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ZX200 4H (T1GR E 00) Service Manual

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100% found this document useful (1 vote)

290 views218 pages

ZX200 4H (T1GR E 00) Service Manual

Uploaded by

Harmoko Mansyur

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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Manual No.

: KM-1GR-E
Vol. No. : T1GR-E-00

200-4H
Service Manual

Excavator
200-4H

Service Manual
Excavator

Service Manual (Manual No. KM-1GR-E) consists of the following two separate volumes;
Service Manual : Vol. No. T1GR-E
Workshop Manual (Engine) : Vol. No. W1GR-E

PRINTED IN SINGAPORE (PS) 2005.04

Zaxis200-4H-SM 1 12/4/05, 14:16

INTRODUCTION
TO THE READER

• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog

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

IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • CAUTION:
signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropri- • NOTE:
ate lifting techniques and equipment when lifting Indicates supplementary technical information or
heavy parts. know-how.

UNITS USED
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.

To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375

IN-02
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. SA-1223

• CAUTION also calls attention to safety messages in

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

• NOTE indicates an additional explanation for an

element of information.
002-E01C-1223

SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the

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

to operate the machine.

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

SA-2
SAFETY
PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.

• Keep a first aid kit and fire extinguisher on hand.
• Thoroughly read and understand the label at-
tached on the fire extinguisher to use it properly.
• To ensure that a fire-extinguisher can be always
used when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
• Establish emergency procedure guidelines to
cope with fires and accidents.
• Keep emergency numbers for doctors, ambu-
lance service, hospital, and fire department SA-437

posted near your telephone.

004-E01A-0437

WEAR PROTECTIVE CLOTHING

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

Be sure to wear the correct equipment and clothing

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

005-E01A-0438

SA-3
SAFETY
PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause

impairment or loss of hearing.
• Wear a suitable hearing protective device such
as earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.

006-E01A-0434

SA-434

INSPECT MACHINE
• Inspect your machine carefully each day or shift by
walking around it before you start it to avoid
personal injury.
• In the walk-around inspection be sure to cover all
points described in the “PRE-START
INSPECTION” chapter in the 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 lo-
cations.
• 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 extin-
guish 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 ma-
chine, always face the machine and maintain a
three-point contact with the steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount
or dismount a moving machine.
• Be careful of slippery conditions on platforms,
steps, and handrails when mounting and dis-
mounting the machine.
SA-439

008-E01B-0439

ADJUST THE OPERATOR'S SEAT

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

009-E01A-0378

SA-6
SAFETY
FASTEN YOUR SEAT BELT

• If the machine should overturn, the operator may

become injured and/or thrown from the cab.
Additionally the operator may be crushed by the
overturning machine, resulting in serious injury or
death.
• Prior to operating the machine, thoroughly
examine webbing, buckle and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine.
• Be sure to remain seated with the seat belt SA-237

securely fastened at all times when the machine

is in operation to minimize the chance of injury
from an accident.
• We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.

010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.
• Take extra care not to run over bystanders.
Confirm the location of bystanders before moving,
swinging, or operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the
machine. SA-426

011-E01A-0426

SA-7
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may
cause the machine to runaway, possibly resulting in
serious injury or death.
• Start the engine only when seated in the
operator's seat.
• NEVER start the engine while standing on the
track or on ground.
• Do not start engine by shorting across starter
terminals.
• Before starting the engine, confirm that all control SA-444

levers are in neutral.

012-E01B-0444

JUMP STARTING

• Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to
follow the instructions shown in the “OPERATING
THE ENGINE” chapter in the 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 SA-032

machine.

S013-E01A-0032

SA-8
SAFETY
KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as

being struck by foreign objects and being thrown off
the machine.
• Only the operator should be on the machine.
Keep riders off.
• Riders also obstruct the operator’s view, resulting
in the machine being operated in an unsafe
manner.

014-E01B-0379
SA-379

PROVIDE SIGNALS FOR FOBS INVOLV-

ING MULTIPLE NUMBERS OF MACHINES

• For jobs involving multiple numbers of machines,

provide signals commonly known by all personnel
involved. Also, appoint a signal person to coordi-
nate the job site. Make sure that all personnel obey
the signal 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, approxi-
mately 200 to 300 mm (A) above the ground.
• If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop traveling.

SA-388

• Driving across the face of a slope or steering on SA-441

a slope may cause the machine to skid or turn-

over. If the direction must be changed, move the
WRONG
machine to level ground, then, change the direc-
tion to ensure sage operation.

019-E01D-0492

SA-590

SA-10
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
• Death or serious injury may result if you attempt to
mount or stop a moving machine.

To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle / acceleration seleclter and the SA-391

H/P mode switch off.

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

020-E08A-0493

SA-11
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.

To avoid back-over and swing accidents:

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

equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP
IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a
signal person.
• No machine motions shall be made unless
signals are clearly understood by both signalman SA-384

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

S021-E01A-0494

SA-12
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF
TIPPING MACHINE---SERIOUS OR FATAL
CRUSHING INJURIES WILL RESULT

MACHINE WILL TIP OVER FASTER THAN YOU

CAN JUMP FREE

FASTEN YOUR SEAT BELT

• The danger of tipping is always present when

operating on a grade, possibly resulting in serious SA-012

injury or death.

To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.
• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or
slipping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is SA-440

unavoidable.
• Reduce swing speed as necessary when
swinging loads.
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to
become soft and make ground travel unstable.

S025-E01B-0495

SA-13
SAFETY
AVOID POWER LINES

• Serious injury or death can result if the machine or

front attachments are not kept a safe distance from
electric lines.
• When operating near an electric line, NEVER
move any part of the machine or load closer than
3 m (10 ft) plus twice the line insulator length.
• Check and comply with any local regulations that
may apply.
• Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site.
SA-381

029-E01A-0381

OBJECT HANDLING

• If a lifted load should fall, any person nearby may

be struck by the falling load or may be crushed
underneath it, resulting in serious injury or death.
• When using the machine for craning operations,
be sure to comply with all local regulations.
• Do not use damaged chains or frayed cables,
sables, slings, or ropes.
• Before craning, position the upperstructure with
the travel motors at the rear.
• Move the load slowly and carefully. Never move it
suddenly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it
is safely and securely situated on supporting
SA-014
blocks or on the ground.
• Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.

032-E01A-0014

SA-14
SAFETY
PROTECT AGAINST FLYING DEBRIS

• If flying debris hit eyes or any other part of the body,

serious injury may result.
• Guard against injury from flying pieces of metal
or debris; wear goggles or safety glasses.
• Keep bystanders away from the working area
before striking any object.

031-E01A-0432
SA-432

PARK MACHINE SAFELY

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

• Close windows, roof vent, and cab door.

• Lock all access doors and compartments.

033-E09B-0390

SA-15
SAFETY
HANDLE FLUIDS SAFELY－AVOID FIRES

• Handle fuel with care; it is highly flammable. If fuel

ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.
• Do not refuel the machine while smoking or when
near open flame or sparks.
• Always stop the engine before refueling the
machine.
• Fill the fuel tank outdoors.

• All fuels, most lubricants, and some coolants are

flammable. SA-018

• Store flammable fluids well away from fire

hazards.
• Do not incinerate or puncture pressurized
containers.
• Do not store oily rags; they can ignite and burn
spontaneously.
• Securely tighten the fuel and oil filler cap.

034-E01A-0496

SA-019

SA-16
SAFETY
SAFETY TRANSPORTING

• The danger of tipping is present when

loading/unloading the machine onto/from a truck or
trailer bed.
• Be sure to observe local regulations when
transporting the machine on public roads.
• Provide an appropriate truck or trailer for
transporting the machine.

Take the following precautions when loading /

unloading the machine:
1) Select firm level ground. SA-395

2) Be sure to use a loading dock or ramp.

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

S035-E08A-0395

SA-17
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:

• Understand service procedures before doing

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

• Before servicing the machine:

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

SA-18
SAFETY
• If a maintenance procedure must be performed
with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or
replace as necessary. Refer to the section
discussing that part in the “MAINTENANCE”
chapter in the operator’s manual.
• Keep all parts in good condition and properly
installed.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
• When cleaning parts, always use nonflammable
SA-028
detergent oil. Never use highly frammable oil
such as fuel oil and gasoline to clean parts or
surfaces.
• Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
• Illuminate your work area adequately but safely.
• Use a portable safety light for working inside or
under the machine.
• Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• Sufficiently illuminate the work site. Use a
maintence work light when working under or SA-527

inside the machine.

• Always use a work light protected with a guard.
In case the light bulb is broken, spilled fuel, oil
antifreeze fluid, or window washer fluid may
catch fire.

S500-E02B-0497

SA-037

SA-19
SAFETY
WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious

injury.
• Before performing any work on the machine, at-
tach a “Do Not Operate” tag on the control lever.
This tag is available from your authorized dealer.

SS2045102

SUPPORT MACHINE PROPERLY

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

STAY CLEAR OF MOVING PARTS

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

502-E01A-0026

SA-026

SA-20
SAFETY
PREVENT PARTS FROM FLYING

• Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in
serious injury, blindness, or death.
• Do not attempt to remove GREASE FITTING or
VALVE ASSEMBLY.
• As pieces may fly off, be sure to keep body and
face away from valve.
• Travel reduction gears are under pressure.
• As pieces may fly off, be sure to keep body and
face away from AIR RELEASE PLUG to avoid
injury. GEAR OIL is hot. SA-344

• Wait for GEAR OIL to cool, then gradually loosen

AIR RELEASE PLUG to release pressure.

503-E01B-0344

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic

hammers, and blades can fall and cause serious
injury or death.
• Securely store attachments and implements to
prevent falling. Keep children and bystanders
away from storage areas.

504-E01A-0034 SA-034

USE TOOLS PROPERLY

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

SA-040
S522-E01A-0040

SA-21
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under
pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
• To avoid possible injury from hot spraying water.
DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the
stop. Allow all pressure to be released before
removing the cap. SA-039

• The hydraulic oil tank is pressurized. Again, be

sure to release all pressure before removing the
cap.

Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become
hot during operation.
The engine, hoses, lines and other parts become
hot as well.
• Wait for the oil and components to cool before
starting any maintenance or inspection work.

505-E01B-0498 SA-225

REPLACE RUBBER HOSES

PERIODICALLY
• Rubber hoses that contain flammable fluids under
pressure may break due to aging, fatigue, and
abrasion. It is very difficult to gauge the extent of
deterioration due to aging, fatigue, and abrasion of
rubber hoses by inspection alone.
• Periodically replace the rubber hoses. (See the
page of “Periodic replacement of parts” in the
operator’s manual.)
• Failure to periodically replace rubber hoses may
cause a fire, fluid injection into skin, or the front SA-019

attachment to fall on a person nearby, which may

result in severe burns, gangrene, or otherwise
serious injury or death.

S506-E01A-0019

SA-22
SAFETY
AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under

pressure can penetrate the skin or eyes causing
serious injury, blindness or death.
• Avoid this hazard by relieving pressure before
disconnecting hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take
care to protect hands and body from
high-pressure fluids. Wear a face shield or SA-031

goggles for eye protection.

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

SA-292

507-E03A-0499

SA-044

SA-23
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to
fires.
• Check for oil leaks due to missing or loose
clamps, kinked hoses, lines or hoses that rub
against each other, damage to the oil-cooler, and
loose oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or SA-019

hoses.

Check for Shorts:

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

Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.
• Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.

SA-24
SAFETY
Check Key Switch:
• If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
• Always check key switch function before
operating the machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to
confirm that the engine stops.
• If any abnormalities are found, be sure to repair
them before operating the machine.

Check Emergency Engine Stop Switch:

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

Check Heat Shields:

• Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be
repaired or replaced before operating the
machine.

S508-E02B-0019

SA-25
SAFETY
EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the machine in the

following way:
• Stop the engine by turning the key switch to the
OFF position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.

• In an emergency, if the cab door and/or the front SA-393

window cannot be opened, break the front or rear

window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on “EMERGENCY
EXIT” in 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 FOR WELDING AND
GRINDING
• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated
and prepared area. Store flammable objects in a
safe place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
• Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before
starting grinding.
• After finishing welding and grinding, recheck that SA-818

there are no abnormalities such as the area sur-

rounding the welded area still smoldering.
523-E01A-0818

AVOID HEATING NEAR PRESSURIZED

FLUID LINES

• Flammable spray can be generated by heating near

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

AVOID APPLYING HEAT TO LINES

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

SA-27
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
• Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated
area. Dispose of paint and solvent properly.

• Remove paint before welding or heating:

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

Wear an approved respirator.

2) If you use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area. Allow
fumes to disperse at least 15 minutes before
welding or heating.

511-E01A-0029

PREVENT BATTERY EXPLOSIONS

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

• Loose terminals may produce sparks. Securely

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

512-E01C-0032

SA-28
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
• If spilled onto skin, refrigerant may cause a cold
contact burn.
• Refer to the freon container for proper use when
servicing the air conditioning system.
• Use a recovery and recycling system to avoid
venting freon into the atmosphere.
• Never let the freon stream make contact with the
skin.

SA-405
513-E01A-0405

HANDLE CHEMICAL PRODUCTS SAFELY

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

safely. Then follow procedures and use

recommended equipment.

S515-E01A-0309

SA-29
SAFETY
DISPOSE OF WASTE PROPERLY

• Improperly disposing of waste can threaten the

environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids.
Do not use food or beverage containers that may
mislead someone into drinking from them.
• Do not pour waste onto the ground, down a drain,
or into any water source.
• Air conditioning refrigerants escaping into the air
can damage the Earth’s atmosphere. SA-226

Government regulations may require a certified

air conditioning service center to recover and
recycle used air conditioning refrigerants.
• Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center.

S516-E01A-0226

BEFORE RETURNING THE MACHINE TO

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

S517-E01A-0435 SA-435

SA-30
SECTION AND GROUP
SECTION 1 GENERAL
CONTENTS Group 1 Component Layout
Group 2 Component Specifications
SECTION 2 SYSTEM
Group 1 Control System
Group 2 ECM System
SERVICE MANUAL Group 3 Electrical System
SECTION 3 COMPONENT OPERATION
SECTION 4 OPERATIONAL PER-
FORMANCE TEST
Group 1 Standard
SECTION 5 TROUBLESHOOTING
Group 1 General
Group 2 Troubleshooting A
Group 3 Troubleshooting B
SECTION 6 UPPERSTRUCTURE
Group 1 Pump Device
WORKSHOP MANUAL (Engine)
ENGINE MECHANICAL
COOLING SYSTEM
FUEL SYSTEM
ENGINE ELECTRICAL
EXHAUST SYSTEM
All information, illustrations and speci-
fications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.

―CONTENTS―
Group 1 Component Layout
Engine ...................................................... T1-1-1

Group 2 Component Specifications

Engine ...................................................... T1-2-1
Engine Accessories .................................. T1-2-4

1GRT-1-1
(Blank)

1GRT-1-2
GENERAL / Component Layout
ENGINE

3 4 5

2
1
6

8 T1GR-01-01-008
T1GR-01-01-007

11 12

T1GR-01-01-009

1 - Cam Angle Sensor 4 - Common Rail Pressure 7 - Crank Revolution Sensor 10 - Boost Pressure Sensor
Sensor
2 - Overheat Switch 5 - Supply Pump Actuator 8 - Oil Pressure Sensor 11 - EGR Valve
3 - Coolant Temperature 6 - Fuel Temperature Sensor 9 - Glow Plug 12 - Boost Temperature Sensor
Sensor

T1-1-1
GENERAL / Component Layout

T1GR-01-01-002

1 2 T1GR-01-01-001

T1GR-01-01-006

1 - Inlet Air Temperature 3 - Air Cleaner 4- ECM 5- Emergency Stop Switch

Sensor
2 - Atmosphere Sensor

T1-1-2
GENERAL / Component Layout
ELECTRICAL SYSTEM (Monitor)

9 10

7
11
6

5 12

4
13

3
2
14
1
15
16

T1GR-01-01-010
18

1 - Engine Oil Pressure 6 - Liquid Crystal Display 11 - Display Selection Switch 15 - Air Filter Restriction Switch
Indicator
2 - Preheat Indicator 7 - Auto-Idle Indicator 12 - SET Switch 16 - Alternator Indicator
3 - Overheat Indicator 8 - Auto-Acceleration Indicator 13 - Work Mode Switch 17 - Check Engine Lamp
4 - Digging Mode Indicator 9 - Coolant Temperature 14 - Fuel Level Indicator 18 - Hydraulic Oil Filter
Gauge Indicator
5 - Attachment Mode Indicator 10 - Fuel Gauge

T1-1-3
GENERAL / Component Layout
(Blank)

T1-1-4
GENERAL / Component Specifications
ENGINE

Manufacturer.......................... ISUZU
Model ................................ AI-4HK1X
Type ................................. Diesel, 4-Cycle, Water-cooled, Over Head Valve Vertical Inline,
Direct Injection
Cyl. No.- Bore × Stroke ................. 4-115 mm×125 mm (4.53 in×4.92 in)
Piston Displacement ................... 5193 cm3 (317 in3)
Rated Output.......................... 114+100 kW/1800 min-1 (155+140 PS/1800 rpm)
HP Mode: 122±3 kW / 2000 min-1 (166±4 PS / 2000 rpm)
Compression Ratio .................... 17.5:1
Dry Weight............................ 478 kg (1050 lb)
Firing Order ........................... 1-3-4-2
Rotation Direction...................... Clockwise (Viewed from fan side)

COOLING SYSTEM
Cooling Fan .......................... Dia. 650 mm (25.6 in), 5 Blades, Draw-in Type
Fan Pulley Ratio ....................... Engine rpm × 1.01
Thermostat ........................... Cracking Temperature at Atmospheric Pressure: 82 °C (180 °F)
Full Open (Stroke: 10 mm or more) Temperature: 95 °C (203 °F)
Water Pump .......................... Centrifugal Type

LUBRICATION SYSTEM
Lubrication Pump Type ................. Gear Pump
Oil Filter .............................. Full-Flow Paper Element Type with Bypass
Oil Cooler ............................ Water Cooled Integral Type

STARTING SYSTEM
Motor ................................ Magnetic Pinion Shift Reduction Type
Voltage / Output ....................... 24 V / 5.0 kW

T1-2-1
GENERAL / Component Specifications
PREHEAT SYSTEM
Preheating Method...................... Glow Plug (QOS 2 Type)

ENGINE STOP SYSTEM

Stop Method ........................... Fuel Shut-Off

ALTERNATOR
Type .................................. Regulator Integrated AC Type (Brushless)
Voltage / Output ........................ 24 V / 50 A

SUPERCHARGING SYSTEM
Type .................................. Exhaust-Turbocharger Type RHF 55

FUEL SYSTEM
Type .................................. Common Rail HP3 Type
Governor .............................. Electronic All Speed Control
Injection Nozzle ....................... Electric Multi-Hole Injector

PERFORMANCE

IMPORTANT: This list shows design specifications, which are not servicing standards.
Fuel Consumption Ratio ................. Less than 224±10 g/kW/h (165±7 g/PS⋅h) at 122±3 kW /
(at Full Load: 2000 min-1)
Less than 219±10 g/kW/h (161±7 g/PS⋅h) at 114+100 kW / (at
Working Load: 1800 min-1)
Maximum Output Torque................. More than 550±60 N⋅m (54±6 kgf⋅m) at approx. 1600 min-1
Compression Pressure .................. 3.04 MPa (31 kgf/cm2)
Valve Clearance (Inlet / Exhaust) ......... 0.4 / 0.4 mm (when cool)
No Load Speed ........................ Slow: (at Full Load: 800 ± 20 min-1)
Fast: (at Full Load: 2000±20 min-1)
(at Working Load: 1800±20 min-1)

T1-2-2
GENERAL / Component Specifications
Engine Performance Curve (AI-4HK1X)

Test Condition: 1. In conformity with JIS D1005 (Performance Test Method for Diesel Engine Used for
Construction Machinery) under standard atmospheric pressure.
2. Equipped with the fan and alternator.

