Technical Manual (Troubleshooting) of ZX 200-225-230-270 Class

Manual No. : KM-178E Vol. No. : TT178E-03

200·225·230·270 class

Technical Manual (Troubleshooting)

Excavator

200 class 200•200LC•210H•210LCH•210•210LC•210N•240

Technical Manual (Troubleshooting)

225 class 225US•225USLC•225USR•225USRLC

230 class 230•230LC•240H•240LCH•250•250LC•250LCN

270 class 270•270LC•280LC•280LCN

Excavator Service Manual (Manual No. KM-178E) consists of the following three separate volumes; Technical Manual (Operational Principle) : Vol. No. TO178E Technical Manual (Troubleshooting) : Vol. No. TT178E Workshop Manual : Vol. No. W178E

PRINTED IN SINGAPORE (PS)

Zaxis200/225/230/270 new-TM/TSh

1

4/3/03, 12:30 PM

INTRODUCTION TO THE READER • This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine. • Be sure to thoroughly read this manual for correct product information and service procedures.

• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.): 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 to this manual. • The Operator’s Manual • The Parts Catalog

• Operation Manual of the Engine • Parts Catalog of the Engine • Hitachi Training Material

MANUAL COMPOSITION • This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual. • Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.

IN-01

• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures. • Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/disassemble procedures.

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 In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

•

CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.

• IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

•

IN-02

NOTE: Indicates supplementary technical information or know-how.

INTRODUCTION UNITS USED • SI Units (International System of Units) are used in

Example : 24.5 MPa (250 kgf/cm2, 3560 psi)

this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units.

Quantity Length Volume

Weight Force Torque

To Convert From mm mm L L m3 kg N N N⋅m N⋅m

Into in ft US gal US qt yd3 lb kgf lbf kgf⋅m lbf⋅ft

A table for conversion from SI units to other system units is shown below for reference purposees.

Quantity

Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375

Pressure Power Temperature Velocity Flow rate

IN-03

To Convert From MPa MPa kW kW °C km/h min-1 L/min mL/rev

Into kgf/cm2 psi PS HP °F mph rpm US gpm cc/rev

Multiply By 10.197 145.0 1.360 1.341 °C×1.8+32 0.6214 1.0 0.2642 1.0

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 table. Class ZX200 Class ZX225 Class ZX230 Class ZX270 Class Model Std. Model

ZAXIS200, 200LC, 210H, 210LCH, 210, 210LC, 210N, 240 ZAXIS225USR, 225USRLC, 225US, 225USLC ZAXIS230, 230LC, 240H, 240LCH, 250, 250LC, 250LCN ZAXIS270, 270LC, 280LC, 280LCN 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 don’t use any of the designated signal words above after the safety alert symbol are occasionally used on this machine. • 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

SA-1223

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 authorized 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 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 machine 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 authorized dealer before operating or performing maintenance work on the machine. 003-E01B-0003

SA-2

SA-003

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 attached 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, ambulance service, hospital, and fire department posted near your telephone.

SA-437

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. 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

SA-438

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 operator’s 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 operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident. Don’t leave parts and/or tools lying around the operator’s seat. Store them in their specified locations. Avoid storing transparent bottles in the cab. Don’t 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 extinguish the match and/or tobacco. Don’t 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 machine, 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 dismounting 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 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.

SA-237

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. 011-E01A-0426

SA-7

SA-426

SAFETY OPERATE SEAT

ONLY

FROM

OPERATOR'S

• 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 levers are in neutral.

SA-444

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 operator’s manual. • The operator must be in the operator’s 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 machine. S013-E01A-0032

SA-8

SA-032

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 operator’s view, resulting in the machine being operated in an unsafe manner. 014-E01B-0379 SA-379

PROVIDE SIGNALS FOR FOBS INVOLVING 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 coordinate the job site. Make sure that all personnel obey the signal person’s 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 operator’s 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. Don’t 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, approximately 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 a slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure sage operation.

SA-441

WRONG

019-E01D-0492

SA-590

SA-10

SAFETY AVOID INJURY ACCIDENTS

FROM

ROLLAWAY

• 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 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-391

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 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 and operator. • Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling. • Keep windows, mirrors, and lights clean and in good condition. • Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting. • Read and understand all operating instructions in the operator’s manual. S021-E01A-0494

SA-12

SA-383

SA-384

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 injury or death.

SA-012

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 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

SA-440

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 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

SA-014

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. • Close windows, roof vent, and cab door. • Lock all access doors and compartments. 033-E09B-0390

SA-15

SA-390

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. • 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.

SA-018

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. 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

SA-395

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) 2) 3) 4) 5) 6) 7) 8) 9) 10)

Park the machine on a level surface. Lower the bucket to the ground. Turn the auto-idle / acceleration selecltor off. Run the engine at slow idle speed without load for 5 minutes. Turn the key switch to OFF to stop engine. Relieve the pressure in the hydraulic system by moving the control levers several times. Remove the key from the switch. Attach a “Do Not Operate” tag on the control lever. Pull the pilot control shut-off lever to the LOCK position. 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 operator’s manual. Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris. When cleaning parts, always use nonflammable 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 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.

SA-028

SA-527

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, attach 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 jack.

SA-527

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. • Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure.

SA-344

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.)

S522-E01A-0040

SA-21

SA-040

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. • The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.

SA-039

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 operator’s manual.) • Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front 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

SA-019

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 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-031

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 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

SA-019

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, hampering fire fighting. • Check the emergency engine stop switch function 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 machine.

replaced

before

operating

the

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 Operator’s 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 GRINDING

FOR

WELDING

AND

• 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 there are no abnormalities such as the area surrounding the welded area still smoldering.

SA-818

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..

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS • Do not weld or flame cut pipes or tubes that contain flammable fluids. them thoroughly with nonflammable solvent before welding or flame cutting them.

• Clean

510-E01B-0030

SA-27

SA-030

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. 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.

SA-029

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 hydrometer. • 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. Explosion of the battery may result. • 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

SA-032

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. 513-E01A-0405

SA-405

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 safely. Then follow procedures and use recommended equipment. S515-E01A-0309

SA-29

SA-309

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 Earth’s atmosphere. 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.

SA-226

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-30

SA-435

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 Swing Speed .............................................T4-4-5

Operational Performance Standard Table 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 Function Check .....................................T4-4-22

ZAXIS225USR ...................................... T4-2-32 ZAXIS225US......................................... T4-2-36

Boom Raise and Arm Roll-In

ZX230 class .......................................... T4-2-40 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

Combined Operation ...........................T4-4-24

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 quantitatively check all system and functions on the machine. Purpose of Performance Tests 1. To comprehensively evaluate each operational function by comparing the performance test data with the standard values. 2. According to the evaluation results, repair, adjust, or replace parts or components as necessary to restore the machine’s performance to the desired standard. 3. To economically operate the machine under optimal conditions.

The machine performance does not always deteriorate as the working hours increase. However, the machine performance is normally considered to reduce in proportion to the increase of the operation hours. Accordingly, restoring the machine performance by repair, adjustment, or replacement shall consider the number of the machine’s working hours. Definition of “Performance Standard” 1. Operation speed values and dimensions of the new machine. 2. Operational performance of new components adjusted to specifications. Allowable errors will be 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 operational performance of each component such as hydraulic pump, motor, and various kinds of valves. Performance Standards “Performance Standard” is shown in tables to evaluate 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 TESTS

FOR

PERFORMANCE

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 extended. 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 coworkers. Once the test is started, be sure to communicate 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 accidents 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 leaking oil. Use oil pans to catch escaping oil. Pay special attention to this when removing hydraulic pipings.

T105-06-01-003

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 Engine Control Dial : Fast Idle Power Mode Switch : P Mode Auto-Idle/Acceleration Selector : OFF Work Mode Switch : Digging Mode Hydraulic Oil Temperature : 50±5 °C (122±9 °F)

The standard Performance values are listed in the table below. Refer to the Group T4-3 to T4-5 for performance test procedures. Values indicated in parentheses are reference values. 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 PERFORMANCE TEST DESIGNATION -1 ENGINE SPEED min Slow Idle Speed Fast Idle Speed (Normal) Fast Idle Speed (Wirh ECO deactivated)

ZX200 class (Performance Standard) 900+150-100 1950+65-50 2050+65-50

Fast Idle Speed (Relief Operation)

1900+65-50

Fast Idle Speed (E mode)

1800+90-70

Fast Idle Speed (HP mode)

2000 to 2250

Auto-Idle Speed Auto-Acceleration Speed Warming Up Speed ENGINE COMPRESSION PRESSURE 2 (After engine warm-up) MPa (kgf/cm , psi) VALVE CLEARANCE (IN, EX) NOZZLE INJECTION PRESSURE

3.04 (31, 440) 0.4

2

18.1 (185, 2630)

2

18.1 (185, 2630)

MPa (kgf/cm , psi)

NOZZLE INJECTION PRESSURE MPa (kgf/cm , psi)

INJECTION TIMING (Degrees before TDC) LUBRICANT CONSUMPTION (Rated output)

1300+135-100 1650+125-100 1400+140-100

deg. mL/h

Remarks

T4-3-1 Value indicated on Dr. ZX. ↑ ↑ Extend the boom cylinder to relieve the boom raise circuit.Value indicated on Dr. ZX. Value indicated on Dr. ZX. Extend the boom and arm cylinder to relieve the boom raise and arm roll-in circuit. Value indicated on Dr. ZX. Value indicated on Dr. ZX. ↑ ↑ After engine warm-up With the engine cold

T4-2-1

T4-3-4 T4-3-6 T4-3-8 T4-3-8 T4-3-10

10° 50 or less

Reference Page

Hour meter: 2000 hours or less

T4-3-12

OPERATIONAL PERFORMANCE TEST / Standard NOTE: 1 mm=0.03937 in PERFORMANCE TEST DESIGNATION TRAVEL SPEED

ZX200 class (Performance Standard)

13.0±1.2

Slow Speed TRACK REVOLUTION SPEED sec/3 rev Fast Speed Slow Speed MISTRACK mm/20 m (With fast and slow travel speed modes) TRAVEL MOTOR LEAKAGE mm/5 min SWING SPEED sec/3 rev SWING FUNCTION DRIFT CHECK mm /180°

SWING MOTOR LEAKAGE mm/5 min MAXIMUM SWINGABLE SLANT ANGLE deg.

SWING BEARING PLAY HYDRAULIC CYLINDER CYCLE TIME

mm

Travel speed isn’t shifted to fast speed mode one sidetrack is jacked up.

20.0±2.0 T4-4-2 17.2±1.0 26.2±2.0

LC: 18.3±1.0 LC: 27.9±2.0 T4-4-3

200 or less 0 13.5±1.0

Bucket empty

1254 or less

Bucket empty

0 22° or possibly more 0.2 to 1.25

Bucket loaded Bucket loaded

T4-4-8 T4-4-10

Allowable limit: 2.0 to 3.05 2.91 m arm 0.8 m3 (PCSA heaped) bucket, bucket empty

T4-4-12 T4-4-14

2.91m arm 0.8 m3 (PCSA heaped) bucket

T4-4-16

sec

Boom Cylinder (Maximum Reach Position) (Arm Roll-In position) Arm Cylinder (Maximum Reach Position) (Arm Roll-In position) Bucket Cylinder (Maximum Reach Position) (Arm Roll-In position) Bucket Bottom (Maximum Reach Position) (Arm Roll-In position)

Reference Page T4-4-1

sec/20 m

Fast Speed

Boom Raise Boom Lower Arm Roll-In Arm Roll-Out Bucket Roll-In Bucket Roll-Out DIG FUNCTION DRIFT CHECK

Remarks

T4-4-4 T4-4-5 T4-4-6

3.1±0.3 2.3±0.3 3.8±0.3 2.8±0.3 3.4±0.3 2.3±0.3 mm/5 min

20 or less 5 or less

Bucket loaded Bucket empty







T4-2-2

OPERATIONAL PERFORMANCE TEST / Standard NOTE: 1 mm=0.03937 in PERFORMANCE TEST DESIGNATION


CONTROL LEVER OPERATING FORCE

Remarks

Reference Page

HITACHI lever pattern

T4-4-18


T4-4-20

2.91 m arm 0.8 m3 (PCSA heaped) bucket, bucket empty

T4-4-22


T4-4-24

N (kgf, lbf･ft)

Boom Lever Arm Lever (ISO Lever Pattern: Swing Lever) Bucket Lever

18 (1.8, 13) or less 15 (1.5, 10.8) or less 15 (1.5, 10.8) or less 18 (1.8, 13) or less

Swing Lever (ISO Lever Pattern: Arm Lever) Travel Lever

28 (2.8, 20.3) or less

CONTROL LEVER STROKE Boom Lever Arm Lever (ISO Lever Pattern: Swing Lever) Bucket Lever Swing Lever (ISO Lever Pattern: Arm Lever) Travel Lever BOOM RAISE/SWING

mm

105±10 84±10 84±10 105±10 120±10 sec

3.6±0.3 (Bucket Teeth Height: H) BOOM RAISE/ARM ROLL-IN

mm

6700 or more

sec

4.5±0.5 PRIMARY PILOT PRESSURE

T4-5-1 2

MPa (kgf/cm , psi)

Engine: Fast Idle

4.0+1.0-0.5 580+142-71) 3.5+1.0-0 +10 (35 -0, 500+142-0) 3.4 to 4.0 (34 to 40, 483 to 570) Value Indicated On Dr. ZX±0.2 (2, 28) 0.7+1.0-0.5 +10 (7 -5, 100+142-71) (41+10-5,

Engine: Slow Idle SECONDARY PILOT PRESSURE) (Engine: Fast Idle and Slow Idle) 2

MPa (kgf/cm , psi)

SOLENOID VALVE SET PRESSURE 2

MPa (kgf/cm , psi)

MAIN PUMP DELIVERY PRESSURE 2

MPa (kgf/cm , psi)

T4-2-3

Value indicated on Dr. ZX (Lever: Full stroke)

T4-5-4

T4-5-6 Value indicated on Dr. ZX

T4-5-9

OPERATIONAL PERFORMANCE TEST / Standard

PERFORMANCE TEST DESIGNATION


NOTE: 1 mm=0.03937 in Reference Remarks Page T4-5-10

MAIN RELIEF VALVE SET PRESSURE 2

MPa (kgf/cm , psi)

34.3+2.0-0.5 (350+20-5, 4980+284-71) Power Boost 36.3+2.0-1.0 (370+20-10, 5260+284-142) 2 RELIEF PRESSURE MPa (kgf/cm , psi) 31.9+2.3-0 (When relieving Swing) (325+25-0, 4620+356-0) 2 RELIEF PRESSURE MPa (kgf/cm , psi) 34.3+2.0-0.5 (When relieving Travel) (350+20-5, 4980+284-71) OVERLOAD RELIEF VALVE SET PRES- (Reference values 2 SURE MPa (kgf/cm , psi) at 50 L/min) Boom (Raise/Lower), Arm Roll-In, and 37.3+1.0-0 Bucket Roll-In (380+10-0, 5400+142-0) Arm Roll-Out, Bucket Roll-Out 39.2+1.0-0 (400+10-0, 5690+142-0) MAIN PUMP FLOW TEST (L/min) SWING MOTOR DRAINAGE (L/min) With constant maximum speed 0.2 to 0.3 With the motor relieved (2 to 5) TRAVEL MOTOR DRAINAGE (L/min) With the track jacked up 1.4 to 2.1 With the motor relieved 1.4 to 4.0 Boom, Arm, and Bucket

T4-2-4

Value indicated on Dr. ZX



T4-5-14


T4-5-16

T4-5-18

Refer to page T4-2-22, 23.

T4-5-22 T4-5-29

T4-5-32 Allowable limit: 2.6 Allowable limit: 5.0

OPERATIONAL PERFORMANCE TEST / Standard ZAXIS225USR OPERATIONAL PERFORMANCE STANDARD TABLE Engine Control Dial : Fast Idle Power Mode Switch : P Mode Auto-Idle/Acceleration Selector : OFF Work Mode Switch : Digging Mode Hydraulic Oil Temperature : 50±5 °C (122±9 °F)



ZAXIS225USR (Performance Standard) 950±100 1965±50 2060±50 1915±50


1820±70 2000 to 2250

Auto-Idle Speed Auto-Acceleration Speed Warming Up Speed ENGINE COMPRESSION PRESSURE 2 (After engine warm-up) MPa (kgf/cm , psi) VALVE CLEARANCE (IN, EX) NOZZLE INJECTION PRESSURE 2

MPa (kgf/cm , psi)


deg. mL/h




Remarks

1335±100 1675±100 1400+140-100 3.04 (31, 440) 0.4

Value indicated on Dr. ZX. ↑ ↑ Extend the boom cylinder to relieve the boom raise circuit.Value indicated on Dr. ZX. Value indicated on Dr. ZX. Extend the boom and arm cylinder to relieve the boom raise and arm roll-in circuit. Value indicated on Dr. ZX. Value indicated on Dr. ZX. ↑ ↑ After engine warm-up With the engine cold

18.1 (185, 2630)

T4-2-5

T4-3-6 T4-3-8 T4-3-10

10° 50 or less

T4-3-4


T4-3-12



21.8±2.0 T4-4-2

sec/3 rev

Slow Speed MISTRACK mm/20 m (With fast and slow travel speed modes) TRAVEL MOTOR LEAKAGE mm/5 min SWING SPEED sec/3 rev SWING FUNCTION DRIFT CHECK mm /180°



mm

17.8±1.0

LC: 18.9±1.0

28.2±2.0

LC: 30.1±2.0 T4-4-3

200 or less 0 13.5±1.0

Bucket empty

1254 or less

Bucket empty



T4-4-8 T4-4-10


T4-4-12 T4-4-14


T4-4-16

sec



13.6±1.2

Fast Speed


Remarks

sec/20 m

Fast Speed Slow Speed TRACK REVOLUTION SPEED

ZAXIS225USR (Performance Standard)

T4-4-4 T4-4-5 T4-4-6

3.1±0.3 2.3±0.3 3.8±0.3 2.8±0.3 3.4±0.3 2.3±0.3 mm/5 min









T4-2-6




Remarks

Reference Page


T4-4-18


T4-4-20


T4-4-22


T4-4-24

N (kgf, lbf･ft)




28 (2.8, 20.3) or less


mm

105±10 84±10 84±10 105±10 120±10 sec


mm

6500 or more

sec


T4-5-1 2

MPa (kgf/cm , psi)

Engine: Fast Idle

4.0+1.0-0.5 580+142-71) 3.5+1.0-0 +10 (35 -0, 500+142-0) 3.4 to 4.0 (34 to 40, 483 to 570) Value Indicated On Dr. ZX±0.2 (2,28) 0.7+1.0-0.5 +10 (7 -5, 100+142-71) (41+10-5,


MPa (kgf/cm , psi)


MPa (kgf/cm , psi)


MPa (kgf/cm , psi)

T4-2-7


T4-5-4


T4-5-9






MPa (kgf/cm , psi)


T4-2-8




T4-5-14


T4-5-16

T4-5-18


T4-5-22 T4-5-29


OPERATIONAL PERFORMANCE TEST / Standard ZAXIS225US OPERATIONAL PERFORMANCE STANDARD TABLE Engine Control Dial : Fast Idle Power Mode Switch : P Mode Auto-Idle/Acceleration Selector : OFF Work Mode Switch : Digging Mode Hydraulic Oil Temperature : 50±5 °C (122±9 °F)



ZAXIS225US (Performance Standard) 950±100 1965±50 2065±50 1915±50


1820±70 2000 to 2250


MPa (kgf/cm , psi)


deg. mL/h




Remarks

1335±100 1675±100 1400+140-100 3.04 (31, 440) 0.4

Value indicated on Dr. ZX. ↑ ↑ Extend the boom cylinder to relieve the boom raise circuit.Value indicated on Dr. ZX. Value indicated on Dr. ZX. Extend the boom and arm cylinder to relieve the boom raise and arm roll-in circuit. Value indicated on Dr. ZX. Value indicated on Dr. ZX. ↑ ↑ After engine warm-up With the engine cold

18.1 (185, 2630)

T4-2-9

T4-3-6 T4-3-8 T4-3-10

10° 50 or less

T4-3-4


T4-3-12



21.8±2.0 T4-4-2

sec/3 rev




mm

17.8±1.0

LC: 18.9±1.0

28.2±2.0

LC: 30.1±2.0 T4-4-3

200 or less 0 13.5±1.0

Bucket empty

1254 or less

Bucket empty



T4-4-8 T4-4-10


T4-4-12 T4-4-14


T4-4-16

sec



13.6±1.2

Fast Speed


Remarks

sec/20 m


ZAXIS225US (Performance Standard)

T4-4-4 T4-4-5 T4-4-6

3.8±0.3 3.0±0.3 3.8±0.3 2.8±0.3 3.4±0.3 2.3±0.3 mm/5 min









T4-2-10




Remarks

Reference Page


T4-4-18


T4-4-20


T4-4-22


T4-4-24

N (kgf, lbf･ft)




28 (2.8, 20.3) or less


mm

105±10 84±10 84±10 105±10 120±10 sec


mm

6800 or more

sec


T4-5-1 2

MPa (kgf/cm , psi)

Engine: Fast Idle

4.0+1.0-0.5 580+142-71) 3.5+1.0-0 +10 (35 -0, 500+142-0) 3.4 to 4.0 (34 to 40, 483 to 570) Value Indicated On Dr. ZX±0.2 (2.28) 0.7+1.0-0.5 +10 (7 -5, 100+142-71) (41+10-5,


MPa (kgf/cm , psi)


MPa (kgf/cm , psi)


MPa (kgf/cm , psi)

T4-2-11


T4-5-4


T4-5-9






MPa (kgf/cm , psi)


T4-2-12




T4-5-14


T4-5-16

T4-5-18


T4-5-22 T4-5-29







2000+65-50


1980+90-70


2000 to 2250


MPa (kgf/cm , psi)


deg. mL/h

1300+135-100 1750+125-100 1400+140-100 3.04 (31, 440) 0.4

Remarks


18.1 (185, 2630)

T4-2-13

T4-3-4 T4-3-6 T4-3-8 T4-3-10

10° 60 or less

Reference Page


T4-3-12



12.9±1.0

Slow Speed TRACK REVOLUTION SPEED sec/3 rev Fast Speed Slow Speed MISTRACK mm/20 m (With fast and slow travel speed modes) TRAVEL MOTOR LEAKAGE mm/5 min SWING SPEED sec/3 rev SWING FUNCTION DRIFT CHECK mm /180°



mm


21.0±2.0 T4-4-2 17.1±1.0 28.2±2.0

LC: 18.7±1.0 LC: 30.0±2.0 T4-4-3

200 or less 0 14.3±1.0

Bucket empty

1730 or less

Bucket empty



T4-4-8 T4-4-10


T4-4-12 T4-4-14

2.96 m arm 1.0 m3 (PCSA heaped) bucket

T4-4-16

sec



sec/20 m

Fast Speed


Remarks

T4-4-4 T4-4-5 T4-4-6

3.3±0.3 2.5±0.3 4.1±0.3 2.9±0.3 4.1±0.3 2.5±0.3 mm/5 min









T4-2-14




Remarks

Reference Page


T4-4-18


T4-4-20


T4-4-22


T4-4-24

N (kgf, lbf･ft)




28 (2.8, 20.3) or less


mm

105±10 84±10 84±10 105±10 120±10 sec


mm

6550 or more

sec


T4-5-1 2

MPa (kgf/cm , psi)

Engine: Fast Idle



MPa (kgf/cm , psi)


MPa (kgf/cm , psi)


MPa (kgf/cm , psi)

T4-2-15

Value indicated on Dr. ZX Value indicated on Dr. ZX Value indicated on Dr. ZX (Lever: Full stroke)

T4-5-4


T4-5-9






MPa (kgf/cm , psi)

34.3+2.0-0.5 (350+20-5, 4980+284-71) Power Boost 36.3+2.0-1.0 (370+20-10, 5260+284-142) 2 RELIEF PRESSURE MPa (kgf/cm , psi) 30.9+2.20-0.5 (When relieving Swing) (315+23-5, 4479+327-71) 2 RELIEF PRESSURE MPa (kgf/cm , psi) 34.3+2.0-0.5 (When relieving Travel) (350+20-5, 4980+284-71) OVERLOAD RELIEF VALVE SET PRES- (Reference values 2 SURE MPa (kgf/cm , psi) at 50 L/min) Boom (Raise/Lower), Arm Roll-In, and 37.2+1.0-0 Bucket Roll-In (379+10-0, 5389+142-0) Arm Roll-Out, Bucket Roll-Out 39.2+1.0-0 (400+10-0, 5690+142-0) MAIN PUMP FLOW TEST (L/min) SWING MOTOR DRAINAGE (L/min) With constant maximum speed 0.2 to 0.5 With the motor relieved (2 to 5) TRAVEL MOTOR DRAINAGE (L/min) With the track jacked up 1.4 to 2.1 With the motor relieved 1.4 to 4.0 Boom, Arm, and Bucket

T4-2-16




T4-5-14


T4-5-16

T4-5-18


T4-5-22 T4-5-29







2050+65-50


2030+90-70


2050 to 2300


MPa (kgf/cm , psi)


deg. mL/h

1300+135-100 1800+125-100 1400+140-100 3.04 (31, 440) 0.4

Remarks


18.1 (185, 2630)

T4-2-17

T4-3-4 T4-3-6 T4-3-8 T4-3-10

10° 60 or less

Reference Page


T4-3-12



24.8±2.0 T4-4-2

sec/3 rev




mm

34.6±2.0

LC: 36.1±2.0

34.6±2.0

LC: 36.1±2.0 T4-4-3

200 or less 0 14.9±1.0

Bucket empty

1483 or less

Bucket empty



T4-4-8 T4-4-10


T4-4-12 T4-4-14


T4-4-16

sec



14.7±1.2

Fast Speed


Remarks

sec/20 m



T4-4-4 T4-4-5 T4-4-6

3.6±0.3 2.6±0.3 3.9±0.3 3.0±0.3 4.3±0.3 2.5±0.3 mm/5 min









T4-2-18




Remarks

Reference Page


T4-4-18


T4-4-20


T4-4-22


T4-4-24

N (kgf, lbf･ft)




28 (2.8, 20.3) or less


mm

105±10 84±10 84±10 105±10 120±10 sec


mm

6600 or more

sec


T4-5-1 2

MPa (kgf/cm , psi)

Engine: Fast Idle



MPa (kgf/cm , psi)


MPa (kgf/cm , psi)


MPa (kgf/cm , psi)

T4-2-19

Value indicated on Dr. ZX Value indicated on Dr. ZX Value indicated on Dr. ZX (Lever: Full stroke)

T4-5-4


T4-5-9






MPa (kgf/cm , psi)

34.3+2.0-0.5 (350+20-5, 4980+284-71) Power Boost 36.3+2.0-1.0 (370+20-10, 5260+284-142) 2 RELIEF PRESSURE MPa (kgf/cm , psi) 31.4+2.3-0.5 (When relieving Swing) (320+23-5, 4550+327-71) 2 RELIEF PRESSURE MPa (kgf/cm , psi) 34.3+2.0-0.5 (When relieving Travel) (350+20-5, 4980+284-71) OVERLOAD RELIEF VALVE SET PRES- (Reference values 2 SURE MPa (kgf/cm , psi) at 50 L/min) Boom (Raise/Lower), Arm Roll-In, and 37.2+1.0-0 Bucket Roll-In (379+10-0, 5389+142-0) Arm Roll-Out, Bucket Roll-Out 39.2+1.0-0 (400+10-0, 5690+142-0) MAIN PUMP FLOW TEST (L/min) SWING MOTOR DRAINAGE (L/min) With constant maximum speed 0.2 to 0.6 With the motor relieved (5 to 12) TRAVEL MOTOR DRAINAGE (L/min) With the track jacked up 3.0 With the motor relieved 6.0 Boom, Arm, and Bucket

T4-2-20




T4-5-15


T4-5-17

T4-5-18


T4-5-22 T4-5-29

T4-5-32 Allowable limit: 5 or more

OPERATIONAL PERFORMANCE TEST / Standard (Blank)

T4-2-21

OPERATIONAL PERFORMANCE TEST / Standard 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)

Flow Rate Delivery Pressure MPa (kgf/cm2, psi) L/min (gpm) A 3.9 (40, 570) 194±3 (51.2±0.8) B 13.9 (142, 2020) [192] ([50.7]) C 16.7 (170, 2420) 163±6 (43.1±1.6) D 20.5 (209, 2970) [123] ([32.5]) E 26.9 (274, 3900) 99±6 (26.2±1.6) F 34.3 (350, 4980) 72±6 (19.0±1.6) The value indicated in parentheses is only a reference value.

• Rated Pump Speed:

ZX200, 225 class: 1900 min-1 (rpm) ZX230 class: 2000±10 min-1 (rpm) ZX270 class: 2050±10 min-1 (rpm) • Hydraulic Oil Temperature: 50±5 °C (122±9 °F) NOTE: Refer to T4-5-22.

• ZX230 class Points on P-Q Line


Flow Rate Delivery Pressure MPa (kgf/cm2) L/min A 3.9 (40) 204±3 B 12.7 (130) 202+3-6 C 15.6 (159) [202] D 17.6 (180) 178±6 E 21.0 (214) [141] F 27.1 (277) 115±6 The valve indicated in parentheses is only a reference valve.

L/min

Flow Rate Delivery Pressure MPa (kgf/cm2) L/min A 3.9 (40) 209±3 B 14.7 (150) 207±3 C 16.5 (168) [207] D 18.6 (190) 182±6 E 21.1 (215) [153] F 27.4 (280) 126±6 The valve indicated in parentheses is only a reference valve.

A B

C

Flow Rate

D

E

F

Delivery Pressure

T4-2-22

MPa (kgf/cm2) T178-04-05-001

OPERATIONAL PERFORMANCE TEST / Standard • P-Q Control by Pump Control Pilot Pressure Signal • ZX200 class, 225 class

∗ (REFERENCE: Measured at Test Stand)

Points on P-Q Line Pump Control Pressure MPa (kgf/cm2, psi)

• Rated Pump Speed:

ZX200 class, 225 class: 1900 min-1 (rpm) ZX230 class: 2000±10 min-1 (rpm) ZX270 class: 2050±10 min-1 (rpm) • Hydraulic Oil Temperature: 50±5 °C (122±9 °F)

1.7±0.05

A

(17±0.5, 242±7)

B NOTE: Refer to T4-5-24.

Flow Rate L/min (gpm)

A

−

62+6−0

B

1.7±0.05 (17±0.5)

C

[92] ([243])

9+0.05−0.3

194±3 (51.2±0.8) (30+0.5−3, 427+7−43) The value indicated in parentheses is only a reference value.

Pump Control Pressure MPa (kgf/cm2, psi)

(30+0.5−3)

67±2 (17.7±0.5)

2.0 (20, 284)

C


2.9+0.05−0.29


• ZX270 class Points on P-Q Line Pump Control Pressure MPa (kgf/cm2, psi)


71±2

A

−

75+6−0

204±3

B

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

B Flow Rate

A

MPa (kgf/cm2) Pump Control Pressure T178-04-05-004

T4-2-23

OPERATIONAL PERFORMANCE TEST / Standard INJECTION PUMP ZX200 class, 225 class Test Conditions: 1. Injection pump: PES6AD 101061-8830 2. Governor: EP/RSV 105419-1660 3. Nozzle and nozzle holder assembly: 105780-8140 (Bosch No. EF8511/9A) 4. Nozzle: 105780-0000 (Bosch No. DN12SD12T) 5. Nozzle holder: 105780-2080 (Bosch No. EF8511/9) 6. Nozzle opening pressure: 17.2 MPa (175 kgf/cm2, 2490 psi) 7. Test fuel: ISO 4113 or SAE J967d

8. Transfer pump pressure: 157 kPa (1.6 kgf/cm2, 23 psi) 9. Injection pipe: Inner Dia. 2 mm×Outer Dia. 6 mm-Length 600 mm (0.079×0.236-23.6 in) 10. Fuel temperature: 40+5 °C (104+9 °F) 11. Overflow valve opening pressure: 127 kPa (1.3 kgf/cm2, 18.5 psi) NOTE: The nozzle test injection pressure is 17.2 MPa (175 kgf/cm2, 2490 psi). However, actual machine injection pressure is 18.1 MPa (185 kgf/cm2, 2630 psi).

Injection rate adjustment Adjusting Point

Pump Speed -1 (mm )

Rack Position (mm)

Strokes

Average Injection Rate 3 (cm /1000 Stroke)

Maximum Variance Between Cylinders (%)

Fixed

Remarks Basic

A

1075

10.3

89±1.5

±2

Lever

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 Rack Position (mm)

A

10.3 9.8±0.1 8.0 C

7.5

10.2-0.5

7.3±0.3

0

450

240 350

(500)

1075 1200 (1110) 1125 -1

Pump Speed min (rpm)

T4-2-24

T178-04-05-003

OPERATIONAL PERFORMANCE TEST / Standard ZX230 class Test Conditions: 1. Injection pump: PES6AD 101605-0090 2. Governor: EP/RSV 105411-2300 3. Nozzle and nozzle holder assembly: 105780-8140 (Bosch No. EF8511/9A) 4. Nozzle: 105780-0000 (Bosch No. DN12SD12T) 5. Nozzle holder: 105780-2080 (Bosch No. EF8511/9) 6. Nozzle opening pressure: 17.2 MPa (175 kgf/cm2, 2490 psi) 7. Test fuel: ISO 4113 or SAE J967d

8. Transfer pump pressure: 255 kPa (2.6 kgf/cm2, 37 psi) 9. Injection pipe: Inner Dia. 2 mm×Outer Dia. 6 mm-Length 600 mm (0.079×0.236-23.6 in) 10. Fuel temperature: 40+5 °C (104+9 °F) 11. Overflow valve opening pressure: 255 kPa (2.6 kgf/cm2, 37 psi) NOTE: The nozzle test injection pressure is 17.2 MPa (175 kgf/cm2, 2490 psi). However, actual machine injection pressure is 18.1 MPa (185 kgf/cm2, 2630 psi).


Pump Speed -1 (mm )

Rack Position (mm)

Strokes



Fixed

Remarks Basic

A

1050

10.4

95±1.5

±2

Lever

C

450

Approx. 7.3

12±1.3

±14

Rack

D

100

-

105±5

-

Lever

Rack limit

Governor adjustment

Above

Rack limit Idle-sub spring setting Governor spring setting

Rack Position (mm)

-1


T4-2-25

T1HD-04-05-001

OPERATIONAL PERFORMANCE TEST / Standard ZX270 class Test Conditions: 1. Injection pump: PES6AD 101605-0100 2. Governor: EP/RSV 105411-2300 3. Nozzle and nozzle holder assembly: 105780-8140 (Bosch No. EF8511/9A) 4. Nozzle: 105780-0000 (Bosch No. DN12SD12T) 5. Nozzle holder: 105780-2080 (Bosch No. EF8511/9) 6. Nozzle opening pressure: 17.2 MPa (175 kgf/cm2, 2490 psi) 7. Test fuel: ISO 4113 or SAE J967d

8. Transfer pump pressure: 255 kPa (2.6 kgf/cm2, 37 psi) 9. Injection pipe: Inner Dia. 2 mm×Outer Dia. 6 mm-Length 600 mm (0.079×0.236-23.6 in) 10. Fuel temperature: 40+5 °C (104+9 °F) 11. Overflow valve opening pressure: 255 kPa (2.6 kgf/cm2, 37 psi) NOTE: The nozzle test injection pressure is 17.2 MPa (175 kgf/cm2, 2490 psi). However, actual machine injection pressure is 18.1 MPa (185 kgf/cm2, 2630 psi).


