Hitachi Excavator Zaxis ZX110-135US Technical Manual & Operational Principle

Manual No.
: KM-187E
Vol. No. : TT187-E-04
110 110M 120 130 130LCN 125US 135US 135UR Excavator Technical Manual (Troubleshooting)
Technical Manual
(Troubleshooting)
110 125US
110M 135US
120 135UR
130
130LCN
Excavator
Service Manual (Manual No. KM-187E) consists of the following three separate volumes;
Technical Manual (Operational Principle) : Vol. No. TO187E
Technical Manual (Troubleshooting) : Vol. No. TT187E
Workshop Manual : Vol. No. W187E
PRINTED IN SINGAPORE (PS) 2003.11
Zaxis110..135UR-TM/TSh 1 14/11/03, 12:54 PM

Technical Manual
(Troubleshooting)
Vol No.: TT187E-04

INTRODUCTION
TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redelivery and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
IN-01
INTRODUCTION
PAGE NUMBER
• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group

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

NOTATIONS
• CAUTION:
In this manual, the following safety alert symbol and Indicated potentially hazardous situation which
signal words are used to alert the reader to the could, if not avoided, result in personal injury or
potential for personal injury of machine damage. death.
This is the safety alert symbol. When you see this • IMPORTANT:
symbol, be alert to the potential for personal injury. Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights. • NOTE:
To avoid injury and damage, be sure to use appropri- Indicates supplementary technical information or
ate lifting techniques and equipment when lifting know-how.
heavy parts.
IN-02
INTRODUCTION
UNITS USED
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-03
INTRODUCTION
(Blank)
IN-04
SAFETY
RECOGNIZE SAFETY INFORMATION
• This is the SAFETY ALERT SYMBOL.

• When you see this symbol on your machine or in
this manual, be alert to the potential for personal
injury.
• Follow recommended precautions and safe
operating practices.
001-E01A-0688
SA-688
UNDERSTAND SIGNAL WORDS

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

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

element of information.
002-E01C-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the

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

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

• Keep a first aid kit and fire extinguisher on hand.
• Thoroughly read and understand the label at-
tached on the fire extinguisher to use it properly.
• To ensure that a fire-extinguisher can be always
used when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
• Establish emergency procedure guidelines to
cope with fires and accidents.
• Keep emergency numbers for doctors, ambu-
lance service, hospital, and fire department SA-437
posted near your telephone.
004-E01A-0437
WEAR PROTECTIVE CLOTHING

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

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

impairment or loss of hearing.
• Wear a suitable hearing protective device such
as earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.
006-E01A-0434
SA-434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by
walking around it before you start it to avoid
personal injury.
• In the walk-around inspection be sure to cover all
points described in the “PRE-START
INSPECTION” chapter in the operator’s manual.
S007-E01A-0435
SA-435
SA-4
SAFETY
GENERAL PRECAUTIONS FOR CAB
• Before entering the cab, thoroughly remove all

dirt and/or oil from the soles of your work boots. If
any controls such as a pedal is operated while
with dirt and/or oil on the soles of the operator’s
work boots the operator’s foot may slip off the
pedal, possibly resulting in a personal accident.
• Don’t leave parts and/or tools lying around the
operator’s seat. Store them in their specified lo-
cations.
• Avoid storing transparent bottles in the cab. Don’t
attach any transparent type window decorations
on the windowpanes as they may focus sunlight,
possibly starting a fire.
• Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab
while operating the machine.
• Keep all flammable objects and/or explosives
away from the machine.
• After using the ashtray, always cover it to extin-
guish the match and/or tobacco.
• Don’t leave cigarette lighters in the cab. When
the temperature in the cab increases, the lighter
may explode.
524-E01A-0000
SA-5
SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.

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

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

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

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

• Bystanders can be run over.
• Take extra care not to run over bystanders.
Confirm the location of bystanders before moving,
swinging, or operating the machine.
• Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
• Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the
machine. SA-426
011-E01A-0426
SA-7
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may
cause the machine to runaway, possibly resulting in
serious injury or death.
• Start the engine only when seated in the
operator's seat.
• NEVER start the engine while standing on the
track or on ground.
• Do not start engine by shorting across starter
terminals.
• Before starting the engine, confirm that all control SA-444
levers are in neutral.
012-E01B-0444
JUMP STARTING
• Battery gas can explode, resulting in serious injury.

• If the engine must be jump started, be sure to
follow the instructions shown in the “OPERATING
THE ENGINE” chapter in the operator’s manual.
• The operator must be in the operator’s seat so
that the machine will be under control when the
engine starts. Jump starting is a two-person
operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway SA-032
machine.
S013-E01A-0032
SA-8
SAFETY
KEEP RIDERS OFF MACHINE
• Riders on machine are subject to injury such as

being struck by foreign objects and being thrown off
the machine.
• Only the operator should be on the machine.
Keep riders off.
• Riders also obstruct the operator’s view, resulting
in the machine being operated in an unsafe
manner.
014-E01B-0379
SA-379
PROVIDE SIGNALS FOR FOBS INVOLV-

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

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

BE DRIVEN
• Incorrect travel pedal/lever operation may result in

serious injury death.
• Before driving the machine, confirm the position
of the undercarriage in relation to the operator’s
position. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.
017-E01A-0491
SA-491
SA-9
SAFETY
DRIVE MACHINE SAFELY
• Before driving the machine, always confirm that the

travel levers/pedals direction corresponds to the
direction you wish to drive.
• Be sure to detour around any obstructions.
• Avoid traveling over obstructions. Soil, fragments
of rocks, and/or metal pieces may scatter around
the machine. Don’t allow personnel to stay
around the machine while traveling.
SA-387
• Driving on a slope may cause the machine to slip or

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

over. If the direction must be changed, move the
WRONG
machine to level ground, then, change the direc-
tion to ensure sage operation.
019-E01D-0492
SA-590
SA-10
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
• Death or serious injury may result if you attempt to
mount or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle / acceleration seleclter and the SA-391
H/P mode switch off.

• Run the engine at slow idle speed without load
for 5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK
position.
• Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
SA-392
020-E08A-0493
SA-11
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.
To avoid back-over and swing accidents:

• Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERS ARE CLEAR.
• Keep the travel alarm in working condition (if SA-383
equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP
IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a
signal person.
• No machine motions shall be made unless
signals are clearly understood by both signalman SA-384
and operator.
• Learn the meanings of all flags, signs, and
markings used on the job and confirm who has
the responsibility for signaling.
• Keep windows, mirrors, and lights clean and in
good condition.
• Dust, heavy rain, fog, etc., can reduce visibility.
As visibility decreases, reduce speed and use
proper lighting.
• Read and understand all operating instructions in
the operator’s manual.
S021-E01A-0494
SA-12
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF
TIPPING MACHINE---SERIOUS OR FATAL
CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU

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

operating on a grade, possibly resulting in serious SA-012
injury or death.
To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.
• Keep the bucket low to the ground and close to
the machine.
• Reduce operating speeds to avoid tipping or
slipping.
• Avoid changing direction when traveling on
grades.
• NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is SA-440
unavoidable.
• Reduce swing speed as necessary when
swinging loads.
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to
become soft and make ground travel unstable.
S025-E01B-0495
SA-13
SAFETY
AVOID POWER LINES
• Serious injury or death can result if the machine or

front attachments are not kept a safe distance from
electric lines.
• When operating near an electric line, NEVER
move any part of the machine or load closer than
3 m (10 ft) plus twice the line insulator length.
• Check and comply with any local regulations that
may apply.
• Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site.
SA-381
029-E01A-0381
OBJECT HANDLING
• If a lifted load should fall, any person nearby may

be struck by the falling load or may be crushed
underneath it, resulting in serious injury or death.
• When using the machine for craning operations,
be sure to comply with all local regulations.
• Do not use damaged chains or frayed cables,
sables, slings, or ropes.
• Before craning, position the upperstructure with
the travel motors at the rear.
• Move the load slowly and carefully. Never move it
suddenly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it
is safely and securely situated on supporting
SA-014
blocks or on the ground.
• Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.
032-E01A-0014
SA-14
SAFETY
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the body,

serious injury may result.
• Guard against injury from flying pieces of metal
or debris; wear goggles or safety glasses.
• Keep bystanders away from the working area
before striking any object.
031-E01A-0432
SA-432
PARK MACHINE SAFELY

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

• Lock all access doors and compartments.
033-E09B-0390
SA-15
SAFETY
HANDLE FLUIDS SAFELY－AVOID FIRES
• Handle fuel with care; it is highly flammable. If fuel

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

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

hazards.
• Do not incinerate or puncture pressurized
containers.
• Do not store oily rags; they can ignite and burn
spontaneously.
• Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
SA-16
SAFETY
SAFETY TRANSPORTING
• The danger of tipping is present when

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

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

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

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

1) Park the machine on a level surface.
2) Lower the bucket to the ground.
3) Turn the auto-idle / acceleration selecltor off.
4) Run the engine at slow idle speed without load
for 5 minutes.
5) Turn the key switch to OFF to stop engine.
6) Relieve the pressure in the hydraulic system by
moving the control levers several times.
7) Remove the key from the switch.
8) Attach a “Do Not Operate” tag on the control
lever.
9) Pull the pilot control shut-off lever to the LOCK
position.
10) Allow the engine to cool.
SA-18
SAFETY
• If a maintenance procedure must be performed
with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Never work under a machine raised by the boom.
• Inspect certain parts periodically and repair or
replace as necessary. Refer to the section
discussing that part in the “MAINTENANCE”
chapter in the operator’s manual.
• Keep all parts in good condition and properly
installed.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
• When cleaning parts, always use nonflammable
SA-028
detergent oil. Never use highly frammable oil
such as fuel oil and gasoline to clean parts or
surfaces.
• Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
• Illuminate your work area adequately but safely.
• Use a portable safety light for working inside or
under the machine.
• Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• Sufficiently illuminate the work site. Use a
maintence work light when working under or SA-527
inside the machine.

• Always use a work light protected with a guard.
In case the light bulb is broken, spilled fuel, oil
antifreeze fluid, or window washer fluid may
catch fire.
S500-E02B-0497
SA-037
SA-19
SAFETY
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause serious

injury.
• Before performing any work on the machine, at-
tach a “Do Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
SS2045102
SUPPORT MACHINE PROPERLY

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

• Entanglement in moving parts can cause serious
injury.
• To prevent accidents, care should be taken to
ensure that hands, feet, clothing, jewelry and hair
do not become entangled when working around
rotating parts.
502-E01A-0026
SA-026
SA-20
SAFETY
PREVENT PARTS FROM FLYING
• Grease in the track adjuster is under high pressure.

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

AIR RELEASE PLUG to release pressure.
503-E01B-0344
STORE ATTACHMENTS SAFELY
• Stored attachments such as buckets, hydraulic

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

• Use tools appropriate for the work to be done.
• Makeshift tools, parts, and procedures can create
safety hazards.
• For loosening and tightening hardware, use the
correct size tools to avoid injury caused by
slipping wrenches.
• Use only recommended replacement parts.
(See the parts catalog.)
SA-040
S522-E01A-0040
SA-21
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under
pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
• To avoid possible injury from hot spraying water.
DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the
stop. Allow all pressure to be released before
removing the cap. SA-039
• The hydraulic oil tank is pressurized. Again, be

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

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

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

result in severe burns, gangrene, or otherwise
serious injury or death.
S506-E01A-0019
SA-22
SAFETY
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under

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

• If an accident occurs, see a doctor familiar with
this type of injury immediately. Any fluid injected
into the skin must be surgically removed within a
few hours or gangrene may result.
SA-292
507-E03A-0499
SA-044
SA-23
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to
fires.
• Check for oil leaks due to missing or loose
clamps, kinked hoses, lines or hoses that rub
against each other, damage to the oil-cooler, and
loose oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or SA-019
hoses.
Check for Shorts:

• Short circuits can cause fires.
• Clean and tighten all electrical connections.
• Check before starting work for loose, kinked,
hardened or frayed electrical cables and wires.
• Check before starting work for missing or
damaged terminal caps.
• DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..
Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.
• Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
SA-24
SAFETY
Check Key Switch:
• If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
• Always check key switch function before
operating the machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to
confirm that the engine stops.
• If any abnormalities are found, be sure to repair
them before operating the machine.
Check Emergency Engine Stop Switch:

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

• Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be
repaired or replaced before operating the
machine.
S508-E02B-0019
SA-25
SAFETY
EVACUATING IN CASE OF FIRE
• If a fire breaks out, evacuate the machine in the

following way:
• Stop the engine by turning the key switch to the
OFF position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
• In an emergency, if the cab door and/or the front SA-393
window cannot be opened, break the front or rear

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

• Prevent asphyxiation. Engine exhaust fumes can
cause sickness or death.
• If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes or open
doors and windows to bring enough outside air
into the area.
509-E01A-0016
SA-016
SA-26
SAFETY
PRECAUTIONS FOR WELDING AND
GRINDING
• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated
and prepared area. Store flammable objects in a
safe place before starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
• Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before
starting grinding.
• After finishing welding and grinding, recheck that SA-818
there are no abnormalities such as the area sur-

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

FLUID LINES
• Flammable spray can be generated by heating near

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

CONTAINING FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that
contain flammable fluids.
• Clean them thoroughly with nonflammable
solvent before welding or flame cutting them.
510-E01B-0030
SA-27
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
• Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated
area. Dispose of paint and solvent properly.
• Remove paint before welding or heating:

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

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

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

tighten all terminals.
• Battery electrolyte is poisonous. If the battery
should explode battery electrolyte may be splashed
into eyes, possibly resulting in blindness.
• Be sure to wear eye protection when checking
electrolyte specific gravity.
512-E01C-0032
SA-28
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
• If spilled onto skin, refrigerant may cause a cold
contact burn.
• Refer to the freon container for proper use when
servicing the air conditioning system.
• Use a recovery and recycling system to avoid
venting freon into the atmosphere.
• Never let the freon stream make contact with the
skin.
SA-405
513-E01A-0405
HANDLE CHEMICAL PRODUCTS SAFELY

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

recommended equipment.
S515-E01A-0309
SA-29
SAFETY
DISPOSE OF WASTE PROPERLY
• Improperly disposing of waste can threaten the

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

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

THE CUSTOMER
• After maintenance or repair work is complete,
confirm that:
• The machine is functioning properly, especially
the safety systems.
• Worn or damaged parts have been repaired or
replaced
S517-E01A-0435 SA-435
SA-30
SECTION AND GROUP SECTION 4 OPERATIONAL PER-
CONTENTS FORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
TECHNICAL MANUAL Group 6 Adjustment
(Troubleshooting) SECTION 5 TROUBLESHOOTING
Group 1 General
Group 2 Component Layout
Group 3 Troubleshooting A
Group 4 Troubleshooting B
Group 5 Troubleshooting C
Group 6 Troubleshooting D
Group 7 Electrical System Inspection
Group 8 ICX
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Control System Group 5 Travel Device
All information, illustrations and speci- Group 2 Front Control System Group 6 Signal Control Valve
fications in this manual are based on Group 3 Hydraulic System Group 7 Others (Upperstructure)
the latest product information available Group 4 Electrical System Group 8 Others (Undercarriage)
at the time of publication. The right is
reserved to make changes at any time WORKSHOP MANUAL
without notice. SECTION 1 GENERAL INFORMA- Group 9 Signal Control Valve
TION Group 10 Solenoid Valve Unit
Group 1 Precautions for Disassem- Group 11 Holding Valve
bling and Assembling SECTION 3 UNDERCARRIAGE
Group 2 Tightening Torque Group 1 Swing Bearing
Group 3 Painting Group 2 Travel Device
SECTION 2 UPPERSTRUCTURE Group 3 Center Joint
COPYRIGHT(C)2003 Group 1 Cab Group 4 Track Adjuster
Hitachi Construction Machinery Co., Ltd. Group 2 Counterweight Group 5 Front Idler
Tokyo, Japan Group 3 Main Frame Group 6 Upper and Lower Roller
All rights reserved Group 4 Pump Device Group 7 Track
Group 5 Control Valve SECTION 4 FRONT ATTACHMENT
Group 6 Swing Device Group 1 Front Attachment
Group 7 Pilot Valve Group 2 Cylinder
Group 8 Pilot Shut-Off Valve
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction
Operational Performance Tests....................T4-1-1 ZAXIS135UR Dr. ZX Monitor Indicating
Preparation for Performance Tests...............T4-1-2 Values..................................................... T4-2-50
Sensor Operational Range Table............... T4-2-56
Group 2 Standard Group 3 Engine Test
ZAXIS110 Operational Performance Engine Speed............................................... T4-3-1
Standard Table............................................T4-2-1 Engine Compression Pressure .................... T4-3-4
ZAXIS110M Operational Performance Valve Clearance Adjustment........................ T4-3-6
Standard Table............................................T4-2-5 Nozzle Check............................................... T4-3-8
ZAXIS120/130/130LCN Operational Injection Timing .......................................... T4-3-10
Performance Standard Table ......................T4-2-9 Lubricant Consumption.............................. T4-3-12
ZAXIS125US Operational Performance
Standard Table..........................................T4-2-13 Group 4 Excavator Test
ZAXIS135US Operational Performance Travel Speed ................................................ T4-4-1
Standard Table..........................................T4-2-17 Track Revolution Speed............................... T4-4-2
ZAXIS135UR Operational Performance Mistrack Check ............................................ T4-4-3
Standard Table..........................................T4-2-21 Travel Parking Function Check.................... T4-4-4
Main Pump P-Q Diagram ...........................T4-2-26 Swing Speed ................................................ T4-4-5
Injection Pump............................................T4-2-28 Swing Function Drift Check ......................... T4-4-6
ZAXIS110 Dr. ZX Monitor Indicating Swing Motor Leakage .................................. T4-4-8
Values .......................................................T4-2-30 Maximum Swingable Slant Angle .............. T4-4-10
ZAXIS110M Dr. ZX Monitor Indicating Swing Bearing Play.................................... T4-4-11
Values .......................................................T4-2-34 Hydraulic Cylinder Cycle Time................... T4-4-12
ZAXIS120/130/130LCN Dr. ZX Monitor Dig Function Drift Check............................ T4-4-14
Indicating Values ......................................T4-2-38 Control Lever Operating Force .................. T4-4-18
ZAXIS125US Dr. ZX Monitor Indicating Control Lever Stroke .................................. T4-4-20
Values .......................................................T4-2-42 Bucket/Cab Collision Prevention System
ZAXIS135US Dr. ZX Monitor Indicating (ZAXIS135UR Only) ............................... T4-1-22
Values .......................................................T4-2-46 Combined Boom Raise/Swing
Function Check ........................................ T4-4-24
Boom Raise and Arm Roll-In
Combined Operation .............................. T4-4-25
187T-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 reliving Swing).......T4-5-14
Relief Pressure (When reliving Travel).......T4-5-16
Overload Relief Valve Set Pressure...........T4-5-18
Main Pump Flow Rate Measurement.........T4-5-22
Swing Motor Drainage................................T4-5-28
Travel Motor Drainage................................T4-5-32
Group 6 Adjustment
Assembly and Adjustment of Link for Arm
Angle Sensor (ZAXIS135UR Only) ............T4-6-1
Adjusting Method of Front Acceleration/
Deceleration Speed (ZAXIS135UR Only) ..T4-6-2
Initial Setting of Angle Sensor
(ZAXIS135UR Only) ...................................T4-6-3
Initializing Depth Limit Control System
(ZAXIS135UR Only) ...................................T4-6-4
Engine Speed Adjustment and Engine
Learning......................................................T4-6-6
Governor Lever/Fuel Cut Lever Position......T4-6-8
187T-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedure to quan- The machine performance does not always deterio-
titatively check all system and functions on the ma- rate as the working hours increase. However, the
chine. machine performance is normally considered to re-
duce in proportion to the increase of the operation
Purpose of Performance Tests hours. Accordingly, restoring the machine perform-
1. To comprehensively evaluate each operational ance by repair, adjustment, or replacement shall con-
function by comparing the performance test data sider the number of the 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 ex-
tended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork-
ers. Once the test is started, be sure to commu-
nicate with each other using these signals, and to
follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid acci-
dents due to landslides or contact with
high-voltage power lines. Always confirm that
there is sufficient space for full swings.
4. Avoid polluting the machine and the ground with T105-06-01-003
leaking oil. Use oil pans to catch escaping oil.

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

1. Accurately calibrate test instruments in advance
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
T105-06-01-004
T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard
ZAXIS110 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
ZAXIS110
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
ENGINE SPEED min
-1
T4-3-1
Slow Idle Speed 1000±100 Value indicated on Dr.ZX
Fast Idle Speed (Normal) 1915±50 ↑
Fast Idle Speed (With ECO deactivated) 1915±50 ↑
Fast Idle Speed (Relief operation) 1960±50 Extend the boom cylinder to
relieve the boom raise
circuit.
Fast Idle Speed (E mode) 1915±70 Value indicated on Dr.ZX
Fast Idle Speed (HP mode) 2150 or more Extend the boom and arm
cylinder to relieve the boom
raise and arm roll-in circuit.
Auto-Idle Speed 1240±100 Value indicated on Dr.ZX
Auto-Acceleration Speed 1725±70 ↑
Warming Up Speed 1190±100 ↑
ENGINE COMPRESSION PRESSURE 2.95 (30.0, 427) T4-3-4
(After engine warm-up) 2
MPa (kgf/cm , psi)
VALVE CLEARANCE (IN, EX) mm 0.4 With the engine cold T4-3-6
NOZZULE INJECTION PRESSURE 18.1 (185, 2630) T4-3-8
2
MPa (kgf/cm , psi)
INJECTION TIMING (Degrees before TDC) deg. 9° T4-3-10
LUBRICANT CONSUMPTION mL/h 40 or less Hour meter: 2000 hours or T4-3-12
less
TRAVEL SPEED sec/10 m T4-4-1
Fast Speed 6.5±0.6
Slow Speed (10.5±1.0)
T4-2-1
ZAXIS110
Reference
Page
Standard)
TRACK REVOLUTION SPEED sec/3 rev T4-4-2
Fast Speed 13.8±1.0
MISTRACK mm/20 m 200 or less T4-4-3
(With fast and slow travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0 T4-4-4
SWING SPEED sec/3 rev 12.9±1.1 Bucket empty T4-4-5
SWING FUNCTION DRIFT CHECK mm /180° 860 or less 2.26 m Arm T4-4-6
0.45 m3 (PCSA heaped)
bucket, bucket empty
SWING MOTOR LEAKAGE mm/5 min 0 2.26 m Arm T4-4-8
bucket, bucket loaded
SWING BEARING PLAY mm 0.2 to 1.25 Allowable Limit: 2.0 to 3.05 T4-4-11
MAXIMUM SWINGABLE SLANT ANGLE deg. 21° or possibly Bucket loaded T4-4-10
more
HYDRAULIC CYLINDER CYCLE TIME sec 2.26 m Arm T4-4-12
Bucket, bucket empty
Boom Raise 2.9±0.3
Boom Lower 2.3±0.3
Arm Roll-In 2.9±0.3
Arm Roll-Out 2.2±0.3
Bucket Roll-In 3.3±0.3
Bucket Roll-Out 2.4±0.3
DIG FUNCTION DRIFT CHECK mm/5 min 2.26 m Arm T4-4-14
Bucket
Boom Cylinder (Maximum Reach Position) 10 or less Bucket loaded
(Arm Roll-In Position) 5 or less Bucket empty
Arm Cylinder (Maximum Reach Position) 20 or less Bucket loaded
Bucket Cylinder (Maximum Reach Position) 15 or less Bucket loaded
Bucket Bottom (Maximum Reach Position) 150 or less Bucket loaded
NOTE: 1 mm=0.03937 in
T4-2-2
ZAXIS110
Reference
Page
Standard)
CONTROL LEVER OPERATING FORCE HITACHI Lever Pattern T4-4-18
N (kgf, lbf)
Boom Lever 18 (1.8, 4.4) or less
Arm Lever (ISO Lever Pattern: Swing Lever) 15 (1.5, 3.3) or less
Bucket Lever 15 (1.5, 3.3) or less
Swing Lever (ISO Lever Pattern: Arm Lever) 18 (1.8, 4.4) or less
Travel Lever 28 (2.8, 6.2) or less
CONTROL LEVER STROKE mm HITACHI Lever Pattern T4-4-20
Boom Lever 105±10
Arm Lever (ISO Lever Pattern: Swing Lever) 84±10
Bucket Lever 84±10
Swing Lever (ISO Lever Pattern: Arm Lever) 105±10
Travel Lever 120±10
BOOM RAISE/SWING (Bucket Empty) sec 2.26 m Arm T4-4-24
3.1±0.3 0.45 m3 (PCSA heaped)
Bucket
(Bucket Teeth Height: H) mm 5400 or more
BOOM RAISE/ARM ROLL-IN (Bucket Empty) 2.26 m Arm T4-4-25
sec 4.3±0.5 0.45 m3 (PCSA heaped)
Bucket
PRIMARY PILOT PRESSURE 2
MPa (kgf/cm , psi) T4-5-1
Engine: Fast Idle 4.0+1.0-0.5
(40 -5, 570+142-71)
+10
Engine: Slow Idle 3.5+1.0-0.5

(35 -5, 500+142-71)
+10
SECONDARY PILOT PRESSURE) Value indicated on T4-5-4

3.4 to 4.0 (34 to 40,
(Engine: Fast Idle and Slow Idel) Dr.ZX
483 to 570)
2
MPa (kgf/cm , psi) (Lever: Full Stroke)
SOLENOID VALVE SET PRESSURE Value Indicated On T4-5-6
2
MPa (kgf/cm , psi) Dr. ZX±0.2 (2, 28)
T4-2-3
ZAXIS110
Reference
Page
Standard)
MAIN PUMP DELIVERY PRESSURE 0.7+1.0-0.7 Value indicated on T4-5-9
2
MPa (kgf/cm , psi) +10 +142 Dr.ZX
(7 -7, 100 -100)
MAIN RELIEF VALVE SET PRESSURE T4-5-10
2
MPa (kgf/cm , psi)
Boom, Arm, and Bucket 34.3+2.0-0.5 (350+20-5, Value indicated on
4980+284-71) Dr.ZX
RELIEF PRESSURE 33.5+2.0-0.5 (340+20-5, Value indicated on T4-5-14
(When relieving Swing) 2
MPa (kgf/cm , psi) 4835+356-71) Dr.ZX
(When relieving Travel) 2
OVERLOAD RELIEF VALVE SET PRESSURE (Reference values T4-5-16
2
MPa (kgf/cm , psi) at 50 L/min)
Boom (Raise/Lower), Arm Roll-In, and 37.3+1.0-0
Bucket Roll-In (380+10-0, 5400+142-0)
Arm Roll-Out, Bucket Roll-Out 39.2+1.0-0
(400+10-0, 5690+142-0)
MAIN PUMP FLOW TEST (L/min) - Refer to page T4-2-26, T4-5-20
27
SWING MOTOR DRAINAGE (L/min) T4-5-26
With constant maximum speed 0.4 or less Allowable Limit: 0.6
With the motor relieved 1.6 or less Allowable Limit: 2.0
TRAVEL MOTOR DRAINAGE (L/min) T4-5-30
With the track jacked up 0.3 to 1.2 Allowable Limit: 1.8
With the motor relieved 0.3 to 1.9 Allowable Limit: 2.5
T4-2-4
ZAXIS110M OPERATIONAL
ZAXIS110M
Reference
Page
Standard)
ENGINE SPEED min
-1
T4-3-1
Fast Idle Speed (Relief operation) 1960±50 Extend the boom cylinder to
relieve the boom raise
circuit.
MPa (kgf/cm , psi)
NOZZULE INJECTION PRESSURE 18.1 (185, 2630) T4-3-8
2
MPa (kgf/cm , psi)
less
Fast Speed 8.7±0.5
T4-2-5
ZAXIS110M
Reference
Page
Standard)
Slow Speed 34.5±2.0
bucket, bucket empty
bucket, bucket loaded
more
Boom Raise 2.9±0.3
Boom Lower 2.3±0.3
Bucket
NOTE: 1 mm=0.03937 in
T4-2-6
ZAXIS110M
Reference
Page
Standard)
N (kgf, lbf)
Boom Lever 105±10
Bucket Lever 84±10
3.1±0.3 0.45 m3 (PCSA heaped)
Bucket
Bucket
(40 -5, 570+142-71)
+10

(35 -5, 500+142-71)
+10

3.4 to 4.0 (34 to 40,
483 to 570)
2
2
T4-2-7
ZAXIS110M
Reference
Page
Standard)
2
MPa (kgf/cm , psi) +10 +142 Dr.ZX
(7 -7, 100 -100)
2
MPa (kgf/cm , psi)
4980+284-71) Dr.ZX
2
Bucket Roll-In (380+10-0, 5400+142-0)
(400+10-0, 5690+142-0)
27
Continuous Pressure 2
MPa (kgf/cm , psi) (0.2 (2.0, 28)) Measured at test stand
Maximum Instantaneous Pressure (0.5 (5.0, 71)) Measured at test stand
2
MPa (kgf/cm , psi)
T4-2-8
ZAXIS120/130/130LCN OPERATIONAL
ZAXIS120/130
ZAXIS130LCN Reference
PERFORMANCE TEST DESIGNATION Remarks
(Performance Page
Standard)
ENGINE SPEED min-1 T4-3-1
Fast Idle Speed (Relief operation) 1960±50 Extend the boom cylinder
to relieve the boom raise
circuit.
cylinder to relieve the
boom raise and arm roll-in
circuit.
(After engine warm-up) MPa (kgf/cm2, psi)
NOZZULE INJECTION PRESSURE 18.1 (185, T4-3-8
MPa (kgf/cm2, psi) 2630)
less
Fast Speed 6.5±0.6
T4-2-9
ZAXIS120/130
(Performance Page
Standard)
Bucket, bucket loaded
more
Boom Raise 3.1±0.3
Boom Lower 2.2±0.3
Bucket
NOTE: 1 mm=0.03937 in
T4-2-10
ZAXIS120/130
(Performance Page
Standard)
N (kgf, lbf)
Boom Lever 18 (1.8, 4.4) or
less
Arm Lever (ISO Lever Pattern: Swing Lever) 15 (1.5, 3.3) or
less
Bucket Lever 15 (1.5, 3.3) or
less
Swing Lever (ISO Lever Pattern: Arm Lever) 18 (1.8, 4.4) or
less
Travel Lever 28 (2.8, 6.2) or
less
Boom Lever 105±10
Bucket Lever 84±10
3.3±0.3 0.50 m3 (PCSA heaped)
Bucket
Bucket
(40 -5, 570+142-71)
+10
Engine: Slow Idle 3.5+1.0-0

(35 -0, 500+142-0)
+10
SECONDARY PILOT PRESSURE) Value indicated on Dr.ZX T4-5-4

3.4 to 4.0 (34 to
(Engine: Fast Idle and Slow Idel) (Lever: Full Stroke)
2 40, 483 to 570)
MPa (kgf/cm , psi)
SOLENOID VALVE SET PRESSURE Value Indicated T4-5-6
2
MPa (kgf/cm , psi) On Dr. ZX±0.2 (2,
28)
T4-2-11
ZAXIS120/130
(Performance Page
Standard)
MAIN PUMP DELIVERY PRESSURE 0.7+1.0-0.7 Value indicated on Dr.ZX T4-5-9
2
MPa (kgf/cm , psi)
(7+10-7, 100+142-100)
2
MPa (kgf/cm , psi)
Boom, Arm 34.5+2.0-0.5 Value indicated on Dr.ZX
(350+20-5,
4980+284-71)
Bucket 35.5+2.0-0.5 Value indicated on Dr.ZX
(360+20-5,
5120+284-71)
RELIEF PRESSURE 34.5+2.0-0.5 Value indicated on Dr.ZX T4-5-14
MPa (kgf/cm , psi) (350+20-5,
4980+284-0)
RELIEF PRESSURE T4-5-15
MPa (kgf/cm , psi)
(When relieving both travel levers) 34.5+2.0-0.5 Value indicated on Dr.ZX
(350+20-5,
4980+284-71)
(When relieving one travel lever) 35.5+2.0-0.5 Value indicated on Dr.ZX
(360+20-5,
5120+284-71)
2

Bucket Roll-In (380+10-0,
5400+142-0)
(400+10-0,
5690+142-0)
MAIN PUMP FLOW TEST (L/min) － Refer to page T4-2-22, T4-5-20
23
T4-2-12
ZAXIS125US OPERATIONAL
ZAXIS125US
Reference
Page
Standard)
ENGINE SPEED min
-1
T4-3-1
Slow Idle Speed 950±100 Value indicated on Dr ZX.
Fast Idle Speed (Relief operation) 1950 or more Extend the boom cylinder
circuit.
ENGINE COMPRESSION PRESSURE 2.95 (30.0, T4-3-4
MPa (kgf/cm , psi) 427)
2
less
Fast Speed 6.9±0.6
T4-2-13
ZAXIS125US
Reference
Page
Standard)
more
Boom Raise 3.8±0.3
Boom Lower 3.2±0.3
Blade Raise 2.4±0.3
Blade Lower 2.6±0.3
Bucket
Blade Cylinder (Maximum Raise Position) 5 or less
NOTE: 1 mm=0.03937 in
T4-2-14
ZAXIS125US
Reference
Page
Standard)
N (kgf, lbf)
Blade Lever 33 (3.3, 24) or less
Boom Lever 105±10
Bucket Lever 84±10
Blade Lever 120±10
3.5±0.3 0.45 m3 (PCSA heaped)
Bucket
Bucket
(40 -5, 570+142-71)
+10

(35 -5, 500+142-71)
+10

3.4 to 4.0 (34 to 40,
483 to 570)
2
T4-2-15
ZAXIS125US
Reference
Page
Standard)
2
2
MPa (kgf/cm , psi) Dr.ZX
(7+10-7, 100+142-100)
2
MPa (kgf/cm , psi)
4980+284-71) Dr.ZX
2
Bucket Roll-In (380+10-0, 5400+142-0)
(400 -0, 5690+142-0)
+10

27
With the motor relieved 1.6 or less Allowable Limit: 2.0 T4-5-30
TRAVEL MOTOR DRAINAGE (L/min)
T4-2-16
ZAXIS135US OPERATIONAL
ZAXIS135US
Reference
Page
Standard)
ENGINE SPEED min
-1
T4-3-1
circuit.
MPa (kgf/cm , psi)
2
less
T4-2-17
ZAXIS135US
Reference
Page
Standard)
more
Boom Raise 3.3±0.3
Boom Lower 2.9±0.3
Bucket
(Arm Roll-In position) 5 or less Bucket empty
NOTE: 1 mm=0.03937 in
T4-2-18
ZAXIS135US
Referenc
e Page
Standard)
N (kgf, lbf)
Boom Lever 105±10
Bucket Lever 84±10
Blade Lever 120±10
3.3±0.3 0.45 m3 (PCSA heaped)
Bucket
Bucket
(40 -5, 570+142-71)
+10

(35 -5, 500+142-71)
+10

3.4 to 4.0 (34 to 40,
2 483 to 570)
MPa (kgf/cm , psi)
T4-2-19
ZAXIS135US
Reference
Page
Standard)
2
2
MPa (kgf/cm , psi)
(7+10-7, 100+142-100)
2
MPa (kgf/cm , psi)
Boom, Arm, and Bucket 34.5+2.0-0.5 (350+20-5, Value indicated on Dr.ZX
4980+284-71)
RELIEF PRESSURE 33.5+2.0-0.5 (340+20-5, Value indicated on Dr.ZX T4-5-14
MPa (kgf/cm , psi) 4835+356-71)
RELIEF PRESSURE 34.5+2.0-0.5 (350+20-5, Value indicated on Dr.ZX T4-5-15
MPa (kgf/cm , psi) 4980+427-284)
2

Bucket Roll-In (380+10-0, 5400+142-0)
(400 -0, 5690+142-0)
+10

27
T4-2-20
ZAXIS135UR OPERATIONAL
ZAXIS135UR
Reference
Page
Standard)
ENGINE SPEED min
-1
T4-3-1
circuit.
cylinder to relieve the
boom raise and arm roll-in
circuit.
ENGINE COMPRESSION PRESSURE 2.95 (30.0, T4-3-4
2
less
Fast Speed 7.9±0.6
T4-2-21
ZAXIS135UR
Reference
Page
Standard)
TRAVEL MOTOR LEAK mm/5 min 0 T4-4-4
SWING BEARING PLAY mm 0.2 to 1.25 Allowable Limit: 2.0 to T4-4-11
3.05
more
Boom Raise 4.0±0.3
Boom Lower 3.3±0.3
Left Offset (Offset Switch) 2.7±0.5
(5.0±2.5)
Right Offset (Offset Switch) 3.4±0.5
(5.0±2.5)
NOTE: 1 mm=0.03937 in
T4-2-22
ZAXIS135UR
Reference
Page
Standard)
Bucket
Blade Cylinder 5 or less
Blade Lower Amount 20 or less
Offset Cylinder 10 or less
N (kgf, lbf)
Offset Pedal 150 (15.3, 133.8) or
less
Boom Lever 105±10
Bucket Lever 84±10
Blade Lever 50±15
Offset Pedal 14±10
T4-2-23
ZAXIS135UR
Reference
Page
Standard)
3.3±0.3 0.45 m3 (PCSA heaped)
Bucket
Bucket
BUCKET/CAB COLLISION PREVENTION SYSTEM mm T4-4-22
Cab Front (235)
Side of Cab (220)
(40 -5, 570+142-71)
+10

(35 -5, 500+142-71)
+10

3.4 to 4.0 (34 to 40,
2 483 to 570)
MPa (kgf/cm , psi)
2
2
MPa (kgf/cm , psi) +10 +142
(7 -7, 100 -100)
T4-2-24
ZAXIS135UR
Reference
Page
Standard)
2
MPa (kgf/cm , psi)
4980+284-71) Dr.ZX
Blade 20.6+2.0-0.5 (210+20-5
2990+284-71)
Offset 28.4+3.0-0.5 (290+30-5,
4120+427-71)
2

Bucket Roll-In (380 -0, 5400+142-0)
+10

(400 -0, 5690+142-0)
+10
Blade Raise 27.5+1.0-0

(280 -0, 3980+142-0)
+10
Blade lower 39.2+1.0-0

(400 -0, 5960+142-0)
+10

27
T4-2-25
MAIN PUMP P-Q DIAGRAM
• Hydraulic P-Q Control
(REFERENCE: Measured at Test Stand)
• Rated Pump Speed: 1950 min-1 (rpm)

(This pump device is not equipped with a trans-
mission so that the pump speed is equal to the
engine speed. Therefore, measure the pump flow
rate with the engine running at the rated pump
speed.)
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
NOTE: Refer to T4-5-20.
• ZAXIS110/110M/125US/135UR Points on P-Q Line • ZAXIS120/130/130LCN/135US Points on P-Q Line

Delivery Pressure Flow Rate Delivery Pressure Flow Rate
MPa (kgf/cm2, psi) L/min (gpm) 2
MPa (kgf/cm , psi) L/min (gpm)
A 3.9 (40, 570) 100±2 (26.4±0.5) A 3.9 (40, 570) 105±2 (27.7±0.5)
B 14.7 (150, 2135) [99 (26.1)] B 15.5 (158, 2250) [104 (27.5)]
C 17.2 (175, 2490) 86±4 (22.7±1.0) C 17.2 (175, 2490) 94±4 (24.8±1.0)
D 19.2 (196, 2790) [73 (19.3)] D 20.1 (205, 2915) [78 (20.6)]
E 23.0 (235, 3345) 63±4 (16.6±1.0) E 24.5 (250, 3555) 66±4 (17.4±1.0)
F 34.3 (350, 4780) [30±6 (7.9±1.6)] F 34.3 (350, 4780) [35±6 (9.2±1.6)]
The value indicated in parentheses is only a reference The value indicated in parentheses is only a reference
value. value.
L/min A
B
Flow D
Rate
Delivery Pressure MPa (kgf/cm2)

T178-04-05-001
T4-2-26
• P-Q Control by Pump Control Pilot Pressure Sig-
nal
∗ (REFERENCE: Measured at Test Stand)
• Rated Pump Speed: 1950 min-1 (rpm)

(This pump device is not equipped with a trans-
mission so that the pump speed is equal to the
engine speed. Therefore, measure the pump flow
rate with the engine running at the rated pump
speed.)
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
NOTE: Refer to T4-5-22.
• ZAXIS110/110M/125US/135UR Points on P-Q Line • ZAXIS120/130/130LCN/135US Points on P-Q Line

Pump Control Flow Rate Pump Control Flow Rate
pressure L/min (gpm) pressure L/min (gpm)
MPa (kgf/cm2, psi) MPa (kgf/cm2, psi)
A Q minimum 35±2 (9.2±0.5) A Q minimum 35±2 (9.2±0.5)
1.96±0.05 (20±0.5, 55±1 (14.5±0.3) 1.96±0.05 (20±0.5, 55±1 (14.5±0.3)
B B
284±7) 284±7)
2.9+0−0.3 2.9+0−0.3
C 100±2 (26.4±0.5) C 105±2 (27.7±0.5)
(30 −3, 427+0−43)
+0
(30 −3, 427+0−43)
+0
The valve indicated in parentheses is only a reference The valve indicated in parentheses is only a reference
valve. valve.
L/min
C
Flow
Rate
2
Pump Control Pressure MPa (kgf/cm )
T178-04-05-002
T4-2-27
INJECTION PUMP
ZAXIS110/110M/125US/135UR
Test Conditions:
1. Injection pump: PES4A 101041-8900 8. Transfer pump pressure:
2. Governor: EP/RSV 105419-4040 157 kPa (1.6 kgf/cm2, 23 psi)
3. Nozzle and nozzle holder assembly: 9. Injection pipe: Inner Dia. 2 mm×Outer Dia. 6
105780-8140 (Bosch No. EF8511/9A) mm-Length 600 mm (0.079×0.236-23.6 in)
4. Nozzle: 105780-0000 (Bosch No. DN12SD12T) 10. Fuel temperature: 40+5 °C (104+9 °F)
5. Nozzle holder: 105780-2080 (Bosch No. 11. Overflow valve opening pressure: 127 kPa (1.3
EF8511/9) kgf/cm2, 18.5 psi)
6. Nozzle opening pressure: NOTE: The nozzle test injection pressure is 17.2
17.2 MPa (175 kgf/cm2, 2490 psi) MPa (175 kgf/cm2, 2490 psi). However,
7. Test fuel: ISO 4113 or SAE J967d actual machine injection pressure is 18.1
MPa (185 kgf/cm2, 2630 psi).
Injection rate adjustment

Average Injection Maximum Variance
Adjusting Pump Speed Rack Position
-1 Strokes Rate Between Cylinders Fixed Remarks
Point (mm ) (mm) 3
(cm /1000 Stroke) (%)
A 1100 8.4 80±1.1 ±2 Lever Basic
C 475 Approx. 6.0 8.8±1.4 ±14 Rack
D 100 - 125±5 - Lever Rack limit
Governor adjustment
Above 14.0
13.0
Rack Limit
Idle-Sub Spring Setting

D
9.5 Governor Spring Setting
9.1±0.1 A
Pack Position
(mm)
8.4
7.9±0.1
6.5 C
6.0
5.7±0.3
300 475 (1115)

145±30 350 (440) 1125 1210
T175-04-05-001
-1
Pump Speed min (rpm)
T4-2-28
ZAXIS120/130/130LCN/135US
Test Conditions:
1. Injection pump: PES4A 101041-8900 8. Transfer pump pressure:
2. Governor: EP/RSV 105419-4040 157 kPa (1.6 kgf/cm2, 23 psi)
3. Nozzle and nozzle holder assembly: 9. Injection pipe: Inner Dia. 2 mm×Outer Dia. 6
105780-8140 (Bosch No. EF8511/9A) mm-Length 600 mm (0.079×0.236-23.6 in)
4. Nozzle: 105780-0000 (Bosch No. DN12SD12T) 10. Fuel temperature: 40+5 °C (104+9 °F)
5. Nozzle holder: 105780-2080 (Bosch No. 11. Overflow valve opening pressure: 127 kPa (1.3
EF8511/9) kgf/cm2, 18.5 psi)
6. Nozzle opening pressure: NOTE: The nozzle test injection pressure is 17.2
17.2 MPa (175 kgf/cm2, 2490 psi) MPa (175 kgf/cm2, 2490 psi). However,
7. Test fuel: ISO 4113 or SAE J967d actual machine injection pressure is 18.1
MPa (185 kgf/cm2, 2630 psi).
Injection rate adjustment

Average Injection Maximum Variance
Adjusting Pump Speed Rack Position
-1 Strokes Rate Between Cylinders Fixed Remarks
Point (mm ) (mm) 3
(cm /1000 Stroke) (%)
A 1100 8.5 81±1.1 ±2 Lever Basic
C 475 Approx. 6.0 8.8±1.4 ±14 Rack
D 100 - 125±5 - Lever Rack limit
Governor adjustment
Above 14.0
13.0
Rack Limit
Idle-Sub Spring Setting

D
Governor Spring Setting
9.5
Pack Position 9.1±0.1 A
(mm)
8.5
8.0±0.1
6.5 C
6.0
6.0±0.3
300 475 (1115)

145±30 1130 1210
350 (430) (1120)
T176-04-05-001
-1
Pump Speed min (rpm)
T4-2-29
ZAXIS110 DR.ZX MONITOR INDICATING
VALUES
Unless specified, test under the following conditions. ∗
NOTE: Items marked ( ) are measurable with the
Engine Speed: Fast Idle built-in diagnosing system.
Work Mode Switch: Digging Mode ∗∗
Items marked ( ) are measurable with the
Power Mode Switch: P mode
built-in diagnosing system. However, it
Auto-Idle/Acceleration Selector: OFF
may be difficult to read the measured value
Reference Measured Value

Item Remarks
Value First Second Third Average
PUMP 1 PRESSURE (MPa)
Control Lever in Neutral∗ 0.5

Boom Raise∗ 35.5 When relieving
∗
Boom Lower -
∗
Arm Roll-In 35.5 When relieving
∗
Arm Roll-Out 35.7 When relieving
∗
Bucket Roll-Out 35.7 When relieving
Bucket Roll-In* 36.0 When relieving
Boom Raise + Arm Roll-In
+ Bucket Roll-In Combined 35.2 When relieving
∗
Operation
∗
Control Lever in Neutral 0.5
∗
Boom Raise 35.5 When relieving
∗
Boom Lower -
∗
∗
∗
∗
Bucket Roll-In 0.8 When relieving
∗
Operation
T4-2-30

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 3.51 When relieving
∗
Operation
T4-2-31

Item Remarks
TARGET ENGINE SPEED (min )
-1
Fast Idle∗ 1750

Fast Idle
(When operating a control lever)∗ 1950
∗
Fast Idle (HP Mode) 2150 When reliev-
ing boom
raise circuit
∗
Fast Idle (E Mode) 1750
∗
Auto-Idle 1050
∗
Slow Idle 800
ACTUAL ENGINE SPEED (min )
-1
∗
Fast Idle 1930
Fast Idle
(When operating a control lever)
∗ 2000
∗
ing boom
raise circuit
∗
∗
Auto-Idle 1190
∗
Slow Idle 920
ENGINE SPEED DEVIATION
-1
(min )
∗
Fast Idle 186
Fast Idle
∗ 56
∗
ing boom
raise circuit
∗
∗
Auto-Idle 134
∗
Slow Idle 128
EC ANGLE (Volt)
∗
Minimum 2.55
∗
Maximum 3.12
DIAL ANGLE (Volt)
∗
Minimum 0.44
∗
Maximum 4.25
T4-2-32

Item Remarks
BOOM RAISE PILOT
∗ 4.03 When relieving
CONTROL PRESSURE (MPa)
ARM ROLL-IN PILOT
SWING PILOT CONTROL
PRESSURE
∗∗
(MPa)
-
TRAVEL PILOT CONTROL
PRESSURE
∗∗
(MPa)
4.00
FRONT ATTACHMENT “ON-OFF” is dis-
CONTROL PRESSURE
∗
(MPa)
- played
Pump 2 Proportional Valve Lever in Neutral
Output (MPa)
3.92
Main Pump Torque Engine Slow Idle
Proportional Valve 3.73 + Travel
Output (MPa)
ARM REGENERATIVE PRO-
PORTIONAL VALVE OUTPUT
(MPa)
Lever in Neutral 1.47
Swing, Arm Roll-In, and Boom
Raise Combined Operation 2.45
TRAVEL MOTOR CONTROL Traveling, Travel
PRESSURE (MPa) 2.92 Mode Switch:
Fast
EC MOTOR POSITION (Step) When relieving
360 arm roll-in circuit
T4-2-33
ZAXIS110M DR.ZX MONITOR INDICATING
VALUES

Item Remarks

∗
Boom Lower -
∗
∗
∗
∗
Operation
∗
∗
∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
T4-2-34

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 3.80 When relieving
∗
Operation
T4-2-35

Item Remarks
TARGET ENGINE SPEED (min )
-1
Fast Idle∗ 1750

Fast Idle
(When operating a control lever)∗ 1950
∗
ing boom
raise and arm
roll-in circuit
∗
∗
Auto-Idle 1050
∗
Slow Idle 800
ACTUAL ENGINE SPEED (min )
-1
∗
Fast Idle 1970
Fast Idle
∗ 2060
∗
ing boom
raise and arm
roll-in circuit
∗
∗
Auto-Idle 1290
∗
Slow Idle 1040
-1
(min )
∗
Fast Idle 220
Fast Idle
∗ 112
∗
ing boom
raise and arm
roll-in circuit
∗
∗
Auto-Idle 248
∗
Slow Idle 244
EC ANGLE (Volt)
∗
Minimum 2.61
∗
Maximum 3.14
DIAL ANGLE (Volt)
∗
Minimum 0.52
∗
Maximum 4.33
T4-2-36

Item Remarks
BOOM RAISE PILOT
ARM ROLL-IN PILOT
SWING PILOT CONTROL
PRESSURE
∗∗
(MPa)
-
PRESSURE
∗∗
(MPa)
3.91
CONTROL PRESSURE
∗
(MPa)
- played
Output (MPa)
3.92
Output (MPa)
(MPa)
Fast
T4-2-37
ZAXIS120/130/130LCN DR.ZX MONITOR
INDICATING VALUES
∗
Unless specified, test under the following conditions. built-in diagnosing system.
Engine Speed: Fast Idle ∗∗
Work Mode Switch: Digging Mode

Item Remarks

∗
Boom Lower -
∗
∗
∗
Boom Raise + Arm
Roll-In + Bucket Roll-In 33.8 When relieving
∗
Combined Operation
∗
∗
∗
Boom Lower -
∗
∗
∗
∗
Boom Raise + Arm
∗
Combined Operation
T4-2-38

Item Remarks
PUMP 1 PUMP CONTROL
PRESSURE (MPa)
∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
PUMP 2 PUMP CONTROL
PRESSURE (MPa)
∗
∗
∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
T4-2-39

Item Remarks
TARGET ENGINE SPEED -1
(min )
Fast Idle∗ 1750

Fast Idle (When operating a
control lever)∗ 1950
Fast Idle (HP Mode)∗ 2000 When reliev-
ing boom
raise circuit
∗
∗
Auto-Idle 1050
∗
Slow Idle 800
ACTUAL ENGINE SPEED -1
(min )
∗
Fast Idle 1890
Fast Idle
(When operating a control 1910
∗
lever)
∗
ing boom
raise circuit
∗
∗
Auto-Idle 1150
∗
Slow Idle 870
-1
(min )
∗
Fast Idle 142
Fast Idle
(When operating a control -34
∗
lever)
∗
Fast Idle (HP Mode) -30 When reliev-
ing boom
raise circuit
∗
∗
Auto-Idle 100
∗
Slow Idle 72
EC ANGLE (Volt)
∗
Minimum 2.51
∗
Maximum 3.08
DIAL ANGLE (Volt)
Minimum∗ 0.58
Maximum∗ 4.37
T4-2-40

Item Remarks
BOOM RAISE PILOT
ARM ROLL-IN PILOT
SWING PILOT CONTROL
PRESSURE
∗∗
(MPa)
-
PRESSURE
∗∗
(MPa)
3.98
CONTROL PRESSURE
∗
(MPa)
- played
Output (MPa)
3.92
Output (MPa)
(MPa)
Fast
T4-2-41
ZAXIS125US DR.ZX MONITOR INDICATING
VALUES

Item Remarks

∗
Boom Lower -
∗
∗
∗
Boom Raise + Arm
∗
Combined Operation
Boom Lower∗ -
Arm Roll-In∗ 35.7 When relieving
Arm Roll-Out∗ 35.7 When relieving
Bucket Roll-Out∗ 0.8 When relieving
Bucket Roll-In∗ 0.8 When relieving
Boom Raise + Arm
Combined Operation∗
T4-2-42

Item Remarks
PUMP 1 PUMP CONTROL
PRESSURE (MPa)
∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
PUMP 2 PUMP CONTROL
PRESSURE (MPa)
∗
∗
∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
T4-2-43

Item Remarks
(min )
Fast Idle∗ 1750

∗
ing boom
raise circuit
∗
∗
Auto-Idle 1050
∗
Slow Idle 800
(min )
∗
Fast Idle 1950
Fast Idle
∗
lever)
∗
ing boom
raise circuit
∗
∗
Auto-Idle 1250
∗
Slow Idle 1030
-1
(min )
∗
Fast Idle 192
Fast Idle
∗
lever)
∗
ing boom
raise circuit
∗
∗
Auto-Idle 208
∗
Slow Idle 236
EC ANGLE (Volt)
∗
Minimum 2.51
∗
Maximum 3.12
DIAL ANGLE (Volt)
Minimum∗ 0.46
Maximum∗ 4.37
T4-2-44

Item Remarks
BOOM RAISE PILOT
ARM ROLL-IN PILOT
SWING PILOT CONTROL
PRESSURE
∗∗
(MPa)
4.62
PRESSURE
∗∗
(MPa)
4.58
CONTROL PRESSURE
∗
(MPa)
- played
Output (MPa)
3.92
Output (MPa)
(MPa)
Fast
EC MOTOR POSITION (Step)
Slow Idle (Lever in Neutral) 0.0

Fast Idle (Lever in Neutral) 280
Fast Idle (When relieving arm
344
roll-in circuit)
T4-2-45
ZAXIS135US DR.ZX MONITOR INDICATING
VALUES

Item Remarks

∗
Boom Lower -
∗
∗
∗
Boom Raise + Arm
∗
Combined Operation
Boom Lower∗ -
Boom Raise + Arm
T4-2-46

Item Remarks
PUMP 1 PUMP CONTROL
PRESSURE (MPa)
∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
PUMP 2 PUMP CONTROL
PRESSURE (MPa)
∗
∗
∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
T4-2-47

Item Remarks
(min )
Fast Idle∗ 1750

ing boom
raise circuit
∗
∗
Auto-Idle 1050
∗
Slow Idle 800
(min )
∗
Fast Idle 1920
Fast Idle
∗
lever)
∗
ing boom
raise circuit
∗
∗
Auto-Idle 1220
∗
Slow Idle 980
-1
(min )
∗
Fast Idle 168
Fast Idle
∗
lever)
∗
ing boom
raise circuit
∗
∗
Auto-Idle 168
∗
Slow Idle 178
EC ANGLE (Volt)
Minimum∗ 2.51
Maximum∗ 3.10
DIAL ANGLE (Volt)
Minimum∗ 0.50
Maximum∗ 4.37
T4-2-48

Item Remarks
BOOM RAISE PILOT
ARM ROLL-IN PILOT
SWING PILOT CONTROL
PRESSURE
∗∗
(MPa)
4.05
PRESSURE
∗∗
(MPa)
4.03
CONTROL PRESSURE
∗
(MPa)
- played.
Output (MPa)
3.92
Output (MPa)
(MPa)
Fast
Slow Idle (Lever in Neutral) 0

roll-in circuit: ) 348
T4-2-49
ZAXIS135UR DR.ZX MONITOR INDICATING
VALUES
Measuring MC

Item Remarks

∗
Boom Lower -
∗
∗
∗
Blade Raise 35.5 When relieving
Bade Lower 35.5 When relieving
Boom Raise + Arm
∗
Combined Operation
Boom Lower∗ -
Blade Lower 0.5 When relieving
Boom Raise + Arm
T4-2-50

Item Remarks
PUMP 1 PUMP CONTROL
PRESSURE (MPa)
∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
PUMP 2 PUMP CONTROL
PRESSURE (MPa)
∗
∗
∗
Boom Lower -
∗
∗
∗
∗
∗
Operation
T4-2-51

Item Remarks
(min )
Fast Idle∗ 1750

ing boom
raise circuit
∗
∗
Auto-Idle 1080
∗
Slow Idle 830
(min )
Fast Idle∗ 1850

ing boom
raise circuit
Fast Idle (E Mode)∗ 1880
Auto-Idle∗ 1170
Slow Idle∗ 930
-1
(min )
∗
Fast Idle 100
Fast Idle
∗
lever)
∗
ing boom
raise circuit
∗
∗
Auto-Idle 100
∗
Slow Idle 100
EC ANGLE (Volt)
∗
Minimum 2.51
∗
Maximum 3.12
DIAL ANGLE (Volt)
∗
Minimum 0.42
∗
Maximum 4.47
T4-2-52

Item Remarks
BOOM RAISE PILOT
ARM ROLL-IN PILOT
SWING PILOT CONTROL
PRESSURE
∗∗
(MPa)
-
PRESSURE
∗∗
(MPa)
4.19
CONTROL PRESSURE
∗
(MPa)
- played.
Output (MPa)
3.92
Output (MPa)
(MPa)
Fast
Slow Idle (Lever in Neutral) 8

