INTRODUCTION
TO THE READER
• This manual is written for an experienced technician
to provide technical information needed to maintain
and repair this machine.
• Be sure to thoroughly read this manual for correct
product information and service procedures.
• If you have any questions or comments, at if you
found any errors regarding the contents of this
manual, please contact using “Service Manual
Revision Request Form” at the end of this manual.
(Note: Do not tear off the form. Copy it for usage.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX: 81-29-831-1162
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition
to this manual.
• The Engine 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 Technical Manual (Operational Principle), the Technical
Manual (Troubleshooting) and the Workshop Manual.
• Information included in the Technical Manual
(Operational Principle):
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems.
• Information included in the Technical Manual
(Troubleshooting):
technical information needed for operational performance tests, and troubleshooting procedures.
• Information included in the Workshop Manual:
technical information needed for maintenance
and repair of the machine, tools and devices
needed for maintenance and repair, maintenance
standards, and removal/installation and assemble/disassemble procedures.
PAGE NUMBER
• Each page has a number, located on the center
lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group
Group Number
Section Number
T: Technical Manual
W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the
potential for personal injury of machine damage.
•
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy
parts.
• IMPORTANT:
CAUTION:
Indicated potentially hazardous situation which could,
if not avoided, result in personal injury or death.
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
•
NOTE:
Indicates supplementary technical information or
know-how.
UNITS USED
• SI Units (International System of Units) are used in
2
Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKSA system units and English units are also
indicated in parenthheses just behind SI units.
Quantity
Length
Volume
Weight
Force
Torque
To Convert
From
mm
mm
L
L
3
m
kg
N
N
N⋅m
N⋅m
Into
in
ft
US gal
US qt
3
yd
lb
kgf
lbf
kgf⋅m
lbf⋅ft
A table for conversion from SI units to other system
units is shown below for reference purposees.
Quantity
Multiply By
0.03937
0.003281
0.2642
1.057
1.308
2.205
0.10197
0.2248
1.0197
0.7375
Pressure
Power
Temperature
Velocity
Flow rate
IN-02
To Convert
From
MPa
MPa
kW
kW
°C
km/h
-1
min
L/min
mL/rev
Into
Multiply By
2
kgf/cm
psi
PS
HP
°F
mph
rpm
US gpm
cc/rev
10.197
145.0
1.360
1.341
°C×1.8+32
0.6214
1.0
0.2642
1.0
SAFETY
RECOGNIZE SAFETY INFORMATION
• These are the SAFETY ALERT SYMBOLS.
• When you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
• Follow recommended precautions and safe operating
practices.
001-E01A-0001
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.
• 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-E01A-1223
SA-1
SA-1223
SAFETY
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
• Safety signs should be installed, maintained and replaced
when necessary.
• If a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in the
same way you order other replacement parts (be sure to
state machine model and serial number when ordering).
Learn
how to operate the machine and its controls correctly
•
and safely.
• Allow only trained, qualified, authorized personnel to operate the machine.
• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
• Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, function, and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
• Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may
deteriorate the safety, function, and/or service life of the
machine. In addition, personal accident, machine trouble,
and/or damage to material caused by using unauthorized
attachments and/or optional parts or equipment will void
Hitachi Warranty Policy.
• The safety messages in this SAFETY chapter are intended to
illustrate basic safety procedures of machines. However it is
impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions,
you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance
work on the machine.
003-E01B-0003
SA-2
SA-003
SAFETY
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or if an accident occurs.
• Keep a first aid kit and fire extinguisher on hand.
• Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
• To ensure that a fire-extinguisher can be always used
when necessary, check and service the fire-extinguisher
at the recommended intervals as specified in the fireextinguisher manual.
• Establish emergency procedure guidelines to cope with
fires and accidents.
• Keep emergency numbers for doctors, ambulance service,
hospital, and fire department posted near your telephone.
SA-437
004-E01A-0437
WEAR PROTECTIVE CLOTHING
• Wear close fitting clothing and safety equipment appropriate to the job.
You may need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing for the
job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other items that
can catch on control levers or other parts of the machine.
• Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating the machine.
005-E01A-0438
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
SA-3
SAFETY
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.
007-E01A-0435
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.
• Do not leave parts and/or tools lying around the operator’
s seat. Store them in their specified locations.
• Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the
windowpanes as they may focus sunlight, possibly starting a fire.
• Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating
the machine.
• Keep all flammable objects and/or explosives away from
the machine.
• After using the ashtray, always cover it to extinguish the
match and/or tobacco.
• Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.
524-E01A-0000
SA-4
SA-435
SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.
• When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount or dismount a moving machine.
• Be careful of slippery conditions on platforms, steps, and
handrails when leaving the machine.
SA-439
008-E01A-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.
• Adjust the rear view mirror position so that the best rear
visibility is obtained from the operator’s seat. If the mirror
is broken, immediately replace it with a new one.
009-E01A-0462
ENSURE SAFETY BEFORE RISING FROM OR LEAVING OPERATOR’S SEAT
• Before rising from the operator’s seat to open/close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with a
control lever, possibly resulting in serious personal injury or
death.
• Before leaving the machine, be sure to first lower the
front attachment to the ground and then move the pilot
control shut-off lever to the LOCK position. Turn the key
switch OFF to stop the engine.
• Before leaving the machine, close all windows, doors, and
access covers and lock them up.
SA-5
SA-378
SAFETY
FASTEN YOUR SEAT BELT
• If the machine should overturn, the operator may become
injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in
serious injury or death.
• Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before
operating the machine.
• Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to
minimize the chance of injury from an accident.
• We recommend that the seat belt be replaced every three
years regardless of its apparent condition.
SA-237
010-E01A-0237
MOVE AND OPERATE MACHINE SAFELY
• Bystanders can be run over.
• Take extra care not to run over bystanders. Confirm the
location of bystanders before moving, swinging, or operating the machine.
• Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine
starts to move.
• Use a signal person when moving, swinging, or operating
the machine in congested areas. Coordinate hand signals
before starting the machine.
• Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it.
SA-083
011-E01A-0398
HANDLE STARTING AIDS SAFELY
Starting fluid:
• Starting fluid is highly flammable.
• Keep all sparks and flame away when using it.
• Keep starting fluid well away from batteries and cables.
• Remove container from machine if engine does not need
starting fluid.
• To prevent accidental discharge when storing a pressurized container, keep the cap on the container, and store it
in a cool, well-protected location.
• Do not incinerate or puncture a starting fluid container.
036-E01A-0293-3
SA-6
SA-293
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 levers
are in neutral.
• Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders.
SA-084
012-E01B-0431
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump started, be sure to follow the
instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual.
• The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SA-032
S013-E01A-0032
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-0427
SA-091
SA-7
SAFETY
PRECAUTIONS FOR OPERATIONS
• Investigate the work site before starting operations.
• Be sure to wear close fitting clothing and safety equipment appropriate for the job, such as a hard hat, etc.
when operating the machine.
• Clear all persons and obstacles from area of operation and
machine movement.
Always beware of the surroundings while operating.
When working in a small area surrounded by obstacles,
take care not to hit the upperstructure against obstacles.
• When loading onto trucks, bring the bucket over the truck
beds from the rear side. Take care not to swing the bucket
over the cab or over any person.
M202-05-014
SA-8
SAFETY
INVESTIGATE JOB SITE BEFOREHAND
• When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death.
• Investigate the configuration and ground conditions of
the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from
collapsing.
• Make a work plan. Use machines appropriate to the work
and job site.
• Reinforce ground, edges, and road shoulders as necessary.
Keep the machine well back from the edges of excavations and road shoulders.
• When working on an incline or on a road shoulder, employ a signal person as required.
• Confirm that your machine is equipped a FOPS cab before
working in areas where the possibility of falling stones or
debris exist.
• When the footing is weak, reinforce the ground before
starting work.
• When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
• Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.
• Make sure the worksite has sufficient strength to firmly support the machine.
SA-085
When working close to an excavation or at road shoulders,
operate the machine with the tracks positioned perpendicular to the cliff face with travel motors at the rear, so that the
machine can more easily evacuate if the cliff face collapses.
• If working on the bottom of a cliff or a high bank is required,
be sure to investigate the area first and confirm that no
danger of the cliff or bank collapsing exists. If any possibility
of cliff or bank collapsing exists, do not work on the area.
• Soft ground may collapse when operating the machine on
it, possibly causing the machine to tip over. When working
on a soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm
enough to easily support the machine.
• Note that there is always a possibility of machine tipping
over when working on rough terrain or on slopes. Prevent
machine tipping over from occurring. When operating on
rough terrain or on slopes:
• Reduce the engine speed.
• Select slow travel speed mode.
• Operate the machine slowly and be cautious with machine movements.
SA-9
M202-05-015
SAFETY
EQUIPMENT OF HEAD GUARD, ROPS, FOPS
In case the machine is operated in areas where the possibility
of falling stones or debris exist, equip a head guard, ROPS, or
FOPS according to the potential hazardous conditions. (The
standard cab for this machine corresponds to ROPS and FOPS.)
ROPS: Roll-Over Protective Structure
FOPS: Falling Object Protective Structure
SA-686
PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES
• For jobs involving multiple numbers of machines, provide
signals commonly known by all personnel involved. Also,
appoint a signal person to coordinate the job site. Make
sure that all personnel obey the signal person’s directions.
018-E01A-0481
SA-481
CONFIRM DIRECTION OF MACHINE TO BE DRIVEN
• Incorrect steering wheel/forward/reverse pedal 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 steering wheel is operated to
the front.
017-E01A-0491
SA-10
SA-092
SAFETY
DRIVE MACHINE SAFELY
• Before driving the machine, always confirm that the steering wheel/forward/reverse switch 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. Do
not allow personnel to stay around the machine while
traveling.
• Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.
SA-090
• Never attempt to ascend or descend 35 degrees or steeper slopes.
• Be sure to fasten the seat belt.
• When driving up or down a slope, keep the bucket facing the direction of travel, approximately 0.5 to 1.0 m (A)
above the ground.
• If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.
SA-288
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.
• Place FNR switch in neutral, and put the brake switch in
the P (parking brake) position.
• Turn the auto-idle 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 tires 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.
020-E02A-0493
SA-11
SA-278
SAFETY
AVOID INJURY FROM BACK-OVER AND SWING
ACCIDENTS
• If any person is present near the machine when backing or
swinging the upperstructure, the machine may hit or run
over that person, resulting in serious injury or death.
To avoid back-over and swing accidents:
• Always look around BEFORE YOU BACK UP AND SWING
THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE
CLEAR.
• Keep the travel alarm in working condition (if equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE
WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW
IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN
VIEW.
Use hand signals, which conform to your local regulations,
when work conditions require a signal person.
• No machine motions shall be made unless signals are
clearly understood by both signalman and operator.
• Learn the meanings of all flags, signs, and markings used
on the job and confirm who has the responsibility for
signaling.
• Keep windows, mirrors, and lights clean and in good condition.
• Dust, heavy rain, fog, etc., can reduce visibility. As visibility
decreases, reduce speed and use proper lighting.
• Read and understand all operating instructions in the
operator’s manual.
021-E01A-0494
SA-12
SA-383
SA-384
SAFETY
KEEP PERSON CLEAR FROM WORKING AREA
• A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed against an
other object, resulting in serious injury or death.
• Keep all persons clear from the area of operation and
machine movement.
• Before operating the machine, set up barriers to the sides
and rear area of the bucket swing radius to prevent anyone from entering the work area.
022-E01A-0386
M202-05-014
NEVER POSITION BUCKET OVER ANYONE
• Never lift, move, or swing bucket above anyone or a truck
cab.
Serious injury or machine damage may result due to bucket
load spill or due to collision with the bucket.
023-E01A-0487
SA-682
AVOID UNDERCUTTING
• Always confirm that ground conditions are strong enough
to support the machine weight when operating near a cliff.
Operate the machine with the chassis frame positioned
perpendicular to the cliff face so that the machine can more
easily evacuate if the cliff face collapses.
• If the footing starts to collapse and if retreat is not possible, do not panic. Often, the machine can be secured by
lowering the front attachment, in such cases.
024-E01A-0488
SA-13
SA-683
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE---SERIOUS OR FATAL CRUSHING INJURIES WILL
RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP
FREE
FASTEN YOUR SEAT BELT
• The danger of tipping is always present when operating on
a grade, possibly resulting in serious injury or death.
To avoid tipping:
• Be extra careful before operating on a grade.
• Prepare machine operating area flat.
• Keep the bucket low to the ground and close to the machine.
• Reduce operating speeds to avoid tipping or slipping.
• Avoid changing direction when traveling on grades.
• NEVER attempt to travel across a grade steeper than 15
degrees if crossing the grade is unavoidable.
• Reduce swing speed as necessary when swinging loads.
SA-088
• Be careful when working on frozen ground.
• Temperature increases will cause the ground to become
soft and make ground travel unstable.
025-E03B-0463
SA-684
NEVER UNDERCUT A HIGH BANK
• The edges could collapse or a land slide could occur causing
serious injury or death.
026-E01A-0519
SA-685
SA-14
SAFETY
DIG WITH CAUTION
• Accidental severing of underground cables or gas lines may
cause an explosion and/or fire, possibly resulting in serious
injury or death.
• Before digging check the location of cables, gas lines, and
water lines.
• Keep the minimum distance required, by law, from cables,
gas lines, and water lines.
• If a fiber optic cable should be accidentally severed, do
not look into the end. Doing so may result in serious eye
injury.
• Contact your local “diggers hot line” if available in your
area , and/or the utility companies directly.
Have them mark all underground utilities.
SA-086
027-E01A-0382
OPERATE WITH CAUTION
• If the front attachment or any other part of the machine hits
against an overhead obstacle, such as a bridge, both the
machine and the overhead obstacle will be damaged, and
personal injury may result as well.
• Take care to avoid hitting overhead obstacles with the
boom or arm.
028-E01A-0389
SA-15
SA-087
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 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-089
029-E01A-0381
PRECAUTIONS FOR LIGHTENING
• The machine is vulnerable to lighting strikes.
• In the event of an electrical storm, immediately stop operation, and lower the bucket to the ground. Evacuate to
a safe place far away from the machine.
• After the electrical storm has passed, check all of the
machine safety devices for any failure. If any failed safety
devices are found, operate the machine only after repairing them.
SA-1241
OBJECT HANDLING
• If a lifted load should fall, any person nearby may be struck
by the falling load or may be crushed underneath it, resulting in serious injury or death.
• When using the machine for craning operations, be sure
to comply with all local regulations.
• Do not use damaged chains or frayed cables, sables,
slings, or ropes.
• Before craning, position the upperstructure with the travel
motors at the rear.
• Move the load slowly and carefully. Never move it suddenly.
• Keep all persons well away from the load.
• Never move a load over a person's head.
• Do not allow anyone to approach the load until it is safely
and securely situated on supporting blocks or on the
ground.
• Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.
032-E01A-0132
SA-014
SA-16
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.
• Place FNR switch in neutral, and put the brake switch in
the P (parking brake) position.
• Turn auto-idle switch OFF.
• Run engine at slow idle speed without load for 5 minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK position.
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.
SA-093
HANDLE FLUIDS SAFELY−AVOID FIRES
• Handle fuel with care; it is highly flammable. If fuel ignites,
an explosion and/or a fire may occur, possibly resulting in
serious injury or death.
• Do not refuel the machine while smoking or when near
open flame or sparks.
• Always stop the engine before refueling the machine.
• Fill the fuel tank outdoors.
• All fuels, most lubricants, and some coolants are flammable.
• Store flammable fluids well away from fire hazards.
• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn spontaneously.
• Securely tighten the fuel and oil filler cap.
SA-018
034-E01A-0496
SA-019
SA-17
SAFETY
TRANSPORT SAFELY
• Take care the machine may turn over when loading or unloading the machine onto or off of a truck or trailer.
• Observe the related regulations and rules for safe transportation.
• Select an appropriate truck or trailer for the machine to
be transported.
• Be sure to use a signal person.
• Always follow the following precautions for loading or
unloading:
1. Select solid and level ground.
Less than 15°
2. Always use a ramp or deck strong enough to support the
machine weight.
SA-094
3. Turn auto-idle switch OFF.
4. Always select the slow speed mode with the travel mode
switch.
5. Never load or unload the machine onto or off a truck or
trailer using the front attachment functions when driving
up or down the ramp.
6. Never steer the machine while on the ramp. If the traveling direction must be changed while the ramp, unload
the machine from the ramp, reposition the machine on
the ground, then try loading again.
7. The top end of the ramp where it meets the flatbed is a
sudden bump. Take care when traveling over it.
8. Place blocks in front of and behind the tires. Securely
hold the machine to the truck or trailer deck with wire
ropes.
Be sure to further follow the details described in the TRANSPORTING section.
035-E07A-0454
SA-18
Less than 15°
SA-095
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
• Understand service procedures before starting work.
• Keep the 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 switch 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.
SA-028
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.
• 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 100˚ angle
between the boom and arm. Securely support any machine elements that must be raised for service work.
• Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the
“MAINTENANCE” chapter in the operator’s manual.
• Keep all parts in good condition and properly installed.
• Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
• When cleaning parts, always use nonflammable detergent
oil. Never use highly flammable oil such as fuel oil and
gasoline to clean parts or surfaces.
• Disconnect battery ground cable (−) before making
adjustments to electrical systems or before performing
welding on the machine.
500-E02C-0520
SA-19
SA-527
SAFETY
• Sufficiently illuminate the work site. Use a maintenance
work light when working under or inside the machine.
• Always use a work light protected with a guard. In case
the light bulb is broken, spilled fuel, oil, antifreeze fluid, or
window washer fluid may catch fire.
SA-037
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause serious injury.
• Before performing any work on the machine, attach a “Do
Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
501-E01A-0287
SS3076175
SS2045102
SUPPORT MACHINE PROPERLY
• Never attempt to work on the machine without securing
the machine first.
• Always lower the attachment to the ground before you
work on the machine.
• If you must work on a lifted machine or attachment,
securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props
that may crumble under continuous load. Do not work
under a machine that is supported solely by a jack.
SA-527
519-E01A-0527
STAY CLEAR OF MOVING PARTS
• Entanglement in moving parts can cause serious injury.
• To prevent accidents, care should be taken to ensure that
hands, feet, clothing, jewelry and hair do not become
entangled when working around rotating parts.
502-E01A-0026
SA-026
SA-20
SAFETY
PREVENT PARTS FROM FLYING
• Travel reduction gears are under pressure.
• As pieces may fly off, be sure to keep body and face away
from AIR RELEASE PLUG to avoid injury.
• GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually
loosen AIR RELEASE PLUG to release pressure.
503-E01B-0344
SA-344
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
SUPPORT MAINTENANCE PROPERLY
• Explosive separation of a tire and rim parts can cause serious injury or death.
• Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Have it done by your authorized dealer or a qualified
repair service.
• Always maintain the correct tire pressure. DO NOT inflate
tire above the recommended pressure.
• When inflating tires, use a chip-on chuck and exten-sion
hose long enough to allow you to stand to one side and
not in front of or over the tire assembly. Use a safety cage
it available.
• Inspect tires and wheels daily. Do not operate with low
pressure, cuts bubbles, damaged rims, or missing lug
bolts and nuts.
• Never cut or weld on an inflated tire or rim assembly. Heat
from welding could cause an increase in pressure and
may result in tire explosion.
521-E02A-0249
SA-21
SA-249
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under pressure.
Hot water or steam is contained in the engine, radiator and
heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
• To avoid possible injury from hot spraying water. DO NOT
remove the radiator cap until the engine is cool. When
opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap.
• The hydraulic oil tank is pressurized. Again, be sure to
release all pressure before removing the cap.
SA-039
Hot fluids and surfaces:
• Engine oil, gear oil and hydraulic oil also become hot during
operation.
The engine, hoses, lines and other parts become hot as well.
• Wait for the oil and components to cool before starting
any maintenance or inspection work.
SA-225
505-E01B-0498
REPLACE RUBBER HOSES PERIODICALLY
• Rubber hoses that contain flammable fluids under pressure
may break due to aging, fatigue, and abrasion. It is very
difficult to gauge the extent of deterioration due to aging,
fatigue, and abrasion of rubber hoses by inspection alone.
• Periodically replace the rubber hoses. (See the page of
“Periodic replacement of parts” in the operator’s manual.)
• Failure to periodically replace rubber hoses may cause a fire,
fluid injection into skin, or the front attachment to fall on a
person nearby, which may result in severe burns, gangrene,
or otherwise serious injury or death.
S506-E01A-0019
SA-22
SA-019
SAFETY
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under pressure can
penetrate the skin or eyes causing serious injury, blindness
or death.
• Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take care to
protect hands and body from high-pressure fluids. Wear a
face shield or goggles for eye protection.
• If an accident occurs, see a doctor familiar with this type
of injury immediately. Any fluid injected into the skin
must be surgically removed within a few hours or gangrene may result.
SA-031
507-E03A-0499
SA-292
SA-044
SA-23
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to fires.
• Check for oil leaks due to missing or loose clamps, kinked
hoses, lines or hoses that rub against each other, damage
to the oil-cooler, and loose oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or damaged
clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or hoses.
SA-019
Check for Shorts:
• Short circuits can cause fires.
• Clean and tighten all electrical connections.
• Check before each shift or after eight(8) to ten(10) hours
operation for loose, kinked, hardened or frayed electrical
cables and wires.
• Check before each shift or after eight(8) to ten(10) hours
operation 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.
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.
508-E02B-0019
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.
508-E02A-0393
SA-24
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 or front window can not
•
be opened, break the front or rear window panes with the
emergency evacuation hammer to escape from the cab.
Refer the explanation pages on the Emergency Evacuation
Method.
SA-393
18-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
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 there are
no abnormalities such as the area surrounding the welded
area still smoldering.
523-E01A-0818
SA-25
SA-818
SAFETY
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 fireresistant guards to protect hoses or other materials before
engaging in welding, soldering, etc..
AVOID APPLYING HEAT TO LINES CONTAINING
FLAMMABLE FLUIDS
SA-030
• 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
REMOVE PAINT BEFORE WELDING OR HEATING
• Hazardous fumes can be generated when paint is heated by
welding, soldering, or using a torch. If inhaled, these fumes
may cause sickness.
• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly.
• Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or paint
stripper containers and other flammable material from
area. Allow fumes to disperse at least 15 minutes before
welding or heating.
511-E01A-0029
SA-26
SA-029
SAFETY
BEWARE OF ASBESTOS DUST
• Take care not to inhale dust produced in the work site. Inhalation of asbestos fibers may be the cause of lung cancer.
• Depending on the wok site conditions, the risk of inhaling
asbestos fiber may exist. Spray water to prevent asbestos
from becoming airborne. Do not use compressed air.
• When operating the machine in a work site where asbestos might be present, be sure to operate the machine
from the upwind side and wear a mask rated to prevent
the inhalation of asbestos.
• Keep bystanders out of the work site during operation.
• Asbestos might be present in imitation parts. Use only
genuine Hitachi Parts.
SA-029
PREVENT BATTERY EXPLOSIONS
• Battery gas can explode.
• Keep sparks, lighted matches, and flame away from the
top of battery.
• Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
• Do not charge a frozen battery; it may explode. Warm the
battery to 16˚C ( 60˚ F ) first.
• Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result.
• Loose terminals may produce sparks. Securely tighten all
terminals.
SA-032
• 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-E01B-0032
SERVICE AIR CONDITIONING SYSTEM SAFELY
• If spilled onto skin, refrigerant may cause a cold contact
burn.
• Refer to the instructions described on the container for
proper use when handling the refrigerant.
• Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
• Never touch the refrigerant.
513-E01A-0405
SA-405
SA-27
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY
• Direct exposure to hazardous chemicals can cause serious
injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and
adhesives.
• A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
• Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the
risks are and how to do the job safely. Then follow procedures and use recommended equipment.
• See your authorized dealer for MSDS’s (available only in
English) on chemical products used with your machine.
SA-309
515-E01A-0309
DISPOSE OF WASTE PROPERLY
• Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with
HITACHI equipment includes such items as oil, fuel, coolant,
brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
• Do not pour waste onto the ground, down a drain, or into
any water source.
• Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
• Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.
516-E01A-0226
SA-28
SA-226
SAFETY
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-29
SAFETY
(Blank)
SA-30
SECTION AND GROUP
CONTENTS
TECHNICAL MANUAL
(Troubleshooting)
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group
Group
Group
Group
Group
1
2
3
4
5
Introduction
Standard
Engine Test
Excavator Test
Component Test
SECTION 5 TROUBLESHOOTING
Group
Group
Group
Group
Group
Group
Group
Group
1 Diagnosing Procedure
2 Monitor Unit
3 Dr. ZX
4 ICF
5 Component Layout
6 Troubleshooting A
7 Troubleshooting B
8 Electrical System Inspection
TECHNICAL MANUAL (Operational Principle)
All information, illustrations and specifications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.
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 5 Electric Lever
Group 1 Controller
Group 6 Transmission
Group 2 Control System
Group 7 Axle
Group 3 ECM System
Group 8 Travel Motor
Group 4 Hydraulic System
Group 9 Signal Control Valve
Group 5 Electrical System
Group 10 Steering Valve
Group 11 Brake Valve
Group 12 Others (Upperstructure)
Group 13 Others (Undercarriage)
COPYRIGHT(C)2007
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
←これ以下
記載しない
WORKSHOP MANUAL
SECTION 1 GENERAL INFORMATION SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 1 Precautions for DisassemGroup 2 Travel Motor
bling and Assembling
Group 3 Center Joint
Group 2 Tightening Torque
Group 4 Transmission
Group 3 Painting
Group 5 Axle
Group 4 Bleeding Air from HydrauGroup 6 Axle Lock Cylinder
lic Oil Tank
SECTION 2 UPPERSTRUCTURE
Group 7 Operate Check Valve
(Axle Lock Cylinder)
Group 1 Cab
SECTION 4 FRONT ATTACHMENT
Group 2 Counterweight
Group 3 Main Frame
Group 1 Front Attachment
Group 4 Pump Device
Group 2 Cylinder
Group 5 Control Valve
Group 3 Hose Rupture Valve
Group 6 Swing Device
Group 4 Operate Check Valve
Group 7 Pilot Valve
(Blade/Outrigger)
Group 8 Electric Lever
Group 9 Pilot Shut-Off Solenoid Valve
Group 10 Signal Control Valve
Group 11 Travel Shockless Valve
Group 12 Swing Shockless Valve
Group 13 Solenoid Valve
Group 14 Steering Valve
Group 15 Brake Valve
Group 16 Accumulator Charging Valve
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction
Group 5 Component Test
Operational Performance Tests ................... T4-1-1
Primary Pilot Pressure ..................................T4-5-1
Preparation for Performance Tests .............. T4-1-2
Secondary Pilot Pressure .............................T4-5-3
Solenoid Valve Set Pressure ........................T4-5-4
Group 2 Standard
Performance Standard ................................. T4-2-1
Main Pump P-Q Diagram ............................. T4-2-6
Sensor Activating Range .............................. T4-2-8
Group 3 Engine Test
Main Pump Delivery Pressure ......................T4-5-6
Main Relief Set Pressure ..............................T4-5-8
Relief Pressure (When relieving Swing) .....T4-5-10
Overload Relief Valve Set Pressure ...........T4-5-12
Main Pump Flow Rate Measurement .........T4-5-14
Engine Speed ............................................... T4-3-1
Swing Motor Drainage ................................T4-5-24
Engine Compression Pressure .................... T4-3-4
Travel Motor Drainage ................................T4-5-26
Valve Clearance ........................................... T4-3-6
Steering Valve Relief Pressure ...................T4-5-28
Lubricant Consumption ................................ T4-3-9
Brake Pressure (Front and Rear) ...............T4-5-30
Brake Accumulated Pressure .....................T4-5-32
Group 4 Excavator Test
Travel Speed ................................................ T4-4-1
Brake Control Function ................................ T4-4-3
Brake Warning Set Pressure (Decrease) ...T4-5-34
Brake Warning Set Pressure (Increase).....T4-5-36
Parking Brake Control Function ................... T4-4-4
Swing Speed ................................................ T4-4-5
Swing Function Drift Check .......................... T4-4-6
Swing Motor Leakage .................................. T4-4-8
Maximum Swingable Slant Angle................. T4-4-9
Swing Bearing Play .................................... T4-4-10
Hydraulic Cylinder Cycle Time ................... T4-4-12
Hydraulic Cylinder Drift Check ................... T4-4-14
Control Lever Operating Control Force ...... T4-4-15
Control Lever Stroke .................................. T4-4-16
Combined Operation of Boom Raise/Swing
Function Check ........................................ T4-4-17
CEBT-4-1
(Blank)
CEBT-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedure to quantitatively check all system and functions on the machine.