Pump Speed -1 (mm )

Rack Position (mm)



Fixed

Boost (kPa)

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

Remarks

Rack limit

Governor adjustment

Above

Rack limit Idle-sub spring setting Boost compensation: 0.3±0.1mm Governor spring setting

-1


T4-2-26

T1HG-04-05-001

OPERATIONAL PERFORMANCE TEST / Standard (Blank)

T4-2-27

OPERATIONAL PERFORMANCE TEST / Standard ZX200 CLASS DR. ZX MONITOR INDICATING VALUES ∗

Unless specified, test under the following conditions. Engine Speed: Fast Idle Work Mode Switch: Digging Mode Power Mode Switch: P mode Auto-Idle/Acceleration Selector: OFF

Item PUMP 1 PRESSURE (MPa) ∗ Control Lever in Neutral ∗ Boom Raise ∗ Boom Lower ∗ Arm Roll-in ∗ Arm Roll-Out ∗ Bucket Roll-Out Bucket Roll-In* Boom Raise + Arm Roll-In + Bucket Roll-In Combined ∗ Operation PUMP 2 PRESSURE (MPa) ∗ Control Lever in Neutral ∗ Boom Raise ∗ Boom Lower ∗ Arm Roll-in ∗ Arm Roll-Out ∗ Bucket Roll-Out ∗ Bucket Roll-In Boom Raise + Arm Roll-In + Bucket Roll-In Combined ∗ Operation

Reference Value

First

NOTE: Items marked ( ) are measurable with the built-in diagnosing system. ∗∗ Items marked ( ) are measurable with the built-in diagnosing system. However, it may be difficult to read the measured value while operating the machine. Measured Value Second Third

Average

Remarks

0.5 23.3 35.0 35.0 35.3 35.5

When relieving When relieving When relieving When relieving

34.8

When relieving

When relieving

0.5 21.1 34.8 34.8 0.8 0.8


34.5

When relieving

When relieving

T4-2-28


Item PUMP 1 PUMP CONTROL PRESSURE (MPa) ∗ Control Lever in Neutral ∗ Boom Raise ∗ Boom Lower ∗ Arm Roll-in ∗ Arm Roll-Out ∗ Bucket Roll-Out ∗ Bucket Roll-In Boom Raise + Arm Roll-In + Bucket Roll-In Combined ∗ Operation PUMP 2 PUMP CONTROL PRESSURE (MPa) ∗ Control Lever in Neutral ∗ Boom Raise ∗ Boom Lower ∗ Arm Roll-in ∗ Arm Roll-Out ∗ Bucket Roll-Out ∗ Bucket Roll-In Boom Raise + Arm Roll-In + Bucket Roll-In Combined ∗ Operation

Reference Value

First

Measured Value Second Third

Average

Remarks

1.06 3.67 3.64 3.61 3.90 3.82


3.67

When relieving

When relieving

0.08 3.90 3.89 3.84 1.03 1.03


3.87

When relieving

When relieving

T4-2-29

OPERATIONAL PERFORMANCE TEST / Standard Reference Value

Item TARGET ENGINE SPEED (min-1) ∗ Fast Idle Fast Idle ∗ (When operating a control lever) ∗ Fast Idle (HP Mode) ∗ Fast Idle (E Mode) ∗ Auto-Idle ∗ Slow Idle ACTUAL ENGINE SPEED (min-1) ∗ Fast Idle Fast Idle ∗ (When operating a control lever) ∗ Fast Idle (HP Mode) ∗ Fast Idle (E Mode) ∗ Auto-Idle ∗ Slow Idle ENGINE SPEED DEVIATION

First

1800 1900 2100 1650 1150 750 2010 1920 2170 1700 1330 920

-1

∗

(min )

Fast Idle Fast Idle ∗ (When operating a control lever) ∗ Fast Idle (HP Mode) ∗ Fast Idle (E Mode) ∗ Auto-Idle ∗ Slow Idle EC ANGLE (Volt) ∗ Minimum ∗ Maximum DIAL ANGLE (Volt) ∗ Minimum ∗ Maximum

208 22 76 92 186 174 2.53 3.20 0.54 4.33

T4-2-30


Average

Remarks


Item BOOM RAISE PILOT ∗ CONTROL PRESSURE (MPa) ARM ROLL-IN PILOT ∗ (MPa) CONTROL PRESSURE SWING PILOT CONTROL ∗ PRESSURE (MPa) TRAVEL PILOT CONTROL ∗ (MPa) PRESSURE FRONT ATTACHMENT ∗ CONTROL PRESSURE (MPa) PUMP 2 PROPORTIONAL VALVE OUTPUT MAIN PUMP TORQUE PROPORTIONAL BALVE OUTPUT ARM FLOW RATE PROPOR∗∗∗ TIONAL VALVE OUTPUT

First


Average

Remarks

4.15

When relieving

4.07

When relieving

4.05 “ON-OFF” is displayed

3.92

Engine Slow Idle + Travel

1.45

(MPa)

Lever in Neutral Swing and Arm Roll-In Combined Operation ARM REGENERATIVE PROPORTIONAL VALVE OUTPUT

1.16 1.13

(MPa)

Lever in Neutral Swing, Arm Roll-In, and Boom Raise Combined Operation POWER DIGGING CONTROL PRESSURE (MPa) During Operation When Relieving Boom Raise Circuit TRAVEL MOTOR CONTROL PRESSURE (MPa) EC MOTOR POSITION (Step)

1.16 2.72

2.92 2.92 2.92

Traveling, Travel Mode Switch: Fast

376

When relieving arm roll-in circuit

NOTE: Up to serial No.104678

T4-2-31

OPERATIONAL PERFORMANCE TEST / Standard ZAXIS225USR DR. ZX MONITOR INDICATING VALUES ∗



Reference Value

First


Average

Remarks

0.3 37.9 35.0 35.2 35.7 36.2


35.2

When relieving

When relieving

0.3 37.9 35.0 35.0 0.8 0.8


35.5

When relieving

When relieving

T4-2-32



Reference Value

First


Average

Remarks

0.98 3.80 3.80 3.82 3.93 3.90


3.85

When relieving

When relieving

0.98 3.80 3.80 3.82 1.01 0.98


3.82

When relieving

When relieving

T4-2-33



First

1800 1900 2100 1650 1150 750 1980 1910 2190 1830 1360 990

-1

∗

(min )

Fast Idle Fast Idle ∗ (When operating a control lever) ∗ Fast Idle (HP Mode) ∗ Fast Idle (E Mode) ∗ Auto-Idle ∗ Slow Idle EC ANGLE (Volt) ∗ Minimum ∗ Maximum ∗ Maximum (HP Mode) ∗ Maximum (E Mode) DIAL ANGLE (Volt) ∗ Minimum ∗ Maximum

178 20 88 188 216 246 2.49 3.16 3.49 3.08 0.46 4.39

T4-2-34


Average

Remarks


Item

Reference Value

BOOM RAISE PILOT ∗ CONTROL PRESSURE (MPa) ARM ROLL-IN PILOT ∗ (MPa) CONTROL PRESSURE SWING PILOT CONTROL ∗ PRESSURE (MPa) TRAVEL PILOT CONTROL ∗ (MPa) PRESSURE FRONT ATTACHMENT ∗ CONTROL PRESSURE (MPa) PUMP 2 PROPORTIONAL VALVE OUTPUT MAIN PUMP TORQUE PROPORTIONAL BALVE OUTPUT ARM FLOW RATE PROPORTIONAL VALVE OUTPUT (MPa) Lever in Neutral Swing and Arm Roll-In Combined Operation ARM REGENERATIVE PROPORTIONAL VALVE OUT∗∗∗ PUT (MPa) Lever in Neutral Swing, Arm Roll-In, and Boom Raise Combined Operation POWER DIGGING CONTROL PRESSURE (MPa) During Operation When Relieving Boom Raise Circuit TRAVEL MOTOR CONTROL PRESSURE (MPa) EC MOTOR POSITION (Step) Minimum Maximum Maximum (Arm Roll-in Relief)

First


Average

Remarks

3.88

When relieving

3.67

When relieving


3.92


1.33

0.79 1.02

1.16 2.72

2.92 2.92

Auto-Power Lift Control

2.92


0 304 336

NOTE: *** Up to serial No.104678

T4-2-35

OPERATIONAL PERFORMANCE TEST / Standard ZAXIS225US DR. ZX MONITOR INDICATING VALUES ∗



Reference Value

First


Average

Remarks

0.8 32.6 35.5 35.5 36.0 36.0


35.2

When relieving

When relieving

0.5 19.9 35.5 35.5 0.5 0.5


35.2

When relieving

When relieving

T4-2-36



Reference Value

First


Average

Remarks

0.98 2.43 3.67 3.69 3.77 3.75


3.67

When relieving

When relieving

0.95 2.40 3.64 3.69 0.98 0.95


3.67

When relieving

When relieving

T4-2-37


Item TARGET ENGINE SPEED (min-1) ∗ Fast Idle Fast Idle ∗ (When operating a control lever) ∗ Fast Idle (HP Mode) ∗

Fast Idle (E Mode) ∗ Auto-Idle ∗ Slow Idle ACTUAL ENGINE SPEED (min-1) ∗ Fast Idle Fast Idle ∗ (When operating a control lever) ∗ Fast Idle (HP Mode) ∗

Fast Idle (E Mode) ∗ Auto-Idle ∗ Slow Idle ENGINE SPEED DEVIATION

First


Average

Remarks

1800 1900 2100

Arm Roll-In Relief

1650 1150 750 2010 1860 2120

Arm Roll-In Relief

1850 1350 940 -1

(min )

∗

Fast Idle Fast Idle ∗ (When operating a control lever) ∗ Fast Idle (HP Mode) Fast Idle (E Mode) ∗ Auto-Idle ∗ Slow Idle EC ANGLE ∗ Minimum ∗ Maximum DIAL ANGLE ∗ Minimum ∗ Maximum

∗

216 36 14

Arm Roll-In Relief

204 198 198 (Volt)

2.51 3.20 (Volt)

0.44 4.19

T4-2-38


Item

Reference Value

BOOM RAISE PILOT ∗ CONTROL PRESSURE (MPa) When Relieving During Operation ARM ROLL-IN PILOT ∗ CONTROL PRESSURE (MPa) SWING PILOT CONTROL ∗ (MPa) PRESSURE TRAVEL PILOT CONTROL ∗ PRESSURE (MPa) FRONT ATTACHMENT ∗ CONTROL PRESSURE (MPa) PUMP 2 PROPORTIONAL VALVE OUTPUT MAIN PUMP TORQUE PROPORTIONAL BALVE OUTPUT ARM FLOW RATE PROPORTIONAL VALVE OUTPUT (MPa) Lever in Neutral Swing and Arm Roll-In Combined Operation ARM REGENERATIVE PROPORTIONAL VALVE OUT∗∗∗ PUT (MPa) Lever in Neutral Swing, Arm Roll-In, and Boom Raise Combined Operation POWER DIGGING CONTROL PRESSURE (MPa) During Operation When Relieving Boom Raise Circuit TRAVEL MOTOR CONTROL PRESSURE (MPa) EC MOTOR POSITION (Step) Minimum Maximum Maximum (Arm Roll-in Relief)

First


Average

Remarks

1.46 3.86 3.81

When relieving


3.92


1.57

0.79 1.54

1.16 1.36

2.92 2.92 Traveling, Travel Mode Switch: Fast

2.92 0 324 360


T4-2-39




Reference Value

First


Average

Remarks

0.8 37.4 34.3 34.5 35.0 35.2


34.3

When relieving

When relieving

0.8 37.1 34.3 34.5 1.0 0.8


34.3

When relieving

When relieving

T4-2-40



Reference Value

First


Average

Remarks

1.03 3.69 3.69 3.72 3.96 3.93


3.75

When relieving

When relieving

0.98 3.59 3.56 3.61 1.03 0.98


3.67

When relieving

When relieving

T4-2-41



First

1920 2050 2150 1850 1120 720 2130 2080 2240 2070 1350 950

-1

∗

(min )


214 24 100 220 236 230 2.51 3.24 0.41 4.25

T4-2-42


Average

Remarks


Item

Reference Value

BOOM RAISE PILOT ∗ CONTROL PRESSURE (MPa) ARM ROLL-IN PILOT ∗ (MPa) CONTROL PRESSURE SWING PILOT CONTROL ∗ PRESSURE (MPa) TRAVEL PILOT CONTROL ∗ (MPa) PRESSURE FRONT ATTACHMENT ∗ CONTROL PRESSURE (MPa) PUMP 2 PROPORTIONAL VALVE OUTPUT MAIN PUMP TORQUE PROPORTIONAL BALVE OUTPUT ARM FLOW RATE PROPORTIONAL VALVE OUTPUT (MPa) Lever in Neutral Swing and Arm Roll-In Combined Operation ARM REGENERATIVE PROPORTIONAL VALVE OUT∗∗∗ PUT (MPa) Lever in Neutral Swing, Arm Roll-In, and Boom Raise Combined Operation POWER DIGGING CONTROL PRESSURE (MPa) During Operation When Relieving Boom Raise Circuit TRAVEL MOTOR CONTROL PRESSURE (MPa) EC MOTOR POSITION (Step)

First


Average

Remarks

4.19

When relieving

4.15

When relieving


3.92


1.69

1.16 1.91

1.16 2.72

2.92 2.92 2.92


400



T4-2-43




Reference Value

First


Average

Remarks

1.2 38.1 36.2 35.5 36.7 36.9


36.0

When relieving

When relieving

1.2 38.8 36.2 35.7 1.2 1.2


36.0

When relieving

When relieving

T4-2-44



Reference Value

First


Average

Remarks

0.98 4.22 4.17 4.14 4.38 4.38


4.06

When relieving

When relieving

0.98 4.22 4.17 4.11 1.01 0.98


4.03

When relieving

When relieving

T4-2-45



First

1870 2000 2100 1800 1120 720 2130 2050 2200 2060 1420 1000

-1

∗

(min )


254 54 110 254 254 254 2.51 3.22 0.46 4.35

T4-2-46


Average

Remarks


Item

Reference Value

BOOM RAISE PILOT ∗ CONTROL PRESSURE (MPa) ARM ROLL-IN PILOT ∗ (MPa) CONTROL PRESSURE SWING PILOT CONTROL ∗ PRESSURE (MPa) TRAVEL PILOT CONTROL ∗ (MPa) PRESSURE FRONT ATTACHMENT ∗ CONTROL PRESSURE (MPa) PUMP 2 PROPORTIONAL VALVE OUTPUT MAIN PUMP TORQUE PROPORTIONAL BALVE OUTPUT ARM FLOW RATE PROPORTIONAL VALVE OUTPUT (MPa) Lever in Neutral Swing and Arm Roll-In Combined Operation ARM REGENERATIVE PROPORTIONAL VALVE OUT∗∗∗ PUT (MPa) Lever in Neutral Swing, Arm Roll-In, and Boom Raise Combined Operation POWER DIGGING CONTROL PRESSURE (MPa) During Operation When Relieving Boom Raise Circuit TRAVEL MOTOR CONTROL PRESSURE (MPa) EC MOTOR POSITION (Step)

First


Average

Remarks

4.48

When relieving

4.50

When relieving


3.92


1.69

0.79 1.50

1.16 1.94

2.92 2.92 2.92


368



T4-2-47

OPERATIONAL PERFORMANCE TEST / Standard SENSOR ACTIVATING RANGE 1. Checking Method • Hydraulic Oil Temperature: 50 ± 5 °C • Unless specified: Engine Control Dial

Power Mode Switch

Work Mode Switch

Auto-Idle /Auto-Accelerati on Selector

Fast Idle

P Mode

Digging Mode

OFF

• Monitor each sensor using Dr. ZX.

2. Sensor Activating Range Sensor

Operation Minimum Speed Engine Control Dial Maximum Speed Minimum Speed Maximum Speed (Power Mode Switch: P) EC Sensor Maximum Speed (Power Mode Switch: HP)

Pressure Sensor Pump Control Pressure Sensor N Sensor

Control Lever: Neutral Pilot Control Shut-Off Lever: LOCK Control Lever: Full Stroke Pilot Control Shut-Off Lever: UNLOCK Control Lever: Neutral Control Lever: Full Stroke 20°C (Between Ground to Signal)

T4-2-48

Specification 0.3 to 1.0 V 4.0 to 4.7 V 2.5 to 2.7 V 3.3 to 3.7 V Maximum Speed (Mode Switch: OFF) +0.2 V or more 0 to 0.1 MPa (0 to 1.0 kgf/cm2) 3.3 to 3.9 MPa (34 to 40 kgf/cm2) 0 to 1 MPa (0 to 10 kgf/cm2) 2.9 to 3.9 MPa (30 to 40 kgf/cm2) 810 ± 240 Ω

OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE SPEED Summary 1. Measure the engine speed using the built-in diagnosing system or Dr. ZX. If the built-in diagnosing system or Dr. ZX is not available, use an 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 performing all other tests to check that the engine speed meets specification. Because, if the engine speed is not adjusted correctly, all other performance data will be unreliable. Preparation: 1. Select the monitor function of the built-in diagnosing 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).

2 1

T107-06-02-002

3

IMPORTANT: Never attempt to the readjust stopper (3). T107-06-02-001

T4-3-1

OPERATIONAL PERFORMANCE TEST / Engine Test Measurement: Evaluation: 1. Check engine speeds for auto-warm up (when Refer to T4-2 Operational Performance Standard. starting the engine), auto-idle, slow idle, fast idle (when normal), fast idle (when the ECO is deacRemedy: 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 condiNOTE: ECO stands for the auto engine speed retions 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/ AutoWork 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 deacMax. Speed P OFF functions with ECO deactiMode tivated) vated. Fast Idle Digging Check the engine speed while Max. Speed P OFF (Relief operation) Mode relieving the boom raise circuit. Digging Fast Idle Max. Speed E Mode OFF Mode (E 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 after returning all control levers Auto-Idle Max. Speed P Auto-Idle 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 temperaWarming Up Max. Speed P OFF Mode ture is lower than 0 °C (32 °F).

T4-3-2

OPERATIONAL PERFORMANCE TEST / Engine Test Monitor Panel

Switch Panel Engine Control Dial

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

T178-01-01-003 T178-01-01-004

T4-3-3

OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE COMPRESSION PRESSURE Summary: 1. Measure compression pressure in the cylinders to check for a decline in engine power. 2. Check exhaust gas color. Keep track of engine oil consumption. 3. Check for abnormalities in the intake system, including 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 disconnected, 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 cylinder and calculate the mean values. Evaluation: Refer to T4-2 Operational Performance Standard. Remedy: Refer to engine shop manual.

T4-3-4

OPERATIONAL PERFORMANCE TEST / Engine Test (Blank)

T4-3-5

OPERATIONAL PERFORMANCE TEST / Engine Test VALVE CLEARANCE ADJUSTMENT Summary: 1. Perform the measurement when the engine is cold. 2. Before starting work, clean the head cover mounting area to avoid contamination in the engine. Preparation: 1. Locate the top dead center (TDC) in the compression stroke. Align the TDC mark on the crank pulley with the pointer located on the timing gear case as illustrated. Piston No.1 (or piston No.6) is now positioned at the TDC in its compression stroke. NOTE: When rotating the crank pulley, remove the fan guard. Then, rotate the fan while holding the fan belt. If it is difficult to rotate, remove all glow plugs to release the compression pressure. 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

Top Mark

TDC Mark Timing Gear Case Crank Pulley

T157-05-02-002

OPERATIONAL PERFORMANCE TEST / Engine Test Measurement: 1. Insert a thickness gauge into the clearance between 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 cylinder, 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 “×”.) Cylinder No. Valve locations When the measurement is started from No.1 cylinder When the measurement is started from No.6 cylinder

No.1 I E {

{

No.2 I E

T107-02-12-005

No.3 I E

{

{ ×

×

3. Rotate the crankshaft 360°. Align the TDC mark with the pointer. Then, continue measurement of other valves in the same way. Evaluation: Refer to T4-2 Operational Performance Standard. Adjustment: If the measurement results are out of specification, adjust the valve clearance in the same order of measurement. 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

No.4 I E

No.5 I E

{

No.6 I E

{ ×

×

×

×

OPERATIONAL PERFORMANCE TEST / Engine Test NOZZLE CHECK Summary: 1. Check the injection pressure and the spray pattern with a nozzle tester. 2. Before starting work, clean the nozzle holder mounting area to avoid contamination in the engine. Preparation: 1. Remove the nozzle holders. Remove all nozzle holders and fuel injection pipings 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 penetrates 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 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 bypass the pressure gauge. Attach the nozzle holder to the nozzle tester. Strongly make several strokes of the tester and check the fuel spray pattern. 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

T107-06-02-006

OPERATIONAL PERFORMANCE TEST / Engine Test Evaluation: 1. Standard Injection Pressure: Refer to T4-2 Operational Performance Standard. 2. Spray Pattern • Large-size spray should not be visible to the naked 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.

Normal

T102-02-11-005

Abnormal

Adjustment: 1. To adjust the injection pressure, loosen the lock nuts. Adjust the adjusting screw. Turn clockwise to increase the pressure, and counterclockwise to decrease the pressure. 2. After adjusting, retighten the lock nuts.

T102-02-11-006

T107-06-02-007

T4-3-9

OPERATIONAL PERFORMANCE TEST / Engine Test INJECTION TIMING Timing Mark

Inspection: 1. Position No.1 piston to the top dead center. Turn the crank pulley in the direction of rotation (clockwise as seen from the front of the engine) to set a “TDC” mark on the crank pulley under the “Top mark”, located on the timing gear case. NOTE: When rotating the crank pulley, remove the fan guard. Then, rotate the fan while holding the fan belt. If it is difficult to rotate, remove all glow plugs to release the compression pressure. 2. Remove the timing check hole cover on the front section of the fuel injection pump. When the mark on the injection pump is set under 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 adjust. NOTE: The alignment mark on the injection pump cannot be directly seen through the check hole. Use a mirror for checking. 3. Remove the injection piping from No.1 cylinder. 4. Remove the delivery valve holder for No.1 cylinder from the injection pump to pull the delivery 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)

Top Mark

TDC Mark Timing Gear Case Crank Pulley

T157-05-02-002

Gear Case Projection

Check Hole

Injection Pump Alignment Mark T107-02-12-007

Gear Case Projection

Injection Pump Alignment Mark

T4-3-10

T107-02-12-008

OPERATIONAL PERFORMANCE TEST / Engine Test 5. Turn the crank pulley at approx. 30 degrees counterclockwise. 6. While supplying fuel with the feed pump, turn the crank pulley slowly clockwise just until fuel cannot 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 pulley 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. When delaying timing, tilt the injection pump inward against the cylinder block.

T4-3-11

T107-02-12-009

OPERATIONAL PERFORMANCE TEST / Engine Test LUBRICANT CONSUMPTION Measuring Method 1. Place the machine on level firm ground, and leave it for at least one hour to let the lubricant lower to the oil pan. At this time, confirm that the machine is level, using a leveler. 2. Record the read-out A (unit: hour) of the hour meter. 3. Replenish the lubricant up to the high-level gauge. 4. Operate the machine for at least 100 hours or until the oil level lowers to the low-level gauge. IMPORTANT: Make sure to keep the machine-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 volume C. NOTE: For measuring, use a high-precision measuring cylinder or the like. 8. Determine lubricant consumption from the following equation: Oil replenishing volume (C) [mL] / Operating hours (B-A) [hr] Evaluation: Refer to T4-2 Operational Performance Standard.

T4-3-12

OPERATIONAL PERFORMANCE TEST / Excavator Test TRAVEL SPEED Summary: Measure the time required for the excavator to travel a 20 m (65.6 ft) test track. Preparation: 1. Adjust the track sag on both sidetracks equally. 2. Prepare a flat and solid test track 20 m (65.6 ft) in length with extra length of 3 to 5 m (9.8 to 16 ft) on both ends for machine acceleration and deceleration. 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 hydraulic oil temperature at 50±5 °C (122±9 °F).

Arm Rolled-In, Bucket Rolled-In

Measurement: 1. Measure both the slow and fast speeds of the machine. 2. Select the following switch positions: Travel Engine Power Work Auto-Idle/ Mode Control Mode Mode Acceleration Switch Dial Switch Switch Selector Slow Digging Fast Idle P Mode OFF Mode Mode Fast Digging Fast Idle P Mode OFF Mode Mode 3. Start traveling the machine in the acceleration 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 travel speed. 6. Repeat steps 4. to 5. three times in each direction and calculate the average values.

End

Bucket Height: 0.3 to 0.5 m Start

20 m

Evaluation: Refer to the Operational Performance Standard in Group T4-2.

Deceleration Zone 3 to 5 m

Acceleration Zone 3 to 5 m

Remedy: Refer to the Troubleshooting B in Group T5-4. T105-06-03-001

T4-4-1

OPERATIONAL PERFORMANCE TEST / Excavator Test TRACK REVOLUTION SPEED Summary: Measure the track revolution cycle time with the track raised off ground. Preparation: 1. Adjust the track sag of both side tracks to be equal. 2. On the track to be measured, mark one shoe with chalk. 3. Swing the upperstructure 90° and lower the bucket to raise the track off ground. Keep the boom-arm angle between 90 to 110° as shown. Place blocks under the machine frame.

90 to 110°

Mark

M104-07-067

Measurement: 1. Measure both the slow and fast travel speeds of the machine. 2. Select the following switch positions: Travel Engine Power Work Auto-Idle/ Mode Control Mode Mode Acceleration Switch Dial Switch Switch Selector Slow Digging Fast Idle P Mode OFF Mode Mode Fast Digging Fast Idle P Mode OFF Mode Mode 3. Operate the travel control lever of the raised 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. 6. Repeat steps 3. to 5. three times and calculate the average values. Evaluation: Refer to the Operational Performance Standard Table in Group T4-2. NOTE: The measurement data obtained through the raised track revolution test may have wide variations. Therefore, the evaluation based on the results obtained from the 20 m travel speed check described before is more recommendable.

CAUTION: Securely support the raised track using wooden blocks. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Remedy: Refer to the Troubleshooting B in Group T5-4.

T4-4-2

OPERATIONAL PERFORMANCE TEST / Excavator Test MISTRACK CHECK Summary: 1. Allow the machine to travel 20 m (65.6 ft). Measure the maximum tread deviation from the tread chord line drawn between the travel start and end points to check the performance equilibrium between both sides of the travel device systems (from the main pump to the travel motor). 2. If measured on a concrete surface, the tread deviation has a trend to decrease. Preparation: 1. Adjust the track sag of both tracks to be equal. 2. Provide a flat, solid test yard 20 m (65.6 ft) in length, with extra length of 3 to 5 m (9.8 to 16 ft) on both ends for machine acceleration and deceleration.

Measurement: 1. Measure the amount of mistracking in both fast, and slow travel speeds. 2. Select the following switch positions: Travel Engine Power Work Auto-Idle/ Mode Control Mode Mode Acceleration Switch Dial Switch Switch Selector Slow Digging Fast Idle P Mode OFF Mode Mode Fast Digging Fast Idle P Mode OFF Mode Mode 3. Start traveling the machine in the acceleration zone with the travel levers at full stroke. 4. Measure the maximum distance between a straight 20 m (65.6 ft) tread chord line and the tread made by the machine. 5. After measuring the tracking in forward travel, turn the upperstructure 180° and measure in reverse travel. 6. Repeat steps 3. to 5. three times and calculate the average values.

Maximum Distance

Acceleration Zone: 3 to 5 m 20 m

Evaluation: Refer to the Operational Performance Standard Table in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.

T105-06-03-022

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

OPERATIONAL PERFORMANCE TEST / Excavator Test TRAVEL PARKING LEAKAGE Summary: To measure the parking brake function on a specified slope. Preparation: 1. The surface of the test slope shall be even with a gradient of 20 % (11.31°). 2. Mark a white line on the travel device cover. 3. Hold the bucket 0.2 to 0.3 m (8 to 12 in) above the ground with the arm and bucket fully rolled in. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

0.2 to 0.3 m

T105-06-03-004

Measurement: 1. Measure the travel parking brake slip amount while parked. 2. Climb the slope and place the travel levers in neutral. 3. Stop the engine. 4. After the machine stops, put alignment marks on a track link or shoe, and the track side frame. 5. After 5 minutes, measure the distance between the marks on the track link or shoe and the track side frame. Evaluation: Refer to the Operational Performance Standard Table in Group T4-2.

Alignment marks on the trackside frame and shoe when the machine comes to a stop. Displacement measured after 5 minutes. T105-06-03-006

T4-4-4

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING SPEED Summary: Measure the time required to swing three complete turns. Preparation: 1. Check the lubrication of the swing gear and swing bearing. 2. Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on slopes. 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.

CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement. Measurement: 1. Select the following switch positions: Auto-Idle/ Engine Con- Power Mode Work Mode Acceleration trol Dial Switch Switch Selector Digging Fast Idle P Mode OFF Mode 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. 5. Repeat steps 2. to 4. three times and calculate the average values.

The same height as the boom foot pin height T105-06-03-013

NOTE: In case a sufficient space for the measurement is difficult to find, carry out the measurement with the boom fully raised and the arm fully rolled-in.

Evaluation: Refer to the Operational Performance Standard in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.

T178-04-03-001

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T4-4-5

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING FUNCTION DRIFT CHECK Summary: Measure the swing drift on the bearing outer circumference when stopping after a 180° full-speed swing. Preparation: 1. Check the lubrication of the swing gear and swing bearing. 2. Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on a slope. 3. With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin is the same as the boom foot pin. The bucket must be empty. 4. Make two chalk marks: one on the swing bearing and one directly below it on the track frame. 5. Swing the upperstructure 180°. 6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement.

T4-4-6

Two Check Marks T105-06-03-008

T105-06-03-009

OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Select the following switch positions: Auto-Idle/ Engine Con- Power Mode Work Mode Acceleration trol Dial Switch Switch Selector Digging Fast Idle P Mode OFF 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° . 3. Measure the distance between the two marks. 4. Align the marks again, swing 180°, then test in the opposite direction. 5. Repeat steps 2. to 4. three times each and calculate the average values. Evaluation: Refer to the Operational Performance Standard in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.

T4-4-7

Measure Difference Between Marks

Marking on the Track Frame Marking on the Swing Bearing T105-06-03-010

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING MOTOR LEAKAGE Summary: Check for upperstructure drift while suspending a load on a slope. Preparation: 1. Check the lubrication of the swing gear and swing bearing. 2. Park the machine on a smooth slope with a gradient of 26.8 % (15°). 3. Load bucket fully. In lieu of loading the bucket, weight (W) of the following specification can be used. ZX200 class, 225 class: W=1050 kg (2320 lb) ZX230 class: W=1350 kg (2980 lb) ZX270 class: W=1500 kg (3310 lb) 4. With the arm rolled out, and bucket rolled in, position the arm top pin height to be level with the boom foot pin. 5. Swing the upperstructure to position it 90° to the slope. Make aligning marks on the swing bearing periphery and track frame using tape, as illustrated. 6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T4-4-8

T105-06-03-011

OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Select the following switch position: Auto-Idle/ Power Mode Work Mode Acceleration Switch Switch Selector P Mode

Digging Mode

Measure Difference Between Marks

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. 3. Perform the measurement in both right and left swing directions. 4. Perform the measurement three times in each direction and calculate the average values. Evaluation: Refer to the Operational Performance Standard in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.

T4-4-9

Marking on the Track Frame Marking on the Swing Bearing T105-06-03-010

OPERATIONAL PERFORMANCE TEST / Excavator Test MAXIMUM SWINGABLE SLANT ANGLE Summary: With the upperstructure swung 90° to the slope, check the maximum slant angle on which the upperstructure can swing to the uphill side.

Measurement: 1. Select the following switch positions: Engine Auto-Idle/ Power Mode Work Mode Control Acceleration Switch Switch Dial Selector

Preparation: 1. Check that the swing gear and bearing are well lubricated. 2. 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) 3. With the arm cylinder fully retracted and the bucket cylinder fully extended, hold the arm top pin to the position flush with the boom foot pin height. 4. Climb a slope and swing the upperstructure 90° to the slope. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Fast Idle

P Mode

Digging Mode

OFF

2. Operate the swing lever to full stroke to swing the upperstructure to the uphill side. 3. If the machine can swing, measure the cab floor slant angle. 4. Increase the slope angle and repeat steps 2. and 3. Check both clockwise and counterclockwise. 5. Perform the measurement three times. Evaluation: Refer to the Operational Performance Standard in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.

T105-06-03-011

T4-4-10

OPERATIONAL PERFORMANCE TEST / Excavator Test (Blank)

T4-4-11

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING BEARING PLAY Summary: Measure the swing bearing play using a dial gauge to check the wear of bearing races and balls. Preparation: 1. Check swing bearing mounting bolts for looseness. 2. Check the lubrication of the swing bearing. Confirm that bearing rotation is smooth and without noise. 3. Install a dial gauge on the track frame as shown, using a magnetic base. 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 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.

Magnetic Base

Dial Gauge

T105-06-03-014

Round Trunk

T105-06-03-015

T4-4-12

OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. 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. 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 h2) as follows: H=h2-h1 Evaluation: Refer to the Operational Performance Standard in Group T4-2.

Measurement: (h1)

The same height as the boom foot pin height

T105-06-03-007

Measurement: (h2)

T105-06-03-017

T4-4-13

OPERATIONAL PERFORMANCE TEST / Excavator Test HYDRAULIC CYLINDER CYCLE TIME Measure the cycle time of the boom, arm, and bucket cylinders. Preparation: 1. Be sure to measure at the position as follows. • To measure the cycle time of the boom cylinders: With the arm rolled out and the empty bucket rolled in, lower the bucket to the ground, as shown. • To measure the cycle time of the arm cylinder: 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. 2. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T105-06-03-018

0.5 m T105-06-03-019

T105-06-03-020

T4-4-14

OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Select the following switch positions: Engine Auto-Idle/ Power Mode Work Mode Control Acceleration Switch Switch Dial Selector Fast Idle

P Mode

Digging Mode

OFF

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 quickly as possible. • 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 quickly as possible. 3. Repeat each measurement three times and calculate the average values. Evaluation: Refer to the Operational Performance Standard in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.

T4-4-15

OPERATIONAL PERFORMANCE TEST / Excavator Test DIG FUNCTION DRIFT CHECK • 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 cylinder for ten minutes to its stroke end to purge air. Preparation: 1. 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) 2. Position the arm cylinder with the rod 50 mm (2 in) extended from the fully retracted position. 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. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Stop the engine. 2. Five minutes after the engine has been stopped, measure the change in the position of the bottom of the bucket, as well as the boom, arm and bucket cylinders. 3. Repeat step 2. three times and calculate the average values.

Retracted Distance

Extended Distance Retracted Distance

Same Height

Bucket Bottom

T105-06-03-021

Arm Cylinder Extension

Mark

T110-06-03-001

Boom and Bucket Cylinder Retraction Mark Mark

Evalution: Refer to the Operational Performance Standard in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.

T110-06-03-002

T4-4-16

OPERATIONAL PERFORMANCE TEST / Excavator Test • Arm Roll-In Position Summary: Measure dig function drift, which can be caused by oil leakage in the control valve and boom, arm, and bucket cylinders. 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. 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 (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. 3. Repeat step 2. three times and calculate the average values.

1m T173-04-03-001

Cylinder Retraction Mark Mark

Evalution: Refer to the Operational Performance Standard in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4. T110-06-03-002

T4-4-17

OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER OPERATING FORCE Summary: 1. Use a spring scale to measure the maximum resistance of each control lever as illustrated. 2. Measure the maximum operating force of the front attachment control lever. 3. Measure the operating force at the grip center of each control lever. Preparation: Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement.

T107-06-03-003

T107-06-03-004

T4-4-18

OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Measure each control lever. 2. Select the following switch positions: Engine Auto-Idle/ Power Mode Work Mode Control Acceleration Switch Switch Dial Selector Fast Idle

P Mode

Digging Mode

OFF

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. 7. Repeat steps 3. to 6. three times and calculate the average values. Evalution: Refer to the Orerational Performance Standard in Group T4-2.

T4-4-19

OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER STROKE Summary: 1. Measure each lever stroke at the lever top using a ruler. 2. Measure the lever stroke at the grip center of each control lever. 3. In case lever stroke play is present in the neutral position, add half (1/2) the play present to both side lever strokes. Preparation: Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Stop the engine. 2. Measure each lever stroke at the lever top from neutral to the stroke end using a ruler. 3. Repeat step 2. three times and calculate the average values. Evalution: Refer to the Orerational Performance Standard in Group T4-2.

T4-4-20

T107-06-03-005

OPERATIONAL PERFORMANCE TEST / Excavator Test (Blank)

T4-4-21

OPERATIONAL PERFORMANCE TEST / Excavator Test COMBINED BOOM RAISE/SWING FUNCTION CHECK Summary: 1. Check boom raise and swing movement and speeds while operating both functions simultaneously. 2. Make sure that the cylinders don’t hesitate while operating the cylinder with the engine running at fast idle. Preparation: 1. With the arm fully rolled out and bucket fully rolled in, lower the bucket to the ground. The bucket must be empty. 2. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement.

T4-4-22

T107-06-03-009

OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Select the following switch positions: Engine Auto-Idle/ Power Mode Work Mode Control Acceleration Switch Switch Dial Selector Fast Idle

P Mode

Digging Mode

OFF

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 the average values.

T107-06-03-010

Evalution: Refer to the Operational Performance Standard in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4. H

T107-06-03-011

T4-4-23

OPERATIONAL PERFORMANCE TEST / Excavator Test BOOM RAISE/ARM ROLL-IN COMBINED OPERATION Summary: 1. Performance of boom raise and arm roll-in combined operation is checked. 2. Make sure that the cylinders don’t hesitate while operating the cylinder with the engine running at fast idle. Preparation: 1. Fully retract the arm cylinder and fully extend the bucket cylinder. Adjust the boom cylinder so that the bucket tooth tip height is 0.5 m (1 ft 8 in) above the ground. (Empty the bucket.) 2. Maintain the hydraulic oil temperature at 50 ± 5 °C (122±9 °F). Measurement: 1. Select the switch positions as follows. Engine Auto-Idle/ Power Mode Work Mode Control Acceleration Switch Switch Dial Selector Fast Idle

P Mode

Digging Mode

0.5 m

T107-06-03-006

OFF

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 calculate the average value. Evaluation: Refer to T4-2 Operational Performance Standard. Remedy: Refer to T5-4 Troubleshooting B.

T107-06-03-008

T4-4-24

OPERATIONAL PERFORMANCE TEST / Component Test PRIMARY PILOT PRESSURE Preparation: 1. Properly shut down the engine. 2. Press the air release valve on top of the hydraulic oil tank to release any remaining pressure. 3. Remove the plug from the pilot filter. Install adapter (ST 6069) and pressure gauge (ST 6942) to the removed plug hole (pressure check port). : 14 mm 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Digging Fast Idle P Mode OFF Mode Digging Slow Idle P Mode OFF Mode 2. Measure the pilot pressure in each specified setting above. 3. Repeat the measurement three times and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2.

T4-5-1

Plug

T178-03-07-001

OPERATIONAL PERFORMANCE TEST / Component Test 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. 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)

1

2

3

4

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

OPERATIONAL PERFORMANCE TEST / Component Test (Blank)

T4-5-3

OPERATIONAL PERFORMANCE TEST / Component Test SECONDARY PILOT PRESSURE Preparation: 1. Properly shut down the engine. 2. Press the air release valve on top of the hydraulic oil tank to release any remaining pressure. 3. Measure the pressure by either of the following methods. NOTE: When disconnecting the pilot lines from the signal control valve, use tool (SNAP-ON GAN850812B: size 19.05 mm) to easily disconnect the lines.

Signal Control Valve

Control Valve

•Measure pressure at the location between the pilot 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. Install tee (ST 6451) and pressure gauge (ST 6942) between the hose and the control valve. : 14 mm, 17 mm

T178-04-04-003

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T157-05-04-011

T4-5-4

OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Digging Fast Idle P Mode OFF Mode Digging Slow Idle P Mode OFF Mode 2. Measure the pilot pressure in each specified setting above with the corresponding control lever operated full stroke. 3. Repeat the measurement three times and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.

T4-5-5

OPERATIONAL PERFORMANCE TEST / Component Test SOLENOID VALVE SET PRESSURE Measure solenoid valve set pressure with both the Dr.ZX and the pressure gauge.