376
roll-in circuit: )
T4-2-53
Measuring Auto-Marccino Controller

Unless specified, test under the following conditions.
Engine Speed: Fast Idle
Auto-MARCCINO Switch: ON
Item Remarks
ANGLE SENSOR VOLTAGE (V) When in
Stroke End
Boom Raise 0.761
Boom Lower -
Arm Roll-In 4.140
Arm Roll-Out 0.703
Left Offset 3.671
Right Offset 1.210
SOLENOID VALVE CURRENT When in Neu-
(mA) tral
Boom Raise Deceleration 461
Boom Lower Deceleration 461
Arm Roll-In Deceleration 423
Arm Roll-Out Deceleration 423
Left Offset Deceleration 423
Boom Raise Acceleration 0
Arm Roll-Out Acceleration 0
Left Offset Acceleration 0
(Offset Switch) (359)
Right Offset Acceleration 0
(Offset Switch) (351)
Right Offset Deceleration 423
PILOT PRESSURE (MPa) When reliev-
ing
Boom Raise 4.18
Arm Roll-In 4.13
ANGLE SENSOR VALUE
BEFORE CORRECTING (V)
Boom 0.761
Arm 4.140
Offset 2.128
ANGLE SENSOR STANDARD
VALUE (V)
Boom 0.722
Arm 4.199
Offset 2.187
T4-2-54
SENSOR OPERATIONAL RANGE TABLE
1. Checking Method
• Hydraulic Oil Temperature: 50 ± 5 °C
• Unless specified:
Auto-Idle
Engine Power ∗
Work Mode /Auto-Accelera
Control Mode
Switch tion
Dial Switch
Selector
Digging
Fast Idle P Mode OFF
Mode
*: The work mode switch is not equipped for
ZAXIS135UR.
• Monitor by Dr.ZX.
2. Sensor Operational Range
Sensor Operation Specification

Minimum Speed 0.3 to 1.0 V
Engine Control Dial
Maximum Speed 4.0 to 4.7 V
Maximum Speed (Power Mode Switch: P) 3.3 to 3.7 V
EC Sensor
Maximum Speed (Power Mode Switch: HP) Maximum Speed
(Mode Switch: OFF) +0.2 V or more
Control Lever: Neutral 0 to 0.1 MPa (0 to 1.0 kgf/cm2)
Pilot Control Shut-Off Lever: LOCK
Pressure Sensor
Control Lever: Full Stroke 3.3 to 3.9 MPa (34 to 40 kgf/cm2)
Pilot Control Shut-Off Lever: UNLOCK
Pump Control Control Lever: Neutral 1 to 1.6 MPa (10 to 16 kgf/cm2)
Pressure Sensor Control Lever: Full Stroke 2.9 to 3.9 MPa (30 to 40 kgf/cm2)
N Sensor 20°C (Between Ground to Signal) 810 ± 240 Ω
T4-2-55
(Blank)
T4-2-56
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary:
1. Measure engine speed with the built-in diagnos-
ing system (Refer to the TROUBLESHOOTING /
General group) or Dr. ZX. If the built-in diagnos-
ing system or Dr. ZX is not available, use an en-
gine speed meter.
2. Measure the engine speeds in each mode.
NOTE: Measure the engine speed before

performing all other tests to check that the
engine speed meets specification.
Because, if the engine speed is not
adjusted correctly, all other performance
data will be unreliable.
Preparation: 2
1. Select the monitor function of the built-in
1
diagnosing system (or Dr.ZX). When using an
engine speed meter, install speed pickup (2) to
injection pipe (1).
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

stopper (3).
T107-06-02-002
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).
NOTE: *: The work mode switch is not equipped
2. Select the switch positions and the test condi- for ZAXIS135UR.
tions corresponding to the engine speed to be
NOTE: ECO stands for the auto engine speed re-
measured as shown in the table below.
duction system by 200 min-1.
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 (Nor- Digging
Max. Speed P OFF
mal) Mode
Fast Idle Check in the Dr. ZX special
Digging
(With ECO deac- Max. Speed P OFF functions with ECO deacti-
Mode
tivated) vated.
Fast Idle Digging Check the engine speed while
Max. Speed P OFF
(Relief operation) Mode relieving the boom raise circuit.
Fast Idle Digging
Max. Speed E Mode OFF
(E mode) Mode
Fast Idle Digging Check the engine speed while
Max. Speed HP Mode OFF
(HP mode) Mode relieving the boom raise circuit.
Check engine speed 4 seconds
Digging
Auto-Idle Max. Speed P Auto-Idle after returning all control levers
Mode
to neutral.
Check reduced engine speed
Auto- Digging
Max. Speed P Auto-Acceleration within 3 seconds after returning
Acceleration Mode
all control levers to neutral.
Digging Check only when oil tempera-
Warming Up Min. Speed P OFF
Mode ture is lower than 0 °C (32 °F).
T4-3-2
ZAXIS110/110M/120/130/125US/135US
Monitor Panel Switch Panel
Engine Control Dial
Auto-Idle/
Acceleration Selector
Power Mode Switch
Work Mode
Switch
T178-01-01-003
T178-01-01-004
ZAXIS135UR Monitor Panel
Power Mode
Switch
Auto-Idle/
Acceleration
Engine Control Selector
Dial
T1CF-01-01-003
T1SM-01-02-014
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 and the amount of

blow-by gas from the crankcase. Keep track of
engine oil consumption.
3. Check for abnormalities in the intake system,

including the air filter.
Preparation:
1. Confirm that valve clearances are correct.
2. Confirm that the batteries are charged properly.
3. Run the engine until the coolant temperature

gauge reaches the operating range.
4. Stop the engine. Remove glow plugs from each T105-06-02-001
cylinder.
NOTE: Unless the fuel delivery pipes are discon-

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

compression gauge in place of the glow plug in
one cylinder. (Be sure to sufficiently tighten the
adaptor and compression gauge to prevent air
leakage.)
Measurement:
1. Turn the starter to crank the engine. Record the
compression pressure of each cylinder.
2. Repeat measurement three times for each

cylinder and calculate the mean values.
Evaluation:
Refer to T4-2 Operational Performance Standard.
Remedy:
Refer to engine shop manual.
T4-3-4
(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
engine.
Preparation:
1. Locate the top dead center (TDC) in the Top Mark
compression stroke.
Align the TDC mark on the crank pulley with the
TDC Mark
pointer located on the timing gear case as
illustrated. Piston No.1(or piston No.6) is now
positioned at the TDC in its compression stroke. Timing Gear
Case
NOTE: When rotating the crank pulley, remove the Crank Pulley
fan guard. Then, rotate the fan while hold-
ing the fan belt. If it is difficult to rotate,
remove all glow plugs to release the com-
pression pressure.
T157-05-02-002
2. Remove the head cover.
3. Move push rods for the intake and exhaust

valves on the No.1 cylinder up and down by hand.
If any clearances on the both ends of the push
rods are found, piston No.1 is positioned at TDC
in the compression stroke. (If the exhaust valve
of cylinder No.1 is pushed down, piston No.4 is
positioned at TDC in the compression stroke.
Start measurement from the cylinder (No.1 or
No.4) positioned at TDC in the compression
stroke.
Measurement:
1. Insert a thickness gauge into the clearance
between the rocker arm and the valve stem end
to measure the valve clearance.
NOTE: The cylinders are aligned from No.1 to

No.4 in that order, as viewed from the fan
side .
T107-02-12-005
T4-3-6
2. When the measurement is started from No.1
cylinder, perform the same measurement to all
valves indicated with the mark “○” in the table
below. (When the measurement is started from
No.4 cylinder, perform the measurement in the
valves shown with mark “×”.)
Cylinder No. No.1 No.2 No.3 No.4

Valve locations I E I E I E I E
When the measurement is
{ { { {
started from No.1 cylinder
When the measurement is
× × × ×
started from No.4 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
pattern with a nozzle tester.
2. Before starting work, clean the nozzle holder

mounting area to avoid contamination in the
engine.
Preparation:
1. Remove the nozzle holders.
Remove all nozzle holders and fuel injection
pipings from the engine.
2. Attach a nozzle holder to the nozzle tester.
Measurement:
CAUTION: Never touch spray directly. The
fuel spray from the nozzle may penetrate the
skin, resulting in serious injury. If fuel
penetrates into the blood stream, it may
cause blood toxication.
1. Injection pressure
After attaching the nozzle holder to the nozzle T107-06-02-006
tester, strongly make several strokes of the tester
to inject fuel. Then, while operating the tester at
approx. 60 time strokes a minute, measure the
fuel injection pressure.
If adjustment is required, loosen the lock nuts
and adjust the adjusting screws. Turn clockwise
to increase the pressure, and counterclockwise
to decrease the pressure.
2. Spray pattern
For this test, turn the pressure tester knob to
bypass the pressure gauge. Attach the nozzle
holder to the nozzle tester. Strongly make several
strokes of the tester and check the fuel spray
pattern.
3. Oil tight condition

Keep the pressure slightly below the injection
pressure. Check for fuel leak from around the
nozzle tip.
NOTE: Use clean diesel fuel.
T4-3-8
Evaluation:
1. Standard Injection Pressure:
Normal
2. Spray Pattern
• Large-size spray should not be visible to the
naked eye.
• No stray sideways sprays should be seen.
• During initial injection stage, spray size should be

fine and injected intermittently.
• There should be no drips found.

T102-02-11-005
• Injection spray angle must be normal.
3. Oil Tight Condition Abnormal

No fuel leaks.
T102-02-11-006
Adjustment:
• To adjust the injection pressure, loosen the lock
nuts. Adjust the adjusting screw.
Turn clockwise to increase the pressure, and
counterclockwise to decrease the pressure.
• After adjusting, retighten the lock nuts.
T107-06-02-007
T4-3-9
INJECTION TIMING Timing Mark
Inspection: Top Mark

1. Position No.1 piston to the top dead center. Turn
the crank pulley in the direction of rotation
TDC Mark
(clockwise as seen from the front of the engine)
to set a “TDC” mark on the crank pulley under
the “Top mark”, located on the timing gear case. Timing Gear
Case
NOTE: When rotating the crank pulley, remove the Crank Pulley
fan guard. Then, rotate the fan while hold-
ing the fan belt. If it is difficult to rotate,
remove all glow plugs to release the com-
pression pressure.
T157-05-02-002
2. Remove the timing check hole cover on the front Gear Case
Projection
section of the fuel injection pump.
When the mark on the injection pump is set
under the projection of the gear case, No.1 piston
is positioned at the top dead center. If the mark is
not set under the projection, keep turning to Check
adjust. Hole
NOTE: The alignment mark on the injection pump Injection Pump

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

Projection
4. Remove the delivery valve holder for No.1
cylinder from the injection pump to pull the
delivery valve and the spring out. Reinstall the
delivery valve holder.
: 39 to 43 N⋅m
(4 to 4.4 kgf⋅m, 28.9 to 31.8 lbf⋅ft)
5. Turn the crank pulley at approx. 30 degrees

counterclockwise.
Injection Pump
Alignment Mark
T107-02-12-008
T4-3-10
6. While supplying fuel with the feed pump, turn the
crank pulley slowly clockwise just until fuel
cannot be seen from the top of the delivery valve
hole. This is the position where the injection
starts.
7. Check the “TDC” mark, located on the crank
pulley for what degrees the “TDC” mark
indicates.
Adjustment:
1. Turn the crank pulley so that the “TDC” mark
comes just above the correct timing position on
the timing gear case.
2. Loosen the mounting nuts of the injection pump.
3. When advancing timing, tilt the injection pump
outward against the cylinder block. T107-02-12-009
When delaying timing, tilt the injection pump
inward against the cylinder block.
T4-3-11
LUBRICANT CONSUMPTION
Measuring Method
1. Place the machine on level firm ground, and
leave it for at least one hour to let the lubricant
lower to the oil pan.
At this time, confirm that the machine is level,
using a leveler.
2. Record the read-out A (unit: hour) of the hour
meter.
3. Replenish the lubricant up to the high-level
gauge.
4. Operate the machine for at least 100 hours or un-
til the oil level lowers to the low-level gauge.
IMPORTANT: Make sure to keep the ma-

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

lowing equation:
Oil replenishing volume (C) [mL] / Operating
hours (B-A) [hr]
Evaluation:
T4-3-12
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary: Measurement:
Measure the time required for the excavator to travel 1. Measure both the slow and fast speeds of the
a 20 m (65.6 ft) test track. machine.
2. Select the following switch positions:
Preparation:
Travel Engine Power * Work Auto-Idle/
1. Adjust the track sag on both side tracks equally.
Mode Control Mode Mode Acceleration
2. Prepare a flat and solid test track 20 m (65.6 ft) in Switch Dial Switch Switch Selector
length with extra length of 3 to 5 m (9.8 to 16 ft) Slow Digging
on both ends for machine acceleration and Fast Idle P Mode OFF
Mode Mode
deceleration. Fast Digging
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above Mode Mode
the ground with the arm and bucket rolled in. * : The work mode switch is not equipped for
ZAXIS135UR.
4. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F). 3. Start traveling the machine in the acceleration
zone with the travel levers to full stroke.
4. Measure the time required to travel 20 m (65.6
ft).
5. After measuring the forward travel speed, turn
Arm Rolled-In, Bucket Rolled-In the upperstructure 180° and measure the reverse
End
Bucket Height: 0.3 to 0.5 m travel speed.
6. Repeat steps 4. to 5. three times in each direc-
Start
20 m Deceleration
tion and calculate the average values.
Zone
3 to 5 m
Acceleration Evaluation:
Zone Refer to T4-2 Operational Performance Standard.
3 to 5 m
T105-06-03-001
Remedy:
Refer to T5-4 Troubleshooting B.
T4-4-1
TRACK REVOLUTION SPEED
Measure the track revolution cycle time with the 1. Measure both the slow and fast travel speeds.
track raised off ground. 2. Select the following switch positions:
Travel Engine Power * Work Auto-Idle/
Preparation: Mode Control Mode Mode Acceleration
1. Adjust the track sag of both side tracks to be Switch Dial Switch Switch Selector
equal. Slow Digging
2. On the track to be measured, mark one shoe with Fast Idle P Mode OFF
Mode Mode
chalk. Fast Digging
3. Swing the upperstructure 90° and lower the Fast Idle P Mode OFF
Mode Mode
bucket to raise the track off ground. Keep the * : The work mode switch is not equipped for
boom-arm angle between 90 to 110° as shown. ZAXIS135UR.
Place blocks under the machine frame. 3. Operate the travel control lever of the raised
CAUTION: Securely support the raised track track to full stroke.
using wooden blocks. 4. Measure the time required for 3 revolutions in
both directions after a constant track revolution
4. Maintain the hydraulic oil temperature at 50±5 °C speed is obtained.
(122±9 °F). 5. Raise the other side and repeat the above
procedures.
6. Repeat steps 3. to 5. three times and calculate
the average values.
90 to 110° Evaluation:
Refer to T4-2 Operational Performance Standard
Table.
M104-07-067
NOTE: The measurement data obtained through
Mark the raised track revolution test may have
wide variations. Therefore, the evaluation
based on the results obtained from the 20
m travel speed check described before is
more recommendable.
Remedy:
T4-4-2
MISTRACK CHECK
1. Allow the machine to travel 20 m (65.6 ft). 1. Measure the amount of mistracking in both fast,
Measure the maximum tread deviation from the and slow travel speeds.
tread chord line drawn between the travel start 2. Select the following switch positions:
and end points to check the performance Travel Engine Power * Work Auto-Idle/
equilibrium between both sides of the travel Mode Control Mode Mode Acceleration
device systems (from the main pump to the travel Switch Dial Switch Switch Selector
motor). Slow Digging
2. If measured on a concrete surface, the tread Fast Idle P Mode OFF
Mode Mode
deviation has a trend to decrease. Fast Digging
Mode Mode
Preparation: * : The work mode switch is not equipped for
1. Adjust the track sag of both tracks to be equal. ZAXIS135UR.
2. Provide a flat, solid test yard 20 m (65.6 ft) in
length, with extra length of 3 to 5 m (9.8 to 16 ft) 3. Start traveling the machine in the acceleration
on both ends for machine acceleration and zone with the travel levers at full stroke.
deceleration. 4. Measure the maximum distance between a
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above straight 20 m (65.6 ft) tread chord line and the
the ground with the arm and bucket rolled in. tread made by the machine.
4. Maintain the hydraulic oil temperature at 50±5 °C 5. After measuring the tracking in forward travel,
(122±9 °F). turn the upperstructure 180° and measure in
reverse travel.
the average values.
Maximum Distance
Evaluation:
Acceleration Table.
Zone:
3 to 5 m
20 m Remedy:
T105-06-03-022
T4-4-3
TRAVEL PARKING FUNCTION CHECK
Summary:
To measure the parking brake function on a speci-
fied slope.
Preparation:
1. The surface of the test slope shall be even with a
gradient of 20 % (11.31°).
0.2 to 0.3 m
2. Hold the bucket 0.2 to 0.3 m (8 to 12 in) above
the ground with the arm and bucket fully rolled in.
3. Maintain the hydraulic oil temperature at 50±5 °C
(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: Alignment marks on the track

Refer to T4-2 Operational Performance Standard side frame and shoe when the
machine comes to a stop.
Table.
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 Measurement:
swing bearing. 1. Select the following switch positions:
2. Place the machine on flat, solid ground with Auto-Idle/
ample space for swinging. Do not conduct this Engine Con- Power Mode *Work Mode
Acceleration
test on slopes. trol Dial Switch Switch
Selector
3. With the arm rolled out and bucket rolled in, hold Digging
the bucket so that the height of the bucket pin is Fast Idle P Mode OFF
Mode
the same as the boom foot pin. The bucket must * : The work mode switch is not equipped for
be empty. ZAXIS135UR.
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
The same height as the direction and measure the time required for 3
boom foot pin height
turns.
T105-06-03-013
the average values.
NOTE: In case a sufficient space for the meas-
urement is difficult to find, carry out the
Evaluation:
measurement with the boom fully raised
and the arm fully rolled-in.
Remedy:
Refer to T5-4 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:
1. Check the lubrication of the swing gear and
swing bearing.
2. Place the machine on flat, solid ground with
Two Check Marks
ample space for swinging. Do not conduct this
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).
T105-06-03-009
CAUTION: Prevent personal injury. Always

make sure that the area is clear and that
co-workers are out of the swing area before
T4-4-6
Measurement:
Auto-Idle/
Engine Con- Power Mode *Work Mode
Acceleration
trol Dial Switch Switch Measure Difference Between Marks
Selector
Digging
Mode
* : The work mode switch is not equipped for
ZAXIS135UR.
2. Operate the swing control lever fully and return it Marking on the Track Frame
to the neutral position when the mark on the
upperstructure aligns with that on the track frame Marking on the Swing Bearing
after swinging 180° .
3. Measure the distance between the two marks. T105-06-03-010
4. Align the marks again, swing 180°, then test in

the opposite direction.
5. Repeat steps 3. to 5. three times each and
calculate the average values.
Evaluation:
Remedy:
Refer to T5-4 Troubleshooting B in Group T5-4.
T4-4-7
SWING MOTOR LEAKAGE
Summary:
Check for upperstructure drift while suspending a
load on a slope.
Preparation:
1. Check the lubrication of the swing gear and
swing bearing.
2. Park the machine on a smooth slope with a
gradient of 26.8 % (15°).
3. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
W=675 kg (1490 lb): ZAXIS110/110M/125US/ T105-06-03-011
ZAXIS135UR
750 kg (1655 lb): ZAXIS120/130/130LCN/
ZAXIS135US
4. With the arm rolled out, and bucket rolled in,
position the arm top pin height to be level with the
boom foot pin.
5. Swing the upperstructure to position it 90° to the
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as
illustrated.
(122±9 °F).
T4-4-8
Measurement:
1. Select the following switch position:
Auto-Idle/
Power Mode *Work Mode
Acceleration
Switch Switch Measure Difference Between Marks
Selector
P Mode Digging Mode OFF
ZAXIS135UR.
2. Maintain the engine at slow idle. After five

Marking on the Track Frame
minutes, measure the difference between the
marks along the swing bearing periphery and the Marking on the Swing Bearing
track frame.
3. Perform the measurement in both right and left T105-06-03-010
swing directions.
4. Perform the measurement three times in each
direction and calculate the average values.
Evaluation:
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. * : The work mode switch is not equipped for
ZAXIS135UR.
weight (W) of the following specification can be 2. Operate the swing lever to full stroke to swing the
used. upperstructure to the uphill side.
W=675 kg (1490 lb): ZAXIS110/110M/125US/ 3. If the machine can swing, measure the cab floor
ZAXIS135UR slant angle.
750 kg (1655 lb): ZAXIS120/130/130LCN/ 4. Increase the slope angle and repeat steps 2. and
ZAXIS135US 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 T4-2 Operational Performance Standard.
4. Climb a slope and swing the upperstructure 90°
to the slope. Remedy:
5. Maintain the hydraulic oil temperature at 50±5 °C Refer to T5-4 Troubleshooting B.
(122±9 °F).
T105-06-03-011
T4-4-10
SWING BEARING PLAY
Summary:
Measure the swing bearing play with 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.
Magnetic Dial
3. Install a dial gauge on the track frame as shown, Base Gauge
using a magnetic base. 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. Round Trunk
NOTE: The measured value will vary depending

on where the magnet base is secured.
Secure the magnet base onto the round
trunk or in a position as close to the round T105-06-03-015
trunk as possible.
Measurement: Measurement: (h1)

1. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. Record the dial
gauge reading (h1).
2. Lower the bucket to the ground and use it to
The same height
raise the front idler 0.5 m (20 in). Record the dial as the boom foot
gauge reading (h2). pin height
3. Calculate bearing play (H) from this data (h1 and

h2) as follows: T105-06-03-007
H=h2-h1
Measurement: (h2)
Evaluation:
T105-06-03-017
T4-4-11
HYDRAULIC CYLINDER CYCLE TIME Boom Cylinder
Summary:
Measure the cycle time of the boom, arm, and
bucket cylinders.
Preparation:
1. When measuring the boom cylinders: With the
arm rolled out and the empty bucket rolled in,
lower the bucket to the ground, as shown. T105-06-03-018
Arm Cylinder
2. When measuring the cycle time of the arm
cylinder: With the empty bucket rolled in, position
the arm so that it is vertical to the ground. Lower
the boom until the bucket is 0.5 m (20 in) above
the ground.
3. When measuring the bucket cylinder: The empty

0.5 m
bucket should be positioned at mid-stroke
between roll-in and roll-out, so that the sideplate
T105-06-03-019
edges are vertical to the ground. Bucket Cylinder
4. When measuring the offset cylinder (ZAXIS
135UR):
Set the offset cylinder in either the right or left
offset stroke end position. (Be sure that the
bucket is out of the collision prevention range.)
5. When measuring the blade cylinder (ZAXIS

135UR):
Lower the bucket to the ground to raise the ma-
chine front off the ground and secure the height
space to allow the blade to move up-and-down
full stroke.
T105-06-03-020

Offset Cylinder
(122±9 °F).
M190-05-034
Blade Cyliner
T191-04-03-009
T4-4-12
Measurement:
Engine Auto-Idle/
Control Acceleration
Switch Switch
Dial Selector
Fast Idle P Mode Digging Mode OFF
ZAXIS135UR.
2. To measure cylinder cycle times:

(Cylinder full stroke includes cylinder cushioning
zone.)
2-1. Measuring 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.
2-2. Measuring 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.
2-3. Measuring 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.
2-4. Measuring the Offset Cylinder (ZAXIS135UR):
Measure the time required to Offset the front
atttachment from right to left or vice versa
while operating the offset pedal full stroke.
2-5. Measuring the blade cylinder (ZAXIS135UR):
Measure the time required to raise or lower
the blade while operating the blade control
lever full stroke.
3. Repeat each measurement three times and

Evaluation:
Remedy:
T4-4-13
DIG FUNCTION DRIFT CHECK
• Maximum Reach Position
Summary:
1. 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.
2. When testing the dig function drift just after
cylinder replacement, slowly operate each
cylinder for ten minutes to its stroke end to purge Extended
Retracted
air. Distance
Distance
Retracted
Distance
Preparation:
Same Height
weight (W) of the following specification can be
used.
W=675 kg (1490 lb): ZAXIS110/110M/125US/ Bucket Bottom
ZAXIS135UR
750 kg (1655 lb): ZAXIS120/130/130LCN/
ZAXIS135US T105-06-03-021
2. Position the arm cylinder with the rod 50 mm (2

Arm Cylinder Extension
in) extended from the fully retracted position.
3. Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position.
4. With the arm rolled out and the bucket rolled in,
hold the bucket so that the height of the bucket
pin is the same as the boom foot pin. Mark
(122±9 °F).
Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped,
T110-06-03-001
measure the change in the position of the bottom
of the bucket, as well as the boom, arm and Boom and Bucket Cylinder Retraction
bucket cylinders.
Mark Mark
3. Repeat step 2. three times and calculate the
average values.
Evalution:
Remedy: T110-06-03-002
T4-4-14
• Arm Roll-In Position
Summary:
1. Measure dig function drift, which can be caused
by oil leakage in the control valve and boom, arm,
and bucket cylinders.
2. 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. 1m
4. With the arm rolled in and the bucket rolled in. T173-04-03-001
Lower the boom until the arm tip is 1 m (40 in)
above the ground.
(122±9 °F).
Measurement:
1. Stop the engine.
Cylinder Retraction
measure the change in the position of the bottom Mark Mark
of the arm tip, as well as the boom, arm and
bucket cylinders.
average values.
Evalution:
T110-06-03-002
Remedy:
T4-4-15
Offset Cylinder (ZAXIS135UR)
Preparation:
1. Load bucket fully. In lieu of loading the bucket, Extended Distance
weight (675 kg) of the following specification can
be used.
2. Position the arm, Bucket, boom Cylinders with
the fuly extended position. Position the offset
Cylinder with the rod 100 mm retracted from the
fully extended position (right offset).
(122±9 °F).
Measurement:
1. Stop the engine.
2. 1 hour after the engine has been stopped,
measure the change in the position of the bottom Blade Bottom
of the offset cylinders.
T197-04-03-001

average values.
Blade Cylinder (ZAXIS135UR) Offset Cylinder Extension
Preparation:
1. Position the blade cylinder with the fully extended
position.
Mark
2. Record the height between the blade tip and
thegroud.
(122±9 °F).
T110-06-03-001
Blade Bottom
A B
T197-04-03-002
T4-4-16
Measurement:
1. Stop the engine.
measure the change in the position of the bottom
of the blade tip calculate the difference between
the before and after data.
average values.
Evalution:
Remedy:
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). T107-06-03-003
T107-06-03-004
T4-4-18
Measurement:
1. Measure each control lever.
Engine Auto-Idle/
Switch Switch
Dial Selector
ZAXIS135UR.
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 T4-2 Orerational Performance Standard
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). T107-06-03-005
Measurement:
1. Stop the engine.
2. Measure each lever stroke at the lever top from
neutral to the stroke end using a ruler.
3. Repeat step (2) three times and calculate the
average values.
Evalution:
Refer to T4-2 Orerational Performance Standard.
T4-4-20
(Blank)
T4-4-21
BUCKET/CAB COLLISION PREVENTION Intrusion Prevention to the Cab Front
SYSTEM (ZAXIS135UR ONLY)
Summary:
Check that the interference prevention device cor-
rectly functions.
Preparation:
1. If an Optional arm or bucket is used, check that
the front or bucket setting is made correctly.
2. Position the front attachment as follows.
2-1. Intrusion prevention to the cab front Position
the upperstructure with the boom cylinder ver-
tical and the bucket at the bucket face the cab M191-03-003
front face.
2-2. Intrusion prevention to the cab side
Position the upperstructure with the boom fully
raised and the arm fully rolled in so that the
bucket is positioned by the cab side.
3. Maintain the hydraulic oil temperature at 50±5 °C.
(122±9 °F)
Bucket Tooth Tip Bumper End
T191-04-03-014
Intrusion Prevention to the Cab Side
M190-03-007
Side Cutter Side Face Cab Right Side Face
T191-04-03-015
T4-4-22
Measurement:
Auto- Auto-Idle/
Engine Con- Power Mode
MARCCINO Acceleration
trol Dial Switch
Mode Switch Selector
Fast Idle OFF P Mode OFF
2. Procedures for the measurement are as follows:

2-1. Intrusion prevention to the cab front Roll the
arm in until it stops. Measure the clearance
between the bucket teeth and the bumper
under the cab.
2-2. Intrusion prevention to the cab side
Operate the left offset function until the front
attachment stops. Measure the clearance be-
tween the bucket side cutter side face and the
cab si
3. Repeat each measurement three times and cal-
culate the average values.
Evalution:
Refer to T4-2 Performance Standard.
Remedy:
Refer to T5-6 Troubleshooting D.
T4-4-23
COMBINED BOOM RAISE/SWING
FUNCTION CHECK
Summary:
Check boom raise and swing movement and speeds
while operating both functions simultaneously.
Preparation:
1. With the arm fully rolled out and bucket fully
rolled in, lower the bucket to the ground. The
bucket must be empty.
T107-06-03-009

(122±9 °F).

Measurement:
Engine Auto-Idle/
Switch Switch
Dial Selector
T107-06-03-010
ZAXIS135UR.
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 H
the bucket teeth.
the average values.
T107-06-03-011
Evalution:
Remedy:
T4-4-24
BOOM RAISE AND ARM ROLL-IN COM-
BINED 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.)
0.5 m
2. Maintain the hydraulic oil temperature at 50 ± 5
°C (122±9 °F).
T107-06-03-006
Measurement:
1. Select the switch positions as follows.
Engine Auto-Idle/
Switch Switch
Dial Selector
ZAXIS135UR.
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.
T107-06-03-008
Evaluation:
Remedy:
T4-4-25
(Blank)
T4-4-26
OPERATIONL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on the 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).
Plug
: 14 mm
4. Start the engine. Confirm that no oil leakage is

observed at the pressure gauge connection.
T178-03-07-001
(122±9 °F).
Measurement:
Auto-Idle /
Engine Power Mode *Work Mode
Acceleration
Control Dial Switch Switch
Selector
Digging
Mode
Digging
Slow Idle P Mode OFF
Mode
ZAXIS135UR.
2. Measure the pilot pressure in each specified

setting above.
3. Repeat the measurement three times and
Evaluation:
Refer to T4-2 Operational Performane Standard.
T4-5-1
Primary Pilot Pressure Adjustment Procedure
Adjustment:
Adjust the relief valve set-pressure as necessary.
: 41 mm
Relief Valve
T178-03-07-001
1. Remove plug (1) from the relief valve.

: 41 mm 1 2 3 4
: 12 mm
2. Remove spring (2), shims (3), and plunger (4)

from the relief valve.
3. Install the estimated number of shims (3) onto
plunger (4).
4. Install plunger (4), shims (3), and spring (2) into T178-04-04-002
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.
NOTE: Standard Change in Pressure (Reference)

Shim Thickness Change in Relief Pressure
(mm) kPa (kgf/cm2) (psi)
0.2 61.8 (0.63) (9)
0.4 124.6 (1.27) (18)
0.8 249.2 (2.54) (36)
T4-5-2
(Blank)
T4-5-3
SECONDARY PILOT PRESSURE
Preparation:
hydraulic oil tank to release any remaining Signal Control Valve
pressure.
3. Measure the pressure by either of the following
methods.
NOTE: When disconnecting the pilot lines from the

signal control valve, use tool (SNAP-ON
GAN850812B: size 19.05 mm) to easily Control
disconnect the lines. Valve
• Measure pressure at the location between the

pilot valve and the signal control valve:
Disconnect the pilot circuit hose to be meas-
ured from the signal control valve. Connect
hose (7/16-20UNF approx. 400 mm long) to the
signal control valve. Install tee (ST 6450) and
pressure gauge (ST 6942) between the hoses.
• Measure pressure at the location between the
control valve and the signal control valve:
Disconnect the pilot circuit line to be measured
between the signal control valve and the control
valve. Connect hose to the signal control valve.
Install tee (ST 6451) and pressure gauge (ST
6942) between the hose and the control valve.
: 14 mm, 17 mm
4. Start the engine. Confirm that no oil leakage is T176-04-04-001

(122±9 °F).
T157-05-04-011
T4-5-4
Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
Digging
Mode
ZAXIS135UR.
2. Measure the pilot pressure in each specified
setting above with the corresponding control
lever operated full stroke.
Evaluation:
Remedy:
T4-5-5
SOLENOID VALVE SET PRESSURE
Measure solenoid valve set pressure with both the
Dr.ZX and the pressure gauge.
Preparation:
pressure.
3. Disconnect line (1) from the solenoid valve to be
measured. Install hose (Parts Number: 4216453), SC
tee (ST 6451), adapter (ST 6461), and pressure SI
gauge (ST 6942) to the disconnected end at the
solenoid valve side, as illustrated. T176-03-07-002
: 17 mm, 19 mm, 22 mm
Connect Dr.ZX to the machine for solenoid valve Solenoid Valve Unit
set pressure monitoring.
Pressure Gauge
1
(122±9 °F).
Hose Tee Adapter T157-05-04-002
T4-5-6
Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
Digging
Mode
ZAXIS135UR.
2. Operate as instructed below for each measuring

solenoid valve:
Solenoid Valve SC: Perform a combined
operation of boom raise and arm roll-in.
Solenoid Valve SI: Travel the machine, then stop
the machine.
3. Read the values on both Dr.ZX and the pressure
gauge.
Evaluation:
Refer to T4-2 Operational performance Standard.
T4-5-7
Solenoid Valve Set Pressure Adjustment 7
Procedure
IMPORTANT: Do not loosen the adjusting screw 8

excessively.
The O-ring on the threads may come
off the sealing surface if loosening
the screw 2 turns or more, causing
oil leakage. T107-06-04-020
The distance between the lock

nut end and screw end should
1. Loosen lock nut (7). Turn adjusting screw (8) to be 2.0 mm (0.079 in) or less.
adjust the set pressure of the solenoid valve.
2. Retighten lock nut (7).
: 10 mm
: 5 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
: 3 mm

Screw Turns 1/4 1/2 3/4 1 8
Change kPa 78 156 234 312 7
in (kgf/cm2) (0.8) (1.6) (2.4) (3.2) T107-06-05-001
Pressure (psi) (11) (23) (34) (46)
3. Check the set pressure of the solenoid valve.

Adjusting
Screw
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-8
MAIN PUMP DELIVERY PRESSURE
The main pump delivery pressure can also be
measured with the built-in diagnosing system or
Dr.ZX.
Preparation:
pressure.
3. Remove the plug from the pump delivery port.
Install adapter (ST 6648), hose (ST 6943) and
pressure gauge (ST 6941) on the port.
: 6 mm
Select the monitoring function of the built-in

diagnosing system (or Dr.ZX).
observed at the pressure gauge connection. Pump 2 Delivery Pump 1 Delivery
Pressure Port Pressure Port
5. Maintain the hydraulic oil temperature at 50±5 °C T176-03-01-001
(122±9 °F).
Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
ZAXIS135UR.
2. Measure the pressure with the control levers in

neutral.
Evaluation:
Remedy:
T4-5-9
MAIN RELIEF VALVE SET PRESSURE
Main Circuit
The main relief pressure can also be measured with
the built-in diagnosing system or Dr.ZX.
Summary:
Measure the main relief valve setting pressure at the
main pump delivery port.
Preparation:
2. Press the air release valve on top the of the
pressure.
3. Remove the plug from the main pump delivery
port. Install adapter (ST 6648), hose (ST 6943)
and pressure gauge (ST 6941) on the port.
: 6 mm
Select the monitoring function of the built-in

diagnosing system (or Dr.ZX).
Pump 2 Delivery Pump 1 Delivery
observed at the pressure gauge connection. Pressure Port Pressure Port
T176-03-01-001
(122±9 °F).
T4-5-10
Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
ZAXIS135UR.
2. Relieve each actuator to measure main relief

pressures.
First, slowly operate bucket, arm, and boom
control levers to the stroke end to relieve each
function one at a time.
3. As for the swing function, secure the
upper-structure so it is immovable. Slowly
operate the swing lever to relieve the swing
function.
4. As for the travel function, secure the tracks
against an immovable object. Slowly operate the
travel levers to relieve the travel function.
Evaluation:
T4-5-11
Blade Circuit
Summary: Blade Pump

Measure the main relief valve pressure setting at the
blade pump delivery port.
Preparation:
1. Stop the engine.
2. Press the air release valve on the hydraulic oil
tank to bleed air.
3. Disconnect the delivery line on blade pump.
Install adapter (ST 6291), hose (ST 6943) and
pressure gauge (ST 6941) to inspection port.
: 24mm, 27 mm
4. Start the engine. Confirm that no oil leakage is T1SM-03-01-001

(122±9 °F).
Measurement:
Auto-Idle /
Acceleration
Selector
Digging
Mode
ZAXIS135UR.
2. Slowly operate bucket control lever until the

cylinder rod reaches both stroke ends to relieve
the function.
Evaluation:
Refer to T4-2 Performance Standard Table.
T4-5-12
NOTE: If the measure pressures for all functions
(except the blade) are lower than the Main Circuit
Lock Nut
specified range, the probable cause is a Adjusting
Screw
decrease of the main relief valve setting
pressure (in main circuit).
If the relief pressure in blade circuit is lower,
the probable cause is a decrease of the
main relief valve setting pressure (in blade
circuit).
Main Relief Pressure Setting Adjustment

W105-02-05-151
Procedure
Adjusting
Adjustment: Screw
1. Loosen the lock nut.
2. Turn the adjustiing screw to adjust the main relief

pressure setting referring to the table below. Pressure Pressure
Increase Decrease

Main Circuit:
: 17 mm T105-06-05-002
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
Blade Circuit: Blade Circuit
: 6 mm Adjusting
: 24 mm Screw
: 9.82 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)
4. Recheck the set pressures.
•Main Circuit
Screw Turns 1/4 1/2 3/4 1
Lock Nut
Change in MPa 2.79 5.59 8.36 11.2
Relief (kgf/cm2) (28.5) (57) (85.2) (114)
T198-04-04-007
Pressure (psi) (405) (811) (1212) (1620)
•Blade circuit Adjusting

Screw
Screw Turns 1
Change in MPa 13.5
Relief (kgf/cm2) (138)
Pressure (psi) (1960) Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-13
RELIEF PRESSURE (When relieving Swing Relief
Swing) Valve
1. Loosen lock nut (1).

: 24 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
2. Turn adjustiing screw (2) to adjust the swing relief

pressure setting referring to the table below.
: 8 mm

Change in MPa 0.9 2.0 2.9 3.9
2
Relief (kgf/cm ) (10) (20) (30) (40)
Pressure (psi) (142) (284) (427) (570)
T176-01-02-002
1 2
T176-04-04-004
Adjusting
Screw
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-14
(Blank)
T4-5-15
RELIEF PRESSURE (When relieving
Travel)
ZAXIS110/120/130/130LCN/125US/135US
1. Remove the travel relief valve.
: 30 mm
2. Remove sleeve (1) and poppet (3).
3. Install shims (5) between poppet (3) and spring Travel Relief
Valve
guide (4) to adjust the set-pressure.
4. Install the travel relief valve.

: 310 N⋅m (32 kgf⋅m, 230 lbf⋅ft)
T155-01-01-006
5. Check the set-pressure.
1 2 5
Shim Change in Relief
Thickness Parts No. Pressure
(mm) kPa (kgf/cm2) (psi)
0.5 4305162 785 (8) (114)
3 4
T135-06-04-001
T4-5-16
ZAXIS110M
1. Loosen lock nut (2).
: 19 mm
2. Turn adjusting screw (1) to adjust the set pres-

sure referring to the table below.
: 6 mm

: 44 N⋅m (4.5 kgf⋅m, 32.5 lbf⋅ft)
Travel Relief
4. Check the set-pressure. Valve
NOTE: Standard Change in Relief Pressure (Ref- T155-01-01-013
erence)
Screw Turns 1
kPa 8.6 2
(kgf/cm2) (88)
(psi) (1250)
1
T133-06-04-002
Adjusting
Screw
Pressure Pressure
Increase Decrease
T105-06-05-002
T4-5-17
OVERLOAD RELIEF VALVE SET
PRESSURE
Summary: Preparation:
1. The circuit pressure must be increased by 1. Properly shut down the engine.
applying an external force while blocking the 2. Press the air release valve on the top of the
return circuit from the control valve. This hydraulic oil tank to release any remaining
measuring method is hazardous and the results pressure.
obtained with this method are unreliable. 3. Main Circuit :
2. The oil flow rate used to set the overload relief Remove the plug from the main pump delivery
pressure is far less than that used to set the main port. Install adapter (ST 6648), hose (ST 6943)
relief pressure. Therefore, measuring the over- and pressure gauge (ST 6941) on the port.
load pressure in the main circuit by increasing the : 6 mm
main relief set-pressure more than the overload
valve set-pressure is not a proper method. In ad- Blade Circuit (ZAXIS 135 UR Only):
dition, in case a main relief valve designed to Disconnect the lines of blade pump. Install
leak a small quantity of oil before reliving is used, adapter (ST 6291), hose (ST 6943), and pressure
its pre-leaking start pressure must be increased gauge (ST 6941).
more than the overload relief valve set-pressure. : 24 mm, 27 mm
However, the pre-leaking start pressure is not
always increased more than the overload relief 4. Select the monitoring function of the built-in
valve set-pressure as the adjustable upper limit diagnosing system (or Dr.ZX).
of the main relief valve set-pressure is provided. Start the engine. Confirm that no oil leakage is
Accordingly, the overload relief valve assembly observed at the pressure gauge connection.
should be removed from the machine and NOTE: When measuring the blade circuit , use the
checked on a specified test stand at a correct oil pressure gauge only.
flow rate. Some overload relief valves come in
contact with the control valve body to block the oil 5. Maintain the hydraulic oil temperature at 50±5 °C
passage. When this type of overload relief valve (122±9 °F).
is checked, the control valve body must be pre-
cisely finished as the test unit. Provide one con-
trol valve other than that on the machine as a test
kit.
3. If the overload relief valve performance must be
checked on the machine, however, measure the
main relief pressure while releasing each front
function respective to the measuring overload
relief valve. And, assume that the overload relief
valve is functioning correctly if the obtained main
relief pressure is within the specified value range.
Measure the main pressure of the front functions
as follows:
T4-5-18
Measurement:
Auto-Idle /
Acceleration Blade Pump
Selector
Digging
Mode
ZAXIS135UR.
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 : Pump 2 Delivery Pump 1 Delivery
Pressure Port Pressure Port
calculate the average value for each front T1SM-03-01-001
function.
T4-5-19
Evaluation:
Performance of the overload relief valves are normal Main Circuit Adjusting
if the measured main relief pressures (in main circuit Lock Nut Screw
or blade circuit) are within the specified value range.
Overload Relief Valve Set Pressure Adjusting

Procedure
NOTE: In principle, adjust the overload relief valve

T176-04-04-003
set pressure on a test stand.
Adjustment:
Adjusting
1. Loosen the lock nut. Screw
Main Circuit :
: 17 mm
: 31.5 N⋅m (3.2 kgf⋅m, 23.1 lbf⋅ft)
Pressure Pressure
Increase Decrease
Blade Circuit :
: 17 mm
: 19.6 N⋅m (2 kgf⋅m, 14.4 lbf⋅ft)
: 6 mm T105-06-05-002
2. Turn adjustiing screw (2) to adjust the overload

relief pressure setting referring to the table below. Blade Circuit
Lock Nut
•Main Circuit
Screw Turns 1/4 1/2 3/4 1 Adjusting Screw
T198-04-04-008
Change in MPa 2.79 5.59 8.36 11.2
2
Relief (kgf/cm ) (28.5) (57) (85.2) (114)
Pressure (psi) (405) (811) (1212) (1620) Lock Nut
Adjusting Screw
•Blade Circuit
Change in MPa 4.9 9.9 14.9 19.8
Relief (kgf/cm2) (50.5) (101.0) (151.4) (201.9)
Pressure (psi) (718) (1436) (2153) (2811) Pressure Pressure
Increase Decrease
T505-06-04-007
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 T4-5-8 Main Relief Pressure
Main pump performance is checked by measuring Check.)
the pump flow rate with a hydraulic tester installed at : 6 mm
the main pump delivery port (one side) to be meas-
ured. Use Dr. ZX and a pressure gauge at the same 6. Disconnect pipe (12) from the regulator. Connect
time. plug (PF 1/4) to the disconnected pipe.
: 17 mm
IMPORTANT: This measurement procedure is a 7. Disconnect the N sensor connector. Connect the
simple method. The measured data pulse counter to the N sensor.
will be lower by approx. 5 % than 8. Disconnect the vacuum pump. Loosen plug (11)
the accurately measured value. To on the top of the pump casing to bleed air from
measure accurately, disconnect the the main pump casing until oil only comes out of
return circuit from the control valve the plug clearance.
and connect it to the hydraulic oil 9. Fully open the loading valve of the hydraulic
tank. tester.
10. Start the engine. Check the pressure gauge con-
Preparation: nection for any oil leaks. Install Dr. ZX and select
1. Stop the engine. Push the air bleed valve to the monitor function.
bleed air. Connect a vacuum pump to the oil filler
port. Measurement:
NOTE: Operate the vacuum pump while connect- 1. Measure the maximum flow rate.
ing the pump flow rate test line.
2. Select each switch position as follows:
2. Disconnect the delivery hose from the main pump Auto-Idle /
(one side) to be measured. Connect pipe (1) to Acceleration
the pump delivery port using the split flanges and Selector
bolts which were used to connect the discon- Digging
nected delivery hose. Mode
: 41 mm : 10 mm * : The work mode switch is not equipped for
ZAXIS135UR.
3. Connect pipe (1) to hydraulic tester (4) using test 3. Adjust the main relief valve set-pressure in the
hose (2) and adapter (3). Connect adapter (5), control valve to each pressure point specified
joint (6), test hose (7) and flange (8) to hydraulic along the main pump P-Q curve. (Refer to
tester (4). T4-2-22) Slowly close the loading valve of the
: 41 mm : 10 mm hydraulic tester while relieving the pressure in the
4. Connect the delivery hose to flange (8) with split arm roll-in circuit. Measure the flow rates and en-
flanges (9) and bolts (10). gine speeds at the pressure points specified in
: 10 mm the P-Q curve.
4. 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)
Qc = (Ns × Q) ⁄ Ne only to the pump to be measured.
Qc : Converted Flow Rate

Q: Measured Flow Rate
Ns : Specified Pump Speed (1950 min-1)
Ne : Measured Engine Speed
Pulse Numbers (Hz)×60/21
1 2 3 4 5 6 7 8 9 10
Delivery Hose
(To Control
Valve)
T173-04-04-002
11
N Sensor T176-03-01-002
12
T176-03-01-001
1 - Pipe (ST 6192) 4 - Hydraulic Tester (ST 6299) 7 - Test Hose (ST 6320) 10 - Bolt (ST 6409) (4 Used)
2 - Test Hose (ST 6145) 5 - Adapter PF1 × UNF1-7/8 8 - Flange (ST 6118) 11 - Plug
(ST 6146)
3 - Adapter PF1 × UNF1-7/8 6 - Joint (ST 6330) 9 - Split Flange (ST 6130) 12 - Pipe
(ST 6146)
T4-5-23
• Pilot Characteristics
Summary: 8. Disconnect the vacuum pump. Loosen plug (11)

Main pump performance is checked by measuring on the top of the pump casing. Bleed air from the
the pump flow rate with a hydraulic tester installed at pump casing until oil only comes out of the plug.
the main pump delivery port (one side) to be meas- 9. Fully open the loading valve of the hydraulic
ured. Use Dr. ZX and a pressure gauge at the same tester.
time. 10. Start the engine. Check the line connections for
any oil leaks.
IMPORTANT: This measurement procedure is a
simple method. The measured data Measurement:
will be lower by approx. 5 % than 1. The pump flow rate in response to the external
the accurately measured value. To command pilot pressure is measured.
measure accurately, disconnect the 2. Select each switch position as follows:
return circuit from the control valve Auto-Idle /
and connect it to the hydraulic oil Engine Power Mode *Work Mode
Acceleration
tank. Control Dial Switch Switch
Selector
Preparation:
Digging
1. Referring to steps 1 to 4 on page T4-5-16, con- Fast Idle P Mode OFF
Mode
nect a hydraulic tester to the main pump to be
measured.
ZAXIS135UR.
2. Disconnect the hose from regulator port Pi of the
pump to be measured. Connect plug (ST 6213) 3. Adjust the reducing valve set-pressure to each
to the disconnected hose. pressure point specified along the main pump
: 6 mm, 19 mm P-Q curve. (Pilot Characteristics) (Refer to
3. Install adapters (14) (3 used) to reducing valve T4-2-18) Measure the flow rates and engine
(15). Remove plug M from the pilot filter. Then, speeds at the pressure points specified in the
install adapter (12) and hose (13) to the pilot filter. P-Q curve.
Connect the other end of hose (13) to regulator 4. Repeat each measurement three times and cal-
port P1 on reducing valve (15). culate the average values.
: 19 mm
4. Install tee (16) to port P2 on reducing valve (15). Evaluation:
Connect pressure gauge (17) and hose (13) to 1. Convert the measured flow rates to those at the
tee (16). Connect hose (13) to the regulator. specified pump speed using the following formu-
: 19 mm las:
5. Connect hose (18) and adapter (19) to port T on
reducing valve (15). Remove plug L from the re- Qc = (Ns × Q) / Ne
turn pipe. Connect hose (18) to the plug L port.
: 19 mm, 22 mm Qc : Converted Flow Rate
6. Disconnect pipe (20) from the regulator. Connect Q: Measured Flow Rate
plug (PF 1/4) to the disconnected pipe. Ns : Specified Pump Speed (1950 min-1)
: 17 mm Ne : Measured Engine Speed
7. Disconnect the N sensor connector. Connect the Pulse Numbers (Hz)×60/21
pulse counter to the N sensor.
2. Standard Flow Rate
T4-5-24
1 2 3 4 5 6 7 8 9 10
Delivery Hose
(To Control
Valve)
T173-04-04-002
11
20
Port Pi N Sensor T176-03-01-002
T176-03-01-001
Reducing Valve
Port Position
Reducing Return Pipe
Valve
T Plug M
L 19
17
18
P1 P2
14
To Regulator To Pilot
Port Pi Filter
13 16 14 14 13 12
15
T178-03-07-001
T178-04-04-004
1 - Pipe (ST 6192) 6 - Joint (ST 6330) 11 - Plug 16 - Tee UNF7/16 × UNF7/16×
PF1/4 (ST 6451)
2 - Test Hose (ST 6145) 7 - Test Hose (ST 6320) 12 - Adapter UNF7/16 × PF1/4 17 - Pressure Gauge (ST 6931)
(ST 6069)
3 - Adapter PF1 × UNF1-7/8 8 - Flange (ST 6118) 13 - Hose UNF7/16 × UNF7/16 18 - Hose UNF7/16 × UNF7/16
(ST 6146) (4334309) (4334309)
4 - Hydraulic Tester 9 - Split Flange (ST 6130) 14 - Adapter PF3/8 × UNF7/16 19 - Adapter PF3/8 × UNF7/16
(ST 6299) (4200465) (4200465)
5 - Adapter PF1 × UNF1-7/8 10 - Bolt (ST 6409) (4 Used) 15 - Reducing Valve (4325439) 20 - Pipe
(ST 6146)
T4-5-25
Regulator Adjustment
6 5 1 2
10
4 3
7 8
T178-03-01-006
1 - Lock Nut 4 - Adjusting Screw 7 - Lock Nut 9 - Lock Nut
(For Minimum Flow Ad- (For Maximum Flow Ad- (For P-Q Control Adjust- (For P-Q Control Adjust-
justment) justment) ment) ment)
2 - Adjusting Screw 5 - Lock Nut 8 - Adjusting Screw 10 - Adjusting Screw
(For Minimum Flow Ad- (For Pilot Pressure Char- (For P-Q Control Adjust- (For P-Q Control Adjust-
justment) acteristic Adjustment) ment) ment)
3 - Lock Nut 6 - Adjusting Screw
(For Maximum Flow Ad- (For Pilot Pressure Char-
justment) acteristic Adjustment)
Adjustment Item Adjustment Procedure Remarks

1. Minimum Flow Rate Loosen lock nut (1) and turn ad- 1) Do not turn the adjusting screw
justing 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 3.45
cm3/rev. (0.21 in3/rev).
: 17 mm
: 19.6 N⋅m
(2 kgf⋅m, 14.4 lbf⋅ft)
Pi
2. Maximum Flow Rate Loosen lock nut (3) and turn ad- 1) Do not turn the adjusting screw
justing 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
2.88 cm3/rev. (0.18 in3/rev). adjusting screw counterclockwise.
: 13 mm 3) Securely retighten lock nut (3) after
: 9.8 N⋅m the adjustment.
(1 kgf⋅m, 7.2 lbf⋅ft)
Pd
T4-5-26
Adjustment Item Adjustment Procedure Remarks

3. Pilot Pressure Characteristics Loosen lock nut (5) and turn 1) Do not turn the adjusting screw
ad-justing screw (6). more than one turn.
Rotating adjusting screw (6) 1/4 2) When adjusting screw (6) is turned
a turn clockwise decreases the clockwise, the maximum flow rate
Q
flow rate by 5.75 cm3/rev (0.35 will also be decreased.
in3/rev). To maintain the maximum flow rate
: 30 mm unchanged, turn adjusting screw (4)
: 29.4 N⋅m counterclockwise twice as much as
(3 kgf⋅m, 21.7 lbf⋅ft) adjusting screw (6) is turned.
This ratio of 2 (adjusting screw (4)
counterclockwise turn) to 1
(adjusting screw (6) clockwise turn)
Pi is to 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
Q 1/4 a turn clockwise increases watching the engine performance.
the flow rate by 5.75 cm3/rev 3) Securely retighten lock nut (7) or (9)
A (0.35 in3/rev.). after the adjustment.
B: Loosen lock nut (9) and turn
adjusting screw (10).
Rotating adjusting screw (10)
1/4 a turn clockwise increases
the flow rate by 1.24 cm3/rev.
Pd (0.08 in3/rev).
Pd
T4-5-27
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:
(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 air release
valve (1) on the top of the hydraulic oil tank to
release any remaining pressure. 2
3. Disconnect 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)
Preconditions for Measurement:

Auto-Idle /
Acceleration
Selector
Digging
Mode
T176-04-04-005
ZAXIS135UR.
T4-5-28
Measurement:
1. Amount of Oil Drained While Swinging the
Upperstructure
(1) Fully retract the arm cylinder. Fully extend the
bucket cylinder. Raise the boom so that the
arm tip pin height is the same as the boom
foot pin height. Be sure that the bucket is
empty.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start draining oil The same height as
measurement after the swing speed reaches boom foot pin height
a constant maximum speed. The measuring
time should be more than 45 seconds. T105-06-03-013
(3) Repeat the measurement at least three times

in both clockwise and counterclockwise
directions, and calculate the average values.
2. Amount of Oil Drained While Relieving Swing

Motor Circuit
(1) Thrust the bucket teeth into the ground as
illustrated so that the upperstructure does not
rotate when the swing lever is operated full
stroke.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start drain oil measurement
when drain oil starts coming out of the drain
T107-06-06-005
hose end. The measuring time should be
more than 45 seconds.
in both clockwise and counterclockwise
directions, and calculate the average values.
T107-06-05-008
T4-5-29
Evaluation:
Table.
∗ Conversion of the amount of drain oil measured

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

calibrated container. Then, convert the measured
drain oil into the per-minute value using the formula
below:
△Q = 60 × q / t
Where:
△Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-30
(Blank)
T4-5-31
TRAVEL MOTOR DRAINAGE
ZAXIS110/120/130/130LCN/125US/135US
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.
Travel motor operational performance must
be judged from travel speed, mistrack, and
so on.
Preparation:
(122±9 °F). Rotate the travel motor to warm the
2. Properly shut down the engine. Press air release

valve (1) on top of the hydraulic oil tank to
release any remaining pressure. T157-05-04-014
3. Disconnect travel motor drain hose (2) at the

travel motor end. Install plug (ST 6637) to the 2
disconnected end. Connect the drain hose
(3/4-16UN) to the travel motor.
: 22 mm, 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)

Auto-Idle /
Acceleration
Selector
Digging
Mode
* : The work mode switch is not equipped for T155-05-04-004
ZAXIS135UR.
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 illustrated.
90 to 110°
CAUTION: Securely support the raised track
using wooden blocks. When working around
moving parts is unavoidable, pay special
attention to ensure that hands, feet, and
clothing do not become entangled. M104-07-067
(2) Rotate the raised track with the travel lever

operated full stroke. Start drain oil
measurement after the track rotation speed
reaches a constant maximum speed. The
measuring time should be more than 45
seconds.

in both forward and reverse directions, and
Evaluation:
∗ 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

calibrated container. Then, convert the measured
drain oil into the per-minute value using the formula
below:
△Q = 60 × q / t
Where:
△Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-33
ZAXIS110M
Summary:
1. 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.
2. Prevent personal injury. Always make sure that
the area is clear and that co-workers are out of
the swing area before starting the measurement.
3. Operational performance of the travel motor
should be totally evaluated taking test results on
the travel speed and mistrack into consideration.
4. The amount of drain oil from the travel motor will
change depending on hydraulic oil temperature.
Travel motor operational performance must be
judged from travel speed, mistrack, and so on.
Preparation:
(122±9 °F). Rotate the travel motor to warm the
2. Properly shut down the engine. Press the air
release valve on top of the hydraulic oil tank to
release any remaining pressure.
3. Remove plug (1) in the travel motor and install
pressure gauge (ST 6925) and adapter (ST
6053).
: 10 mm
T133-06-04-003
T4-5-34
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Selector
Digging 90 to 110°
Fast Idle P OFF
Mode
Measurement:
1. Start the engine. Jack up the measuring side
track using the front attachment, as illustrated.
M104-07-067
CAUTION: Securely support the raised track

using wooden blocks. When working around
moving parts is unavoidable, pay special
attention to ensure that hands, feet, and
clothing do not become entangled.
2. Rotate the raised track with the travel lever

operated full stroke. Measure the drain oil
pressure.
Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.
T4-5-35
(Blank)
T4-5-36
OPERATIONAL PERFORMANCE TEST / Adjustment
ASSEMBLY AND ADJUSTMENT OF LINK
FOR ARM ANGLE SENSOR (ZAXIS135UR
3
ONLY)
2 1
IMPORTANT: Compared to other angle sensors, it
is more difficult to assemble or
adjust the link for the arm angle
sensor. When replacing the arm
angle sensor, follow the assembly 2
and adjustment procedures below.
Assembling and Adjusting the Link
IMPORTANT: In the case of pressing–in of a 1

bushing, vertically press the bushing 5
by using protective plate so that the 4
surrounding areas are not damaged. 5
1. Press bushing (2) into link (1) (2 places).
2. Press bushing (3) into the arm side.
3. Install end rod (5) to lever (4). Turn and adjust

lever (4) so that the clearance between pins is 205 Angle Sensor
mm.
5 4 5
T1CF-05-06-001
4. Install lever (4) with the edge of angle sensor
lining with the end rod side.
IMPORTANT: Before attaching the link, apply

grease generously to sliding and 205 mm
rotating areas. Be sure to replace
Angle Sensor
cotter pins (9, 10) with new ones and
wind them. 20 mm
5. Attach the link to the front attachment as shown at
right.
NOTE: When replacing the arm, replace it after
removing pin (10).
1- Link 8- Spacer
2- Bushing 9- Cottor Pin (Cylinder:
Stay Side)
3- Bushing 10 - Pin
4- Lever 11 - Spacer
5- End Rod 12 - Spacer
6- Pin 13 - Cottor Pin 4
7- Spacer
Aligning Surfaces
6 7 8 9
(Arm Side)
10 11 12 13
T1CF-05-06-002
T4-6-1
ADJUSTING METHOD OF FRONT
ACCELERATION SPEED AND Lock Nut
DECELERATION SPEED (ZAXIS135UR
ONLY) Adjusting
Screw
Adjust solenoid valve set pressure to change front
acceleration or deceleration.
Repeat adjusting pressure and operating front.
IMPORTANT: Do not adjust arm acceleration

solenoid valve (for cab collision
prevention control). T107-06-05-001
1. Select the following switch positions: Lock Nut Adjusting Screw

Engine Control Power Mode Auto-MARCCINO
Dial Switch Mode Switch
Fast Idle P ON
2. Paint matching marks on adjusting screw and lock Pressure Pressure

nut before working. (Note do not paint on threads Increase Decrease
of adjusting screw)
W107-02-05-129
3. Loosen lock nut and adjust by adjusting screw.
Clockwise : acceleration
8-Unit Solenoid Valve Layout
Counterclockwise : deceleration
: 10 mm
: 5 N⋅m (0.5 kgf⋅m, 0.08 lbf⋅in) 1
8
: 3 mm
2
Reference: Standard Pressure Change 7
kPa 78 156 234 312 3
(kgf/cm2) 0.8 1.6 2.4 3.2 6
(psi) 11.3 22.6 33.9 45.2
4
5
4. Tighten lock nut.
T1SM-01-02-003
1 - Solenoid Valve 5- Solenoid Valve
(C1 : Boom Raise (C4 : Arm Roll-In
Acceleration) Deceleration)
2 - Solenoid Valve 6 - Solenoid Valve
(C6 : Right Offset (C8 : Left Offset
(C9 : Left Offset (C5 : Right Offset
(C7 : Arm Roll-Out (C3 : Boom Lower
T4-6-2
INITIAL SETTING OF ANGLE SENSOR
(ZAXIS135UR ONLY)
Initial setting of the angle sensor is required when the Side Cutter Cab Right
angle sensor or the front attachment (boom, arm) is Side Face Side Face
replaced.
1. Set the front attachment in the following standard

position.
Standard position:
Boom : Fully raised
(with the boom cylinder fully extended)
Arm : Fully rolled in
(with the arm cylinder fully extended) T191-04-03-015
Offset : Set the offset position by referring to the

below table.
Clearance between the
side cutter of the bucket
Bucket Type
and the operator’s cab.
(Unit: mm)
Standard
220
or Optional Bucket
2. Stop the engine. Turn the key switch into OFF.
3. Wait for 10 seconds.
4. Connect the initial setting connector.