-1
655±60 N⋅m / 1500 min
(67±6 kgf⋅m / 1500 rpm) Torque
N⋅m (kgf⋅m)

700 (71)

600(61)

500(51)

122±3 kW / 2000 min

-1 400(41)
Output
kW (PS) (166±4 PS / 2000 rpm)

120 (163)

100 (136)

80 (109)

60 (82)

40 (54)

20 (27)
Fuel Consumption
g/kW⋅h (g/PS⋅h)
0
260 (191)

240 (177)

220 (162)

200 (147)

-1
Engine Speed min (rpm) T1GR-01-02-002

T1-2-3
GENERAL / Component Specifications
ENGINE ACCESSORIES

RADIATOR ASSEMBLY
Type .................................. Radiator/Oil Cooler Tandem Type Assembly
Weight ................................ 80 kg (176 lb)

Radiator Oil Cooler

Capacity............................... 8.0 L (2.1 US gal) 6.35 L (1.7 US gal)
Air-Tight Test Pressure .................. 100 kPa (1.0 kgf/cm2, 14 psi) 1500 kPa (15 kgf/cm2, 218 psi)
Cap Opening Pressure .................. 49 kPa (0.5 kgf/cm2, 7 psi) −

Intercooler
Capacity............................... 7.9 L (2.1 US gal)
Air-Tight Test Pressure .................. 250 kPa (2.6 kgf/cm2, 36 psi)
Cap Opening Pressure .................. −

T1-2-4
MEMO

.......................................................................................................................................................................

.......................................................................................................................................................................
MEMO

.......................................................................................................................................................................

.......................................................................................................................................................................
SECTION 2
SYSTEM

—CONTENTS—
Group 1 Control System
Outline ...................................................... T2-1-1
Engine Control .......................................... T2-1-3

Group 2 ECM System

Outline ...................................................... T2-2-1
Fuel Injection Control .............................. T2-2-2
Engine Start Control ............................ T2-2-10
EGR (Exhaust Gas Recirculation)
Control ................................................ T2-2-12
Correction of Fuel Injection Volume ........ T2-2-14
Engine Stop Control ................................ T2-2-15

Group 3 Electrical System

Outline ...................................................... T2-3-1
Main Circuit............................................... T2-3-2
Electric Power Circuit (Key Switch: Off) .... T2-3-3
Starting Circuit (Key Switch: Start) ............ T2-3-4
Engine Stop Circuit ................................... T2-3-7

1GRT-2-1
(Blank)

1GRT-2-2
SYSTEM / Control System
OUTLINE
The main controller (MC) is used to control machine The MC sends the ECM (Engine Control Module) the
operations. Electronic signals from the engine control voltage signals corresponding to the target engine
dial, various sensors and switches are sent to the MC. speed to regulate the engine speed. In addition, the
MC drives the solenoid valve units and the torque
control solenoid valve to regulate the pump and valve
operations. (Refer to the SYSTEM / ECM System
group.)

Input Signals Output Signals

• Engine Control Dial → Engine Control (ECM)
• Pump 1 Control Pressure Sensor → Engine Control Dial
• Pump 2 Control Pressure Sensor → HP Mode Control
• Pump 1 Delivery Pressure Sensor → E Mode Control
• Pump 2 Delivery Pressure Sensor → Auto-Idle Control
• Pump 3 Delivery Pressure Sensor Auto-Acceleration Control
(Oprtional) → Auto-Warming Up Control
• N sensor → Idle Speed-Up Control
∗
Attachment Operation Speed Increase Control
∗
• Pressure Sensor (Travel) → Attachment Operation Speed Limit Control
• Pressure Sensor (Front Attachment) →
• Pressure Sensor (Swing) →
• Pressure Sensor (Boom Raise) →
• Pressure Sensor (Arm Roll-In) → Pump Control (Torque Control Solenoid Valve)
• Pressure Sensor (Auxiliary) MC Speed Sensing Control
(Optional) → Slow Speed Torque Increase Control
∗
Pump 1 Flow Rate Limit Control
∗
• Hydraulic Oil Temperature Sensor → Pump 2 Flow Rate Limit Control
∗
• Auto-Idle/Acceleration Selector → Pump 3 Torque Decrease Control
• Power Digging Switch →
• Power Mode Switch (HP/E/P) → Valve Control (Solenoid Valve Unit)
• Travel Mode Switch (Fast/Slow) → Power Digging Control
• Work Mode Switch Arm Flow Rate Control
(Digging/Attachment) → Arm Regenerative Control
• Key Switch Travel Motor Swash Angle Control
• Auxiliary Mode Switch (Optional) → Auto-Power Lift Control
∗
Auxiliary Flow Rate Control

Other Controls
Work Mode Control
∗
Travel Alarm Control
∗
Overload Alarm Control

∗
NOTE: Only on the machines equipped with the
corresponding optional parts.

T2-1-1
SYSTEM / Control System
IMPORTANT: Refer to the ZAXIS200 Technical
Manual (Operation Principle Section)
for the control described below.

Pump Control (Torque Control Solenoid Valve)

Speed Sensing Control
Slow Speed Torque Increase Control
∗
Pump 1 Flow Rate Limit Control
∗
Pump 2 Flow Rate Limit Control
∗
Pump 3 Torque Decrease Control

Valve Control (Solenoid Valve Unit)

Power Digging Control
Arm Flow Rate Control
Arm Regenerative Control
Travel Motor Swash Angle Control
Auto-Power Lift Control
∗
Auxiliary Flow Rate Control

Other Controls
Work Mode Control
∗
Travel Alarm Control
∗
Overload Alarm Control

∗
NOTE: Only on the machines equipped with the
corresponding optional parts.

T2-1-2
SYSTEM / Control System
ENGINE CONTROL
The engine control system is grouped as follows:

• Engine Control Dial Control • Idle Speed-Up Control

∗
• HP Mode Control • Attachment Operation Speed Increase Control
∗
• E Mode Control • Attachment Operation Speed Limit Control
• Auto-Idle Control
• Auto-Acceleration Control ∗
NOTE: Only on the machines with the corre-
• Auto-Warming Up Control sponding optional parts.

Engine Control System Layout

Pressure Sensor

Travel
Front Attachment Pump 2 Pump 1
Swing Delivery Delivery
Key Switch Boom Raise Pressure Pressure
Arm Roll-In Sensor Sensor

Auxiliary (Optional)
Engine
Control Dial
Auto-Idle /
Acceleration
Selector

Auto-Idle ECM

Auto-Acceleration

Power Mode Switch

HP Mode Pump 2 Pump 1

Control Control
E Mode Pressure Pressure
Work Mode Sensor Sensor
Switch
P Mode Auxiliary Mode Hydraulic Oil
Digging Attachment Switch Temperature
Mode Mode (Optional) Sensor
T1GR-02-01-001

T2-1-3
SYSTEM / Control System
Engine Control Dial Control

Function: Controls the engine speed in response to Engine

the rotation angle of the engine control dial Speed
and reduces the engine speed by 100 min-1
to reduce fuel consumption and noise level
when all control levers are in neutral. Engine speed is
Control Range reduced by 100
-1
min when the
Operation: control levers are in
1. In proportion to the rotational angle of the engine neutral.
control dial, the MC outputs voltage signals cor-
responding to the target engine speed to the
ECM. Engine
2. The ECM regulates the engine speed in response Control Dial
to the received voltage signals. Slow Fast Position
3. In addition, approximately 1 second after all con- Idle Idle
trol levers have been returned to neutral (the
pressure sensors for the travel and front attach-
ment systems are turned OFF), the MC sends the NOTE: The engine speed is reduced from the
voltage signal to the ECM. maximum speed by 100 min-1. Therefore,
4. Then, the ECM reduces the engine speed from when the engine speed set by the engine
the maximum running speed (P mode operating control dial is already slower than the
speed) by 100 min-1. maximum speed by 100 min-1, the engine
speed remains unchanged. This engine
speed reduction control is activated re-
gardless of whether the auto-idle and/or
auto-acceleration control is activated or
not.

T2-1-4
SYSTEM / Control System

Pressure Sensor
Travel
Front Attachment

Engine
Control Dial

ECM

T1GR-02-01-002

T2-1-5
SYSTEM / Control System
HP Mode Control

Function: Slightly increases digging power such as

arm roll-in operation while excavating Engine
Speed Maximum
deeply. 1650 min
-1
speed increases
-1
by 200 min .

Operation: 1500 min

-1

1. When all the following conditions exist with the

power mode switch set in the HP mode position,
the MC outputs voltage signals corresponding to
the target engine speed to the ECM.
2. The ECM slightly increases the engine speed
from that set by the engine control dial to increase Engine
the output power. Control Dial
Slow Fast Position
Idle Idle

• Engine Control Dial: Set at 1500 min-1 or faster.

• Boom Raise and/or Arm Roll-In Control: In Op-
eration
• Average Delivery Pressure of Pumps 1 and 2:
High

T2-1-6
SYSTEM / Control System

Pressure Sensor

Pump 2 Pump 1
Delivery Delivery
Boom Raise Pressure Pressure
Arm Roll-In Sensor Sensor

Engine
Control Dial

Power Mode Switch

HP Mode

T1GR-02-01-003

T2-1-7
SYSTEM / Control System
E Mode Control
Engine
Function: Reduce the engine speed by the constant Speed
specified ratio.
Engine speed is
Operation: reduced at the
1. When the power mode switch is in the E mode constant speci-
fied ratio.
position, the MC outputs voltage signals corre-
sponding to the target engine speed to the ECM.
2. The ECM reduces the engine speed from that set
by the engine control dial. The engine speed de-
creases in proportion to the rotational angle of the Engine
engine control dial. Control Dial
Position
Slow Idle Fast Idle

Engine
Control Dial

ECM

Power Mode Switch

E Mode

T1GR-02-01-004

T2-1-8
SYSTEM / Control System
(Blank)

T2-1-9
SYSTEM / Control System
Auto-Idle Control

Function: Reduces the engine speed when all control

levers are in neutral to reduce fuel con-
sumption and noise level.

Operation:
1. When the auto idle / auto acceleration selector is Engine speed is
in the auto idle position, approximately 3.5 sec- Engine reduced to the
onds after all control levers have been returned to Speed auto-idle speed
3.5 seconds later.
neutral, the MC sends the voltage signal corre-
Fast
sponding to the auto idle running speed to the Speed
ECM.
2. The ECM sets the engine speed to the auto idle
running speed. Auto-Idle
3. When any one of the control levers is operated Speed
(the pressure sensor for the travel or front at-
tachment systems is turned ON), the MC imme-
diately increases the output voltage signal to the Engine
ECM up to the voltage signal corresponding to the Control Dial
target engine speed. Slow Fast Position
Idle Idle
4. Then, the ECM resumes the engine speed to the
original speed.

Auto-Idle System Deactivation Requirements:

• Control Levers: Being operated (either travel or
front attachment control levers with pilot sensor
ON)
• Power Mode Switch: When the E mode is
changed to P mode or the P mode is changed to
the E mode.
• Engine Control Dial: When engine speed is
changed.

T2-1-10
SYSTEM / Control System

Pressure Sensor

Travel
Front Attachment

Engine
Control Dial

Auto-Idle

Auto-Idle/ ECM
Acceleration
Selector

Power Mode Switch

E Mode

T1GR-02-01-005

T2-1-11
SYSTEM / Control System
Auto Acceleration Control

Function: Automatically regulates the engine speed to Engine Speed VS. Control Lever Operations:
meet the machine operating conditions.
When all the control levers are in neutral,
the engine speed is reduced to reduce fuel Engine
Speed
consumption and noise level.
Engine speed is reduced
Fast Speed from the maximum speed
Operation: -1
by 400 min .
1. When any one of the control levers is operated Auto-
with the auto idle / auto acceleration selector set Acceleration
in the auto acceleration position, the MC decides Speed
Engine speed is reduced
the most appropriate engine speed through an Auto-Idle to the auto-idle speed 3.5
arithmetic operation performed based on the Speed seconds later.
signals sent from the pressure sensors (travel, Slow Speed
swing, boom raise, and arm roll-in), the pump
Engine
control pressure sensor, and the pump delivery Control Dial
Slow Fast
pressure sensor. Idle Idle
Position
2. Then, the MC outputs voltage signals corre-
sponding to the target engine speed to the ECM.
3. The ECM increases the engine speed to the run-
ning speed decided by the MC.
Operating Time Progress VS. Engine Speed Change
When all control levers are returned to neutral, Control Lever Stroke
the engine speed is reduced by 400 min-1 from the
maximum speed first. Then, 3.5 seconds later, the Full Stroke
engine speed is further reduced to the auto-idle
speed.
Neutral
NOTE: When all control levers are returned to Position
neutral, the engine speed is reduced by
400 min-1 from the maximum speed. In Time
case the engine speed is set by the engine
control dial and is running at a speed
slower than the maximum speed by 100 In response to the control
lever stroke and the pump
min-1, the engine speed will be reduced by delivery pressure, the
300 min-1. optimum engine speed is
Engine Speed selected.

Fast Idle Speed

(P Mode)
Auto
Acceleration
Control
Auto-Idle
Engine Speed

Time

T2-1-12
SYSTEM / Control System

Pressure Sensor
Travel

Swing Pump 2 Pump 1

Delivery Delivery
Boom Raise Pressure Pressure
Engine Arm Roll-In Sensor Sensor
Control Dial

Auto-Idle/ ECM
Acceleration
Selector

Auto-
Acceleration

Pump 2 Pump 1
Control Control
Pressure Pressure
Sensor Sensor

T1GR-02-01-006

T2-1-13
SYSTEM / Control System
Auto Warming Up Control

Function: Automatically warms up the hydraulic sys-

tem (similar to the auto choke on automo- Engine
Speed
biles).

Fast
Operation: Speed
1. During initial stage of 15 minutes after the engine
is started, or when the hydraulic oil temperature is
below 0 °C (32 °F), the MC outputs voltage sig- Auto
nals corresponding to the target engine speed to Warm Up Increasing
Speed Speed
the ECM based on the signals sent from the key
switch and the hydraulic oil temperature sensor. Slow
Speed Engine
2. The ECM increases the engine speed to the auto Control Dial
warming up speed. Slow Idle Fast Idle Position

IMPORTANT: When adjusting the auto-idle speed

deactivate the auto warming up
control function using Dr. ZX, or wait
to adjust until 15 minutes after
starting the engine.

Key Switch

Engine
Control Dial

ECM

Hydraulic Oil
Temperature
Sensor
T1GR-02-01-007

T2-1-14
SYSTEM / Control System
Idle Speed-Up Control

Engine
Function: Prevents the engine from hunting when Speed
running the engine at slow speed.

Operation:
1. When the travel or front attachment system is
operated with the engine running at the speed
Idle
range between the minimum running speed and Speed-Up
the idle up running speed, the MC outputs voltage Speed
signals corresponding to the target engine speed Increasing
Speed
to the ECM. Engine
2. The ECM increases the engine speed to the idle Control Dial
up speed. Slow Fast Position
Idle Idle

Pressure Sensor

Travel
Front Attachment

Engine
Control Dial

T1GR-02-01-008

T2-1-15
SYSTEM / Control System
Attachment Operation Speed Increase Control
(Only on the machines equipped with the auxil-
iary mode switch (Optional).)

Function: Increases the maximum engine speed to Engine When all

conditions exist,
the attachment (hydraulic breaker, secon- Speed
the maximum
dary crusher, primary crusher or vibrating engine speed is
hammer) operating engine speed set by Dr. increased to the
speed set by Dr.
ZX when the attachment is operated. ZX.

Operation:
1. When the attachment is operated under the fol-
lowing conditions, the MC outputs voltage signals
corresponding to the target engine speed set by
Dr. ZX to the ECM. Engine
2. The ECM increases the engine speed from the Control Dial
maximum running speed by the running speed Slow Fast Position
Idle Idle
level set by Dr. ZX.

Operating Conditions:
Dr. ZX: Resets the maximum engine speed to a faster
(+) attachment (hydraulic breaker, secondary crusher, NOTE: When the P mode engine speed is preset
primary crusher, or vibrating hammer) operating speed to a slower speed in the Dr. ZX service
in the service mode. mode, the maximum engine speed won’t
Engine Control Dial: Maximum Speed Position be increased when operating the attach-
Power Mode Switch: HP Mode ment.
Auxiliary: In Operation
Work Mode Switch: Attachment Mode
Auxiliary Mode Switch (Optional): Attachment position
(hydraulic breaker, secondary crusher, primary crusher,
or vibrating hammer) reset by Dr. ZX.

T2-1-16
SYSTEM / Control System

Pressure Sensor

Auxiliary (Optional)
Engine
Control Dial

Power Mode Switch

HP Mode

Work Mode
Switch
Auxiliary Mode
Attachment Switch
Mode (Optional)
T1GR-02-01-013

T2-1-17
SYSTEM / Control System
Attachment Operation Speed Limit Control (Only
on the machines equipped with the auxiliary
mode switch (Optional).)

Function: Decreases the maximum engine speed to Engine

the attachment (hydraulic breaker, secon- Speed
When all condi-
dary crusher, primary crusher or vibrating tions exist, the
hammer) operating engine speed set by Dr. maximum en-
ZX when the attachment mode is selected. gine speed is
reduced to the
speed set by Dr.
Operation: ZX.
1. When the attachment mode is selected under the
following conditions, the MC outputs voltage sig-
nals corresponding to the target engine speed set
by Dr. ZX to the ECM.
2. The ECM reduces the engine speed from the
maximum running speed by the running speed Slow Fast
level set by Dr. ZX. Idle Idle

Operating Conditions:
Dr. ZX: Resets the maximum engine speed to a slower
(−) attachment (hydraulic breaker, secondary crusher,
primary crusher, or vibrator) operating speed in the
service mode.
Work Mode Switch: Attachment Mode
Auxiliary Mode Switch (Optional): Attachment position
(hydraulic breaker, secondary crusher, primary crusher,
or vibrating hammer) set by Dr. ZX.

T2-1-18
SYSTEM / Control System

ECM

Work Mode
Switch
Auxiliary Mode
Attachment Switch
Mode (Optional)
T1GR-02-01-014

T2-1-19
SYSTEM / Control System
(Blank)

T2-1-20
SYSTEM / ECM System
OUTLINE

Signals from sensors and MC (Main Controller) are • Supply pump is driven by engine and generates
input to ECM (Engine Control Module). high pressure fuel.
ECM executes computation and drives solenoid values • Common rail destributes high pressure fuel gen-
and motors in order to control supply pump, injector erated by supply pump to injector of each engine
valve and EGR valve. cylinder.
• Injector injects high pressure fuel from common
• Fuel Injection Control rail.
• Engine Start Control
• EGR Control
• Correction of Fuel Injection Volume
• Engine Stop Control
Crank Revolution Sensor

Cam Angle Sensor

Atmosphere Sensor

Fuel Temperature Sensor

Coolant Temperature Sensor

Inlet Air Temperature Sensor

Boost Pressure Sensor

Boost Temperature Sensor

Engine Oil Pressure Sensor

EGR Motor Position Sensor

EGR Motor

ECM
MC

Common Rail
Pressure Sensor

Common Rail

Supply Pump

Injector
Fuel Tank

T1GR-02-02-001

T2-2-1
SYSTEM / ECM System
FUEL INJECTION CONTROL

ECM detects running state of engine according to

signals from each sensor and MC. ECM controls the
volume, pressure, timing and rate of fuel injection

Control by Two Way Valve Crank Revolution Sensor

• Fuel injection volume control Cam Angle Sensor
• Fuel injection (volume) timing
control Atmosphere Sensor
• Fuel injection rate control
Fuel Temperature Sensor
Control by Suction Control Valve
• Fuel injection pressure control Coolant Temperature Sensor

Inlet Air Temperature Sensor

Boost Pressure Sensor

Boost Temperature Sensor

Engine Oil Pressure Sensor

EGR Motor Position Sensor

EGR Motor

ECM
MC

Common Rail Two Way Valve

Pressure Sensor

Suction Control
Valve

Common Rail

Supply Pump

Injector
Fuel Tank

T1GR-02-02-001

T2-2-2
SYSTEM / ECM System
(Blank)

T2-2-3
SYSTEM / ECM System
Fuel Injection Volume Control

Function: Controls fuel injection volume in order to be

optimum.

