum 0
Maximum 324
Maximum (Arm Roll-in Relief) 360
T4-2-39

CATING VALUES

Item Remarks
Boom Lower -
Operation
Boom Lower -
Operation
T4-2-40


Item Remarks
PUMP 1 PUMP CONTROL
PRESSURE (MPa)
Boom Lower -
Operation
PUMP 2 PUMP CONTROL
PRESSURE (MPa)
Boom Lower -
Operation
T4-2-41


Item Remarks
Fast Idle 1920
Fast Idle
2050
Auto-Idle 1120
Slow Idle 720
Fast Idle 2130
Fast Idle
2080
Auto-Idle 1350
Slow Idle 950
(min-1)
Fast Idle 214
Fast Idle
24
Auto-Idle 236
Slow Idle 230
EC ANGLE (Volt)
Minimum 2.51
Maximum 3.24
DIAL ANGLE (Volt)
Minimum 0.41
Maximum 4.25
T4-2-42


Item Remarks
BOOM RAISE PILOT
4.19 When relieving
ARM ROLL-IN PILOT
4.15 When relieving
SWING PILOT CONTROL
-
PRESSURE (MPa)
4.31
PRESSURE (MPa)
-
PUMP 2 PROPORTIONAL
3.92
VALVE OUTPUT
1.69
1.91
Combined Operation
PUT (MPa)
2.72
PRESSURE (MPa)
2.92
Circuit
2.92
400
roll-in circuit
T4-2-43

CATING VALUES

Item Remarks
Boom Lower -
Operation
Boom Lower -
Operation
T4-2-44


Item Remarks
PUMP 1 PUMP CONTROL
PRESSURE (MPa)
Boom Lower -
Operation
PUMP 2 PUMP CONTROL
PRESSURE (MPa)
Boom Lower -
Operation
T4-2-45


Item Remarks
Fast Idle 1870
Fast Idle
2000
Auto-Idle 1120
Slow Idle 720
Fast Idle 2130
Fast Idle
2050
Auto-Idle 1420
Slow Idle 1000
(min-1)
Fast Idle 254
Fast Idle
54
Auto-Idle 254
Slow Idle 254
EC ANGLE (Volt)
Minimum 2.51
Maximum 3.22
DIAL ANGLE (Volt)
Minimum 0.46
Maximum 4.35
T4-2-46


Item Remarks
BOOM RAISE PILOT
4.48 When relieving
ARM ROLL-IN PILOT
4.50 When relieving
SWING PILOT CONTROL
-
PRESSURE (MPa)
4.90
PRESSURE (MPa)
-
PUMP 2 PROPORTIONAL
3.92
VALVE OUTPUT
1.69
1.50
Combined Operation
PUT (MPa)
1.94
PRESSURE (MPa)
2.92
Circuit
2.92
368
roll-in circuit
T4-2-47

SENSOR ACTIVATING RANGE
1. Checking Method
Hydraulic Oil Temperature: 50 5 C

Unless specified:
Auto-Idle
Engine Power
Work Mode /Auto-Accelerati
Control Mode
Switch on
Dial Switch
Selector
Digging
Fast Idle P Mode OFF
Mode
Monitor each sensor using Dr. ZX.
2. Sensor Activating Range
Sensor Operation Specification

Minimum Speed 0.3 to 1.0 V
Engine Control Dial
Maximum Speed 4.0 to 4.7 V
Minimum Speed 2.5 to 2.7 V
Maximum Speed (Power Mode Switch: P) 3.3 to 3.7 V
EC Sensor
Maximum Speed (Power Mode Switch: HP) Maximum Speed
(Mode Switch: OFF) +0.2 V or more
Control Lever: Neutral 0 to 0.1 MPa (0 to 1.0 kgf/cm2)
Pilot Control Shut-Off Lever: LOCK
Pressure Sensor
Control Lever: Full Stroke 3.3 to 3.9 MPa (34 to 40 kgf/cm2)
Pilot Control Shut-Off Lever: UNLOCK
2
Pump Control Control Lever: Neutral 0 to 1 MPa (0 to 10 kgf/cm )
2
Pressure Sensor Control Lever: Full Stroke 2.9 to 3.9 MPa (30 to 40 kgf/cm )
N Sensor 20 C (Between Ground to Signal) 810 240
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.
NOTE: Measure the engine speed before per-

forming all other tests to check that the
engine speed meets specification. Be-
cause, if the engine speed is not adjusted
correctly, all other performance data will be
unreliable. T107-06-02-002
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).
IMPORTANT: Never attempt to the readjust stop-

per (3).
T107-06-02-001
T4-3-1

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

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

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.
NOTE: Unless the fuel delivery pipes are discon-

nected, fuel will ignite in the cylinders so
that pressure in the cylinders will increase.
T105-06-02-001
5. Install an adaptor (Isuzu 5-85317-001-0) and

compression gauge in place of the glow plug in
one cylinder. (Be sure to sufficiently tighten the
adaptor and compression gauge to prevent air
leakage.)
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

(Blank)
T4-3-5

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

Measurement:
1. Insert a thickness gauge into the clearance be-
tween the rocker arm and the valve stem end to
measure the valve clearance.
NOTE: The cylinders are aligned from No.1 to

No.6 in that order, as viewed from the fan
side.
2. When the measurement is started from No.1 cyl-

inder, perform the same measurement to all
valves indicated with the mark in the table
below. (When the measurement is started from
No.6 cylinder, perform the measurement in the
valves shown with mark .) T107-02-12-005
Cylinder No. No.1 No.2 No.3 No.4 No.5 No.6

Valve locations I E I E I E I E I E I E
When the measurement is
started from No.1 cylinder
When the measurement is
started from No.6 cylinder
3. Rotate the crankshaft 360 . Align the TDC mark

with the pointer. Then, continue measurement of
other valves in the same way.
Evaluation:
Adjustment:
If the measurement results are out of specification,
adjust the valve clearance in the same order of
measurement.
1. Loosen the adjusting screw lock nuts for the

rocker arms. Insert the thickness gauge set at 0.4
mm, adjust the adjusting screws.
2. After adjusting, retighten the lock nuts to the
specification.
Recheck the valve clearance after the lock nuts
are tightened.
: 25.5 4.9 N m
(2.6 0.5 kgf m, 18.8 3.6 lbf ft)
T4-3-7

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.
NOTE: Use clean diesel oil.
T4-3-8

Evaluation:
1. Standard Injection Pressure:
Normal
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
Turn clockwise to increase the pressure, and

counterclockwise to decrease the pressure.
2. After adjusting, retighten the lock nuts.
T107-06-02-007
T4-3-9

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
NOTE: The alignment mark on the injection pump

cannot be directly seen through the check Injection Pump
hole. Use a mirror for checking. Alignment Mark
3. Remove the injection piping from No.1 cylinder. T107-02-12-007
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

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
When delaying timing, tilt the injection pump in-

ward against the cylinder block.
T4-3-11

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.
IMPORTANT: Make sure to keep the ma-

chine-leaving time in Step 1 above.
5. 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.
6. Record the read-out B (unit: hour) of the hour
meter.
7. Replenish the lubricant up to the high-level
gauge while measuring the oil-replenishing vol-
ume C.
NOTE: For measuring, use a high-precision
measuring cylinder or the like.
8. Determine lubricant consumption from the fol-

lowing equation:
Oil replenishing volume (C) [mL] / Operating
hours (B-A) [hr]
Evaluation:
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

TRACK REVOLUTION SPEED
Measure the track revolution cycle time with the 1. Measure both the slow and fast travel speeds of
track raised off ground. the machine.
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
chalk. Mode Mode
3. Swing the upperstructure 90 and lower the Fast Digging
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:
T4-4-2

MISTRACK CHECK
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
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:
T105-06-03-022
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above

the ground with the arm and bucket rolled in.
4. Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
T4-4-3

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.
(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

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
starting the measurement.
Preparation:
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
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
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

(122 9 F).
T4-4-5

SWING FUNCTION DRIFT CHECK
Summary:
Measure the swing drift on the bearing outer
circumference when stopping after a 180 full-speed
swing.
Preparation:
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 .
(122 9 F).
CAUTION: Prevent personal injury. Always

make sure that the area is clear and that T105-06-03-009

T4-4-6

Measurement:
Auto-Idle/
Engine Con- Power Mode Work Mode
Acceleration
trol Dial Switch Switch
Selector
Measure Difference Between Marks
Digging
Mode
2. Operate the swing control lever fully and return it

to the neutral position when the mark on the
upperstructure aligns with that on the track frame
after swinging 180 . Marking on the Track Frame
3. Measure the distance between the two marks.
Marking on the Swing Bearing
4. Align the marks again, swing 180 , then test in
the opposite direction.
5. Repeat steps 2. to 4. three times each and T105-06-03-010
calculate the average values.
Evaluation:
Group T4-2.
Remedy:
T4-4-7

SWING MOTOR LEAKAGE
Summary:
Check for upperstructure drift while suspending a
load on a slope.
Preparation:
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.
(122 9 F).
T4-4-8

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
2. Maintain the engine at slow idle. After five

minutes, measure the difference between the
marks along the swing bearing periphery and the
track frame.
Marking on the Track Frame
3. Perform the measurement in both right and left
swing directions. Marking on the Swing Bearing
4. Perform the measurement three times in each
direction and calculate the average values. T105-06-03-010
Evaluation:
Group T4-2.
Remedy:
T4-4-9

MAXIMUM SWINGABLE SLANT ANGLE
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/
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

(Blank)
T4-4-11

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.
NOTE: The measured value will vary depending Round Trunk

on where the magnet base is secured.
Secure the magnet base onto the round
trunk or in a position as close to the round
trunk as possible.
T105-06-03-015
T4-4-12

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

Group T4-2. Measurement: (h2)
T105-06-03-017
T4-4-13

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
With the empty bucket rolled in, position the arm

so that it is vertical to the ground. Lower the
boom until the bucket is 0.5 m (20 in) above the
ground.
To measure the cycle time of the bucket cylinder:
The empty bucket should be positioned at
mid-stroke between roll-in and roll-out, so that
the sideplate edges are vertical to the ground.
0.5 m
(122 9 F).
T105-06-03-019
T105-06-03-020
T4-4-14

Measurement:
Engine Auto-Idle/
Control Acceleration
Switch Switch
Dial Selector
Fast Idle P Mode Digging Mode OFF
2. To measure cylinder cycle times:

(Cylinder full stroke includes cylinder cushioning
zone.)
Boom cylinders:
Measure the time it takes to raise the boom, and
the time it takes to lower the boom. To do so,
position the boom at one stroke end, then move
the control lever to the other stroke end as
quickly as possible.
Arm cylinder:
Measure the time it takes to roll in the arm, and
the time it takes to roll out the arm. To do so,
position the arm at one stroke end, then move
the control lever to the other stroke end as
Bucket cylinder:
Measure the time it takes to roll in the bucket,
and the time it takes to roll out the bucket. To do
so, position the bucket at one stroke end, then
move the control lever to the other stroke end as
3. Repeat each measurement three times and

Evaluation:
Group T4-2.
Remedy:
T4-4-15

DIG FUNCTION DRIFT CHECK
Maximum Reach Position
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.
NOTE: When testing the dig function drift just after

cylinder replacement, slowly operate each
Extended
cylinder for ten minutes to its stroke end to Retracted
Distance
Distance
purge air. Retracted
Distance
Preparation:
1. Load bucket fully. In lieu of loading the bucket, Same Height
weight (W) of the following specification can be
used.
ZX200 class, 225 class: W=1050 kg (2320 lb) Bucket Bottom
ZX230 class: W=1350 kg (2980 lb)
ZX270 class: W=1500 kg (3310 lb)
2. Position the arm cylinder with the rod 50 mm (2 T105-06-03-021
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
(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
bucket cylinders. Boom and Bucket Cylinder Retraction

3. Repeat step 2. three times and calculate the
average values. Mark Mark
Evalution:
Group T4-2.
Remedy:
T110-06-03-002
T4-4-16

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.
NOTE: When testing the dig function drift just after

cylinder replacement, slowly operate each
cylinder for ten minutes to its stroke end to
purge air.
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
average values. Mark Mark
Evalution:
Group T4-2.
Remedy:
T110-06-03-002
T4-4-17

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).
CAUTION: Prevent personal injury. Always T107-06-03-003
make sure that the area is clear and that

T107-06-03-004
T4-4-18

Measurement:
1. Measure each control lever.
Engine Auto-Idle/
Switch Switch
Dial Selector
3. Operate each boom (raise), arm and bucket lever

to the fully and measure the maximum operating
force for each with each actuator relieved.
4. Operate boom (lower) lever and measure the
maximum operating force with the boom (lower)
relieved by jacking up the machine in a safe
area.
5. Operate swing lever and measure the maximum
operating force with swing relieved after securing
the front attachment to prevent swinging.
6. Lower the bucket to the ground to raise one track
off the ground. Operate the travel lever to full
stroke and measure the maximum operating
force required. When finished, lower the track
and then jack-up the other track.
the average values.
Evalution:
Refer to the Orerational Performance Standard in
Group T4-2.
T4-4-19

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
1. Stop the engine.

2. Measure each lever stroke at the lever top from
neutral to the stroke end using a ruler.
average values.
Evalution:
Refer to the Orerational Performance Standard in
Group T4-2.
T4-4-20

(Blank)
T4-4-21

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 dont 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.
(122 9 F).
CAUTION: Prevent personal injury. Always T107-06-03-009

T4-4-22

Measurement:
Engine Auto-Idle/
Switch Switch
Dial Selector
2. Raise the boom and swing simultaneously, both

at full stroke.
3. When the upperstructure rotates 90 , release the
control levers to stop both functions. Measure the
time required to swing 90 and the height (H) of
the bucket teeth. (The bucket must be empty.)
4. Repeat steps 2. to 3. three times and calculate T107-06-03-010
the average values.
Evalution:
Group T4-2.
Remedy:
H
T107-06-03-011
T4-4-23

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 dont 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
1. Select the switch positions as follows.

Engine Auto-Idle/
Switch Switch
Dial Selector
2. Raise the boom and roll the arm in full stroke at

the same time.
3. Measure the time required for the arm to reach
the stroke end with the bucket empty.
4. Repeat the measurement three times and calcu-
late the average value.
Evaluation:
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
4. Start the engine. Confirm that no oil leakage is

observed at the pressure gauge connection.
(122 9 F). T178-03-07-001
Measurement:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Digging
Mode
Digging
Slow Idle P Mode OFF
Mode
2. Measure the pilot pressure in each specified set-

ting above.
late the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-5-1

Primary Pilot Pressure Adjustment Procedure
Adjustment:
Adjust the relief valve set-pressure as necessary.
: 41 mm
Relief Valve
1. Remove plug (1) from the relief valve.

: 41 mm
: 12 mm T178-03-07-001
2. Remove spring (2), shims (3), and plunger (4)

from the relief valve. 1 2 3 4
3. Install the estimated number of shims (3) onto
plunger (4).
4. Install plunger (4), shims (3), and spring (2) into
the relief valve. Tighten plug (1).
: 68 6.8 N m (7 0.7 kgf m, 50 5 lbf ft)
5. Check the set-relief pressure.

T178-04-04-002
NOTE: Standard Change in Pressure (Reference)

Shim Thickness Change in Relief Pressure
(mm) kPa (kgf/cm2) (psi)
0.2 61.8 (0.63) (9)
0.4 124.6 (1.27) (18)
0.8 249.2 (2.54) (36)
T4-5-2

(Blank)
T4-5-3

SECONDARY PILOT PRESSURE
Preparation:
Signal Control Valve
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.
Measure pressure at the location between the pi-

lot valve and the signal control valve:
Disconnect the pilot circuit hose to be measured
from the signal control valve. Connect hose
(7/16-20UNF approx. 400 mm long) to the signal
control valve. Install tee (ST 6450) and pressure
gauge (ST 6942) between the hoses.
Measure pressure at the location between the
control valve and the signal control valve:
Disconnect the pilot circuit line to be measured
between the signal control valve and the control
valve. Connect hose to the signal control valve. T178-04-04-003
Install tee (ST 6451) and pressure gauge (ST

6942) between the hose and the control valve.
: 14 mm, 17 mm

(122 9 F).
T157-05-04-011
T4-5-4

Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
Digging
Mode
2. Measure the pilot pressure in each specified set-
ting above with the corresponding control lever
operated full stroke.
Evaluation:
T4-2.
Remedy:
T4-5-5

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:
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
Connect Dr.ZX to the machine for solenoid valve

set pressure monitoring.
4. Start the engine. Confirm that no oil leakage is T178-03-07-005
7 8 9
(122 9 F).
Up to serial No.104678 (ZX200 class and 225 class)

Up to serial No.010326 (ZX230 class)
6 7 8 9 T178-01-02-003
Solenoid Valve
Pressure Gauge
Hose Tee Adapter T157-05-04-002
T4-5-6

Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
Digging
Mode
2. Operate as instructed below for each measuring

solenoid valve:
Solenoid Valve SG: Repeat pressing and releas-
ing of the power boost switch.
Solenoid Valve SE*: Perform a combined opera-
tion. of swing and arm roll-in.
Solenoid Valve SC: Perform a combined opera-
tion of boom raise and arm roll-in.
Solenoid Valve SI: Drive the machine, then stop
the machine.
NOTE: *Up to serial No.104678 (ZX200 class and
225 class)
3. Read the values on both Dr.ZX and the pressure

gauge.
Evaluation:
Refer to the performance Standard Table in Group
T4-2.
T4-5-7

Solenoid Valve Set Pressure Adjustment Proce-
dure 7
IMPORTANT: Do not loosen the adjusting screw

excessively. 8
The O-ring on the threads may come
off the sealing surface, causing oil
to leak. Be sure not to loosen more
than 2 turns.
1. Loosen lock nut (7). Turn adjusting screw (8) to T107-06-04-020
adjust the set pressure of the solenoid valve.
2. Retighten lock nut (7). The distance between the
lock nut end and screw end
: 10 mm should be 2.0 mm (0.079 in)
: 3 mm or less.
: 5 N m (0.5 kgf m, 3.6 lbf ft)
3. Check the set pressure of the solenoid valve.

Screw Turns 1/4 1/2 3/4 1
Change kPa 78 156 234 312
in Pres- (kgf/cm2) (0.8) (1.6) (2.4) (3.2)
sure (psi) (11) (23) (34) (46)
8
7
T107-06-05-001
7 8
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-8

MAIN PUMP DELIVERY PRESSURE
The main pump delivery pressure can also be meas-
ured with Dr.ZX.
Preparation:
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
Or connect Dr.ZX to the machine for main pump

delivery pressure monitoring.
(122 9 F).
Measurement:
Auto-Idle /
Acceleration
Control Dial Switch Switch T157-05-04-005
Selector
Digging
Mode
2. Measure the pressure with the control levers in

neutral.
Evaluation:
T4-2.
Remedy:
T4-5-9

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:
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
Or connect Dr.ZX to monitor the main pump de-

livery pressure.
(122 9 F).
T157-05-04-005
T4-5-10

Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
2. Relieve each actuator to measure main relief

pressures.
First, slowly operate bucket, arm, and boom con-
trol levers to the stroke end to relieve each func-
tion one at a time.
3. As for the swing function, secure the up-
per-structure so it is immovable. Slowly operate
the swing lever to relieve the swing function.
4. As for the travel function, secure the tracks
against an immovable object. Slowly operate the
travel levers to relieve the travel function.
5. With power boost switch depressed, then slowly
operate bucket, arm, and boom control levers to
the stroke ends to relieve each function within
eight seconds after power boost switch de-
pressed.
Evaluation:
T4-2.
NOTE: If the measure pressures for all functions

are lower than the specified range, the
probable cause is a decrease of the main
relief valve setting pressure.
If the relief pressure of a particular function
is lower, the probable cause is other than
main relief valve.
T4-5-11

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).
High-Side Relief Pressure Setting Adjustment

Procedure
1. Loosen lock nut (1). Lightly tighten plug (3) until
the end of plug (3) comes into contact with piston
(2). Retighten lock nut (1).
: 27 mm
: Plug (3): 19.5 N m (2 kgf m, 14.5 lbf ft)
: Lock Nut (1):
68 to 78 N m
(7 to 8 kgf m, 51 to 58 lbf ft)
2. Loosen lock nut (4). Turn plug (5) to adjust the M178-05-003
relief pressure setting referring to the table below. 3

: 27 mm, 32 mm
: Lock Nut (4): 1
78 to 88 N m
(8 to 9 kgf m, 58 to 65 lbf ft) 5
4
2
T157-05-04-009
Plug (5, 3)
Pressure Pressure
Increase Decrease
W107-02-05-127
T4-5-12

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)
2. Recheck the set pressures.

Plug Turns 1/4 1/2 3/4 1
Change in Relief MPa 7.1 14.2 21.3 28.4
Pressure: Plug (5) (kgf/cm2) 72.5 145 217.5 290
(High-Side Relief
(psi) 1030 2060 3090 4120
Pressure)
Change in Relief MPa 5.3 10.7 16.0 21.3
Pressure: Plug (3) (kgf/cm2) 54 109 163 217
(Low-Side Relief
(psi) 770 1550 2320 3090
Pressure)
T4-5-13

RELIEF PRESSURE (When relieving
Swing)
ZX200 class, 225 class, 230 class
Adjust pressure by changing the number of shims
(2).
1. Remove the swing relief valve.

Swing Relief Valve
: 41 mm
2. Remove plug (5), sleeve (4), and piston (3).

: 30 mm
3. Adjust the set-pressure by installing shims (2)

between piston (3) and spring seat (1).
4. After adjusting, install piston (3), sleeve (4), and

plug (5).
: 118 N m (12 kgf m, 88 lbf ft)
NOTE: Replace seals (A, B, and C) with new ones.

A: JIS B 2401 G30 1B T178-03-02-001
B: AS568-023 (Aero-Space Standard)

C: AS568-125 (Aero-Space Standard) 1 2 3 4 5
5. Install the swing relief valve.

: 176 N m (18 kgf m, 130 lbf ft)
6. Check the set-pressure.

Shim Thickness Change in Relief Pressure
(mm) A B C T178-03-02-005
kPa (kgf/cm2) (psi)
0.1 610 6.3 (60)
T4-5-14

ZX270 class Swing Relief
Valve
Adjustment
Loosen lock nut (2) to release adjusting screw (1).
1. Loosen lock nut (2).

:24 mm, 32 mm
2. Turn adjusting screw (1) to adjust.
3. Tighten lock nut (2).
4. Check the set pressure.

