Performance Check

SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction Group 4 Excavator Test
Operational Performance Tests................ T4-1-1 Travel Speed ........................................... T4-4-1
Preparation for Performance Tests .......... T4-1-2 Track Revolution Speed ........................... T4-4-2
Mistrack Check ........................................ T4-4-3
Group 2 Standard Travel Parking Function Check ................ T4-4-4
Operational Performance Standard Table Swing Speed............................................ T4-4-5
ZX200 class ........................................... T4-2-1 Swing Function Drift Check ...................... T4-4-6
ZAXIS225USR ....................................... T4-2-5 Swing Motor Leakage .............................. T4-4-8
ZAXIS225US ......................................... T4-2-9 Maximum Swingable Slant Angle ........... T4-4-10
ZX230 class ......................................... T4-2-13 Swing Bearing Play ................................ T4-4-12
ZX270 class ......................................... T4-2-17 Hydraulic Cylinder Cycle Time ............... T4-4-14
Main Pump P-Q Diagram ....................... T4-2-22 Dig Function Drift Check ........................ T4-4-16
Injection Pump....................................... T4-2-24 Control Lever Operating Force............... T4-4-18
Dr.ZX Monitor Indicating Values Control Lever Stroke .............................. T4-4-20
ZX200 class ......................................... T4-2-28 Combined Boom Raise/Swing
ZAXIS225USR ..................................... T4-2-32 Function Check .................................... T4-4-22
ZAXIS225US ....................................... T4-2-36 Boom Raise and Arm Roll-In
ZX230 class ......................................... T4-2-40 Combined Operation .......................... T4-4-24
ZX270 class ......................................... T4-2-44
Sensor Activating Range ...................... T4-2-48
Group 3 Engine Test

Engine Speed .......................................... T4-3-1
Engine Compression Pressure ................ T4-3-4
Valve Clearance Adjustment .................... T4-3-6
Nozzle Check .......................................... T4-3-8
Injection Timing ..................................... T4-3-10
Lubricant Consumption ........................ T4-3-12
178T-4-1
Group 5 Component Test
Primary Pilot Pressure ............................. T4-5-1
Secondary Pilot Pressure ........................ T4-5-4
Solenoid Valve Set Pressure.................... T4-5-6
Main Pump Delivery Pressure.................. T4-5-9
Main Relief Valve Set Pressure.............. T4-5-10
Relief Pressure (When relieving
Swing)................................................ T4-5-14
Relief Pressure (When relieving
Travel) ............................................... T4-5-16
Overload Relief Valve Set Pressure ....... T4-5-18
Main Pump Flow Rate Measurement ..... T4-5-22
Swing Motor Drainage ........................... T4-5-29
Travel Motor Drainage ........................... T4-5-32
Group 6 Adjustment
Engine Speed Adjustment and
Engine Learning ................................... T4-6-1
Govenor Lever and Fuel
Cut Lever Position................................ T4-6-4
178T-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedure to quan- The machine performance does not always deteriorate
titatively check all system and functions on the ma- as the working hours increase. However, the machine
chine. performance is normally considered to reduce in pro-
portion to the increase of the operation hours. Accord-
Purpose of Performance Tests ingly, restoring the machine performance by repair,
1. To comprehensively evaluate each operational adjustment, or replacement shall consider the number
function by comparing the performance test data of the machine’s working hours.
with the standard values.
2. According to the evaluation results, repair, adjust, Definition of “Performance Standard”
or replace parts or components as necessary to 1. Operation speed values and dimensions of the
restore the machine’s performance to the desired new machine.
standard. 2. Operational performance of new components
3. To economically operate the machine under op- adjusted to specifications. Allowable errors will be
timal conditions. indicated as necessary.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the op-
erational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to evalu-
ate the performance test data.
Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out

performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 20 m (65 ft 7 in), and to make
a full swing with the front attachment extended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork-
ers. Once the test is started, be sure to commu-
nicate with each other using these signals, and to
follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic T105-06-01-003
pipings.
MAKE PRECISE MEASUREMENT