Initiol Setting Connector
5. Turn the key switch into ON. At this time the (With Initial Setting Label)
engine must stop.
6. Disconnect the initial setting connector again. The

setting is complete if the buzzer sounds a short
(beep).
7. Turn the key switch into OFF.
IMPORTANT: If the buzzer sounds continuously,

the initial setting is failed. Check the
angle sensor system for
abnormalities and repair if necessary.
Then, perform the initial setting
again.
T1CF-05-01-002
T4-6-3
INITIALIZING THE DEPTH LIMIT CONTROL
SYSTEM (ZAXIS135UR ONLY)
It is required to initialize the Depth Limit Control
System in the following case:
• The front attachment, angle sensor, link for angle
sensor, 8-unit solenoid valve, 2-unit solenoid valve
(optional), or auto-MARCCINO control unit is
exchanged.
CAUTION: When initializing the depth limit

control system, the front attachment will be
automatically moved through the
auto-MARCCINO control unit. Therefore, the
initialization must be carried out on firm level
ground in a wide space so that work crew is
not hit or injured by the moving front
attachment.
IMPORTANT: If initialization is interrupted, stop

the engine, and reset Dr. ZX to
restart initialization.
Depth Limit Control System Initializing

Procedures Service Switch
(Plug)
1. Connect Dr. ZX to the auto-MARCCINO control

unit, and connect the service switch. Confirm that
hydraulic oil temperature is 20ºC or higher. (Refer
to T5-1-16.)
2. Choose the Target Digging Range Correction from

the Service Modes of Dr. ZX. Follow the
instructions on the window of Dr. ZX.
サービス
3. Choose the Boom Metering Adjustment from the

サービス
Service Modes of Dr. ZX. Follow the instructions

on the window of Dr. ZX.
T1CF-05-01-001
Dr.ZX Connector
(Auto-MARCCINO Controller)
(Stamped Position : UR)
T4-6-4
4. Choose the Arm Metering Adjustment from the
Service Modes of Dr. ZX. Follow the instructions
on the window of Dr. ZX.
5. Choose the Auto Adjustment Of Level Crowd

Operation (for Optional Monitor) from the Service
Modes of Dr. ZX. Follow the instructions on the
window of Dr. ZX.
6. Stop the engine.
Operational Check
1. With Dr. ZX connected, start the engine.
NOTE: If Dr.ZX is not connected to the

auto-MARCCINO control unit, or the
service switch is not connected, setting the
depth to plus side cannot be made.
2. Set the depth to ‘‘+0.1’’ m on the system monitor.
3. Align the bucket teeth with an extension

straight-line passing through the boom top pin and
arm top pin, and make full boom lowering and arm
roll-in at the same time.
Evaluation
Setting is OK when the bucket tooth tip can be

level-crowded at height of 0.1 m above the ground, T197-05-06-005
without touching the ground, in the above operation.
T4-6-5
ENGINE SPEED ADJUSTMENT AND
ENGINE LEARNING
After removing and/or replacing the components as
described below for repair and/or inspection, or if error
in engine speed is found, readjust engine speed and
perform engine learning.
• Removal of the engine, engine control cable, or

EC motor
• Replacement of MC
Adjustment of Engine Speed:

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

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

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

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

lever to the motor output shaft.
: 13 N⋅m (1.3 kgf⋅m, 9.4 lbf⋅ft)
NOTE: Don’t lubricate the motor output shaft.
8. Perform engine learning.
T4-6-6
Engine Learning: ZAXIS110/110M/120/130/130LCN
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
ZAXIS125US/135US
Learning Switch is
Turned to Stamp E
Learning Switch
Stamp
T1SM-01-02-006
T1CC-05-01-001
Learning Switch Dr.ZX Connector
to MC
ZAXIS135UR
Dr.ZX Connector
to MC
Learning Switch
T1CF-01-01-004
T4-6-7
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
T4-6-8
• 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
T4-6-9
(Blank)
T4-6-10
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SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 General
Introduction ............................................... T5-1-1 Components in Control Valve ..................T5-2-16
Diagnosing Procedure .............................. T5-1-2 Signal Control Valve
Built-In Diagnosing System Operation ...... T5-1-6 Port Location .........................................T5-2-26
Built-In Diagnosing Function Display List .. T5-1-7
Dr. ZX Operation ....................................... T5-1-8
Group 3 Troubleshooting A
Troubleshooting A Procedure ....................T5-3-1
Dr. ZX Fault Code List (MC).................... T5-1-10
Fault Code List ..........................................T5-3-2
Dr. ZX Fault Code List
Fault Code 01, 02, 03................................T5-3-3
(Auto-MARCCINO Controller) ............. T5-1-12
Fault Code 04............................................T5-3-3
Dr. ZX Monitoring Item List (MC)............. T5-1-16
Fault Code 06............................................T5-3-4
Dr. ZX Monitoring Item List
Fault Code 07............................................T5-3-5
(Auto-MARCCINO Controller) ............. T5-1-18
Fault Code 10, 11 ......................................T5-3-6
Dr. ZX Special Function .......................... T5-1-19
Fault Code 12, 13......................................T5-3-7
Dr. ZX Service Mode (MC) ...................... T5-1-20
Fault Code 14, 15, 16, 18..........................T5-3-8
Adjustment Data List............................... T5-1-32
Fault Code 19............................................T5-3-9
Group 2 Component Layout
Group 4 Troubleshooting B
Main Component Layout ........................... T5-2-1
Troubleshooting B Procedure ....................T5-4-1
Electrical Component Layout (Overview) .. T5-2-4
Relationship between Machine Trouble
Electrical System
Symptoms and Related Parts ..................T5-4-2
(Relays and Related Equipment) ............ T5-2-7
Correlation between Trouble
Electrical System
Symptoms and Part Failures .................T5-4-20
(Monitors and Switches)........................ T5-2-10
Engine System Troubleshooting ..............T5-4-33
Pump Device .......................................... T5-2-12
All Actuator System Troubleshooting .......T5-4-54
Swing Device .......................................... T5-2-13
Front Attachment System
Control Valve .......................................... T5-2-13
Troubleshooting.....................................T5-4-60
Signal Control Valve................................ T5-2-13
Swing System Troubleshooting ...............T5-4-72
Solenoid Valve Unit................................. T5-2-13
Travel System Troubleshooting ...............T5-4-75
Travel Device .......................................... T5-2-14
Blade System Troubleshooting................T5-4-82
8-Spool Solenoid Valve ........................... T5-2-14
Other System Troubleshooting ................T5-4-86
Blade Control Valve ................................ T5-2-14
Exchange Inspection ............................. T5-4-112
Positioning Control Valve ........................ T5-2-14
Emergency Boom Lowering
Procedure............................................ T5-4-114
187T-5-1
Group 5 Troubleshooting C Fault Code 92..........................................T5-6-22
Troubleshooting C Procedure ................... T5-5-1
Malfunction of Coolant Group 7 Electrical System Inspection
Temperature Gauge ................................ T5-5-2 Precautions for Inspection and
Malfunction of Fuel Gauge ........................ T5-5-4 Maintenance............................................T5-7-1
Malfunction of Indicator Light Instructions for Disconnecting
Check System ......................................... T5-5-6 Connectors ..............................................T5-7-3
Malfunction of Preheat Indicator ............... T5-5-7 Fuse Inspection.........................................T5-7-4
Malfunction of Engine Oil Level Fusible Link Inspection..............................T5-7-6
Indicator .................................................. T5-5-8 Battery Voltage Check...............................T5-7-7
Malfunction of Coolant Level How to Troubleshoot Alternator
Indicator ................................................ T5-5-10 Malfunctions ............................................T5-7-8
Malfunction of Alternator Indicator .......... T5-5-12 Continuity Check .......................................T5-7-9
Malfunction of Engine Oil Pressure Voltage and Current Measurement.......... T5-7-11
Indicator ................................................ T5-5-14 Check by False Signal.............................T5-7-17
Malfunction of Overheat Indicator ........... T5-5-16 Test Harness ...........................................T5-7-18
Malfunction of Air Filter Restriction
Indicator ................................................ T5-5-18 Group 8 ICX
Malfunction of Buzzer ............................. T5-5-20 Outline ......................................................T5-8-1
Malfunction of LCD ................................. T5-5-22 ICX Fault Code List ...................................T5-8-6
Malfunction of Hour Meter....................... T5-5-23 Satellite Terminal Fault Code List ..............T5-8-6
Malfunction of Hydraulic Oil Filter Fault Code 1 to 4 and 6.............................T5-8-7
Indicator (Optional) ............................... T5-5-24 Fault Code 7 to 10.....................................T5-8-7
Some Parts of Data in Daily Report,
Group 6 Troubleshooting D (ZAXIS 135
UR Only) Frequency Distribution, Cumulative
Troubleshooting D Procedure ................... T5-6-1 Operation Hours are not Recorded..........T5-8-8
Auto-MARCCINO Controller
Fault Code List........................................ T5-6-2
Fault Code 05 ........................................... T5-6-6
Fault Code 06 ........................................... T5-6-6
Fault Code 07 ........................................... T5-6-7
Fault Code 08 ........................................... T5-6-7
Fault Code 11 to 13, 17............................. T5-6-8
Fault Code 14 to 16, 19 to 22 ................. T5-6-10
Fault Code 37, 38, 40 to 42, 44............... T5-6-12
Fault Code 43, 45, 47, 48 ....................... T5-6-13
Fault Code 50 to 52 ................................ T5-6-14
Fault Code 53 ......................................... T5-6-16
Fault Code 60 to 63 ................................ T5-6-18
Fault Code 80 to 83 ................................ T5-6-19
Fault Code 90 ......................................... T5-6-20
Fault Code 91 ......................................... T5-6-21
187T-5-2
TROUBLESHOOTING / General
INTRODUCTION
Refer to the inspection and troubleshooting proce- • Troubleshooting C (monitor diagnosis)
dures after any machine trouble has occurred. The Refer to these procedures when gauges and/or
inspection and troubleshooting procedures are pre- indicators are malfunctioning.
sented in an orderly fashion in this section to quickly
find the cause of the machine trouble and solution. Example: Malfunction of fuel gauge
The troubleshooting section in this manual consists of • Troubleshooting D (troubleshooting of the front
8 groups; General, Component Layout, Troubleshoot- attachment operational control using fault codes
ing A (base machine diagnosis using fault codes), (ZAXIS135UR).
Troubleshooting B (base machine diagnosis starting Use there charts when the self-diagnosing func-
with inspection of abnormal operational status), Trou- tion of Dr.ZX shows any fault codes in diagnosing
bleshooting C (monitor diagnosis), Troubleshooting D the Auto-MARCCINO Control Unit. Some fault
(Auto-Marccino diagnosis), Electrical System Inspec- codes may be displayed on the standard monitor.
tion, and ICX.
Example;
• General Dr. ZX : Fault Code 11 ---
Arm Roll-Out Malfunction
• Component Layout Standard Monitor : Fault Code UE11 ---
Arm Roll-Out Malfunction
• Troubleshooting A (base machine diagnosis using
fault codes) • Electrical System Inspection
Refer to these procedures if any fault codes are Refer to this group when required to obtain pre-
displayed when the main controller (MC) is diag- cautions and/or information for the electrical sys-
nosed with Dr. ZX. (or the built-in diagnosing system inspection.
tem)
(MC self-diagnosing function retains a record of Example: Fuse Inspection
the electrical signal system malfunction in the
form of fault codes.) • ICX
Refer to these procedures after any fault code is
Example: Fault Code 06: Abnormal EC Sensor displayed after diagnosing ICX (Information Con-
troller) or the satellite terminal (optional) with Dr.
• Troubleshooting B (base machine diagnosis ZX. (The controller self-diagnosing function re-
starting with inspection of abnormal operational tains a record of the electrical signal system mal-
status) function in the form of fault codes.)
Refer to these procedures when no fault codes
are displayed after diagnosing the machine with Example: ICX Fault Code 7: MC Communication
Dr. ZX (or the built-in diagnosing system). Trace Time Out
the cause of trouble based on the inspected result
of the abnormal symptom. In addition, information on the following items is
described in this group.
Example: Even if the engine control dial is oper- (1) Trouble shooting and setting procedures of
ated, engine speed remains unchanged. ICX and satellite terminal using Dr. ZX.
(2) Information on the satellite communication
system
T5-1-1
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient
troubleshooting:
1. Study the System

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

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

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

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

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

previously? If so, which parts were repaired
before?
T107-07-01-002
T5-1-2
3. Inspect the machine
Before starting the troubleshooting procedure,
check the machine’s daily maintenance points, as
shown in the operator's manual.
Also, check the electrical system, including the

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

Try to identify the trouble by operating the
machine yourself.
If the trouble cannot be confirmed, stop the
engine and obtain further details of the
malfunction from the operator.
Also, check for any incomplete connections of the
wire harnesses.
T5-1-3
5. Perform troubleshooting
CAUTION: Never attempt to disconnect
harnesses or hydraulic lines while the engine
is running. The machine may malfunction or
pressurized oil may spout, possibly resulting
in personal injury. Be sure to stop the engine
before disconnecting harnesses or hydraulic
lines.
Perform diagnosis by connecting Dr. ZX to the

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

and retry self-diagnosis again. If the fault code is
displayed again, check the cause of the trouble by
referring to Troubleshooting A in this section (As
for ZAXIS135UR, refore to Trouble shooting D).
After the machine trouble has been corrected, the
fault code (displayed by the built-in diagnosing
function) will be deleted. Therefore, in case prob-
lems which are not easily re-predicable are en-
countered, use Dr. ZX to display the fault code. In
case no fault codes are displayed, check all re-
lated parts/component operating condition using
the monitor function of Dr. ZX (or the built-in di-
agnosing system) while referring to troubleshoot-
ing B in this section.
T107-07-01-006
※ Note that the fault codes displayed do not

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

Before reaching a conclusion, check the most
T107-07-01-007
likely causes again. Try to identify the actual
cause of the trouble.
Based on your conclusion, make a plan for
appropriate repairs to avoid consequent
malfunctions.
T5-1-4
(Blank)
T5-1-5
BUILT-IN DIAGNOSING SYSTEM OPERA-
TION
IMPORTANT: This system is to be operated by the ZAXIS110/110M/120/130/130LCN/125US/135US
HITACHI Dealer Only. Don’t explain
this system function to the customer.
In the service mode, the monitor LCD displays the

diagnosing items, fault codes and monitored results
(not all of them) without using Dr. ZX.
Display
Built-In Diagnosing System Activation Selection
1. While pressing the monitor SET switch, turn the Switch
key switch ON.
SET Switch
Built-In Diagnosing System Operation
1. Each time the display selection switch is pressed,
the displayed item will be changed as shown on
next page.
LCD
NOTE: The fault code is indicated in the display
order 8. All fault codes (18 in total) can be
indicated. In case more than one fault code
is indicated, they will be displayed with an
interval of 1 second in order. After the ma-
chine malfunction has been repaired, the
fault codes are automatically deleted. Ac-
T178-01-01-003
cordingly, if any trouble, which is not re-
producible, is encountered, it is recom- ZAXIS135UR
mended to use Dr. ZX.
• The LCD in the service mode displays only the item LCD
No. on the left and the monitored result on the right.
The item description is not displayed. SET Switch
Display
Selection
Switch
T1SM-01-02-014
T5-1-6
BUILT-IN DIAGNOSING FUNCTION DISPLAY LIST
Display
Description Monitored Result Unit Remarks
Order
1 Hour Meter {{{{{ h Standard Mode
2 Trip 1 {{{{{ h Standard Mode (Subtraction)
3 Trip 2 {{{{{ h Standard Mode (Subtraction)
4 Engine Actual Speed n {{{{ -1 User Mode (Required to set
min
in the Dr. ZX service mode)
5 Hydraulic Oil Tempera- {{{ °C User Mode (Required to set
ture in the Dr. ZX service mode)
6 L1 {{{ － Display Purpose Only
7 Overload Alarm L2 {{{ % European Spec. Only
8 Fault Code* 0 {{ －
9 ML Switch** 1 {{ 0: Switch OFF
1: Switch ON
10 Pump 1 Delivery Pres- 2 {{ MPa
sure
11 Pump 2 Delivery Pres- 3 {{ MPa
sure
12 Pump 1 Pump (Flow) 4 {{ MPa
Control Pressure
13 Pump 2 Pump (Flow) 5 {{ MPa
Control Pressure
14 Engine Target Speed 6 {{ -1
min
15 EC Angle 7 {{ V
16 Dial Angle 8 {{ V
17 Boom Raise Pilot Pres- 9 {{ MPa
sure
18 Arm Roll-In Pilot Pres- A {{ MPa
sure
19 Swing Control Pilot b {{ MPa
Pressure
20 Travel Control Pilot c {{ MPa
Pressure
21 Front Att. Operation d {{ 0: Not Operating
1: Operating
22 Att. Control Pressure E {{ MPa
23 Work Mode F {{ 0: Digging
1: Breaker
2: Secondary
Crusher
(Demolisher)
3: Crusher
4: Vibro-Hammer
NOTE: *: Refer to T5-1-8 for the Fault Codes.

**: ML specification is only available in Japanese domestic market.
T5-1-7
Dr.ZX OPERATION ZAXIS110/110M/120/130/130LCN:
Rear Console Fuse Box
Dr. ZX is a troubleshooting tool to diagnose the elec-
tronic control system including the MC (main Control-
ler) and ICX (Information Controller). When Dr. ZX is Dr. ZX Connector
(MC)
connected to either the MC or the ICX, it displays
whether the controllers and sensors operate normally
in the form of fault codes (Self-Diagnosing Result Dis-
play Function).
In addition, Dr. ZX can display the inputs from sensors
and switches to the MC and/or the outputs to actuators
such as solenoid valves from the MC and
auto-MARCCINO Controller (ZAXIS135UR) in real
time while operating the machine (Monitor Display
Function).
NOTE: Refer to Group 8 “ICX” for operation of Dr. Dr. ZX Connector

EX connected to the ICX. (ICX)
T178-01-02-006
ZAXIS125US/135US:
Fuse
Box
Dr. ZX Dr. ZX
Connector Connector
to ICX to MC
T1SM-01-02-006
ZAXIS135UR:
Dr. ZX Connector Fuse Box

to MC
Dr. ZX Connector
Dr. ZX Connector
to Auto-Marccino
to ICX
Controller (UR)
T1CF-01-01-013
T5-1-8
Operation
1. Connect palm (Dr. ZX) to the diagnosis connec-
Palm
tors (MC, ICX and Auto-MARCCINO Controller （Dr. ZX）
(ZAXIS135UR)) located in the cab, using Hot
Sync cable and battery box cable.
Hot Sync Cable
2. Turn the key switch ON, or start the engine.
3. When the palm power is turned ON, palm displays
the following screens in order. Battery Box
3-1. Title Screen Cable
Select the Dr. ZX icon
3-2. Select Kind Screen T178-05-01-167
+ Select the EPVC-Mid
3-3. Menu Screen
Start
Select the Start.
3-4. Model Name Screen
(Example) Model: ZX110
3-5. Function Selection Screen Title Screen
+ Self-Diagnostic Results
+ Monitor Display
+ Special Function Select Kind
Cannot
Screen
NOTE: Special functions allow the ECO and WU Communicate
deactivation. (Refer to T5-1-19)
· Check harness
· Check fuse
4. Select Self-Diagnostic Results. Then, continue to Menu Screen
operate palm by following instructions to be dis-
played at the screen bottom hereafter.
Model Name
NOTE: Refer to the Dr. ZX Operation Manual for Confirmation
the detailed operation of Dr. ZX.
NOT OK
OK ?
OK
Replace software
Self-Diagnosing
Result Display Special
Function Select Monitor Function
function
Self-diagnostic
Result by con- Enter model
troller is displayed Record
code and serial
No.
Retry B
Select data to
be monitored
Self-diagnostic
Result is displayed
Monitored data
is displayed
T5-1-9
Dr.ZX FAULT CODE LIST (MC)
Fault Code Trouble Cause

01 Abnormal EEPROM • Faulty MC
02 Abnormal RAM
03 Abnormal A/D Conversion
04 Abnormal Sensor Voltage • Faulty MC
• Faulty Harness
• Faulty Sensor
06 Abnormal EC Sensor • Faulty MC
• Faulty Harness
• Faulty EC Sensor
07 Abnormal Engine Control Dial Angle • Faulty MC
• Faulty Harness
• Faulty Engine Control Dial
10 Abnormal Pump 1 Delivery Pressure • Faulty MC
11 Abnormal Pump 2 Delivery Pressure • Faulty Harness
• Faulty Pump Delivery Pressure Sensor
12 Abnormal Pump1 Pump Control Pressure • Faulty MC
13 Abnormal Pump2 Pump Control Pressure • Faulty Harness
• Faulty Pump Control Pressure Sensor
14 Abnormal Swing Pilot Pressure • Faulty MC
15 Abnormal Boom Raise Pilot Pressure • Faulty Harness
16 Abnormal Arm Roll-In Pilot Pressure • Faulty Pilot Pressure Sensor
18 Abnormal Travel Pilot Pressure
19 Abnormal Hydraulic Oil Temperature • Faulty MC
• Faulty Harness
• Faulty Hydraulic Oil Temperature Sensor
T5-1-10
(Blank)
T5-1-11
FAULT CODE LIST (AUTO-MARCCINO
CONTROLLER) (ZAXIS135UR ONLY)
Fault Code
Buzzer System
System Cause of Trouble
Dr. ZX Sound Indicator
Monitor
05 − − ON Faulty monitor (switch box) communication
06 − − ON Abnormal metering correction value
Continuously
07 UE07 ON Abnormal front angle sensor calibration value
sounds
Continuously
08 UE08 ON Abnormal code setting
sounds
11 UE11 Abnormal arm roll-out function
12 UE12 Continuously Abnormal right offset function
ON
13 UE13 sounds Abnormal left offset function
17 UE17 Abnormal boom raise function
14 − − Abnormal arm roll-out acceleration pilot pressure sensor
15 − − Abnormal right offset acceleration pilot pressure sensor
16 − − Abnormal left offset acceleration pilot pressure sensor
19 − − ON Abnormal boom raise acceleration pilot pressure sensor
20 − − Abnormal boom raise pilot pressure sensor
21 − − Abnormal boom lower pilot pressure sensor
22 − − Abnormal arm roll-in pilot pressure sensor
23 − Abnormal auxiliary pilot pressure sensor
37 UE37 Abnormal arm roll-out deceleration proportional solenoid valve

38 UE38 Abnormal 8-unit solenoid valve unit (right offset deceleration)
Long beep
40 UE40 Abnormal 8-unit solenoid valve unit (boom raise deceleration)
sounds in- ON
41 UE41 Abnormal 8-unit solenoid valve unit (arm roll-in deceleration)
termittently
42 UE42 Abnormal 8-unit solenoid valve unit (left offset deceleration)
44 UE44 Abnormal 8-unit solenoid valve unit (boom lower deceleration)
43 − − Faulty 8 unit solenoid valve unit (right offset acceleration)
45 − − Faulty 8 unit solenoid valve unit (arm roll-out acceleration)
47 ON Faulty 8 unit solenoid valve unit (left offset acceleration)
− −
48 − − Faulty boom raise acceleration proportional solenoid valve
NOTE: *Unless the solenoid valve has failed, boom raise operation is correctly controlled in the range lower
than boom foot pin height.
T5-1-12
Trouble on the Machine Corrective Action Group
1) Check harness.
− 2) Replace the controller. G4
3) Replace the system monitor.
1) Abnormal metering correction
Depth limit control stops G4
value.
1) Replace the controller if the con-
* Movement to the cab stops. troller does not operate correctly. G1
1) Input the front and bucket codes

* Movement to the cab stops. G1
again.
1) Check harness.
2) Replace the pilot pressure
All movement stops.(No pilot pressure) sensor. G0
3) Replace the solenoid valve.
Cab collison prevention control stops. 1) Check harness.
Offset movement by offset switch stops. 2) Replace pilot pressure sensor.
Offset movement by offset switch stops.
Cab collison prevention control stops, depth limit control stops
Cab collison prevention control stops.
1) Check harness.
G8
2) Replace pilot pressure sensor.
Arm roll-out movement stops. 1) Check harness.
Right offset movement stops. 2) Replace the solenoid valve.
Boom raise movement stops.
G3
Arm roll-in movement stops.
Left offset movement stops.
Boom lower movement stops.
Offset movement by offset switch stops. 1) Check harness.
Cab collison prevention control stops. 2) Replace the solenoid valve.
Offset movement by offset switch stops. G4
Depth limit control stops.
NOTE: If two or more trouble occurs at the same time, the system monitor displays the fault code for the lower
group number only.
T5-1-13
Fault Code
Buzzer System
Monitor
50 UE50 Abnormal boom angle sensor
51 UE51 Abnormal arm angle sensor
52 UE52 Abnormal offset angle sensor
53 UE53 Continuously Abnormal slide arm sensor
ON
sounds
80 UE80 Boom angle sensor deviation

81 UE81 Arm angle sensor deviation
82 UE82 Offset angle sensor deviation
83 UE83 Continuously Slide arm sensor deviation
ON
sounds
60 UE60 Faulty boom angle sensor initial setting.

61 UE61 Continuously Faulty arm angle sensor initial setting.
ON
62 UE62 sounds Faulty offset angle sensor initial setting.
63 UE63 Faulty slide arm sensor initial setting.
Faulty hydraulic oil temperature sensor.
90 − − ON
Abnormal sensor power source.
91 − − ON
Abnormal reference power source. (Abnormal voltage supplied
92 − − −
to Auto-MARCCINO controller)
Complete front attachment angle sensor initial setting.
F0 − − −
Continuously Invasion of hazardous area by emergency evacuation switch.
F2 − −
sounds
Escape out of hazardous area.
F3 − − −
Short beep Invasion of hazardous area by interference prevention mode.
F4 UE00 sounds ON
intermittently
FA − − − Install attachment select switch
FB − − − Remove attachment select switch
FC − − −
group number only.
T5-1-14
Interference prevention control system functions 1) Check harness.

as if boom is raised to the highest position. 2) Replace the angle sensor.
Interference prevention control system functions
as if arm is fully rolled in.
G2
as if the front attachment is fully offset to the left
side.
as if boom is raised to the highest position. 2) Check angle sensor installation.
Interference prevention control system functions 3) Replace the angle sensor.
as if arm is fully rolled in. Interference prevention
G2
control system functions as if the front attach-
ment is fully offset to the left side.
as if slide arm is fully extension.
1) Check harness.
2) Replace the angle sensor

G4
as if oil temperature is lowest. 2) Replace the hydraulic oil temperature sensor.
Depth limit control stops 1) Initialize the angle sensor again.
G4
Cab collison control stops. 2) Replace the angle sensor.
Normal Movement by backup function. 1) Check harness.
G8
* Movement to the cab stops.
G5
− G7
− G8
All movement stops. (No pilot pressure) G0
G8
G8
G8
T5-1-15
Dr.ZX MONITORING ITEM LIST (MC)
Dr. ZX displays the input signals from the switches and
sensors to the MC and the control signals to the ac-
tuators from the MC.
Item Data Unit

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

Engine Actual Speed Input signal from N sensor min-1
Deviation in Engine Speed Calculated Value min-1
(Engine Speed Differencial) (Target Engine Speed - Actual Engine Speed)
EC Angle Input signal from EC sensor V
Dial Angle Input signal from engine control dial V
Boom Raise Pilot Pressure Input signal from pressure sensor (boom raise) MPa
Arm Roll-In Pilot Pressure Input signal from pressure sensor (arm roll-in) MPa
Swing Control Pressure Input signal from pressure sensor (swing) MPa
Travel Control Pressure Input signal from pressure sensor (travel) MPa
Front Att. Operation Input signal from pressure sensor (front att.) FR
Hydraulic Oil Temperature Input signal from oil temperature sensor °C
E/P/HP Mode Switch Power mode switch selection status E, P, HP
Auto-Idle/Auto-Accel Switch Auto-Idle/Acceleration selection status AI, AA
Travel Mode Travel mode switch selection status Lo, Hi
Power Digging (Boost) Power digging switch status Pd
Switch
Work mode Work mode switch selection status STD, ATT
ATT. Mode BU, CS, CL, HB
Engine Learning Status Done, Undone,
Aborted Ky
Pump 2 Proportional Sole- Control signal to max. pump 2 flow rate limit solenoid MPa
noid Valve Output valve
Pump Torque Proportional Control signal to torque control solenoid valve MPa
Solenoid Valve Output
Arm Regenerative Propor- Control signal to solenoid valve SC MPa
tional Solenoid Valve Out-
put
Travel Motor Control Pres- Control signal to solenoid valve SI MPa
sure
EC Motor Position step
T5-1-16
Optional
Item Data Unit
Optional Pump 3 Delivery Pressure Input signal from pump 3 delivery pressure sensor MPa
Boom Cylinder Bottom Pressure MPa
Boom Cylinder Rod Pressure MPa
Arm Roll-Out Pilot Pressure Input signal from pressure sensor (arm roll-out) MPa
ATT. Control Pressure Input signal from pressure sensor (auxiliary) MPa
Boom Angle V
Arm Angle V
Offset Angle V
Pump 1 Max. Displacement cm3
Boom Dampener Switch OFF, SOFT, HARD
Pump 1 Proportional Solenoid Valve Control signal to max. pump 1 flow rate limit so- MPa
Output lenoid valve
ATT. Proportional Solenoid Valve MPa
Output
Travel/Swing/Overload Alarm Tr, Sw, Load
Initial *ML Setting Unf, Done, Abrt,
Und
NOTE: ML specification is only available in Japanese domestic market.
T5-1-17
Dr.ZX MONITORING ITEM LIST
(AUTO-MARCCINO CONTROLLER)
(ZAXIS135UR ONLY)
Dr.ZX has a function to monitor the command signals
from the Auto-MARCCINO Controller Unit and input
signals from various switches and sensors.
Data Unit Data Unit

Boom angle sensor voltage V ON/OFF signal from slide arm retracted solenoid Dsd*
Arm angle sensor voltage V valve
Offset angle sensor voltage V ON/OFF signal from slide arm extended sole- Dss*
Slide arm sensor voltage V noid valve
Oil temperature ºC Boom angle sensor value before correction V
Boom raise deceleration solenoid valve current mA Arm angle sensor value before correction V
Boom lower deceleration solenoid valve current mA Offset angle sensor correction value V
Arm roll-in deceleration solenoid valve current mA Slide arm angle sensor correction value V
Arm roll-out deceleration solenoid valve current mA Boom angle sensor standard value V
Left offset deceleration solenoid valve current mA Arm angle sensor standard value V
Boom raise acceleration solenoid valve current mA Offset angle sensor standard value V
Arm roll-out acceleration solenoid current mA Slide arm angle sensor standard value V
Left offset acceleration solenoid valve current mA Monitored height m
Right offset acceleration solenoid valve current mA Monitored reach m
Right offset deceleration solenoid valve current mA Monitored offset amount m
Boom raise pilot pressure MPa ON/OFF signal from breaker switch Sbr *
Boom raise acceleration pilot pressure MPa ON/OFF signal from bucket switch Sbk *
Boom lower pilot pressure MPa ON/OFF signal from breaker lamp LMP*
Arm roll-in pilot pressure MPa Auxiliary pilot pressure MPa
Arm roll-out acceleration pilot pressure MPa NOTE: * White letters (or figures) are shown on
Right offset acceleration pilot pressure MPa the black screen when the switches are
Left offset acceleration pilot pressure MPa ON (connected).
ON/OFF signal from right offset switch Sor *
ON/OFF signal from left offset switch Sol *
ON/OFF signal from prohibited-area release Sav *
switch
ON/OFF signal from interference prevention Sin *
mode switch
ON/OFF signal from emergency evacuation Spr *
switch
ON/OFF signal from initial setting switch Scl *
ON/OFF signal from service switch Ssv *
ON/OFF signal from range limit release switch Slm *
Buzzer output Dbz *
Lock/Unlock signal of pilot pressure Dpi *
T5-1-18
Dr. ZX SPECIAL FUNCTION
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS110.
Start the service software in the Select a special function

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

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

Select ESC to return Select ESC to return Select ESC to return Select ESC to return
to Fig. B. to Fig. B. to Fig. B. to Fig. B.
T5-1-19
Dr.ZX SERVICE MODE (MC) ZAXIS110/110M/120/130/130LCN
Engine
Dr. ZX has three (3) modes, learning value display, Learning
Switch
parameter change, and monitor display information
setting.
Learning Value Display Dr.ZX

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

Items to be displayed on the monitor LCD can be
added.
T178-01-02-006
• Accessing Service Mode
1. After turning the key switch OFF, wait for more ZAXIS125US/135US
than 10 seconds.
2. Connect Dr. ZX to the connector to MC on the
base machine.
3. Turn the engine learning switch to the learning
position (the stamped mark E side).
4. Turn the key switch ON. Don’t start the engine at
this time.
5. Turn Dr. ZX switch ON.
Learning Switch T1SM-01-02-006

Dr.ZX Connector
to MC
ZAXIS135UR
Dr.ZX Connector to
The learning switch is MC
turned to the stamped
mark E
Learning Switch
Stamped
Mark E
T1CC-05-01-001
Learning Switch
T1CF-01-01-004
T5-1-20
(Blank)
T5-1-21
Item Data
Learning Data Display
EC Motor Stop Position Display of the engine stop value in engine learning
EC Motor Maximum Speed Position Display of max. engine speed valve in engine learning
Boom Angle Sensor Correction Value Display of boom angle sensor correction value
Arm Angle Sensor Correction Value Display of arm angle sensor correction value
Offset Angle Sensor Correction Value Display of offset angle sensor correction valve
Parameter Change
Li Speed Adjustment Adjustment of minimum engine speed
WU Speed Adjustment Adjustment of warming up engine speed
AI Speed Adjustment Adjustment of auto-idle engine speed
E Speed Adjustment Adjustment of E-mode engine speed
P Speed Adjustment Adjustment of P-mode engine speed
Breaker Engine Speed Adjustment Adjustment of breaker operation engine speed
Secondary Crusher (Demolisher) Engine Adjustment of secondary crusher (demolisher) operation en-
Speed Adjustment gine speed
Crusher Engine Speed Adjustment Adjustment of crusher operation engine speed
Vibro-Hammer Speed Adjustment Adjustment of vibratory hammer operation engine speed
Hyd. Breaker P1 Max Swash Angle Adjust- Adjustment of lowest pump 1 max. flow rate in breaker opera-
ment tion
Secondary Crusher (Demolisher) P1 Max Adjustment of lowest pump 1 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P1 Max Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in crusher opera-
tion
Vibro P1 Max Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in vibratory ham-
mer operation
Hyd. Breaker P2 Max Swash Angle Adjust- Adjustment of lowest pump 2 max. flow rate in breaker opera-
ment tion
Secondary Crusher (Demolisher) P2 Max Adjustment of lowest pump 2 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P2 Max Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in crusher opera-
tion
Vibro P2 Max Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in vibratory ham-
mer operation
Pump PQ Base Torque Correction Adjustment of pump P-Q curve
ATT Proportional Solenoid Valve Adjustment Adjustment of optional solenoid valve
T5-1-22
Item Data
Boom Lower Dampener Proportional Sole- Adjustment of solenoid valve
noid Valve Adjustment
ATT Speed Increase Down Waiting Time Setting of time required for engine speed increase
*ML Crane Front Code Change Setting of front att. code for ML models
*ML Crane Bucket Code Change Setting of bucket code for ML models
Max. *ML Crane Speed Adjustment Setting of engine speed in crane mode
*ML Crane Bucket Weight Adjustment
Min, Boom CYL. Bottom Pressure Over Bal-
ance
Monitor Display Change
Engine Actual Speed Display/Non-display Monitor setting of display/no-display of actual engine speed
Hydraulic Oil Temperature Display/No-display Monitor setting of display/no-display of hydraulic oil tempera-
ture
Overload Alarm Display/No-display Monitor setting of display/no-display of overload alarm.
NOTE: ML specification is only available in Japanese domestic market.
T5-1-23
Displaying Engine Learning Data and Angle Sensor Correction Valve
Start the service software in The service software will

the service mode start in the service mode
Select Start from the Press Correct if the dis- Confirm that you are in the Select Special Function.
EPVC_Mid software menu. played model name is cor- service mode, and select
rect. Rechecked.
Fig. A T178-05-01-006 Fig. B T187-05-01-001 Fig.C T178-05-01-034 Fig. D T178-05-01-035

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

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

Select ESC to return Select ESC to return
to Fig. D. to Fig. F.
T5-1-24
EC Motor stop position EC Motor Maximum Boom angle sensor Arm angle sensor correction
engine speed position correction value value
T178-05-01-038 T178-05-01-039 T178-05-01-040 T178-05-01-041

Select ESC to return Select ESC to return Select ESC to return Select ESC to return
to Fig. F. to Fig. F. to Fig. F. to Fig. F.
T5-1-25
Changing Parameters In The Controller
Start the service mode on the condition that the engine learning switch is turned on.
To change the parameter, it is necessary to enter the password. To change the password, refer to the “Changing the password”
section.
Start the service software in The service software will start in

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

Fig. B T187-05-01-001 Select ESC to return Select ESC to return
Select ESC to return to Fig. A. to Fig. A
to Fig. A.
Execute the parameter Select a parameter change

change Enter the password
item
The menu will be displayed. Enter the password to change Select the item you want to change. The
Select Parameter Change from the parameter. up- and down-arrow buttons can be
the menu. used to scroll through the item list.
Fig. F
Fig. E T178-05-01-042
T178-05-01-043
Fig. G
Select ESC to return T178-05-01-044
Select ESC to return to Fig. E. Select ESC to return
to Fig. D. to Fig. E.
T5-1-26
Enter the new value Confirm the new value Parameter adjustment
result
Enter the new value in the Ad- The new value will be displayed
The adjusted value will be dis-
justment space, and press in the Adjustment space. Select
played.
Execution. Execute to change to this value.
T178-05-01-045 T178-05-01-046 T178-05-01-047

to Fig. G. to Fig. G. to Fig. G.
T5-1-27
Changing The User Mode Display on The Monitor Panel
Start the service mode on the condition that the engine learning switch is turned on.
Start the service software in The service software will start in

the service mode the service mode
Select Start from the Press Correct if the displayed Confirm that you are in the
EPVC_Mid software menu. model name is correct. service mode, and select Re- Select Special Function.
checked.
Fig. A T178-05-01-006 Fig. B T187-05-01-001 Fig. C T178-05-01-034 Fig. D T178-05-01-035

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

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

to Fig. D. to Fig. E. to Fig. F.
T5-1-28
Confirm Disp/No Disp Confirm the result

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

Select ESC to return
to Fig.F. Select ESC to return to Fig. F.
T5-1-29
• Operational Performance Check After Adjustment
(Check that pump flow rate and engine speed
have been changed.)
IMPORTANT: After adjusting the engine speed and

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

2. Wait approx. 10 seconds.
3. Turn the engine learning switch to neutral.
4. Disconnect the Dr. ZX. connector (When moni-
toring with Dr. ZX, pass this step.)
5. Turn the key switch ON.
6. Start the engine.
7. Check operational performances of the machine.
T5-1-30
(Blank)
T5-1-31
ADJUSTMENT DATA LIST
ZAXIS110, 110M, ZAXIS125US

Min. Adjust- Adjustable Range Standard
Adjustment Data Remarks
ment Value Model Range Adjustment
Li Speed 10 min-1 ZX110/110M/125US 0 to 120 0 min-1
WU Speed 10 min-1 ZX110/110M/125US -120 to 120 0 min-1
AI Speed 10 min-1 ZX110/110M/125US -120 to 120 0 min-1
E Speed 10 min-1 ZX110/110M/125US -120 to 120 0 min-1
P Speed 10 min-1 ZX110/110M/125US -120 to 120 0 min-1
Breaker Speed 10 min-1 ZX110/110M/125US -500 to 200 0 min-1
Secondary Crusher ZX110/110M/125US
10 min-1 -500 to 200 200 min-1
(Demolisher) Speed
Crusher Speed 10 min-1 ZX110/110M/125US -500 to 200 200 min-1
Vibro-Hammer Speed 10 min-1 ZX110/110M/125US -500 to 200 0 min-1
Hyd. Breaker P1 Max ZX110/110M/125US
0.6 cm3/rev 25.8 to 57 57 cm3/rev
Swash Angle
Secondary (Demolisher) P1 ZX110/110M/125US
0.6 cm3/rev 25.8 to 57 57 cm3/rev
Max Crusher Swash Angle
Crusher P1 Max Swash ZX110/110M/125US
0.6 cm3/rev 25.8 to 57 57 cm3/rev
Angle
Vibro PI Max Swash Angle 0.6 cm3/rev ZX110/110M/125US 25.8 to 57 57 cm3/rev
Hyd. Breaker P2 Max ZX110/110M/125US
0.6 cm3/rev 25.8 to 57 57 cm3/rev
Swash Angle
Secondary Crusher ZX110/110M/125US
(Demolisher) P2 Max 0.6 cm3/rev 25.8 to 57 57 cm3/rev
Swash Angle
Crusher P2 Max Swash ZX110/110M/125US
0.6 cm3/rev 25.8 to 57 57 cm3/rev
Angle
Vibro P2 Max Swash Angle 0.6 cm3/rev ZX110/110M/125US 25.8 to 57 57 cm3/rev
Pump PQ Base Torque ZX110/110M/125US
2.45 N･m -78.4 to 0 0 N･m
Adjustment
T5-1-32
Min. Adjust- Standard

Adjustment Data Adjustable Range Remarks
ment Value Adjustment
ATT Proportional Solenoid
0.1 MPa ZX110/110M/125US -0.89 to 0.89 0 MPa
Valve
Boom Lower Dampener ZX110/110M/125US
0.1 MPa -0.89 to 0.89 0 MPa
Proportional Solenoid Valve
ATT Speed Increase Down ZX110/110M/125US
500 ms 0 to 3000 3000 ms
Wait Time
*ML Crane Front Code 1 ZX110/110M/125US 0 to 2 0
*ML Crane Bucket Code 1 ZX110/110M/125US 0 to 1 0
Max. *ML Crane Speed 10 min -1
ZX110/110M/125US -450 to 400 0 min-1
*ML Crane Bucket Weight 4 kg ZX110/110M/125US -512 to 508 0 kg
Min Boom Cyl. Bottom ZX110/110M/125US
0.1 MPa -9.81 to 9.81 0 MPa
Pressure Over Balance
NOTE: 1 MPa = 98.07 kPa

1 kgf⋅m = 9.807 N⋅m
ML specification is only available in Japa-
nese domestic market.
T5-1-33
ZAXIS120, ZAXIS130, ZAXIS130LCN, ZAXIS135US, ZAXIS135UR

Min. Adjustment Adjustable Range Standard
Value Model Range Adjustment
Li Speed ZX120/130/130LCN/
10 min-1 0 to 120 0 min-1
135US/135UR
WU Speed ZX120/130/130LCN/
10 min-1 -120 to 120 0 min-1
135US/135UR
AI Speed ZX120/130/130LCN/
10 min-1 -120 to 120 0 min-1
135US/135UR
E Speed ZX120/130/130LCN/
10 min-1 -120 to 120 0 min-1
135US/135UR
P Speed ZX120/130/130LCN/
10 min-1 -120 to 120 0 min-1
135US/135UR
Breaker Speed ZX120/130/130LCN/
10 min-1 -500 to 200 0 min-1
135US/135UR
Secondary Crusher (De- ZX120/130/130LCN/
10 min-1 -500 to 200 200 min-1
molisher) Speed 135US/135UR
Crusher Speed ZX120/130/130LCN/
10 min-1 -500 to 200 200 min-1
135US/135UR
Vibro-Hammer Speed ZX120/130/130LCN/
10 min-1 -500 to 200 0 min-1
135US/135UR
Hyd. Breaker P1 Max ZX120/130/130LCN/
0.6 cm3/rev 27 to 60 60 cm3/rev
Swash Angle 135US/135UR
Secondary (Demolisher)
ZX120/130/130LCN/
P1 Max Crusher Swash 0.6 cm3/rev 27 to 60 60 cm3/rev
135US/135UR
Angle
Crusher P1 Max Swash ZX120/130/130LCN/
0.6 cm3/rev 27 to 60 60 cm3/rev
Angle 135US/135UR
Vibro Pi Max Swash Angle ZX120/130/130LCN/
0.6 cm3/rev 27 to 60 60 cm3/rev
135US/135UR
Hyd. Breaker P2 Max ZX120/130/130LCN/
0.6 cm3/rev 27 to 60 60 cm3/rev
Swash Angle 135US/135UR
T5-1-34
Min. Adjustment Adjustable Range Standard

Value Model Range Adjustment
Secondary Crusher
ZX120/130/130LCN/
(Demolisher) P2 Max 0.6 cm3/rev 27 to 60 60 cm3/rev
135US/135UR
Swash Angle
Crusher P2 Max Swash ZX120/130/130LCN/
0.6 cm3/rev 27 to 60 60 cm3/rev
Angle 135US/135UR
Vibro P2 Max Swash An- ZX120/130/130LCN/
0.6 cm3/rev 27 to 60 60 cm3/rev
gle 135US/135UR
Pump PQ Base Torque ZX120/130/130LCN/
2.45 N･m -78.4 to 0 0 N･m
Adjustment 135US/135UR
ATT Proportional Solenoid ZX120/130/130LCN/
0.1 MPa -0.89 to 0.89 0 MPa
Valve 135US/135UR
Boom Lower Dampener
ZX120/130/130LCN/
Proportional Solenoid 0.1 MPa -0.89 to 0.89 0 MPa
135US/135UR
Valve
ATT Speed Increase ZX120/130/130LCN/
500 ms 0 to 3000 3000 ms
Down Wait Time 135US/135UR
*ML Crane Front Code ZX120/130/130LCN/
1 0 to 2 0
135US/135UR
*ML Crane Bucket Code ZX120/130/130LCN/
1 0 to 1 0
135US/135UR
Max. *ML Crane Speed ZX120/130/130LCN/
10 min-1 -450 to 400 0 min-1
135US/135UR
*ML Crane Bucket Weight ZX120/130/130LCN/
4 kg -512 to 508 0 kg
135US/135UR
Min Boom Cyl. Bottom ZX120/130/130LCN/
0.1 MPa -9.81 to 9.81 0 MPa
Pressure Over Balance 135US/135UR
NOTE: 1 MPa = 98.07 kPa

1 kgf⋅m = 9.807 N⋅m
ML specification is only available in Japa-
T5-1-35
(Blank)
T5-1-36
TROUBLESHOOTING / Component Layout
MAIN COMPONENT LAYOUT
ZAXIS110, 110M, ZAXIS120, ZAXIS130, ZAXIS130LCN
1
3
4
5
6
7
10
11
12
13
14
20 15
16
19
18 17
T176-01-02-001
1 - Bucket Cylinder 7 - Fuel Tank 13 - Intercooler 19 - Pilot Shut-Off Valve

(ZAXIS120,130,130LCN
Only)
2 - Arm Cylinder 8 - Hydraulic Oil Tank 14 - Radiator 20 - Travel Pilot Valve
3 - Boom Cylinder 9 - Control Valve 15 - Oil Cooler 21 - Front Attachment/Swing
Pilot Valve
4 - Center Joint 10 - Pilot Filter and Pilot Relief 16 - Battery
Valve
5 - Swing Bearing 11 - Pump Device 17 - Travel Device
6 - Swing Device 12 - Engine 18 - Signal Control Valve
T5-2-1
ZAXIS125US, ZAXIS135US
2 3
1 5
19
6
7
8
18
17
16
9
10
11 T1SE--01-02-001
12
14 13
15
1 - Front Attachment / Swing 6 - Boom Cylinder 11 - Signal Control Valve 16 - Engine

Pilot Valve
2 - Pilot Shut-Off Valve 7 - Hydraulic Oil Tank 12 - Center Joint 17 - Radiator
3 - Travel Pilot Valve 8 - Fuel Tank 13 - Swing Device 18 - Oil Cooler
4 - Arm Cylinder 9 - Control Valve 14 - Pilot Filter / Pilot Relief 19 - Intercooler (ZAXIS 135US
Valve Only)
5 - Bucket Cylinder 10 - Solenoid Valve Unit 15 - Pump Device
T5-2-2
ZAXIS135UR
2
3
4
1
5
6
7
8
9
10
11
12
13
29
14
28 15
16
17
18
27
26
25
24
23
22 19
21
20 T1SM-01-02-001
1- Bucket Cylinder 9- Solenoid Valve Unit 16 - Pump Device 23 - Emergency Stop Valve
2- Arm Cylinder 10 - Signal Control Valve 17 - Engine 24 - Blade Pilot Valve
3- Offset Cylinder 11 - Fuel Tank 18 - Blade Cylinder 25 - Pilot Shut-Off Valve
4- Offset Anti-Drift Valve 12 - Hydraulic Oil Tank 19 - Radiator 26 - Travel Pilot Valve
5- Boom Cylinder 13 - Pilot Filter / Pilot Relief 20 - Oil Cooler 27 - Travel Device
Valve
6- Blade Signal Switch 14 - Swing Device 21 - Center Joint 28 - Offset Pilot Valve
Valve
7 - Control Valve 15 - Blade Control Valve 22 - Battery 29 - Front Attachment / Swing
Pilot Valve
8- 8-Unit Solenoid Valve
Unit
T5-2-3
ELECTRICAL COMPONENT LAYOUT
(Overview)
3
• Pressure Sensor (Front Attachment)
Refer to the Swing Device group. 4
2 • Pressure Sensor
1 (Boom Raise)
• Pressure Sensor
(Arm Roll-In)
Refer to the Control Valve
group.
16
• Pressure Sensor (Travel)

• Pressure Sensor (Swing)
Refer to the Signal Control
Valve group.
15 7
8
14
13 • Pump 1 and 2 Delivery Pressure Sensor

• Pump 1 and 2 Control Pressure Sensor T176-01-02-004
9 • N Sensor
10 • Torque Control Solenoid Valve
12 11 • Pump 2 Flow Rate Control Solenoid Valve
Refer to the Pump Device group.
1 - Horn 5 - Hydraulic Oil Temperature 9 - Overheat Switch 13 - *Coolant Level Switch

Sensor
2 - Work Light 6 - EC Motor and EC Sensor 10 - Coolant Temperature 14 - Battery
Sensor
3 - Fuel Sensor 7 - Engine Oil Pressure Switch 11 - Battery Relay 15 - Air Cleaner Restriction
Switch
4 - Solenoid Valve Unit 8 - *Engine Oil Level Switch 12 - Glow Plug Relay 16 - Wiper Motor
NOTE: * ZAXIS110, 110M: Up to serial No.010576
ZAXIS120: Up to serial No.062964
T5-2-4
• Pump 1 and 2 Delivery Pressure Sensor

• Pump 1 and 2 Control Pressure Sensor
• N Sensor
• Torque Control Solenoid Valve
• Pump 2 Flow Rate Control Solenoid Valve
1 3
2
4
15
6
7
14
13
8
10
• Pressure Sensor • Pressure Sensor

(Boom Raise) (Travel)
• Pressure Sensor • Pressure Sensor
(Arm Roll-In) (Swing)
Refer to the Control Valve Refer to the Signal 11
group Control Valve group 12
T1SE-01-02-002
• Pressure Sensor
(Front Attachment)
Refer to the Swing Device group
1 - EC Motor and EC Sensor 5 - Coolant Temperature 9 - Battery 13 - Solenoid Valve Unit

Sensor
2 - *Engine Oil Level Switch 6 - *Coolant Level Switch 10 - Air Cleaner Restriction 14 - Hydraulic Oil Temperature
Switch Sensor
3 - Engine Oil Pressure Switch 7 - Battery Relay 11 - Wiper Motor 15 - Fuel Sensor
4 - Overheat Switch 8 - Glow Plug Relay 12 - Horn
NOTE: * ZAXIS125US: Up to serial No.010576
ZAXIS135US: Up to serial No.062964
T5-2-5
ZAXIS135UR
1 2
• Pump 1 and 2 Delivery Pressure