: 24 mm, 32 mm
: 177 N m (18 kgf m)
NOTE: Standard Change in Pressure (Reference) T158-01-01-001
Serial No.20038 and up

Serial No.20038 and up 1 2
Adjusting Screw
1/4 1/2 3/4 1
Turns
Change MPa 2.5 5.0 7.5 10.0
in (kgf/cm2) (25.5) (51) (76.5) (102)
Pressure (psi) (363) (725) (1088) (1450)
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

RELIEF PRESSURE (When relieving
Travel)
ZX200 , 225 class, 230 class
1. Remove the travel relief valve.
: 36 mm
2. Remove sleeve (1) and poppet (3).
3. Install shims (5) between poppet (3) and spring Travel Relief
guide (4) to adjust the set-pressure. Valve
4. Install the travel relief valve.

: 450 N m (46 kgf m, 330 lbf ft)
T155-01-01-006
5. Check the set-pressure.
NOTE: Standard Change in Pressure (Reference) 1 2 5

Shim Change in Relief
Thickness Parts No. Pressure
(mm) kPa (kgf/cm2) (psi)
0.5 A590103 900 (9.2) (130)
3 4
T135-06-04-001
T4-5-16

ZX270 class
Adjustment
Loosen lock nut (2) to adjust adjusting screw (1).
: 19 mm
: 6 mm
2. Turn adjusting screw (1) to adjust.
3. Tighten lock nut (2).

: 49 N m (5 kgf m, 36 lbf ft) Travel Relief
Valve
T157-05-04-010
Adjusting Screw
1/4 1/2 3/4 1
Turns 2 1
MPa 2.9 5.9 8.8 11.8
Change in
(kgf/cm2) (30) (60) (90) (120)
Pressure
(psi) (430) (850) (1280) (1710)
T157-05-04-008
2 1
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-17

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

Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
2. Slowly operate bucket, arm, and boom control

levers to the stroke ends to relieve each function
one at a time.
3. Read the pressures on the pressure gauge while
releasing the front functions.
4. Perform the measurement for the bucket, arm,
and boom, in that order.
late the average value for each front function.
Evaluation:
1. Performance of the overload relief valves are
normal if the measured main relief pressures are T157-05-04-005
within the specified value range.
Refer to the Performance Standard Table in

Group T4-2.
T4-5-19

Overload Relief Valve Set Pressure Adjusting
Procedure
NOTE: In principle, adjust the overload relief valve

set pressure on a test stand.
Adjustment:
Adjust the pressure setting of the overload relief
valve using adjusting screw (2) after loosening lock 1
nut (1).
2. Turn adjusting screw (2) to adjust the pressure

setting referring to the table below.
2
3. Retighten lock nut (1). W107-02-05-128
: 17 mm
: 6 mm
: 29.5 N m (3.0 kgf m, 22 lbf ft)
4. Check the set pressure.

Screw Turns 1/4 1/2 3/4 1 1 2
Change in MPa 5.2 10.6 15.9 21.1
Relief (kgf/cm2) (54) (108) (162) (216)
Pressure (psi) (770) (1540) (2300) (3070) Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-20

(Blank)
T4-5-21

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 /
(1 or 2) to the pump delivery port using the split Acceleration
flanges and bolts which were used to connect the Selector
disconnected delivery hose. Digging
: 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

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
Qc : Converted Flow Rate

Q : Measured Flow Rate
Ns : Specified Pump Speed
(ZX200 class, 225 class: 1900 min-1)
-1
(ZX230 class: 2000 min )
(ZX270 class: 2050 min-1)
Ne : Measured Engine Speed:
Pulse Numbers (Hz) 60/34
1, 2 3 4 5 6 7 8 9 10 11
Delivery Hose (To

Control Valve)
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

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

1, 2 3 4 5 6 7 8 9 10 11
Delivery Hose (To

Control Valve)
T173-04-04-002
21 Port Pi
Plug M
N Sensor
12 T178-03-07-001
T178-03-01-001
Reducing Valve Port Location

Reducing Valve Return Pipe
T L
20
18
P1 P2 19
15
To Regulator To Pilot Filter

Port Pi
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

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
Acceleration
Selector Qc : Converted Flow Rate
Digging Q : Measured Flow Rate
Fast Idle P Mode OFF Ns : Specified Pump Speed
Mode
-1
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 )
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

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)
Adjustment Item Adjustment Procedure Remarks

1. Minimum Flow Rate Loosen lock nut (1) and turn 1) Do not turn the adjusting screw
adjusting screw (2). more than two turns.
Q Rotating adjusting screw (2) 1/4 2) Securely retighten lock nut (1) after
a turn clockwise increases the the adjustment.
minimum pump flow rate by 5.35
cm3/rev. (0.33 in3/rev).
: 17 mm
: 19.6 N m
(2 kgf m, 14.4 lbf ft)
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

Adjustment Item Adjustment Procedure Remarks

3. Pilot Pressure Characteris- Loosen lock nut (5) and turn ad- 1) Do not turn the adjusting screw
tics justing screw (6). more than one turn.
Rotating adjusting screw (6) 1/4 2) When adjusting screw (6) is turned
a turn clockwise decreases the clockwise, the maximum flow rate
Q
flow rate by 11.65 cm3/rev. will also be decreased.
3
(0.71 in /rev). To maintain the maximum flow rate
: 30 mm unchanged, turn adjusting screw (4)
: 29.4 N m counterclockwise twice as much as
(3 kgf m, 21.7 lbf ft) adjusting screw (6) is turned.
This ratio of 2 (adjusting screw (4)
counterclockwise turn) to 1 (adjust-
ing screw (6) clockwise turn) is to
Pi counterbalance.
3) Securely retighten lock nut (5) after
the adjustment.
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)
3
A by 13.43 cm /rev. after the adjustment.
3
(0.82 in /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

SWING MOTOR DRAINAGE
Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while
swinging the upperstructure.
NOTE: The amount of drain oil from the swing

motor will change depending on hydraulic
oil temperature.
1
CAUTION: Prevent personal injury. Always
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

Preconditions for Measurement:
Auto-Idle /
Acceleration
Selector
Digging
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
bucket cylinder. Raise the boom so that the T105-06-03-013
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.
2. Amount of Oil Drained While Relieving Swing T107-06-06-005

Motor Circuit
(1) Thrust the bucket teeth into the ground as il-
lustrated so that the upperstructure does not
rotate when the swing lever is operated full
stroke.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start drain oil measurement
when drain oil starts coming out of the drain
hose end. The measuring time should be
more than 45 seconds.
in both clockwise and counterclockwise direc-
tions, and calculate the average values.
T4-5-30

Evaluation:
T4-2.
Conversion of the amount of drain oil measured

into the per-minute value
First measure the amount of drain oil using a cali-

brated container. Then, convert the measured
drain oil into the per-minute value using the
formula below:
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

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.
NOTE: The amount of drain oil from the travel

motor will change depending on hydraulic
1
oil temperature.
Preparation:
1. Main hydraulic oil temperature at 50 5 C
(122 9 F). Rotate the travel motor to warm the
inside of the motor.
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.
3. Disconnect the travel motor drain hose (2) at the

travel motor end. Install plug (ST 6637) to the T157-05-04-014
disconnected end. Connect the drain hose

(3/4-16UN) to the travel motor.
: 22 mm, 27 mm 2
(ZX200 class, 225 class, 230 class)
: 27 mm (ZX270 class)
: 93 N m (9.5 kgf m, 69 lbf ft)
Preconditions for Measurement:

Auto-Idle /
Acceleration
Selector
Digging
Mode
T157-05-04-010
T4-5-32

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
CAUTION: Securely support the raised track

using wooden blocks. When working around
moving parts is unavoidable, pay special at-
tention to ensure that hands, feet, and cloth- M104-07-067
ing do not become entangled.

(2) Rotate the raised track with the travel lever
operated full stroke. Start drain oil measure-
ment after the track rotation speed reaches a
constant maximum speed. The measuring
time should be more than 45 seconds.

in both forward and reverse directions, and
Evaluation:
T4-2.
Conversion of the amount of drain oil measured

into the per-minute value
T157-05-04-019
First measure the amount of drain oil using a cali-
brated container. Then, convert the measured
drain oil into the per-minute value using the for-
mula below:
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

(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.
Removal of the engine, engine control cable, or

EC motor
Replacement of MC
Adjustment of Engine Speed:

1. Turn the key switch to the START position to start
the engine.
NOTE: Turn the air conditioner OFF.
2. Rotate the engine control dial to the minimum

speed position. (The output voltage from the EC
sensor is 2.5 V.)
3. Deactivate the auto warming up and ECO control

systems by Dr. ZX.
4. When Dr. ZX is not available, keep the engine

running for about 15 minutes to warm coolant
temperature to more than 30 C (86 F ) until the
auto warming up control system is deactivated.
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.
7. Tighten the lever holding bolt to secure the control

lever to the motor output shaft.
: 13 N m (1.3 kgf m, 9.4 lbf ft)
NOTE: Dont lubricate the motor output shaft.
8. Perform engine learning.
T4-6-1

Engine Learning:
1. Turn the key switch OFF
Learning
NOTE: In case the engine doesnt 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.
4. Turn the key switch ON. Wait for 5 seconds.
5. Turn the key switch OFF. Wait for 5 seconds.
6. Turn the learning switch OFF.
7. Check the engine speed. T178-01-02-006
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

(Blank)
T4-6-3

GOVERNOR LEVER AND FUEL CUT
LEVER POSITION
Check the fuel cut lever position during cranking.
If the position is normal, the engine unit and/or
fuel system may have trouble.
Governor Lever and Fuel Cut Lever
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

Governor Lever Position
A - Key Switch OFF (Engine Stop Position)

B - Key Switch ON (Engine Start Position)
A B
STOP FULL
FULL
T105-07-04-003
STOP
Fuel Cut Lever Position
A - Fuel Cut-Off Handle Pulled Position

B - Fuel Cut-Off Handle Returned Position
A
B
T105-07-04-003
T4-6-5

(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
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
Group 6 Electrical System Inspection

Precautions for Inspection and
Maintenance ........................................... T5-6-1
Instructions for Disconnecting
Connectors ............................................. T5-6-3
Fuse Inspection ........................................ T5-6-4
Fusible Link Inspection ............................. T5-6-5
Battery Voltage Check .............................. T5-6-6
How to Troubleshoot Alternator
Malfunctions............................................ T5-6-7
Continuity Check....................................... T5-6-8
Voltage and Current Measurement ......... T5-6-11
Check by False Signal ............................ T5-6-15
Test Harness........................................... T5-6-16
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.
Component Layout Example: Malfunction of fuel gauge
Troubleshooting A (base machine diagnosis using Electrical System Inspection

fault codes) Refer to this group when required to obtain pre-
Refer to these procedures if any fault codes are cautions and/or information for the electrical sys-
displayed when the main controller (MC) is diag- tem inspection.
nosed with Dr. ZX (or the built-in diagnosing sys-
tem). Example: Fuse Inspection
(MC self-diagnosing function retains a record of
the electrical signal system malfunction in the ICX
form of fault codes.) Refer to these procedures after any fault code is
displayed after diagnosing ICX (Information Con-
Example: Fault Code 06: Abnormal EC Sensor troller) or the satellite terminal (optional) with Dr.
ZX. (The controller self-diagnosing function re-
tains a record of the electrical signal system mal-
function in the form of fault codes.)
Example: ICX Fault Code 7: MC Communication

Time Out
In addition, information on the following items is

described in this group.
1. Trouble shooting and setting procedures of
ICX and satellite terminal using Dr. ZX.
2. Information on the satellite communication
system
T5-1-1

DIAGNOSING PROCEDURE
These six basic steps are essential for efficient
troubleshooting:
1. Study the System

Study the machines technical manuals. Know the
system and how it works, and what the
construction, functions and specifications of the
system components are.
2. Ask the operator T107-07-01-001
Before inspecting, get the full story of

malfunctions from your star witness the
operator.
(a) How is the machine being used? (Find out if

the machine is being operated correctly)
(b) When was the trouble noticed, and what

types of work the machine doing at that
time?
(c) What are the details of the trouble? Is the

trouble getting worse, or did it appear
suddenly for the first time?
(d) Did the machine have any other troubles

previously? If so, which parts were repaired
before?
T107-07-01-002
T5-1-2

3. Inspect the machine
Before starting the troubleshooting procedure,
check the machines daily maintenance points, as
shown in the operator's manual.
Also, check the electrical system, including the

batteries, as troubles in the electrical system
such as low battery voltage, loose connections
and blown fuses will result in malfunction of the
controllers, causing total operational failure of the
machine.
If troubleshooting is started without checking for
blown fuses, a wrong diagnosis may result,
wasting time. Be sure to check for blown fuses
before troubleshooting. Even if a fuse looks
normal by visual inspection, a fine crack is
difficult to find. Always use a tester when
checking the fuses. T107-07-01-003
4. Operate the machine yourself

Try to identify the trouble by operating the
machine yourself.
If the trouble cannot be confirmed, stop the
engine and obtain further details of the
malfunction from the operator.
Also, check for any incomplete connections of the
wire harnesses.
T5-1-3

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.
Perform diagnosis by connecting Dr. ZX to the

machine or by operating the built-in diagnosing
system. In case any fault code has been dis-
played by diagnosis using Dr. ZX (or the built-in
diagnosing system), delete the fault code once T107-07-01-005
and retry self-diagnosis again. If the fault code is

displayed again, check the cause of the trouble
by referring to Troubleshooting A in this section.
After the machine trouble has been corrected, the
fault code (displayed by the built-in diagnosing
function) will be deleted. Therefore, in case prob-
lems, which are not easily re-predicable are
encountered, use Dr. ZX to display the fault code.
In case no fault codes are displayed, check all re-
lated parts/component operating condition using
the monitor function of Dr. ZX (or the built-in di-
agnosing system) while referring to troubleshoot-
ing B in this section.
Note that the fault codes displayed do not

necessarily indicate machine trouble. The T107-07-01-006
controller stores even temporary electrical
malfunctions, such as a drop in battery output
voltage or disconnections of the switches,
sensors, etc., for inspections.
For this reason, the RETRIAL is required to
erase the accumulated fault codes from the
controller memory and to confirm if any fault
codes are indicated after the RETRIAL.
6. Trace possible causes

Before reaching a conclusion, check the most
likely causes again. Try to identify the actual
cause of the trouble.
Based on your conclusion, make a plan for T107-07-01-007
appropriate repairs to avoid consequent

malfunctions.
T5-1-4

(Blank)
T5-1-5

BUILT-IN DIAGNOSING SYSTEM OPERA-
TION
IMPORTANT: This system is to be operated by the
HITACHI Dealer Only. Dont explain
this system function to the cus-
tomer.
In the service mode, the monitor LCD displays the

diagnosing items, fault codes and monitored results
(not all of them) without using Dr. ZX.
Built-In Diagnosing System Activation

1. While pressing the monitor SET switch, turn the
key switch ON.
Display Selection
Switch
Built-In Diagnosing System Operation
1. Each time the display selection switch is pressed,
SET Switch
the displayed item will be changed as shown on
next page.
NOTE: The fault code is indicated in the display

order 8. All fault codes (Dr. ZX fault code
list) can be indicated. In case more than LCD
one fault code is indicated, they will be dis-
played with an interval of 1 second in order.
After the machine malfunction has been
repaired, the fault codes are automatically
deleted. Accordingly, if any trouble, which
is not reproducible, is encountered, it is
recommended to use Dr. ZX.
The built-in diagnosing system displays only the
item No. on the left and the monitored result on the T178-01-01-003
right. The item description is not displayed.
T5-1-6

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)
4 Engine Actual Speed n -1
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
NOTE: *: Refer to T5-1-10 for the Fault Codes.

**: ML specification is only available in Japanese domestic market.
T5-1-7

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).
NOTE: This group describes how to operate Dr.

ZX connected to the MC. Refer to Group 7
ICX for operation of Dr. ZX connected to Dr. ZX Connector (ICX)
the ICX. (Located at Backside of
Sheet)
T178-01-02-006
ZAXIS225US:
Fuse Box
Dr. ZX
Dr. ZX Connector Connector
(ICX) (MC)
(Located at Back-
side of Sheet) T1SM-01-02-006
Palm
Dr. ZX
Hot Sync Cable
Battery Box
Cable
T178-05-01-167
T5-1-8

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.
2. Turn the key switch ON, or start the engine.

3. When the palm power is turned ON, palm dis- Title Screen
plays the following screens in order.
3-1. Title Screen
Select the Dr. ZX icon
3-2. Select Kind Screen Cannot Select Kind
Communicate Screen
+ Select the EPVC-Mid
3-3. Menu Screen
· Check harness
Select the Start. · Check fuse
3-4. Model Name Screen Menu Screen
(Example) Model: ZX200/ZX225USR
3-5. Function Selection Screen
+ Self-Diagnostic Results
Model Name
+ Monitor Display Confirmation
+ Special Function
NOTE: Special functions allow the ECO and WU NOT OK
deactivation. (Refer to T5-1-14) OK ?
4. Select Self-Diagnostic Results. Then, continue to OK

Replace software
operate palm by following instructions to be dis-
played at the screen bottom hereafter.
Self-Diagnosing
NOTE: Refer to the Dr. ZX Operation Manual for Result Display Special
Function Select Monitor Function
the detailed operation of Dr. ZX.
function
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

DR. ZX FAULT CODE LIST
Fault Code Trouble 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
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 Pilot Pressure Faulty MC
15 Abnormal Boom Raise Pilot Pressure Faulty Harness
16 Abnormal Arm Roll-In Pilot Pressure Faulty Pilot Pressure Sensor
18 Abnormal Travel Pilot Pressure
19 Abnormal Hydraulic Oil Temperature Faulty MC
Faulty Harness
Faulty Hydraulic Oil Temperature Sensor
T5-1-10

(Blank)
T5-1-11

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.
Item Data Unit

Pump 1 Delivery Pressure Input signals from pump 1 delivery pressure sensor MPa
Pump 1 Pump (Flow) Con- Input signals from pump 1control pressure sensor MPa
trol Pressure
Pump 2 Delivery Pressure Input signals from pump 2 delivery pressure sensor MPa
Pump 2 Pump (Flow) Con- Input signals from pump 2control pressure sensor MPa
trol Pressure
Pump 2 Max. Displacement cm3
Engine Target Speed Target speed when loaded. Approx. 150 min differs min-1
-1
from speed when unloaded.

-1
Engine Actual Speed Input signal from N sensor min
Deviation in Engine Speed Calculated Value min-1
(Engine Speed Differential) (Target Engine Speed - Actual Engine Speed)
EC Angle Input signal from EC sensor V
Dial Angle Input signal from engine control dial V
Boom Raise Pilot Pressure Input signal from pressure sensor (boom raise) MPa
Arm Roll-In Pilot Pressure Input signal from pressure sensor (Arm Roll-In) MPa
Swing Control Pressure Input signal from pressure sensor (swing) MPa
Travel Control Pressure Input signal from pressure sensor (travel) MPa
Front Att. Operation Input signal from pressure sensor (front att.) FR
Hydraulic Oil Temperature Input signal from oil temperature sensor C
E/P/HP Mode Switch Power mode switch selection status E, P, HP
Auto-Idle/Auto-Accel Auto-Idle/Auto-Acceleration selector selection status AI, AA
Switch
Travel Mode Travel mode switch selection status Lo, Hi
Power Digging (Boost) Power digging switch selection status Pd
Switch
Key Switch Key switch selection status Ky
Work mode Work mode switch selection status STD, ATT
ATT. Mode BU, CS, CL, HB
Engine Learning Status Done, Undone,
Aborted Ky
Pump 2 Proportional Sole- Control signal to max. pump 2 flow rate limit solenoid MPa
noid Valve Output valve
Pump Torque Proportional Control signal to torque control solenoid valve MPa
Solenoid Valve Output
T5-1-12

Item Data Unit

****Arm Flow Rate Proportional So- Control signal to solenoid valve SE MPa
lenoid Valve Output
Arm Regenerative Proportional So- Control signal to solenoid valve SC MPa
lenoid Valve Output
***Boom Damper P/S Valve Output Control signal to boom electronic cushion sole- MPa
(BDMO) noid valve
Power Digging (Boost) Control Pres- Control signal to solenoid valve SG MPa
sure
Travel Motor Control Pressure Control signal to solenoid valve SI MPa
EC Motor Position step
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
3
Pump 1 Max. Displacement cm
*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

Dr. ZX SPECIAL FUNCTION
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS200.
Start the service software in the Select a special function

operation mode
If the following screen appears, Select the function you want to
you are in the operation mode. execute.
Select Special Function.
T178-05-01-013 T178-05-01-168
Fig. A Fig. B
Select ESC to return
to Fig. A.
Special function
Select Execute to execute the

function.
WU deactivation ECO control deactivation
Execute Execute
T178-05-01-030 T178-05-01-031 T178-05-01-032 T178-05-01-033

Select ESC to return Select ESC to return Select ESC to return Select ESC to return
to Fig. B. to Fig. B. to Fig. B. to Fig. B.
T5-1-14

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.
Learning Value Display

Displays the values set by learning function. Dr. ZX
Connector
to MC
Parameter Change
Engine speed, pump delivery flow rate, and solenoid
valve output pressure can be adjusted.
Monitor Display Information Setting

Items to be displayed on the monitor LCD can be
added.
Accessing Service Mode T178-01-02-006

1. After turning the key switch OFF, wait for more
than 10 seconds. ZAXIS225US
2. Connect Dr. ZX to the connector to MC on the
base machine.
3. Turn the engine learning switch to the learning
position (the stamped mark E side).
4. Turn the key switch ON. Dont start the engine at
this time.
5. Turn Dr. ZX switch ON.
Learning Switch T1SM-01-02-006

Dr. ZX Connector
to MC
The learning switch is

turned to the stamped
mark E
Learning Switch
Stamped
Mark E
T1CC-05-01-001
T5-1-15

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

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

Displaying Engine Learning Data and Angle Sensor Correction Valve
Start the service software in The service software will

the service mode start in the service mode
Select Start from the Press Correct if the Confirm that you are in the Select Special Function.
EPVC_Mid software menu. displayed model name is service mode, and select
correct. Rechecked.
Fig. A T178-05-01-006 Fig. B T178-05-01-012 Fig.C T178-05-01-034 Fig. D T178-05-01-035

Select ESC to return Select ESC to return Select ESC to return
to Fig. A. to Fig. A. to Fig. A.
Select the function you Learning data items will

want to execute be displayed
The menu will be displayed. Select the item you want to
Select Learning Data Display execute.
from the menu.
Fig. E T178-05-01-036 Fig. F T178-05-01-037

Select ESC to return Select ESC to return
to Fig. D. to Fig. F.
T5-1-18

EC Motor stop position EC Motor Maximum Boom angle sensor Arm angle sensor correction
engine speed position correction value value
T178-05-01-038 T178-05-01-039 T178-05-01-040 T178-05-01-041

Select ESC to return Select ESC to return Select ESC to return Select ESC to return
to Fig. F. to Fig. F. to Fig. F. to Fig. F.
T5-1-19

Changing Parameters In The Controller
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.
Start the service software in The service software will start in

the service mode the service mode
Select Start from the Press Correct if the displayed Confirm that you are in the Select Special Function.
EPVC_Mid software menu. model name is correct. service mode, and select
Rechecked.
Fig. A T178-05-01-006 Fig. B T178-05-01-012 Fig. C T178-05-01-034 Fig. D T178-05-01-035

to Fig. A. to Fig. A. to Fig. A
Execute the parameter Select a parameter change

change Enter the password
item
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

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.
T178-05-01-045 T178-05-01-046 T178-05-01-047

to Fig. G. to Fig. G. to Fig. G.
T5-1-21

Changing The User Mode Display on The Monitor Panel
Start the service mode on the condition that the engine learning switch is turned on.
Start the service software in The service software will start in

the service mode the service mode
Select Start from the Press Correct if the displayed Confirm that you are in the
EPVC_Mid software menu. model name is correct. service mode, and select Select Special Function.
Rechecked.
Fig. A T178-05-01-006 Fig. B T178-05-01-012 Fig. C T178-05-01-034 Fig. D T178-05-01-035

to Fig. A. to Fig. A. to Fig. A.
Execute the monitor display Select a display change Select Display or

change item No Display
The menu will be displayed. Select the monitor display Select Disp or No Disp.
Select Monitor Display from change item you want to
the menu. execute.
Fig. E T178-05-01-042 Fig. F T178-05-01-048 Fig. G T178-05-01-049

to Fig. D. to Fig. E. to Fig. F.
T5-1-22

Confirm Disp/No Disp Confirm the result

Confirm that the Monitor space
shows Disp or No Disp. If it is It has been changed as shown
correctly displayed, select on-screen. Select ESC.
Execute.
Fig. H T178-05-01-050 Fig. I T178-05-01-051

Select ESC to return
to Fig.F. Select ESC to return to Fig. F.
T5-1-23

Operational Performance Check After Adjustment

(Check that pump flow rate and engine speed
have been changed.)
IMPORTANT: After adjusting the engine speed and

flow rate to the attachment, turn the
engine learning switch to neutral. If
the engine is started with the engine
learning switch in the engine
learning position, the MC will not
control the engine, pumps, and
valves so that change in the pump
flow rate and the engine speed
cannot be checked.
1. Turn the key switch OFF.