1. Accurately calibrate test instruments in advance
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
T105-06-01-004
T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard
ZX200 CLASS OPERATIONAL
PERFORMANCE STANDARD TABLE
The standard Performance values are listed in the Engine Control Dial : Fast Idle
table below. Refer to the Group T4-3 to T4-5 for Power Mode Switch : P Mode
performance test procedures. Values indicated in Auto-Idle/Acceleration Selector : OFF
parentheses are reference values. Work Mode Switch : Digging Mode
Hydraulic Oil Temperature : 50±5 °C (122±9 °F)
The following switch positions shall be selected and
the hydraulic oil temperature shall be maintained as
indicated below as the preconditions of performance
tests unless otherwise instructed in each performance
test procedure:
NOTE: 1 mm=0.03937 in
ZX200 class
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
ENGINE SPEED min-1 T4-3-1
+150
Slow Idle Speed 900 -100 Value indicated on Dr. ZX.
+65
Fast Idle Speed (Normal) 1950 -50 ↑
+65
Fast Idle Speed (Wirh ECO deactivated) 2050 -50 ↑
Extend the boom cylinder to
+65 relieve the boom raise
Fast Idle Speed (Relief Operation) 1900 -50
circuit.Value indicated on Dr.
ZX.
+90
Fast Idle Speed (E mode) 1800 -70 Value indicated on Dr. ZX.
Extend the boom and arm
cylinder to relieve the boom
Fast Idle Speed (HP mode) 2000 to 2250
raise and arm roll-in circuit.
Value indicated on Dr. ZX.
+135
Auto-Idle Speed 1300 -100 Value indicated on Dr. ZX.
+125
Auto-Acceleration Speed 1650 -100 ↑
+140
Warming Up Speed 1400 -100 ↑
ENGINE COMPRESSION PRESSURE After engine warm-up T4-3-4
3.04 (31, 440)
(After engine warm-up) MPa (kgf/cm2, psi)
VALVE CLEARANCE (IN, EX) 0.4 With the engine cold T4-3-6
NOZZLE INJECTION PRESSURE T4-3-8
18.1 (185, 2630)
MPa (kgf/cm2, psi)
18.1 (185, 2630)
MPa (kgf/cm2, psi)
INJECTION TIMING T4-3-10
10°
(Degrees before TDC) deg.
LUBRICANT CONSUMPTION Hour meter: 2000 hours or T4-3-12
50 or less
(Rated output) mL/h less
T4-2-1
NOTE: 1 mm=0.03937 in
ZX200 class
Reference
Page
Standard)
TRAVEL SPEED sec/20 m T4-4-1
Travel speed isn’t shifted to
Fast Speed 13.0±1.2 fast speed mode one side-
track is jacked up.
Slow Speed 20.0±2.0
TRACK REVOLUTION SPEED sec/3 rev T4-4-2
Fast Speed 17.2±1.0 LC: 18.3±1.0
Slow Speed 26.2±2.0 LC: 27.9±2.0
MISTRACK mm/20 m T4-4-3
200 or less
(With fast and slow travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0 T4-4-4
SWING SPEED sec/3 rev 13.5±1.0 Bucket empty T4-4-5
SWING FUNCTION DRIFT CHECK T4-4-6
1254 or less Bucket empty
mm /180°
SWING MOTOR LEAKAGE mm/5 min 0 Bucket loaded T4-4-8
MAXIMUM SWINGABLE SLANT ANGLE 22° or possibly Bucket loaded T4-4-10
deg. more
SWING BEARING PLAY mm 0.2 to 1.25 Allowable limit: 2.0 to 3.05 T4-4-12
HYDRAULIC CYLINDER CYCLE TIME 2.91 m arm T4-4-14
3
sec 0.8 m (PCSA heaped) bucket,
bucket empty
Boom Raise 3.1±0.3
Boom Lower 2.3±0.3
Arm Roll-In 3.8±0.3
Arm Roll-Out 2.8±0.3
Bucket Roll-In 3.4±0.3
Bucket Roll-Out 2.3±0.3
DIG FUNCTION DRIFT CHECK mm/5 min 2.91m arm T4-4-16
3
0.8 m (PCSA heaped) bucket
Boom Cylinder
(Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In position) 5 or less Bucket empty
Arm Cylinder
Bucket Cylinder
Bucket Bottom
T4-2-2
NOTE: 1 mm=0.03937 in
ZX200 class
Reference
Page
Standard)
CONTROL LEVER OPERATING FORCE HITACHI lever pattern T4-4-18
N (kgf, lbf･ft)
Boom Lever 18 (1.8, 13) or less
Arm Lever 15 (1.5, 10.8) or
(ISO Lever Pattern: Swing Lever) less
Bucket Lever 15 (1.5, 10.8) or
less
Swing Lever 18 (1.8, 13) or less
(ISO Lever Pattern: Arm Lever)
Travel Lever 28 (2.8, 20.3) or
less
CONTROL LEVER STROKE mm HITACHI lever pattern T4-4-20
Boom Lever 105±10
Arm Lever
84±10
(ISO Lever Pattern: Swing Lever)
Bucket Lever 84±10
Swing Lever 105±10
Travel Lever 120±10
BOOM RAISE/SWING sec 2.91 m arm T4-4-22
3
3.6±0.3 0.8 m (PCSA heaped) bucket,
bucket empty
(Bucket Teeth Height: H) mm 6700 or more
BOOM RAISE/ARM ROLL-IN sec 2.91 m arm T4-4-24
3
bucket empty
PRIMARY PILOT PRESSURE T4-5-1
MPa (kgf/cm2, psi)
+1.0
Engine: Fast Idle 4.0 -0.5
+10 +142
(41 -5, 580 -71)
+1.0
Engine: Slow Idle 3.5 -0
+10 +142
(35 -0, 500 -0)
SECONDARY PILOT PRESSURE) 3.4 to 4.0 Value indicated on Dr. ZX T4-5-4
(Engine: Fast Idle and Slow Idle) (34 to 40, 483 to (Lever: Full stroke)
MPa (kgf/cm2, psi) 570)
SOLENOID VALVE SET PRESSURE Value Indicated On T4-5-6
MPa (kgf/cm2, psi) Dr. ZX±0.2 (2, 28)
+1.0
MAIN PUMP DELIVERY PRESSURE 0.7 -0.5 Value indicated on Dr. ZX T4-5-9
+10 +142
MPa (kgf/cm2, psi) (7 -5, 100 -71)
T4-2-3
NOTE: 1 mm=0.03937 in
ZX200 class Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks Page
Standard)
MAIN RELIEF VALVE SET PRESSURE T4-5-10
MPa (kgf/cm2, psi)
+2.0
Boom, Arm, and Bucket 34.3 -0.5 Value indicated on Dr. ZX
+20
(350 -5,
+284
4980 -71 )
+2.0
Power Boost 36.3 -1.0 Value indicated on Dr. ZX
+20
(370 -10,
+284
5260 -142 )
+2.3
RELIEF PRESSURE MPa (kgf/cm2, psi) 31.9 -0 Value indicated on Dr. ZX T4-5-14
(When relieving Swing) +25
(325 -0,
+356
4620 -0 )
+2.0
RELIEF PRESSURE MPa (kgf/cm2, psi) 34.3 -0.5 Value indicated on Dr. ZX T4-5-16
(When relieving Travel) +20
(350 -5,
+284
4980 -71 )
OVERLOAD RELIEF VALVE SET PRES- (Reference values T4-5-18
SURE MPa (kgf/cm2, psi) at 50 L/min)
+1.0
Boom (Raise/Lower), Arm Roll-In, and 37.3 -0
Bucket Roll-In +10
(380 -0,
+142
5400 -0 )
+1.0
Arm Roll-Out, Bucket Roll-Out 39.2 -0
+10
(400 -0,
+142
5690 -0 )
MAIN PUMP FLOW TEST (L/min) - Refer to page T4-2-22, 23. T4-5-22
SWING MOTOR DRAINAGE (L/min) T4-5-29
With constant maximum speed 0.2 to 0.3
With the motor relieved (2 to 5)
TRAVEL MOTOR DRAINAGE (L/min) T4-5-32
With the track jacked up 1.4 to 2.1 Allowable limit: 2.6
With the motor relieved 1.4 to 4.0 Allowable limit: 5.0
T4-2-4
ZAXIS225USR OPERATIONAL
test procedure:
NOTE: 1 mm=0.03937 in
ZAXIS225USR
Reference
Page
Standard)
Slow Idle Speed 950±100 Value indicated on Dr. ZX.
Fast Idle Speed (Normal) 1965±50 ↑
Fast Idle Speed (Wirh ECO deactivated) 2060±50 ↑
relieve the boom raise
Fast Idle Speed (Relief Operation) 1915±50
ZX.
Fast Idle Speed (E mode) 1820±70 Value indicated on Dr. ZX.
Auto-Idle Speed 1335±100 Value indicated on Dr. ZX.
Auto-Acceleration Speed 1675±100 ↑
+140
3.04 (31, 440)
18.1 (185, 2630)
MPa (kgf/cm2, psi)
10°
50 or less
T4-2-5
NOTE: 1 mm=0.03937 in
ZAXIS225USR
Reference
Page
Standard)
track is jacked up.
17.8±1.0 LC: 18.9±1.0
Fast Speed
28.2±2.0 LC: 30.1±2.0
Slow Speed
200 or less
mm /180°
deg. more
3
bucket empty
Boom Raise 3.1±0.3
Boom Lower 2.3±0.3
3
Boom Cylinder
Arm Cylinder
Bucket Cylinder
Bucket Bottom
T4-2-6
NOTE: 1 mm=0.03937 in
ZAXIS225USR
Reference
Page
Standard)
N (kgf, lbf･ft)
Arm Lever 15 (1.5, 10.8) or
less
less
Boom Lever 105±10
Arm Lever
84±10
Bucket Lever 84±10
Swing Lever 105±10
3
bucket empty
3
bucket empty
MPa (kgf/cm2, psi)
+1.0
+10 +142
(41 -5, 580 -71)
+1.0
+10 +142
(35 -0, 500 -0)
MPa (kgf/cm2, psi) Dr. ZX±0.2 (2,28)
+1.0
+10 +142
MPa (kgf/cm2, psi) (7 -5, 100 -71)
T4-2-7
NOTE: 1 mm=0.03937 in
ZAXIS225USR Reference
Standard)
MPa (kgf/cm2, psi)
+2.0
+20
(350 -5,
+284
4980 -71 )
+2.0
+20
(370 -10,
+284
5260 -142 )
+2.3
(325 -0,
+356
4620 -0 )
+2.0
(350 -5,
+284
4980 -71 )
+1.0
Bucket Roll-In +10
(380 -0,
+142
5400 -0 )
+1.0
+10
(400 -0,
+142
5690 -0 )
T4-2-8
ZAXIS225US OPERATIONAL
test procedure:
NOTE: 1 mm=0.03937 in
ZAXIS225US
Reference
Page
Standard)
Slow Idle Speed 950±100 Value indicated on Dr. ZX.
Fast Idle Speed (Normal) 1965±50 ↑
Fast Idle Speed (Wirh ECO deactivated) 2065±50 ↑
relieve the boom raise
Fast Idle Speed (Relief Operation) 1915±50
ZX.
Fast Idle Speed (E mode) 1820±70 Value indicated on Dr. ZX.
Auto-Idle Speed 1335±100 Value indicated on Dr. ZX.
Auto-Acceleration Speed 1675±100 ↑
+140
3.04 (31, 440)
18.1 (185, 2630)
MPa (kgf/cm2, psi)
10°
50 or less
T4-2-9
NOTE: 1 mm=0.03937 in
ZAXIS225US
Reference
Page
Standard)
track is jacked up.
17.8±1.0 LC: 18.9±1.0
Fast Speed
28.2±2.0 LC: 30.1±2.0
Slow Speed
200 or less
mm /180°
deg. more
3
bucket empty
Boom Raise 3.8±0.3
Boom Lower 3.0±0.3
3
Boom Cylinder
Arm Cylinder
Bucket Cylinder
Bucket Bottom
T4-2-10
NOTE: 1 mm=0.03937 in
ZAXIS225US
Reference
Page
Standard)
N (kgf, lbf･ft)
Arm Lever 15 (1.5, 10.8) or
less
less
Boom Lever 105±10
Arm Lever
84±10
Bucket Lever 84±10
Swing Lever 105±10
3
bucket empty
3
bucket empty
MPa (kgf/cm2, psi)
+1.0
+10 +142
(41 -5, 580 -71)
+1.0
+10 +142
(35 -0, 500 -0)
MPa (kgf/cm2, psi) Dr. ZX±0.2 (2.28)
+1.0
+10 +142
MPa (kgf/cm2, psi) (7 -5, 100 -71)
T4-2-11
NOTE: 1 mm=0.03937 in
ZAXIS225US Reference
Standard)
MPa (kgf/cm2, psi)
+2.0
+20
(350 -5,
+284
4980 -71 )
+2.0
+20
(370 -10,
+284
5260 -142 )
+2.3
(325 -0,
+356
4620 -0 )
+2.0
(350 -5,
+284
4980 -71 )
+1.0
Bucket Roll-In +10
(380 -0,
+142
5400 -0 )
+1.0
+10
(400 -0,
+142
5690 -0 )
T4-2-12
test procedure:
NOTE: 1 mm=0.03937 in
ZX230 class
Reference
Page
Standard)
+150
+65
+65
ZX.
+90
+135
+125
+140
3.04 (31, 440)
18.1 (185, 2630)
MPa (kgf/cm2, psi)
10°
60 or less
T4-2-13
NOTE: 1 mm=0.03937 in
ZX230 class
Reference
Page
Standard)
track is jacked up.
Fast Speed 17.1±1.0 LC: 18.7±1.0
Slow Speed 28.2±2.0 LC: 30.0±2.0
200 or less
mm /180°
deg. more
3
bucket empty
Boom Raise 3.3±0.3
Boom Lower 2.5±0.3
DIG FUNCTION DRIFT CHECK mm/5 min 2.96 m arm T4-4-16
3
Boom Cylinder
Arm Cylinder
Bucket Cylinder
Bucket Bottom
T4-2-14
NOTE: 1 mm=0.03937 in
ZX230 class
Reference
Page
Standard)
N (kgf, lbf･ft)
Arm Lever 15 (1.5, 10.8) or
less
less
Boom Lever 105±10
Arm Lever
84±10
Bucket Lever 84±10
Swing Lever 105±10
3
bucket empty
3
bucket empty
MPa (kgf/cm2, psi)
+1.0
Engine: Fast Idle 4.0 -0.5 Value indicated on Dr. ZX
+10 +142
(41 -5, 580 -71)
+1.0
Engine: Slow Idle 3.5 -0 Value indicated on Dr. ZX
+10 +142
(35 -0, 500 -0)
+1.2
+12 +171
MPa (kgf/cm2, psi) (8 -5, 114 -71)
T4-2-15
NOTE: 1 mm=0.03937 in
Standard)
MPa (kgf/cm2, psi)
+2.0
+20
(350 -5,
+284
4980 -71 )
+2.0
+20
(370 -10,
+284
5260 -142 )
+2.20
(315 -5,
+327
4479 -71 )
+2.0
(350 -5,
+284
4980 -71 )
+1.0
Bucket Roll-In +10
(379 -0,
+142
5389 -0 )
+1.0
+10
(400 -0,
+142
5690 -0 )
T4-2-16
test procedure:
NOTE: 1 mm=0.03937 in
ZX270 class
Reference
Page
Standard)
+150
+65
+65
ZX.
+90
+135
+125
+140
3.04 (31, 440)
18.1 (185, 2630)
MPa (kgf/cm2, psi)
10°
60 or less
T4-2-17
NOTE: 1 mm=0.03937 in
ZX270 class
Reference
Page
Standard)
track is jacked up.
34.6±2.0 LC: 36.1±2.0
Fast Speed
34.6±2.0 LC: 36.1±2.0
Slow Speed
200 or less
mm /180°
deg. more
3
bucket empty
Boom Raise 3.6±0.3
Boom Lower 2.6±0.3
3
Boom Cylinder
Arm Cylinder
Bucket Cylinder
Bucket Bottom
T4-2-18
NOTE: 1 mm=0.03937 in
ZX270 class
Reference
Page
Standard)
N (kgf, lbf･ft)
Arm Lever 15 (1.5, 10.8) or
less
less
Boom Lever 105±10
Arm Lever
84±10
Bucket Lever 84±10
Swing Lever 105±10
3
bucket empty
3
bucket empty
MPa (kgf/cm2, psi)
+1.0
Engine: Fast Idle 4.0 -0.5 Value indicated on Dr. ZX
+10 +142
(41 -5, 580 -71)
+1.0
Engine: Slow Idle 3.5 -0 Value indicated on Dr. ZX
+10 +142
(35 -0, 500 -0)
+1.2
+12 +171
MPa (kgf/cm2, psi) (8 -5, 114 -71)
T4-2-19
NOTE: 1 mm=0.03937 in
Standard)
MPa (kgf/cm2, psi)
+2.0
+20
(350 -5,
+284
4980 -71 )
+2.0
+20
(370 -10,
+284
5260 -142 )
+2.3
(320 -5,
+327
4550 -71 )
+2.0
(350 -5,
+284
4980 -71 )
+1.0
Bucket Roll-In +10
(379 -0,
+142
5389 -0 )
+1.0
+10
(400 -0,
+142
5690 -0 )
With the track jacked up 3.0 Allowable limit: 5 or more
With the motor relieved 6.0
T4-2-20
(Blank)
T4-2-21
MAIN PUMP P-Q DIAGRAM
• Hydraulic P-Q Control (Torque Control)

• ZX200 class, 225 class Points on P-Q Line
(REFERENCE: Measured at Test Stand) Delivery Pressure Flow Rate
2
MPa (kgf/cm , psi) L/min (gpm)
• Rated Pump Speed: A 3.9 (40, 570) 194±3 (51.2±0.8)
-1
ZX200, 225 class: 1900 min (rpm) B 13.9 (142, 2020) [192] ([50.7])
-1
ZX230 class: 2000±10 min (rpm) C 16.7 (170, 2420) 163±6 (43.1±1.6)
-1
ZX270 class: 2050±10 min (rpm) D 20.5 (209, 2970) [123] ([32.5])
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F) E 26.9 (274, 3900) 99±6 (26.2±1.6)
F 34.3 (350, 4980) 72±6 (19.0±1.6)
NOTE: Refer to T4-5-22. The value indicated in parentheses is only a reference
value.
• ZX230 class Points on P-Q Line • ZX270 class Points on P-Q Line
Delivery Pressure Flow Rate Delivery Pressure Flow Rate
2
MPa (kgf/cm ) L/min MPa (kgf/cm )
2
L/min
A 3.9 (40) 204±3 A 3.9 (40) 209±3
+3
B 12.7 (130) 202 -6 B 14.7 (150) 207±3
C 15.6 (159) [202] C 16.5 (168) [207]
D 17.6 (180) 178±6 D 18.6 (190) 182±6
E 21.0 (214) [141] E 21.1 (215) [153]
F 27.1 (277) 115±6 F 27.4 (280) 126±6
The valve indicated in parentheses is only a reference The valve indicated in parentheses is only a reference
valve. valve.
L/min A
B
Flow D
Rate
Delivery Pressure MPa (kgf/cm2)