Solenoid Valve Unit Serial No.104679 and up (ZX200 class and 225 class) Serial No.010327 and up (ZX230 class) Serial No.020043 and up (ZX270 class)

Preparation: 1. Properly shut down the engine. 2. Press the air release valve on top of the hydraulic oil tank to release any remaining pressure. 3. Disconnect line (1) from the solenoid valve to be measured. Install hose (Parts Number: 4216453), tee (ST 6451), adapter (ST 6461), and pressure gauge (ST 6942) to the disconnected end at the solenoid valve side, as illustrated. : 17 mm, 19 mm, 22 mm Connect Dr.ZX to the machine for solenoid valve set pressure monitoring. 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

7

8

T178-03-07-005

9

Up to serial No.104678 (ZX200 class and 225 class) Up to serial No.010326 (ZX230 class) Up to serial No.020042 (ZX270 class)

6

7

8

9

T178-01-02-003

Solenoid Valve Pressure Gauge

1

Hose

T4-5-6

Tee

Adapter

T157-05-04-002

OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Digging Fast Idle P Mode OFF Mode Digging Slow Idle P Mode OFF Mode 2. Operate as instructed below for each measuring solenoid valve: Solenoid Valve SG: Repeat pressing and releasing of the power boost switch. Solenoid Valve SE*: Perform a combined operation. of swing and arm roll-in. Solenoid Valve SC: Perform a combined operation 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) Up to serial No.010326 (ZX230 class) Up to serial No.020042 (ZX270 class) 3. Read the values on both Dr.ZX and the pressure gauge. 4. Repeat the measurement three times and calculate the average values. Evaluation: Refer to the performance Standard Table in Group T4-2.

T4-5-7

OPERATIONAL PERFORMANCE TEST / Component Test Solenoid Valve Set Pressure Adjustment Procedure

7

IMPORTANT: Do not loosen the adjusting screw excessively. 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 adjust the set pressure of the solenoid valve. 2. Retighten lock nut (7). : 10 mm : 3 mm : 5 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft) 3. Check the set pressure of the solenoid valve. NOTE: Standard Change in Pressure (Reference) Screw Turns 1/4 1/2 3/4 1 kPa 78 156 234 312 Change in Pres- (kgf/cm2) (0.8) (1.6) (2.4) (3.2) sure (psi) (11) (23) (34) (46)

8

T107-06-04-020

The distance between the lock nut end and screw end should be 2.0 mm (0.079 in) or less.

8 7 T107-06-05-001

7

Pressure Increase

8

Pressure Decrease

W107-02-05-129

T4-5-8

OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP DELIVERY PRESSURE The main pump delivery pressure can also be measured with Dr.ZX. Preparation: 1. Properly shut down the engine. 2. Press the air release valve on top of the hydraulic oil tank to release any remaining pressure. 3. Remove the plug from the main pump delivery port. Install adapter (ST 6069), hose (ST 6943) and pressure gauge (ST 6941) on the port. : 6 mm Or connect Dr.ZX to the machine for main pump delivery pressure monitoring. 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Digging Fast Idle P Mode OFF Mode 2. Measure the pressure with the control levers in neutral. 3. Repeat the measurement three times and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2. Remedy: Refer to the Troubleshooting B in Group T5-4.

T4-5-9

T157-05-04-005

OPERATIONAL PERFORMANCE TEST / Component Test MAIN RELIEF VALVE SET PRESSURE The main relief pressure can also be measured with Dr.ZX. Summary: Measure the main relief valve setting pressure at the main pump delivery port. Preparation: 1. Properly shut down the engine. 2. Press the air release valve on top of the hydraulic oil tank to release any remaining pressure. 3. Remove the plug from the main pump delivery port. Install adapter (ST 6069), hose (ST 6943) and pressure gauge (ST 6941) on the port. : 6 mm Or connect Dr.ZX to monitor the main pump delivery pressure. 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T157-05-04-005

T4-5-10

OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Digging Fast Idle P Mode OFF Mode 2. Relieve each actuator to measure main relief pressures. First, slowly operate bucket, arm, and boom control levers to the stroke end to relieve each function one at a time. 3. As for the swing function, secure the upper-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 depressed. Evaluation: Refer to the Performance Standard Table in Group 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

OPERATIONAL PERFORMANCE TEST / Component Test Main Relief Pressure Setting Adjustment Procedure

Main Relief Valve

Adjustment: Adjust the pressure setting of the main relief valve using plug (3) (for the low-side relief pressure setting) 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 relief pressure setting referring to the table below. : 27 mm, 32 mm : Lock Nut (4): 78 to 88 N⋅m (8 to 9 kgf⋅m, 58 to 65 lbf⋅ft)

M178-05-003

3 1 5 4 2

T157-05-04-009

Plug (5, 3)

Pressure Increase

Pressure Decrease

W107-02-05-127

T4-5-12

OPERATIONAL PERFORMANCE TEST / Component Test • Low-Side Relief Pressure Setting Adjustment Procedure 1. Loosen lock nut (1). Turn plug (3) counter clockwisely until the specified value is obtained referring 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. NOTE: Standard Change in Pressure (Reference) Plug Turns 1/4 1/2 3/4 Change in Relief MPa 7.1 14.2 21.3 Pressure: Plug (5) (kgf/cm2) 72.5 145 217.5 (High-Side Relief (psi) 1030 2060 3090 Pressure) Change in Relief MPa 5.3 10.7 16.0 2 Pressure: Plug (3) (kgf/cm ) 54 109 163 (Low-Side Relief (psi) 770 1550 2320 Pressure)

1 28.4 290 4120 21.3 217 3090

T4-5-13

OPERATIONAL PERFORMANCE TEST / Component Test RELIEF Swing)

PRESSURE

(When

relieving

ZX200 class, 225 class, 230 class Adjust pressure by changing the number of shims (2). 1. Remove the swing relief valve. : 41 mm

Swing Relief Valve

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 B: AS568-023 (Aero-Space Standard) C: AS568-125 (Aero-Space Standard)

T178-03-02-001

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. NOTE: Standard Change in Pressure (Reference) Shim Thickness

Change in Relief Pressure

(mm)

kPa

(kgf/cm2)

(psi)

0.1

610

6.3

(60)

A

T4-5-14

B

C

T178-03-02-005

OPERATIONAL PERFORMANCE TEST / Component Test Swing Relief Valve

ZX270 class 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 Adjusting Screw Turns Change in Pressure

MPa

2

1 1/4

1/2

3/4

1

2.5

5.0

7.5

10.0

(kgf/cm2)

(25.5)

(51)

(76.5)

(102)

(psi)

(363)

(725)

(1088)

(1450)

T107-02-04-020

Up to serial No.20037 Adjusting Screw

1/4

1/2

3/4

1

MPa (kgf/cm2)

2.9 (30)

5.8 (59.5)

8.7 (89)

11.7 (119)

(psi)

(430)

(850)

(1270)

(1690)

Turns Change in Pressure

Up to serial No.20037 1

2

T157-02-04-006

1

Pressure Increase

Pressure Decrease T157-05-04-023

T4-5-15

OPERATIONAL PERFORMANCE TEST / Component Test RELIEF Travel)

PRESSURE

(When

relieving

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 guide (4) to adjust the set-pressure.

Travel Relief 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) Change in Relief Shim Pressure Thickness Parts No. (mm) kPa (kgf/cm2) (psi) 0.5 A590103 900 (9.2) (130)

1

2

3

5

4 T135-06-04-001

T4-5-16

OPERATIONAL PERFORMANCE TEST / Component Test ZX270 class Adjustment Loosen lock nut (2) to adjust adjusting screw (1). : 19 mm : 6 mm 1. Loosen lock nut (2). 2. Turn adjusting screw (1) to adjust. 3. Tighten lock nut (2). : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

Travel Relief Valve

NOTE: Standard Change in Pressure (Reference) Adjusting Screw

1/4

1/2

3/4

1

MPa

2.9

5.9

8.8

11.8

(kgf/cm2)

(30)

(60)

(90)

(120)

(psi)

(430)

(850)

Turns Change in Pressure

T157-05-04-010

2

1

(1280) (1710)

T157-05-04-008

2

Pressure Increase

1

Pressure Decrease W107-02-05-129

T4-5-17

OPERATIONAL PERFORMANCE TEST / Component Test OVERLOAD RELIEF VALVE SET PRESSURE Summary: 1. The circuit pressure must be increased by applying an external force while blocking the return circuit from the control valve. This measuring method is hazardous and the results obtained with this method are unreliable. 2. The oil flow rate used to set the overload relief pressure is far less than that used to set the main relief pressure. Therefore, measuring the overload pressure in the main circuit by increasing the main relief set-pressure more than the overload valve set-pressure is not a proper method. In addition, in case a main relief valve designed to leak a small quantity of oil before reliving is used, its pre-leaking start pressure must be increased more than the overload relief valve set-pressure. However, the pre-leaking start pressure is not always increased more than the overload relief valve set-pressure as the adjustable upper limit of the main relief valve set-pressure is provided. Accordingly, the overload relief valve assembly should be removed from the machine and checked on a specified test stand at a correct oil flow rate. Some overload relief valves come in contact with the control valve body to block the oil passage. When this type of overload relief valve is checked, the control valve body must be precisely finished as the test unit. Provide one control valve other than that on the machine as a test kit.

3. If the overload relief valve performance must be checked on the machine, however, measure the main relief pressure while releasing each front function respective to the measuring overload relief valve. And, assume that the overload relief valve is functioning correctly if the obtained main relief pressure is within the specified value range. Measure the main pressure of the front functions as follows: Preparation: 1. Properly shut down the engine. 2. Press the air release valve on top of the hydraulic oil tank to release any remaining pressure. 3. Remove the plug from the main pump delivery port. Install adapter (ST 6069), hose (ST 6943) and pressure gauge (ST 6941) on the port. : 6 mm 4. Connect Dr.ZX to the machine for main pump delivery pressure monitoring. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T4-5-18

OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Digging Fast Idle P Mode OFF Mode 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. 5. Repeat the measurement three times and calculate the average value for each front function. Evaluation: 1. Performance of the overload relief valves are normal if the measured main relief pressures are within the specified value range. Refer to the Performance Standard Table in Group T4-2.

T4-5-19

T157-05-04-005

OPERATIONAL PERFORMANCE TEST / Component Test 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 nut (1).

1

1. Loosen lock nut (1). 2. Turn adjusting screw (2) to adjust the pressure setting referring to the table below. 2

3. Retighten lock nut (1). : 17 mm : 6 mm : 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft)

W107-02-05-128

4. Check the set pressure.

NOTE: Standard Change in Pressure (Reference) Screw Turns 1/4 1/2 3/4 1 5.2 10.6 15.9 21.1 Change in MPa Relief (kgf/cm2) (54) (108) (162) (216) Pressure (psi) (770) (1540) (2300) (3070)

1

Pressure Increase

2

Pressure Decrease

W107-02-05-129

T4-5-20


T4-5-21

OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP FLOW RATE MEASUREMENT • P-Q Control (Torque Control) Summary: Main pump performance is checked by measuring the pump flow rate with a hydraulic tester installed at the main pump delivery port (one side) to be measured. Use Dr. ZX and a pressure gauge at the same time. IMPORTANT: This measurement procedure is a simple method. The measured data will be lower by approx. 5 % than the accurately measured value. To measure accurately, disconnect the return circuit from the control valve and connect it to the hydraulic oil tank. Preparation: 1. Stop the engine. Push the air bleed valve to bleed air. Connect a vacuum pump to the oil filler port. NOTE: Operate the vacuum pump while connecting the pump flow rate test line. 2. Disconnect the delivery hose from the main pump (one side) to be measured. Connect pipe (1 or 2) to the pump delivery port using the split flanges and bolts which were used to connect the disconnected delivery hose. : 41 mm : 10 mm 3. Connect hose (1 or 2) to hydraulic tester (5) using test hose (3) and adapter (4). Connect adapter (6), joint (7), test hose (8) and flange (9) to hydraulic tester (5). : 41 mm : 10 mm 4. Connect the delivery hose to flange (9) with split flanges (10) and bolts (11). : 10 mm

5. Install a pressure gauge to the main pump to be measured. (Refer to T4-5-9 Main Pump Delivery Pressure.) : 6 mm 6. Disconnect pipe (13) from the regulator. Connect plug (PF 1/4) to the disconnected pipe. : 17 mm 7. Disconnect the N sensor connector. Connect the pulse counter to the N sensor. 8. Disconnect the vacuum pump. Loosen plug (12) on top of the pump casing to bleed air from the main pump until oil only comes out of the plug clearance. 9. Fully open the loading valve of the hydraulic tester. 10. Start the engine. Check the pressure gauge connection for any oil leaks. Install Dr. ZX and select the monitor function. Measurement: 1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). 2. Measure the maximum flow rate. 3. Select each switch position as follows: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Digging Fast Idle P Mode OFF Mode 4. Adjust the main relief valve set-pressure in the control valve to each pressure point specified along the main pump P-Q curve. (Refer to T4-2-22) Slowly close the loading valve of the hydraulic tester while relieving the pressure in the arm roll-in circuit. Measure the flow rates and engine speeds at the pressure points specified in the P-Q curve. 5. Repeat each measurement three times and calculate the average values.

T4-5-22

OPERATIONAL PERFORMANCE TEST / Component Test Evaluation: 1. Convert the measured flow rates to those at the specified pump speed using the following formulas:

2. Standard Flow Rate Refer to T4-2 Operational Performance Standard. 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) (ZX230 class: 2000 min-1) (ZX270 class: 2050 min-1) Ne : Measured Engine Speed: Pulse Numbers (Hz)×60/34

1, 2

3

4

6

5

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) 2 - Pipe B (ST 6143) 3 - Test Hose (ST 6145) 4 - Adapter PF1 × UNF1-7/8 (ST 6146)

5 - Hydraulic Tester (ST 6299) 6 - Adapter PF1 × UNF1-7/8 (ST 6146) 7 - Joint (ST 6330)

89-

Test Hose (ST 6320) Flange (ST 6118)

10 - Split Flange (ST 6130)

T4-5-23

11 - Bolt (ST 6409) (4 used) 12 - Plug 13 - Pipe

OPERATIONAL PERFORMANCE TEST / Component Test •Pilot Characteristics Summary: Main pump performance is checked by measuring the pump flow rate with a hydraulic tester installed at the main pump delivery port (one side) to be measured. Use Dr. ZX and a pressure gauge at the same time. IMPORTANT: This measurement procedure is a simple method. The measured data will be lower by approx. 5 % than the accurately measured value. To measure accurately, disconnect the return circuit from the control valve and connect it to the hydraulic oil tank. Preparation: 1. Referring to steps 1 to 4 on page T4-5-22, connect a hydraulic tester to the main pump to be 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

5. Connect hose (19) to port T on reducing valve (16). Connect adapter (20) to the other end of hose (19). Remove plug L from the return pipe. Connect hose (19) to the plug L port. : 19 mm, 22 mm 6. Disconnect pipe (21) from the regulator. Connect plug (PF 1/4) to the disconnected pipe. : 17 mm 7. Disconnect the N sensor connector. Connect the pulse counter to the N sensor. 8. Disconnect the vacuum pump. Loosen the plug from the top of the pump casing. Bleed air from the casing until oil only comes out of the plug clearance. 9. Fully open the loading valve of the hydraulic tester. 10.Start the engine. Check the line connections for any oil leaks.

T4-5-24

OPERATIONAL PERFORMANCE TEST / Component Test 1, 2

3

4

6

5

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 P2

P1

19 15

To Regulator Port Pi

To Pilot Filter

14

17

15

16

15

14

13 T178-04-04-004

1 - Pipe E (ST 6144)

7 - Joint (ST6330)

12 - Plug M

2 - Pipe B (ST 6143)

8 - Test Hose (ST 6320)

3 - Test Hose (ST 6145)

9 - Flange (ST 6118)

4 - Adapter PF1 × UNF1-7/8 (ST 6146) 5 - Hydraulic Tester (ST 6299) 6 - Adapter PF1 × UNF1-7/8 (ST 6146)

10 - Split Flange (ST 6130)

13 - Adapter UNF7/16 × PF1/4 (ST 6069) 14 - Hose U UF7/16 × UNF7/16 (4334309) 15 - Adapter PF3/8 × UNF7/16 (4200465) 16 - Reducing Valve (4325439)

11 - Bolt (ST 6409) (4 used)

T4-5-25

17 - Tee UNF7/16 × UNF7/16× PF1/4 (ST 6451) 18 - Pressure Gauge (ST 6931) 19 - Hose UNF7/16 × UNF7/16 (4334309) 20 - Adapter PF3/8 × UNF7/16 (4200465) 21 - Pipe

OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F) 2. The pump flow rate in response to the external command pilot pressure is measured. 3. Select each switch position as follows: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Digging Fast Idle P Mode OFF Mode 4. Adjust the reducing valve set-pressure to each pressure point specified along the main pump P-Q curve. (Pilot Characteristics) (Refer to T4-2-23.) Measure the flow rates and engine speeds at the pressure points specified in the P-Q curve. 5. Repeat each measurement three times and calculate the average values.

Evaluation: 1. Convert the measured flow rates to those at the specified pump speed using the following formulas: Qc = (Ns × Q) ⁄ Ne Qc : Converted Flow Rate Q : Measured Flow Rate Ns : Specified Pump Speed (ZX200 class, 225 class: 1900 min-1) (ZX230 class: 2000 min-1) (ZX270 class: 2050 min-1) Ne : Measured Engine Speed Pulse Numbers (Hz)×60/34 2. Standard Flow Rate Refer to T4-2 Operational Performance Standard. NOTE: Both pipes (1 and 2) are illustrated as if they are installed. When actually measuring, install pipe (1 or 2) only to the pump to be measured.

T4-5-26

OPERATIONAL PERFORMANCE TEST / Component Test Regulator Adjustment 6

5

1

2

9 10 4

3

7

8 T178-03-01-006

1 - Lock Nut (For Minimum Flow Adjustment) 2 - Adjusting Screw (For Minimum Flow Adjustment) 3 - Lock Nut (For Maximum Flow Adjustment)

4 - Adjusting Screw (For Maximum Flow Adjustment) 5 - Lock Nut (For Pilot Pressure Characteristic Adjustment) 6 - Adjusting Screw (For Pilot Pressure Characteristic Adjustment)

Adjustment Item 1. Minimum Flow Rate

7 - Lock Nut (For P-Q Line Adjustment)

9 - Lock Nut (For P-Q Line Adjustment)

8 - Adjusting Screw (For P-Q Line Adjustment)

10 - Adjusting Screw (For P-Q Line Adjustment)

Adjustment Procedure Remarks Loosen lock nut (1) and turn 1) Do not turn the adjusting screw adjusting screw (2). more than two turns. 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)

Q

Pi

2. Maximum Flow Rate Q

Pd

Loosen lock nut (3) and turn 1) Do not turn the adjusting screw adjusting screw (4). more than two turns. 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 ad7.14 cm3/rev. (0.44 in3/rev). justing screw counterclockwise. In: 13 mm creasing the maximum flow rate (turning the adjusting screw coun: 9.8 N⋅m terclockwise), however, will be re(1 kgf⋅m, 7.2 lbf⋅ft) quired after adjusting the pilot pressure characteristics. 3) Securely retighten lock nut (3) after the adjustment.

T4-5-27

OPERATIONAL PERFORMANCE TEST / Component Test 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. (0.71 in3/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 (adjusting screw (6) clockwise turn) is to counterbalance. Pi 3) Securely retighten lock nut (5) after the adjustment. 4. P-Q Control (Torque Adjustment) Q

A

Pd

A: Loosen lock nut (7) and turn 1) Do not turn the adjusting screws more than one turn. adjusting screw (8). Rotating adjusting screw (8) 2) Rotate the adjusting screws watching the engine performance. 1/4 a turn clockwise increases the maximum pump flow rate 3) Securely retighten lock nut (7) or (9) after the adjustment. by 13.43 cm3/rev. (0.82 in3/rev.). B: Loosen lock nut (9) and turn adjusting screw (10). Rotating adjusting screw (10) 1/4 a turn clockwise increases the maximum pump flow rate by 2.36 cm3/rev. (0.14 in3/rev).

Q

B

Pd

T4-5-28

OPERATIONAL PERFORMANCE TEST / Component Test SWING MOTOR DRAINAGE Summary: To check swing motor performance, measure the amount of oil draining from the swing motor while swinging the upperstructure. NOTE: The amount of drain oil from the swing motor will change depending on hydraulic oil temperature. CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement. Also, take care not to fall off the machine while the measurement.

1

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 release valve (1) on top of the hydraulic oil tank to release any remaining pressure. 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)

2

T178-04-04-005

T4-5-29

OPERATIONAL PERFORMANCE TEST / Component Test Preconditions for Measurement: 1. Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Digging Fast Idle P Mode OFF Mode Measurement: 1. Amount of Oil Drained While Swinging the Upperstructure (1) Fully retract the arm cylinder. Fully extend the bucket cylinder. Raise the boom so that the arm tip pin height is the same as the boom foot pin height. Be sure that the bucket is empty. (2) Start the engine. Operate and hold the swing lever full stroke. Start draining oil measurement after the swing speed reaches a constant maximum speed. The measuring time should be more than 45 seconds. (3) Repeat the measurement at least three times in both clockwise and counterclockwise directions, and calculate the average values. 2. Amount of Oil Drained While Relieving Swing Motor Circuit (1) Thrust the bucket teeth into the ground as illustrated 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. (3) Repeat the measurement at least three times in both clockwise and counterclockwise directions, and calculate the average values.

T4-5-30

The same height as boom foot pin height T105-06-03-013

T107-06-06-005

OPERATIONAL PERFORMANCE TEST / Component Test Evaluation: Refer to the Performance Standard Table in Group T4-2. ∗ Conversion of the amount of drain oil measured into the per-minute value First measure the amount of drain oil using a calibrated 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

OPERATIONAL PERFORMANCE TEST / Component Test TRAVEL MOTOR DRAINAGE Summary: To check travel motor performance, measure the amount of oil draining from the travel motor while rotating the travel motor with the measuring side track jacked up. NOTE: The amount of drain oil from the travel motor will change depending on hydraulic oil temperature.

1

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 release 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 disconnected end. Connect the drain hose (3/4-16UN) to the travel motor. : 22 mm, 27 mm (ZX200 class, 225 class, 230 class) : 27 mm (ZX270 class) : 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)

T157-05-04-014

2

Preconditions for Measurement: 1. Select the following switch positions: Auto-Idle / Engine Power Mode Work Mode Acceleration Control Dial Switch Switch Selector Digging Fast Idle P Mode OFF Mode T157-05-04-010

T4-5-32

OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Amount of Oil Drained While Rotating Travel Motor (1) Start the engine. Jack up the measuring side track using the front attachment, as illustrated. CAUTION: Securely support the raised track using wooden blocks. When working around moving parts is unavoidable, pay special attention to ensure that hands, feet, and clothing do not become entangled. (2) Rotate the raised track with the travel lever operated full stroke. Start drain oil measurement after the track rotation speed reaches a constant maximum speed. The measuring time should be more than 45 seconds.

90 to 110°

M104-07-067

(3) Repeat the measurement at least three times in both forward and reverse directions, and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2. ∗ Conversion of the amount of drain oil measured into the per-minute value First measure the amount of drain oil using a calibrated 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)

T4-5-33

T157-05-04-019


T4-5-34

OPERATIONAL PERFORMANCE TEST / Adjustment ENGINE SPEED ADJUSTMENT ENGINE LEARNING

AND

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. Holding Bolt

5. Loosen the bolt holding the control lever to the EC motor output shaft. 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: Don’t lubricate the motor output shaft. 8. Perform engine learning.

T4-6-1

Control Lever

T157-07-04-015

OPERATIONAL PERFORMANCE TEST / Adjustment Engine Learning: 1. Turn the key switch OFF NOTE: In case the engine doesn’t stop when the key switch is turned OFF, pull the handle located under the seat to stop the engine.

Learning Switch

Dr.ZX Connector to MC

2. Disconnect Dr. ZX. Wait for 5 seconds. 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)

Learning Switch

Dr.ZX Connector to MC

T1SM-01-02-006

Learning Switch is Turned to Stamp E Learning Switch

Stamp

T1CC-05-01-001

T4-6-2

OPERATIONAL PERFORMANCE TEST / Adjustment (Blank)

T4-6-3

OPERATIONAL PERFORMANCE TEST / Adjustment GOVERNOR LEVER LEVER POSITION

AND

FUEL

CUT

• 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

OPERATIONAL PERFORMANCE TEST / Adjustment • Governor Lever Position A - Key Switch OFF (Engine Stop Position) B - Key Switch ON (Engine Start Position) A

B

FULL

STOP

FULL T105-07-04-003

STOP

• Fuel Cut Lever Position A - Fuel Cut-Off Handle Pulled Position B - Fuel Cut-Off Handle Returned Position

B

A B

T105-07-04-003

T4-6-5

OPERATIONAL PERFORMANCE TEST / Adjustment (Blank)

T4-6-6

SECTION 5

TROUBLESHOOTING CONTENTS Group 1 General

Group 3 Troubleshooting A

Introduction ............................................... T5-1-1

Troubleshooting A Procedure ....................T5-3-1

Diagnosing Procedure .............................. T5-1-2

Fault Code List ..........................................T5-3-2

Built-In Diagnosing System Operation ...... T5-1-6

Fault Code 01, 02, 03................................T5-3-3

Built-In Diagnosing Function Display List .. T5-1-7

Fault Code 04............................................T5-3-3

Dr. ZX Operation ....................................... T5-1-8

Fault Code 06............................................T5-3-4

Dr. ZX Fault Code List............................. T5-1-10

Fault Code 07............................................T5-3-5

Dr. ZX Monitoring Item List ..................... T5-1-12

Fault Code 08............................................T5-3-6

Dr. ZX Special Function .......................... T5-1-14

Fault Code 10, 11 ......................................T5-3-7

Dr. ZX Service Mode............................... T5-1-15

Fault Code 12, 13......................................T5-3-8

Adjustment Data List............................... T5-1-25

Fault Code 14, 15, 16, 18..........................T5-3-9

Initial Setting of Boom Electronic

Fault Code 19..........................................T5-3-10

Cushion................................................. T5-1-27

Group 4 Troubleshooting B Group 2 Component Layout

Troubleshooting B Procedure ....................T5-4-1

Main Component Layout ........................... T5-2-1

Relationship between Machine Trouble Symptoms and Related Parts ..................T5-4-2

Electrical Component Layout (Overview) .. T5-2-4

Correlation between Trouble

Electrical System

Symptoms and Part Failures .................T5-4-24

(Relays and Related Equipment) ............ T5-2-7

Engine System Troubleshooting ..............T5-4-37

Electrical System (Monitors and Switches).......................... T5-2-9 Pump Device .......................................... T5-2-10

All Actuator System Troubleshooting .......T5-4-58 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 Signal Control Valve Port Location......................................... T5-2-26

178T-5-1

Procedure............................................ T5-4-116

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 procedures after any machine trouble has occurred. The inspection and troubleshooting procedures are presented in an orderly fashion in this section to quickly find the cause of the machine trouble and solution. The troubleshooting section in this manual consists of 7 groups; General, Component Layout, Troubleshooting A (base machine diagnosis using fault codes), Troubleshooting B (base machine diagnosis starting with inspection of abnormal operational status), Troubleshooting C (monitor diagnosis), Electrical System Inspection, and ICX.

• Troubleshooting B (base machine diagnosis starting with inspection of abnormal operational status) Refer to these procedures when no fault codes are displayed after diagnosing the machine with Dr. ZX (or the built-in diagnosing system). Trace the cause of trouble based on the inspected result of the abnormal symptom. Example: Even if the engine control dial is operated, engine speed remains unchanged.

• Troubleshooting C (monitor diagnosis)

• General

Refer to these procedures when gauges and/or indicators are malfunctioning.

• Component Layout

Example: Malfunction of fuel gauge

• Troubleshooting A (base machine diagnosis using fault codes) Refer to these procedures if any fault codes are displayed when the main controller (MC) is diagnosed with Dr. ZX (or the built-in diagnosing system). (MC self-diagnosing function retains a record of the electrical signal system malfunction in the form of fault codes.) Example: Fault Code 06: Abnormal EC Sensor

• Electrical System Inspection Refer to this group when required to obtain precautions and/or information for the electrical system inspection. Example: Fuse Inspection

• ICX Refer to these procedures after any fault code is displayed after diagnosing ICX (Information Controller) or the satellite terminal (optional) with Dr. ZX. (The controller self-diagnosing function retains a record of the electrical signal system malfunction 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

TROUBLESHOOTING / General DIAGNOSING PROCEDURE These six basic steps are essential for efficient troubleshooting: 1. Study the System Study the machine’s 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 Before inspecting, get malfunctions from your operator.

T107-07-01-001

the star

full story of witness … the

(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

TROUBLESHOOTING / General 3. Inspect the machine Before starting the troubleshooting procedure, check the machine’s daily maintenance points, as shown in the operator's manual. 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. 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

T107-07-01-003

TROUBLESHOOTING / General 5. Perform troubleshooting CAUTION: Never attempt to disconnect harnesses or hydraulic lines while the engine is running. The machine may malfunction or pressurized oil may spout, possibly resulting in personal injury. Be sure to stop the engine before disconnecting harnesses or hydraulic lines. Perform diagnosis by connecting Dr. ZX to the machine or by operating the built-in diagnosing system. In case any fault code has been displayed by diagnosis using Dr. ZX (or the built-in diagnosing system), delete the fault code once 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 problems, 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 related parts/component operating condition using the monitor function of Dr. ZX (or the built-in diagnosing system) while referring to troubleshooting B in this section. ※ Note that the fault codes displayed do not necessarily indicate machine trouble. The 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 appropriate repairs to avoid consequent malfunctions.

T5-1-4

T107-07-01-005

T107-07-01-006

T107-07-01-007

TROUBLESHOOTING / General (Blank)

T5-1-5

TROUBLESHOOTING / General BUILT-IN DIAGNOSING SYSTEM OPERATION IMPORTANT: This system is to be operated by the HITACHI Dealer Only. Don’t explain this system function to the customer. 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. Built-In Diagnosing System Operation 1. Each time the display selection switch is pressed, 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 one fault code is indicated, they will be displayed 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 right. The item description is not displayed.

T5-1-6

Display Selection Switch SET Switch

LCD

T178-01-01-003

TROUBLESHOOTING / General BUILT-IN DIAGNOSING FUNCTION DISPLAY LIST Display Order 1 2 3 4 5 6 7 8 9 10

Description Hour Meter Trip 1 Trip 2 Engine Actual Speed

{{{{{ h {{{{{ h {{{{{ h n {{{{

Hydraulic Oil Temperature

{{{

Overload Alarm Fault Code* ML Switch**

21

Pump 1 Delivery Pressure Pump 2 Delivery Pressure Pump 1 Pump (Flow) Control Pressure Pump 2 Pump (Flow) Control Pressure Engine Target Speed EC Angle Dial Angle Boom Raise Pilot Pressure Arm Roll-In Pilot Pressure Swing Control Pilot Pressure Travel Control Pilot Pressure Front Att. Operation

22 23

Att. Control Pressure Work Mode

11 12 13 14 15 16 17 18 19 20

Monitored Result

Unit

min

-1

°C

L1 {{{ L2 {{{ 0 {{ 1 {{

－ % － 0: Switch OFF 1: Switch ON MPa

Remarks Standard Mode Standard Mode (Subtraction) Standard Mode (Subtraction) User Mode (Required to set in the Dr. ZX service mode) User Mode (Required to set in the Dr. ZX service mode) Display Purpose Only European Spec. Only Possible to display Possible to display

2

{{

3

{{

MPa

Possible to display

4

{{

MPa

Possible to display

5

{{

MPa

Possible to display

6 7 8 9

{{ {{ {{ {{

min V V MPa

-1

Possible to display Possible to display Possible to display Possible to display

A

{{

MPa

Possible to display

b

{{

MPa

Possible to display

c

{{

MPa

Possible to display

d

{{

Possible to display

E F

{{ {{

0: Not Operating 1: Operating MPa 0: Digging 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

Possible to display

Possible to display Possible to display

TROUBLESHOOTING / General Dr. ZX OPERATION

Except ZAXIS225US: Rear Console

Dr. ZX is a troubleshooting tool to diagnose the electronic control system including the MC (main Controller) and ICX (Information Controller). When Dr. ZX is connected to either the MC or the ICX, it displays whether the controllers and sensors operate normally in the form of fault codes (Self-Diagnosing Result Display Function). In addition, Dr. ZX can display the inputs from sensors and switches to the MC and/or the outputs to actuators such as solenoid valves from the MC in real time while operating the machine (Monitor Display Function).

Fuse Box Dr. ZX Connector (MC)

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 the ICX.

Dr. ZX Connector (ICX) (Located at Backside of Sheet) T178-01-02-006

ZAXIS225US:

Fuse Box Dr. ZX Connector (ICX) (Located at Backside of Sheet)

Dr. ZX Connector (MC) T1SM-01-02-006

Palm （Dr. ZX）

Hot Sync Cable

Battery Box Cable

T178-05-01-167

T5-1-8

TROUBLESHOOTING / General Operation 1. Connect palm (Dr. ZX) to the diagnosis connectors (MC and ICX) located in the cab, using Hot 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 displays the following screens in order. 3-1. Title Screen Select the Dr. ZX icon 3-2. Select Kind Screen + Select the EPVC-Mid 3-3. Menu Screen Select the Start. 3-4. Model Name Screen (Example) Model: ZX200/ZX225USR 3-5. Function Selection Screen + Self-Diagnostic Results +

Monitor Display

+

Special Function

Start

Title Screen

Cannot Communicate · Check harness · Check fuse

OK ?

4. Select Self-Diagnostic Results. Then, continue to operate palm by following instructions to be displayed at the screen bottom hereafter.

OK

Self-Diagnosing Result Display Function

Self-diagnostic Result by controller is displayed

Retry B

Self-diagnostic Result is displayed

T5-1-9

Menu Screen

Model Name Confirmation

NOTE: Special functions allow the ECO and WU deactivation. (Refer to T5-1-14)

NOTE: Refer to the Dr. ZX Operation Manual for the detailed operation of Dr. ZX.

Select Kind Screen

Select function

Record

NOT OK

Replace software

Monitor

Special Function

Enter model code and serial No.

Select data to be monitored

Monitored data is displayed

TROUBLESHOOTING / General DR. ZX FAULT CODE LIST Fault Code 01 02 03 04

Trouble Abnormal EEPROM Abnormal RAM Abnormal A/D Conversion Abnormal Sensor Voltage

Cause • Faulty MC

06

Abnormal EC Sensor

07

Abnormal Engine Control Dial Angle

10 11

Abnormal Pump 1 Delivery Pressure Abnormal Pump 2 Delivery Pressure

12 13

Abnormal Pump1 Pump Control Pressure Abnormal Pump2 Pump Control Pressure

14 15 16 18 19

Abnormal Swing Pilot Pressure Abnormal Boom Raise Pilot Pressure Abnormal Arm Roll-In Pilot Pressure Abnormal Travel Pilot Pressure Abnormal Hydraulic Oil Temperature

• Faulty MC • Faulty Harness • Faulty Sensor • Faulty MC • Faulty Harness • Faulty EC Sensor • Faulty MC • Faulty Harness • Faulty Engine Control Dial • Faulty MC • Faulty Harness • Faulty Pump Delivery Pressure Sensor • Faulty MC • Faulty Harness • Faulty Pump Control Pressure Sensor • Faulty MC • Faulty Harness • Faulty Pilot Pressure Sensor • Faulty MC • Faulty Harness • Faulty Hydraulic Oil Temperature Sensor

T5-1-10

TROUBLESHOOTING / General (Blank)

T5-1-11

TROUBLESHOOTING / General DR. ZX MONITORING ITEM LIST DR. ZX displays the input signals from the switches and sensors to the MC and the control signals to the actuators from the MC. Item Pump 1 Delivery Pressure Pump 1 Pump (Flow) Control Pressure Pump 2 Delivery Pressure Pump 2 Pump (Flow) Control Pressure Pump 2 Max. Displacement Engine Target Speed Engine Actual Speed Deviation in Engine Speed (Engine Speed Differential) EC Angle Dial Angle Boom Raise Pilot Pressure Arm Roll-In Pilot Pressure Swing Control Pressure Travel Control Pressure Front Att. Operation Hydraulic Oil Temperature E/P/HP Mode Switch Auto-Idle/Auto-Accel Switch Travel Mode Power Digging (Boost) Switch Key Switch Work mode ATT. Mode Engine Learning Status Pump 2 Proportional Solenoid Valve Output Pump Torque Proportional Solenoid Valve Output

Data Input signals from pump 1 delivery pressure sensor Input signals from pump 1control pressure sensor

MPa MPa

Unit

Input signals from pump 2 delivery pressure sensor Input signals from pump 2control pressure sensor

MPa MPa

cm3 Target speed when loaded. Approx. 150 min differs min-1 from speed when unloaded. Input signal from N sensor min-1 Calculated Value min-1 (Target Engine Speed - Actual Engine Speed) Input signal from EC sensor V Input signal from engine control dial V Input signal from pressure sensor (boom raise) MPa Input signal from pressure sensor (Arm Roll-In) MPa Input signal from pressure sensor (swing) MPa Input signal from pressure sensor (travel) MPa Input signal from pressure sensor (front att.) FR Input signal from oil temperature sensor °C Power mode switch selection status E, P, HP Auto-Idle/Auto-Acceleration selector selection status AI, AA -1

Travel mode switch selection status Power digging switch selection status Key switch selection status Work mode switch selection status

Lo, Hi Pd

Ky STD, ATT BU, CS, CL, HB Done, Undone, Aborted Ky Control signal to max. pump 2 flow rate limit solenoid MPa valve Control signal to torque control solenoid valve MPa

T5-1-12

TROUBLESHOOTING / General

Item ****Arm Flow Rate Proportional Solenoid Valve Output Arm Regenerative Proportional Solenoid Valve Output ***Boom Damper P/S Valve Output (BDMO) Power Digging (Boost) Control Pressure Travel Motor Control Pressure EC Motor Position

Data Control signal to solenoid valve SE

MPa

Unit

Control signal to solenoid valve SC

MPa

Control signal to boom electronic cushion sole- MPa noid valve Control signal to solenoid valve SG MPa Control signal to solenoid valve SI

MPa step

Optional Item Optional Pump 3 Delivery Pressure Boom Cylinder Bottom Pressure Boom Cylinder Rod Pressure Arm Roll-Out Pilot Pressure ATT. Control Pressure Boom Angle Arm Angle Pump 1 Max. Displacement *Boom Dampener Switch Pump 1 Proportional Solenoid Valve Output ATT. Proportional Solenoid Valve Output *Boom Dampener Proportional Valve Output Travel/Swing/Load Alarm Initial **ML Setting

Data Input signal from pump 3 delivery pressure sensor

Input signal from pressure sensor (arm roll-out) Input signal from pressure sensor (auxiliary)

Control signal to pump 1 flow rate control solenoid valve

Unit MPa MPa MPa MPa MPa V V cm3 OFF, SOFT, HARD MPa MPa MPa Tr, Sw, Load Unf, Done, Abrt, Und Unf, Done, Abrt, Und

Initial Boom-Angle Setting

NOTE: ML specification is only available in Japanese domestic market. * Available for only ZX200 class and ZAXIS225USR. ** Initial boom electronic cushion setting is also possible in this item for ZAXIS225US (Up to serial No. 104908).