2. Wait approx. 10 seconds.
3. Turn the engine learning switch to neutral.
4. Disconnect the Dr. ZX. connector (When
monitoring with Dr. ZX, pass this step.)
5. Turn the key switch ON.
6. Start the engine.
7. Check operational performances of the machine.
T5-1-24

ADJUSTMENT DATA LIST
Min. Adjustable Range

Standard
Adjustment Data Adjustment Remarks
Model Range Adjustment
Value
ZX200/225/230/
Li Speed 10 min-1 0 to 120 0 min-1
270 class
ZX200/225/230/
WU Speed 10 min-1 -120 to 120 0 min-1
270 class
ZX200/225/230/
AI Speed 10 min-1 -120 to 120 0 min-1
270 class
-1 ZX200/225/230/ -1
E Speed 10 min -120 to 120 0 min
270 class
ZX200/225 class -120 to 120
P Speed 10 min-1 0 min-1
ZX270/270 class -120 to 100
-1 ZX200/225 class -500 to 200 -1
Breaker Speed 10 min 0 min
ZX270/270 class -500 to 100
-1
Secondary Crusher ZX200/225 class -500 to 200 200 min
10 min-1
(Demolisher) Speed ZX270/270 class -500 to 100 100 min-1
-1
ZX200/225 class -500 to 200 200 min
Crusher Speed 10 min-1 -1
ZX270/270 class -500 to 100 100 min
ZX200/225 class -500 to 200
Vibro-Hammer Speed 10 min-1 0 min-1
ZX270/270 class -500 to 100
Hyd. Breaker P1 Max ZX200/225/230/
0.6 cm3/rev 51 to 112.8 112.8 cm3/rev
Swash Angle 270 class
Secondary (Demolisher) P1 ZX200/225/230/
0.6 cm3/rev 51 to 112.8 112.8 cm3/rev
Max Crusher Swash Angle 270 class
Crusher P1 Max Swash 3 ZX200/225/230/ 3
0.6 cm /rev 51 to 112.8 112.8 cm /rev
Angle 270 class
ZX200/225/230/
Vibro Swash Angle 0.6 cm3/rev 51 to 112.8 112.8 cm3/rev
270 class
Hyd. Breaker P2 Max ZX200/225/230/
0.6 cm3/rev 51 to 112.8 112.8 cm3/rev
Swash Angle 270 class
Secondary Crusher
ZX200/225/230/
(Demolisher) P2 Max 0.6 cm3/rev 51 to 112.8 112.8 cm3/rev
270 class
Swash Angle
Crusher P2 Max Swash 3 ZX200/225/230/ 3
0.6 cm /rev 51 to 112.8 112.8 cm /rev
Angle 270 class
ZX200/225/230/
Vibro P2 Max Swash Angle 0.6 cm3/rev 51 112.8 112.8 cm3/rev
270 class
T5-1-25

Min. Adjustable Range Standard

Adjustment Data Adjustment Adjustme Remarks
Model Range
Value nt
Pump PQ Base Torque ZX200/225/
2.45 N m -78.4 to 0 0Nm
Adjustment 230/270 class
ATT Proportional Solenoid ZX200/225/
0.1 MPa -0.89 to 0.89 0 MPa
Valve 230/270 class
Boom Lower Dampener ZX200/225/
0.1 MPa -0.89 to 0.89 0 MPa
Proportional Solenoid Valve 230/270 class
ATT Speed Increase Down ZX200/225/
500 ms 0 to 3000 3000 ms
Wait Time 230/270 class
0: ATT Torque Down
**ATT Torque Down ZX200/ Control Activation
1 digit 0 to 1 1 digit
ON/OFF 225 class 1: ATT Torque Down
Control Deactivation
ZX200/225/
*ML Crane Front Code 1 0 to 2 0
230/270 class
ZX200/225/
*ML Crane Bucket Code 1 0 to 1 0
230/270 class
ZX200/
-500 to 300
225class
Max. *ML Crane Speed 10 min-1 0 min-1
230 class -550 to 430
270 class -600 to 430
ZX200/225/
*ML Crane Bucket Weight 4 kg -512 to 508 0 kg
230/270 class
Min Boom CYL Bottom ZX200/225/
0.1 MPa -9.81 to 9.81 0 MPa
Pressure Over Balance 230/270 class
NOTE: 1 MPa=10.197 kgf/cm2

1 kgf/cm2=0.098 MPa
* ML specification is only available in
Japanese domestic market.
**Available for ZX200 class and ZX225
class only.
T5-1-26

INITIAL SETTING OF BOOM ELECTRONIC
CUSHION
(Available on the ZAXIS225US (Serial No.104908
and earlier).) Monitor:
After the front attachment is changed or the boom

angle sensor is replaced, be sure to perform the initial
setting of the boom electronic cushion (the angle
sensor.) Display
NOTE: Every boom operation is kept at slow Selection
Switch
speed, if the initial setting fails or the
related sensor is faulty.
Set Switch
Procedure
1. The front attachment is set at the initial setting
position.
Boom Cylinder: Fully extended.
2. Turn the key OFF and wait for 10 seconds. LCD
3. The learning switch is turned to the initial setting
of the boom electronic cushion side.
4. The key switch is turned ON pressing the set
switch on the monitor and select the built-in
diagnosing system mode.
(Be sure not to start the engine.)
5. Press the display selection switch 6 times.
Overload Alarm is displayed. L2 000 is T178-01-02-008
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

Fault Code Contents Remarks

000 Initial Setting Not Completed Initial setting has not been completed yet.
80 Abnormal Boom Angle Value on the sensor before the initial setting is over (standard
Sensor Connection initial setting valve) 0.3 V.
83 Abnormal Boom Angle Value on the sensor is 0.25 V and less, or 4.75 V and more.
Sensor
87 Abnormal EEPROM Writing EEPROM is abnormal.
88 Key OFF During Initial During the initial setting, the key switch was turned OFF.
Setting
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
13
20 14
15
19 16
18
17 T178-01-02-001
1- Bucket Cylinder 7- Fuel Tank 13- Intercooler 19- Pilot Shut-Off Valve
2- Arm Cylinder 8- Hydraulic Oil Tank 14- Radiator 20- Travel Pilot Valve
3- Boom Cylinder 9- Control Valve 15- Oil Cooler 21- Front Attachment/Swing
Pilot Valve
4- Center Joint 10- Pilot Filter and Pilot Relief Valve 16- Battery
5- Swing Bearing 11- Pump Device 17- Travel Device
6- Swing Device 12- Engine 18- Signal Control Valve
T5-2-1

ZAXIS225US
3
4
5
6
7
8
9
21
18
20
19
10
18
11
17
16 12
13
15 14 T1GF-01-02-001
1 - Bucket Cylinder 7 - Hydraulic Oil Tank 13 - Oil Cooler 19 - Pilot Shut-Off Valve
2 - Arm Cylinder 8 - Swing Device 14 - Intercooler 20 - Travel Pilot Valve
3 - Boom Cylinder 9 - Pump Device 15 - Battery 21 - Boom Electronic Cushion
Solenoid Valve*
4 - Signal Control Valve 10 - Pilot Filter and Pilot Relief 16 - Fuel Tank
Valve
5 - Control Valve 11 - Engine 17 - Center Joint
6 - Solenoid Valve Unit 12 - Radiator 18 - Front Attachment/Swing
Pilot Valve
NOTE: *Up to serial No.104908.
T5-2-2

ZAXIS225USR
1
2
3
4
5
6
7
8
20
9
10
11
19
18 12
17 13
14 T1GD-01-02-001
16
15
1 - Bucket Cylinder 6 - Solenoid Valve Unit 11 - Pilot Filter and Pilot Relief 16 - Battery
Valve
2- Arm Cylinder 7- Fuel Tank 12 - Engine 17 - Center Joint
3- Boom Cylinder 8- Hydraulic Oil Tank 13 - Radiator 18 - Pilot Shut-Off Valve
4- Signal Control Valve 9- Swing Device 14 - Oil Cooler 19 - Travel Pilot Valve
5- Control Valve 10 - Pump Device 15 - Inter Cooler 20 - Front Attachment/Swing
Pilot Valve
T5-2-3

ELECTRICAL COMPONENT LAYOUT
(Overview)
ZX200 class, 230 class and 270 class

Pump 1 and 2 Delivery Pressure Sensor
Pump 1 and 2 Control Pressure Sensor
N Sensor 1 2 3
Torque Control Solenoid Valve 4
Pump 2 Flow Rate Control Solenoid Valve 5
Refer to the Pump Device group.
7
6 8 Pressure Sensor (Travel)
Pressure Sensor (Swing)
9 Refer to the Signal Control
Valve group.
18
17
16
15
14
10
13
Pressure Sensor (Boom Raise)

Pressure Sensor (Arm Roll-In)
11 Refer to the Control Valve group.
T178-01-02-002
Pressure Sensor (Front Attachment)
Refer to the Swing Device group. 12
1 - Overheat Switch 6 - Coolant Level Switch* 11 - Horn 15 - Solenoid Valve Unit

2 - Coolant Temperature Sen- 7 - Battery 12 - Work Light 16 - Engine Oil Level Switch*
sor
3 - Battery Relay 8 - Starter Relay 13 - Fuel Sensor 17 - Engine Oil Pressure Switch
4 - Glow Relay 9 - Air Cleaner Restriction 14 - Hydraulic Oil Temperature 18 - EC Motor and EC Sensor
Switch Sensor
5 - Fusible Link 10 - Wiper Motor
NOTE: *Up to serial No.104679 (ZX200 class)

T5-2-4

ZAXIS225US
N Sensor 1 2 3 4 5 6
Torque Control Solenoid Valve
Pump 2 Flow Rate Control Solenoid Valve
9
10
11
12
19
18
17
16
15
13 T1GF-01-02-002
14
Pressure Sensor (Boom Raise) Pressure Sensor (Travel) Pressure Sensor (Front Attachment)
Pressure Sensor (Arm Roll-In) Pressure Sensor (Swing) Refer to the Swing Device group.
Refer to the Control Valve group. Refer to the Signal Control
Valve group.
1 - Overheat Switch 6 - Air Cleaner Restriction 11 - Wiper Motor 16 - Hydraulic Oil Temperature
Switch sensor
2 - Coolant Temperature 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

ZAXIS225USR
N Sensor 1 2 3 4 5
Pump 2 Flow Rate Control Solenoid Valve
6
17
8
9
10
16
15
14
13
12
T1GD-01-02-002
11
Pressure Sensor (Boom Raise) Pressure Sensor (Travel) Pressure Sensor (Front Attachment)
Pressure Sensor (Arm Roll-In) Pressure Sensor (Swing) Refer to the Swing Device group.
Refer to the Control Valve group. Refer to the Signal Control
Valve group.
1 - Over Heat Switch 6 - Fusible Link 11 - Horn 16 - Fuel Sensor

2 - Coolant Temperature Sen- 7 - Starter Relay 12 - Solenoid Valve Unit 17 - EC Motor and EC Sensor
sor
3 - Air Cleaner Restriction 8 - Coolant Level Switch* 13 - Hydraulic Oil Temperature
Switch Sensor
4 - Glow Relay 9 - Battery 14 - Engine Oil Lever Switch*
5 - Battery Relay 10 - Wiper Motor 15 - Engine Oil Pressure switch
T5-2-6

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

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)
NOTE: It is used for engine learning and the ini-

tialization of the boom electronic cushion
(Up to serial No.104908).
T5-2-8

ELECTRICAL SYSTEM (Monitors and
Switches)
1 2
20
19
21
18
3
17
22
16 4
15
23
5
14 24
6
13 7
12 8
25
11
9
10
T178-01-02-008
T178-01-01-004
1- Coolant Temperature Gauge 8- Alternator Indicator 15- Digging Mode Indicator 22- Power Mode Switch
2- Fuel Gauge 9- Hydraulic Oil Filter Indicator 16- Attachment Mode Indicator 23- Travel Mode Switch
(Optional)
3- Display Selection Switch 10- Coolant Level Indicator * 17- Liquid Crystal Display 24- Work Light Switch
4- SET Switch 11- Engine Oil Level Indicator * 18- Auto-Idle Indicator 25- Wiper/Washer Switch
5- Work Mode Switch 12- Engine Oil Pressure 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
NOTE: * Up to serial No.104679 (ZX200 class and 225 class)

T5-2-9

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)
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)
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
ZX270 class ZX230 class and ZX270 class
2
1
3
T178-03-03-068
T1HG-01-02-002
1- Counterbalance Valve 2- Travel Relief Valve 3- Overload Relief Valve

(Positioning)
T5-2-12

(Blank)
T5-2-13

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

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
cuit)
Circuit)
Valve Circuit)
T5-2-15

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

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
cuit)
Circuit)
Valve Circuit)
T5-2-17

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

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
cuit)
Circuit)
Valve Circuit)
T5-2-19

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

Swing
Boom 2 Boom 1
29 19
27
18
32 25
14
15
26
17
T178-03-03-008
T178-03-03-006
T5-2-20

Cross Section E Cross Section G
22
31 16
30
23
20
T178-03-03-009
24
28
T178-03-03-007
cuit)
Circuit)
Valve Circuit)
T5-2-21

1 2 3 4 5 6 7 8 9 10
36
35
34
33
11
12
13
32 14
31 15
30
16
17
29
28
18
19
20
21
27 22
26
25 24 23
T178-03-03-016
Cross Section H Cross Section I
21
4
2
T178-03-03-042 T178-03-03-041
T5-2-22

View K Cross Section L

36
T178-03-03-045
M Cross Section M
35
T178-03-03-046
T178-03-03-048
cuit)
Circuit)
Valve Circuit)
T5-2-23

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

Positioning Control Valve

(2-Piece Boom Only)
ZX200 class
X
2
X
3 1 - Section X-X T198-03-03-003
T198-03-03-002
ZX230 class, ZX270 class

2
4 D
Section D-D
1 3
T178-03-03-067
T178-03-03-066
T5-2-25

SIGNAL CONTROL VALVE PORT LOCA-
TION
Pilot Valve Side
Port Name Connecting to Note
Port A Right Pilot Valve Boom Raise Pilot Pressure
Boom Electronic Cushion Solenoid Valve (Up
to serial No.104908 (ZAXIS225US))
Port B Right Pilot Valve Boom Lower Pilot Pressure
Port C Left Pilot Valve Arm Roll-Out Pilot Pressure
Port D Left Pilot Valve Arm Roll-In Pilot Pressure
Port E Left Pilot Valve Left Swing Pilot Pressure
Port F Left Pilot Valve Right Swing Pilot Pressure
Port G Right Pilot Valve Bucket Roll-In Pilot Pressure
Port H Right Pilot Valve Bucket Roll-Out Pilot Pressure
Port I Travel Pilot Valve Left Travel Forward Pilot Pressure
Port J Travel Pilot Valve Left Travel Reverse Pilot Pressure
Port K Travel Pilot Valve Right Travel Forward Pilot Pressure
Port L Travel Pilot Valve Right Travel Reverse Pilot Pressure
Port M Auxiliary Pilot Valve Auxiliary Open Pilot Pressure
Port N Auxiliary Pilot Valve Auxiliary Close Pilot Pressure
Port SA Pump 1 Regulator Pump 1 Control Pressure
Port SB Pump 2 Regulator Pump 2 Control Pressure
Port PI Pilot Shut-Off Valve Primary Pilot Pressure
Port PH Pilot Shut-Off Valve Primary Pilot Pressure (Heating Circuit)
Port SH Swing Parking Brake Brake Release Pressure
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank
T5-2-26

Pilot Valve Side

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

SM
3
1 5
13
2 4
SK
SE

8
14
Control Valve Side
7
9
6
10
SN
SL
11
Pressure Sensor (Travel) 12 SP T178-03-06-015
T5-2-27

Control Valve Side

Port Name Connecting to Note
Port 1 Control Valve Boom Raise Pilot Pressure
Port 2 Control Valve Boom Lower Pilot Pressure
Port 3 Control Valve Arm Roll-Out Pilot Pressure
Port 4 Control Valve Arm Roll-In Pilot Pressure
Port 5 Control Valve Left Swing Pilot Pressure
Port 6 Control Valve Right Swing Pilot Pressure
Port 7 Control Valve Bucket Roll-In Pilot Pressure
Port 8 Control Valve Bucket Roll-Out Pilot Pressure
Port 9 Control Valve Left Travel Forward Pilot Pressure
Port 10 Control Valve Left Travel Reverse Pilot Pressure
Port 11 Control Valve Right Travel Forward Pilot Pressure
Port 12 Control Valve Right Travel Reverse Pilot Pressure
Port 13 Control Valve Auxiliary Open Pilot Pressure
Port 14 Control Valve Auxiliary Close Pilot Pressure
Port SE Plug
(Up to serial No.104678 (ZX200 class and (Up to serial No.104678 (ZX200 class and 225
225 class), Up to serial No.010326 (ZX230 class), Up to serial No.010326 (ZX230 class), Up
class), Up to serial No.020042 (ZX270 to serial No.020042 (ZX270 class))
class))
Control Valve
(Serial No.104679 and up (ZX200 class and Arm Flow Rate Control Valve Control Pressure
225 class), Serial No.010327 and up (ZX230 (Serial No.104679 and up (ZX200 class and 225
class) Serial No.020043 and up (ZX270 class), Serial No.010327 and up (ZX230 class)
class)) Serial No.020043 and up (ZX270 class))
Port SM Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port SN Plug
Port SP Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port SL Control Valve Flow Combiner Valve Control Pressure
Port SK Control Valve Bucket Flow Rate Control Valve Control Pressure
T5-2-28

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

SM
3
1 5
13
2 4
SK
SE

8
14
Control Valve Side
7
9
6
10
SN
SL
11
Pressure Sensor (Travel) 12 SP T178-03-06-015
T5-2-29

(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).
How to Read Troubleshooting Flow Charts
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)
Instructions, reference, and/or inspection methods and/or measurements are occasionally

described under the box. If incorrectly checked or measured, not only will troubleshooting
· Key switch: ON be unsuccessful but also damage to the components may result.
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.
NOTE: All harness end connectors are seen from

the open-end side.
Harness
Open End
Side
Harness End Connector
T158-05-03-001
T5-3-1

FAULT CODE LIST
Fault code Problem Cause
01 Abnormal EEPROM Faulty MC
02 Abnormal RAM
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

FAULT CODE 01 (ABNORMAL EEPROM)
FAULT CODE 02 (ABNORMAL RAM)
FAULT CODE 03
(ABNORMAL A/D CONVERSION)
YES * Faulty MC.
Check if engine and machine

actuators operate normally.
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)
YES Faulty sensor.
Disconnect connectors from

all sensors relating to the in- Short-circuited harness be-
dicated fault code, and retry. YES tween MC and sensor in
Does fault code 04 disappear? Disconnect all con- section where continuity is
nectors from MC. present.
NOTE: If fault code 04 Is there continuity be-
(abnormal sensor NO
tween terminals #1 and
voltage) appears, #3 of harness at each
sensor? Faulty MC.
other fault codes
NO
appear at the same · Key switch: OFF
· Refer to T4-6-1.
time.
T5-3-3

FAULT CODE 06
(ABNORMAL EC SENSOR)
Faulty harness between

Check harness between YES MC and EC sensor.
MC connector C (31P)
YES terminal #18 and EC
sensor terminal #2 for
breakage or short circuit.
Disconnect EC sensor. Faulty MC.
Check if voltage between
harness end connectors NO
YES #1 and #3 is 5 0.5 V. · Refer to T4-6-1.
Disconnect EC sensor. Check
if resistance between sensor Broken harness be-
side connector terminals #1 Check if voltage between YES tween MC and EC
and #3 is less than 2.0 0.4 EC sensor harness end sensor terminal #3.
k . Connect test harness · Key switch: ON connector terminal #1 and
between EC sensor and base vehicle frame matches
machine side harness. Check NO specification.
if voltage changes in accor- Broken harness be-
dance with specifications tween MC and EC
NO
when engine control dial is sensor terminal #1.
rotated. · Key switch: ON
· Specification: 5 0.5 V
Faulty EC sensor.
NO
· Test Harness: ST 7129 · Refer to T4-6-1.
· Specification: Refer to the
table below.
EC Sensor Specification Connector (Harness End Connector Viewed from the