Sensor
• Pump 1 and 2 Control Pressure
Sensor
• N Sensor
• Torque Control Solenoid Valve
• Pump 2 Flow Rate Control 17
Solenoid Valve
4
17
16
15
5
6
• Pressure Sensor
(Travel)
• Pressure Sensor
(Swing)
Refer to the Signal
7
Control Valve group 8
14
10
13
12
• Pressure Sensor (Boom Raise)
• Pressure Sensor
(Arm Roll-In) 11
Refer to the Control Valve group. T1SM-01-02-008
1 - Arm Angle Sensor 6- Coolant Temperature 11 - Emergency Stop Solenoid 16 - Hydraulic Oil Temperature
Sensor Valve Sensor
2 - Offset Angle Sensor 7 - Battery Relay 12 - Horn 17 - Pressure Sensor (Front
Attachment)
3 - Boom Angle Sensor 8 - Glow Plug Relay 13 - 8-Unit Solenoid Valve Unit 18 - EC Motor / EC Sensor
4 - Engine Oil Pressure Switch 9 - Battery 14 - Solenoid Valve Unit
5 - Overheat Switch 10 - Air Cleaner Restriction 15 - Fuel Sensor
Switch
T5-2-6
ELECTRICAL SYSTEM
(Relays and Related Equipment) Rear Deck
5
3 4
2
10
T178-01-02-006
15
14
18 13
17 12
16 11
T178-01-02-007
1- Mail Switch (Satellite 6- Fuse Box 11- Load Damp Relay (R1) 16- Wiper Relay A (R6)
Navigation System
Equipped Machines only)
2- QOS Controller 7- Learning Switch 12- Washer Relay (R2) 17- Wiper Relay B (R7)
3- ICX (Information Controller) 8- Dr. ZX Connector to MC 13- Work Light Relay 2 (R3) 18- Wiper Relay C (R8)
4- MC (Main Controller) 9- Download Connector (Not connected on 14- Work Light Relay 1 (R4)
Satellite Navigation System equipped
machines)
5-Satellite Terminal (Optional) 10- Dr. ZX Connector to ICX 15- Horn Relay (R5)
T5-2-7
15
ZAXIS125US、ZAXIS135US 4
16
14
17
13
12
11 5
10
T1GF-01-02-003
6
1, 2 3
9 8 7
T1SM-01-02-006
1- ICX (Information Controller) 6- Fuse Box 11 - Work Light Relay 1 (R4) 16 - Wiper Relay B (R7)
2- MC (Main Controller) 7- Dr.ZX Connector to MC 12 - Work Light Relay 2 (R3) 17 - Wiper Relay C (R8)
3- Satellite Terminal (Optional) 8- Dr.ZX Connector to ICX 13 - Washer Relay (R2)
4- Download Connector (Not 9- Learning Switch 14 - Load Damp Relay (R1)
connected on Satellite
Navigation System equipped
machines)
5 - Diode D1, D2, D3 and D4 10 - Horn Relay (R5) 15 - Wiper Relay A (R6)
T5-2-8
ZAXIS135UR
Behind Seat
1 2 3
Upward
Speaker
T1CF-01-01-011
T1CF-01-01-012
6
7
5 8
4
9
18
10
17
16
15
14
11
12
13
T1CF-01-01-013
1 - Auto - Marccino Control Unit 6 - Fuse Box 11 - Wiper Relay (R6) 15 - Work Right Relay 1 (R4)
2 - MC (Main Controller) 7 - Emergency Evacuation 12 - MC Relay (Optional) 16 - Work Right Relay 2 (R3)
Switch
3 - ICX (Information Controller) 8 - Learning Switch 13 - Air Bleed Relay 17 - Washer Relay (R2)
(R8) (Optional)
4 - Dr. ZX Connector to ICX 9 - Dr. ZX Connector for UR 14 - Horn Relay (R5) 18 - Load Damp Relay (R1)
5 - Dr. ZX Connector to MC 10 - Personal Computer
Connector to ICX
T5-2-9
ELECTRICAL SYSTEM
(Monitors and Switches)
ZAXIS110/110M/120/130/130LCN/125US/135US
1 2
20
19
21
18
3
17
22
16 4
15
5 23
14 24
6
13 7
12 8
25
11
9
10
T178-01-01-012
T178-01-01-013
1- Coolant Temperature 8- Alternator Indicator 15 - Digging Mode Indicator 21 - Auto-Idle/Acceleration

Gauge Selector
2 - Fuel Gauge 9- Hydraulic Oil Filter 16 - Attachment Mode Indicator 22 - Power Mode Switch
Indicator (Optional)
3- Display Selection Switch 10 - *Coolant Level Indicator 17 - Liquid Crystal Display 23 - Travel Mode Switch
4- SET Switch 11 - *Engine Oil Level Indicator 18 - Auto-Idle Indicator 24 - Work Light Switch
5- Work Mode Switch 12 - Engine Oil Pressure 19 - Auto-Acceleration Indicator 25 - Wiper/Washer Switch
Indicator
6- Fuel Level Indicator 13 - Preheat Indicator 20 - Engine Control Dial
7- Air Filter Restriction Switch 14 - Overheat Indicator
NOTE: * ZAXIS110/110M/125US: Up to serial No.010576

ZAXIS120/135US: Up to serial No.062964
T5-2-10
ZAXIS135UR Monitor 6 7
1
8
2 9
3 10
11
24
4 12
23 13
5
22
14
21 15
T1CF-01-01-003
20 16
19 17
18
T1SM-01-02-014
1- Left Offset Switch 7- Fuel Gauge 13 - Auto-Idle / Acceleration 19 - Preheat Indicator

Selector
2- Right Offset Switch 8 - Liquid Crystal Display 14 - Work Light Switch 20 - Air Filter Restriction Switch
3- Prohibited-Area Release 9 - Set Switch 15 - Auto - Marccino Switch 21 - Alternator Indicator
Switch
4 - Engine Control Dial 10 - Display Selection Switch 16 - Washer Switch 22 - Fuel Level Indicator
5 - Key Switch 11 - Power Mode Switch 17 - Wiper Switch 23 - Overheat Indicator
6 - Coolant Temperature 12 - Travel Mode Switch 18 - Hydraulic Oil Filter 24 - Engine Oil Pressure
Gauge Indicator (Optional) Indicator
T5-2-11
PUMP DEVICE
ZAXIS110/110M/120/130/130LCN/125US/135US
3 4
2 1
T176-03-01-002
7 6 5 10 9 8
T176-03-01-001
ZAXIS135UR
3 4 2 1
T1SM-03-01-002
11 7 6 5 10 9 8
T1SM-03-01-001
1 - Pump 1 4- Pump 2 Control Pressure 7- Max. Pump 2 Flow Rate 10 - Pump 2 Delivery Pressure
Sensor Limit Solenoid Valve Sensor
2 - Pump 2 5 - Pump 1 Control Pressure 8 - N Sensor 11 - Blade Pump
Sensor
3 - Pilot Pump 6 - Torque Control Solenoid 9- Pump 1 Delivery Pressure
Valve Sensor
T5-2-12
SWING DEVICE CONTROL VALVE 3
4
1
T176-01-02-003
T176-01-02-002
SIGNAL CONTROL VALVE SOLENOID VALVE UNIT
8
7
9
T176-03-07-002
T178-03-06-015
1 - Pressure Sensor 4- Main Relief Valve 7- Pressure Sensor (Travel) 9- Solenoid Valve Unit (SI)
(Front Attachment) (Except
Swing Device of
ZAXIS135UR)
2 - Swing Relief Valve 5- Pressure Sensor 8- Solenoid Valve Unit (SC)
(Boom Raise)
3 - Pressure Sensor 6 - Pressure Sensor (Swing)
(Arm Roll-In)
T5-2-13
8-UNIT SOLENOID VALVE UNIT BLADE CONTROL VALVE
(ZAXIS135UR Only) (ZAXIS135UR Only)
POSITIONING CONTROL VALVE
1 (2-piece Boom Only)
2
15 3
4
5
14
6
7
13
8
9
12
16
10
T178-03-03-071
T1SM-01-02-003
11
TRAVEL DEVICE
ZAXIS110, 120, 130, 130LCN, 125US, 135US, ZAXIS110M
135UR
18
17
18
T155-01-01-006 T155-01-01-013
17
1 - Pilot Pressure Sensor (E1: 6 - Pilot Pressure Sensor (E4: 11 - Hydraulic Oil Temperature 15 - Solenoid Valve (C3: Boom
Boom Raise) Left Offset Acceleration) Sensor Lower Deceleration)
2 - Solenoid Valve (C1: Boom 7 - Solenoid Valve (C9: Left 12 - Solenoid Valve (C4: Arm 16 - Overload Relief Valve
Raise Acceleration) Offset Acceleration) Roll - In Deceleration) (Blade), (Positioning)
3 - Pilot Pressure Sensor (E2: 8 - Pilot Pressure Sensor (E5: 13 - Solenoid Valve (C8: Left 17 - Travel Relief Valve
Boom Lower) Arm Roll - Out) Offset Deceleration)
4 - Pilot Pressure Sensor (E6: 9 - Solenoid Valve (C7: Arm 14 - Solenoid Valve (C5: Right 18 - Counterbalance Valve
Right Offset Acceleration) Roll - Out Acceleration) Offset Deceleration)
5 - Solenoid Valve (C6: Right 10 - Pilot Pressure Sensor (E3:
Offset Acceleration) Arm Roll - In)
T5-2-14
(Blank)
T5-2-15
COMPONENTS IN CONTROL VALVE
Travel Motor (Left) Travel Motor (Right)
1 2 3 4 5 6 7 8 9 10
11
Auxiliary Bucket Cylinder
(ZX135UR: Offset)
12
40
39
13
38 Boom Cylinder
14
Arm Cylinder
37 15
16
36
17 Blade Cylinder
35 (ZX135UR Only)
34 18
23
Swing Motor 19
22
33
32 20
21
27
24
Main Pump 25
31 30 29 28
Blade Pump
26 (ZX135UR Only)
T1SM-03-03-001
T5-2-16
Control Valve
16
Machine Front
26 ZAXIS125US
ZAXIS135US
ZAXIS135UR
4
29
18, 19
5
21
12
9, 10
Machine Front
ZAXIS110/110M
ZAXIS120
ZAXIS130 T176-03-03-038
ZAXIS130LCN
1 - Load Check Valve 11 - Bucket Regenerative 21 - Bypass Shut-Out Valve 31 - Arm Regenerative Valve
(Travel Tandem Circuit) Valve (Selector Valve)
2 - Load Check Valve 12 - Overload Relief Valve 22 - Overload Relief Valve (Blade: 32 - Arm Regenerative Valve
(Travel Parallel Circuit) (Bucket: Rod Side) Rod Side) (ZX135UR Only)
3 - Check Valve 13 - Overload Relief Valve 23 - Overload Relief Valve (Blade: 33 - Overload Relief Valve
(Main Relief Circuit) (Bucket: Bottom Side) Bottom Side) (ZX135UR Only) (Arm: Bottom Side)
4 - Main Relief Valve 14 - Load Check Valve 24 - Load Check Valve (Blade) 34 - Overload Relief Valve
(Boom 1 Parallel Circuit) (ZX135UR Only) (Arm: Rod Side)
5 - Check Valve 15 - Boom Regenerative Valve 25 - Load Check Valve (Blade 35 - Arm Anti-Drift Valve
(Main Relief Circuit) Tandem Circuit) (ZX135UR (Check Valve)
Only)
6 - Flow Combiner Valve 16 - Overload Relief Valve 26 - Main Relief Valve (Blade) 36 - Arm Anti-Drift Valve
(Boom: Bottom Side) (ZX135UR Only) (Selector Valve)
7 - Check Valve 17 - Overload Relief Valve 27 - Check Valve (Orifice) (Arm 2 37 - Load Check Valve
(Flow Combining Circuit) (Boom: Rod Side) Parallel Circuit) (Boom 2 Parallel Circuit)
8 - Aux. Flow Combining Valve 18 - Boom Anti-Drift Valve 28 - Load Check Valve (Arm 1 38 - Aux. Flow Rate Control
(Check Valve) Parallel Circuit) Valve (Poppet Valve)
9 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 29 - Load Check Valve (Arm 1 39 - Aux. Flow Rate Control
Valve (Selector Valve) (Selector Valve) Tandem Circuit) Valve (Selector Valve)
10 - Bucket Flow Rate Control 20 - Load Check Valve 30 - Load Check Valve 40 - Load Check Valve
Valve (Poppet Valve) (Arm 2 Tandem Circuit) (Swing Circuit) (Bucket Parallel Circuit)
T5-2-17
1 2 3 4 5 6 7 8 9 10
11
(ZX135UR: Offset)
12
40
39
13
38 Boom Cylinder
14
Arm Cylinder
37 15
16
36
17 Blade Cylinder
35 (ZX135UR Only)
34 18
19 23
Swing Motor
22
33
32 20
21
27
24
Main Pump 25
31 30 29 28
Blade Pump
26 (ZX135UR Only)
T1SM-03-03-001
T5-2-18
35, 36
Machine Front
ZAXIS125US
ZAXIS135US
ZAXIS135UR
38, 39
33
Machine Front
ZAXIS110/110M
ZAXIS120
ZAXIS130
ZAXIS130LCN 8 17 T176-03-03-036
13
6 40 7
5 - Check Valve 15 - Boom Regenerative Valve 25 - Load Check Valve (Blade 35 - Arm Anti-Drift Valve
Only)
T5-2-19
1 2 3 4 5 6 7 8 9 10
11
(ZX135UR: Offset)
12
40
13
39
14 Boom Cylinder
38 15
Arm Cylinder 16
37
36 17
Blade Cylinder
35 18 (ZX135UR Only)
34
19 23
Swing Motor
22
33
32 20
21
27
24
Main Pump 25
31 30 29 28
Blade Pump
F 26 (ZX135UR Only)
E T1SM-03-03-001
D Cross Section A
C
B
4
A 5
39
8
7
6
T176-03-03-035
T176-03-03-002
T5-2-20
Cross Section B Cross Section C

Travel (Right) Travel (Left) Bucket Auxiliary (ZX135UR: Offset)
12
1
10 38
9 39
2
11
13
T176-03-03-003
T176-03-03-004
5 - Check Valve 15 - Boom Regenerative 25 - Load Check Valve (Blade 35 - Arm Anti-Drift Valve
(Main Relief Circuit) Valve Tandem Circuit) (ZX135UR (Check Valve)
Only)
T5-2-21
1 2 3 4 5 6 7 8 9 10
11
(ZX135UR: Offset)
12
40
39
13
38 Boom Cylinder
14
Arm Cylinder
37 15
16
36
17 Blade Cylinder
35 (ZX135UR Only)
34 18
19 23
Swing Motor
22
33
32 20
21
27
24
Main Pump 25
31 30 29 28
Blade Pump
26 (ZX135UR Only)
T1SM-03-03-001
Cross Section D Boom 1 Boom 2
19
16
18
14
37
15
17
T176-03-03-005
T5-2-22
Cross Section E Cross Section F

Arm 2 Arm 1 Swing
36
34
31
35
30
20 28
27
29
32
33 21
T176-03-03-007
T176-03-03-006
1- Load Check Valve 11 - Bucket Regenerative 21 - Bypass Shut-Out Valve 31 - Arm Regenerative Valve
5- Check Valve 15 - Boom Regenerative 25 - Load Check Valve (Blade 35 - Arm Anti-Drift Valve
(Main Relief Circuit) Valve Tandem Circuit) (ZX135UR (Check Valve)
Only)
6- Flow Combiner Valve 16 - Overload Relief Valve 26 - Main Relief Valve (Blade) 36 - Arm Anti-Drift Valve
7- Check Valve 17 - Overload Relief Valve 27 - Check Valve (Orifice) (Arm 2 37 - Load Check Valve
8 - Aux. Flow Combining 18 - Boom Anti-Drift Valve 28 - Load Check Valve (Arm 1 38 - Aux. Flow Rate Control
Valve (Check Valve) Parallel Circuit) Valve (Poppet Valve)
T5-2-23
1 2 3 4 5 6 7 8 9 10
11
(ZX135UR: Offset)
12
40
39
13
38 Boom Cylinder
14
Arm Cylinder
37 15
16
36
17 Blade Cylinder
35 (ZX135UR Only)
34 18
19 23
Swing Motor
22
33
32 20
21
27
24
Main Pump 25
31 30 29 28
Blade Pump
26 (ZX135UR Only)
T1SM-03-03-001
T5-2-24
Blade Control Valve (ZAXIS135UR Only)
Positioning Control Valve (2-piece Boom Only)
Cross Section X-X
X
22
24
25
23
X
T198-03-03-002 T198-03-03-003
1- Load Check Valve 11 - Bucket Regenerative 21 - Bypass Shut-Out Valve 31 - Arm Regenerative Valve
5- Check Valve 15 - Boom Regenerative Valve 25 - Load Check Valve (Blade 35 - Arm Anti-Drift Valve
Only)
6- Flow Combiner Valve 16 - Overload Relief Valve 26 - Main Relief Valve (Blade) 36 - Arm Anti-Drift Valve
7- Check Valve 17 - Overload Relief Valve 27 - Check Valve (Orifice) (Arm 2 37 - Load Check Valve
8 - Aux. Flow Combining 18 - Boom Anti-Drift Valve 28 - Load Check Valve (Arm 1 38 - Aux. Flow Rate Control
Valve (Check Valve) Parallel Circuit) Valve (Poppet Valve)
T5-2-25
SIGNAL CONTROL VALVE PORT
LOCATION
Pilot Valve Side

PH
C
A
E
M
D
H
B
F
SB
PI G
Pilot Valve Side
K N
I
SH
J
DF
SA L
T178-03-06-016
T5-2-26
Pilot Valve Side

Port Name Connecting to Note
Port A Right Pilot Valve Boom Raise Pilot Pressure
Port B Right Pilot Valve Boom Lower Pilot Pressure
Port C Left Pilot Valve Arm Roll-Out Pilot Pressure
Port D Left Pilot Valve Arm Roll-In Pilot Pressure
Port E Left Pilot Valve Left Swing Pilot Pressure
Port F Left Pilot Valve Right Swing Pilot Pressure
Port G Right Pilot Valve Bucket Roll-In Pilot Pressure
Port H Right Pilot Valve Bucket Roll-Out Pilot Pressure
Port I Travel Pilot Valve Left Travel Forward Pilot Pressure
Port J Travel Pilot Valve Left Travel Reverse Pilot Pressure
Port K Travel Pilot Valve Right Travel Forward Pilot Pressure
Port L Travel Pilot Valve Right Travel Reverse Pilot Pressure
Port M Auxiliary Pilot Valve Auxiliary Open Pilot Pressure
(ZAXIS135UR : Offset Pilot Valve) (ZAXIS135UR : Left Offset Pilot Pressure)
Port N Auxiliary Pilot Valve Auxiliary Close Pilot Pressure
(ZAXIS135UR : Offset Pilot Valve) (ZAXIS135UR : Right Offset Pilot Pressure)
Port SA Pump 1 Regulator Pump 1 Control Pressure
Port SB Pump 2 Regulator Pump 2 Control Pressure
Port PI Pilot Shut-Off Valve Primary Pilot Pressure
Port PH Pilot Shut-Off Valve Primary Pilot Pressure (Heating Circuit)
Port SH Swing Parking Brake Brake Release Pressure
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank
T5-2-27
Control Valve Side

SM
3
1 5
13
2 4
SK
SE
Pressure Sensor 8
(swing)
14
Control Valve Side 7
9
6
10
SN
SL
11
Pressure Sensor 12 SP T178-03-06-015

(Travel)
T5-2-28
Control Valve Side

Port Name Connecting to Note
Port 1 Control Valve Boom Raise Pilot Pressure
Port 2 Control Valve Boom Lower Pilot Pressure
Port 3 Control Valve Arm Roll-Out Pilot Pressure
Port 4 Control Valve Arm Roll-In Pilot Pressure
Port 5 Control Valve Left Swing Pilot Pressure
Port 6 Control Valve (ZAXIS135UR: Right Swing Pilot Pressure
Offset Anti-Drift Valve)
Port 7 Control Valve Bucket Roll-In Pilot Pressure
Port 8 Control Valve Bucket Roll-Out Pilot Pressure
Port 9 Control Valve Left Travel Forward Pilot Pressure
Port 10 Control Valve Left Travel Reverse Pilot Pressure
Port 11 Control Valve Right Travel Forward Pilot Pressure
Port 12 Control Valve Right Travel Reverse Pilot Pressure
Port 13 Control Valve Auxiliary Open Pilot Pressure
(ZAXIS135UR : Left Offset Pilot Pressure)
Port 14 Control Valve Auxiliary Close Pilot Pressure
(ZAXIS135UR : Right Offset Pilot Pressure)
Port SE - Plug
Port SM Hydraulic Oil Tank (ZAXIS135UR : Returning to Hydraulic Oil Tank (ZAXIS135UR :
Offset Anti-Drift Valve) Offset Pilot Pressure)
Port SN - Plug
Port SP Solenoid Valve Unit Returning to Hydraulic Oil Tank
Port SL Control Valve Flow Combiner Valve Control Pressure
Port SK Control Valve Bucket Flow Rate Control Valve Control Pressure
T5-2-29
(Blank)
T5-2-30
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault
codes are displayed after diagnosing the main con-
troller (MC) using Dr. ZX (or the built-in diagnosing
system).
• How to Read Troubleshooting Flow Charts
YES(OK)
(2)
(1) After completing the checking and/or measuring procedures in box
・ (1) (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
(3)
NO(NOT OK)
Instructions, reference, and/or inspection methods and/or measurements are occasionally

・
described under the box. If incorrectly checked or measured, not only will troubleshooting
· Key switch: ON be unsuccessful but also damage to the components may result.
・ Refer to “Electrical System Inspection” Group (Group 6) for descriptions in the dotted-line
box.
・ Use Dr. ZX (or the built-in diagnosing system) for descriptions in the double-line box.
・ Causes of machine problems are stated in the thick-line box. Scanning quickly through the
thick-line boxes allows you to estimate the possible causes before actually following the
flow chart.
NOTE: All harness end connectors are seen from

the open-end side.
Harness
Open End
Side
Harness End Connector
T158-05-03-001
T5-3-1
FAULT CODE LIST
Fault code Problem Cause
01 Abnormal EEPROM • Faulty MC
02 Abnormal RAM
04 Abnormal Sensor Voltage • Faulty MC
• Faulty Harness
• Faulty Sensor
06 Abnormal EC Sensor • Faulty MC
• Faulty Harness
• Faulty EC Sensor
07 Abnormal Engine Control Dial Angle • Faulty MC
• Faulty Harness
• Faulty Engine Control Dial
10 Abnormal Pump 1 Delivery Pressure • Faulty MC
11 Abnormal Pump 2 Delivery Pressure • Faulty Harness
• Faulty Pump Delivery Pressure Sensor
12 Abnormal Pump1 Pump Control Pressure • Faulty MC
13 Abnormal Pump2 Pump Control Pressure • Faulty Harness
• Faulty Pump Control Pressure Sensor
14 Abnormal Swing Lever Stroke • Faulty MC
15 Abnormal Boom Raise Lever Stroke • Faulty Harness
16 Abnormal Arm Roll-In Lever Stroke • Faulty Pilot Pressure Sensor
18 Abnormal Travel Lever Stroke
19 Abnormal Oil Temperature • Faulty MC
• Faulty Harness
• Faulty Oil Temperature Sensor
T5-3-2
FAULT CODE 01 (ABNORMAL EEPROM)
FAULT CODE 02 (ABNORMAL RAM)
FAULT CODE 03
(ABNORMAL A/D CONVERSION)
YES * Faulty MC.
Check if engine and machine

actuators operate normally. · Refer to T4-6-6.
Faulty MC.
NO
· Refer to T4-6-6.
* Even if any fault codes are still displayed after re-
trying, as long as the engine and machine operate
normally, the machine can be operated as it is.
FAULT CODE 04
(ABNORMAL SENSOR VOLTAGE)
YES Faulty sensor.

Disconnect connectors from
all sensors relating to the in-
dicated fault code, and retry. Short-circuited harness be-
Does fault code 04 disappear? tween MC and sensor in
Disconnect all con- section where continuity is
nectors from MC. YES
present.
Is there continuity be-
tween terminals #1 and
NOTE: If fault code 04 #3 of harness at each
(abnormal sensor NO sensor?
voltage) appears,
Faulty MC.
other fault codes
NO
appear at the same · Key switch: OFF
time. · Refer to T4-6-1.
T5-3-3
FAULT CODE 06
(ABNORMAL EC SENSOR)
Faulty harness between

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

Slow Idle 2.5 to 2.7 V Open End Side)
Fast Idle (HP mode 3.3 to 3.7 V
Switch: OFF)
MC Connector C
Fast Idle (HP mode Voltage at Fast Idle (HP Mode
Switch: ON) Switch: OFF) plus 0.2 V or C1 C10
more
C23 C31
#18
EC Sensor
1 2 3
T5-3-4
FAULT CODE 07 Faulty harness be-
(ABNORMAL ENGINE CONTROL DIAL Check harness between MC and engine
ANGLE) tween MC connector C control dial.
(31P) harness end ter- YES
minal #6 and switch
NOTE: The terminal NO. in parenthesis is for
YES panel terminal #3 (#2)
ZAXIS135UR. Disconnect switch for breakage or short
panel. Check if voltage circuit. Faulty MC.
Disconnect switch panel.
Check if resistance be- between harness end
tween switch panel side connector terminals #2 NO
· Refer to 4-6-6.
connector terminals #2 (#1) YES (#1) and #4 (#3) is
and #4 (#3) is 5±0.5 kΩ. 5±0.5 V.
Broken harness be-
Reconnect switch panel. Check if voltage be- YES tween MC and engine
Insert tester probe into tween switch panel control dial terminal
connector terminal #3 (#2) harness end connector #4 (#3).
from the reverse side. terminal #2 (#1) and ve-
Check if voltage varies as · Key switch: ON NO hicle frame matches
specified when engine con- specification.
trol dial is turned.
Broken harness be-
tween MC and engine
NO control dial terminal
#2 (#1).
· Key switch: ON
· Specification: Refer to the Faulty engine control

table below. dial.
NO
Engine Control Dial Specification

Maximum Speed 4.0 to 4.7 V
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#6
C1 C10
C23 C31
Switch Panel #3 #1
#4 #2
T5-3-5
FAULT CODE 10
(ABNORMAL PUMP 1 DELIVERY PRES-
SURE)
FAULT CODE 11
(ABNORMAL PUMP 2 DELIVERY PRES-
SURE)
Checking Instruction
• Both pump 1 and pump 2 delivery pressure sen-
sors seldom fail at the same time. Accordingly, if
both fault codes 10 and 11 are displayed simulta- Faulty harness be-
neously, faulty harness may be the cause of this Check harness between MC and pump
problem. tween MC connector C delivery pressure
(31P) harness end ter-
YES sensor.
minal #1 (pump 1) or
#4 (pump 2) and pump
YES delivery pressure sen-
sor terminal #2 for
breakage or short cir-
Faulty MC.
cuit.
Disconnect pump de- NO
livery pressure sensor.
Check if voltage be- · Refer to T4-6-6.
tween harness end
NO connector terminals #1 Broken harness be-
and #3 is 5±0.5 V. tween MC and pump
Check if voltage be- delivery pressure
Check if fault codes are tween pump delivery YES sensor terminal #3.
switched after switching pressure sensor har-
pump 1 delivery pressure ness end connector
sensor with pump 2 de- · Key switch: ON terminal #1 and vehicle
livery pressure sensor frame matches speci-
NO Broken harness be-
and retrying. fication. tween MC and pump
delivery pressure
NO sensor terminal #1.
· Key switch: ON
· Specification: 5±0.5 V Faulty pump delivery
pressure sensor.
YES
MC Connector C
#1 #4
C1 C10
C23 C31
Pump Delivery Pressure Sensor
3 2 1
T5-3-6
FAULT CODE 12
(ABNORMAL PUMP 1 CONTROL PRES-
SURE)
FAULT CODE 13
(ABNORMAL PUMP 2 CONTROL PRES-
SURE)
Checking Instruction
• Both pump 1 and pump 2 control pressure sen-
sors seldom fail at the same time. Accordingly, if
both fault codes 12 and 13 are displayed simul-
taneously, faulty harness may be the cause of Check harness be- Faulty harness be-
this problem. tween MC connector C tween MC and pump
(31P) harness end ter- control pressure sen-
minal #7 (pump 1) or
YES sor.
#13 (pump 2) and
pump control pressure
YES sensor terminal #2 for
breakage or short cir-
cuit.
Disconnect pump con- Faulty MC.

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

pressure sensor.
YES
MC Connector C
#13 #7
C1 C10
C23 C31
Pump Control Pressure Sensor
1 2 3
T5-3-7
FAULT CODE 14
(ABNORMAL SWING PILOT PRESSURE)
FAULT CODE 15
(ABNORMAL BOOM RAISE PILOT
PRESSURE)
FAULT CODE 16
(ABNORMAL ARM ROLL-IN PILOT Check harness be-
Faulty harness be-
PRESSURE) tween MC connector C
(31P) harness end tween MC and
FAULT CODE 18 each corresponding
YES pressure sensor.
(ABNORMAL TRAVEL PILOT PRESSURE) terminal and pressure
YES sensor terminal #2 for
Checking Instruction breakage or short cir-
• All pressure sensors seldom fail at the same time. cuit. Faulty MC.
Accordingly, if fault codes 14, 15, 16, and 18 are NO
displayed simultaneously, faulty harness may be · Refer to T4-6-6.
the cause of this problem.
Connector C Terminal:
Disconnect pressure #14: Pressure Sensor (Swing)
sensor. Check if volt- #2: Pressure Sensor
NO age between harness (Boom Raise)
end connector termi- #5: Pressure Sensor
nals #1 and #3 is 5±0.5 (Arm Roll-In)
V. #3: Pressure Sensor
(Travel)
Check if fault code dis-
Broken harness be-
appears after switching
· Key switch: ON tween MC and
pressure sensor with an-
pressure sensor ter-
other pressure sensor Check if voltage be- minal #3.
and retrying. tween pressure YES
sensor harness end
connector terminal #1
and vehicle frame
NO matches specification. Broken harness be-
tween MC and
Fault Code: pressure sensor ter-
14: Pressure Sensor (Swing) NO
minal #1.
15: Pressure Sensor
(Boom Raise) · Key switch: ON
16: Pressure Sensor · Specification: 5±0.5 V
(Arm Roll-In)
18: Pressure Sensor Faulty pressure sen-
(Travel) sor.
YES
MC Connector C
#2 #3 #5
C1 C10
C23 C31
#14
Pilot Pressure Sensor
1 2 3
T5-3-8
FAULT CODE 19
(ABNORMAL OIL TEMPERATURE)
Connect oil tempera-

ture sensor harness Faulty MC.
YES
end connector terminal
#1 to #2 with a clip.
Remove connector B · Refer to T4-6-6.
(25P) and connector C
(31P) from MC. Check Broken harness be-
Connect MC connec- tween MC and oil
YES for continuity between
tor B (25P) harness YES temperature sensor
connector B harness
end terminal #22 to terminal #1.
end terminal #22 and
vehicle frame. Check
connector C terminal
for continuity between
#24.
Disconnect oil tempera- oil temperature sensor
ture sensor. Check if NO harness end connec-
sensor side connector tor terminal #2 and Broken harness be-
resistance matches vehicle frame. tween MC and oil
specification. temperature sensor
NO terminal #2.
· Specification: Refer to
the table below.
Faulty oil temperature
sensor.
NO
Oil Temperature Specification Connector (Harness End Connector Viewed from the Open End Side)
Oil Temperature Resistance
(°C) (kΩ) MC Connector B
−20 16.2±1.6 B8
B1
0 (5.88)
20 2.45±0.24
40 (1.14)
60 (0.534) B19 B25
80 0.322 #22
MC Connector C
C1 C10
C23 C31
#24
Oil Temperature Sensor
1 2
T5-3-9
(Blank)
T5-3-10
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code
is displayed on the Dr.ZX (or the built-in diagnosing
system) although the machine’s operation is
abnormal.
On the front section pages of this group T5-4, are
tables indicating the relationship between machine
trouble symptoms and related parts which may cause
such trouble if failed.
Start the troubleshooting with more probable causes
selected by referring to these tables.
• How to Read the Troubleshoting Flow Charts
YES(OK)
(2)
• After checking or measuring item (1), select either YES (OK) or
・ (1) NO (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO(NOT OK)
・ • Special instructions or reference item are indicated in the spaces under the box.
Incorrect measuring or checking methods will render troubleshooting impossible,
· Key switch: ON and may damage components as well.
• Explanation of how to use test harness kit required. Refer to “Electrical System
・
Inspection” Group (Group 7) in this section.
・ • Use Dr.ZX (or the built-in diagnosing system) function.
・ • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
T5-4-1
RELATIONSHIP BETWEEN MACHINE
TROUBLE SYMPTOMS AND RELATED
PARTS
This table indicates the relationship between machine
trouble symptoms and the potential problem parts,
which may cause trouble if failed, and the evaluation
methods of these components.
Parts
EC Motor EC Sensor
• Moves governor. • Detects minimum governor speed position (2.5
V) only when key switch is turned ON.
• Detects minimum and maximum speed posi-
tion when engine learning is conducted.
Function
• Governor lever doesn’t move. • Engine speed is controlled based on idle posi-
tion set when key switch is turned ON. There-
Symptoms in control fore, engine speed is always controlled with
system when trouble error in idle position setting if set incorrectly.
occurs.
• Even if engine control dial is turned, engine • Error in setting will seldom occur so that
speed doesn’t increase from slow idle speed. change in machine operation will not be no-
• Engine start may be difficult though starter ro- ticed.
tates. • In case error is set on lower side, engine
• Engine will stall if discontinuity occurs in EC speed changes but runs slower than normal
motor while engine is running at more than a through the full range when engine control dial
specified speed. is turned. (Note: In case error is set on upper
• Engine will become uncontrollable if disconti- side, EC motor is driven so that it runs faster
nuity occurs in EC motor while engine is run- than the control range. However, motor, a
ning at lower than a specified speed. Engine worm gear type, holds governor lever at
cannot be stopped with key switch. maximum constant position, preventing engine
Symptoms in machine stall. When engine control dial is turned to
operation when trouble minimum speed position, governor lever is re-
occurs. turned to idle position.)
• When starting engine, engine speed fluctuates.
• Starting engine is occasionally difficult.
By Fault Code Fault code 06 is displayed.


Monitor Item: EC Angle (Displayed by built-in di-
By Monitor agnostic system)

Evalua-
Function
tion • Install lamp harness (ST 7125) to check EC
Using Test output signal and harness for any abnormality.

Harness
Others  
• Engine is stopped by EC motor. (Engine stop • If EC sensor is faulty, engine learning is not
motor is not provided.) performed.
NOTE • Fuel cut-off cable is provided.
Descriptions of Control T2-1 T2-1

(Operational Principle
Section in T/M)
T5-4-2
Engine Control Dial Pump Control Pressure Sensor Pump 1 Delivery Pressure Sensor
• Indicates governor lever position (engine • Monitors pump control pressure to con- • Monitors pump delivery pressure to con-
target speed). trol auto-acceleration system and travel trol HP mode, auto-acceleration, and
motor swash angle controls. travel motor swash angle controls.
• Engine speed doesn’t change even if • No signals arrive to MC • If pump delivery pressure sensor output
engine control dial is turned. is 0 or 5 V, following symptoms will be
• If discontinuity or short circuit occurs in presented by back-up mode function.
engine control dial, target speed of 1400
-1
min is used as back-up value.
• Engine speed is kept unchanged from • Auto-acceleration control is inoperable • HP mode is inoperable.
-1
1400 min . (Auto-idle system functions. (but not noticeable). • Auto-acceleration control is inoperable.
Engine can be stopped by key switch.) • Travel speed is kept in slow mode, not • Travel speed is kept in slow mode, not
allowing to automatically change to fast allowing to automatically change to fast
mode. mode.
Fault code 07 is displayed. Fault codes 12 and 13 are displayed. Fault codes 10 is displayed.
Monitor Item: Engine Target Speed, Dial Monitor Item: Pump 1 and 2 pump control Monitor Item: Pump 1 delivery pressure
Angle (Displayed by built-in diagnostic pressure (Displayed by built-in diagnostic (Displayed by built-in diagnostic system)
system) system)
  
  
• Evaluation by Dr. ZX
Broken Circuit: 0.25 V or less
 Short Circuit: 4.75 V or more 
T2-1 T2-1 T2-1
T5-4-3
Parts Pump 3 Delivery Pressure Sensor

Pump 2 Delivery Pressure Sensor
(Optional)
• Monitors pump delivery pressure to control • Monitors pump delivery pressure to control
HP mode, auto-acceleration, arm regenera- pump 3 torque decrease control.
tive and travel motor swash angle control.
Function
• If pump delivery pressure sensor output is • Engine stalls if pump torque is increased.
Symptoms in control system 0 or 5 V, following symptoms will be pre-
sented by back-up mode function.
when trouble occurs.
• HP mode is inoperable. • Engine stalls if pump torque is increased.

• Auto-acceleration control is inoperable.
• Arm is slow when arm roll-in and swing
combined operation is made.
• Travel speed is kept in slow mode, not al-
lowing to automatically change to fast
mode.
Symptoms in machine opera-

tion when trouble occurs.
By Fault Code Fault codes 11 is displayed. 

Monitor Item: Pump 2 delivery pressure (Dis-
played by built-in diagnostic system)
By Monitor Func-

Evaluation
tion
Using Test Harness  

Others  
NOTE  
Descriptions of Control (Opera- T2-1 T2-1

tional Principle Section in T/M)
T5-4-4
Pressure Sensor
Pressure Sensor (Travel) Pressure Sensor (Swing)
(Front Attachment)
• Monitors travel pilot pressure to control • Monitors front attachment pilot pressure • Monitors swing pilot pressure to control
auto-idle, auto-acceleration, idle to control auto-idle, and idle speed in- arm regenerative systems.
speed-up, and travel motor swash angle crease systems.
controls.
• No signals arrive to MC • No signals arrive to MC • No signals arrive to MC
• Engine speed doesn’t increase even if • Engine speed doesn’t increase even if • Since arm regenerative function is inop-
auto-idle/auto-acceleration selector is any front attachment actuator is oper- erable, when swing/arm roll-in combined
auto-idle position. ated with auto-idle/auto-acceleration se- operation is made, initial arm moving
• Engine speed doesn’t increase even if lector is auto-idle position. speed is slow. (Not remarkable)
auto-idle/auto-acceleration selector is • Occasionally, engine speed hunts while • During arm level crowding operation,
auto-acceleration position. operating front attachment at slow idle. arm speed is slightly slow.
• Occasionally, engine speed hunts while
traveling at slow idle.
• Fast travel mode cannot be selected
even if travel mode switch is turned to
the FAST position.
Fault code 18 is displayed.  Fault code 14 is displayed.

Monitor Item: Travel Control Pressure (dis- Monitor Item: Front Attachment Operation Monitor Item: Swing Control Pressure (dis-
played built-in diagnostic system). (displayed built-in diagnostic system). played built-in diagnostic system).
Monitor pressure change while traveling Monitor pressure change while operating Monitor pressure change while swinging
machine. front attachment. upperstructure.
  
  
• Judge if pressure sensor is faulty or port • Judge if pressure sensor is faulty or port • Judge if pressure sensor is faulty or port
is clogged by switching pressure sensor is clogged by switching pressure sensor is clogged by switching pressure sensor
with another pressure sensor. with another pressure sensor. with another pressure sensor.
T2-1 T2-1 T2-1
T5-4-5
Parts
Pressure Sensor Pressure Sensor
(Boom Raise) (Arm Roll-In)
• Monitors boom raise pilot pressure to control • Monitors arm roll-in pilot pressure to control
HP mode, auto-acceleration, and arm regen- HP mode, auto-acceleration, and arm regen-
erative controls. erative controls.
Function
• No signals arrive to MC • No signals arrive to MC
Symptoms in control sys-

tem when trouble occurs.
• Even if boom is raised with HP mode switch • Even if boom is raised with HP mode switch
ON, engine speed doesn’t increase. ON, engine speed doesn’t increase.
• Even if boom is raised with • Even if boom is raised with
auto-idle/auto-acceleration selector is auto-idle/auto-acceleration selector is
auto-acceleration position, engine speed auto-acceleration position, engine speed
doesn’t increase. doesn’t increase.
• Arm roll-in speed becomes slightly slower • Arm speed is slow in arm level crowd opera-
Symptoms in machine op- than normal in boom raise and arm roll-in tion.
eration when trouble oc- combined operation as arm regenerative sys-
tem doesn’t work. (Not remarkable)
curs. • Arm roll-in and boom raise speeds become
slightly slower at the beginning stage of arm
level crowd operation.
By Fault Code Fault Code 15 is displayed. Fault code 16 is displayed.
By Monitor Func- Monitor Item: Boom Raise Pilot Pressure (dis- Monitor Item: Arm Roll-In Pilot Pressure (dis-
played built-in diagnosing system). played built-in diagnosing system).
tion Monitor pressure change while raising boom. Monitor pressure change while rolling arm in.
Evalua-
tion
Using Test Har-
 
ness
Others  
• Judge if pressure sensor is faulty or port is • Judge if pressure sensor is faulty or port is
clogged by switching pressure sensor with clogged by switching pressure sensor with
another pressure sensor. another pressure sensor.
NOTE

(Operational Principle Sec-
tion in T/M)
T5-4-6
Pressure Sensor (Auxiliary)

Torque Control Solenoid Valve Solenoid Valve Unit (SC)
(Optional)
• Monitors attachment pilot pressure when • Supplies control pressure to pumps 1 • Routes return oil from arm cylinder rod
attachment is installed to control at- and 2 to control speed sensing. side to bottom side when rolling arm in
tachment operation speed increase, to increase arm speed.
pump 1 and pump 2 flow rate limit, and
auxiliary flow rate controls.
• No signals arrive to MC • If torque control solenoid valve is not • In case solenoid valve unit (SC) is not
activated, output pressure from solenoid activated, pressure at port SC becomes
2 2
valve is 0 MPa (0 kgf/cm ). 0 MPa (0 kgf/cm ). Arm regenerative
valve will not operate at this time.
• Engine speed doesn’t increase when • Even if speed sensing system doesn’t • Solenoid valve unit (SC) is closed:
attachment is operated. work, upper limit power is restricted so • Arm speed is slow in arm level crowd
• When attachment is operated, operation that machine is operable. operation.
speed increases. • Solenoid valve unit (SC) is open:
• As the arm regenerative valve is always
operated, arm speed is fast.
  
Monitor Item: ATT Control Pressure (dis- Monitor Item: Pump Torque Proportional Monitor Item: Arm Regenerative Propor-
played built-in diagnosing system). Solenoid Valve Output tional Sol. Valve Output
Monitor pressure change while operating
attachment.
• Install lamp harness (ST 7226) to check

output signals from MC and harness
  condition.
  
• Judge if pressure sensor is faulty or port
is clogged by switching pressure sensor
with another pressure sensor.
 
T2-1 T2-1 T2-1
T5-4-7
Parts Max. Pump 1 Flow Rate Limit Solenoid

Solenoid Valve Unit (SI)
Valve (Optional)
• When pump delivery pressure is low in fast • When operating attachment, limits maximum
travel mode, travel motor swash angle is re- pump 1 flow rate.
duced to increase travel speed.
Function
• Fast travel mode cannot be selected. • In case max. pump 1 flow rate limit solenoid
valve is not activated, pressure at output port
2
becomes 0 MPa (0 kgf/cm ).
Symptoms in control sys-
tem when trouble occurs.
• Solenoid valve unit (SI) is closed: • Max. pump 1 flow rate limit solenoid valve is
• Even if travel mode switch is turned to FAST closed:
position, fast travel mode cannot be selected. • When operating attachment, operating speed
• Solenoid valve unit (SI) is open: doesn’t decrease.
• Travel speed is always fast. • Max. pump 1 flow rate limit solenoid valve is
open:
• Right travel, bucket, arm and boom speeds
Symptoms in machine op- become slow as the max. flow of pump 1 de-
eration when trouble oc- creases.
curs. • Machine mistracks to the right when traveling.
By Fault Code  
By Monitor
 
Function
Evaluation
Using Test • Install lamp harness (ST 7226) to check out-
put signals from MC and harness condition.
Harness 
Others  
NOTE  
T2-1 T2-1
Descriptions of Control
tion in T/M)
T5-4-8
Max. Pump 2 Flow Rate Auxiliary Flow Rate Control Hydraulic Oil Tempera-
N Sensor
Limit Solenoid Valve Solenoid Valve (Optional) ture Sensor
• When operating attachment, • Restricts oil flow to auxiliary • Monitors engine speed to • Monitors hydraulic oil tem-
limits maximum pump 2 flow spool during a combined op- operate engine speed sens- perature to control
rate. eration to improve operability. ing control. auto-warming up and arm
regenerative control.
• In case max. pump 2 flow rate • In case auxiliary flow rate con- • Speed sensing control is in- • If circuit breakage occurs,
limit solenoid valve is not ac- trol solenoid valve is not acti- operable. system operates as if hy-
tivated, pressure at output vated, pressure at output port draulic oil temperature is
2
port becomes 0 MPa (0 becomes 0 MPa (0 kgf/cm ). 40 °C (Dr. ZX or monitor
2
kgf/cm ). will not indicate 40 °C in
diagnosis operation).
• Max. pump 2 flow rate limit • If valve is bound closed, at- • Engine stalls under adverse • Even if oil temperature is
solenoid valve is closed: tachment speed will become operating conditions such as lower than 0 °C,
• When operating attachment, slow. at high altitude. auto-warming up control
operating speed doesn’t de- • If valve is bound open, boom doesn’t operate so that en-
crease. will not move in 3-combined gine runs at idle speed
• Max. pump 2 flow rate limit operation of boom raise. when engine is started.
solenoid valve is open: • When oil temperature is
• Left travel, arm, boom and lower than 10 °C, arm re-
swing speeds become slow generative control is inop-
as the max. flow of pump 2 erable.
decreases.
• Machine mistracks to the left
when traveling.
Fault code 19 is displayed.

  
Monitor Item: Actual engine Monitor Item: Hydraulic Oil
speed (If N sensor fails, engine Temperature
  speed is not measured.)
   
   
• Even if signals from N sensor
are not delivered due to bro-
ken circuit or poor sensor in-
stallation, few changes in
operational performance oc-
  cur, making troubleshooting 
difficult. Use monitor func-
tion.
T2-1 T2-1 T2-1 T2-1
T5-4-9
Parts
Engine Learning Switch Travel Mode Switch MC
• Starts engine learning. • Changes travel mode. • Controls engine, pump, and
• ON: 0V→Learning • Fast Mode: 0V valve operation.
• OFF: 5V→Normal Control • Slow Mode: 5V
Function
• Engine learning is not per- • Broken Circuit in Switch: Travel • Depending on trouble situations,
formed. speed remains unchanged in control system malfunction may
slow mode (5V). differ. (The following symptoms
• Short Circuit in Switch: Travel in machine operation indicates
speed remains unchanged in that MC logic circuit has failed.)
Symptoms in control fast mode (0V).
system when trouble
occurs.
• Engine learning: • Even if travel mode switch is • Even if key switch is turned ON,
• Machine will operate nor- turned to the FAST position, fast step motor will not move to the
mally problem is caused by travel mode cannot be selected. START position so that engine
broken circuit or discontinu- • Even if travel mode switch is cannot start. Even though en-
ity of switch. (Only learning turned to the slow position, gine starts, speed stays slow.
cannot be performed.) travel speed is fast. • Since pump displacement is
• If short circuit occurs, held at minimum, all actuator
learning mode operation speeds are slow.
Symptoms in machine starts when key switch is
operation when trou- turned ON. Therefore, en-
gine will stall at 2 second or
ble occurs. 20 seconds after engine
starts.
Fault codes 01, 02, and 03 are

By Fault displayed. Other fault codes may
  be displayed.
Code
Evalua- By Monitor Monitor Item: Engine Learning Monitor Item: Travel Mode
tion Function 
Using Test   
Harness
Others   
• Before suspecting a failure in
MC, be sure to check the fuses
in control system. If any sensor
in 5 V system is short-circuited,
NOTE   all sensor fault codes will be dis-
played.
Descriptions of Con- T2-1 T2-1

trol (Operational Prin- 
ciple Section in T/M)
T5-4-10
Auto-Idle/Auto-Acceleratio Auto-Idle/Auto-Acceleration Power Mode Switch Power Mode Switch

n Selector (Auto-Idle) Selector (HP Mode) (E Mode)
• Activates auto-idle control.
(Auto Acceleration)
• Activates auto-acceleration • Activates HP mode control. • Selects E mode.
• ON: 0 V → Auto-idle is oper- control. • ON: 0 V → HP mode is op- • ON: 0 V → E mode
able. • ON: 0 V → Auto-acceleration is erable. • OFF: 5 V → Normal
• OFF: 5 V → Inoperable. operable. • OFF: 5 V → Normal
• OFF: 5 V → Inoperable.
• Broken Circuit: Auto-idle sys- • Broken Circuit: • Broken Circuit: Even if HP • Broken Circuit: Even if E
tem is inoperable. Auto-acceleration control is mode is selected, HP mode mode is selected, engine
• Short Circuit: Even if inoperable. is inoperable. speed doesn’t decrease.
auto-idle/auto-acceleration • Short Circuit: Even if • Short Circuit: Even if HP • Short Circuit: Engine
selector is OFF, auto-idle con- auto-idle/auto-acceleration se- mode switch is turned OFF, speed doesn’t increase to
trol is always performed. lector is OFF, auto-acceleration HP mode system is not de- the maximum. Auto-idle
control is always performed. activated. Attachment speed control is inoperable.
increase control (optional)
becomes inoperable.
• Same as described above. • Same as described above. • Same as described above. • Same as described above
   
Monitor Item: Monitor Item: Monitor Item: E/P/HP Mode Monitor Item: E/P/HP Mode
Auto-Idle/Auto-Accel Switch Auto-Idle/Auto-Accel Switch Switch Switch
   
   
   
T2-1 T2-1 T2-1 T2-1
T5-4-11
Parts Work Mode Switch Work Mode Switch Auxiliary Mode Switch
(Digging Mode) (Attachment Mode) (Optional)
• Allows normal control to be • Functions only when optional • Functions only when optional
performed. attachment kit is equipped. (At- attachment kit is equipped. (At-
tachment operation speed in- tachment operation speed in-
Function crease/limit control) crease/limit control)
• In response to operation of the • In response to operation of the

auxiliary valve, engine speed auxiliary valve, engine speed
related to the attachment is con- related to the attachment is con-
trolled. trolled.
Symptoms in control
system when trouble ―
occurs.
• Even if auxiliary valve is oper- • Even if auxiliary valve is oper-

ated, engine speed doesn’t in- ated, engine speed doesn’t in-
crease. crease.
• Even if attachment mode is se- • Even if attachment mode is se-
lected, maximum engine speed lected, maximum engine speed
doesn’t decrease. doesn’t decrease.
Symptoms in machine
operation when trou- ―
ble occurs.
By Fault   
By Monitor Monitor Item: Work Mode Monitor Item: Work Mode Switch
Switch 
Evalua- Function
tion Using Test   
Harness
Others   
NOTE   
Descriptions of Con- T2-1 T2-1 T2-1

trol (Operational Prin-
T5-4-12
Bucket Flow Rate Con- Auxiliary Flow Rate Boom Regenerative

Flow Combiner Valve
trol Valve Control Valve Valve
• Supplies hydraulic oil to both • Restricts oil flow to bucket • To be shifted by pilot pres- • Prevents boom cylinder hesi-
right and left travel spools during 3-combined operation sure from auxiliary flow rate tation by routing return oil
from pump 1 during com- of bucket, arm roll-in, and control solenoid valve. from boom cylinder bottom
bined operation of travel and boom raise to allow boom to side to rod side.
front/swing. raise.
• During combined operation • If switch valve is bound with • If spool is bound or spring is • If check valve is kept closed,
of travel and front/swing, in- valve activated, bucket cir- broken, orifice doesn’t vary. boom is not smoothly low-
sufficient oil is supplied to left cuit is always restricted. ered.
travel spool. • If check valve is kept open,
machine cannot be raised off
ground with front attachment.
• While traveling, when • If poppet valve is bound at • If bound at fully closed posi- • Same as described above.
front/swing lever is operated, fully closed position or if tion, attachment speed be-
machine mistracks to the left. switch valve is bound when comes slow.
poppet valve is fully closed, • If bound at fully opened posi-
bucket speed becomes slow. tion, boom doesn’t move dur-
• If poppet valve is bound at ing 3-combined operation of
fully opened position or if swing, arm roll-in, and boom
switch valve is bound when raise.
poppet valve is fully opened,
boom doesn’t move during
3-combined operation of
bucket, arm roll-in, and boom
raise.
   
   
   
   
   
T3-3 T3-3 T3-3 T3-3
T5-4-13
Parts
Arm Regenerative Valve Bucket Regenerative Valve Arm Anti-Drift Valve
• To be shifted by pilot pressure • Prevents bucket cylinder hesi- • Prevents arm from drifting
from solenoid valve unit (SC). tation by routing return oil from due to oil leaks in control
• Increases arm speed by rout- bucket cylinder rod side to bot- valve. Check valve in arm
ing return oil from arm cylinder tom side. roll-in return circuit is forcibly
rod side to bottom side. opened to allow arm to move
Function only when arm is rolled in.
• Arm regenerative function is • If check valve is kept closed, • If switch valve is bound,
inoperable. bucket is not smoothly rolled in. check valve doesn’t open.
• If check valve is kept open,
bucket power is weak.
Symptoms in control
system when trouble
occurs.
• Arm speed is extremely slow • Same as described above. • If check valve is kept closed,
during arm level crowd opera- arm roll-in speed becomes
tion while arm regenerative slow.
valve is kept closed. • If check valve is kept opened,
• The lever operated first is front attachment drift in-
given priority during combined creases due to oil leaks in
Symptoms in machine operation of arm roll-in and control valve.
operation when trou- swing while arm regenerative • Arm moves jerky or arm
valve is kept open. speed becomes slow de-
ble occurs. pending on valve bound con-
ditions.
By Fault   
By Monitor
  
Evalua- Function
tion Using Test
  
Harness
Others   
NOTE   

T5-4-14
Boom Anti-Drift Valve Auxiliary Flow Combiner Valve Bypass Cut Valve
• Prevents boom from drifting due to oil • Supplies pressure oil from pump 1 to • Supplies pressure oil from pump 1 to
leaks in control valve. Check valve in auxiliary spool when auxiliary spool is auxiliary spool when auxiliary spool is
boom lower return circuit is forcibly operated. operated.
opened to allow boom to move only
when boom is lowered.
• If switch valve is bound, check valve • If switch valve is kept closed, operating • If spool is bound in the fully opened po-
doesn’t open. speed doesn’t increase in single auxil- sition, single attachment operation
iary operation. speed becomes slow.
• If spool is bound in the fully closed posi-
tion, main relief valve continues to re-
lieve with all control levers positioned in
neutral.
• If spool is bound in opened position,
when all control levers are in neutral,
pump 1 pressure is higher than pump 2
pressure.
• If check valve is kept closed, boom • Same as described above. • Same as described above.
doesn’t lower.
• If check valve is kept opened, front at-
tachment drift increases due to oil leaks
in control valve.
• Boom moves jerky or arm speed be-
comes slow depending on valve bound
conditions.
  
  
  
  
  
T3-3 T3-3 T3-3
T5-4-15
Parts
Pump 1 Flow Control Valve Pump 2 Flow Control Valve
• Supplies flow rate control pressure Pi to pump 1 • Supplies flow rate control pressure Pi to
regulator in response to lever stroke when boom pump 2 regulator in response to lever stroke
(raise/lower), arm (roll out/in), bucket when boom (raise/lower), arm (roll out/in),
(roll-out/in), right travel, or auxiliary is operated. swing (right/left), or left travel is operated.
Function
• If spool is bound in the fully opened position, • If spool is bound in the fully opened position,
even if control lever is in neutral, pump 1 swash even if control lever is in neutral, pump 2
angle is tilted to maximum. (When traveling with swash angle is tilted to maximum. (When
travel levers held in half way stroke, machine traveling with travel levers held in half way
mistracks to the left.) stroke, machine mistracks to the right.)
• If spool is bound in the fully opened position, • If spool is bound in the fully opened position,
pump 1 control pressure sensor indicates the pump 2 control pressure sensor indicates
maximum pressure. the maximum pressure.
• If spool is bound in the fully closed position, • If spool is bound in the fully closed position,
even if control lever is operated, pump 1 swash even if control lever is operated, pump 2
angle is held to minimum. (Right travel is inop- swash angle is held to minimum. (Left travel
erable in single travel operation. Bucket speed is inoperable in single travel operation.
is very slow.) Swing speed is very slow.)
• If spool is bound in the fully closed position, • If spool is bound in the fully closed position,
Symptoms in control sys- pump 1 control pressure sensor can not detect pump 2 control pressure sensor can not
tem when trouble occurs. pump control pressure. (Right travel doesn’t run detect pump control pressure. (Left travel
fast with right track jacked up.) doesn’t run fast with left track jacked up.)
• Same as described above. • Same as described above.