T178-04-05-001
T4-2-22
• P-Q Control by Pump Control Pilot Pressure Signal
∗ (REFERENCE: Measured at Test Stand) • ZX200 class, 225 class

Points on P-Q Line
• Rated Pump Speed: Pump Control Pressure Flow Rate
-1 2
ZX200 class, 225 class: 1900 min (rpm) MPa (kgf/cm , psi) L/min (gpm)
-1
ZX230 class: 2000±10 min (rpm) 1.7±0.05
-1
ZX270 class: 2050±10 min (rpm) A 67±2 (17.7±0.5)
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F) (17±0.5, 242±7)
B 2.0 (20, 284) [92] ([243])
NOTE: Refer to T4-5-24. 9+0.05−0.3
C 194±3 (51.2±0.8)
(30+0.5−3, 427+7−43)
The value indicated in parentheses is only a reference
• ZX230 class Points on P-Q Line value.
Pump Control Pressure Flow Rate
2
MPa (kgf/cm , psi) L/min (gpm) • ZX270 class Points on P-Q Line
A Pump Control Pressure Flow Rate
− 62+6−0 2
MPa (kgf/cm , psi) L/min (gpm)
B 1.7±0.05 (17±0.5) 71±2 A − 75+6−0
C 2.9+0.05−0.29 (30+0.5−3) 204±3 B 1.8±0.05 (18.5±0.5) 88±2
C 2.9+0.05−0.29 (30+0.5−3) 209±3
L/min
C
Flow
Rate
MPa (kgf/cm2)
Pump Control Pressure
T178-04-05-004
T4-2-23
INJECTION PUMP
ZX200 class, 225 class
Test Conditions:
1. Injection pump: PES6AD 101061-8830 8. Transfer pump pressure:
2
2. Governor: EP/RSV 105419-1660 157 kPa (1.6 kgf/cm , 23 psi)
3. Nozzle and nozzle holder assembly: 105780-8140 9. Injection pipe: Inner Dia. 2 mm×Outer Dia. 6
(Bosch No. EF8511/9A) mm-Length 600 mm (0.079×0.236-23.6 in)
4. Nozzle: 105780-0000 (Bosch No. DN12SD12T) 10. Fuel temperature: 40+5 °C (104+9 °F)
5. Nozzle holder: 105780-2080 (Bosch No. 11. Overflow valve opening pressure: 127 kPa (1.3
2
EF8511/9) kgf/cm , 18.5 psi)
6. Nozzle opening pressure:
2
17.2 MPa (175 kgf/cm , 2490 psi) NOTE: The nozzle test injection pressure is 17.2
2
7. Test fuel: ISO 4113 or SAE J967d MPa (175 kgf/cm , 2490 psi). However,
actual machine injection pressure is 18.1
2
MPa (185 kgf/cm , 2630 psi).
Injection rate adjustment

Average Injection Maximum Variance
Adjusting Pump Speed Rack Position
Strokes Rate Between Cylinders Fixed Remarks
Point (mm-1) (mm)
(cm3/1000 Stroke) (%)
A 1075 10.3 89±1.5 ±2 Lever Basic
C 450 Approx. 7.4 9±1.3 ±14 Rack
D 100 - 150±5 - Lever Rack limit
Governor adjustment
Above 14.0
Rack limit
D Idle-sub spring setting
11.0
Governor spring setting
10.9±0.1
A
10.3
Rack Position
(mm) 9.8±0.1
8.0
7.5 C
10.2-0.5
7.3±0.3
0 240 450
1075 1200
350 (500) (1110) 1125
T178-04-05-003
Pump Speed min-1 (rpm)
T4-2-24
ZX230 class
Test Conditions:
2
2
EF8511/9) kgf/cm , 37 psi)
2
7. Test fuel: ISO 4113 or SAE J967d 2
MPa (175 kgf/cm , 2490 psi). However,
2
MPa (185 kgf/cm , 2630 psi).

Adjusting Pump Speed Rack Position
Strokes Rate Between Cylinders Fixed Remarks
Point (mm-1) (mm)
(cm3/1000 Stroke) (%)
A 1050 10.4 95±1.5 ±2 Lever Basic
C 450 Approx. 7.3 12±1.3 ±14 Rack
D 100 - 105±5 - Lever Rack limit
Governor adjustment
Rack limit
Above Idle-sub spring setting
Rack Position
(mm)
Pump Speed min-1 (rpm) T1HD-04-05-001
T4-2-25
ZX270 class
Test Conditions:
2
2
EF8511/9) kgf/cm , 37 psi)
2
7. Test fuel: ISO 4113 or SAE J967d 2
MPa (175 kgf/cm , 2490 psi). However,
2
MPa (185 kgf/cm , 2630 psi).

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

T1HG-04-05-001
T4-2-26
(Blank)
T4-2-27
ZX200 CLASS DR. ZX MONITOR INDI-
CATING VALUES
Unless specified, test under the following conditions. ∗
NOTE: Items marked ( ) are measurable with the
Engine Speed: Fast Idle built-in diagnosing system.
Work Mode Switch: Digging Mode ∗∗
Items marked ( ) are measurable with the
Power Mode Switch: P mode
built-in diagnosing system. However, it may
Auto-Idle/Acceleration Selector: OFF
be difficult to read the measured value
while operating the machine.
Reference Measured Value

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

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

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

Item Remarks
BOOM RAISE PILOT
∗ 4.15 When relieving
CONTROL PRESSURE (MPa)
ARM ROLL-IN PILOT
SWING PILOT CONTROL
∗ -
PRESSURE (MPa)
TRAVEL PILOT CONTROL
∗ 4.05
PRESSURE (MPa)
FRONT ATTACHMENT “ON-OFF” is dis-
∗ -
CONTROL PRESSURE (MPa) played
PUMP 2 PROPORTIONAL
3.92
VALVE OUTPUT
MAIN PUMP TORQUE PRO- Engine Slow Idle +
1.45
PORTIONAL BALVE OUTPUT Travel
ARM FLOW RATE PROPOR-
∗∗∗
TIONAL VALVE OUTPUT
(MPa)
Lever in Neutral 1.16
Swing and Arm Roll-In
1.13
Combined Operation
ARM REGENERATIVE PRO-
PORTIONAL VALVE OUTPUT
(MPa)
Swing, Arm Roll-In, and Boom
2.72
Raise Combined Operation
POWER DIGGING CONTROL
PRESSURE (MPa)
During Operation 2.92
When Relieving Boom Raise
2.92
Circuit
TRAVEL MOTOR CONTROL Traveling, Travel
2.92
PRESSURE (MPa) Mode Switch: Fast
EC MOTOR POSITION (Step) When relieving arm
376
roll-in circuit
NOTE: Up to serial No.104678
T4-2-31
ZAXIS225USR
DR. ZX MONITOR INDICATING VALUES

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

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

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

Item Remarks
BOOM RAISE PILOT
ARM ROLL-IN PILOT
SWING PILOT CONTROL
∗ -
PRESSURE (MPa)
∗ 4.00
PRESSURE (MPa)
∗ -
PUMP 2 PROPORTIONAL
3.92
VALVE OUTPUT
1.33
TIONAL VALVE OUTPUT (MPa)
1.02
Combined Operation
PORTIONAL VALVE OUT-
∗∗∗
PUT (MPa)
2.72
PRESSURE (MPa)
When Relieving Boom Raise Auto-Power
2.92
Circuit Lift Control
2.92
EC MOTOR POSITION (Step)
Minimum 0
Maximum 304
Maximum (Arm Roll-in Relief) 336
NOTE: *** Up to serial No.104678
T4-2-35
ZAXIS225US
DR. ZX MONITOR INDICATING VALUES

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

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

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

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

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

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

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

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

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

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

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

Item Remarks
BOOM RAISE PILOT
ARM ROLL-IN PILOT
SWING PILOT CONTROL
∗ -
PRESSURE (MPa)
∗ 4.90
PRESSURE (MPa)
∗ -
PUMP 2 PROPORTIONAL
3.92
VALVE OUTPUT
1.69
1.50
Combined Operation
∗∗∗
PUT (MPa)
1.94
PRESSURE (MPa)
2.92
Circuit
2.92
368
roll-in circuit
T4-2-47
SENSOR ACTIVATING RANGE
1. Checking Method
• Hydraulic Oil Temperature: 50 ± 5 °C

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

Minimum Speed 0.3 to 1.0 V
Engine Control Dial
Maximum Speed 4.0 to 4.7 V
Minimum Speed 2.5 to 2.7 V
Maximum Speed (Power Mode Switch: P) 3.3 to 3.7 V
EC Sensor
Maximum Speed (Power Mode Switch: HP) Maximum Speed
(Mode Switch: OFF) +0.2 V or more
2
Control Lever: Neutral 0 to 0.1 MPa (0 to 1.0 kgf/cm )
Pilot Control Shut-Off Lever: LOCK
Pressure Sensor 2
Control Lever: Full Stroke 3.3 to 3.9 MPa (34 to 40 kgf/cm )
Pilot Control Shut-Off Lever: UNLOCK
2
Pump Control Control Lever: Neutral 0 to 1 MPa (0 to 10 kgf/cm )
2
Pressure Sensor Control Lever: Full Stroke 2.9 to 3.9 MPa (30 to 40 kgf/cm )
N Sensor 20°C (Between Ground to Signal) 810 ± 240 Ω
T4-2-48
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary
1. Measure the engine speed using the built-in di- 2
agnosing system or Dr. ZX. If the built-in diag-
nosing system or Dr. ZX is not available, use an 1
engine speed meter or a pulse counter. (Refer to
the TROUBLESHOOTING / General group.)
2. Measure the engine speeds in each mode.
NOTE: Measure the engine speed before per-

forming all other tests to check that the en-
gine speed meets specification. Because, if
the engine speed is not adjusted correctly,
all other performance data will be unreli-
able. T107-06-02-002
Preparation: 3
1. Select the monitor function of the built-in diag-
nosing system (In case of Dr. ZX, connect it first).
When using an engine speed meter, install speed
pickup (2) to injection pipe (1).
When using a pulse counter, disconnect the
N-sensor connector.
2. Warm up the machine until the engine coolant
temperature reaches 50 °C (122 °F) or more, and
hydraulic oil is 50±5 °C (122±9 °F).
IMPORTANT: Never attempt to the readjust stop-

per (3).
T107-06-02-001
T4-3-1
Measurement: Evaluation:
1. Check engine speeds for auto-warm up (when Refer to T4-2 Operational Performance Standard.
starting the engine), auto-idle, slow idle, fast idle
(when normal), fast idle (when the ECO is deac- Remedy:
tivated), fast idle (in the E mode), and fast idle (in Refer to T5-4 Troubleshooting B.
the HP mode).
2. Select the switch positions and the test conditions NOTE: ECO stands for the auto engine speed re-
corresponding to the engine speed to be meas- duction system by 200 min .
-1
ured as shown in the table below.