Purpose of Performance Tests
1. To comprehensively evaluate each operational
function by comparing the performance test data
with the standard values.
2. According to the evaluation results, repair, adjust,
or replace parts or components as necessary to
restore the machine’s performance to the desired
standard.
3. To economically operate the machine under optimal conditions.
The machine performance does not always deteriorate
as the working hours increase. However, the machine
performance is normally considered to reduce in proportion to the increase of the operation hours. Accordingly, restoring the machine performance by repair,
adjustment, or replacement shall consider the number
of the machine’s working hours.
Definition of “Performance Standard”
1. Operation speed values and dimensions of the
new machine.
2. Operational performance of new components
adjusted to specifications. Allowable errors will be
indicated as necessary.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the operational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to evaluate the performance test data.
Precautions for Evaluation of Test Data
1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION
TESTS
FOR
PERFORMANCE
Observe the following rules in order to carry out
performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 300 m (984 ft 3 in), and to
make a full swing with the front attachment extended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among coworkers. Once the test is started, be sure to communicate with each other using these signals, and to
follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic
pipings.
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.
T4-1-2
T105-06-01-003
T212-07-01-003
OPERATIONAL PERFORMANCE TEST / Standard
PERFORMANCE STANDARD
The performance standard values are listed in the
table below.
For details including measuring method, refer to T4-3
onward.
The value indicated in parentheses is only a reference.
* The standard measurement conditions are as follows.
• Engine Control Dial: Fast Idle
• Power Mode Switch: P mode
• Auto-Idle Switch: OFF
• Work Mode: Digging mode
• Engine Speed Control Mode Selection Switch:
Dial mode
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
Performance
Standard
Descriptions
ENGINE SPEED
Remarks
min−1
T4-3-1
Slow Idle Speed
Fast Idle Speed
Fast Idle Speed (with ECO deactivated)
Fast Idle Speed (Relief operation)
900±100
1700±50
1800±50
1800±50
Value indicated on Dr. ZX.
Fast Idle Speed (E mode)
Fast Idle Speed (HP mode, Relief operation)
1600±50
2000±50
Slow Idle Speed (Pedal mode)
1100±50
Value indicated on Dr. ZX.
Arm roll-in relief control. Value
indicated on Dr. ZX.
Travel speed mode switch:
Fast speed
Brake switch: OFF or Axle lock
Jack up and measure.
Value indicated on Dr. ZX.
FNR switch: N
Brake switch: OFF, Auto axle
lock or Axle lock
Value indicated on Dr. ZX.
Travel speed mode switch:
Fast speed
Brake switch: OFF, Auto axle
lock or Axle lock
Depress the brake pedal,
perform travel relief or jack up
and measure.
Values indicated on Dr. ZX.
Value indicated on Dr. ZX.
Fast Idle Speed
accelerator)
(Pedal
mode,
Working
Fast Idle Speed (Pedal mode, Relief operation)
Auto-Idle Speed
Warming-Up Speed
ENGINE COMPRESSION PRESSURE
MPa (kgf/cm2, psi)
VALVE CLEARANCE (IN, EX)
LUBRICANT CONSUMPTION
(Rated Output)
mm
Reference
Page
1800±50
2200±50
1100±100
1400±100
3.04±0.2
(31±2, 440)
0.15
30 or less
mL/h
T4-2-1
↑
↑
Arm roll-in relief control. Value
indicated on Dr. ZX.
↑
-1
Engine speed: at 200 min
T4-3-4
With engine cold
Hour meter: 2000 hours or less
T4-3-6
T4-3-9
OPERATIONAL PERFORMANCE TEST / Standard
Performance
Standard
Descriptions
TRAVEL SPEED
km/h (100 m)
Fast
35.0
+1.0
-3.0
Slow
8.6±0.5
Creeper
2.2±0.3
SERVICE BRAKE FUNCTION
T4-4-2
Tire
lock
Tire
lock
(0)
13.1±1.0
Parking Brake
Reference
Page
T4-4-1
Engine speed control mode
selection switch: Pedal mode,
Travel speed mode switch: Fast
Engine speed control mode
selection switch: Pedal mode,
Travel speed mode switch: Slow
Engine speed control mode
selection switch: Creeper mode
N (kgf)
Service Brake
PARKING BRAKE FUNCTION mm/5 min
SWING SPEED
sec/3 rev
SWING FUNCTION DRIFT
mm/90° 720 or less
SWING MOTOR LEAKAGE
mm/5 min
0
MAXIMUM
SWINGABEL
SLANT 18 or more
ANGLE
deg.
SWING BEARING PLAY
mm
0.2 to 1.25
HYDRAULIC CYLINDER CYCLE TIME
sec
Boom Raise (Monoblock Boom)
Boom Raise (2-Piece Boom)
Boom Lower (Monoblock Boom)
Boom Lower (2-Piece Boom)
Arm Roll-In
Arm Roll-Out
Bucket Roll-In
Bucket Roll-Out
Positioning Extend
Positioning Retract
Blade Raise
Blade Lower
Outrigger Raise
Outrigger Lower
Remarks
3.0±0.3
3.6±0.3
2.8±0.3
3.0±0.3
3.3±0.3
2.7±0.3
3.5±0.3
2.4±0.3
7.4±0.5
4.5±0.4
1.5±0.3
2.0±0.3
1.9±0.3
1.9±0.3
T4-2-2
Bucket: empty
Bucket: empty
T4-4-3
T4-4-4
T4-4-5
Bucket: loaded
Bucket: loaded
T4-4-7
T4-4-8
Allowable limit: 2.0 to 3.05
2.52 m arm
3
0.3 m (PCSA heaped) bucket,
Bucket: empty
T4-4-9
T4-4-10
OPERATIONAL PERFORMANCE TEST / Standard
Performance
Standard
Descriptions
DIG FUNCTION DRIFT
2.52 m arm
3
0.3 m (PCSA heaped)
bucket, bucket loaded
mm/5 min
(Maximum Reach Position)
Boom Cylinder
Arm Cylinder
Bucket Cylinder
Positioning Cylinder
Front Drift Amount (Bucket Bottom)
T4-4-13
N (kgf)
Right Lever: Forward/Backward
Right Lever: Right/Left
Left Lever: Forward/Backward
Left Lever: Right/Left
Steering Wheel Turns (lock-to-lock)
COMBINED OPERATION
RAISE/SWING
Bucket Teeth Height: H
15 (1.5) or less
15 (1.5) or less
15 (1.5) or less
15 (1.5) or less
20 (2.0) or less
T4-4-14
mm
Right Lever: Forward/Backward
Right Lever: Right/Left
Left Lever: Forward/Backward
Left Lever: Right/Left
Steering Wheel Turns (lock-to-lock)
OF
Reference
Page
T4-4-12
5 or less
10 or less
15 or less
15 or less
100 or less
CONTROL LEVER OPERATING FORCE
CONTROL LEVER STROKE
Remarks
74±10
68±10
74±10
68±10
7.0±0.5
BOOM
sec
3.6±0.3
mm
5500 or more
T4-2-3
2.52 m arm
T4-4-15
3
0.3 m (PCSA heaped)
bucket, Bucket: empty
OPERATIONAL PERFORMANCE TEST / Standard
Performance Standard
Descriptions
Reference
Page
Remarks
HYDRAULIC SYSTEM
PRIMARY PILOT PRESSURE
T4-5-1
MPa (kgf/cm2, psi)
Fast Idle
+1.0
-0.5
+145
581 -73)
4.0
+10
(41 -5,
SECONDARY PILOT PRESSURE
(For Fast Idle, Slow Idle)
3.3 to 3.9
(34 to 40,
480 to 567)
MPa (kgf/cm2, psi)
STEERING PUMP PRESSURE
MPa (kgf/cm2, psi)
SOLENOID VALVE SET PRESSURE
Value indicated on
Dr. ZX.
(Control lever: Full
stroke)
1.5±1.0
(15±10, 218±145)
T4-5-4
MPa (kgf/cm2, psi)
(Value of Dr. ZX) ±0.2
(2, 29)
Solenoid Valve Unit Set Pressure
MAIN PUMP DELIVERY PRESSURE
MPa (kgf/cm , psi)
MAIN
RELIEF
PRESSURE
VALVE
RELIEF
+1.2
34.3 -0.8
+175
4980 -115)
T4-5-6
Value indicated on
Dr. ZX.
MPa (kgf/cm2, psi)
+2.3
33.4 -0
+335
4860 -0)
+2.0
35.3 -0
+20
+290
(360 -0, 5130 -0)
+2.0
28.0 -1.5
+20
+290
(285 -15, 4070 -220)
+2.0
28.0 -0.5
+20
+290
(285 -5, 4070 -73)
+23
(340 -0,
Relief operation of travel
Relief operation of blade/outrigger raise
Relief operation of blade/outrigger lower
RELIEF
Value indicated on
Dr. ZX.
In neutral, Value
indicated on Dr. ZX
T4-5-8
+12
(350 -8,
Relief operation of swing
OVERLOAD
PRESSURE
+10
(10 -5.0,
MPa (kgf/cm2, psi)
Boom, Arm, Bucket (Relief operation for each)
RELIEF PRESSURE
+1.0
-0.5
+145
145 -73)
1.0
2
T4-5-3
VALVE
RELIEF
Value indicated
Dr. ZX.
Value indicated
Dr. ZX.
Value indicated
Dr. ZX.
Value indicated
Dr. ZX.
on
T4-5-10
on
on
on
T4-5-12
MPa (kgf/cm2, psi)
Boom (lower), Arm (roll-in), Bucket (roll-in),
Blade/Outrigger (raise/lower)
Boom (raise), Arm (roll-out), Bucket (roll-out)
37.2 (379, 5410)
Auxiliary
28.0 (285, 4070)
39.2 (400, 5700)
T4-2-4
(Reference values
at 50 L/min)
(Reference values
at 50 L/min)
(Reference values
at 135 L/min)
OPERATIONAL PERFORMANCE TEST / Standard
Descriptions
Performance Standard
MAIN PUMP FLOW RATE
L/min
SWING MOTOR DRAINAGE
L/min
-
With constant speed
With motor relieved
Remarks
Refer to T4-2-6.
0.2 to 0.3
(2 to 5)
TRAVEL MOTOR DRAINAGE
Reference
Page
T4-5-14
T4-5-24
L/min
With machine raised
With motor relieved
STEERING VALVE RELIEF PRESSURE
MPa kgf/cm2, psi)
BRAKE PRESSURE (FRONT/REAR)
(including work brake operating pressure)
Contact Hitachi
Construction
Machinery.
Contact Hitachi
Construction
Machinery.
17.5±1.0
(179±10, 2540±145)
7.0±1.0
(70±10, 1020±145)
T4-5-26
Value indicated on
Dr. ZX.
T4-5-28
T4-5-30
MPa (kgf/cm2, psi)
BRAKE ACCUMULATOR PRESSURE
MPa kgf/cm2, psi)
BRAKE ALARM PRESSURE
Decrease
Increase
17.7±1.0
(181±10, 2570±145)
T4-5-32
8.3±0.3
(85±3, 1210±44)
9.0±0.3
(92±3, 1310±44)
T4-5-34
MPa (kgf/cm2, psi)
T4-2-5
T4-5-36
OPERATIONAL PERFORMANCE TEST / Standard
MAIN PUMP P-Q DIAGRAM
• Hydraulic P-Q Control (Torque Control)
(NOTE: Measured at Test Stand)
• Rated Pump Speed: 2200 min-1 (rpm)
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
NOTE: Refer to T4-5-14.
P-Q Point
A
Delivery Pressure
2
MPa (kgf/cm , psi)
Flow Rate
L/min (gpm)
3.9 (40, 570)
Pump 1: 220±3
(58.0±0.8)
A’
3.9 (40, 570)
Pump 2: 165±3
(43.5±0.8)
B
11.8 (120, 1720)
Pump 1: [218 (57.5)]
B’
16.7 (170, 2430)
Pump 2: [163 (43.0)]
C
18.6 (190, 2700)
147±6 (38.8±1.6)
D
20.6 (210, 2990)
[125 (33.0)]
E
22.5 (230, 3270)
110±6 (29.0±1.6)
F
34.3 (350, 4990)
53±10 (14.0±2.6)
The value indicated in parentheses is only a reference.
L/min
A
A’
B
B’
C
D
Flow Rate
E
F
Delivery Pressure
T4-2-6
MPa (kgf/cm 2 )
TCEB-04-02-001
OPERATIONAL PERFORMANCE TEST / Standard
• P-Q Control by Pump Control Pilot Pressure
Signal
(NOTE: Measured at Test Stand)
• Rated Pump Speed: 2200 min-1 (rpm)
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
NOTE: Refer to T4-5-16.
P-Q Point
Pump Control Pressure
2
MPa (kgf/cm , psi)
Flow Rate
L/min (gpm)
Pump 1: 91±2
A
1.9±0.05
(24.0±0.5)
(19±0.5, 276±7.3)
Pump 2: 70±2
(18.5±0.5)
B
C
3.4±0.05
129±8
(35±0.5, 494±7.3)
(34.0±2.1)
Pump 1: 220±3
(58.0±0.8)
Pump 2: 165±3
(43.5±0.8)
2.9+0.05−0.29
(30 −3, 422+7.3−42.2)
+0.5
NOTE: B: With flow rate limit control
C: Without flow rate limit control
L/min
C
B
Flow Rate
A
Pump Control Pressure
MPa (kgf/cm 2 , psi)
T1T1-04-02-001
T4-2-7
OPERATIONAL PERFORMANCE TEST / Standard
SENSOR ACTIVATING RANGE
1. Measuring Method
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
• Unless specified:
Engine
Control Dial
Fast Idle
Speed
Power
Mode
Switch
P
Work
Mode
Auto-Idle
Switch
Digging
mode
OFF
• Monitor each sensor by using Dr. ZX.
2. Sensor Activating Range
Item
Operation
Engine
Slow Idle
Control
Fast Idle
Dial
Control lever: Neutral position
Pressure Sensor
Pilot shut-off lever: LOCK position
(Boom Raise,
Control lever: Full stroke
Arm Roll-In, Swing)
Pilot shut-off lever: UNLOCK position
Control Lever: Neutral position
Pilot shut-off lever: LOCK position
Pressure Sensor
(Travel)
Control lever: Full stroke
Pilot shut-off lever: UNLOCK position
Pump
Control lever: Neutral position
Control Pressure
Sensor
Control lever: Full stroke
Travel N Sensor
20 °C (GND to SIGNAL)
T4-2-8
Standard
0.3 to 1.0 V
4.0 to 4.7 V
0 to 0.1 MPa
(0 to 1.0 kgf/cm2, 0 to 14.5 psi)
3.3 to 3.9 MPa
(34 to 40 kgf/cm2, 480 to 570 psi)
0 to 0.1 MPa
(0 to 1.0 kgf/cm2, 0 to 14.5 psi)
2.7 to 3.3 MPa
(28 to 34 kgf/cm2, 390 to 480 psi)
0.7 to 1.3 MPa
(7 to 13 kgf/cm2, 100 to 190 psi)
2.9 to 3.9 MPa
(30 to 40 kgf/cm2, 420 to 570 psi)
810 ± 240 Ω
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary:
1. Measure the engine speed by using the monitor
unit or Dr. ZX.
2. Measure the engine speeds in each mode.
NOTE: If the engine speed is not adjusted correctly,
all other performance data will be unreliable.
Consequently, measure the engine speed
before performing all other tests in order to
check that the engine speed meets
specification.
Preparations:
1. Select the service menu of monitor (In case of Dr.
ZX, install Dr. ZX first).
2. Warm up the machine until coolant temperature
reaches 50 °C (122 °F) or more, and hydraulic oil
temperature is 50±5 °C (122±9 °F).
T4-3-1
OPERATIONAL PERFORMANCE TEST / Engine Test
Measurement:
1. Measure the engine speeds in the "dial mode" and
"pedal mode" positions for the engine speed
control mode selection switch.
2. When measuring, set the switch and test condition
as shown in the table below in response to the
engine speed to be measured.
Remedy:
Refer to Troubleshooting B in Group T5-7.
NOTE: ECO stands for the auto engine speed
-1
reduction system by 100 min .
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
•
Engine Speed Control Mode Selection Switch: Dial mode
Engine
Power
AutoItem
Control
Mode
Idle
Work Mode
Dial
Switch
Switch
Slow Idle
Digging
Slow Idle
P
OFF
mode
Fast Idle
(with ECO
Digging
Fast Idle
P
OFF
deactivated)
mode
Fast Idle
(Heater control
OFF)
Fast Idle
(Relief operation)
Fast Idle
(E mode)
Fast Idle
(HP mode)
Auto-Idle
Digging
mode
Fast Idle
P
OFF
Fast Idle
P
OFF
Fast Idle
E mode
OFF
Fast Idle
HP mode
OFF
Fast Idle
P
ON
Digging
mode
Slow Idle
P
OFF
Digging
mode
Warming-Up
T4-3-2
Digging
mode
Digging
mode
Digging
mode
Test Conditions
Lever in neutral.
Check in the Dr. ZX special
functions with ECO deactivated.
Measure engine speed with the
lever in neutral.
Move the pilot shut-off lever to the
UNLOCK position. Measure engine
speed with the lever in neutral.
Measure engine speed while
relieving the boom raise circuit.
Lever in neutral.
Measure engine speed while
relieving the boom raise circuit.
Measure engine speed 4 seconds
after returning all control levers to
neutral.
Engine speed can be measured
only when hydraulic oil
temperature is 0 °C (32 °F) or less.
OPERATIONAL PERFORMANCE TEST / Engine Test
•
Engine Speed Control Mode Selection Switch: Pedal mode
Accelerator Power Mode
Auto-Idle
Work
Pedal
Switch
Switch
Mode
Test Conditions
•
Slow Idle
Not
depressed
P
Digging •
mode
OFF
•
Fast Idle
Fast Idle
(Relief
operation)
Max.
depressing
Max.
depressing
P
Digging •
mode •
OFF
P
Brake switch:
OFF or Axle lock
Engine control dial: Slow
FNR switch: N
Work brake: Operable
•
Travel speed mode switch: Fast
•
Brake switch:
Digging
mode •
OFF
FNR switch: (F or R)
•
OFF or Axle lock
Raising Machine
Travel operation with brake
depressed
Method Raising Machine:
As for a machine attached with an outrigger or a blade
in front and rear of the chassis, raise the machine off
the ground by using the outrigger or blade.
CAUTION: Securely support the raised
machine by using the blocks.
As for a machine attached with an outrigger or a blade
only in rear of the chassis, raise the machine by using
a front attachment as illustrated in the right.
Switch Panel:
T1F3-04-02-002
Monitor Unit:
Engine Control
Dial
Digging Mode
Travel Speed
Mode Switch
Engine Speed
Control Mode
Selection Switch
Power Mode
Switch
Auto-Idle
Switch
TCJB-04-03-001
TCJB-05-02-064
T4-3-3
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders
and check for a decline in engine power.
2. Check exhaust gas color. Keep track of engine oil
consumption.
3. Check for abnormalities in the intake system,
including the air filter.
Preparation:
1. Confirm that valve clearances are correct.
2. Confirm that the batteries are charged properly.
3. Run the engine until the coolant temperature
gauge reaches the operating range.
4. Remove the negative terminal of the battery.
Remove all the glow plugs from each cylinder.
： 20 N⋅m (2.0 kgf⋅m, 14.8 lbf⋅ft)
IMPORTANT: If disconnecting the connector of
injector, fuel cannot be jetted.
Therefore, ECM judges that the fuel
system is faulty and the fault code is
displayed.
After
measurement,
delete the displayed fault code.
Injector
5. Disconnect the connector of injector.
6. Install the negative terminal of the battery.
7. Turn the starter. Exhaust foreign subjects from the
cylinder.
8. Install a pressure gauge and an adaptor (Isuzu
5-8840-2815-0) to the glow plug mounting part.
(Sufficiently install them in order to prevent air
leakage.)
Glow Plug
T1T1-04-03-001
Measurement:
1. Turn the starter and measure compression
pressure of each cylinder.
2. Repeat the measurement three times and
calculate the mean values.
Evaluation:
Refer to OERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Remedy:
Refer to the engine shop manual.
T1T1-04-03-002
T4-3-4
OPERATIONAL PERFORMANCE TEST / Engine Test
(Blank)
T4-3-5
OPERATIONAL PERFORMANCE TEST / Engine Test
VALVE CLEARANCE
Injector
Summary:
1. Perform the measurement when the engine is
cold.
2. Before starting any work, clean the head cover
mounting area and avoid contamination in the
engine.
Preparation:
1. Disconnect the connector of inject.
2. Remove the leak off hose.
3. Remove the head cover.
4. Rotate the crank pulley. Align the top dead center
(TDC) mark on crank pulley with the top mark
located on timing gear case.
T1T1-04-03-001
Leak Off Hose
NOTE: When rotating the crank pulley, remove the
fan guard. Then, rotate the fan while
holding the fan belt. If it is difficult to rotate,
remove all glow plugs and release
compression pressure.
Crank Pulley
5. Check if cylinder No.1 (or cylinder No.4) is now
positioned at the TDC in the compression stroke.
NOTE: When both intake and exhaust valve are
closed, this cylinder is positioned at TDC in
the compression stroke.
6. Start measurement from the cylinder No.1 (or
cylinder No.4) positioned at TDC in the
compression stroke.
T4-3-6
Top Mark
T1T1-04-03-003
TDC Mark
OPERATIONAL PERFORMANCE TEST / Engine Test
Measurement:
1. Insert a thickness gauge into the clearance
between rocker arm roller and cam shaft and
measure the valve clearance.
A
A
A
NOTE: The cylinders are aligned from No.1 to
No.4 in that order, as viewed from the fan
side. Injection Order: 1-3-4-2
A
A
A
2. When measurement is started from No.1 cylinder,
perform the same measurement to all valves
indicated with the mark “ ” in the table below.
(When measurement is started from No.4 cylinder,
perform the measurement in the valves shown
with mark “×”.)
A
○
Cylinder No.
Valve locations
When the measurement is
started from No.1 cylinder
When the measurement is
started from No.4 cylinder
No.1
I
E
No.2
I
E
A
T1T1-04-03-006
No.3
I
E
○ ○ ○
No.4
I
E
○
×
×
3. Rotate the crankshaft 360°. Align the TDC mark
with the pointer. Continue measurement of other
valves in the same way.
×
×
Section A
Valve Clearance
Caam Shaft
Valve Clearance
Evaluation:
Refer to OERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
T1T1-04-03-005
Rocker Arm Roller
T4-3-7
OPERATIONAL PERFORMANCE TEST / Engine Test
Adjustment:
If the measurement results are out of specification,
adjust the valve clearance in the same order of
measurement.
1. Loosen the lock nuts (16 used) and adjusting
screws (16 used), which secure the rocker arm by
using adjust nut wrench (Isuzu 5-8840-2822-0).
2. Insert a thickness gauge into the clearance
between rocker arm roller and cam shaft.
3. Tighten the adjusting screw of rocker arm until
condition for the thickness gauge is proper.
4. Tighten the lock nut of rocker arm.
: 18 N⋅m (1.8 kgf⋅m, 13.2 lbf⋅ft)
5. Check the valve clearance after the lock nuts are
tightened.
Cam Shaft
Thickness
Gauge
Adjust Nut Wrench
Valve Clearance
Rocker Arm
Cam Shaft
T1T1-04-03-004
Valve Clearance
T1T1-04-03-005
Rocker Arm Roller
T4-3-8
OPERATIONAL PERFORMANCE TEST / Engine Test
LUBRICANT CONSUMPTION
Measuring Method
1. Place the machine on level firm ground and leave
the machine for at least one hour in order to let
the lubricant lower to the oil pan when the engine
stops.
At this time, confirm that the machine is level by
using a leveler.
2. Record read-out A (unit: hour) of the hour meter.
3. Replenish the lubricant up to the high-level
gauge.
4. Operate the machine for at least 100 hours or
until the oil level lowers to the low-level gauge.
IMPORTANT: Keep the machine-leaving time in
Step 1 above.
5. Place the machine on level firm ground and leave
the machine for at least one hour in order to let
the lubricant lower to the oil pan when the engine
stops.
At this time, confirm that the machine is level by
using a leveler.
6. Record read-out B (unit: hour) of the hour meter.
7. Replenish the lubricant up to the high-level gauge
while measuring the oil-replenishing volume C.
NOTE: When measuring, use a high-precision
measuring cylinder or the like.
8. Determine lubricant
following equation:
consumption
from
the
Oil replenishing volume (C) [mL] / Operating hours
(B-A) [hr]
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
T4-3-9
OPERATIONAL PERFORMANCE TEST / Engine Test
(Blank)
T4-3-10
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
1. Measure the time required for the excavator to
travel a 100 m (328 ft) test track and check the
performance of travel device systems (from main
pump to travel motor).
Preparation:
CAUTION: Set the swing lock lever to the
LOCK position while traveling.
1. Adjust pressure of all tires equally.
2
Pressure: 650 kPa (6.5 kgf/cm , 94 psi)
2. Prepare a flat and solid test track 100 m (328 ft)
long, with an extra length of 400 m (1310 ft) on
both ends of the test track for machine
acceleration and deceleration.
NOTE: If it is difficult to prepare a test track 400 m
(1310 ft) long, set the travel speed mode
switch to slow idle before measurement.
NOTE: When measuring travel speed at slow idle
or creeper speed, prepare a test track 200
m (656 ft) long.
3. Position the front attachment as illustrated in the
operator’s manual.
4. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
T4-4-1
End
100 m
Start
Acceleration Zone
400 m
T1F3-04-04-003
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
CAUTION: Do not measure travel speed
when traveling in reverse. (FNR Switch: F)
1. Measure at fast, slow and creeper speed.
2. Select the following switch positions:
Engine Travel Speed Engine Speed Control Accelerator Power Mode
Auto-Idle
Work Mode
Switch
Control Dial Mode Switch Mode Selection Switch
Pedal
Switch
Max.
Fast
Slow idle
Fast
Pedal mode
P
Digging mode
OFF
depressing
Max.
Slow
Slow idle
Slow
Pedal mode
P
Digging mode
OFF
depressing
Max.
Creeper Slow idle
Slow
Creeper mode
P
Digging mode
OFF
depressing
3. Turn the FNR switch to the F (forward) position.
Depress the accelerator pedal to full stroke and
travel the machine from the acceleration zone.
4. Measure travel speed (second) in each mode.
5. Repeat the measurement three times. Calculate
the average values.
6. Convert the measured values to km/h.
Measured value (second) = S (sec)
Converted value (km per hour) = A (km/h)
A=
100 × 3600
S ×1000
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B
in Group T5-7.
T4-4-2
OPERATIONAL PERFORMANCE TEST / Excavator Test
BRAKE CONTROL FUNCTION
Summary:
1. Check the performance of hydraulic brake circuit
and brake.
2. Brake control function is the safety item. Carry out
the performance test of brake certainly.
Preparation:
1.
2.
3.
4.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B
in Group T5-7.
CAUTION: Set the swing lock lever to the
LOCK position while traveling.
Adjust pressure of all tires equally.
2
Pressure: 650 kPa (6.5 kgf/cm , 94 psi)
Prepare a dry and paved test track 200 m (656 ft)
long (acceleration zone 100 m (328 ft) and test
track 100 m (328 ft)). Determine the brake start
position.
Position the front attachment as illustrated in the
operator’s manual.
Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
Stop Position
CAUTION: Do not measure travel speed
when traveling in reverse. (FNR Switch: F)
Stop Distance
Brake
Start Position (100 m Position)
1. Measure travel speed in fast idle.
2. Select the following switch positions:
Travel Speed
Mode Switch
3.
4.
5.
6.
T1F3-04-04-004
Engine Speed Control
Mode Selection Switch
Accelerator
Pedal
Max.
Fast
Pedal
depressing
Turn the FNR switch to the F (forward) position.