Operation:
1. ECM detects engine speed according to input
signals from crank revolution sensor and cam
angle sensor.
2. MC computes target engine speed according to
input signals from engine control dial, sensors
and switches. MC outputs corresponding voltage
signal to ECM.
(Refer to System/Control System.)
3. ECM turns two way valve in the injector into ON
or OFF mainly according to the engine speed and
voltage signal from MC in order to control fuel in-
jection volume.

T2-2-4
SYSTEM / ECM System

Pressure Sensor
Travel Crank Revolution Sensor
Front Attachment
Cam Angle Sensor
Swing
Boom Raise Atmosphere Sensor
Arm Roll-In
Fuel Temperature Sensor
Auxiliary (Optional)
Coolant Temperature Sensor
Engine
Control Dial Inlet Air Temperature Sensor

Boost Pressure Sensor

Auto-Idle Boost Temperature Sensor

Switch
Engine Oil Pressure Sensor
Auto-Acceleration
Switch EGR Motor Position Sensor

EGR Motor
Power Mode MC
ECM
Switch

HP Mode

E Mode Common Rail Pres- Two Way Valve

sure Sensor

P Mode

Work Mode
Switch
Common Rail

Digging Attachment
Mode Mode

Pump 2 Delivery
Pressure Sensor
Fuel Tank Supply Injector
Pump

Pump 1 Delivery
Pressure Sensor
Auxiliary Hydraulic Oil
Mode Switch Temperature
Pump 1 Control (Optional) Sensor
Pressure Sensor
T1GR-02-02-009
Pump 2 Control
Pressure Sensor

T2-2-5
SYSTEM / ECM System
Fuel Injection Pressure Control

Function: Controls fuel injection pressure according

to fuel pressure in common rail.

Operation:
1. ECM computes fuel injection volume according to
engine speed and voltage signal of MC. (Refer to
Fuel Injection Volume Control.).
2. Common rail pressure sensor inputs signal cor-
responding to pressure in common rail to ECM.
3. ECM computes appropriate pressure in common
rail according to engine speed, fuel injection
volume and common rail pressure sensor signal.
ECM drives suction control valve in supply pump
and appropriate amount of fuel to common rail.
4. Fuel in common rail is supplied to each engine
cylinder through injector from common rail.

T2-2-6
SYSTEM / ECM System

Auto-Idle Boost Pressure Sensor

Switch
Boost Temperature Sensor

Engine Oil Pressure Sensor

Auto-Acceleration
Switch EGR Motor Position Sensor

EGR Motor
Power Mode MC
ECM
Switch

HP Mode

E Mode Two Way Valve

Common Rail
Pressure Sensor
P Mode

Work Mode
Switch
Common Rail

Suction
Control
Digging Attachment Valve
Mode Mode

Pump 2 Delivery
Pressure Sensor
Fuel Tank Supply Injector
Pump

Pump 1 Delivery
Pressure Sensor
Auxiliary Hydraulic Oil
Mode Switch Temperature
Pump 1 Control (Optional) Sensor
Pressure Sensor
T1GR-02-02-010
Pump 2 Control
Pressure Sensor

T2-2-7
SYSTEM / ECM System
Fuel Injection Timing Control

Function: Calculates appropriate fuel injection timing.

Operation:
1. ECM computes fuel injection timing according to
engine speed and fuel injection volume.
2. ECM drives ON/OFF of two way valve in injector
in order to control fuel injection timing.

Fuel Injection Rate Control

Function: Improves combustion inside the engine

cylinders.

Operation:
1. Injector initially injects small amount of fuel (pilot
injection) for ignition.
2. Injector executes the second injection (main in-
jection) after ignition. ECM drives ON/OFF of two
way valve in injector in order to control fuel injec-
tion timing and volume.

Fuel Injection
1. Fuel pressure is constantly applied to injector
nozzle.
2. When two way valve becomes ON, high pressure
fuel flows out from control chamber through orifice
1.
3. Hydraulic piston goes up, opens the nozzle and
the injection starts.
4. When two way valve becomes OFF, high pres-
sure fuel flows from common rail to control
chamber through orifice 2.
5. High pressure fuel flows into to control chamber.
Hydraulic piston goes down, closes the nozzle
and fuel injection stops.

T2-2-8
SYSTEM / ECM System
1. Two Way Valve: ON 2. Fuel Injection Start
From ECM From ECM

Two Way Valve Two Way Valve

Return to Fuel Return to Fuel

Tank Tank
From Common Rail From Common
Rail
Orifice 1

Control Chamber Control Chamber

Hydraulic Piston

Nozzle Nozzle

3. Two Way Valve: OFF 4. Fuel Injection Stop

From ECM From ECM

Two Way Valve Two Way Valve

From Common Rail From Common Rail

Control Chamber Control Chamber

Orifice 2

Hydraulic Piston Hydraulic Piston

Nozzle Nozzle

T1GR-02-02-012

T2-2-9
SYSTEM / ECM System
ENGINE START CONTROL
Coolant Temperature From Key Switch
Sensor Terminal #5
Function: Controls energizing time of glow plug by
coolant temperature and improves start-
ability of engine.

Operation: Fuse Box

1. Coolant temperature sensor inputs signal corre-
ECM
sponding to coolant temperature to ECM.
2. ECM connects the ground circuit of glow relay
according to signals and controls energizing time
of glow plug.

From Battery

Glow Relay

Glow Plug T1GR-02-02-006

T2-2-10
SYSTEM / ECM System
(Blank)

T2-2-11
SYSTEM / ECM System
EGR (EXHAUST GAS RECIRCULATION)
CONTROL

Function: Reduces generation of nitrogen oxide

(NOx) by letting part of exhaust gas recir-
culate inside intake manifold and mix it with
intake air in order to lower the combustion
temperature.

Operation:
• EGR Gas Amount Control
1. ECM determines amount of EGR gas according
to engine speed, fuel flow rate, coolant tempera-
ture, atmospheric pressure and intake air tem-
perature.
2. ECM drives EGR motor and opens EGR value.
ECM exhausts suitable amount of EGR gas ac-
cording to engine condition and mix it with intake
air.
3. At the same time, EGR motor position sensor
detects amount of opening of EGR valve.

• EGR Gas Coolant

EGR gas is cooled by coolant system located along
EGR gas passage.
By mixing cooled down EGR gas with intake air,
combustion temperature drops and NOx reduces.
• Lead Valve
Lead valve prevents new air from entering into EGR
gas passage and reverse flow of EGR gas.
As EGR gas flows in one direction, amount of EGR
gas increases.

T2-2-12
SYSTEM / ECM System

To Inter Cooler
Exhaust Gas

From Air Cleaner

Coolant Out

Coolant System
Engine

Coolant In

EGR Valve

Intake
Manifold EGR Motor
Position Sensor
From Inter Cooler
EGR Motor

Lead Valve
Intake Air

ECM

T1GR-02-02-011

T2-2-13
SYSTEM / ECM System
CORRECTION OF FUEL INJECTION Atmosphere
Pressure Sensor
VOLUME

1. Atmosphere pressure sensor inputs signal cor-

responding to atmospheric pressure to ECM.
2. ECM computes atmospheric pressure according
to input signal. ECM controls two way valve in
injector and corrects of fuel injection volume. ECM

Two Way
Valve

T1GR-02-02-002

T2-2-14
SYSTEM / ECM System
ENGINE STOP CONTROL

1. When emergency stop switch is turned ON, elec-

tric current flows from battery to terminal #47 of
ECM through fuse #3 and main relay.
2. ECM controls and stop the engine.

Key Switch

ECM

Main
Relay

ON
OFF
#47

Emergency Stop T1GR-02-02-008

Switch

T2-2-15
SYSTEM / ECM System
(Blank)

T2-2-16
SYSTEM / Electrical System
OUTLINE

The electrical circuit is broadly divided into the main

circuit, monitor circuit, and control circuit.

• Main Circuit
The engine and accessory operation related circuit.

• Monitor Circuit
The electrical circuit group consists of the monitors,
sensors, and switches, and displays the machine
operation status.

• Control Circuit (Refer to the SYSTEM / Control

System group.)
The control circuit is categorized into the engine,
pump, and valve control circuits. Each circuit
consists of the actuators such as solenoid valves,
MC, ECM, switch boxes, sensors and pressure
switches.

T2-3-1
SYSTEM / Electrical System
MAIN CIRCUIT

The major functions and circuits in the main circuit are

as follows.

• Electric Power Circuit: Supplies all electric power

to all electrical systems on this machine. [Key
Switch, Batteries, Fuses (Fuse Boxes, Fusible
Links), Battery Relay]

• Starting Circuit
Starts the engine. [Key Switch, Starter, Starter
Relay]

• Engine Stop Circuit

Stops the engine using the ECM. [MC, ECM]

T2-3-2
SYSTEM / Electrical System
ELECTRIC POWER CIRCUIT
(KEY SWITCH: OFF)
The battery ground terminal is connected to the vehicle
frame. Current from the battery plus terminal flows as
shown below when the key switch is OFF.

Battery
↓ →Glow Plug Relay
→Terminal #1: Radio (Backup Power)
(Power)
Fusible Link Monitor (Backup Power)
→Key Switch (B)
ICX Controller (Backup Power)
→Load Damp Relay
→Terminal #2: MC (Power)
→Fuse Box
→Terminal #3: ECM (Power)
→Terminal #10: Optional
Key Switch

Fusible Link

Battery

Load
Damp
Relay

Fuse Box

Glow
Plug
Relay Radio, Monitor,
ECM ICX Controller
Optional

ECM

T1GR-02-03-003

T2-3-3
SYSTEM / Electrical System
STARTING CIRCUIT
(KEY SWITCH: START)
1. When the key switch is turned to the START 5. Consequently, the relay in the starter is turned ON
position, terminal B is connected to terminals M so that the starter begins rotating.
and ST in the key switch.
6. On the other hand, current from key switch
2. As current from terminal M excites the battery terminal M flows to the MC via fuse #6 as a signal
relay, battery current is routed to starter terminal B indicating that the key switch is in the ON or
and starter relay terminal B via the battery relay. START position.

3. Key switch terminal ST is connected to starter 7. When this signal arrives in the MC, the MC sends
relay terminal S so that current flows through the the voltage signal to the ECM.
starter relay coil.
8. The ECM set the engine in the ready-to-start
4. Then, the starter relay is turned ON, allowing status.
current to flow from starter relay terminal C to
starter terminal C.

T2-3-4
SYSTEM / Electrical System

Key Switch

Battery

Battery
Relay
Starter Fuse
Box

Starter Relay

ECM

T1GR-02-03-001

T2-3-5
SYSTEM / Electrical System
Starter Relay Operation
• When the key switch is turned to the START • When this voltage increases up to 21 to 22 V,
position, key switch terminal B is connected to Zener diode (Z) is turned ON so that transistor
terminal ST so that current is routed to the base in (Q1) is turned ON. Then, current to the base of
transistor (Q2) through resistance R4 in the transistor (Q2) is not routed, turning transistor
starter relay. Then, transistor (Q2) is turned ON, (Q2) OFF. At this moment, starter terminal B is
allowing current to flow to coil (L) in the starter disconnected from terminal C, stopping the
relay. Therefore, starter terminal B is connected to starter.
terminal C, rotating the starter.
Condenser C1 is used to stabilize the operating
• After the engine starts, the alternator starts voltage and diode D4 protects the circuit in case the
generating electricity, increasing voltage at starter battery terminals are reversely connected.
relay terminal R.

Starter Relay

S B
D3
(1)
R4 L
C
R3 (2) (1)
R2 Z C
R D2
From Alternator Q2 M B
Terminal L Q1
(2)
C1 C Starter
E D4

12V
B
ST

Key Switch 12V

Battery

T107-04-04-003

T2-3-6
SYSTEM / Electrical System
ENGINE STOP CIRCUIT

1. When the key switch is turned from the ON

position to the OFF position, the signal current
indicating that the key switch is ON stops flowing
from terminal M to MC terminal C-31.
2. The MC stops sending the voltage signal to the
ECM.
3. The ECM stops the engine.

ECM

T1GR-02-03-002

T2-3-7
SYSTEM / Electrical System
(Blank)

T2-3-8
MEMO

.......................................................................................................................................................................

.......................................................................................................................................................................
MEMO

.......................................................................................................................................................................

.......................................................................................................................................................................
SECTION 3
COMPONENT OPERATION

Refer to the ZAXIS200 Technical Manual (Operation

Principle Section) .

1GRT-3-1
(Blank)

1GRT-3-2
MEMO

....................................................................................................................................................................

....................................................................................................................................................................
MEMO

....................................................................................................................................................................

....................................................................................................................................................................
SECTION 4
OPERATIONAL
PERFORMANCE TEST

CONTENTS
Group 1 Standard
Operational Performance
Standard Table ........................................ T4-1-1
Main Pump P-Q Diagram .......................... T4-1-4

1GRT-4-1
(Blank)

1GRT-4-2
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE
STANDARD TABLE
The standard Performance values are listed in the Engine Control Dial : Fast Idle
table below. Power Mode Switch : P Mode
Auto-Idle/Acceleration Selector : OFF
The following switch positions shall be selected and Work Mode Switch : Digging Mode
the hydraulic oil temperature shall be maintained as Hydraulic Oil Temperature : 50±5 °C (122±9 °F)
indicated below as the preconditions of performance
tests unless otherwise instructed in each performance
test procedure:

NOTE: 1 mm=0.03937 in
ZAXIS200-4H
PERFORMANCE TEST DESIGNATION (Performance Remarks
Standard)
ENGINE SPEED min
-1

Slow Idle Speed 800±50 Value indicated on Dr. ZX.

Fast Idle Speed (Normal) 1700±50 ↑
Fast Idle Speed (Wirh ECO deactivated) 1800±50 ↑
Extend the boom cylinder to
relieve the boom raise
Fast Idle Speed (Relief Operation) 1800±50
circuit.Value indicated on Dr.
ZX.
Fast Idle Speed (E mode) 1600±50 Value indicated on Dr. ZX.
Extend the boom and arm
cylinder to relieve the boom
Fast Idle Speed (HP mode) 2000±50
raise and arm roll-in circuit.
Value indicated on Dr. ZX.
Auto-Idle Speed 1100±50 Value indicated on Dr. ZX.
Auto-Acceleration Speed 1550±50 ↑
Warming Up Speed 1100±50 ↑
ENGINE COMPRESSION PRESSURE After engine warm-up
3.04 (31, 440)
(After engine warm-up) 2
MPa (kgf/cm , psi)
VALVE CLEARANCE (IN, EX) 0.4 With the engine cold
LUBRICANT CONSUMPTION Hour meter: 2000 hours or
40 or less
(Rated output) mL/h less

T4-1-1
OPERATIONAL PERFORMANCE TEST / Standard

NOTE: 1 mm=0.03937 in
ZAXIS200-4H
PERFORMANCE TEST DESIGNATION (Performance Remarks
Standard)
TRAVEL SPEED sec/10 m
Fast Speed 6.3±0.6
Slow Speed 9.3±1.0
TRACK REVOLUTION SPEED sec/3 rev
Fast Speed 16.4±1.0 LC: 17.5±1.0
Slow Speed 24.2±2.0 LC: 25.8±2.0
MISTRACK mm/20 m
200 or less
(With fast and slow travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0
SWING SPEED sec/3 rev 12.9±1.0 Bucket empty
SWING FUNCTION DRIFT CHECK
1254 or less Bucket empty
mm /180°
SWING MOTOR LEAKAGE mm/5 min 0 Bucket loaded
MAXIMUM SWINGABLE SLANT ANGLE 22° or possibly Bucket loaded
deg. more
SWING BEARING PLAY mm 0.2 to 1.25 Allowable limit: 2.0 to 3.05
HYDRAULIC CYLINDER CYCLE TIME 2.91 m arm
sec 0.8 m3 (PCSA heaped)
bucket, bucket empty
Boom Raise 3.0±0.3
Boom Lower 2.3±0.3
Arm Roll-In 3.5±0.3
Arm Roll-Out 2.4±0.3
Bucket Roll-In 3.0±0.3
Bucket Roll-Out 2.0±0.3
DIG FUNCTION DRIFT CHECK mm/5 min 2.91m arm
0.8 m3 (PCSA heaped) bucket
Boom Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 5 or less Bucket empty
Arm Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 15 or less Bucket empty
Bucket Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 10 or less Bucket empty
Bucket Bottom
(Maximum Reach Position) 150 or less Bucket loaded
(Arm Roll-In position) 110 or less Bucket empty

T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard

NOTE: 1 mm=0.03937 in
ZAXIS200-4H
PERFORMANCE TEST DESIGNATION (Performance Remarks
Standard)
CONTROL LEVER OPERATING FORCE HITACHI lever pattern
N (kgf, lbf･ft)
Boom Lever 18 (1.8, 13) or less
Arm Lever 15 (1.5, 10.8) or
(ISO Lever Pattern: Swing Lever) less
Bucket Lever 15 (1.5, 10.8) or
less
Swing Lever 18 (1.8, 13) or less
(ISO Lever Pattern: Arm Lever)
Travel Lever 28 (2.8, 20.3) or
less
CONTROL LEVER STROKE mm HITACHI lever pattern
Boom Lever 105±10
Arm Lever
84±10
(ISO Lever Pattern: Swing Lever)
Bucket Lever 84±10
Swing Lever 105±10
(ISO Lever Pattern: Arm Lever)
Travel Lever 120±10
BOOM RAISE/SWING sec 2.91 m arm
3.6±0.3 0.8 m3 (PCSA heaped)
bucket, bucket empty
(Bucket Teeth Height: H) mm 6700 or more
BOOM RAISE/ARM ROLL-IN sec 2.91 m arm
4.5±0.5 0.8 m3 (PCSA heaped)
bucket, bucket empty
PRIMARY PILOT PRESSURE
2
MPa (kgf/cm , psi)
Engine: Fast Idle 4.0+1.0-0.5
(41+10-5, 580+142-71)
Engine: Slow Idle 3.5+1.0-0
(35 -0, 500+142-0)
+10

SECONDARY PILOT PRESSURE) 3.4 to 4.0 Value indicated on Dr. ZX

(Engine: Fast Idle and Slow Idle) (34 to 40, 483 to (Lever: Full stroke)
2
MPa (kgf/cm , psi) 570)
SOLENOID VALVE SET PRESSURE Value Indicated On
2
MPa (kgf/cm , psi) Dr. ZX±0.2 (2, 28)
MAIN PUMP DELIVERY PRESSURE 0.7+1.0-0.5 Value indicated on Dr. ZX
2
MPa (kgf/cm , psi) (7 -5, 100+142-71)
+10

T4-1-3
OPERATIONAL PERFORMANCE TEST / Standard

NOTE: 1 mm=0.03937 in
ZAXIS200-4H
PERFORMANCE TEST DESIGNATION (Performance Remarks
Standard)
MAIN RELIEF VALVE SET PRESSURE
2
MPa (kgf/cm , psi)
Boom Raise, Arm 34.3+2.0-0.5 Value indicated on Dr. ZX
(350+20-5,
4980+284-71)
Boom Lower 33.2+2.0-0.5 Value indicated on Dr. ZX
(340+20-5,
4830+284-71)
Bucket 35.3+2.0-0.5 Value indicated on Dr. ZX
(360+20-5,
2600+284-71)
Power Boost 36.3+2.0-1.0 Value indicated on Dr. ZX
(Boom, Arm) (370+20-10,
5260+284-142)
Power Boost 37.3+2.0-1.0 Value indicated on Dr. ZX
(Bucket) (380+20-10,
5400+284-142)
RELIEF PRESSURE 32.9+2.3-0 Value indicated on Dr. ZX
2
MPa (kgf/cm , psi)
(When relieving Swing) (335+25-0,
4760+356-0)
RELIEF PRESSURE 2
MPa (kgf/cm , psi)
(When relieving Travel)
(When relieving both travel levers) 34.3+2.0-0.5 Value indicated on Dr. ZX
(350+20-5,
4980+284-71)
(When relieving one travel lever) 35.3+2.0-0.5 Value indicated on Dr. ZX
(360+20-5,
2600+284-71)
OVERLOAD RELIEF VALVE SET PRES- (Reference values
SURE MPa (kgf/cm , psi) at 50 L/min)
2

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 Allowable limit: 2.6
With the motor relieved 1.4 to 4.0 Allowable limit: 5.0

T4-1-4
OPERATIONAL PERFORMANCE TEST / Standard
MAIN PUMP P-Q DIAGRAM

• Hydraulic P-Q Control (Torque Control)

(REFERENCE: Measured at Test Stand) • Points on P-Q Line

Delivery Pressure Flow Rate
• Rated Pump Speed: 1800 min-1 (rpm) MPa (kgf/cm2, psi) L/min (gpm)
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F) A 4.9 (50, 710) 212 (56.0)
B 14.7 (150, 2140) 210 (55.4)
C 19.6 (200, 2850) 164 (43.3)
D 24.5 (250, 3560) 132 (34.8)
E 29.4 (300, 4270) 110 (29.0)
F 34.3 (350, 4980) 87 (23.0)

Flow Rate
L/min
A B
200

C
150
D

E
100
F

0
4.9 9.8 14.7 19.6 24.5 29.4 34.3 T1GR-04-02-001
(50) (100) (150) (200) (250) (300) (350)
Delivery Pressure
2
MPa (kgf/cm )

T4-1-5
OPERATIONAL PERFORMANCE TEST / Standard
(Blank)

T4-1-6
MEMO

....................................................................................................................................................................