Symptoms in machine op-
eration when trouble oc-
curs.
By Fault Code  
By Monitor
 
Function
Evaluation Using Test
Harness  
Others
 
NOTE ― ―

tion in T/M)
T5-4-16
Flow Combiner Valve Control Swing Parking Brake Bucket Flow Rate Control Valve
Spool Release Spool Control Spool
• Supplies control pressure to flow com- • Supplies swing parking brake release • Supplies boom raise pilot pressure to
biner valve when shifted by right travel pressure when shifted by boom, arm, bucket flow rate control valve when
pilot pressure. bucket, or swing pilot pressure. shifted by arm roll-in pilot pressure.
• If spool is bound in the fully opened po- • If spool is bound in the fully open posi- • If spool is bound in the fully opened po-
sition, when boom, arm, bucket, or tion, swing parking brake is kept re- sition, bucket speed becomes slow
swing is operated, flow combiner valve leased. when boom raise and bucket combined
is shifted. (Machine vibrates while traveling.) operation is made. (Bucket flow rate
• If spool is bound in the fully closed posi- • If spool is bound in the fully open posi- control is inoperable.)
tion, when travel and front/swing com- tion, the pressure sensor (front) is al- • If spool is bound in the fully closed posi-
bined operation is made, machine mis- ways turned into ON. tion, boom doesn’t move during
tracks to the right. (right travel speed is Thus, engine speed doesn’t decrease 3-combined operation of bucket, arm
slow.) when the control lever is in neutral dur- roll-in, and boom raise.
ing auto-idle/acceleration control.
tion, swing parking brake is kept applied.
(Dragging is felt.)
tion, the pressure sensor (front) is al-
ways turned into OFF.
Thus, engine speed doesn’t increase
when the control lever is operated during
auto-idle/acceleration control.
• Same as described above. • Same as described above. • Same as described above.
  
  
  
  
  
T3-6 T3-3 T3-3
T5-4-17
Parts Emergency Stop

Offset Anti-Drift Valve 8-Unit Solenoid Valve
Solenoid Valve
(ZAXIS135UR) (ZAXIS135UR)
(ZAXIS135UR)
• Prevents the offset front at- • To control pilot pressure to con- • If front control fails, the
tachment from being offset by trol front function (Front Move- emergency stop solenoid
its own weight to the right. ment Restriction, Cab collision valve shuts off the pilot pres-
(Being provided in the offset Prevention, Auto-MARCCINO sure to stop all operations.
Function cylinder rod circuit.) control.
• If stuck in the open position, • Front does not move or stop. • When fault code is not dis-
the offset cylinder hold circuit • When front movement restric- played (this is normal state),
is kept released, allowing the tion and cab collison prevention the emergency stop solenoid
front attachment to offset to control deceleration solenoid valve works.
the right depending on the valve spool stuck open causing
stop position of the front at- the front function not to stop or
tachment. decelerate.
• If stuck in the fully closed posi- • Deceleration solenoid valve
tion, the return oil from the spool stuck shut making the
Symptoms in control offset cylinder rod side is front function immovable.
system when trouble
blocked so that the right offset • Acceleration solenoid valve
function becomes inoperable. spool stuck open causing the
occurs. front function not to stop.
• Acceleration solenoid valve
spool stuck shut making the
front function immovable.
• Same as described above. • Same as described above. • If this solenoid valve is stuck
during its operation, it be-
comes inoperative. If stuck
with the solenoid valve open,
the pilot pressure cannot be
Symptoms in machine shut off even if front control
fails.
operation when trou-
ble occurs.
Fault code 40, 41, 43, 45, 47, 48

By Fault is displayed (Auto-MARCCINO
― system) 
Code
Evalua- By Monitor
tion   
Function
Using Test   
Harness
Others   
NOTE   

T5-4-18
Blade Signal Switch Valve Front Angle Sensor Oil Temperature Sensor
(ZAXIS135UR) (ZAXIS135UR) （ZAXIS135UR）
• Shifts the flow combiner valve when the • The position of the bucket is detected by • Detects the hydraulic oil temperature
blade pilot pressure is supplied. angle sensors for the boom, arm and and sends as a signal to the
offset; and the detected data is sent to auto-Marccino control unit.
the auto-MARCCINO control unit.
• Even though the blade control lever is • If one of angle sensors fails, the • The system is controlled based on the
operated, the flow combiner valve is not auto-MARCCINO control unit works to oil temperature at which the trouble had
shifted. input a maximum value as a data on the occurred
failed angle sensor in order to avoid in-
terference.
• If stuck in the closed position, the flow • Part of the front attachment fitted with a • When a trouble occurrs at lower than 10
combiner valve is not shifted so that the sensor that seems to be failed does not °C, deceleration and stop functions in
blade speed becomes slow when a move toward the cab. the cab collision prevention system are
combined operation is made. activated earlier than the normal posi-
tions.
• When a trouble occurrs at 10 °C or
higher, deceleration and stop functions
in the cab collision prevention system
are activated at the normal position
Fault code 90 is displayed.
 
Monitor Item:
Boom Angle, Arm Angle,
 Offset Angle 
  
  
― ― 
T2-3 T2-2

T5-4-19
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine
troubles and parts contributing to the cause of the
trouble if failed.
Engine System Troubleshooting
E-1 E-2 E-3
Starter doesn’t ro- Although starter When engine control dial is fully rotated, engine
Trouble tate rotates, engine stalls. Occasionally engine stalls during opera-
Symptom doesn’t start. tion with engine control dial fully rotated and
auto-idle ON. Engine speed is slower than
specification in all operating range. Idle speed is
faster or slower than specification.
Parts
MC (Main Controller) z z
QOS Controller
EC Motor z
EC Sensor { z
Pump 1 Control Pressure Sensor
Pressure Sensor (Travel)
Pressure Sensor (Front Attachment)
Pressure Sensor (Swing)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Auxiliary)
N Sensor
Hyd. Oil Temperature Sensor
Coolant Temperature Sensor
Key Switch z
Engine Control Dial
Auto-Idle/Acceleration Selector
Power Mode Switch
Work Mode Switch
Auxiliary Mode Switch
Engine Learning Switch z
Battery Relay z
Glow Relay
Engine Electrical Equipment z
Engine Unit z z
Governor z z
Swing Parking Brake Release Spool
(Signal Control Valve)
Check batteries. Check fuel system Check fuel cut-off handle and engine control
(filters and piping). cable. Be sure to perform engine learning after
replacing engine.
Remarks
T5-4-20
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
E-4 E-5 E-6 E-7 E-8 E-9

Even if engine con- Engine speed Faulty HP mode. Even if key switch is Faulty auto-idle Faulty E mode.
trol dial is rotated, doesn’t increase turned OFF, engine system.
engine speed re- after engine is doesn’t stop.
mains unchanged. started.
z z z { z z
z { {
{ {
{
{
{
{
{
{
z {
z
z
z { z
z {
z {
Check engine con-

trol cable.
z : Related, required to check { : Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will not
be the direct cause of the trouble concerned.
T5-4-21
E-10 E-11 E-12

Faulty auto-acceleration When traveling or operating Engine speed doesn’t in-
Trouble system. front attachment with engine crease even if attachment is
Symptom running at slow idle, engine operated in attachment
hunts. mode.
Parts
MC (Main Controller) z z z
QOS Controller
EC Motor
EC Sensor
Torque Control Solenoid Valve
Pump 1 Delivery Pressure Sensor {
Pump 1 Control Pressure Sensor {
Pump 2 Control Pressure Sensor {
Pressure Sensor (Travel) {
Pressure Sensor (Front Attachment) {
Pressure Sensor (Boom Raise) {
Pressure Sensor (Arm Roll-In) {
Pressure Sensor (Auxiliary) z
N Sensor
Coolant Temperature Switch
Key Switch
Engine Control Dial
Auto-Idle/Acceleration Selector z
Power Mode Switch
Work Mode Switch z
Auxiliary Mode Switch z
Engine Learning Switch
Battery Relay
Glow Relay
Engine Electrical Equipment
Engine Unit z
Governor
Pump Regulator
Remarks
T5-4-22
E-13 E-14 E-15 E-16

When attachment mode Engine stalls within Engine stalls during Engine is difficult to
is selected, engine several seconds after operation under ad- start at low temperature.
speed doesn’t de- engine has started. verse condition such as
crease. at high altitude.
z z
z
z
z
z
{
Check fuel system for Check batteries.
clogging.
z : Related, required to check

{ : Related. However, in case this component fails, other trouble
T5-4-23
All Actuator System Troubleshooting

A-1 A-2 A-3
All actuator speeds are slow. Left travel is inoperable during Right travel is inoperable dur-
Trouble single travel operation. Single ing single travel operation. Sin-
Symptom swing operation speed is slow. gle bucket operation speed is
Arm is slightly slow during arm slow. Boom is not raised prop-
level crowding. erly during arm level crowding.
Parts
MC (Main Controller) z
Torque Control Solenoid Valve {
N Sensor {
Spool
Main Relief Valve {
Arm Flow Rate Control Valve
Main Pump z z z
Regulator { z z
Pilot Pump z
Pilot Valve
Pilot Relief Valve z
Pump 1 Flow Rate Control Valve z
Pump 2 Flow Rate Control Valve z
Remarks
NOTE: The trouble symptoms in this table are de-

scribed provided that each trouble occurs
independently. In case more than one trou-
ble occurs at the same time, find out all
faulty components while checking all sus-
pected components in each trouble symp-
tom.

symptom will be more noticeable so that this component will
not be the direct cause of the trouble concerned.
T5-4-24
A-4 A-5
Actuator doesn’t stop Actuator speed is faster
even if control lever is than normal.
returned to neutral. Machine mistracks when
the travel lever is oper-
ated at half stroke.
Precise control can not
be performed.
z
z
T5-4-25
Front Attachment System Troubleshooting

F-1 F-2 F-3
All front attachment actuator Some cylinder are inoper- Arm speed is slow in a com-
Trouble power is weak. able or speeds are slow. bined operation. Arm speed
Symptom is slow during arm level
crowding.
Parts
MC (Main Controller) z
Solenoid Valve Unit (SC) z
Pressure Sensor (Swing) {
Pressure Sensor (Boom Raise) {
Pressure Sensor (Arm Roll-In) {
Spool z
Main Relief Valve z
Overload Relief Valve z
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve z
Bucket Regenerative Valve
Bucket Flow Rate Control Valve
Boom Anti-Drift Valve
Arm Anti-Drift Valve
Emergency Valve
Shockless Valve (Signal Control Valve) z
Shuttle Valve (Signal Control Valve) z
Bucket Flow Rate Control Valve Control

Spool (Signal Control Valve)
Pilot Valve z
Cylinder
Offset Anti-Drift Valve (ZAXIS135UR)
8-Unit Solenoid Valve Unit (ZAXIS135UR) z
Emergency Stop Solenoid Valve
z
(ZAXIS135UR)
z
(ZAIXS135UR)
Remarks
T5-4-26
scribed provided that each trouble occurs
the same time, find out all faulty compo-
independently.
nents while checking all suspected com-
F-4 F-5 F-6 F-7

Bucket is slow in bucket roll-in When starting to move in com- When starting to move in com- When boom raise or arm roll-out
single operation. Bucket doesn’t bined operation, arm doesn’t bined operation, boom doesn’t is operated, boom or arm starts
move smoothly in bucket roll-in smoothly move. Arm starts to smoothly move. Boom starts to to move after slightly moving
single operation. move slow slightly in arm roll-in move slow slightly in boom downward.
single operation. These troubles lower single operation.
often occur when oil tempera-
ture is low.
z
z
z
z
z
z z
z z

T5-4-27
Front Attachment System Troubleshooting
F-8 F-9 F-10 F-11
Front attachment Offset is slow or Offset cylinder drifts Abnormal front con-
Trouble drifts remarkably. does not move in remarkably. trol (ZAXIS135UR
Symptom offset single opera- (ZAXIS135UR Only) Only)
tion. (ZAIXS135UR
Only)
Parts
MC (Main Controller)
Solenoid Valve Unit (SC)
Pressure Sensor (Boom Raise)
Spool z z z
Main Relief Valve
Overload Relief Valve z
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve
Bucket Regenerative Valve
Bucket Flow Rate Control Valve
Boom Anti-Drift Valve z
Arm Anti-Drift Valve z
Emergency Valve
Shockless Valve (Signal Control Valve)
Shuttle Valve (Signal Control Valve)
Bucket Flow Rate Control Valve Control Spool

Pilot Valve z z z
Cylinder z z
Offset Anti-Drift Valve (ZAXIS135UR) z z
8-Unit Solenoid Valve Unit (ZAXIS135UR) z z
(ZAXIS135UR)
Auto-MARCCINO Controller (ZAIXS135UR) z
Remarks

T5-4-28
(Blank)
T5-4-29
Swing/Travel/Blade (ZAXIS135UR) System Troubleshooting

S-1 T-1 T-2
Swing is slow or unmoving. Both right and left tracks do One side track doesn’t rotate
Trouble not rotate or rotate slowly. or rotates slowly. Machine
Symptom mistracks.
Parts
Travel Mode Switch
Pump Device
Spool z
Main Relief Valve
Travel Relief Valve
Overload Relief Valve
Load Check Valve
Flow Combiner Valve
Bypass Cut Valve
Swing Parking Brake Release Spool
z
Pump 1 Flow Control Valve
{
z {
Flow Combiner Control Spool
Shuttle Valve (Signal Control Valve) { {
Swing Device z
Travel Device z
Center Joint z
Pilot Valve z z
Blade Signal Switch Valve
(ZAXIS135UR)
Also, refer to T-5. In case either bucket or swing
is also slow, refer to A-2 or
Remarks A-3.
T5-4-30
T-3 T-4 B-1 B-2

Machine mistracks dur- Fast travel is inoperable. Blade is slow or weak in Blade drifts remarkably.
ing travel and front at- Travel mode does not blade single operation.
tachment combined op- change from slow mode
eration. to fast mode.
z
{
{
{
{
{
z
z
z
z
z z
{
z
z
z

T5-4-31
Other System Troubleshooting

O-1 O-2 O-3
Wiper is inoperable or not Wiper is inoperable. Air Conditioner Malfunction
Trouble retracted. (ZAXIS125US/135US/
Symptom (ZAXIS110/110M/120/130/ 135UR)
130LCN)
Parts
Travel Mode Switch
Pump Device
Spool
Main Relief Valve
Travel Relief Valve
Overload Relief Valve
Load Check Valve
Flow Combiner Valve
Swing Parking Brake
Flow Combiner Control Spool
Shuttle Valve (Signal Control Valve)
Swing Device
Travel Device
Center Joint
Pilot Valve
Blade Signal Switch Valve
Offset Anti-Drift Valve (ZAXIS135UR)
8-Unit Solenoid Valve Unit (ZAXIS 135 UR)
(ZAXIS 135 UR)
(ZAXIS 135 UR)
Remarks
T5-4-32
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter doesn’t rotate.
Related Fault Code: None
• This trouble has nothing to do with the electronic

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

Terminal A
T178-05-04-001
T105-07-04-002
T5-4-33
E-2 Although starter rotates, engine doesn’t
start.
• Check the fuel cut lever position during cranking.

If the position is normal, the engine unit and/or
fuel system may have trouble.
hand.
Faulty engine.
YES
· Refer to engine shop manual.
Check if governor lever
moves to the START position
when key switch is turned ON.
YES Faulty EC motor.
· Key switch: ON · Refer to T4-6-6.

Check if EC motor drive
circuit is normal.
NO
Faulty MC.
· Test harness: 4274589 NO
(ST 7125)
• Governor Lever and Fuel Cut Lever · Refer to T4-6-6.
1 2 3 4
T105-07-04-003
1 - Governor Cable (From EC Mo-
tor)
2 - Fuel Cut-Off Cable
(Fuel Cut-Off Handle)
3 - Fuel Cut Lever
4 - Governor Lever
T5-4-34
• Governor Lever Position
A - Key Switch OFF (Engine Stop Position)

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

B - Fuel Cut-Off Handle Returned Position
A
B
T105-07-04-003
T5-4-35
E-3 When engine control dial is fully rotated,
engine stalls.
Occasionally engine stalls during operation
with engine control dial fully rotated and
auto-idle ON.
Engine speed is slower than specification in
all operating ranges.
Idle speed is faster or slower than specifica-
tion.
Related Fault Code: 06
• In case engine learning has not been performed • Refer to pages for Engine Learning in the SYS-
or engine learning has been incorrectly per- TEM/Control System group in the T/M (Opera-
formed, engine speed becomes slower than tional Principle).
specification across the operating range. • Check for loose harness connections before-
• In case the EC sensor is faulty, engine speed is hand.
controlled based on the governor lever position,
which is judged as the idle position when the key
switch is turned ON. Accordingly, discrepancies
in engine speed from specification will result.
Depending on where the governor lever is posi-
tioned when the key switch is turned ON, dis-
crepancy will differ, causing this trouble to be not
reproducible.
Return fuel cut

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

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

06 is displayed.
NO YES End.
Check if problem is
corrected after en-
gine learning.
NO
NO Monitor engine
· Refer to T4-6-6 for learning status.
engine learning
procedures.
· Monitor item: En-
gine learning con-
trol
T5-4-36
Faulty engine and/or fuel sys-

YES tem.
Check if governor lever

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

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

switch, or broken harness be-
tween learning switch and MC.
NOT OK
· Refer to T4-6-6.
T5-4-37
E-4 Even if engine control dial is rotated, engine
speed remains unchanged.
• If the EC fails, the engine will not stop with the

key switch OFF.
hand.
Faulty engine control dial or

broken harness between en-
gine control dial and MC.
YES
Check if fault code 07 is dis-
played. Using Dr. ZX, monitor
engine control dial angles
(standard voltages). Check if
voltages are normal. Faulty EC motor.
YES
Install test harness (ST 7125)
to EC motor. Check if lamp
comes ON while turning en- · Refer to T4-6-6.
gine control dial.
· Standard voltages NO
Slow idle position: 0.3 to 1 V Faulty MC or broken harness
Fast idle position: 4.0 to 4.7 V between MC and EC motor.
· Possible to display with built-in
diagnosing system. NO
· Refer to T4-6-6.
T5-4-38
E-5 Engine speed doesn’t increase after engine
is started.
• Refer to the pages for the Auto Warming Up Con-

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

NO perature.
Faulty key switch or

broken harness be-
· Monitor item: Hydraulic oil
YES tween key switch and
temperature Monitor key switch. MC.
· Possible to display with Check if displayed
built-in diagnosing system “ky” is highlighted in
response to key
switch operation.
Check if fault code
19 is displayed. Lower than 0 °C
when starting Faulty MC.
NO
· Refer to T4-6-6.
· Monitor item: Key
switch
Faulty hyd. oil tem-
perature sensor or
broken harness be-
tween oil tempera-
ture sensor and MC.
YES
T5-4-39
E-6 Faulty HP mode
• Even if power mode switch is turned to the HP

mode position, HP mode is inoperable. (General
mode normally operates.)
Related Fault Codes: 10, 11, 15, and 16
• Sensors detect the conditions necessary to oper- • Refer to the pages for HP Mode Control in the
ate the HP mode. Therefore, if any of these sen- SYSTEM / Control System group in the T/M (Op-
sor fails, the HP mode becomes inoperable. erational Principle).
• Pressure sensors (arm roll-in and boom raise) • Check for loose harness connections before-
and pump 1 and 2 delivery pressure sensors are hand.
also engaged in the HP mode control. However, if
these sensors fail, other operating functions will
be also affected. (Refer to the relationship be-
tween machine trouble symptoms and related
parts on page T5-4-2.)
Faulty power mode
switch or broken
harness between
NO power mode switch
and MC.
Monitor power mode
switch. Check if indica-
tion HP is highlighted
when power mode
NO switch is turned to “HP Check if governor
mode”. lever comes in contact YES Faulty engine.
with full-side stopper
while relieving boom
raise circuit pressure.
YES
Check if any fault Faulty MC.
codes are displayed. · Monitor item: E/P/HP
mode switch NO
· Refer to T4-6-6.
Faulty corresponding
sensor or broken
harness between
sensor and MC.
YES
· Fault codes:
Pump 1 delivery pressure sensor: 10
Pump 2 delivery pressure sensor: 11
Pilot pressure sensor (boom raise): 15
Pilot pressure sensor (arm roll-in): 16
T5-4-40
• Although the power mode switch isn’t turned to the
HP mode position, HP mode is operable.
• Boom raise and arm roll-in must be operated

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

Check if the symp- End.
mode switch. Check Check if the governor YES
tom disappears after
if “HP” is displayed. lever comes in contact completing engine
with full side stopper YES learning.
when the key switch is Faulty MC.
turned ON (engine not
running) and the engine NO
· Monitor item: E/P/HP control dial is turned to · Refer to T4-6-6.
mode switch NO
Fast Idle.
· Power mode switch:
P mode Faulty engine.
NO
T5-4-41
E-7 Even if key switch is turned OFF, engine
doesn’t stop. (In case the engine doesn’t
stop, stop the engine by pulling the engine
stop handle located under the seat stand.
Then, begin inspection.)
Related Fault Codes: 06 and 07
• Probably symptoms such as “Engine speed is

slower than specification in all operating ranges”
or “Even if engine control dial is rotated, engine
speed remains unchanged” will come up. Per-
form troubleshooting for these symptoms.
T5-4-42
E-8 Faulty auto-idle system
• Even if control lever is turned to neutral. Auto-idle

system is inoperable.
• In case trouble symptoms E1 to E7 are recog- • Refer to the pages for Auto-Idle Control in the
nized, perform the troubleshooting of these trou- SYSTEM / Control System group in the T/M (Op-
bles beforehand. erational Principle).
• Although the failure in pressure sensors (travel • Check for loose harness connections before-
and front attachment) will have relevance to mal- hand.
function of the auto-idle control. However, if these
sensors fail, other operating functions will also be
affected. (Refer to the relationship between ma- Normal (Turn power
chine trouble symptoms and related parts on mode switch to a posi-
page T5-4-2.) YES tion other than the E
mode.)
Check if power mode

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

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

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

auto-acceleration control. between MC and auto-idle
/ auto-acceleration selec-
YES tor.
Monitor auto-idle /
auto-acceleration se-
lector. Check if “AI” is
displayed.
Faulty MC.
· Monitor item: Auto-idle / NO
auto-accel switch
· Auto-idle / · Refer to T4-6-6.
auto-acceleration selec-
tor: OFF
T5-4-43
E-9 Faulty E mode
• Even if power mode switch is turned to the E mode

position, engine speed remains unchanged. (En-
gine speed doesn’t decrease.)
• In case trouble symptoms E-1 to E-8 are recog-

nized, perform the troubleshooting of these trou-
bles beforehand.
• Refer to the pages for E Mode Control in the
SYSTEM / Control System group in the T/M (Op-
erational Principle).
hand. Faulty power mode switch or
broken harness between
NO power mode switch and MC.
Monitor power mode switch.
Check if displayed “E Mode” is
turned OFF or ON in re-
sponse to power mode switch
operation.
Faulty MC.
YES
· Monitor item: · Refer to T4-6-6.
E/P/HP mode switch
• Although power mode switch isn’t turned into E

mode, engine speed decrease.
Short circuited harness be-

tween MC and power mode
YES
switch.
Monitor power mode switch.
Check if “E” is displayed.
Faulty MC.
· Monitor item: E/P/HP switch NO
· Power mode switch: P mode
· Refer to T4-6-6.
T5-4-44
E-10 Faulty auto-acceleration system
• Auto-acceleration system is inoperable.
Related Fault Code: 10, 11, 12, 13, 14, 15, 16, and
18
• In case trouble symptoms E-1 to E-9 are recog- • Refer to the pages for Auto-Acceleration Control
nized, perform the troubleshooting of these trou- in the SYSTEM / Control System group in the
bles beforehand. T/M (Operational Principle).
• Although the failure in pressure sensors (travel,
swing, boom raise, and arm roll-in), pump 1 and
2 delivery pressure sensors, and pump 1 and 2
control pressure sensors will have relevance to
malfunction of the auto-acceleration control.
However, if these sensors fail, other operating
functions will also be affected. (Refer to the rela-
tionship between machine trouble symptoms and
related parts on page T5-4-2.) Faulty auto-idle /
auto-acceleration selector or
broken harness between
Monitor auto-idle / auto-acceleration switch and MC.
NO
auto-acceleration selector.
Check if displayed “AA” is
turned OFF or ON in response
to auto-acceleration switch
operation.
Faulty MC.
YES
· Refer to T4-6-6.
· Monitor item:
Auto-idle/auto-accel
switch
• Although auto-idle / acceleration selector is turned

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

auto-acceleration control. Short circuited harness between
MC and auto-idle /
YES auto-acceleration selector.
Monitor auto-idle / accelera-
tion selector.
Check if “AA” is displayed.
Faulty MC.
· Monitor item: Auto-idle / NO
auto-accel switch
· Auto-idle / auto-acceleration se- · Refer to T4-6-6.
lector:
Auto-idle position
T5-4-45
E-11 When traveling or operating front attach-
ment with engine running at slow idle, en-
gine hunts.
• Although the failure in pressure sensors (travel

and front attachment) will have relevance to mal-
function of the engine speed increase control.
However, if these sensors fail, other operating
functions will also be affected. (Refer to the rela-
tionship between machine trouble symptoms and
related parts on page T5-4-2.)
• Refer to the pages for Idle Speed-Up Control in
the SYSTEM / Control System group in the T/M
(Operational Principle).
YES Faulty engine.
Check if engine speed is

faster than increased idle · Refer to the Engine Shop
speed. Manual.
Faulty MC.
· Monitor item: NO
Engine target speed
· Possible to display with built-in · Refer to T4-6-6.
diagnosing system
T5-4-46
E-12 Engine speed doesn’t increase even if at-
tachment is operated in attachment mode.
NOTE: The attachment mode is not equipped for
ZAXIS135UR.
• In case trouble symptoms E-1 to E-11 are recog- • Refer to the pages for Attachment Operation
nized, perform the troubleshooting of these trou- Speed Increase Control in the SYSTEM / Control
bles beforehand. System group in the T/M (Operational Principle).
• Although the failure in pressure sensor (auxiliary) • Check for loose harness connections before-
and power mode switch will have relevance to hand.
the malfunction of the attachment operation
speed increase control. However, if these sensor
and switches fail, other operating functions will
also be affected. (Refer to the relationship be-
tween machine trouble symptoms and related
parts on page T5-4-2.)
Normal (Set to “In-
NO crease (+)”.)
Check if attachment
speed adjustment
has been set to “In-
NO crease (+)” in Dr. ZX Monitor attachment
service mode. pilot pressure. Check YES
if pressure varies in To A
response to lever
Check if P speed ad-
stroke.
justment has been YES
set to “Decrease” in Faulty auxiliary pres-
Dr. ZX service mode. sure sensor.
NO
· Monitor item: Att. con-

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

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

switch.
NO
· Monitor item:
Work mode switch
T5-4-47
E-13 When attachment mode is selected, engine
speed doesn’t decrease.
NOTE: The attachment mode is not equipped for
ZAXIS135UR.
• In case trouble symptoms E-1 to E-11 are recog-

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

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

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

(+)”.)
NO
T5-4-48
E-14 Engine stalls within several seconds after
engine has started.
• Refer to the pages for Engine Learning Control in

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

YES neutral.)
Check if engine learn-

ing switch is turned to
the learning position.
Faulty learning switch, or
short-circuited harness be-
tween learning switch and
MC, or check fuel system for
clogging.
NO
T5-4-49
E-15 Engine stalls during operation under ad-
verse condition such as at high altitude.
• If speed-sensing control is inoperable, the engine

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

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

YES solenoid valve.
A
Broken harness be-
tween torque control so-
lenoid valve and MC.
NO
T5-4-50
(Blank)
T5-4-51
E-16 Engine is difficult to start at low tempera-
ture. (During cold weather or in cold dis-
tricts, the engine is difficult to start or
doesn’t start although pre-heated.)
• Check if electricity is routed to the glow plugs. • Check battery at the same time.
Check the glow plugs for any abnormality. • Check for loose harness connections before-
• The pre-heat system operates only when coolant hand.
temperature is below 10 °C (50 °F). When cool-
ant temperature is higher than 10 °C (50 °F), the
pre-heat system doesn’t operate.
Faulty coolant temperature

YES switch.
Disconnect coolant tempera-

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

Voltage Check
Resistance Check
Remove
the
copper
plate.
Specification: 20 to 24 V
Specification: Below 10 Ω
T105-07-04-006
T105-07-04-007
T5-4-52
Faulty glow plug.

∞Ω
Faulty engine unit, faulty glow

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

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

(ZAXIS135UR: #20) is normal.
T5-4-53
ALL ACTUATOR SYSTEM TROUBLE-
SHOOTING
A-1 All actuator speeds are slow.

ZAXIS135UR:
• Reduction in pump 1 and 2 flow rate due to some • Blade operations use different control valve from
reasons or faulty pilot system may cause this trou- that of front attachment operation. Therefore,
ble. there is a small possibility to have faulty main re-
• Also, check for fuse of the torque control solenoid lief valves of two control valves at the same time.
valve.
• Although speed is satisfactory, in case power is
weak, refer to the troubleshooting for faulty relief
valve (F-1).
• Check for loose harness connections beforehand.
Faulty pilot pump or

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

roll-in Monitor actual en-
· Monitor item: Boom gine speed. Check
Raise Pilot Pressure, Arm if abnormal speed
YES
Roll-In Pilot Pressure YES is indicated. Monitor torque con-
trol solenoid valve
output. Check if
· Monitor item: Engine torque control sole-
Actual Speed noid valve output is
· Possible to display NO normal.
with monitor service
mode.
· Monitor item:
Pump torque NO
proportional solenoid
valve output
· Refer to the opera-
tional performance
Test section
T5-4-54
Pressure Gauge Torque Control

Mounting Port Solenoid Valve
T176-03-01-001
Faulty pump device.
Install pressure YES
gauge between
YES torque control sole-
noid valve and regu- Faulty torque control solenoid
Check if harness
lator. Check if the valve.
between MC and
pressure changes. NO
torque control so-
lenoid valve is
normal
Faulty harness between torque

control solenoid valve and MC.
· Key Switch: OFF NO
Faulty MC.
· Refer to T4-6-6.
T5-4-55
A-2 Left travel is inoperable during single travel
operation. Single swing operation speed is
slow. Arm is slightly slow during arm level
crowding. (All problems occur at the same
time.)
• The pump 2 flow rate is minimized (approx. 20

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

YES lator.
Monitor pump 2
pump control pres-
sure. Check if
pressure in-
creases in propor-
tion to left travel
lever stroke. Bound pump 2 flow
rate control valve in
signal control valve.
NO
· Monitor item: Pump
2 Flow Control
Pressure
· Possible to display
with built-in diag-
nosing system.
T5-4-56
A-3 Right travel is inoperable during single
travel operation. Single bucket operation
speed is slow. Boom is not raised properly
during arm level crowding. (All problems
occur at the same time.)
• The pump 1 flow rate is minimized (approx. 20

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

YES lator.
Monitor pump 1
pump control pres-
sure. Check if
pressure increases
in proportion to
right travel lever
stroke. Bound pump 1 flow
rate control valve in
signal control valve.
NO
· Monitor item: Pump
1 Flow Control
Pressure
with built-in diag-
nosing system.
T5-4-57
A-4 Actuator doesn’t stop even if control lever is
returned to neutral.
• Bound spool in the pilot valve or bound main spool

in the control valve is suspected.
YES Faulty pilot valve.
Check if actuator stops when

· When control lever is in neu-
pilot control shut-off lever is
tral, pilot pressure is routed to
raised.
spool end in control valve.
Faulty control valve.

NO
· Although pilot pressure is not

routed to spool end in control
valve, spool is kept opened
due to binding of spool.
T5-4-58
A-5 Actuator speed is faster than normal
Machine mistracks when travel lever is op-
erated at half stroke. Precise control can not
be performed.
• The pump 1 or 2 flow rate is maximized due to

some reasons.
Therefore, the maximum flow rate is supplied and
actuator speed is faster though the control lever
doesn’t reach the full stroke.
• The pressure oil from pump 1 makes right travel
perform, and the pressure oil from pump 2 makes
left travel. Perform on the single travel operation.
Different flow rates between pump 1 and pump 2
occur, and the machine mistracks. When the
travel lever is operated at half stroke.
• Refer to the SYSTEM / Hydraulic System group
in the T/M (Operational Principle).
Faulty pump regulator.

YES
Monitor pump control pres-
sure of pump 1 and 2. Check
if the pressure changes in re-
sponse to the lever operation.
Bound pump flow rate control
valve in signal control valve.
· Pump 1: Bucket operation NO
· Pump 2: Swing operation
· Monitor item: Pump 1 and 2
pump control pressures
· Possible to display with
built-in diagnosing system.
T5-4-59
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
F-1 All front attachment actuator is weak or
slow.
• In case operating speeds are extremely slow,

pump control may be malfunctioning (A-2 and/or
A-3). Faulty pilot system may also cause this
trouble.
ZAXIS135UR:
• An emergency stop solenoid valve is provided
between the pilot shut-off valve and the front at-
tachment pilot valve to control the front attach-
ment oprtation. In case the unload valve in the
emergency stop solenoid valve should become
stuck, the primary pilot oil pressure to the front
attachment pilot valve will become abnormal, and
the similar symptom may appear.
Main relief valve should be

normal. Find out cause of
trouble by tracing other trou-
34.3 to 36.3 MPa ble symptoms.
(350 to 370 kgf/cm2)
Monitor pump 1 and 2 delivery

pressures.
Adjust main relief valve.
· Monitor item: Pump 1 and 2 De- Less than 34.3 MPa

livery Pressures (350 kgf/cm2)
· Possible to display with built-in
diagnosing system.
· Relieve boom, arm, and bucket
circuits.
· Power Mode Switch: OFF
· Work Mode: Digging
T5-4-60
F-2 Some cylinders are inoperable or speeds
are slow.

ZAXIS135UR:
• When other actuators (travel and swing motors) • When the auto-Marccino fault codes are dis-
operate normally, the pilot pump (primary pilot played, refer to the Troubleshooting D.
pressure) is considered to be normal. • In case only the single offset operation is slow,
• In case single bucket operation speed is slow, refer to F-9 also.
refer to F-4.
• In case single arm roll-in operation speed is slow,
refer to F-5.
• In case single boom lower operation speed is
Bound control valve
slow, refer to F-6.
YES spool or faulty cylinder
(faulty seal kit).
Monitor pump con- Check if overload
trol pressure. Check YES relief pressure is
if pump control pres- normal.
Faulty overload relief
sure changes valve.
smoothly while mov-
NO
ing control lever
YES slowly.
Monitor or meas- Faulty shuttle valve in

ure secondary pilot signal pressure con-
· Monitor item: trol valve.
pressure. Check if · Pump 1 Flow Control NO
secondary pilot Pressure, Pump 2 Flow
pressure is normal. Control Pressure
· Possible to display with Bound shockless
built-in diagnosing sys- YES valve spool.
tem.
· Secondary Pilot
Check if secondary
Pressure: YES
pilot pressure at inlet Bound corresponding
· Refer to Operational Check if secon-
Performance Test NO port to signal control solenoid valve spool ,
valve is normal. dary pilot pres- or bound shuttle valve
Section. sure at inlet port
· Monitor item: Boom in solenoid valve.
to 8-unit solenoid
Raise Pilot Pressure, NO valve is normal.
Arm Roll-In Pilot
Pressure · Check only when
· Possible to display Faulty pilot valve.
boom is not raised. NO
with built-in diagnos- · Check only ZAXIS
In case cylinders
ing system. 135UR. Skip this
other than boom
step and proceed to
are abnormal, skip
the NO line except
this step and pro-
ZAXIS135UR.
ceed to the NO line.
T5-4-61
F-3 Arm speed is slow in a combined operation.
Arm speed is slow during arm level crowd-
ing.
• Refer to the pages for the Arm Regenerative

Control and the Arm Flow Rate Control in the
SYSTEM / Control System group in the T/M (Op-
erational Principle).
Disconnect solenoid
valve unit (SC). Con-
nect test harness (ST Faulty solenoid valve
7226) between sole- YES unit (SC).
Monitor output from noid valve unit (SC)
solenoid valve unit NO and harness. Check if
(SC). Install pressure test harness lamp
comes ON. Broken harness be-
gauge to port SC.
tween solenoid valve
Compare pressure NO unit (SC) and MC.
measured by Dr. ZX
NO with that measured by
pressure gauge. Check · Perform boom raise and
if both pressure values arm roll-in combined
vary identically. operation.
Faulty arm regenerative

YES valve.
Check if arm regenera-
Check if any fault
· Monitor item: tive valve in 5-spool
codes are dis-
played. · Arm Regenerative Pro- YES section of control valve
portional Solenoid Valve is scored or bound. Find out cause of trou-
Output ble by tracing other
NO trouble symptoms.
· Perform boom raise and
· Fault Codes: arm roll-in combined op-
11: Pump 2 Delivery eration.
Pressure Sensor · Refer to the Operational
14: Pressure Sen- Performance Test.
sor (Swing) Faulty corresponding
15: Pressure Sen- sensor or faulty MC, or
sor (Boom Raise) broken harness be-
16: Pressure Sen- YES tween MC and sensor.
sor (Arm Roll-In)
NOTE: In case other fault · Refer to T4-6-6.

codes are displayed,
perform trouble-
shooting corre-
sponding to the dis-
played fault code.
T5-4-62
F-4 Bucket is slow in bucket roll-in single op-
eration. Bucket doesn’t move smoothly in
bucket roll-in single operation.
• Faulty bucket flow rate control valve or bucket

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

control valve (Disas-
YES semble and clean, or
replace.)
Signal Control Valve

Bucket Flow Hose (SK)
Rate Control
Valve
T176-05-04-001
T5-4-63
F-5 When starting to move in combined opera-
tion, arm doesn’t smoothly move. Arm starts
to move slightly slow in arm roll-in single
operation. These troubles often occur when
oil temperature is low.
• Refer to the COMPONENT OPERATION / Con-

trol Valve group in the T/M (Operational Princi-
ple).
Faulty arm regenerative valve

YES (Disassemble to clean, or re-
Check if arm regenera- place.)
tive valve is bound or
NO
scored.
Check if arm anti-drift valve is
bound or scored. Find out cause of trouble by
tracing other trouble symp-
NO toms.
Faulty arm anti-drift valve

YES (Disassemble to clean, or re-
place.)
F-6 When starting to move in combined opera-

tion, boom doesn’t move smoothly. Boom
starts to move slow slightly in boom lower
single operation.

Find out cause of
• Refer to the COMPONENT OPERATION / Con- trouble by tracing
other trouble symp-
trol Valve group in the T/M (Operational Princi- toms.
ple). NO
Check if boom regen-

erative valve is bound
NO or scored. Faulty boom regen-
erative valve (Disas-
Check if boom semble to clean, or
anti-drift valve is replace.)
YES
bound or scored.
Faulty boom anti-drift

valve (Disassemble to
YES clean, or replace.)
T5-4-64
F-7 When boom raise or arm roll-out is operated,
boom or arm starts to move after moving
slightly downward.
YES Faulty anti-drift valve.

Check if anti-drift
valves (arm and
YES boom) are bound or
scored.
Oil leaks in cylinder.
Check if load check
valve in control NO
valve is normal.
Faulty load check

· Disassemble / valve.
Visual Inspection NO
NOTE: 1. During the initial stage of operation, oil

pressure and flow rate from the pump is
low. Therefore, if the load check valve
is malfunctioning, the oil in the bottom (B)
side of the boom cylinder flows back
into the circuit through the load check When the load check
valve, causing the boom cylinder to valve is faulty: (A)
temporarily retract.
2. Since oil pressure and flow rate from
the pump is low, if oil leaks from bottom
side (A) to rod side (B) due to faulty
boom cylinder piston or cylinder barrel,
the boom cylinder is temporarily re-
tracted during the initial stage of opera-
tion. In addition, cylinder force is
reduced, increasing the cylinder drift in T105-07-04-012
this case.
T5-4-65
F-8 Front attachment drifts remarkably.
• In case a large oil leak is detected in the right

offset system (ZAXIS135UR), refer to F-10.
YES Normal.
Correctly adjust
Check if each front
NO emergency valve and
attachment cylin- Check if emergency lock it up.
der drift is within valve at boom 1 sec-
specification. tion in control valve
NO
4-spool section is cor- Check if symptom is
rectly adjusted. deleted when overload
Check if cylinder drift
· Specification: relief valve is tempo-
is reduced when pilot
Refer to YES rarily switched with
shut-off valve is
Operational another overload relief
NO closed.
Performance valve.
Test
Faulty pilot valve.
YES
• Boom Cylinder Internal Leakage Check
1. With the bucket cylinder fully retracted and the

arm cylinder slightly extended from the fully re-
tracted position, lower the bucket tooth tips onto
the ground.
2. Disconnect hoses from the boom cylinder rod T105-07-04-009

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

ground. If oil flows out of the hose disconnected
pipe ends and the boom cylinders are retracted
at this time, oil leaks in the boom cylinders. In
case no oil flows out of the hose disconnected
pipe ends but the boom cylinders are retracted,
oil leaks in the control valve.
T5-4-66
Emergency
Valve
Scored control 2
valve spool, broken
NO spring, or loose
spool end.
Check if oil
NO leaks in cylin-
ders.
Faulty cylinder
(Replace seal kit.).
YES
Faulty overload
relief valve.
YES T155-06-04-001
Adjustment Procedure:
Turn screw (1) counterclockwise to the stop, then
tighten lock nut (2).
: 4 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf·ft)
T5-4-67
F-9 The single offset operation is slow or im-
movable. (ZAXIS135UR only)
End (Stuck offset

YES anti-drift valve)
Disassemble to clean
offset anti-drift valve.
YES Check if symptom is
Check if pressure at
corrected. Stuck spool in con-
port SM on signal con-
YES trol valve is equal to trol valve.
primary pilot pressure. NO
Stuck shuttle valve

in signal control
Check if primary NO valve
pilot pressure is · Offset front attachment
normal. to right and left.
Faulty 8-unit sole-

Check if secondary YES noid valve (Stuck
· Standard: Refer to pilot pressure at 8-unit spool or shuttle
Operational Per- solenoid valve inlet valve)
formance Test port is normal
section. NO
· Offset front attachment Faulty pilot valve

to right and left.
NO
Control Valve
Port SM (Control Valve Side)
8-Unit Solenoid
Valve
Left Offset Pilot

Pressure
Front
Ring Offset
Pilot Pressure
T1SM-05-04-001
T178-03-06-015
T5-4-68
F-10 Offset cylinder drifts remarkably (right side).
(ZAXIS135UR Only)
YES Faulty pilot valve.
Check if Cylinder
drift is reduced
when pilot shut-off
valve is closed. Faulty offset anti-drift
YES valve.
Disassemble and
clean offset anti-drift
valve. Check if symp-
NO tom disappears. Faulty control valve.
YES
Scored control valve

spool, broken spring or
NO loosened spool end. Faulty cylinder
(internal leakage).
NO
T5-4-69
F-11 Front control (front movement restriction,
cab collision prevention, auto-MARCCINO)
is abnormal. (ZAXIS135UR Only)
• When a fault code is displayed, refer to T5-6

(Trouble shooting D).
• When adjusting front speed, refer to T4-6-2.
hand. End (Binding
8-unit solenoid
YES
valve.)
Disassemble and
clean 8-unit sole-
noid valve.
Reassemble. YES Faulty harness.
Check if trouble is Check 8-unit sole-
corrected. noid valve harness
NO breakage or short Faulty Auto-
circuit. MARCCINO con-
NO
trol unit.
T5-4-70
(Blank)
T5-4-71
SWING SYSTEM TROUBLESHOOTING
S-1 Swing is slow or unmoving.
• Check whether the pilot system is faulty or the

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

Check if swing parking YES brake release valve is
brake release pres- scored or bound.
sure is approx. 3.9
Monitor pump control MPa (40 kgf/cm2).
pressure while slowly YES
operating swing lever.
Check if pump control Faulty swing parking
pressure varies · Relieve arm circuit. brake release spool in
smoothly. · Monitor item: signal control valve.
YES Front Attachment Con- NO
Monitor secondary trol Pilot Pressure.
pilot pressure. · Possible to display with
Check if secondary built-in diagnosing sys- Bound pump 2 flow rate
pilot pressure is · Monitor item: tem. control valve in signal
normal. Pump 2 Flow Control control valve.
Pressure NO
· Possible to display with
built-in diagnosing sys-
tem. Faulty pilot valve.
· Specification: NO
Refer to OPERA-
TIONAL PER-
FORMANCE TEST
Section.
· Monitor item:
Swing Control Pilot
Pressure
with built-in diag-
nosing system.
T5-4-72
Faulty swing reduction

YES
gear.
Check if swing motor
drain oil amount is
YES normal.
Check if swing relief · Measurement: Faulty swing motor.

pressure is normal. Refer to OPERA-
YES NO
TIONAL PER-
FORMANCE TEST
· Relieve swing circuit. Section.
· Monitor item: Pump 2 De-
livery Pressure Faulty swing relief
· Specification: valve.
Refer to OPERATIONAL NO
PERFORMANCE TEST
Section.
Faulty swing motor

NO parking brake release
valve.
T5-4-73
(Blank)
T5-4-74
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Both right and left tracks do not rotate or
rotate slowly.
• Both right and left pilot valves, travel motors,

and/or control valve spools are unlikely to be
faulty at the same time.
• In case both travel systems do not operate, the
pilot system, which is applied to both side travel
motors, may be faulty. If the primary pilot pres-
sure is lower than specification, the front attach-
ment operating speed becomes slow as well.
Refer to A-1.
• In case the fast travel mode cannot be selected,
refer to T-5.
T5-4-75
T-2 One side track doesn’t rotate or rotates
slowly. Machine mistracks.
• Check that both side track sags are equally ad- • In one side track only doesn’t rotate, the pilot
justed. valve, control valve, travel motor, or center joint
• Faulty pump control will cause the machine to may be faulty.
mistrack. In this case, other trouble symptoms
such as slow bucket or swing single operation Check if travel motor
YES drain oil amount is nor-
speed, or slow arm roll-in and boom raise speed mal.
in level crowd operation will occur at the same
Check if travel relief
time. If both mistrack and other symptoms as
pressure in slow speed · Specification: Refer
described above occurs at the same time, refer side is normal. to OPERATIONAL
to A-2 and A-3. NO PERFORMANCE
TEST section.
· Relieve travel circuit.
Check if symptom is · Monitor item: Pump 1 and Switch forward travel
reversed when right 2 Delivery Pressure relief valve with reverse
and left travel line · Possible to display with travel one, or right travel
built-in diagnosing system relief valve with left one.
YES hoses are switched · Specification: Check if symptom is
each other at the top of
center joint. Refer to OPERATIONAL reversed.
PERFORMANCE TEST NO
Check if secondary section.
travel pilot pressure
is normal.
Bound control valve
spool.
Measurement: YES
Refer to OPERA-
TIONAL PER- Faulty pilot valve.
FORMANCE NO
TEST section.
Relationship between Faulty Seal Location Seal Location

and Mistrack Direction
Seal When traveling When pivot turn
No. straight: is performed:
2 Blade Lower
（ZAXIS135UR Only）
Blade Raise
1
3 Right Travel
(Reverse)
Left Travel 2
(Reverse) 3
4
Right Travel
(Forward)
Left Travel
(Forward) 4
5
5
T198-05-04-004
NOTE: The figure shows for ZAXIS135UR.
T5-4-76
Faulty travel motor.

NO
YES Faulty travel reduction

Disassemble and clean
gear.
travel motor servo pis-
YES ton. Check if same
Disassemble and symptom occurs.
clean travel motor Faulty travel motor
counterbalance valve. servo piston.
Check if same symp- NO
YES tom occurs.
Faulty counterbalance
valve.
NO
NO Faulty center joint.
Faulty travel relief

valve.
YES
Arrangement of Upper Pipe Line in Center Joint

Front
Dr port
Left Travel
(Forward) Right Travel
(Forward)
Blade Lower
Left Travel Right Travel
(Reverse) (Reverse)
Blade Raise
Back
T198-05-04-003
T5-4-77
T-3 Machine mistracks during travel and front
attachment combined operation.
Related Fault Code: None Faulty flow combiner

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

YES valve.
Control Valve
Hose (SL)
T176-05-04-001
T5-4-78
(Blank)
T5-4-79
T-4 Fast travel is inoperable.
Travel mode doesn’t change from slow
mode to fast mode.
• Refer to the pages for the Travel Motor Swash

Angle Control in the SYSTEM / Control section in
Faulty travel mode switch or
• Check for loose harness connections before- broken harness between
hand. travel mode switch and MC.
NO
Monitor travel mode

switch. Check if dis- Check if symptom is re-
played indication is versed when pressure
highlighted in response sensor (travel) is switched
to travel mode switch NO with another pressure sen-
NO operation. sor.
Monitor pressure sen-

sor (travel). Check if
· Monitor item: Monitor travel motor
pressure varies in re-
Travel Mode swash angle. Install pres-
sponse to travel lever
sure gauge to solenoid
operation.
valve unit (SI) output port.
YES Check if pressure meas-
ured by Dr. ZX varies iden-
Check if any fault tically with pressure
· Monitor item: Travel Con- measured by pressure
codes are displayed.
trol Pressure gauge while repeating to
travel and stop.
YES
· Monitor item:
Travel Motor Swash Angle
Control Pressure
· Travel Mode: Fast
· Measurement: Refer to
OPERATIONAL PER-
FORMANCE TEST section.
Faulty corresponding sen-

sor or broken harness be-
YES tween MC and sensor.
· Fault Codes:
10: Pump 1 Delivery Pressure Sen-
sor
11: Pump 2 Delivery Pressure Sen-
sor
12: Pump 1 Control Pressure Sensor
NOTE: In case other fault
codes are displayed,
perform troubleshooting
corresponding to the
displayed fault code.
T5-4-80
Faulty pressure sensor

YES (travel).
Broken harness between

travel pressure sensor and
MC or clogged shuttle
valve in signal pressure
control valve.
NO
Disconnect solenoid
valve unit (SI). Connect Faulty solenoid valve unit
test harness (ST 7226) YES
(SI).
between solenoid valve
NO unit (SI) and harness.
Check if test harness
lamp comes ON. Broken harness between
solenoid valve and MC.
NO
· Travel Mode: Fast YES
Faulty travel motor swash
Check if travel motor angle control valve.
swash angle control
YES valve is bound or
scored. Faulty travel motor or faulty
travel reduction gear.
NO
T5-4-81
BLADE SYSTEM TROUBLESHOOTING
(ZAXIS135UR ONLY)
B-1 Single blade operation is slow or weak in
power.
• Check whether the pilot system or the main cir- • The pressure oil from main pumps 1 and 2 is
cuit system is faulty. jointlysupplied to the blade circuit to increase the
• In case the machine mistracks, a potential cause blade speed. In case only the operation speed is
is sticking of the flow combiner valve or the shut- slow (strong in power), potential cause may be
tle valve between the signal control valve and the faulty main relief valve (in the blade circuit). Even
flow combiner valve. if the main relief valve (in the blade circuit) is
faulty, the oil pressure is maintained by the main
relief valve in the main circuit.
IInstall pressure gauge

to outlet port (P2) on YES
Install tee to port Pi on YES blade signal switch
blade signal switch valve. Check if pres-
valve. Check if pressure is 4 MPa or more.
sure at port Pi is equal Stuck blade signal
YES to secondary pilot switch valve
pressure. NO
Stuck shuttle valve (b)

Check if secondary between blade pilot
pilot pressure is valve and blade signal
normal. NO switch valve
· Standard:
Refer to Operational
Performance Test.
Faulty blade pilot valve
NO
Blade Pilot Circuit
Blade Pilot Valve

Signal Control Valve Shuttle Valve (a)
Shuttle
Shuttle Valve (a)
Valve (b)
Control
Port (P2) Valve
Flow Combiner
Port （Pi） Port
Valve Port
（Pi）
Bypass
Blade Signal Shut-Off
Switch Valve Valve Port
Port
(P2)
Pilot Pump
Blade Signal T1SM-05-04-003
Switch Valve
T1SM-05-04-002
T5-4-82
Stuck bypass shut off

YES valve.
Disassemble to clean by- Remove blade cylin- Faulty center joint or oil
pass shut off valve in con- der. Retract blade cyl- NO leakage in control valve.
trol valve. Check if symp- inder full stroke. Con-
tom is corrected. nect only rod side pipe
line to cylinder. Check
YES if oil flows out of bot-
tom side port when oil
Check if main relief is supplied into cylinder
pressure in blade cir- via rod side oil port.
cuit is normal.
Faulty cylinder seal.
NO
YES
Faulty main relief valve in

blade circuit.
NO
T5-4-83
B-2 Blade Drift is Large.
Checking Instructions
• When the blade does not stop lowering, refer to
A-4. Faulty center joint,
Remove blade cylinder or control valve
and fully retract it. Then, internal leakage.
connect hydraulic line to NO
cylinder rod side only and
NO perform blade raise op-
Check if symptom eration. Check if oil flows
disappears when up- out of cylinder bottom Faulty cylinder
per and lower over- side oil port. seal.
load relief valves are YES
switched.
Faulty overload
relief valve.
NOTE: Be sure to reinstall YES
overload relief valves
to their original posi-
tions since each of
their set pressures is
different.
T5-4-84
(Blank)
T5-4-85
OTHER SYSTEM TROUBLESHOOTING
O-1 Wiper is inoperable or not retracted.
(ZAXIS110/110M/120/130)
• The wiper is driven by electric power routed via

the relay circuit controlled by the monitor assem-
bly. In case the wiper is inoperable, first check
the wiper motor and links for any abnormality us-
ing an auxiliary electric power and the test har-
ness.
• If the front window is open, the wiper won’t oper-
ate. Check that the front window is securely
closed.
Faulty front window
open/close switch or
short-circuited harness
between front window
YES open/close switch and
monitor.
Disconnect front
window open / close Remove test harness
switch. Check if and reconnect circuit to YES Faulty wiper relay.
Connect test har- the original position.
wiper operates. ness (ST 7227) be- Replace wiper relay
tween auxiliary elec- YES one at a time. Check if
tric power (fuse box wiper operates.
· Key switch: ON #19) and wiper motor
as illustrated to the To A
right. Check if wiper NO
NO · Key switch: ON
operates.
Faulty wiper motor or
NO or test har- faulty links.
ness lamp doesn’t
· Key switch: ON light normally.
NOTE: When the wiper motor
is normal, lamp S lights
while the wiper is mov-
ing within the operating End (Faulty monitor).
YES
range. Both lamps B
and S light for a mo-
ment at the same time Replace monitor as-
only when the wiper A sembly. Check if wiper
reaches the intermittent operates. Faulty cab harness.
stop position.
NO
T5-4-86
Test Harness Application Circuit

Fuse Box #19
Lamp S
M B S
Lamp B Wiper Motor
L E
Ground
T178-05-04-004
Wiper Operating Range Intermittent Stop Position
Retracted Position
Operating Range
T178-05-04-005
Test Harness Connection Method
Wiper Motor Lamp B
Lamp S
Test Harness Fuse Box
T157-07-04-004
T5-4-87
O-2 Wiper is inoperable
(ZAXIS125US / 135US/ 135UR)
• When the front window is opene, the wiper will

not operate. Make sure that the window is se-
curely closed. Dust on the contact points of the
switch may cause discontinuity in the circuit. Be
sure to carefully inspect wiring connections prior
to troubleshooting.
YES
Faulty wiper relay
Switch wiper relay with Measure voltage at

washer relay. Check if connector terminal S YES Faulty wiper motor
wiper operates. on wiper motor.
Check if voltage varies
0 to 24 V in response
YES to wiper operation in-
Check if voltage at tervals.
Connector terminal B
on wiper motor is 24 V
or more.
NO · Key Switch: ON
· Wiper Switch: ON NO
· Without disconnecting,
· Key Switch: ON
ground the connector to
· Without disconnecting,
vehicle using a clip from
ground the connector to Blown fuse #12 or bro-
the reverse side of the
vehicle using a clip from ken wire between fuse
connector.
the reverse side of the #12 and wiper motor
connector. terminal B.
NO
ZAXIS125US, 135US
Wiper Relay
ZAXIS135UR
Washer Relay
Washer Relay
Wiper Relay
T1SM-01-02-006
T1CF-01-01-013
T5-4-88
Faulty monitor
Check if continuity be- YES
tween wiper relay terminal
#2 and terminals shown
below is present.