Depress the accelerator pedal to full stroke and
travel the machine at fast.
Depress the brake pedal at the brake start
position and stop the machine completely.
Measure the distance from the brake start position
to the tread of a front tire.
Repeat the measurement three times. Calculate
the average values.
T4-4-3
Power Mode
Switch
Work Mode
Auto-Idle
Switch
P
Digging
mode
OFF
OPERATIONAL PERFORMANCE TEST / Excavator Test
PARKING BRAKE CONTROL FUNCTION
Summary:
1. Measure the parking brake function on a specified
slope.
2. Brake control function is the safety item. Carry out
the performance test of brake certainly.
Preparation:
1. The surface of test slope shall be even paved
road with a gradient (11.31°).
2. Position the front attachment as illustrated in the
operator’s manual.
3. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Climb a slope and set the brake switch to the P
(parking brake) position.
2. Stop the engine.
3. After the machine stops, put the mark (white line)
on the tire and slope.
4. After 5 minutes, measure the distance between
marks (white line) on the tire and slope.
T1F3-04-04-005
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
T4-4-4
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING SPEED
Summary:
Measure the time required to swing three complete
turns and check the performance of swing device
systems (from main pump to swing motor).
Preparation:
1. Check lubrication of the swing gear and swing
bearing.
2. Place the machine on flat, solid ground with
ample space for swinging. Do not conduct this test
on a slope.
3. With the arm cylinder fully retracted and the
bucket cylinder fully extended, hold the bucket so
that the height of the boom foot pin is the same as
the arm tip pin. (The bucket must be empty.)
4. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
Height of the boom
foot pin is the
same as the
arm tip pin
T1F3-04-04-006
CAUTION: Prevent personal injury. Always
make sure that the area is clear and that
co-workers are out of the swing area before
starting the measurement.
Measurement:
1. Select the following switch positions:
Engine
Power Mode
Work
Auto-Idle
Control Dial
Switch
Mode
Switch
Digging
Fast idle
P
OFF
mode
2. Operate the swing control lever fully.
3. Measure the time required to swing three turns in
one direction.
4. Measure for the right and left swing.
5. Repeat the measurement three times. Calculate
the average values.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B
in Group T5-7.
T4-4-5
Brake Switch
Work Brake
Axle lock or
Auto axle lock
Operable
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING FUNCTION DRIFT CHECK
Summary:
1. Measure the swing drift on swing bearing outer
circumference when stopping after a 90°
full-speed swing and check the performance of
swing brake valve.
2. The mechanical brake for swing parking brake is
equipped for the swing motor.
Preparation:
1. Check lubrication of the swing gear and swing
bearing.
2. Place the machine on flat, solid ground with
ample space for swinging. Do not conduct this test
on a slope.
3. With the arm cylinder fully retracted and the
bucket cylinder fully extended, hold the bucket so
that the height of the boom foot pin is the same as
the arm tip pin. (The bucket must be empty.)
4. Put the matching marks on the swing bearing
outer circumference (upperstructure side) and the
chassis.
5. Set the marks on swing bearing and chassis with
an angle of 90°.
6. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
Put the matching marks on swing
bearing outer circumference and
chassis.
T202-07-03-005
Before starting the measurement,
swing the upperstructure 90°
CAUTION: Prevent personal injury. Always
make sure that the area is clear and that
co-workers are out of the swing area before
starting the measurement.
T1F3-04-04-007
T4-4-6
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Select the following switch positions:
Engine
Power Mode
Work
Auto-Idle
Control Dial
Switch
Mode
Switch
Digging
Fast idle
P
OFF
mode
2. Operate the swing control lever fully. Return the
swing control lever to the neutral position when
the mark on upperstructure aligns with that on
chassis after swinging 90°.
3. After the upperstructure stops, measure the
distance between the marks along swing bearing
outer circumference and chassis.
4. Measure for the right and left swing.
5. Repeat the measurement three times. Calculate
the average values.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B
in Group T5-7.
T4-4-7
Brake Switch
Work Brake
Axle lock or
Auto axle lock
Operable
Measure the distance between the marks.
Mark on Chassis
Mark on Swing Bearing
T105-06-03-010
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING MOTOR LEAKAGE
Summary:
1. Measure the upperstructure drift while keeping the
upperstructure with an angle of 90° relative to the
slope on a 15±1° slope and check the
performance of swing parking brake.
(The mechanical brake for swing parking brake is
equipped for the swing device.)
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B
in Group T5-7.
Preparation:
1. Check lubrication of the swing gear and swing
bearing.
2. Load a specified weight 750 kg (1660 lb) into the
bucket.
3. With the arm cylinder fully retracted and the
bucket cylinder fully extended, hold the bucket so
that the height of the boom foot pin is the same as
the arm tip pin.
4. The test slope angle shall be flat with a gradient
(15±1°).
5. Climb a slope and swing the upperstructure to
position it 90° relative to the slope. Put the
matching marks on the outer circumference of
swing bearing (upperstructure side) and chassis
by using the tape.
6. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Select the following switch positions:
Engine
Power Mode
Work
Auto-Idle
Control Dial
Switch
Mode
Switch
Digging
Slow idle
P
OFF
mode
2. Maintain the engine at slow idle. After five minutes,
measure the distance between the marks along
swing bearing outer circumference and chassis.
3. Measure on the right and left swing.
4. Repeat the measurements three times. Calculate
the average values.
T212-07-03-001
Brake Switch
Work Brake
Axle lock or
Auto axle lock
Operable
Measure the distance between the marks.
Mark on Chassis
Mark on Swing Bearing
T105-06-03-010
T4-4-8
OPERATIONAL PERFORMANCE TEST / Excavator Test
MAXIMUM SWINGABLE SLANT ANGLE
CAUTION: As the machine may turn over
during swing operation, turn the brake switch
to the Axle Lock or Auto Axle Lock position.
Summary:
1. With the upperstructure swing 90° relative to the
slope, check the maximum slant angle on which
the upperstructure can swing to the uphill side.
Preparation:
1. Check lubrication of the swing gear and swing
bearing.
2. Load a specified weight 750 kg (1660 lb) into the
bucket.
3. With the arm cylinder fully retracted and the
bucket cylinder fully extended, hold the bucket so
that the height of the boom foot pin is the same as
the arm end pin.
4. Climb a slope and swing the upperstructure 90°
relative to the slope.
5. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
T212-07-03-001
Measurement:
1. Select the following switch positions:
Engine
Power Mode
Work
Auto-Idle
Control Dial
Switch
Mode
Switch
Digging
Fast idle
P
OFF
mode
2. Operate the swing control lever to full stroke and
swing the upperstructure to the uphill side.
3. If the machine can swing, measure the cab floor
slant angle.
4. Increase the slope angle. Measure for the right
and left swing.
5. Repeat the measurement three times.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B
in Group T5-7.
T4-4-9
Brake Switch
Work Brake
Axle lock or
Auto axle lock
Operable
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING BEARING PLAY
Summary:
1. Measure the swing bearing play between inner
race and outer race and check the wear of swing
bearing races and balls.
Dial Gauge
Preparation:
1. Check the swing bearing mounting bolts for
looseness.
2. Check lubrication of the swing bearing. Check that
the swing bearing rotation is smooth and without
noise.
3. Secure a dial gauge on the round trunk of chassis
by using a magnetic base.
4. Position the upperstructure in the same direction
as traveling the chassis.
5. Position the dial gauge so that its needle point
comes into contact with the bottom surface of
swing bearing outer race.
6. The bucket must be empty.
Magnetic
Base
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 swing
bearing as possible.
Measurement:
1. With the arm cylinder fully retracted and the
bucket cylinder fully extended, hold the bucket
100 mm above the ground. Record dial gauge
reading (h1).
2. Lower the bucket to the ground and raise the front
idler 0.5 m (20 in) by using the front attachment.
Record dial gauge reading (h2).
3. Calculate swing bearing play (H) from these data
(h1 and h2) as follows:
[H]=[h2]ー[h1]
T202-07-03-008
Dial Gauge
Round Trunk
Magnetic
Base
T105-06-03-015
Measurement [h 1]
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
100 mm
T212-07-05-003
Measurement [h 2]
T1F3-04-04-008
T4-4-10
OPERATIONAL PERFORMANCE TEST / Excavator Test
(Blank)
T4-4-11
OPERATIONAL PERFORMANCE TEST / Excavator Test
HYDRAULIC CYLINDER CYCLE TIME
Summary:
1. Measure the cycle time of boom, arm, bucket,
blade (optional) and outrigger (optional) cylinders
and check the performance of front attachment
systems (from main pump to each cylinder).
2. The bucket must be empty.
Preparation:
1. Measure at the position as follows.
1-1. Measurement of the cycle time of boom
cylinders:
With the arm cylinder fully retracted and the
bucket cylinder fully extended, lower the bucket
on to the ground.
Boom Cylinder:
1-2. Measurement of the cycle time of arm cylinder:
Retract or extend the bucket cylinder so that the
arm and bucket teeth are vertical to the ground.
Set the arm so that the center of arm operation
is vertical.
1-3. Measurement of the cycle time of bucket
cylinder:
Adjust each cylinder of boom and arm so that
the center of bucket full stroke is vertical.
T202-07-03-012
Arm Cylinder:
1-4. Measurement of the cycle time of blade
cylinders:
Raise the machine by using the front
attachment in order to be able to move the
blade cylinder to fully stroke.
1-5. Measurement of the cycle time of outrigger
cylinders:
Raise the machine by using the front
attachment in order to be able to move the
outrigger cylinder to fully stroke.
0.5 m
2. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
T1V1-04-05-005
Bucket Cylinder:
T105-06-03-018
T4-4-12
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Select the following switch positions:
Engine
Power Mode
Auto-Idle
Work Mode
Work Brake
Control Dial
Switch
Switch
Digging
Fast idle
P
OFF
Operable
mode
2. Measure the cylinder cycle times as follows.
(Cylinder full stroke includes cylinder cushioning
Blade Cylinder:
zone.)
1-1. Boom cylinder:
Operate the boom control lever to full stroke.
Measure the time to raise and lower the boom.
1-2. Arm cylinder:
Operate the arm control lever to full stroke.
Measure the time to roll in and roll out the arm.
1-3. Bucket cylinder:
Operate the bucket control lever to full stroke.
Measure the time to roll in and roll out the
bucket.
1-4. Blade cylinder:
Operate the blade control lever to full stroke.
Measure the time to raise and lower the blade.
1-5. Outrigger cylinder:
TCJB-04-04-001
Operate the outrigger control lever to full stroke.
NOTE: The illustration shows the rear blade.
Measure the time to raise and lower the
outrigger. Measure the time for the cylinders
one by one.
Outrigger Cylinder:
3. Repeat the measurement three times. Calculate
the average values.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B
in Group T5-7.
T4-4-13
TCJB-04-04-002
NOTE: The illustration shows the rear outrigger.
OPERATIONAL PERFORMANCE TEST / Excavator Test
HYDRAULIC CYLINDER DRIFT CHECK
• Maximum Reach Position
Summary:
1. Load a specified weight into the bucket. Measure
the cylinder rod drift and judge oil leakage in the
boom, arm and bucket cylinders, and the control
valve.
2. When measuring the drift just after cylinder
replacement, slowly operate the cylinder for ten
minutes and bleed air from the cylinder.
Preparations:
1. Load a specified weight 750 kg (1660 lb) into the
bucket.
2. With the arm cylinder fully retracted and the
bucket cylinder fully extended, hold the bucket so
that the height of the boom foot pin is the same as
the arm tip pin.
3. Position the arm and buckets cylinders with the
rod 50 mm (2 in) retracted from the fully extended
position.
4. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in position of bottom of the
bucket, as well as the boom, arm and bucket
cylinders.
3. Repeat the measurement three times. Calculate
the average values.
Extended Distance
Retracted Distance
Retracted
Distance
Height of the
boom foot pin is
the same as the arm tip pin.
Drift Amount
T1F3-04-04-011
Boom and Bucket Cylinder Retraction
Mark Mark
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
T110-06-03-002
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B
in Group T5-7.
Arm Cylinder Extension
Mark
T110-06-03-001
T4-4-14
OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER OPERATING CONTROL FORCE
Summary:
1. Measure a play and operating condition of each
control lever.
2. Measure the maximum operating force of front
attachment control lever.
3. Measure the operating force at the grip center of
each control lever.
Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
CAUTION: Prevent personal injury. Always
make sure that the area is clear and that
co-workers are out of the swing area before
starting the measurement.
T107-06-03-003
Knob
Measurement:
1. Measure for each control lever.
2. Select the following switch positions:
Engine
Control Dial
4.
5.
6.
7.
Work Mode
Auto-Idle
Switch
Work Brake
OFF
Operable
Digging
mode
In case of boom (raise), arm and bucket control
lever, measure the maximum operating force for
each with each actuator relieved.
In case of boom (lower) control lever, measure the
maximum operating force with the boom (lower)
relieved by raising the machine in a safe area.
In case of swing control lever, measure the
maximum operating force with swing relieved after
securing the front attachment to prevent swinging.
In case of handle, measure the maximum
operating force by using a spring balance
attached to knob.
Repeat the measurement three times. Calculate
the average values.
Fast idle
3.
Power Mode
Switch
TCJB-04-04-003
P
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
T4-4-15
OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER STROKE
Summary:
1. Check a play and operating condition of each
control lever and measure the stroke.
2. Measure the control lever stroke at the grip center
of each control lever.
3. In case control lever stroke play is present in the
neutral position, add half (1/2) the play present to
both side control lever strokes.
Preparations:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Stop the engine.
2. Measure each control lever stroke from neutral to
the stroke end of each control lever of boom, arm,
bucket, swing and travel.
3. Measure the number of rotation of handle from
right to left stroke end and from left to right stroke
end.
4. Measure the straight dimension.
5. Repeat the measurement three times. Calculate
the average values.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
T4-4-16
Stroke
Stroke
Neutral
T1F3-04-04-012
OPERATIONAL PERFORMANCE TEST / Excavator Test
COMBINED OPERATION OF BOOM RAISE
/ SWING FUNCTION CHECK
Summary:
1. Check boom raise and swing movement and
speeds
while
operating
both
functions
simultaneously.
2. Check that the cylinders do not hesitate while
operating the cylinder with the engine running at
fast.
Preparation:
1. With the arm cylinder fully retracted and the
bucket cylinder fully extended, lower the bucket
onto the ground. (The bucket must be empty.)
2. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
T212-07-03-005
CAUTION: Prevent personal injury. Always
make sure that the area is clear and that
co-workers are out of the swing area before
starting the measurement.
Measurement:
T212-07-03-006
1. Select the following switch positions:
Engine
Power Mode
Work Mode
Control Dial
Switch
Digging
Fast idle
P
mode
2. Raise the boom and roll the swing in full stroke at
the same time. When the upperstructure rotates
90°, release the control levers to stop both
functions. Measure the time required to swing 90°
and height (H) of the bucket teeth. (The bucket
must be empty.)
3. Repeat the measurement three times. Calculate
the average values.
Auto-Idle
Switch
Work Brake
OFF
Operable
H
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B
in Group T5-7.
T4-4-17
90°
T212-07-03-007
OPERATIONAL PERFORMANCE TEST / Excavator Test
(Blank)
T4-4-18
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Stop the engine.
2. Push the air bleed valve of the oil supply cap and
release any remaining pressure.
3. Remove the plug from the pilot filter. Install
adapter (ST 6069) and pressure gauge (ST 6942)
to the pressure check port.
: 14 mm
4. Start the engine. Check for any oil leaks at the
pressure gauge connection.
5. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Select the following switch positions.
Power
Engine
Auto-Idle
Mode
Work Mode
Control Dial
Switch
Switch
Digging
Fast idle
P
OFF
mode
Digging
Slow idle
P
OFF
mode
2. Measure pilot pressure in each specified setting
above without load by using a pressure gauge.
3. Repeat the measurement three times. Calculate
the average values.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
T4-5-1
Plug
T178-03-07-001
OPERATIONAL PERFORMANCE TEST / Component Test
Primary Pilot Pressure Adjustment Procedure
Adjustment:
Adjust the relief valve set pressure if necessary.
Relief Valve
1. Remove plug (1) from the relief valve.
: 22 mm
2. Install the estimated number of shims (2).
3. After adjustment, tighten plug (1).
+2
+0.2
+1.5
: 25 N⋅m (2.5
kgf⋅m, 18.4
lbf·ft)
4. After adjustment, check the set pressure.
T178-03-07-001
1
NOTE: Standard Change in Pressure (Reference)
Change in Pressure
Shim
Thickness
kPa
(kgf/cm2)
(psi)
(mm)
0.25
78
(0.8)
(11)
0.5
157
(1.6)
(23)
1.0
304
(3.1)
(44)
2
T111-06-04-004
T4-5-2
OPERATIONAL PERFORMANCE TEST / Component Test
SECONDARY PILOT PRESSURE
Preparation:
1. Stop the engine.
2. Push the air bleed valve of the oil supply cap and
release any remaining pressure.
3. Measure pressure at the location between pilot
valve and signal control valve. Remove the pilot
hose from the circuit to be measured. Install the
hose (9/16-18UNF, Length: approx. 400 mm (16
in)) to the signal control valve side. Install tee
(4351843), adapter (ST 6460), fitting (ST 6069),
coupling (ST 6332) and pressure gauge (ST 6315)
between the hoses.
: 17 mm, 19 mm
Pilot Valve
Signal Control Valve
Hose
Fitting
Pressure
Gauge
Tee
NOTE: When removing the lines from signal control
valve,
use
tool
(SNAP-ON
GAN850812B: size 19.05 mm) in order to
easily remove the lines.
4. Start the engine. Check for any oil leaks at the
pressure gauge connection.
5. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Select the following switch positions.
Power
Engine
Auto-Idle
Mode
Work Mode
Control Dial
Switch
Switch
Digging
Fast idle
P
OFF
mode
Digging
Slow idle
P
OFF
mode
2. Measure pilot pressure by using a pressure gauge
with the corresponding control lever operated to
full stroke.
3. Repeat the measurement three times. Calculate
the average values.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B
in Group T5-7.
T4-5-3
Adapter
T1F3-04-05-008
OPERATIONAL PERFORMANCE TEST / Component Test
SOLENOID VALVE SET PRESSURE
Use both Dr. ZX and a pressure gauge.
Preparation:
1. Stop the engine.
2. Push the air bleed valve of the oil supply cap and
release any remaining pressure.
3. Remove the line from the solenoid valve to be
measured. Install tee (ST 6451), hose (Parts
Number: 4216453), adapter (ST 6461) and pressure gauge (ST 6942).
: 17 mm, 19 mm, 22 mm
4. Connect Dr. ZX and select the monitoring function.
5. Start the engine. Check for any oil leaks at the
pressure gauge connection.
6. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Select the following switch positions.
Power
Engine
Auto-Idle
Mode
Work Mode
Control Dial
Switch
Switch
Digging
Fast idle
P
OFF
mode
Digging
Slow idle
P
OFF
mode
2. Operate as instructed below for each measuring
solenoid valve:
• Solenoid Valve SI:
Set the brake switch to the Axle lock position.
• Solenoid Valve SF:
When setting the brake switch to the Axle lock or
Auto axle lock position and stopping the machine,
depress the brake pedal.
• Solenoid Valve SC:
Combined operation of swing and arm roll-in.
3. Read the values on both Dr. ZX and the pressure
gauge.
4. Repeat the measurement three times. Calculate
the average values.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
T4-5-4
Solenoid Valve Unit
Pressure Gauge
Hose
Tee
SC
SF
Adapter
T157-05-04-002
SI
TCGB-03-12-001
OPERATIONAL PERFORMANCE TEST / Component Test
Solenoid Valve Adjustment Procedure
O-Ring
7
IMPORTANT: As O-ring is damaged and oil leakage may cause, do not loosen adjusting screw (8) excessively.
Do not loosen adjusting screw (8)
more than 2 turns.
8
1. Loosen lock nut (7). Turn adjusting screw (8) and
adjust the set pressure.
2. After adjustment, tighten lock nut (7).
: 10 mm
: 3 N⋅m (0.3 kgf⋅m, 2.2 lbf·ft)
: 3 mm
3. After adjustment, check the set pressure.
NOTE: Standard Change in Pressure (Reference)
Screw Turns
1/4
1/2
3/4
1
kPa
69
137
206
275
Change
(kgf/cm2) (0.7) (1.4) (2.1) (2.8)
in Pressure
(psi)
(10) (20) (30) (40)
T1V1-04-05-004
2.0 mm (0.079 in) or less
from end of Lock Nut
7
8
T1V1-04-05-003
7
Pressure
Increase
8
Pressure
Decrease
W107-02-05-129
T4-5-5
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN PUMP DELIVERY PRESSURE
This pressure can also be measured by using Dr. ZX.
Preparation:
1. Stop the engine.
2. Push the air bleed valve of the oil supply cap and
release any remaining pressure.
3. Remove the plug of pressure check port from the
main pump delivery port. Install adapter (ST 6069),
hose (ST 6943) and pressure gauge (ST 6941).
: 6 mm
4. Connect Dr. ZX and select the monitoring function.
5. Start the engine. Check for any oil leaks at the
pressure gauge connection.
6. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Select the following switch positions.
Power
Engine
Auto-Idle
Work Mode
Mode
Control Dial
Switch
Switch
Fast idle
P
OFF
Digging
mode
2. Measure pressure with the control levers in neutral without load.
3. Repeat the measurement three times. Calculate
the average values.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B
in Group T5-7.
T4-5-6
T157-05-04-005
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)
T4-5-7
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN RELIEF SET PRESSURE
Summary:
Measure the main relief valve set pressure at the delivery port in main pump. (This pressure can also be
measured by using Dr. ZX.)
Preparation:
1. Stop the engine.
2. Push the air bleed valve of the oil supply cap and
release any remaining pressure.
3. Remove the plug of pressure check port from
main pump delivery port. Install adapter (ST 6069),
hose (ST 6943) and pressure gauge (ST 6941).
: 6 mm
4. Connect Dr. ZX and select the monitoring function.
5. Start the engine. Check for any oil leaks at the
pressure gauge connection.
6. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Select the following switch positions.
Power
Engine
Auto-Idle
Mode
Work Mode
Control Dial
Switch
Switch
Digging
Fast idle
P
OFF
mode
2. First, slowly operate the bucket, arm and boom
control levers to the stroke end and relieve each
function.
3. As for the swing control function, secure the upperstructure so it is immovable. Slowly operate
the swing control lever and relieve the swing
function.
4. As for the travel function, secure the tracks
against an immovable object. Slowly operate the
travel control levers and relieve the travel function.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
T4-5-8
T157-05-04-005
OPERATIONAL PERFORMANCE TEST / Component Test
NOTE: If the measure pressures for all functions
are lower than the specified range, the
probable cause is a decrease of the main
relief valve setting pressure.
If the relief pressure of a particular function
is lower, the probable cause is other than
main relief valve.
Main Relief
Valve
Main Relief Pressure Setting Adjustment Procedure
Adjustment:
1. Loosen lock nut (1).
: 17 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
2. Turn adjusting screw (2) to adjust the main relief
set pressure referring to the table below.
3. Retighten lock nut (1).
T16W-03-03-032
4. Recheck the set pressures.
1
2
NOTE: Standard Change in Pressure (Reference)
Plug Turns
1/4
1/2
3/4
1
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)
T176-03-03-010
Adjusting
Screw
Pressure
Increase
Pressure
Decrease
T105-06-05-002
T4-5-9
OPERATIONAL PERFORMANCE TEST / Component Test
RELIEF PRESSURE (WHEN RELIEVING
SWING)
Swing Relief
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
3. Retighten lock nut (1).
4. Recheck the set pressures.
NOTE: Standard Change in Pressure (Reference)
Screw Turns
1/4
1/2
3/4
1
0.9
2.0
2.9
3.9
Change in MPa
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
Increase
Pressure
Decrease
W107-02-05-129
T4-5-10
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)
T4-5-11
OPERATIONAL PERFORMANCE TEST / Component Test
OVERLOAD RELIEF VALVE SET PRESSURE
Summary:
1. The circuit pressure must be increased by applying an external force while blocking the return circuit from the control valve. This measuring
method is hazardous and the results obtained with
this method are unreliable.
2. The oil flow rate used to set the overload relief
pressure is far less than that used to set the main
relief pressure. Therefore, measuring the overload
pressure in the main circuit by increasing the main
relief set pressure more than the overload valve
set-pressure is not a proper method. In addition, in
case a main relief valve designed to leak a small
quantity of oil before reliving is used, its
pre-leaking start pressure must be increased
more than the overload relief valve set pressure.
However, the pre-leaking start pressure is not always increased more than the overload relief
valve set-pressure as the adjustable upper limit of
the main relief valve set pressure is provided.
Accordingly, the overload relief valve assembly
should be removed from the machine and
checked on a specified test stand at a correct oil
flow rate. Some overload relief valves come in
contact with the control valve body to block the oil
passage. When this type of overload relief valve is
checked, the control valve body must be precisely
finished as the test unit. Provide one control valve
other than that on the machine as a test kit.
3. If the overload relief valve performance must be
checked on the machine, however, measure the
main relief pressure while releasing each front
function respective to the measuring overload relief valve. And, assume that the overload relief
valve is functioning correctly if the obtained main
relief pressure is within the specified value range.
Measure the main pressure of the front functions
by using Dr. ZX as follows.
5. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Select the following switch positions.
Engine
Power Mode Auto-Idle
Work Mode
Control Dial
Switch
Switch
Digging
Fast idle
P
OFF
mode
2. Slowly operate the bucket, arm or boom control
levers to the stroke ends and relieve each function.
3. Read pressures on the pressure gauge at this
time.
4. Perform the measurement for the bucket, arm and
boom in that order.
5. Repeat the measurement three times. Calculate
the average value for each.
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the oil supply
cap and release any remaining pressure.
3. Remove the plug from pressure check port of
main pump delivery port. Install adapter (ST 6069),
hose (ST 6943) and pressure gauge (ST 6941).
: 6 mm
4. Connect Dr. ZX and select the monitoring function.
Start the engine. Check for any oil leaks at the
pressure gauge connection.
T4-5-12
T157-05-04-005
OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation:
1. Performance of the overload relief valves are
normal if the measured main relief pressures are
within the specified value range.
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Overload Relief Valve Pressure Adjustment Procedure
NOTE: In principle, adjust the overload relief valve
pressure on a test stand.
Loosen lock nut (1) and adjust pressure with adjusting screw (2).
1. Loosen lock nut (1).
: 17 mm
2. Turn adjusting screw (2) in order to adjust pressure.
: 6 mm
3. Tighten lock nut (1).
: 17 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf·ft)
4. After adjustment, check the set pressure.
1
2
NOTE: Standard Change in Pressure (Reference)
Adjusting Screw (2)
1/4
1/2
3/4
1
Turns
MPa
Change
2
(kgf/cm )
in Pressure
(psi)
5.2
(54)
(770)
10.6
(108)
(1540)
15.9
(162)
(2300)
W107-02-05-128
21.1
(216)
(3070)
2
Pressure
Increase
Pressure
Decrease
W107-02-05-129
T4-5-13
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN PUMP FLOW RATE MEASUREMENT
• P-Q Control (Torque Control)
Summary:
Main pump performance is checked by measuring
the pump flow rate by using a hydraulic tester installed at the main pump delivery port (one side) to
be measured. Use Dr. ZX and a pressure gauge at
the same time.
IMPORTANT: This measurement procedure is a
simple method. The measured data
will be lower by approx. 5 % than the
accurately measured value. In order
to measure accurately, disconnect
the return circuit from the control
valve and connect it to the hydraulic
oil tank.
Preparation:
1. Stop the engine. Push the air bleed valve and
bleed air. Install a vacuum pump to the oil filler
port.
NOTE: Operate the vacuum pump with the pump
flow rate test line connected.
2. Remove the delivery hose from main pump (one
side) to be measured. Install pipe (1 or 2) by using
the split flanges and bolts which were used for the
removed delivery hose.
: 41 mm
: 10 mm
3. Install pipe (1 or 2) to hydraulic tester (5) by using
test hose (3) and adapter (4). Install adapter (6),
joint (7), test hose (8) and flange (9) to hydraulic
tester (5).
: 41 mm
: 10 mm
4. Install the delivery hose to flange (9) with split
flanges (10) and bolt (11).