....................................................................................................................................................................
MEMO

....................................................................................................................................................................

....................................................................................................................................................................
SECTION 5
TROUBLESHOOTING

CONTENTS
Group 1 General
Introduction ............................................... T5-1-1
Diagnosing Procedure .............................. T5-1-2
Built-In Diagnosing System Operation ...... T5-1-6
Built-In Diagnosing Function Display List .. T5-1-7
Dr. ZX Operation ....................................... T5-1-8
Dr. ZX Fault Code List............................. T5-1-10
Dr. ZX Monitoring Item List ..................... T5-1-12
Dr. ZX Special Function .......................... T5-1-14
Dr. ZX Service Mode............................... T5-1-15
Adjustment Data List............................... T5-1-25

Group 2 Troubleshooting A
Troubleshooting A Procedure .................... T5-2-1
Fault Code List.......................................... T5-2-2
Fault Code 01, 02, 03 ............................... T5-2-3
Fault Code 04 ........................................... T5-2-3
Fault Code 07 ........................................... T5-2-4
Fault Code 10, 11 ..................................... T5-2-5
Fault Code 12, 13 ..................................... T5-2-6
Fault Code 14, 15, 16, 18 ......................... T5-2-7
Fault Code 19 ........................................... T5-2-8

Group 3 Troubleshooting B
Troubleshooting B Procedure ................... T5-3-1
Engine System Troubleshooting ............... T5-3-2

1GRT-5-1
(Blank)

1GRT-5-2
TROUBLESHOOTING / General
INTRODUCTION
Refer to the inspection and troubleshooting proce-
dures after any machine trouble has occurred. The
inspection and troubleshooting procedures are pre-
sented 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

3 groups; General, Troubleshooting A (base machine
diagnosis using fault codes), and Troubleshooting B
(base machine diagnosis starting with inspection of
abnormal operational status).

• General

• Troubleshooting A (base machine diagnosis using

fault codes)
Refer to these procedures if any fault codes are
displayed when the main controller (MC) is diag-
nosed with Dr. ZX (or the built-in diagnosing sys-
tem).
(MC self-diagnosing function retains a record of
the electrical signal system malfunction in the
form of fault codes.)

Example: Fault Code 01: Abnormal MC

• Troubleshooting B (base machine diagnosis start-

ing 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 re-
sult of the abnormal symptom.

Example: Even if the engine control dial is oper-

ated, engine speed remains unchanged.

IMPORTANT: Refer to the ZAXIS200 Technical

Manual (Troubleshooting Section)
for the troubleshooting described
below.

• Troubleshooting (monitor diagnosis)

• Electrical system Inspection
• ICX

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 T107-07-01-001

Before inspecting, get the full story of

malfunctions from the operator below.

(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. T107-07-01-003

4. Operate the machine yourself

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

T5-1-3
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 dis-
played by diagnosis using Dr. ZX (or the built-in
diagnosing system), delete the fault code once T107-07-01-005

and retry self-diagnosis again. If the fault code is

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

※ Note that the fault codes displayed do not

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

6. Trace possible causes

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

appropriate repairs to avoid consequent

malfunctions.

T5-1-4
TROUBLESHOOTING / General
(Blank)

T5-1-5
TROUBLESHOOTING / General
BUILT-IN DIAGNOSING SYSTEM OPERA-
TION
IMPORTANT: This system is to be operated by the
HITACHI Dealer Only. Don’t explain
this system function to the cus-
tomer.

In the service mode, the monitor LCD displays the

diagnosing items, fault codes and monitored results
(not all of them) without using Dr. ZX.

Built-In Diagnosing System Activation

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

NOTE: The fault code is indicated in the display

order 8. All fault codes (Dr. ZX fault code
list) can be indicated. In case more than LCD
one fault code is indicated, they will be dis-
played with an interval of 1 second in order.
After the machine malfunction has been
repaired, the fault codes are automatically
deleted. Accordingly, if any trouble, which
is not reproducible, is encountered, it is
recommended to use Dr. ZX.
• The built-in diagnosing system displays only the
item No. on the left and the monitored result on the T1GR-01-01-010

right. The item description is not displayed.

T5-1-6
TROUBLESHOOTING / General
BUILT-IN DIAGNOSING FUNCTION DISPLAY LIST

Display
Description Monitored Result Unit Remarks
Order
1 Hour Meter {{{{{ h Standard Mode
2 Trip 1 {{{{{ h Standard Mode (Subtraction)
3 Trip 2 {{{{{ h Standard Mode (Subtraction)
4 Engine Actual Speed n {{{{ -1 User Mode (Required to set
min
in the Dr. ZX service mode)
5 Hydraulic Oil {{{ °C User Mode (Required to set
Temperature in the Dr. ZX service mode)
6 L1 {{{ - Display Purpose Only
7 Overload Alarm L2 {{{ % European Spec. Only
8 Fault Code* 0 {{ - Possible to display
9 1 {{ - Display Purpose Only
10 Pump 1 Delivery 2 {{ MPa Possible to display
Pressure
11 Pump 2 Delivery 3 {{ MPa Possible to display
Pressure
12 Pump 1 Pump (Flow) 4 {{ MPa Possible to display
Control Pressure
13 Pump 2 Pump (Flow) 5 {{ MPa Possible to display
Control Pressure
14 -1
Engine Target Speed 6 {{ min Possible to display
15 7 {{ - Display Purpose Only
16 Dial Angle 8 {{ V Possible to display
17 Boom Raise Pilot 9 {{ MPa Possible to display
Pressure
18 Arm Roll-In Pilot A {{ MPa Possible to display
Pressure
19 Swing Control Pilot b {{ MPa Possible to display
Pressure
20 Travel Control Pilot c {{ MPa Possible to display
Pressure
21 Front Att. Operation d {{ 0: Not Operating Possible to display
1: Operating
22 Att. Control Pressure E {{ MPa Possible to display
23 Work Mode F {{ 0: Digging Possible to display
1: Breaker
2: Secondary
Crusher
(Demolisher)
3: Crusher
4: Vibro-Hammer

NOTE: *: Refer to T5-1-10 for the Fault Codes.

T5-1-7
TROUBLESHOOTING / General
Dr. ZX OPERATION
Rear Console
Dr. ZX is a troubleshooting tool to diagnose the elec- Fuse Box
tronic control system including the MC (main Control-
ler) and ICX (Information Controller). When Dr. ZX is Dr. ZX
connected to either the MC or the ICX, it displays Connector
whether the controllers and sensors operate normally (MC)
in the form of fault codes (Self-Diagnosing Result Dis-
play Function).
In addition, Dr. ZX can display the inputs from sensors
and switches to the MC and/or the outputs to actua-
tors such as solenoid valves from the MC in real time
while operating the machine (Monitor Display Func-
tion).

Dr. ZX Connector (ICX)

(Located at Backside of
Sheet)
T178-01-02-006

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 connec-
tors (MC and ICX) located in the cab, using Hot Start
Sync cable and battery box cable.

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

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

4. Select Self-Diagnostic Results. Then, continue to OK

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

Self-diagnostic
Result by control- Enter model
ler is displayed Record
code and serial
No.

Retry B
Select data to
be monitored

Self-diagnostic
Result is displayed Monitored data
is displayed

T5-1-9
TROUBLESHOOTING / General
DR. ZX FAULT CODE LIST

Fault Code Trouble Cause

01 Abnormal EEPROM • Faulty MC
02 Abnormal RAM
03 Abnormal A/D Conversion
04 Abnormal Sensor Voltage • Faulty MC
• Faulty Harness
• Faulty Sensor
07 Abnormal Engine Control Dial Angle • Faulty MC
• Faulty Harness
• Faulty Engine Control Dial
10 Abnormal Pump 1 Delivery Pressure • Faulty MC
11 Abnormal Pump 2 Delivery Pressure • Faulty Harness
• Faulty Pump Delivery Pressure Sensor
12 Abnormal Pump1 Pump Control Pressure • Faulty MC
13 Abnormal Pump2 Pump Control Pressure • Faulty Harness
• Faulty Pump Control Pressure Sensor
14 Abnormal Swing Pilot Pressure • Faulty MC
15 Abnormal Boom Raise Pilot Pressure • Faulty Harness
16 Abnormal Arm Roll-In Pilot Pressure • Faulty Pilot Pressure Sensor
18 Abnormal Travel Pilot Pressure
19 Abnormal Hydraulic Oil Temperature • Faulty MC
• Faulty Harness
• Faulty Hydraulic Oil Temperature Sensor

T5-1-10
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 Data Unit

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

from speed when unloaded.

Engine Actual Speed Input signal from N sensor min-1
Deviation in Engine Speed Calculated Value min-1
(Engine Speed Differential) (Target Engine Speed - Actual Engine Speed)
EC Angle Don’t use
Dial Angle Input signal from engine control dial V
Boom Raise Pilot Pressure Input signal from pressure sensor (boom raise) MPa
Arm Roll-In Pilot Pressure Input signal from pressure sensor (Arm Roll-In) MPa
Swing Control Pressure Input signal from pressure sensor (swing) MPa
Travel Control Pressure Input signal from pressure sensor (travel) MPa
Front Att. Operation Input signal from pressure sensor (front att.) FR
Hydraulic Oil Temperature Input signal from oil temperature sensor °C
E/P/HP Mode Switch Power mode switch selection status E, P, HP
Auto-Idle/Auto-Accel Auto-Idle/Auto-Acceleration selector selection status AI, AA
Switch
Travel Mode Travel mode switch selection status Lo, Hi
Power Digging (Boost) Power digging switch selection status Pd
Switch
Key Switch Key switch selection status Ky
Work mode Work mode switch selection status STD, ATT
ATT. Mode BU, CS, CL, HB
Engine Learning Status Don’t use
Pump 2 Proportional Control signal to max. pump 2 flow rate limit solenoid MPa
Solenoid Valve Output valve
Pump Torque Proportional Control signal to torque control solenoid valve MPa
Solenoid Valve Output

T5-1-12
TROUBLESHOOTING / General

Item Data Unit

Arm Regenerative Proportional Control signal to solenoid valve SC MPa
Solenoid Valve Output
Power Digging (Boost) Control Control signal to solenoid valve SG MPa
Pressure
Travel Motor Control Pressure Control signal to solenoid valve SI MPa
EC Motor Position Don’t use

Optional
Item Data Unit
Optional Pump 3 Delivery Pressure Input signal from pump 3 delivery pressure sen- Don’t use
sor
Boom Cylinder Bottom Pressure MPa
Boom Cylinder Rod Pressure MPa
Arm Roll-Out Pilot Pressure Input signal from pressure sensor (arm roll-out) MPa
ATT. Control Pressure Input signal from pressure sensor (auxiliary) MPa
Boom Angle V
Arm Angle V
Pump 1 Max. Displacement cm3
Boom Dampener Switch Don’t use
Pump 1 Proportional Solenoid Valve Control signal to pump 1 flow rate control sole- MPa
Output noid valve
ATT. Proportional Solenoid Valve MPa
Output
Boom Dampener Proportional Valve MPa
Output
Travel/Swing/Load Alarm Tr, Sw, Load
Initial ML Setting Don’t use
Initial Boom-Angle Setting Unf, Done, Abrt,
Und

T5-1-13
TROUBLESHOOTING / General
Dr. ZX SPECIAL FUNCTION
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS200.

Start the service software in the Select a special function

operation mode
If the following screen appears, Select the function you want to
you are in the operation mode. execute.
Select Special Function.

T178-05-01-013 T178-05-01-168
Fig. A Fig. B
Select ESC to return
to Fig. A.

Special function

Select Execute to execute the

function.

WU deactivation ECO control deactivation

Execute Execute

T178-05-01-030 T178-05-01-031 T178-05-01-032 T178-05-01-033

Select ESC to return Select ESC to return Select ESC to return Select ESC to return
to Fig. B. to Fig. B. to Fig. B. to Fig. B.

T5-1-14
TROUBLESHOOTING / General
Dr. ZX SERVICE MODE

Dr. ZX has three (3) modes, learning value display, Engine

parameter change, and monitor display information Learning
Switch
setting.

Learning Value Display

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

Monitor Display Information Setting

Items to be displayed on the monitor LCD can be
added.

• Accessing Service Mode T178-01-02-006

1. After turning the key switch OFF, wait for more
than 10 seconds.
2. Connect Dr. ZX to the connector to MC on the
The learning switch is
base machine. turned to the stamped
3. Turn the engine learning switch to the learning mark E
position (the stamped mark E side). Learning Switch
4. Turn the key switch ON. Don’t start the engine at
this time.
5. Turn Dr. ZX switch ON.

Stamped
Mark E

T1CC-05-01-001

T5-1-15
TROUBLESHOOTING / General

Item Data
Learning Data Display
EC Motor Stop Position Don’t use
EC Motor Maximum Speed Position Don’t use
Boom Angle Sensor Correction Value Don’t use
Arm Angle Sensor Correction Value Don’t use
Parameter Change
Li Speed Adjustment Adjustment of minimum engine speed
WU Speed Adjustment Adjustment of warming up engine speed
AI Speed Adjustment Adjustment of auto-idle engine speed
E Speed Adjustment Adjustment of E-mode engine speed
P Speed Adjustment Adjustment of P-mode engine speed
Breaker Engine Speed Adjustment Adjustment of breaker operation engine speed
Secondary Crusher (Demolisher) Engine Adjustment of secondary crusher (demolisher) operation
Speed Adjustment engine speed
Crusher Engine Speed Adjustment Adjustment of crusher operation engine speed
Vibro-Hammer Speed Adjustment Adjustment of vibratory hammer operation engine speed
Hyd. Breaker P1 Max Swash Angle Adjust- Adjustment of lowest pump 1 max. flow rate in breaker
ment operation
Secondary Crusher (Demolisher) P1 Max Adjustment of lowest pump 1 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P1 Max Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in crusher opera-
tion
Vibro P1 Max Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in vibratory
hammer operation
Hyd. Breaker P2 Max Swash Angle Adjust- Adjustment of lowest pump 2 max. flow rate in breaker
ment operation
Secondary Crusher (Demolisher) P2 Max Adjustment of lowest pump 2 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P2 Max Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in crusher
operation
Vibro P2 Max Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in vibratory
hammer operation
Pump PQ Base Torque Correction Adjustment of pump P-Q curve
ATT Proportional Solenoid Valve Adjustment Adjustment of optional solenoid valve

T5-1-16
TROUBLESHOOTING / General

Item Data
Boom Lower Dampener Proportional Adjustment of solenoid valve
Solenoid Valve Adjustment
ATT Speed Increase Down Waiting Time Setting of time required for engine speed increase
ATT Torque Down ON/OFF ON/OFF of torque down control, when a front attachment is
operated.
ML Crane Front Code Change Don’t use
ML Crane Bucket Code Change Don’t use
Max. *ML Crane Speed Adjustment Don’t use
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.

T5-1-17
TROUBLESHOOTING / General
Displaying Engine Learning Data and Angle Sensor Correction Valve

Start the service software in The service software will

the service mode start in the service mode
Select Start from the Press Correct if the dis- Confirm that you are in the Select Special Function.
EPVC_Mid software menu. played model name is cor- service mode, and select
rect. Rechecked.

Fig. A T178-05-01-006 Fig. B T178-05-01-012 Fig.C T178-05-01-034 Fig. D T178-05-01-035

Select ESC to return Select ESC to return Select ESC to return
to Fig. A. to Fig. A. to Fig. A.

Select the function you Learning data items will

want to execute be displayed
The menu will be displayed. Don’t use to this mode of
Select Learning Data Display ZAXIS200-4H.
from the menu.

Fig. E T178-05-01-036
Select ESC to return
to Fig. D.

T5-1-18
TROUBLESHOOTING / General
(Blank)

T5-1-19
TROUBLESHOOTING / General
Changing Parameters In The Controller

NOTE: Start the service mode on the condition that the engine learning switch is turned on.
To change the parameter, it is necessary to enter the password. To change the password, refer to the “Changing the password”
section.

Start the service software in The service software will start in

the service mode the service mode
Select Start from the Press Correct if the displayed Confirm that you are in the Select Special Function.
EPVC_Mid software menu. model name is correct. service mode, and select Re-
checked.

Fig. A T178-05-01-006 Fig. B T178-05-01-012 Fig. C T178-05-01-034 Fig. D T178-05-01-035

Select ESC to return Select ESC to return Select ESC to return
to Fig. A. to Fig. A. to Fig. A

Execute the parameter Select a parameter change

change Enter the password
item

The menu will be displayed. Enter the password to change Select the item you want to change. The
Select Parameter Change from the parameter. up- and down-arrow buttons can be
the menu. used to scroll through the item list.

Fig. F
Fig. E T178-05-01-042
T178-05-01-043
Fig. G
Select ESC to return T178-05-01-044
Select ESC to return to Fig. E. Select ESC to return
to Fig. D. to Fig. E.

T5-1-20
TROUBLESHOOTING / General

Enter the new value Confirm the new value Parameter adjustment
result
Enter the new value in the Ad- The new value will be displayed
The adjusted value will be dis-
justment space, and press in the Adjustment space. Select
played.
Execution. Execute to change to this value.

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

Select ESC to return Select ESC to return Select ESC to return
to Fig. G. to Fig. G. to Fig. G.

T5-1-21
TROUBLESHOOTING / General
Changing The User Mode Display on The Monitor Panel

NOTE: Start the service mode on the condition that the engine learning switch is turned on.

Start the service software in The service software will start in

the service mode the service mode
Select Start from the Press Correct if the displayed Confirm that you are in the
EPVC_Mid software menu. model name is correct. service mode, and select Select Special Function.
Rechecked.

Fig. A T178-05-01-006 Fig. B T178-05-01-012 Fig. C T178-05-01-034 Fig. D T178-05-01-035

Select ESC to return Select ESC to return Select ESC to return
to Fig. A. to Fig. A. to Fig. A.

