178T-4-1

SECTION 4

OPERATIONALPERFORMANCE TEST

CONTENTS

Group 1 IntroductionOperational Performance Tests ................T4-1-1

Preparation for Performance Tests ...........T4-1-2

Group 2 Engine TestEngine Speed...........................................T4-2-1

Engine Compression Pressure .................T4-2-3

Valve Clearance Adjustment.....................T4-2-4

Nozzle Check ...........................................T4-2-6

Injection Timing ........................................T4-2-8

Group 3 Excavator TestTravel Speed............................................T4-3-1

Track Revolution Speed ...........................T4-3-2

Mistrack Check ........................................T4-3-3

Travel Parking Function Check.................T4-3-4

Swing Speed ............................................T4-3-5

Swing Function Drift Check ......................T4-3-6

Swing Motor Leakage...............................T4-3-7

Maximum Swingable Slant Angle..............T4-3-8

Swing Bearing Play ..................................T4-3-9

Hydraulic Cylinder Cycle Time ................T4-3-10

Dig Function Drift Check ........................T4-3-12

Control Lever Operating Force ...............T4-3-14

Control Lever Stroke ..............................T4-3-15

Combined Boom Raise/Swing

Function Check ....................................T4-3-16

Boom Raise and Arm Roll-In

Combined Operation ............................T4-3-17

Group 4 Component TestPrimary Pilot Pressure..............................T4-4-1

Secondary Pilot Pressure .........................T4-4-3

Solenoid Valve Set Pressure ....................T4-4-4

Main Pump Delivery Pressure...................T4-4-6

Main Relief Valve Set Pressure.................T4-4-8

Overload Relief Valve Set Pressure ........T4-4-14

Main Pump Flow Rate Measurement ......T4-4-16

Swing Motor Drainage ............................T4-4-22

Travel Motor Drainage ............................T4-4-24

Group 5 StandardOperational Performance Standard Table

ZAXIS200 ...............................................T4-5-1

ZAXIS225USR........................................T4-5-4

ZAXIS225US ..........................................T4-5-7

ZAXIS230 .............................................T4-5-10

ZAXIS270 .............................................T4-5-13

Main Pump P-Q Diagram........................T4-5-16

Injection Pump .......................................T4-5-18

Dr.EX Monitor Indicating Values

ZAXIS200 .............................................T4-5-22

ZAXIS225USR......................................T4-5-26

ZAXIS225US ........................................T4-5-30

ZAXIS230 .............................................T4-5-34

ZAXIS270 .............................................T4-5-38

178T-5-1

SECTION 5

TROUBLESHOOTING

CONTENTS

Group 1 GeneralIntroduction ..............................................T5-1-1

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

Built-In Diagnosing System Operation ......T5-1-4

Built-In Diagnosing Function Display List ..T5-1-5

Dr. EX Operation ......................................T5-1-6

Dr. EX Fault Code List ..............................T5-1-7

Dr. EX Monitoring Item List .......................T5-1-8

Dr. EX Special Function..........................T5-1-10

Dr. EX Service Mode ..............................T5-1-12

Adjustment Data List ..............................T5-1-22

Initial Setting of Boom Electronic

Cushion ................................................T5-1-24

Group 2 Component LayoutMain Component Layout...........................T5-2-1

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

Electrical System

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

Electrical System

(Monitors and Switches) .........................T5-2-9

Pump Device..........................................T5-2-10

Swing Device .........................................T5-2-10

Control Valve.......................................... T5-2-11

Signal Control Valve ............................... T5-2-11

Solenoid Valve Unit ................................ T5-2-11

Travel Device .........................................T5-2-12

Components in Control Valve .................T5-2-14

Signal Control Valve

Port Location ........................................T5-2-22

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

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

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

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

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

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

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

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

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

Fault Code 14, 15, 16, 18 .........................T5-3-8

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

Sensor Activating Range ........................T5-3-11

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

Relationship between Machine Trouble

Symptoms and Related Parts..................T5-4-2

Correlation between Trouble

Symptoms and Part Failures .................T5-4-18

Engine System Troubleshooting .............T5-4-29

All Actuator System Troubleshooting ......T5-4-48

Front Attachment System

Troubleshooting ....................................T5-4-54

Swing System Troubleshooting...............T5-4-66

Travel System Troubleshooting...............T5-4-69

Other System Troubleshooting ...............T5-4-76

Engine Speed Adjustment and

Engine Learning ...................................T5-4-94

Exchange Inspection ..............................T5-4-96

Emergency Boom Lowering

Procedure.............................................T5-4-98

178T-5-2

Group 5 Troubleshooting CTroubleshooting C Procedure ...................T5-5-1

Malfunction of Coolant

Temperature Gauge................................T5-5-2

Malfunction of Fuel Gauge .......................T5-5-4

Malfunction of Indicator Light

Check System ........................................T5-5-6

Malfunction of Preheat Indicator ...............T5-5-7

Malfunction of Engine Oil Level

Indicator .................................................T5-5-8

Malfunction of Coolant Level

Indicator ...............................................T5-5-10

Malfunction of Alternator Indicator ..........T5-5-12

Malfunction of Engine Oil Pressure

Indicator ...............................................T5-5-14

Malfunction of Overheat Indicator ...........T5-5-16

Malfunction of Air Filter Restriction

Indicator ...............................................T5-5-18

Malfunction of Buzzer .............................T5-5-20

Malfunction of LCD.................................T5-5-22

Malfunction of Hour Meter ......................T5-5-23

Malfunction of Hydraulic Oil Filter

Indicator (Optional) ...............................T5-5-24

Group 6 Electrical System InspectionPrecautions for Inspection and

Maintenance...........................................T5-6-1

Instructions for Disconnecting

Connectors .............................................T5-6-3

Fuse Inspection........................................T5-6-4

Fusible Link Inspection.............................T5-6-5

Battery Voltage Check ..............................T5-6-6

How to Troubleshoot Alternator

Malfunctions ...........................................T5-6-7

Continuity Check ......................................T5-6-8

Voltage and Current Measurement .........T5-6-10

Check by False Signal ............................T5-6-13

Test Harness ..........................................T5-6-14

Group 7 ICXOutline .....................................................T5-7-1

ICX Fault Code List ..................................T5-7-6

Satellite Terminal Fault Code List .............T5-7-6

Fault Code 1 to 4 and 6 ............................T5-7-7

Fault Code 7 to 10 ....................................T5-7-7

Some Parts of Data in Daily Report,

Frequency Distribution, Cumulative

Operation Hours are not Recorded .........T5-7-8

Troubleshooting and Setting of ICX and

Satellite Terminal Using Dr. EX .............T5-7-10

Satellite Communication System ............T5-7-27