: 10 mm
5. Install a pressure gauge to the main pump to be
measured. (Refer to “Main Relief Set Pressure”.)
: 6 mm
6. Remove pipe (13) from the regulator. Install plug
(G 1/4) to pipe (13) in the regulator.
: 17 mm
7. Remove the vacuum pump. Loosen plug (12) on
top of the pump casing. Bleed air from the casing
until oil only comes out.
8. Fully open the loading valve of hydraulic tester.
9. Start the engine. Check for any oil leaks at the
pressure gauge connection. Install Dr. ZX and
select the monitoring function.
Measurement:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
2. Measure the maximum flow rate.
3. Select each switch position as follows.
Engine
Power Mode Auto-Idle
Work Mode
Control Dial
Switch
Switch
Digging
Fast idle
P
OFF
mode
4. Adjust the relief set pressure of main relief valve in
control valve to each pressure point specified
along the main pump P-Q curve. (Refer to
T4-2-13.) Slowly restrict the loading valve of hydraulic tester while relieving pressure in the arm
roll-in circuit. Measure the flow rates and engine
speeds at each pressure point specified in the
P-Q curve.
5. Repeat each measurement three times. Calculate
the average values.
T4-5-14
OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation:
1. Convert the measured flow rates to those at the
specified pump speed by using the following formulas:
2. Standard Flow Rate
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Qc = Ns×Q/Ne
Qc
Q
Ns
Ne
:
:
:
:
NOTE: When actually measuring, install pipe (1 or
2) only to the pump to be measured.
Converted Flow Rate
Measured Flow Rate
-1
Specified Engine Speed: 2200 min
Measured Engine Speed:
Values indicated on Dr. ZX
1, 2
3
4
6
5
7
8
9
10
11
Delivery Hose
(To Control
Valve)
T173-04-04-002
13
12
TCEB-03-01-001
1 - Pipe E (ST 6144)
2 - Pipe B (ST 6143)
3 - Test Hose (ST 6145)
4 - Adapter PF1 × UNF1-7/8
(ST 6146)
56-
Hydraulic Tester (ST 6299)
Adapter PF1 × UNF1-7/8
(ST 6146)
7 - Joint (ST 6330)
89-
Test Hose (ST 6320)
Flange (ST 6118)
10 - Split Flange (ST 6130)
T4-5-15
11 - Bolt (ST 6409) (4 Used)
12 - Plug
13 - Pipe
OPERATIONAL PERFORMANCE TEST / Component Test
• Pilot Pressure Characteristics
Summary:
Main pump performance is checked by measuring
the pump flow rate by using a hydraulic tester installed at the main pump delivery port (one side) to
be measured. Use Dr. ZX and a pressure gauge at
the same time.
IMPORTANT: This measurement procedure is a
simple method. The measured data
will be lower by approx. 5 % than the
accurately measured value. In order
to measure accurately, disconnect
the return circuit from the control
valve and connect it to the hydraulic
oil tank.
5. Install hose (19) and adapter (20) to port T of
pressure reducing valve (16). Remove plug L
from the return pipe. Install hose (19).
: 19 mm, 22 mm
6. Remove pipe (21) from the regulator. Install plug
(G 1/4) to the mounting hole for pipe (21) in the
regulator.
: 17 mm
7. Remove the vacuum pump. Loosen the plug from
top of the pump casing. Bleed air from the pump
casing until oil only comes out.
8. Fully open the loading valve of hydraulic tester.
9. Start the engine. Check the connections for any
oil leaks.
Preparation:
1. While referring to steps 1 to 4 on page T4-5-18.
Install a hydraulic tester to the main pump to be
measured.
2. Remove the hose from regulator port Pi of the
pump to be measured. Install plug (ST 6213) to
the removed hose.
: 6 mm, 19 mm
3. Install adapters (15) (3 used) to pressure reducing
valve (16). Remove plug M from the pilot filter.
Install adapter (13) and hose (14) to the pilot filter.
Install hose (14) to regulator port P1 on pressure
reducing valve (16).
: 19 mm
4. Install tee (17) to port P2 of pressure reducing
valve (16). Install pressure gauge (18) and hose
(14) to tee (17). Install hose (14) to the regulator.
: 19 mm
T4-5-16
OPERATIONAL PERFORMANCE TEST / Component Test
1, 2
3
4
6
5
7
8
9
10
11
Delivery Hose
(To Control
Valve)
T173-04-04-002
21
12
Plug M
Port Pi
T178-03-07-001
TCEB-03-01-001
Pressure Reducing Valve Port Position
Pressure Reducing
Valve
Return Pipe
T
L
20
18
P2
P1
19
15
To Pilot Filter
To Regulator
Port Pi
14
17
15
16
15
14
13
T178-04-04-004
1 - Pipe E (ST 6144)
7 - Joint (ST 6330)
12 - Plug M
2 - Pipe B (ST 6143)
8 - Test Hose (ST 6320)
3 - Test Hose (ST 6145)
9 - Flange (ST 6118)
4 - Adapter PF1 × UNF1-7/8
(ST 6146)
5 - Hydraulic Tester (ST 6299)
10 - Split Flange
(ST 6130)
11 - Bolt (ST 6409) (4 Uded)
13 - Adaptor UNF7/16
×PF1/4 (ST 6069)
14 - Hose UNF7/16×
UNF7/16(4334309)
15 - Adapter PF3/8×UNF7/16
(4200465)
16 - Pressure Reducing Valve
(4325439)
6 - Adapter PF1 × UNF1-7/8
(ST 6146)
T4-5-17
17 - Tee UNF7/16×UNF7/16×
PF1/4 (ST 6451)
18 - Pressure Gauge (ST
6931)
19 - Hose UNF7/16×
UNF7/16 (4334309)
20 - Adapter PF3/8×UNF7/16
(4200465)
21 - Pipe
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
2. Measure pump flow rate in response to the external command pilot pressure.
3. Select the following switch positions.
Power
Engine
Auto-Idle
Mode
Work Mode
Control Dial
Switch
Switch
Digging
Fast idle
P
OFF
mode
4. Adjust the pressure reducing valve set pressure
to each pressure point specified along the main
pump P-Q curve. (Pilot Characteristics) (Refer to
T4-2-14.)
Measure the flow rates and engine speeds at the
pressure points specified in the P-Q curve.
5. Repeat the measurement three times. Calculate
the average values.
Evaluation:
1. Convert the measured flow rates to those at the
specified engine speed by using the following
formulas:
Qc = Ns×Q/Ne
Qc : Converted Flow Rate
Q : Measured Flow Rate
-1
Ns : Specified Engine Speed: 2200 min
Ne : Measured Engine Speed:
Values indicated on Dr. ZX
2. Standard Flow Rate
Refer to OPERATIONAL PERFORMANCE TEST
/ Standard in Group T4-2.
NOTE: When actually measuring, install pipe (1)
(ST 6144) or (2) (ST 6143) only to the
pump to be measured.
T4-5-18
OPERATIONAL PERFORMANCE TEST / Component Test
1, 2
3
4
6
5
7
8
9
10
11
Delivery Hose
(To Control Valve)
T173-04-04-002
21
12
Plug M
Port Pi
T178-03-07-001
TCEB-03-01-001
Pressure Reducing Valve Port Position
Pressure Reducing Valve
Return Pipe
T
L
20
18
P1
P2
19
15
To Regulator Port Pi
To Pilot Filter
14
17
15
16
15
14
13
T178-04-04-004
1 - Pipe E (ST 6144)
7-
Joint (ST 6330)
12 - Plug M
2 - Pipe B (ST 6143)
8-
Test Hose (ST 6320)
3 - Test Hose (ST 6145)
9-
Flange (ST 6118)
4 - Adapter PF1 × UNF1-7/8
(ST 6146)
5 - Hydraulic Tester (ST 6299)
10 - Split Flange
(ST 6130)
11 - Bolt (ST 6409) (4 Used)
13 - Adaptor UNF7/16
×PF1/4 (ST 6069)
14 - Hose UNF7/16×
UNF7/16 (4334309)
15 - Adapter PF3/8×UNF7/16
(4200465)
16 - Pressure Reducing Valve
(4325439)
6 - Adapter PF1 × UNF1-7/8
(ST 6146)
T4-5-19
17 - Tee UNF7/16×UNF7/16×
PF1/4 (ST 6451)
18 - Pressure Gauge (ST
6931)
19 - Hose UNF7/16×
UNF7/16 (4334309)
20 - Adapter PF3/8×UNF7/16
(4200465)
21 - Pipe
OPERATIONAL PERFORMANCE TEST / Component Test
Regulator Adjustment
6
5
1
2
9
10
4
3
7
1 - Lock Nut (For Minimum
Flow Rate)
2 - Adjusting Screw (For
Minimum Flow Rate)
3 - Lock Nut (For Maximum
Flow Rate)
4 - Adjusting Screw (For
Maximum Flow Rate)
5 - Lock Nut (For Pilot
Pressure Characteristic)
6 - Adjusting Screw (For Pilot
Pressure Characteristic)
7 - Lock Nut (For P-Q
Control)
8 - Adjusting Screw (For P-Q
Control)
8
T1V1-03-01-009
9 - Lock Nut (For P-Q
Control)
10 - Adjusting Screw (For P-Q
Control)
Adjustment Item
1. Minimum Flow Rate
Adjustment Procedure
Remarks
Loosen lock nut (1) and turn adjusting 1) Do not turn adjusting screw (2)
screw (2).
more than two turn.
Rotating adjusting screw (2) 1/4 a 2) Securely tighten lock nut (1) after
turn clockwise increases the miniadjustment.
mum pump flow rate by 6.56 cm3/rev.
3
(0.4 in /rev).
: 17 mm
: 19.6 N⋅m
(2 kgf⋅m, 14.5 lbf·ft)
2. Maximum Flow Rate
Loosen lock nut (3) and turn adjusting 1) Do not turn adjusting screw (4)
screw (4).
more than two turn.
Rotating adjusting screw (4) 1/4 a 2) Do not increase the maximum flow
turn clockwise decreases the maxirate.
mum pump flow rate by 8.22 cm3/rev.
In other words, do not turn adjust3
ing screw (4) counterclockwise.
(0.5 in /rev).
: 13 mm
3) Securely tighten lock nut (3) after
adjustment.
: 9.8 N⋅m (1 kgf⋅m, 7.2 lbf·ft)
T4-5-20
OPERATIONAL PERFORMANCE TEST / Component Test
Adjustment Item
3. Pilot Pressure Characteristics
Q
Pi
4. P-Q Control
(Torque Adjustment)
Q
A
Pd
Adjustment Procedure
Remarks
Loosen lock nut (5) and turn ad- 1) Do not turn adjusting screw (6) more
than one turn.
justing screw (6).
Rotating adjusting screw (6) 1/4 2) When adjusting screw (6) is turned
clockwise, the maximum flow rate
a turn clockwise decreases the
3
will also be decreased.
flow rate by 13.2 cm /rev.
3
In order to maintain the maximum
(0.71 in /rev).
flow rate unchanged, turn adjusting
: 30 mm
screw (4) counterclockwise twice as
: 29.5 N⋅m
much as adjusting screw (6) is
(3 kgf⋅m, 21.5 lbf⋅ft)
turned.
This ratio of 2 (adjusting screw (4)
counterclockwise turn) to 1 (adjusting screw (6) clockwise turn) is to
counterbalance.
3) Securely tighten lock nut (5) after
adjustment.
A: Loosen lock nut (7) and turn
adjusting screw (8).
Rotating adjusting screw (8)
1/4 a turn clockwise increases
3
the flow rate by 15.3 cm /rev.
3
(0.93 in /rev.).
B: Loosen lock nut (9) and turn
adjusting screw (10).
Rotating adjusting screw (10)
1/4 a turn clockwise increases
3
the flow rate by 3.60 cm /rev.
3
(0.22 in /rev).
Q
B
Pd
T4-5-21
1) Do not turn the adjusting screws
more than one turn.
2) Rotate the adjusting screws watching the engine performance.
3) Securely tighten lock nut (7) or (9)
after adjustment.
4) Do not decrease the maximum flow
rate. In other words, do not turn adjusting screws (8, 10) counterclockwise.
OPERATIONAL PERFORMANCE TEST / Component Test
Adjustment of Maximum Pump 1 and 2 Flow Rate
Limit Control Solenoid Valve
Maximum Pump 2 Flow Rate Limit
Control Solenoid Valve
1
2
Torque Control
Solenoid Valve
2
1
Maximum Pump 1 Flow Rate Limit
Control Solenoid Valve
TCEB-03-01-001
Adjustment Item
1. Flow Rate of Flow Rate
Limit
(When using boom, arm,
bucket, swing and attachment)
Q
Adjustment Procedure
Remarks
Loosen lock nut (1) of the solenoid 1) Adjust only maximum pump 2 flow
valve and turn adjusting screw (2).
rate limit control solenoid valve at
Rotating adjusting screw (2) 1/4 a
the pump 2 side.
turn clockwise decreases the pump 2) Do not turn adjusting screw (2)
flow rate by 13.2 cm3/rev. (0.8
more than one turn.
3
3) Securely tighten lock nut (1) after
in /rev).
adjustment.
: 10 mm
: 5.0 N⋅m (0.5 kgf⋅m, 3.7 lbf·ft)
Pi
T4-5-22
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)
T4-5-23
OPERATIONAL PERFORMANCE TEST / Component Test
SWING MOTOR DRAINAGE
Summary:
1. Measure amount of oil draining from the swing
motor while swinging the upperstructure and
check the swing motor performance.
2. Secure absolute safety for the measuring persons
as well as for the surrounding while measuring.
3. Keep oil temperature constant as the drain
amount from the swing motor is much influenced
by oil temperature.
Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F). Rotate the swing motor in order to
warm inside of the motor.
2. Stop the engine. Push air bleed valve (1) of the oil
supply cap and release any remaining pressure.
3. Remove drain hose (2) of the swing motor at the
hydraulic oil tank end. Install plug (ST 6213) to the
removed end on the hydraulic oil tank.
: 22 mm
: 39 N⋅m (4 kgf⋅m, 28.5 lbf·ft)
CAUTION: Prevent personal injury. Always
make sure that the area is clear and that
co-workers are out of the swing area before
starting the measurement.
Also, take care not to fall off the machine
while the measurement.
1
T157-05-04-014
2
Conditions for Measurement
1. Select the following switch positions.
Power
Engine
Auto-Idle
Mode
Work Mode
Control Dial
Switch
Switch
Digging
Fast idle
P
OFF
mode
T178-04-04-005
T4-5-24
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
CAUTION: Prevent personal injury. Always
make sure that the area is clear and that
co-workers are out of the swing area before
starting the measurement.
Also, take care not to fall off the machine
while the measurement.
• Amount of Oil Drained While Swinging the Upperstructure
1. Fully retract the arm cylinder. Fully extend the
bucket cylinder. Hold the boom so that the arm tip
pin height is the same as the boom foot pin height.
The bucket must be empty.
2. Start the engine. Operate and hold the swing
control lever to full stroke. After the swing speed
reaches a constant maximum speed, start draining oil measurement when drain oil starts coming
out of the drain hose end.
3. Repeat the measurement three times in both
clockwise and counterclockwise directions. Calculate the average values.
4. The measuring time should be for more than 45
seconds.
Height of the boom
foot pin is the same
as the arm tip pin
T212-07-04-001
T212-07-04-002
• Amount of Oil Drained While Relieving Swing
Motor Circuit
1. Thrust the bucket teeth into the ground so that the
upperstructure does not rotate. Set the swing lock
lever to the LOCK position so that the upperstructure does not rotate.
2. Start the engine. Operate and hold the swing
control lever to full stroke. Start draining oil
measurement when drain oil starts coming out of
the drain hose end.
3. Repeat the measurement three times in both
clockwise and counterclockwise directions. Calculate the average values.
4. The measuring time should be for more than 45
seconds.
Swing Lock Lever
M216-05-004
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
∗ Conversion of amount of drain oil measured into the
per-minute value
First measure amount of drain oil by using a calibrated container. Then, convert the measured drain
oil into the per-minute value by using the formula
below:
∆Q = 60 × q / t
∆Q : Amount of drain oil per minute (L/min)
t
: Measured time (seconds)
q
: Total amount of drain oil (L)
T107-06-05-008
T4-5-25
OPERATIONAL PERFORMANCE TEST / Component Test
TRAVEL MOTOR DRAINAGE
Summary:
1. While rotating the travel motor with the track to be
measured jacked up, measure amount of oil
draining from the travel motor and check travel
motor performance.
2. Secure absolute safety for the measuring persons
as well as for the surrounding while measuring.
3. Keep oil temperature constant as the drain
amount from the travel motor is much influenced
by oil temperature.
1
Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F). Rotate the travel motor in order to
warm inside of the motor.
2. Stop the engine. Push air bleed valve (1) of the oil
supply cap and release any remaining pressure.
3. Remove hose (2) of the travel motor at the travel
motor end. Install plug (9/16-18UNF) (4174545) to
the removed end.
Install plug (9/16-18UNF-2B) (ST 6214) to the
removed hose at the travel motor end.
4. Remove drain hose (3) in the travel motor at the
travel motor end. Install plug 3/16-18UNF
(4174546) to the removed end.
Install the drain hose (3/4-16UNF) to the travel
motor.
: 22 mm, 27 mm
Conditions for Measurement
1. Select the following switch positions.
Engine
Power
Work
Auto-Idle
Control
Mode
Mode
Switch
Dial
Switch
Digging
Fast idle
P
OFF
mode
Travel Speed
Mode Switch
Fast
MCBB-07-025
3
2
T1GL-04-05-001
Brake Switch
Axle lock
T1GL-04-05-002
T4-5-26
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Amount of drain oil while the travel motor rotates
1-1. Start the engine.
CAUTION: When working around moving
parts is unavoidable, pay special attention to
ensure that hands, feet, and clothing do not
become entangled.
Securely support the raised machine by using
the blocks.
1-2. As for the machine attached with outriggers or
blade in the front and the rear of undercarriage,
raise the machine by using the outriggers or the
blade. As for the machine attached with outriggers
or blade only in the rear of undercarriage, raise
the machine by using the front attachment as illustrated in the right.
Depress the accelerator pedal to full stroke, rotate
the travel motor, put draining oil into the container,
and measure the time.
1-3. Repeat the measurement three times in both
forward and reverse directions. Calculate the average values.
1-4. The measuring time should be more than 45
seconds.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
∗ Conversion of amount of drain oil measured into the
per-minute value
First measure 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
∆Q : Amount of drain oil per minute (L/min)
t
: Measured time (seconds)
q
: Total amount of drain oil (L)
T4-5-27
T1F3-04-02-002
OPERATIONAL PERFORMANCE TEST / Component Test
STEERING VALVE RELIEF PRESSURE
Use both Dr. ZX and a pressure gauge.
CAUTION: If air is mixed in the brake system,
the brake function is reduced, and serious
hazard may occur. Bleed air from the brake
system after removing and installing the pipe
lines of steering and brake and replacing hydraulic oil.
(Refer to the TROUBLESHOOTING / Troubleshooting B group.)
Summary:
The steering circuit is provided with the steering relief
valve. When the steering relief valve is faulty, the
handle will turn heavily.
Preparation:
1. Stop the engine.
2. Push the air bleed valve (1) on top of the hydraulic
oil tank and release any remaining pressure.
3. Remove the hoe of steering filter outlet or inlet.
Install tee 3/4-16UNF (ST 6477), fitting (ST 6069)
and pressure gauge assembly (ST 6933) between
steering filter and hose.
: 22 mm, 24 mm
4. Connect Dr. ZX and monitor the pump 3 pressure.
5. Start the engine. Check for any oil leaks at the
pressure gauge connection.
6. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
1
Steering Filter
MCBB-07-025
MCBB-07-027
T4-5-28
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions.
Engine
Power
Work
Auto-Idle
Control
Mode
Mode
Switch
Dial
Switch
Digging
Fast idle
P
OFF
mode
2. Measure the steering pressure in the handle from
right to left stroke end and from left to right stroke
end by using a pressure gauge.
3. Repeat the measurements three times. Calculate
the average values.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Remedy
The steering relief valve cannot be adjusted. If the
steering pressure does not meet standard value, replace the steering relief valve as an assembly.
T4-5-29
OPERATIONAL PERFORMANCE TEST / Component Test
BRAKE PRESSURE (FRONT AND REAR)
CAUTION: If air is mixed in the brake system,
the brake function is reduced and serious
hazard may occur. Bleed air from the brake
system after removing and installing the pipe
lines and replacing hydraulic oil.
(Refer to TROUBLESHOOTING / Troubleshooting B in Group T5-7.)
Summary:
Measure the brake pressure at the brake valve outlet
side. Measure the pressure when depressing the
brake pedal and applying the working brake.
Preparation:
CAUTION: Install the measuring equipment
under a machine. Install it on flat and solid
ground after securing the front attachment in
order to prevent running away and an operating error.
1. Stop the engine.
2. Push the air bleed valve of the oil supply cap and
release any remaining pressure from the hydraulic
oil tank.
3. Depress the brake at least 50 strokes in order to
reduce the accumulated pressure left in the brake
circuit.
4. Install the measuring equipment to front and rear
wheel brake circuit.
4-1. Front wheel brake circuit pressure: Remove
front wheel brake hose (1). Install tee
9/16-18UNF (ST 6485), fitting (ST 6069) and
pressure gauge assembly (ST 6932) to the removed hose.
: 19 mm, 22 mm
4-2. Rear wheel brake circuit pressure: Remove rear
wheel brake hose (2). Install tee 9/16-18UNF
(ST 6485), fitting (ST 6069) and pressure gauge
assembly (ST 6932) to the removed hose.
: 19 mm, 22 mm
5. Start the engine. Check for any oil leaks at the
pressure gauge connection.
6. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
SA-1140
Front
Axle
T1F3-04-05-003
1
Rear
Axle
T1F3-04-05-004
2
T4-5-30
OPERATIONAL PERFORMANCE TEST / Component Test
Conditions for Measurement
1. Select the following switch positions.
Engine
Power Mode
Control Dial
Switch
Fast idle
P
Work Mode
Auto-Idle
FNR
Brake
Switch
Switch
Switch
OFF
N
OFF
Digging mode
Measurement:
1. Measure the pressure when fully depressing the
brake pedal.
2. Measure the pressure when the work brake is
operable.
3. Repeat the measurement three times. Calculate
the average values.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Remedy
Refer to TROUBLESHOOTING / Troubleshooting B
in Group T5-7.
Normally, the front and rear wheel brake pressures
become equal. If not, malfunction of the brake valve
and dirt caught in the valve are suspected.
T4-5-31
OPERATIONAL PERFORMANCE TEST / Component Test
BRAKE ACCUMLATED PRESSURE
CAUTION: If air is mixed in the brake system,
the brake function is reduced serious hazard
may occur. Bleed air from the brake system
after removing and installing the pipe lines
and replacing hydraulic oil.
Refer to TROUBLESHOOTING / Troubleshooting B group.
Summary:
The accumulated brake pressure is measured at
output port of the accumulator. The accumulated
brake pressure varies according to operation of the
brake. Record the maximum value.
Preparation:
CAUTION: Install the measuring equipment
under a machine. Install it on flat and solid
ground after securing the front attachment in
order to prevent running away and an operating error.
1. Stop the engine.
2. Push the air bleed valve on the oil supply cap and
release any remaining pressure in the hydraulic oil
tank.
3. Depress the brake at least 50 strokes in order to
reduce the accumulated pressure left in the brake
circuit.
4. Remove the cover under the cab.
Remove brake hose (1).
Install tee (9/16-18UNF) (ST 6485), fitting (ST
6069) and pressure gauge assembly (ST 6932)
between the removed hoses.
: 19 mm, 22 mm
5. Start the engine. Check for any oil leaks at the
pressure gauge connection.
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T4-5-32
OPERATIONAL PERFORMANCE TEST / Component Test
Conditions for Measurement
1. Select the following switch positions.
Engine
Power Mode
Control Dial
Switch
Fast idle
P
Work Mode
Digging mode
Auto-Idle
FNR
Brake
Switch
Switch
Switch
OFF
N
OFF
Measurement:
1. When depressing the brake pedal slowly several
times, measure the maximum pressure.
2. Repeat the measurement three times. Calculate
the average values.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Remedy
Refer to TROUBLESHOOTING / Troubleshooting B
in Group T5-7.
T4-5-33
OPERATIONAL PERFORMANCE TEST / Component Test
BRAKE WARNING SET PRESSURE
(DECREASE)
CAUTION: If air is mixed in the brake system,
the brake function is reduced serious hazard
may occur. Bleed air from the brake system
after removing and installing the pipe lines
and replacing hydraulic oil.
(Refer to the TROUBLESHOOTING / Troubleshooting B group.)
Summary:
When the warning buzzer sounds by reducing the
accumulated brake pressure, measure the pressure
at the output port of accumulator.
Preparation:
CAUTION: Install the measuring equipment
under a machine. Install it on flat and solid
ground after securing the front attachment in
order to prevent running away and an operating error.
1. Stop the engine.
2. Push the air bleed valve on the oil supply cap and
release any remaining pressure in the hydraulic oil
tank.
3. Depress the brake at least 50 strokes in order to
reduce the accumulated pressure left in the brake
circuit.
4. Remove the cover under the cab.
Remove brake hose (1).
Install tee (9/16-18UNF) (ST 6485), fitting (ST
6069) and pressure gauge assembly (ST 6932)
between the removed hoses.
： 19 mm, 22 mm
5. Start the engine. Check for any oil leaks at the
pressure gauge connection.
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T4-5-34
OPERATIONAL PERFORMANCE TEST / Component Test
Conditions for Measurement:
1. Select the following switch positions.
Forward/Reverse Lever Parking Brake Switch
N
P (Parking Brake)
Measurement:
1. Stop the engine. Turn the key switch to ON position.
2. Measure the pressure when warning buzzer
sounds by slowly depressing the brake pedal
several times.
3. Repeat the measurement three times. Calculate
the average values.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B
in Group T5-7.
T4-5-35
OPERATIONAL PERFORMANCE TEST / Component Test
BRAKE WARNING SET PRESSURE
(INCREASE)
CAUTION: If air is mixed in the brake system,
the brake function is reduced serious hazard
may occur. Bleed air from the brake system
after removing and installing the pipe lines
and replacing hydraulic oil.
(Refer to the TROUBLESHOOTING / Troubleshooting group.)
Summary:
When sounding of the warning buzzer stops by increasing the accumulated brake pressure, measure
the pressure at the output port of accumulator.
Preparation:
CAUTION: Install the measuring equipment
under a machine. Install it on flat and solid
ground after securing the front attachment in
order to prevent running away and an operating error.
1. Stop the engine.
2. Push the air bleed valve on the oil supply cap and
release any remaining pressure in the hydraulic oil
tank.
3. Depress the brake at least 50 strokes in order to
reduce the accumulated pressure left in the brake
circuit.
4. Remove the cover under the cab.
Remove brake hose (1).
Install tee (9/16-18UNF) (ST 6485), fitting (ST
6069) and pressure gauge assembly (ST 6932)
between the removed hoses.
： 19 mm, 22 mm
5. Start the engine. Check for any oil leaks at the
pressure gauge connection.
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T4-5-36
OPERATIONAL PERFORMANCE TEST / Component Test
Conditions for Measurement
1. Select the following switch positions.
Engine
Power Mode
Work Mode
Control Dial
Switch
Fast idle
P
Digging mode
Auto-Idle
Switch
OFF
Measurement:
1. Stop the engine. Turn the key switch to ON position.
2. Set the engine control dial to slow idle.
3. Depress the brake pedal several times and make
the warning buzzer sound.
4. Start the engine. Measure the pressure when
sounding of the warning buzzer stops. Notice that
it is difficult to read the gauge as the pressure increases rapidly.
5. Repeat the measurement three times and calculate the average values.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B
in Group T5-7.