T5-1-13

NOTE: *** Available for ZAXIS225US (Up to serial No. 104908). **** Available for ZX200, 225 class (Up to serial No.104678) and ZX230 class (Up to serial No. 010326) and ZX270 class (Up to Serial No 020042).

TROUBLESHOOTING / General Dr. ZX SPECIAL FUNCTION NOTE: The following explanation exemplifies the transition diagrams for ZAXIS200. Start the service software in the operation mode

Select a special function

If the following screen appears, you are in the operation mode. Select Special Function.

Select the function you want to execute.

Fig. A

T178-05-01-013

Fig. B

T178-05-01-168

Select ESC to return to Fig. A.

Special function Select Execute to execute the function.

ECO control deactivation

WU deactivation

Execute

Execute

T178-05-01-030

Select ESC to return to Fig. B.

T178-05-01-031


T5-1-14

T178-05-01-032


T178-05-01-033


TROUBLESHOOTING / General Dr. ZX SERVICE MODE Except ZAXIS225US

Dr. ZX has three (3) modes, learning value display, parameter change, and monitor display information setting.

Engine Learning Switch

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 1. After turning the key switch OFF, wait for more than 10 seconds. 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. Don’t start the engine at this time. 5. Turn Dr. ZX switch ON.

T178-01-02-006

ZAXIS225US

Learning Switch

Dr. ZX Connector to MC

T1SM-01-02-006

The learning switch is turned to the stamped mark E Learning Switch

Stamped Mark E

T1CC-05-01-001

T5-1-15

TROUBLESHOOTING / General Item Learning Data Display EC Motor Stop Position EC Motor Maximum Speed Position Boom Angle Sensor Correction Value Arm Angle Sensor Correction Value Parameter Change Li Speed Adjustment WU Speed Adjustment AI Speed Adjustment E Speed Adjustment P Speed Adjustment Breaker Engine Speed Adjustment Secondary Crusher (Demolisher) Engine Speed Adjustment Crusher Engine Speed Adjustment Vibro-Hammer Speed Adjustment Hyd. Breaker P1 Max Swash Angle Adjustment Secondary Crusher (Demolisher) P1 Max Swash Angle Adjustment Crusher P1 Max Swash Angle Adjustment Vibro P1 Max Swash Angle Adjustment Hyd. Breaker P2 Max Swash Angle Adjustment Secondary Crusher (Demolisher) P2 Max Swash Angle Adjustment Crusher P2 Max Swash Angle Adjustment Vibro P2 Max Swash Angle Adjustment Pump PQ Base Torque Correction ATT Proportional Solenoid Valve Adjustment

Data Display of the engine stop value in engine learning Display of max. engine speed valve in engine learning Display of boom angle sensor correction value Display of arm angle sensor correction value Adjustment of minimum engine speed Adjustment of warming up engine speed Adjustment of auto-idle engine speed Adjustment of E-mode engine speed Adjustment of P-mode engine speed Adjustment of breaker operation engine speed Adjustment of secondary crusher (demolisher) operation engine speed Adjustment of crusher operation engine speed Adjustment of vibratory hammer operation engine speed Adjustment of lowest pump 1 max. flow rate in breaker operation Adjustment of lowest pump 1 max. flow rate in secondary crusher operation Adjustment of lowest pump 1 max. flow rate in crusher operation Adjustment of lowest pump 1 max. flow rate in vibratory hammer operation Adjustment of lowest pump 2 max. flow rate in breaker operation Adjustment of lowest pump 2 max. flow rate in secondary crusher operation Adjustment of lowest pump 2 max. flow rate in crusher operation Adjustment of lowest pump 2 max. flow rate in vibratory hammer operation Adjustment of pump P-Q curve Adjustment of optional solenoid valve

T5-1-16

TROUBLESHOOTING / General Item Data Boom Lower Dampener Proportional Adjustment of solenoid valve Solenoid Valve Adjustment ATT Speed Increase Down Waiting Time Setting of time required for engine speed increase **ATT Torque Down ON/OFF ON/OFF of torque down control, when a front attachment is operated. *ML Crane Front Code Change Setting of front att. code for ML models *ML Crane Bucket Code Change Setting of bucket code for ML models Max. *ML Crane Speed Adjustment Setting of engine speed in crane mode *ML Crane Bucket Weight Adjustment Min, Boom CYL. Bottom Pressure Over Balance Monitor Display Change Engine Actual Speed Display/Non-display Monitor setting of display/no-display of actual engine speed Hydraulic Oil Temperature Display/No-display Monitor setting of display/no-display of hydraulic oil temperature Hydraulic Oil Filter LED Display/No-display Monitor setting of ON/OFF of hydraulic oil filter LED. NOTE: * ML specification is only available in Japanese domestic market. ** Available for ZX200 class and ZX225 class.

T5-1-17

TROUBLESHOOTING / General Displaying Engine Learning Data and Angle Sensor Correction Valve NOTE: The following explanation exemplifies the transition diagrams for ZAXIS200. Start the service software in the service mode Select Start from the EPVC_Mid software menu.

Fig. A

T178-05-01-006

The service software will start in the service mode Press Correct displayed model correct.

Fig. B

if the name is

T178-05-01-012

Confirm that you are in the service mode, and select Rechecked.

Fig.C

Select the function you want to execute

Learning data items will be displayed

The menu will be displayed. Select Learning Data Display from the menu.

Select the item you want to execute.

Fig. E

Fig. F

T178-05-01-036

Select ESC to return to Fig. D.

T178-05-01-034



T178-05-01-037

Select ESC to return to Fig. F.

T5-1-18

Select Special Function.

Fig. D

T178-05-01-035



EC Motor stop position

T178-05-01-038


EC Motor Maximum engine speed position

T178-05-01-039


T5-1-19

Boom angle sensor correction value

T178-05-01-040


Arm angle sensor correction value

T178-05-01-041


TROUBLESHOOTING / General Changing Parameters In The Controller NOTE: The following explanation exemplifies the transition diagrams for ZAXIS200. Start the service mode on the condition that the engine learning switch is turned on. To change the parameter, it is necessary to enter the password. To change the password, refer to the “Changing the password” section. Start the service software in the service mode Select Start from the EPVC_Mid software menu.

Fig. A

T178-05-01-006

The service software will start in the service mode Press Correct if the displayed model name is correct.

Fig. B


Fig. C

T178-05-01-012

Enter the password

The menu will be displayed. Select Parameter Change from the menu.

Enter the password to change the parameter.

T178-05-01-042


Fig. F

Fig. D


Execute the parameter change

Fig. E

T178-05-01-034



T178-05-01-043

Select ESC to return to Fig. E.

T178-05-01-035

Select ESC to return to Fig. A

Select a parameter change item Select the item you want to change. The up- and down-arrow buttons can be used to scroll through the item list.

Fig. G

T5-1-20

T178-05-01-044



Enter the new value

Confirm the new value

Parameter adjustment result

Enter the new value in the Adjustment space, and press Execution.

The new value will be displayed in the Adjustment space. Select Execute to change to this value.

The adjusted value will be displayed.

T178-05-01-045

Select ESC to return to Fig. G.

T178-05-01-047

T178-05-01-046



T5-1-21

TROUBLESHOOTING / General Changing The User Mode Display on The Monitor Panel NOTE: The following explanation exemplifies the transition diagrams for ZAXIS200. Start the service mode on the condition that the engine learning switch is turned on. Start the service software in the service mode Select Start from the EPVC_Mid software menu.

Fig. A

T178-05-01-006

The service software will start in the service mode Press Correct if the displayed model name is correct.

Fig. B

T178-05-01-012


Fig. C


T178-05-01-034


Fig. D

T178-05-01-035



Execute the monitor display change

Select a display change item

The menu will be displayed. Select Monitor Display from the menu.

Select the monitor display change item you want to execute.

Select Disp or No Disp.

Fig. F

Fig. G

Fig. E

T178-05-01-042


T178-05-01-048


T5-1-22

Select Display or No Display

T178-05-01-049



Confirm Disp/No Disp

Confirm the result

Confirm that the Monitor space shows Disp or No Disp. If it is correctly displayed, select Execute.

It has been changed as shown on-screen. Select ESC.

Fig. H

Fig. I

T178-05-01-050

Select ESC to return to Fig.F.

T178-05-01-051


T5-1-23

TROUBLESHOOTING / General • 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. 2. 3. 4.

Turn the key switch OFF. Wait approx. 10 seconds. Turn the engine learning switch to neutral. 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

TROUBLESHOOTING / General ADJUSTMENT DATA LIST Adjustment Data

Min. Adjustment Value

Li Speed

10 min-1

WU Speed

10 min-1

AI Speed

10 min-1

E Speed

10 min-1

P Speed

10 min-1

Breaker Speed

10 min-1

Secondary Crusher (Demolisher) Speed

10 min-1

Crusher Speed

10 min-1

Vibro-Hammer Speed

10 min-1

Hyd. Breaker P1 Max Swash Angle Secondary (Demolisher) P1 Max Crusher Swash Angle Crusher P1 Max Swash Angle

0.6 cm3/rev

Vibro Swash Angle

0.6 cm3/rev

Hyd. Breaker P2 Max Swash Angle Secondary Crusher (Demolisher) P2 Max Swash Angle Crusher P2 Max Swash Angle

0.6 cm3/rev

Vibro P2 Max Swash Angle

0.6 cm3/rev 0.6 cm3/rev

Adjustable Range Model ZX200/225/230/ 270 class ZX200/225/230/ 270 class ZX200/225/230/ 270 class ZX200/225/230/ 270 class ZX200/225 class ZX270/270 class ZX200/225 class ZX270/270 class ZX200/225 class ZX270/270 class ZX200/225 class ZX270/270 class ZX200/225 class ZX270/270 class ZX200/225/230/ 270 class ZX200/225/230/ 270 class ZX200/225/230/ 270 class ZX200/225/230/ 270 class ZX200/225/230/ 270 class

0.6 cm3/rev

ZX200/225/230/ 270 class

0.6 cm3/rev

ZX200/225/230/ 270 class ZX200/225/230/ 270 class

0.6 cm3/rev

T5-1-25

Range

Standard Adjustment

0 to 120

0 min-1

-120 to 120

0 min-1

-120 to 120

0 min-1

-120 to 120

0 min-1

-120 to 120 -120 to 100 -500 to 200 -500 to 100 -500 to 200 -500 to 100 -500 to 200 -500 to 100 -500 to 200 -500 to 100

0 min-1 0 min-1 200 min-1 100 min-1 200 min-1 100 min-1 0 min-1

51 to 112.8

112.8 cm3/rev

51 to 112.8

112.8 cm3/rev

51 to 112.8

112.8 cm3/rev

51 to 112.8

112.8 cm3/rev

51 to 112.8

112.8 cm3/rev

51 to 112.8

112.8 cm3/rev

51 to 112.8

112.8 cm3/rev

51～112.8

112.8 cm3/rev

Remarks


Adjustment Data Pump PQ Base Torque Adjustment ATT Proportional Solenoid Valve Boom Lower Dampener Proportional Solenoid Valve ATT Speed Increase Down Wait Time **ATT Torque Down ON/OFF

Min. Adjustment Value 2.45 N⋅m 0.1 MPa 0.1 MPa 500 ms

1 digit

*ML Crane Front Code

1

*ML Crane Bucket Code

1

Max. *ML Crane Speed

10 min-1

*ML Crane Bucket Weight Min Boom CYL Bottom Pressure Over Balance

4 kg 0.1 MPa

Adjustable Range Model ZX200/225/ 230/270 class ZX200/225/ 230/270 class ZX200/225/ 230/270 class ZX200/225/ 230/270 class ZX200/ 225 class ZX200/225/ 230/270 class ZX200/225/ 230/270 class ZX200/ 225class 230 class 270 class ZX200/225/ 230/270 class ZX200/225/ 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

Range

Standard Adjustme nt

-78.4 to 0

0 N⋅m

-0.89 to 0.89

0 MPa

-0.89 to 0.89

0 MPa

0 to 3000

3000 ms

0 to 1

1 digit

0 to 2

0

0 to 1

0

-500 to 300 -550 to 430 -600 to 430

0 min-1

-512 to 508

0 kg

-9.81 to 9.81

0 MPa

Remarks

0: ATT Torque Down Control Activation 1: ATT Torque Down Control Deactivation

TROUBLESHOOTING / General 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.) NOTE: Every boom operation is kept at slow speed, if the initial setting fails or the related sensor is faulty. 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. 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 displayed on LCD. 6. Turn the learning switch to neutral. 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.

Display Selection Switch Set Switch

LCD

T178-01-02-008

Engine Learning Switch:

Initial Setting of Boom Electronic Cushion Side


T5-1-27

T1SM-01-02-006


Fault Code 000 80 83 87 88

Contents Initial Setting Not Completed Abnormal Boom Angle Sensor Connection Abnormal Boom Angle Sensor Abnormal EEPROM Key OFF During Initial Setting

Remarks Initial setting has not been completed yet. Value on the sensor before the initial setting is over (standard initial setting valve) ± 0.3 V. Value on the sensor is 0.25 V and less, or 4.75 V and more. Writing EEPROM is abnormal. During the initial setting, the key switch was turned OFF.

T5-1-28

TROUBLESHOOTING / Component Layout MAIN COMPONENT LAYOUT ZX200 class, 230 class, 270 class

2 1

3

4

5

6

7 8 9

21

10 11 12 20 19

16 18

17

1- Bucket Cylinder 2- Arm Cylinder 3- Boom Cylinder

7- Fuel Tank 8- Hydraulic Oil Tank 9- Control Valve

13- Intercooler 14- Radiator 15- Oil Cooler

4- Center Joint 5- Swing Bearing 6- Swing Device

10- Pilot Filter and Pilot Relief Valve 11- Pump Device 12- Engine

16- Battery 17- Travel Device 18- Signal Control Valve

T5-2-1

15

14

13

T178-01-02-001

19- Pilot Shut-Off Valve 20- Travel Pilot Valve 21- Front Attachment/Swing Pilot Valve

TROUBLESHOOTING / Component Layout ZAXIS225US

1 2

3 4 5 6 7 8 9 21 18

20 19

10

18

11 17 16

12 13 15

1 - Bucket Cylinder 2 - Arm Cylinder 3 - Boom Cylinder

7 - Hydraulic Oil Tank 8 - Swing Device 9 - Pump Device

13 - Oil Cooler 14 - Intercooler 15 - Battery

4 - Signal Control Valve

10 - Pilot Filter and Pilot Relief Valve 11 - Engine 12 - Radiator

16 - Fuel Tank

5 - Control Valve 6 - Solenoid Valve Unit

17 - Center Joint 18 - Front Attachment/Swing Pilot Valve

NOTE: *Up to serial No.104908.

T5-2-2

14

T1GF-01-02-001

19 - Pilot Shut-Off Valve 20 - Travel Pilot Valve 21 - Boom Electronic Cushion Solenoid Valve*

TROUBLESHOOTING / Component Layout ZAXIS225USR

1

2

3 4 5 6

7

20

8 9

10 11

19 12

18

13

17 14

16

T1GD-01-02-001

15

1 - Bucket Cylinder

6 - Solenoid Valve Unit

2345-

78910 -

Arm Cylinder Boom Cylinder Signal Control Valve Control Valve

Fuel Tank Hydraulic Oil Tank Swing Device Pump Device

11 - Pilot Filter and Pilot Relief Valve 12 - Engine 13 - Radiator 14 - Oil Cooler 15 - Inter Cooler

T5-2-3

16 - Battery 17 18 19 20 -

Center Joint Pilot Shut-Off Valve Travel Pilot Valve Front Attachment/Swing Pilot Valve

TROUBLESHOOTING / Component Layout ELECTRICAL (Overview)

COMPONENT

LAYOUT

ZX200 class, 230 class and 270 class • Pump 1 and 2 Delivery Pressure Sensor • Pump 1 and 2 Control Pressure Sensor • N Sensor • Torque Control Solenoid Valve • Pump 2 Flow Rate Control Solenoid Valve Refer to the Pump Device group.

1

2

3

4 5 7 6

8

• Pressure Sensor (Travel) • Pressure Sensor (Swing) 9 Refer to the Signal Control Valve group.

18 17 16 15 14

10

13

11

T178-01-02-002

• Pressure Sensor (Front Attachment) Refer to the Swing Device group.

1 - Overheat Switch 2 - Coolant Temperature Sensor 3 - Battery Relay 4 - Glow Relay 5 - Fusible Link

• Pressure Sensor (Boom Raise) • Pressure Sensor (Arm Roll-In) Refer to the Control Valve group.

12

6 - Coolant Level Switch* 7 - Battery

11 - Horn 12 - Work Light

15 - Solenoid Valve Unit 16 - Engine Oil Level Switch*

8 - Starter Relay 9 - Air Cleaner Restriction Switch 10 - Wiper Motor

13 - Fuel Sensor 14 - Hydraulic Oil Temperature Sensor

17 - Engine Oil Pressure Switch 18 - EC Motor and EC Sensor

NOTE: *Up to serial No.104679 (ZX200 class) Up to serial No.010326 (ZX230 class) Up to serial No.020042 (ZX270 class)

T5-2-4

TROUBLESHOOTING / Component Layout ZAXIS225US • Pump 1 and 2 Delivery Pressure Sensor • Pump 1 and 2 Control Pressure Sensor • N Sensor • Torque Control Solenoid Valve • Pump 2 Flow Rate Control Solenoid Valve Refer to the Pump Device group.

1

2

3

4

5

6

7

8 9 10

11

12

19

18

17

16

15 13

14 • Pressure Sensor (Boom Raise) • Pressure Sensor (Arm Roll-In) Refer to the Control Valve group.

1 - Overheat Switch 2 - Coolant Temperature Sensor 3 - Battery Relay 4 - Glow Relay 5 - Fusible Link

• Pressure Sensor (Travel) • Pressure Sensor (Swing) Refer to the Signal Control Valve group.

6 - Air Cleaner Restriction Switch 7 - Fuel Sensor 8 - Coolant Level Switch* 9 - Starter Relay 10 - Battery

T1GF-01-02-002


11 - Wiper Motor 12 - Boom Angle Sensor 13 - Horn 14 - Boom Electronic Cushion Solenoid Valve 15 - Solenoid Valve Unit


T5-2-5

16 - Hydraulic Oil Temperature sensor 17 - Engine Oil Level Switch* 18 - EC Motor and EC Sensor

TROUBLESHOOTING / Component Layout ZAXIS225USR • Pump 1 and 2 Delivery Pressure Sensor • Pump 1 and 2 Control Pressure Sensor • N Sensor • Torque Control Solenoid Valve • Pump 2 Flow Rate Control Solenoid Valve Refer to the Pump Device group.

1

2

3

4

5

6

7 17

8 9

10

16 15 14 13

12 T1GD-01-02-002

11 • Pressure Sensor (Boom Raise) • Pressure Sensor (Arm Roll-In) Refer to the Control Valve group.

1 - Over Heat Switch 2 - Coolant Temperature Sensor 3 - Air Cleaner Restriction Switch 4 - Glow Relay 5 - Battery Relay

• Pressure Sensor (Travel) • Pressure Sensor (Swing) Refer to the Signal Control Valve group.


6 - Fusible Link 7 - Starter Relay

11 - Horn 12 - Solenoid Valve Unit

8 - Coolant Level Switch*

13 - Hydraulic Oil Temperature Sensor 14 - Engine Oil Lever Switch* 15 - Engine Oil Pressure switch

9 - Battery 10 - Wiper Motor


T5-2-6

16 - Fuel Sensor 17 - EC Motor and EC Sensor

TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM (Relays and Related Equipment) Except ZAXIS225US 4

Rear Deck

5

3

6

2

7

8 9 1

10

T178-01-02-006

15 14

18

13

17

12

16

11 T178-01-02-007

1- Satellite Terminal ON/OFF Switch (Satellite Navigation System Equipped Machines only) 2- QOS Controller 3- ICX (Information Controller) 4- MC (Main Controller) 5- Satellite Terminal (Optional)

6- Fuse Box

11- Load Damp Relay (R1)

16- Wiper Relay A (R6)

7- Learning Switch 8- Dr. ZX Connector to MC 9- Download Connector (Not connected in Satellite Terminal equipped machines) 10- Dr. ZX Connector to ICX

12- Washer Relay (R2) 13- Work Light Relay 2 (R3) 14- Work Light Relay 1 (R4)

17- Wiper Relay B (R7) 18- Wiper Relay C (R8)

T5-2-7

15- Horn Relay (R5)

TROUBLESHOOTING / Component Layout ZAXIS225US 15

4 16

14

17

13 12 11

5

10

T1GF-01-02-003

1, 2

3 6 9

8

7 T1SM-01-02-006

1 - ICX (Information Controller) 2 - MC (Main Controller) 3 - Satellite Terminal (Optional) 4 - Download Connector 5 - Diode D1, D2, D3, D4

6 - Fuse Box 7 - Dr. ZX Connector to MC 8 - Dr. ZX Connector to ICX

11 - Work Light Relay 1 (R4) 12 - Work Light Relay 2 (R3) 13 - Washer Relay (R2)

9 - * Learning Switch 10 - Horn Relay (R5)

14 - Load Dump Relay (R1) 15 - Wiper Relay A (R6)

NOTE: It is used for engine learning and the initialization of the boom electronic cushion (Up to serial No.104908).

T5-2-8

16 - Wiper Relay B (R7) 17 - Wiper Relay C (R8)

TROUBLESHOOTING / Component Layout ELECTRICAL Switches)

SYSTEM

1

(Monitors

and

2 20

19

21

18 17

3 22

16

4

15

23

5

14 13 12 11

24

6 7 8

25 9 10 T178-01-02-008 T178-01-01-004

1- Coolant Temperature Gauge 2- Fuel Gauge 3- Display Selection Switch 4- SET Switch 5- Work Mode Switch 6- Fuel Level Indicator 7- Air Filter Restriction Switch

8- Alternator Indicator 9- Hydraulic Oil Filter Indicator (Optional) 10- Coolant Level Indicator * 11- Engine Oil Level Indicator * 12- Engine Oil Pressure Indicator 13- Preheat Indicator 14- Overheat Indicator

15- Digging Mode Indicator 16- Attachment Mode Indicator

22- Power Mode Switch 23- Travel Mode Switch

17- Liquid Crystal Display 18- Auto-Idle Indicator 19- Auto-Acceleration Indicator

24- Work Light Switch 25- Wiper/Washer Switch

20- Engine Control Dial 21- Auto-Idle/Acceleration Selector

NOTE: * Up to serial No.104679 (ZX200 class and 225 class) Up to serial No.010322 (ZX230 class) Up to serial No.020040 (ZX270 class)

T5-2-9

TROUBLESHOOTING / Component Layout PUMP DEVICE 9 3

2

1

6 7

8

5

4

10

T178-03-01-001 T178-03-01-003

SWING DEVICE ZX200 class, 225 class, 230 class

11

ZX270 class

11 12

12

T178-03-02-001

1- Pump 1 2- Pump 2 3- Pilot Pump

4- Pump 1 Delivery Pressure Sensor 5- Pump 2 Delivery Pressure Sensor 6- Pump 2 Flow Rate Control Solenoid Valve

T1HG-03-02-003

7- Torque Control Solenoid Valve

10- N Sensor

8- Pump 1 Control Pressure Sensor

11- Swing Relief Valve

9- Pump 2 Control Pressure Sensor

12- Pressure Sensor (Front Attachment)

T5-2-10

GENERAL / Component Layout CONTROL VALVE

SOLENOID VALVE UNIT 2

1

Serial No.104679 and up (ZX200 class and 225 class) Serial No.010327 and up (ZX230 class) Serial No.020043 and up (ZX270 class)

7 3

8

9

T178-03-07-005

T178-03-03-001

Up to serial No.104678 (ZX200 class and 225 class) Up to serial No.010326 (ZX230 class) Up to serial No.020042 (ZX270 class)

SIGNAL CONTROL VALVE

4

5 6

7

8

9

T178-01-02-003

T178-03-06-015

1 - Main Relief Valve 2 - Pressure Sensor (Arm Roll-in) 3 - Pressure Sensor (Boom Raise)

4 - Pressure Sensor (Swing) 5 - Pressure Sensor (Travel)

7 - Solenoid Valve Unit (SC) 8 - Solenoid Valve Unit (SI)

6 - Solenoid Valve Unit (SE)*


T5-2-11

10 - Solenoid Valve Unit (SG)

GENERAL / Component Layout TRAVEL DEVICE

POSITIONING CONTROL VALVE

ZX200 class, 225 class and 230 class

(2-piece Boom Only) ZX200 class 1

2

3

T178-03-03-071

1

T1HD-01-02-001

ZX270 class

ZX230 class and ZX270 class

2

1

3

T178-03-03-068

1

T1HG-01-02-002

1- Counterbalance Valve

2- Travel Relief Valve

3- Overload Relief Valve (Positioning)

T5-2-12

TROUBLESHOOTING / Component Layout (Blank)

T5-2-13

TROUBLESHOOTING / Component Layout COMPONENTS IN CONTROL VALVE 1

2

3

4

5

6

7

8

9

10

36

35 34 33

11 12 13

32 31 30

14 15

16 17

29 28

18 19 20 21 22

27 26

25

24 23

T178-03-03-016

1 - Load Check Valve (Travel Parallel Circuit) 2 - Check Valve (Main Relief Circuit) 3 - Main Relief Valve

4 - Check Valve (Main Relief Circuit) 5 - Check Valve (Flow Combiner Valve Circuit) 6 - Flow Combiner Valve 7 - Auxiliary Flow Combiner Valve 8 - Check Valve (Aux. Flow Combiner Valve Circuit) 9 - Bucket Flow Rate Control Valve (Switch Valve)

10 - Bucket Flow Rate Control Valve (Poppet Valve) 11 - Bucket Regenerative Valve 12 - Overload Relief Valve (Bucket: Rod Side) 13 - Overload Relief Valve (Bucket: Bottom Side) 14 - Load Check Valve (Boom 1 Parallel Circuit) 15 - Boom Regenerative Valve 16 - Overload Relief Valve (Boom: Bottom Side) 17 - Overload Relief Valve (Boom: Rod Side) 18 - Boom Anti-Drift Valve (Check Valve)

19 - Boom Anti-Drift Valve (Switch Valve) 20 - Load Check Valve (Arm Tandem Circuit) 21 - Check Valve (Orifice) (4-Spool Side Parallel Circuit) 22 - Bypass Shut-Out Valve

28 - Overload Relief Valve (Arm: Bottom Side) 29 - Overload Relief Valve (Arm: Rod Side) 30 - Arm Anti-Drift Valve (Check Valve)

23 - Arm Flow Rate Control Valve (Poppet Valve)

31 - Arm Anti-Drift Valve (Switch Valve) 32 - Load Check Valve (Boom 2 Parallel Circuit)

24 - Arm Flow Rate Control Valve (Switch Valve) 25 - Load Check Valve (Swing Circuit) 26 - Check Valve (Arm Regenerative Circuit)

33 - Auxiliary Flow Rate Control Valve (Switch Valve) 34 - Auxiliary Flow Rate Control Valve (Poppet Valve) 35 - Load Check Valve (Travel Tandem Circuit)

27 - Arm Regenerative Valve

36 - Load Check Valve (Orifice) (Bucket)

T5-2-14

TROUBLESHOOTING / Component Layout

19 12

Front ZX225 class

29 3 18

22 35

2 20 4

14 9, 10

Front ZX200 class ZX230 class ZX270 class

36

W178-02-05-017












T5-2-15


1

2

3

4

5

6

7

8

9

10

36

35 34 33

11 12 13

32 31 30

14 15

16 17

29 28

18 19 20 21 22

27 26

25

24 23

T178-03-03-016

T5-2-16


Front ZX225 class

25 31 16 30 23, 24

32 33, 34 1 8

7

26 28

Front ZX200 class ZX230 class ZX270 class

17 13 W178-02-05-018

6












T5-2-17

TROUBLESHOOTING / Component Layout 1

2

3

4

5

6

7

8

9

10

36

35 34 33

11 12 13

32 31 30

14 15

16 17

29 28

18 19 20 21 22

27 26

25

H I

24 23

T178-03-03-016

A B

Cross Section C Auxiliary

C

Bucket

D E View K

12

F G

J

34

33

M178-05-003

T5-2-18

10

9 11 13 T178-03-03-005

TROUBLESHOOTING / Component Layout Cross Section A

Cross Section a 5

3

Cross Section J

1

T178-03-03-047

8 a

7

6

T178-03-03-044

T178-03-03-003












T5-2-19


2

3

4

5

6

7

8

9

10

36

35 34 33

11 12 13

32 31 30

14 15

16 17

29 28

18 19 20 21 22

27 26

25

24 23

T178-03-03-016

Cross Section D

Cross Section F Boom 2

29

Boom 1

19 27

18 32

Swing

25

14

15 26

17 T178-03-03-006

T5-2-20

T178-03-03-008

TROUBLESHOOTING / Component Layout Cross Section G

Cross Section E

22

31

16

30

23 20

T178-03-03-009

24

28 T178-03-03-007












T5-2-21


2

3

4

5

6

7

8

9

10

36

35 34 33

11 12 13

32 31 30

14 15

16 17

29 28

18 19 20 21 22

27 26

25

24 23

T178-03-03-016

Cross Section H

Cross Section I

21 4 2

T178-03-03-042

T5-2-22

T178-03-03-041

TROUBLESHOOTING / Component Layout View K

Cross Section L 36

T178-03-03-045

Cross Section M

M

35

L

T178-03-03-046

T178-03-03-048












T5-2-23

TROUBLESHOOTING / Component Layout 2-piece Boom (Optional)

1

2

4 T178-03-03-064

3 1 - Load Check Valve (Positioning Circuit)

2-

Overload Relief Valve (Positioning: Rod Side)

3-

Overload Relief Valve (Positioning: Bottom Side)

T5-2-24

4-

Load Check Valve (Positioning Parallel Circuit)

TROUBLESHOOTING / Component Layout Positioning Control Valve (2-Piece Boom Only) ZX200 class X

2

1 4

X

3

1 - Section X-X

T198-03-03-003

T198-03-03-002

ZX230 class, ZX270 class

2 4

D

D

Section D-D

1

3

T178-03-03-067 T178-03-03-066

T5-2-25

TROUBLESHOOTING / Component Layout SIGNAL CONTROL VALVE PORT LOCATION Pilot Valve Side Port Name Port A

Port B Port C Port D Port E Port F Port G Port H Port I Port J Port K Port L Port M Port N Port SA Port SB Port PI Port PH Port SH Port DF

Connecting to Right Pilot Valve Boom Electronic Cushion Solenoid Valve (Up to serial No.104908 (ZAXIS225US)) Right Pilot Valve Left Pilot Valve Left Pilot Valve Left Pilot Valve Left Pilot Valve Right Pilot Valve Right Pilot Valve Travel Pilot Valve Travel Pilot Valve Travel Pilot Valve Travel Pilot Valve Auxiliary Pilot Valve Auxiliary Pilot Valve Pump 1 Regulator Pump 2 Regulator Pilot Shut-Off Valve Pilot Shut-Off Valve Swing Parking Brake Hydraulic Oil Tank

T5-2-26

Note Boom Raise Pilot Pressure

Boom Lower Pilot Pressure Arm Roll-Out Pilot Pressure Arm Roll-In Pilot Pressure Left Swing Pilot Pressure Right Swing Pilot Pressure Bucket Roll-In Pilot Pressure Bucket Roll-Out Pilot Pressure Left Travel Forward Pilot Pressure Left Travel Reverse Pilot Pressure Right Travel Forward Pilot Pressure Right Travel Reverse Pilot Pressure Auxiliary Open Pilot Pressure Auxiliary Close Pilot Pressure Pump 1 Control Pressure Pump 2 Control Pressure Primary Pilot Pressure Primary Pilot Pressure (Heating Circuit) Brake Release Pressure Returning to Hydraulic Oil Tank

TROUBLESHOOTING / Component Layout Pilot Valve Side

PH

C

A

E M D H B

F

SB G

PI

Pilot Valve Side

N

K

I SH

J DF SA

L T178-03-06-016

Control Valve Side SM

3 5

1 13 2 SK

4 SE 8

Pressure Sensor (Swing)

14 Control Valve Side

7 9 6

10

SN

SL

11

Pressure Sensor (Travel)

12

T5-2-27

SP

T178-03-06-015

TROUBLESHOOTING / Component Layout Control Valve Side Port Name Port 1 Port 2 Port 3 Port 4 Port 5 Port 6 Port 7 Port 8 Port 9 Port 10 Port 11 Port 12 Port 13 Port 14 Port SE

Connecting to Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve  (Up to serial No.104678 (ZX200 class and 225 class), Up to serial No.010326 (ZX230 class), Up to serial No.020042 (ZX270

Note Boom Raise Pilot Pressure Boom Lower Pilot Pressure Arm Roll-Out Pilot Pressure Arm Roll-In Pilot Pressure Left Swing Pilot Pressure Right Swing Pilot Pressure Bucket Roll-In Pilot Pressure Bucket Roll-Out Pilot Pressure Left Travel Forward Pilot Pressure Left Travel Reverse Pilot Pressure Right Travel Forward Pilot Pressure Right Travel Reverse Pilot Pressure Auxiliary Open Pilot Pressure Auxiliary Close Pilot Pressure Plug (Up to serial No.104678 (ZX200 class and 225 class), Up to serial No.010326 (ZX230 class), Up to serial No.020042 (ZX270 class))

class))

Port SM Port SN Port SP Port SL Port SK

Control Valve (Serial No.104679 and up (ZX200 class and 225 class), Serial No.010327 and up (ZX230 class) Serial No.020043 and up (ZX270 class)) Hydraulic Oil Tank  Hydraulic Oil Tank Control Valve Control Valve

T5-2-28

Arm Flow Rate Control Valve Control Pressure (Serial No.104679 and up (ZX200 class and 225 class), Serial No.010327 and up (ZX230 class) Serial No.020043 and up (ZX270 class)) Returning to Hydraulic Oil Tank Plug Returning to Hydraulic Oil Tank Flow Combiner Valve Control Pressure Bucket Flow Rate Control Valve Control Pressure

TROUBLESHOOTING / Component Layout Pilot Valve Side

PH

C

A

E M D H B

F

SB G

PI

Pilot Valve Side

N

K

I SH

J DF SA

L T178-03-06-016

Control Valve Side SM

3 5

1 13 2 SK

4 SE 8


14 Control Valve Side

7 9 6

10

SN

SL

11


12

T5-2-29

SP

T178-03-06-015

TROUBLESHOOTING / Component Layout (Blank)

T5-2-30

TROUBLESHOOTING / Troubleshooting A TROUBLESHOOTING A PROCEDURE Refer to troubleshooting A procedure in case any fault codes are displayed after diagnosing the main controller (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), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).

(1)

NO(NOT OK)

・ · Key switch: ON

(3)

Instructions, reference, and/or inspection methods and/or measurements are occasionally described under the box. If incorrectly checked or measured, not only will troubleshooting 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

TROUBLESHOOTING / Troubleshooting A FAULT CODE LIST Fault code 01 02 03 04

Problem Abnormal EEPROM Abnormal RAM Abnormal A/D Conversion Abnormal Sensor Voltage

• Faulty MC

06

Abnormal EC Sensor

07

Abnormal Engine Control Dial Angle

08

Abnormal Boom Angle Sensor

10 11

Abnormal Pump 1 Delivery Pressure Abnormal Pump 2 Delivery Pressure

12 13

Abnormal Pump1 Pump Control Pressure Abnormal Pump2 Pump Control Pressure

14 15 16 18 19

Abnormal Swing Lever Stroke Abnormal Boom Raise Lever Stroke Abnormal Arm Roll-In Lever Stroke Abnormal Travel Lever Stroke Abnormal Oil Temperature

• • • • • • • • • • • • • • • • • • • • •

Cause

Faulty MC Faulty Harness Faulty Sensor Faulty MC Faulty Harness Faulty EC Sensor Faulty MC Faulty Harness Faulty Engine Control Dial Faulty MC Faulty Harness Faulty Boom Angle Sensor Faulty MC Faulty Harness Faulty Pump Delivery Pressure Sensor Faulty MC Faulty Harness Faulty Pump Control Pressure Sensor Faulty MC Faulty Harness Faulty Pilot Pressure Sensor

• Faulty MC • Faulty Harness • Faulty Oil Temperature Sensor

T5-3-2

TROUBLESHOOTING / Troubleshooting A FAULT CODE 01 (ABNORMAL EEPROM) FAULT CODE 02 (ABNORMAL RAM) FAULT CODE 03 (ABNORMAL A/D CONVERSION) 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 retrying, as long as the engine and machine operate normally, the machine can be operated as it is.

FAULT CODE 04 (ABNORMAL SENSOR VOLTAGE)

YES

Disconnect connectors from all sensors relating to the indicated fault code, and retry. Does fault code 04 disappear?