Execute the monitor display Select a display change Select Display or

change item No Display
The menu will be displayed. Select the monitor display Select Disp or No Disp.
Select Monitor Display from change item you want to exe-
the menu. cute.

Fig. E T178-05-01-042 Fig. F T178-05-01-048 Fig. G T178-05-01-049

Select ESC to return Select ESC to return Select ESC to return
to Fig. D. to Fig. E. to Fig. F.

T5-1-22
TROUBLESHOOTING / General

Confirm Disp/No Disp Confirm the result

Confirm that the Monitor space
shows Disp or No Disp. If it is It has been changed as shown
correctly displayed, select on-screen. Select ESC.
Execute.

Fig. H T178-05-01-050 Fig. I T178-05-01-051

Select ESC to return
to Fig.F. Select ESC to return to Fig. F.

T5-1-23
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 learn-
ing position, the MC will not control
the engine, pumps, and valves so
that change in the pump flow rate
and the engine speed cannot be
checked.

1. Turn the key switch OFF.

2. Wait approx. 10 seconds.
3. Turn the engine learning switch to neutral.
4. Disconnect the Dr. ZX. connector (When moni-
toring 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

Min. Adjustment Standard

Adjustment Data Adjustable Range Remarks
Value Adjustment
Li Speed 10 min-1 0 to 120 0 min-1
WU Speed 10 min-1 -120 to 120 0 min-1
AI Speed 10 min-1 -120 to 120 0 min-1
E Speed 10 min-1 -120 to 120 0 min-1
-120 to 120
P Speed 10 min-1 0 min-1
-120 to 100
-500 to 200
Breaker Speed 10 min-1 0 min-1
-500 to 100
Secondary Crusher (Demolisher) -500 to 200 200 min-1
10 min-1
Speed -500 to 100 100 min-1
-500 to 200 200 min-1
Crusher Speed 10 min-1
-500 to 100 100 min-1
-500 to 200
Vibro-Hammer Speed 10 min-1 0 min-1
-500 to 100
Hyd. Breaker P1 Max Swash Angle 0.6 cm3/rev 51 to 112.8 112.8 cm3/rev
Secondary (Demolisher) P1 Max
0.6 cm3/rev 51 to 112.8 112.8 cm3/rev
Crusher Swash Angle
Crusher P1 Max Swash Angle 0.6 cm3/rev 51 to 112.8 112.8 cm3/rev
Vibro Swash Angle 0.6 cm3/rev 51 to 112.8 112.8 cm3/rev
Hyd. Breaker P2 Max Swash Angle 0.6 cm3/rev 51 to 112.8 112.8 cm3/rev
Secondary Crusher (Demolisher)
0.6 cm3/rev 51 to 112.8 112.8 cm3/rev
P2 Max Swash Angle
Crusher P2 Max Swash Angle 0.6 cm3/rev 51 to 112.8 112.8 cm3/rev
Vibro P2 Max Swash Angle 0.6 cm3/rev 51 to 12.8 112.8 cm3/rev

T5-1-25
TROUBLESHOOTING / General

Min. Adjust- Adjustable Standard

Adjustment Data Remarks
ment Value Range Adjustment
Pump PQ Base Torque
2.45 N⋅m -78.4 to 0 0 N⋅m
Adjustment
ATT Proportional Solenoid Valve 0.1 MPa -0.89 to 0.89 0 MPa
Boom Lower Dampener
0.1 MPa -0.89 to 0.89 0 MPa
Proportional Solenoid Valve
ATT Speed Increase Down Wait
500 ms 0 to 3000 3000 ms
Time
0: ATT Torque Down
Control Activation
ATT Torque Down ON/OFF 1 digit 0 to 1 1 digit
1: ATT Torque Down
Control Deactivation
*ML Crane Front Code 1 - Don’t use
*ML Crane Bucket Code 1 - Don’t use
-
Max. *ML Crane Speed 10 min-1 - Don’t use
-
*ML Crane Bucket Weight 4 kg - Don’t use
Min Boom CYL Bottom Pressure
0.1 MPa -9.81 to 9.81 0 MPa
Over Balance

NOTE: 1 MPa=10.197 kgf/cm2

1 kgf/cm2=0.098 MPa

T5-1-26
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault
codes are displayed after diagnosing the main con-
troller (MC) using Dr. ZX (or the built-in diagnosing
system).

• How to Read Troubleshooting Flow Charts

YES(OK)
(2)
(1) After completing the checking and/or measuring procedures in box
・ (1) (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
(3)
NO(NOT OK)

Instructions, reference, and/or inspection methods and/or measurements are occasionally

・
described under the box. If incorrectly checked or measured, not only will troubleshooting
· Key switch: ON be unsuccessful but also damage to the components may result.

・ 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

T5-2-1
TROUBLESHOOTING / Troubleshooting A
FAULT CODE LIST
Fault code Problem Cause
01 Abnormal EEPROM • Faulty MC
02 Abnormal RAM
03 Abnormal A/D Conversion
04 Abnormal Sensor Voltage • Faulty MC
• Faulty Harness
• Faulty Sensor
07 Abnormal Engine Control Dial Angle • Faulty MC
• Faulty Harness
• Faulty Engine Control Dial
10 Abnormal Pump 1 Delivery Pressure • Faulty MC
11 Abnormal Pump 2 Delivery Pressure • Faulty Harness
• Faulty Pump Delivery Pressure Sensor
12 Abnormal Pump1 Pump Control Pressure • Faulty MC
13 Abnormal Pump2 Pump Control Pressure • Faulty Harness
• Faulty Pump Control Pressure Sensor
14 Abnormal Swing Lever Stroke • Faulty MC
15 Abnormal Boom Raise Lever Stroke • Faulty Harness
16 Abnormal Arm Roll-In Lever Stroke • Faulty Pilot Pressure Sensor
18 Abnormal Travel Lever Stroke
19 Abnormal Oil Temperature • Faulty MC
• Faulty Harness
• Faulty Oil Temperature Sensor

T5-2-2
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

* Even if any fault codes are still displayed after re-

trying, as long as the engine and machine operate
normally, the machine can be operated as it is.

FAULT CODE 04
(ABNORMAL SENSOR VOLTAGE)

YES Faulty sensor.

Disconnect connectors from

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

T5-2-3
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 07
(ABNORMAL ENGINE CONTROL DIAL
ANGLE)

Faulty harness be-

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

· Specification: Refer to the

table below.

Engine Control Dial Specification Connector (Harness End Connector Viewed from the
Minimum Speed 0.3 to 1.0 V Open End Side)
Maximum Speed 4.0 to 4.7 V
MC Connector C

#6
C1 C10

C23 C31

Switch Panel

#4 #3 #2

T5-2-4
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 10
(ABNORMAL PUMP 1 DELIVERY PRES-
SURE)
FAULT CODE 11
(ABNORMAL PUMP 2 DELIVERY PRES-
SURE)
Checking Instruction
• Both pump 1 and pump 2 delivery pressure sen-
sors seldom fail at the same time. Accordingly, if
both fault codes 10 and 11 are displayed simulta- Faulty harness be-
neously, faulty harness may be the cause of this Check harness between MC and pump
problem. tween MC connector C delivery pressure
(31P) harness end ter-
YES sensor.
minal #1 (pump 1) or
#4 (pump 2) and pump
YES delivery pressure sen-
sor terminal #2 for
breakage or short cir-
Faulty MC.
cuit.
Disconnect pump de- NO
livery pressure sensor.
Check if voltage be-
tween harness end
NO connector terminals #1 Broken harness be-
and #3 is 5±0.5 V. tween MC and pump
Check if voltage be- delivery pressure
Check if fault codes are tween pump delivery YES sensor terminal #3.
switched after switching pressure sensor har-
pump 1 delivery pres- ness end connector
· Key switch: ON
sure sensor with pump 2 terminal #1 and vehicle
delivery pressure sensor frame matches speci-
NO Broken harness be-
and retrying. fication. tween MC and pump
delivery pressure
NO sensor terminal #1.

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

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

MC Connector C
#1 #4
C1 C10

C23 C31

Pump Delivery Pressure Sensor

3 2 1

T5-2-5
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 12
(ABNORMAL PUMP 1 CONTROL PRES-
SURE)
FAULT CODE 13
(ABNORMAL PUMP 2 CONTROL PRES-
SURE)
Checking Instruction
• Both pump 1 and pump 2 control pressure sen-
sors seldom fail at the same time. Accordingly, if
both fault codes 12 and 13 are displayed simul-
taneously, faulty harness may be the cause of Check harness be- Faulty harness be-
this problem. tween MC connector C tween MC and pump
(31P) harness end ter- control pressure sen-
minal #7 (pump 1) or sor.
YES
#13 (pump 2) and
pump control pressure
YES sensor terminal #2 for
breakage or short cir-
cuit.

Disconnect pump con- Faulty MC.

trol pressure sensor. NO
Check if voltage be-
tween harness end
NO connector terminals #1
and #3 is 5±0.5 V. Broken harness be-
Check if voltage between MC and pump
tween pump control control pressure sen-
Check if fault codes are pressure sensor har- YES sor terminal #3.
switched after switching ness end connector
pump 1 control pressure · Key switch: ON terminal #1 and vehicle
sensor with pump 2 con- frame matches speci-
trol pressure sensor and NO fication. Broken harness be-
retrying. tween MC and pump
NO control pressure sen-
sor 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
C1 C10

C23 C31

Pump Control Pressure Sensor

1 2 3

T5-2-6
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 14
(ABNORMAL SWING PILOT PRESSURE)
FAULT CODE 15
(ABNORMAL BOOM RAISE PILOT
PRESSURE)
FAULT CODE 16
(ABNORMAL ARM ROLL-IN PILOT Check harness be-
Faulty harness be-
PRESSURE) tween MC connector C
(31P) harness end tween MC and
FAULT CODE 18 each corresponding
YES pressure sensor.
(ABNORMAL TRAVEL PILOT PRESSURE) terminal and pressure
YES sensor terminal #2 for
Checking Instruction breakage or short cir-
• All pressure sensors seldom fail at the same time. cuit. Faulty MC.
Accordingly, if fault codes 14, 15, 16, and 18 are NO
displayed simultaneously, faulty harness may be
the cause of this problem.
Connector C Terminal:
Disconnect pressure #14: Pressure Sensor (Swing)
sensor. Check if volt- #2: Pressure Sensor
NO age between harness (Boom Raise)
end connector termi- #5: Pressure Sensor
nals #1 and #3 is 5±0.5 (Arm Roll-In)
V. #3: Pressure Sensor
(Travel)
Check if fault code dis-
Broken harness be-
appears after switching
· Key switch: ON tween MC and
pressure sensor with an-
pressure sensor ter-
other pressure sensor Check if voltage be- minal #3.
and retrying. tween pressure YES
sensor harness end
connector terminal #1
and vehicle frame
NO matches specification. Broken harness be-
tween MC and
Fault Code: pressure sensor ter-
14: Pressure Sensor (Swing) NO
minal #1.
15: Pressure Sensor
(Boom Raise) · Key switch: ON
16: Pressure Sensor · Specification: 5±0.5 V
(Arm Roll-In)
18: Pressure Sensor Faulty pressure sen-
(Travel) sor.
YES

Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#2 #3 #5

C1 C10

C23 C31
#14

Pilot Pressure Sensor

1 2 3

T5-2-7
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 19
(ABNORMAL OIL TEMPERATURE)

Connect oil tempera-

ture sensor harness Faulty MC.
YES
end connector terminal
#1 to #2 with a clip.
Remove connector B
(25P) and connector C
(31P) from MC. Check Broken harness be-
Connect MC connec- tween MC and oil
YES for continuity between
tor B (25P) harness YES temperature sensor
connector B harness
end terminal #22 to terminal #1.
end terminal #22 and
vehicle frame. Check
connector C terminal
for continuity between
#24.
Disconnect oil tempera- oil temperature sen-
ture sensor. Check if NO sor harness end
sensor side connector connector terminal #2 Broken harness be-
resistance matches and vehicle frame. tween MC and oil
specification. temperature sensor
NO terminal #2.

· Specification: Refer to
the table below.
Faulty oil temperature
sensor.
NO

Oil Temperature Specification Connector (Harness End Connector Viewed from the Open End Side)
Oil Temperature Resistance
(°C) (kΩ) MC Connector B
-20 16.2±1.6 B8
B1
0 (5.88)
20 2.45±0.24
40 (1.14)
60 (0.534) B19 B25
80 0.322 #22

MC Connector C

C1 C10

C23 C31
#24

Oil Temperature Sensor

1 2

T5-2-8
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 T5-3, are
tables indicating the relationship between machine
trouble symptoms and related parts which may cause
such trouble if failed.
Start the troubleshooting with more probable causes
selected by referring to these tables.

• How to Read the Troubleshoting Flow Charts

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

(3)
NO(NOT OK)

・ • Special instructions or reference item are indicated in the spaces under the box.
Incorrect measuring or checking methods will render troubleshooting impossible,
and may damage components as well.
· Key switch: ON

・ • 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.

T5-3-1
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.
Faulty starter or faulty
YES harness between
starter and battery re-
lay.
YES Check if voltage at
battery relay terminal A
is 24 V.
Faulty battery relay.
NO
YES Check if both voltages
at key switch terminal
#5 and #6 are 24 V.
YES Faulty key switch.
· Key switch: START
Check for continuity
between battery posi-
Check if battery voltage
NO tive terminal and key
and electrolyte density is
switch terminal #1. Faulty harness be-
normal, and fusible link
tween battery and key
(40 A) is not blown. NO switch.
· Voltage: More than 24 V
Density: More than 1.26

Faulty battery or fusible

NO link.

Key Switch Battery Relay

Terminal A

T105-07-04-002
T178-05-04-001

T5-3-2
TROUBLESHOOTING / Troubleshooting B
E-2 Although starter rotates, engine doesn’t
start.

Related Fault Code: None

• Check for loose harness connections beforehand.

YES Harness open circuit

between key switch
and MC.
· Verify that fuse #6 is
Check if voltage be- normal
tween machine and
C31 terminal of con- YES Harness open circuit
nector of MC meets between key switch
specification. Disconnect connector
of ECM, and check if and ECM.
· Key switch: ON voltage between ma-
· Insert a test bar intro Check if voltage be-
chine and #24 terminal
the rear of connector. NO tween C25 terminal of
of connector of har- NO Faulty MC.
· Specification: 24 V MC’s C connector and
ness side meets speci-
machine as well as
fication.
between D16 terminal
· Key switch: ON NO of D connector and
· Specification: 24 V machine meets the
specifications. To A
YES
· Key switch: START
Insert a test bar intro
the rear of connector.
· Specification:
Between C25 terminal
and machine 3.75 V
Between D16 terminal
and machine 1 V

YES Refer to Engine

Trouble shooting
Check for continuity manual.
A between MC and ECM
Harness
Broken harness
· Between C connector’s between MC and
C25 terminal of MC and NO
ECM.
ECM connector’s #68
terminal.
· Between D connector’s
D16 terminal of MC and
ECM connector’s #63
terminal as well as #64
terminal.
Connector (Harness side)

MC
C Connector D Connector ECM #24
C1 C10

D16

C23 C31
C25 C31 T1GR-05-04-002
T183-05-04-009 #63 #64 #68

T5-3-3
TROUBLESHOOTING / Troubleshooting B
E-3 Operating with engine control dial turned to
maximum will cause engine failure.
Engine’s speed is low when operated with
engine control dial turned to maximum.

Related Fault Code: None

• Check for loose harness connections beforehand.

YES Refer to Engine

Trouble Shooting
manual.
Check if voltage between C25
terminal of MC’s C connector
and machine as well as be-
tween D16 terminal of D con- YES Faulty MC.
nector and machine meets the
specifications.
Check for continuity between
· Insert a test bar into the rear NO MC and ECM Harness
of connector.
· Specification: · Between C connector’s C25
Broken harness be-
Engine Control Dial: Full terminal of MC and ECM
NO tween MC and ECM.
Between C25 terminal and connector’s #68 terminal.
machine 3.75 V · Between D connector’s D16
Between D16 terminal and terminal of MC and ECM
machine connector’s #63 terminal as
About 2.76 V well as #64 terminal.
(P mode Lever neutral)
About 2.96 V
(P mode Lever operated)
3.35 V (HP mode)

Connector (Harness side)

MC
C Connector D Connector ECM
C1 C10

D16

C23 C31
C25 T1GR-05-04-002
T183-05-04-009 #63 #64 #68

T5-3-4
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

YES broken harness between en-
gine control dial and MC.

Check if fault code 07 is dis-

played. Using Dr. ZX, monitor
engine control dial angles
(standard voltages). Check if YES Refer to Engine Trouble
voltages are normal. Check if voltage between C25 Shooting manual.
terminal of MC’s C connector
· Standard voltages
and machine as well as be-
Slow idle position: 0.3 to 1 V
NO tween D16 terminal of D con-
Fast idle position: 4.0 to 4.7 V
nector and machine meets the
· Possible to display with built-in
specifications.
diagnosing system. To A
NO
· Insert a test bar into the rear of
connector.
· Specification:
Engine Control Dial : Min to Max
Between C25 terminal and machine
3.75 V
Between D16 terminal and machine
1 to 2.76 V

YES Faulty MC.

Check for continuity between

A MC and ECM Harness.
NO
· Between C connector’s C25 termi- Broken harness between MC
nal of MC and ECM connector’s NO and ECM
#68 terminal
· Between D connector’s D16 termi-
nal of MC and ECM connector’s
#63 terminal as well as #64 terminal

Connector (Harness side)

MC
C Connector D Connector ECM
C1 C10

D16

C23 C31
C25 T1GR-05-04-002
T183-05-04-009 #63 #64 #68

T5-3-5
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 Con-

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

More than 0 °C
when starting Normal.

NO Monitor oil tempera-

ture.
· Monitor item: Hydraulic oil
temperature
· Possible to display with
built-in diagnosing system Faulty key switch or
Monitor key switch. YES broken harness be-
Check if displayed tween key switch and
“ky” is highlighted in MC.
Lower than 0 °C response to key
Check if fault code when starting switch operation.
19 is displayed. To A
· Monitor item: Key NO
switch

Faulty hyd. oil tem-

perature sensor or
broken harness be-
YES tween oil temperature
sensor and MC.

T5-3-6
TROUBLESHOOTING / Troubleshooting B

NO Faulty MC.
Check if voltage between
C25 terminal of MC’s C
connector and machine as
A well as between D16 ter-
minal of connector and YES Refer to Engine Trou-
machine meets the speci- ble Shooting manual.
fications. Check for continuity
between MC and
· Insert a test bar into the rear YES ECM Harness.
of connector. Broken harness be-
· Specification: · Between C connector’s tween MC and ECM.
NO
Between C25 terminal and C25 terminal of MC and
machine 3.75 V ECM connector’s #68
Between D16 terminal and terminal
machine About 1.88 V · Between D connector’s
D16 terminal of MC and
ECM connector’s #63
terminal as well as #64
terminal

Connector (Harness side)

MC
C Connector D Connector ECM
C1 C10

D16

C23 C31
C25 T1GR-05-04-002
T183-05-04-009 #63 #64 #68

T5-3-7
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 sen- SYSTEM / Control System group in the T/M (Op-
sor fails, the HP mode becomes inoperable. erational Principle).
• Pressure sensors (arm roll-in and boom raise) • Check for loose harness connections beforehand.
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.

Faulty power mode

NO switch or broken
harness between
power mode switch
Monitor power mode and MC.
switch. Check if indica-
NO tion HP is highlighted
when power mode
switch is turned to “HP Check if voltage be-
tween C25 terminal of YES Refer to Engine Trou-
mode”.
MC’s C connector and ble Shooting manual.
· Monitor item: E/P/HP machine as well as
mode switch between D16 terminal
YES of D connector and
machine meets the
Check if any fault To A
specifications. NO
codes are displayed.
· Insert a test bar into
the rear of connector.
· Specification:
Between C25 terminal
and machine 3.75 V
Between D16 terminal
and machine 3.35 V Faulty corresponding
sensor or broken
YES harness between
sensor and MC.