· ZAXIS125US, 135US: Con- wiper relay and monitor
nector C terminal #6 NO
· ZAXIS135UR: Connector C
terminal #5
Connector (Harhess End Connector Viewed the Open Side)

ZAXIS125US, 135US
Monitor Connector
10 1 Wiper Motor
1
20 11
T1SM-05-04-004
ZAXIS135UR
Monitor Connector C
Relay
8 1
1
16 9
T1SM-05-04-005
T5-4-89
O-3 Malfunction of Air Conditioner
NOTE: The self-diagnosis function is not equipped
for ZAXIS135UR.
ZAXIS110, ZAXIS110M, ZAXIS120, ZAXIS130,
ZAXIS130LCN
The air conditioner has a self-diagnosis function.
The self-diagnosis functions to:
1) Display Fault Codes
2) Change Displayed Fault Codes
3) Delete Fault Code
4) End Fault Code Display
• Display Fault Code

1. Press the fan OFF switch to turn the fan OFF. Temperature
2. Press and hold both the upper and lower sides of Fan OFF Switch Control Switch
the temperature control switch on the air condi-
tioner control panel at the same time for more
than 3 seconds with the key switch ON.
NOTE: After operation has been performed, the
buzzer will sound.
3. If any fault codes are found, the LCD displays the M178-01-017
fault codes as E{{. LCD
NOTE: If more than one fault code is found, the

lower number fault code will be displayed
first.
T5-4-90
Fault Code List
Fault
Location in Trouble Cause Symptom
Code
Abnormal circulation E11 Broken circuit in air circulation Y value (air flow-in temperature) cannot
air sensor sensor be adjusted in response to the
E12 Short-circuited circulation air set-temperature.
sensor
Abnormal fresh air E13 Broken circuit in fresh air sensor Operation is controlled under such cir-
sensor E14 Short-circuited fresh air sensor cumstance as no fresh air sensor is pro-
vided.
Abnormal solar E18 Short-circuited solar radiation Operation is controlled under such cir-
radiation sensor sensor cumstance as no solar radiation sensor is
provided.
Abnormal evapora- E21 Broken circuit in evaporator sen- Operation is controlled under such cir-
tor sensor sor cumstance as the evaporator temperature
E22 Short-circuited evaporator sen- is set to 10 °C (50 °F).
sor
Abnormal damper E43 Abnormal air vent damper Corresponding damper servo becomes
E44 Abnormal air mix damper inoperable.
E45 Abnormal circulation/fresh air
damper
Water temperature E15 Broken circuit in water tempera- Operation is controlled under such cir-
sensor ture sensor cumstance as the water temperature is
E16 Short-circuited water tempera- set to 60 °C (140 °F). (Warm-up control is
ture sensor not performed.)
Abnormal refrigerant E51 Abnormal high/low refrigerant The compressor clutch is disengaged.
pressure (The compressor stops.)
T5-4-91
• Change Displayed Fault Code
1. When displaying more than one fault code, press Temperature
either the upper or bottom side of the tempera- Control Switch
ture control switch key. The following fault code is
displayed.
NOTE: Each time the displayed fault code is
changed, the buzzer sounds. In case only
one fault code exists, the displayed fault
code remains unchanged.
M178-01-017
LCD
• Delete Fault Code

LCD
1. Press and hold both the circulation air switch and
the fresh air vent switch for more than 3 seconds
at the same time to delete the fault code.
NOTE: After the fault code is deleted, the buzzer
will sound.
2. After the fault code has been deleted, the LCD

displays E{{. M178-01-017
Circulation Fresh Air vent
Air Switch Switch
Fan OFF Switch
• End Fault Code Display

1. Press the fan OFF switch, or press the upper
side of the fan switch key. The self-diagnostic
mode is complete.
M178-01-017
Fan Switch
T5-4-92
The air conditioner operation system has a

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

conditioner switch and mode switch.
Keep pressing OFF switch

for more than 3 seconds. STEP 0
Check Model Confirmation
Press lower side fan switch. Press upper side fan switch.
Keep pressing OFF switch STEP 1
for more than 3 seconds. Display Function Con-
firmation
Keep pressing OFF switch STEP 2
for more than 3 seconds. Present Trouble
Diagnosing
Keep pressing OFF switch STEP 3 Keep pressing air conditioner

for more than 3 seconds. Past Trouble Di- switch for more than 3 seconds.
agnosing
Sensing Temperature
Display
Component Operation Check
Press AUTO switch and Press AUTO Press A/C Press A/C switch and
lower side fan switch. Switch and switch and lower side fan switch.
upper side upper side
fan switch. fan switch.
Keep pressing OFF switch STEP 6-1 STEP 6-2
for more than 3 seconds. Correction of the Set Selection of Celsius and Fahrenheit
Temperature Temperature Indication
for more than 3 seconds.
Self-Diagnosis
T5-4-93
Self-Diagnostic System Activation
Fan Switch LCD Air Conditioner Switch
Turn the key switch ON while pressing the air condi-
tioner switch and mode switch on air conditioner
control panel.
STEP 0 Check Model Confirmation

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

• The LCD will indicate “Sd” as the check model
name (ZAXIS125US/135US).
• Select next step to be performed by operating the
switch as described below.
• Upper side fan switch: To proceed to Step 1
• Keep pressing OFF switch for more than 3 sec-
onds: To return to normal operation
NOTE: The system operation will automatically
proceed to STEP 1 after 5 seconds have
passed after the check model is displayed.
STEP 1 Display Function Confirmation

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

• Select the next step to be performed by operating
the switches as follows:
• Press the upper side of the fan switch: To pro-
ceed to “STEP 2.”
• Press the lower side of the fan switch: To return
to “STEP 0.”
• Keep pressing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed)
T5-4-94
STEP 2 Present Trouble Diagnosing
The LCD indicates the fault codes for present ab-
Fan Switch LCD
normalities of the mix door, mode encoder, and/or
sensors.
• In case any abnormalities are present, the LCD in-

dicates the fault codes. If more than one fault code
is detected, the following fault code is displayed af-
ter flashing (0.5 seconds) twice.
Fault Code T178-05-08-001
Breakage Short Circuit OFF Switch
Mix Door 21 −21
Mode Encoder 22
In-Cab Ambient 23 −23
Temperature Sen-
sor
Outdoor Ambient 24 −24
Temperature Sen-
sor
Coolant Tempera-  
ture Sensor
∗
Solar Radiation 26 −26
Sensor
∗
: When solar radiation is shaded, the solar radiation
sensor indicates the fault code of breakage.
NOTE: As for coolant temperature sensor, no fault
codes display. In case no failures are pre-
sent, the LCD indicates “20.”
to “STEP 1.”
T5-4-95
STEP 3 Past Trouble Diagnosing
The LCD indicates the fault codes for past abnor-
malities of the mix door, mode encoder, and/or sen-
sors.
The past stored fault codes are deleted.
• In case any abnormalities occurred in the past, the

LCD indicates the fault codes. If more than one fault
code is detected, the following fault code is dis-
played after flashing (0.5 seconds) twice. T178-05-08-001
Fault Code OFF Switch
Breakage Short Circuit
Mix Door 21 −21
Mode Encoder 22
In-Cab Ambient
Temperature Sen- 23 −23
sor
Outdoor Ambient
Temperature Sen- 24 −24
sor
Coolant Tempera-  
ture Sensor
Solar Radiation −26
Sensor
NOTE: As for coolant temperature sensor, no fault
codes display. In case no failures are pre-
sent, the LCD indicates “30.”
• When the air conditioner switch is kept pressed for
more than 3 seconds, failure records are deleted.
After this operation, the air conditioner switch indi-
cator flashes 5 times. Then, the self-diagnosing
system is deactivated. (Normal functions are re-
sumed.)
to “STEP 2.”
T5-4-96
STEP 4 Sensing Temperature Display Fan Mark
The LCD indicates the sensing temperature detected
by each temperature sensor (excluding the insulation
sensor).
• The sensing temperature detected by the in-cab

ambient temperature sensor, outdoor ambient tem-
perature sensor, and coolant temperature sensor
are displayed on the LCD in real time. (Figures less
than the decimal point are not displayed.) T178-05-08-001
NOTE: The coolant temperature sensor indicates Fresh Air Switch OFF Switch
“H” when coolant temperature is more than
21 °C (70 °F) and “L” when coolant tem-
perature is less than 21 °C (70 °F).
• Sensing temperature detected by each sensor is
automatically displayed on the LCD and is cycled at
an interval of 3 seconds with the timer. The timer is
turned ON or OFF by operating the fresh air vent
switch.
• Referring to the fan mark can check which sensing
temperature is displayed.
to “STEP 3.”
T5-4-97
STEP 5 Component Operation Check Air Conditioner
Fan Switch LCD Switch AUTO Switch
Each component operation is checked by performing
pattern operation.
• Each time the fresh air vent switch is pressed, the

component to be checked is selected in order.
Check which component has been selected by re-
ferring to No. indicated on the LCD. (See table 1.)
• Operating pattern of the selected component is T178-05-08-001
shifted at an interval of 10 seconds. Operating pat-
Fresh Air Vent switch OFF Switch
tern is cycled. (See table 1.)
NOTE: The components other than selected oper-
ate under the standard conditions (shown
by marks* in table 1).
• Press the AUTO switch and upper side of the fan
switch: To proceed to “STEP 6-1”.
• Press the air conditioner switch and upper side of
the fan switch: To proceed to “STEP 6-2”.
to “STEP 4.”
Table 1
Component Indication Operation Pattern Remarks
on LCD
Air Mix Damper 51 Controls opening extent of air mix 0%, 50%, 100%: “C”, “5”, and “H” are
damper: 0% (fully closed) → indicated next to the decimal point
50%*→ 100% (fully opened) respectively.
Fan 52 Controls air flow volume: Lo → Indicators corresponding to air flow
M (Lo) → M (Hi) → Hi volume light.
Air Vent Location 53 Selects air vent: Front*→ Indicator corresponding to selected
Front/Rear → Front/Foot → Foot air vent lights.
Fresh/Circulation 54 Select Ventilation Mode: Circula- Indicator corresponding to selected
Air Vent Selection tion* → Fresh mode light.
Air Conditioner 55 Turns air conditioner switch: ON* → ON: Indicator lights.
OFF OFF: Indicator is extinguished.
T5-4-98
STEP 6-1 Correction of the Set Temperature
Fine correction of the set temperature. Temperature
Fan Switch LCD Control Switch AUTO Switch
• Each time when the top or bottom of the tempera-

ture control switch is pressed, temperature correc-
tion, displayed on the LCD window, can be
changed.
• Actually controlled temperature is the normally set
temperature plus the set temperature correction.
For instance, when the normally set temperature is T178-05-08-001
25°C (77 °F) and set temperature correction is -1°C OFF Switch
(-34 °F), the actually controlled temperature be-
comes 24°C (75 °F).
• Press the AUTO switch and lower side of the fan
switch: To return to “STEP 5.”
T5-4-99
STEP 6-2 Selection of Celsius and Fahrenheit
Temperature Indication
Selection of Celsius and Fahrenheit Temperature In-
dication.
• Each time when the fresh air vent switch is pressed,
Celsius or Fahrenheit temperature may be dis-
played alternately.
• Temperature is displayed at the top of the LCD
window as follows.
(C: Celsius, F: Fahrenheit) T178-05-08-001
C F Fresh Air Vent Switch OFF Switch

• Press the Air Conditioner Switch and lower side
of the fan switch: To return to “STEP 5.”
T5-4-100
∗ Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to Hitachi Tsuchiura Works Quality Assurance Dept. after
experiencing a problem with your machine’s air conditioning system.
< AIR CONDITIONER TROUBLE REPORT > File No.
(1) What Checked by:
Model (Serial No. )
Operation Type Manual Semi-Auto Full-Auto
Delivery Date Year Month
(2) When
Date Year Month Day Operating Hour ( h)
Time Morning Daytime Evening Night
Frequency Every Day Once a Week Once a Month Times per
(3) Where
Job Site Address State County Town
Access Road Condition Paved Not Paved (Gravel Sand Soil)
(4) How (Operating Conditions)
Weather Fine Cloudy Rain Snow
Atmospheric Temperature Very Hot Hot Cold Very Cold
Operating Conditions Parking Traveling Working
Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when
full-auto operation
A/C ON OFF
Control Air Induction Re-Circulation Fresh Air Circulation
Panel AUTO ON OFF Not Available
Fill following items when operated in manual mode or when manual control type unit is used.
Vent Position Front Front / Rear Foot Front / Rear and Foot
Fan First Second Third Fourth Fifth Sixth
(5) How (Problem Symptom)
Abnormal Compressor Operation
Symptom Not turned ON <Check Result>
Not turned OFF (1) Is problem reproducible ?
Others Reproducible
Uncontrollable air temperature Not reproducible
(2) Pressure (To be measured at gauge manifold)
Symptom No cool air
Low Pressure
No warm air
High Pressure
Others
(3) Which parts have been replaced ?
Uncontrollable air volume
1
Symptom Air flows in Hi mode only
No air flows
2
Small air volume
Others
Uncontrollable vent hole
∗ Before replacing the control amplifier, be sure to
check that the connectors are correctly connected
Symptom Vent hole isn’t selected
while repeatedly disconnecting and reconnecting
Others connectors.
Abnormal panel indication
Faulty Indicator Vent Hole
A/C
AUTO
Fresh Air Circulation
Fan OFF
Fan (Lo • •• Hi)
Temperature Control
Symptom Stays OFF
Stays ON
Blinks
Others
T5-4-101
ZAXIS110, ZAXIS110M, ZAXIS120, ZAXIS130, ZAXIS130LCN:
Refrigerant Quantity ....................... 900±50 g
Compressor Oil Quantity................ 180 cm3
ZAXIS135UR
T5-4-102
(Blank)
T5-4-103
Cooling Circuit
Refrigerant pressure Bubbles can be seen in sight Piping and/or parts are stained with oil,
in both high and glass. respond to gas detector.
low-pressure sides is
low.
No oil stain is found or gas detector
doesn’t respond. Refrigerant has not
been refilled for longer than one sea-
son.
No bubbles are seen in sight
glass.
After cooling at fast speed continu-

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

ously, cooling power is reduced. Air Frost forms. Thermistor doesn’t cool.
flow volume is reduced.
Thermistor cools.
T5-4-104
Gas leaks from pipe joints and/or parts. Re-tighten or replace parts.
Normal leakage of refrigerant from hoses. Refill refrigerant.
Improper adjustment (excessive restriction) of expansion Readjust or replace expansion valve.

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

valve.
Clogged low-pressure circuit and/or evaporator. Remove clog, or replace parts.
Frozen expansion valve or water in circuit. After evacuation, refill refrigerant and/or replace re-
ceiver dryer.
Gas leaks from case. Seal gaps using vinyl tape or packing compound.
Poor contact of expansion valve temperature sensing cylinder. Make good contact. Replace temperature sensing
stay.
Improper adjustment (excessive open) of expansion valve. Readjust or replace.
Insufficient compressor discharge (faulty gasket and/or valve). Replace.
Improper water stop valve wire adjustment and/or faulty stop

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

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

Air is mixed in system.
ceiver dryer.
Incorrect thermistor location. Correct thermistor location.
Gas leaks from case. Seal gaps using vinyl tape or packing compound.
Faulty thermistor (stays ON). Disconnected thermistor cord.
Even if function and performance are normal, when Instruct user on correct air-conditioner operation.
air-conditioner is kept operated for a long time with thermistor (Reset thermistor to either minimum or middle cooling
in max. cooling position and air flow in M or L mode, frost may position or increase air flow.)
form.
T5-4-105
Cooling Circuit
Case connection. Louver resonance.
Fan contacts case, or foreign matter enters case.

Blower fan connection.
Brush friction noise, metal and/or thrust washer con-
tact noise.
Gas blowing sound (roaring). Gas vibration noise (compressor discharge and/or
suction gas noise).
Expansion valve connection, whistle Abnormal noise from expansion valve (Expansion
Noise sound, gas blowing sound. valve is normally functioning.).
Faulty clutch bearing, and/or idle pulley bearing.
Clutch disengaging sound.

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

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

Abnormal smell.
T5-4-106
Repair or replace.
Remove foreign matter. Readjust fan motor location.
Slight noise is unavoidable.

Replace if loud.
No functional problem exists.

Provide silencer if intolerable.
Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.
Replace.
Repair or replace clutch. Re-tighten screws.
Repair or replace.
Re-adjust drive belt.
Replace.
Clean.
Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in
L mode for more than 10 minutes, flush smell out by condensed water.
T5-4-107
Compressor
Compressor doesn’t rotate. Clutch terminal voltage is normal 24 V.
Inoperable
cooling Clutch terminal voltage is low.
system.
Clutch terminal voltage is 0 V.
Bubbles exist even after refrigerant is refilled.
Both high and

low side Check for oil and refrigerant leaks from parts other than
pressures are compressor and pipe joints using gas detector.
low.
Both com- Check for oil and refrigerant leaks from compressor (no
pressor and leaks from parts other than compressor) using gas de-
blower mo- tector. (Refer to NOTE 2 on page T5-4-111.)
tor rotate.
Stain on exterior.
(Refer to NOTE 1
on page T5-4-111.)
Refrigerant has not been refilled for longer

than one season.
Refrigerant is discharged within 1 to 2

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

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

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

sight glass.
High pressure side is high.
Refer to the Cooling Circuit Troubleshooting
Table on page T5-4-104.
Temperature is not cooled when compressor is
operated at fast speed continuously.
Air flow from blower is insufficient.
T5-4-108
Seized clutch. Replace.
Improper gap between amature and rotor (improper air gap).

Replace.
Broken or short-circuited core cable.
Shaft doesn’t rotate (internally locked). Replace.
Faulty Electrical System.
Faulty Electrical System.
Oil leaks from mechanical seal, gasket, and/or charge valve.

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

refrigerant.
No leaks (normal).
Refer to the Cooling Circuit Troubleshooting Table on page T5-4-104.
Broken valve (See NOTE 3 on page T5-4-111.)
Replace.
Blown gasket (See NOTE 3 on page T5-4-111.)
Check and adjust

Excessive oil. oil level.
T5-4-109
Compressor
Noise is heard when clutch is OFF.
Abnormal
noise
Noise is heard when clutch is ON.
T5-4-110
Broken clutch bearing.

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

Troubleshooting Table on
page T5-4-104.
Loose screws.
Broken valve.
Replace.
Blown gasket.
Abnormal internal noise. Replace.
Vibration due to saggy belt.

Refer to the Cooling Circuit
Loose screws. Troubleshooting Table on
page T5-4-104.
NOTE:
1. Don’t quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A
slight oil seepage will appear due to the seal construction. However, this oil seepage will not
cause malfunction. Be sure to accurately check whether oil is leaking or seeping only.
2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose sur-
face may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
high pressure side and low pressure side is 0.5 MPa (5 kgf/cm2) or less. When the clutch is
turned OFF, the pressure difference between high pressure side and low pressure side will
disappear within about 10 seconds.
T5-4-111
EXCHANGE INSPECTION
Pump2 Pump1
(5-Spool Side) (4-Spool Side)
Exchange inspection method is a troubleshooting
method to find the trouble location by exchanging the
suspected part / component with another part
/component having identical characteristics.
Many sensors and solenoid valves used on this ma-

chine are identical. Therefore, using this switch-check
method, faulty part /component, and/or harness can
be easily found.
Example: Abnormal pump 1 delivery pressure (Fault

code: 10) PP2 PP1
Check Method: Figure A T176-03-01-002
1. Switch two delivery pressure sensors located as

shown in figure A to figure B.
2. Retry troubleshooting. Pump2 Pump1
(5-Spool Side) (4-Spool Side)
Result:
In case the pump 2 delivery pressure is abnormal
(fault code 11), the pump 1 delivery pressure sensor
is considered to be faulty.
In case the pump 1 delivery pressure is abnormal

(fault code 10), the pump 1 delivery pressure sensor
harness is considered to be faulty.
PP1 PP2
Figure B T176-03-01-002
T5-4-112
Applicability of Exchange Inspection Method

Fault Code Trouble Applicability
01 Abnormal EEPROM Not Applicable
02 Abnormal RAM
04 Abnormal Sensor Voltage
06 Abnormal EC Angle Sensor Not Applicable
07 Abnormal EC Dial Not Applicable
10 Abnormal Pump 1 Delivery Pressure Applicable (Harness)
11 Abnormal Pump 2 Delivery Pressure
12 Abnormal Pump 1 Control Pressure Applicable (Harness)
13 Abnormal Pump 2 Control Pressure
14 Abnormal Swing Pilot Pressure Applicable (Harness/Sensor)
15 Abnormal Boom Raise Pilot Pressure
16 Abnormal Arm Roll-In Pilot Pressure
18 Abnormal Travel Pilot Pressure
19 Abnormal Hydraulic Oil Temperature Not Applicable
Sensor
T5-4-113
EMERGENCY BOOM LOWERING PRO- Rear
CEDURE
1 Boom 1
CAUTION: Never allow anyone to come

under the front attachment while performing
the emergency boom lowering procedure.
2
If the engine stalls and cannot be restarted, lower the
boom and the bucket to the ground referring to the
emergency boom lowering procedure stated below.
1. Remove rubber caps (1) and (2) from the boom I

section of the 4-spool control valve.
2. Remove lock nut (8) using a wrench (17 mm). Be

sure to turn the wrench counterclockwise to
remove lock nut (8).
3. Turn socket-head screw (7) clockwise to the stop Control Valve M175-05-001
using an allen wrench (4 mm).
4. Turn lock nut (5) counterclockwise to loosen it, 6

using a wrench (17 mm). 3
4
Loosen socket-head screw (6) clockwise using an 1
allen wrench (4 mm) while closely watching the boom
5
lower. Note that the loosened degree of screw (6)
determines the boom lowering speed. Adjust the
boom lowering speed with the allen wrench as 7
required.
Take care not to remove snap ring (3) and washer (4) 2
at this time. Also, do not loosen screw (6) excessively
or cause washer (4) to be deformed. 8
6. After the bucket is lowered to the ground, turn

screws (6) and (7) counterclockwise to the stop.
Loosen screw (7) 1/8 of a turn clockwise. Tighten
lock nuts (5) and (8).
Tightening Torque: 19.5 N⋅m (2 kgf⋅m) M154-05-001
7. Re-install rubber caps (1) and (2). Be sure to

return them to their original positions.
NOTE: Be sure to work on screw (7) first, then, on

screw (6), as stated above.
T5-4-114
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C (TROUBLE-
SHOOTING FOR MONITOR) PROCEDURE
Use troubleshooting C when any monitors, such as
gauges or indicators malfunction.
• How to Read Troubleshooting Flow Charts
YES (OK)
(2)
After completing the checking and/or measuring procedures in box
・ (1) (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
(3)
NO (NOT OK)
・ Instructions, reference, and/or instruction methods on inspection and/or measurements

are occasionally described under the box. If incorrectly checked or measured, not only
· Key switch: ON will troubleshooting be unsuccessful but also damage to components may result.
・ Causes of machine problems are stated in the thick-line box. Scanning quickly through
the thick-line boxes, allows you to estimate the possible causes before actually following
the flow chart.
NOTE: All harness end connector are seen from

the open end side.
Wire Harness Side
Open End
Side Harness End Connector
T158-05-03-001
T5-5-1
MALFUNCTION OF COOLANT TEM-
PERATURE GAUGE
hand. YES
Disconnect coolant temperature

Gauge pointer doesn’t move sensor. Ground harness end
Without connecting coolant
at all. terminal to vehicle frame.
temperature sensor, check for
Check if pointer swings to (H)
continuity between terminals
side.
below.
NO
· Key switch: ON
· ZAXIS110/110M/120/130/130LCN/
125US/135US: Disconnect monitor
connector B. Between monitor har-
ness end connector terminal #18 and
coolant temperature sensor terminal.
· ZAXIS135UR: Disconnect monitor
connector A. Between monitor har-
coolant temperature sensor terminal.
YES
Gauge pointer swings over Disconnect coolant tempera-

scale. In case of ZAXIS135 ture sensor. Check if pointer
UR, all the points on gauge returns to zero. Without connecting coolant
are blinking. temperature sensor, check for
continuity between terminals
· Key switch: ON below.
NO
· ZAXIS110/110M/120/130/130LCN/
connector B. Between monitor harness
end connector terminal #18 and vehicle
frame.
connector A. Between monitor harness
end connector terminal #15 and vehicle
frame.
Disconnect coolant tempera-
YES
ture sensor. Ground harness
Gauge pointer keeps moving end terminal to vehicle frame,
unstably. Check if pointer swings and is
stabilized to (H) side.
NO
· Key switch: ON
T5-5-2
Coolant Temperature Gauge Board

(ZAXIS110/110M/120/130/130LCN/125US/135US)
Faulty coolant temperature
sensor.
105 ﾟC
(95 ﾟC)
YES Faulty monitor.

70 ﾟC

monitor and sensor.
NO
Coolant Temperature Gauge Board T157-07-05-001
(ZAXIS135UR)
E F
D
C
Faulty coolant temperature A

sensor.
T1CF-05-05-001
Short-circuited harness be-
YES tween monitor and sensor.
Gauge Point Coolant Temperature
A Blinking 20 ˚C or lower
Faulty monitor. A ON 20 to 39 ˚C
B ON 40 to 59 ˚C
NO C ON 60 to 84 ˚C
D ON 85 to 99 ˚C
E ON 100 to 106 ˚C
F ON 107 ˚C or higher
Coolant Temperature Sensor

Coolant Temperature Resistance (kΩ)
Faulty coolant temperature °C (°F)
sensor. 25 (77) 7.6±0.76
40 (104) 4.0±0.35
50 (122) 2.7±0.22
Faulty monitor. 80 (176) 0.92±0.07
95 (203) 0.56±0.04
105 (221) 0.42±0.03
120 (248) 0.28±0.01
Connector (Harness end connector terminals seen
from the open end side)
ZAXIS110/110M/120/130/130LCN/125US/135US ZAXIS135UR
Monitor Connector B Monitor Connector A
10 1 10 1
18 15
20 11 20 11
T5-5-3
MALFUNCTION OF FUEL GAUGE
hand.
YES
Disconnect fuel sensor. Con-
Fuel gauge pointer doesn’t nect harness end connector
move at all. terminals #1 to terminal #2 with
In case of ZAXIS135UR, all a clip. Check if pointer swings
the points on gauge are Without connecting fuel sensor,
to (FULL) side. check for continuity between
blinking.
terminals below.
· Key switch: ON NO
· ZAXIS110/110M/120/130/130LCN/125US/
135US: Disconnect monitor connector B. Be-
tween monitor harness end connector terminal
#19 and fuel sensor terminal #1.
· ZAXIS135UR: Disconnect monitor connector A.
Between monitor harness end connector termi-
nal #14 and fuel sensor terminal #1.
YES
Fuel gauge pointer swings over Disconnect fuel sensor. Check Without connecting fuel sensor,
scale. if pointer returns to zero. check for continuity between
In case of ZAXIS135UR, all the terminals below.
points on gauge are blinking.
· Key switch: ON
NO
· ZAXIS110/110M/120/130/130LCN/125US/135US:
Disconnect monitor connector B. Between monitor
harness end connector terminal #19 and vehicle
frame.
· ZAXIS135UR: Disconnect monitor connector A.
Between monitor harness end connector terminal
#14 and vehicle frame.
YES
Disconnect fuel sensor. Con-
nect harness end connector
Fuel gauge pointer keeps mov- terminals #1 to #2 with a clip.
ing unstably. Check if pointer swings and is
stabilized to (FULL) side.
NO
· Key switch: ON
T5-5-4
Fuel Sensor
Float
Faulty fuel sensor.
FULL
R370 mm
YES Faulty monitor. 257 mm 3/4
93 mm
monitor and sensor. 70.5 mm
NO 204 mm 1/2
1/4
338 mm
EMPTY
Faulty fuel sensor.
T178-05-05-001
NOTE: 1 mm = 0.03937 in
YES tween monitor and sensor. Float Position Resistance (Ω)
Upper Limit (FULL) 10+0-4
3/4 26
1/2 38±5
Faulty monitor. 1/4 53
NO Warning Level 85±3
Lower Limit (EMPTY) 90+10-0

Faulty fuel sensor. ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
Monitor Connector B Fuel Sensor
10 1
2 1
19
Faulty monitor. 20 11
ZAXIS135UR
Monitor Connector A
10 1
14
20 11
T5-5-5
MALFUNCTION OF INDICATOR LIGHT
CHECK SYSTEM
Disconnect monitor
connector C. Check if YES Burnt fuse or faulty
there is continuity monitor.
hand. between harness end
connector terminal
YES #1(power input) and
fuse box terminal
Indicator doesn’t light Broken harness be-
#5(switch box).
when indicator light Check if all indicators tween fuse and
check operation is per- don’t light. monitor.
formed.
NO
Conduct trouble-
shooting of each in-
NO dicator which does
not light.

ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
Monitor Connector C
10 1
1
20 11
ZAXIS135UR
Monitor Connector C
8 1
1
16 9
T5-5-6
MALFUNCTION OF PREHEAT INDICATOR
• The preheat system operates only when coolant
temperature is below 10 °C (50 °F), lighting the
preheat indicator for 8 seconds. (Refer to the
SYSTEM /Electrical Circuit group.)
• In case the preheat system malfunctions, refer to
the troubleshooting B for E-16 Engine is difficult
to start at low temperature.
Faulty coolant tem-
hand.
YES perature switch.
Remove connector
Preheat indicator (with black and
lights even though white cables) from Faulty QOS con-
preheat system coolant tempera- YES troller.
doesn’t operate ture switch. Check
if indicator goes Disconnect QOS
(coolant tempera- controller. Check if
ture is more than OFF by grounding Without connecting
harness end con- indicator goes QOS controller, Short-circuited har-
10 °C (50 °F)). OFF. YES ness between QOS
nector to vehicle check for continuity
frame. NO between terminals controller and moni-
below. tor.
· Key switch: ON
NO
· ZAXIS110/110M/120/130/125US/135US: NO Faulty monitor.

· Key switch: ON
Disconnect monitor connector B. Be-
tween monitor harness end connector
terminal #20 and vehicle frame.
· ZAXIS 135UR: Disconnect monitor con-
nector B. Between monitor harness end
Remove connector connector terminal #6 and vehicle frame. Faulty coolant tem-
(with black and YES
Preheat indicator perature switch.
white cables) from
doesn’t light al-
coolant tempera-
though preheat
ture switch. Check
system operates Disconnect QOS Faulty QOS control-
if indicator comes YES
(coolant tempera- controller. Check if ler.
ON.
ture is lower than indicator comes
10 °C (50 °F)). ON by grounding
harness end con-
Connect terminals Broken harness
nector terminal #6
below to vehicle between QOS con-
to vehicle frame. YES
· Key switch: ON frame. Check if troller and monitor.
indicator comes
NO
ON.
NO
Connector (Harness end connector terminals · Key switch: ON Faulty monitor.
· ZAXIS110/110M/120/130/ NO
seen from the open end side) 130LCN/125US/135US: Monitor
ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US harness end connector B termi-
nal #20
Monitor Connector B
· ZAXIS135UR: Monitor harness
end connector B terminal #6
10 1 · Without disconnecting connec-
tor, ground connector to vehicle
20 frame with a clip from reverse
11 side of connector.
ZAXIS135UR
Monitor Connector B QOS Controller

8 1
6 1 2 3
4 5 6
16 11
T5-5-7
MALFUNCTION OF ENGINE OIL LEVEL
INDICATOR
(ZAXIS110/110M/125US: Up to serial No. 010576)
(ZAXIS120/135US: Up to serial
No. 062964)
• Check that indicator light is not burned out.

• Check that all other indicators work correctly.
• Check that machine is parked on level surface.
hand.
YES
Without connecting
connector to engine oil
NO level switch, check for
continuity between
Check if indicator terminals below.
lights by removing
Indicator doesn’t connector (with NO
· Disconnect monitor connector
light even if engine black and white ca- B. Between monitor harness
oil level is lower ble) from engine oil end connector terminal #8 and
than specification. level switch. vehicle frame.
YES
Without connecting
connector to engine oil
Remove connector level switch, check for
(with black and white NO continuity between
Lower than 3.5 mm cables) from engine oil terminals below.
below LOW level mark level switch. Check if
on oil level gauge indicator goes OFF by
grounding harness · Disconnect monitor connector A.
end connector to vehi- Between monitor harness end
cle frame. connector terminal #8 and engine
oil level switch connector.
Indicator comes ON Check oil level with
even if engine oil oil level gauge.
level matches
specification.
YES
Above 3.5 mm
below LOW level mark
on oil level gauge
T5-5-8
Engine Oil Level Switch

tween engine oil level switch
and monitor. Oil Level
Gauge Engine Oil Level
Switch
ON
Faulty monitor. H A (Indicator ON)
L
(Indicator
OFF)
OFF
A: 3.5mm
T107-04-03-010
Faulty engine oil level switch.

YES Faulty monitor. from the open end side)
Monitor Connector B
Broken harness between en-
gine oil level switch and moni- 10 1
NO tor. 8
20 11
Faulty engine oil level switch.
Normal (Lack of engine oil).
T5-5-9
MALFUNCTION OF COOLANT LEVEL IN-
DICATOR
(ZAXIS110/110M/125US: Up to serial No. 010576)
(ZAXIS120/135US: Up to serial No. 062964)
• Check that indicator light is not burned out.

• Check that all other indicators work correctly.
• Check that machine is parked on level surface.
hand.
Without connecting YES

connector to coolant
level switch, check for
NO continuity between
Check if indicator terminals below.
Indicator doesn’t
lights by removing
light even if coolant
connector (with NO
level is lower than
gray cable) from
specification. · Disconnect monitor connector B.
coolant level switch.
Between monitor harness end
connector terminal #9 and vehicle
frame.
YES
Without connecting
connector to coolant
Remove connector level switch, check for
(with gray cables) from NO continuity between
coolant level switch. terminals below.
Check if indicator
goes OFF by ground-
NO ing harness end
connector terminal #1
to vehicle frame. · Disconnect monitor connector B.
Indicator comes ON Check if coolant Between monitor harness end
even if coolant level level in coolant res- connector terminal #9 and coolant
matches specifica- ervoir is lower than level switch connector.
tion. LOW mark.
YES
YES
T5-5-10
Coolant Level Switch

tween coolant level switch
and monitor. Reserve Tank
ON
FULL
Faulty monitor.
LOW
Radiator
OFF
T107-04-03-012
Faulty coolant level switch.

Faulty monitor. from the open end side)
YES
coolant level switch and moni-
tor. 1 2
NO
Monitor Connector B
10 1
19
20 11
Faulty coolant level switch.
Normal (Lack of coolant).
T5-5-11
MALFUNCTION OF ALTERNATOR INDI-
CATOR
hand.
NOTE: *Regulator terminals L are water-resistant

type connectors so that it is not practical to
measure voltage at these terminals.
Measure voltage at starter relay terminal R
instead. Check for continuity between
starter relay terminal R and regulator ter-
minal L beforehand.
Between 13 V
Measure voltage at and 33.5 V
monitor connector A
Between 13 V terminal below.
and 33.5 V
Alternator indicator · ZAXIS110/110M/120/130/130LCN/125US/

Measure voltage at
stays ON after en- ∗
135US: Monitor connector A terminal #2
regulator terminal L.
gine is started. · ZAXIS135UR : Monitor connector A terminal Less than 13 V or
#13 higher than 33.5 V
· Engine: Running
· Engine: Running
Less than 13 V or
higher than 33.5 V
Between 10 V
and 33.5 V
Measure voltage at
regulator terminal L.*
YES
Although alternator Check if indicator
output is low, alter- lights when key
nator indicator switch is turned ON. · Key switch: ON
· Engine: Stopped Less than 10 V or
doesn’t light.
higher than 33.5 V
· Key switch: ON
NO
T5-5-12

Faulty monitor. from the open end side)
Starter Relay
regulator terminal L and moni- E
tor. S R
ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US

Faulty regulator or faulty al-
Monitor Connector A
ternator.
8 1
2
16 9
Faulty monitor.
ZAXIS135UR
Monitor Connector A
Faulty regulator. 10 1
13
20 11
Burned out indicator light.
T5-5-13
MALFUNCTION OF ENGINE OIL PRES-
SURE INDICATOR
hand.
NOTE: During one or two minutes after the engine

is stopped, engine oil pressure may still
exist. When the engine is restarted under
this condition, the indicator may not light.
Disconnect engine oil YES
pressure switch.
Check if indicator lights ZAXIS110/110M/120/130/125US/
when harness end 135US: Reconnect engine oil
YES connector terminal #1 pressure switch connector. Con-
(white and red cable) is nect monitor connector C terminal
grounded to vehicle #18 to the vehicle frame. Check if
frame. the indicator lights.
Indicator doesn’t Check if indicator ZAXIS135UR: Reconnect engine
light even if engine lights when key NO oil pressure switch connector.
oil pressure is low. switch is turned ON. · Key switch: ON Connect monitor connector A ter-
minal #5 to the vehicle frame.
Check if the indicator lights.
· Key switch: ON
· Engine: Stopped
· Key switch: ON
· Without disconnecting con-
nector, ground connector to
vehicle frame with a clip
from reverse side of con-
nector.
NO
YES
Check if indicator
Indicator stays ON goes OFF when
after engine is engine oil pressure
started. switch is discon- YES
nected.
Reconnect engine oil
pressure switch. Check
· Check oil filter for
for continuity between
clogging. · Key switch: ON NO terminals below.
· Engine: Stopped
· ZAXIS110/110M/120/130/ NO
125US/135US: Disconnect
monitor connector C. Be-
tween monitor harness end
connector terminal #18 and
vehicle frame.
· ZAXIS135UR: Disconnect
monitor connector A. Between
monitor harness end connec-
tor terminal #5 and vehicle
frame.
T5-5-14
Engine Oil Pressure Switch

Pressure Operation
Faulty engine oil pressure
Approx. 39 kPa
switch.
(0.4 kgf/cm2, 5.7 psi) or ON
less
Approx. 39 kPa
monitor and engine oil pres- (0.4 kgf/cm2, 5.7 psi) or OFF
YES sure switch. higher
Faulty monitor.
NO

ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US

Burnt indicator light.
Monitor Connector C
10 1
Faulty engine oil pressure
switch or faulty engine oil
pressure system, or clogged 18
oil filter. 20 11
ZAXIS135UR
tween monitor and engine oil Monitor Connector A
pressure switch.
10 1
5
Faulty monitor. 20 11
T5-5-15
MALFUNCTION OF OVERHEAT INDICA-
TOR
hand.
Remove connector
(red and blue cable) YES
from overheat switch.
Check if indicator lights
when harness end
YES terminal is grounded to
vehicle frame.
· Key Switch: ON
NO
· Key switch: ON
Indicator doesn’t light Check if indicator
even if engine over- lights when key
heats. switch is turned ON.
· Key switch: ON
NO
Check if indicator
goes OFF when YES
overheat switch is
disconnected.
Indicator lights even
if coolant tempera-
ture is low. Disconnect overheat
switch. Remove con- YES
· Key switch: ON nector below from
· Engine: Stopped monitor. Check for con-
tinuity between con-
NO nector terminal #6 and
vehicle frame.
NO
· ZAXIS110/110M/120/130/130LCN/
125US/135US: Monitor connector B
· ZAXIS135UR: Monitor connector A
T5-5-16
Overheat Switch
Faulty overheat switch. Coolant Temperature Operation
Lower than 105 °C OFF
(221 °F)
Reconnect overheat 105 °C (221 °F) or ON
switch. Check if indi- Broken harness between higher
cator lights when YES monitor and overheat
monitor connector switch.
below terminal #6 is
grounded to vehicle
frame.
Faulty monitor.
NO
· ZAXIS110/110M/120/130/130LCN/
125US/135US: Monitor connector B
· ZAXIS135UR: Monitor connector A Connector (Harness end connector terminals seen
· Key switch: ON
· Without disconnecting connector, ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
ground connector to vehicle frame us-
Monitor Connector B
ing such jumper wire as clip from re-
verse side of connector. 10 1
Burnt indicator light.
6
20 11
ZAXIS135UR
Faulty overheat switch. Monitor Connector A
10 1
6
Short-circuited harness
between monitor and 20 11
overheat switch.
Faulty monitor.
T5-5-17
MALFUNCTION OF AIR FILTER RESTRIC-
TION INDICATOR
hand.
Disconnect air filter re-

striction switch at plug
receptacle with green YES
and blue cable. Check if
indicator lights when
harness end plug con-
YES nector is grounded to Reconnect air filter re-
vehicle frame. striction switch. Check for
continuity between ter-
minals below.
Check if indicator NO
Even if air filter is lights when key
clogged, indicator switch is turned ON. · Key switch: ON
doesn’t light. · ZAXIS110/110M/120/130/130LCN/
125US/135US: Disconnect monitor con-
nector B. Between monitor harness end
connector terminal #7 and vehicle frame.
· Key switch: ON · ZAXIS135UR: Disconnect monitor con-
nector A. Between monitor harness end
connector terminal #10 and vehicle frame.
NO
YES
Check if indicator
goes OFF when air
Although air filter is
filter restriction switch
not clogged, indi-
is disconnected. Disconnect air filter re-
cator lights.
striction switch at plug YES
receptacle with green
and blue cable from
· Disassemble and monitor. Check for con-
visually inspect. · Key switch: ON tinuity between terminals
· Verify that air filter NO below.
is not moist.
NO
· ZAXIS110/110M/120/130/130LCN/
connector B. Between monitor har-
vehicle frame.
connector A. Between monitor har-
vehicle frame.
T5-5-18
Faulty air filter restriction

switch.
Air Filter Restriction Switch
Pressure Operation
YES Faulty monitor. 5.1 kPa (520 mmH2O) OFF
6.2 kPa (630 mmH2O) ON

monitor and air filter re-
striction switch.
NO

Burned out indicator light.
ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
Monitor Connector B
10 1
7
Faulty air filter restriction
switch.
20 11
Short-circuited harness ZAXIS135UR

between monitor and air
filter restriction switch. Monitor Connector A
10 1
10
20 11
Faulty monitor.
T5-5-19
MALFUNCTION OF BUZZER
hand.
NOTE: *Regulator terminals L are water-resistant

Measure voltage at starter relay 1 terminal
R instead. Check for continuity between
starter relay 1 terminal R and regulator
terminal L beforehand.
Measure voltage at 13 V or higher Faulty regulator.
Buzzer continues monitor connector A
to sound when key terminal below.
switch is turned ON
without starting en-
gine. Faulty monitor.
· ZAXIS110/110M/120/130/
Lower than 13
130LCN/125US/135US:
Monitor harness end connec-
tor terminal #2
· ZAXIS135UR: Monitor har-
ness end connector terminal
#13
· Key switch: ON (without start-
ing engine)
Faulty engine oil pres-

YES sure system.
Buzzer continues to Check if engine oil

sound when engine pressure indicator
is started. lights. YES Overheat of engine.
Check if overheat in-
dicator lights.
NO
Faulty monitor.
NO
NO Normal.
Buzzer doesn’t
sound even if en- Check if engine
gine oil pressure Perform troubleshooting
speed is 900 min-1 NO of indicator staying ON.
indicator or over- (rpm) or faster.
heat indicator lights
with engine running. Check if alternator in-
YES dicator lights. Measure voltage at regu-
lator terminal L.*
YES
· Engine speed: 900 min-1

(rpm) or faster.
T5-5-20

ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
Monitor Connector A Starter Relay

8 1
2 E
S R
16 9
ZAXIS135UR
Monitor Connector A
10 1
13
20 11
Lower than 13 V or Faulty regulator or faulty al-

higher than 33.5 V ternator.
Lower than 13 V or Broken harness between

higher than 33.5 V regulator terminal L and moni-
tor.
Measure voltage at monitor
connector A terminal below.
Between 13 V Faulty monitor.
and 33.5 V
· ZAXIS110/110M/120/130/ Between 13 V
130LCN/125US/135US: Moni- and 33.5 V
tor harness end connector ter-
minal #2
· ZAXIS135UR: Monitor harness
end connector terminal #13
· Engine speed: 900 min-1 (rpm)
or faster
T5-5-21
MALFUNCTION OF LCD
• The following items are described:

1 to 3: To be displayed in the standard mode.
4 to 8: To be displayed in the user’s mode.
9 to 24: To be displayed with built-in diagnosing
system
• In case only LCD is abnormal, the machine will
normally operate.
Display
Description Cause of Trouble
Order
1 Hour Meter Refer to the next page.
2 Trip 1 Faulty Monitor.
3 Trip 2
4 Actual Engine Speed In case Dr. ZX can display data, monitor is abnormal or communication
5 Hydraulic Oil Tempera- between monitor and MC is interrupted. In case Dr. ZX doesn’t display
ture data, corresponding signal sensor is faulty. (The machine must have
any abnormality in the control system. Refer to Troubleshooting B.)
6 Faulty monitor or interrupted communication between ML controller
7 Load Alarm and monitor.
8 Hydraulic Oil Filter Faulty monitor or interrupted communication between ICX controller
and monitor.
9 Fault Code In case Dr. ZX can display data, monitor is abnormal or communication
10 ML Switch between monitor and MC is interrupted. In case Dr. ZX doesn’t display
11 Pump 1 Delivery Pres- data, corresponding signal sensor is faulty. (The machine must have
sure any abnormality in the control system. Refer to Troubleshooting B.)
12 Pump 2 Delivery Pres-
sure
13 Pump 1 Control Pres-
sure
14 Pump 2 Control Pres-
sure
15 Target Engine Speed
16 EC Angle
17 Dial Angle
18 Boom Raise Lever
Stroke
19 Arm Roll-In Lever Stroke
20 Swing Lever Stroke
21 Travel Lever Stroke
22 Front Attachment Lever
Stroke
23 Attachment Lever Stroke
24 Work Mode
T5-5-22
MALFUNCTION OF HOUR METER

hand.
∗
NOTE: Regulator terminals L are water-resistant
Measure voltage at starter relay terminal R
instead. Check for continuity between
starter relay terminal R and regulator ter-
minal L beforehand.
Lower than 13 V or
higher than 33.5 V Faulty regulator or
faulty alternator.
Hour meter
doesn’t count
operating hours Measure voltage at Between 13V
∗
with engine run- regulator terminal L. and 33.5 V Faulty monitor.
ning.
Measure voltage
· Engine speed: 900 min-1
· Engine: Running at monitor con-
(rpm) or faster
nector A terminals
below.
Between 13V
and 33.5 V
· ZAXIS110/110M/120/130/
130LCN/125US/135US: Ter-
minal #2 Broken harness be-
· ZAXIS 135UR: Terminal #13 tween regulator ter-
minal L and monitor.
Connector (Harness end connector terminals seen Lower than 13 V or
from the open end side) higher than 33. 5 V
ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
Monitor Connector A Starter Relay

8 1
2 E
S R
16 9
ZAXIS135UR
Monitor Connector A
10 1
13
20 11
T5-5-23
MALFUNCTION OF HYDRAULIC OIL FIL-
TER INDICATOR (Optional)
hand.
Disconnect hydraulic
oil filter restriction
switch at plug recepta-
cle with black and yel-
low cable. Check if in- YES
dicator lights when
YES harness end plug
connector is grounded
to vehicle frame.
Even if hydraulic oil Check if indicator

filter is clogged, indi- lights when key
cator doesn’t light. switch is turned ON. NO
· Key switch: ON
· Key switch: ON
NO
Check if indicator
goes OFF when
hydraulic oil filter YES
Although hydraulic restriction switch at
oil filter is not plug receptacle with
clogged, indicator black and yellow
lights. cable is discon-
nected. Disconnect hydraulic oil
filter restriction switch at
YES
plug receptacle with
black and yellow cable
from monitor. Check for
· Key switch: ON NO continuity between ter-
· Engine: Stopped minals below.
NO
· ZAXIS110/110M/120/130/
130LCN/125US/135US: Dis-
connect monitor connector C.
Between monitor harness end
connector terminal #14 and
vehicle frame.
· ZAXIS135UR: Disconnect
monitor connector A. Between
monitor harness end connector
terminal #9 and vehicle frame.
T5-5-24
Faulty hydraulic oil filter

restriction switch.
Reconnect hydraulic oil

filter restriction switch. Broken harness between Connector (Harness end connector terminals seen
Check if indicator lights YES monitor and hydraulic oil
when monitor connector from the open end side)
filter restriction switch.
is grounded to vehicle
frame. ZAXIS110, 110M, 120, 130, 130LCN, 125US, 135US
Monitor Connector A
NO Faulty monitor.
10 1
· Key switch: ON
· ZAXIS110/110M/120/130/130LCN/ 14
125US/135US: Monitor connector C 20 11
terminal #14
· ZAXIS135UR: Monitor connector A ZAXIS135UR
terminal #9
· Without disconnecting connector, Monitor Connector A
ground connector to vehicle frame
with a clip from reverse side of con- 10 1
nector. Burned out indicator light. 9
20 11
Faulty hydraulic oil filter

restriction switch.
between monitor and hy-
draulic oil filter restriction
switch.
Faulty monitor.
T5-5-25
(Blank)
T5-5-26
TROUBLESHOOTING / Troubleshooting D
TROUBLESHOOTING D PROCEDURE
(ZAXIS135UR ONLY)
Troubleshooting D procedures are to be applied to the front
attachment control system.
Use troubleshooting D procedure when fault codes
are shown on Dr. ZX after monitoring the main con-
troller (MC) with Dr. ZX or on the system monitor.
• How to Read the Troubleshooting Flow Charts
YES (OK)
(2)
• After checking or measuring item (1), according to the results
・ (1) select either YES (OK) or NO (NOT OK) and proceed to next
item (2) or (3), as appropriate.
(3)
NO (NOT OK)
・ • Special instructions or reference items are indicated in the space under the box.
Incorrect checking or measuring methods will render the troubleshooting impossi-
· Key switch: ON ble, and may damage components as well.
・ • Use Dr. ZX when the item is shown in a double line frame.
・ • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes and locations can be found.
NOTE: For all connector drawings illustrated in

this group, harness end connector
terminals seen from the open end side are
shown.
Wire Harness Side
Open End
Side Harness End Connector
T158-05-03-001
T5-6-1
FAULT CODE LIST (AUTO-MARCCINO
CONTROLLER) (ZAXIS135UR ONLY)
Fault Code
Buzzer System
Monitor
05 − − ON Faulty monitor (switch box) communication
06 − − ON Abnormal metering correction value
Continuously
07 UE07 ON Abnormal front angle sensor calibration value
sounds
Continuously
08 UE08 ON Abnormal code setting
sounds
11 UE11 Abnormal arm roll-out function
12 UE12 Continuously Abnormal right offset function
ON
13 UE13 sounds Abnormal left offset function
17 UE17 Abnormal boom raise function
14 − − Abnormal arm roll-out acceleration pilot pressure sensor
15 − − Abnormal right offset acceleration pilot pressure sensor
16 − − Abnormal left offset acceleration pilot pressure sensor
19 − − ON Abnormal boom raise acceleration pilot pressure sensor
20 − − Abnormal boom raise pilot pressure sensor
21 − − Abnormal boom lower pilot pressure sensor
22 − − Abnormal arm roll-in pilot pressure sensor
23 − Abnormal auxiliary pilot pressure sensor
37 UE37 Abnormal arm roll-out deceleration proportional solenoid valve

38 UE38 Abnormal 8-unit solenoid valve unit (right offset deceleration)
Long beep
40 UE40 Abnormal 8-unit solenoid valve unit (boom raise deceleration)
sounds in- ON
41 UE41 Abnormal 8-unit solenoid valve unit (arm roll-in deceleration)
termittently
42 UE42 Abnormal 8-unit solenoid valve unit (left offset deceleration)
44 UE44 Abnormal 8-unit solenoid valve unit (boom lower deceleration)
43 − − Faulty 8 unit solenoid valve unit (right offset acceleration)
45 − − Faulty 8 unit solenoid valve unit (arm roll-out acceleration)
47 ON Faulty 8 unit solenoid valve unit (left offset acceleration)
− −
48 − − Faulty boom raise acceleration proportional solenoid valve
T5-6-2
1) Check harness.
− 2) Replace the controller. G4
3) Replace the system monitor.
1) Abnormal metering correction
value.
1) Replace the controller if the con-
* Movement to the cab stops. troller does not operate correctly. G1
1) Input the front and bucket codes

again.
1) Check harness.
2) Replace the pilot pressure
All movement stops.(No pilot pressure) sensor. G0
3) Replace the solenoid valve.
Cab collison prevention control stops. 1) Check harness.
Offset movement by offset switch stops. 2) Replace pilot pressure sensor.
Offset movement by offset switch stops.
Depth limit control stops
G4
Cab collison prevention control stops, depth limit control
stops
1) Check harness.
G8
2) Replace pilot pressure sensor.
Arm roll-out movement stops. 1) Check harness.
Right offset movement stops. 2) Replace the solenoid valve.
Boom raise movement stops.
G3
Arm roll-in movement stops.
Left offset movement stops.
Boom lower movement stops.
Offset movement by offset switch stops. 1) Check harness.
Cab collison prevention control stops. 2) Replace the solenoid valve.
Offset movement by offset switch stops. G4
Depth limit control stops.
group number only.
T5-6-3
Fault Code
Buzzer System
Monitor
50 UE50 Abnormal boom angle sensor
51 UE51 Abnormal arm angle sensor
52 UE52 Abnormal offset angle sensor
53 UE53 Continuously Abnormal slide arm sensor
ON
sounds
80 UE80 Boom angle sensor deviation

81 UE81 Arm angle sensor deviation
82 UE82 Offset angle sensor deviation
83 UE83 Continuously Slide arm sensor deviation
ON
sounds
60 UE60 Faulty boom angle sensor initial setting.

61 UE61 Continuously Faulty arm angle sensor initial setting.
ON
62 UE62 sounds Faulty offset angle sensor initial setting.
63 UE63 Faulty slide arm sensor initial setting.
Faulty hydraulic oil temperature sensor.
90 − − ON
Abnormal sensor power source.
91 − − ON
Abnormal reference power source. (Abnormal voltage sup-
92 − − −
plied to Auto-MARCCINO controller)
Complete front attachment angle sensor initial setting.
F0 − − −
Continuously Invasion of hazardous area by emergency evacuation switch.
F2 − −
sounds
Escape out of hazardous area.
F3 − − −
Short beep Invasion of hazardous area by interference prevention mode.
F4 UE00 sounds ON
intermittently
FA − − − Install attachment select switch
FB − − − Remove attachment select switch
The auxiliary pedal is operated without setting the attachment
FC − − − select switch properly
group number only.
T5-6-4

as if boom is raised to the highest position. 2) Replace the angle sensor.
as if arm is fully rolled in.
G2
as if the front attachment is fully offset to the left
side.
as if boom is raised to the highest position. 2) Check angle sensor installation.
Interference prevention control system functions 3) Replace the angle sensor.
as if arm is fully rolled in. Interference prevention
G2
control system functions as if the front attach-
ment is fully offset to the left side.
as if slide arm is fully extension.
1) Check harness.
2) Replace the angle sensor

G4
as if oil temperature is lowest. 2) Replace the hydraulic oil temperature sensor.
Depth limit control stops 1) Initialize the angle sensor again.
G4
Cab collison control stops. 2) Replace the angle sensor.
Normal Movement by backup function. 1) Check harness.
G8
* Movement to the cab stops.
G5
− G7
− G8
All movement stops. (No pilot pressure) G0
G8
G8
G8
T5-6-5
FAULT CODE 05 (FAULT MONITOR
(SWITCH BOX) COMMUNICATION)

hand.
Breakage and/or short circuit

Disconnect connector (B) and connector (EF-4) YES of harness where abnormality
from monitor (switch box) and is found.
auto-MARCCINO controller respectively. Check
if circuits described below have any abnormali-
ties. When optional with front movement Re-
striction system monitor is provided, disconnect
4P connector from optional monitor. Then,
check if harness has any abnormalities.
Faulty auto-MARCCINO
controller.
NO
Machines Equipped with front
Standard Model: movement Restriction System Moni-
Monitor Auto-MARC tor (Optional):
(Switch Box) CINO Optional Auto-MARCCI Monitor Optional
Connector B Controller monitor 4P NO Controller (Switch Box) monitor 4P
Connector Connector(Bla Connector Connector B Connector(Blac
(EF-4) ck) (EF-4) k)
#10 #11 #1 #3 #12 #2
#11 #12 #3 #2 #13 #4

Monitor Connector (B) Auto-MARCCINO Controller Connector (EF-4) Front Movement Restriction Control
5 5 System Monitor 4P Connector (Black)
8 1
2 3
11 12
11 10 2 1
16 9
13 16 4 3
FAULT CODE 06 (ABNORMAL METERING

CORRECTION VALUE)
YES Normal.
Adjust metering by Dr.ZX. Check

if fault code disappears.
NO controller.
T5-6-6
FAULT CODE 07 (ABNORMAL CALIBRA-
TION VALUE)
• Calibration values are input into the

auto-MARCCINO controller beforehand. Accord-
ingly, this fault code is rarely displayed during
machine operation.
YES
Normal.
Check if any fault codes on

system monitor are deleted
when sensor is initialized.
· Refer to T4-6-1
· After initializing, re-start the
engine Faulty auto-MARCCINO con-
NO troller.
FAULT CODE 08 (ABNORMAL CODE SET-

TING)
• When no front attachment or bucket codes are

registered, this fault code is displayed. Register
the front attachment or bucket code.
YES
Normal.
Register front attachment or
bucket code using the Dr. ZX.
Check if fault codes displayed
on system monitor are de-
leted.
· After initializing, restart the

engine. Faulty auto-MARCCINO con-
troller.
T5-6-7
FAULT CODE 11 FAULT CODE 13
(ABNORMAL ARM ROLL-OUT OPERA- (ABNORMAL LEFT OFFSET OPERATION)
TION) FAULT CODE 17
FAULT CODE 12 (ABNORMAL BOOM RAISE)
(ABNORMAL RIGHT OFFSET OPERA-
TION)
• Fault code 11 is displayed when the arm roll-out • Fault code 17 is displayed when the boom raise
pilot-pressure sensor sends a signal corre- acceleration pilot-pressure sensor sends a signal
sponding to a pressure of 0.98 MPa (10 kgf/cm2) corresponding to a pressure of 0.98 MPa (10
or more to the auto-MARCCINO controller while kgf/cm2) or more to the auto-MARCCINO con-
the auto-MARCCINO controller sends no signal troller while the auto-MARCCINO controller
to the 8-unit solenoid valve unit (arm roll-out ac- sends no signal to the 2-unit solenoid valve unit
celeration) by arm keep-off. (boom raise acceleration) by depth limit control.
• Fault codes 12 and 13 are displayed when right • Check for loose harness connections beforehand.
or left offset pilot pressure sensor sends a signal
corresponding to a pressure of 0.98 MPa (10
kgf/cm2) or more to the auto-MARCCINO con-
troller while the offset switch is not depressed.
Sticking solenoid valve or delayed response in
the hydraulic system at very low temperature
may be the cause of these troubles.
With pilot control shut-off lever
held in the LOCK position,
monitor pilot pressure sensor
corresponding to the fault code
using Dr. ZX. Check if 0
With pilot control shut-off lever YES kgf/cm2 pressure is displayed.
held in the UNLOCK position,
monitor pilot pressure sensor
NO corresponding to the fault
code using Dr. ZX. Check if
10 kgf/cm2 or more pressure · Engine: Running
is displayed. · System deactivation switch:
ON
Faulty auto-MARCCINO con-

Check if any fault codes are troller.
deleted when engine is · Engine: Running
re-started. · System deactivation switch: NO
ON · Refer to Countermeasure - 2.
Normal.
YES
· Check operation of the arm
keep-off control, depth limit
control and the offset switch.
T5-6-8
8-Unit Solenoid
Valve
Front
Port P
Faulty solenoid valve.