3. When using the pulse counter, read the pulse
counter. Calculate the engine speed using the
following formula:
-1
Engine Speed (min ) =
Pulse Numbers (Hz) × 60 / 34
Engine Power Auto-Idle/ Auto- Work
Control Mode Acceleration Mode Test Conditions
Dial Switch Selector Switch
Digging
Slow Idle Min. Speed P OFF
Mode
Fast Idle Digging
Max. Speed P OFF
(Normal) Mode
Fast Idle Check in the Dr. ZX special
Digging
(With ECO deac- Max. Speed P OFF functions with ECO deacti-
Mode
tivated) vated.
Fast Idle Digging Check the engine speed while
Max. Speed P OFF
(Relief operation) Mode relieving the boom raise circuit.
Fast Idle Digging
Max. Speed E Mode OFF
(E mode) Mode
Fast Idle Digging Check the engine speed while
Max. Speed HP Mode OFF
(HP mode) Mode relieving the boom raise circuit.
Check engine speed 4 sec-
Digging
Auto-Idle Max. Speed P Auto-Idle onds after returning all control
Mode
levers to neutral.
Check reduced engine speed
Digging
Auto-Acceleration Max. Speed P Auto-Acceleration within 3 seconds after return-
Mode
ing all control levers to neutral.
Digging Check only when oil tempera-
Warming Up Max. Speed P OFF
Mode ture is lower than 0 °C (32 °F).
T4-3-2
Monitor Panel Switch Panel
Engine Con-
trol Dial
Auto-Idle/Acceleration
Selector
Power Mode
Switch
Work Mode
Switch
T178-01-01-003
T178-01-01-004
T4-3-3
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders to
check for a decline in engine power.
2. Check exhaust gas color. Keep track of engine oil
consumption.
3. Check for abnormalities in the intake system, in-
cluding the air filter.
Preparation:
1. Confirm that valve clearances are correct.
2. Confirm that the batteries are charged properly.
3. Run the engine until the coolant temperature
gauge reaches the operating range.
4. Stop the engine. Remove glow plugs from each
cylinder.
NOTE: Unless the fuel delivery pipes are discon-

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

compression gauge in place of the glow plug in
one cylinder. (Be sure to sufficiently tighten the
adaptor and compression gauge to prevent air
leakage.)
Measurement:
1. Turn the starter to crank the engine. Record the
compression pressure of each cylinder.
2. Repeat measurement three times for each cylin-
der and calculate the mean values.
Evaluation:
Refer to T4-2 Operational Performance Standard.
Remedy:
Refer to engine shop manual.
T4-3-4
(Blank)
T4-3-5
VALVE CLEARANCE ADJUSTMENT
Summary:
1. Perform the measurement when the engine is
cold.
2. Before starting work, clean the head cover
mounting area to avoid contamination in the en-
gine.
Preparation:
1. Locate the top dead center (TDC) in the com-
pression stroke. Top Mark
Align the TDC mark on the crank pulley with the
pointer located on the timing gear case as illus-
TDC Mark
trated. Piston No.1 (or piston No.6) is now posi-
tioned at the TDC in its compression stroke.
Timing Gear
Case
NOTE: When rotating the crank pulley, remove the
fan guard. Then, rotate the fan while hold- Crank Pulley
ing the fan belt. If it is difficult to rotate, re-
move all glow plugs to release the com-
pression pressure.
T157-05-02-002
2. Remove the head cover.
3. Move push rods for the intake and exhaust valves
on the No.1 cylinder up and down by hand. If any
clearances on the both ends of the push rods are
found, piston No.1 is positioned at TDC in the
compression stroke. (If the exhaust valve of cyl-
inder No.1 is pushed down, piston No.6 is posi-
tioned at TDC in the compression stroke.
Start measurement from the cylinder (No.1 or
No.6) positioned at TDC in the compression
stroke.
T4-3-6
Measurement:
1. Insert a thickness gauge into the clearance be-
tween the rocker arm and the valve stem end to
measure the valve clearance.
NOTE: The cylinders are aligned from No.1 to

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

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

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

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

rocker arms. Insert the thickness gauge set at 0.4
mm, adjust the adjusting screws.
2. After adjusting, retighten the lock nuts to the
specification.
Recheck the valve clearance after the lock nuts
are tightened.
: 25.5±4.9 N⋅m
(2.6±0.5 kgf⋅m, 18.8±3.6 lbf⋅ft)
T4-3-7
NOZZLE CHECK
Summary:
1. Check the injection pressure and the spray pat-
tern with a nozzle tester.
2. Before starting work, clean the nozzle holder
mounting area to avoid contamination in the en-
gine.
Preparation:
1. Remove the nozzle holders.
Remove all nozzle holders and fuel injection pip-
ings from the engine.
2. Attach a nozzle holder to the nozzle tester.
Measurement:
CAUTION: Never touch spray directly. The
fuel spray from the nozzle may penetrate the
skin, resulting in serious injury. If fuel pene-
trates into the blood stream, it may cause
blood toxication.
1. Injection pressure
After attaching the nozzle holder to the nozzle
tester, strongly make several strokes of the tester
to inject fuel. Then, while operating the tester at T107-06-02-006
approx. 60 time strokes a minute, measure the
fuel injection pressure.
If adjustment is required, loosen the lock nuts and
adjust the adjusting screws. Turn clockwise to in-
crease the pressure, and counterclockwise to de-
crease the pressure.
2. Spray pattern
For this test, turn the pressure tester knob to by-
pass the pressure gauge. Attach the nozzle
holder to the nozzle tester. Strongly make several
strokes of the tester and check the fuel spray pat-
tern.
3. Oil tight condition
Keep the pressure slightly below the injection
pressure. Check for fuel leak from around the
nozzle tip.
NOTE: Use clean diesel oil.
T4-3-8
Evaluation:
1. Standard Injection Pressure:
Normal
2. Spray Pattern
• Large-size spray should not be visible to the na-
ked eye.
• No stray sideways sprays should be seen.
• During initial injection stage, spray size should be
fine and injected intermittently.
• There should be no drips found.
• Injection spray angle must be normal.
3. Oil Tight Condition
No fuel leaks.
T102-02-11-005
Abnormal
Adjustment:
1. To adjust the injection pressure, loosen the lock
T102-02-11-006
nuts. Adjust the adjusting screw.
Turn clockwise to increase the pressure, and
counterclockwise to decrease the pressure.
2. After adjusting, retighten the lock nuts.
T107-06-02-007
T4-3-9
INJECTION TIMING
Timing Mark
Inspection:
1. Position No.1 piston to the top dead center. Turn Top Mark
the crank pulley in the direction of rotation (clock-
wise as seen from the front of the engine) to set a
TDC Mark
“TDC” mark on the crank pulley under the “Top
mark”, located on the timing gear case.
Timing Gear
Case
NOTE: When rotating the crank pulley, remove the
fan guard. Then, rotate the fan while hold- Crank Pulley
ing the fan belt. If it is difficult to rotate, re-
move all glow plugs to release the com-
pression pressure.
T157-05-02-002
2. Remove the timing check hole cover on the front
section of the fuel injection pump. Gear Case
Projection
When the mark on the injection pump is set un-
der the projection of the gear case, No.1 piston is
positioned at the top dead center. If the mark is
not set under the projection, keep turning to ad-
just. Check
Hole
NOTE: The alignment mark on the injection pump

cannot be directly seen through the check Injection Pump
hole. Use a mirror for checking. Alignment Mark
3. Remove the injection piping from No.1 cylinder. T107-02-12-007
4. Remove the delivery valve holder for No.1 cylin- Gear Case
der from the injection pump to pull the delivery Projection
valve and the spring out. Reinstall the delivery
valve holder.
: 39 to 44 N⋅m
(4 to 4.5 kgf⋅m, 28.9 to 32.6 lbf⋅ft)
Injection Pump
Alignment Mark T107-02-12-008
T4-3-10
5. Turn the crank pulley at approx. 30 degrees coun-
terclockwise.
6. While supplying fuel with the feed pump, turn the
crank pulley slowly clockwise just until fuel cannot
be seen from the top of the delivery valve hole.
This is the position where the injection starts.
7. Check the “TDC” mark, located on the crank pul-
ley for what degrees the “TDC” mark indicates.
Adjustment:
1. Turn the crank pulley so that the “TDC” mark
comes just above the correct timing position on
the timing gear case.
2. Loosen the mounting nuts of the injection pump.
3. When advancing timing, tilt the injection pump
outward against the cylinder block.
When delaying timing, tilt the injection pump in- T107-02-12-009
ward against the cylinder block.
T4-3-11
LUBRICANT CONSUMPTION
Measuring Method
1. Place the machine on level firm ground, and
leave it for at least one hour to let the lubricant
lower to the oil pan.
At this time, confirm that the machine is level, us-
ing a leveler.
2. Record the read-out A (unit: hour) of the hour
meter.
3. Replenish the lubricant up to the high-level
gauge.
4. Operate the machine for at least 100 hours or un-
til the oil level lowers to the low-level gauge.
IMPORTANT: Make sure to keep the ma-

chine-leaving time in Step 1 above.
5. Place the machine on level firm ground, and
leave it for at least one hour to let the lubricant
lower to the oil pan.
At this time, confirm that the machine is level, us-
ing a leveler.
6. Record the read-out B (unit: hour) of the hour
meter.
7. Replenish the lubricant up to the high-level gauge
while measuring the oil-replenishing volume C.
NOTE: For measuring, use a high-precision
measuring cylinder or the like.
8. Determine lubricant consumption from the fol-

lowing equation:
Oil replenishing volume (C) [mL] / Operating hours
(B-A) [hr]
Evaluation:
T4-3-12
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary: Measurement:
Measure the time required for the excavator to travel 1. Measure both the slow and fast speeds of the
a 20 m (65.6 ft) test track. machine.
2. Select the following switch positions:
Preparation: Travel Engine Power Work Auto-Idle/
1. Adjust the track sag on both sidetracks equally. Mode Control Mode Mode Acceleration
2. Prepare a flat and solid test track 20 m (65.6 ft) in Switch Dial Switch Switch Selector
length with extra length of 3 to 5 m (9.8 to 16 ft) Slow Digging
on both ends for machine acceleration and de- Fast Idle P Mode OFF
Mode Mode
celeration. Fast Digging
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above Fast Idle P Mode OFF
Mode Mode
the ground with the arm and bucket rolled in.
4. Maintain hydraulic oil temperature at 50±5 °C 3. Start traveling the machine in the acceleration
(122±9 °F). zone with the travel levers to full stroke.
4. Measure the time required to travel 20 m (65.6 ft).
5. After measuring the forward travel speed, turn the
upperstructure 180° and measure the reverse
travel speed.
Arm Rolled-In, Bucket Rolled-In 6. Repeat steps 4. to 5. three times in each direction
End and calculate the average values.
Bucket Height: 0.3 to 0.5 m
Evaluation:
Start
20 m Deceleration
Refer to the Operational Performance Standard in
Zone Group T4-2.
3 to 5 m
Acceleration Remedy:
Zone
3 to 5 m Refer to the Troubleshooting B in Group T5-4.
T105-06-03-001
T4-4-1
TRACK REVOLUTION SPEED
Measure the track revolution cycle time with the track 1. Measure both the slow and fast travel speeds of
raised off ground. the machine.
Preparation: Travel Engine Power Work Auto-Idle/
1. Adjust the track sag of both side tracks to be Mode Control Mode Mode Acceleration
equal. Switch Dial Switch Switch Selector
2. On the track to be measured, mark one shoe with Slow Digging
chalk. Mode Mode
3. Swing the upperstructure 90° and lower the Fast Digging
bucket to raise the track off ground. Keep the Mode Mode
boom-arm angle between 90 to 110° as shown. 3. Operate the travel control lever of the raised track
Place blocks under the machine frame. to full stroke.
4. Measure the time required for 3 revolutions in
both directions after a constant track revolution
speed is obtained.
5. Raise the other side and repeat the above
procedures.
90 to 110° 6. Repeat steps 3. to 5. three times and calculate
the average values.
Evaluation:
Refer to the Operational Performance Standard
M104-07-067 Table in Group T4-2.
Mark
CAUTION: Securely support the raised track NOTE: The measurement data obtained through
using wooden blocks. the raised track revolution test may have
wide variations. Therefore, the evaluation
4. Maintain the hydraulic oil temperature at 50±5 °C based on the results obtained from the 20
(122±9 °F). m travel speed check described before is
more recommendable.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-2
MISTRACK CHECK
1. Allow the machine to travel 20 m (65.6 ft). 1. Measure the amount of mistracking in both fast,
Measure the maximum tread deviation from the and slow travel speeds.
tread chord line drawn between the travel start 2. Select the following switch positions:
and end points to check the performance Travel Engine Power Work Auto-Idle/
equilibrium between both sides of the travel Mode Control Mode Mode Acceleration
device systems (from the main pump to the travel Switch Dial Switch Switch Selector
motor). Slow Digging
2. If measured on a concrete surface, the tread Fast Idle P Mode OFF
Mode Mode
deviation has a trend to decrease. Fast Digging
Mode Mode
Preparation:
1. Adjust the track sag of both tracks to be equal. 3. Start traveling the machine in the acceleration
2. Provide a flat, solid test yard 20 m (65.6 ft) in zone with the travel levers at full stroke.
length, with extra length of 3 to 5 m (9.8 to 16 ft) 4. Measure the maximum distance between a
on both ends for machine acceleration and straight 20 m (65.6 ft) tread chord line and the
deceleration. tread made by the machine.
5. After measuring the tracking in forward travel,
turn the upperstructure 180° and measure in
Maximum Distance reverse travel.
6. Repeat steps 3. to 5. three times and calculate
the average values.
Acceleration
Zone: Evaluation:
3 to 5 m
20 m Refer to the Operational Performance Standard Table
in Group T4-2.
Remedy:
T105-06-03-022
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above