Slow Idle 2.5 to 2.7 V Open End Side)
Fast Idle (HP mode 3.3 to 3.7 V
Switch: OFF)
MC Connector C
Fast Idle (HP mode Voltage at Fast Idle (HP Mode
Switch: ON) Switch: OFF) plus 0.2 V or C1 C10
more
C23 C31
#18
EC Sensor
1 2 3
T5-3-4

FAULT CODE 07
(ABNORMAL ENGINE CONTROL DIAL
ANGLE)
Faulty harness between

Check harness between MC and engine control
MC connector C (31P) YES dial.
harness end terminal #6
YES and switch panel terminal
#3 for breakage or short
circuit.
Disconnect switch panel.
Faulty MC.
Check if voltage between
harness end connector NO
Disconnect switch panel. · Refer to T4-6-1.
Check if resistance between YES terminals #2 and #4 is
switch panel side connector 5 0.5 V. Broken harness be-
terminals #2 and #4 is 5 0.5 Check if voltage between YES tween MC and engine
k . switch panel harness end control dial terminal #4.
Reconnect switch panel. In- connector terminal #2 and
sert tester probe into · Key switch: ON vehicle frame matches
connector terminal #3 from the NO specification. Broken harness be-
reverse side. Check if voltage tween MC and engine
varies as specified when en- NO control dial terminal #2.
gine control dial is turned.
· Key switch: ON
Faulty engine control
NO dial.
· Specification: Refer to the

table below.
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

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 k . 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.
Faulty boom angle

NO sensor.
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
C1 C10
C23 C31
#17
Boom Angle Sensor
1 2
3
T5-3-6

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 between 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
MC Connector C
#1 #4
C1 C10
C23 C31
Pump Delivery Pressure Sensor
3 2 1
T5-3-7

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.
Disconnect pump con- Faulty MC.

trol pressure sensor. NO
Check if voltage be-
tween harness end · Refer to T4-6-1.
NO connector terminals #1
and #3 is 5 0.5 V. Broken harness be-
Check if voltage between MC and pump
tween pump control control pressure sen-
Check if fault codes are pressure sensor har- YES sor terminal #3.
switched after switching ness end connector
pump 1 control pressure · Key switch: ON terminal #1 and vehicle
sensor with pump 2 con- frame matches specifi-
trol pressure sensor and NO cation. Broken harness be-
retrying. tween MC and pump
NO control pressure sen-
sor terminal #1.
· Key switch: ON
Faulty pump control

pressure sensor.
YES
MC Connector C
#13 #7
C1 C10
C23 C31
Pump Control Pressure Sensor
1 2 3
T5-3-8

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
MC Connector C
#2 #3 #5
C1 C10
C23 C31
#14
Pilot Pressure Sensor
1 2 3
T5-3-9

FAULT CODE 19
(ABNORMAL OIL TEMPERATURE)
Connect oil tempera-

ture sensor harness Faulty MC.
YES
end connector terminal
#1 to #2 with a clip.
Remove connector B · Refer to T4-6-1.
(25P) and connector C
(31P) from MC. Check Broken harness be-
Connect MC connec- tween MC and oil
YES for continuity between
tor B (25P) harness YES temperature sensor
connector B harness
end terminal #22 to terminal #1.
end terminal #22 and
vehicle frame. Check
connector C terminal
for continuity between
#24.
Disconnect oil tempera- oil temperature sensor
ture sensor. Check if NO harness end connec-
sensor side connector tor terminal #2 and Broken harness be-
resistance matches vehicle frame. tween MC and oil
specification. temperature sensor
NO terminal #2.
· 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) (k ) 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
Oil Temperature Sensor
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 machines 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.
How to Read the Troubleshoting Flow Charts
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.
Use Dr.ZX (or the built-in diagnosing system) function.
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

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 doesnt 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 doesnt 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.
By Fault Code Fault code 06 is displayed.
Monitor Item: EC Angle (Displayed by built-in

By Monitor diagnosing system)
Function
Evaluation
Install lamp harness (ST 7125) to check EC
Using Test output signal and harness for any abnormality.
Harness
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.
Descriptions of Control T2-1 T2-1

(Operational Principle Sec-
tion in T/M)
T5-4-2

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 doesnt 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
min-1 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
T2-1 T2-1 T2-1
T5-4-3

Parts Pump 3 Delivery Pressure Sensor

Pump 2 Delivery Pressure Sensor
(Optional)
Monitors pump delivery pressure to control HP Monitors pump delivery pressure to control
mode, auto-acceleration, slow speed torque pump 3 torque decrease control.
increase, arm flow rate, arm regenerative and
travel motor swash angle control.
Function
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.
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.
By Fault Code Fault codes 11 is displayed.

Monitor Item: Pump 2 delivery pressure (Dis-
played by built-in diagnostic system)
By Monitor
Function
Evaluation
Using Test
Harness
Others
NOTE

tion in T/M)
T5-4-4

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.
No signals arrive to MC No signals arrive to MC No signals arrive to MC
Engine speed doesnt increase even if Engine speed doesnt 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 doesnt 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 isnt 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 isnt increased.
(Not remarkable)
Fault code 18 is displayed. Fault code 14 is displayed.

Monitor Item: Travel Control Pressure (dis- Monitor Item: Front Attachment Operation Monitor Item: Swing Control Pressure (dis-
played built-in diagnostic system). (displayed built-in diagnostic system). played built-in diagnostic system).
Monitor pressure change while traveling Monitor pressure change while operating Monitor pressure change while swinging
machine. front attachment. upperstructure.
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.
T2-1 T2-1 T2-1
T5-4-5

Parts Pressure Sensor Pressure Sensor

(Boom Raise) (Arm Roll-In)
Monitors boom raise pilot pressure to control HP Monitors arm roll-in pilot pressure to con-
mode, auto-acceleration, arm regenerative, and trol HP mode, auto-acceleration, arm flow
auto-power lift controls. rate, and arm regenerative controls.
Function
No signals arrive to MC No signals arrive to MC
Symptoms in control system

when trouble occurs.
Even if boom is raised with HP mode switch ON, Even if arm is rolled-in with HP mode
engine speed doesnt increase. switch ON, engine speed doesnt 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 doesnt auto-idle/auto-acceleration selector is
increase. auto-acceleration position, engine speed
Arm roll-in speed becomes slightly slower than doesnt 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 doesnt 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 doesnt 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 Fault Code Fault Code 15 is displayed. Fault code 16 is displayed.
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
Using Test Har-

ness
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
Descriptions of Control (Op- T2-1 T2-1

erational Principle Section in
T/M)
T5-4-6

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
valve is 0 MPa (0 kgf/cm2). 0 MPa (0 kgf/cm2).
Engine speed doesnt increase when Even if speed sensing system doesnt 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. (350 kfg/cm2). Even if power digging
speed increases. Machine may occasionally mistrack switch is pressed, relief pressure doesnt
when traveling at slow idle speed. increase. Power doesnt 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.
Install lamp harness (ST 7226) to check

output signals from MC and harness
condition.
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.
T2-1 T2-1 T2-1
T5-4-7

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.
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.
Symptoms in machine op-

curs.
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

tion in T/M)
NOTE:* Up to serial No.104678 (ZX200 class and 225 class)
T5-4-8

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 doesnt decrease. speed doesnt 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.
T2-1 T2-1 T2-1
T5-4-9

Parts Boom Electronic Cushion Auxiliary Flow Rate Control Sole-

Solenoid Valve* noid Valve (Optional)
When operating boom raise, the boom Restricts oil flow to auxiliary spool during
raise pressure decreases near the boom a combined operation to improve oper-
cylinder stroke end. ability.
Function
Boom electronic cushion isnt performed. In case auxiliary flow rate control sole-
noid valve is not activated, pressure at
2
output port becomes 0 MPa (0 kgf/cm ).

Boom electronic cushion solenoid valve is If valve is bound closed, attachment

bound: speed will become slow.
Boom electronic cushion solenoid valve If valve is bound open, boom will not
isnt always performed. move in 3-combined operation of boom
raise.
Boom electronic cushion solenoid valve is
open:
Boom isnt easy to be operated as the
boom raise pilot circuit is restricted.
Symptoms in machine operation

By Fault Code
Monitor item: Bu Damper Proportional Sole-
By Monitor Function noid Valve Output
Evaluation
Using Test Harness
Others
NOTE
Descriptions of Control (Opera- T2-1 T2-1

tional Principle Section in T/M)
NOTE: *: Up to serial No.104908 (ZAXIS225US)
T5-4-10

N Sensor Hydraulic Oil Temperature Sensor Engine Learning Switch

Monitors engine speed to operate en- Monitors hydraulic oil temperature to Starts engine learning.
gine speed sensing control. control auto-warming up and arm re- ZAXIS225US only:
generative control. The initial setting of the boom electronic
cushion is performed.
ON: 0V Learning
OFF: 5V Normal Control
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* cant 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 doesnt 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.
Initial setting of boom electronic cushion*:

Machine will operate normally. Problem
is caused by broken circuit or disconti-
nuity of switch.
The boom electronic cushion solenoid
valve is always operated as the initial
setting hasnt been completed on short
circuit.
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.
T2-1 T2-1 T2-1
NOTE: *Boom electronic cushion control is avail-

able on the ZAXIS225US (Up to serial
No.104908)
T5-4-11

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 doesnt 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).
Power digging control doesnt 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.
curs.
By Fault Code
By Monitor Monitor Item: Power Digging (Boost) Switch Monitor Item: Travel Mode
Evaluation Function
Using Test
Harness
Others
NOTE

tion in T/M)
T5-4-12

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.
T2-1 T2-1 T2-1
NOTE: * Up to serial No.104908 (ZAXIS225US)
T5-4-13

Parts Auto-Idle/Auto-Acceleration Selector Power Mode Switch

(Auto-Acceleration) (HP Mode)
Activates auto-acceleration control. Activates HP mode control.
ON: 0 V Auto-acceleration is operable. ON: 0 V HP mode is operable.
OFF: 5 V Inoperable. OFF: 5 V Inoperable.
Function
Broken Circuit: Auto-acceleration control is Broken Circuit: Even if HP mode is selected,

inoperable. HP mode is inoperable.
Short Circuit: Even if Short Circuit: Even if HP mode switch is
auto-idle/auto-acceleration selector is OFF, turned OFF, HP mode system is not deacti-
auto-acceleration control is always performed. vated. Attachment speed increase control (op-
tional) becomes inoperable.
Symptoms in control
system when trouble oc-
curs.
Same as described above. Same as described above.
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

(Operational Principle
Section in T/M)
T5-4-14

Power Mode Switch Work Mode Switch Work Mode Switch

(E Mode) (Digging Mode) (Attachment Mode)
Selects E mode. Allows normal control to be performed. Functions only when optional attach-
ON: 0 V E mode ment kit is equipped. (Attachment opera-
OFF: 5 V Normal tion speed increase/limit control)
Broken Circuit: Even if E mode is se- In response to operation of the auxiliary

lected, engine speed doesnt decrease. valve, engine speed related to the at-
Short Circuit: Engine speed doesnt in- tachment is controlled.
crease to the maximum. Auto-idle con-
trol is inoperable.
Same as described above Even if auxiliary valve is operated, en-

gine speed doesnt increase.
Even if attachment mode is selected,
maximum engine speed doesnt de-
crease.
Monitor Item: E/P/HP Mode Switch Monitor Item: Work Mode Switch Monitor Item: Work Mode Switch
T2-1 T2-1 T2-1
T5-4-15

Parts Auxiliary Mode Switch

Flow Combiner Valve
(Optional)
Functions only when optional attachment kit is Supplies hydraulic oil to both right and left
equipped. (Attachment operation speed in- travel spools from pump 1 during com-
crease/limit control) bined operation of travel and front/swing.
Function
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 doesnt increase. operated, machine mistracks to the left.
Even if attachment mode is selected, maxi-
mum engine speed doesnt decrease.

eration when trouble occurs.
By Fault Code
By Monitor
Function
Evaluation
Using Test Har-
ness
Others
NOTE

T/M)
T5-4-16

Bucket Flow Rate Auxiliary Flow Rate

Arm Flow Rate Control Valve
Control Valve Control Valve
To be shifted by pilot pressure from Restricts oil flow to bucket during To be shifted by pilot pressure from auxil-
solenoid valve unit (SE)*. 3-combined operation of bucket, arm roll-in, iary flow rate control solenoid valve.
Shift arm 1 spool and swing spool and boom raise to allow boom to raise.
circuits from parallel to tandem.
Ensures swing power.
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 doesnt vary. bucket circuit is always restricted. fice doesnt 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. doesnt 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 doesnt
move during 3-combined operation of
bucket, arm roll-in, and boom raise.
T3-3 T3-3 T3-3
NOTE: *Serial No.104679 and up (ZX200 class

and 225 class), serial No.010327 and up
(ZX230 class), Serial No.020043 and up
(ZX270 class), changeover is made by the
pilot pressure from the arm flow rate con-
trol valve (signal control valve).
T5-4-17

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.

Same as described above. Arm speed is extremely slow during arm

level crowd operation while arm regenera-
tive valve is kept closed.
The lever operated first is given priority
during combined operation of arm roll-in
and swing while arm regenerative valve is
Symptoms in machine op- kept open.
By Fault Code
By Monitor
Function
Evaluation
Using Test Har-
ness
Others
NOTE

T/M)
T5-4-18

Bucket Regenerative Valve Arm Anti-Drift Valve Boom Anti-Drift Valve

Prevents bucket cylinder hesitation Prevents arm from drifting due to oil leaks in Prevents boom from drifting due to oil
by routing return oil from bucket cyl- control valve. Check valve in arm roll-in re- leaks in control valve. Check valve in
inder rod side to bottom side. turn circuit is forcibly opened to allow arm to boom lower return circuit is forcibly
move only when arm is rolled in. opened to allow boom to move only when
boom is lowered.
If check valve is kept closed, bucket If switch valve is bound, check valve doesnt If switch valve is bound, check valve
is not smoothly rolled in. open. doesnt 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. doesnt 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.
T3-3 T3-3 T3-3
T5-4-19

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,
doesnt 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

T/M)
T5-4-20

Flow Combiner Valve

Pump 1 Flow Control Valve Pump 2 Flow Control Valve
Control Spool
Supplies flow rate control pressure Pi to Supplies flow rate control pressure Pi to Supplies control pressure to flow
pump 1 regulator in response to lever pump 2 regulator in response to lever combiner valve when shifted by right
stroke when boom (raise/lower), arm (roll stroke when boom (raise/lower), arm (roll travel pilot pressure.
out/in), bucket (roll-out/in), right travel, or out/in), swing (right/left), left travel, or aux-
auxiliary is operated. iliary is operated.
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 cant pump 2 control pressure sensor cant moni-
monitor the pump control pressure. tor the pump control pressure.
(Right travel doesnt run fast with right track (Left travel doesnt run fast with left track
jacked-up.) jacked-up.)
Same as described above. Same as described above. Same as described above.
T3-6 T3-6 T3-6
T5-4-21

Parts Swing Parking Brake Bucket Flow Rate Control Valve

Release Spool Control Spool
Supplies swing parking brake release pres- Supplies boom raise pilot pressure to
sure when shifted by boom, arm, bucket, or bucket flow rate control valve when shifted
swing pilot pressure. by arm roll-in pilot pressure.
Function
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 doesnt decrease when tion, boom doesnt 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 doesnt 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

T/M)
T5-4-22


Control Spool*
The arm roll-in pilot pressure
changes over to supply the change-
over pressure to the arm flow rate
control valve on the five-spool side of
the control valve.
If stuck in the full-open state, the arm

speed decreases in a single opera-
tion of the arm. (Arm flow rate control
is activated constantly.)
If stuck in the full-close state, arm
pressing force to wall becomes insuf-
ficient in combined operation of
swing and arm roll-in. (Arm flow rate
control is deactivated.)
T3-6
NOTE:* Serial No.10469 and up (ZX200 class and

225 class)
T5-4-23

CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine : 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.
Engine System Troubleshooting

E-1 E-2 E-3
Starter doesnt rotate Although starter ro- When engine control dial is fully rotated, engine
Trouble tates, engine doesnt stalls. Occasionally engine stalls during opera-
Symptom start. tion with engine control dial fully rotated and
auto-idle ON. Engine speed is slower than
specification in all operating range. Idle speed
is faster or slower than specification.
Parts
MC (Main Controller)
EC Motor
EC Sensor
Pump 1 Control Pressure

Sensor
Pump 2 Control Pressure
Sensor
Pressure Sensor (Travel)

Hyd. Oil Temperature Sensor
Key Switch
Engine Control Dial
Auto-Idle/Acceleration Selector
Power Mode Switch

Work Mode Switch
Auxiliary Mode Switch
Engine Learning Switch
Battery Relay
Engine Electrical Equipment
Engine Unit
Governor
Swing Parking Brake Release Spool
(Signal Control Valve)
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

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.
E-4 E-5 E-6 E-7 E-8 E-9

Even if engine con- Engine speed Faulty HP mode. Even if key switch is Faulty auto-idle Faulty E mode.
trol dial is rotated, doesnt increase turned OFF, engine system.
engine speed re- after engine is doesnt stop.
mains unchanged. started.
Check engine con-

trol cable.
T5-4-25

: Related, required to check
symptom will be more noticeable so that this component will not
be the direct cause of the trouble concerned.
E-10 E-11 E-12

Faulty auto-acceleration When traveling or oper- Engine speed doesnt
Trouble system. ating front attachment increase even if at-
Symptom with engine running at tachment is operated in
slow idle, engine hunts. attachment mode.
Parts
QOS Controller
Pump 1 Control Pressure Sensor

Pressure Sensor (Auxiliary)
N Sensor
Hyd. Oil Temperature Sensor
Coolant Temperature Switch
Key Switch
Engine Control Dial
Auto-Idle/Acceleration Selector
Power Mode Switch

Work Mode Switch
Auxiliary Mode Switch
Engine Learning Switch
Battery Relay
Glow Relay
Engine Electrical Equipment
Engine Unit
Pump Regulator
Remarks
T5-4-26

E-13 E-14 E-15 E-16

When attachment mode Engine stalls within Engine stalls during op- Engine is difficult to
is selected, engine several seconds after eration under adverse start at low temperature.
speed doesnt de- engine has started. condition such as at
crease. high altitude.
Check fuel system for Check batteries.

clogging.
T5-4-27

All Actuator System Troubleshooting

A-1 A-2 A-3
All actuator speeds are slow. Left travel is inoperable during Right travel is inoperable during
Trouble single travel operation. Single single travel operation. Single
Symptom swing operation speed is slow. bucket operation speed is slow.
Arm is slightly slow during arm Boom is not raised properly dur-
level crowding. ing arm level crowding.
Parts
Solenoid Valve Unit (SE)*
Pump 2 Delivery Pressure
Sensor
N Sensor
Spool
Main Relief Valve
Main Pump
Regulator
Pilot Pump
Pilot Valve
Pilot Relief Valve
Pump 1 Flow Rate Control
Valve
Pump 2 Flow Rate Control
Valve
Spool**
Remarks
NOTE: The trouble symptoms in this table are de- : Related, required to check
scribed provided that each trouble occurs : Related. However, in case this component fails, other trouble
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

A-4 A-5 A-6

Actuator doesnt stop Occasionally, swing or Actuator speed is faster
even if control lever is arm roll-in speed be- than normal.
returned to neutral. comes slow during swing Machine mistracks when
and arm roll-in combined the travel lever is oper-
operation. ated at half stroke.
Precise control can not
be performed.

** Serial No.104679 and up (ZX200 class and 225 class)
T5-4-29

Front Attachment System Troubleshooting

F-1 F-2 F-3 F-4
All front attach- Even if power dig- Some cylinder are Arm speed is slow
Trouble ment actuator ging switch is inoperable or in a combined op-
Symptom power is weak. pressed, power speeds are slow. eration. Arm
doesnt increase. speed is slow dur-
Boom raise power ing arm level
is weak when dig- crowding.
ging.
Parts
MC (Main Controller) *
Solenoid Valve Unit (SG)
Solenoid Valve Unit (SC)
Power Digging Switch
Spool
Main Relief Valve
Overload Relief Valve
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve
Bucket Regenerative Valve
Bucket Flow Rate Control Valve
Boom Anti-Drift Valve
Arm Anti-Drift Valve
Emergency Valve
Shockless Valve (Signal Control Valve)
Shuttle Valve (Signal Control Valve)
Bucket Flow Rate Control Valve Control Spool

Arm Flow Rate Control Valve Control Spool

(Signal Control Valve)**
Pilot Valve
Cylinder
Boom Electronic Cushion Solenoid Valve*** *
Remarks

*** Up to serial No.104908 (ZAXIS225US)
T5-4-30

F-5 F-6 F-7 F-8

Bucket is slow in bucket roll-in When starting to move in When starting to move in When boom raise or arm
single operation. Bucket combined operation, arm combined operation, boom roll-out is operated, boom or
doesnt move smoothly in doesnt smoothly move. Arm doesnt smoothly move. Boom arm starts to move after
bucket roll-in single operation. starts to move slow slightly in starts to move slow slightly in slightly moving downward.
arm roll-in single operation. boom lower single operation.
These troubles often occur
when oil temperature is low.

T5-4-31

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.
Solenoid Valve Unit (SG)
Power Digging Switch
Spool
Main Relief Valve
Overload Relief Valve
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve
Bucket Regenerative Valve
Bucket Flow Rate Control Valve
Boom Anti-Drift Valve
Arm Anti-Drift Valve
Emergency Valve
Shockless Valve (Signal Control Valve)
Bucket Flow Rate Control Valve Control Spool
Pilot Valve
Cylinder
Boom Electronic Cushion Solenoid Valve***
Remarks

*** Up to serial No.104908 (ZAXIS225US)
T5-4-32

(Blank)
T5-4-33

Swing/Travel/Other System Troubleshooting

S-1 S-2 T-1
Swing is slow or unmov- Swing is slow (weak in Both right and left tracks
Trouble ing. power) in swing and arm do not rotate or rotate
Symptom roll-in combined operation. slowly.
Swing doesnt start
smoothly. Swing power is
weak.
Parts
Solenoid Valve Unit (SI)
Travel Mode Switch
Pump Device
Spool
Load Check Valve
Flow Combiner Valve
Pump 1 Flow Control Valve
Flow Combiner Control Spool
Swing Device
Travel Device
Center Joint
Pilot Valve
Also, refer to T-5.
Remarks

T5-4-34

T-2 T-3 T-4 T-5 Q-1
One side track doesnt 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.
In case either bucket or

swing is also slow, refer
to A-2 or A-3.