· 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

T5-3-8
TROUBLESHOOTING / Troubleshooting B

YES Faulty MC.

Check for continuity between

A MC and ECM Harness
· Between C connector’s C25 terminal Broken harness be-
of MC and ECM connector’s #68 NO tween MC and ECM.
terminal
· Between D connector’s D16 terminal
of MC and ECM connector’s #63
terminal as well as #64 terminal

Connector (Harness side)

MC
C Connector D Connector ECM
C1 C10

D16

C23 C31
C25 T1GR-05-04-002
T183-05-04-009 #63 #64 #68

T5-3-9
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 har-

YES
ness between MC and
power mode switch.

NO Broken harness be-

Monitor the power
Check for continuity tween MC and ECM.
mode switch. Check YES
if “HP” is displayed. between MC and ECM
Harness.
· Monitor item: E/P/HP Refer to Engine Trou-
mode switch Check if voltage be- · Between C connector’s YES ble Shooting manual.
· Power mode switch: tween C25 terminal of C25 terminal of MC and
P mode MC’s C connector and ECM connector’s #68
machine as well as be- terminal
NO tween D16 terminal of D · Between D connector’s
connector and machine D16 terminal of MC and
meets the specifications. ECM connector’s #63
terminal as well as #64
· Insert a test bar into the terminal
rear of connector. Faulty MC.
· Specification: NO
Between C25 terminal
and machine 3.75 V
Between D16 terminal
and machine 3.35 V

Connector (Harness side)

MC
C Connector D Connector ECM
C1 C10

D16

C23 C31
C25 T1GR-05-04-002
T183-05-04-009 #63 #64 #68

T5-3-10
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: 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.

T5-3-11
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 trou- SYSTEM / Control System group in the T/M (Op-
bles beforehand. erational Principle).
• Although the failure in pressure sensors (travel • Check for loose harness connections beforehand.
and front attachment) will have relevance to mal-
function of the auto-idle control. However, if these
sensors fail, other operating functions will also be
affected.
Normal (Turn power
YES mode switch to a posi-
tion other than the E
mode.)

Check if power mode

YES
switch is in the E mode
position. Bound swing parking
YES brake release spool in
the signal control
valve.
Monitor the pressure
sensor (front).
NO Check if “ON” is dis-
Monitor auto-idle switch. played.
Check if displayed “AI” is
turned OFF or ON in re- · Engine: Running
To A
sponse to auto-idle / NO
auto- acceleration se-
lector operation.

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

T5-3-12
TROUBLESHOOTING / Troubleshooting B

NO Refer to Engine Trou-

Check if voltage between ble Shooting manual.
C25 terminal of MC’s C
connector and machine as
A well as between D16 ter-
minal of D connector and YES Faulty MC.
machine meets the speci-
fications. Check for continuity
between MC and ECM
· Insert a test bar into the rear YES Harness.
of connector. Broken harness be-
· Specification: · Between C connector’s tween MC and ECM.
NO
Between C25 terminal and C25 terminal of MC and
machine 3.75 V ECM connector’s #68
Between D16 terminal and terminal
machine About 1.78 V · Between D connector’s
D16 terminal of MC and
ECM connector’s #63
terminal as well as #64
terminal

Connector (Harness side)

MC
C Connector D Connector ECM
C1 C10

D16

C23 C31
C25 T1GR-05-04-002
T183-05-04-009 #63 #64 #68

T5-3-13
TROUBLESHOOTING / Troubleshooting B
• 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.

Short circuited harness

YES between MC and auto-idle
/ auto-acceleration selec-
tor.

Monitor auto-idle /
auto-acceleration selector.
Check if “AI” is displayed.
Check if voltage between C25 YES Faulty MC.
· Monitor item: Auto-idle / terminal of MC’s C connector
auto-accel switch and machine as well as be-
· Auto-idle / auto-acceleration tween D16 terminal of D con-
selector: OFF NO
nector and machine meets the
specifications. To A
NO
· Insert a test bar into the rear
of connector.
· Specification:
Between C25 terminal and
machine 3.75 V
Between D16 terminal and
machine About 1.78 V

YES Refer to Engine Trouble

Shooting manual.
Check for continuity between
A MC and ECM Harness
· Between C connector’s C25 Broken harness between
terminal of MC and ECM NO MC and ECM.
connector’s #68 terminal
· Between D connector’s D16
terminal of MC and ECM
connector’s #63 terminal as
well as #64 terminal

Connector (Harness side)

MC
C Connector D Connector ECM #24
C1 C10

D16

C23 C31
C25 T1GR-05-04-002
T183-05-04-009 #63 #64 #68

T5-3-14
TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-3-15
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 recog-

nized, perform the troubleshooting of these trou-
bles beforehand.
• Refer to the pages for E Mode Control in the
SYSTEM / Control System group in the T/M (Op-
erational Principle).
• Check for loose harness connections beforehand.

Faulty power mode switch or

NO
broken harness between
Monitor power mode switch. power mode switch and MC.
Check if displayed “E Mode”
is turned OFF or ON in re-
YES Refer to Engine Trouble
sponse to power mode switch Check if voltage between C25
operation. terminal of MC’s C connector and Shooting manual.
machine as well as between D16
· Monitor item: YES terminal of D connector and ma-
E/P/HP mode switch chine meets the specifications.
To A
· Insert a test bar into the rear of NO
connector.
· Specification:
Between C25 terminal and machine
3.75 V
Between D16 terminal and machine
About 2.57 V

YES Faulty MC.

Check for continuity between MC

A and ECM Harness.
· Between C connector’s C25 termi- Broken harness between
nal of MC and ECM connector’s #68 NO MC and ECM.
terminal
· Between D connector’s D16 termi-
nal of MC and ECM connector’s #63
terminal as well as #64 terminal

Connector (Harness side)

MC
C Connector D Connector ECM
C1 C10

D16

C23 C31
C25 T1GR-05-04-002
T183-05-04-009 #63 #64 #68

T5-3-16
TROUBLESHOOTING / Troubleshooting B
• Although power mode switch isn’t turned into E
mode, engine speed decrease.

Short circuited harness be-

YES
tween MC and power mode
switch.
Monitor power mode switch.
Check if “E” is displayed. YES Faulty MC.
Check if voltage between C25
· Monitor item: E/P/HP switch terminal of MC’s C connector and
· Power mode switch: P mode machine as well as between D16
NO terminal of D connector and ma-
chine meets the specifications.
To A
NO
· Insert a test bar into the rear of
connector.
· Specification:
Between C25 terminal and machine
3.75 V
Between D16 terminal and machine
About 2.57V

YES Refer to Engine Trouble

Shooting manual.
Check for continuity between MC
A and ECM Harness.
· Between C connector’s C25 termi- Broken harness between
nal of MC and ECM connector’s #68 NO MC and ECM.
terminal
· Between D connector’s D16 termi-
nal of MC and ECM connector’s #63
terminal as well as #64 terminal

Connector (Harness side)

MC
C Connector D Connector ECM
C1 C10

D16

C23 C31
C25 T1GR-05-04-002
T183-05-04-009 #63 #64 #68

T5-3-17
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 trou- in the SYSTEM / Control System group in the T/M
bles beforehand. (Operational Principle).
• Although the failure in pressure sensors (travel,
swing, boom raise, and arm roll-in), pump 1 and 2
delivery pressure sensors, and pump 1 and 2
control pressure sensors will have relevance to
malfunction of the auto-acceleration control.
However, if these sensors fail, other operating
functions will also be affected.
Faulty auto-idle /
auto-acceleration selector or
NO broken harness between
auto-acceleration switch and
Monitor auto-idle / MC.
auto-acceleration selector.
Check if displayed “AA” is
YES Refer to Engine Trouble
turned OFF or ON in re- Check if voltage between C25
sponse to auto-acceleration terminal of MC’s C connector and Shooting manual.
switch operation. machine as well as between D16
YES terminal of D connector and ma-
· Monitor item:
chine meets the specifications.
Auto-idle/auto-accel switch To A
NO
· Insert a test bar into the rear of
connector.
· Specification:
Between C25 terminal and machine
3.75 V
Between D16 terminal and machine
About 2.16 to 2.96 V
(It changes according to lever’s op-
erating pressure.)
YES Faulty MC.

Check for continuity between MC

A and ECM Harness
· Between C connector’s C25 termi- Broken harness between
nal of MC and ECM connector’s #68 NO MC and ECM.
terminal
· Between D connector’s D16 termi-
nal of MC and ECM connector’s #63
terminal as well as #64 terminal

Connector (Harness side)

MC
C Connector D Connector ECM
C1 C10

D16

C23 C31
C25 T1GR-05-04-002
T183-05-04-009 #63 #64 #68

T5-3-18
TROUBLESHOOTING / Troubleshooting B
• Although auto-idle / acceleration selector is turned
OFF, the auto-idle acceleration control is operated.

• Be sure to separate the auto-idle control from the

auto-acceleration control.

Short circuited harness be-

YES tween MC and auto-idle /
auto-acceleration selector.
Monitor auto-idle / accelera-
tion selector.
Check if “AA” is displayed. Check if voltage between C25 NO Faulty MC.
terminal of MC’s C connector and
· Monitor item: Auto-idle / machine as well as between D16
auto-accel switch NO terminal of D connector and ma-
· Auto-idle / auto-acceleration chine meets the specifications.
selector: To A
YES
Auto-idle position · Insert a test bar into the rear of
connector.
· Specification:
Between C25 terminal and machine
3.75 V
Between D16 terminal and machine
About 2.16 to 2.96 V
(It changes according to lever’s op-
erating pressure.)
YES Refer to Engine Trouble
Shooting manual.
Check for continuity between MC
A and ECM Harness.
· Between C connector’s C25 termi- Broken harness between
nal of MC and ECM connector’s #68 NO MC and ECM.
terminal
· Between D connector’s D16 termi-
nal of MC and ECM connector’s #63
terminal as well as #64 terminal

Connector (Harness side)

MC
C Connector D Connector ECM
C1 C10

D16

C23 C31
C25 T1GR-05-04-002
T183-05-04-009 #63 #64 #68

T5-3-19
TROUBLESHOOTING / Troubleshooting B
E-11 When traveling or operating front attach-
ment with engine running at slow idle, en-
gine hunts.

Related Fault Code: 18

• Although the failure in pressure sensors (travel

and front attachment) will have relevance to mal-
function of the engine speed increase control.
However, if these sensors fail, other operating
functions will also be affected.
• Refer to the pages for Idle Speed-Up Control in
the SYSTEM / Control System group in the T/M
(Operational Principle).

YES Faulty engine.

· Refer to the Engine

Shop Manual.
Check if engine speed
is faster than in- Refer to Engine
creased idle speed. YES Trouble Shooting
· Monitor item: Check if voltage be- manual.
Engine target speed tween C25 terminal of
· Possible to display MC’s C connector and
with built-in diagnosing machine as well as be-
NO YES Faulty MC.
system tween D16 terminal of D
connector and machine Check for continuity
meets the specifications. between MC and ECM
· Insert a test bar into the NO Harness.
rear of connector. Broken harness
· Specification: · Between C connector’s between MC and
C25 terminal of MC and NO ECM.
Between C25 terminal and
machine 3.75 V ECM connector’s #68
Between D16 terminal and terminal
machine About 1.78 V · Between D connector’s
D16 terminal of MC and
ECM connector’s #63
terminal as well as #64
terminal

Connector (Harness side)

MC
C Connector D Connector ECM
C1 C10

D16

C23 C31
C25 T1GR-05-04-002
T183-05-04-009 #63 #64 #68

T5-3-20
TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-3-21
TROUBLESHOOTING / Troubleshooting B
E-12 Engine speed doesn’t increase even if at-
tachment 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 trou- Speed Increase Control in the SYSTEM / Control
bles beforehand. System group in the T/M (Operational Principle).
• Although the failure in pressure sensor (auxiliary) • Check for loose harness connections beforehand.
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.

NO Normal (Set to “In-

crease (+)”.)
Check if attachment
speed adjustment
NO
has been set to “In-
crease (+)” in Dr. ZX YES
Monitor attachment To A
service mode.
pilot pressure. Check
if pressure varies in
YES response to lever
Check if P speed Faulty auxiliary pres-
adjustment has been stroke. sure sensor.
set to “Decrease” in · Monitor item: Att. con- NO
Dr. ZX service mode. trol pilot pressure

Normal (If set to “De-

crease”, this control
system is deacti-
YES
vated.)

Check if voltage be-

YES Faulty MC.
tween C25 terminal of
MC’s C connector and
YES machine as well as
between D16 terminal
of D connector and
machine meets the To B
specifications. NO
Monitor work mode
switch. Check if dis- · Insert a test bar into the
A play switches in re- rear of connector.
sponse to work mode · Specification:
switch operation. Between C25 terminal and
machine 3.75 V
· Monitor item: Between D16 terminal and
Work mode switch machine More than 3.35 V
Faulty work mode
NO switch.

T5-3-22
TROUBLESHOOTING / Troubleshooting B

YES Refer to Engine Trou-

ble Shooting manual.
Check for continuity between
B MC and ECM Harness.
· Between C connector’s C25 termi- Broke harness be-
nal of MC and ECM connector’s NO tween MC and ECM.
#68 terminal
· Between D connector’s D16 termi-
nal of MC and ECM connector’s
#63 terminal as well as #64 terminal

Connector (Harness side)

MC
C Connector D Connector ECM
C1 C10

D16

C23 C31
C25 T1GR-05-04-002
T183-05-04-009 #63 #64 #68

T5-3-23
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 recog-

nized, perform the troubleshooting of these trou-
bles beforehand.
• Refer to the pages for Attachment Operation
Speed Limit Control in the SYSTEM / Control
System group in the T/M (Operational Principle).
• Check for loose harness connections beforehand.
Check if voltage between
C25 terminal of MC’s C Refer to Engine
YES Trouble Shooting
connector and machine
as well as between D16 manual.
YES
terminal of D connector
and machine meets the
specifications. To A
NO
Monitor work mode · Insert a test bar into the
switch. Check if dis- rear of connector.
YES
play switches in re- · Specification:
sponse to work mode Between C25 terminal and
switch operation. machine 3.75 V
Check if attachment · Monitor item: Between D16 terminal and
speed adjustment has Work mode switch machine Less than 3.35 V Faulty work mode
been set to “Decrease switch.
NO
(-)” in Dr. ZX service
mode.

Normal (Set to “In-

NO crease (+)”.)

YES Faulty MC.

A Check for continuity between MC

and ECM Harness
Broken harness be-
· Between C connector’s C25
NO tween MC and ECM.
terminal of MC and ECM
connector’s #68 terminal
· Between D connector’s D16
terminal of MC and ECM
connector’s #63 terminal as
well as #64 terminal

Connector (Harness side)

MC
C Connector D Connector ECM
C1 C10

D16

C23 C31
C25 T1GR-05-04-002
T183-05-04-009 #63 #64 #68

T5-3-24
TROUBLESHOOTING / Troubleshooting B
E-14 Engine stalls within several seconds after
engine has started.

Related Fault Code: None

• Refer to Engine Trouble Shooting manual.

T5-3-25
TROUBLESHOOTING / Troubleshooting B
E-15 Engine stalls during operation under ad-
verse condition such as at high altitude.

Related Fault Code: 05 Parts Number (ST 7226)

• If speed-sensing control is inoperable, the engine When the corresponding control lever or switch is
will stall under adverse operating conditions. operated: Lamp is ON.
• Check for loose harness connections beforehand.

4
3
50

150 50 50
1 2 2 1

T107-07-06-015

Disconnect torque con-

trol solenoid valve. Con-
NO nect test harness (ST
Monitor torque control sole-
7226) between solenoid To A
noid valve output. Install
valve and harness.
pressure gauge to output port
Check if test harness
so that pressure can be
NO lamp comes ON.
measured by pressure gauge
and Dr. ZX. Check if both
measured pressure values by
pressure gauge and Dr. ZX
vary identically. Disassemble to check
YES regulator.
Monitor actual engine · Monitor item: Pump torque
speed. Check if engine proportional solenoid valve
speed is abnormal. output
· Refer to the Operational Per-
· Monitor item: formance Test section.
Engine actual speed

Faulty N sensor, or faulty

harness between N
YES sensor and MC.

YES Faulty torque control so-

lenoid valve.

A
Broken harness between
torque control solenoid
NO valve and MC.

T5-3-26
TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-3-27
TROUBLESHOOTING / Troubleshooting B
E-16 Engine is difficult to start at low tempera-
ture. (During cold weather or in cold dis-
tricts, the engine is difficult to start or
doesn’t start although pre-heated.)

Related Fault Code: None

• Check if electricity is routed to the glow plugs. • Check battery at the same time.
Check the glow plugs for any abnormality. • Check for loose harness connections beforehand.
• 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.

YES Faulty coolant temperature

sensor.

Disconnect coolant tempera-

ture sensor. Check if voltage at
glow plug is 20 to 24 V. YES Faulty ECM.
· Key switch: ON
Disconnect ECM. Ground har-
ness end connector terminal #4
NO to machine. Check if problem is
corrected.
· Using a clip, ground from the Measure each glow plug re-
reverse side of the connector sistance.
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 Ω

T105-07-04-006 T105-07-04-007

T5-3-28
TROUBLESHOOTING / Troubleshooting B

∞Ω Faulty glow plug.

Faulty engine unit, faulty glow

NO plug relay, or broken harness
between glow plug relay and
Disconnect glow plug re- glow plug.
YES lay. Connect harness end
connector terminal #4 to
machine. Check if voltage
is 20 to 24 V.
Broken harness between
· Key switch: ON glow plug relay and ECM.
YES
Disconnect glow plug re-
lay. Check if voltage at
glow plug relay harness
Below 10 Ω end connector terminals
#1 or #3 is 20 to 24 V.
· Key switch: ON
In case voltage at terminal #1
is 0 V, broken harness be-
tween glow relay and batter-
ies. In case voltage at termi-
NO nal #3 is 0 V, broken harness
between glow relay and key
switch terminal M.
· Verify that fuse #19 is normal.

T5-3-29
TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-3-30
MEMO

.......................................................................................................................................................................

.......................................................................................................................................................................
MEMO

.......................................................................................................................................................................

.......................................................................................................................................................................
SECTION 1
UPPERSTRUCTURE

 CONTENTS 
Group 1 Pump Device
Remove and Install Pump Device................W1-1-1
Disassemble Pump Device..........................W1-1-2
Assemble Pump Device.............................W1-1-10
Disassemble Regulator..............................W1-1-22
Assemble Regulator ..................................W1-1-24
Disassemble Solenoid Valve .....................W1-1-26
Assemble Solenoid Valve ..........................W1-1-28
Disassemble and Assemble Pilot
Pump ........................................................W1-1-30
Maintenance Standard...............................W1-1-32

1GRW-1-1
(Blank)

1GRW-1-2
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE
1 2 3 4 5
IMPORTANT: Release any pressure in the hydrau-
lic oil tank before doing any work.
12
Removal
1. Disconnect connectors (4 places).
11
CAUTION: Pump device weight: 170 kg
(375 lb)

2. Disconnect hoses (1 to 4 and 6, 7, 9 to 12) and

pipe (8) from the pump device.
: 19 mm, 27 mm, 36 mm
: 8 mm, 10 mm
6
IMPORTANT: Do not install the eyebolt to the
regulator which is with solenoid 10 9 8 7 W178-02-04-053

valve.