the ground with the arm and bucket rolled in.
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T4-4-3
TRAVEL PARKING LEAKAGE
Summary:
To measure the parking brake function on a specified
slope.
Preparation:
1. The surface of the test slope shall be even with a
gradient of 20 % (11.31°).
0.2 to 0.3 m
2. Mark a white line on the travel device cover.
3. Hold the bucket 0.2 to 0.3 m (8 to 12 in) above
the ground with the arm and bucket fully rolled in.
(122±9 °F).
T105-06-03-004
Measurement:
1. Measure the travel parking brake slip amount
while parked.
2. Climb the slope and place the travel levers in
neutral.
3. Stop the engine.
4. After the machine stops, put alignment marks on
a track link or shoe, and the track side frame.
5. After 5 minutes, measure the distance between
the marks on the track link or shoe and the track
side frame.
Evaluation:
Refer to the Operational Performance Standard
Table in Group T4-2.
Alignment marks on the trackside
frame and shoe when the machine
comes to a stop.
Displacement measured
after 5 minutes.
T105-06-03-006
T4-4-4
SWING SPEED
Summary:
CAUTION: Prevent personal injury. Always
Measure the time required to swing three complete
make sure that the area is clear and that
turns.
co-workers are out of the swing area before
starting the measurement.
Preparation:
1. Check the lubrication of the swing gear and swing
Measurement:
bearing.
2. Place the machine on flat, solid ground with
ample space for swinging. Do not conduct this Auto-Idle/
Engine Con- Power Mode Work Mode
test on slopes. Acceleration
trol Dial Switch Switch
3. With the arm rolled out and bucket rolled in, hold Selector
the bucket so that the height of the bucket pin is Digging
the same as the boom foot pin. The bucket must Mode
be empty.
2. Operate swing control lever fully.
3. Measure the time required to swing 3 turns in one
direction.
4. Operate swing control lever fully in the opposite
direction and measure the time required for 3
turns.
The same height as the
boom foot pin height the average values.
T105-06-03-013 Evaluation:
NOTE: In case a sufficient space for the meas- Group T4-2.
urement is difficult to find, carry out the
measurement with the boom fully raised Remedy:
and the arm fully rolled-in. Refer to the Troubleshooting B in Group T5-4.
T178-04-03-001

(122±9 °F).
T4-4-5
SWING FUNCTION DRIFT CHECK
Summary:
Measure the swing drift on the bearing outer
circumference when stopping after a 180° full-speed
swing.
Preparation:
bearing.
2. Place the machine on flat, solid ground with
ample space for swinging. Do not conduct this Two Check Marks
test on a slope.
T105-06-03-008
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. The bucket must
be empty.
4. Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
5. Swing the upperstructure 180°.
(122±9 °F).

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

T4-4-6
Measurement:
Auto-Idle/
Engine Con- Power Mode Work Mode
Acceleration
trol Dial Switch Switch
Selector
Measure Difference Between Marks
Digging
Mode
2. Operate the swing control lever fully and return it

to the neutral position when the mark on the
upperstructure aligns with that on the track frame
after swinging 180° . Marking on the Track Frame
3. Measure the distance between the two marks.
Marking on the Swing Bearing
4. Align the marks again, swing 180°, then test in
the opposite direction.
5. Repeat steps 2. to 4. three times each and T105-06-03-010
calculate the average values.
Evaluation:
Group T4-2.
Remedy:
T4-4-7
SWING MOTOR LEAKAGE
Summary:
Check for upperstructure drift while suspending a
load on a slope.
Preparation:
bearing.
2. Park the machine on a smooth slope with a
gradient of 26.8 % (15°).
3. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
ZX200 class, 225 class: W=1050 kg (2320 lb)
ZX230 class: W=1350 kg (2980 lb)
ZX270 class: W=1500 kg (3310 lb)
4. With the arm rolled out, and bucket rolled in,
position the arm top pin height to be level with the
boom foot pin.
5. Swing the upperstructure to position it 90° to the T105-06-03-011
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as
illustrated.
(122±9 °F).
T4-4-8
Measurement:
1. Select the following switch position:
Auto-Idle/
Power Mode Work Mode
Acceleration
Switch Switch
Selector
Measure Difference Between Marks
P Mode Digging Mode OFF
2. Maintain the engine at slow idle. After five

minutes, measure the difference between the
marks along the swing bearing periphery and the
track frame.
Marking on the Track Frame
3. Perform the measurement in both right and left
swing directions. Marking on the Swing Bearing
4. Perform the measurement three times in each
direction and calculate the average values. T105-06-03-010
Evaluation:
Group T4-2.
Remedy:
T4-4-9
MAXIMUM SWINGABLE SLANT ANGLE
With the upperstructure swung 90° to the slope, 1. Select the following switch positions:
check the maximum slant angle on which the upper- Engine Auto-Idle/
structure can swing to the uphill side. Control Acceleration
Switch Switch
Dial Selector
Preparation: Fast Idle P Mode Digging Mode OFF
1. Check that the swing gear and bearing are well
lubricated.
2. Load bucket fully. In lieu of loading the bucket, 2. Operate the swing lever to full stroke to swing the
weight (W) of the following specification can be upperstructure to the uphill side.
used. 3. If the machine can swing, measure the cab floor
ZX200 class, 225 class: W=1050 kg (2320 lb) slant angle.
ZX230 class: W=1350 kg (2980 lb) 4. Increase the slope angle and repeat steps 2. and
ZX270 class: W=1500 kg (3310 lb) 3. Check both clockwise and counterclockwise.
3. With the arm cylinder fully retracted and the 5. Perform the measurement three times.
bucket cylinder fully extended, hold the arm top
pin to the position flush with the boom foot pin Evaluation:
height. Refer to the Operational Performance Standard in
4. Climb a slope and swing the upperstructure 90° Group T4-2.
to the slope.
5. Maintain the hydraulic oil temperature at 50±5 °C Remedy:
(122±9 °F). Refer to the Troubleshooting B in Group T5-4.
T105-06-03-011
T4-4-10
(Blank)
T4-4-11
SWING BEARING PLAY
Summary:
Measure the swing bearing play using a dial gauge to
check the wear of bearing races and balls.
Preparation:
1. Check swing bearing mounting bolts for loose-
ness.
2. Check the lubrication of the swing bearing. Con-
firm that bearing rotation is smooth and without
noise.
3. Install a dial gauge on the track frame as shown, Magnetic Dial
using a magnetic base. Base Gauge
T105-06-03-014
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the front
idlers.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race.
6. Bucket should be empty.
NOTE: The measured value will vary depending Round Trunk

on where the magnet base is secured.
Secure the magnet base onto the round
trunk or in a position as close to the round
trunk as possible.
T105-06-03-015
T4-4-12
Measurement:
1. With the arm rolled out and bucket rolled in, hold
Measurement: (h1)
the bucket so that the height of the bucket pin is
the same as the boom foot pin. Record the dial
gauge reading (h1).
2. Lower the bucket to the ground and use it to raise
the front idler 0.5 m (20 in). Record the dial gauge
reading (h2).
3. Calculate bearing play (H) from this data (h1 and The same height
as the boom foot
h2) as follows: pin height
H=h2-h1
Evaluation: T105-06-03-007

Group T4-2. Measurement: (h2)
T105-06-03-017
T4-4-13
HYDRAULIC CYLINDER CYCLE TIME
Measure the cycle time of the boom, arm, and bucket
cylinders.
Preparation:
1. Be sure to measure at the position as follows.
• To measure the cycle time of the boom cylinders:
With the arm rolled out and the empty bucket
rolled in, lower the bucket to the ground, as
shown.
• To measure the cycle time of the arm cylinder: T105-06-03-018
With the empty bucket rolled in, position the arm

so that it is vertical to the ground. Lower the boom
until the bucket is 0.5 m (20 in) above the ground.
• To measure the cycle time of the bucket cylinder:
The empty bucket should be positioned at
mid-stroke between roll-in and roll-out, so that the
sideplate edges are vertical to the ground.
0.5 m
(122±9 °F).
T105-06-03-019
T105-06-03-020
T4-4-14
Measurement:
Engine Auto-Idle/
Control Acceleration
Switch Switch
Dial Selector
Fast Idle P Mode Digging Mode OFF
2. To measure cylinder cycle times:

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

Evaluation:
Group T4-2.
Remedy:
T4-4-15
DIG FUNCTION DRIFT CHECK
• Maximum Reach Position
Summary:
Measure dig function drift, which can be caused by
oil leakage in the control valve and boom, arm, and
bucket cylinders, with the loaded bucket.
NOTE: When testing the dig function drift just after

cylinder replacement, slowly operate each
Extended
cylinder for ten minutes to its stroke end to Retracted
Distance
Distance
purge air. Retracted
Distance
Preparation:
1. Load bucket fully. In lieu of loading the bucket, Same Height
weight (W) of the following specification can be
used.
ZX200 class, 225 class: W=1050 kg (2320 lb) Bucket Bottom
ZX230 class: W=1350 kg (2980 lb)
ZX270 class: W=1500 kg (3310 lb)
2. Position the arm cylinder with the rod 50 mm (2 T105-06-03-021
in) extended from the fully retracted position. Arm Cylinder Extension
3. Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position.
4. With the arm rolled out and the bucket rolled in,
hold the bucket so that the height of the bucket
pin is the same as the boom foot pin.
Mark
(122±9 °F).
Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the bucket, as well as the boom, arm and T110-06-03-001
bucket cylinders. Boom and Bucket Cylinder Retraction