NOTE: If fault code 04 (abnormal sensor voltage) appears, other fault codes appear at the same time.

Faulty sensor.

YES

NO

Disconnect all connectors from MC. Is there continuity between terminals #1 and #3 of harness at each sensor? · Key switch: OFF

T5-3-3

Short-circuited harness between MC and sensor in section where continuity is present.

Faulty MC. NO · Refer to T4-6-1.

TROUBLESHOOTING / Troubleshooting A FAULT CODE 06 (ABNORMAL EC SENSOR)

Disconnect EC sensor. Check if resistance between sensor side connector terminals #1 and #3 is less than 2.0±0.4 kΩ. Connect test harness between EC sensor and base machine side harness. Check if voltage changes in accordance with specifications when engine control dial is rotated.

Disconnect EC sensor. Check if voltage between harness end connectors YES #1 and #3 is 5±0.5 V.

Faulty harness between YES MC and EC sensor.

Check harness between MC connector C (31P) YES terminal #18 and EC sensor terminal #2 for breakage or short circuit.

Faulty MC. NO

Broken harness beYES tween MC and EC sensor terminal #3.

Check if voltage between EC sensor harness end connector terminal #1 and vehicle frame matches specification.

· Key switch: ON NO

· Refer to T4-6-1.

NO

Broken harness between MC and EC sensor terminal #1.

· Key switch: ON · Specification: 5±0.5 V Faulty EC sensor.

NO · Test Harness: ST 7129 · Specification: Refer to the table below.

EC Sensor Specification Slow Idle 2.5 to 2.7 V Fast Idle (HP mode 3.3 to 3.7 V Switch: OFF) Fast Idle (HP mode Voltage at Fast Idle (HP Mode Switch: ON) Switch: OFF) plus 0.2 V or more

· Refer to T4-6-1.

Connector (Harness End Connector Viewed from the Open End Side) MC Connector C C10

C1

C23

C31 #18

EC Sensor

1

T5-3-4

2

3

TROUBLESHOOTING / Troubleshooting A FAULT CODE 07 (ABNORMAL ENGINE CONTROL DIAL ANGLE)

Disconnect switch panel. Check if resistance between switch panel side connector terminals #2 and #4 is 5±0.5 kΩ. Reconnect switch panel. Insert tester probe into connector terminal #3 from the reverse side. Check if voltage varies as specified when engine control dial is turned.

Disconnect switch panel. Check if voltage between harness end connector YES terminals #2 and #4 is 5±0.5 V.

· Key switch: ON

Faulty harness between MC and engine control YES dial.

Check harness between MC connector C (31P) harness end terminal #6 YES and switch panel terminal #3 for breakage or short circuit.

Faulty MC. NO

Broken harness beYES tween MC and engine control dial terminal #4.

Check if voltage between switch panel harness end connector terminal #2 and vehicle frame matches specification.

NO

· Refer to T4-6-1.

NO

Broken harness between MC and engine control dial terminal #2.

· Key switch: ON · Specification: 5±0.5 V Faulty engine control dial.

NO · Specification: Refer to the table below.

Engine Control Dial Specification Minimum Speed 0.3 to 1.0 V Maximum Speed 4.0 to 4.7 V

Connector (Harness End Connector Viewed from the Open End Side) MC Connector C #6 C10

C1

C23

C31

Switch Panel

#4

T5-3-5

#3

#2

TROUBLESHOOTING / Troubleshooting A FAULT CODE 08 (ABNORMAL BOOM ANGLE SENSOR) (Up to serial No.104908 (ZAXIS225US))

Disconnect boom angle sensor. Check if voltage between harness end connector YES terminals #1 and #3 is 5 ±0.5 V.

Check harness between MC connector C (31 P) harness end YES terminal #17 and boom angle sensor terminal #2 for breakage or short circuit.

· Key switch: ON

Check if voltage between boom angle NO sensor harness end connector terminal #2 and vehicle frame is 5 ±0.5 V.

Broken harness beYES tween MC and boom angle sensor terminal #3.

NO

Broken harness between MC and boom angle sensor terminal #1.

Faulty boom angle sensor.

NO

Connector (Harness End Connector Viewed from the Open End Side) C10

C31 #17

Boom Angle Sensor 1

Faulty MC. · Refer to T4-6-1.

· Key switch: ON

C23

Faulty harness between MC and boom angle sensor.

NO

Disconnect boom angle sensor. Check if resistance between harness end connector terminals #1 and #3 is 5 ±0.5 kΩ.

MC Connector C C1

YES

2 3

T5-3-6

TROUBLESHOOTING / Troubleshooting A FAULT CODE 10 (ABNORMAL PUMP 1 DELIVERY PRESSURE) FAULT CODE 11 (ABNORMAL PUMP 2 DELIVERY PRESSURE) Checking Instruction

• Both pump 1 and pump 2 delivery pressure sensors seldom fail at the same time. Accordingly, if both fault codes 10 and 11 are displayed simultaneously, faulty harness may be the cause of this problem.

NO

Check if fault codes are switched after switching pump 1 delivery pressure sensor with pump 2 delivery pressure sensor and retrying.

Disconnect pump delivery pressure sensor. Check if voltage between harness end connector terminals #1 and #3 is 5±0.5 V.

Check harness between MC connector C (31P) harness end terminal #1 (pump 1) or #4 (pump 2) and pump YES delivery pressure sensor terminal #2 for breakage or short circuit.

Faulty harness between MC and pump delivery pressure YES sensor.



Check if voltage between pump delivery pressure sensor harness end connector terminal #1 and vehicle frame matches specification.

Broken harness between MC and pump delivery pressure YES sensor terminal #3.

NO · Key switch: ON · Specification: 5±0.5 V YES

Connector (Harness End Connector Viewed from the Open End Side) MC Connector C #1

#4 C10

C1

C23

C31

Pump Delivery Pressure Sensor

3

2

1

T5-3-7

Broken harness between MC and pump delivery pressure sensor terminal #1.

Faulty pump delivery pressure sensor.

TROUBLESHOOTING / Troubleshooting A FAULT CODE 12 (ABNORMAL PUMP 1 CONTROL PRESSURE) FAULT CODE 13 (ABNORMAL PUMP 2 CONTROL PRESSURE) Checking Instruction • Both pump 1 and pump 2 control pressure sensors seldom fail at the same time. Accordingly, if both fault codes 12 and 13 are displayed simultaneously, faulty harness may be the cause of this problem.

Disconnect pump control pressure sensor. Check if voltage between harness end NO connector terminals #1 and #3 is 5±0.5 V.

Check if fault codes are switched after switching pump 1 control pressure sensor with pump 2 control pressure sensor and retrying.

· Key switch: ON

Check harness between MC connector C (31P) harness end terminal #7 (pump 1) or #13 (pump 2) and pump control pressure YES sensor terminal #2 for breakage or short circuit.

Faulty harness between MC and pump control pressure senYES sor.


Check if voltage between pump control pressure sensor harness end connector terminal #1 and vehicle frame matches specifiNO cation.

Broken harness between MC and pump control pressure senYES sor terminal #3.

NO

Broken harness between MC and pump control pressure sensor terminal #1.

· Key switch: ON · Specification: 5±0.5 V Faulty pump control pressure sensor. YES

Connector (Harness End Connector Viewed from the Open End Side) MC Connector C #13

#7 C10

C1

C23

C31

Pump Control Pressure Sensor

1

2

3

T5-3-8

TROUBLESHOOTING / Troubleshooting A FAULT CODE 14 (ABNORMAL SWING PILOT PRESSURE) FAULT CODE 15 (ABNORMAL BOOM RAISE PILOT PRESSURE) FAULT CODE 16 (ABNORMAL ARM ROLL-IN PILOT PRESSURE) FAULT CODE 18 (ABNORMAL TRAVEL PILOT PRESSURE) Checking Instruction

• All pressure sensors seldom fail at the same time.

Check harness between MC connector C (31P) harness end each corresponding terminal and pressure YES sensor terminal #2 for breakage or short circuit.

Accordingly, if fault codes 14, 15, 16, and 18 are displayed simultaneously, faulty harness may be the cause of this problem.

· Refer to T4-6-1. Connector C Terminal: #14: Pressure Sensor (Swing) #2: Pressure Sensor (Boom Raise) #5: Pressure Sensor (Arm Roll-In) #3: Pressure Sensor (Travel)

· Key switch: ON

NO Fault Code: 14: Pressure Sensor (Swing) 15: Pressure Sensor (Boom Raise) 16: Pressure Sensor (Arm Roll-In) 18: Pressure Sensor (Travel)

Check if voltage between pressure sensor harness end connector terminal #1 and vehicle frame matches specification.

YES

C10

C23

C31 #14

Pilot Pressure Sensor

1

2

Broken harness between MC and pressure sensor terminal #1.

Faulty pressure sensor.

#5

C1

Broken harness between MC and pressure sensor terminal #3.

· Key switch: ON · Specification: 5±0.5 V

MC Connector C #3

YES

NO

Connector (Harness End Connector Viewed from the Open End Side) #2

Faulty MC. NO

Disconnect pressure sensor. Check if voltNO age between harness end connector terminals #1 and #3 is 5±0.5 V. Check if fault code disappears after switching pressure sensor with another pressure sensor and retrying.

Faulty harness between MC and YES pressure sensor.

3

T5-3-9

TROUBLESHOOTING / Troubleshooting A FAULT CODE 19 (ABNORMAL OIL TEMPERATURE)

Disconnect oil temperature sensor. Check if sensor side connector resistance matches specification.

Connect oil temperature sensor harness end connector terminal #1 to #2 with a clip. Remove connector B (25P) and connector C (31P) from MC. Check YES for continuity between connector B harness end terminal #22 and connector C terminal #24.

Faulty MC.

YES

· Refer to T4-6-1. Connect MC connector B (25P) harness end terminal #22 to vehicle frame. Check for continuity between oil temperature sensor NO harness end connector terminal #2 and vehicle frame.

· Specification: Refer to the table below.

Broken harness between MC and oil temperature sensor NO terminal #2.

Faulty oil temperature sensor.

NO

Oil Temperature Specification Oil Temperature Resistance (°C) (kΩ) −20 16.2±1.6 0 (5.88) 20 2.45±0.24 40 (1.14) 60 (0.534) 80 0.322

Broken harness between MC and oil YES temperature sensor terminal #1.

Connector (Harness End Connector Viewed from the Open End Side) MC Connector B B8

B1

B19

B25 #22

MC Connector C C10

C1

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 machine’s operation is abnormal. On the front section pages of this group T5-4, are tables indicating the relationship between machine trouble symptoms and related parts which may cause such trouble if failed. Start the troubleshooting with more probable causes selected by referring to these tables.

• How to Read the Troubleshoting Flow Charts YES(OK)

・

• After checking or measuring item (1), select either YES (OK) or NO (NOT OK) and proceed to item (2) or (3), as appropriate.

(1) NO(NOT OK)

(3)

• Special instructions or reference item are indicated in the spaces under the box.


・

(2)

Incorrect measuring or checking methods will render troubleshooting impossible, 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

TROUBLESHOOTING / Troubleshooting B RELATIONSHIP BETWEEN MACHINE TROUBLE SYMPTOMS AND RELATED PARTS This table indicates the relationship between machine trouble symptoms and the potential problem parts, which may cause trouble if failed, and the evaluation methods of these components. Parts EC Motor

•

EC Sensor

•

Moves governor.

• Function

•

Governor lever doesn’t move.

•

Engine speed is controlled based on idle position set when key switch is turned ON. Therefore, engine speed is always controlled with error in idle position setting if set incorrectly.

•

Even if engine control dial is turned, engine speed doesn’t increase from slow idle speed. Engine start may be difficult though starter rotates. Engine will stall if discontinuity occurs in EC motor while engine is running at more than a specified speed. Engine will become uncontrollable if discontinuity occurs in EC motor while engine is running at lower than a specified speed. Engine cannot be stopped with key switch.

•

Error in setting will seldom occur so that change in machine operation will not be noticed. In case error is set on lower side, engine speed changes but runs slower than normal through the full range when engine control dial is turned. (Note: In case error is set on upper side, EC motor is driven so that it runs faster than the control range. However, motor, a worm gear type, holds governor lever at maximum constant position, preventing engine stall. When engine control dial is turned to minimum speed position, governor lever is returned to idle position.) When starting engine, engine speed fluctuates. Starting engine is occasionally difficult.

Symptoms in control system when trouble occurs.

• • • Symptoms in machine operation when trouble occurs.

•

• •

By Fault Code

Using Test Harness Others NOTE Descriptions of Control (Operational Principle Section in T/M)

Fault code 06 is displayed.



By Monitor Function Evaluation

Detects minimum governor speed position (2.5 V) only when key switch is turned ON. Detects minimum and maximum speed position when engine learning is conducted.

Monitor Item: EC Angle (Displayed by built-in diagnosing system)



•

Install lamp harness (ST 7125) to check EC output signal and harness for any abnormality.

•



 

Engine is stopped by EC motor. (Engine stop motor is not provided.) Fuel cut-off cable is provided.

•

T2-1

T2-1

T5-4-2

If EC sensor is faulty, engine learning is not performed.

TROUBLESHOOTING / Troubleshooting B

Engine Control Dial

Pump Control Pressure Sensor

Pump 1 Delivery Pressure Sensor

•

Indicates governor lever position (engine target speed).

•

Monitors pump control pressure to control auto-acceleration system and travel motor swash angle controls.

•

Monitors pump delivery pressure to control HP mode, auto-acceleration, slow speed torque increase, auto power lift and travel motor swash angle controls.

•

Engine speed doesn’t change even if engine control dial is turned. If discontinuity or short circuit occurs in engine control dial, target speed of 1400 -1 min is used as back-up value.

•

No signals arrive to MC

•

If pump delivery pressure sensor output is 0 or 5 V, following symptoms will be presented by back-up mode function.

Engine speed is kept unchanged from -1 1400 min . (Auto-idle system functions. Engine can be stopped by key switch.)

•

Auto-acceleration control is inoperable (but not noticeable). Travel speed is kept in slow mode, not allowing to automatically change to fast mode.

• • •

HP mode is inoperable. Auto-acceleration control is inoperable. Machine mistakes occasionally when traveling at slow idle speed. Boom raise power is weak during digging operation. Travel speed is kept in slow mode, not allowing to automatically change to fast mode.

•

•

•

• •


Fault codes 12 and 13 are displayed.

Fault codes 10 is displayed.

Monitor Item: Engine Target Speed, Dial Angle (Displayed by built-in diagnosing system)

Monitor Item: Pump 1 and 2 pump control pressure (Displayed by built-in diagnostic system)

Monitor Item: Pump 1 delivery pressure (Displayed by built-in diagnostic system)

   T2-1

•









Evaluation by Dr. ZX Broken Circuit: 0.25 V or less Short Circuit: 0.75 V or more T2-1

 T2-1

T5-4-3


Parts

Pump 2 Delivery Pressure Sensor

•

Monitors pump delivery pressure to control HP mode, auto-acceleration, slow speed torque increase, arm flow rate, arm regenerative and travel motor swash angle control.

•

Monitors pump delivery pressure to control pump 3 torque decrease control.

•

If pump delivery pressure sensor output is 0 or 5 V, following symptoms will be presented by back-up mode function.

•

Engine stalls if pump torque is increased.

• • •

HP mode is inoperable. Auto-acceleration control is inoperable. Machine mistakes occasionally when traveling at slow idle speed. Swing power is weak during a combined operation. During short circuited, swing is given priority. Arm is slow when arm roll-in and swing combined operation is made. Travel speed is kept in slow mode, not allowing to automatically change to fast mode.

•

Engine stalls if pump torque is increased.

Function


• • • Symptoms in machine operation when trouble occurs.

By Fault Code

Evaluation

By Monitor Function

•



Fault codes 11 is displayed. Monitor Item: Pump 2 delivery pressure (Displayed by built-in diagnostic system)



Using Test Harness Others

NOTE Descriptions of Control (Operational Principle Section in T/M)

Pump 3 Delivery Pressure Sensor (Optional)













T2-1

T2-1

T5-4-4


Pressure Sensor (Front Attachment)



•

Monitors travel pilot pressure to control auto-idle, auto-acceleration, idle speed-up, engine speed automatic increase at travel (ZX270 class only), slow speed torque increase, and travel motor swash angle controls.

•

Monitors front attachment pilot pressure to control auto-idle, and idle speed-up, and engine speed automatic increase at travel (ZX270 class only).

•

Monitors swing pilot pressure to control arm flow rate and arm regenerative systems.

•


•


•


•

Engine speed doesn’t increase even if auto-idle/auto-acceleration selector is auto-idle position. Engine speed doesn’t increase even if auto-idle/auto-acceleration selector is auto-acceleration position. Occasionally, engine speed hunts while traveling at slow idle. If there is a difference in delivery flow rate between pumps 1 and 2, machine may mistrack when traveling at minimum speed. (Not remarkable) Fast travel mode cannot be selected even if travel mode switch is turned to the FAST position. (Not remarkable) ZX270 class only: Travel speed isn’t increased. (Not remarkable)

•

Engine speed doesn’t increase even if any front attachment actuator is operated with auto-idle/auto-acceleration selector is auto-idle position. Occasionally, engine speed hunts while operating front attachment at slow idle. ZX270 class only: Travel speed isn’t increased. (Not remarkable)

•

Since arm regenerative function is inoperable, when swing/arm roll-in combined operation is made, initial arm moving speed is slow. (Not remarkable) During arm level crowding operation, arm speed is slightly slow.

• • • • •

• •



Fault code 18 is displayed. Monitor Item: Travel Control Pressure (displayed built-in diagnostic system). Monitor pressure change while traveling machine.

Monitor Item: Front Attachment Operation (displayed built-in diagnostic system). Monitor pressure change while operating front attachment.



•

 Judge if pressure sensor is faulty or port is clogged by switching pressure sensor with another pressure sensor.

T2-1

•

Fault code 14 is displayed. Monitor Item: Swing Control Pressure (displayed built-in diagnostic system). Monitor pressure change while swinging upperstructure.



•


T2-1



•


T2-1

T5-4-5


Parts

Pressure Sensor (Boom Raise)

Pressure Sensor (Arm Roll-In)

•

Monitors boom raise pilot pressure to control HP mode, auto-acceleration, arm regenerative, and auto-power lift controls.

•

Monitors arm roll-in pilot pressure to control HP mode, auto-acceleration, arm flow rate, and arm regenerative controls.

•


•


•

Even if boom is raised with HP mode switch ON, engine speed doesn’t increase. Even if boom is raised with auto-idle/auto-acceleration selector is auto-acceleration position, engine speed doesn’t increase. Arm roll-in speed becomes slightly slower than normal in boom raise and arm roll-in combined operation as arm regenerative system doesn’t work. (Not remarkable) Arm roll-in and boom raise speeds become slightly slower at the beginning stage of arm level crowd operation. Boom raise power is weak. (Not remarkable)

•

Even if arm is rolled-in with HP mode switch ON, engine speed doesn’t increase. Even if arm is rolled-in with auto-idle/auto-acceleration selector is auto-acceleration position, engine speed doesn’t increase. Arm roll-in and swing speeds become slightly slower in swing and arm roll-in combined operation as arm flow rate control doesn’t work. (Not remarkable) Arm speed is slow in arm level crowd operation.

Function


• • Symptoms in machine operation when trouble occurs.

• •

By Fault Code By Monitor Function

• • •

Fault Code 15 is displayed.


Monitor Item: Boom Raise Pilot Pressure (displayed built-in diagnosing system). Monitor pressure change while raising boom.

Monitor Item: Arm Roll-In Pilot Pressure (displayed built-in diagnosing system). Monitor pressure change while rolling arm in.





Evaluation

Using Test Harness Others

•


•


NOTE

Descriptions of Control (Operational Principle Section in T/M)

T2-1

T2-1

T5-4-6


Pressure Sensor (Auxiliary) (Optional)

Torque Control Solenoid Valve

Solenoid Valve Unit (SG)

•

Monitors attachment pilot pressure when attachment is installed to control attachment operation speed increase, pump 1 and pump 2 flow rate limit, and auxiliary flow rate controls.

•

Supplies control pressure to pumps 1 and 2 to control speed sensing and slow speed torque increase controls.

•

Temporarily increases main relief valve set-pressure when operating machine either in power digging and auto-power lift mode.

•


•

If torque control solenoid valve is not activated, output pressure from solenoid 2 valve is 0 MPa (0 kgf/cm ).

•

In case solenoid valve unit (SG) is not activated, pressure at port SG becomes 2 0 MPa (0 kgf/cm ).

•

Engine speed doesn’t increase when attachment is operated. When attachment is operated, operation speed increases.

•

Even if speed sensing system doesn’t work, upper limit power is restricted so that machine is operable. Machine may occasionally mistrack when traveling at slow idle speed.

•

•

Solenoid valve unit (SG) is closed: Relief pressure stays at normal 34 MPa 2 (350 kfg/cm ). Even if power digging switch is pressed, relief pressure doesn’t increase. Power doesn’t increase. Solenoid valve unit (SG) is open: • The pressure always increases. Every operation makes the force increase.

•







Monitor Item: ATT Control Pressure (displayed built-in diagnosing system). Monitor pressure change while operating attachment.

Monitor Item: Pump Torque Proportional Solenoid Valve Output

Monitor Item: Power Boost Control Pressure

•









Judge if pressure sensor is faulty or port is clogged by switching pressure sensor with another pressure sensor.



T2-1

T2-1

•

Install lamp harness (ST 7226) to check output signals from MC and harness condition.

•

Proportional solenoid valve is used as an ON/OFF valve. Therefore, even if power digging switch is pressed or released, lamp will come ON when normal. In case lamp goes OFF, it may be due to broken harness.



T2-1

T5-4-7


Parts

Solenoid Valve Unit (SE)*

• Function

• •


Solenoid Valve Unit (SC)

Changes oil flow restriction at arm flow rate control valve in 5-spool control valve to shift arm 1 and swing spool circuits from parallel circuit to tandem circuit. This is to secure sufficient swing force.

•

Routes return oil from arm cylinder rod side to bottom side when rolling arm in to increase arm speed.

In case solenoid valve unit (SE) is not activated, pressure at port SE becomes 0 MPa (0 2 kgf/cm ).

•

In case solenoid valve unit (SC) is not activated, pressure at port SC becomes 0 MPa (0 2 kgf/cm ). Arm regenerative valve will not operate at this time.

Solenoid valve unit (SE) is closed: Actuator which is operated earlier is given priority to operate in arm roll-in and swing combined operation. • Swing becomes slow when pump 2 delivery pressure is high. Solenoid valve unit (SE) is open: • Arm speed becomes slow as the parallel circuit in arm 1 spool is restricted.

•

Solenoid valve unit (SC) is closed: Arm speed is slow in arm level crowd operation. Solenoid valve unit (SC) is open: • Arm speed is fast as the arm regeneration is always operated.

•

Symptoms in machine operation when trouble occurs.





Monitor Item: Arm Regenerative Proportional Sol. Valve Output

Monitor Item: Arm Flow Rate Proportional Sol. Valve Output

•

•

By Fault Code

Evaluation

By Monitor Function Using Test Harness


Others

NOTE











T2-1

T2-1

NOTE:* Up to serial No.104678 (ZX200 class and 225 class) Up to serial No.010326 (ZX230 class) Up to serial No.020042 (ZX270 class)

T5-4-8


Solenoid Valve Unit (SI)

Max. Pump 1 Flow Rate Limit Solenoid Valve (Optional)

Max. Pump 2 Flow Rate Limit Solenoid Valve

•

When pump delivery pressure is low in fast travel mode, travel motor swash angle is reduced to increase travel speed.

•

When operating attachment, limits maximum pump 1 flow rate.

•

When operating attachment, limits maximum pump 2 flow rate.

•

Fast travel mode cannot be selected.

•

In case max. pump 1 flow rate limit solenoid valve is not activated, pressure at 2 output port becomes 0 MPa (0 kgf/cm ).

•

In case max. pump 2 flow rate limit solenoid valve is not activated, pressure at 2 output port becomes 0 MPa (0 kgf/cm ).

Solenoid valve unit (SI) is closed: Even if travel mode switch is turned to FAST position, fast travel mode cannot be selected.

Max. pump 1 flow rate limit solenoid valve is closed: • When operating attachment, operating speed doesn’t decrease.

Max. pump 2 flow late limit solenoid valve is closed: • When operating attachment, operating speed doesn’t decrease.

Solenoid valve unit (SI) is open: Travel speed is always fast.

Max. pump 1 flow rate limit solenoid valve is open: • Right travel, bucket, arm and boom speeds are slow as maximum flow rate of pump 1 decreases. • Machine mistracks to the right when traveling.

Max. pump 2 flow rate limit solenoid valve is open: • Left travel, arm, boom and swing speeds are slow as maximum flow rate of pump 2 decreases. • Machine mistracks to the left when traveling.

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•

•

•


T2-1

T2-1

T2-1

T5-4-9

TROUBLESHOOTING / Troubleshooting B Parts

Boom Electronic Cushion Solenoid Valve*

Auxiliary Flow Rate Control Solenoid Valve (Optional)

•

When operating boom raise, the boom raise pressure decreases near the boom cylinder stroke end.

•

Restricts oil flow to auxiliary spool during a combined operation to improve operability.

•

Boom electronic cushion isn’t performed.

•

In case auxiliary flow rate control solenoid valve is not activated, pressure at 2 output port becomes 0 MPa (0 kgf/cm ).

•

If valve is bound closed, attachment speed will become slow. If valve is bound open, boom will not move in 3-combined operation of boom raise.

Function


Boom electronic cushion solenoid valve is bound: • Boom electronic cushion solenoid valve isn’t always performed.

•

Boom electronic cushion solenoid valve is open: • Boom isn’t easy to be operated as the boom raise pilot circuit is restricted.


Evaluation

By Monitor Function





By Fault Code

Monitor item: Bu Damper Proportional Solenoid Valve Output



Using Test Harness





Others









NOTE


T2-1

T2-1

NOTE: *: Up to serial No.104908 (ZAXIS225US)

T5-4-10

TROUBLESHOOTING / Troubleshooting B N Sensor

Hydraulic Oil Temperature Sensor


•

Monitors engine speed to operate engine speed sensing control.

•

Monitors hydraulic oil temperature to control auto-warming up and arm regenerative control.

• •

Starts engine learning. ZAXIS225US only: 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 operates as if hydraulic oil temperature is 40 °C (Dr. ZX or monitor will not indicate 40 °C in diagnosis operation).

• •

Engine learning is not performed. The initial setting of the boom electronic cushion* can’t be performed.

•

Engine stalls under adverse operating conditions such as at high altitude.

•

Even if oil temperature is lower than 0 °C, auto-warming up control doesn’t operate so that engine runs at idle speed when engine is started. When oil temperature is lower than 10 °C, arm regenerative control is inoperable.

•

Engine learning: Machine will operate normally problem is caused by broken circuit or discontinuity of switch. (Only learning cannot be performed.) • If short circuit occurs, learning mode 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 discontinuity of switch. • The boom electronic cushion solenoid valve is always operated as the initial setting hasn’t been completed on short circuit.

•





Monitor Item: Actual engine speed (If N sensor fails, engine speed is not measured.)



















•

Monitor Item: Engine Learning Control

Even if signals from N sensor are not delivered due to broken circuit or poor sensor installation, few changes in operational performance occur, making troubleshooting difficult. Use monitor function.

T2-1



T2-1

T2-1

NOTE: *Boom electronic cushion control is available on the ZAXIS225US (Up to serial No.104908)

T5-4-11


Parts

Power Digging Switch

Travel Mode Selector

•

Activates power digging control. ON: 0V→Increasing Pressure OFF: 5V→ Not Increasing Pressure

•

Changes travel mode. Fast Mode: 0V Slow Mode: 5V

• •

Broken Circuit: Pressure doesn’t increase. Short Circuit: Pressure increases for 8 seconds after turning key switch and stops increasing.

•

Broken Circuit in Switch: Travel speed remains unchanged in slow mode (5V). Short circuit in Switch: Travel speed remains unchanged in fast mode (0 V).

•

Power digging control doesn’t operate if broken circuit or short circuit occurs.

•

Function


•

• Symptoms in machine operation when trouble occurs.

By Monitor Function Using Test Harness Others

Monitor Item: Power Digging (Boost) Switch

NOTE






By Fault Code Evaluation

Even if travel mode selector is turned to the FAST position, fast travel mode cannot be selected. Even if travel mode selector is turned to the SLOW position, travel mode is turned to the FAST position.

Monitor Item: Travel Mode

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

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T2-1

T2-1

T5-4-12


Boom Angle Sensor*

MC

Auto-Idle/Auto-Acceleration Selector (Auto-Idle)

•

Monitors boom angle to perform the boom electronic cushion control.

•

Controls engine, pump, and valve operation.

•

Activates auto-idle control. ON: 0 V → Auto-idle is operable. OFF: 5 V → Inoperable.

•

MC makes the boom electronic cushion solenoid valve perform even with a broken or short circuit.

•

Depending on trouble situations, control system malfunction may differ. (The following symptoms in machine operation indicates that MC logic circuit has failed.)

•

Broken Circuit: Auto-idle system is inoperable. Short Circuit: Even if auto-idle/auto-acceleration selector is OFF, auto-idle control is always performed.

Boom speed becomes slow as the boom raise pilot circuit is reduced by the boom electronic cushion solenoid valve even with a broken or short circuit.

•

Even if key switch is turned ON, step motor will not move to the START position so that engine cannot start. Even though engine starts, speed stays slow. Since pump displacement is held at minimum, all actuator speeds are slow.

•

•

Fault Code 08 is displayed.

•







T2-1

Same as described above.

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 system. If any sensor in 5 V system is short-circuited, all sensor fault codes will be displayed.

T2-1



T2-1

NOTE: * Up to serial No.104908 (ZAXIS225US)

T5-4-13


Auto-Idle/Auto-Acceleration Selector (Auto-Acceleration)

Parts

Power Mode Switch (HP Mode)

•

Activates auto-acceleration control. ON: 0 V → Auto-acceleration is operable. OFF: 5 V → Inoperable.

•

Activates HP mode control. ON: 0 V → HP mode is operable. OFF: 5 V → Inoperable.

•

•

•

Broken Circuit: Auto-acceleration control is inoperable. Short Circuit: Even if auto-idle/auto-acceleration selector is OFF, auto-acceleration control is always performed.

Broken Circuit: Even if HP mode is selected, HP mode is inoperable. Short Circuit: Even if HP mode switch is turned OFF, HP mode system is not deactivated. Attachment speed increase control (optional) becomes inoperable.

•


•

Function

•




By Fault Evaluation

By Monitor Function Using Test Harness Others



NOTE




Monitor Item: Auto-Idle/Auto-Accel Switch

Monitor Item: E/P/HP Mode Switch





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T2-1

T2-1

T5-4-14

TROUBLESHOOTING / Troubleshooting B .

Power Mode Switch (E Mode)

•

Selects E mode. ON: 0 V → E mode OFF: 5 V → Normal

• •

•

Work Mode Switch (Digging Mode) Allows normal control to be performed.

Broken Circuit: Even if E mode is selected, engine speed doesn’t decrease. Short Circuit: Engine speed doesn’t increase to the maximum. Auto-idle control is inoperable.

Work Mode Switch (Attachment Mode)

•

Functions only when optional attachment kit is equipped. (Attachment operation speed increase/limit control)

•

In response to operation of the auxiliary valve, engine speed related to the attachment is controlled.

•

Even if auxiliary valve is operated, engine speed doesn’t increase. Even if attachment mode is selected, maximum engine speed doesn’t decrease.



•

Same as described above

• 

 Monitor Item: E/P/HP Mode Switch

T2-1

 Monitor Item: Work Mode Switch

 Monitor Item: Work Mode Switch





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

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T2-1

T2-1

T5-4-15


Auxiliary Mode Switch (Optional)

Parts

Flow Combiner Valve

•

Functions only when optional attachment kit is equipped. (Attachment operation speed increase/limit control)

•

Supplies hydraulic oil to both right and left travel spools from pump 1 during combined operation of travel and front/swing.

•

In response to operation of the auxiliary valve, engine speed related to the attachment is controlled.

•

During combined operation of travel and front/swing, insufficient oil is supplied to left travel spool.

•

Even if auxiliary valve is operated, engine speed doesn’t increase. Even if attachment mode is selected, maximum engine speed doesn’t decrease.

•

While traveling, when front/swing lever is operated, machine mistracks to the left.

Function



Evaluation

By Fault Code By Monitor Function Using Test Harness Others NOTE


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T2-1

T3-3

T5-4-16


Bucket Flow Rate Control Valve

Arm Flow Rate Control Valve

•

Auxiliary Flow Rate Control Valve

To be shifted by pilot pressure from solenoid valve unit (SE)*. Shift arm 1 spool and swing spool circuits from parallel to tandem. Ensures swing power.

•

Restricts oil flow to bucket during 3-combined operation of bucket, arm roll-in, and boom raise to allow boom to raise.

•

To be shifted by pilot pressure from auxiliary flow rate control solenoid valve.

•

If spool is bound or spring is broken, orifice doesn’t vary.

•

If switch valve is bound with valve activated, bucket circuit is always restricted.

•

If spool is bound or spring is broken, orifice doesn’t vary.

• •

If fully opened: Swing power is weak. If fully closed: Arm speed is slow during arm level crowd operation.

•

If poppet valve is bound at fully closed position or if switch valve is bound when poppet valve is fully closed, bucket speed becomes slow. If poppet valve is bound at fully opened position or if switch valve is bound when poppet valve is fully opened, boom doesn’t move during 3-combined operation of bucket, arm roll-in, and boom raise.

•

If bound at fully closed position, attachment speed becomes slow. If bound at fully opened position, boom doesn’t move during 3-combined operation of swing, arm roll-in, and boom raise.

• •

•

T3-3

•

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

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 control valve (signal control valve).

T5-4-17


Parts

Boom Regenerative Valve

•

Arm Regenerative Valve

Prevents boom cylinder hesitation by routing return oil from boom cylinder bottom side to rod side.

• •

To be shifted by pilot pressure from solenoid valve unit (SC). Increases arm speed by routing return oil from arm cylinder rod side to bottom side.

•

Arm regenerative function is inoperable.

•

If check valve is kept closed, boom is not smoothly lowered. If check valve is kept open, machine cannot be raised off ground with front attachment.

•


•

Arm speed is extremely slow during arm level crowd operation while arm regenerative 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 kept open.

Function

•



Evaluation

By Fault Code By Monitor Function Using Test Harness Others NOTE


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T3-3

T3-3

T5-4-18


Bucket Regenerative Valve

Arm Anti-Drift Valve

Boom Anti-Drift Valve

•

Prevents bucket cylinder hesitation by routing return oil from bucket cylinder rod side to bottom side.

•

Prevents arm from drifting due to oil leaks in control valve. Check valve in arm roll-in return circuit is forcibly opened to allow arm to move only when arm is rolled in.

•

Prevents boom from drifting due to oil leaks in control valve. Check valve in boom lower return circuit is forcibly opened to allow boom to move only when boom is lowered.

•

•

If switch valve is bound, check valve doesn’t open.

•

•

If check valve is kept closed, bucket is not smoothly rolled in. If check valve is kept open, bucket power is weak.

If switch valve is bound, check valve doesn’t open.

•


•

If check valve is kept closed, arm roll-in speed becomes slow. If check valve is kept open, front attachment drift increases due to oil leaks in control valve. Arm moves jerky or arm speed becomes slow depending on valve bound conditions.

•

If check valve is kept closed, boom doesn’t lower. If check valve is kept open, front attachment drift increases due to oil leaks in control valve. Boom moves jerky or arm speed becomes slow depending on valve bound conditions.

• •

T3-3

• •

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T3-3

T3-3

T5-4-19


Parts

Auxiliary Flow Combiner Valve

Bypass Cut Valve

•

Supplies pressure oil from pump 1 to auxiliary spool when auxiliary spool is operated.

•

Supplies pressure oil from pump 1 to auxiliary spool when auxiliary spool is operated.

•

If control valve is kept closed, operating speed doesn’t increase in single auxiliary operation.

•

If spool is bound in the fully open position, single attachment operation speed becomes slow. If spool is bound in the fully closed position, 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.

Function

• •


•


•



Evaluation

By Fault Code By Monitor Function Using Test Harness Others

NOTE






















T3-3

T3-3

T5-4-20


Pump 1 Flow Control Valve

Flow Combiner Valve Control Spool

Pump 2 Flow Control Valve

•

Supplies flow rate control pressure Pi to pump 1 regulator in response to lever stroke when boom (raise/lower), arm (roll out/in), bucket (roll-out/in), right travel, or auxiliary is operated.

•

Supplies flow rate control pressure Pi to pump 2 regulator in response to lever stroke when boom (raise/lower), arm (roll out/in), swing (right/left), left travel, or auxiliary is operated.

•

Supplies control pressure to flow combiner valve when shifted by right travel pilot pressure.

•

If spool is bound in the fully open position, even if control lever is in neutral, pump 1 swash angle is tilted to maximum. (When traveling with travel levers held in half way stroke, machine mistracks to the left.) If spool is bound in the fully open position, pump 1 control pressure sensor monitors the maximum pressure. If spool is bound in the fully closed position, even if control lever is operated, pump 1 swash angle is held to minimum. (Right travel is inoperable in single travel operation. Bucket speed is very slow.) If spool is bound in the fully open position, pump 1 control pressure sensor can’t monitor the pump control pressure. (Right travel doesn’t run fast with right track jacked-up.)

•

If spool is bound in the fully open position, even if control lever is in neutral, pump 2 swash angle is tilted to maximum. (When traveling with travel levers held in half way stroke, machine mistracks to the right.) If spool is bound in the fully open position, pump 2 control pressure sensor monitors the maximum pressure. If spool is bound in the fully closed position, even if control lever is operated, pump 2 swash angle is held to minimum. (Left travel is inoperable in single travel operation. Swing speed is very slow.) If spool is bound in the fully open position, pump 2 control pressure sensor can’t monitor the pump control pressure. (Left travel doesn’t run fast with left track jacked-up.)