T4-5-37
FNR
Switch
N
Brake
Switch
OFF
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)
T4-5-38
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 Diagnosing Procedure
Group 3 Dr. ZX
Introduction ..............................................T5-1-1
Outline .....................................................T5-3-1
Diagnosing Procedure ..............................T5-1-2
MC Monitoring List ...................................T5-3-2
ECM Monitoring List .................................T5-3-5
Group 2 Monitor Unit
Outline .....................................................T5-2-1
How to Use Screens...............................T5-2-17
Screen Display When An Alarm
is Issued...............................................T5-2-24
Contents of Alarms .................................T5-2-26
Time Setting ...........................................T5-2-29
Attachment Adjustment
(Pump 2 Flow Rate Adjustment) ...........T5-2-30
Displaying Operating Conditions.............T5-2-32
Maintenance Settings .............................T5-2-34
Monitor Unit Monitoring List ......................T5-3-6
Steering Column Monitor
Monitoring List ........................................T5-3-7
Option Controller Monitoring List ..............T5-3-8
MC Adjustment List ................................T5-3-10
MC Attachment Adjustment List ..............T5-3-12
ICF Adjustment Item List ........................T5-3-16
Option Controller Adjustment List ...........T5-3-18
Dr. ZX Operation Procedure ...................T5-3-20
Group 4 ICF
Work Mode (Attachment Selection) ........T5-2-40
Outline .....................................................T5-4-1
Mail (Optional)........................................T5-2-44
List of Daily Report Data...........................T5-4-2
Meter Display Selection ..........................T5-2-46
List of Frequency Distribution Data ...........T5-4-5
Password Change (Optional) ..................T5-2-48
List of Total Operating Hours ....................T5-4-6
Back Monitor Settings ............................T5-2-52
How to Download and
Language Settings .................................T5-2-56
Meter Combination Settings ...................T5-2-58
Upload Data of ICF .................................T5-4-8
Various Setup of ICF and
Unit Settings...........................................T5-2-60
Satellite Communication Terminal
Service Menu (Built-In Diagnosing System)
by Using Dr. ZX .................................... T5-4-11
Operation .............................................T5-2-63
List of Fault Code ...................................T5-4-23
Troubleshooting......................................T5-2-64
Satellite Communication System ............T5-4-24
Monitoring ..............................................T5-2-66
Controller Version...................................T5-2-70
Blade/Outrigger Settings ........................T5-2-72
Keyless Hour Meter ................................T5-2-74
List of Monitor Unit Sitting Function ........T5-2-75
CEBT-5-1
Group 5 Component Layout
MC Fault Code 11203 ...........................T5-6-109
Main Component Layout...........................T5-5-1
MC Fault Code 11206 ........................... T5-6-110
Electrical Component Layout
MC Fault Code 11208 ........................... T5-6-111
(Overview) ..............................................T5-5-5
Electrical Component Layout
MC Fault Code 11301 ........................... T5-6-112
MC Fault Code 11302 ........................... T5-6-113
(Monitors and Switches) .........................T5-5-7
Electrical Component Layout
MC Fault Code 11303 ........................... T5-6-114
MC Fault Code 11305 ........................... T5-6-115
(Controllers and Relays) .......................T5-5-10
MC Fault Code 11306 ........................... T5-6-116
Engine....................................................T5-5-12
MC Fault Code 11307 ........................... T5-6-117
Pump Device..........................................T5-5-13
MC Fault Code 11310 ........................... T5-6-118
Swing Device .........................................T5-5-13
MC Fault Code 11311 ........................... T5-6-119
Signal Control Valve ...............................T5-5-13
MC Fault Code 11400 ...........................T5-6-120
Control Valve..........................................T5-5-14
MC Fault Code 11401 ...........................T5-6-121
Brake Valve ............................................T5-5-14
MC Fault Code 11403 ...........................T5-6-122
3-Spool Solenoid Valve Unit....................T5-5-14
MC Fault Code 11404 ...........................T5-6-123
Solenoid Valve Unit (for Electric Lever)...T5-5-14
MC Fault Code 11410 ...........................T5-6-124
Travel Shockless Valve ..........................T5-5-15
MC Fault Code 11422 ...........................T5-6-125
Transmission Changeover
MC Fault Code 11424 ...........................T5-6-126
Solenoid Valve......................................T5-5-15
MC Fault Code 11425 ...........................T5-6-127
Travel Device .........................................T5-5-15
MC Fault Codes 11910 to 11920 ...........T5-6-128
Filter.......................................................T5-5-15
MC Fault Code 11901 ...........................T5-6-129
Components in Control Valve .................T5-5-16
ECM Fault Codes 100 to 190................T5-6-130
Pilot Port ................................................T5-5-30
ECM Fault Codes 628 to 1485 ..............T5-6-131
ECM Fault Codes 10001 to 10013 ........T5-6-132
Group 6 Troubleshooting A
Troubleshooting A Procedure....................T5-6-1
ICF Fault Codes 14000 to 14003 ..........T5-6-133
MC Fault Code List...................................T5-6-2
Information C/U: Intialize ......................T5-6-134
ECM Fault Code List ..............................T5-6-24
Control Data: Intialize ...........................T5-6-135
ICF Fault Code List ................................T5-6-48
Enter Model and Serial No....................T5-6-136
Satellite Terminal Fault Code List ...........T5-6-49
ICF Fault Codes 14006, 14008 .............T5-6-137
Monitor Unit Fault Code List ...................T5-6-49
Satellite Terminal Fault Codes
Option Controller Fault Code List............T5-6-50
14100 to 14106...................................T5-6-138
Monitor Unit Fault Code 13303 .............T5-6-139
Steering Column Monitor
Fault Code............................................T5-6-68
MC Fault Codes 11000 to 11002.............T5-6-70
Monitor Unit Fault Code 13304 .............T5-6-140
Monitor Unit Fault Codes
MC Fault Code 11003.............................T5-6-71
13306 and 13308................................T5-6-141
MC Fault Code 11004.............................T5-6-72
Monitor Unit Fault Code 13310 .............T5-6-142
CAN Harness Check ..............................T5-6-73
Monitor Unit Fault Code 13311 .............T5-6-143
MC Fault Code 11100 ........................... T5-6-105
Pilot Shut-Off Lever Alarm ....................T5-6-144
MC Fault Code 11101 ........................... T5-6-106
Option Controller Fault Codes
MC Fault Code 11200........................... T5-6-107
15500 to 15504...................................T5-6-145
MC Fault Code 11202........................... T5-6-108
Option Controller Fault Code 15505......T5-6-146
CEBT-5-2
Option Controller Fault Code 15506 ..... T5-6-147
Group 7 Troubleshooting B
Option Controller Fault Code 15510 ..... T5-6-148
Troubleshooting B Procedure ...................T5-7-1
Option Controller Fault Code 15511...... T5-6-149
Relationship between Machine Trouble
Option Controller Fault Code 15514 ..... T5-6-150
Option Controller Fault Code 15515 ..... T5-6-151
Symptoms and Related Parts .................T5-7-2
Correlation between Trouble
Option Controller Fault Code 15516 ..... T5-6-152
Symptoms and Part Failures.................T5-7-22
Option Controller Fault Code 15517 ..... T5-6-153
Engine System Troubleshooting .............T5-7-38
Option Controller Fault Code 15518 ..... T5-6-154
All Actuator System Troubleshooting ......T5-7-66
Option Controller Fault Code 15519 ..... T5-6-155
Front Attachment System
Option Controller Fault Code 15570 ..... T5-6-156
Troubleshooting ....................................T5-7-74
Option Controller Fault Code 15571 ..... T5-6-157
Swing System Troubleshooting ...............T5-7-88
Option Controller Fault Code 15572 ..... T5-6-158
Travel System Troubleshooting...............T5-7-90
Option Controller Fault Code 15573 ..... T5-6-159
Brake System Troubleshooting .............T5-7-102
Option Controller Fault Codes
Steering System Troubleshooting .........T5-7-105
15574-3 and 15578-3 ......................... T5-6-160
Other System Troubleshooting .............T5-7-106
Exchange Inspection ............................T5-7-126
Option Controller Fault Codes
15574-4 and 15578-4 ......................... T5-6-161
Bleeding Air from Transmission ............T5-7-130
Bleeding Air from Brake (Axle)..............T5-7-131
Option Controller Fault Codes
15575-3 and 15579-3 ......................... T5-6-162
Emergency Boom Lowering Procedure
(without Hose Rupture Valve) .............T5-7-132
Option Controller Fault Codes
15575-4 and 15579-4 ......................... T5-6-163
Attachment Circuit Pressure Release
Procedure...........................................T5-7-133
Option Controller Fault Codes
20300 to 20303 .................................. T5-6-164
Option Controller Fault Code 15520 ..... T5-6-165
Option Controller Fault Code 15521 ..... T5-6-166
Option Controller Fault Code 15522 ..... T5-6-167
Group 8 Electrical System Inspection
Precautions for Inspection and
Maintenance ...........................................T5-8-1
Instructions for Disconnecting
Option Controller Fault Code 15523 ..... T5-6-168
Connectors .............................................T5-8-3
Option Controller Fault Code 15524 ..... T5-6-169
Fuse Inspection ........................................T5-8-4
Option Controller Fault Code 15525 ..... T5-6-170
Fusible Link Inspection .............................T5-8-6
Option Controller Fault Code 15526 ..... T5-6-171
Battery Voltage Check ..............................T5-8-7
Option Controller Fault Code 15527 ..... T5-6-172
How to Check Alternator ...........................T5-8-8
Option Controller Fault Code 15528 ..... T5-6-173
Continuity Check ......................................T5-8-9
Option Controller Fault Code 15529 ..... T5-6-174
Voltage and Current Measurement .........T5-8-10
Option Controller Fault Code 15530 ..... T5-6-175
Check by False Signal ............................T5-8-17
Option Controller Fault Codes
Test Harness ..........................................T5-8-18
15565 to 15577 .................................. T5-6-176
Steering Column Monitor
Fault Code 16000 ............................... T5-6-177
CEBT-5-3
(Blank)
CEBT-5-4
TROUBLESHOOTING / Diagnosing Procedure
INTRODUCTION
Refer to the inspection and troubleshooting procedures after any machine trouble has occurred. The
inspection and troubleshooting procedures are presented in an orderly fashion in this section to quickly
find the cause of the machine trouble and solution.
The troubleshooting section in this manual consists of
8 groups; Diagnosing Procedure, Monitor Unit, Dr. ZX,
ICF, Component Layout, Troubleshooting A (base
machine diagnosis by using fault codes), Troubleshooting B (base machine diagnosis starting with inspection of abnormal operational status) and Electrical
System Inspection.
• Diagnosing Procedure
• Troubleshooting A (base machine diagnosis by
using fault codes)
Refer to these procedures if any fault codes are
displayed when each controller (MC, ECM, ICF
and monitor unit) is diagnosed by using Dr. ZX (or
the service menu of monitor unit).
• Monitor Unit
Refer to this group as for the display screen and
operating procedures of monitor unit.
• Dr. ZX
This group contains the operating procedures for
Dr. ZX.
• ICF
This group contains as follows.
Download data from ICF and Upload
Procedures when starting satellite communication,
when installing the satellite communication controller and when replacing ICF
Explanation for the satellite communication system
IMPORTANT: ICF receives and retains a record of
the electrical signal system malfunction of each controller in the
form of fault codes by using CAN
communication. In addition, ICF
self-diagnosing function records the
electrical signal system malfunction
in the form of fault codes
Ex.) Fault Code 11004-2: Failure of CAN Communication
• Component Layout
• Troubleshooting B (base machine diagnosis starting with inspection of abnormal operational
status)
Refer to these procedures when no fault codes
are displayed after diagnosing the machine with
Dr. ZX (or the service menu of monitor unit).
Ex.) Although the engine control dial is turned,
engine speed does not change.
• Electrical System Inspection
Refer to this group when required to obtain precautions and/or information for the electrical system inspection.
Ex.) Fuse Check
T5-1-1
TROUBLESHOOTING / Diagnosing Procedure
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient
troubleshooting:
1. Study the System
Study the machine’s technical manuals. Know the
system and how it works, and what the
construction, functions and specifications of the
system components are.
2. Ask the operator
Before inspecting, get the full
malfunctions from the operator below.
story
of
T107-07-01-001
(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?
3. Inspect the machine
Before starting the troubleshooting procedure,
check the machine’s daily maintenance points, as
shown in the operator's manual.
T107-07-01-002
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. 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
T5-1-2
TROUBLESHOOTING / Diagnosing Procedure
4. Operate the machine yourself
Try to identify the trouble by operating
machine yourself.
If the trouble cannot be confirmed, stop
engine and obtain further details of
malfunction from the operator.
Also, check for any incomplete connections of
wire harnesses correponding to the trouble.
the
the
the
the
T5-1-3
TROUBLESHOOTING / Diagnosing Procedure
5. Perform troubleshooting
CAUTION: Do not disconnect harnesses or
hydraulic lines while the engine is running.
The machine may malfunction or pressurized
oil may spout, possibly resulting in personal
injury. Stop the engine before disconnecting
harnesses or hydraulic lines.
Perform diagnosis by connecting Palm to the
machine or by using the service menu of monitor
unit. In case any fault code has been displayed by
diagnosis by using Dr. ZX (the service menu of
monitor unit), check the cause of the trouble by
referring to Troubleshooting A in this section. In
case any fault code has been displayed by diagnosis by using Dr. ZX (the service menu of monitor unit), write the fault code. Delete the fault code
once and retry self-diagnosis again. If the fault
code is displayed again, check the cause of the
trouble by referring to Troubleshooting A in this
section. After the machine trouble has been corrected, the fault code (displayed by the service
menu of monitor unit) will be deleted. Therefore,
in case the problems which are not easily
re-predicable are encountered, check the fault
code by using Dr. ZX.
In case the fault code is not displayed, check
operating condition of each component by referring to Troubleshooting B in this section and by
using Dr. ZX (the service menu of monitor unit).
NOTE: 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”.
T5-1-4
T107-07-01-005
T107-07-01-006
T107-07-01-007
TROUBLESHOOTING / Diagnosing Procedure
6. Trace possible causes
Before reaching a conclusion, check the most
likely causes again. Try to identify the actual
cause of the trouble.
Based on your conclusion, make a plan for
appropriate repairs to avoid consequent
malfunctions.
T5-1-5
TROUBLESHOOTING / Diagnosing Procedure
(Blank)
T5-1-6
TROUBLESHOOTING / Monitor Unit
OUTLINE
Primary Screen
7
1
2
3
4
5
6
8
9
10
11
12
13
14
15
16
17
18
35
34
20
33
1 - Work Mode Display
2 - Auto-Idle Display
3 - Overload Alarm Display
(Optional)
4 - Auto Axle Lock Display
5 - Auxiliary
6 - Glow Signal Display
7 - Trip Meter
8 - Odometer
9 - Hour Meter
32 31 30 29 28 27 26 25
24
23
22
20
19
TCJB-05-02-043
10 - Parking Brake Display
11 - Work Brake Display
12 - Axle Lock Display
19 - Trip Meter Display
20 - Odometer Display
21 - Hour Meter Display
13 - Work Light Display
14 - Auxiliary 2 (Positioning)
Selection Display
15 - Auxiliary 1 (Attachment)
Selection Display
16 - Blade/Outrigger Settings
and Brake Mode Display
17 - Mail Display (Optional)
18 - Clock
22 - Back Monitor Selection
23 - Menu
28 - Work Mode Display
29 - Auxiliary Selection
30 - Coolant Temperature
Gauge
31 - Work Mode Selection
32 - Return to Primary Screen
24 - Meter Display Selection
33 - Brake Oil Pressure Gauge
25 - Fuel Gauge
34 - Speedometer
26 - Auxiliary
27 - Mail Selection (Optional)
35 - Tachometer
T5-2-1
TROUBLESHOOTING / Monitor Unit
7
• Display of Meters
Data to be displayed on each meter are displayed on
the monitor unit according to the input signal from
sensor, the signal received from ICF by using CAN
and the internal data of monitor unit.
Items to be displayed
Trip Meter (Signal received from MC by using CAN)
Odometer (Signal received from MC by using CAN)
Hour Meter (Internal data of the monitor unit)
Clock (Signal received from ICF by using CAN)
Fuel Gauge (Input signal from the fuel sensor)
Coolant Temperature Gauge (Input signal from the
coolant temperature sensor)
33. Brake Oil Pressure Gauge (Signal received from
MC by using CAN)
34. Speedometer (Signal received from MC by using
CAN)
35. Tachometer (Signal received through MC from
ECM by using CAN)
18
7.
8.
9.
18.
25.
30.
34
33
30
25
8
9
TCJB-05-02-057
TCJB-05-02-056
TCJB-05-02-042
35
T5-2-2
TCJB-05-02-041
TROUBLESHOOTING / Monitor Unit
• Work Mode Display (1)
1
7
The attachments being used are displayed according to the signals received from MC by using CAN.
Digging Mode
18
T1V1-05-01-108
Attachment Mode
Breaker
T1V1-05-01-104
Pulverizer
TCJB-05-02-057
34
T1V1-05-01-105
Crusher
T1V1-05-01-106
Vibrating Hammer
T1V1-05-01-107
Others
T1V1-05-02-003
NOTE: The items on monitor unit and HITACHI
pattern are same.
Monitor Unit
HITACHI pattern
Breaker1
Hydraulic Breaker1
Breaker2
Hydraulic Breaker2
Pulverizer1
Secondary Crusher1
Crusher1
Primary Crusher1
T5-2-3
33
30
25
TROUBLESHOOTING / Monitor Unit
• Auto-Idle Display (2)
When the auto-idle switch on switch panel is turned
ON, the data is displayed.
When the key switch is turned ON with the auto-idle
switch ON, the data blinks for 10 seconds.
2
3
4
6
• Overload Alarm (3)
TCJB-05-02-061
The system measures the load of suspended load
from the boom cylinder bottom pressure sensor.
When overload is detected, an alarm is displayed.
(Refer to T5-2-15.)
• Auto Axle Lock Display (4)
The data is displayed when the brake switch in the
auto axle lock position.
• Glow Signal Display (5)
While ECM is supplying current to the glow plug, the
data is displayed according to the signal from ECM.
T5-2-4
TCJB-05-02-042
TROUBLESHOOTING / Monitor Unit
• Fuel Gauge (25)
30
25
The data of fuel level is displayed.
• Coolant Temperature Gauge (30)
Temperature of engine coolant is displayed.
TCJB-05-02-064
34
• Brake Oil Pressure Gauge (33)
33
Pressure in the brake circuit is displayed.
• Speedometer (34)
Travel speed is displayed.
NOTE: When the machine travels forward and although other setting on the monitor unit is
done, the primary screen is displayed.
(Screen Forcible Transition Control)
(Refer to the SYSTEM / Control System
group.)
TCJB-05-02-064
35
• Tachometer (35)
Engine speed is displayed.
NOTE: Speedometer (34) or tachometer (35) is
displayed on the monitor screen due to the
setting.
TCJB-05-02-065
T5-2-5
TROUBLESHOOTING / Monitor Unit
• Parking Brake Display (10)
When the parking brake is applied, the red indicator
lights.
(Brake Switch: P (Parking Brake) Position
4
10
11
12
• Work Brake Display (11)
When the work brake is applied (under the work
brake control), the red indicator lights.
(Refer to the SYSTEM/Control System group.)
• Axle Lock Display (12)
When the axle lock is operated, the red indicator
lights. (Brake Switch: Axle Lock or Auto Axle Lock
position)
(Refer to the SYSTEM/Control System group.)
NOTE: When the brake switch is in the auto axle
lock position and the lever is in neural, auto
axle lock display (4) or axle lock display
(12) lights.
At this time, the accelerator pedal is depressed, the axle lock is released by the
axle lock control and axle lock display (12)
goes off.
As the brake switch is in the auto axle lock
position, auto axle lock display (4) is kept to
light.
(Refer to the SYSTEM/Control System
group.)
T5-2-6
TCJB-05-02-042
TROUBLESHOOTING / Monitor Unit
• Work Light Display (13)
15
The work light switch is turned ON, the green indicator lights.
14
13
• Auxiliary 2 (Positioning) Selection Display (14)
When the auxiliary/positioning selection switch is in
the Positioning position, the green indicator lights.
16
• Auxiliary 1 (Attachment) Selection Display (15)
When the auxiliary/positioning selection switch is in
the Auxiliary (Attachment) position, the green indicator lights.
• Blade/Outrigger Setup and Brake Mode Display (16)
The combination data of blade/outrigger is displayed.
When the parking brake, work brake or
blade/outrigger is operated, the green indicator related to the operated function lights.
TCJB-05-02-042
When applying parking brake
NOTE: The illustration shows the screen on the
front outrigger and rear blade specification.
Green indicator
lights.
TCJB-05-02-074
When applying work brake
Green indicator
lights.
Green indicator
lights.
TCJB-05-02-075
When operating blade/outrigger
Green indicator
lights.
Green indicator
lights.
TCJB-05-02-102
T5-2-7
TROUBLESHOOTING / Monitor Unit
• Fuel Sensor Error Display
Coolant Temperature
Sensor Error Display
Fuel Sensor Error
Display
TCJB-05-02-104
When the fuel sensor is faulty or if the harness between fuel sensor and monitor unit is open circuit,
the data is displayed on the fuel gauge.
• Coolant Temperature Sensor Error Display
TCJB-05-02-103
When the coolant temperature sensor is faulty, the
data is displayed on the coolant temperature gauge.
TCJB-05-02-045
• Alarm and Remedy Displays against Alarm
Alarm marks are displayed on bottom of the screen
according to the alarm signals from pilot shut-off
lever, overheat switch, fuel sensor, hydraulic oil filter,
alarm switch (optional), air cleaner restriction switch,
alternator, battery system and ECM and the alarm
signals received from MC by using CAN. The remedy for each alarm is displayed by key operation.
T5-2-8
Alarm Display
TCJB-05-02-049
Remedy Display against
Alarm
T1V5-05-01-013
TROUBLESHOOTING / Monitor Unit
Main Menu
• Time Setting
Time is set. (Refer to T5-2-29.)
Time Set Screen
T1V5-05-01-021
Operating Conditions Screen
T1V5-05-01-025
• Operating Conditions
This screen displays machine operating hour, fuel
usage and fuel consumption rate registered by the
monitor unit.
(Refer to T5-2-32.)
• Attachment Selection (Work Mode)
(Only machines equipped with optional parts)
Selects digging mode and attachment mode set by
Dr. ZX on this screen.
(Refer to T5-2-40.)
NOTE: In attachment mode, the following four
modes are set by default.
1 - Digging
2 - Breaker 1
3 - Breaker 2
4 - Pulverizer 1
5 - Crusher 1
1
NOTE: The items on monitor unit and HITACHI
pattern are same.
Monitor Unit
HITACHI pattern
Breaker1
Hydraulic Breaker1
Breaker2
Hydraulic Breaker2
Pulverizer1
Secondary Crusher1
Crusher1
Primary Crusher1
T5-2-9
2
3
4
5
Attachment Selection Screen
T1V5-05-01-109
TROUBLESHOOTING / Monitor Unit
• Pump 2 Flow Rate Adjustment (Attachment Adjustment)
(Only machines equipped with optional parts)
When using the attachments, fine adjust flow rate of
pump 2 by keys 1 and 2 operation.
(Refer to T5-2-30.)
The signals from monitor unit are sent to MC by using CAN.
When breaker 1 or 2 is used, MC adjusts maximum
flow rate of pump 2 while controlling maximum pump
2 flow rate limit control solenoid valve. (Figure 1)
(Pump 2 Flow Rate Limit Control)
When pulverizer 1 or crusher 1 is used, MC adjusts
flow rate of pressure oil that flows from pump 2 to
pulverizer or crusher while controlling the auxiliary
flow rate control solenoid valve. (Figure 2) (Pulverizer / Crusher Control)
(Refer to the SYSTEM / Control System group.)
NOTE: When the 2-speed selector circuit is OFF,
maximum flow rate of pump 2 can be adjusted while controlling the maximum pump
2 flow rate limit control solenoid valve.
(Figure 1)
When the 2-speed selector circuit is ON,
flow rate of pressure oil that flows from
pump 2 to the attachments can be adjusted
while controlling the auxiliary flow rate control solenoid valve. (Figure 2)
The table blow shows the default.
Figure 1
Key 1
Key 2
When using Breaker 1
T1V5-05-01-111
Figure 2
Key 1
Key 2
When using Pulverizer 1
Type of
Attachments
Display
2-Speed
Selector Circuit
Valve Selector
Circuit
Accumulator
Circuit
Breaker 1
Breaker 2
Pulverizer 1
Crusher 1
Figure 1
Figure 1
Figure 2
Figure 2
OFF
OFF
ON
ON
O/T
O/T
C/V
C/V
OFF
OFF
OFF
OFF
NOTE: O/T: Hydraulic Oil Tank
C/V: Control Valve
NOTE: The items on monitor unit and HITACHI
pattern are same.
Monitor Unit
HITACHI pattern
Breaker 1
Hydraulic Breaker 1
Breaker 2
Hydraulic Breaker 2
Pulverizer 1
Secondary Crusher 1
Crusher 1
Primary Crusher 1
T5-2-10
T1V5-05-01-024
Secondary
Hydraulic
Relief Selector
Circuit
ON
OFF
OFF
OFF
TROUBLESHOOTING / Monitor Unit
• Maintenance Settings
The data; date of the last replacement, hour meter,
the remaining hours until the next replacement and
the replacement interval are displayed.
As the items to be replaced are displayed in a list,
record performed replacement by selecting an item
from the list.
(Refer to T5-2-34.)
• Interval ON/OFF Settings
Set change interval for each item to be replaced.
• Items included in Maintenance Settings
Engine Oil
Engine Oil Filter
Hydraulic Oil
Hydraulic Oil Pilot Filter
Hydraulic Oil Filter
Pump Transmission Oil
Swing Reduction Gear Oil
Swing Bearing Grease
Hydraulic Oil Brake Steering Filter
Travel Device Transmission Oil
Axle Gear Oil (Front, Rear, each Hub)
Drive Shaft Greasing
Front Axle King Pin Greasing
Front Axle Center Pin Greasing
Wheel Nut Torque Check
Air Filter
Engine/Air Conditioner V-belt
Fuel Filter
Air Conditioner Filter
User Setting (TRIP 1)
T5-2-11
Maintenance Setup Screen
T1V5-05-01-049
Interval ON/OFF Setup Screen
T1V5-05-01-052
TROUBLESHOOTING / Monitor Unit
• Mail (Optional Function)
Sends requests such as general, fuel replenishment,
service maintenance and forwarding requests in the
mail switch screen.
Contents of mails are registered in ICF, and are sent
to the central server by a satellite terminal.
(Refer to T5-2-44.)
Mail Switch Screen
T1V5-05-01-037
Meter Display Selection Screen
TCJB-05-02-072
• Meter Display Selection (HOUR↔ODO↔TRIP)
The meter display; hour meter, odometer and trip
meter on primary screen is switched.
The selected item is displayed on the primary
screen.
When the key switch is turned OFF, the item is reset
into the meter combination setting.
(Refer to T5-2-46.)
• Back Monitor Settings
By key operation, image display ON/OFF of
Auto-Control for switching image of the back monitor
while the machine travels backward.
(Refer to T5-2-52.)
T1V5-05-01-173
T5-2-12
TROUBLESHOOTING / Monitor Unit
• Language Settings
Select a language to be used in screens from
among preset languages, according to work environment. (Refer to T5-2-56.)
Language Setup Screen
T1V1-05-01-137
Meter Combination Setup Screen
TCJB-05-02-068
Unit Setup Screen
TCJB-05-02-016
• Meter Combination Settings (km/h↔min-1)
-1
Speedometer (km/h), tachometer (min ), hour meter,
odometer and trip meter on the primary screen are
combined and set respectively.
(Default: Speedometer+Hour Meter)
(Refer to T5-2-58.)
• Unit Setting (km↔mile)
The units; km and mile, in the primary screen are set.
(Refer to T5-2-60.)
T5-2-13
TROUBLESHOOTING / Monitor Unit
• Service Menu (Built-In Diagnosing System)
• Troubleshooting
This screen displays the fault codes according to
the signals received from each controller by using
CAN.
(Refer to T5-2-64.)
Fault Code Display
T1V5-05-01-097
Monitoring Screen
T1V5-05-01-087
• Monitoring
This screen displays temperature and pressure
data received from each controller by using CAN.
By key operation, the displayed data can be hold.
(Refer to T5-2-66.)
• Controller Version
This screen displays the version of MC, ICF,
monitor unit, steering column monitor and option
controller.
(Refer to T5-2-70.)
NOTE: The version of ECM is not displayed.