3. Repeat step 2. three times and calculate the
average values. Mark Mark
Evalution:
Group T4-2.
Remedy:
T110-06-03-002
T4-4-16
• Arm Roll-In Position
Summary:
Measure dig function drift, which can be caused by
oil leakage in the control valve and boom, arm, and
bucket cylinders.
NOTE: When testing the dig function drift just after

cylinder replacement, slowly operate each
cylinder for ten minutes to its stroke end to
purge air.
Preparation:
1. The bucket must be empty.
2. Position the arm cylinder with the rod 50 mm (2
in) retracted from the fully extended position.
3. Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position.
4. With the arm rolled in and the bucket rolled in.
1m
Lower the boom until the arm tip is 1 m (40 in)
above the ground.
T173-04-03-001
(122±9 °F).
Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the arm tip, as well as the boom, arm and
bucket cylinders. Cylinder Retraction
average values. Mark Mark
Evalution:
Group T4-2.
Remedy:
T110-06-03-002
T4-4-17
CONTROL LEVER OPERATING FORCE
Summary:
1. Use a spring scale to measure the maximum
resistance of each control lever as illustrated.
2. Measure the maximum operating force of the
front attachment control lever.
3. Measure the operating force at the grip center of
each control lever.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
CAUTION: Prevent personal injury. Always T107-06-03-003

T107-06-03-004
T4-4-18
Measurement:
1. Measure each control lever.
Engine Auto-Idle/
Switch Switch
Dial Selector
3. Operate each boom (raise), arm and bucket lever

to the fully and measure the maximum operating
force for each with each actuator relieved.
4. Operate boom (lower) lever and measure the
maximum operating force with the boom (lower)
relieved by jacking up the machine in a safe area.
5. Operate swing lever and measure the maximum
operating force with swing relieved after securing
the front attachment to prevent swinging.
6. Lower the bucket to the ground to raise one track
off the ground. Operate the travel lever to full
stroke and measure the maximum operating
force required. When finished, lower the track
and then jack-up the other track.
the average values.
Evalution:
Refer to the Orerational Performance Standard in
Group T4-2.
T4-4-19
CONTROL LEVER STROKE
Summary:
1. Measure each lever stroke at the lever top using
a ruler.
2. Measure the lever stroke at the grip center of
each control lever.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both
side lever strokes.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement: T107-06-03-005
1. Stop the engine.

2. Measure each lever stroke at the lever top from
neutral to the stroke end using a ruler.
average values.
Evalution:
Refer to the Orerational Performance Standard in
Group T4-2.
T4-4-20
(Blank)
T4-4-21
COMBINED BOOM RAISE/SWING
FUNCTION CHECK
Summary:
1. Check boom raise and swing movement and
speeds while operating both functions
simultaneously.
2. Make sure that the cylinders don’t hesitate while
operating the cylinder with the engine running at
fast idle.
Preparation:
1. With the arm fully rolled out and bucket fully rolled
in, lower the bucket to the ground. The bucket
must be empty.
(122±9 °F).
CAUTION: Prevent personal injury. Always T107-06-03-009

T4-4-22
Measurement:
Engine Auto-Idle/
Switch Switch
Dial Selector
2. Raise the boom and swing simultaneously, both

at full stroke.
3. When the upperstructure rotates 90°, release the
control levers to stop both functions. Measure the
time required to swing 90° and the height (H) of
the bucket teeth. (The bucket must be empty.)
4. Repeat steps 2. to 3. three times and calculate T107-06-03-010
the average values.
Evalution:
Group T4-2.
Remedy:
H
T107-06-03-011
T4-4-23
BOOM RAISE/ARM ROLL-IN COMBINED
OPERATION
Summary:
1. Performance of boom raise and arm roll-in com-
bined operation is checked.
2. Make sure that the cylinders don’t hesitate while
operating the cylinder with the engine running at
fast idle.
Preparation:
1. Fully retract the arm cylinder and fully extend the
bucket cylinder. Adjust the boom cylinder so that
the bucket tooth tip height is 0.5 m (1 ft 8 in)
above the ground. (Empty the bucket.)
2. Maintain the hydraulic oil temperature at 50 ± 5
°C (122±9 °F). 0.5 m
Measurement: T107-06-03-006
1. Select the switch positions as follows.

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

the same time.
3. Measure the time required for the arm to reach
the stroke end with the bucket empty.
4. Repeat the measurement three times and calcu-
late the average value.
Evaluation:
Remedy:
Refer to T5-4 Troubleshooting B.
T107-06-03-008
T4-4-24
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove the plug from the pilot filter. Install
adapter (ST 6069) and pressure gauge (ST 6942)
to the removed plug hole (pressure check port).
: 14 mm
Plug
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
(122±9 °F).
T178-03-07-001
Measurement:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Digging
Mode
Digging
Slow Idle P Mode OFF
Mode
2. Measure the pilot pressure in each specified set-

ting above.
late the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-5-1
Primary Pilot Pressure Adjustment Procedure
Adjustment:
Adjust the relief valve set-pressure as necessary.
: 41 mm
Relief Valve
1. Remove plug (1) from the relief valve.

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

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

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

Shim Thickness Change in Relief Pressure
(mm) kPa (kgf/cm 2) (psi)
0.2 61.8 (0.63) (9)
0.4 124.6 (1.27) (18)
0.8 249.2 (2.54) (36)
T4-5-2
(Blank)
T4-5-3
SECONDARY PILOT PRESSURE
Preparation:
Signal Control Valve
3. Measure the pressure by either of the following
methods.
NOTE: When disconnecting the pilot lines from the
Control
signal control valve, use tool (SNAP-ON Valve
GAN850812B: size 19.05 mm) to easily
disconnect the lines.
•Measure pressure at the location between the pilot

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

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

(122±9 °F).
T157-05-04-011
T4-5-4
Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
Digging
Mode
2. Measure the pilot pressure in each specified set-
ting above with the corresponding control lever
operated full stroke.
Evaluation:
T4-2.
Remedy:
T4-5-5
SOLENOID VALVE SET PRESSURE
Solenoid Valve Unit
Measure solenoid valve set pressure with both the Serial No.104679 and up (ZX200 class and 225 class)
Dr.ZX and the pressure gauge. Serial No.010327 and up (ZX230 class)
Serial No.020043 and up (ZX270 class)
Preparation:
3. Disconnect line (1) from the solenoid valve to be
measured. Install hose (Parts Number: 4216453),
tee (ST 6451), adapter (ST 6461), and pressure
gauge (ST 6942) to the disconnected end at the
solenoid valve side, as illustrated.
: 17 mm, 19 mm, 22 mm
Connect Dr.ZX to the machine for solenoid valve

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

Up to serial No.010326 (ZX230 class)
6 7 8 9 T178-01-02-003
Solenoid Valve
Pressure Gauge
Hose Tee Adapter T157-05-04-002
T4-5-6
Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
Digging
Mode
2. Operate as instructed below for each measuring

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

gauge.
Evaluation:
Refer to the performance Standard Table in Group
T4-2.
T4-5-7
Solenoid Valve Set Pressure Adjustment Proce-
dure 7
IMPORTANT: Do not loosen the adjusting screw

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

Screw Turns 1/4 1/2 3/4 1
kPa 78 156 234 312
Change in 2
(kgf/cm ) (0.8) (1.6) (2.4) (3.2)
Pressure
(psi) (11) (23) (34) (46)
8
7
T107-06-05-001
7 8
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-8
MAIN PUMP DELIVERY PRESSURE
The main pump delivery pressure can also be meas-
ured with Dr.ZX.
Preparation:
3. Remove the plug from the main pump delivery
port. Install adapter (ST 6069), hose (ST 6943)
and pressure gauge (ST 6941) on the port.
: 6 mm
Or connect Dr.ZX to the machine for main pump

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

neutral.
Evaluation:
T4-2.
Remedy:
T4-5-9
MAIN RELIEF VALVE SET PRESSURE
The main relief pressure can also be measured with
Dr.ZX.
Summary:
Measure the main relief valve setting pressure at the
main pump delivery port.
Preparation:
3. Remove the plug from the main pump delivery
port. Install adapter (ST 6069), hose (ST 6943)
and pressure gauge (ST 6941) on the port.
: 6 mm
Or connect Dr.ZX to monitor the main pump de-

livery pressure.
(122±9 °F).
T157-05-04-005
T4-5-10
Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
2. Relieve each actuator to measure main relief

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

are lower than the specified range, the
probable cause is a decrease of the main
relief valve setting pressure.
If the relief pressure of a particular function
is lower, the probable cause is other than
main relief valve.
T4-5-11
Main Relief Pressure Setting Adjustment Proce-
dure Main Relief
Valve
Adjustment:
Adjust the pressure setting of the main relief valve
using plug (3) (for the low-side relief pressure set-
ting) and plug (5) (for the high-side relief pressure
setting).
• High-Side Relief Pressure Setting Adjustment

Procedure
1. Loosen lock nut (1). Lightly tighten plug (3) until
the end of plug (3) comes into contact with piston
(2). Retighten lock nut (1).
: 27 mm
: Plug (3): 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
: Lock Nut (1):
68 to 78 N⋅m
(7 to 8 kgf⋅m, 51 to 58 lbf⋅ft)
M178-05-003
2. Loosen lock nut (4). Turn plug (5) to adjust the re-
lief pressure setting referring to the table below. 3
: 27 mm, 32 mm
: Lock Nut (4): 1
78 to 88 N⋅m
(8 to 9 kgf⋅m, 58 to 65 lbf⋅ft) 5
4
2
T157-05-04-009
Plug (5, 3)
Pressure Pressure
Increase Decrease
W107-02-05-127
T4-5-12
• Low-Side Relief Pressure Setting Adjustment
Procedure
1. Loosen lock nut (1). Turn plug (3) counter clock-
wisely until the specified value is obtained refer-
ring to the table below. Retighten lock nut (1).
: 27 mm
: Lock Nut (1):
59 to 68 N⋅m
(6 to 7 kgf⋅m, 43 to 51 lbf⋅ft)
2. Recheck the set pressures.

Plug Turns 1/4 1/2 3/4 1
Change in Relief MPa 7.1 14.2 21.3 28.4
Pressure: Plug (5) (kgf/cm2) 72.5 145 217.5 290
(High-Side Relief
(psi) 1030 2060 3090 4120
Pressure)
Change in Relief MPa 5.3 10.7 16.0 21.3
Pressure: Plug (3) (kgf/cm2) 54 109 163 217
(Low-Side Relief
(psi) 770 1550 2320 3090
Pressure)
T4-5-13
RELIEF PRESSURE (When relieving
Swing)
ZX200 class, 225 class, 230 class

Adjust pressure by changing the number of shims
(2).
1. Remove the swing relief valve.

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

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

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

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

A: JIS B 2401 G30 1B T178-03-02-001
B: AS568-023 (Aero-Space Standard)
C: AS568-125 (Aero-Space Standard) 1 2 3 4 5
5. Install the swing relief valve.

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

Shim Thickness Change in Relief Pressure
(mm) A B C T178-03-02-005
kPa (kgf/cm 2) (psi)
0.1 610 6.3 (60)
T4-5-14
ZX270 class Swing Relief
Valve
Adjustment
Loosen lock nut (2) to release adjusting screw (1).
1. Loosen lock nut (2).

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

: 24 mm, 32 mm
: 177 N⋅m (18 kgf⋅m)
T158-01-01-001
Serial No.20038 and up
Serial No.20038 and up 1 2
Adjusting Screw
1/4 1/2 3/4 1
Turns
Change MPa 2.5 5.0 7.5 10.0
in (kgf/cm2) (25.5) (51) (76.5) (102)
Pressure (psi) (363) (725) (1088) (1450)
T107-02-04-020
Up to serial No.20037
Adjusting Screw Up to serial No.20037
1/4 1/2 3/4 1
Turns 1 2
Change MPa 2.9 5.8 8.7 11.7
in (kgf/cm2) (30) (59.5) (89) (119)
Pressure (psi) (430) (850) (1270) (1690)
T157-02-04-006
Pressure Pressure
Increase Decrease
T157-05-04-023
T4-5-15
RELIEF PRESSURE (When relieving
Travel)
ZX200 , 225 class, 230 class

1. Remove the travel relief valve.
: 36 mm
2. Remove sleeve (1) and poppet (3).
3. Install shims (5) between poppet (3) and spring Travel Relief
guide (4) to adjust the set-pressure. Valve
4. Install the travel relief valve.