• •

If spool is bound in the fully open position, when boom, arm, bucket, or swing is operated, flow combiner valve is shifted. If spool is bound in the fully closed position, when travel and front/swing combined operation is made, machine mistracks to the left. (left travel speed is slow.)


•


•


• •

•

•

T3-6

• •

•































T3-6

T3-6

T5-4-21

TROUBLESHOOTING / Troubleshooting B Swing Parking Brake Release Spool

Parts

•

Supplies swing parking brake release pressure when shifted by boom, arm, bucket, or swing pilot pressure.

•

•

If spool is bound in the fully open position, swing parking brake is kept released. (Machine vibrates while traveling.) If spool is bound in the fully open position, the pressure sensor (front) is always turned into ON. Thus, engine speed doesn’t decrease when the control lever is in neutral during auto-idle/acceleration control. If spool is bound in the fully closed position, swing parking brake is kept applied. (Dragging is felt.) If spool is bound in the fully closed position, the pressure sensor (front) is always turned into OFF. Thus, engine speed doesn’t increase when the control lever is operated during auto-idle/acceleration control.

•


•

Bucket Flow Rate Control Valve Control Spool Supplies boom raise pilot pressure to bucket flow rate control valve when shifted by arm roll-in pilot pressure.

Function

•

• Symptoms in control system when trouble occurs.

•

•

•

If spool is bound in the fully open position, bucket speed becomes slow when boom raise and bucket combined operation is made. (Bucket flow rate control is inoperable.) If spool is bound in the fully closed position, boom doesn’t move during 3-combined operation of bucket, arm roll-in, and boom raise.



Evaluation

By Fault Code By Monitor Function Using Test Harness Others

NOTE






















T3-3

T3-6

T5-4-22


•

• •

Arm Flow Rate Control Valve Control Spool* The arm roll-in pilot pressure changes over to supply the changeover 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 operation of the arm. (Arm flow rate control is activated constantly.) If stuck in the full-close state, arm pressing force to wall becomes insufficient 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) Serial No.10327 and up (ZX230 class) Serial No.020043 and up (ZX270 class)

T5-4-23

TROUBLESHOOTING / Troubleshooting B CORRELATION BETWEEN TROUBLE SYMPTOMS AND PART FAILURES This table indicates the relationship between machine troubles and parts contributing to the cause of the trouble if failed.

z : Related, required to check { : Related. However, in case this component fails, other trouble symptom will be more noticeable so that this component will not be the direct cause of the trouble concerned.

Engine System Troubleshooting E-2 Although starter rotates, engine doesn’t start.

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 range. Idle speed is faster or slower than specification.

MC (Main Controller)

z

z

EC Motor

z

EC Sensor

{

Trouble Symptom

E-1 Starter doesn’t rotate

Parts

z

Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Control Pressure Sensor Pressure Sensor (Travel) Pressure Sensor (Front Attachment) Pressure Sensor (Swing) Pressure Sensor (Boom Raise) Pressure Sensor (Arm Roll-In) Hyd. Oil Temperature Sensor Key Switch

z

Engine Control Dial Auto-Idle/Acceleration Selector Power Mode Switch Work Mode Switch Auxiliary Mode Switch Engine Learning Switch Battery Relay

z z

Engine Electrical Equipment

z

Engine Unit

z

z

Governor

z

z

Swing Parking Brake Release Spool (Signal Control Valve) Check batteries. Remarks

Check fuel system (filters and piping).

T5-4-24

Check fuel cut-off handle and engine control cable. Be sure to perform engine learning after replacing engine.

TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently.

E-4 Even if engine control dial is rotated, engine speed remains unchanged.

z

E-5 Engine speed doesn’t increase after engine is started.

z

E-6 Faulty HP mode.

In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom.

E-7 Even if key switch is turned OFF, engine doesn’t stop.

z

z {

E-8 Faulty auto-idle system.

{

z

{

{

E-9 Faulty E mode.

z

{

{ {

{ {

{ { z z

{

z z z

{

{

z

{

z

{ z

Check engine control cable.

T5-4-25

z

TROUBLESHOOTING / Troubleshooting B z : Related, required to check { : Related. However, in case this component fails, other trouble symptom will be more noticeable so that this component will not be the direct cause of the trouble concerned.

Trouble Symptom

E-10 Faulty auto-acceleration system.

E-11 When traveling or operating front attachment with engine running at slow idle, engine hunts.

E-12 Engine speed doesn’t increase even if attachment is operated in attachment mode.

z

z

z

Parts MC (Main Controller) QOS Controller Torque Control Solenoid Valve Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Control Pressure Sensor Pressure Sensor (Travel) Pressure Sensor (Front Attachment)

{ { { { { {

Pressure Sensor (Swing) Pressure Sensor (Boom Raise) Pressure Sensor (Arm Roll-In)

{ {

Pressure Sensor (Auxiliary)

z

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

z

Power Mode Switch Work Mode Switch

z

Auxiliary Mode Switch

z

Engine Learning Switch Battery Relay Glow Relay Engine Electrical Equipment Engine Unit

z

Pump Regulator Remarks

T5-4-26

TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently. E-13 When attachment mode is selected, engine speed doesn’t decrease.

E-14 Engine stalls within several seconds after engine has started.

z

E-15 Engine stalls during operation under adverse condition such as at high altitude.

In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom. E-16 Engine is difficult to start at low temperature.

z z z

z

z

z z z

z {

Check fuel system for clogging.

Check batteries.

T5-4-27


All Actuator System Troubleshooting Trouble Symptom

A-1 All actuator speeds are slow.

A-2 Left travel is inoperable during single travel operation. Single swing operation speed is slow. Arm is slightly slow during arm level crowding.

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.

Parts MC (Main Controller)

z


{

Solenoid Valve Unit (SE)* Pump 2 Delivery Pressure Sensor Pressure Sensor (Swing) Pressure Sensor (Arm Roll-In) N Sensor

{

Spool Main Relief Valve

{

Arm Flow Rate Control Valve Main Pump

z

z

z

Regulator

{

z

z

Pilot Pump

z

Pilot Valve Pilot Relief Valve

z

Pump 1 Flow Rate Control Valve

z

Pump 2 Flow Rate Control Valve

z

Arm Flow Rate Control Valve Spool** Remarks

NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently. In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom.


T5-4-28


A-4 Actuator doesn’t stop even if control lever is returned to neutral.

A-5 Occasionally, swing or arm roll-in speed becomes slow during swing and arm roll-in combined operation.

A-6 Actuator speed is faster than normal. Machine mistracks when the travel lever is operated at half stroke. Precise control can not be performed.

z { z

{ {

z z z z z z z

NOTE: *

Up to serial No.104678 (ZX200 class and 225 class) Up to serial No.010326 (ZX230 class) Up to serial No.020042 (ZX270 class) ** Serial No.104679 and up (ZX200 class and 225 class) Serial No.010327 and up (ZX230 class) Serial No.020043 and up (ZX270 class)

T5-4-29


Front Attachment System Troubleshooting F-2 Even if power digging switch is pressed, power doesn’t increase. Boom raise power is weak when digging.

F-3 Some cylinder are inoperable or speeds are slow.

F-4 Arm speed is slow in a combined operation. Arm speed is slow during arm level crowding.


z

z*

z

Solenoid Valve Unit (SG)

z

Trouble Symptom

F-1 All front attachment actuator power is weak.

Parts

Solenoid Valve Unit (SE)*

z

Solenoid Valve Unit (SC)

z

Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor

{


{

Pressure Sensor (Boom Raise)

{


{

Oil Temperature Sensor Power Digging Switch

z

Spool

z

Main Relief Valve

z

z

Overload Relief Valve

z

z

Load Check Valve Boom Regenerative Valve Arm Regenerative Valve

z

Bucket Regenerative Valve Arm Flow Rate Control Valve

z

Bucket Flow Rate Control Valve Boom Anti-Drift Valve Arm Anti-Drift Valve Emergency Valve Shockless Valve (Signal Control Valve)

z

Shuttle Valve (Signal Control Valve)

z

Bucket Flow Rate Control Valve Control Spool (Signal Control Valve) Arm Flow Rate Control Valve Control Spool (Signal Control Valve)**

z

Pilot Valve

z

Cylinder Boom Electronic Cushion Solenoid Valve***

z*

Remarks

NOTE: *

Up to serial No.104678 (ZX200 class and 225 class) Up to serial No.010326 (ZX230 class) Up to serial No.020042 (ZX270 class) ** Serial No.104679 and up (ZX200 class and 225 class) Serial No.010327 and up (ZX230 class) Serial No.020043 and up (ZX270 class) *** Up to serial No.104908 (ZAXIS225US)

T5-4-30

TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently. F-5 Bucket is slow in bucket roll-in single operation. Bucket doesn’t move smoothly in bucket roll-in single operation.

F-6 When starting to move in combined operation, arm doesn’t smoothly move. Arm starts to move slow slightly in arm roll-in single operation. These troubles often occur when oil temperature is low.

In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom. F-7 When starting to move in combined operation, boom doesn’t smoothly move. Boom starts to move slow slightly in boom lower single operation.

F-8 When boom raise or arm roll-out is operated, boom or arm starts to move after slightly moving downward.

z z z z z z z

z z

{ z

z


T5-4-31



Front Attachment System Troubleshooting Trouble Symptom


F-9∗ The shock is larger at the full stroke of boom raise.

F-10 Front attachment drifts remarkably.

z

Solenoid Valve Unit (SG) Solenoid Valve Unit (SE)* Solenoid Valve Unit (SC) Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pressure Sensor (Swing) Pressure Sensor (Boom Raise) Pressure Sensor (Arm Roll-In) Oil Temperature Sensor Power Digging Switch Spool

z

z

z

z

Boom Anti-Drift Valve

z

z

Arm Anti-Drift Valve

z

z

z

z

z

z

Main Relief Valve Overload Relief Valve Load Check Valve Boom Regenerative Valve Arm Regenerative Valve Bucket Regenerative Valve Arm Flow Rate Control Valve Bucket Flow Rate Control Valve

Emergency Valve Shockless Valve (Signal Control Valve) Shuttle Valve (Signal Control Valve) Bucket Flow Rate Control Valve Control Spool (Signal Control Valve) Arm Flow Rate Control Valve Control Spool (Signal Control Valve)** Pilot Valve Cylinder

z

Boom Electronic Cushion Solenoid Valve*** Remarks z

: Related, required to check

NOTE: *

Up to serial No.104678 (ZX200 class and 225 class) Up to serial No.010326 (ZX230 class) Up to serial No.020042 (ZX270 class) ** Serial No.104679 and up (ZX200 class and 225 class) Serial No.010327 and up (ZX230 class) Serial No.020043 and up (ZX270 class) *** Up to serial No.104908 (ZAXIS225US)

T5-4-32

TROUBLESHOOTING / Troubleshooting B (Blank)

T5-4-33


Swing/Travel/Other System Troubleshooting Trouble Symptom

S-1 Swing is slow or unmoving.

S-2 Swing is slow (weak in power) in swing and arm roll-in combined operation. Swing doesn’t start smoothly. Swing power is weak.

T-1 Both right and left tracks do not rotate or rotate slowly.

Parts MC (Main Controller)

z

Torque Control Solenoid Valve Solenoid Valve Unit (SE)*

z

Solenoid Valve Unit (SC) Solenoid Valve Unit (SI) Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Control Pressure Sensor

{

Pressure Sensor (Travel) Pressure Sensor (Swing)

{


{

Travel Mode Switch Pump Device Spool Load Check Valve Arm Flow Rate Control Valve

z

Flow Combiner Valve Swing Parking Brake Release Spool (Signal Control Valve)

z

Pump 1 Flow Control Valve (Signal Control Valve) Pump 2 Flow Control Valve (Signal Control Valve)

z

Flow Combiner Control Spool (Signal Control Valve) Arm Flow Rate Control Valve Control Spool (Signal Control Valve)**

z

Shuttle Valve (Signal Control Valve)

{

Swing Device

z

z

Travel Device Center Joint Pilot Valve

z Also, refer to T-5. Remarks

NOTE: *

Up to serial No.104678 (ZX200 class and 225 class) Up to serial No.010326 (ZX230 class) Up to serial No.020042 (ZX270 class) ** Serial No.104679 and up (ZX200 class and 225 class) Serial No.010327 and up (ZX230 class) Serial No.020043 and up (ZX270 class)

T5-4-34

TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently. T-2 One side track doesn’t rotate or rotates slowly. Machine mistracks.

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


T-4 Occasionally, machine mistracks when traveling with engine running at slow speed.

T-5 Fast travel is inoperable. Travel mode does not change from slow mode to fast mode.

z z

z { {

{ { { {

{

{

z z z z z

{ { z

{ z z z z In case either bucket or swing is also slow, refer to A-2 or A-3.


T5-4-35

Q-1 Wiper is inoperable or not retracted.


Trouble Symptom

Q-2 Air Conditioner Malfunction

Parts MC (Main Controller) Torque Control Solenoid Valve Solenoid Valve Unit (SE)* Solenoid Valve Unit (SC) Solenoid Valve Unit (SI) Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Control Pressure Sensor Pressure Sensor (Travel) Pressure Sensor (Swing) Pressure Sensor (Arm Roll-In) Travel Mode Switch Pump Device Spool Load Check Valve Arm Flow Rate Control Valve Flow Combiner Valve Swing Parking Brake Release Spool (Signal Control Valve) Pump 1 Flow Control Valve (Signal Control Valve) Pump 2 Flow Control Valve (Signal Control Valve) Flow Combiner Control Spool (Signal Control Valve) Arm Flow Rate Control Valve Control Spool (Signal Control Valve)** Shuttle Valve (Signal Control Valve) Swing Device Travel Device Center Joint Pilot Valve Remarks

NOTE: *

Up to serial No.104678 ((ZX200 class and 225 class) Up to serial No.010326 (ZX230 class) Up to serial No.020042 (ZX270 class) ** Serial No.104679 and up (ZX200 class and 225 class) Serial No.010327 and up (ZX230 class) Serial No.020043 and up (ZX270 class)

T5-4-36


TROUBLESHOOTING / Troubleshooting B ENGINE SYSTEM TROUBLESHOOTING E-1 Starter doesn’t 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 beforehand. Check if voltage at battery relay terminal A is 24 V.

YES

Faulty starter or faulty harness between starter and battery relay.

YES Faulty battery relay.

Check if both voltages at key switch terminal #5 and #6 are 24 V.

NO

YES Check if battery voltage and electrolyte density is normal, and fusible link (40 A) is not blown.

Check for continuity between battery positive terminal and key switch terminal #1.

· Key switch: START

Faulty key switch. YES Faulty harness between battery and key switch.

NO 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

TROUBLESHOOTING / Troubleshooting B E-2 Although starter rotates, engine doesn’t start. Related Fault Code: None

• Check the fuel cut lever position during cranking. If the position is normal, the engine unit and/or fuel system may have trouble. • Check for loose harness connections beforehand.

Faulty engine. YES · Refer to engine shop manual.

Check if governor lever moves to the START position when key switch is turned ON. YES

· Key switch: ON

Faulty EC motor.

Check if EC motor drive circuit is normal. NO Faulty MC. · Test harness: 4274589 (ST 7125)

NO

• 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

T5-4-38

TROUBLESHOOTING / Troubleshooting B • Governor Lever Position A - Key Switch OFF (Engine Stop Position) B - Key Switch ON (Engine Start Position) A

B

FULL

STOP

FULL T105-07-04-003

STOP

• Fuel Cut Lever Position A - Fuel Cut-Off Handle Pulled Position B - Fuel Cut-Off Handle Returned Position

B

A B

T105-07-04-003

T5-4-39

TROUBLESHOOTING / Troubleshooting B E-3 When engine control dial is fully rotated, engine stalls. Occasionally engine stalls during operation with engine control dial fully rotated and auto-idle ON. Engine speed is slower than specification in all operating ranges. Idle speed is faster or slower than specification. 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 performed, engine speed becomes slower than specification across the operating range. • In case the EC sensor is faulty, engine speed is 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 positioned when the key switch is turned ON, discrepancy will differ, causing this trouble to be not reproducible.

TEM/Control System group in the T/M (Operational Principle). • Check for loose harness connections beforehand.

Return fuel cut lever to original position.

YES Check if fuel cut lever has been moved up to half way stroke.

Faulty EC sensor.

YES

· Refer to T4-6-1.

Check if fault code 06 is displayed. NO

NO

Check if problem is corrected after engine learning.

· Refer to T4-6-1 for engine learning procedures.

YES

End.

NO

Monitor engine learning status. · Monitor item: Engine learning control

T5-4-40


YES

OK

Check if governor lever comes in contact with stopper when performing engine learning. NO

Faulty engine and/or fuel system.

Faulty control cable and/or incorrectly adjusted engine governor lever.

· Adjust engine speed. (Refer to T4-6-1.) Faulty MC, faulty learning switch, or broken harness between learning switch and MC. NOT OK · Refer to T4-6-1.

T5-4-41

TROUBLESHOOTING / Troubleshooting B E-4 Even if engine control dial is rotated, engine speed remains unchanged. Related Fault Code: 07

• If the EC fails, the engine will not stop with the key switch OFF.

• Check for loose harness connections beforehand. Faulty engine control dial or broken harness between engine control dial and MC. YES Check if fault code 07 is displayed. Using Dr. ZX, monitor engine control dial angles (standard voltages). Check if voltages are normal. Install test harness (ST 7125) to EC motor. Check if lamp comes ON while turning engine control dial. · Standard voltages Slow idle position: 0.3 to 1 V Fast idle position: 4.0 to 4.7 V · Possible to display with built-in diagnosing system.

YES

Faulty EC motor.

· Refer to T4-6-1.

NO Faulty MC or broken harness between MC and EC motor. NO · Refer to T4-6-1.

T5-4-42

TROUBLESHOOTING / Troubleshooting B E-5 Engine speed doesn’t increase after engine is started. Related Fault Code: 19

• Refer to the pages for the Auto Warming Up Control in the SYSTEM / Control System group in the T/M (Operational Principle). • Check for loose harness connections beforehand. More than 0 °C when starting

NO

Monitor oil temperature.

· Monitor item: Hydraulic oil temperature · Possible to display with built-in diagnosing system Check if fault code 19 is displayed.

Normal.

Lower than 0 °C when starting

Monitor key switch. Check if displayed “ky” is highlighted in response to key switch operation.

YES

Faulty key switch or broken harness between key switch and MC.

Faulty MC. NO · Monitor item: Key switch

· Refer to T4-6-1.

Faulty hyd. oil temperature sensor or broken harness between oil temperature sensor and MC.

YES

T5-4-43

TROUBLESHOOTING / Troubleshooting B 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 sensor fails, the HP mode becomes inoperable. • Pressure sensors (arm roll-in and boom raise) and pump 1 and 2 delivery pressure sensors are also engaged in the HP mode control. However, if these sensors fail, other operating functions will be also affected. (Refer to the relationship between machine trouble symptoms and related parts on page T5-4-2.)

SYSTEM / Control System group in the T/M (Operational Principle). • Check for loose harness connections beforehand.

Faulty power mode switch or broken harness between power mode switch and MC.

NO

NO

Monitor power mode switch. Check if indication HP is highlighted when power mode switch is turned to “HP mode”.

Check if governor lever comes in contact with full-side stopper while relieving boom raise circuit pressure.

YES

YES Check if any fault codes are displayed.

· Monitor item: E/P/HP mode switch

Faulty engine.

Faulty MC. NO · Refer to T4-6-1. Faulty corresponding sensor or broken harness between sensor and MC.

YES

· Fault codes: Pump 1 delivery pressure sensor: 10 Pump 2 delivery pressure sensor: 11 Pilot pressure sensor (boom raise): 15 Pilot pressure sensor (arm roll-in): 16

T5-4-44

TROUBLESHOOTING / Troubleshooting B • Although the power mode switch isn’t turned to the HP mode position, HP mode is operable.

• 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 mode switch.

YES

Monitor the power mode switch. Check if “HP” is displayed.

· Monitor item: E/P/HP mode switch · Power mode switch: P mode

NO

Check if the governor lever comes in contact with full side stopper when the key switch is turned ON (engine not running) and the engine control dial is turned to Fast Idle.

Check if the symptom disappears after completing engine YES learning.

YES

End.

Faulty MC. NO · Refer to T4-6-1. Faulty engine. NO

T5-4-45

TROUBLESHOOTING / Troubleshooting B E-7 Even if key switch is turned OFF, engine doesn’t stop. (In case the engine doesn’t stop, stop the engine by pulling the engine stop handle located under the seat stand. Then, begin inspection.) 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. Perform troubleshooting for these symptoms.

T5-4-46

TROUBLESHOOTING / Troubleshooting B E-8 Faulty auto-idle system

• Even if control lever is turned to neutral. Auto-idle system is inoperable. Related Fault Code: 18

• 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 troubles beforehand. • Although the failure in pressure sensors (travel and front attachment) will have relevance to malfunction of the auto-idle control. However, if these sensors fail, other operating functions will also be affected. (Refer to the relationship between machine trouble symptoms and related parts on page T5-4-2.)

SYSTEM / Control System group in the T/M (Operational Principle). • Check for loose harness connections beforehand.

YES

Normal (Turn power mode switch to a position other than the E mode.)

YES

Check if power mode switch is in the E mode position. YES

Monitor auto-idle switch. Check if displayed “AI” is turned OFF or ON in response to auto-idle / auto- acceleration selector operation.

NO

Monitor the pressure sensor (front). Check if “ON” is displayed.

Bound swing parking brake release spool in the signal control valve.

Faulty MC. · Engine: Running

NO · Refer to T4-6-1. Faulty auto-idle / autoacceleration selector or broken harness between auto-idle switch and MC.

· Monitor item: Auto-idle / auto-accel switch 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 auto-acceleration control. Monitor auto-idle / auto-acceleration selector. Check if “AI” is displayed.

YES

Short circuited harness between MC and auto-idle / auto-acceleration selector.

Faulty MC. · Monitor item: Auto-idle / auto-accel switch · Auto-idle / auto-acceleration selector: OFF

NO

T5-4-47

TROUBLESHOOTING / Troubleshooting B E-9 Faulty E mode

• Even if power mode switch is turned to the E mode position, engine speed remains unchanged. (Engine speed doesn’t decrease.) Related Fault Code: None

• In case trouble symptoms E-1 to E-8 are recognized, perform the troubleshooting of these troubles beforehand. • Refer to the pages for E Mode Control in the SYSTEM / Control System group in the T/M (Operational Principle). • Check for loose harness connections beforehand. Monitor power mode switch. Check if displayed “E Mode” is turned OFF or ON in response to power mode switch operation.

NO

Faulty power mode switch or broken harness between power mode switch and MC.

Faulty MC. YES · Monitor item: E/P/HP mode switch

· Refer to T4-6-1.

• Although power mode switch isn’t turned into E mode, engine speed decrease. Short circuited harness between MC and power mode switch.

YES Monitor power mode switch. Check if “E” is displayed.

Faulty MC. · Monitor item: E/P/HP switch · Power mode switch: P mode

NO · Refer to T4-6-1.

T5-4-48

TROUBLESHOOTING / Troubleshooting B 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 troubles beforehand. • 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 relationship between machine trouble symptoms and related parts on page T5-4-2.)

in the SYSTEM / Control System group in the T/M (Operational Principle).

Monitor auto-idle / auto-acceleration selector. Check if displayed “AA” is turned OFF or ON in response to auto-acceleration switch operation.

NO

Faulty auto-idle / auto-acceleration selector or broken harness between auto-acceleration switch and MC.

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 Short circuited harness between MC and auto-idle / auto-acceleration selector.

auto-acceleration control. YES Monitor auto-idle / acceleration selector. Check if “AA” is displayed.

Faulty MC. · Monitor item: Auto-idle / auto-accel switch · Auto-idle / auto-acceleration selector: Auto-idle position


T5-4-49

TROUBLESHOOTING / Troubleshooting B E-11 When traveling or operating front attachment with engine running at slow idle, engine hunts. Related Fault Code: 18

• Although the failure in pressure sensors (travel and front attachment) will have relevance to malfunction of the engine speed increase control. However, if these sensors fail, other operating functions will also be affected. (Refer to the relationship 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).

Faulty engine.

YES Check if engine speed is faster than increased idle speed.

· Refer to the Engine Shop Manual. Faulty MC.

· Monitor item: Engine target speed · Possible to display with built-in diagnosing system


T5-4-50

TROUBLESHOOTING / Troubleshooting B E-12 Engine speed doesn’t increase even if attachment is operated in attachment mode. Related Fault Code: None

• In case trouble symptoms E-1 to E-11 are recog-

• Refer to the pages for Attachment Operation

nized, perform the troubleshooting of these troubles beforehand. • Although the failure in pressure sensor (auxiliary) and power mode switch will have relevance to 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 between machine trouble symptoms and related parts on page T5-4-2.)

Speed Increase Control in the SYSTEM / Control System group in the T/M (Operational Principle). • Check for loose harness connections beforehand.

Normal (Set to “Increase (+)”.)

NO

NO

Check if attachment speed adjustment has been set to “Increase (+)” in Dr. ZX service mode.

Check if P speed adjustment has been set to “Decrease” in Dr. ZX service mode.

Monitor attachment pilot pressure. Check if pressure varies in response to lever stroke.

YES

To A

Faulty auxiliary pressure sensor. NO · Monitor item: Att. control pilot pressure

YES

YES

A

YES

Monitor work mode switch. Check if display switches in response to work mode switch operation.

Normal (If set to “Decrease”, this control system is deactivated.)

Faulty MC. · Refer to T4-6-1.

Faulty work mode switch. NO · Monitor item: Work mode switch

T5-4-51

TROUBLESHOOTING / Troubleshooting B E-13 When attachment mode is selected, engine speed doesn’t decrease. Related Fault Code: None

• In case trouble symptoms E-1 to E-11 are recognized, perform the troubleshooting of these troubles beforehand. • Refer to the pages for Attachment Operation Speed Limit Control in the SYSTEM / Control System group in the T/M (Operational Principle). • Check for loose harness connections beforehand.

YES

Monitor work mode switch. Check if display switches in response to work mode switch operation.

YES

Faulty MC.

· Refer to T4-6-1.

Faulty work mode switch.

Check if attachment speed adjustment has been set to “Decrease (-)” in Dr. ZX service mode.

NO · Monitor item: Work mode switch

Normal (Set to “Increase (+)”.) NO

T5-4-52

TROUBLESHOOTING / Troubleshooting B E-14 Engine stalls within several seconds after engine has started. Related Fault Code: None

• Refer to the pages for Engine Learning Control in the SYSTEM / Control System group in the T/M (Operational Principle). • If the engine-learning switch is turned to the learning position, the engine will stall in 5 seconds after the engine starts. • Check for loose harness connections beforehand.

Normal (Return switch to neutral.)

YES Check if engine learning switch is turned to the learning position.

Faulty learning switch, or short-circuited harness between learning switch and MC, or check fuel system for clogging.

NO

T5-4-53

TROUBLESHOOTING / Troubleshooting B E-15 Engine stalls during operation under adverse condition such as at high altitude. Related Fault Code: 05

• If speed-sensing control is inoperable, the engine will stall under adverse operating conditions.

• Check for loose harness connections beforehand.

NO

Monitor torque control solenoid valve output. Install pressure gauge to output port so that pressure can be measured by pressure gauge and Dr. ZX. Check if both measured pressure values by pressure gauge and Dr. ZX vary identically.

NO

Disconnect torque control solenoid valve. Connect test harness (ST 7226) between solenoid valve and harness. Check if test harness lamp comes ON.

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 Performance Test section.

· Monitor item: Engine actual speed

Faulty N sensor, or faulty harness between N sensor and MC. YES

Faulty torque control solenoid valve.

YES

A Broken harness between torque control solenoid valve and MC.

NO

T5-4-54

To A


T5-4-55

TROUBLESHOOTING / Troubleshooting B E-16 Engine is difficult to start at low temperature. (During cold weather or in cold districts, the engine is difficult to start or doesn’t start although pre-heated.) Related Fault Code: None

• Check if electricity is routed to the glow plugs. Check the glow plugs for any abnormality. • The pre-heat system operates only when coolant temperature is below 10 °C (50 °F). When coolant temperature is higher than 10 °C (50 °F), the pre-heat system doesn’t operate.

• Check battery at the same time. • Check for loose harness connections beforehand.

Faulty coolant temperature switch.

YES Disconnect coolant temperature switch. Check if voltage at glow plug is 20 to 24 V. YES

Faulty QOS controller.

Disconnect QOS controller. Ground harness end connector terminal #4 to vehicle frame. Check if problem is corrected.


Measure each glow plug resistance. · Using a clip, ground from the reverse side of the connector without disconnecting.

NO · 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

Ω T105-07-04-007

T5-4-56


Faulty glow plug.

∞Ω

YES

Disconnect glow plug relay. Connect harness end connector terminal #4 to vehicle frame. Check if voltage is 20 to 24 V.

NO

Faulty engine unit, faulty glow plug relay, or broken harness between glow plug relay and glow plug. · Refer to the engine shop manual. Broken harness between glow plug relay and QOS controller.

Below 10 Ω

Disconnect glow plug relay. Check if voltage at glow plug relay harness end connector terminals #1 or #3 is 20 to 24 V.

· Key switch: ON

YES

In case voltage at terminal #1 is 0 V, harness between glow relay and batteries is broken. In case voltage at terminal #3 is 0 V, harness between glow relay and key switch terminal M is broken.

· Key switch: ON

NO

· Verify that fuse #19 is normal.

T5-4-57

TROUBLESHOOTING / Troubleshooting B ALL ACTUATOR SHOOTING

SYSTEM

TROUBLE-

A-1 All actuator speeds are slow. Related Fault Code: None

•

•

Reduction in pump 1 and 2 flow rate due to some reasons or faulty pilot system may cause this trouble. • Also, check for fuse of the torque control solenoid valve.

NO

Check if same symptom still appears after disassembling, cleaning, and adjusting pilot relief valve.

Although speed is satisfactory, in case power is weak, refer to the troubleshooting for faulty relief valve (F-1). • Check for loose harness connections beforehand.

Faulty pilot pump or clogged pilot filter.

YES

End. NO

Check if primary pilot pressure is normal.

· Fully boom raised or arm roll-in · Monitor item: Boom Raise Pilot Pressure, Arm Roll-In Pilot Pressure

Faulty N sensor or broken harness in N sensor circuit.

YES

YES

Monitor actual engine speed. Check if abnormal speed is indicated.

· Monitor item: Engine Actual Speed · Possible to display with monitor service mode.

NO

Monitor torque control solenoid valve output. Check if torque control solenoid valve output is normal.

· Monitor item: Pump torque proportional solenoid valve output · Refer to the operational performance Test section

T5-4-58

YES

NO


Pressure Gauge Mounting Port


YES Check if harness between MC and torque control solenoid valve is normal

· Key Switch: OFF

T178-03-01-001

Install pressure gauge between torque control solenoid valve and regulator. Check if the pressure changes.

Faulty pump device. YES

NO

Faulty torque control solenoid valve.

Faulty harness between torque control solenoid valve and MC.

NO

Faulty MC.

· Refer to T4-6-6.

T5-4-59

TROUBLESHOOTING / Troubleshooting B A-2 Left travel is inoperable during single travel operation. Single swing operation speed is slow. Arm is slightly slow during arm level crowding. (All problems occur at the same time.) Related Fault Code: None

• 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).

Monitor pump 2 pump control pressure. Check if pressure increases in proportion to left travel lever stroke.

Faulty pump 2 regulator.

YES

Bound pump 2 flow rate control valve in signal control valve. · Monitor item: Pump 2 flow control pressure · Possible to display with built-in diagnosing system.

NO

T5-4-60

TROUBLESHOOTING / Troubleshooting B A-3 Right travel is inoperable during single travel operation. Single bucket operation speed is slow. Boom is not raised properly during arm level crowding. (All problems occur at the same time.) Related Fault Code: None

• 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. • Refer to the SYSTEM / Hydraulic System group in the T/M (Operational Principle).

Monitor pump 1 pump control pressure. Check if pressure increases in proportion to right travel lever stroke.

· Monitor item: Pump 1 flow control pressure · Possible to display with built-in diagnosing system.

Faulty pump 1 regulator.

YES

Bound pump 1 flow rate control valve in signal control valve.

NO

T5-4-61

TROUBLESHOOTING / Troubleshooting B A-4 Actuator doesn’t stop even if control lever is returned to neutral. Related Fault Code: None

• 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 neutral, pilot pressure is routed to spool end in control valve.

Check if actuator stops when pilot control shut-off lever is 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


T5-4-63

TROUBLESHOOTING / Troubleshooting B A-5 Occasionally, swing or arm roll-in speed becomes slow during swing and arm roll-in combined operation. 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 (Operational Principle).

• Up to serial No.104678 (ZX200 class and 225 class) Up to serial No.010326 (ZX230 class) Up to serial No.020042 (ZX270 class) Faulty corresponding sensor or faulty MC, or broken harness between MC and sensor.

YES

Check if fault code is displayed.

· Fault Codes: 11: Pump 2 delivery pressure sensor 14: Pressure sensor (Swing) 16: Pressure sensor (Arm Roll-In)

NO

NOTE: In case other fault codes are displayed, perform troubleshooting corresponding to the displayed fault code.

Monitor output from solenoid valve unit (SE). Install pressure gauge to port SE. Compare pressure measured by Dr. ZX with that measured by pressure gauge. Check if both pressure values vary identically.

· Monitor item: Arm flow rate proportional solenoid valve output · Perform swing and arm roll-in combined operation.

Faulty arm flow rate control valve in control valve.

YES

NO

Disconnect solenoid valve unit (SE). Connect test harness (ST 7226) between solenoid valve unit (SE) and harness. Check if test harness lamp comes ON.

YES

NO · Perform swing and arm roll-in combined operation.

T5-4-64

Faulty solenoid valve unit (SE).

Broken harness between solenoid valve unit (SE) and MC.

TROUBLESHOOTING / Troubleshooting B Serial No.104679 and up (ZX200 class and 225 class) Serial No.010327 and up (ZX230 class) Serial No.020043 and up (ZX270 class) • Faulty arm flow rate control valve may cause this trouble. • Refer to the COMPONENT OPERATION / Control Valve group in the T/M (Operational Principle).

NO

Install pressure gauge to hose SE connecting signal control valve to arm flow rate control valve in control valve. Check if relief pressure is approx. 3.9 MPa (40 kgf/cm2) while performing 2-function combined operation of arm roll-in, and swing.

. Check if any fault codes are displayed.

· Fault codes: 11: Pump 2 delivery pressure sensor 14: Pressure sensor (swing) 16: Pressure sensor (arm roll-in)

NOTE: The arm flow rate control valve control spool in the signal control valve is provided, instead of the solenoid valve SE.

YES

Faulty arm flow rate control valve.

Bound arm flow rate control valve control spool in signal control valve. NO

Faulty corresponding sensor or faulty MC, or broken harness between MC and sensor.

YES


Signal Control Valve (Control Valve Side)

Control Valve Front Side ZX225 class Hose SE Arm Flow Rate Control Valve

T178-03-06-015

Front Side ZXS200 class, 230 class, 270 class

W178-02-05-018

T5-4-65

TROUBLESHOOTING / Troubleshooting B A-6 Actuator speed is faster than normal Machine mistracks when travel lever is operated at half stroke. Precise control cannot be performed. Related Fault Code: None

• 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 doesn’t 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. • Refer to the SYSTEM / Hydraulic System group in the T/M (Operational Principle).

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. · Pump 1: Bucket operation · Pump 2: Swing operation · Monitor item: Pump 1 and 2 pump control pressures · Possible to display with built-in diagnosing system.

NO

T5-4-66

TROUBLESHOOTING / Troubleshooting B FRONT ATTACHMENT SYSTEM TROUBLESHOOTING F-1 All front attachment actuator power is weak. Related Fault Code: None

• 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. 34.3 to 36.3 MPa (350 to 370 kgf/cm2)

Main relief valve should be normal. Find out cause of trouble by tracing other trouble symptoms.

Monitor pump 1 and 2 delivery pressures.

· Monitor item: Pump 1 and 2 delivery pressure · Possible to display with built-in diagnosing system · Relieve boom, arm, and bucket circuits. · Power mode switch: OFF · Work mode: Digging

Adjust main relief valve. Less than 34.3 MPa (Less than 350 kgf/cm2)

T5-4-67

TROUBLESHOOTING / Troubleshooting B F-2 Even if power digging switch is pressed, power doesn’t 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). • Check for loose harness connections beforehand.

Pressure Increases. Less than 34.3 MPa (350 kgf/cm2) Normal (Possibly, NO ↓ HP mode is taken 36.3 MPa (370 kgf/cm2) for power digging mode.) Monitor pump 1 and 2 delivery pressures. Monitor power digging switch. Check if indication Pressure “Pd” is turned ON doesn’t or OFF in response · Monitor item: Pump 1 and 2 Deliv- increase. to power digging YES switch operation. ery Pressure · Possible to display with built-in diagnostic system · Check pump delivery pressure change · Monitor item: while pressing power Power Digging (Boost) digging switch. Switch · Proceed to YES if boom raise power is weak in digging operation.

Faulty power digging switch or broken harness between power digging switch and MC.

Remains unchanged. Check pressure at solenoid valve unit (SG) port.

· Check pressure change while pressing power digging switch. · Measurement: Refer to the Operational Performance Test section.

T5-4-68

Changes. 2 0.49 MPa (5 kgf/cm ) or less ↓ 0.98 MPa (10 kgf/cm2) or less


Disconnect solenoid valve unit (SG). Connect test harness (ST 7226) between solenoid valve unit and harness. Check if test harness lamp comes ON.

YES

Faulty solenoid valve unit (SG).

NO

Faulty harness between solenoid valve unit (SG) and MC.

· Power Digging Switch: ON

Faulty main relief valve.

T5-4-69

TROUBLESHOOTING / Troubleshooting B F-3 Some cylinders are inoperable or speeds are slow. Related Fault Code: None

• 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 slow, refer to F-7. In case single boom raise / lower operation speed is slow, refer to the next as for ZAXIS225US.

YES

Monitor or measure secondary pilot pressure. Check if secondary pilot pressure is normal.