3. Attach eyebolts (M12, Pitch 1.75) (ST 0002) to the

pump device, then hold it by crane. Eyebolt Mounting
Position
4. Remove pump device mounting bolts (5) (8 used)
to remove the pump device.
: 17 mm

Installation
1. Install eyebolt (M12, Pitch 1.75) (ST 0002) on the
pump device and lift by crane.
2. Insert the drive shaft of pump device into the
pump mission, and install it with pump device
mounting bolts (5) (8 used).
: 17 mm
: 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)
3. Connect hoses (1 to 4 and 6, 7, 9 to 12) and pipe
(8).
4. Connect connectors.
Wrench size Tightening torque W178-02-04-019
Remark
(mm) N⋅m kgf⋅m(Ibf⋅ft)
: 27 93 9.5 (69) Hose
: 36 175 18 (130) Hose
: 10 90 9.2 (67) Bolt
: 17 50 5.1 (37) Bolt
:8 50 5.1 (37) Bolt
: 19 29.5 3 (21.5) Hose

IMPORTANT: Bleed the air from the pump.

Be sure to check hydraulic oil level,
and any oil leaks, after assembling.
: 27 mm
: 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)

W1-1-1
UPPERSTRUCTURE / Pump Device
DISASSEMBLE PUMP DEVICE
4
3 5
1 2
17
16
15
14
18
13
6
12
11
10
9
56
7

55
8 17
54 16
14
53 15
52 19

12
51
20
11
49 10
9

21
22
23
50 24
49 21
48 22
28

27
26
25
47

33
35
29
46 26
45 34
36
37
32 38
31 30
39
40
41
42
43
44 W178-02-04-004
42

W1-1-2
UPPERSTRUCTURE / Pump Device

68
69
70
67
67
66
71

65
64
63

60 61 72
58 62 61 74
58 73

58 61
59
78 77 61 75
60
57 76
58 68
59
58 78
58
79

57
58

79 W178-02-04-005

1- Socket Bolt (4 Used) 21 - O-Ring (2 Used) 41 - Retaining Ring 61 - Pin (4 Used)

2- Right Regulator 22 - Plug (2 Used) 42 - Ball Bearing (2 Used) 62 - Right Valve Plate
3- Socket Bolt (2 Used) 23 - O-Ring 43 - Gear 63 - Backup Ring
4- Socket Bolt (2 Used) 24 - Stopper 44 - Gear Shaft 64 - O-Ring
5- Socket Bolt (2 Used) 25 - Plug 45 - Retaining Ring 65 - Spring Pin (2 Used)
6- Left Regulator 26 - Retaining Ring (2 Used) 46 - Oil Seal 66 - Selector Head
7- O-Ring (4 Used) 27 - Gear 47 - Gear Casing 67 - O-Ring (4 Used)
8- O-Ring (6 Used) 28 - Gasket 48 - Spring Pin (2 Used) 68 - Socket Bolt (16 Used)
9- Bearing Nut (2 Used) 29 - Gear 49 - Oil Seal (2 Used) 69 - Stopper S (2 Used)
10 - Bearing (2 Used) 30 - Plug 50 - Retaining Ring (2 Used) 70 - O-Ring (2 Used)
11 - Ring (2 Used) 31 - O-Ring 51 - Pump Casing 71 - Socket Bolt (12 Used)
12 - Bearing (2 Used) 32 - Gasket 52 - Spring Washer (6 Used) 72 - Set Screw (2 Used)
13 - Shaft 33 - Socket Bolt (2 Used) 53 - Bolt (6 Used) 73 - Servo Piston (2 Used)
14 - Pin (2 Used) 34 - Pipe 54 - Spring Pin (2 Used) 74 - Pin (2 Used)
15 - Center Shaft (2 Used) 35 - Level Gauge 55 - O-Ring (2 Used) 75 - O-Ring (2 Used)
16 - Spring (2 Used) 36 - Socket Bolt (2 Used) 56 - O-Ring (2 Used) 76 - Stopper L (2 Used)
17 - Plunger (14 Used) 37 - Spring Washer (2 Used) 57 - Pin (2 Used) 77 - Left Valve Plate
18 - Rotor (2 Used) 38 - Washer (2 Used) 58 - Retaining Ring (12 Used) 78 - Pin (4 Used)
19 - Shaft 39 - Pilot Pump 59 - Pin (2 Used) 79 - Link (2 Used)
20 - Slide Ring 40 - Retaining Ring 60 - Lever (4 Used)

W1-1-3
UPPERSTRUCTURE / Pump Device

4
3 5
1 2

68
6 69

66
71

25
47

33 35

34 36

32
30
39

W178-02-04-010

W1-1-4
UPPERSTRUCTURE / Pump Device
1. Remove plug (25) from gear casing (47). 8. Remove socket bolts (71) (12 used) from selector
: 17 mm head (66).
2. Remove plug (30) from gear casing (47) to drain : 10 mm
gear oil. (Approx 1.0 L, 0.2642 US gal)
: 22 mm NOTE: When loosening the socket bolts, the se-
3. Remove socket bolts (1) (4 used) to remove right lector head will jump out due to the force of
regulator (2) from pump casing (51). spring (16). Be sure to record the clearance
: 8 mm between pump casing (51) and the selector
head to ensure the internal parts of pump
NOTE: Pry up the right regulator to the selector casing is in correct position when reas-
head (66) side for easy removal. sembling.

4. Remove socket bolts (3) (2 used) and (5) (2 used),

CAUTION: Selector head weight: 28 kg
remove left regulator (6) from pump casing (51).
Socket bolts (4) are used to install the solenoid (60 lb)
valve, don’t remove it.
9. Install eyebolt (M12, pitch 1.75) to the bolt hole on
NOTE: Pry up the left regulator to selector head the top of selector head (66), lift it by crane and
(66) side for easy removal. remove the selector head from pump casing (51).
: 8 mm At this time, the O-ring is removed with the lower
surface of the selector head. Remove it before
setting down.
CAUTION: Pump device weight: 160 kg
(350 lb) 10. Remove socket bolts (68) (16 used) from selector
head (66), remove stopper S (69) and stopper L
CAUTION: When lifting, don’t take pump (76). (2 places)
casing (51) off the ground. Turn it to the gear : 6 mm
casing (47) side.
NOTE: O-rings (70) and (75) is attached on stop-
5. Install eyebolt (M10, Pitch 1.5) to the threaded
per S (69) and stopper L (76).If they are
hole for socket bolts (1) and (3) of pump casing
assembled too tightly to remove, tap the
(51), lift it up by crane, position the pump device
outer periphery of the stopper to the position
with gear casing (47) facing down. At this time,
where about half of the hole for the mounting
place 80 mm square wooden blocks under the
bolt can be seen. Turn the stopper, insert a
gear casing.
screwdriver into the mounting bolt hole to
6. Remove socket bolts (33) (2 used) from gear
pry the stopper for easy removing.
casing (47), remove level gauge (35), pipe (34)
and gasket (32).
: 6 mm
7. Remove socket bolt (36) from gear casing (47),
remove pilot pump (39). Stopper
: 8 mm

NOTE: THREEBOND has been applied to the

mounting surface of the pilot pump, tap the
flange of the pilot pump along the periphery
with a plastic hammer lightly and then re-
move it.

W178-02-04-055

W1-1-5
UPPERSTRUCTURE / Pump Device

18
17
16
15
13

17
53 15
19
51

27
26

66 71
47

29 64
26 63

60 72
61
58 62
61 73
74
58
61
77
78 61

78
79 58
60

79 W178-02-04-011

W1-1-6
UPPERSTRUCTURE / Pump Device
11. Remove set screw (72) out of servo piston (73), 17. Remove bolts (53) (6 used) from gear casing (47).
then remove pins (74). (2 places) : 24 mm

NOTE: LOCTITE has been applied to the set CAUTION: Pump casing weight: 105 kg
screw. Heat it with a drier etc. for easy re- (230 lb)
moval.
: 6 mm 18. Install eye bolt (M12, Pitch 1.75) to the threaded
hole for socket bolt (71) of pump casing (51), lift it
12. Pull out servo piston (73) from selector head (66). up by crane, remove the pump casing from gear
(2 places) casing (47). At this time, shafts (13) and (19),
gears (27), (29) and etc. are removed with the
13. Remove backup ring (63) and O-ring (64) from pump casing.
pump casing (51). Place the pump casing with the mounting surface
of the regulator facing up.
IMPORTANT: Both valve plates (62, right), (77, left)
are very similar. Their installation 19. Remove gasket (28) from gear casing (47).
direction are determined. Record
their position and direction before IMPORTANT: The position where the gears en-
disassemble. gaging is determined. Make aligning
marks on the gears for easy reas-
14. Remove retaining rings (58) (8 used) from pins sembling.
(61) (4 used) and (78) (4 used) to remove levers
(60) (4 used) and valve plates (62, right) and (77, 20. Make aligning marks on meshed position of
left) from links (79) (2 used). splines on shafts (13) (19) and gears (27) (29).
And make aligning marks on meshed position of
NOTE: Pin (61) has been attached on valve plates gears (27) and (29).
(62) and (77) with LOCTITE. Do not re-
move it unless necessary. 29
27
15. Remove rotor (18), spring (16), center shaft (15)
and plunger (17) from pump casing (51) in order.
(Both right and left)

NOTE: When remove the plunger, turn over the

plunger inside and pull it out. 13 19

W137-02-04-007
IMPORTANT: If link (79) is distorted, the pump
performance will be changed. Don’t
21. Remove retaining rings (26) from shafts (13) and
apply excess loads.
(19), and then remove gears (27) and (29).

16. Remove the two link (79) assemblies from pump

casing (51). Don’t disassemble the link assembly CAUTION: Pump casing weight: 70 kg (154 lb)
unless necessary.
22. Attach a nylon sling to pump casing (51), lift it up
and position selector head (66) with the mounting
NOTE: If it is difficult to remove, tap the two roots
side facing down.
of the link lightly with a plastic hammer.

W1-1-7
UPPERSTRUCTURE / Pump Device

12
11
10
9

12
51
20
11
49 10
9

50 24
49

46
45

40
41
42
43
44 W178-02-04-004
42

W1-1-8
UPPERSTRUCTURE / Pump Device
22. Remove stopper (24) from pump casing (51). 27. Remove bearings (10) and (12) as well as ring
(11) from shafts (13) and (19) with a press.
CAUTION: Pump casing weight: 70 kg (154 lb)
CAUTION: Pump casing weight: 42 kg (93 lb)
23. Attach a nylon sling to pump device (51), lift it up
and place the pump casing on the wooden blocks 28. Attach a nylon sling to pump casing (51), lift it up
with mission side facing down. Wooden block by crane and position the regulator with the
size: 100 mm or more in width and height. mounting surface facing up.

24. Remove shafts (13) and (19) from pump casing 29. Remove retaining rings (50) (2 used), oil seals
(51) with special tool (ST 1470) (ST 1471). At this (49) (2 used) from pump casing (51).
time, bearings (10) and (12) are removed with the
shafts. 30. Remove retaining ring (40) from gear casing (47)
and remove retaining ring (41) from gear shaft
Special Tool
ST 1470 (44).
Special Tool
ST 1471 31. Pull out upper ball bearing (42) and gear shaft
(44) from gear casing (47) using special tool (ST
13 1393).

44
51

W178-02-04-054

25. Remove slide ring (20) from shaft (19).

26. Remove bearing nut (9) from shafts (13) and (19) W178-02-04-009

using special tool (ST 3058).

32. Remove gear (43) and ball bearing (42) from gear
ST 3058 casing (47).

9 33. Install a shackle to the bolt hole on the periphery

of gear casing (47), lift it up with a rope and turn it
over.

34. Remove retaining ring (45), oil seal (46) from gear
casing (47).

W137-02-04-023

W1-1-9
UPPERSTRUCTURE / Pump Device
ASSEMBLE PUMP DEVICE
77 64 63 18 16 15 17 12 20 11 10 9 49 29

13
26

62 58,61 60 18 78 16 15 17 12 11 9 49
10
68 69 67 70 8 7 54 55 59 58
57 56 51

76 79 14 24 23
21
65 22 W178-02-04-003

75
68

W1-1-10
UPPERSTRUCTURE / Pump Device

32, 33, 34
30, 31 39 36, 37, 38 25 6 5 4 35 3 41 40 43 42

47
W178-02-04-002

71 2 1 53 52 28

1- Socket Bolt (4 Used) 21 - O-Ring (2 Used) 41 - Retaining Ring 61 - Pin (4 Used)

2- Right Regulator 22 - Plug (2 Used) 42 - Ball Bearing (2 Used) 62 - Right Valve Plate
3- Socket Bolt (2 Used) 23 - O-Ring 43 - Gear 63 - Backup Ring
4- Socket Bolt (2 Used) 24 - Stopper 44 - Gear Shaft 64 - O-Ring
5- Socket Bolt (2 Used) 25 - Plug 45 - Retaining Ring 65 - Spring Pin (2 Used)
6- Left Regulator 26 - Retaining Ring (2 Used) 46 - Oil Seal 66 - Select Head
7- O-Ring (4 Used) 27 - Gear 47 - Gear Casing 67 - O-Ring (4 Used)
8- O-Ring (6 Used) 28 - Gasket 48 - Spring Pin (2 Used) 68 - Socket Bolt (16 Used)
9- Bearing Nut (2 Used) 29 - Gear 49 - Oil Seal (2 Used) 69 - Stopper S (2 Used)
10 - Bearing (2 Used) 30 - Plug 50 - Retaining Ring (2 Used) 70 - O-Ring (2 Used)
11 - Ring (2 Used) 31 - O-Ring 51 - Pump Casing 71 - Socket Bolt (12 Used)
12 - Bearing (2 Used) 32 - Gasket 52 - Spring Washer (6 Used) 72 - Set Screw (2 Used)
13 - Shaft 33 - Socket Bolt (2 Used) 53 - Bolt (6 Used) 73 - Servo Piston (2 Used)
14 - Pin (2 Used) 34 - Pipe 54 - Spring Pin (2 Used) 74 - Pin (2 Used)
15 - Center Shaft (2 Used) 35 - Level Gauge 55 - O-Ring (10 Used) 75 - O-Ring (2 Used)
16 - Spring (2 Used) 36 - Socket Bolt (2 Used) 56 - O-Ring (2 Used) 76 - Stopper L (2 Used)
17 - Plunger (14 Used) 37 - Spring Washer (2 Used) 57 - Pin (2 Used) 77 - Left Valve Plate
18 - Rotor (2 Used) 38 - Washer (2 Used) 58 - Retaining Ring (12 Used) 78 - Pin (4 Used)
19 - Shaft 39 - Pilot Pump 59 - Pin (2 Used) 79 - Link (2 Used)
20 - Slide Ring 40 - Retaining Ring 60 - Lever (4 Used)

W1-1-11
UPPERSTRUCTURE / Pump Device

30, 31 25 41 40 42 43

47
W178-02-04-002

51 12 20 11 10

12 11 10 9 W178-02-04-013

W1-1-12
UPPERSTRUCTURE / Pump Device
1. With a guide bar and hammer, tap the inside ball 10. Set the pre-loads of bearings (10) and (12) installed
bearing (42) into gear casing (47), with the stamp on shaft (13) according to the following proce-
mark facing inside. dures.
• Apply a film of hydraulic oil to bearing nut (9)
NOTE: Tap the bearing and listen to ring to confirm threads. Tighten bearing nut (9) until it comes in
installation is completed. contact with bearing (10) using special tool (ST
3058).
2. Put gear (43) to ball bearing (42), insert gear shaft ST 3058
(44) while aligning the spline.
9
10
3. With a guide bar and hammer, tap the outside ball
bearing (42) into gear casing (44), with the stamp
mark facing outward.

NOTE: Tap the bearing and listen to ring to confirm

installation is complated. W137-02-04-023

4. Install retaining ring (40) onto gear casing (47), • Attach special tool (ST 3070) on bearing (10),
and install retaining ring (41) onto gear shaft (44). rotate bearing (10) 2 to 3 turns and measure the
starting torque.
5. Install O-ring (31) onto plug (30) and install them
to gear casing (47). ST 3070
: 22 mm
: 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft) 10

6. Heat bearings (10), (12) (each 2 used) to 50 to 80

°C (122 to 176 °F).

CAUTION: Be careful, bearing (12) is hot. W107-02-04-052

7. Apply a film of hydraulic oil to the inside of bear-

• Adjust the starting torque repeatedly, until it
ings (12) (2 used), and install them onto shafts
reaches specification.
(13) and (19) with a press.
Torque: 2.16±0.49 N･m
(0.22±0.05 kgf･m, 1.59±0.36 Ibf･ft)
8. Install ring (11) onto shafts (13) and (19).

NOTE: If the starting torque is higher than the limit

CAUTION: Be careful, bearing (10) is hot. of specified torque, loosen the bearing nut,
tap the shaft end to release the bearing’s
9. Apply a film of hydraulic oil to the inside of bear- load, and repeat the procedure.
ings (10) (2 used), and install them onto shafts
(13) and (19) with a press. 11. Set the pre-loads for bearing (10) and (12) installed
on shaft (19) by the same procedure as step 10
above mentioned.

12. Install slide ring (20) to the shaft (19) at inserting

side to pump casing (51).

W1-1-13
UPPERSTRUCTURE / Pump Device

12 20 10 49

Regulator Mounting Surface

24 23 W178-02-04-003

W1-1-14
UPPERSTRUCTURE / Pump Device
13. Heat pump casing (51) to 50 to 80 °C (122 to 176 19. Install special tools (ST 2649), (ST 2650) over the
°F). spline parts of shafts (13) and (19).

CAUTION: Use special tool to insert the shaft NOTE: If the special tools are not available, wind
(19) assembly, because pump casing (51) has vinyl tape and etc. over spline part of the
been heated. shaft to protect the oil seal (49) from being
damaged.
14. Apply a film of hydraulic oil to the outside of bear-
ings (10), (12) installed on shaft (19), install shaft
(19) to pump casing (51) using the special tool.
If it is difficult to insert, tap in shaft (19) with a
ST 2650
guide bar, etc.
49
Special Tool

M8, Pitch 1.25

19 W157-02-04-022
ST 2649

IMPORTANT: Apply a film of grease to the inner

diameter of oil seals (49) (2 used).
Wooden Block Wooden
Block
20. Evenly tap oil seals (49) (2 used) onto shafts (13)
W178-02-04-012 and (19).

15. Install shaft (13) into pump casing (51), using the 21. Remove special tool (ST 2649), (ST 2650) from
same procedure as above step 14. shafts (13) and (19).

16. Wait for pump casing (51) cooling down to the 22. Install retaining rings (50) (2 used) to pump casing
temperature lower than 40 °C (104 °F). (51).

17. Install O-rings (23) (2 used) to stoppers (24) (2

used), and install them to pump casing (51).
: 19 mm
: 34.5 N⋅m (3.5 kgf⋅m, 25.3 Ibf⋅ft)

CAUTION: Pump casing weight: 65 kg (143 lb)

18. Attach a nylon sling to pump casing (51), lift it up

and position the regulator with the mounting sur-
face facing up.

W1-1-15
UPPERSTRUCTURE / Pump Device

39 36, 37, 38 25 32, 33, 34 41 40 42 43 43

W178-02-04-002

71 53 52 28

66 60 58, 78 79 15 14 17 51 29

60 58, 78 79 15 14 17 27 W178-02-04-013

W1-1-16
UPPERSTRUCTURE / Pump Device
23. Install gears (27) and (29) onto shafts (13) and 26. Apply THREEBOND #1215 to the mounting sur-
(19), aligning the matching marks made when face of pilot pump (39), install the pilot pump to
disassembling, and install retaining rings (26) (2 gear casing (47) with socket bolts (36), spring
used). washers (37), washers (38) (2 for each).
When replacing the shafts and gears, install the : 8 mm
gear according to the following procedure. : 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
• Secure the special tool (ST 7934) to the mounting
surface of shafts (13) and (19) for plunger (17) . 27. Install gasket (32), pipe (34) to gear casing (47).
Tighten them with socket bolts (33) (2 used).
19 : 6 mm
: 19.5 N⋅m (2 kgf⋅m, 14 Ibf⋅ft)
ST 7934 13
28. Install levers (60), pins (78), retaining rings (58) (4
for each) to links (79) (2 used).