T1CF-01-01-014
YES
· Refer to Countermeasure -
1.
Faulty pilot pressure sensor.

NO
· Refer to Countermeasure -
2.
CAUTION: Countermeasures 1 and 2 are to
be used only when the machine must be
temporarily operated. Carefully operate the
front attachment by means of these counter
measures as the cab collision prevention
system and the auto-MARCCINO system will
be inoperable.
• Countermeasure-1 • Countermeasure-2
After disconnecting the hose from port P on the Disconnect the emergency stop solenoid valve
8-unit solenoid valve, install plugs to the hose located under the cab.
end and port P. In case the machine is equipped
with the front movement restriction system (op-
tional), disconnect the hose from port P on the
2-unit solenoid valve and install plugs to the hose
end and port P. Thereby, the offset switch be-
comes inactivated.
T5-6-9
(ABNORMAL ARM ROLL-OUT ACCEL- (ABNORMAL BOOM RAISE PILOT
ERATION PILOT PRESSURE SENSOR) PRESSURE SENSOR)
(ABNORMAL RIGHT OFFSET ACCELERA- (ABNORMAL BOOM LOWER PILOT
TION PILOT PRESSURE SENSOR) PRESSURE SENSOR)
(ABNORMAL LEFT OFFSET ACCELERA- (ABNORMAL ARM ROLL-IN PILOT PRES-
TION PILOT PRESSURE SENSOR) SURE SENSOR)
FAULT CODE 19
(ABNORMAL BOOM RAISE ACCELERA-
TION PILOT PRESSURE SENSOR)
• These fault codes are displayed when signal volt-
age from the pilot pressure sensor to the After disconnecting pilot pressure
auto-MARCCINO controller is in the range of sensor, directly connect terminals
#1 and #3 on harness end
0.25 V or less, or 4.75 V or more. connector.
YES
• Check for loose harness connections before- Remove connector (EF-2) from
hand. auto-MARCCINO controller.
After disconnecting pilot Check if continuity between
pressure sensor, directly terminal #19 and #21on the
connect terminals #1 and #3 harness end connector is
NO on harness end connector. present.
Remove connector (EF-2)
from auto-MARCCINO
controller. Check if continuity
between terminal #19 or
#21on the harness end
connector and the vehicle
frame is present.
Switch pilot pressure sensor
with other nornal one. Check if
the fault code is deleted. Broken harness between pilot
pressure sensor (Terminals
NO #1 and #3) and
auto-MARCCINO controller.
Faulty pilot pressure sensor.

YES

Pilot Pressure Sensor Connector (EF-3)
Connector Connector (EF-2)
1 8 1 10
2 5 6
1 2 3
12 15 16 17
19 21
19 25 23 31
T5-6-10
Without reconnecting pilot

pressure sensor Short-circuited harness
Disconnect pilot pressure
andauto-MARCCINO between pilot pressure sensor
sensor and auto-MARCCINO
controller connector (EF-2), (terminal #2) and
controller connector (EF-3).
check if continuity between YES auto-MARCCINO controller.
Check if continuity between
harness end connector sensor harness end connector
terminal #2 and YES terminal #2 and the vehicle
auto-MARCCINO controller frame is present.
connector (EF-3) harness end
NO Faulty auto-MARCCINO con-
terminal
NO troller.
· Terminal #: Broken harness between pilot

Boom raise: #17 pressure sensor terminal #2
Boom raise acceleration NO
and auto-MARCCINO con-
(Optional): #5 troller.
Boom lower: #16
Arm roll-out: #15
Arm roll-in: #6
Right offset: #12
Left offset: #2
between pilot pressure sensor
YES (terminals #1 and 3) and
T5-6-11
FAULT CODE 37 (ABNORMAL ARM FAULT CODE 41 (ABNORMAL 8-UNIT
ROLL-OUT DECELERATION PROPOR- SOLENOID VALVE UNIT (ARM ROLL-IN
TIONAL SOLENOID VALVE) DECELERATION)
FAULT CODE 38 (ABNORMAL 8-UNIT FAULT CODE 42 (ABNORMAL 8-UNIT
SOLENOID VALVE UNIT (RIGHT OFFSET SOLENOID VALVE UNIT (LEFT OFFSET
DECELERATION) DECELERATION)
FAULT CODE 40 (ABNORMAL 8-UNIT FAULT CODE 44 (ABNORMAL 8-UNIT
SOLENOID VALVE UNIT (BOOM RAISE SOLENOID VALVE UNIT (BOOM LOWER
DECELERATION) DECELERATION)
・Check for loose harness connections first.
Disconnect solenoid
valve. Disconnect con-
nector (EF-1) from NO Faulty auto-MARCCINO
auto-MARCCINO con-
troller. Check for continu- controller.
ity between harness con-
nector terminal and vehi-
Disconnect solenoid valve. YES cle.
Connect harness side con-
nector terminals #1 to #2. Short-circuited harness
Remove connector (EF-1) between solenoid valve
· Boom raise : #16, #23 and auto-MARCCINO
from auto-MARCCINO
Arm roll-in : #6, #11 controller.
controller. Check for conti-
YES nuity between harness end Arm roll-out : #15, #22 YES
Right offset : #4, #9
connector terminals.
Left offset : #5, #10
Disconnect solenoid Boom lower : #17, #24
valve. Check if solenoid
valve electrical resis-
tance is approx. 2.24 Broken harness between
kΩ. solenoid valve and
· Boom raise : #16, #23
NO auto-MARCCINO con-
Arm roll-in : #6, #11
troller.
Arm roll-out : #15, #22
Right offset : #4, #9
Left offset : #5, #10
Boom lower : #17, #24

NO

Solenoid Valve Controller Auto-MARCCINO Controller Connector (EF-1)

1 11
1 2 4 5 6 9 10 11
15 16 17 22 23 24
25 32
T5-6-12
(ABNORMAL 8-UNIT SOLENOID VALVE (ABNORMAL 8-UNIT SOLENOID VALVE
UNIT [RIGHT OFFSET ACCELERATION]) UNIT [LEFT OFFSET ACCELERATION])
(ABNORMAL 8-UNIT SOLENOID VALVE (ABNORMAL BOOM RAISE ACCELERA-
UNIT [ARM ROLL-OUT ACCELERATION]) TION SOLENOID VALVE)
・Check for loose harness connections first.
Disconnect solenoid
valve. Check for continu- NO Faulty auto-MARCCINO
ity between controller.
auto-MARCCINO con-
troller connector (EF-1)
harness connector ter-
YES
Disconnect solenoid valve. minal below and vehicle.
Connect harness side con-
nector terminal #1 to #2.
Remove connector (EF-1) Short circuit of harness
from auto-MARCCINO between solenoid valve
controller. Check for · Right offset (#7, #29) YES and auto-MARCCINO
YES
continuity between harness · Arm roll-out (#18, #32) controller.
end connector terminals · Left offset (#19, #30)
With solenoid valve below. · Boom raise (#20, #31)
disconnected, check if
solenoid valve electrical
resistance is approx. Broken harness between
2.24 kΩ. solenoid valve and
· Right offset (#7, #29) auto-MARCCINO con-
· Arm roll-out (#18, #32) NO
troller.
· Left offset (#19, #30)
· Boom raise (#20, #31)

NO

Solenoid Valve Connector Auto-MARCCINO Controller Connector (EF-1)
1 11
1 2 7
18 19 20
30 31 32
25 32
T5-6-13
FAULT CODE 50
(ABNORMAL BOOM ANGLE SENSOR)
FAULT CODE 51
(ABNORMAL ARM ANGLE SENSOR)
FAULT CODE 52
(ABNORMAL OFFSET ANGLE SENSOR)
• Fault codes 50 to 52 are displayed when input

voltage from the angle sensor to the
auto-MARCCINO controller is 0.1 V or less, or
4.9 V or more.
• Check for loose harness connections first.
Disconnect angle sensor.

Check for continuity between
MC connector (MCX-B) har-
YES ness connector terminal #20
or #22 and vehicle.
Disconnect angle sensor.
Connect harness end con-
nector terminals #1 to #3.
YES Disconnect MC connector
(MCX-B).
harness connector terminal
#20 and #22. Broken harness between an-
With angle sensor discon- gle sensor (terminals #1, #3)
nected, check if angle sensor NO and MC.
electrical resistance is 5±1.0
kΩ.
Faulty angle sensor.
NO
· Refer to T4-6 (Adjustment).

Boom Angle Arm/Offset Angle

Sensor Connector MC Connector (MCX-B)
Sensor Connector
B1 B8
1 2 1 2 3
20 22
3
B19 B25
T5-6-14

Disconnect angle sensor con- tween angle sensor (terminal
nector and auto-MARCCINO #2) and auto-MARCCINO
Disconnect angle sensor con- controller connector (EF-3). YES controller.
nector and auto-MARCCINO Check for continuity between
controller connector (EF-3). sensor harness connector
Check for continuity between YES terminal #2 and vehicle.
sensor harness connector
terminal #2 and
auto-MARCCINO controller Faulty auto-MARCCINO con-
harness terminal. NO troller.
NO
Broken harness between an-

· Terminals: gle sensor (terminal #2) and
NO auto-MARCCINO controller.
Boom (Terminal #7)
Arm (Terminal #19)
Offset (Terminal #18)

tween angle sensor (terminals
YES #1, #3) and MC.
Auto-MARCCINO Controller Connector (EF-3)

C1 C10
7
18 19
C23 C31
T5-6-15
FAULT CODE 53
(ABNORMAL SLIDE ARM SENSOR)
• Fault code 53 is displayed when input voltage
from the slide arm sensor to the
auto-MARCCINO controller is 0.5 V or less, or
2.95 V or more.
Disconnect slide arm sensor.

auto-MARCCINO end con-
Disconnect slide arm sensor. troller connector (EF-2) har-
Connect harness end con- YES ness end connector terminals
nector terminals #1 to #3. #19, #22 and vehicle.
Disconnect auto-MARCCINO
Controller connector (EF-2).
YES harness end connector ter-
minals #19 and #22.
Broken harness between slide
arm sensor (terminals #1 and
With slide arm sensor dis- #3) and auto-MARCCINO
connected, check if slide arm controller.
sensor electrical resistance is NO
5±1.0 kΩ.
Faulty slide arm sensor.
NO
· Refer to T4-6 Adjustment.

Angle Sensor Connector Auto-MARCCINO Controller Connector (EF-2)
1 8
1 2
3 19 22
19 25
T5-6-16

tween slide arm sensor (ter-
Disconnect slide arm sensor minal #2) and
connector and YES auto-MARCCINO controller.
auto-MARCCINO controller
connector (EF-3). Check for
YES continuity between sensor
Disconnect slide arm sensor harness end connector ter-
connector and minal #2 and vehicle.
auto-MARCCINO controller Faulty auto-MARCCINO con-
NO connector (EF-3). Check for NO troller.
continuity between sensor
harness end connector ter-
minal #2 and
auto-MARCCINO controller
Broken harness between slide
harness end terminal #11.
arm sensor (terminal #2) and
NO auto-MARCCINO controller.

tween slide arm sensor and
YES auto-MARCCINO controller.

C1 C10
11
C23 C31
T5-6-17
(FAULTY INITIAL SETTING OF BOOM (FAULTY INITIAL SETTING OF OFFSET
ANGLE SENSOR) ANGLE SENSOR)
(FAULTY INITIAL SETTING OF ARM AN- (FAULTY INITIAL SETTING OF SLIDE ARM
GLE SENSOR) SENSOR)
• Fault codes 60 to 62 are displayed when input

voltage from the angle sensor to the
auto-MARCCINO controller is at the deviation of
±0.3 V or more from the specified value.
• Fault code 63 is displayed when input voltage
from the angle sensor to the auto-MARCCINO
controller is at the deviation of ±0.1 V or more
from the specified value .
Measure the voltage at angle Faulty auto-MARCCINO con-

sensor with the front attach- troller.
ment in angle sensor initializa- YES
tion position. Check if signal
voltage is within ±0.3 V of the
specification.
NO
Faulty angle sensor.

· Specifications:
Check if fault codes Boom : 0.664 V ± 0.3 V
disappear when angle Arm : 4.247 V ± 0.3 V NO
sensor is initialized. Offset : 2.153 V ± 0.3 V · Refer to T4-6 Adjust-
· With the connector connected, ment.
ground connector to vehicle
· Refer to T4-6 Adjust- with a clip from the rear side of
ment. the connector.
End.
YES

Boom Angle Sensor/Slide Arm/Offset Angle

Arm Sensor Connectors Sensor Connectors
1 2
1 2 3
3
T5-6-18
(BOOM ANGLE SENSOR DEVIATION) (OFFSET ANGLE SENSOR DEVIATION)
(ARM ANGLE SENSOR DEVIATION) (SLIDE ARM SENSOR DEVIATION)
NOTE: The attachments marked with “*” are op-

tional.
• Check for deformation in the link part of angle

sensor first.
• These fault codes are displayed if the value be-
yond the sensor operating range below is output
to the auto-MARCCINO controller.
Sensor Activating Range

Sensor
Boom Angle Sensor Arm Angle Sensor Offset Angle Sensor *Slide Arm Sensor
Attachment
Standard Arm 0.165 V to 4.305 V 0.265 V to 4.746 V 0.684 V to 4.338 V －
*Long Arm ↑ 0.215 V to 4.480 V ↑ －
*Slide Arm
YES Faulty auto-MARCCINO con-

Measure voltage at terminal troller.
#2 on angle sensor connector
on fault code. Check if voltage
is within sensor operating
range above.
· Using a clip, ground from the Faulty angle sensor installing.

rear side of the connector NO
without disconnecting. · Refer to T4-6 Adjustment.
Connector (Harness end connector terminals seen from the open end side)
Boom Angle Sensor/Slide Arm Arm/Offset Angle

Sensor Connectors Sensor Connectors
1 2
1 2 3
3
T5-6-19
FAULT CODE 90
(FAULTY OIL TEMPERATURE SENSOR)
• The auto-MARCCINO controller activates the Oil Temperature Electrical Resis-
deceleration and stop functions in the cab colli- (°C) tance (kΩ)
sion prevention system earlier than the normal -20 15.0±1.5
positions when the input signals from the oil tem-
perature sensor are lower than 10 °C. 0 (5.74)
• Fault code 90 is displayed when signal voltage 20 2.45±0.24
corresponding to -30° C or lower, or +100° C or
more is sent out of the oil temperature sensor to 40 (1.15)
the auto-MARCCINO controller. 60 (0.584)
hand. 80 0.318±0.031
Disconnect oil tempera-

ture sensor. Short-circuited harness
Check for continuity be- between oil temperature
tween auto-MARCCINO YES sensor and
Disconnect oil tempera- controller connector auto-MARCCINO con-
ture sensor, and connect (EF-2) terminal #21 or troller.
harness end connector
YES connector (EF-4) termi-
terminals No.1 and No.2. nal #4 and vehicle.
Disconnect
auto-MARCCINO con-
troller connector, check
for continuity between NO Faulty auto-MARCCINO
YES harness end terminals controller.
Disconnect oil
temperature sen- below.
sor. Check if oil
temperature sen-
sor electrical re-
oil temperature sensor
sistance is within
and auto-MARCCINO
specification. NO
· Terminals: controller.
Connector (EF-2): #21
Connector (EF-4): #4
Faulty oil temperature

NO sensor.

Oil Temperature Sensor Auto-MARCCINO Controller (EF-2) Auto-MARCCINO Controller (EF-4)

1 8 1 5
4
1 2
21 25
19 13 16
T5-6-20
FAULT CODE 91 (ABNORMAL SENSOR
POWER SOURCE)
• Fault code 91 means that the voltage of the sen-

sor in the auto-MARCCINO control unit is ab-
normal. In case fault code is displayed after the
retrial, replace the auto-MARCCINO control unit.
T5-6-21
FAULT CODE 92 (ABNORMAL REFER-
ENCE POWER SOURCE)
• If reference voltage (5V) delivered from the MC to
the auto- MARCCINO controller is abnormal,
fault code 92 is displayed. Even if any abnormal-
ity occurs, the backup function is activated so
that machine operation is not affected.
Remove connector (MCX-B)

from MC. Connect hatness
end connector terminal #19 to
#21.
Remove connector (EF-3)
from auto-MARCCINO
controller. Check if continuity
Remove connector (EF-3) NO between harness end
from auto-MARCCINO connector terminals #30 and
controller. Check if voltage #31 is present.
between harness end
connector terminals #30 and
NO #31 is 5 ± 0.25 V.
Check if MC fault code 04 is YES controller.
displayed
Conduct the troubleshooting

for MC.
YES
· Refer to T5-3-3.


MC Connector (MCX-B) 1 10
1 8
30 31
19 21 23 31
19 25
T5-6-22
NO Faulty auto-MARCCINO con-

troller.
Without reconnecting con-
nector to MC, check if conti-
nuity between the vehicle
YES frame and terminal #30 or #31
on auto-MARCCINO control-
ler harness end connector is
present.
YES between MC and
Broken harness between MC

NO and auto-MARCCINO
controller.
T5-6-23
(Blank)
T5-6-24
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.
Be sure to remove the negative terminals from
the batteries first when taking wire harnesses
and connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses, and fusible links and, in some
cases, cause fire due to short circuiting.
2. Color coding of wire harnesses. Code Color Code Color
The color codes of the wire harnesses in the R Red W White
electrical system are shown inn the table onn the L Blue G Green
right. Or Orange Lg Light
In cases on the design sheet where two colors green
are indicated for one wire, the left initial stands Y Yellow B Black
for the base color, while the right initial stands for Br Brown P Pink
the marking color.
Gr Gray V Violet
NOTE: 1) Code BW indicates a black base wire

with white fine-line marking.
2) Initials “O” and “Or” both stand for the
color orange.
3) Wires with longitudinal stripes printed
on them are not color coded. Be sure
not to confuse them with color coded
wires.
T5-7-1
3. Precautions for connecting and disconnecting

terminal connectors.
Right Wrong
1) When disconnecting harnesses, grasp them
by their connectors. Do not pull on the wire
itself. Be sure to release the lock first before
attempting to separate connectors, if a lock
is provided. (Refer to “Instructions for
Disconnecting Connector” on page T5-7-3.) T107-07-06-001
2) Water-resistant connectors keep water out

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

is correctly connected.Precaution for using a
circuit tester.
1) Before using a circuit tester, refer to the Sharpen the end of the Wire
T107-07-06-003
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object
to be measured, voltage range and current
polarity.
2) Before starting the connector test, always
check the connector terminal numbers,
referring to the circuit diagram.
When the connector size is very small, and
the standard probe size is too large to be
used for testing, wind a fine piece of
sharpened wire or a pin around the probe to
make the test easier.
T5-7-2
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
• Push to Unlock and Separate Type
NOTE: Connectors will not be easily separated

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

Fuel Gauge N Sensor *Engine Oil Level Switch Radio
Hydraulic Oil Level Switch EC Motor *Coolant Level Switch Speaker
Horn EC Sensor Diode Learning Switch
Cab Harness Pump Delivery Pressure Sensor Key Switch Wiper
Pressure Sensor General Relay Engine Control Dial Monitor
Washer Solenoid Valve
NOTE:* ZAXIS110/110M/125US
: Up to serial No.010576
ZAXIS120/135US:
Up to serial No.062964
• Pull Up to Unlock and Separate Type

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

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

Dr.ZX
T5-7-3
FUSE INSPECTION
Cracks in a fuse are so fine that it is very difficult or NOTE: All terminals located along the lengthwise
impossible to find by visual inspection. Use a tester to centerline of the fuse box are connected to
correctly inspect fuse continuity by following the in- the power source, while terminals located
structions described below. away from the center of the fuse box are
connected to loads (accessories). There-
1. Turn Key Switch ON fore, test all fuses in the same method ex-
When the key switch is turned ON, current from cept for the glow plug relay circuit fuse.
key switch terminal M activates the battery relay Check the glow plug relay circuit fuse with
so that electric power is supplied to all circuits the key switch turned to the ON position
except the glow plug relay circuit. (Refer to the then follow the procedure in step 3.
circuit diagram.)
2. Remove the fuse box cover. Set the tester volt-
age to meet the circuit specification to be meas- 10 20
ured. (Measurement Range: 0 to 30 V) 9 19
3. Ground the negative probe of the tester to the
vehicle frame. Touch the terminals located away 8 18
from the center of the fuse box with the positive 7 17
probe of the tester one at a time. When normal
continuity of a fuse is intact, the tester will indi- 6 16
cate 20 to 25 volts (battery voltage). 5 15
4 14
3 13
2 12
1 11
M178-07-034
T5-7-4
Fuse Fuse
Capacity Connected to Capacity Connected to
No. No.
1 5A Radio, Monitor ICX (Backup 11 20 A Work Light Relays 1 and 2
Power)
2 5A MC (Main Power) 12 10 A Wiper Relays A, B, and C,
Wiper Motor, Washer Relay
3 10 A MC (EC Motor Power) 13 20 A Heater (Air Conditioner Unit)
4 10 A MC (Solenoid Valve Power) 14 10 A Horn Relay
5 5A Monitor 15 5A Radio (ZAXIS135UR: Room
(10A) Light, Cigarette Lighter, Radio)
6 5A MC, ICX (Power ON Signal) 16 10 A Cigarette Lighter
(ZAXIS135UR: Auxiliary)
7 5A Air Conditioner Unit 17 5A Room Light (ZAXIS135UR:
URX Controller Power)
8 5A Optional 1 18 10 A Auxiliary (ZAXIS135UR: Sole-
noid Valve Power)
9 10 A Optional 2 19 5A QOS Controller, Glow Plug
(10A) Relay (ZAXIS135UR: Emer-
gency Evacuation Switch)
10 5A Optional 3 20 − Empty (ZX135UR: QOS Con-
(5A) troller, Glow Plug Relay)
T5-7-5
FUSIBLE LINK INSPECTION Battery Relay
Inspection
1. Remove the negative cable from the battery.

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

the battery.
2. Remove bolt M8 to take the fusible link off the T178-05-06-002
battery relay.
3. Open the upper and bottom side covers of the
fusible link box. Remove screws M6 (2 used).
4. Take out the fusible link to replace it. Battery
Relay
5. Retighten two screws M6 (2 used). Bolt M8
6. Install the fusible link box and the cable to the
battery relay.
7. Reconnect the negative cable to the battery.
Cable Screw M6
T107-04-05-008
T5-7-6
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between
the battery positive terminal and the vehicle
frame.
Normal Voltage: 24 V
NOTE: If voltage is abnormal, recharge or replace

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

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

system.
T157-07-06-007
T5-7-7
HOW TO TROUBLESHOOT ALTERNATOR
MALFUNCTIONS
In general, the alternator indicator remains off when
the alternator is generating power.
If the alternator indicator comes on while the engine is
running, the alternator might be defective.
How to check the circuit
1. Stop the engine. Turn the key switch to the ON

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

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

generated while as the alternator rotates.
As described above, measure the voltage
between terminals B and E on the side of the
alternator. If the voltage is around 28 V, the
alternator is operating normally.
If the rated voltage is not being generated, there
is some trouble with the alternator or the regula-
tor.
T5-7-8
CONTINUITY CHECK
Harness
Single-line continuity check A a
Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity
Ω
NOTE: When the one end connector is far apart

from the other, connect one end of Connect to
A a
connector (A) to the machine chassis the vehicle
using a clip. Then, check continuity of the frame.
harness through the vehicle frame as
illustrated.
Connect to
Ω
the vehicle
If the ohm-meter reading is: 0 Ω = Continuity frame.
∞ Ω = Discontinuity
A a
Single-line short-circuit check
Disconnect both end connectors of the harness and × Short-circuit
check continuity between one end connector of the between the
harness and
harness and the vehicle frame: the vehicle
If the ohm-meter reading is: Ω frame.
0 Ω = Short circuit is present.
∞ Ω = No short circuit is present.
T107-07-05-003
T5-7-9
Multi-line continuity check
Disconnect both end connectors of the harness,
and short-circuit two terminals, (A) and (B), at one First short-circuit
end connector, as illustrated. Then, check continuity
between terminals (a) and (b) at the other connector.
A a
If the ohm-meter reading is ∞ Ω, either line (A) - (a), B b
or (B) - (b) is in discontinuity. To find out which line C c
is discontinued, conduct the single line continuity
check on both lines individually, or, after changing Second short-circuit
the short-circuit terminals from (A) - (B) to (A) - (C),
check continuity once more between terminals (a)
and (c).
Ω
NOTE: By conducting the multi-line continuity

check twice, it is possible to find out which T107-07-05-004
line is discontinued. With terminals (A) and
(C) short-circuited, check continuity Short-circuit between harnesses.
between terminals (a) and (c).
If the ohm-meter reading is: A
×
a
B b
0 Ω = Line (B) - (b) has discontinuity. C c
∞ Ω = Line (A) - (a) has discontinuity.
Multi-line short-circuit check

Disconnect both end connectors of the harness,
and check continuity between terminals (A) and (B)
or (C). Ω
If the ohm-meter reading is:
0 Ω = Short-circuit exists between the lines.
∞ Ω = No short-circuit exists between the lines. T107-07-05-005
T5-7-10
VOLTAGE AND CURRENT MEASURE-
MENT
Turn key switch ON so that the specified voltage (cur-
rent) is supplied to the location to be measured.
Judge if the circuit is normal by evaluating whether
the measured voltage (current) matches the specifica-
tion.
24-Volt Circuit
Start checking the circuit in order up to the location
to be measured from either power source or actua-
tor side. Thereby, the faulty location in the circuit will
be found.
Black Probe (Minus) of Tester: To ground to the
vehicle frame
Red Probe (Plus) of Tester: To touch the location
to be measured
T5-7-11
ZAXIS110/120/130/130LCN/125US/135US
Engine Key Switch Location to be Measured Specification

Power Source Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Battery Power 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (6) and Ground: Backup Current* 6 mA
Preheat Circuit
Stopped ON or START Between (6) and Ground: Key Switch 20 to 25 V
Stopped ON or START Between (7) and Ground: Glow Plug 20 to 25 V
Starting Circuit
Started START Between (8) and Ground: Key Switch 20 to 25 V
Started START Between (9) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (10) and Ground: Battery Relay (Switch) 20 to 25 V
Started START Between (11) and Ground: Starter (B) 20 to 25 V
Started START Between (12) and Ground: Starter (C) 20 to 25 V
Started START Between (13) and Ground: Starter Relay (S) 20 to 25 V
Charging Circuit
Fast Speed ON Between (14) and Ground: Alternator Generating Volt- 26 to 30 V
Fast Speed ON age (B)/Generating Voltage 26 to 30 V
Between (10) and Ground: Battery Relay / Generating
Fast Speed ON Voltage 26 to 30 V
Between (15) and Ground: Fuse Box / Starter Relay (R)/
Fast Speed ON Generating Voltage 13 to 30 V
Fast Speed ON Between (16) and Ground: Generating Voltage 13 to 30 V
Between (17) and Ground: Monitor
Surge Voltage Pre-
vention Circuit
Slow Idling ON Between (14) and Ground: Alternator (B) 26 to 30 V
Slow Idling ON Between (16) and Ground: Starter Relay (R) 13 to 30 V
Slow Idling ON Between (18) and Ground: Load Damp Relay 26 to 30 V
Slow Idling ON Between (10) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (19) and Ground: Auxiliary 20 to 25 V
Stopped ON Between (20) and Ground: Room light 20 to 25 V
Stopped ON Between (21) and Ground: Cigar Lighter 20 to 25 V
Stopped ON Between (22) and Ground: Radio 20 to 25 V
Stopped ON Between (23) and Ground: Horn 20 to 25 V
Stopped ON Between (9) and Ground: Battery Relay 20 to 25 V
*Measure after disconnecting the negative cable from the battery.
T5-7-12
Key Switch
Battery
6 8
1 2 3 5 4 9
15
Battery Relay
Fuse
10 Box
Starter
18 Load
Damp
Relay
11
12 23 22 21 20 19 17
13
Monitor
Starter Relay
16
Alternator
G
lo
w
P
14
Glow Plug
T178-05-06-001
T5-7-13
ZAXIS135UR
Engine Key Switch Location to be Measured Specification

Power Source Circuit
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Battery Power 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (6) and Ground: Backup Current* 6 mA
Preheat Circuit
Stopped ON or START Between (6) and Ground: Key Switch 20 to 25 V
Stopped ON or START Between (7) and Ground: Glow Plug 20 to 25 V
Starting Circuit
Started START Between (8) and Ground: Key Switch 20 to 25 V
Started START Between (9) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (10) and Ground: Battery Relay (Switch) 20 to 25 V
Started START Between (11) and Ground: Starter (B) 20 to 25 V
Started START Between (12) and Ground: Starter (C) 20 to 25 V
Started START Between (13) and Ground: Starter Relay (S) 20 to 25 V
Charging Circuit
Fast Speed ON Between (14) and Ground: Alternator Generating Volt- 26 to 30 V
Fast Speed ON age (B)/Generating Voltage 26 to 30 V
Between (10) and Ground: Battery Relay / Generating
Fast Speed ON Voltage 26 to 30 V
Between (15) and Ground: Fuse Box / Starter Relay (R)/
Fast Speed ON Generating Voltage 13 to 30 V
Fast Speed ON Between (16) and Ground: Generating Voltage 13 to 30 V
Between (17) and Ground: Monitor
Surge Voltage Pre-
vention Circuit
Slow Idling ON Between (14) and Ground: Alternator (B) 26 to 30 V
Slow Idling ON Between (16) and Ground: Starter Relay (R) 13 to 30 V
Slow Idling ON Between (18) and Ground: Load Damp Relay 26 to 30 V
Slow Idling ON Between (10) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (19) and Ground: Room Light/Radio/Cigar 20 to 25 V
Stopped ON Lighter 20 to 25 V
Stopped ON Between (20) and Ground: Auxiliary 20 to 25 V
Stopped ON Between (21) and Ground: Horn 20 to 25 V
Between (9) and Ground: Battery Relay
*Measure after disconnecting the negative cable from the battery
T5-7-14
Key Switch
Battery
1 2 3 5 4 9
6 8
15
Battery Relay
Starter 10 Fuse
Box
11
12 18 Load
Damp
Relay
13
21 20 19
Starter Relay
16
Alternator Glow
Plug
14 Relay
A13 Monitor
7
17
Glow Plug
T1SM-05-07-001
T5-7-15
5 Voltage Circuit
Signal or
• Voltage between terminal No.1 and the vehicle Two polarities Power source ground
frame (ground) 1 2
With the key switch turned OFF, disconnect the
sensor connector.
Measure the voltage between terminal No.1 on the
machine harness side connector and the vehicle
(ground) under the following conditions.
V
• Key switch position: ON
• Tester black terminal (negative):
Connected to the vehicle (ground)
• Tester red terminal (positive):
T107-07-05-006
Connected to terminal No.1
Three polarities Power source Signal Ground
Evaluation: 1 2 3
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal No.1 is normal.
• Voltage between terminal No.1 and the ground T107-07-05-007
terminal
With the key switch turned OFF, disconnect the Two polarities
1 2
sensor connector.
Measure the voltage between terminal No.1 on the
machine harness side connector and the ground
terminal (terminal No.2 for two polarities, or terminal
No.3 for three polarities) under the following V
conditions.
• Key switch position: ON

• Tester black terminal (negative):
Connected to the ground terminal
(terminal No.2 or 3) T107-07-05-008
• Tester red terminal (positive):
Connected to terminal No.1 Three polarities
1 2 3
Evaluation:
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal No.1 or the ground terminal is
normal.
V
T107-07-05-009
T5-7-16
CHECK BY FALSE SIGNAL
Two-Polarities
Turn the key switch OFF. After disconnecting the sen- (Oil Temperature)
sor connector, turn the key switch ON. Then, connect (N Sensor)
1 2
machine side harness end connector terminal #1
(power) to terminal #2 (signal). (Power voltage is used
as a false signal.) Check the controller using Dr. ZX
monitor function under this condition. When the maxi-
mum value is displayed, the MC and the circuit up to
the machine side harness end connector are normal.
When the pressure switch circuits are normal, Dr. ZX Connect
displays “ON.”
IMPORTANT: Don’t connect terminal #1 or #2 to

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

three-polarity connector. (Pressure Sensor)
(Pump Delivery Pressure Sensor)
(Pump Control Pressure Sensor) 1 2 3
NOTE: Some kinds of sensors can be monitored (EC Sensor)
by the built-in diagnosing system. (Refer to
the TROUBLESHOOTING / General
group.)
Connect
T107-07-05-011
T5-7-17
TEST HARNESS
With a test harness installed between connectors, the
circuit condition is checked depending on whether the
test harness lamp lights or extinguishes during opera-
tion.
Parts Number 4283594 (ST 7126)

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

Use to check the solenoid valve unit circuits.
When the corresponding control lever or switch is 4
operated: Lamp is ON. 3 50
(Refer to T5-4-50, 62 and 81.) 150 50 50
1 2 2 1
T107-07-06-015

Use to check the EC motor circuit.
(Refer to T5-4-34 and 38.) 5
6
50
• EC Motor Circuit
When the engine control dial is rotated: 1 2 2 1
150 50
Both lamps ON: Normal 50
Only one lamp ON: Check for continuity of the 4 3 4 3
circuit connected to the lamp OFF. 7 50
Both lamps OFF: Check the harness together 8
with the relay.
Parts Number 4274589 (ST 7125) T107-07-06-024

Use to measure the EC sensor circuit signal line (Red)
voltage (between terminals #2 and #3).
(Black)
Parts Number 4284347 (ST 7129) T107-07-03-009
T5-7-18
Use to check the wiper circuit.
(Refer to T5-4-86.)
2
5 1
2 4 7
1
Parts Number (ST 7227) T178-05-06-003
T5-7-19
(Blank)
T5-7-20
TROUBLESHOOTING / ICX
OUTLINE
The ICX (information controller) stores signals from
various kinds of sensors and switches provided on the
machine as data. The various input signals are
grouped into “Daily Report Data List”, “Frequency Dis-
tribution Data List”, “Cumulative Operation Hour List”,
“Alarm List”, and “Trouble List” and are recorded in
the ICX.
Data stored in the ICX is downloadable by the PALM.

This data, after being uploaded to a personal com-
puter, can be read with the “data-viewer”, a data read-
ing software. Using the HAU from e-Service, the data
can be uploaded to a server to which customers,
distributor and Hitachi are accessible.
T5-8-1
Daily Report Data List
Data Details
1 Key Switch ON Time Time when key switch is first turned ON during daily operation
(Time is recorded by key switch ON signal.)
2 Key Switch OFF Time Time when key switch is last turned OFF during daily operation
(Time is recorded by key switch ON signal.)
3 Engine Start Time Time when engine is first started during daily operation
(Time is recorded by alternator output signal.)
4 Engine Stop Time Time when engine is last stopped during daily operation
(Time is recorded by alternator output signal.)
5 Hour Meter Hour meter cumulative hours

(Hours are recorded by hour meter signal from monitor.)
6 Fuel Level The value of the final remained fuel during a day
(Value is recorded by fuel sensor signal from monitor.)
7 Engine Operating Hours Total engine operating hours during daily operation
(Hours are recorded by alternator output signal.)
8 Swing Operating Hours Total swing operating hours during daily operation
(Hours are recorded by signals from swing pressure sensor.)
9 Travel Operating Hours Total travel operating hours during daily operation
(Hours are recorded by signals from travel pressure sensor.)
10 Front Attachment Operat- Total front attachment operating hours during daily operation
ing Hours (Hours are recorded by signals from front attachment pressure sensor.)
11 Breaker Operating Hours Total breaker operating hours during daily operation
(Hours are recorded by signals from auxiliary pressure sensor and attach-
ment mode switch.)
12 Auxiliary Attachment Ex- Total auxiliary attachment except for breaker operating hours during daily
cept for Breaker Operating operation
Hours (Hours are recorded by signals from auxiliary pressure sensor and attach-
ment mode switch.)
13 *ML Operating Hours Total *ML crane operating hours during daily operation
(Hours are recorded by signals from crane mode switch.)
14 Engine Operating Hour Engine operating hour distribution during daily operation
Distribution (Operating hours are recorded only when alternator output signal is con-
tinuously delivered for more than 10 minutes.)
T5-8-2
NOTE: The daily operation in this table is equiva-

lent to the hours between 0:00 and
23:59:59 counted by the ICX built-in clock.
In case the engine is kept operated be-
yond 0:00, such data are recorded as
those for the following day.
* ML/ML crane specification is only avail-

able in Japanese domestic market.
Frequency Distribution Data List
Data Details
1 Coolant Temperature in Radiator Frequency distribution of coolant temperature
(Temperatures are recorded by signals from coolant tempera-
ture sensor.)
Cumulative Operation Hour List
Data Details
1 Engine Operation Hour Cumulative engine operation hours
(Hours are recorded by alternator output signal.)
2 Travel Operation Hour Cumulative travel operation hours
(Hours are recorded by signals from travel pressure sensor.)
3 Front Attachment Operation Hour Cumulative front attachment operation hours
(Hours are recorded by signals from front attachment pressure
sensor.)
4 *ML Operation Hour Cumulative *ML operation hours
(Hours are recorded by signals from crane mode switch.)
NOTE: * ML specification is only available in Japa-

T5-8-3
Alarm List
Code Data Details

86 Hydraulic Oil Filter Date and time when hydraulic oil filter indicator lighted are recorded
by signals from hydraulic oil filter restriction switch.
89 Overheat Date and time when overheat indicator lighted are recorded by sig-
nals from overheat switch.
90 Engine Oil Pressure Date and time when engine oil pressure indicator lighted are re-
corded by signals from engine oil pressure switch.
93 Air Filter Restriction Date and time when air filter restriction indicator lighted are re-
corded by signals from air filter restriction switch.
94 Alternator Indicator Date and time when alternator indicator lighted are recorded by sig-
nals from monitor controller.
NOTE: In case the above alarms are recorded,

check individual item. If malfunction of the
monitor is found, refer to troubleshooting
C.
T5-8-4
Trouble List
Fault
Trouble Details
Code
01 Abnormal EEPROM Occurrence time and date of fault code 01
02 Abnormal RAM Occurrence time and date of fault code 02
03 Abnormal A/D Conversion Occurrence time and date of fault code 03
04 Abnormal Sensor Voltage Occurrence time and date of fault code 04
06 Abnormal EC Sensor Occurrence time and date of fault code 06
07 Abnormal Engine Control Dial Occurrence time and date of fault code 07
18 Abnormal Travel Lever Stroke Occurrence time and date of fault code 18
64 MC Communication Error Time and date when communication error between MC
and ICX occurred.
65 Monitor Communication Error Time and date when communication error between
monitor and ICX occurred.
66 Satellite Terminal Communication Error Time and date when communication error between sat-
ellite terminal and ICX occurred.
NOTE: In case the above fault codes are re-

corded, refer to troubleshooting A.
T5-8-5
ICX FAULT CODE LIST
Fault
Trouble Remarks
Code
1 Abnormal Internal Ram In case of SAM error
2 Abnormal Flush Memory In case of SAM error
3 Abnormal Exterior In case of SAM error or read-write error
4 Abnormal EEPROM In case of SAM error
6 Abnormal Time In case RTC data was other than figures.
7 MC Communication Timeout In case MC communication lasted for less than 7 sec-
onds.
8 Monitor Communication Timeout In case monitor communication did not last for more
than 24 seconds.
9* MC Communication Timeout In case MC communication did not last for more than 20
seconds.
10 Satellite Terminal Communication Timeout In case satellite communication did not last for more
than 1 minute.
NOTE: *Fault code 9 may be displayed on only

the machine to which the ICX is installed
later.
SATELLITE TERMINAL FAULT CODE LIST
Fault
Trouble Remarks
Code
101 Satellite Terminal: Internal Error Abnormal EEPROM
102 Satellite Terminal: Internal Error Abnormal sent data
103 Satellite Terminal: Internal Error In case reception is difficult.
104 Satellite Terminal: Communication Error In case satellite communication cannot be accom-
plished.
105 Satellite Terminal: Internal Error In case sending retry over occurred or local loop back
test failed with power ON.
106 Satellite Terminal: Communication Error In case sending retry over occurred.
107 Satellite Terminal: Abnormal Harness In case reception data does not match sending data.
T5-8-6
FAULT CODE 1 TO 4 AND 6
YES Faulty ICX
Check if all data are normally

cumulated.
Faulty ICX
NO
* Even if the fault code remains displayed after retry-

ing, the machine can be operated as it is when data
record is normally cumulated.
FAULT CODE 7 TO 10
YES Faulty ICX

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

7 Connector C terminal #11 MC connector D terminal #10
8 Connector C terminal #1 Monitor connector B terminal #3
10 Connector B terminal #5 Satellite terminal #2
T5-8-7
SOME PARTS OF DATA IN DAILY REPORT,
FREQUENCY DISTRIBUTION, CUMULA-
TIVE OPERATION HOURS ARE NOT RE-
CORDED
• All necessary data signals may not be input into
the ICX. Individual signals are utilized to record
more than one data. While referring to the table
below, check the corresponding system for any
abnormality.
Related Data Input Signal

Key switch ON and OFF time Key switch
Engine start and stop time, Engine operating hours (Daily report and cu- Alternator
mulative operation hour), Engine operating hour distribution
Hour meter Monitor controller
Coolant temperature distribution in radiator Coolant temperature sensor
Remaining fuel level (detected at regular data sending time) Fuel level sensor
Travel operating hours (Daily report and cumulative operation hour), Av- Travel pressure sensor
erage pump delivery pressure distribution in travel operation
Front attachment operating hours (Daily report and cumulative operation Front attachment pressure sensor
hour)
*ML operating hours (Daily report and cumulative operation hour) Crane mode switch
NOTE: *ML specification is available only in Japa-

T5-8-8
Corrective Action Remarks

Check harness between ICX terminal A5 and key In case engine does not start, refer to troubleshooting
switch terminal M. B.
Check harness between ICX terminal A2 and alterna- In case alternator indicator malfunctions, refer to trou-
tor terminal L. bleshooting C.
Check harness between ICX terminal B1 and monitor In case hour meter malfunctions, refer to trouble-
terminal B3. shooting C.
Check harness between ICX terminal B1 and monitor In case coolant temperature gauge malfunctions, refer
terminal B3. to troubleshooting C.
Check harness between ICX terminal B1 and monitor In case fuel gauge malfunctions, refer to troubleshoot-
terminal B3. ing C.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
T5-8-9
Downloading from and Uploading to the
ICX
The data stored in the ICX is downloadable by the
PALM using the “MIC Download” program or the “Dr.
ZX” program. Downloading using each program as
well as uploading to a PC are explained below. For
uploading of the downloaded data to a server using
the e-Service, refer to the “e-Service Manual”.
T5-8-10
THE ATTACHED DIAGRAM LIST
(The following diagrams are attached to this manual.)
ZAXIS110/120/130/130LCN ELECTRICAL CIRCUIT DIAGRAM
ZAXIS110/120/130/130LCN CONNECTORS
ZAXIS125US/135US ELECTRICAL CIRCUIT DIAGRAM
ZAXIS125US/135US CONNECTORS
ZAXIS135UR ELECTRICAL CIRCUIT DIAGRAM
ZAXIS135UR CONNECTORS
ZAXIS110/120/130/130LCN CAB HARNESS
ZAXIS125US/135US CAB HARNESS
ZAXIS135UR CAB HARNESS
ZAXIS110/120/130/130LCN ENGINE HARNESS
ZAXIS125US/135US ENGINE HARNESS
ZAXIS135UR ENGINE HARNESS
ZAXIS110/120/130/130LCN MONITOR HARNESS
ZAXIS135UR CONSOLE HARNESS
ZAXIS110/120/130/130LCN HYDRAULIC CIRCUIT DIAGRAM
ZAXIS125US/135US HYDRAULIC CIRCUIT DIAGRAM
ZAXIS135UR HYDRAULIC CIRCUIT DIAGRAM

CAUTION: Parts numbers on the drawing are provided only for reference purpose.
To order parts on the drawing, be sure to consult the Parts Catalog.
Attach to Vol. No. : TT187E-04
ZAXIS110/110M/120/130/130LCN ELECTRICAL CIRCUIT DIAGRAM

LUBRICATOR
CAB OUTSIDE CAB INSIDE

OPTION(330)
LUBRICATOR
MONITOR
CAB INSIDE CAB OUTSIDE
CONTROLLER MONITOR
STARTER SWITCH
MONITOR
POWER IN-PUT
BUCK UP POWER IN-PUT POWER
WATER TENP. SWITCH GLOW IN-PUT CIRCUIT HOUR METER DATA COMMUNICATION OUT-PUT
NOT IN SMJ SERIAL COMMUNICATION TXD
COMMUNICATION SW.
SERIAL COMMUNICATION RXD
REG IN-PUT SATELLITE/PC
CONNECTION SW.
INTERIOR
INTERIOR LAMP
POWER ON SIGNAL
LAMP
POWER-IN
REG. IN-PUT
FUSIBLE LINK(45A) BATT.(DIRECT) COOLANT TEMP. FUEL
EC DIAL SIGNAL IN-PUT
EC DIAL SIGNAL IN-PUT(GND)
BUCK UP
WIPER SIGNAL IN-PUT(+5V)
BATTERY 12V X 2 WIPER SIGNAL IN-PUT
ACC(LOAD)
120 GROUP
BATTERY RELAY ALT(LOAD) WIPER SIGNAL IN-PUT(GND)
LIQUID
CRYSTAL PANEL
OVER-HEAT
FUSIBLE LINK(65A)
LOAD DUMP FUSE AIR FILTER
RELAY
FUEL
GLOW
LIGHT
WIPER
HEATER
HORN
RADIO
LIGHTER
ROOM LIGHT
AUX.
GLOW/R
BACK-UP
CONTROLLER
EC MOTOR
SOLENOID
SWITCH BOX
POWER ON SIGNAL
AIR-CON.
STARTER WIRING TOOL WORK LIGHT
DISPLAY CHANGE MAIN
SAFETY RELAY COMPLETED CHARGE
POWER
(120 GROUP) SET ENG. OIL LEVEL CONTROLLER
MONITOR
SPARE 1
ROOM LIGHT WORK MODE MAIN
SPARE 2 GND
WIPER MOTOR ENG. OIL LEVEL
WIRING COMPLETED
120 GROUP
COOLANT LEVEL
AUTO RE-FUELING LIGHTER

HYD.OIL FILTER
SYSTEM SPARE 4 B9:MONITOR COMMUNICATION GND
C10:MCX COMMUNICATION GND
SPARE 5 D11:DIGITAL GND
SPARE 6
SPARE 6 SW. IN-PUT OPTION

ALTERNATOR HYD. OIL FILTER SW. IN-PUT
SPARE 4 EXT. HYD. OIL FILTER WARNING #4448754
GLOW RELAY OPTION
LIGHT 1
LIGHT 2
CHARGE EXT.
SPEAKER R SPARE 2 SW. IN-PUT RADIATOR LEVEL SW. #4153251
WARNING LAMP LOCATION AIR FILTER RESTRICTION SW. IN-PUT
SPARE 5 EXT. AIR CLEANER RESTRICTION SW. #4224238
NO.12 IS OPT., NO.5 IS NOT USE (120 GROUP #4334759)
WORK LIGHT SW. IN-PUT
FUEL
REGULATOR SPEAKER L GLOW EXT.
WIPER
ENG. OIL LEVEL EXT.
RADIO COOLANT LEVEL EXT.
GLOW PLUG
FUEL SIGNAL
COOLANT TEMP. SIGNAL FUEL SENSOR #4257128
AUTO- AUTO-IDLE DIGGING ATTACHMENT COOLANT TEMP SENSOR #4436537
ACCELERATION MODE 1 SIGNAL OUT-PUT
(ONLY ZX200 PASS THROUGH NO.12)
LOAD DUMP RELAY OUT-PUT MODE 2 SIGNAL OUT-PUT
ENG. OIL LEVEL SW.(ON ENG.) #4371903
RELAY DRIVE CIRCUIT

LIGHT 1 RELAY OUT-PUT WIPER, WASHER MOVE SIGNAL OUT-PUT ENG. OIL PRESSURE SW.(ON ENG.) #*******
LIGHT 2 RELAY OUT-PUT
WIPER C RELAY OUT-PUT SPARE 1 SW. IN-PUT
WIPER B RELAY OUT-PUT
ENG. OIL PRESS. SW. IN-PUT
WIPER A RELAY OUT-PUT OVER-HEAT SW. IN-PUT
WASHER RELAY OUT-PUT ENG. OIL LEVEL SW. IN-PUT OVER-HEAT SW. #4371318
COOLANT LEVEL SW. IN-PUT
WIPER WIPER WIPER WIPER AUTO-IDLE SW. IN-PUT AUTO-IDLE
PULL-UP
A/I A/A SW
RELAY A RELAY B RELAY B1 RELAY B2 AUTO-ACCELERATION SW. IN-PUT AUTO-ACCELERATION WASHER SW.
WASHER SW. IN-PUT
LIGHT SW. 2 IN-PUT
LIGHT SW. 1 IN-PUT
LIGHT SW.
WIPER, WASHER EN SW. IN-PUT
BACK-UP EN SW. IN-PUT
HOUR METER GROUND
WASHER RELAY SIGNAL WIPER VR.
INTERIOR LIGHT
INTERIOR LIGHT
POWER IN-PUT
BUZZER SIGNAL
WASHER ENG. SPEED CONTROL DIAL
FRONT WINDOW UP-ON HIGH-SPEED

LOW-SPEED TRAVEL 2-SPEED SW.
LIGHT RELAY 2
NORMAL OPEN HP, P, E MODE SW.
SWITCH BOX
BOOM LIGHT
LIGHT RELAY 1
WORK LIGHT ZX200, ZX225USR ADDITIONAL PUMP ELECTRICAL DIAGRAM
PUMP 3 DELIVERY PRESSURE

PROPORTIONAL SOL-2
PROPORTIONAL SOL-1
ARM DUMP PILOT(S)

PRESSURE
SENSOR (H)
HORN RELAY
HORN SIDE/
MALE ON
BOTH SIDE HORN (H)
HORN SWITCH
ML-CRANE BOOM DUMPING

(JAPANESE DOMESTIC ONLY) (JAPANESE DOMESTIC ONLY) SWING ALARM
HORN (L)
TRAVEL ALARM
BOOM ROD SIDE PRESSURE (S)

TRAVEL ALARM
OPTION
ARM DUMP PILOT (S)

OPTION
INITIAL SETTING SW.
BOOM BOTTOM (S)
BOOM BOTTOM (S)

CRANE MODE SW.
LOAD ALARM: EN
BOOM ANGLE (S)
SWING OUT-PUT
ARM ANGLE (S)
TO MCX CONNECTOR
LEARNING SW.
POWER DIGGING SW. CANCEL SW.
PRESSURE SWITCH
SOLAR RADIATION
GROUP ONLY SENSOR NATURAL
COMPRESSOR
SUB HARNESS
GROUP
MONITOR
KEY MAIN SOLENOID EC MOTOR

SIGNAL POWER POWER POWER
SOLAR RADIATION
SENSOR
CONTROLLER
EC MOTOR
MAIN SOLENOID
AIR-CON. UNIT GND GND
AMBIENT SENSOR
GROUP
BOOM DUMPING
SEALED WIRE
RE-GENERATION
PUMP TORQUE
ANGLE LIMIT
ANGLE LIMIT
PUMP 2 TILT
PUMP 1 TILT
DUMPENER
OIL TEMP. SENSOR

AUX. FLOW
ARM FLOW
DIGGING
2-SPEED
TRAVEL
POWER
BOOM
CONTROL 1
CONTROL 2
PRESSURE
ARM
PUMP
PUMP
SENSOR 2 PRESSURE
CAB INSIDE CAB OUTSIDE SENSOR 1
EC MOTOR EC ANGLE
SENSOR PUMP 2 PUMP 1
N SENSOR PRESSURE PRESSURE ARM BOOM
VALVE SOLENOID PUMP MOTOR TRAVEL SWING FRONT ROLL-IN
SOLENOID SENSOR (L) PRESSURE SENSOR (L) PRESSURE RAISE
SENSOR (H) SENSOR (H)
OPTION
PRESSURE SENSOR (LOW)
Up to serial No. 010576 (ZAXIS110/110M)

OPTION
Up to serial No. 062964 (ZAXIS120)

ZAXIS110/110M/120/130/130LCN CONNECTORS
THESE CONNECTORS ARE THE HARNESS END CAUTION: Parts numbers on the drawing are provided only for reference purpose.
CONNECTORS, UNLESS OTHERWISE SPECIFIED. To order parts on the drawing, be sure to consult the Parts Catalog.
FUEL GAUGE BUZZAR CANCEL SW. AMBIENT SENSOR SOLAR-RADIATION SENSOR

(TRAVEL ALARM) (120 GROUP) (120 GROUP)
YAZAKI YAZAKI
YAZAKI 7323-2064
QOS CONTROLER COMPRESSOR PUMP/H(ENG SIDE) AMBIENT SENSOR SOLAR-RADIATION SENSOR AIR-CON PRESSURE SW.
(200 GROUP) (200 GROUP) (200 GROUP)
LOCK
2P FEMALE
YAZAKI 7123-7464-40 YAZAKI 7323-6214-40 SUMITOMO 6188-0494 SUMITOMO 6189-0533
DIODE SPEAKER PRESSURE SENSOR(L) GLOW RELAY OPTION POWER WWES

SWING ALARM
WATER PROOF PLUG CONNECTOR

MALE SHARE PLUG
YAZAKI 7113-1020
WATER PROOF CAP
YAZAKI 7120-8018
FEMALE RECEPTACLE
YAZAKI YAZAKI GROUND YAZAKI 7115-1050
YAZAKI 7283-1223-30 YAZAKI RV03FB YAZAKI 7323-2044 WATER PROOF CAP
YAZAKI 7120-1157
CONNECTOR
ALTERNATOR LEARNING SW. BOOM DUMPING FLAT TERMINAL
PRESSURE SENSOR(H) SOLENOID WIPER(CAB/H-SIDE) HYD. OIL TEMP. SENSOR WASHER
(ENG. OIL PRESS. SW.)
SCREW TERMINAL FLAT TERMINAL
LOCK WITH LOCK
AMP 172320-2
3P-FEMALE SUMITOMO 6189-0031 (CN. WITH OUT LOCK) YAZAKI 7323-1424-40
RELAY EO LEVEL RAD. LAVEL N-SENSOR EC ANGLE SENSOR EC-MOTOR STARTER SW. WIPER
COOLANT TENP. SW. BOOM DUMPING
SUMITOMO 6098-1493 YAZAKI 7323-7414-40 SUMITOMO 6189-0133 ALTERNATOR

*COOLANT LEVEL SW
ML-CRANE WASHER
ENG. OIL PRESSURE SW.
RADIO GLOW RELAY
STARTER RELAY
BATTERY RELAY
DETAIL 1 AIR CLEANER RESTRICTION SW
BODY LIGHT
FUEL GAUGE
DIODE(1, 3)
YAZAKI 7123-1402
EARTH LINE WIPER
HORN SW
MCX-A MCX-B MCX-C MCX-D LEARNING SW
CAB
RADIO
S-REINFORCEMENT PLATE
AUX. POWER
BOOM DUMPING POWER LIGHTER
MONITOR
AIR-CON
TRAVEL ALARM
MONITOR A (CAB/H SIDE) MONITOR B (CAB/H SIDE) MONITOR C (CAB/H SIDE)
ADDITIONAL PUMP ATT1
ADDITIONAL PUMP ATT2 CONTROL SYSTEM
GROUND LINE
POWER DIGGING SW
MONITOR A MONITOR B MONITOR C SATELLITE/PC

DETAIL 2
CAB COVER
S-REINFORCEMENT PLATE
FLAME
NOTE : Up to serial No. 010576 (ZAXIS110)

Up to serial No. 062964 (ZAXIS120)
ZAXIS125US/135US ELECTRICAL CIRCUIT DIAGRAM To order parts on the drawing, be sure to consult the Parts Catalog.
CAB OUTSIDE CAB INSIDE CAB INSIDE CAB OUTSIDE

STARTER SWITCH
CONTROLLER
MONITOR
POWER IN-PUT
BUCK UP POWER IN-PUT POWER HOUR METER DATA
WATER TENP. SWITCH GLOW IN-PUT CIRCUIT COMMUNICATION OUT-PUT
COMMUNICATION SW.
NOT IN SMJ SERIAL COMMUNICATION TXD
CONSOLE SERIAL COMMUNICATION RXD ICX Dr. ZX
CONNECTION SW.
POWER ON SIGNAL
REG IN-PUT INTERIOR SATELLITE/PC
LAMP INTERIOR LAMP
POWER-IN
REG. IN-PUT
FUSIBLE LINK(45A) COOLANT FUEL
BATT.(DIRECT) TEMP
EC DIAL SIGNAL IN-PUT
EC DIAL SIGNAL IN-PUT(GND)
BACK UP
WIPER SIGNAL IN-PUT(+5V)
BATTERY WIPER SIGNAL IN-PUT
BATTERY RELAY LIGHT WIPER SIGNAL IN-PUT(GND)
GROUP
FUSIBLE LINK(65A) LIQUID CRYSTAL PANEL
OVER-HEAT
LOAD DUMP FUSE
AIR FILTER
RELAY
FUEL
BACK-UP
CONTROLLER
SOLENOID
SWITCH BOX
POWER ON SIGNAL
AIR-CON.
EC-MOTOR
GLOW
LIGHT
WIPER
HEATER
HORN
RADIO
LIGHTER
ROOM LIGHT
AUX.
GLOW/R
TOOL
WORK LIGHT
STARTER WIRING MAIN
SAFETY RELAY COMPLETED DISPLAY CHANGE CHARGE POWER
GROUP ENG. OIL LEVEL CONTROLLER
SET
SPARE 1 MAIN
ROOM LIGHT WORK MODE GND
WIPER SUB 1 SPARE 2
WIPER MOTOR DOOR SWITCH
WIPER ENG. OIL LEVEL
GROUP
COOLANT LEVEL
HYD. OIL FILTER B9:MONITOR
LIGHTER COMMUNICATION GND
AUTO RE-FUELING SPARE 4
C10:MCX
SPARE 5 COMMUNICATION
GND
SPARE 6 D11:DIGITAL GND
CONSOLE
SPARE 6 SW. IN-PUT OPTION
SPEAKER R HYD. OIL FILTER SW. IN-PUT
ALTERNATOR GLOW SPARE 4 EXT.
HYD. OIL FILTER WARNING
RELAY OPTION
LIGHT 1
LIGHT 2
CHARGE EXT.
SPARE 2 SW. IN-PUT
AIR FILTER RESTRICTION SW. IN-PUT
RADIATOR LEVEL SW.
WARNIG LAMP LOCATION AIR CLEANER RESTRICTION SW.
SPARE 5 EXT.
NO.12 IS OPT., NO.5 IS NOT USE WORK LIGHT SW. IN-PUT GROUP
WIPER MOTOR WIPER SUB 2 FUEL EXT.
REGULATOR GLOW EXT.
ENG. OIL LEVEL EXT.
RADIO SPEAKER L COOLANT LEVEL EXT.
GLOW PLUG CONSOLE FUEL SIGNAL
FUEL SENSOR
COOLANT TEMP. SIGNAL COOLANT TEMP. SENSOR
AUTO- AUTO-IDLE DIGGING ATTACHMENT
ACCELERATION MODE 1 SIGNAL OUT-PUT
(ONLY ZX200 PASS THROUGH NO.12)
LOAD DUMP RELAY OUT-PUT MODE 2 SIGNAL OUT-PUT
ENG. OIL LEVEL SW.(ON ENG.)
LIGHT 1 RELAY OUT-PUT ENG. OIL PRESSURE SW.(ON ENG.)
RELAY DRIVE
WIPER, WASHER MOVE SIGNAL OUT-PUT
LIGHT 2 RELAY OUT-PUT
CIRCUIT
LIGHT C RELAY OUT-PUT SPARE 1 SW. IN-PUT
LIGHT B RELAY OUT-PUT
ENG. OIL PRESS. SW. IN-PUT
LIGHT A RELAY OUT-PUT
OVER-HEAT SW. IN-PUT
WASHER RELAY OUT-PUT
ENG. OIL LEVEL SW. IN-PUT OVER-HEAT SW.
COOLANT LEVEL SW. IN-PUT
PULL-UP
WIPER AUTO-IDLE SW. IN-PUT AUTO-IDLE
RELAY A AUTO-ACCELERATION SW. IN-PUT AUTO-ACCELERATION
A/I A/A SW
WASHER SW. IN-PUT WASHER SW.
LIGHT SW. 2 IN-PUT
LIGHT SW. 1 IN-PUT
WIPER, WASHER EN SW. IN-PUT
BACK-UP EN SW. IN-PUT LIGHT SW.
HOUR METER GROUND
WASHER RELAY SIGNAL WIPER VR.
INTERIOR LIGHT
INTERIOR LIGHT
POWER IN-PUT
SIGNAL
WASHER BUZZER
ENG. SPEED
CONTROL DIAL
HIGH-SPEED
LOW-SPEED TRAVEL 2-SPEED SW.
LIGHT RELAY 2
NORMAL OPEN HP,P,E MODE SW.