· Secondary pilot pressure: Refer to Operational Performance Test Section. · Monitor item: Boom raise pilot pressure, arm roll-in pilot pressure · Possible to display with built-in diagnosing system

Monitor pump control pressure. Check if pump control pressure changes smoothly while moving control lever slowly.

· Monitor item: Pump 1 flow control pressure, pump 2 flow control pressure · Possible to display with built-in diagnosing system

Check if overload YES relief pressure is normal.

NO

NO

YES

NO

YES

Bound control valve spool or faulty cylinder (faulty seal kit).

Check if secondary pilot pressure at inlet port to signal control valve.

Faulty overload relief valve.

Faulty shuttle valve in signal pressure control valve.

Bound shockless valve spool.

Faulty pilot valve. NO · Check only when boom is not raised. In case cylinders other than boom are abnormal, skip this step and proceed to the NO line.

T5-4-70

TROUBLESHOOTING / Troubleshooting B • Boom speed is slow. (Up to serial No.104908 (ZAXIS225US)) Related Fault Code: 08

• 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 provided on up to serial No.104908. Failed initial setting of boom electronic cushion, or faulty related sensors.

YES Check if initial setting of boom electronic cushion has been completed correctly, or check if related fault code is displayed.

· Refer to Initial Setting of Boom Electronic Cushion in the TROUBLESHOOTING / General group.

Disconnect the connector in the boom electronic cushion NO solenoid valve. Check if the symptom is improved.

YES

NO

· Be aware that the boom electronic cushion is inoperable.

T5-4-71

Faulty MC.

Bound boom electronic cushion solenoid valve.

TROUBLESHOOTING / Troubleshooting B F-4 Arm speed is slow in a combined operation. Arm speed is slow during arm level crowding. Related Fault Codes: 11, 14, 15, and 16

• 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 (Operational Principle).

• Up to serial No.104678 (ZX200 class and 225 class) Up to serial No.010326 (ZX230 class) Up to serial No.020042 (ZX270 class) Monitor output from solenoid valve unit (SC). Install pressure gauge to port SC. NO Compare pressure measured by Dr. ZX with that measured by pressure gauge. Check if both pressure values vary identically.

Check if any fault codes are displayed.

· Fault codes: 11: Pump 2 delivery pressure sensor 14: Pressure sensor (Swing) 15: Pressure sensor (Boom raise) 16: Pressure sensor (Arm roll-In)

Disconnect solenoid valve unit (SC). Connect test harness (ST 7226) between solenoid valve unit (SC) and harness. Check if NO test harness lamp comes ON.

YES Faulty solenoid valve unit (SC).

NO · Perform boom raise and arm roll-in combined operation.

YES

· Monitor item: Arm regenerative proportional solenoid valve output · Perform boom raise and arm roll-in combined operation. · Refer to the Operational Performance Test.

Broken harness between solenoid valve unit (SC) and MC.

Monitor output from solenoid valve unit (SE). Install pressure gauge to port SE. Compare pressure measured by Dr. ZX with that measured by pressure gauge. Check if both pressure values vary identically.

· Monitor item: Arm flow rate proportional solenoid valve · Perform swing and arm roll-in combined operation. · Refer to the Operational Performance Test. Faulty corresponding sensor or faulty MC, or broken harness between MC and sensor.

YES

NOTE: In

case other fault codes are displayed, perform troubleshooting corresponding to the displayed fault code.

T5-4-72


Disconnect solenoid valve unit (SE). Connect test harness (ST 7226) between solenoid valve unit (SE) and harness. Check if test harness lamp NO comes ON.

· Perform swing and arm roll-in combined operation.

Check if arm regenerative valve in YES 5-spool section of control valve is scored or bound.


YES


NO

Faulty arm regenerative valve.

YES

YES Check if arm flow rate control valve in 5-spool NO section of control valve is scored or bound. NO

T5-4-73


Find out cause of trouble by tracing other trouble symptoms.

TROUBLESHOOTING / Troubleshooting B • Serial No.104679 and up (ZX200 class and 225 class) Up to serial No.010327 and up (ZX230 class) Up to serial No.020043 and up (ZX270 class)

Monitor output from solenoid valve unit (SC). Install pressure gauge to port SC. NO Compare pressure measured by Dr. ZX with that measured by pressure gauge. Check if both pressure values vary identically.


· Fault codes: 11: Pump 2 delivery pressure sensor 14: Pressure sensor (Swing) 15: Pressure sensor (Boom raise) 16: Pressure sensor (Arm roll-In)

Disconnect solenoid valve unit (SC). Connect test harness (ST 7226) between solenoid valve unit (SC) and harness. Check if NO test harness lamp comes ON.

YES Faulty solenoid valve unit (SC).

NO · Perform boom raise and arm roll-in combined operation.

YES

· Monitor item: Arm regenerative proportional solenoid valve output · Perform boom raise and arm roll-in combined operation. · Refer to the Operational Performance Test.

Broken harness between solenoid valve unit (SC) and MC.

Install pressure gauge to hose SK connecting signal control valve to bucket flow rate control valve in control valve. Check if relief pressure is approx. 3.9 MPa (40 kgf/cm2) while performing 3-function combined operation of boom raise, arm roll-in, and bucket roll-in.

Faulty corresponding sensor or faulty MC, or broken harness between MC and sensor.

YES

NOTE: In

case other fault codes are displayed, perform troubleshooting corresponding to the displayed fault code.

T5-4-74


Faulty arm flow rate control valve control spool (signal control valve).

NO

Faulty arm regenerative valve.

YES Check if arm regenerative valve in YES 5-spool section of control valve is scored or bound.

YES


Check if arm flow rate control valve in 5-spool NO section of control valve is scored or bound.


NO

Control Valve Signal Control Valve (Control Valve Side)

Front Side ZX225 class 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

TROUBLESHOOTING / Troubleshooting B F-5 Bucket is slow in bucket roll-in single operation. Bucket doesn’t move smoothly in bucket roll-in single operation. Related Fault Code: None

• Faulty bucket flow rate control valve or bucket regenerative valve may cause this trouble. • Refer to the COMPONENT OPERATION / Control Valve group in the T/M (Operational Principle).

NO

Check if bucket flow rate control valve in control valve is bound or scored.

Install pressure gauge to hose SK connecting signal control valve to bucket flow rate control valve in control valve. Check if relief pressure is approx. 3.9 MPa (40 kgf/cm2) while performing 3-function combined operation of boom raise, arm roll-in, and bucket roll-in.

YES

Check if bucket reYES generative valve in bucket spool is bound or scored. NO

NO

Faulty bucket regenerative valve (Disassemble and clean, or replace.)


Bound bucket flow rate control valve control spool in signal control valve.

Faulty bucket flow rate control valve (Disassemble and clean, or replace.)

YES Signal Control Valve

Hose (SK)

Bucket Flow Rate Control Valve

T178-05-04-002

T5-4-76

TROUBLESHOOTING / Troubleshooting B F-6 When starting to move in combined operation, arm doesn’t smoothly move. Arm starts to move slightly slow in arm roll-in single operation. These troubles often occur when oil temperature is low. Related Fault Code: None

• Refer to the COMPONENT OPERATION / Control Valve group in the T/M (Operational Principle). YES NO

Faulty arm regenerative valve. (Disassemble to clean, or replace.)

Check if arm regenerative valve is bound or scored.

Check if arm anti-drift valve is bound or scored.

NO


Faulty arm anti-drift valve. (Disassemble to clean, or replace.)

YES

F-7 When starting to move in combined operation, boom doesn’t move smoothly. Boom starts to move slow slightly in boom lower single operation. Related Fault Code: None

• Refer to the COMPONENT OPERATION / Control Valve group in the T/M (Operational Principle).

NO

NO


Check if boom regenerative valve is bound or scored. Faulty boom regenerative valve. (Disassemble to clean, or replace.)

Check if boom anti-drift valve is bound or scored.

YES

Faulty boom anti-drift valve. (Disassemble to clean, or replace.)

YES

T5-4-77

TROUBLESHOOTING / Troubleshooting B F-8 When boom raise or arm roll-out is operated, boom or arm starts to move after moving slightly downward. 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 control valve is normal.

NO

· 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 side of the boom cylinder flows back into the circuit through the load check valve, causing the boom cylinder to 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 retracted during the initial stage of operation. In addition, cylinder force is reduced, increasing the cylinder drift in this case.

T5-4-78

(B) When the Load Check Valve is Faulty:

(A)

T105-07-04-012

TROUBLESHOOTING / Troubleshooting B F-9 The shock is larger at the full stroke of boom raise Up to serial No.104908 (ZAXIS225US) Disconnect connector A in MC. Connect harness end connector terminal #23 to terminal #24 with a clip. Disconnect the connector in the boom electronic cushion solenoid valve. Check if continuity between harness end connector terminals #1 and #2.

Monitor output for boom electronic cushion solenoid valve with Dr.ZX. YES Check if the pressure changes when the boom is operated with in the reducing area.

YES

Faulty MC. NO

Broken harness between MC and boom electronic cushion solenoid valve.

· Monitor item Boom damper P/S valve output · Key switch: OFF

Faulty boom electronic cushion solenoid valve.

NO

NOTE: The boom cushion solenoid valve is provided on up to serial No.104908.

Speed Reduction Area

Approx. 60°

Boom Full Stroke Position

T1GF-02-01-001

T5-4-79

TROUBLESHOOTING / Troubleshooting B F-10 Front attachment drifts remarkably. Related Fault Code: None Normal YES

Check if each front attachment cylinder drift is within specification.

NO NO

NO

Check if emergency valve at boom 1 section in control valve 4-spool block is correctly adjusted.

Check if cylinder drift is reduced when pilot shut-off valve is closed.

YES

Correctly adjust emergency valve and lock it up.

Check if symptom is deleted when overload relief valve is temporarily switched with another overload relief valve.

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 retracted 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.) 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

T105-07-04-009


Emergency Valve

NO

NO Check if oil leaks in cylinders.

1

Scored control valve spool, broken spring, or loose spool end.

2

Faulty cylinder. (Replace seal kit.) YES T178-05-04-003

YES

Faulty overload relief valve.

Adjustment Procedure: Loosen (1) and tighten (2). Tightening Torque: (1)- 13 N⋅m (1.3 kgf⋅m) (2)- 7 N⋅m (0.7 kgf⋅m)

T5-4-81

TROUBLESHOOTING / Troubleshooting B SWING SYSTEM TROUBLESHOOTING S-1 Swing is slow or unmoving. Related Fault Code: None • Check whether the pilot system is faulty or the main circuit is faulty. • In case other functions (front attachment and travel) operate normally, the pilot pump is considered to be normal. If the pilot system is displaying a problem, the cause of the trouble may exist in the circuit after the pilot valve.

Monitor secondary pilot pressure. Check if secondary pilot pressure is normal.

Monitor pump control pressure while slowly operating swing lever. YES Check if pump control pressure varies smoothly.

A-2.

Check if swing parking brake release pressure is YES approx. 3.9 MPa (40 kgf/cm2).

· Relieve arm circuit. · Monitor item: · Front attachment operation · Possible to display with built-in diagnosing system

· Monitor item: · Pump 2 flow control pressure · Possible to display with built-in diagnosing system

· Specification: · Refer to Operational Performance Test Section. · Monitor item: · Swing control pilot pressure · Possible to display with built-in diagnosing system

• In case the left travel speed is also slow, refer to

Check if swing parking brake release valve is YES scored or bound.

NO

Faulty swing parking brake release spool in signal control valve.

Bound pump 2 flow rate control valve in signal control valve.

NO

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.

· Relieve swing circuit. · Monitor item: Pump 2 delivery pressure · Specification: · Refer to Operational Performance Test Section.

A

· Measurement: · Refer to Operational Performance Test Section.

Faulty swing motor. NO

Faulty swing relief valve. NO

Faulty swing motor parking brake release valve.

NO

T5-4-82

To A


T5-4-83

TROUBLESHOOTING / Troubleshooting B S-2 Swing is slow (weak in power) in swing and arm roll-in combined operation. Swing doesn’t start smoothly. Swing power is weak. Related Fault Codes: 11, 14, and 16

• Up to serial No.104678 (ZX200 class and 225 class) Up to serial No.010326 (ZX230 class) Up to serial No.020042 (ZX270 class) • Refer to the pages for the Arm Flow Rate Control in the SYSTEM / Control System group in the T/M (Operational Principle). • Check for loose harness connections beforehand.

Faulty corresponding sensor or Faulty MC, or broken harness between MC and sensor.

YES


· Fault codes: 11: Pump 2 delivery pressure sensor 14: Pressure sensor (Swing) 16: Pressure sensor (Arm roll-in)

NO

Monitor output from solenoid valve unit (SE). Install pressure gauge to port SE. Check if pressure measured by pressure gauge varies identically with pressure measured by Dr. ZX.

Faulty arm flow rate control vale in control valve.

YES

NO

Disconnect solenoid valve unit (SE). Connect test harness (ST 7226) between solenoid valve unit (SE) and harness. Check if test harness lamp comes ON.

NOTE: In case other fault

codes are displayed, perform troubleshooting corresponding to the displayed fault code.


· Perform swing and arm roll-in combined operation.

T5-4-84

YES

NO



TROUBLESHOOTING / Troubleshooting B • Up to serial No.104679 and up (ZX200 class and 225 class) Up to serial No.010327 and up (ZX230 class) Up to serial No.020043 and up (ZX270 class)

• Refer to the COMPONENT/Control Valve group (Operational Principle).

• Check for loose harness connections before-

Faulty corresponding sensor or Faulty MC, or broken harness between MC and sensor.

hand. YES


· Fault ccodes: 11: Pump 2 delivery pressure sensor 14: Pressure sensor (Swing) 16: Pressure sensor (Arm roll-in)

NO

Install pressure gauge to hose SE connecting signal control valve to bucket flow rate control valve in control valve. Check if relief pressure is approx. 3.9 MPa (40 kgf/cm2) while performing 3-function combined operation of boom raise, arm roll-in, and bucket roll-in.

Faulty arm flow rate control valve in control valve.

YES

Bound bucket flow rate control valve control spool in signal control valve.

NO

NOTE: In case other fault

codes are displayed, perform troubleshooting corresponding to the displayed fault code.


Control Valve Signal Control Valve (Control Valve Side)

Front Side ZX225 class 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


T5-4-86

TROUBLESHOOTING / Troubleshooting B TRAVEL SYSTEM TROUBLESHOOTING T-1 Both right and left tracks do not rotate or rotate slowly. Related Fault Code: None

• 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 pressure is lower than specification, the front attachment 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

TROUBLESHOOTING / Troubleshooting B T-2 One side track doesn’t rotate or rotates slowly. Machine mistracks. Related Fault Code: None

• Check that both side track sags are equally ad-

• In one side track only doesn’t rotate, the pilot

justed. • Faulty pump control will cause the machine to 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 to A-2 and A-3.

valve, control valve, travel motor, or center joint may be faulty.

YES

Check if travel relief pressure in slow speed NO side is normal.

Check if symptom is reversed when right and left travel line hoses are switched each other at YES the top of center joint.

· Relieve travel circuit. · Monitor item: Pump 1 and 2 delivery pressure · Possible to display with built-in diagnosing system · Measurement: Refer to Operational Performance Test Section.

Check if secondary travel pilot pressure is normal.

YES

· Monitor item: Travel control pressure · Possible to display with built-in diagnosing system NO · Measurement: Refer to Operational Performance Test Section.

Switch forward travel relief valve with reverse travel one, or right travel relief valve with left one. Check if NO symptom is reversed.

Bound control valve spool.

Faulty travel motor.

A

YES Disassemble and clean travel motor counterbalance valve. Check if same symptom occurs.

Disassemble and clean travel motor servo piston. Check if same symptom occurs.

YES

NO

Faulty travel reduction gear.

Faulty travel motor servo piston.

Faulty counterbalance valve.

NO

T5-4-88

To A

· Measurement: Refer to Operational Performance Test Section.

Faulty pilot valve.

NO

YES

Check if travel motor drain oil amount is normal.

To B

TROUBLESHOOTING / Troubleshooting B NO

Faulty center joint.

B

Faulty travel relief valve.

YES

Relationship between Faulty Seal Location and Mistrack Direction

Seal No. 1

When traveling straight: External Oil Leak

Seal Location

When pivot turn is performed: 1

←

2 2 3

3

Left Travel (Reverse)

4

Right Travel (Reverse)

4 5 Right

Left Travel (Forward)

5

6

Travel (Forward)

7

6 T105-07-04-015

7

External Oil Leak

←

Arrangement of Pipe Line 1

2

Front

6

3

5

4 W157-03-03-003

1 - Left Travel (Forward) 2 - Right Travel (Forward)

3 - Pilot 4 - Right Travel (Reverse)

5 - Left Travel (Reverse)

T5-4-89

6 - Drain

TROUBLESHOOTING / Troubleshooting B T-3 Machine mistracks during travel and front attachment combined operation. Related Fault Code: None

Disconnect hose (SL), connecting to flow combiner valve, from signal control valve. Install pressure gauge to signal NO control valve. Check if signal pressure is approx. 3.9 MPa (40 kgf/cm2). Check flow combiner valve in control valve for any abnormality.

Faulty flow combiner valve control spool in signal pressure control valve.

YES

YES

NO

Check load check valve for any abnormality.

Faulty load check valve.

Find out cause of trouble by tracing other trouble symptoms. NO

Faulty flow combiner valve.

YES

Signal Control Valve

Hose (SL)

Flow Combiner Valve

T178-05-04-002

T5-4-90

TROUBLESHOOTING / Troubleshooting B T-4 Occasionally, machine mistracks when traveling with engine running at slow speed. Related Fault Codes: 10, 11, and 18

• Refer to the pages for the Slow Speed Torque Increase Control in the SYSTEM / Control System group in the T/M (Operational Principle). • Check for loose harness connections beforehand.

Faulty corresponding sensor or broken harness between MC and corresponding sensor.

YES

Check is any fault code is displayed.

· Fault codes: 10: Pump 1 delivery pressure sensor 11: Pump 2 delivery pressure sensor 18: Pressure sensor (Travel) · Possible to display with built-in diagnostic system

NO

Monitor output pressure from torque control solenoid valve. Install pressure gauge to torque control solenoid valve output port. Check if both pressures measured by pressure gauge and Dr. ZX varies identically by approx. 1.5 MPa (15 kgf/cm2) when travel operation is made.

Faulty pump device.

YES

Monitor travel pilot pressure. Check if pressure varies in response to travel lever operation.

Faulty torque control solenoid valve or MC, or YES broken harness between torque control solenoid valve and MC.

NO

· Monitor item: Travel control pilot pressure · Monitor item: Pump torque proportional solenoid valve output · Engine: Running at slow idle speed

T5-4-91

NO

Faulty pressure sensor (travel).

TROUBLESHOOTING / Troubleshooting B T-5 Fast travel is inoperable. Travel mode doesn’t change from slow mode to fast mode. Related Fault Codes: 10, 11, 12, and 13

• Refer to the pages for the Travel Motor Swash Angle Control in the SYSTEM / Control section in the T/M (Operational Principle). • Check for loose harness connections beforehand.

NO

Faulty travel mode switch or broken harness between travel mode switch and MC.

NO

Monitor travel mode switch. Check if displayed indication is highlighted in response to travel mode switch operation.

· Monitor item: Travel mode

· Check if symptom is reversed when pressure NO sensor (travel) is switched with another pressure sensor. Monitor pressure sensor (travel). Check if pressure varies in response to travel lever operation. YES

Check if any fault codes are displayed. · Monitor item: Travel control pressure YES

Monitor travel motor swash angle. Install pressure gauge to solenoid valve unit (SI) output port. Check if pressure measured by Dr. ZX varies identically with pressure measured by pressure gauge while repeating to travel and stop.

· Monitor item: Travel motor swash angle control pressure · Travel mode: Fast · Measurement: Refer to Operational 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


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

NO

Disconnect solenoid valve unit (SI). Connect test harness (ST 7226) between solenoid valve unit (SI) and harness. Check if test harness lamp comes ON.

YES

Faulty solenoid valve unit (SI).

Broken harness between solenoid valve and MC. NO · Travel mode: Fast Faulty travel motor swash angle control valve.

YES

YES

Check if travel motor swash angle control valve is bound or scored. Faulty travel motor or travel reduction gear.

NO

T5-4-93

TROUBLESHOOTING / Troubleshooting B OTHER SYSTEM TROUBLESHOOTING O-1 Wiper is inoperable or not retracted. Related Fault Code: None Checking Instructions

• The wiper is driven by electric power routed via

• If the front window is open, the wiper won’t oper-

the relay circuit controlled by the monitor assembly. In case the wiper is inoperable, first check the wiper motor and links for any abnormality using an auxiliary electric power and the test harness.

ate. Check that the front window is securely closed.

Faulty front window open/close switch or short-circuited harness between front window open/close switch and monitor.

YES

Disconnect front window open / close switch. Check if wiper operates.

· Key switch: ON

NO

Connect test harness (ST 7227) between auxiliary electric power (fuse box #19) and wiper motor as illustrated to the right. Check if wiper operates.

Remove test harness and reconnect circuit to the original position. Replace wiper relay YES one at a time to see if wiper operates.

YES Faulty wiper relay.

NO

To A

· Key switch: ON Faulty wiper motor or links.

· Key switch: ON 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 same time only when the wiper reaches the intermittent stop position.

NO or test harness lamp doesn’t light normally.

A

Replace monitor assembly to see if wiper operates.

YES End (Faulty monitor).

Faulty cab harness. NO

T5-4-94


Test Harness Application Circuit Fuse Box #19

M

B

Lamp S

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

TROUBLESHOOTING / Troubleshooting B 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 below: 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 Fahrenheit 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. Keep pressing OFF switch for more than 3 seconds.

Press upper side fan switch.

STEP 1 Display Function Confirmation



STEP 2 Present Trouble Diagnosing

Press lower side fan switch.

Press upper side fan switch. Keep pressing air conditioner switch for more than 3 seconds.

STEP 3 Past Trouble Diagnosing

Keep pressing OFF switch for more than 3 seconds.



STEP 4 Sensing Temperature Display

Press lower side fan switch. Press upper side fan switch. Keep pressing OFF switch for more than 3 seconds. STEP 5 Component Operation Check Press AUTO switch and lower side fan switch. Keep pressing OFF switch for more than 3 seconds.

Press AUTO Switch and upper side fan switch.

Press A/C switch and lower side fan switch.

STEP 6-1 Correction of the Set Temperature

Keep pressing OFF switch for more than 3 seconds.

Self-Diagnosis

T5-4-96

Press A/C switch and upper side fan switch.

STEP 6-2 Selection of Celsius and Fahrenheit Temperature Indication

TROUBLESHOOTING / Troubleshooting B Self-Diagnostic System Activation Turn the key switch ON while pressing the air conditioner switch and mode switch on air conditioner control panel.

Fan Switch

LCD

Air Conditioner Switch

STEP 0 Check Model Confirmation The liquid crystal display (LCD) indicates the machine model name this system can diagnose.

• 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 seconds: 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 proceed 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

T178-05-08-001

Mode Switch

OFF Switch

TROUBLESHOOTING / Troubleshooting B STEP 2 Present Trouble Diagnosing The LCD indicates the fault codes for present abnormalities of the mix door, mode encoder, and/or sensors.

Fan Switch

LCD

• In case any abnormalities are present, the LCD indicates the fault codes. If more than one fault code is detected, the following fault code is displayed after flashing (0.5 seconds) twice. Fault Code Breakage Short Circuit Mix Door 21 −21 Mode Encoder 22 In-Cab Ambient 23 −23 Temperature Sensor Outdoor Ambient 24 −24 Temperature Sensor Coolant Tempera25 −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 isn’t displayed. In case no failures are present, the LCD indicates “20.” • Select the next step to be performed by operating the switches as follows: • Press the upper side of the fan switch: To proceed to “STEP 3.” • Press the lower side of the fan switch: To return to “STEP 1.” • Keep pressing the OFF switch for more than 3 seconds: Deactivate the self-diagnostic system. (Normal function is resumed)

T5-4-98

T178-05-08-001

OFF Switch

TROUBLESHOOTING / Troubleshooting B STEP 3 Past Trouble Diagnosing The LCD indicates the fault codes for past abnormalities of the mix door, mode encoder, and/or sensors. The past stored fault codes are deleted.

Fan Switch

LCD


• 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 displayed after flashing (0.5 seconds) twice. Fault Code Breakage Short Circuit Mix Door 21 −21 Mode Encoder 22 In-Cab Ambient Temperature Sen23 −23 sor Outdoor Ambient Temperature Sen24 −24 sor Coolant Tempera25 −25 ture Sensor Solar Radiation −26 Sensor NOTE: As for ZAXIS225US, the fault code for the coolant temperature sensor isn’t 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 indicator flashes 5 times. Then, the self-diagnosing system is deactivated. (Normal functions are resumed.) • Select the next step to be performed by operating the switches as follows: • Press the upper side of the fan switch: To proceed to “STEP 4.” • Press the lower side of the fan switch: To return to “STEP 2.” • Keep pressing the OFF switch for more than 3 seconds: Deactivate the self-diagnostic system. (Normal function is resumed)

T5-4-99

T178-05-08-001

OFF Switch

TROUBLESHOOTING / Troubleshooting B STEP 4 Sensing Temperature Display The LCD indicates the sensing temperature detected by each temperature sensor (excluding the insulation sensor).

Fan Mark Fan Switch

LCD


• The sensing temperature detected by the in-cab ambient temperature sensor, outdoor ambient temperature sensor, and coolant temperature sensor are displayed on the LCD in real time. (Figures less than the decimal point are not displayed.) NOTE: The coolant temperature sensor indicates “H” when coolant temperature is more than 21 °C (70 °F) and “L” when coolant temperature is less than 21 °C (70 °F). • Sensing temperature detected by each sensor is automatically displayed on the LCD and is cycled at an interval of 3 seconds with the timer. The timer is turned ON or OFF by operating the fresh air vent switch. • Referring to the fan mark can check which sensing temperature is displayed. • Select the next step to be performed by operating the switches as follows: • Press the upper side of the fan switch: To proceed to “STEP 5.” • Press the lower side of the fan switch: To return to “STEP 3.” • Keep pressing the OFF switch for more than 3 seconds: Deactivate the self-diagnostic system. (Normal function is resumed)

T5-4-100

T178-05-08-001

Fresh Air Vent Switch

OFF Switch

TROUBLESHOOTING / Troubleshooting B STEP 5 Component Operation Check Each component operation is checked by performing pattern operation.

Fan Switch

LCD

Air Conditioner Switch AUTO Switch

• 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 referring to No. indicated on the LCD. (See table 1.) • Operating pattern of the selected component is shifted at an interval of 10 seconds. Operating pattern is cycled. (See table 1.) NOTE: The components other than selected operate under the standard conditions (shown by marks* in table 1). • Select the next step to be performed by operating the switches as follows: • 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”. • Press the lower side of the fan switch: To return to “STEP 4.” • Keep pressing the OFF switch for more than 3 seconds: Deactivate the self-diagnostic system. (Normal function is resumed) Table 1 Component Air Mix Damper

Indication on LCD 51

Fan

52

Air Vent Location Fresh/Circula-tio n Air Vent Selection Air Conditioner

53 54

55

Operation Pattern

T178-05-08-001

Fresh Air Vent switch

OFF Switch

Remarks

Controls opening extent of air mix damper: 0% (fully closed) → 50%*→ 100% (fully opened) Controls air flow volume: Lo → M(Lo) → M(Hi) → Hi Selects air vent: Front*→ Front/Rear → Front/Foot → Foot Select Ventilation Mode: Circulation* → Fresh

0%, 50%, 100%: “C”, “5”, and “H” are indicated next to the decimal point respectively. Indicators corresponding to air flow volume light. Indicator corresponding to selected air vent lights. Indicator corresponding to selected mode light.

Turns air conditioner switch: ON* → OFF

ON: Indicator lights. OFF: Indicator is extinguished.

T5-4-101

TROUBLESHOOTING / Troubleshooting B STEP 6-1 Correction of the Set Temperature Fine correction of the set temperature.

Fan Switch

LCD

Temperature Control Switch

AUTO Switch

• Each time when the top or bottom of the temperature control switch is pressed, temperature correction, 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 25°C (77 °F) and set temperature correction is -1°C (-34 °F), the actually controlled temperature becomes 24°C (75 °F). • Select the next step to be performed by operating the switches as follows: • Press the AUTO switch and lower side of the fan switch: To return to “STEP 5.” • Keep pressing the OFF switch for more than 3 seconds: Deactivate the self-diagnostic system. (Normal function is resumed)

T5-4-102

T178-05-08-001

OFF Switch

TROUBLESHOOTING / Troubleshooting B STEP 6-2 Selection of Celsius and Fahrenheit Temperature Indication Selection of Celsius and Fahrenheit Temperature In-

Fan Switch

LCD


dication.

• Each time when the fresh air vent switch is pressed, Celsius or Fahrenheit temperature may be displayed alternately. • Temperature is displayed at the top of the LCD window as follows. (C: Celsius, F: Fahrenheit) C

T178-05-08-001

Fresh Air Vent Switch

F

• Select the next step to be performed by operating the switches as follows: • Press the Air Conditioner Switch and lower side of the fan switch: To return to “STEP 5.” • Keep pressing the OFF switch for more than 3 seconds: Deactivate the self-diagnostic system. (Normal function is resumed)

T5-4-103

OFF Switch

TROUBLESHOOTING / Troubleshooting B ※ Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to Hitachi Tsuchiura Works Quality Assurance Dept. after experiencing a problem with your machine’s air conditioning system. < AIR CONDITIONER TROUBLE REPORT > File No. (1) What Checked by: Model (Serial No. ) Operation Type Manual Semi-Auto Full-Auto Delivery Date Year Month (2) When Date Year Month Day Operating Hour ( h) Time Morning Daytime Evening Night Frequency Every Day Once a Week Once a Month Times per (3) Where Job Site Address State County Town Access Road Condition Paved Not Paved (Gravel Sand Soil) (4) How (Operating Conditions) Weather Fine Cloudy Rain Snow Atmospheric Temperature Very Hot Hot Cold Very Cold Operating Conditions Parking Traveling Working Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when full-auto operation A/C ON OFF Air Induction Re-Circulation Fresh Air Circulation Control 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 (1) Is problem reproducible ? Not turned OFF Reproducible Others Not reproducible Uncontrollable air temperature (2) Pressure (To be measured at gauge manifold) Symptom No cool air Low Pressure No warm air High Pressure Others (3) Which parts have been replaced ? Uncontrollable air volume 1 Symptom Air flows in Hi mode only No air flows 2 Small air volume Others ∗ Before replacing the control amplifier, be sure to Uncontrollable vent hole check that the connectors are correctly connected Symptom Vent hole isn’t selected while repeatedly disconnecting and reconnecting Others connectors. Abnormal panel indication Faulty Indicator Vent Hole A/C AUTO Fresh Air Circulation Fan OFF Fan (Lo • •• Hi) Temperature Control Symptom Stays OFF Stays ON Blinks Others

T5-4-104

TROUBLESHOOTING / Troubleshooting B 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

TROUBLESHOOTING / Troubleshooting B Cooling Circuit Refrigerant pressure in both high and low-pressure sides is low.

Bubbles can be seen in sight glass.

No bubbles are seen in sight glass.

Piping and/or parts are stained with oil, respond to gas detector. No oil stain is found or gas detector doesn’t respond. Refrigerant has not been refilled for longer than one season.

After cooling at fast speed continuously, cooling power is reduced. Air flow volume remains unchanged.

Air flow volume is reduced.

Insufficient Cooling Power

Refrigerant pressure in low-pressure side is high.


Compressor cylinder is extremely hot, emitting a smell.

Refrigerant pressure in high-pressure side is low.

Compressor cylinder is extremely hot, emitting a smell.

Heater unit emits hot air.

Refrigerant pressure in high-pressure side is high.


Refrigerant pressure in low-pressure side is low.

Condenser is stained and clogged. Even if condenser is sprayed with water, few bubbles appear. Receiver dryer temperature is low.

After cooling at fast speed continuously, cooling power is reduced. Air flow volume is reduced.

Frost forms.

Thermistor doesn’t cool. Thermistor cools.

T5-4-106

TROUBLESHOOTING / Troubleshooting B 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 valve.

Readjust or replace expansion 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 receiver 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 type).

Repair.

Clogged high-pressure circuit before receiver dryer.

Remove clog, or replace parts. Clean Condenser.

Excessive refrigerant.

Remove excessive refrigerant to proper level.

Air is mixed in system.

After evacuation, refill refrigerant and/or replace receiver 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 air-conditioner is kept operated for a long time with thermistor in max. cooling position and air flow in M or L mode, frost may form.

Instruct user on correct air-conditioner operation. (Reset thermistor to either minimum or middle cooling position or increase air flow.)

T5-4-107

TROUBLESHOOTING / Troubleshooting B Cooling Circuit

Case connection.

Louver resonance. Fan contacts case, or foreign matter enters case.

Blower fan connection.

Noise

Brush friction noise, metal and/or thrust washer contact noise.

Gas blowing sound (roaring).

Gas vibration noise (compressor discharge and/or suction gas noise).

Expansion valve connection, whistle sound, gas blowing sound.

Abnormal noise from expansion valve (Expansion 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.

Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in L mode for more than 10 minutes, flush smell out by condensed water.

T5-4-109

TROUBLESHOOTING / Troubleshooting B Compressor Compressor doesn’t rotate.

Clutch terminal voltage is normal 24 V.

Inoperable cooling system.

Clutch terminal voltage is low.

Clutch terminal voltage is 0 V. Bubbles exist even after refrigerant is refilled. Both high and low side pressures are low. Both compressor and blower motor rotate.

Check for oil and refrigerant leaks from parts other than compressor and pipe joints using gas detector. Check for oil and refrigerant leaks from compressor (no leaks from parts other than compressor) using gas detector. (Refer to NOTE 2 on page T5-4-89.) 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.

High pressure side is slightly low and low pressure side is high.

Bubbles can be seen through sight glass.

Compressor cylinder is not hot. (Refrigerant returns to compressor in liquid form.) No refrigerant returns in liquid form. High pressure side is low. Others

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 doesn’t 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. Normal leaks from hoses.

Replace. 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 oil level.

Excessive oil.

T5-4-111

TROUBLESHOOTING / Troubleshooting B Compressor Compressor rotation is abnormally draggy. Overheating is susceptible to occur. Trouble other than compressor.

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 doesn’t 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 Troubleshooting Table on page T5-4-106.

Saggy belt. Loose screws.

Broken valve. Replace. Blown gasket. Abnormal internal noise.

Replace.

Vibration due to saggy belt.


Loose screws.

NOTE: 1. Don’t quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A slight oil seepage will appear due to the seal construction. However, this oil seepage will not cause malfunction. Be sure to accurately check whether oil is leaking or seeping only. 2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose surface may be detected. As long as the specified rubber hoses are used, the problem should not occur. (In case a large leaks is detected, the hose may be broken.) 3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between high-pressure side and low-pressure side is 0.49 MPa (5 kgf/cm2) or less. When the clutch is turned OFF, the pressure difference between high-pressure side and low-pressure side will disappear within about 10 seconds.

T5-4-113

TROUBLESHOOTING / Troubleshooting B EXCHANGE INSPECTION Exchange inspection method is a troubleshooting method to find the trouble location by exchanging the suspected part / component with another part /component having identical characteristics. Many sensors and solenoid valves used on this machine are identical. Therefore, using this switch-check method, faulty part /component, and/or harness can be easily found. Example: Abnormal pump 1 delivery pressure (Fault code: 10) Check Method: 1. Switch two delivery pressure sensors located as shown in figure A to figure B. 2. Retry troubleshooting.

Pump 2 (5-Spool Section)

PP2


PP1

Figure A 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 (fault code 10), the pump 1 delivery pressure sensor harness is considered to be faulty.


PP1

Figure B

T5-4-114


PP2

T157-07-04-006

TROUBLESHOOTING / Troubleshooting B Applicability of Switch-Check Method Fault Code Trouble 01 Abnormal EEPROM 02 Abnormal RAM 03 Abnormal A/D Conversion 04 Abnormal Sensor Voltage 06 Abnormal EC Angle Sensor 07 Abnormal EC Dial 08 Abnormal Boom Angle Sensor 10 Abnormal Pump 1 Delivery Pressure 11 Abnormal Pump 2 Delivery Pressure 12 Abnormal Pump 1 Control Pressure 13 Abnormal Pump 2 Control Pressure 14 Abnormal Swing Pilot Pressure 15 Abnormal Boom Raise Pilot Pressure 16 Abnormal Arm Roll-In Pilot Pressure 18 Abnormal Travel Pilot Pressure Abnormal Hydraulic Oil Temperature 19 Sensor

T5-4-115

Applicability Not Applicable

Not Applicable Not Applicable Not Applicable Applicable (Harness) Applicable (Harness) Applicable (Harness/Sensor)

Not Applicable

TROUBLESHOOTING / Troubleshooting B EMERGENCY BOOM LOWERING PROCEDURE Front Attachment Side

CAUTION: Prevent personal injury. Confirm that no one is under the front attachment before starting the procedure below.

2

If the engine stalls and cannot be restarted, lower the boom to lower the bucket to the ground referring to the emergency boom lowering procedure stated below.

1

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 located under the solenoid valve. Pay attention to the screw turns.

M178-05-003

2. After the bucket is lowered to the ground, retighten screw (2), then lock nut (1) to the specifications below. Emergency Valve

Lock Nut (1) Tool : 13 mm Torque : 13 N⋅m (1.3 kgf⋅m, 9.4 lbf⋅ft)

1

Screw (2) Tool : 4 mm (Hexagonal wrench) Torque : 6.9 N⋅m (0.7 kgf⋅m, 5.0 lbf⋅ft)

2

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.

T5-4-116

T178-05-04-003

TROUBLESHOOTING / Troubleshooting C TROUBLESHOOTING C (TROUBLESHOOTING 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), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).

(1) 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 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

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PERATURE GAUGE

COOLANT

TEM-

• Check for loose harness connections beforehand.

Gauge pointer doesn’t move at all.