T5-4-35

Q-2
Air Conditioner Malfunc-
Trouble tion
Symptom
Parts
Solenoid Valve Unit (SI)
Travel Mode Switch
Pump Device
Spool
Load Check Valve
Flow Combiner Valve
Flow Combiner Control Spool
Swing Device
Travel Device
Center Joint
Pilot Valve
Remarks
NOTE: * Up to serial No.104678 ((ZX200 class and 225 class)

T5-4-36

ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter doesnt rotate.
Related Fault Code: None
This trouble has nothing to do with the electronic

control system such as the MC.
Check for loose harness connections before-
hand. Faulty starter or faulty
harness between
starter and battery re-
Check if voltage at YES lay.
battery relay terminal A
is 24 V.
YES
Faulty battery relay.
Check if both voltages
at key switch terminal
#5 and #6 are 24 V. NO
YES
Faulty key switch.
Check for continuity
Check if battery voltage YES
· Key switch: START between battery posi-
and electrolyte density is tive terminal and key
normal, and fusible link switch terminal #1. Faulty harness be-
(40 A) is not blown.
NO tween battery and key
switch.
NO
· Voltage: More than 24 V
Density: More than 1.26 Faulty battery or fusible
link.
NO
Key Switch Battery Relay

Terminal A
T178-05-04-001
T105-07-04-002
T5-4-37

E-2 Although starter rotates, engine doesnt
start.
Check the fuel cut lever position during cranking.

If the position is normal, the engine unit and/or
fuel system may have trouble.
hand.
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.
· Key switch: ON Check if EC motor drive

circuit is normal.
NO
Faulty MC.
· Test harness: 4274589 NO
(ST 7125)
Governor Lever and Fuel Cut Lever
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

Governor Lever Position
A - Key Switch OFF (Engine Stop Position)

B - Key Switch ON (Engine Start Position)
A B
STOP FULL
FULL
T105-07-04-003
STOP
Fuel Cut Lever Position
A - Fuel Cut-Off Handle Pulled Position

B - Fuel Cut-Off Handle Returned Position
A
B
T105-07-04-003
T5-4-39

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.
Related Fault Code: 06
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.
Return fuel cut

lever to original po-
YES sition.
Check if fuel cut

lever has been
moved up to half YES Faulty EC sensor.
way stroke.
Check if fault code · Refer to T4-6-1.

06 is displayed.
NO YES End.
Check if problem is
corrected after en-
gine learning.
NO
NO Monitor engine
· Refer to T4-6-1 for learning status.
engine learning
procedures.
· Monitor item: En-
gine learning con-
trol
T5-4-40

Faulty engine and/or fuel sys-

YES tem.
Check if governor lever

OK comes in contact with stopper
when performing engine Faulty control cable and/or in-
learning. correctly adjusted engine gov-
ernor lever.
NO
· Adjust engine speed.

(Refer to T4-6-1.)
Faulty MC, faulty learning

switch, or broken harness be-
tween learning switch and MC.
NOT OK
· Refer to T4-6-1.
T5-4-41

E-4 Even if engine control dial is rotated, engine
speed remains unchanged.
If the EC fails, the engine will not stop with the

key switch OFF.
hand.
Faulty engine control dial or

broken harness between en-
gine control dial and MC.
YES
Check if fault code 07 is dis-
played. Using Dr. ZX, monitor
engine control dial angles
(standard voltages). Check if
voltages are normal. Faulty EC motor.
YES
Install test harness (ST 7125)
to EC motor. Check if lamp
comes ON while turning en- · Refer to T4-6-1.
gine control dial.
· Standard voltages NO
Slow idle position: 0.3 to 1 V Faulty MC or broken harness
Fast idle position: 4.0 to 4.7 V between MC and EC motor.
· Possible to display with built-in
diagnosing system. NO
· Refer to T4-6-1.
T5-4-42

E-5 Engine speed doesnt increase after engine
is started.
Refer to the pages for the Auto Warming Up Con-

trol in the SYSTEM / Control System group in the
T/M (Operational Principle).
hand.
More than 0 C
when starting Normal.
Monitor oil tem-

NO perature.
Faulty key switch or

broken harness be-
· Monitor item: Hydraulic oil
YES tween key switch and
temperature Monitor key switch. MC.
· Possible to display with Check if displayed
built-in diagnosing system ky is highlighted in
response to key
switch operation.
Check if fault code
19 is displayed. Lower than 0 C
when starting Faulty MC.
NO
· Refer to T4-6-1.
· Monitor item: Key
switch
Faulty hyd. oil tem-
perature sensor or
broken harness be-
tween oil tempera-
ture sensor and MC.
YES
T5-4-43

E-6 Faulty HP mode
Even if power mode switch is turned to the HP

mode position, HP mode is inoperable. (General
mode normally operates.)
Related Fault Codes: 10, 11, 15, and 16
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

Although the power mode switch isnt turned to the
HP mode position, HP mode is operable.
Boom raise and arm roll-in must be operated

when the average delivery pressures of pump 1
and 2 are high, if HP mode control is performed.
The sensors related to this condition may not be
broken at the same time.
Short circuited harness
between MC and power
YES mode switch.
Monitor the power

Check if the symp- End.
mode switch. Check Check if the governor YES
tom disappears after
if HP is displayed. lever comes in contact completing engine
with full side stopper YES learning.
when the key switch is Faulty MC.
turned ON (engine not
running) and the engine NO
· Monitor item: E/P/HP control dial is turned to · Refer to T4-6-1.
mode switch NO
Fast Idle.
· Power mode switch:
P mode Faulty engine.
NO
T5-4-45

E-7 Even if key switch is turned OFF, engine
doesnt stop. (In case the engine doesnt
stop, stop the engine by pulling the engine
stop handle located under the seat stand.
Then, begin inspection.)
Related Fault Codes: 06 and 07
Probably symptoms such as Engine speed is

slower than specification in all operating ranges
or Even if engine control dial is rotated, engine
speed remains unchanged will come up. Per-
form troubleshooting for these symptoms.
T5-4-46

E-8 Faulty auto-idle system
Even if control lever is turned to neutral. Auto-idle

system is inoperable.
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.)
Check if power mode

switch is in the E
YES mode position. Bound swing parking
brake release spool in
YES the signal control
valve.
Monitor the pressure
sensor (front).
Check if ON is dis-
Monitor auto-idle switch.
played.
Check if displayed AI is NO
turned OFF or ON in re-
sponse to auto-idle / Faulty MC.
auto- acceleration selec-
tor operation. · Engine: Running NO
· Refer to T4-6-1.
Faulty auto-idle / auto-

acceleration selector
· Monitor item:
or broken harness
Auto-idle / auto-accel
between auto-idle
switch
switch and MC.
NO
Although the auto-idle / auto-acceleration selector is

turned OFF, the auto-idle control is operated.
Be sure to separate auto-idle control from Short circuited harness

auto-acceleration control. between MC and auto-idle
/ auto-acceleration selec-
YES tor.
Monitor auto-idle /
auto-acceleration se-
lector. Check if AI is
displayed.
Faulty MC.
· Monitor item: Auto-idle / NO

auto-accel switch
· Auto-idle /
auto-acceleration selec-
tor: OFF
T5-4-47

E-9 Faulty E mode
Even if power mode switch is turned to the E mode

position, engine speed remains unchanged. (En-
gine speed doesnt decrease.)
In case trouble symptoms E-1 to E-8 are recog-

nized, perform the troubleshooting of these trou-
bles beforehand.
Refer to the pages for E Mode Control in the
SYSTEM / Control System group in the T/M (Op-
erational Principle).
hand. Faulty power mode switch or
broken harness between
NO power mode switch and MC.
Monitor power mode switch.
Check if displayed E Mode is
turned OFF or ON in re-
sponse to power mode switch
operation.
Faulty MC.
YES
· Monitor item: · Refer to T4-6-1.
E/P/HP mode switch
Although power mode switch isnt turned into E

mode, engine speed decrease.
Short circuited harness be-

tween MC and power mode
YES
switch.
Monitor power mode switch.
Check if E is displayed.
Faulty MC.
· Monitor item: E/P/HP switch NO
· Power mode switch: P mode
· Refer to T4-6-1.
T5-4-48

E-10 Faulty auto-acceleration system
Auto-acceleration system is inoperable.
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
Although auto-idle / acceleration selector is turned

OFF, the auto-idle acceleration control is operated.
Be sure to separate the auto-idle control from the

auto-acceleration control. Short circuited harness between
MC and auto-idle /
YES auto-acceleration selector.
Monitor auto-idle / accelera-
tion selector.
Check if AA is displayed.
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

E-11 When traveling or operating front attach-
ment with engine running at slow idle, en-
gine hunts.
Although the failure in pressure sensors (travel

and front attachment) will have relevance to mal-
function of the engine speed increase 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.)
Refer to the pages for Idle Speed-Up Control in
the SYSTEM / Control System group in the T/M
(Operational Principle).
YES Faulty engine.
Check if engine speed is

faster than increased idle · Refer to the Engine Shop
speed. Manual.
Faulty MC.
· Monitor item: NO
Engine target speed
· Possible to display with built-in · Refer to T4-6-1.
diagnosing system
T5-4-50

E-12 Engine speed doesnt 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
· Monitor item: Att. con-

trol pilot pressure Normal (If set to De-
crease, this control
system is deacti-
YES vated.)
YES Faulty MC.

Monitor work mode
switch. Check if display
switches in response · Refer to T4-6-1.
to work mode switch
A operation.
Faulty work mode

switch.
NO
· Monitor item:
Work mode switch
T5-4-51

E-13 When attachment mode is selected, engine
speed doesnt decrease.
In case trouble symptoms E-1 to E-11 are recog-

nized, perform the troubleshooting of these trou-
bles beforehand.
Refer to the pages for Attachment Operation
Speed Limit Control in the SYSTEM / Control
System group in the T/M (Operational Principle).
hand.
YES Faulty MC.

Monitor work mode
switch. Check if dis-
play switches in re-
sponse to work mode · Refer to T4-6-1.
YES switch operation.
Check if attachment Faulty work mode switch.

speed adjustment has NO
been set to Decrease
(-) in Dr. ZX service · Monitor item:
mode. Work mode switch
Normal (Set to Increase

(+).)
NO
T5-4-52

E-14 Engine stalls within several seconds after
engine has started.
Refer to the pages for Engine Learning Control in

the SYSTEM / Control System group in the T/M
If the engine-learning switch is turned to the
learning position, the engine will stall in 5 sec-
onds after the engine starts.
hand.
Normal (Return switch to

YES neutral.)
Check if engine learn-

ing switch is turned to
the learning position.
Faulty learning switch, or
short-circuited harness be-
tween learning switch and
MC, or check fuel system for
clogging.
NO
T5-4-53

E-15 Engine stalls during operation under ad-
verse condition such as at high altitude.
If speed-sensing control is inoperable, the engine

will stall under adverse operating conditions.
hand.
Disconnect torque control

solenoid valve. Connect
test harness (ST 7226)
Monitor torque control sole- between solenoid valve
noid valve output. Install NO and harness. Check if
pressure gauge to output port test harness lamp comes To A
so that pressure can be ON.
measured by pressure gauge
and Dr. ZX. Check if both
NO measured pressure values by
pressure gauge and Dr. ZX
vary identically.
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
Faulty torque control

YES solenoid valve.
A
Broken harness be-
tween torque control so-
lenoid valve and MC.
NO
T5-4-54

(Blank)
T5-4-55

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
doesnt 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 doesnt operate.
Faulty coolant temperature

YES switch.
Disconnect coolant tempera-

ture switch. Check if voltage at
glow plug is 20 to 24 V.
YES Faulty QOS controller.
Disconnect QOS controller.
Ground harness end connector
· Key switch: ON terminal #4 to vehicle frame.
Check if problem is corrected.
NO
Measure each glow plug re-
sistance.
· Using a clip, ground from the NO
reverse side of the connector
without disconnecting. · Key switch: OFF
· Before measuring, remove
copper plates connecting
each glow plug.
Measurement of Glow Plug Voltage and Resistance

Voltage Check
Resistance Check
Remove
the
copper
plate.
Specification: 20 to 24 V
Specification: Below 10
T105-07-04-006
T105-07-04-007
T5-4-56

Faulty glow plug.
Faulty engine unit, faulty glow

NO plug relay, or broken harness
Disconnect glow plug re- between glow plug relay and
lay. Connect harness end glow plug.
connector terminal #4 to
YES vehicle frame. Check if
voltage is 20 to 24 V. · Refer to the engine shop manual.
Broken harness between glow

plug relay and QOS controller.
Disconnect glow plug re- · Key switch: ON YES
lay. Check if voltage at
glow plug relay harness
end connector terminals
#1 or #3 is 20 to 24 V.
Below 10
In case voltage at terminal #1
is 0 V, harness between glow
relay and batteries is broken.
· Key switch: ON In case voltage at terminal #3
is 0 V, harness between glow
relay and key switch terminal
NO M is broken.
· Verify that fuse #19 is normal.
T5-4-57

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.
Faulty pilot pump or

YES clogged pilot filter.
Check if same
symptom still ap-
pears after disas-
NO sembling, cleaning,
and adjusting pilot
relief valve.
End.
NO
Check if primary
pilot pressure is Faulty N sensor or
normal. broken harness in N
YES sensor circuit.
· Fully boom raised or arm

roll-in Monitor actual en-
· Monitor item: Boom gine speed. Check
Raise Pilot Pressure, Arm if abnormal speed
YES
Roll-In Pilot Pressure YES is indicated. Monitor torque con-
trol solenoid valve
output. Check if
· Monitor item: Engine torque control sole-
Actual Speed noid valve output is
· Possible to display NO normal.
with monitor service
mode.
· Monitor item:
Pump torque NO
proportional solenoid
valve output
· Refer to the opera-
tional performance
Test section
T5-4-58

Pressure Gauge
Mounting Port
Torque Control T178-03-01-001
Solenoid Valve
Faulty pump device.

Install pressure YES
gauge between
YES torque control sole-
noid valve and regu- Faulty torque control solenoid
Check if harness
lator. Check if the valve.
between MC and
pressure changes. NO
torque control so-
lenoid valve is
normal
Faulty harness between torque

control solenoid valve and MC.
· Key Switch: OFF NO
Faulty MC.
· Refer to T4-6-6.
T5-4-59

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.)
The pump 2 flow rate is minimized (approx. 20

L/min) due to some reasons. Accordingly, the left
travel and swing motors, which are driven by
pressure oil from pump 2, moves very slow.
Pressure oil from pump 1 is also routed to the
arm and boom cylinders so that the arm and
boom can move at a slightly slow speed in single
operation. However, in level crowd operation,
pressure oil is routed to the boom prior to the arm
so that arm speed becomes very slow.
Refer to the SYSTEM / Hydraulic System group
in the T/M (Operational Principle).
YES Faulty pump 2 regulator.

Monitor pump 2 pump
control pressure. Check
if pressure increases in
proportion to left travel
lever stroke.
Bound pump 2 flow rate
control valve in signal con-
trol valve.
NO
· Monitor item: Pump 2
flow control pressure
· Possible to display with
built-in diagnosing sys-
tem.
T5-4-60

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.)
The pump 1 flow rate is minimized (approx. 20

L/min) due to some reasons. Accordingly, the
right travel motor and bucket cylinder, which are
actuated by pressure oil from pump 1, moves
very slow.
Pressure oil from pump 2 is also routed to the
arm and boom cylinders so that the arm and
boom can move at a slightly slow speed in single
operation. However, in level crowd operation,
pressure oil is routed to the arm prior to the boom
so that boom is scarcely raised.
YES Faulty pump 1 regulator.

Monitor pump 1 pump
control pressure. Check if
pressure increases in
proportion to right travel
lever stroke.
Bound pump 1 flow rate
control valve in signal control
valve.
NO
· Monitor item: Pump 1 flow
control pressure
tem.
T5-4-61

A-4 Actuator doesnt stop even if control lever
is returned to neutral.
Bound spool in the pilot valve or bound main

spool in the control valve is suspected.
Faulty pilot valve.

YES
· When control lever is in neu-

Check if actuator stops when tral, pilot pressure is routed to
pilot control shut-off lever is spool end in control valve.
raised.
Faulty control valve.
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

(Blank)
T5-4-63

A-5 Occasionally, swing or arm roll-in speed
becomes slow during swing and arm roll-in
combined operation.
Related Fault Code: 11, 14, and 16
Machines produced until March 2002:

Refer to the pages for the Arm Flow Rate Control
in the SYSTEM / Control System group in the T/M
Up to serial No.104678 (ZX200 class and 225

class)
sensor or faulty MC, or
YES
broken harness be-
tween MC and sensor.
Check if fault code

Monitor output from
is displayed. Faulty arm flow rate
solenoid valve unit
(SE). Install pres- YES control valve in control
sure gauge to port valve.
· Fault Codes: SE. Compare pres-
11: Pump 2 delivery sure measured by Disconnect solenoid
pressure sensor Dr. ZX with that valve unit (SE).
NO YES Faulty solenoid valve
14: Pressure sensor measured by pres- Connect test har- unit (SE).
(Swing) sure gauge. Check if ness (ST 7226)
16: Pressure sensor both pressure val- between solenoid
(Arm Roll-In) ues vary identically. valve unit (SE) and
NO
harness. Check if
NOTE: In case other test harness lamp
fault codes are comes ON. Broken harness be-
displayed, per- tween solenoid valve
form trouble- · Monitor item: Arm unit (SE) and MC.
shooting corre- NO
flow rate propor- · Perform swing and
sponding to the tional solenoid
displayed fault arm roll-in com-
valve output bined operation.
code. · Perform swing and
arm roll-in com-
bined operation.
T5-4-64

(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
YES Faulty arm flow rate control
valve in control valve. Check if
valve.
relief pressure is approx. 3.9
2
MPa (40 kgf/cm ) 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
· Fault codes: Faulty corresponding sen-

11: Pump 2 delivery sor or faulty MC, or broken
pressure sensor harness between MC and
14: Pressure sensor YES sensor.
(swing)
16: Pressure sensor
(arm roll-in)
NOTE: In case other fault

codes are dis-
played, perform
troubleshooting
corresponding to
the displayed fault (Control Valve Side)
code.
Control Valve
Front Side
ZX225 class
Hose SE
Arm Flow Rate

Control Valve
T178-03-06-015
W178-02-05-018
Front Side
ZXS200 class, 230 class, 270 class
T5-4-65

A-6 Actuator speed is faster than normal
Machine mistracks when travel lever is op-
erated at half stroke. Precise control cannot
be performed.
The pump 1 or 2 flow rate is maximized due to

some reasons.
Therefore, the maximum flow rate is supplied and
actuator speed is faster though the control lever
doesnt reach the full stroke.
The pressure oil from pump 1 makes right travel
perform, and the pressure oil from pump 2 makes
left travel. Perform on the single travel operation.
Different flow rates between pump 1 and pump 2
occur, and the machine mistracks. When the
travel lever is operated at half stroke.
Faulty pump regulator.

YES
Monitor pump control pressure
of pump 1 and 2. Check if the
pressure changes in response
to the lever operation.
Bound pump flow rate control

valve in signal control valve.
NO
· Pump 1: Bucket operation
· Pump 2: Swing operation
· Monitor item: Pump 1 and 2
pump control pressures
diagnosing system.
T5-4-66

FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
F-1 All front attachment actuator power is weak.
In case operating speeds are extremely slow,

pump control may be malfunctioning (A-2 and/or
A-3). Faulty pilot system may also cause this
trouble.
Main relief valve should be
34.3 to 36.3 MPa normal. Find out cause of trou-
2
(350 to 370 kgf/cm ) ble by tracing other trouble
symptoms.
Monitor pump 1 and 2 delivery

pressures.
· Monitor item: Pump 1 and 2 de-

livery pressure Adjust main relief valve.
diagnosing system Less than 34.3 MPa
· Relieve boom, arm, and bucket (Less than 350 kgf/cm2)
circuits.
· Power mode switch: OFF
· Work mode: Digging
T5-4-67

F-2 Even if power digging switch is pressed,

power doesnt increase. Boom raise power
is weak when digging.
Related fault Code: None
Refer to the pages for the Power Digging Control

and the Auto-Power Lift Control in the SYSTEM /
Control System group in the T/M (Operational
Principle).
hand.
Pressure Increases.
Less than 34.3 MPa (350 kgf/cm2) Normal (Possibly, Faulty power digging
NO switch or broken har-
HP mode is taken
36.3 MPa (370 kgf/cm2) for power digging ness between power
mode.) digging switch and MC.
Monitor pump 1
and 2 delivery
pressures. Monitor power
digging switch. Remains unchanged.
Check if indication
Pressure Pd is turned ON
Check pressure at
· Monitor item: doesnt or OFF in response
solenoid valve unit
Pump 1 and 2 Deliv- increase. to power digging YES (SG) port.
ery Pressure switch operation.
· Possible to display
with built-in diagnos-
tic system · Check pressure
· Check pump delivery change while pressing Changes.
pressure change · Monitor item: power digging switch. 0.49 MPa (5 kgf/cm2) or less
while pressing power Power Digging (Boost) · Measurement: Refer to
digging switch. Switch the Operational Per- 2
0.98 MPa (10 kgf/cm ) or less
· Proceed to YES if boom formance Test section.
raise power is weak in
digging operation.
T5-4-68

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.
· Power Digging Switch:

ON Faulty main relief valve.
T5-4-69

F-3 Some cylinders are inoperable or speeds
are slow.
When other actuators (travel and swing motors)

operate normally, the pilot pump (primary pilot
pressure) is considered to be normal.
In case single bucket operation speed is slow,
refer to F-5.
In case single arm roll-in operation speed is slow,
refer to F-6.
In case single boom lower operation speed is
Bound control valve
slow, refer to F-7.
spool or faulty cylinder
In case single boom raise / lower operation YES (faulty seal kit).
speed is slow, refer to the next as for
ZAXIS225US. Check if overload
YES relief pressure is nor-
mal.
Monitor pump control
pressure. Check if
pump control pres- Faulty overload relief
sure changes valve.
NO
smoothly while mov-
YES ing control lever
slowly.
Faulty shuttle valve in

signal pressure control
Monitor or measure valve.
· Monitor item: NO
secondary pilot
pressure. Check if Pump 1 flow control
secondary pilot pressure, pump 2 flow
pressure is normal. control pressure
tem
Bound shockless valve

YES spool.
· Secondary pilot Check if secondary
pressure: pilot pressure at inlet
Refer to Operational port to signal control
Performance Test valve.
Section. NO
Faulty pilot valve.
· Monitor item: Boom
raise pilot pressure, NO
arm roll-in pilot pres-
sure · Check only when
· Possible to display boom is not raised.
with built-in diagnos- In case cylinders
ing system other than boom are
abnormal, skip this
step and proceed to
the NO line.
T5-4-70