SWITCH BOX
SWITCH BOX
BOOM LIGHT
CONSOLE
LIGHT RELAY 1
WORK LIGHT
PRESSURE SWITCH
CONSOLE
(ASSY)
HORN RELAY
HORN SWITCH
COMPRESSOR
ML-CRANE
HORN SIDE/ (JAPANESE DOMESTIC ONLY)
MALE ON
BOTH SIDE HORN (H) BOOM DUMPING
SEPARATE CONSOLE A2 (JAPANESE DOMESTIC ONLY) SWING ALARM
BOOM ROD SIDE PRESSURE(S)

TRAVEL ALARM
TRAVEL ALARM
OPTION
HORN (L)
ARM DUMP PILOT(S)
INITIAL SETTING SW.

OPTION
CRANE MODE SW.
BOOM BOTTOM(S)
BOOM BOTTOM(S)
LOAD ALARM:EN
SWING OUT-PUT
BOOM ANGLE(S)
ARM ANGLE(S)
LEARNING SW.
POWER DIGGING SW. Dr. ZX
CANCEL SW.
LO
CONSOLE
REGISTER HEATER CONTROLLER
MACHINE
SELECTION
KEY MAIN SOLENOID EC-MOTOR

IN DETAILS:COMMON TO A/C SIGNAL POWER POWER POWER
OPTION
3 IS DIFFERENT
CONTROLLER
MAIN EC-MOTOR
SOLENOID
GND GND
AIR-CON. CONTROLLER
SENSOR
GND
TEMP. BOOM DUMPING
HUSE SEALED
WIRE
CIRC AIR SENSOR
AMBIENT SENSOR
SOLAR
RADIATION
SENSOR
Up to serial No. 010576 (ZAXIS125US)
GENERATION
TORQUE
THERMISTER
DUMPENER
AUX. FOLW
PUMP
PUMP
FLOW
OIL TEMP.
2-SPEED
SENSOR 1
PRESSURE
TILT ANGLE
TRAVEL
ARM RE-
SENSOR
PUMP 1
CONTROL 1
PUMP
CONTROL 2
PUMP
PRESSURE
LIMIT
SENSOR
SENSOR 2
BOOM
LO REGISTER CAB INSIDE CAB OUTSIDE EC

N
PUMP EC-MOTOR ANGLE

VALVE SOLENOID SENSOR
SOLENOID PUMP 2 PUMP 1
MOTOR TRAVEL SWING FRONT ARM BOOM BOOM
PRESSURE PRESSURE PRESSURE PRESSURE ROLL-IN RAISE ANGLE
AIR-CON UNIT SENSOR(L) SENSOR(H) SENSOR(L) SENSOR(H)
OPTION
PRESSURE SENSOR(L) ANGLE SENSOR
ONLY ZAXIS225US
ZAXIS125US/135US CONNECTORS To order parts on the drawing, be sure to consult the Parts Catalog.
THESE CONNECTORS ARE THE HARNESS END

CONNECTORS, UNLESS OTHERWISE SPECIFIED.
YAZAKI YAZAKI YAZAKI YAZAKI YAZAKI YAZAKI
WIPER MOTOR WIPER SUB2 DOOR SW. WIPER SUB1 CANCEL SW. BUZZER CIRC AIR SENSOR
MOTOR SIDE : M MOTOR SIDE : M CAB/H SIDE : F CAB/H SIDE : F TRAVEL ALARM
SUB1
SUB2
ROOF
SUMITOMO YAZAKI NILES YAZAKI YAZAKI GLASS DOOR SW
QOS CONTROLLOR COMPRESSOR PUMP/H(ENG. SIDE) AMBIENT SENSOR SOLAR RADIATION SENSOR A/C PRESSURE SW.
MOTOR
WIPER
LOCK
2P F
YAZAKI YAZAKI SUMITOMO SUMITOMO
DIODE SPEAKER PRESS. SENSOR(L) GLOW RELAY OPT. POWER WWES SWING ALARM
WATER PROOF CONNECTOR

MALE SHARE PLUG
YAZAKI YAZAKI YAZAKI
WATER PROOF CAP
YAZAKI YAZAKI YAZAKI YAZAKI
FEMALE RECEPTACLE
GROUND YAZAKI
PRESS. SENSOR(H) SOLENOID FUEL GAUGE HYD. OIL TEMP. SENSOR WASHER ALTERNATOR LEARNING SW. BOOM DUMPING WATER PROOF CAP
ENG. OIL PRESSURE SW. YAZAKI
LOCK CONNECTOR
FLAT TERMINAL
SCREW TERMINAL FLAT TERMINAL

WITH LOCK
AMP 172320-2
3P F SUMITOMO CN. WITHOUT LOCK YAZAKI
GP RELAY EO LEVEL RAD. LEVEL N-SENSOR EC ANGLE SENSOR EC-MOTOR STARTER SW. WIPER
COOLANT TEMP.SW. BOOM DUMPING CAB/H SIDE : F
ALTERNETOR
*RAD. LEVEL SW.
DETAIL 1 WASHER
GLOW RELAY
STARTER RELAY
BATTERY RELAY
AIR CLEANER RESTRICTION SW.
BODY LIGHT
FUEL GAUGE
SUMITOMO YAZAKI YAZAKI
AIR-CON. CONTROLLER(1) AIR-CON. CONTROLLER(2) ML CLANE RADIO DIODE

HEATER CONTROLLER(1) HEATER CONTROLLER(2)
EARTH LINE WIPER
HORN SW.
AIR-CON.
A/C BOX RADIO
YAZAKI AUX. POWER

LIGHTER
POWER
MONITOR
TRAVEL ALARM
ML CLANE
CONTROL SYSTEM GROUND LINE

POWER DIGGING SW.
LEARNING SW.
BOOM DUMPING
CONSOLE A(CAB/H SIDE) CONSOLE C(CAB/H SIDE) SW-BOX
CONSOLE B(CAB/H SIDE)
DETAIL 2
MONITOR A MONITOR B MONITOR C SATELLITE/PC C/U BRACKET
FRAME
NOTE : Up to serial No. 010576 (ZAXIS125US)

ZAXIS135UR ELECTRICAL CIRCUIT DIAGRAM CAUTION: Parts numbers on the drawing are provided only for reference purpose.
COOLANT TEMP. SW.
STARTER SW.
RESISTER S
RESISTER D
EMERGENCY
EVACUATION SW.
K
A
RESISTER
K
STARTER SW.
A
FUSIBLE LINK (45A)
OPT DECEL.
NOT IN SMJ 2-9 OUT 1-32
BATTERY 12V×2 ACC (LOAD) EMERGENCY
BATTERY RELAY
IN 1-18 ACCEL.
ALT (LOAD) EVACUATION
4-2 RECEPTION (+) OUT 1-29
LCD 4-11 TRANSMISSION (+) SW.
FUSIBLE LINK (65A)
IN 1-7 ACCEL.
AUTO LOAD DUMP DISPLAY 4-3 RECEPTION (-)
RE-FUELING 4-12 TRANSMISSION (-) OUT 1-10
SYSTEM RELAY IN 1-5 DECEL.
OUT 1-23
IN 1-16 DECEL.
MONITOR
HORN
LIGHT
WIPER
AIR-CON.
AUX.
ROOM LIGHT, LIGHTER, RADIO

HEATER
BACK-UP
LCD MONITOR
EMERGENCY SW.
GLOW
POWER IN-OUT OUT 1-24
BACK-UP POWER IN-PUT POWER DECEL.
GLOW IN-PUT CIRCUIT
IN 1-17
STARTER SERIAL COMMUNICATION TXD
SAFETY RELAY
GND SERIAL COMMUNICATION RXD OUT 1-11
SERIAL COMMUNICATION 2TXD- IN 1-6 DECEL.
WASHER SERIAL COMMUNICATION 2TXD+
REG IN-PUT SERIAL COMMUNICATION 2RXD+
GLOW RELAY SERIAL COMMUNICATION 2RXD- 3-10 OFFSET-LEFT OUT 1-30
2-2 OFFSET-RIGHT IN 1-19 ACCEL.
WASHER CAB OUT
RELAY 2-14 RESTRICTION SW. OUT 1-31
CAB IN ROOM LIGHT COOLANT
FUEL
IN 1-20
POWER-ON SIGNAL
TEMP. ACCEL.
LIQUID EC DIAL SIGNAL IN-PUT OPT
CRYSTAL EC DIAL SIGNAL IN-PUT (GND) RIGHT CONTROL OUT 1-22
EC MOTOR
PANEL LEVEL IN 1-15 DECEL.
WIPER L1 : LOAD ALARM
RELAY
L2 : STROKE END 2-12 INITIAL SETTING 5V (PRES.) 2-19
××× ×××× ×××× ××
L3 : HOOK
3B
BOOM RAIS. PRES. 3-17 BOOM RAIS. PRES.
ALTERNATOR
L4 : ARM VERTICALITY A 6 GND (PRES.) 2-21
××
L5 : ENG. OIL PRESS.
××
DISPLAY CHANGE
2-3 SERVICE SW. ARM DUMP PRES. 3-15 ARM DUMP PRES. 2
LIGHT
L6 : OVER-HEAT
××××× 1-25 GND (RELAY) ARM ROLL-IN DECEL. PRES. 3-6
××× SET L7 : FUEL
BOOM LOWER DECEL. PRES. 3-16 ARM ROLL-IN DECEL. PRES. 5
K
××× WORK MODE

L8 : CHARGE 1-26 BUZZER
×× L9 : AIR FILTER 2-4 SWING MODE OFFSET RIGHT ACCEL. PRES. 3-12
A
RADIO LIGHT IC/U BUZZER

GLOW PLUG WIPER MOTOR ××× L10 : GLOW
××
L11 : HYD. OIL FILTER
OFFSET LEFT ACCEL. PRES. 3-2 BOOM LOWER DECEL. PRES. 6
AUTO M
L12 : SPARE BOOM RAISE ACCEL. PRES. 3-5
TRAVEL SW
REGULATOR HYD. OIL FILTER SW. IN-PUT OFFSET RIGHT ACCEL. PRES. 7
SPARE
CHARGE EXT
WASHER
AIR FILTER SW. IN-PUT OFFSET LEFT ACCEL. PRES. 8
CRANE MODE SW. 2-13 CONNECT DETECTION
FUEL EXT
WIPER
GLOW EXT
4-9 TRANSMISSION
WARNING LAMP LOCATION 4-10 RECEPTION
BOOM RAISE
HIGH- LOW- ACCEL. PRES.
SPEED SPEED FUEL SIGNAL
HORN RELAY COOLANT TEMP SIGNAL 3-11 SLIDE SENSOR
2-15 ARM RETRACT OPT
AUTO - MARCCINO
135UR ONLY 2-6 ARM EXTEND EMERGENCY HYD. OIL TEMP. SENSOR
HORN SW LIGHT TRAVEL MODE
STOP SOL.
AUTO M WIPER
AUTO - IDLE
SLIDE ARM 2-16
HP MODE EMERGENCY STOP
SOL. VALVE
E MODE
HORN SIDE LOAD DUMP RELAY OUT-PUT AUTO - IDLE
MALE ON SATELLITE / PC LIGHT 1 RELAY OUT-PUT WORK MODE
RELAY DRIVE
HORN WIPER RELAY OUT-PUT

BOTH SIDE WASHER RELAY OUT-PUT ML MODE 1
CURCUIT
LIGHT RELAY 2 ML1 RELAY OUT-PUT BOOM ANGLE SENSOR

ML2 RELAY OUT-PUT
ML3 RELAY OUT-PUT
ML4 RELAY OUT-PUT ARM ANGLE SENSOR
(NORMAL OPEN ML CONNECT)

PULL - UP
ML SWITCH
(BOOM LIGHT) ML - MODE 2 OFFSET ANGLE SENSOR
BUCK UP EN
ENG. OIL PRES. SW. IN-PUT
LIGHT RELAY 1 OVER - HEAT SW. IN-PUT
HOUR METER GND.
ENG. SPEED BOOM ROD
PRESSURE (S)
CONTROL DIAL
INITIAL BOOM BOTTOM

(WORK LIGHT) PRESSURE (S)
SETTING SW.
NORMAL OPEN OPT
ARM ROLL-OUT PRES. (S)

COOLANT TEMP. SENSOR
FUEL SENSOR
OVER-HEAT SW.
AIR CLEANER RESTRICTION SW.
HYD. OIL FILTER WARNING (OPT)
LEARNING SW.
ML RELAY
SWING
A NATURAL ALARM
BUCKET LOCK SOL.
ML LIGHT
SOL. PUMP AUTO

AIR BLEED
A
OPTION
SEALED WIRE
CANCEL SW.
PRESSURE SWITCH
HYD. OIL TEMP. SENSOR

ANGLELIMIT
PUMP 1
TORQUE
PUMP
ANGLELIMIT
PUMP 2
AUX. FLOW
OUTSIDE INSIDE N-SENSOR

COMPRESSOR
CONTROL 2
PUMP
CONTROL 1
PUMP
INSIDE OUTSIDE OPTION TRAVEL FRONT SWING SWING ARM BOOM
ROLL-IN RAISE
OPTION
Attach to vol. No. : TT187E-04
ZAXIS135UR CONNECTORS
THESE CONNECTORS ARE THE HARNESS END
CONNECTORS, UNLESS OTHERWISE SPECIFIED
RESISTOR S FUEL GAUGE LCD DISPLAY (2) LCD LAMP (2) CANCEL SW. ML CRANE
(TRAVEL ALARM)
SUMITOMO 6189-4172 SUMITOMO 6189-4171

YAZAKI 7323-2064 SUMITOMO 6242-5061
QOS CONTROLLER MONITOR BUZZER BOOM ANGLE SENSOR INITIAL SETTING RADIO SUB/H. (CAB/H SIDE)
IC/U BUZZER
EFCT SUB/H. (CAB SIDE)
YAZAKI 7123-7464-40 SUMITOMO 6030-2981
DIODE SPEAKER PRESS. SENSOR (L) DR. ZX (MC, UR, ICX) GLOW RELAY OPT. POWER
WWES SWING ALARM
YAZAKI YAZAKI
YAZAKI 7283-1223-30 YAZAKI RV03FB YAZAKI 7323-2044 7323-2228 7323-3010
PRESS. SENSOR (H) SOLENOID FRONT ANGLE SENSOR HYD. OIL TEMP. SENSOR WASHER ALTERNATOR LEARNING SW. CONSOLE B (CAB/H SIDE)
RELAY/H (ENG-OIL PRESSURE SW.)
LOCK
AMP EJ <> 070 YAZAKI 7232-1424-40

3PF SUMITOMO 6189-0031 (CN WITH OUT LOCK)
GP RELAY COOLANT TEMP. SW. N-SENSOR EC ANGLE SENSOR EC-MOTOR STARTER SW. SLIDE ARM
ARM ANGLE SENSOR RESISTOR D
OFFSET ANGLE SENSOR
SUMITOMO 6098-1493 YAZAKI 7323-7414-40
AUTO AIR BLEED PT

RADIO
YAZAKI 7123-1402
CONSOLE A (CON A) ; CAB H SIDE
MONITOR - A MONITOR - B MONITOR - C SATELLITE / PC

ZAXIS110/110M/120/130/130LCN CAB HARNESS To order parts on the drawing, be sure to consult the Parts Catalog.
LIGHTER
LEARNING SW-2
DIRECTION
PULLING
HARNESS
POWER BOOST SW
TIN PLATE
ML-CRANE-10
MEASURE HERE
ML-CRANE-11
CANCEL SW-1 BLACK RETAINER
CANCEL SW-3 BACK COVER
YAZAKI
MONITOR C-12
ML-CRANE-7
CANCEL SW.
MONITOR A-1
MONITOR A-2
MONITOR A-3
MONITOR A-4
MONITOR A-5
MONITOR A
SWING ALARM-1 MONITOR A-6 INSTALL MONITOR A, B AND C AS FOLLOWS.
RELAY BOX
· TURN BACK CONNECTOR'S SURFACE TO A. SLEEVE MUST BE SHORT LIGHTER
ML-CRANE-8
· VIEW C-C' IS AS FOLLOWS.
MONITOR A, B, C
MONITOR A-16
MONITOR B
RELAY BOX
RELAY BOX
MONITOR A-8
MONITOR A-9 ML-CRANE-6 VIEW C-C'
MONITOR A-7 MONITOR A-10 MONITOR C-9 MONITOR C
LEARNING SW-1 MONITOR A, B, C * MONITOR A, B AND C MUST BE UPPER SIDE
WHEN THE RELAY BOX IS RIGHT SIDE
MONITOR C-11
MONITOR A-12
MONITOR A-13 MONITOR C-10
1. IF NO COMMENT, WIRE 0.3~1.25 MAY BE CAVS AND
MONITOR A-14 MONITOR C-8
MONITOR A-15
WIRE 2~5 MAY BE AVS.
ML-CRANE-3
ML-CRANE-4 MONITOR A-16
MONITOR B-1 HARNESS END OF TAPE 2. PIN ARRANGEMENT OF THIS DRAWING
MONITOR B-2 PULLING INDICATE VIEW POINT FROM THE
DIRECTION MEASURE HERE
MONITOR B-3 OTHER SIDE CONNECTOR.
MONITOR B-4
MONITOR B-5 ALL SIRSUITS MUST BE TIGHTER TOGETHER 3. NO ELECTRIC JOINT MAY BE BETWEEN FH AND KC.
MONITOR B-6
MONITOR B-7
MONITOR B-8
4. PUT THE PART No. LEBEL ON THE HARNESS.
MONITOR B-9
5. PULG CONNECTORS MUST BE BRASS.
MONITOR B-10 6. COLOR SIGN DUE TO JASO D607.
MONITOR B-11 LIGHTER 7. GENERAL EXPRESS ON THE DRAWING DUE TO #X4259303.
MONITOR B-2 8. OUTSIDE DIAMETER OF CORRUGATE TUBE FOR CAB EARTH 1,
MONITOR B-13 CAB EARTH 2, QOS-CON AND G-LIGHTER MUST BE LESS THAN 20mm.
MONITOR B-14
MONITOR B-15
MONITOR B-16
FASTEN
MONITOR C-1 WITH TAPE
MONITOR C-2
MONITOR C-3
MONITOR A-11
1. ICX-A AND B MUST BE ARRANGED AS FOLLOWS 2. ICX-C AND D MMUST BE ARRANGED AS FOLLOWS
MONITOR C-7 BY USING THE TAPE. BY USING THE TAPE.
MONITOR C-15 MONITOR C-13 · TURN BACK CONNECTION'S SUR FACE TO C. · TURN BACK CONNECTOR'S SURFACE TO A.
· ON THE LINE OF ICX-A AND B, FASTEN ICX-A AND B WITH · ON THE LINE OF ICX-C AND D, FASTEN ICX-C AND D WITH
IN 50mm FROM I AND IN BETWEEN MCX-A AND B USING A TAPE. IN 50mm FROM I AND IN BETWEEN MCX-C AND D USING A TAPE.
MONITOR C-14
· VIEW A-A' IS AS FOLLOWS · VIEW B-B' IS AS FOLLOW.
MONITOR C-6
ML-CRANE-1
VIEW B-B'
VIEW A-A'
ML-CRANE-5
* ICX-C AND D MUST BE UPPER SIDE SATELLITE / PC
* ICX-A AND B MUST BE UPPER SIDE WHEN MCX-D IS RIGHT SIDE.
SATELLITE/PC-10 WHEN MCX-A IS RIGHT SIDE.
ML-CRANE-2
SATELLITE/PC-2
SATELLITE/PC-1
LEARNING SW MOVE THIS SIDE
ASS'Y HOUSING CNO4M (N)
SATELLITE/PC-3
INSTALL A PULLER
ALL SIRSUITS MUST BE TIGHTER TOGETHER (YAZAKI 7147-9178) AND
SATELLITE/PC-4 SPARE FUSES 5A, 5A, 10A AND 20A.
SATELLITE/PC-5
HORN-SW.
TIN PLATE
SATELLITE/PC-7 PRINT USAGE AND AMPERE
SATELLITE/PC-8 ON THE COVER.
APPLY RED TAPE
SATELLITE/PC-6
RADIO SWING ALARM

SATELLITE/PC-9
LABEL
SPARE
YAZAKI 7123-2044
ML CRANE ASSY FEMALE PIUG
CN TYPE FLANGE
ZAXIS125US/135US CAB HARNESS To order parts on the drawing, be sure to consult the Parts Catalog.
G
CONSOLE LIGHTER
LEANING CONSOLE A ICX-D

RELAY BOX
H 90
B 90
MCX-A DIRECTION FOR
R1
LOCK REMOVING HARNESS
FUSE-BOX
CONSOLE
MEASURE HERE
90
J06FGY ICX DR.EX

DIRECTION FOR
CRANE DR.EX REMOVING HARNESS
CANCEL SW D E
SOLAR RADIATION SENSOR
CONSOLE
90
CRANE WIPER DIRECTION FOR
REMOVING HARNESS FUSE NO.1,11
CANCEL CONSOLE
CANCEL C
LEARNING
SWING ALARM
MONITOR ML CRANE
WIPER CONNECT
CRANE
MONITOR
MONITOR
MONITOR
MONITOR LIGHTER
MONITOR CONSOLE CONSOLE MONITOR
MONITOR CONSOLE
MONITOR CONSOLE
CORRUGATE TUBE 20MM DIA
FASTEN WITH TAPE
SWING ALARM
CRANE
MONITOR
SPEAKER
BUZZER
MONITOR BUZZER
MONITOR BUZZER
CONSOLE MONITOR
CONSOLE MONITOR CRANE ALL SIRSUITS MUST BE
MONITOR MONITOR WIPER TIGHTER TOGETHER
LERNING
CONSOLE WIPER
MONITOR
MONITOR WIPER
CONSOLE MONITOR
CRANE MONITOR
CRANE MONITOR
CONSOLE MONITOR
MONITOR CONSOLE CONSOLE
MONITOR CONSOLE
MONITOR CONSOLE CONSOLE
CONSOLE CONSOLE
MONITOR CONSOLE
MONITOR CONSOLE
CONSOLE MONITOR CONSOLE
MONITOR CONSOLE
CONSOLE MONITOR
MONITOR
MONITOR
MONITOR LIGHTER NOTE
MONITOR 1. UNDER 1.25 WIRE MAY BE CAVS WIRE, IF NO COMMENT.
MONITOR OVER 2 WIRE MAY BE AVS WIRE.
MONITOR
2. PIN ARRANGEMENTS OF THIS DRAWING INDICATE
VIEW POINTS FROM THE OTHER SIDE CONNECTORS.
CONSOLE
MONITOR
CONSOLE 3. NO ELECTRIC TURNING POINT MAY BE BETWEEN AH
CONSOLE MONITOR
AND J-CAB EARTH, K-CAB EARTH.
MONITOR CONSOLE
MONITOR CONSOLE SPEAKER 4. PUT THE PART NO. LABEL ON THE HARNESS.
MONITOR
MONITOR SOLAR RADIATION SENSOR CONSOLE 5. NO PLATE ON THE CB TYPE CONNECTORS.
6. COLOR SIGN DUE TO JASO D607.

7. GENERAL EXPRESS ON THE DRAWING
MONITOR DUE TO # X4259303
CRANE
CRANE
RELAY BOX
SATELLITE
CN
CRANE
SATELLITE
SATELLITE
CN
YAZAKI
LEARNING SWITCH
DIRECTION FOR REMOVING
HARNESS ALL SIRSUITS MUST BE
TIGHTER TOGETHER
MEASURE HERE
SATELLITE
SATELLITE
L02MB
SATELLITE
SATELLITE
SATELLITE
SATELLITE
M04MB
SATELLITE C16MW
LABEL
C010MW AUX.
SATTELLITE
Attach to Vol. No.: TT187E-04
ZAXIS135UR CAB HARNESS CAUTION: Parts numbers on the drawing are provided only for reference purpose.
To order parts on the drawing,be sure to consult the Parts Catalog.
MONITOR C-2
MONITOR C-3
MONITOR C-4 5V SENSOR
MONITOR C-5 CONSOLE B-3
MONITOR C-6 GND SENSOR
MONITOR C-7 GND SENSOR
MONITOR C-8
MONITOR C-9
MONITOR C-10
MONITOR C-11
MONITOR C-12
MONITOR C-13 BUZZER 1 CONSOLE B-4
MONITOR C-14
MONITOR C-15
CONSOLE B-2 CONSOLE A-4
SLIDE -2
Dr. ZX-3
Dr. ZX-1
CONSOLE A-8
Dr. ZX-2 AIR BLEED
LEARNING SW -2 AIR BLEED PT-3
SWING ALARM -1 AIR BLEED PT-4
EN LOAD AIR BLEED PT-2
AIR BLEED PT-5
BUZZER 2 CONSOLE A-7
EMERGENCY STOP SW-1
CANCEL SW -1 EMERGENCY STOP SW-4 RESISTOR S
CANCEL SW -3 EMERGENCY STOP SW-2 EF Dr ZX-1
MONITOR B-2 INITIAL SETTING GND-2 EF Dr ZX-3
MONITOR B-3
MONITOR B-4
LEARNING SW -1 WIPER E
MONITOR B-1 SLIDE -2
EF Dr ZX-2
MONITOR A-1 CONSOLE A-11 SATELLITE / PC-10 CONSOLE A-12
MONITOR B-5 MONITOR A-2 CONSOLE A-9
INITIAL SETTING -1 MONITOR A-3 WIPER S
MONITOR A-20 MONITOR A-4 SATELLITE / PC-2 SERVICE -M
MONITOR A-5 SATELLITE / PC-1 WIPER P
MONITOR A-6
MONITOR A-7 WIPER B
MONITOR A-19 MONITOR A-8
MONITOR A-9
MONITOR A-10
CONSOLE A-1 EMERGENCY STOP SW -3
RADIO -3
CONSOLE A-3 MONITOR A-13 ICX DR. ZX-1 RESISTOR D-1
MONITOR A-14 ICX DR. ZX-3 RADIO -8 RESISTOR D-2
AIR BLEED PT-1 MONITOR A-15 SATELLITE / PC-3 RADIO -2 RESISTOR D-3
MONITOR A-16 SATELLITE / PC-4 RADIO -5 RESISTOR D-4
MONITOR A-17 SATELLITE / PC-5 RADIO -1 RESISTOR D-5
MONITOR A-18 RADIO -4 RESISTOR D-6
ICX DR. ZX-2 RADIO -7
SATELLITE / PC-7
SATELLITE / PC-8 CONSOLE A-10
CONSOLE A-2 LIGHTER ( + )
MONITOR B-6
SATELLITE / PC-6
MONITOR B-8
SATELLITE / PC-9 CONSOLE A-5
MONITOR B-10 SERVICE -F
MONITOR B-11
MONITOR B-12
MONITOR B-13 SLIDE 5
CONSOLE A-14 24V EMERGENCY STOP VALVE
MONITOR B-15 SLIDE ARM -1
MONITOR B-16 SLIDE ARM -6
INITIAL SETTING -2
LIGHTER ( - ) EF Dr ZX-4
CONSOLE A-6
CONSOLE B-1 SLIDE 3
MONITOR C-1 CONSOLE A-13
FUSE NO.1,11
R1
FUSE BOX INSTALL A PULLER
(YAZAKI 7147-9178) AND
SPARE FUSES 5A,5A,10A AND 20A
PRINT USAGE AND AMPERE

ON THE COVER.
#4480089
FASTEN WITH TAPE

EMERGENCY SW.
MEASURE HERE SATELLITE / PC
AUX.
RELAY BOX
YAZAKI 7123-7464-40
R1 : LOAD DUMP
R2 : WASHER
R3 : LIGHT 2
connect R4 : LIGHT 1
MONITOR A R5 : HORN
R6 : WIPER
R7 : ML OPT.
R8 : AIR BLEED SWING ALARM
MONITOR B SERVICE RESISTOR D

RESISTOR S
MONITOR C
YAZAKI 7123-2044
CN TYPE
BUZZER
INITINAL SET. GND
SUMITOMO
6030-2981
EN LOAD
TO_E ９０゜
POINT_A
INITINAL SET. CANCEL SW.
LEARNING
YAZAKI 7123-2044
CN TYPE
ALL SIRSUITS MUST BE TIGHTER

MCX
YAZAKI 7123-2044
CN TYPE
AIR BLEED PT
ICX-C,D
TO_C
ALL SIRSUITS MUST BE TIGHTER MCX
A
FASTEN
WITH TAPE
MCX-A
50mm
AIR BLEED
MCX-B D
1. IF NO COMMENT, WIRE 0.3 1.25 MAY BE CAVS AND
MCX-C ICX-A,B WIRE 2 5 MAY BE AVS.
C
MCX-D 2. PIN ARRANGEMENT OF THIS DRAWING
INDICATE VIEW POINT FROM THE
1. ICX-A AND B MUST BE ARRANGED AS FOLLOWS 2. ICX-C AND D MMUST BE ARRANGED AS FOLLOWS
BY USING THE TAPE. BY USING THE TAPE. OTHER SIDE CONNECTOR.
á TURN BACK CONNECTION'S SUR FACE TO C. á TURN BACK CONNECTOR'S SURFACE TO A.
á ON THE LINE OF ICX-A AND B, FASTEN ICX-A AND B WITH á ON THE LINE OF ICX-C AND D, FASTEN ICX-C AND D WITH
IN 50mm FROM I AND IN BETWEEN MCX-A AND B USING A TAPE. IN 50mm FROM I AND IN BETWEEN MCX-C AND D USING A TAPE. 3. NO ELECTRIC JOINT MAY BE BETWEEN FH AND KC.
á VIEW A-A' IS AS FOLLOWS á VIEW B-B' IS AS FOLLOW.
SLIDE ARM
4. PUT THE PART No. LEBEL ON THE HARNESS.

5. PULG CONNECTORS MUST BE BRASS.
VIEW B-B'
CONSOLE B
VIEW A-A' 6. COLOR SIGN DUE TO JASO D607.
* ICX-C AND D MUST BE UPPER SIDE 7. GENERAL EXPRESS ON THE DRAWING DUE TO #X4259303.
* ICX-A AND B MUST BE UPPER SIDE WHEN MCX-D IS RIGHT SIDE.
CONSOLE A WHEN MCX-A IS RIGHT SIDE. 8. OUTSIDE DIAMETER OF CORRUGATE TUBE FOR CAB EARTH 1,
CAB EARTH 2, QOS-CON AND G-LIGHTER MUST BE LESS THAN 20mm.
LIGHTER
SLEEVE MUST BE SHORT
SPEAKER
MEASURE HERE
RADIO
HARNESS PULLING
ROOM LAMP
DIRECTION
ZAXIS110/110M/120/130/130LCN ENGINE HARNESS
090 WATERPROOF SLEEVE 090 WATERPROOF SLEEVE

3P FEMALE 3P FEMALE
YAZAKI FL
AM
EP
RO
OTC
OF
OF
&H
RO
ATP
EA
HE
TP
RO
F&
OO
OF
PR
CO
ME
T YAZAKI
FLA
FLAMEPROOF &
FLA
HEATPROOF COT
ME
TRAVEL ALARM-2
PR
OFO
& HE
ATP
RO
OF
CO
LIGHT GND
(WATERPROOF SLEEVE)
T
(WATERPROOF SLEEVE) FLAM FLAMEPROOF & HEATPROOF COT
E PROO
F & HE
ATPR
OOF
COT
090 WATERPROOF SLEEVE 090 WATERPROOF SLEEVE
EC MOTOR
170(HEARTPROOFVT)
H TYPE
SUMITOMO
(WATERPROOF SLEEVE)
STARTER RELAY
FLAMEPROOF & HEATPROOF COT (WATERPROOF SLEEVE)
HYD. OIL FILTER
(WATERPROOF SLEEVE)
FLAMEPROOF & HEATPROOF COT
TRAVEL ALARM-4
TRAVEL ALARM-3 FLAMEPROOF & HEATPROOF COT
TRAVEL ALARM-1 T YAZAKI
CO
OF
RO
HEATPROOF COT
P
PLUG AT
FLAMEPROOF &
& HE
F
OO
EPR
WATERPROOF SLEEVE AM
FL
SUMITOMO

FLAMEPROOF &
WATERPROOF JOINT-1 HEATPROOF COT
WATERPROOF JOINT-1
WATERPROOF JOINT-1
WATERPROOF JOINT-1 YAZAKI YAZAKI WATERPROOF SLEEVE

WATERPROOF JOINT-1 SUMITOMO
GLOW PLUG
FLAMEPROOF &
HEATPROOF COT
FLAMEPROOF &
HEATPROOF COT
FLAMEPROOF &
HEATPROOF COT
WATERPROOF JOINT-2
YAZAKI
WATERPROOF JOINT-2
WATERPROOF JOINT-2 YAZAKI COOLANT TEMP. SW
WATERPROOF JOINT-2
LEVEL YAZAKI
WATERPROOF JOINT-2
YAZAKI

SUMITOMO
YAZAKI
WATERPROOF JOINT-1 YAZAKI

WATERPROOF JOINT-2
SUMITOMO
FLAMEPROOF &
HEATPROOF COT
OF &
EPRO COT
FLAMTPROOF
EC MOTOR 1 HEA TERMINAL CAP
EC MOTOR 3
FLAMEPROOF &
EC MOTOR 2 FLAMEPROOF & HEATPROOF COT HEATPROOF COT
EC MOTOR 4
(WATERPROOF SLEEVE)
400mm
DO NOT INSTALL A/C (COMPRESSOR)
JOINT IN THIS AREA. YAZAKI
CLAMP

SUMITOMO
PLUG
ASSEMBLE EMPTY PLUG

HYD. OIL FILTER YAZAKI
CLIP
YAZAKI
or EQUIVALENT YAZAKI
10
CLIP
COOLANT TEMP. SW YAZAKI 7047-3241
or EQUIVALENT RED COLOR TAPE
28
0(
CO
T)
SUMITOMO
SUMITOMO
WHITE COLOR TAPE
BATTERY RELAY
YAZAKI
588 597
(WATERPROOF SLEEVE)
AC GLOW RELAY
AMBIENT SENSOR YAZAKI
YAZAKI 090-Ⅱ
7383-7028
GLOW RELAY
YAZAKI 2 USED
BLACK RETAINER
A/C(COMPRESSOR)
AMBIENT SENSOR-1
SCALE POINT
SUMITOMO
CLIP
AMBIENT SENSOR-2
LIGHT GND
MOVE TO THIS SIDE.
ZAXIS125US/135US ENGINE HARNESS
090 WATER PROOF YAZAKI RV03FB

SUMITOMO 6189-0031
090 WATER PROOF

SUMITOMO 6189-0031
YAZAKI RV03FB 090 WATER PROOF
EC MOTOR SUMITOMO 6189-0031 090 WATER PROOF
SUMITOMO 6189-0031
YAZAKI RV03FB YAZAKI RV03FB
TRAVEL-2
YAZAKI RV03FB
AMP EJ(2)3P FEMALE

YAZAKI RV03FB
AMP EJ(2)3P FEMALE
(WATER PROOF SLEEVE)

SUMITOMO
6800-3859
TRAVEL-4
TRAVEL-3 PLUG
TRAVEL-1
WATERPROOF JOINT-1
SUMITOMO 6409-2325
FUEL FILTER
LIGHT GND (WATER PROOF SLEEVE) YAZAKI 7323-1424-40
WATERPROOF JOINT-1 (WATER PROOF SLEEVE) WATERPROOF JOINT-2
WATERPROOF JOINT-1 SUMITOMO 6409-2325
WATERPROOF JOINT-1 GLOW PLUG
WATERPROOF JOINT-1 STARTER RELAY
YAZAKI RV03FB (WATER PROOF)
WATERPROOF JOINT-1
WATERPROOF JOINT-2 WATER TEMP. SW.

WATERPROOF JOINT-2 ENG. OIL LEVEL SW. YAZAKI 7323-4714-40
SUMITOMO 6188-0494
WATERPROOF JOINT-2 YAZAKI 7323-7414-40
WATERPROOF JOINT-2
TRAVEL PLUG
WATERPROOF JOINT-2 YAZAKI
7323-1424-40
PLUG
WATERPROOF JOINT-1
WATERPROOF JOINT-2 SUMITOMO
6189-0714 TERMINAL CAP
EC MOTOR 1
(WATER PROOF SLEEVE)
EC MOTOR 2
EC MOTOR 3
EC MOTOR 4
AC (COMPRESSOR)
YAZAKI 7323-6214-40
FUEL FILTER AC PRESS

SUMITOMO 6189-0533
YAZAKI 7322-4125-50 YAZAKI 7322-4123-30
ASSY 7323-3525-50 ASSY 7323-3527-30
J06MGY ASSY
SUMITOMO 6098-0852
WATER TEMP. 560

BLUE RETAINER NO JOINT
YAZAKI 7323-2228
SUMITOMO
6270-3963
CLAMP
YAZAKI 7323-3010x2
SUMITOMO 6400-7601 AC AMB SENSOR

ASSY AMP EJ(2)2P FEMALE
SUMITOMO 6409-0033 174352-2
SCALE POINT
AIR_FILT SW.
(WATER PROOF)
AC PRESS. SW-1 BATTERY
YAZAKI 7323-2228
AC PRESS. SW-2
AMB. TEMP.SENSOR-1
591 AIR_ FILT-M
AMB. TEMP.SENSOR-2
LIGHT GND CLAMP POINT
ZAXIS135UR ENGINE HARNESS
090 WATER PROOF

SLEEVE YAZAKI
RV03FB
SUMITOMO
6189-0031 2
1 3
090 WATER PROOF

SLEEVE
220
SUMITOMO YAZAKI 090 WATERPROOF
( HE
6189-0031 RV03FB EC MOTOR SLEEVE 090 WATERPROOF
2 SUMITOMO 6189-0031 SLEEVE
AT
220 3
(HE 1 SUMITOMO 6189-0031
PR
ATP
O
ROO
LIGHT GND YAZAKI
OF
F VT YAZAKI
) RV03FB
VT
(WATER PROOF SLEEVE) RV03FB
)
2
180 MEPR OF CO
(FLAATPRO
BODY_LIGHT 1 1 3
HE
2
OFF-L-I ARM-D-I (WATER PROOF SLEEVE) 1 3
OFF-R-I
BOOM-U 090 WATER PROOF 090 WATER PROOF 090 WATER PROOF
47
TPR RO 160
090 WATER PROOF SLEEVE & )
OO OF &
SLEEVE
SLEEVE (F 0
OT)
0 OF OT
OOF T)
SLEEVE SUMITOMO
HELAM
SUMITOMO SUMITOMO
14 RO F C
FC
SUMITOMO 6189-0032 6189-0032 6189-0032
6189-0032 AT EP EP OO
HEALAMEP
&
PR RO M
OO OF L A PR
YAZAKI F & (F AT
HE
(F
RV03FB CO
2 220 160 T)
1 3
(FLAMEPROOF & (FLAMEPROOF &
YAZAKI HEATPROOF COT) HEATPROOF COT)
TRAVEL ALARM -2 RV03FB
660 (FLAMEPROOF & HEATPROOF COT)

T)
AMP EJ( ) 3P FEMALE
CO
HEATPROOF COT)
OF
2 FUEL/M
(FLAMEPROOF &
RO
1 3
TP
EA
&H
OF
RO
P
ME
460
A
FL
0(
AMP EJ( ) 3P FEMALE
70
36 LA ATP
(F E
0 ME R
H
P R OO
SUMITOMO
O FC
OIL_TEMP/S
O O
6800-3859
F T
& )
PLUG
WATERPROOF 100
(FL
SLEEVE JOINT-1 A
HEA MEPR
SUMITOMO TPR OOF
OO
6409-2325 FC & 500
OT) (FLAMEPROOF &
160
HEATPROOF COT)
HYD. OIL FILTER (FLAMEPROOF & ENG._OIL_P_SW.
HEATPROOF COT)
(WATERPROOF SLEEVE)
WATERPROOF YAZAKI 7323-1424-40
SLEEVE JOINT-2
HEATPROOF COT)
SUMITOMO
(FLAMEPROOF &
6409-2325
)
GLOW PLUG
OT
TRAVEL ALARM -4
FC
STARTER RELAY
TRAVEL ALARM -3
OO
(WATERPROOF SLEEVE)
PR
TRAVEL ALARM -1
100
AT
(FLAMEPROOF &
HE
210
BOOM ANGLE SENSOR HEATPROOF COT)
AP PLUG
&
HYD. OIL TEMP_S
OF
RO
BOOM-D OFF-R OFF-L ARM-C
ASSENBLE
EP
090 WATER PROOF 090 WATER PROOF 090 WATER PROOF 090 WATER PROOF
EMPTY PLUG
AM
SLEEVE SLEEVE SLEEVE SLEEVE
SUMITOMO
(FL
SUMITOMO SUMITOMO SUMITOMO COOLANT TEMP. SW.
WATER PROOF JOINT -1 6189-0031 6189-0031 6189-0031 6189-0031 HYD. OIL TEMP_S
220

SUMITOMO ENG._OIL_LEVEL_SW. YAZAKI 7323-7414-40
WATER PROOF JOINT -1
TRAVEL PLUG 6188-0494 YAZAKI 7323-7414-40
WATER PROOF JOINT -1 ASSY ASSY ASSENBLE
A/C PRESSURE_SW. -1 EMPTY PLUG YAZAKI 7323-1424-40
(FLAMEPROOF & HEATPROOF COT)

A/C PRESSURE_SW. -2
FASTEN
WITH TAPE
LIGHT GND
OT)
SUMITOMO
WATER PROOF JOINT -2 C 6189-0714 TERMINAL CAP
ARM AND OFFSET O OF
WATER PROOF JOINT -2 ANGLE SENSOR EA TPR
F &H
WATER PROOF JOINT -2 SOL. VALVE B5-2 OO &
EPR OF OT)
360
WATER PROOF JOINT -2 SOL. VALVE B8-2 AM RO
(FL 260 AMEP OOF C
WATER PROOF JOINT -2 33 0 (FL ATPR
SOL. VALVE B4-2
HE
SOL. VALVE B7-2
SOL. VALVE B2-2 470 (FLAMEPROOF & HEATPROOF COT)
SOL. VALVE B3-2
SOL. VALVE B6-2 400 1270
(FLAMEPROOF & (FLAMEPROOF &
WATER PROOF JOINT -1 SOL. VALVE B9-2 HEATPROOF COT) HEATPROOF COT)
WATER PROOF JOINT -2 SOL. VALVE B7-1
SOL. VALVE B9-2 A/C (COMPRESSOR)
YAZAKI 7323-6214-40

SOL. VALVE B6-1
YAZAKI
RV03FB
EC MOTOR 1 PRES. SENSOR 8-2 2
1 3
EC MOTOR 2 PRES. SENSOR 5-2
EC MOTOR 3 ANGLE SENSOR 1-2
EC MOTOR 4 PRES. SENSOR 7-2
PRES. SENSOR 2-2
PRES. SENSOR 6-2
PRES. SENSOR 1-2 A/C PRESSURE_SW.
ANGLE SENSOR 2-5 SUMITOMO 6189-0533
YAZAKI 7322-4125-50 RED COLOR
ASSY 7323-3525-50 YAZAKI 7322-4123-30
ANGLE SENSOR 2-2 TAPE WHITE COLOR ASSY 7323-3527-30
OIL TEMP. SENSOR 1 TAPE
SOL. VALVE B8-1
SOL. VALVE B2-1
SOL. VALVE B3-1
SOL. VALVE B4-1
SOL. VALVE B5-1
GLOW RELAY
YAZAKI 7323-2228
ANGLE SENSOR 1-3
ANGLE SENSOR 2-1
ANGLE SENSOR 2-4
PRES. SENSOR 1-1 CLAMP
PRES. SENSOR 6-1 SUMITOMO
6810-0184 RAD_LEVEL
PRES. SENSOR 7-1
HYD. OIL FILTER PRES. SENSOR 8-1 GLOW RELAY
PRES. SENSOR 2-1 YAZAKI
7323-3010×2ヶ
PRES. SENSOR 5-1
ANGLE SENSOR 1-1
COOLANT TEMP SW. ANGLE SENSOR 2-3
ANGLE SENSOR 2-6
PRES. SENSOR 1-3
PRES. SENSOR 6-3 AIR FILT. SW.
PRES. SENSOR 7-3 (WATERPROOF SLEEVE)
PRES. SENSOR 8-3
WASHER
PRES. SENSOR 2-3 YAZAKI BATTERY RELAY
PRES. SENSOR 5-3 7323-2228
OIL TEMP. SENSOR 2
CLAMP A, B, C
ZAXIS110/110M/120/130/130LCN MONITOR HARNESS CAUTION: Parts numbers on the drawing are provided only for reference purpose.
MONITOR A-8 CAB A-7
WIPER E CAB C-12
MONITOR A-2 CAB A-1

MONITOR A-3 CAB A-2
MONITOR A-4 CAB A-3
MONITOR A-5 CAB A-4
MONITOR A-6 CAB A-5
MONITOR A-7 CAB A-6
MONITOR A-10
MONITOR A-11 CAB B-16
MONITOR A-14 BUZZER 2

MONITOR A-15 BUZZER 1
WIPER
MONITOR B-1 CAB A-8

MONITOR B-2 CAB A-9
MONITOR B-3 CAB A-10
MONITOR B-5 CAB C-4 CAB A

MONITOR B-7 CAB A-13 MONITOR A
CONNECT
MONITOR B-11 CAB B-1
MONITOR B-12 CAB B-2 CAB B MONITOR B
MONITOR B-16
MONITOR B-17 MONITOR C
CAB C
MONITOR B-20 CAB B-8 TAPE
MONITOR C-1 CAB B-9

MONITOR C-2 CAB B-10
MONITOR C-5 CAB B-13 BUZZER

MONITOR C-8 CAB C-16
MONITOR C-9 CAB C-1
MONITOR C-12 CAB A-11

WIPER L CAB C-9

WIPER S CAB C-11
WIPER B CAB C-10
WIPER M CAB C-8
SOLAR-RADIATION SENSOR-1 CAB C-13
SOLAR-RADIATION SENSOR-2 CAB C-14
ZAXIS135UR CONSOLE HARNESS
OFFSET SW-3
RESTRICTION DEACT. SW.-GND
CRANE SW-3
CRANE SW-1
NOTE
1. WIRE SHALLBE CAVS ,IF NO COMMENT.
2. PUT THE LABEL FOR THE HARNESS.

IC/U BUZZER 1
OFFSET SW-2 3. SYMBOL OF THES DROWING DUE TO #4259303
RESTRICTION DEACT. SW.-S
4. NO ELECTRIC TURNING POINT MAY BE BETWEEN
EMERGENCY STOP SOL-1
A-HORN SW ,A-EMERGENCY STOP SOL.
OFFSET SW-1
IC/U BUZZER 2
EMERGENCY STOP SOL-2
EMERGENCY STOP SOL.

090 WATER PROOF SLEEVE
SUMITOMO 6189-0031
CRANE SW.
SUMITOMO
6242-5061
RESTRICTION
DEACT. SW.
OFFSET SW
IC/U BUZZER
SUMITOMO
6030-2981
TR/MO TR/MO
SH SW/MO
M
A B
A B A B
SL SN SM SK T3
PROPEL RH 1
RR
RF P1
2
B8
4
LR
T A8
TRAVEL;L
TRAVEL;R
P 12 RR 11 RF
LF
9 LF 10 LR
3 B1
A5
T3 T4
PROPEL LH A1
T1
DK
B7
T2
VALVE
COMB-
FUNCTION
A1 A7
P AUX
A2
7 BKT IN 8 BKT OUT
A3
13 AUX B
14 AUX A
A4
BUCKET
B2
SY
A2
BKT CYL.
DY
PI1 SEC.BOOM
PRIM.BOOM
2 BM DWN 1 BM UP
TO 1
B3
ARM CYL.
A3
B6
PI2
ZAXIS110/110M/120/130/130LCN HYDRAULIC CIRCUIT DIAGRAM
A6
PRIM.ARM
4 ARM IN
3 ARM OUT
BOOM CYL.
SC TO 3
PI3
SEC.ARM
A4
SJ
B5
PF
PG A5 A9 DC DH T2
SWING
DY
5 SW L 6 SW R
SC
DD
ARM FLOW
DH
T1 P2
SI
DX
TR. SPEED
DS PD
VALVE SOL.
PD2 PD1
PA
PA
Eng.
PE
PF
PUMP FL PUMP PQ
PG
for the relief valve pressure setting valve.
PC
PD
TA
SB
SA
PC1 PC2
Note:Refer to the PEFORMANCE STANDARD in the technical manual
N 14
SM TR/MO TR/MO
M 13 DB
5
E SW L
BUCKET S3
F SW R 6
3 SH SW/MO
IN
G BKT IN 7
OUT 1 M
H BKT OUT 8
4
SE
UP
T
P A B
SL
DOWN
2
SH
BOOM A BOOM UP 1
ARM SK
3
A B A B
OUT
SB
IN
1
4 B BOOM DWN 2
L C ARM OUT 3
T
P
SP
R SN
2
SWING SL SN SM SK T3
SA
PROPEL RH D
1 ARM IN 4
L
RR
12
RF K 11 P1
2
TR B8
4 J
10
LR
T I A8
9 TRAVEL;L
TRAVEL;R
P 12 RR 11 RF
LF
9 LF 10 LR
PH DF
3 B1
A4
T3 T4
PROPEL LH A1
T1
DK
B7
VALVE
COMB-
T2
FUNCTION
A1 A7
P AUX
A2
7 BKT IN 8 BKT OUT
A3 13 AUX B
14 AUX A
BUCKET
B2
SY
A2
DY
BKT CYL.
PI1 SEC.BOOM
ZAXIS125US/135US HYDRAULIC CIRCUIT DIAGRAM
PRIM.BOOM
2 BM DWN 1 BM UP
TO 1
B3
ARM CYL.
A3
B6
PI2
A6
PRIM.ARM
4 ARM IN
3 ARM OUT
BOOM CYL.
SC TO 3
PI3
SEC.ARM
A4
SJ
B5
PF
PG A5 A9 DC DH T2
SWING
DY
5 SW L 6 SW R
SC
DD
ARM FLOW
P2
DH T1
SI
DX
TR. SPEED
DS PD
VALVE SOL.
PD2 PD1
PA
Eng.
PA
PE
PF
PUMP FL PUMP PQ
PG
PC
PD
TA
SB
SA
PC1 PC2
Note:Refer to the PEFORMANCE STANDARD in the technical manual
Attach to Vol. No.: TT187E-04 Note:Refer to the PEFORMANCE STANDARD in the technical manual
ZAXIS135UR HYDRAULIC CIRCUIT DIAGRAM
VALVE SOL.(OPT)
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162
SERVICE MANUAL REVISION REQUEST FORM
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Hitachi Excavator Zaxis ZX110-135US Technical Manual &amp; Operational Principle

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Hitachi Excavator Zaxis ZX110-135US Technical Manual &amp; Operational Principle

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Manual No.

PRINTED IN SINGAPORE (PS) 2003.11

Zaxis110..135UR-TM/TSh 1 14/11/03, 12:54 PM

Vol No.: TT187E-04

• Each page has a number, located on the center

Consecutive Page Number for Each Group

SAFETY ALERT SYMBOL AND HEADLINE

• This is the SAFETY ALERT SYMBOL.

UNDERSTAND SIGNAL WORDS

• CAUTION also calls attention to safety messages in

• NOTE indicates an additional explanation for an

• Carefully read and follow all safety signs on the

to operate the machine.

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

posted near your telephone.

WEAR PROTECTIVE CLOTHING

Be sure to wear the correct equipment and clothing

• Prolonged exposure to loud noise can cause

• Before entering the cab, thoroughly remove all

• Falling is one of the major causes of personal injury.

ADJUST THE OPERATOR'S SEAT

• If the machine should overturn, the operator may

securely fastened at all times when the machine

MOVE AND OPERATE MACHINE SAFELY

levers are in neutral.

• Battery gas can explode, resulting in serious injury.

• Riders on machine are subject to injury such as

PROVIDE SIGNALS FOR FOBS INVOLV-

• For jobs involving multiple numbers of machines,

CONFIRM DIRECTION OF MACHINE TO

• Incorrect travel pedal/lever operation may result in

• Before driving the machine, always confirm that the

• Driving on a slope may cause the machine to slip or

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

a slope may cause the machine to skid or turn-

H/P mode switch off.

To avoid back-over and swing accidents:

MACHINE WILL TIP OVER FASTER THAN YOU

FASTEN YOUR SEAT BELT

• The danger of tipping is always present when

• Serious injury or death can result if the machine or

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

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

PARK MACHINE SAFELY

• Close windows, roof vent, and cab door.

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

• All fuels, most lubricants, and some coolants are

• Store flammable fluids well away from fire

• The danger of tipping is present when

Take the following precautions when loading /

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

• Understand service procedures before doing

• Before servicing the machine:

inside the machine.

• Unexpected machine movement can cause serious

SUPPORT MACHINE PROPERLY

STAY CLEAR OF MOVING PARTS

• Grease in the track adjuster is under high pressure.

• Wait for GEAR OIL to cool, then gradually loosen

STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic

USE TOOLS PROPERLY

• The hydraulic oil tank is pressurized. Again, be

Hot fluids and surfaces:

Hitachi Excavator Zaxis ZX110-135US Technical Manual & Operational Principle

Hitachi Excavator Zaxis ZX110-135US Technical Manual & Operational Principle