Controller Version Display
TCHB-05-02-008
Blade/Outrigger Setup Screen
TCHB-05-02-009
• Blade/Outrigger Settings
Combination of blade and outrigger displayed on
the primary screen is set.
(Refer to T5-2-72.)
T5-2-14
TROUBLESHOOTING / Monitor Unit
• Overload Alarm
Overload Alarm
(Only the machines equipped with optional parts)
IMPORTANT: When using overload alarm, make
overload alarm available by using Dr.
ZX.
1. MC detects load of the suspended load by the
signal from the boom bottom pressure sensor.
2. When the overload alarm switch (optional) is
turned ON and load of the suspended load becomes overloaded, the monitor unit displays an
alarm message on the primary screen and rings a
buzzer according to the signal from MC by using
CAN.
3. If overload of the suspended load is dissolved, the
alarm message disappears and the buzzer stops
ringing.
Primary Screen
TCJB-05-02-042
Overload Alarm Switch
(Optional)
NOTE: Even if the work is done while displaying a
screen except the primary screen, when an
overload condition is reached, the screen
of monitor unit is switched to the primary
screen, an alarm message is displayed and
a buzzer is rung.
Even after the overload alarm is dissolved,
the monitor unit keeps on displaying the
primary screen without returning to the
screen while the work is done.
T1V1-05-02-004
T5-2-15
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-16
TROUBLESHOOTING / Monitor Unit
HOW TO USE SCREENS
Displaying Primary Screen
IMPORTANT: Start the engine after the primary
screen is displayed.
When the key switch is turned to the ON position, the
starting screen appears for about two seconds and the
primary screen appears.
Key Switch: ON
T1V1-05-01-115
Primary Screen
TCJB-05-02-064
IMPORTANT: Until the alternator starts generating
power after the engine starts, alternator alarm is displayed on the primary screen.
Alternator Alarm
T5-2-17
TCJB-05-02-050
TROUBLESHOOTING / Monitor Unit
Displaying Primary Screen by Password Input
(Optional)
IMPORTANT: Before performing this operation,
make the password function available by using Dr. ZX.
1. When the key switch is turned to the ON position,
the starting screen appears and the primary
screen appears.
NOTE: Only the operations including the engine
start and key 1 on the monitor unit can be
done on this screen.
Starting Screen
T1V1-05-01-115
Primary Screen
TCJB-05-02-054
Password
Icon
Key 1
2. When key 1 is pushed or the key switch is turned
to the START position, the password input screen
appears.
Password Input Screen
T5-2-18
T1V5-05-01-093
TROUBLESHOOTING / Monitor Unit
3. Input a password by using the keys located under
the screen. If pushing the confirm key, the monitor
unit matches the input password to the registered
one. If they match, the primary screen appears.
NOTE: When inputting the password again, the
entered characters can be erased by
pushing the erase key.
Confirm Key
Erase Key
T1V5-05-01-002
Primary Screen
T5-2-19
TCJB-05-02-064
TROUBLESHOOTING / Monitor Unit
In Case of Inputting an Incorrect Password
1. If inputting an incorrect password, the message
“Password is incorrect.” appears by pushing the
confirm key.
Password Input Screen
Confirm Key
T1V5-05-01-093
Erase Key
T1V5-05-01-002
Back Key
T1V5-05-01-004
2. Return to the password input screen by pushing
the back key.
NOTE: When inputting the password again, the
entered characters can be erased by
pushing the erase key.
T1V5-05-01-093
T5-2-20
TROUBLESHOOTING / Monitor Unit
3. If inputting an incorrect password three times, a
screen appears informing that the security lock
has been applied, and a buzzer rings. While the
key switch is turned to the ON position, the buzzer
does not stop ringing. When the key switch is
turned to the OFF position, the security lock display disappears and the buzzer rings for thirty
seconds.
4. If the key switch is turned to the ON position after
the buzzer stops ringing, the starting screen appears and the primary screen appears again.
Then a password can be input again. After that,
when key 1 is pushed or the key switch is turned
to the START position, the password input screen
appears and the password can be re-input. If inputting an incorrect password even once this time,
the security lock screen appears again and a
buzzer rings. While the key switch is turned to the
ON position, the buzzer does not stop ringing.
When the key switch is turned to the OFF position,
the buzzer rings for thirty seconds.
Security Lock Screen
T1V5-05-01-005
Primary Screen
TCJB-05-02-054
Password
Icon
Key 1
5. After the buzzer stops ringing, a password can be
input. Turn the key switch to the ON position and
input a password after the password input screen
appears. (Refer to T5-2-20).
6. If inputting an incorrect password again, the security lock screen appears again and a buzzer
rings. While the key switch is turned to the ON
position, the buzzer does not stop ringing. When
the key switch is turned to the OFF position, the
buzzer rings for thirty seconds.
Password Input Screen
T5-2-21
T1V5-05-01-093
TROUBLESHOOTING / Monitor Unit
Extending Password Duration Time
IMPORTANT: This operation is applicable only to
those machines that display the
primary screen based upon password input.
By using the password duration screen, password
duration time can be set. When restarting the machine,
a password need not be input within that timeframe.
1. When the key switch is turned to the OFF position,
the monitor unit displays the password duration
screen for ten seconds.
Key 1
2. While the password duration screen is still displayed, push a relevant key, and password duration time is set.
Duration time assigned to each key is as follows:
key 1: 0 minute
key 2: 30 minutes
key 3: 60 minutes
key 4: 90 minutes
key 5: 120 minutes
Key 2
Key 3
Key 4
Key 5
T1V1-05-01-012
Password Duration Screen (Key Switch: OFF)
NOTE: If password duration time is not set explicitly, 0 minute on duration time is assumed.
3. If the key switch is turning to the ON position
within password duration time, the monitor unit
displays the primary screen after the starting
screen.
T5-2-22
Key Switch: ON
T1V1-05-01-115
Primary Screen
TCJB-05-02-064
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-23
TROUBLESHOOTING / Monitor Unit
SCREEN DISPLAY WHEN AN ALARM IS
ISSUED
When an alarm is issued, the alarm marks are displayed at the bottom of screen.
• When the number of alarm is three or less
TCJB-05-02-046
• When the number of alarm is four to five
TCJB-05-02-047
• When the number of alarm is six to seven
TCJB-05-02-048
• When the number of alarm is eight or more
TCJB-05-02-049
T5-2-24
TROUBLESHOOTING / Monitor Unit
When an alarm is issued, if the key under a relevant
alarm mark is pushed, the remedy against the alarm is
displayed.
Push a Relevant Key
TCJB-05-02-046
T1V5-05-01-013
T5-2-25
TROUBLESHOOTING / Monitor Unit
CONTENTS OF ALARMS
Display
Buzzer
Contents of Alarms
Overheat Alarm
Continuously
sounds
M178-01-036
Engine Warning Alarm
-
Remedy
Temperature of engine coolant is going up abnormally
higher.
Stop the work. Run the engine at low idle in order to
lower the coolant temperature.
Failure of the engine or its related parts.
Please contact our authorized distributor or dealer.
M183-01-080
Continuously
sounds
Engine Oil Pressure Pressure of engine lubricant oil is decreasing.
Alarm
Stop the engine immediately and inspect the engine oil
system and oil level of the engine.
M178-01-037
Alternator Alarm
The electrical system is faulty.
Inspect the alternator and battery system.
Fuel Level Alarm
Level of remaining oil is becoming less.
Refuel oil earlier.
M183-01-071
M178-01-034
-
Hydraulic
Alarm
Oil
Filter The hydraulic oil filter is clogged.
Clean or replace the hydraulic oil filter.
Air Filter
Alarm
Restriction The air filter is clogged.
Clean or replace the air filter.
M1CC-01-039
M183-01-067
-
Hydraulic Oil
perature Alarm
Tem- Hydraulic oil temperature is going up abnormally higher.
Stop operation. Run the engine at low idle in order to
lower the oil temperature.
T1JB-05-02-001
T5-2-26
TROUBLESHOOTING / Monitor Unit
Display
Buzzer
Contents of Alarms
Brake Pressure Alarm
Remedy
Brake oil pressure is low.
Please contact our authorized distributor or dealer.
Attachment Operating
Signal Alarm
Attachment pedal operating signal is abnormal.
Please contact our authorized distributor or dealer.
Blade/Outrigger Operating Signal Alarm
Blade/outrigger operating signal is abnormal.
Please contact our authorized distributor or dealer.
Assist Operating Signal
Alarm
Assist operating signal is abnormal.
Please contact our authorized distributor or dealer.
Electric Lever Solenoid
Valve Output Alarm
Electric lever solenoid valve output is abnormal.
Please contact our authorized distributor or dealer.
Network Alarm
Network system is abnormal.
Please contact our authorized distributor or dealer.
Work Mode Alarm
Network system is abnormal.
Please contact our authorized distributor or dealer.
Continuously
sounds
TCJB-05-02-032
Intermittently
sounds
TCJB-05-02-033
Intermittently
sounds
TCJB-05-02-034
TCJB-05-02-035
Continuously
sounds
TCJB-05-02-036
TCJB-05-02-037
T1V1-05-01-102
Pilot Shut-Off Lever Alarm The pilot shut-off lever system is abnormal.
Please contact our authorized distributor or dealer.
T1V1-05-01-103
T5-2-27
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-28
TROUBLESHOOTING / Monitor Unit
TIME SETTING
1. When the primary screen appears, push the
menu key and display main menu.
Menu Key
Primary Screen
TCJB-05-02-064
2. Select time set from main menu by using keys 1
and 2. Push the confirm key. Then, the time setup
screen appears.
Back Key
Key 1
Key 2
T1V5-05-01-019
Confirm Key
3. On the time setup screen, select the items to be
set (Year, Month, Day and Time) by using keys 1
and 2 and set the figures by using keys 3 and 4.
Move the
item to
this icon
4. By using key 2, move the item to
. Push the
confirm key. Then, system time is updated with
the values specified on the screen.
NOTE: When pushing the back key, return to the
previous screen.
Back Key
5. Push key 6, and return to the primary screen.
Key 1
Key 2
Key 3
Key 4
Confirm Key
T1V5-05-01-021
Back Key
Key 6
T5-2-29
T1V5-05-01-022
TROUBLESHOOTING / Monitor Unit
ATTACHMENT ADJUSTMENT
(PUMP 2 FLOW RATE ADJUSTMENT)
NOTE: Only the machines equipped with optional
parts.
IMPORTANT: This operation is effective when attachments are used.
When using breaker 1 or breaker 2
1. When the primary screen appears, push the
menu key and display main menu.
Menu Key
Primary Screen
2. Select Attachment Adjustment from main menu
by using keys 1 and 2. Push the confirm key.
Then, the attachment adjustment screen appears.
TCJB-05-02-0064
3. Push key 2. Then, the attachment adjustment
screen for currently installed attachments appears.
Key 1
Key 2
Key 1
Key 2
Confirm Key
T1V5-05-01-019
4. Adjust flow rate of pump 2 by using keys 1 and 2.
When breaker 1 or breaker 2 is used, pushing key
1 will decrease flow rate of pump 2 and pushing
key 2 will increase respectively.
NOTE: When pushing the back key, return to the
previous screen.
5. Push key 6, and the primary screen appears.
T5-2-30
Back Key
T1V5-05-01-111
TROUBLESHOOTING / Monitor Unit
NOTE: Only the machines equipped with optional
parts.
IMPORTANT: This operation is effective when attachments are used.
When using pulverizer or crusher
1. When the primary screen appears, push the
menu key and display main menu.
2. Select attachment adjustment from main menu by
using keys 1 and 2. Push the confirm key. Then,
the attachment adjustment screen appears.
Menu Key
Primary Screen
TCJB-05-02-0064
3. Push key 2. Then, the attachment adjustment
screen for currently installed attachments appears.
Key 1
Key 2
Confirm Key
T1V5-05-01-019
4. When the pulverizer or crusher is used, pushing
key 1 will increase flow rate of boom raise, arm
roll-out, swing or travel circuit sides.
Pushing key 2 will increase flow rate of attachment side.
NOTE: When pushing the back key, return to the
previous screen.
5. Push key 6, and the primary screen appears.
Key 1
T5-2-31
Key 6
Key 2
Back Key
T1V5-05-01-024
TROUBLESHOOTING / Monitor Unit
DISPLAYING OPERATING CONDITIONS
1. When the primary screen appears, push the
menu key and display main menu.
Menu Key
Primary Screen
TCJB-05-02-064
2. Select operating conditions from main menu by
using keys 1 and 2. Push the confirm key. Then,
the operating conditions screen appears.
Key 1
Key 2
T1V5-05-01-019
Confirm Key
3. Push the reset key, and a screen appears in order
to confirm if it's OK to reset data.
If it’s OK to reset data, push the confirm key.
NOTE: When pushing the back key, return to the
previous screen.
IMPORTANT: Total fuel consumption and fuel
consumption rate depend on the
operating environment and the operation method of machine.
The values shown on the screen are
just for reference.
There could arise ± 20% of differences between actual fuel consumption and fuel consumption
which is displayed by the monitor
unit.
Reset Key
Back Key
T1V5-05-01-025
4. Push key 6, and the primary screen appears.
Back Key
Key 6
T5-2-32
Confirm Key
T1V5-05-01-026
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-33
TROUBLESHOOTING / Monitor Unit
MAINTENANCE SETTINGS
1. When the primary screen appears, push the
menu key and display main menu.
Menu Key
Primary Screen
2. Select maintenance settings from main menu by
using keys 1 and 2. Push the confirm key. Then,
the maintenance settings screen appears.
TCJB-05-02-064
Key 1
Key 2
Confirm Key
T1V5-05-01-019
Key 1
Key 2
Confirm Key
T1V5-05-01-049
3. Select an item to be set from among the list of
maintenance settings screen by using keys 1 and
2. Push the confirm key. Then, the interval
ON/OFF setup screen appears.
(In the right example, Engine Oil is selected.)
T5-2-34
TROUBLESHOOTING / Monitor Unit
Maintenance Information Display ON/OFF
Example: Maintenance Information Display OFF→ON
ON:
When time comes to change, the information message is displayed on the screen.
OFF: No information message is displayed.
1. Select maintenance information display by using
keys 1 and 2.
Key 1
Confirm
Key
Key 2
2. Push the confirm key and select ON.
Key 6
3. In order to complete setting, push key 6. Then,
the primary screen appears.
T5-2-35
Interval ON/OFF Setup Screen
T1V5-05-01-052
Primary Screen
TCJB-05-02-064
TROUBLESHOOTING / Monitor Unit
Change Interval Settings
IMPORTANT: Change interval can only be set
when maintenance information display is set to ON.
1. Select change interval by using keys 1 and 2.
2. Set time for change interval by using keys 3 and
4.
Key 1
Key 2
Key 3
Key 4
T1V5-05-01-052
Interval ON/OFF Setup Screen
3. Select remaining hours by using keys 1 and 2 and
push the confirm key.
Key 1
Key 2
Confirm Key
T1V5-05-01-138
4. The message “Adjust remaining hours to new
change interval. OK?” appears. Then, push the
confirm key.
5. Push key 6, and the primary screen appears.
Key 6
Confirm Key
T1V5-05-01-139
Menu Key
Primary Screen
T5-2-36
TCJB-05-02-064
TROUBLESHOOTING / Monitor Unit
Resetting Data
If data is reset, push key 5 on the interval ON/OFF
setup screen.
The message “Reset Data. OK?” appears. Then,
push the confirm key.
The value of remaining hours is reset to that of
change interval. The previous change date/hour is
updated with current date and time.
Key 5
Interval ON/OFF Setup Screen
Confirm Key
T5-2-37
T1V5-05-01-052
T1V5-05-01-140
TROUBLESHOOTING / Monitor Unit
Screen Display when Maintenance Information
Display is ON
Notice
• When only one item is displayed
1. If the key switch is turned to the ON position, the
primary screen appears. At this time, if maintenance is required, the primary screen gives notice
of the maintenance item. In three seconds, the
maintenance information display screen is displayed automatically.
(In the right example, Hydraulic Oil is displayed.)
NOTE: As for a machine which the primary screen
is displayed according to a password on,
after the password is input successfully and
the confirm key is pushed. And then the
primary screen appears.
Primary Screen
2. If data is reset, push the reset key while the
maintenance information display screen is displayed.
The message “Reset Data. OK?” appears. Then,
push the confirm key.
The value of remaining hours is reset to that of
change interval. The previous change date/hour
is updated with current date and time.
NOTE: When pushing the back key while the
maintenance information display screen is
displayed, return to the primary screen.
TCJB-05-02-055
Back Key
Reset Key
Maintenance Information Display Screen
T1V5-05-01-170
NOTE: When pushing the back key while reset
screen is displayed, return to the maintenance information display screen.
3. After the maintenance information display screen
is displayed for ten seconds, the primary screen is
displayed.
Back Key
Confirm Key
T5-2-38
Reset Screen
T1V5-05-01-171
Primary Screen
TCJB-05-02-064
TROUBLESHOOTING / Monitor Unit
Notice
• When more than two items are displayed
1. If the key switch is turned to the ON position, the
primary screen appears. At this time, if maintenance is required, the primary screen gives notice
of the maintenance item. In three seconds, the
maintenance information display screen is displayed automatically.
(In the right example, Hydraulic Oil is displayed.)
NOTE: As for a machine which the primary screen
is displayed according to a password on,
after the password is input successfully and
the confirm key is pushed. And then the
primary screen appears.
Primary Screen
TCJB-05-02-055
2. If data is reset, while the scheduled maintenance
screen is displayed, select the required item by
using keys 1 and 2. Push the confirm key. Then,
the maintenance information display screen for
the selected item appears.
(In the right example, Hydraulic Oil is selected.)
NOTE: When pushing the back key while the
scheduled maintenance screen is displayed, the primary screen appears.
Key 1
Back Key
Key 2
Confirm
Key
3. Push the reset key while the maintenance information display screen is displayed.
The message “Reset Data. OK?” appears. Then,
push the confirm key.
The value of remaining hours is reset to that of
change interval. The previous change date/hour
is updated with current date and time.
Scheduled Maintenance Screen
NOTE: When pushing the back key while the
maintenance information display screen is
displayed, return to the scheduled maintenance screen.
T1V5-05-01-169
Back Key
Reset Key
NOTE: When pushing the back key while the reset
screen is displayed, return to the maintenance information display screen.
Maintenance Information Display Screen
TCHB-05-02-011
4. After the maintenance information display screen
is displayed for ten seconds, the primary screen is
displayed.
Back Key
Reset Screen
T5-2-39
T1V5-05-01-171
TROUBLESHOOTING / Monitor Unit
WORK MODE (ATTACHMENT SELECTION)
NOTE: Only the machines equipped with optional
parts.
IMPORTANT: Select the attachments from the
work mode screen.
In order to display the work mode
screen, push key F1 after the primary screen appears, or select from
main menu.
Selecting Attachment by Using Key F1
Key F1
1. When the primary screen appears, push key F1
and display the work mode screen.
Primary Screen
TCJB-05-02-064
2. Push a relevant key under an attachment mark to
be used in order to select the attachment.
(In the right example, Crusher 1 is selected.)
NOTE: When selecting Digging, return to the primary screen.
Digging
Back Key
Select Crusher
1
Work Mode Screen
T1V5-05-01-109
3. On the attachment specification screen, confirm if
specification of the installed attachment agrees
with that displayed on the screen.
NOTE: When pushing the back key, return to the
previous screen.
4. Push the confirm key, and the primary screen
appears.
Back Key
Confirm
Key
Attachment Specification Screen
T5-2-40
TCEB-05-02-008
TROUBLESHOOTING / Monitor Unit
Selecting Attachment from Main Menu
1. When the primary screen appears, push the
menu key and display main menu.
Menu Key
Primary Screen
TCJB-05-02-064
2. Select work mode from main menu by using keys
1 and 2. Push the confirm key. Then, the work
mode screen appears.
Back Key
Key 1
Key 2
Confirm Key
TCHB-05-02-001
3. Push the relevant key under an attachment mark
to be used in order to select the attachment.
(In the right example, Crusher 1 is selected.)
NOTE: When selecting digging, return to main
menu.
4. On the attachment specification screen, confirm if
specification of the installed attachment agrees
with that displayed on the screen.
If they do not match, perform the setting of attachment by using Dr. ZX.
For details of the attachment specification screen,
refer to T5-2-42 and 43.
Digging
Back Key
Select
Crusher 1
Work Mode Screen
T1V5-05-01-109
NOTE: When pushing the back key, return to the
previous screen.
5. Push the confirm key, and the primary screen
appears.
Back Key
Confirm
Key
Attachment Specification Screen
T5-2-41
TCEB-05-02-008
TROUBLESHOOTING / Monitor Unit
Attachment Specification Screen
Maximum Pump 2 Flow Rate
Maximum Engine Speed
Accumulator Control Solenoid Valve:
OFF
Secondary Hydraulic Relief Selector
Control Solenoid Valve: ON
Selector Valve Control Solenoid Valve: ON
The selector valve is connected to the
hydraulic oil tank.
Auxiliary Flow Combiner Solenoid
Valve: OFF
TCEB-05-02-005
Maximum Pump 2 Flow Rate
Maximum Engine Speed
Accumulator Control Solenoid Valve:
OFF
Secondary Hydraulic Relief Selector
Control Solenoid Valve: OFF
Selector Valve Control Solenoid Valve: ON
The selector valve is connected to the
hydraulic oil tank.
Auxiliary Flow Combiner Solenoid Valve:
OFF
TCEB-05-02-006
T5-2-42
TROUBLESHOOTING / Monitor Unit
Maximum Pumps 1 and 2 Flow Rate
Maximum Engine Speed
Accumulator Control Solenoid Valve:
OFF
Secondary Hydraulic Relief Selector
Control Solenoid Valve: OFF
Selector Valve Control Solenoid Valve: OFF
The selector valve is connected to the control
valve.
Auxiliary Flow Combiner Solenoid Valve:
ON
TCEB-05-02-007
Maximum Pumps 1 and 2 Flow Rate
Maximum Engine Speed
Accumulator Control Solenoid Valve:
OFF
Secondary Hydraulic Relief Selector
Control Solenoid Valve: OFF
Selector Valve Control Solenoid Valve: OFF
The selector valve is connected to the control
valve.
Auxiliary Flow Combiner Solenoid Valve:
ON
TCEB-05-02-008
T5-2-43
TROUBLESHOOTING / Monitor Unit
MAIL (Optional)
IMPORTANT: This function is available only to a
machine equipped with a satellite
terminal.
When using the mail function, make
the mail function available by using
Dr. ZX.
1. When the primary screen appears, push key F3
and display the mail screen.
2. If a relevant request key is pushed, mail information is sent to ICF.
1 - General Request
2 - Fuel Replenishment Request
3 - Service Maintenance Request
4 - Forwarding Request
Primary Screen
Key F3
1
2
3
Mail Screen
TCJB-05-02-044
4
T1V5-05-01-037
3. While mail information is sent to ICF, the message
“Mail is being delivered.” is displayed on the
screen.
4. When ICF completes receives mail information,
the message “Mail delivery successful.” is displayed on the screen.
When pushing the back key, return to the mail
screen.
T1V5-05-01-038
5. Then, a mail is sent from the satellite terminal to
the central server via the satellite.
NOTE: Depending on machine operating environment or position of the satellite on its
orbit, the mail may not be sent.
Back Key
T1V5-05-01-039
T5-2-44
TROUBLESHOOTING / Monitor Unit
NOTE: When ICF could not receive the mail, the
message “Mail delivery failed.” is displayed
on the screen.
T1V5-05-01-040
T5-2-45
TROUBLESHOOTING / Monitor Unit
METER DISPLAY SELECTION
NOTE: The meter display selection screen is displayed by pushing key F4 or selecting main
menu after the primary screen is displayed.
Select Meter Display Selection from Key F4
1. After the primary screen is displayed, push key F4.
Then, the meter display selection screen is displayed.
Key F4
NOTE: If key F4 is pushed for two seconds or more,
the meter display is changed on the primary
screen as follows.
Hour Meter → Odometer → Trip Meter
Primary Screen
2. Select the meter by using keys 1 and 2. Push the
confirm key. (In the right example, Trip Meter is
selected.)
NOTE: When pushing the back key, return to the
previous screen.
3. Only when the trip meter is selected, the data reset icon is displayed. If data is reset, push key 5.
TCJB-05-02-064
Data Reset
Icon
Key 1
Back Key
Key 6
Key 2
4. The message “Reset Data. OK?” appears. Push
the confirm key.
Confirm
Key
Meter Display Selection Screen
Key 5
TCJB-05-02-012
5. Push key 6, and the primary screen is displayed.
NOTE: The contents which are set by the meter
display selection are available until the key
switch is turned OFF. When the key switch
is turned OFF, the contents are reset to
those by the meter combination settings.
Back Key
Confirm
Key
Key 6
TCHB-05-02-006
Primary Screen
T5-2-46
TCJB-05-02-071
TROUBLESHOOTING / Monitor Unit
NOTE: The meter display selection screen is displayed by pushing key F4 or selecting main
menu after the primary screen is displayed.
Select Meter Display Selection from Main Menu
1. After the primary screen is displayed, push the
menu key. The main menu is displayed.
Primary Screen
2. Select HOUR ↔ ODO ↔ TRIP from main menu
by using keys 1 and 2. Push the confirm key. Then,
the meter display selection screen is displayed.
TCJB-05-02-069
Back Key
Key 1
Key 2
Confirm Key
TCHB-05-02-001
3. Select the meter by using keys 1 and 2. Push the
confirm key. (In the right example, Hour Meter is
selected.)
NOTE: When pushing the back key, return to the
previous screen.
4. Push key 6, and the primary screen is displayed.
Key 1
Back Key
NOTE: The contents which are set by the meter
display selection are available until the key
switch is turned OFF. When the key switch
is turned OFF, the contents are reset to
those by the meter combination settings.
Key 2
Key 6
T5-2-47
Confirm
Key
Meter Display Selection Screen
TCJB-05-02-072
Primary Screen
TCJB-05-02-064
TROUBLESHOOTING / Monitor Unit
PASSWORD CHANGE (OPTIONAL)
1. After the primary screen is displayed, push the
menu key and display main menu.
Menu Key
Primary Screen
TCJB-05-02-064
2. Select password change from main menu by using keys 1 and 2. Push the confirm key. Then, the
password change screen appears.
Key 1
Key 2
Confirm Key
TCHB-05-02-002
T1V5-05-01-041
Registered Password
3. Input the registered password and push the confirm key.
4. If inputting the password again, the entered
characters can be erased by pushing the erase
key.
Confirm Key
T5-2-48
Erase Key
T1V5-05-01-042
TROUBLESHOOTING / Monitor Unit
NOTE: If inputting an incorrect password after
pushing the confirm key, the message
“Password is incorrect.” appears.
Push the back key and go back to the previous screen. Input the password again.
Back Key
T1V5-05-01-044
5. The message “Enter password to be registered.”
appears. Then, input a new password with three
or four digits and push the confirm key.
6. If inputting the password again, push the erase
key.
T1V5-05-01-130
A New Password
Confirm Key
T5-2-49
Erase Key
T1V5-05-01-131
TROUBLESHOOTING / Monitor Unit
7. The message “Re-enter password.” appears.
Then, input a new password again and push the
confirm key.
8. If inputting the password again, push the erase
key in order to erase the entered characters.
T1V5-05-01-132
Confirm Key
Erase Key
T1V5-05-01-133
9. The message “New password has been registered.” appears. This completes the password
change process.
T1V5-05-01-043
Key 6
10. Push key 6, and the primary screen appears.
Primary Screen
T5-2-50
TCJB-05-02-064
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-51
TROUBLESHOOTING / Monitor Unit
BACK MONITOR SETTINGS
IMPORTANT: Image displayed on the back monitor
is of auxiliary nature at best. When
the machine is operated, pay thorough attention to surrounding situation.
Auto-Control: ON
When the FNR switch is turned to the R (reverse)
position, image on the monitor unit is automatically
switched to that of the back monitor.
Menu Key
Primary Screen
1. When the primary screen appears, push the menu
key and display main menu.
TCJB-05-02-064
2. Select back monitor settings from main menu by
using keys 1 and 2. Push the confirm key. Then,
the back monitor settings screen appears.
Back Key
Key 1
Key 2
Confirm Key
TCHB-05-02-003
3. Push the confirm key. Then, auto-control is set to
ON.