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.
Failed initial setting of

boom electronic
YES cushion, or faulty re-
lated sensors.
Check if initial setting of
boom electronic cushion
has been completed
correctly, or check if
related fault code is
displayed.
Disconnect the con- YES Faulty MC.

nector in the boom
· Refer to Initial Setting of electronic cushion
Boom Electronic Cushion NO solenoid valve. Check
in the if the symptom is im- Bound boom elec-
TROUBLESHOOTING / proved. tronic cushion sole-
NO
General group. noid valve.
· Be aware that the

boom electronic cush-
ion is inoperable.
T5-4-71

F-4 Arm speed is slow in a combined operation.
Arm speed is slow during arm level crowd-
ing.
Refer to the pages for the Arm Regenerative

Control and the Arm Flow Rate Control in the
SYSTEM / Control System group in the T/M (Op-
erational Principle).
Disconnect solenoid
Up to serial No.104678 (ZX200 class and 225 valve unit (SC). Con-
class) nect test harness (ST
7226) between sole- YES Faulty solenoid valve
Up to serial No.010326 (ZX230 class) noid valve unit (SC)
unit (SC).
Up to serial No.020042 (ZX270 class) and harness. Check if
NO test harness lamp
Monitor output from comes ON. Broken harness be-
solenoid valve unit tween solenoid valve
(SC). Install pressure unit (SC) and MC.
NO
gauge to port SC.
NO Compare pressure · Perform boom raise and
measured by Dr. ZX arm roll-in combined
with that measured by operation. Monitor output from
pressure gauge. Check solenoid valve unit (SE).
if both pressure values Install pressure gauge
vary identically. to port SE. Compare
YES pressure measured by
Dr. ZX with that meas-
ured by pressure gauge.
Check if any fault Check if both pressure
codes are dis- · Monitor item:
Arm regenerative propor- values vary identically.
played.
tional solenoid valve out-
put
· Perform boom raise and
· Fault codes: · Monitor item:
arm roll-in combined op-
11: Pump 2 delivery Arm flow rate propor-
eration.
pressure sensor tional solenoid valve
· Refer to the Operational
14: Pressure sensor · Perform swing and arm
Performance Test.
(Swing) roll-in combined opera-
15: Pressure sensor tion.
(Boom raise) · Refer to the Operational
16: Pressure sensor Performance Test.
(Arm roll-In)
YES broken harness be-
codes are displayed,
perform troubleshooting
corresponding to the
displayed fault code.
T5-4-72

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.
Check if arm regen-

erative valve in YES Faulty arm flow rate
YES 5-spool section of control valve.
control valve is
scored or bound. Check if arm flow rate
control valve in 5-spool
NO section of control valve
is scored or bound. Find out cause of
trouble by tracing
NO other trouble symp-
toms.
T5-4-73


(ZX200 class and 225 class) Disconnect solenoid
valve unit (SC). Con-
Up to serial No.010327 and up (ZX230 class)
nect test harness (ST
Up to serial No.020043 and up (ZX270 class) 7226) between sole- YES Faulty solenoid valve
unit (SC).
noid valve unit (SC)
and harness. Check if
NO test harness lamp
Monitor output from comes ON. Broken harness be-
solenoid valve unit tween solenoid valve
(SC). Install pressure unit (SC) and MC.
NO
gauge to port SC.
NO Compare pressure · Perform boom raise and
measured by Dr. ZX arm roll-in combined
with that measured by operation. Install pressure gauge
pressure gauge. Check to hose SK connecting
if both pressure values signal control valve to
vary identically. bucket flow rate control
YES valve in control valve.
Check if relief pressure
Check if any fault is approx. 3.9 MPa (40
2
codes are dis- · Monitor item: kgf/cm ) while perform-
played. Arm regenerative propor- ing 3-function combined
tional solenoid valve out- operation of boom raise,
put arm roll-in, and bucket
· Perform boom raise and roll-in.
· Fault codes: arm roll-in combined op-
11: Pump 2 delivery eration.
pressure sensor · Refer to the Operational
14: Pressure sensor Performance Test.
(Swing)
15: Pressure sensor
(Boom raise)
16: Pressure sensor
(Arm roll-In)
YES broken harness be-
codes are displayed,
perform troubleshooting
corresponding to the
T5-4-74

Faulty arm flow rate

control valve control
NO spool (signal control
valve).
YES Faulty arm regen-

erative valve.
Check if arm regen-

erative valve in YES Faulty arm flow rate
YES 5-spool section of control valve.
control valve is
scored or bound. Check if arm flow rate
control valve in 5-spool
NO section of control valve
is scored or bound. Find out cause of
trouble by tracing
NO other trouble symp-
toms.
Control Valve
Front Side Signal Control Valve
ZX225 class (Control Valve Side)
Arm Flow Rate

Control Valve
Hose SE
Front Side
ZX200 class, 230 class, 270 class W178-02-05-018
T178-03-06-015
T5-4-75

F-5 Bucket is slow in bucket roll-in single op-
eration. Bucket doesnt move smoothly in
bucket roll-in single operation.
Faulty bucket flow rate control valve or bucket

regenerative valve may cause this trouble. Faulty bucket regen-
erative valve (Disas-
Refer to the COMPONENT OPERATION / Con- semble and clean, or
YES
trol Valve group in the T/M (Operational Princi- replace.)
ple).
Check if bucket re-
YES generative valve in
bucket spool is
Install pressure gauge Find out cause of trou-
bound or scored.
to hose SK connecting ble by tracing other
signal control valve to NO trouble symptoms.
bucket flow rate con-
NO trol valve in control
valve. Check if relief
pressure is approx. 3.9
MPa (40 kgf/cm2)
while performing Bound bucket flow rate
Check if bucket flow 3-function combined control valve control
rate control valve in operation of boom NO spool in signal control
control valve is raise, arm roll-in, and valve.
bound or scored. bucket roll-in.
Faulty bucket flow rate

control valve (Disas-
semble and clean, or
YES replace.)
Hose (SK)
Bucket Flow
Rate Control
Valve
T178-05-04-002
T5-4-76

F-6 When starting to move in combined opera-
tion, arm doesnt smoothly move. Arm starts
to move slightly slow in arm roll-in single
operation. These troubles often occur when
oil temperature is low.

trol Valve group in the T/M (Operational Princi-
ple). Faulty arm regenerative
valve. (Disassemble to clean,
YES or replace.)
Check if arm regenera-

NO tive valve is bound or
scored.
Find out cause of trouble by
tracing other trouble symp-
Check if arm anti-drift valve is toms.
NO
bound or scored.
Faulty arm anti-drift valve.

(Disassemble to clean, or
replace.)
YES
F-7 When starting to move in combined opera-

tion, boom doesnt move smoothly. Boom
starts to move slow slightly in boom lower
single operation.

trol Valve group in the T/M (Operational Princi- Find out cause of trouble by
tracing other trouble symp-
ple). NO toms.
Check if boom regen-
erative valve is bound or
NO scored.
Faulty boom regenerative

valve. (Disassemble to
clean, or replace.)
Check if boom anti-drift valve YES
is bound or scored.
Faulty boom anti-drift valve.

(Disassemble to clean, or
replace.)
YES
T5-4-77

F-8 When boom raise or arm roll-out is operated,
boom or arm starts to move after moving
slightly downward.
Related Fault Code: None YES Faulty anti-drift valve.
Check if anti-drift valves

(arm and boom) are
YES bound or scored.
Oil leaks in cylinder.

Check if load check valve in NO
control valve is normal.
· Disassemble / Visual
Inspection Faulty load check valve.
NO
NOTE: 1. During the initial stage of operation, oil

pressure and flow rate from the pump is
low. Therefore, if the load check valve
is malfunctioning, the oil in the bottom (B)
side of the boom cylinder flows back When the Load
into the circuit through the load check Check Valve is
valve, causing the boom cylinder to Faulty:
(A)
temporarily retract.
2. Since oil pressure and flow rate from
the pump is low, if oil leaks from bottom
side (A) to rod side (B) due to faulty
boom cylinder piston or cylinder barrel,
the boom cylinder is temporarily re-
tracted during the initial stage of opera-
tion. In addition, cylinder force is re-
duced, increasing the cylinder drift in T105-07-04-012
this case.
T5-4-78

F-9 The shock is larger at the full stroke of
boom raise
Up to serial No.104908 (ZAXIS225US)
Monitor output for

Disconnect connector A in boom electronic cush- YES Faulty boom electronic cushion
MC. Connect harness end ion solenoid valve with solenoid valve.
connector terminal #23 to Dr.ZX.
terminal #24 with a clip. YES Check if the pressure
Disconnect the connector changes when the
in the boom electronic boom is operated with Faulty MC.
cushion solenoid valve. in the reducing area.
Check if continuity be- NO
tween harness end con-
nector terminals #1 and
#2.
· Monitor item Broken harness between MC
Boom damper P/S and boom electronic cushion
valve solenoid valve.
output
· Key switch: OFF NO
NOTE: The boom cushion solenoid valve is pro-

vided on up to serial No.104908.
Speed Reduction Area
Boom Full Stroke

Approx. 60 Position
T1GF-02-01-001
T5-4-79

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.
Faulty pilot valve.

YES
Boom Cylinder Internal Leakage Check
1. With the bucket cylinder fully retracted and the

arm cylinder slightly extended from the fully re-
tracted position, lower the bucket tooth tips onto
the ground.
2. Disconnect hoses from the boom cylinder rod

side. Drain oil from the hoses and cylinders.
(Plug the disconnected hose ends.) T105-07-04-009
3. Retract the arm cylinder to lift the bucket off the

ground. If oil flows out of the hose disconnected
pipe ends and the boom cylinders are retracted
at this time, oil leaks in the boom cylinders. In
case no oil flows out of the hose disconnected
pipe ends but the boom cylinders are retracted,
oil leaks in the control valve.
T5-4-80

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

SWING SYSTEM TROUBLESHOOTING
S-1 Swing is slow or unmoving.

Check whether the pilot system is faulty or the In case the left travel speed is also slow, refer to
main circuit is faulty. A-2.
In case other functions (front attachment and
travel) operate normally, the pilot pump is con-
sidered to be normal. If the pilot system is dis-
playing a problem, the cause of the trouble may
exist in the circuit after the pilot valve.
Check if swing parking

brake release valve is
Check if swing parking YES scored or bound.
To A
brake release pressure is
Monitor pump control YES approx. 3.9 MPa (40
Monitor secondary pressure while slowly kgf/cm2).
pilot pressure. Check if operating swing lever.
secondary pilot pres- YES Check if pump control
sure is normal. pressure varies Faulty swing parking
smoothly. brake release spool in
· Relieve arm circuit. signal control valve.
NO
· Monitor item:
· Monitor item: · Front attachment op-
· Specification: · Pump 2 flow control eration
· Refer to Operational pressure · Possible to display with
Performance Test · Possible to display with built-in diagnosing sys-
tem Bound pump 2 flow
Section. built-in diagnosing sys- rate control valve in
· Monitor item: tem signal control valve.
· Swing control pilot
pressure NO
built-in diagnosing
system Faulty pilot valve.
NO
YES Faulty swing reduction

gear.
Check if swing motor drain
YES oil amount is normal.
Check if swing relief

YES pressure is normal. · Measurement: Faulty swing motor.
· Refer to Operational Per-
formance Test Section. NO
· Relieve swing circuit.

· Monitor item: Pump 2 de-
A livery pressure Faulty swing relief
· Specification: valve.
· Refer to Operational Per- NO
formance Test Section.
Faulty swing motor

parking brake release
valve.
NO
T5-4-82

(Blank)
T5-4-83

S-2 Swing is slow (weak in power) in swing and
arm roll-in combined operation.
Swing doesnt start smoothly.
Swing power is weak.
Related Fault Codes: 11, 14, and 16
Up to serial No.104678 (ZX200 class and 225

class)
Refer to the pages for the Arm Flow Rate Control
in the SYSTEM / Control System group in the
T/M (Operational Principle).
hand. Faulty corresponding
sensor or Faulty MC,
or broken harness
YES between MC and sen-
sor.
Check if any fault

codes are dis- Faulty arm flow rate
played. Monitor output YES
from solenoid control vale in control
valve unit (SE). valve.
Install pressure
gauge to port SE. Disconnect solenoid
· Fault codes:
Check if pressure valve unit (SE). YES Faulty solenoid valve
11: Pump 2 deliv- NO
measured by Connect test har- unit (SE).
ery pressure sen-
pressure gauge ness (ST 7226)
sor
varies identically between solenoid
14: Pressure sen-
with pressure NO valve unit (SE) and
sor (Swing) Broken harness be-
measured by Dr. harness. Check if
16: Pressure sen- tween solenoid valve
ZX. test harness lamp NO
sor (Arm roll-in) unit (SE) and MC.
comes ON.
codes are dis-
played, perform · Monitor item:
troubleshooting Arm flow rate pro-
portional solenoid · Perform swing and
corresponding to arm roll-in combined
the displayed fault valve output
· Perform swing and operation.
code.
arm roll-in com-
bined operation.
T5-4-84

Up to serial No.104679 and up

(ZX200 class and 225 class)
Refer to the COMPONENT/Control Valve group

hand. Faulty corresponding
sensor or Faulty MC,
or broken harness
YES between MC and sen-
sor.
Check if any fault Install pressure gauge

codes are dis- to hose SE connecting
signal control valve to Faulty arm flow rate
played. YES
bucket flow rate con- control valve in control
trol valve in control valve.
valve. Check if relief
· Fault ccodes: pressure is approx.
11: Pump 2 delivery NO 3.9 MPa (40 kgf/cm2)
pressure sensor while performing Bound bucket flow
14: Pressure sensor 3-function combined rate control valve con-
(Swing) operation of boom trol spool in signal
16: Pressure sensor raise, arm roll-in, and NO control valve.
(Arm roll-in) bucket roll-in.

codes are dis-
played, perform · Monitor item:
troubleshooting Arm flow rate pro-
corresponding to portional solenoid
the displayed fault valve output
code. · Perform swing and
arm roll-in com-
bined operation.
Control Valve
Front Side Signal Control Valve
ZX225 class (Control Valve Side)
Arm Flow Rate

Control Valve
Hose SE
Front Side
ZX200 class, 230 class, 270 class W178-02-05-018
T178-03-06-015
T5-4-85

(Blank)
T5-4-86

TRAVEL SYSTEM TROUBLESHOOTING
T-1 Both right and left tracks do not rotate or
rotate slowly.
Both right and left pilot valves, travel motors,

and/or control valve spools are unlikely to be
faulty at the same time.
In case both travel systems do not operate, the
pilot system, which is applied to both side travel
motors, may be faulty. If the primary pilot pres-
sure is lower than specification, the front attach-
ment operating speed becomes slow as well.
Refer to A-1.
In case the fast travel mode cannot be selected,
refer to T-5.
T5-4-87

T-2 One side track doesnt rotate or rotates
slowly. Machine mistracks.
Check that both side track sags are equally ad- In one side track only doesnt 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
Check if travel relief

pressure in slow speed
NO side is normal. · Measurement: Refer to Op-
erational Performance Test
Section.
Check if symptom is Switch forward travel
reversed when right and · Relieve travel circuit. relief valve with re-
left travel line hoses are · Monitor item: Pump 1 verse travel one, or
switched each other at and 2 delivery pres- right travel relief valve
YES
the top of center joint. sure with left one. Check if
· Possible to display with To B
NO symptom is reversed.
built-in diagnosing
Check if secondary system
travel pilot pressure · Measurement:
is normal. Refer to Operational
Performance Test
Section. Bound control valve
· Monitor item: Travel con- YES spool.
trol pressure
built-in diagnosing sys- Faulty pilot valve.
tem NO
· Measurement:
Refer to Operational
Performance Test Sec-
tion.
NO Faulty travel motor.
Disassemble and clean YES Faulty travel reduction

travel motor servo piston. gear.
Check if same symptom
A YES occurs.
Disassemble and clean
travel motor counter- Faulty travel motor
balance valve. Check if servo piston.
same symptom occurs. NO
YES
Faulty counterbalance
NO valve.
T5-4-88

NO Faulty center joint.
B
Faulty travel relief
valve.
YES
Relationship between Faulty Seal Location

and Mistrack Direction Seal Location
Seal When traveling When pivot turn
No. straight: is performed:
External Oil 1
1 Leak
2
2
3
3 Left Travel Right
(Reverse) Travel
(Reverse)
4
4 Left Travel 5 Right
(Forward) Travel
(Forward)
5 6
7
6
T105-07-04-015
External Oil
7 Leak
Arrangement of Pipe Line

Front
1 2
5 4
W157-03-03-003
1 - Left Travel (Forward) 3 - Pilot 5 - Left Travel (Reverse) 6 - Drain

2 - Right Travel (Forward) 4 - Right Travel (Reverse)
T5-4-89

T-3 Machine mistracks during travel and front
attachment combined operation.

Faulty flow combiner
valve control spool in
Disconnect hose (SL), signal pressure control
YES
connecting to flow com- valve.
biner valve, from signal
control valve. Install
pressure gauge to signal
NO control valve. Check if
signal pressure is YES Faulty load check
approx. 3.9 MPa (40 valve.
kgf/cm2). Check load check
valve for any abnor-
Check flow combiner mality.
valve in control valve NO Find out cause of trou-
for any abnormality. ble by tracing other
trouble symptoms.
NO
Faulty flow combiner

valve.
YES
Hose (SL)
Flow
Combiner
Valve
T178-05-04-002
T5-4-90

T-4 Occasionally, machine mistracks when
traveling with engine running at slow speed.
Related Fault Codes: 10, 11, and 18
Refer to the pages for the Slow Speed Torque In-

crease Control in the SYSTEM / Control System
group in the T/M (Operational Principle).
hand.
sensor or broken har-
ness between MC and
corresponding sensor.
YES
Monitor output pres-

Check is any fault sure from torque con-
code is displayed. trol solenoid valve. Faulty pump device.
YES
Install pressure gauge
to torque control so-
· Fault codes: lenoid valve output
10: Pump 1 deliv- port. Check if both Faulty torque control
ery pressure sen- pressures measured Monitor travel pilot solenoid valve or MC, or
NO by pressure gauge pressure. Check if
sor YES broken harness between
11: Pump 2 deliv- and Dr. ZX varies pressure varies in torque control solenoid
ery pressure sen- identically by approx. response to travel valve and MC.
sor 1.5 MPa (15 kgf/cm2) lever operation.
18: Pressure sen- when travel operation NO
sor (Travel) is made.
· Possible to display Faulty pressure sensor
with built-in diag- NO (travel).
nostic system · Monitor item:
Travel control pilot
pressure
· Monitor item:
Pump torque proportional
solenoid valve output
· Engine:
Running at slow idle
speed
T5-4-91

T-5 Fast travel is inoperable.
Travel mode doesnt change from slow
mode to fast mode.
Refer to the pages for the Travel Motor Swash

Angle Control in the SYSTEM / Control section in
the T/M (Operational Principle). Faulty travel mode switch or
Check for loose harness connections before- broken harness between
hand. travel mode switch and MC.
NO
Monitor travel mode

switch. Check if dis-
played indication is · Check if symptom is re-
highlighted in response versed when pressure
NO sensor (travel) is switched
NO to travel mode switch
operation. with another pressure sen-
sor.
Monitor pressure sen-
sor (travel). Check if
pressure varies in
response to travel Monitor travel motor
· Monitor item: swash angle. Install pres-
Travel mode lever operation.
sure gauge to solenoid
YES
valve unit (SI) output port.
Check if any fault Check if pressure meas-
codes are displayed. ured by Dr. ZX varies iden-
tically with pressure
· Monitor item: Travel con- measured by pressure
trol pressure gauge while repeating to
travel and stop.
YES
· Monitor item:
Travel motor swash angle
control pressure
· Travel mode: Fast
· Measurement: Refer to Op-
erational Performance Test
Section.
Faulty corresponding sensor

or broken harness between
MC and sensor.
YES
· 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
NOTE: In case other fault codes are

displayed, perform trouble-
shooting corresponding to the
T5-4-92

Faulty pressure sensor (travel).

YES
Broken harness between travel

pressure sensor and MC or
clogged shuttle valve in signal
pressure control valve.
NO
Disconnect solenoid valve

unit (SI). Connect test har- YES Faulty solenoid valve unit (SI).
ness (ST 7226) between
solenoid valve unit (SI) and
NO harness. Check if test har-
ness lamp comes ON.
Broken harness between so-
lenoid valve and MC.
NO
· Travel mode: Fast

Faulty travel motor swash an-
YES gle control valve.
Check if travel motor swash
angle control valve is bound
or scored.
YES
Faulty travel motor or travel
reduction gear.
NO
T5-4-93

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 wont 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.
Disconnect front win-

dow open / close Remove test harness
switch. Check if wiper and reconnect circuit to
YES Faulty wiper relay.
operates. the original position.
Replace wiper relay
Connect test harness YES one at a time to see if
(ST 7227) between wiper operates.
auxiliary electric power
· Key switch: ON
(fuse box #19) and To A
wiper motor as illus- NO
trated to the right.
Check if wiper oper-
NO · Key switch: ON
ates.
Faulty wiper motor or

links.
NO or test har-
· Key switch: ON
ness lamp doesnt
light normally.
NOTE: When the wiper motor
is normal, lamp S lights while
the wiper is moving within the
operating range. Both lamps B
and S light for a moment at the YES End (Faulty monitor).
Replace monitor as-
same time only when the wiper sembly to see if wiper
reaches the intermittent stop A operates.
position.
Faulty cab harness.
NO
T5-4-94

Test Harness Application Circuit

Fuse Box #19
Lamp S
M B S
Lamp B Wiper Motor
L E
Ground
T178-05-04-004
Wiper Operating Range Intermittent Stop Position
Retracted Position
Operating Range
T178-05-04-005
Test Harness Connection Method
Wiper Motor Lamp B
Lamp S
Test Harness Fuse Box
T157-07-04-004
T5-4-95

O-2 Air Conditioner Malfunction
The air conditioner operation system has a

self-diagnosing function. This system performs the
diagnosis by 8-steps as shown in the flow chart be-
low: Check Model Confirmation, Display Function
Confirmation, Present Trouble Diagnosing, Past
Trouble Diagnosing, Sensing Temperature Display,
and Component Operation Check, Correction of the
Set Temperature and Selection of Celsius and Fahr-
enheit Temperature Indication.
Normal Operation
Turn key switch ON while pressing air

conditioner switch and mode switch.
Keep pressing OFF switch

for more than 3 seconds. STEP 0
Check Model Confirmation
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
Keep pressing OFF switch STEP 2
for more than 3 seconds. Present Trouble
Diagnosing
Keep pressing OFF switch STEP 3 Keep pressing air conditioner

for more than 3 seconds. Past Trouble Di- switch for more than 3 seconds.
agnosing
Sensing Temperature
Display
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
for more than 3 seconds.
Self-Diagnosis
T5-4-96

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.
STEP 0 Check Model Confirmation

The liquid crystal display (LCD) indicates the ma-
chine model name this system can diagnose. T178-05-08-001
Mode Switch OFF Switch

The LCD will indicate Sd as the check model
name.
(ZX200 class, ZAXIS225USR 230 class and 270
class)
The LCD will indicate Usr as the check model
name. (ZAXIS225US)
Select next step to be performed by operating the
switch as described below.
Upper side fan switch: To proceed to Step 1
Keep pressing OFF switch for more than 3 sec-
onds: To return to normal operation
NOTE: The system operation will automatically
proceed to STEP 1 after 5 seconds have
passed after the check model is displayed.
STEP 1 Display Function Confirmation

Turn all indicators ON to check indicator bulbs.
The LCD panel and all switch indicators light.