IMPORTANT: If link (79) is distorted, the pump

performance will be changed. Do not
M8, Pitch 1.25 W137-02-04-029 apply unreasonable loads.

• Turn shafts (13) and (19) clockwise, viewed from 29. Install the link (79) assemblies (2 used), aligning
the mounting side of gears (27) and (29), until it the groove for pin (57) in pump casing (51). At this
comes into contact with the special tool. (To re- time, lever (60) faces selector head (66).
move the play in periphery direction)
• Install gear (27) and retaining ring (26) to the NOTE: Both surfaces of pin (57) are parallel to
spline of shaft (13). each other. Insert the pin aligning the par-
• Install gear (29) onto the spline of shaft (19), with allel face with the groove.
engaging to gear (27). If it does not engage, turn
57
shaft (19) in the play range of special tool to find 79
the engaging position. 51
• Install retaining ring (26) to the spline of shaft
(19).
• Remove the special tool.

24. Tap spring pins (48) (2 used) into gear casing (47), Parallel Face Parallel Face W176-02-04-016
and install gasket (28).
30. Apply hydraulic oil to the plunger (17) mounting
CAUTION: Pump casing weight: 70 kg (154 lb) surface of shafts (13) and (19).

25. Install eye bolts (M12, Pitch 1.75) (2 used) to the 31. Insert plungers (17) (7 for each) into shafts (13)
threaded hole for socket bolt (71) in pump casing and (19).
(51), lift it up by crane.
Engaging gear (43) and gear (29), install the 32. Apply a film of grease to pins (14) (2 used), and
gears into gear casing (47). Install the gear casing then install them to center shafts (15) (2 used).
to the pump casing with bolts (53), spring wash-
ers (52) (6 for each). 33. Apply a film of grease to the spherical surface of
: 24 mm center shafts (15) (2 used), and then install them
: 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft) to shafts (13) and (19).

W1-1-17
UPPERSTRUCTURE / Pump Device

58 60 18 16 79 18 15 14 17 51

W178-02-04-013
62 58, 61 60 18 58, 78 79 16 15 14 17

8 7 54 55 59 56

5 6 3

74
73
2 1
64 63 W178-02-04-018

W1-1-18
UPPERSTRUCTURE / Pump Device
34. Install springs (16) (2 used) to center shafts (15) 41. Install right regulator (2) into pump casing (51),
(2 used). according to the following procedure.
• Adjust the sleeve position so that the grooves in
35. Insert center shafts (15) (2 used) and plungers both sleeves on the right regulator are in a line.
(17) (14 used) into rotors (18) (2 used). • Put the right regulator on the pump casing, install
pin (59) for link (79) into the both grooves in the
36. Insert a file’s shank etc. into the center hole of sleeve.
center shaft (15), rotate the center shaft to install • Move the right regulator, so that spring pin (54)
pin (14) into the groove of rotor (18). (Both right extended from the pump casing can enter into the
and left pump) right regulator.
• Install the right regulator into the pump casing
NOTE: If the pin does not enter into the groove of with socket bolts (1) (4 used).
the rotor, selector head (66) cannot be as- : 8 mm
sembled to pump casing (51). : 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
59
37. Apply a film of LOCTITE LI829 to the threads of 2 Sleeve
pins (61) (4 used), and then install the pins to
valve plates (62, right) and (77, left).
: 7 mm
: 9.8 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft)

IMPORTANT: Pay attention to the mounting direc-

tion of right regulator (62). 51 54 W178-02-04-015
79
38. Insert pins (61) (2 used) for right valve plate (62) 42. Install left regulator (6) onto pump casing (51) in
into the hole of levers (60) (2 used) for right regu- the same procedure as step 41, and secure the
lator (2), and install retaining rings (58) (2 used). left regulator with socket bolts (3) (2 used) and (5)
(2 used).
: 8 mm
77 62 : 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
Upper

43. Install backup ring (63), O-ring (64) and O-rings

(8) (6 used) into pump casing (51).

44. Insert servo pistons (73) (2 used) into selector

head (66).

W178-02-04-014
45. Install pin (74) into servo piston (73), fix the servo
piston with set screw (72). (Both right and left
IMPORTANT: Pay attention to the mounting direc- servo pistons)
tion of left regulator (77). Beforehand, apply a film of LOCTITE LI829 to the
threads of the set screw.
39. Insert pins (61) (2 used) for left valve plate (77) : 6 mm
into the hole of levers (60) (2 used) for left regu- : 34.3 N⋅m (3.5 kgf⋅m, 25 Ibf⋅ft)
lator (6), and install retaining rings (58) (2 used).

40. Install O-rings (56) (2 used), (55) (10 used), (7) (4

used) and spring pins (54) (2 used) into pump
casing (51).

W1-1-19
UPPERSTRUCTURE / Pump Device

25 35 34

W178-02-04-002

68 67 69 70 18 51

Mounting Surface
for Suction Pipe
W178-02-04-016

75 68 62 76 65 14

W1-1-20
UPPERSTRUCTURE / Pump Device
46. Install spring pins (65) (2 used) into selector head
CAUTION: Pump device weight: 160 kg
(66).
(350 lb)

CAUTION: Selector head weight: 29 kg (64 lb) 52. Install eye bolts (M12, Pitch 1.75) (4 used) to the
threaded hole for suction pipe in selector head
47. Install eye bolts (M12, pitch 1.75) (2 used) into the (66). Lift the selector head up by crane and posi-
threaded hole for suction pipe in selector head tion it with the regulator mounting side upward.
(66), lift it up by crane.
Install the selector head on pump casing (51), 53. Insert special tool (ST 2650) on shaft (19). Apply a
while aligning the selector head with spring pin film of grease to oil seal (46) and install the oil
(65). seal to shaft (19).
Pull out the special tool, tap oil seal (46) into the
NOTE: Measure the clearance between the se- gear casing.
lector head and pump casing. Compare it
with the clearance which was recorded NOTE: If special tool (ST 2650) is not available,
during disassembling. If it is larger, pin (14) wind vinyl tape etc. over the spline parts of
can’t be inserted into the groove in rotor shaft (19) to protect the oil seal from being
(18), or pin (14) can’t be inserted into the damaged, and then install the oil seal.
holes in valve plates (62) and (77). Please ST 2650
confirm it.

48. Tighten selector head (66) to pump casing (51) 46

with socket bolts (71) (12 used).
: 10 mm
: 108 N⋅m (11 kgf⋅m, 80 Ibf⋅ft)

49. Install O-rings (67) (4 used) to selector head (66).

50. Install O-ring (70) to stopper S (69). Install the

stopper S to selector head (66) with socket bolts W157-02-04-023
(68) (4 used). (2 places)
: 6 mm
54. Install retaining ring (45) to gear casing (47).
: 19.5 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
55. Supply engine oil 1.0 L (0.2642 US gal) into gear
51. Install O-ring (75) to stopper L (76). Install the casing (47) through the hole for plug (25).
stopper L to selector head (66) with socket bolts
(68) (4 used). (2 places) IMPORTANT: The breather hole for plug (25) lo-
: 6 mm cates at left side, seen from the front
: 19.5 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft) of gear casing (47).

56. Wind the plug (25) with seal tape and install it to
gear casing (47).
: 17 mm
: 39.5 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)

57. Insert level gauge (35) into pipe (34).

W1-1-21
UPPERSTRUCTURE / Pump Device
DISASSEMBLE REGULATOR

1 2 3

Right Regulator Left Regulator

6 7 8 9 10 11 12 13 14 15

5 16

4 17

18
19
33
W176-02-04-001

32
31 30 29 28 27 26 25 24 23 22 21 20

1- Pipe 10 - Spool 18 - Lock Nut 26 - Spool

2- Socket Bolt (2 Used) 11 - Sleeve 19 - Lock Nut 27 - Piston
3- Solenoid Valve 12 - Piston 20 - Socket Bolt (4 Used) 28 - Cylinder
4- Lock Nut 13 - Cylinder 21 - Stopper Assembly 29 - O-Ring
5- Lock Nut 14 - O-Ring 22 - O-Ring 30 - Backup Ring
6- Stopper Assembly 15 - Cover 23 - Spring 31 - O-Ring
7- O-Ring 16 - Set Bolt 24 - Spring 32 - Socket Bolt (4 Used)
8- Spring 17 - Lock Nut 25 - Sleeve 33 - Cover
9- Casing

W1-1-22
UPPERSTRUCTURE / Pump Device
Disassemble Regulator

• Regulators are used for right pump and left pump. 5. Pull out springs (23) and (24) from casing (9).
The regulator’s inner structure is fully identical,
and the difference is only in its accessories. Here 6. Insert a round bar into the hole of casing (9). Push-
is the description of left regulator. ing the spool (26) end, push out cylinder (28),
sleeve (25) and the spool from the casing. At this
IMPORTANT: If adjusting screws (4, 5, 16, 17, 18 time, piston (27) is removed with the cylinder.
and 19) are disassembled, their set
values will change. So, do not 7. Pull out piston (27) from cylinder (28).
disassemble them.
When these adjusting screws must 8. Remove spring (8) from casing (9).
be disassembled, carry out adjust-
ment according to the procedure of 9. Insert a round bar into the hole of casing (9).
performance test after assembling. Pushing the spool (10) end, push out cylinder (13),
sleeve (11) and the spool. At this time, piston (12)
1. Clamp casing (9) in a vise, then remove pipe (1) is removed with the cylinder.
from the casing.
: 17 mm 10. Pull out piston (12) from cylinder (13).

2. Remove socket bolts (2) (2 used) and remove

solenoid valve (3) from the casing (9).

IMPORTANT: Do not loosen set bolt (16), lock nuts

(17), (18) and (19). Otherwise, the set
values will change.

3. Remove socket bolts (20) (4 used), then remove

cover (15) from casing (9). At this time, set bolt
(16) and stopper assembly (21) are removed with
the cover.
: 6 mm

IMPORTANT: Do not loosen lock nuts (4) and (5).

Otherwise, set values will changed.

4. Remove socket bolts (32) (4 used), then remove

cover (33) from casing (9). At this time, stopper
assembly (6) is removed with the cover.
: 6 mm

W1-1-23
UPPERSTRUCTURE / Pump Device
ASSEMBLE REGULATOR

1 2 3

Right Pump Regulator Left Pump Regulator

6 7 8 9 10 11 12 13 14 15

5 16

4 17

18
19
33
W176-02-04-001

32
31 30 29 28 27 26 25 24 23 22 21 20

1- Pipe 10 - Spool 18 - Lock Nut 26 - Spool

W1-1-24
UPPERSTRUCTURE / Pump Device
Assemble Regulator

IMPORTANT: Two holes for sleeve in casing (9) 9. Install O-ring (22) and springs (23), (24) to stop-
are with identical bores, and the per assembly (21) on cover (15). Install the cover
shapes of various parts are very on casing (9) with socket bolts (20) (4 used).
similar. Pay attention not to misas- : 6 mm
semble them. Perform assembling : 19.6 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)
as illustrated.
10. With socket bolts (2) (2 used), install solenoid
1. Clean all parts neatly and apply hydraulic oil. valve (3) onto casing (9).
: 8 mm
IMPORTANT: Pay attention to the direction for : 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)
sleeve (11), spool (10) and piston
(12) when assembling. 11. Apply a film of grease to the threaded part of pipe
(1). Install pipe (1) to casing (9).
2. Insert spool (10) into sleeve (11). With a round bar, : 17 mm
assemble it at the position closed to the center of : 34 N⋅m (3.5 kgf⋅m, 25.3 Ibf⋅ft)
casing (9).

3. Install O-ring (14) onto cylinder (13).

4. Insert piston (12) into cylinder (13), then assem-

ble on casing (9).

IMPORTANT: Pay attention to the direction for

sleeve (25) and spool (26) when as-
sembling.

5. Insert spool (26) into sleeve (25), with a round bar

to assemble it at the position closed to the center
of casing (9).

6. Install O-rings (29), (31) and backup ring (30)

onto cylinder (28).

7. Insert piston (27) into cylinder (28), then install the

cylinder into casing (9).

8. Install O-ring (7) and spring (8) to stopper as-

sembly (6) on cover (33). Install the cover on
casing (9) with socket bolts (32) (4 used).
: 6 mm
: 19.6 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

W1-1-25
UPPERSTRUCTURE / Pump Device
DISASSEMBLE SOLENOID VALVE

1
2
3
4
5
6
7
8
9
10
11
12

13
14
15

17
18
19
20
21

W178-02-04-050

1- Socket Bolt 7- Spring 13 - Orifice 19 - O-Ring

2- Solenoid 8- O-Ring 14 - Plate 20 - Filter
3- Spring 9- O-Ring 15 - Wave Washer 21 - O-Ring
4- O-Ring 10 - O-Ring 16 - Filter
5- Diaphragm 11 - Sleeve 17 - Body
6- Retaining Ring 12 - Spool 18 - O-Ring

W1-1-26
UPPERSTRUCTURE / Pump Device
Disassemble Solenoid Valve IMPORTANT: Do not remove orifice (13) from
• Be sure not to damage the mating surface for the spool (12).
regulator.
• When replacing inner parts, replace solenoid 4. Remove retaining ring (6), then remove spring (7)
valve as an assembly. and spool (12).
• Pay attention not to hit the solenoid part.
• When removing the connector, do not pry, but pull NOTE: Spool (7) and spool (12) should be pulled
out straight. out from the opposite direction.

1. Remove socket bolt (1), then remove solenoid (2) 5. Remove filters (16), (20) from body (17).
and O-ring (4). : 6 mm
: 4 mm
NOTE: When cleaning filter (16), first blow the filter
NOTE: When solenoid (2) is removed, O-ring (4) with air from both surfaces, and finally blow
and spring (3) may come off occasionally. the filter with air from outer side (threaded
side).
2. Using special tool (ST 2953), pull out the sleeve
(11) assembly from body (17).

NOTE: When pulling out sleeve (11), built-in plate

(14) and wave washer (15) may come off
occasionally.
ST 2953

W178-02-04-052

3. Remove plate (14) and wave washer (15) from

body (17).

W1-1-27
UPPERSTRUCTURE / Pump Device
ASSEMBLE SOLENOID VALVE

2 1 5 6 7 11 12 13 14 15 17 16

3 4 8 9 10
21 20

W178-02-04-051

1- Socket Bolt 7- Spring 13 - Orifice 19 - O-Ring

W1-1-28
UPPERSTRUCTURE / Pump Device
Assemble Solenoid Valve IMPORTANT: When installing sleeve (11), keep the
1. Install filters (16), (20) onto body (17). sleeve end and body (17) end in the
: 6 mm same position.
: 10+3 N⋅m (1+0.3 kgf⋅m, 7.2+2.2 Ibf⋅ft) In addition, when installing the
sleeve, be sure not to pry and cause
2. Install wave washer (15) and plate (14) on body damage to O-ring.
(17).
5. Using special tool (ST 2953), install sleeve (11)
NOTE: When body (17) is horizontally inserted, assembly to body (17).
apply a film of grease to wave washer (15)
and plate (14) to prevent them from coming NOTE: When there is no special tool (ST 2953)
off. available, tighten solenoid (2) alternately
After assembling, check for straight posi- with socket bolts (1) (2 used). Then sleeve
tion of plate (14). (11) end and body (17) end should be
placed in the same position. Install the so-
3. Install O-rings (8), (9) and (10) to sleeve (11). lenoid.

4. Insert spool (12) into sleeve (11), then install

ST 2953
spring (7), retaining ring (6) and diaphragm (5) on
spool (12).

NOTE: Install diaphragm (5) and let it crimp to-

wards out.
After installing, check that spool (12) moves
smoothly.

W178-02-04-052

6. Install solenoid (2) to body (17) with socket bolt

(1) (2 used).
: 4 mm
: 5+2 N⋅m (0.5+0.2 kgf⋅m, 3.6+1.4 lbf⋅ft)

W1-1-29
UPPERSTRUCTURE / Pump Device
DISASSEMBLE AND ASSEMBLE PILOT
PUMP

10
1

12
9
6
26
14

6
9
2
3
5

16
15
7
W137-02-04-034
12

W1-1-30
UPPERSTRUCTURE / Pump Device
IMPORTANT: The housing is made of aluminum.
Be sure not to damage it. Besides,
take extreme care to control tight-
ening torque.

Wrench Size Tightening Torque

Key No. Part Name Q’ty Remarks
(mm) N⋅m kgf⋅m (Ibf⋅ft)
1 Housing 1
2 Flange 1
3 Oil Seal 1 Apply a film of grease on
bushing when installing
5 Retaining Ring 1
6 Seal 2 Apply a film of grease
when installing
7 Cover 1
9 Backup Ring 2 Apply a film of grease
when installing
10 Key 2
12 O-Ring 2 Apply a film of grease
when installing
13 Gear 1
14 Gear 1
15 Washer 4
16 Bolt 4 4 to 4.5
: 17 39 to 44 (28.9 to 32.5)

26 Bushing 2 Apply a film of hydraulic

oil when installing
27 Bushing 2 Apply a film of hydraulic
oil when installing

W1-1-31
UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARD

Pump Device
Unit: mm (in)
Standard Allowable Limit Remedy
Gear Backlash 0.68 (0.027) 1.5 (0.059) Replace

Main Pump
1. Drive Disc: Spline tooth thickness.
Unit: mm (in)
Standard Allowable Limit 1

5.4 (0.213) 3.8 (0.150)

3 2

2. Drive Disc: Oil seal outer diameter.

Unit: mm (in)
Standard Allowable Limit
1 45 (1.77) 44.8 (1.76)
2 55 (2.17) 54.8 (2.16) W157-02-04-015

3 55 (2.17) 54.8 (2.16)

3. Spherical joint: The clearance between plunger

and drive disc.
Unit: mm (in)
Standard Allowable Limit
0.058 (0.0023) 0.4 (0.0157)

4. Cylinder Block: Clearance between plunger outer

diameter and cylinder block bore.
D–a
Unit: mm (in) W157-02-04-016

Standard Allowable Limit

0.043 (0.0017) 0.08 (0.0031)

W157-02-04-017

W1-1-32
UPPERSTRUCTURE / Pump Device
5. Plunger clearance between connecting rod and
plunger
Unit: mm (in)
Standard Allowable Limit
0.15 (0.0059) 0.4 (0.0157) Plunger

Conneting Rod

6. Clearance between small chamber I.D. and servo

piston O.D. W157-02-04-033

D-a D

Unit: mm (in) a Small Diameter

Standard Allowable Limit End
0.083 (0.0033) 0.2 (0.0079)

7. Clearance between large chamber I.D. and servo

piston O.D.
D-a
Unit: mm (in)
Standard Allowable Limit
0.079 (0.0031) 0.2 (0.0079)

a Large Diameter
End
8. Clearance between servo pin and valve plate D W157-02-04-018
D-a
Unit: mm (in)
Standard Allowable Limit
0.051 (0.0020) 0.3 (0.0118)

D a

W157-02-04-019

W1-1-33
UPPERSTRUCTURE / Pump Device
(Blank)

W1-1-34
MEMO

....................................................................................................................................................................

....................................................................................................................................................................
MEMO

....................................................................................................................................................................

SERVICE MANUAL REVISION REQUEST FORM

NAME OF COMPANY: MODEL:

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

DATE: PAGE NO.:

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

YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.

REPLY:

(Copy this form for usage)

THE ATTACHED DIAGRAM LIST

(The following diagrams are attached to this manual.)

ZAXIS200-4H ELECTRICAL CIRCUIT DIAGRAM

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ZAXIS200-4H ENGINE HARNESS 1

ZAXIS200-4H MONITOR HARNESS

ZAXIS200-4H ENGINE HARNESS 2

ZAXIS200-4H HYDRAULIC CIRCUIT DIAGRAM

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