NOTE: When pushing the back key, return to the
previous screen.
4. Push key 6, and return to the primary screen.
Back Key
Key 1
Key 2
Confirm Key
T1V5-05-01-173
Back Key
Key 6
T1V5-05-01-174
T5-2-52
TROUBLESHOOTING / Monitor Unit
5. When the FNR switch is turned to the R (reverse)
position, image on the monitor unit is switched to
rear view image.
NOTE: After rear view image is displayed on the
monitor unit screen and although the accelerator pedal returns to the neutral position, rear view image is displayed for three
seconds. If step 2 below is done in three
seconds after rear view image is displayed,
rear view image is not displayed on the
monitor unit screen.
1. Return rear view image to the primary
screen.
2. Turn the FNR switch to the R (reverse)
position.
(While the FNR switch is in the R (reverse)
position, rear view image is not displayed.)
If step 1 above is done in three seconds
after rear view image is displayed, rear view
image is displayed on the monitor unit
screen.
T5-2-53
TROUBLESHOOTING / Monitor Unit
Auto-Control: OFF
When the FNR switch is the R (reverse) position,
automatic switching function of images between
monitor unit and back monitor is set to OFF.
1. When the primary screen appears, push the menu
key and display main menu.
Menu Key
TCJB-05-02-064
Primary Screen
2. Select back monitor settings from main menu by
using keys 1 and 2. Push the confirm key. Then,
the back monitor settings screen appears.
Key 1
Key 2
Confirm Key
Back Key
TCHB-05-02-003
3. Push the confirm key. Then, auto-control is set to
OFF.
NOTE: When pushing the back key, return to the
previous screen.
4. Push key 6, and return to the primary screen.
Confirm Key
Back Key
T1V5-05-01-174
Back Key
Key 6
T1V5-05-01-173
T5-2-54
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-55
TROUBLESHOOTING / Monitor Unit
LANGUAGE SETTINGS
1. When the primary screen appears, push the menu
key and display main menu.
Menu Key
Primary Screen
TCJB-05-02-064
2. Select language from main menu by using keys 1
and 2. Push the confirm key. Then, the language
settings screen appears.
Key 1
Key 2
Confirm Key
Back Key
TCHB-05-02-003
3. Select a desired language by using keys 1 and 2.
Push the confirm key.
NOTE: Languages to be displayed on the screen
of monitor unit have been selected from
twelve languages, namely display languages 1 or 2, as default.
(Refer to the next page.)
NOTE: When pushing the back key, return to the
previous screen.
Back Key
4. Push key 6, and the primary screen appears.
Key 1
T5-2-56
Key 6
Key 2
Confirm Key
T1V1-05-01-137
TROUBLESHOOTING / Monitor Unit
Lists of Display Languages
Display Languages 1
Language
Screen Display
Japanese
T1V1-05-01-141
English
T1V1-05-01-142
Chinese
T1V1-05-01-143
Taiwanese
T1V1-05-01-144
Korean
T1V1-05-01-145
Indonesian
T1V1-05-01-146
Thai
T1V1-05-01-147
Vietnamese
T1V1-05-01-148
Myanmarese
T1V1-05-01-149
Arabic
T1V1-05-01-150
Persian
T1V1-05-01-151
Turkish
T1V1-05-01-152
Display Languages 2
Language
Screen Display
English
T1V1-05-01-142
Spanish
T1V1-05-01-153
Italian
T1V1-05-01-154
French
T1V1-05-01-155
German
T1V1-05-01-156
Netherlandish
T1V1-05-01-157
Russian
T1V1-05-01-158
Portugese
T1V1-05-01-159
Finlandish
T1V1-05-01-160
Swedish
T1V1-05-01-161
Norwegean
T1V1-05-01-162
Danish
T1V1-05-01-163
T5-2-57
TROUBLESHOOTING / Monitor Unit
METER COMBINATION SETTINGS
1. After the primary screen is displayed, push the
menu key and display main menu.
Menu Key
Primary Screen
TCJB-05-02-064
Confirm Key
TCHB-05-02-003
-1
2. Select km/h ↔ min from main menu by using
keys 1 and 2. Push the confirm key. Then, the
meter combination setup screen is displayed.
NOTE: If mile is selected by unit settings (km ↔
-1
mile), mph ↔ min is displayed.
Key 1
Key 2
Back Key
3. Select the meter combination by using keys 1 and
2. Push the confirm key.
NOTE: When pushing the back key, return to the
previous screen.
4. Push key 6, and the primary screen is displayed.
Key 1
Back Key
Key 2
Confirm
Key
Key 6
Meter Combination Setup Screen
TCJB-05-02-015
Key 1
Back Key
Key 2
Confirm
Key
Key 6
T5-2-58
Meter Combination Setup Screen
TCJB-05-02-068
TROUBLESHOOTING / Monitor Unit
NOTE: Examples of combination
Odometer
• When selecting km (speedometer) and odometer
Speedometer
(km)
TCJB-05-02-069
• When selecting min-1 (tachometer) and hour me-
Hour Meter
ter
Tachometer
TCJB-05-02-065
Trip
Meter
• When selecting mph (speedometer) and trip meter
(Unit: When selecting mile)
Speedometer
(mile)
TCJB-05-02-070
T5-2-59
TROUBLESHOOTING / Monitor Unit
UNIT SETTINGS
1. After the primary screen is displayed, push the
menu key and display main menu.
Menu Key
Primary Screen
TCJB-05-02-064
2. Select km/h ↔ mile from main menu by using
keys 1 and 2. Push the confirm key. Then, the unit
combination setup screen is displayed.
Key 1
Key 2
Confirm Key
Back Key
TCHB-05-02-003
3. Select the unit by using keys 1 and 2. Push the
confirm key.
NOTE: When pushing the back key, return to the
previous screen.
4. Push key 6, and the primary screen is displayed.
Key 1
Back Key
Key 2
Confirm
Key
Key 6
T5-2-60
Unit Setup Screen
TCJB-05-02-016
TROUBLESHOOTING / Monitor Unit
NOTE: Examples
• When selecting km
TCJB-05-02-069
• When selecting mile
TCJB-05-02-070
T5-2-61
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-62
TROUBLESHOOTING / Monitor Unit
SERVICE MENU (BUILT-IN DIAGNOSING
SYSTEM) OPERATION
IMPORTANT: This system is to be operated by the
HITACHI dealer only. Do not explain
this system function to the customer.
Although Dr.ZX id not used, the following items can be
displayed on the monitor unit.
• Troubleshooting:
The fault code is displayed.
• Monitoring:
A part of monitor items of Dr.ZX is displayed.
• Controller Version:
Each controller version is displayed.
• Blade/Outrigger Settings:
The blade/outrigger settings are changed.
Turn key switch ON while pushing the key
T1V1-05-01-115
1. Turn the key switch to the ON position while
pushing the key at upper right corner of the
monitor unit. Therefore, service menu is added to
main menu.
2. When the primary screen appears, push the
menu key and display main menu.
Menu Key
Primary Screen
3. Select service menu from main menu by using
keys 1 and 2. Push the confirm key. Then, the
service menu screen appears.
TCJB-05-02-064
NOTE: When pushing the back key, return to the
previous screen.
Key 1
T5-2-63
Key 2
Confirm
Key
Back Key
TCHB-05-02-005
Back Key
TCHB-05-02-007
TROUBLESHOOTING / Monitor Unit
TROUBLESHOOTING
1. Displaying Service Menu
Turn the key switch to the ON position while
pushing the key at upper right corner of the
monitor unit. Therefore, service menu is added to
main menu.
Turn key switch ON while pushing the key
T1V1-05-01-115
2. When the primary screen appears, push the
menu key and display main menu.
Menu Key
Primary Screen
TCJB-05-02-064
3. Select service menu from main menu by using
keys 1 and 2. Push the confirm key. Then, the
service menu screen appears.
NOTE: When pushing the back key, return to the
previous screen.
Key 1
T5-2-64
Key 2
Confirm
Key
Back Key
TCHB-05-02-005
Back Key
TCHB-05-02-007
TROUBLESHOOTING / Monitor Unit
4. Select troubleshooting by using keys 1 and 2.
Push the confirm key. Then, the troubleshooting
screen appears.
Key 1
5. Results of trouble analyses for each controller are
displayed on the screen.
Displayed Controller:
• Main Controller
• Engine Governor Controller
• Monitor Controller
• ICF Controller
• Steering Column Monitor
• Option Controller
6. Select Abnormal of a faulty controller by using
keys 1 and 2. Push the confirm key. Then, fault
code is displayed.
As for details of trouble analyses, refer to “Troubleshooting A.”
Key 2
Confirm Key
Back Key
TCHB-05-02-007
A figure enclosed in ( ) indicates the number of fault codes.
Key 1
Key 2
Confirm Key
Back Key
T1V5-05-01-085
IMPORTANT: Up to twenty fault codes can be displayed. But, one screen can contain
only ten fault codes maximum.
If the screen is fully filled with ten
items, push key 1 and check other
fault codes on the next page.
When returning to the previous page,
push key 2.
NOTE: When pushing the back key, return to the
previous screen.
Key 1
Key 6
Key 2
Back Key
T1V5-05-01-097
7. Push key 6, and the primary screen appears.
Primary Screen
T5-2-65
TCJB-05-02-064
TROUBLESHOOTING / Monitor Unit
MONITORING
1. Displaying Service Menu
Turn the key switch to the ON position while
pushing the key at upper right corner of the monitor unit. Therefore, service menu is added to main
menu.
Turn the key switch ON while pushing the key
T1V1-05-01-115
2. When the primary screen appeared, push the
menu key and display main menu.
Menu Key
Primary Screen
TCJB-05-02-064
3. Select service menu from main menu by using
keys 1 and 2. Push the confirm key. Then, the
service menu screen appears.
NOTE: When pushing the back key, return to the
previous screen.
Key 1
T5-2-66
Key 2
Confirm
Key
Back Key
TCHB-05-02-005
Back Key
TCHB-05-02-007
TROUBLESHOOTING / Monitor Unit
4. Select monitoring by using keys 1 and 2. Push the
confirm key. Then, the monitoring screen appears.
As for items to be monitored, refer to the next
page.
Key 1
Key 2
TCHB-05-02-007
Confirm Key
5. Select an item to be monitored by using keys 1
and 2. Push the confirm key. Then, the selected
item is brought up to the top.
NOTE: When the key switch is turned OFF, the
order of items to be monitored is reset to
the initial state.
6. Push key 3, and the displayed data are put on
hold.
Push key 3 again, and the records are updated
with the displayed data.
7. The order of items to be monitored is reset to the
initial state by pushing key 4.
When key 4 is pushed and a confirmation message appears, push the confirm key.
Back Key
Key 1
Key 2
Key 3
Key 4
Confirm Key
T1V5-05-01-087
NOTE: When pushing the back key, return to the
previous screen.
Back Key
Key 6
Confirm Key
T1V5-05-01-088
8. Push key 6, and the primary screen appears.
Primary Screen
T5-2-67
TCJB-05-02-064
TROUBLESHOOTING / Monitor Unit
A List of Items to be Monitored
Items
Engine Torque
Coolant Temperature (E)
Units
%
°C
Fuel Temperature
Engine Oil Pressure
Atmospheric Pressure
Intake Air Temperature
Boost Pressure
Boost Temperature
Coolant Temperature (M)
°C
kPa
kPa
°C
kPa
°C
°C
Target Engine Speed
Actual Engine Speed
Pump 1 Delivery Pressure
Pump 1 Pump Control Pressure
Target Pump 1 Flow Rate
Pump 2 Delivery Pressure
Pump 2 Pump Control Pressure
Target Pump 2 Flow Rate
Swing/Front Attachment Control Pilot Pressure
Boom Up Pilot Pressure
Arm In Pilot Pressure
Swing Pilot Pressure
Forward Travel Pilot Pressure
Reverse Travel Pilot Pressure
EC Dial Angle
Hydraulic Oil Temperature (Tank)
Pump Torque Proportional Valve
Arm Regeneration Proportional Valve
Power Digging Control Pressure
Power Mode
Power Digging Switch
Radio Signal strength
min−1
min−1
MPa
MPa
L/min
MPa
MPa
L/min
MPa
MPa
MPa
MPa
MPa
MPa
V
°C
MPa
MPa
MPa
E/P/HP
OFF/ON
×/○
T5-2-68
Remarks
Input signal to the monitor unit from ECM by
using CAN
Directly Input signal to the monitor unit from
the coolant temperature sensor (coolant
temperature gauge)
Signal from main hydraulic oil temperature
sensor
0 MPa is displayed.
OFF is displayed.
TROUBLESHOOTING / Monitor Unit
Items
Speed
Travel Motor Over Speed
Brake Pressure
Emergency Stop
Attachment1/Positioning1 Signal
Attachment2/Positioning2 Signal
Blade1/Outrigger1 Signal
Blade2/Outrigger2 Signal
Assist1 Signal
Assist2 Signal
Assist3 Signal
Assist4 Signal
Hydraulic Oil Temperature (Pilot)
Assist1 Proportional Valve
Assist2 Proportional Valve
Positioning1 Proportional Valve
Positioning2 Proportional Valve
Blade1/Outrigger1 Proportional Valve
Blade2/Outrigger2 Proportional Valve
Assist1 Proportional Valve
Assist2 Proportional Valve
Assist3 Proportional Valve
Assist4 Proportional Valve
Units
km/h
Remarks
Although mile is selected from main menu, travel
speed (km/h) is displayed.
(Count)
MPa
OFF/ON
V
V
V
V
V
V
V
V
°C
MPa
MPa
MPa
MPa
MPa
MPa
MPa
MPa
MPa
MPa
Signal from pilot hydraulic oil temperature sensor
“-” is displayed as default.
“-” is displayed as default.
T5-2-69
TROUBLESHOOTING / Monitor Unit
CONTROLLER VERSION
1. Displaying Service Menu
Turn the key switch to the ON position while
pushing the key at upper right corner of the monitor unit. Therefore, service menu is added to main
menu.
Turn the key switch ON while pushing the key
T1V1-05-01-115
2. When the primary screen appeared, push the
menu key and display main menu.
Menu Key
Primary Screen
TCJB-05-02-064
3. Select service menu from main menu by using
keys 1 and 2. Push the confirm key. Then, the
service menu screen appears.
NOTE: When pushing the back key, return back to
the previous screen.
Key 1
T5-2-70
Key 2
Confirm
Key
Back Key
TCHB-05-02-005
Back Key
TCHB-05-02-007
TROUBLESHOOTING / Monitor Unit
4. Select controller version by using keys 1 and 2.
Push the confirm key. Then, the controller version
screen appears.
NOTE: The version of ECM is not displayed.
NOTE: When pushing the back key, return to the
previous screen.
Key 1
Key 2
Key 6
Confirm Key
Back Key
Back Key
TCHB-05-02-007
TCHB-05-02-008
5. Push key 6, and the primary screen appears.
Primary Screen
T5-2-71
TCJB-05-02-064
TROUBLESHOOTING / Monitor Unit
BLADE/OUTRIGGER SETTINGS
1. Displaying Service Menu
Turn the key switch to the ON position while
pushing the key at upper right corner of the monitor unit. Therefore, service menu is added to main
menu.
Turn the key switch ON while pushing the key
T1V1-05-01-115
2. When the primary screen appeared, push the
menu key and display main menu.
Menu Key
Primary Screen
TCJB-05-02-064
3. Select service menu from main menu by using
keys 1 and 2. Push the confirm key. Then, the
service menu screen appears.
NOTE: When pushing the back key, return back to
the previous screen.
Key 1
T5-2-72
Key 2
Confirm
Key
Back Key
TCHB-05-02-005
Back Key
TCHB-05-02-007
TROUBLESHOOTING / Monitor Unit
4. Select blade/outrigger settings by using keys 1
and 2. Push the confirm key. Then, the
blade/outrigger setup screen appears.
Key 1
Key 2
Confirm Key
TCHB-05-02-007
5. Select the screen corresponded to the combination by using keys 1 and 2.
NOTE: When pushing the back key, return to the
previous screen.
Key 1
Back Key
Key 2
Key 6
Blade/Outrigger Setup Screen
TCHB-05-02-009
Display the
Selected
Screen
Screen Transition
TCJB-05-02-067
6. Push key 6, and the primary screen is displayed.
The last screen is displayed as the primary
screen.
NOTE: the blade/outrigger during operation is displayed in green on the primary screen.
T5-2-73
Primary Screen
TCJB-05-02-064
TROUBLESHOOTING / Monitor Unit
KEYLESS HOUR METER
When the key switch is turned OFF, the following items
can be displayed on the monitor unit screen.
• Hour Meter
• Odometer
• Fuel Gauge
When the back monitor selection key is
pushed for one second or more, the keyless
hour meter screen is displayed.
Back Monitor
Selection Key
NOTE: While the back monitor selection key is
pushed, the keyless hour meter screen is
displayed.
T1V1-05-01-010
Hour Meter
Odometer
Fuel Gauge
Back Monitor
Selection Key
Keyless Hour Meter Screen
2. When the back monitor selection key is released,
the keyless hour meter screen disappears.
T5-2-74
TCJB-05-02-001
TROUBLESHOOTING / Monitor Unit
LIST OF MONITOR UNIT SETTING FUNCTION
○: with setting function
×: without setting function
Setting Function
Function
Alarm
Security
Item
Monitor
Unit
Check alarms while trouble occurs
Password function Enable/Disable
Password change
Permission/no permission of password change on the
monitor
○
×
○
○(Troubleshooting)
○(Security)
×
×
○(Security)
Maximum password digit change
×
○(Security)
×
×
○
×
○
×
○
×
×
○
○
○
○
×
○
○
○
○
×
○
×
○
○
×
○
×
○
○
○(Security)
○(Security)
×
○(Monitor Controller)
○(ICF)
○(Monitor Controller)
×
○(Monitor Controller)
○(Monitor Controller)
○(Monitor Controller)
×
×
×
○(Monitor Controller)
○(Monitor Controller)
×
×
×
○(Monitor Controller)
○(Monitor Controller)
×
×
×
○(Monitor Controller)
○(Monitor Controller)
×
×
×
Password check
Extending function Enable/Disable
Selection on extra time
Time Setting Time set function Enable/Disable
Time change
Operating
Operational condition Enable/Disable
Condition
Operational condition reset
Maintenance Maintenance operation Allow/Not Allow
Setting
Maintenance display items ON/OFF
Notification function Enable/Disable
Engine Oil Change interval
Remaining hours data reset
Previous change Date/Hour Meter check
Maintenance display items ON/OFF
Notification function Enable/Disable
Engine Oil
Change interval
Filter
Remaining hours data reset
Previous change Date/Hour Meter check
Maintenance display items ON/OFF
Notification function Enable/Disable
Hydraulic
Change interval
Oil
Remaining hours data reset
Previous change Date/Hour Meter check
Maintenance display items ON/OFF
Notification function Enable/Disable
Hydraulic
Oil Pilot
Change interval
Filter
Remaining hours data reset
Previous change Date/Hour Meter check
T5-2-75
Dr.ZX
Default
－
Disable
0000
Permission
Max.
4 digits
－
Enable
－
Enable
－
Enable
－
Allow
ON
Enable
500 hours
－
－
ON
Enable
500 hours
－
－
ON
Enable
5000 hours
－
－
ON
Enable
1000 hours
－
－
TROUBLESHOOTING / Monitor Unit
Setting Function
Function
Item
Monitor
Unit
Maintenance
Setting
Maintenance display items ON/OFF
Notification function Enable/Disable
Hydraulic
Change interval
Oil Filter
Remaining hours data reset
Previous change Date/Hour Meter check
Maintenance display items ON/OFF
Notification function Enable/Disable
Pump
Transmission Change interval
Oil
Remaining hours data reset
Previous change Date/Hour Meter check
Maintenance display items ON/OFF
Notification function Enable/Disable
Swing
Reduction
Change interval
Gear
Remaining hours data reset
Previous change Date/Hour Meter check
Maintenance display items ON/OFF
Notification function Enable/Disable
Swing
Bearing
Change interval
Grease
Remaining hours data reset
Previous change Date/Hour Meter check
Maintenance display items ON/OFF
Hydraulic
Notification function Enable/Disable
Oil Brake
Change interval
Steering
Remaining hours data reset
Filter
Previous change Date/Hour Meter check
Maintenance display items ON/OFF
Travel Device Notification function Enable/Disable
Transmission Change interval
Oil
Remaining hours data reset
Previous change Date/Hour Meter check
Maintenance display items ON/OFF
Axle Gear
Notification function Enable/Disable
Oil
Change interval
(Front, Rear,
Remaining hours data reset
each Hub)
Previous change Date/Hour Meter check
×
○
×
○
○
×
○
×
○
○
×
○
×
○
○
×
○
×
○
○
×
○
×
○
○
×
○
×
○
○
×
○
×
○
○
T5-2-76
Dr.ZX
Default
○(Monitor Controller)
ON
○(Monitor Controller)
Enable
×
1000 hours
×
－
×
－
○(Monitor Controller)
ON
○(Monitor Controller)
Enable
×
1000 hours
×
－
×
－
○(Monitor Controller)
ON
○(Monitor Controller)
Enable
×
1000 hours
×
－
×
－
○(Monitor Controller)
ON
○(Monitor Controller)
Enable
×
500 hours
×
－
×
－
○(Monitor Controller)
ON
○(Monitor Controller)
Enable
×
500 hours
×
－
×
－
○(Monitor Controller)
ON
○(Monitor Controller)
Enable
×
500 hours
×
－
×
－
○(Monitor Controller)
ON
○(Monitor Controller)
Enable
×
500 hours
×
－
×
－
TROUBLESHOOTING / Monitor Unit
Setting Function
Function
Maintenance
Setting
Item
Drive Shaft
Greasing
Front Axle
King Pin
Greasing
Front Axle
Center Pin
Greasing
Wheel Nut
Torque
Check
Air Filter
Engine / Air
Conditioner
V-belt
Fuel Filter
Maintenance display items ON/OFF
Notification function Enable/Disable
Change interval
Remaining hours data reset
Previous change Date/Hour Meter check
Maintenance display items ON/OFF
Notification function Enable/Disable
Change interval
Remaining hours data reset
Previous change Date/Hour Meter check
Maintenance display items ON/OFF
Notification function Enable/Disable
Change interval
Remaining hours data reset
Previous change Date/Hour Meter check
Maintenance display items ON/OFF
Notification function Enable/Disable
Change interval
Remaining hours data reset
Previous change Date/Hour Meter check
Maintenance display items ON/OFF
Notification function Enable/Disable
Change interval
Remaining hours data reset
Previous change Date/Hour Meter check
Maintenance display items ON/OFF
Notification function Enable/Disable
Change interval
Remaining hours data reset
Previous change Date/Hour Meter check
Maintenance display items ON/OFF
Notification function Enable/Disable
Change interval
Remaining hours data reset
Previous change Date/Hour Meter check
T5-2-77
Monitor
Unit
Dr.ZX
×
○
×
○
○
×
○
×
○
○
×
○
×
○
○
×
○
×
○
○
×
○
×
○
○
×
○
×
○
○
×
○
×
○
○
○(Monitor Controller)
○(Monitor Controller)
×
×
×
○(Monitor Controller)
○(Monitor Controller)
×
×
×
○(Monitor Controller)
○(Monitor Controller)
×
×
×
○(Monitor Controller)
○(Monitor Controller)
×
×
×
○(Monitor Controller)
○(Monitor Controller)
×
×
×
○(Monitor Controller)
○(Monitor Controller)
×
×
×
○(Monitor Controller)
○(Monitor Controller)
×
×
×
Default
ON
Enable
500 hours
－
－
ON
Enable
30 days
－
－
ON
Enable
250 hours
－
－
ON
Enable
250 hours
－
－
ON
Enable
1500 hours
－
－
ON
Enable
1000 hours
－
－
ON
Enable
500 hours
－
－
TROUBLESHOOTING / Monitor Unit
Setting Function
Function
Item
Monitor
Unit
Maintenance
Setting
Air
Conditioner
Filter
Optional
Function
Maintenance display items ON/OFF
Notification function Enable/Disable
Change interval
Remaining hours data reset
Previous change Date/Hour Meter check
Maintenance display items ON/OFF
Notification function Enable/Disable
User Setting
Change interval
(TRIP 1)
Remaining hours data reset
Previous change Date/Hour Meter check
Work mode function Set/Unset
Mail function Set/Unset
Send the mail
Language
Setting
Troubleshooting
Monitoring
Default
×
○
×
○
○
×
○
○
×
○
×
×
○
○(Monitor Controller)
ON
○(Monitor Controller)
Enable
×
3000 hours
×
－
×
－
×
ON
×
Disable
×
5000 hours
×
－
×
－
○(Monitor Controller)
Set
○(Monitor Controller)
Unset
×
－
×
○(Monitor Controller)
Disable
×
○(Monitor Controller)
○
×
×
×
×
○(Monitor Controller)
○(Monitor Controller)
○(Monitor Controller)
Meter combination setting change
○
×
Unit setup function Enable/Disable
Unit Change
Select language
Register/delete language
Registered language check
Check alarms while trouble occurs
Check alarms which occurred
Clear fault code (Retry B)
Item order change
Reset item order to default
×
○
○
×
○
○
×
×
○
○
○(Monitor Controller)
×
×
×
×
○(Troubleshooting)
○(Troubleshooting)
○(Troubleshooting)
×
×
Enable
No auto
display
Normal
NTSC
Enable
Speedometer
+
Hour Meter
Enable
km
English
－
－
－
－
－
－
－
○
×
Overload
Overload alarm Enable/Disable
Alarm
Back Monitor Back monitor function Enable/Disable
Setting
Auto-display/no auto-display of camera image during
travel reverse operation (auto-control)
Back monitor display Normal/Flip Vertical
Selection of NTSC/PAL (image method)
Meter Setting Meter setup function Enable/Disable
Unit Setting
Dr.ZX
Blade / OutBlade/Outrigger setting change
rigger Setting
T5-2-78
1/12
TROUBLESHOOTING / Dr. ZX
OUTLINE
Dr. ZX is a tool used for troubleshooting of the
electronic control system of MC, ECM, ICF, monitor
unit, steering column monitor and option controller.
It displays the fault code of each controller or sensor by
connecting Dr. ZX to ICF. (Display of Troubleshooting
Result)
Dr. ZX also displays input status of sensor and switch
that connected to each controller and output status of
actuators from controllers to solenoid valves in real
time while it's running. (Controller Troubleshooting)
NOTE: For operation detail about Dr. ZX, refer to
separated "Dr. ZX Manual".
T5-3-1
TROUBLESHOOTING / Dr. ZX
MC MONITORING LIST
Dr. ZX displays the input signals from switches and
sensors to MC and the control signals to the actuators
from MC.