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

Shim Change in Relief
Thickness Parts No. Pressure
(mm) kPa (kgf/cm2) (psi)
0.5 A590103 900 (9.2) (130)
3 4
T135-06-04-001
T4-5-16
ZX270 class
Adjustment
Loosen lock nut (2) to adjust adjusting screw (1).
: 19 mm
: 6 mm
2. Turn adjusting screw (1) to adjust.
3. Tighten lock nut (2).

: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) Travel Relief
Valve
T157-05-04-010
Adjusting Screw
1/4 1/2 3/4 1
Turns 2 1
MPa 2.9 5.9 8.8 11.8
Change in
(kgf/cm2) (30) (60) (90) (120)
Pressure
(psi) (430) (850) (1280) (1710)
T157-05-04-008
2 1
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-17
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary:
1. The circuit pressure must be increased by apply- 3. If the overload relief valve performance must be
ing an external force while blocking the return cir- checked on the machine, however, measure the
cuit from the control valve. This measuring main relief pressure while releasing each front
method is hazardous and the results obtained function respective to the measuring overload re-
with this method are unreliable. lief valve. And, assume that the overload relief
2. The oil flow rate used to set the overload relief valve is functioning correctly if the obtained main
pressure is far less than that used to set the main relief pressure is within the specified value range.
relief pressure. Therefore, measuring the over- Measure the main pressure of the front functions
load pressure in the main circuit by increasing the as follows:
main relief set-pressure more than the overload
valve set-pressure is not a proper method. In ad- Preparation:
dition, in case a main relief valve designed to leak 1. Properly shut down the engine.
a small quantity of oil before reliving is used, its 2. Press the air release valve on top of the hydraulic
pre-leaking start pressure must be increased oil tank to release any remaining pressure.
more than the overload relief valve set-pressure. 3. Remove the plug from the main pump delivery
However, the pre-leaking start pressure is not al- port. Install adapter (ST 6069), hose (ST 6943)
ways increased more than the overload relief and pressure gauge (ST 6941) on the port.
valve set-pressure as the adjustable upper limit of : 6 mm
the main relief valve set-pressure is provided.
Accordingly, the overload relief valve assembly 4. Connect Dr.ZX to the machine for main pump de-
should be removed from the machine and livery pressure monitoring.
checked on a specified test stand at a correct oil Start the engine. Confirm that no oil leakage is
flow rate. Some overload relief valves come in observed at the pressure gauge connection.
contact with the control valve body to block the oil
passage. When this type of overload relief valve 5. Maintain the hydraulic oil temperature at 50±5 °C
is checked, the control valve body must be pre- (122±9 °F).
cisely finished as the test unit. Provide one con-
trol valve other than that on the machine as a test
kit.
T4-5-18
Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
2. Slowly operate bucket, arm, and boom control

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

Group T4-2.
T4-5-19
Overload Relief Valve Set Pressure Adjusting
Procedure
NOTE: In principle, adjust the overload relief valve

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

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

Screw Turns 1/4 1/2 3/4 1 1 2
Change in MPa 5.2 10.6 15.9 21.1
2
Relief (kgf/cm ) (54) (108) (162) (216)
Pressure (psi) (770) (1540) (2300) (3070)
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-20
(Blank)
T4-5-21
MAIN PUMP FLOW RATE MEASUREMENT
• P-Q Control (Torque Control) 5. Install a pressure gauge to the main pump to be
Summary: measured. (Refer to T4-5-9 Main Pump Delivery
Main pump performance is checked by measuring Pressure.)
the pump flow rate with a hydraulic tester installed at : 6 mm
the main pump delivery port (one side) to be meas- 6. Disconnect pipe (13) from the regulator. Connect
ured. Use Dr. ZX and a pressure gauge at the same plug (PF 1/4) to the disconnected pipe.
time. : 17 mm
7. Disconnect the N sensor connector. Connect the
IMPORTANT: This measurement procedure is a pulse counter to the N sensor.
simple method. The measured data 8. Disconnect the vacuum pump. Loosen plug (12)
will be lower by approx. 5 % than the on top of the pump casing to bleed air from the
accurately measured value. To main pump until oil only comes out of the plug
measure accurately, disconnect the clearance.
return circuit from the control valve 9. Fully open the loading valve of the hydraulic
and connect it to the hydraulic oil tester.
tank. 10. Start the engine. Check the pressure gauge con-
nection for any oil leaks. Install Dr. ZX and select
Preparation: the monitor function.
1. Stop the engine. Push the air bleed valve to bleed
air. Connect a vacuum pump to the oil filler port. Measurement:
NOTE: Operate the vacuum pump while connect- 1. Maintain the hydraulic oil temperature at 50±5 °C
ing the pump flow rate test line. (122±9 °F).
2. Disconnect the delivery hose from the main pump 2. Measure the maximum flow rate.
(one side) to be measured. Connect pipe (1 or 2) 3. Select each switch position as follows:
to the pump delivery port using the split flanges Auto-Idle /
and bolts which were used to connect the dis- Acceleration
connected delivery hose. Selector
: 41 mm : 10 mm Digging
3. Connect hose (1 or 2) to hydraulic tester (5) using Mode
test hose (3) and adapter (4). Connect adapter
(6), joint (7), test hose (8) and flange (9) to hy- 4. Adjust the main relief valve set-pressure in the
draulic tester (5). control valve to each pressure point specified
: 41 mm : 10 mm along the main pump P-Q curve. (Refer to
4. Connect the delivery hose to flange (9) with split T4-2-22) Slowly close the loading valve of the hy-
flanges (10) and bolts (11). draulic tester while relieving the pressure in the
: 10 mm arm roll-in circuit. Measure the flow rates and en-
gine speeds at the pressure points specified in
the P-Q curve.
5. Repeat each measurement three times and cal-
culate the average values.
T4-5-22
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified pump speed using the following formu- Refer to T4-2 Operational Performance Standard.
las: NOTE: When actually measuring, install pipe (1 or
2) only to the pump to be measured.
Qc = (Ns × Q) ⁄ Ne
Qc : Converted Flow Rate

Q : Measured Flow Rate
Ns : Specified Pump Speed
-1
(ZX200 class, 225 class: 1900 min )
-1
(ZX230 class: 2000 min )
-1
(ZX270 class: 2050 min )
Ne : Measured Engine Speed:
Pulse Numbers (Hz)×60/34
1, 2 3 4 5 6 7 8 9 10 11
Delivery Hose
(To Control
Valve)
T173-04-04-002
13
N Sensor
T178-03-01-001
12
1 - Pipe E (ST 6144) 5 - Hydraulic Tester (ST 6299) 8- Test Hose (ST 6320) 11 - Bolt (ST 6409) (4 used)
2 - Pipe B (ST 6143) 6 - Adapter PF1 × UNF1-7/8 9- Flange (ST 6118) 12 - Plug
(ST 6146)
3 - Test Hose (ST 6145) 7 - Joint (ST 6330) 10 - Split Flange (ST 6130) 13 - Pipe
4 - Adapter PF1 × UNF1-7/8
(ST 6146)
T4-5-23
•Pilot Characteristics
Summary:
Main pump performance is checked by measuring 5. Connect hose (19) to port T on reducing valve
the pump flow rate with a hydraulic tester installed at (16). Connect adapter (20) to the other end of
the main pump delivery port (one side) to be meas- hose (19). Remove plug L from the return pipe.
ured. Use Dr. ZX and a pressure gauge at the same Connect hose (19) to the plug L port.
time. : 19 mm, 22 mm
6. Disconnect pipe (21) from the regulator. Connect
IMPORTANT: This measurement procedure is a plug (PF 1/4) to the disconnected pipe.
simple method. The measured data : 17 mm
will be lower by approx. 5 % than the 7. Disconnect the N sensor connector. Connect the
accurately measured value. To pulse counter to the N sensor.
measure accurately, disconnect the 8. Disconnect the vacuum pump. Loosen the plug
return circuit from the control valve from the top of the pump casing. Bleed air from
and connect it to the hydraulic oil the casing until oil only comes out of the plug
tank. clearance.
9. Fully open the loading valve of the hydraulic
Preparation: tester.
1. Referring to steps 1 to 4 on page T4-5-22, con- 10.Start the engine. Check the line connections for
nect a hydraulic tester to the main pump to be any oil leaks.
measured.
2. Disconnect the hose from regulator port Pi of the
pump to be measured. Connect plug (ST 6213) to
the disconnected hose.
: 6 mm, 19 mm
3. Install adapters (15) (3 used) to reducing valve
(16). Remove plug M from the pilot filter. Then,
install adapter (13) and hose (14) to the pilot filter.
Connect the other end of hose (14) to regulator
port P1 on reducing valve (16).
: 19 mm
4. Install tee (17) to port P2 on reducing valve (16).
Connect pressure gauge (18) and hose (14) to
tee (17). Connect hose (14) to the regulator.
: 19 mm
T4-5-24
1, 2 3 4 5 6 7 8 9 10 11
Delivery Hose
(To Control
Valve)
T173-04-04-002
21 Port Pi
Plug M
N Sensor
T178-03-07-001
12
T178-03-01-001
Reducing Valve Port Location

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

Port Pi
14 17 15 16 15 14 13
T178-04-04-004
1 - Pipe E (ST 6144) 7 - Joint (ST6330) 12 - Plug M 17 - Tee UNF7/16 × UNF7/16×
PF1/4
(ST 6451)
2 - Pipe B (ST 6143) 8 - Test Hose (ST 6320) 13 - Adapter UNF7/16 × PF1/4 18 - Pressure Gauge
(ST 6069) (ST 6931)
3 - Test Hose (ST 6145) 9 - Flange (ST 6118) 14 - Hose U UF7/16 × UNF7/16 19 - Hose UNF7/16 × UNF7/16
(4334309) (4334309)
4 - Adapter PF1 × UNF1-7/8 10 - Split Flange (ST 6130) 15 - Adapter PF3/8 × UNF7/16 20 - Adapter PF3/8 × UNF7/16
(ST 6146) (4200465) (4200465)
5 - Hydraulic Tester (ST 6299) 11 - Bolt (ST 6409) (4 used) 16 - Reducing Valve (4325439) 21 - Pipe
6 - Adapter PF1 × UNF1-7/8
(ST 6146)
T4-5-25
Measurement:
1. Maintain the hydraulic oil temperature at 50±5 °C Evaluation:
(122±9 °F) 1. Convert the measured flow rates to those at the
2. The pump flow rate in response to the external specified pump speed using the following formu-
command pilot pressure is measured. las:
3. Select each switch position as follows:
Auto-Idle / Qc = (Ns × Q) ⁄ Ne
Acceleration
Selector Qc : Converted Flow Rate
Digging Q : Measured Flow Rate
Fast Idle P Mode OFF Ns : Specified Pump Speed
Mode
-1
4. Adjust the reducing valve set-pressure to each (ZX200 class, 225 class: 1900 min )
-1
pressure point specified along the main pump (ZX230 class: 2000 min )
-1
P-Q curve. (Pilot Characteristics) (Refer to (ZX270 class: 2050 min )
T4-2-23.) Measure the flow rates and engine Ne : Measured Engine Speed
speeds at the pressure points specified in the Pulse Numbers (Hz)×60/34
P-Q curve.
5. Repeat each measurement three times and cal- 2. Standard Flow Rate
culate the average values. Refer to T4-2 Operational Performance Stan-
dard.
NOTE: Both pipes (1 and 2) are illustrated as if
they are installed. When actually measur-
ing, install pipe (1 or 2) only to the pump to
be measured.
T4-5-26
Regulator Adjustment
6 5 1 2
4 3
7 8
T178-03-01-006
1 - Lock Nut (For Minimum 4 - Adjusting Screw (For 7 - Lock Nut 9 - Lock Nut
Flow Adjustment) Maximum Flow Adjust- (For P-Q Line Adjustment) (For P-Q Line Adjustment)
ment)
2 - Adjusting Screw (For 5 - Lock Nut 8 - Adjusting Screw 10 - Adjusting Screw
Minimum Flow Adjustment) (For Pilot Pressure Char- (For P-Q Line Adjustment) (For P-Q Line Adjustment)
acteristic Adjustment)
3 - Lock Nut (For Maximum 6 - Adjusting Screw
Flow Adjustment) (For Pilot Pressure Char-
acteristic Adjustment)
Adjustment Item Adjustment Procedure Remarks