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 2.
Press the lower side of the fan switch: To return
to STEP 0.
Keep pressing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed)
T5-4-97

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.
In case any abnormalities are present, the LCD in-

dicates the fault codes. If more than one fault code
is detected, the following fault code is displayed af-
ter flashing (0.5 seconds) twice.
Fault Code T178-05-08-001
Breakage Short Circuit OFF Switch
Mix Door 21 21
Mode Encoder 22
In-Cab Ambient 23 23
Temperature Sen-
sor
Outdoor Ambient 24 24
Temperature Sen-
sor
Coolant Tempera- 25 25
ture Sensor
Solar Radiation 26 26
Sensor
: When solar radiation is shaded, the solar radiation
sensor indicates the fault code of breakage.
NOTE: As for ZAXIS225US, the fault code for the
coolant temperature sensor isnt displayed.
In case no failures are present, the LCD
indicates 20.
ceed to STEP 3.
to STEP 1.
T5-4-98

STEP 3 Past Trouble Diagnosing
The LCD indicates the fault codes for past abnor-
malities of the mix door, mode encoder, and/or sen-
sors.
The past stored fault codes are deleted.
In case any abnormalities occurred in the past, the

LCD indicates the fault codes. If more than one fault
code is detected, the following fault code is dis-
played after flashing (0.5 seconds) twice. T178-05-08-001
Fault Code OFF Switch
Breakage Short Circuit
Mix Door 21 21
Mode Encoder 22
In-Cab Ambient
Temperature Sen- 23 23
sor
Outdoor Ambient
Temperature Sen- 24 24
sor
Coolant Tempera- 25 25
ture Sensor
Solar Radiation 26
Sensor
NOTE: As for ZAXIS225US, the fault code for the
coolant temperature sensor isnt displayed.
In case no failures are present, the LCD
indicates 30.
When the air conditioner switch is kept pressed for
more than 3 seconds, failure records are deleted.
After this operation, the air conditioner switch indi-
cator flashes 5 times. Then, the self-diagnosing
system is deactivated. (Normal functions are re-
sumed.)
ceed to STEP 4.
to STEP 2.
T5-4-99

STEP 4 Sensing Temperature Display Fan Mark
The LCD indicates the sensing temperature detected
by each temperature sensor (excluding the insulation
sensor).
The sensing temperature detected by the in-cab

ambient temperature sensor, outdoor ambient tem-
perature sensor, and coolant temperature sensor
are displayed on the LCD in real time. (Figures less
than the decimal point are not displayed.) T178-05-08-001
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.
ceed to STEP 5.
to STEP 3.
T5-4-100

STEP 5 Component Operation Check Air Conditioner
Fan Switch LCD Switch AUTO Switch
Each component operation is checked by performing
pattern operation.
Each time the fresh air vent switch is pressed, the

component to be checked is selected in order.
Check which component has been selected by re-
ferring to No. indicated on the LCD. (See table 1.)
Operating pattern of the selected component is T178-05-08-001
shifted at an interval of 10 seconds. Operating pat-
Fresh Air Vent switch OFF Switch
tern is cycled. (See table 1.)
NOTE: The components other than selected oper-
ate under the standard conditions (shown
by marks* in table 1).
Press the AUTO switch and upper side of the fan
switch: To proceed to STEP 6-1.
Press the A/C switch and upper side of the fan
switch: To proceed to STEP 6-2.
to STEP 4.
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

STEP 6-1 Correction of the Set Temperature
Fine correction of the set temperature. Temperature
Fan Switch LCD Control Switch AUTO Switch
Each time when the top or bottom of the tempera-

ture control switch is pressed, temperature correc-
tion, displayed on the LCD window, can be
changed.
Actually controlled temperature is the normally set
temperature plus the set temperature correction.
For instance, when the normally set temperature is T178-05-08-001
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).
Press the AUTO switch and lower side of the fan
switch: To return to STEP 5.
T5-4-102

STEP 6-2 Selection of Celsius and Fahrenheit
Temperature Indication
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
C F Fresh Air Vent Switch OFF Switch

Press the Air Conditioner Switch and lower side
of the fan switch: To return to STEP 5.
T5-4-103

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 machines 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
Symptom No cool air (2) Pressure (To be measured at gauge manifold)
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
Before replacing the control amplifier, be sure to
Uncontrollable vent hole
check that the connectors are correctly connected
Symptom Vent hole isnt 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

ZX200 class, ZAXIS225USR, 230 class, 270 class:

Refrigerant Quantity ....................... 850 50 g
Compressor Oil Quantity................ 210 cm3
ZAXIS225US:
Refrigerant Quantity ....................... 900 50 g
Compressor Oil Quantity................ 210 cm3
T5-4-105

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
doesnt respond. Refrigerant has not
been refilled for longer than one sea-
son.
No bubbles are seen in sight
glass.
After cooling at fast speed continu-

ously, cooling power is reduced. Air
flow volume remains unchanged.
Air flow volume is reduced.
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.
Heater unit emits hot air.
Refrigerant pressure
in high-pressure side Bubbles can be seen in sight Refrigerant pressure in low-pressure
is high. glass. side is low.
Condenser is stained and clogged.
Even if condenser is sprayed with water, few bubbles appear. Receiver dryer tem-
perature is low.
After cooling at fast speed continu-

ously, cooling power is reduced. Air Frost forms. Thermistor doesnt cool.
flow volume is reduced.
Thermistor cools.
T5-4-106

Gas leaks from pipe joints and/or parts. Re-tighten or replace parts.
Normal leakage of refrigerant from hoses. Refill refrigerant.
Improper adjustment (excessive restriction) of expansion Readjust or replace expansion valve.

valve.
Clogged expansion valve. Remove clog, or replace receiver and/or expansion

valve.
Clogged low-pressure circuit and/or evaporator. Remove clog, 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.
Improper adjustment (excessive open) of expansion valve. Readjust or replace.
Insufficient compressor discharge (faulty gasket and/or valve). Replace.
Improper water stop valve wire adjustment and/or faulty stop

valve. Check and readjust or replace.
Poor airtight fitting of outside air damper (outside air induction

Repair.
type).
Clogged high-pressure circuit before receiver dryer. Remove clog, or replace parts.
Clean Condenser.
Excessive refrigerant. Remove excessive refrigerant to proper level.
After evacuation, refill refrigerant and/or replace re-

Air is mixed in system.
ceiver dryer.
Incorrect thermistor location. Correct thermistor location.
Gas leaks from case. Seal gaps using vinyl tape or packing compound.
Faulty thermistor (stays ON). Disconnected thermistor cord.
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

Cooling Circuit
Case connection. Louver resonance.
Fan contacts case, or foreign matter enters case.

Blower fan connection.
Brush friction noise, metal and/or thrust washer con-
tact noise.
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.).
Faulty clutch bearing, and/or idle pulley bearing.
Clutch disengaging sound.

Contact of clutch amature due to resonance, or loose
belt and/or screws.
Noisy compressor.
Compressor rotating sound.
Vibration and/or loose screws due to excessive drive
belt looseness.
Broken heater core and/or hose.

Water leak and/or splash.
Clogged case drain port and/or drain hose.
Others
Absorbed cigarette and dust smell on evaporator fins.

Abnormal smell.
T5-4-108

Repair or replace.
Remove foreign matter. Readjust fan motor location.
Slight noise is unavoidable.

Replace if loud.
No functional problem exists.

Provide silencer if intolerable.
Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.
Replace.
Repair or replace clutch. Re-tighten screws.
Repair or replace.
Re-adjust drive belt.
Replace.
Clean.
-1
Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min in
L mode for more than 10 minutes, flush smell out by condensed water.
T5-4-109

Compressor
Compressor doesnt rotate. Clutch terminal voltage is normal 24 V.
Inoperable
cooling Clutch terminal voltage is low.
system.
Clutch terminal voltage is 0 V.
Bubbles exist even after refrigerant is refilled.
Both high and

low side Check for oil and refrigerant leaks from parts other than
pressures are compressor and pipe joints using gas detector.
low.
Both com- Check for oil and refrigerant leaks from compressor (no
pressor and leaks from parts other than compressor) using gas de-
blower mo- tector. (Refer to NOTE 2 on page T5-4-89.)
tor rotate.
Stain on exterior.
(Refer to NOTE 1
on page T5-4-113.)
Refrigerant has not been refilled for longer

than one season.
Refrigerant is discharged within 1 to 2

months after being recharged. Check for
refrigerant leaks using gas detector.
Refrigerant is kept charged for longer than

2 years.
Compressor cylinder is not hot. (Refrigerant returns to com-

High pressure side is pressor in liquid form.)
slightly low and low pres-
sure side is high.
No refrigerant returns in liquid form. High pressure side is low.
Bubbles can be seen through Others

sight glass.
High pressure side is high.
Refer to the Cooling Circuit Troubleshooting
Table on page T5-4-106.
Temperature is not cooled when compressor is
operated at fast speed continuously.
Air flow from blower is insufficient.
T5-4-110

Seized clutch. Replace.
Improper gap between amature and rotor (improper air gap).

Replace.
Broken or short-circuited core cable.
Shaft doesnt rotate (internally locked). Replace.
Faulty Electrical System.
Faulty Electrical System.
Oil leaks from mechanical seal, gasket, and/or charge valve.

Replace.
Oil leaks from oil plug.
Oil and refrigerant leaks from front housing, and/or cylinder block joint. Replace.
Normal leaks from hoses. Charge

refrigerant.
No leaks (normal).
Refer to the Cooling Circuit Troubleshooting Table on page T5-4-113.
Broken valve (See NOTE 3 on page T5-4-113.)
Replace.
Blown gasket (See NOTE 3 on page T5-4-113.)
Check and adjust

Excessive oil. oil level.
T5-4-111

Compressor
Compressor rotation is abnormally draggy.

Overheating
is susceptible
to occur.
Trouble other than compressor. Refer to the Cooling Circuit Troubleshooting Ta-
ble on page T5-4-106.
Noise is heard when clutch is OFF.
Abnormal
noise
Noise is heard when clutch is ON.
T5-4-112

Broken clutch bearing due to overly tightened belt. Replace.
Shaft doesnt rotate.

Replace.
Shaft rotates draggy.
Broken clutch bearing.

Replace.
Contact or slip due to poor air gap.
Faulty idle pulley bearing.
Refer to the Cooling Circuit

Saggy belt. Troubleshooting Table on
page T5-4-106.
Loose screws.
Broken valve.
Replace.
Blown gasket.
Abnormal internal noise. Replace.
Vibration due to saggy belt.

Refer to the Cooling Circuit
Troubleshooting Table on
Loose screws. page T5-4-106.
NOTE:
1. Dont 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
2
high-pressure side and low-pressure side is 0.49 MPa (5 kgf/cm ) 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

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.
In case the pump 1 delivery pressure is abnormal Pump 2 Pump 1

(5-Spool (4-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

Applicability of Switch-Check Method

Fault Code Trouble Applicability
01 Abnormal EEPROM Not Applicable
02 Abnormal RAM
04 Abnormal Sensor Voltage
06 Abnormal EC Angle Sensor Not Applicable
07 Abnormal EC Dial Not Applicable
08 Abnormal Boom Angle Sensor Not Applicable
10 Abnormal Pump 1 Delivery Pressure Applicable (Harness)
11 Abnormal Pump 2 Delivery Pressure
12 Abnormal Pump 1 Control Pressure Applicable (Harness)
13 Abnormal Pump 2 Control Pressure
14 Abnormal Swing Pilot Pressure Applicable (Harness/Sensor)
15 Abnormal Boom Raise Pilot Pressure
16 Abnormal Arm Roll-In Pilot Pressure
18 Abnormal Travel Pilot Pressure
19 Abnormal Hydraulic Oil Temperature Not Applicable
Sensor
T5-4-115

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.
If the engine stalls and cannot be restarted, lower the 1

boom to lower the bucket to the ground referring to
the emergency boom lowering procedure stated be-
low.
1. Loosen lock nut (1). Loosen screw (2) one half of

a turn. The boom will start to lower. The boom
lowering speed can be somewhat adjusted by
loosening screw (2) more.
IMPORTANT: Lock nut (1) and screw (2) are lo-

cated under the solenoid valve.
Pay attention to the screw turns. M178-05-003
2. After the bucket is lowered to the ground, re-

tighten screw (2), then lock nut (1) to the specifi-
cations below.
Emergency Valve
Lock Nut (1)
Tool : 13 mm
Torque : 13 N m (1.3 kgf m, 9.4 lbf ft) 1
Screw (2) 2
Tool : 4 mm (Hexagonal wrench)
Torque : 6.9 N m (0.7 kgf m, 5.0 lbf ft)
NOTE: Excessive leakage may result if the screw

and the lock nut are tightened insufficiently.
Be sure to retighten the screw and the lock
nut to specifications. T178-05-04-003
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.
How to Read Troubleshooting Flow Charts
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).
NO (NOT OK) (3)
Instructions, reference, and/or instruction methods on inspection and/or measurements

are occasionally described under the box. If incorrectly checked or measured, not only
· Key switch: ON will troubleshooting be unsuccessful but also damage to components may result.
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.
NOTE: All harness end connector are seen from

the open-end side.
Wire Harness Side
Open End
Side
Harness End Connector
T158-05-03-001
T5-5-1

MALFUNCTION OF COOLANT TEM-
PERATURE GAUGE
Check for loose harness connections beforehand.
Disconnect coolant Faulty coolant temperature

YES sensor.
temperature sensor.
Ground harness end
Gauge pointer terminal to vehicle
doesnt move frame. Check if pointer Without connecting coolant
at all. swings to (H) side. temperature sensor, remove Faulty monitor.
connector B (20P) from moni- YES
tor. Check for continuity be-
tween monitor harness end
connector terminal #18 and
NO coolant temperature sensor Broken harness between
· Key switch: ON terminal. monitor and sensor.
NO
Faulty coolant temperature

YES sensor.
Disconnect coolant
Gauge pointer temperature sensor.
swings over Check if pointer returns Without connecting coolant Short-circuited harness be-
scale. to zero. temperature sensor, remove tween monitor and sensor.
YES
connector B (20P) from moni-
tor. Check for continuity be-
tween monitor harness end
terminal #18 and vehicle
NO
frame. Faulty monitor.
· Key switch: ON
NO
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

Coolant Temperature Gauge Board
105 C
(95
70 C
T157-07-05-001
Coolant Temperature Sensor
Coolant Temperature Resistance (k )

C ( F)
25 (77) 7.6 0.76
40 (104) 4.0 0.35
50 (122) 2.7 0.22
80 (176) 0.92 0.07
95 (203) 0.56 0.04
105 (221) 0.42 0.03
120 (248) 0.28 0.01
Connector (Harness end connector terminals seen

from the open end side)
Monitor Connector B (20P)
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-3

MALFUNCTION OF FUEL GAUGE
Disconnect fuel sensor. YES Faulty fuel sensor.

Connect harness end con-
nector terminal #1 to
Fuel gauge terminal #2 using jumper
pointer doesnt wire such as clip. Check if Without connecting fuel
move at all. pointer swings to (FULL) sensor, remove connec-
side. tor B (20P) from monitor. YES Faulty monitor.
Check for continuity be-
tween monitor terminal
#19 and fuel sensor ter-
NO minal #1. Broken harness between
monitor and sensor.
· Key switch: ON NO
YES Faulty fuel sensor.
Disconnect fuel sensor.

Fuel gauge pointer Check if pointer returns to Without connecting fuel
swings over scale. zero. sensor, remove connector Short-circuited harness be-
B (20P) from monitor. YES tween monitor and sensor.
Check for continuity be-
tween monitor harness
· Key switch: ON end terminal #19 and ve-
NO hicle frame.
Faulty monitor.
NO
Disconnect fuel sensor.

Connect harness end con- YES Faulty fuel sensor.
nector terminal #1 to
Fuel gauge pointer terminal #2 using jumper
keeps moving un- wire such as clip. Check if
stably. pointer swings and is stabi-
lized to (FULL) side.
Faulty monitor.
NO
· Key switch: ON
T5-5-4

Fuel Sensor
Float
FULL
R381.9 mm
257 mm 3/4
93 mm
70.5 mm
1/2
204 mm
338 mm 1/4
EMPTY
T178-05-05-001
NOTE: 1 mm = 0.03937 in
Float Position Resistance ( )

Upper Limit (FULL) 10+0-4
3/4 26
1/2 38 5
1/4 53
Warning Level 85 3
Lower Limit (EMPTY) 90+10-0

Monitor Connector B (20P) Fuel Sensor
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

MALFUNCTION OF INDICATOR LIGHT
CHECK SYSTEM
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 doesnt box terminal #5(switch box). Broken harness between
light when indicator Check if all in- fuse and monitor.
light check operation dicators dont
is performed. light. NO
Conduct troubleshooting of
each indicator, which does
NO not light.

Monitor Connector C (20P)
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-6

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-
doesnt 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
Remove connector Faulty coolant tem-

Preheat indicator YES perature switch.
doesnt light al- (with black and
though preheat white cables) from
system operates coolant tempera-
ture switch. Check YES Faulty QOS control-
(coolant tempera-
if indicator comes ler.
ture is lower than Disconnect QOS
10 C (50 F)). ON. controller. Check if
indicator comes Ground monitor
ON by grounding connector B (20P) Broken harness
harness end con- terminal #20 to ve- between QOS con-
hicle frame. Check YES
nector terminal #6 troller and monitor.
NO to vehicle frame. if indicator comes
ON.
· Key switch: ON NO
Faulty monitor.
NO
· Key switch: ON
· Without discon-
necting connector,
ground connector
Connector (Harness end connector terminals seen to vehicle frame
using jumper wire
such as clip from
reverse side of
Monitor Connector B (20P) QOS Controller connector.
10 9 8 7 6 4 3 2 1 1 2 3
20 19 18 17 14 13 12 11 4 5 6
T5-5-7

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))
Check that indicator light is not burned out.

Check that all other indicators work correctly.
Check that machine is parked on level surface.
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 doesnt frame. Faulty monitor.
light even if engine black and white ca-
ble) from engine oil NO
oil level is lower
than specification. level switch.
Faulty engine oil level switch.

YES
Without connecting
connector to engine oil
level switch, remove
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
Normal (Lack of engine oil).

Above 3.5 mm
below LOW level mark
on oil level gauge
YES Faulty monitor.
A
Broken harness between en-
gine oil level switch and moni-
NO tor.
T5-5-8

Engine Oil Level Switch

Oil Level
Gauge Engine Oil Level
Switch
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

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))
Check that indicator light is not burned out.

Check that all other indicators work correctly.
Check that machine is parked on level surface.
Without connecting
connector to coolant Short-circuited harness be-
level switch, remove tween coolant level switch and
connector B (20P) YES
monitor.
from monitor. Check
NO for continuity between
Check if indicator monitor harness end
Indicator doesnt lights by removing connector terminal #9
light even if coolant connector (with and vehicle frame. Faulty monitor.
level is lower than gray cable) from NO
specification. coolant level switch.
Faulty coolant level switch.

YES
Without connecting
connector to coolant
level switch, remove
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.
Indicator comes ON Check if coolant

even if coolant level level in coolant res-
matches specifica- ervoir is lower than
tion. LOW mark. Faulty coolant level switch.
YES
Normal (Lack of coolant).

YES
YES Faulty monitor.
A
Broken harness between
coolant level switch and moni-
NO tor.
T5-5-10

Coolant Level Switch
Reserve Tank
ON
FULL
LOW
Radiator OFF

T107-04-03-012


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

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.
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
Faulty regulator or alter-

· Engine: Running nator.
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
doesnt light. switch is turned ON. higher than 33.5 V
Burned indicator light.

· Key switch: ON
NO

Starter Relay Monitor Connector A (16P)
E
8 7 6 5 4 3 2 1
S R 16 15 14 13 12 11 10 9
T5-5-12

(Blank)
T5-5-13

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.
Disconnect engine oil Faulty engine oil pressure

YES switch.
pressure switch. Check
if indicator lights when
harness end connector
terminal #1 (white and
red cable) is grounded Reconnect engine oil pres-
YES to vehicle frame. sure switch. Check if indica-
tor lights when monitor con-
nector C (20P) terminal #18
is grounded to vehicle frame.
To A
NO
Indicator doesnt Check if indicator
light even if engine lights when key · Key switch: ON
oil pressure is low. switch is turned ON. · Key switch: ON
· Without disconnecting con-
nector, ground connector to
vehicle frame using such
· Key switch: ON jumper wire as clip from re-
· Engine: Stopped verse side of connector.

NO

monitor and engine oil pres-
YES
sure switch.
Faulty monitor.
NO
Faulty engine oil pressure

switch or engine oil pressure
YES system, or clogged oil filter.
Check if indicator
goes OFF when
Indicator stays ON engine oil pressure
after engine is switch is discon- Reconnect engine oil
started. nected. pressure switch and re- Short-circuited harness be-
move connector C (20P) tween monitor and engine oil
from monitor. Check for YES
pressure switch.
continuity between har-
· Check oil filter for ness end connector ter-
clogging. minal #18 and vehicle
· Key switch: ON NO frame.
· Engine: Stopped
Faulty monitor.
NO
T5-5-14

Engine Oil Pressure Switch

Pressure Operation
Approx. 98 kPa
(1.0 kgf/cm2, 14.22 psi) ON
or less
Approx. 98 kPa
(1.0 kgf/cm2, 14.22 psi) OFF
or higher

10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-15

MALFUNCTION OF OVERHEAT INDICA-
TOR
Faulty overheat switch.