Disconnect coolant temperature sensor. Ground harness end terminal to vehicle frame. Check if pointer swings to (H) side.

Faulty coolant temperature sensor.

YES

NO · Key switch: ON

Without connecting coolant temperature sensor, remove connector B (20P) from monitor. Check for continuity between monitor harness end connector terminal #18 and coolant temperature sensor terminal.

YES

Broken harness between monitor and sensor. NO


YES Gauge pointer swings over scale.

Disconnect coolant temperature sensor. Check if pointer returns to zero.

NO · Key switch: ON

Gauge pointer keeps moving unstably.

Disconnect coolant temperature sensor. Ground harness end terminal to vehicle frame, Check if pointer swings and is stabilized to (H) side.

Faulty monitor.

Without connecting coolant temperature sensor, remove connector B (20P) from monitor. Check for continuity between monitor harness end terminal #18 and vehicle frame.

YES

Short-circuited harness between monitor and sensor.

Faulty monitor. NO


YES

Faulty monitor. NO · Key switch: ON

T5-5-2

TROUBLESHOOTING / Troubleshooting C

Coolant Temperature Gauge Board 105 ﾟ C (95 ﾟ

70 ﾟ C

T157-07-05-001

Coolant Temperature Sensor Coolant Temperature °C (°F) 25 (77) 40 (104) 50 (122) 80 (176) 95 (203) 105 (221) 120 (248)

Resistance (kΩ) 7.6±0.76 4.0±0.35 2.7±0.22 0.92±0.07 0.56±0.04 0.42±0.03 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

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF FUEL GAUGE • Check for loose harness connections beforehand.

Fuel gauge pointer doesn’t move at all.

Disconnect fuel sensor. Connect harness end connector terminal #1 to terminal #2 using jumper wire such as clip. Check if pointer swings to (FULL) side.

Faulty fuel sensor.

YES

Without connecting fuel sensor, remove connector B (20P) from monitor. Check for continuity between monitor terminal #19 and fuel sensor terminal #1.

NO

YES Faulty monitor.

Broken harness between monitor and sensor. NO

· Key switch: ON

YES Fuel gauge pointer swings over scale.

Disconnect fuel sensor. Check if pointer returns to zero.

· Key switch: ON

Faulty fuel sensor. Without connecting fuel sensor, remove connector B (20P) from monitor. Check for continuity between monitor harness end terminal #19 and vehicle frame.

NO

Short-circuited harness beYES tween monitor and sensor.

Faulty monitor. NO

Fuel gauge pointer keeps moving unstably.

Disconnect fuel sensor. Connect harness end connector terminal #1 to terminal #2 using jumper wire such as clip. Check if pointer swings and is stabilized to (FULL) side.

YES

Faulty fuel sensor.

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 Upper Limit (FULL) 3/4 1/2 1/4 Warning Level Lower Limit (EMPTY)

Resistance (Ω) 10+0-4 26 38±5 53 85±3 90+10-0


Fuel Sensor

1

2

T5-5-5

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF INDICATOR LIGHT CHECK SYSTEM • Check for loose harness connections beforehand.

YES Indicator doesn’t light when indicator light check operation is performed.

Check if all indicators don’t light.

Disconnect monitor connector C. Check if there is continuity between harness end connector terminal #1(power input) and fuse box terminal #5(switch box).

YES

Burnt fuse or faulty monitor.

Broken harness between fuse and monitor. NO

Conduct troubleshooting of each indicator, which does not light.

NO

Connector (Harness end connector terminals seen from the open end side) 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

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PREHEAT INDICATOR • The preheat system operates only when coolant temperature is below 10 °C (50 °F), lighting the preheat indicator for 8 seconds. (Refer to the SYSTEM /Electrical Circuit group.)

Preheat indicator lights even though preheat system doesn’t operate (coolant temperature is more than 10 °C (50 °F)).

Remove connector (with black and white cables) from coolant temperature switch. Check if indicator goes OFF by grounding harness end connector to vehicle frame.

• In case the preheat system malfunctions, refer to the troubleshooting B for E-16 Engine is difficult to start at low temperature. • Check for loose harness connections beforehand. Faulty coolant temperature switch.

YES


YES

Disconnect QOS controller. Check if indicator goes OFF.

NO

· Key switch: ON

· Key switch: ON

Without connecting QOS controller, remove connector B (20P) from monitor. Check for continuity between monitor harness end conNO nector terminal #20 and vehicle frame.

YES

Short-circuited harness between QOS controller and monitor.

Faulty monitor. NO

Preheat indicator doesn’t light although preheat system operates (coolant temperature is lower than 10 °C (50 °F)).

Remove connector (with black and white cables) from coolant temperature switch. Check if indicator comes ON.

Faulty coolant temperature switch.

YES


YES Disconnect QOS controller. Check if indicator comes ON by grounding harness end connector terminal #6 NO to vehicle frame.

· Key switch: ON

Ground monitor connector B (20P) terminal #20 to vehicle frame. Check if indicator comes ON.

YES

Broken harness between QOS controller and monitor.

NO Faulty monitor. NO · Key switch: ON


QOS Controller 1 2 3 4 5 6

T5-5-7

· Without disconnecting connector, ground connector to vehicle frame using jumper wire such as clip from reverse side of connector.

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE OIL LEVEL INDICATOR (Up to serial No.104679 (ZX200 class and 225 class), Up to serial No.010322 (ZX230 class), Up to serial No.020040 (ZX270 class))

• • • •

Check that indicator light is not burned out. Check that all other indicators work correctly. Check that machine is parked on level surface. Check for loose harness connections beforehand.

Indicator doesn’t light even if engine oil level is lower than specification.

Check if indicator lights by removing connector (with black and white cable) from engine oil level switch.

Without connecting connector to engine oil level switch, remove connector B (20P) from monitor. Check for continuity between monitor harness end connector terminal #8 and vehicle frame.

NO

YES

Short-circuited harness between engine oil level switch and monitor.

Faulty monitor. NO

Faulty engine oil level switch. YES

Lower than 3.5 mm below LOW level mark on oil level gauge Indicator comes ON even if engine oil level matches specification.

Remove connector (with black and white cables) from engine oil level switch. Check if indicator goes OFF by grounding harness end connector to vehicle frame.

NO

Check oil level with oil level gauge.

Without connecting connector to engine oil level switch, remove connector B (20P) from monitor. Check for continuity between monitor harness end connector terminal #8 and engine oil level switch connector.

To A

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.

NO

Broken harness between engine oil level switch and monitor.

A

T5-5-8


Engine Oil Level Switch Oil Level Gauge

Engine Oil Level Switch ON

H

A

L

(Indicator ON) (Indicator OFF) OFF

A: 3.5 mm T107-04-03-010


T5-5-9

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF COOLANT 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. Check for loose harness connections beforehand.

Indicator doesn’t light even if coolant level is lower than specification.

Check if indicator lights by removing connector (with gray cable) from coolant level switch.

NO

Without connecting connector to coolant level switch, remove connector B (20P) from monitor. Check for continuity between monitor harness end connector terminal #9 and vehicle frame.

YES

Short-circuited harness between coolant level switch and monitor.

Faulty monitor. NO

Faulty coolant level switch. YES

NO Indicator comes ON even if coolant level matches specification.

Remove connector (with gray cables) from coolant level switch. Check if indicator goes OFF by grounding harness end connector terminal #1 to vehicle frame.

Check if coolant level in coolant reservoir is lower than LOW mark.

NO

Without connecting connector to coolant level switch, remove connector B (20P) from monitor. Check for continuity between monitor harness end connector terminal #9 and coolant level switch connector.

To A

Faulty coolant level switch. YES

Normal (Lack of coolant). YES

YES

Faulty monitor.

NO

Broken harness between coolant level switch and monitor.

A

T5-5-10


Coolant Level Switch Reserve Tank ON FULL LOW

Radiator

OFF Coolant Level Switch T107-04-03-012


Coolant Level Switch

1

2

T5-5-11

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ALTERNATOR INDICATOR • 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 stays ON after engine is started.

Measure voltage at regulator terminal L.*

· Engine: Running

Broken harness between regulator terminal L and monitor. Less than 13 V or higher than 33.5 V Faulty regulator or alternator.

· Engine: Running 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, alternator indicator doesn’t light.

Check if indicator lights when key switch is turned ON.

· Key switch: ON

· Key switch: ON · Engine: Stopped

E S

R

Less than 10 V or higher than 33.5 V Burned indicator light.

NO

Connector (Harness end connector terminals seen from the open end side) Starter Relay

Faulty regulator.

Monitor Connector A (16P) 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9

T5-5-12

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-5-13

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE OIL PRESSURE 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 pressure switch. Check if indicator lights when harness end connector terminal #1 (white and red cable) is grounded YES to vehicle frame.

YES

Faulty engine oil pressure switch.

Reconnect engine oil pressure switch. Check if indicator lights when monitor connector C (20P) terminal #18 is grounded to vehicle frame. NO

Indicator doesn’t light even if engine oil pressure is low.


To A

· Key switch: ON · Key switch: ON · Without disconnecting connector, ground connector to vehicle frame using such jumper wire as clip from reverse side of connector.


Burned indicator light. NO

YES

Broken harness between monitor and engine oil pressure switch.

A

Faulty monitor. NO

Indicator stays ON after engine is started.

· Check oil filter for clogging.

Check if indicator goes OFF when engine oil pressure switch is disconnected.


Faulty engine oil pressure switch or engine oil pressure system, or clogged oil filter.

YES

NO

Reconnect engine oil pressure switch and remove connector C (20P) from monitor. Check for continuity between harness end connector terminal #18 and vehicle frame.

YES

Short-circuited harness between monitor and engine oil pressure switch.

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

Connector (Harness end connector terminals seen from the open end side) Monitor Connector C (20P) 10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11

T5-5-15

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF OVERHEAT INDICATOR • Check for loose harness connections beforehand. Remove connector (red and blue cable) from overheat switch. Check if indicator lights when harness end terminal is YES grounded to vehicle frame.

YES

Faulty overheat switch.

Reconnect overheat switch. Check if indicator lights when monitor connector B (20P) terminal #6 is grounded to vehicle frame. NO

Indicator doesn’t light even if engine overheats.


To A

· Key switch: ON · Key switch: ON · Without disconnecting connector, ground connector to vehicle frame using such jumper wire as clip from reverse side of connector.

· Key switch: ON


YES

Broken harness between monitor and overheat switch.

A

Faulty monitor. NO

Faulty overheat switch.

YES Indicator lights even if coolant temperature is low.

Check if indicator goes OFF when overheat switch is disconnected.


NO

Disconnect overheat switch. Remove connector B (20P) from monitor. Check for continuity between connector terminal #6 and vehicle frame.

YES

Short-circuited harness between monitor and overheat switch.

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


T5-5-17

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF AIR FILTER RESTRICTION INDICATOR • Check for loose harness connections beforehand. Disconnect air filter restriction switch at plug receptacle with green and blue cable. Check if indicator lights when harness end plug conYES nector is grounded to vehicle frame.

Even if air filter is clogged, indicator doesn’t light.


YES

NO

Faulty air filter restriction switch.

Reconnect air filter restriction switch. Remove connector B (20P) from monitor. Check for continuity between monitor harness end connector terminal #7 and vehicle frame.

To A

· Key switch: ON · Key switch: ON Burned indicator light. NO

YES

A

NO

Although air filter is not clogged, indicator lights.

· Disassemble and visually inspect. · Verify that air filter is not moist.

· Key switch: ON

NO

Broken harness between monitor and air filter restriction switch.

Faulty air filter restriction switch.

YES Check if indicator goes OFF when air filter restriction switch is disconnected.

Faulty monitor.

Disconnect air filter restriction switch at plug receptacle with green and blue cable and remove connector B (20P) from monitor. Check for continuity between connector terminal #7 and vehicle frame.

YES

Short-circuited harness between monitor and air filter restriction switch.

Faulty monitor. NO

T5-5-18


Air Filter Restriction Switch Pressure 5.1 kPa (520 mmH2O) 6.2 kPa (630 mmH2O)

Operation OFF ON


T5-5-19

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF BUZZER • Check for loose harness connections beforehand.

Buzzer continues to sound when key switch is turned ON without starting engine.

Measure voltage at monitor connector A (16P) terminal #2.

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.

Faulty regulator.

13 V or more

Faulty monitor. · Key switch: ON (without starting engine)

Less than 13

Faulty engine oil pressure system.

YES Buzzer continues to sound when engine is started.

Check if engine oil pressure indicator lights.

YES

Overheat of engine.

Check if overheat indicator lights. NO

Faulty monitor. NO

Buzzer doesn’t sound even if engine oil pressure indicator or overheat indicator lights with engine running.

Normal.

NO Check if engine -1 speed is 900 min (rpm) or faster.

NO

YES

Perform troubleshooting of indicator staying ON.

Check if alternator indicator lights.

YES

Measure voltage at regulator terminal L.* -1

· Engine speed: 900 min (rpm) or faster.

T5-5-20


Connector (Harness end connector terminals seen from the open end side) Monitor Connector A (16P)

Starter Relay

8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9

E S

R

Lower than 13 V or more than 33.5 V

Faulty regulator and alternator.

Lower than 13 V or higher than 33.5 V

Broken harness between regulator terminal L and monitor.

Measure voltage at monitor connector A (16P) terminal #2. Between 13 V and 33.5 V

Faulty monitor. -1

· Engine speed: 900 min (rpm) or faster

Between 13 V and 33.5 V

T5-5-21

TROUBLESHOOTING / Troubleshooting C 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 user’s mode. 9 to 24: To be displayed with built-in diagnosing system • In case only LCD is abnormal, the machine will normally operate.

Display Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Description Hour Meter Trip 1 Trip 2 Actual Engine Speed Hydraulic Oil Temperature

Load Alarm Hydraulic Oil Filter Fault Code ML Switch Pump 1 Delivery Pressure Pump 2 Delivery Pressure Pump 1 Control Pressure Pump 2 Control Pressure Target Engine Speed EC Angle Dial Angle Boom Raise Lever Stroke Arm Roll-In Lever Stroke Swing Lever Stroke Travel Lever Stroke Front Attachment Lever Stroke Attachment Lever Stroke Work Mode

Cause of Trouble Refer to the next page. Faulty Monitor. In case Dr. ZX can display data, monitor is abnormal or communication between monitor and MC is interrupted. In case Dr. ZX doesn’t display data, corresponding signal sensor is faulty. (The machine must have any abnormality in the control system. Refer to Troubleshooting B.) Faulty monitor or interrupted communication between ML controller and monitor. Faulty monitor or interrupted communication between ICX controller and monitor. In case Dr. ZX can display data, monitor is abnormal or communication between monitor and MC is interrupted. In case Dr. ZX doesn’t display data, corresponding signal sensor is faulty. (The machine must have any abnormality in the control system. Refer to Troubleshooting B.)

T5-5-22

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF HOUR METER • 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.

Lower than 13 V or higher than 33.5 V Hour meter doesn’t count operating hours with engine running.

· Engine: Running

Measure voltage at ∗ regulator terminal L. · Engine speed: 900 min-1 (rpm) or faster Between 13V and 33.5 V

Measure voltage at monitor connector A (16P) terminal #2.

Faulty regulator or alternator.

Between 13V and 33.5 V Faulty monitor.

Broken harness between regulator terminal L and monitor. Lower than 13 V or higher than 33.5 V

Connector (Harness end connector terminals seen from the open end side) Monitor Connector A 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9

Starter Relay E S

R

T5-5-23

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF HYDRAULIC OIL FILTER INDICATOR (Optional) • Check for loose harness connections beforehand. Disconnect hydraulic oil filter restriction switch at plug receptacle with white and blue cable. Check if indicator lights when harness end plug YES connector is grounded to vehicle frame.

YES

NO Even if hydraulic oil filter is clogged, indicator doesn’t light.


Faulty hydraulic oil filter restriction switch.

Reconnect hydraulic oil filter restriction switch. Check if indicator lights when monitor connector C (16P) terminal #14 is grounded to vehicle frame.

To A

· Key switch: ON · Without disconnecting connector, ground connector to vehicle frame using jumper wire such as clip from reverse side of connector.

· Key switch: ON

· Key switch: ON


YES

Broken harness between monitor and hydraulic oil filter restriction switch.

A

Faulty monitor. NO Faulty hydraulic oil filter restriction switch.

YES Although hydraulic oil filter is not clogged, indicator lights.

Check if indicator goes OFF when hydraulic oil filter restriction switch is disconnected.


NO

Disconnect hydraulic oil filter restriction switch at plug receptacle with white and blue cable and remove connector C (16P) from monitor. Check for continuity between connector terminal #14 and vehicle frame.

YES

Short-circuited harness between monitor and hydraulic oil filter restriction switch.

Faulty monitor. NO

Connector (Harness end connector terminals seen from the open end side) Monitor Connector C (16P) 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. The color codes of the wire harnesses in the electrical system are shown in the table on the right. In cases on the design sheet where two colors are indicated for one wire, the left initial stands for the base color, while the right initial stands for the marking color. 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

Code R L Or

Color Red Blue Orange

Code W G Lg

Y Br Gr

Yellow Brown Gray

B P V

Color White Green Light green Black Pink Violet

TROUBLESHOOTING / Electrical System Inspection 3. Precautions for connecting and disconnecting terminal connectors. 1) When disconnecting harnesses, grasp them 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 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 thoroughly dried. 3) Before connecting terminal connectors, check that no terminals are bent or coming off. In addition, as most connectors are made of brass, check that no terminals are rusting. 4) When connecting terminal connectors 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 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. When the connector size is very small, and 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

Right

Wrong

T107-07-06-001

Right Rust Wrong (Deformation) Wrong (Separation) T107-07-06-002

Wind a Piece of Wire

Tester Probe

Sharpen the end of the Wire T107-07-06-003

TROUBLESHOOTING / Electrical System Inspection INSTRUCTIONS CONNECTORS

FOR

DISCONNECTING

• 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 connector (harness end side).

T107-04-05-002

Locations of This Type Connector Fuel Gauge Hydraulic Oil Level Switch Horn Cab Harness Pressure Sensor Washer

N Sensor EC Motor EC Sensor Pump Delivery Pressure Sensor General Relay Solenoid Valve

Engine Oil Level Switch* Coolant Level Switch* Diode Key Switch Engine Control Dial

Radio Speaker Learning Switch Wiper Monitor


• Pull Up to Unlock and Separate Type Locations of This Type Connector Starter Relay

T107-04-05-003

• Pull to Separate Type IMPORTANT: Generally, the solenoid valve connector 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

Locations of This Type Connector Oil Temperature Sensor Dr. ZX

T5-6-3

TROUBLESHOOTING / Electrical System Inspection FUSE INSPECTION Cracks in a fuse are so fine that it is very difficult or impossible to find by visual inspection. Use a tester to correctly inspect fuse continuity by following the instructions described below.

NOTE: All terminals located along the lengthwise centerline of the fuse box are connected to the power source, while terminals located away from the center of the fuse box are connected to loads (accessories). Therefore, test all fuses in the same method except for the glow plug relay circuit fuse. Check the glow plug relay circuit fuse with the key switch turned to the ON position then follow the procedure in step 3.

1. Turn Key Switch ON When the key switch is turned ON, current from key switch terminal M activates the battery relay so that electric power is supplied to all circuits except the glow plug relay circuit. (Refer to the circuit diagram.) 2. Remove the fuse box cover. Set the tester voltage to meet the circuit specification to be measured. (Measurement Range: 0 to 30 V) 3. Ground the negative probe of the tester to the vehicle frame. Touch the terminals located away from the center of the fuse box with the positive probe of the tester one at a time. When normal continuity of a fuse is intact, the tester will indicate 20 to 25 V (battery voltage).

10

20

9

19

8

18

7

17

6

16

5

15

4

14

3

13

2

12

1

11

M178-07-034

Fuse No. 1

Capacity

Connected to

5A

Fuse No. 11

Capacity

2

5A

Radio, Monitor ICX (Backup Power) MC (Main Power)

3 4 5 6 7 8 9

10 A 10 A 5A 5A 5A 5A 10 A

MC (EC Motor Power) MC (Solenoid Valve Power) Monitor MC, ICX (Power ON Signal) Air Conditioner Unit Optional 1 Optional 2

13 14 15 16 17 18 19

20 A 10 A 5A 10 A 5A 10 A 5A

10

5A

Optional 3

20

−

Connected to

20 A

Work Light Relays 1 and 2

12

10 A

Wiper Relays A, B, and C, Wiper Motor, Washer Relay Heater (Air Conditioner Unit) Horn Relay Radio Cigarette Lighter Room Light Auxiliary QOS Controller, Glow Plug Relay Empty

T5-6-4

TROUBLESHOOTING / Electrical System Inspection 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

Fusible Link

M178-07-049

Cover

Replacement 1. Check that the negative cable is removed from the battery. 2. Remove bolt M8 to take the fusible link off the 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. 5. Retighten screws M6 (2 used). 6. Install the fusible link box and the cable to the battery relay. 7. Reconnect the negative cable to the battery.

T178-05-06-002

Battery Relay Bolt M8

Cable

Screw M6

T107-04-05-008

T5-6-5

TROUBLESHOOTING / Electrical System Inspection BATTERY VOLTAGE CHECK 1. Turn the key switch OFF. Check voltage between the battery positive terminal and the vehicle frame. Normal Voltage: 24 V 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 system.

V

T157-07-06-007

T5-6-6

TROUBLESHOOTING / Electrical System Inspection HOW TO TROUBLESHOOT ALTERNATOR MALFUNCTIONS In general, the alternator indicator remains off when the alternator is generating power. If the alternator indicator comes on while the engine is running, the alternator might be defective. 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 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 disconnected. Also, the alternator cannot generate electricity if the ground line is disconnected. 3. Next, start the engine and measure the voltage 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 regulator.

T5-6-7

B

E

T157-07-06-003

TROUBLESHOOTING / Electrical System Inspection CONTINUITY CHECK Harness

Single-line continuity check Disconnect both end connectors of the harness and check continuity between both ends: If the ohm-meter reading is: 0 Ω = Continuity ∞ Ω = Discontinuity NOTE: When the one end connector is far apart from the other, connect one end of connector (A) to the machine chassis using a clip. Then, check continuity of the harness through the vehicle frame as illustrated.

A

Ω

Connect to the vehicle frame.

Connect to the vehicle frame.

If the ohm-meter reading is: 0 Ω = Continuity ∞ Ω = Discontinuity

a

Single-line short-circuit check Disconnect both end connectors of the harness and check continuity between one end connector of the harness and the vehicle frame: If the ohm-meter reading is: 0 Ω = Short circuit is present. ∞ Ω = No short circuit is present.

a

A

Ω

a

A ×

Ω

Short-circuit between the harness and the vehicle frame.

T107-07-05-003

T5-6-8

TROUBLESHOOTING / Electrical System Inspection Multi-line continuity check Disconnect both end connectors of the harness, and short-circuit two terminals, (A) and (B), at one end connector, as illustrated. Then, check continuity between terminals (a) and (b) at the other connector. If the ohm-meter reading is ∞ Ω, either line (A) - (a), or (B) - (b) is in discontinuity. To find out which line is discontinued, conduct the single line continuity 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).

First short-circuit

A B C

a b c

Second short-circuit

Ω

NOTE: By conducting the multi-line continuity 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 Ω = Line (B) - (b) has discontinuity. ∞ Ω = Line (A) - (a) has discontinuity.

T107-07-05-004

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 Ω = Short-circuit exists between the lines. ∞ Ω = No short-circuit exists between the lines. Short-circuit between harnesses. A B C

×

a b c

Ω

T107-07-05-005

T5-6-9

TROUBLESHOOTING / Electrical System Inspection (Blank)

T5-6-10

TROUBLESHOOTING / Electrical System Inspection VOLTAGE MENT

AND

CURRENT

MEASURE-

Turn key switch ON so that the specified voltage (current) is supplied to the location to be measured. Judge if the circuit is normal by evaluating whether the measured voltage (current) matches the specification. 24-Volt Circuit Start checking the circuit in order up to the location 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 vehicle frame Red Probe (Plus) of Tester : To touch the location to be measured

T5-6-11

TROUBLESHOOTING / Electrical System Inspection Engine Power Source Circuit

Key Switch

Location to be Measured

Specification

OFF OFF OFF OFF OFF OFF

Between (2) and (1): One Battery Between (3) and (2): One Battery Between (3) and (1): Two Batteries Between (4) and Ground: Battery Power Between (5) and Ground: Fusible Link Between (1) and Ground: Backup Current*

10 to 12.5 V 10 to 12.5 V 20 to 25 V 20 to 25 V 20 to 25 V 6 mA

ON or START ON or START

Between (6) and Ground: Key Switch Between (7) and Ground: Glow Plug

20 to 25 V 20 to 25 V

START START START START START START

Between (8) and Ground: Key Switch Between (9) and Ground: Battery Relay (Coil) Between (10) and Ground: Battery Relay (Switch) Between (11) and Ground: Starter (B) Between (12) and Ground: Starter (C) Between (13) and Ground: Starter Relay (S)

20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V

Fast Speed

ON

26 to 30 V

Fast Speed

ON

Fast Speed

ON

Fast Speed Fast Speed

ON ON

Between (14) and Ground: Alternator (B) / Generating Voltage Between (10) and Ground: Battery Relay / Generating Voltage Between (15) and Ground: Fuse Box / Starter Relay (R) / Generating Voltage Between (16) and Ground: Generating Voltage Between (17) and Ground: Monitor

ON ON ON ON

Between (14) and Ground: Alternator (B) Between (16) and Ground: Starter Relay (R) Between (18) and Ground: Load Damp Relay Between (10) and Ground: Battery Relay

26 to 30 V 13 to 30 V 26 to 30 V 26 to 30 V

ON ON ON ON ON ON

Between (19) and Ground: Auxiliary Between (20) and Ground: Room light Between (21) and Ground: Lighter Between (22) and Ground: Radio Between (23) and Ground: Horn Between (9) and Ground: Battery Relay

20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V

Stopped Stopped Stopped Stopped Stopped Stopped

Preheat Circuit Stopped Stopped

Starting Circuit Started Started Started Started Started Started

Charging Circuit 26 to 30 V 26 to 30 V 13 to 30 V 13 to 30 V

Surge Voltage Prevention Circuit Slow Idle Slow Idle Slow Idle Slow Idle

Accessory Circuit Stopped Stopped Stopped Stopped Stopped Stopped

NOTE: *Measure after disconnecting the negative cable from the battery.

T5-6-12

TROUBLESHOOTING / Electrical System Inspection

Key Switch

Battery

1

2

3

5

4

6

9

8

15

Battery Relay

Fuse Box

10

Starter

18

Load Damp Relay

11 12

23

22 21 20 19

13

Starter Relay

17

Monitor

16

Alternator Glow Plug Relay

14 7 Glow Plug T178-05-06-001

T5-6-13

TROUBLESHOOTING / Electrical System Inspection 5 Voltage Circuit

• Voltage between terminal #1 and the vehicle

Signal or Ground

Power Source 1

Two Polarities

frame (ground) 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.

2

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 Source Signal Ground 1 2 3

Three Polarities

Evaluation: If the measuring voltage is within 5±0.5 volts, the circuit up to terminal #1 is normal.

V

• Voltage between terminal #1 and the ground terminal With the key switch turned OFF, disconnect the 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 conditions.

T107-07-05-007

Two Polarities 1

2

V

• Key switch position: ON • Tester black terminal (negative): Connected to the ground terminal (terminal #2 or 3) • Tester red terminal (positive): Connected to terminal #1

T107-07-05-008

Three Polarities 1

Evaluation: If the measuring voltage is within 5±0.5 volts, the circuit up to terminal #1 or the ground terminal is normal.

2

3

V

T107-07-05-009

T5-6-14

TROUBLESHOOTING / Electrical System Inspection CHECK BY FALSE SIGNAL

Two Polarities

Turn the key switch OFF. After disconnecting the sensor connector, turn the key switch ON. Then, connect 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, Dr. ZX displays “ON”. IMPORTANT: Don’t connect terminal #1 or #2 to terminal #3 or to the vehicle frame (ground) when checking a three-polarity connector. NOTE: Some kinds of sensors can be monitored by the built-in diagnosing system. (Refer to the TROUBLESHOOTING / General group.)

(Oil Temperature) (N Sensor)

1

2

Connect

T107-07-05-010

Three Polarities (Pressure Sensor) (Pump Delivery Pressure Sensor) (Pump Control Pressure Sensor) (EC Sensor)

1

2

3

Connect

T107-07-05-011

T5-6-15

TROUBLESHOOTING / Electrical System Inspection TEST HARNESS With a test harness installed between connectors, the circuit condition is checked depending on whether the test harness lamp lights or extinguishes during operation. Parts Number 4283594 (ST 7126) Use to check a single-line (discontinuity and/or voltage). During Operation: Lamp is ON.

To Location to be Measured.

To Ground T107-07-05-012

Parts Number 4283594 (ST 7126)

Parts Number (ST 7226) Use to check the solenoid valve unit circuits. When the corresponding control lever or switch is operated: Lamp is ON. (Refer to T5-4-54, 64, 69, 72, 73, 82, 84 and 93.)

4 3 1

50

150

2

50

50

2

1 T107-07-06-015

Parts Number (ST 7226)

Parts Number 4274589 (ST 7125) Use to check the EC motor circuit. (Refer to T5-4-38 and 42.)

5 6

• EC Motor Circuit When the engine control dial is rotated: Both lamps ON: Normal Only one lamp ON: Check for continuity of the circuit connected to the lamp OFF. Both lamps OFF: Check the harness together with the relay.

1

2

4

3

50

150

50 50

1

4

3

50

7 8


T5-6-16

2

T107-07-06-024

TROUBLESHOOTING / Electrical System Inspection Parts Number 4284347 (ST 7129) Use to measure the EC sensor circuit signal line voltage (between terminals #2 and #3). (Refer to T5-3-4.)

(Red)

(Black) V


Parts Number (ST 7227) Use to check the wiper circuit. (Refer to T5-4-94.)

T107-07-03-009

2 5

1

2 4

7

1

Parts Number (ST 7227)

T5-6-17

T178-05-06-003

TROUBLESHOOTING / Electrical System Inspection (Blank)

T5-6-18

TROUBLESHOOTING / ICX OUTLINE The ICX (information controller) stores signals from various kinds of sensors and switches provided on the machine as data. The various input signals are grouped into “Daily Report Data List”, “Frequency Distribution Data List”, “Cumulative Operation Hour List”, “Alarm List”, and “Trouble List” and are recorded in the ICX.

T5-7-1

TROUBLESHOOTING / ICX Daily Report Data List

1

Data Key Switch ON Time

Details 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

12

Auxiliary Attachment ExTotal 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 attachment mode switch.)

Total breaker operating hours during daily operation (Hours are recorded by signals from auxiliary pressure sensor and attachment mode switch.)

T5-7-2

TROUBLESHOOTING / ICX

13

14

Data *ML Operating Hours

Engine Operating Distribution

Details Total *ML crane operating hours during daily operation (Hours are recorded by signals from crane mode switch.) Hour Engine operating hour distribution during daily operation (Operating hours are recorded only when alternator output signal is continuously delivered for more than 10 minutes.)

NOTE: The daily operation in this table is equivalent to the hours between 0:00 and 23:59:59 counted by the ICX built-in clock. In case the engine is kept operated beyond 0:00, such data are recorded as those for the following day.

*ML specification is only available in Japanese domestic market.

Frequency Distribution Data List

1

Data Engine Speeds

Oil

Details Frequency distribution of engine speeds (Speeds are recorded by signals from N sensor.)

2

Hydraulic perature

Tem-

Frequency distribution of hydraulic oil temperature (Temperatures are recorded by signals from hydraulic oil temperature sensor.)

3

Coolant Temperature in Radiator

Frequency distribution of coolant temperature (Temperatures are recorded by signals from coolant temperature sensor.)

4

Average Pump Delivery Pressure

Frequency distribution of average delivery pressure from pumps 1 and 2 (Average pressures are recorded by signals from delivery pressure sensors of pumps 1 and 2.)

5

Average Pump Delivery Pressure in Digging Operation

Frequency distribution of average delivery pressure from pumps during digging operation (Average pressures are recorded by signals from arm roll-in pressure sensor.)

6

Average Pump Delivery Pressure in Travel Operation

Frequency distribution of average delivery pressure from pumps during travel operation (Average pressures are recorded by signals from travel pressure sensor.)

T5-7-3

TROUBLESHOOTING / ICX Cumulative Operation Hour List

1

Data Engine Operation Hour

Details 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 Hour

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

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

Cumulative *ML operation hours (Hours are recorded by signals from crane mode switch.)

NOTE: ∗ML specification is only available in Japanese domestic market.

T5-7-4

TROUBLESHOOTING / ICX Alarm List Code 81

Data Engine Oil Level

Details 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 signals from overheat switch.

90

Engine Oil Pressure

Date and time when engine oil pressure indicator lighted are recorded by signals from engine oil pressure switch.

93

Air Filter Restriction

Date and time when air filter restriction indicator lighted are recorded by signals from air filter restriction switch.

94

Alternator Indicator

Date and time when alternator indicator lighted are recorded by signals 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 failure codes 81 (engine oil level) and 85 (radiator coolant).

T5-7-5

TROUBLESHOOTING / ICX Trouble List Fault Code 01

Trouble

Details

Abnormal EEPROM

Occurrence time and date of fault code 01

02

Abnormal RAM


03

Abnormal A/D Conversion


04

Abnormal Sensor Voltage


06

Abnormal EC Sensor


07

Abnormal Engine Control Dial


10

Abnormal Pump 1 Delivery Pressure


11

Abnormal Pump 2 Delivery Pressure


12

Abnormal Pump 1 Control Pressure


13

Abnormal Pump 2 Control Pressure


14

Abnormal Swing Lever Stroke


15

Abnormal Boom Raise Lever Stroke


16

Abnormal Arm Roll-In Lever Stroke


18

Abnormal Travel Lever Stroke


19

Abnormal Oil Temperature Sensor


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 satellite terminal and ICX occurred.

NOTE: In case the above fault codes are recorded, refer to troubleshooting A.

T5-7-6

TROUBLESHOOTING / ICX (Blank)

T5-7-7

TROUBLESHOOTING / ICX ICX FAULT CODE LIST Fault Code 1

Abnormal Internal RAM

In case of SAM error

2

Abnormal Flush Memory


3

Abnormal Exterior

In case of SAM error or read-write error

4

Abnormal EEPROM


6

Abnormal Time

In case RTC data was other than figures.

7

MC Communication Timeout (For ZAXIS)

In case MC communication didn’t last for more than 7 seconds.

8

Monitor Communication Timeout

In case monitor communication didn’t last for more than 24 seconds.

9*

MC Communication Timeout (For EX5)

In case MC communication didn’t last for more than 20 seconds.

10

Satellite Terminal Communication Timeout

In case satellite communication didn’t last for more than 1 minute.

Trouble

Remarks

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 Code 101

Satellite Terminal: Internal Error

Abnormal EEPROM

102


Abnormal sent data

103


In case reception is difficult.

104

Satellite Terminal: Communication Error

In case satellite communication cannot be accomplished.

105


In case sending retry over occurred or local loop back test failed with power ON.

106

Satellite Terminal: Communication Error

In case sending retry over occurred.

107

Satellite Terminal: Abnormal Harness

In case reception data doesn’t match sending data.

Trouble

Remarks

T5-7-8

TROUBLESHOOTING / ICX FAULT CODE 1 TO 4 AND 6

*Faulty ICX.

YES 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 record is normally cumulated.

FAULT CODE 7 TO 10 Check for continuity between ICX and corresponding component while referring to the following table.

Fault code

YES

Faulty ICX.

NO

Broken harness between ICX and corresponding component.

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

TROUBLESHOOTING / ICX SOME PARTS OF DATA IN DAILY REPORT, FREQUENCY DISTRIBUTION, CUMULATIVE OPERATION HOURS ARE NOT RECORDED • 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

Key switch ON and OFF time

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 sensor Fuel level sensor

Remaining fuel level (detected at regular data sending time)

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) Swing operating hours (Daily report and cumulative operation hour)

Front attachment pressure sensor Swing pressure sensor

Average pump delivery pressure distribution in digging operation

Arm roll-in pressure sensor Breaker operating hours (Daily report and cumulative operation hour), Auxiliary Auxiliary pressure sensor attachment except for breaker operating hours (Daily report and cumulative operation 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) NOTE: *ML specification is available only in Japanese domestic market.

T5-7-10

Crane mode switch

TROUBLESHOOTING / ICX

Corrective Action Remarks Check harness between ICX terminal A5 and key In case engine doesn’t start, refer to troubleshooting B. switch terminal M. Check harness between ICX terminal A2 and alter- In case alternator indicator malfunctions, refer to trounator terminal L. bleshooting C. Check harness between ICX terminal B1 and monitor terminal B3. Check harness between ICX terminal B1 and monitor terminal B3. Check harness between ICX terminal B1 and monitor terminal B3. Check harness between ICX terminal C11 and MC terminal D10. Check harness terminal D10. Check harness terminal D10. Check harness terminal D10. Check harness terminal D10.

In case hour meter malfunctions, refer to troubleshooting C. In case coolant temperature gauge malfunctions, refer to troubleshooting C. In case fuel gauge malfunctions, refer to troubleshooting C. In case machine control system malfunctions, refer to troubleshooting B.

between ICX terminal C11 and MC In case machine control troubleshooting B. between ICX terminal C11 and MC In case machine control troubleshooting B. between ICX terminal C11 and MC In case machine control troubleshooting B. between ICX terminal C11 and MC In case machine control troubleshooting B.

system malfunctions, refer to system malfunctions, refer to system malfunctions, refer to system malfunctions, refer to

Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to terminal D10. troubleshooting B. Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to terminal D10. troubleshooting B. Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to terminal D10. troubleshooting B. Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to terminal D10. troubleshooting B. Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to terminal D10. troubleshooting B. Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to terminal D10. troubleshooting B.

T5-7-11

TROUBLESHOOTING / ICX (Blank)

T5-7-12

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Technical Manual (Troubleshooting) of ZX 200-225-230-270 Class

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