1. Minimum Flow Rate Loosen lock nut (1) and turn 1) Do not turn the adjusting screw
adjusting screw (2). more than two turns.
Q Rotating adjusting screw (2) 1/4 2) Securely retighten lock nut (1) after
a turn clockwise increases the the adjustment.
minimum pump flow rate by 5.35
3 3
cm /rev. (0.33 in /rev).
: 17 mm
: 19.6 N⋅m
(2 kgf⋅m, 14.4 lbf⋅ft)
Pi
2. Maximum Flow Rate Loosen lock nut (3) and turn 1) Do not turn the adjusting screw
adjusting screw (4). more than two turns.
Q Rotating adjusting screw (4) 1/4 2) Do not increase the maximum flow
a turn clockwise decreases the rate.
maximum pump flow rate by In other words, do not turn the ad-
3 3
7.14 cm /rev. (0.44 in /rev). justing screw counterclockwise. In-
: 13 mm creasing the maximum flow rate
: 9.8 N⋅m (turning the adjusting screw coun-
(1 kgf⋅m, 7.2 lbf⋅ft) terclockwise), however, will be re-
quired after adjusting the pilot pres-
sure characteristics.
3) Securely retighten lock nut (3) after
Pd the adjustment.
T4-5-27
Adjustment Item Adjustment Procedure Remarks

3. Pilot Pressure Characteristics Loosen lock nut (5) and turn ad- 1) Do not turn the adjusting screw
justing screw (6). more than one turn.
Rotating adjusting screw (6) 1/4 2) When adjusting screw (6) is turned
a turn clockwise decreases the clockwise, the maximum flow rate
Q 3
flow rate by 11.65 cm /rev. will also be decreased.
3
(0.71 in /rev). To maintain the maximum flow rate
: 30 mm unchanged, turn adjusting screw (4)
: 29.4 N⋅m counterclockwise twice as much as
(3 kgf⋅m, 21.7 lbf⋅ft) adjusting screw (6) is turned.
This ratio of 2 (adjusting screw (4)
counterclockwise turn) to 1 (adjust-
ing screw (6) clockwise turn) is to
Pi counterbalance.
3) Securely retighten lock nut (5) after
the adjustment.
4. P-Q Control A: Loosen lock nut (7) and turn 1) Do not turn the adjusting screws
(Torque Adjustment) adjusting screw (8). more than one turn.
Rotating adjusting screw (8) 2) Rotate the adjusting screws watch-
Q 1/4 a turn clockwise increases ing the engine performance.
the maximum pump flow rate 3) Securely retighten lock nut (7) or (9)
3
A by 13.43 cm /rev. after the adjustment.
3
(0.82 in /rev.).
B: Loosen lock nut (9) and turn
adjusting screw (10).
Rotating adjusting screw (10)
1/4 a turn clockwise increases
Pd the maximum pump flow rate
3 3
by 2.36 cm /rev. (0.14 in /rev).
Q
Pd
T4-5-28
SWING MOTOR DRAINAGE
Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while
swinging the upperstructure.
NOTE: The amount of drain oil from the swing

motor will change depending on hydraulic
oil temperature.
1
Also, take care not to fall off the machine
while the measurement.
Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F). Rotate the swing motor to warm the
inside of the motor.
T157-05-04-014
2. Properly shut down the engine. Press the air re-
lease valve (1) on top of the hydraulic oil tank to
release any remaining pressure.
2
3. Disconnect the swing motor drain hose (2) at the
hydraulic oil tank end. Install plug (ST 6213) to
the disconnected end on the hydraulic oil tank.
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
T178-04-04-005
T4-5-29
Preconditions for Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
Measurement:
1. Amount of Oil Drained While Swinging the Up- The same height as
perstructure boom foot pin height
(1) Fully retract the arm cylinder. Fully extend the
T105-06-03-013
bucket cylinder. Raise the boom so that the
arm tip pin height is the same as the boom
foot pin height. Be sure that the bucket is
empty.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start draining oil measure-
ment after the swing speed reaches a con-
stant maximum speed. The measuring time
should be more than 45 seconds.
(3) Repeat the measurement at least three times
in both clockwise and counterclockwise direc-
tions, and calculate the average values.
2. Amount of Oil Drained While Relieving Swing T107-06-06-005

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

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

brated container. Then, convert the measured
drain oil into the per-minute value using the for-
mula below:
∆Q = 60 × q / t
Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L) T107-06-05-008
T4-5-31
TRAVEL MOTOR DRAINAGE
Summary:
To check travel motor performance, measure the
amount of oil draining from the travel motor while
rotating the travel motor with the measuring side
track jacked up.
NOTE: The amount of drain oil from the travel

motor will change depending on hydraulic
1
oil temperature.
Preparation:
1. Main hydraulic oil temperature at 50±5 °C (122±9
°F). Rotate the travel motor to warm the inside of
the motor.
2. Properly shut down the engine. Press the air re-

lease valve (1) on top of the hydraulic oil tank to
release any remaining pressure.
3. Disconnect the travel motor drain hose (2) at the

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

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

Auto-Idle /
Acceleration
Selector
Digging
Mode
T157-05-04-010
T4-5-32
Measurement:
1. Amount of Oil Drained While Rotating Travel
Motor
(1) Start the engine. Jack up the measuring side
track using the front attachment, as illus-
trated. 90 to 110°
CAUTION: Securely support the raised track

using wooden blocks. When working around
moving parts is unavoidable, pay special at-
tention to ensure that hands, feet, and cloth- M104-07-067
ing do not become entangled.
(2) Rotate the raised track with the travel lever
operated full stroke. Start drain oil measure-
ment after the track rotation speed reaches a
constant maximum speed. The measuring
time should be more than 45 seconds.

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

into the per-minute value
T157-05-04-019
First measure the amount of drain oil using a cali-
brated container. Then, convert the measured
drain oil into the per-minute value using the
formula below:
∆Q = 60 × q / t
Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-33
(Blank)
T4-5-34
OPERATIONAL PERFORMANCE TEST / Adjustment
ENGINE SPEED ADJUSTMENT AND
ENGINE LEARNING
After removing and/or replacing the components as
described below for repair and/or inspection, or if error
in engine speed is found, readjust engine speed and
perform engine learning.
• Removal of the engine, engine control cable, or

EC motor
• Replacement of MC
Adjustment of Engine Speed:

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

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

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

running for about 15 minutes to warm coolant
temperature to more than 30 °C (86 F°) until the
auto warming up control system is deactivated.
5. Loosen the bolt holding the control lever to the EC Holding Bolt
motor output shaft.
T157-07-04-015
Control Lever
6. While monitoring the actual engine speed with Dr.
ZX or the engine speed meter, adjust the control
lever so that the minimum speed (slow idle)
matches the specification.
Specification: Refer to T4-2 OPERATIONAL PER
FORMANCE TEST.
7. Tighten the lever holding bolt to secure the control

lever to the motor output shaft.
: 13 N⋅m (1.3 kgf⋅m, 9.4 lbf⋅ft)
NOTE: Don’t lubricate the motor output shaft.
8. Perform engine learning.
T4-6-1
Engine Learning:
1. Turn the key switch OFF
Learning
NOTE: In case the engine doesn’t stop when the Switch
key switch is turned OFF, pull the handle
located under the seat to stop the engine.
Dr.ZX
2. Disconnect Dr. ZX. Wait for 5 seconds. Connector
to MC
3. Turn the learning switch ON.
4. Turn the key switch ON. Wait for 5 seconds.
5. Turn the key switch OFF. Wait for 5 seconds.
6. Turn the learning switch OFF.
7. Check the engine speed. T178-01-02-006
225 class
(ZAXIS225US)
T1SM-01-02-006
Learning Switch Dr.ZX Connector
to MC
Learning Switch is
Turned to Stamp E
Learning Switch
Stamp
T1CC-05-01-001
T4-6-2
(Blank)
T4-6-3
GOVERNOR LEVER AND FUEL CUT
LEVER POSITION
• Check the fuel cut lever position during cranking.

If the position is normal, the engine unit and/or
fuel system may have trouble.
• Governor Lever and Fuel Cut Lever
1 2 3 4
T105-07-04-003
1 - Governor Cable (From EC Motor)
2 - Fuel Cut-Off Cable
(Fuel Cut-Off Handle)
3 - Fuel Cut Lever
4 - Governor Lever
T4-6-4
• Governor Lever Position
A - Key Switch OFF (Engine Stop Position)

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

B - Fuel Cut-Off Handle Returned Position
A
B
T105-07-04-003
T4-6-5
(Blank)
T4-6-6
MEMO
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SECTION 4

Group 3 Engine Test

Precautions for Evaluation of Test Data

Observe the following rules in order to carry out

MAKE PRECISE MEASUREMENT

• Hydraulic P-Q Control (Torque Control)

Delivery Pressure MPa (kgf/cm2)

∗ (REFERENCE: Measured at Test Stand) • ZX200 class, 225 class

Injection rate adjustment

Injection rate adjustment

Pump Speed min-1 (rpm) T1HD-04-05-001

Injection rate adjustment

Pump Speed min-1 (rpm)

Reference Measured Value

Reference Measured Value

Reference Measured Value

Reference Measured Value

NOTE: Up to serial No.104678

Reference Measured Value

Reference Measured Value

Reference Measured Value

Reference Measured Value

NOTE: *** Up to serial No.104678

Reference Measured Value

Reference Measured Value

Reference Measured Value

Reference Measured Value

NOTE: *** Up to serial No.104678

Reference Measured Value

Reference Measured Value

Reference Measured Value

Reference Measured Value

NOTE: *** Up to serial No.010326

Reference Measured Value

Reference Measured Value

Reference Measured Value

Reference Measured Value

NOTE: *** Up to serial No.020042

• Hydraulic Oil Temperature: 50 ± 5 °C

• Monitor each sensor using Dr. ZX.

2. Sensor Activating Range

Sensor Operation Specification

NOTE: Measure the engine speed before per-

IMPORTANT: Never attempt to the readjust stop-

ured as shown in the table below.

NOTE: Unless the fuel delivery pipes are discon-

5. Install an adaptor (Isuzu 5-85317-001-0) and

NOTE: The cylinders are aligned from No.1 to

2. When the measurement is started from No.1 cyl-

Cylinder No. No.1 No.2 No.3 No.4 No.5 No.6

3. Rotate the crankshaft 360°. Align the TDC mark

1. Loosen the adjusting screw lock nuts for the

NOTE: Use clean diesel oil.

NOTE: The alignment mark on the injection pump

3. Remove the injection piping from No.1 cylinder. T107-02-12-007

ward against the cylinder block.

IMPORTANT: Make sure to keep the ma-

8. Determine lubricant consumption from the fol-

3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above