Remove connector (red YES
and blue cable) from
overheat switch. Check
if indicator lights when
harness end terminal is
Reconnect overheat switch.
YES grounded to vehicle Check if indicator lights when
frame.
monitor connector B (20P)
terminal #6 is grounded to
vehicle frame.
To A
NO
Indicator doesnt Check if indicator · Key switch: ON
light even if engine lights when key
overheats. switch is turned ON. · Key switch: ON
vehicle frame using such
jumper wire as clip from re-
· Key switch: ON
verse side of connector.

NO

YES monitor and overheat switch.
Faulty monitor.
NO
Faulty overheat switch.

YES
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

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

MALFUNCTION OF AIR FILTER RESTRIC-
TION INDICATOR
Disconnect air filter re- Faulty air filter restriction

striction switch at plug YES switch.
receptacle with green
and blue cable. Check if
indicator lights when
harness end plug con-
Reconnect air filter restriction
YES nector is grounded to
switch. Remove connector B
vehicle frame.
(20P) from monitor. Check
for continuity between moni-
tor harness end connector
To A
Even if air filter is Check if indicator NO terminal #7 and vehicle
clogged, indicator lights when key frame.
doesnt light. switch is turned ON.
· Key switch: ON
· Key switch: ON
NO
YES Faulty monitor.
A
monitor and air filter restriction
switch.
NO
Faulty air filter restriction

YES
switch.
Check if indicator
goes OFF when air Disconnect air filter re-
Although air filter is filter restriction
not clogged, indi- striction switch at plug
switch is discon- receptacle with green
cator lights. nected. Short-circuited harness be-
and blue cable and re-
YES tween monitor and air filter
move connector B (20P)
restriction switch.
from monitor. Check for
· Disassemble and continuity between con-
visually inspect. · Key switch: ON nector terminal #7 and
· Verify that air filter NO vehicle frame.
is not moist. Faulty monitor.
NO
T5-5-18

Air Filter Restriction Switch

Pressure Operation
5.1 kPa (520 mmH2O) OFF
6.2 kPa (630 mmH2O) ON

10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-19

MALFUNCTION OF BUZZER
Check for loose harness connections beforehand. NOTE: *Regulator terminals L are water-resistant
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.
Buzzer continues to Faulty regulator.

sound when key 13 V or more
Measure voltage at
switch is turned ON monitor connector A
without starting en- (16P) terminal #2.
gine.
Faulty monitor.
Less than 13
· Key switch: ON
(without starting
engine)
Faulty engine oil pres-

YES sure system.
Buzzer continues to Check if engine oil

sound when engine pressure indicator
is started. lights. YES Overheat of engine.
Check if overheat in-
dicator lights.
NO
Faulty monitor.
NO
Buzzer doesnt NO Normal.

sound even if en-
gine oil pressure Check if engine
-1
indicator or over- speed is 900 min
heat indicator lights (rpm) or faster. NO Perform troubleshooting
with engine running. of indicator staying ON.
Check if alternator in-
dicator lights.
YES
Measure voltage at regu-
lator terminal L.*
YES
· Engine speed: 900 min-1

(rpm) or faster.
T5-5-20


Monitor Connector A (16P) Starter Relay
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.
Lower than 13 V or Broken harness between

higher than 33.5 V regulator terminal L and
monitor.
Measure voltage at monitor
connector A (16P) terminal #2.
Between 13 V Faulty monitor.
and 33.5 V -1
· Engine speed: 900 min Between 13 V
(rpm) or faster and 33.5 V
T5-5-21

MALFUNCTION OF LCD
The following items are described:
1 to 3: To be displayed in the standard mode.
4 to 8: To be displayed in the users mode.
9 to 24: To be displayed with built-in diagnosing
system
In case only LCD is abnormal, the machine will
normally operate.
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 doesnt 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 doesnt 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

MALFUNCTION OF HOUR METER
Check for loose harness connections beforehand. NOTE: Regulator terminals L are water-resistant
measure voltage at these terminals. Meas-
ure voltage at starter relay terminal R in-
stead. Check for continuity between starter
relay terminal R and regulator terminal L
beforehand.
Lower than 13 V or Faulty regulator or

higher than 33.5 V alternator.
Hour meter doesnt
count operating
hours with engine Measure voltage at Between 13V
running. regulator terminal L. and 33.5 V
Measure voltage Faulty monitor.
at monitor con-
-1
nector A (16P)
· Engine speed: 900 min terminal #2.
· Engine: Running (rpm) or faster Between 13V Broken harness be-
and 33.5 V tween regulator ter-
minal L and monitor.
Lower than 13 V or
higher than 33.5 V

Monitor Connector A Starter Relay
8 7 6 5 4 3 2 1 E
16 15 14 13 12 11 10 9 S R
T5-5-23

MALFUNCTION OF HYDRAULIC OIL FIL-
TER INDICATOR (Optional)
Faulty hydraulic oil filter restric-
Disconnect hydraulic oil YES tion switch.
filter restriction switch at
plug receptacle with
white and blue cable.
Check if indicator lights Reconnect hydraulic oil filter
when harness end plug restriction switch. Check if
YES
connector is grounded indicator lights when monitor
to vehicle frame. connector C (16P) terminal
#14 is grounded to vehicle To A
frame.
NO
Even if hydraulic oil Check if indicator

filter is clogged, in- lights when key
dicator doesnt light. switch is turned ON. · Key switch: ON · Key switch: ON
vehicle frame using jumper
· Key switch: ON wire such as clip from reverse
side of connector.

NO
Broken harness between moni-

YES tor and hydraulic oil filter restric-
tion switch.
A
Faulty monitor.
NO
Faulty hydraulic oil filter restric-

YES
tion switch.
Check if indicator
Although hydraulic goes OFF when
oil filter is not Disconnect hydraulic oil
hydraulic oil filter
clogged, indicator filter restriction switch at
restriction switch is
lights. plug receptacle with white Short-circuited harness between
disconnected.
and blue cable and re- YES monitor and hydraulic oil filter
move connector C (16P) restriction switch.
from monitor. Check for
continuity between con-
· Key switch: ON nector terminal #14 and
· Engine: Stopped NO vehicle frame.
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
NOTE: 1) Code BW indicates a black base wire

with white fine-line marking.
2) Initials O and Or both stand for the
color orange.
3) Wires with longitudinal stripes printed
on them are not color coded. Be sure
not to confuse them with color coded
wires.
T5-6-1

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
so that if water enters them, water will not

easily drain from them. When checking
water-resistant connectors, take extra care
not to allow water to enter the connectors. In
case water should enter the connectors,
reconnect only after the connectors are Right
thoroughly dried.
Rust
3) Before connecting terminal connectors,
check that no terminals are bent or coming Wrong
(Deformation)
off. In addition, as most connectors are
made of brass, check that no terminals are Wrong
rusting. (Separation)
4) When connecting terminal connectors T107-07-06-002
provided with a lock, be sure to insert them
together until the lock clicks.
5) Pull the harness near the connector to
check if it is correctly connected.
4. Precaution for using a circuit tester.

1) Before using a circuit tester, refer to the
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object
Wind a Piece of Wire Tester Probe
to be measured, voltage range and current
polarity.
2) Before starting the connector test, always
check the connector terminal numbers,
referring to the circuit diagram. Sharpen the end of the Wire
When the connector size is very small, and T107-07-06-003
the standard probe size is too large to be

used for testing, wind a fine piece of
sharpened wire or a pin around the probe to
make the test easier.
T5-6-2

INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
Push to Unlock and Separate Type
NOTE: Connectors will not be easily separated

even if the lock is pushed while being
pulled. Push the lock first before pulling the
connectors.
The lock is located on female side con-
nector (harness end side). T107-04-05-002
Locations of This Type Connector

Fuel Gauge N Sensor Engine Oil Level Switch* Radio
Hydraulic Oil Level Switch EC Motor Coolant Level Switch* Speaker
Horn EC Sensor Diode Learning Switch
Cab Harness Pump Delivery Pressure Sensor Key Switch Wiper
Pressure Sensor General Relay Engine Control Dial Monitor
Washer Solenoid Valve
NOTE: * Up to serial No.104679 (ZX200 class and

225 class)
Pull Up to Unlock and Separate Type

Starter Relay
T107-04-05-003
Pull to Separate Type
IMPORTANT: Generally, the solenoid valve con-

nector has a lock. Always pull to
separate the connector only after
unlocking using a tool such as a
pair of needle nose pliers.
T107-04-05-004

Dr. ZX
T5-6-3

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

FUSIBLE LINK INSPECTION Battery Relay
Inspection
1. Remove the negative cable from the battery.

2. Loosen bolt M8 holding the cable routed in front
of the fusible link box to move the cable out of the
way of the front cover.
3. Open the fusible link box front cover and visually
inspect the fusible link.
Fusible Link M178-07-049
Fusible Link Cover
Replacement
1. Check that the negative cable is removed from

the battery.
2. Remove bolt M8 to take the fusible link off the T178-05-06-002
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

BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between
the battery positive terminal and the vehicle
frame.
Normal Voltage: 24 V
NOTE: If voltage is abnormal, recharge or replace

the battery.
2. Start the engine. Check voltage between the

battery positive terminal and the vehicle frame.
Normal Voltage: 26 to 28 V
NOTE: If voltage is abnormal, check the charging V

system.
T157-07-06-007
T5-6-6

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.
How to check the circuit
1. Stop the engine. Turn the key switch to the ON

position. Confirm that the alternator indicator
comes on.
2. Measure the voltage between teminals B and E B

terminals of the alternator. If the measured
voltage is around 24 V, the alternator circuit can
be considered normal. If the measured voltage
is low, a shortage in battery capacity or
looseness of the wire connectors of the alternator
circuit might be the cause of the malfunction.
When the voltage is 0 V, the wiring between the
fuse box and alternator might be loose or E
disconnected.
Also, the alternator cannot generate electricity if
the ground line is disconnected.
3. Next, start the engine and measure the voltage T157-07-06-003

generated while as the alternator rotates.
As described above, measure the voltage
between terminals B and E on the side of the
alternator. If the voltage is around 28 V, the
alternator is operating normally.
If the rated voltage is not being generated, there
is some trouble with the alternator or the regula-
tor.
T5-6-7

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 Continuity
Discontinuity
NOTE: When the one end connector is far apart

from the other, connect one end of Connect to
A a
connector (A) to the machine chassis the vehicle
using a clip. Then, check continuity of the frame.
harness through the vehicle frame as
illustrated.
Connect to
the vehicle
If the ohm-meter reading is: 0 Continuity frame.
Discontinuity
A a
Single-line short-circuit check
Disconnect both end connectors of the harness and Short-circuit
check continuity between one end connector of the between the
harness and
harness and the vehicle frame: the vehicle
If the ohm-meter reading is: frame.
0 Short circuit is present.
No short circuit is present.
T107-07-05-003
T5-6-8

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 , 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)
and (c).
NOTE: By conducting the multi-line continuity T107-07-05-004

check twice, it is possible to find out which
line is discontinued. With terminals (A) and
(C) short-circuited, check continuity
between terminals (a) and (c).
If the ohm-meter reading is:
0 Line (B) - (b) has discontinuity.
Line (A) - (a) has discontinuity.
Multi-line short-circuit check

Disconnect both end connectors of the harness,
and check continuity between terminals (A) and (B)
or (C).
If the ohm-meter reading is:
0 Short-circuit exists between the lines.
No short-circuit exists between the lines.
Short-circuit between harnesses.
A a
B b
C c
T107-07-05-005
T5-6-9

(Blank)
T5-6-10

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

Engine Key Switch Location to be Measured Specification

Power Source
Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (2): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Battery Power 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (1) and Ground: Backup Current* 6 mA
Preheat Circuit
Stopped ON or START Between (6) and Ground: Key Switch 20 to 25 V
Stopped ON or START Between (7) and Ground: Glow Plug 20 to 25 V
Starting Circuit
Started START Between (8) and Ground: Key Switch 20 to 25 V
Started START Between (9) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (10) and Ground: Battery Relay (Switch) 20 to 25 V
Started START Between (11) and Ground: Starter (B) 20 to 25 V
Started START Between (12) and Ground: Starter (C) 20 to 25 V
Started START Between (13) and Ground: Starter Relay (S) 20 to 25 V
Charging Circuit
Fast Speed ON Between (14) and Ground: Alternator (B) / Generating 26 to 30 V
Voltage
Fast Speed ON Between (10) and Ground: Battery Relay / Generating 26 to 30 V
Voltage
Fast Speed ON Between (15) and Ground: Fuse Box / Starter Relay (R) / 26 to 30 V
Generating Voltage
Fast Speed ON Between (16) and Ground: Generating Voltage 13 to 30 V
Fast Speed ON Between (17) and Ground: Monitor 13 to 30 V
Surge Voltage
Prevention Circuit
Slow Idle ON Between (14) and Ground: Alternator (B) 26 to 30 V
Slow Idle ON Between (16) and Ground: Starter Relay (R) 13 to 30 V
Slow Idle ON Between (18) and Ground: Load Damp Relay 26 to 30 V
Slow Idle ON Between (10) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (19) and Ground: Auxiliary 20 to 25 V
Stopped ON Between (20) and Ground: Room light 20 to 25 V
Stopped ON Between (21) and Ground: Lighter 20 to 25 V
Stopped ON Between (22) and Ground: Radio 20 to 25 V
Stopped ON Between (23) and Ground: Horn 20 to 25 V
Stopped ON Between (9) and Ground: Battery Relay 20 to 25 V
NOTE: *Measure after disconnecting the negative

cable from the battery.
T5-6-12

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

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.
Voltage between terminal #1 and the ground T107-07-05-007
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.
Key switch position: ON

Tester black terminal (negative):
Connected to the ground terminal
(terminal #2 or 3) T107-07-05-008
Tester red terminal (positive):
Connected to terminal #1 Three Polarities
1 2 3
Evaluation:
If the measuring voltage is within 5 0.5 volts, the
circuit up to terminal #1 or the ground terminal is
normal.
V
T107-07-05-009
T5-6-14

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.
IMPORTANT: Dont connect terminal #1 or #2 to

terminal #3 or to the vehicle frame Three Polarities
T107-07-05-010
(ground) when checking a

three-polarity connector. (Pressure Sensor)
(Pump Delivery Pressure Sensor)
(Pump Control Pressure Sensor) 1 2 3
NOTE: Some kinds of sensors can be monitored (EC Sensor)
by the built-in diagnosing system. (Refer to
the TROUBLESHOOTING / General
group.)
Connect
T107-07-05-011
T5-6-15

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.
Parts Number 4283594 (ST 7126)

Use to check a single-line (discontinuity and/or volt-
age).
To Location to be Measured.
During Operation: Lamp is ON. To Ground
T107-07-05-012
Parts Number (ST 7226)

Use to check the solenoid valve unit circuits.
When the corresponding control lever or switch is 4
operated: Lamp is ON. 3 50
(Refer to T5-4-54, 64, 69, 72, 73, 82, 84 and 93.) 150 50 50
1 2 2 1
T107-07-06-015

Use to check the EC motor circuit.
(Refer to T5-4-38 and 42.) 5
6
EC Motor Circuit 50
When the engine control dial is rotated: 1 2 2 1

150 50
Both lamps ON: Normal 50
Only one lamp ON: Check for continuity of the 4 3 4 3
circuit connected to the lamp OFF. 7 50
Both lamps OFF: Check the harness together 8
with the relay.
Parts Number 4274589 (ST 7125) T107-07-06-024
T5-6-16

Use to measure the EC sensor circuit signal line
voltage (between terminals #2 and #3).
(Red)
(Refer to T5-3-4.)
(Black)
Parts Number 4284347 (ST 7129) T107-07-03-009

Use to check the wiper circuit. 2
5 1
(Refer to T5-4-94.)
2 4 7
1
Parts Number (ST 7227) T178-05-06-003
T5-6-17

(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

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.)
5 Hour Meter Hour meter cumulative hours

(Hours are recorded by hour meter signal from monitor.)
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

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.
Frequency Distribution Data List
Data Details
1 Engine Speeds Frequency distribution of engine speeds
(Speeds are recorded by signals from N sensor.)
2 Hydraulic Oil Tem- Frequency distribution of hydraulic oil temperature

perature (Temperatures are recorded by signals from hydraulic oil temperature sensor.)
3 Coolant Temperature Frequency distribution of coolant temperature

in Radiator (Temperatures are recorded by signals from coolant temperature 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

Cumulative Operation Hour List
Data Details
1 Engine Operation Hour Cumulative engine operation hours
(Hours are recorded by alternator output signal.)
2 Swing Operation Hour Cumulative swing operation hours

(Hours are recorded by signals from swing pressure sensor.)
3 Travel Operation Hour Cumulative travel operation hours

(Hours are recorded by signals from travel pressure sensor.)
4 Front Attachment Cumulative front attachment operation hours

Operation Hour (Hours are recorded by signals from front attachment pressure sensor.)
5 Breaker Operation Cumulative breaker operation hours

Hour (Hours are recorded by signals from auxiliary pressure sensor and attachment
mode switch.)
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.)
7 *ML Operation Hour Cumulative *ML operation hours

(Hours are recorded by signals from crane mode switch.)
NOTE: ML specification is only available in Japa-

nese domestic market.
T5-7-4

Alarm List
Code Data Details

81 Engine Oil Level Date and time when engine oil level indicator lighted are recorded
by signals from engine oil level switch.
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.
NOTE: In case the above alarms are recorded,

check individual item. If malfunction of the
monitor is found, refer to troubleshooting
C.
NOTE: The monitors mounted on the machines

(Up to serial No.030652) indicate the fail-
ure codes 81 (engine oil level) and 85 (ra-
diator coolant).
T5-7-5

Trouble List
Fault
Trouble Details
Code
01 Abnormal EEPROM Occurrence time and date of fault code 01
02 Abnormal RAM Occurrence time and date of fault code 02
03 Abnormal A/D Conversion Occurrence time and date of fault code 03
04 Abnormal Sensor Voltage Occurrence time and date of fault code 04
06 Abnormal EC Sensor Occurrence time and date of fault code 06
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
64 MC Communication Error Time and date when communication error between MC

and ICX occurred.
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.
NOTE: In case the above fault codes are recorded,

refer to troubleshooting A.
T5-7-6

(Blank)
T5-7-7

ICX FAULT CODE LIST
Fault
Trouble Remarks
Code
1 Abnormal Internal RAM In case of SAM error
2 Abnormal Flush Memory In case of SAM error
3 Abnormal Exterior In case of SAM error or read-write error
4 Abnormal EEPROM In case of SAM error
6 Abnormal Time In case RTC data was other than figures.
7 MC Communication Timeout (For ZAXIS) In case MC communication didnt last for more than 7
seconds.
8 Monitor Communication Timeout In case monitor communication didnt last for more than
24 seconds.
9* MC Communication Timeout (For EX5) In case MC communication didnt last for more than 20
seconds.
10 Satellite Terminal Communication Timeout In case satellite communication didnt last for more than
1 minute.
NOTE * Fault code 9 may be displayed on only the

machine (Type: EX5 with minor change), to
which the ICX is installed later.
SATELLITE TERMINAL FAULT CODE LIST
Fault
Trouble Remarks
Code
101 Satellite Terminal: Internal Error Abnormal EEPROM
102 Satellite Terminal: Internal Error Abnormal sent data
103 Satellite Terminal: Internal Error In case reception is difficult.
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 doesnt match sending data.
T5-7-8

FAULT CODE 1 TO 4 AND 6
YES *Faulty ICX.
Check if all data are normally

cumulated.
Faulty ICX.
NO
*Even if the fault code remains displayed after retrying,

the machine can be operated as it is when data re-
cord is normally cumulated.
FAULT CODE 7 TO 10
Check for continuity between Faulty ICX.

ICX and corresponding com- YES
ponent while referring to the
following table.
Broken harness between ICX
and corresponding compo-
NO nent.
Fault code ICX terminal # Corresponding component terminal #

7 Connector C terminal #11 MC connector D terminal #10
8 Connector B terminal #1 Monitor connector B terminal #3
10 Connector B terminal #5 Satellite terminal DSUb9 pin terminal #2
T5-7-9

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.
Related Data Input Signal

Key switch ON and OFF time Key switch
Engine start and stop time, Engine operating hours (Daily report and cumulative Alternator
operation hour), Engine operating hour distribution
Hour meter Monitor controller
Coolant temperature distribution in radiator Coolant temperature sen-

sor
Remaining fuel level (detected at regular data sending time) Fuel level sensor
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
Engine speed distribution N 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
NOTE: *ML specification is available only in Japa-

nese domestic market.
T5-7-10

Corrective Action Remarks

Check harness between ICX terminal A5 and key In case engine doesnt start, refer to troubleshooting B.
switch terminal M.
Check harness between ICX terminal A2 and alter- In case alternator indicator malfunctions, refer to trou-
nator terminal L. bleshooting C.
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.
T5-7-11

(Blank)
T5-7-12

Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162
SERVICE MANUAL REVISION REQUEST FORM
NAME OF COMPANY: MODEL:

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

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

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

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Technical Manual

Vol No.: TT178E-03

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Consecutive Page Number for Each Group

SAFETY ALERT SYMBOL AND HEADLINE

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

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UNDERSTAND SIGNAL WORDS

On machine safety signs, signal words designating

CAUTION also calls attention to safety messages in

NOTE indicates an additional explanation for an

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to operate the machine.

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posted near your telephone.

WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment

Be sure to wear the correct equipment and clothing

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ADJUST THE OPERATOR'S SEAT

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securely fastened at all times when the machine

MOVE AND OPERATE MACHINE SAFELY

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levers are in neutral.

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PROVIDE SIGNALS FOR FOBS INVOLV-

For jobs involving multiple numbers of machines,

CONFIRM DIRECTION OF MACHINE TO

Incorrect travel pedal/lever operation may result in

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Driving on a slope may cause the machine to slip or

 Driving across the face of a slope or steering on SA-441

a slope may cause the machine to skid or turn-

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H/P mode switch off.

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To avoid back-over and swing accidents:

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MACHINE WILL TIP OVER FASTER THAN YOU

FASTEN YOUR SEAT BELT

The danger of tipping is always present when

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PARK MACHINE SAFELY

 Close windows, roof vent, and cab door.

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All fuels, most lubricants, and some coolants are

 Store flammable fluids well away from fire

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Take the following precautions when loading /

2) Be sure to use a loading dock or ramp.

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 Understand service procedures before doing

Driving across the face of a slope or steering on SA-441

Close windows, roof vent, and cab door.

Store flammable fluids well away from fire

Understand service procedures before doing

Before servicing the machine:

Wait for GEAR OIL to cool, then gradually loosen

The hydraulic oil tank is pressurized. Again, be

Remove paint before welding or heating:

Loose terminals may produce sparks. Securely