Item
Selecting
Monitoring
Unit
Data
-1
Input signal from engine control dial
Input signal from ECM
-1
Requested Engine Speed
Actual Engine Speed
Req. Eng
Actual Speed
min
-1
min
Engine Speed Deviation
Vehicle Speed
Eng Speed Deviat
Vehicle Speed
min
km/h
A value subtracted required engine speed from actual engine speed
Input value from travel N sensor
Pump 1 Delivery Pressure
Pump 1 Flow Control Pressure
P1 Delivery Pres
PC 1 Pressure
MPa
MPa
Input signal from pump 1 delivery pressure sensor
Input signal from pump 1 control pressure sensor
Pump 1 Flow Rate Limit P/S/V Out
P1 P/S Valve
MPa
Control instruction signal to maximum pump 1 flow rate limit control solenoid
valve
Pump 1 Upper Limit Displacement
P1 Pres Maxq
cm3
Calculation from engine speed and pump 1 delivery pressure
(With attachment only)
Pump 1 Target Flow Rate
P1 Set Flow Rate
L/min
Pump 2 Delivery Pressure
P2 Delivery Pres
MPa
Pump 2 Flow Control Pressure
Pump 2 Flow Rate Limit P/S/V Out
PC 2 Pressure
P2 P/S Valve
MPa
MPa
Pump 2 Upper Limit Displacement
P2Maxq
cm3
Pump 2 Target Flow Rate
P2 Set Flow Rate
L/min
Control instruction signal to maximum pump 2 flow rate limit control solenoid
valve
Pump Torque P/S Valve Output
Pump 3 Delivery Pressure
P Torque P/S/V
P3 Pressure
MPa
MPa
Control instruction signal to torque control solenoid valve
Input signal from steering pump delivery pressure sensor
Pump 4 Delivery Pressure
Front Pilot Pressure
P4 Pressure
Fr Pilot Press
MPa
MPa
Input signal from pump 4 delivery pressure sensor
Input signal from pressure sensor (front)
Boom Raise Pilot Pressure
Arm Roll-In Pilot Pressure
Boom Raise
Arm Roll-In
MPa
MPa
Input signal from pressure sensor (boom raise)
Input signal from pressure sensor (arm roll-in)
Arm Roll-Out Pilot Pressure
Swing Pilot Pressure
Arm Roll-Out
SW Pilot Press
MPa
MPa
Input signal from pressure sensor (arm roll-out)
Input signal from pressure sensor (swing)
Travel Forward Pilot Pressure
Travel Reverse Pilot Pressure
Tr F Pilot Press
Tr R Pilot Pilot Press
MPa
MPa
Input signal from pressure sensor (travel forward)
Input signal from pressure sensor (travel reverse)
ATT Control Pilot Pressure
EC Dial Angle
ATT Pilot Press
Dial Angle
MPa
V
Input signal from pressure sensor (auxiliary)
Input signal from engine control dial
Boom Bottom Pressure
Brake Remain Pressure
Bm Bottom Press
Brake Remain P
MPa
MPa
Input signal from boom bottom pressure sensor
Input signal from brake remaining pressure sensor
Brake Pressure
E/P SW
Brake Pressure
E/P SW
MPa
E, P
Input signal from brake pressure sensor
Power mode switch selection status
HP Mode SW
Auto-Idle SW
HP Mode SW
AI SW
ON, OFF
AI
Control instruction signal to maximum pump 1 flow rate limit control solenoid
valve
Input signal from pump 2 delivery pressure sensor
Input signal from pump 2 control pressure sensor
Control instruction signal to maximum pump 2 flow rate limit control solenoid
valve
Calculation from engine speed and pump 2 delivery pressure
(With attachment only)
Power mode switch selection status
Auto-idle switch selection status
NOTE: BR: Breaker
PU: Pulverizer
CR: Crusher
VI: Vibrating hammer
Un: Other
ATT: Attachment
OPT: Optional
T5-3-2
TROUBLESHOOTING / Dr. ZX
Item
Unit
Data
Selecting
Power Boost SW
Monitoring
Power Boost SW
ON, OFF
Power digging switch ON/OFF selection status
Key SW
Slight Travel SW
Key SW
Slight Travel SW
ON, OFF
ON, OFF
Pedal EC SW
Pedal EC SW
ON, OFF
Implement Brake Deactive
Imp Brk Release
ON, OFF
Key switch ON/OFF selection status
Engine control mode selection switch (creeper) ON/OFF selection
status
Engine control mode selection switch (pedal) ON/OFF selection
status
Work brake release switch ON/OFF selection status
Parking Brake SW
Parking Brake SW
ON, OFF
Transmission H/L SW
T/M H/L SW
Lo, Hi
FNR (R) SW
FNR (R) SW
ON, OFF
Arm Regenerative P/S Valve Output
Am Regen P/S/V
MPa
Control instruction signal to solenoid valve unit (SC)
Power Boost Control Pressure
ATT P/S Valve Output
PD Ctrl Pressure
ATT P/S Valve
MPa
MPa
Control instruction signal to solenoid valve unit (SG)
Control instruction signal to auxiliary flow rate control solenoid valve
Pump 1 Flow Rate Limit P/S/V Out FB
Pump 2 Flow Rate Limit P/S/V Out FB
P1 Flow P/V FB
P2 Flow P/V FB
mA
mA
Feedback from maximum pump 1 flow rate limit solenoid valve output
Feedback from maximum pump 2 flow rate limit control solenoid valve
output
Pump Torque P/S/V Output FB
ATT P/S Valve Output FB
P Torque P/V FB
ATT P/S/V FB
mA
mA
Feedback from torque control solenoid valve output
Feedback from auxiliary flow rate control solenoid valve output
Arm Regenerative P/S/V Output FB
Am Rege P/V FB
mA
Feedback from solenoid valve unit (SC) output
Power Boost chg. Over Pressure FB
PD Ctrl Puress FB
mA
Feedback from solenoid valve unit (SG) output
Travel Motor Swash Angle P/V Valve
Output
TrM Swash Angle P/V Out
MPa
Control instruction signal to travel motor displacement angle control
solenoid valve
Travel Makeup P/S/V Output
Implement Brake P/S/V Output
Travel Makeup P/S/V Out
Implement Brake P/S/V
MPa
MPa
Control instruction signal to travel make-up solenoid valve
Control instruction signal to solenoid valve unit (SF)
Axle Lock Output
Travel Motor Swash Angle P/V FB
Axle Lock Output
TrM Swash Angle P/V FB
MPa
mA
Brake switch (parking brake) ON/OFF selection status
Travel speed mode switch ON/OFF selection status
FNR switch (R) ON/OFF selection status
Travel Makeup P/S/V FB
Travel Makeup P/S/V FB
mA
Control instruction signal to solenoid valve unit (SI)
Feedback from travel motor displacement angle control solenoid
valve output
Feedback from travel make-up solenoid valve output
Axle Lock Output FB
Implement Brake FB
Axle Lock Output FB
Implement Brake FB
mA
mA
Feedback from solenoid valve unit (SI) output
Feedback from solenoid valve unit (SF) output
Travel Alarm
Travel Alarm
Action/
No Action
Action/No Action status of travel alarm
Swing Alarm
Swing Alarm
Action/No Action status of swing alarm
Hydraulic Oil Temperature (HOT)
Hyd Oil Temp.
Action/
No Action
°C
T/M Change (Low Speed)
T/M Change (High Speed)
T/M Change (Low Speed)
T/M Change (High Speed)
ON, OFF
ON, OFF
Travel mode selector solenoid valve (fast) ON/OFF selection status
Axle Lock Control State
Implement Brake State
Axle Lock Control State
Implement Brake State
ON, OFF
ON, OFF
Brake switch (axle lock) ON/OFF selection status
Work brake ON/OFF selection status
Travel Motor Over Rotation Count
TrM Over Rotation Count
Count
NOTE: BR: Breaker
PU: Pulverizer
CR: Crusher
VI: Vibrating hammer
Un: Other
ATT: Attachment
OPT: Optional
T5-3-3
Input signal from hydraulic oil temperature sensor
Travel mode selector solenoid valve (slow) ON/OFF selection status
Input value from travel N sensor
TROUBLESHOOTING / Dr. ZX
Item
Selecting
Monitoring
Speed Meter Auto Change Flag
Speed Meter Auto Change Flag
Current ATT Type
Current ATT Type
Current ATT No.
Current ATT No.
ATT1 Type
ATT1 Type
ATT1 No.
ATT1 No.
ATT2 Type
ATT2 Type
ATT2 No.
ATT2 No.
ATT3 Type
ATT3 Type
ATT3 No.
ATT3 No.
ATT4 Type
ATT4 Type
ATT4 No.
ATT4 No.
ATT5 Type
ATT5 Type
ATT5 No.
Trip Meter
Unit
ON, OFF
BR, PU, CR, VI, Un
Data
Speed meter auto switch ON/OFF selection status
Communication from monitor unit
1, 2, 3, 4, 5
Communication from monitor unit
BR, PU, CR, VI, Un
Communication from monitor unit
1, 2, 3, 4, 5
Communication from monitor unit
BR, PU, CR, VI, Un
Communication from monitor unit
1, 2, 3, 4, 5
Communication from monitor unit
BR, PU, CR, VI, Un
Communication from monitor unit
1, 2, 3, 4, 5
Communication from monitor unit
BR, PU, CR, VI, Un
Communication from monitor unit
1, 2, 3, 4, 5
Communication from monitor unit
BR, PU, CR, VI, Un
Communication from monitor unit
ATT5 No.
1, 2, 3, 4, 5
Communication from monitor unit
Trip Meter
km
Unit setting status for monitor unit
Odo Meter
Odo Meter
km
(German) Specifications Change SW
(German) Specifications Change
FNR (F) SW
FNR (F) SW
Unit setting status for monitor unit
ON, OFF
German specification selection switch ON/OFF selection status
ON, OFF
FNR switch (Forward) ON/OFF selection status
SW
NOTE: BR: Breaker
PU: Pulverizer
CR: Crusher
VI: Vibrating hammer
Un: Other
ATT: Attachment
OPT: Optional
T5-3-4
TROUBLESHOOTING / Dr. ZX
ECM MONITORING LIST
Item
Unit
Selecting
Monitoring
Engine Torque
Engine Torque
％
Act. Eng Speed
min-1
Target Engine Speed
Tar. Eng Speed
min-1
Glow Signal
Glow Signal
Coolant Temperature (Engine)
Coolant Temp.
°C
Fuel Temperature
Fuel Temp.
°C
Engine Oil Pressure
Eng Oil Pressure
Actual Engine Speed
(Engine Speed)
Data
Input signal from ECM
Input signal from crank speed sensor and cam angle sensor
Input signal from engine control dial
OFF, ON
kPa
Glow Plug Relay ON/OFF selection status
Input signal from coolant temperature sensor
Input signal from fuel level sensor
Input signal from engine oil pressure sensor
Fuel Flow
Fuel Flow
L/h
Input signal from ECM
Barometric Pressure
Barome. Press
kPa
Input signal from atmospheric pressure sensor
Intake Air Temperature
Intake Air Temp.
°C
Input signal from intake air temperature sensor
Boost Pressure
Boost Pressure
kPa
Input signal from boom boost pressure sensor
Boost Temperature
Boost Temp.
°C
Input signal from boom boost temperature sensor
Battery Voltage
Battery Volt
V
Input signal from ECM
Total Used Fuel
Total Used Fuel
L
Input signal from ECM
T5-3-5
TROUBLESHOOTING / Dr. ZX
MONITOR UNIT MONITORING LIST
Item
Unit
Data
Selecting
Monitoring
Monitor SW Status Check
Monitor SW Status Check
−
Monitor unit switch status
Coolant Temperature
Coolant Temp.
°C
Input signal from coolant temperature sensor
Fuel Level
Fuel Level
%
Input signal from fuel level sensor
Security Signal
Security Signal
Mail SW
Mail SW
OFF, ON
OFF
Communication from monitor unit
Mail Operation Status
Fuel
Forward
Repair
General
T5-3-6
TROUBLESHOOTING / Dr. ZX
STEERING COLUMN MONITOR MONITORING LIST
Item
Selecting
Monitoring
Unit
Data
Speed Pulse
Speed Pulse
Hz
Communication from MC
Vehicle Speed Pulse
Vehicle Speed Pulse
Hz
Communication from MC
T5-3-7
TROUBLESHOOTING / Dr. ZX
OPTION CONTROLLER MONITORING LIST
Item
Unit
Data
Selecting
Monitoring
Assist 1 Operation
Assist 1 Ope
V
Input signal from assist switch
Assist 2 Operation
Assist 2 Ope
V
Input signal from assist switch
Posn/Aux 1 Operation
Posn/Aux 1 Ope
V
Input signal from positioning/auxiliary pedal
Posn/Aux 2 Operation
Posn/Aux 2 Ope
V
Input signal from positioning/auxiliary pedal
Outrigger/Blade 1 Operation
OR/BL1 Ope
V
Input signal from blade/outrigger lever
Outrigger/Blade 2 Operation
OR/BL2 Ope
V
Input signal from blade/outrigger lever
Posn/Assist Pilot Monitor Pressure
Posn/Assi P Press
MPa
Input signal from pressure sensor (positioning, assist)
Outrgr/Blade/Aux Pilot Montr Pressr
OR/BL/Aux P Press
MPa
Input signal from pressure sensor (blade/outrigger, auxiliary)
Hydraulic Oil Temperature (OPT)
Hyd Oil Temp.
Boom Bottom Pressure
Bm Bottom Press
Gate Lock Signal
Gate Lock Signal
Up, Down Pilot shut-off lever up/down status (Pilot shut-off switch
Assist SW
Assist SW
ON, OFF
Aux SW
Aux SW
Aux, Posn Auxiliary/positioning selection switch ON/OFF selection status
Assist SW1
Assist SW1
ON, OFF
Assist switch ON/OFF selection status
Assist SW2
Assist SW2
ON, OFF
Assist switch ON/OFF selection status
Outrigger Control SW1
Outrigger Control SW1
ON, OFF
Outrigger selection switch ON/OFF selection status
Outrigger Control SW2
Outrigger Control SW2
ON, OFF
Outrigger selection switch ON/OFF selection status
Outrigger Control SW3
Outrigger Control SW3
ON, OFF
Outrigger selection switch ON/OFF selection status
Outrigger Control SW4
Outrigger Control SW4
ON, OFF
Outrigger selection switch ON/OFF selection status
Slewing Parking Release
Slewing P R
°C
MPa
Input signal from pilot oil temperature sensor
Input signal from boom bottom pressure sensor
ON/OFF selection status)
MPa
Electric operation main switch ON/OFF selection status
Control instruction signal to swing parking brake release
solenoid valve
Aux 1 P/S/V
Aux 1 P/S/V
MPa
Control instruction signal to auxiliary solenoid valve
Aux 2 P/S/V
Aux 2 P/S/V
MPa
Control instruction signal to auxiliary solenoid valve
Blade 1/Outrigger 1 P/S/V
BL1/OR1 P/V
MPa
Control instruction signal to blade/outrigger solenoid valve
Blade 2/Outrigger 2 P/S/V
BL2/OR2 P/V
MPa
Control instruction signal to blade/outrigger solenoid valve
Positioning 1 P/S/V
Posn 1 P/V
MPa
Control instruction signal to positioning solenoid valve
Positioning 2 P/S/V
Posn 2 P/V
MPa
Control instruction signal to positioning solenoid valve
Assist 1 P/S/V
Assist 1 P/S/V
MPa
Control instruction signal to assist solenoid valve
Assist 2 P/S/V
Assist 2 P/S/V
MPa
Control instruction signal to assist solenoid valve
Assist 3 P/S/V
Assist 3 P/S/V
MPa
Control instruction signal to assist solenoid valve
Assist 4 P/S/V
Assist 4 P/S/V
MPa
Control instruction signal to assist solenoid valve
T5-3-8
TROUBLESHOOTING / Dr. ZX
Item
Selecting
Slewing Parking Release FB
Aux 1 P/S/V FB
Unit
Data
Monitoring
Slewing P R FB
mA
Feedback from swing parking brake release solenoid valve
output
Aux 1 P/S/V FB
mA
Feedback from auxiliary solenoid valve output
Aux 2 P/S/V FB
Aux 2 P/S/V FB
mA
Feedback from auxiliary solenoid valve output
Blade 1/Outrigger 1 P/S/V FB
BL1/OR1 P/V FB
mA
Feedback from blade/outrigger solenoid valve output
Blade 2/Outrigger 2 P/S/V FB
BL2/OR2 P/V FB
mA
Feedback from blade/outrigger solenoid valve output
Positioning 1 P/S/V FB
Posn 1 P/V FB
mA
Feedback from positioning solenoid valve output
Positioning 2 P/S/V FB
Posn 2 P/V FB
mA
Feedback from positioning solenoid valve output
Assist 1 P/S/V FB
Assist 1 P/V FB
mA
Feedback from assist solenoid valve output
Assist 2 P/S/V FB
Assist 2 P/V FB
mA
Feedback from assist solenoid valve output
Assist 3 P/S/V FB
Assist 3 P/V FB
mA
Feedback from assist solenoid valve output
Assist 4 P/S/V FB
Assist 4 P/V FB
mA
Feedback from assist solenoid valve output
Outrigger Control
Outrigger Control
ON, OFF
Outrigger main relay 2 ON/OFF selection status
Valve Selector
Valve Selector
ON, OFF
Selector valve control solenoid valve ON/OFF selection status
2nd Relief Selector
2nd Relief Selector
ON, OFF
Secondary pilot relief pressure control solenoid valve ON/OFF
Acc Change
Acc Change
ON, OFF
Accumulator control solenoid valve ON/OFF selection status
Electric Lever Pilot Cut
Electric Lever Pilot Cut
ON, OFF
Outrigger selection switch (pilot cut) ON/OFF selection status
Load Alarm On/Off SW
Load Alarm On/Off SW
ON, OFF
Overload alarm switch ON/OFF selection status
selection status
T5-3-9
TROUBLESHOOTING / Dr. ZX
MC ADJUSTMENT LIST
Engine speed, pump delivery flow rate, solenoid valve
output pressure and so on can be adjusted.
Adjustment Item List
Item
Unit
Data
-1
Adjustment of minimum engine speed
-1
Adjustment of minimum engine speed when traveling
-1
Adjustment of warming up engine speed
-1
Li Speed Adjustment
min
Travel Li Speed Adjustment
min
WU Speed Adjustment
min
AI Speed Adjustment
min
Adjustment of auto-idle engine speed
E Speed Adjustment
min-1
Adjustment of E-mode engine speed
P Speed Adjustment
min
-1
Adjustment of P-mode engine speed
Travel P Speed Adjustment
min-1
Adjustment of pedal mode speed
PQ Torque Control
N⋅m
Adjustment of pump P-Q curve
Pump 2 P/S Valve Adjustment
MPa
Adjustment of maximum pump 2 flow rate limit control solenoid valve
Tr Motor Swash Angle P/V Adjust
MPa
Adjustment of travel motor displacement angle control solenoid valve
Pump 1 P/S Valve Adjustment
MPa
Adjustment of maximum pump 1 flow rate limit control solenoid valve
Pump Torque P/S/V Adjustment
MPa
Adjustment of torque control solenoid valve
ATT P/S Valve Adjustment
MPa
Adjustment of auxiliary flow rate control solenoid valve
Arm Regenerative P/S/V Adjustment
MPa
Adjustment of solenoid valve unit (SC)
Slight Travel Flow Adjustment
cm3
Adjustment of maximum pump 1 flow rate upper level
Front P1 Control Flow Adjustment
cm3
Adjustment of pump 1 delivery flow rate
Front P2 Control Flow Adjustment
cm3
Adjustment of pump 2 delivery flow rate
Implement Brake Lock Pressure
MPa
Adjustment of solenoid valve unit (SF)
ATT Torque Reducing On/Off
ON, OFF
ECO Mode On/Off
ON, OFF
ON/OFF of torque down control, when a front attachment is operated
ECO control ON/OFF
HP Mode On/Off
ON, OFF
HP mode control ON/OFF
Coolant Temp. WU_B Mode On/Off
ON, OFF
Coolant temperature warming-up control ON/OFF
Engine Burglar Proof On/Off
ON, OFF
Engine Control Theft Prevention Selection ON/OFF
Pump Burglar Proof On/Off
ON, OFF
Pump Control Theft Prevention Selection ON/OFF
Heater Mode On/Off
ON, OFF
Heater control ON/OFF
ATT Mode On/Off
ON, OFF
Attachment Mode ON/OFF
New E-mode Fix Control Change
ON, OFF
E-mode control ON/OFF
Speed Meter Auto Change On/Off
ON, OFF
Speed meter auto switch ON/OFF
ATT Speed Increase Down Waiting Time
Axle Lock Timer
Travel Motor Over Rotation Count
ms
s
Times
Setting of time required for engine speed decrease
Time setting for axle lock release (auto axle lock)
Setting for travel motor over rotation counter
T5-3-10
TROUBLESHOOTING / Dr. ZX
Adjustment List
Unit
Minimum Adjustment
Adjustable Range
Initial Value
Li Speed Adjustment
Item
min-1
10
0 to 400
0
Travel Li Speed Adjustment
min
-1
10
0 to 400
0
-1
10
-600 to 200
0
-1
10
-300 to 400
0
-1
10
Temporarily release
0
WU Speed Adjustment
min
AI Speed Adjustment
min
E Speed Adjustment
min
P Speed Adjustment
min
-1
10
-200 to 200
0
Travel P Speed Adjustment
min-1
10
-200 to 300
0
(valid only when key is ON)
PQ Torque Control
N⋅m
2.45
-60 to 60
0
Pump 2 P/S Valve Adjustment
MPa
0.0196
-1 to 1
0
Tr Motor Swash Angle P/V Adjust
MPa
0.0196
-1 to 1
0
Pump 1 P/S Valve Adjustment
MPa
0.0196
-1 to 1
0
Pump Torque P/S/V Adjustment
MPa
0.0196
-1 to 1
0
ATT P/S Valve Adjustment
MPa
0.0196
-1 to 1
0
Arm Regenerative P/S/V Adjustment
MPa
0.0196
-1 to 1
0
Slight Travel Flow Adjustment
cm3
0.5
32.5 to 100.0
65.0
Front P1 Control Flow Adjustment
cm3
0.5
32.5 to 100.0
58.5
Front P2 Control Flow Adjustment
cm3
0.5
32.5 to 100.0
58.5
Implement Brake Lock Pressure
MPa
0.02394
4.7 to 8.0
6.6
ATT Torque Reducing On/Off
ON, OFF
-
ON/OFF
ON
ECO Mode On/Off
ON, OFF
-
ON/OFF
ON
HP Mode On/Off
ON, OFF
-
ON/OFF
ON
Coolant Temp. WU_B Mode On/Off
ON, OFF
-
ON/OFF
ON
Engine Burglar Proof On/Off
ON, OFF
-
ON/OFF
OFF
OFF
Pump Burglar Proof On/Off
ON, OFF
-
ON/OFF
Heater Mode On/Off
ON, OFF
-
-
-
ATT Mode On/Off
ON, OFF
-
ON/OFF
OFF
New E-mode Fix Control Change
ON, OFF
-
ON/OFF
OFF
Speed Meter Auto Change On/Off
ON, OFF
-
ON/OFF
ON
ms
40
0 to 3000
0
s
0.5
0 to 10
0
Times
1
0 to 253
0
ATT Speed Increase Down Waiting Time
Axle Lock Timer
Travel Motor Over Rotation Count
T5-3-11
TROUBLESHOOTING / Dr. ZX
MC ATTACHMENT ADJUSTMENT LIST
Adjustment Item List
Item
Unit
Data
ATT1
ATT1 ATT Type
BR PU CR VI Un Non
Attachment selection
ATT1 ATT No.
12345
Attachment setting number selection
ATT1 P1 Swash Angle Adjustment
L/min
Adjustment of lower limit of maximum pump 1 flow rate when using attachment
ATT1 P2 Swash Angle Adjustment
L/min
Adjustment of lower limit of maximum pump 2 flow rate when using attachment
ATT1 Engine Speed Adjustment
min
Adjustment of engine speed when using attachment
ATT1 2nd Relief Selector (OPT)
ON OFF
Secondary pilot relief pressure control valve ON/OFF selection
ATT1 Valve Selector (OPT)
ON OFF
Selector valve ON/OFF selection
ATT1 Accumulator Change (OPT)
ON OFF
Accumulator control valve ON/OFF selection
ATT1 2-Speed Change (OPT)
ON OFF
2-speed selection ON/OFF selection
-1
ATT2
ATT2 ATT Type
BR PU CR VI Un Non
Attachment selection
ATT2 ATT No.
12345
Attachment setting number selection
ATT2 P1 Swash Angle Adjustment
L/min
Adjustment of lower limit of maximum pump 1 flow rate when using attachment
ATT2 P2 Swash Angle Adjustment
L/min
Adjustment of lower limit of maximum pump 2 flow rate when using attachment
ATT2 Engine Speed Adjustment
min-1
Adjustment of engine speed when using attachment
ATT2 2nd Relief Selector (OPT)
ON OFF
Secondary pilot relief pressure control valve ON/OFF selection
ATT2 Valve Selector (OPT)
ON OFF
Selector valve ON/OFF selection
ATT2 Accumulator Change (OPT)
ON OFF
Accumulator control valve ON/OFF selection
ATT2 2-Speed Change (OPT)
ON OFF
2-speed selection ON/OFF selection
ATT3
ATT3 ATT Type
BR PU CR VI Un Non
Attachment selection
ATT3 ATT No.
12345
Attachment setting number selection
ATT3 P1 Swash Angle Adjustment
L/min
Adjustment of lower limit of maximum pump 1 flow rate when using attachment
ATT3 P2 Swash Angle Adjustment
L/min
Adjustment of lower limit of maximum pump 2 flow rate when using attachment
ATT3 Engine Speed Adjustment
min-1
Adjustment of engine speed when using attachment
ATT3 2nd Relief Selector (OPT)
ON OFF
Secondary pilot relief pressure control valve ON/OFF selection
ATT3 Valve Selector (OPT)
ON OFF
Selector valve ON/OFF selection
ATT3 Accumulator Change (OPT)
ON OFF
Accumulator control valve ON/OFF selection
ATT3 2-Speed Change (OPT)
ON OFF
2-speed selection ON/OFF selection
NOTE: ATT:
BR:
PU:
CR:
VI:
Un:
Non:
Attachment
Breaker
Pulverizer
Crusher
Vibrating hammer
Other attachment
No setting for attachment
T5-3-12
TROUBLESHOOTING / Dr. ZX
Item
Unit
Data
ATT4
ATT4 ATT Type
BR PU CR VI Un Non
Attachment selection
ATT4 ATT No.
12345
Attachment setting number selection
ATT4 P1 Swash Angle Adjustment
L/min
Adjustment of lower limit of maximum pump 1 flow rate when using attachment
ATT4 P2 Swash Angle Adjustment
L/min
Adjustment of lower limit of maximum pump 2 flow rate when using attachment
ATT4 Engine Speed Adjustment
min
Adjustment of engine speed when using attachment
ATT4 2nd Relief Selector (OPT)
ON OFF
Secondary pilot relief pressure control valve ON/OFF selection
ATT4 Valve Selector (OPT)
ON OFF
Selector valve ON/OFF selection
ATT4 Accumulator Change (OPT)
ON OFF
Accumulator control valve ON/OFF selection
ATT4 2-Speed Change (OPT)
ON OFF
2-speed selection ON/OFF selection
-1
ATT5
ATT5 ATT Type
BR PU CR VI Un Non
Attachment selection
ATT5 ATT No.
12345
Attachment setting number selection
ATT5 P1 Swash Angle Adjustment
L/min
Adjustment of lower limit of maximum pump 1 flow rate when using attachment
ATT5 P2 Swash Angle Adjustment
L/min
Adjustment of lower limit of maximum pump 2 flow rate when using attachment
ATT5 Engine Speed Adjustment
min-1
Adjustment of engine speed when using attachment
ATT5 2nd Relief Selector (OPT)
ON OFF
Secondary pilot relief pressure control valve ON/OFF selection
ATT5 Valve Selector (OPT)
ON OFF
Selector valve ON/OFF selection
ATT5 Accumulator Change (OPT)
ON OFF
Accumulator control valve ON/OFF selection
ATT5 2-Speed Change (OPT)
ON OFF
2-speed selection ON/OFF selection
T5-3-13
TROUBLESHOOTING / Dr. ZX
Adjustment Value List
Adjustment Data
Minimum Adjustment
Adjustable Range
Initial Value
-
BR PU CR VI Un Non
BR
ATT1
ATT1 ATT Type
ATT1 ATT No.
-
1 to 5
1
ATT1 P1 Swash Angle Adjustment
0.5 L/min
52.8 to 105.6 L/min
105.6 L/min
ATT1 P2 Swash Angle Adjustment
0.5 L/min
52.8 to 105.6 L/min
105.6 L/min
ATT1 Engine Speed Adjustment
10 min
ATT1 2nd Relief Selector (OPT)
-1
-1
-1
-500 to 200 min
0 min
-
ON/OFF
ON
ATT1 Valve Selector (OPT)
-
C/V or O/T
O/T
ATT1 Accumulator Change (OPT)
-
ON/OFF
OFF
ATT1 2-Speed Change (OPT)
-
ON/OFF
OFF
ATT2 ATT Type
-
BR PU CR VI Un Non
BR
ATT2
ATT2 ATT No.
-
1 to 5
2
ATT2 P1 Swash Angle Adjustment
0.5 L/min
52.8 to 105.6 L/min
105.6 L/min
ATT2 P2 Swash Angle Adjustment
0.5 L/min
52.8 to 105.6 L/min
105.6 L/min
ATT2 Engine Speed Adjustment
10 min-1
-500 to 200 min-1
0 min-1
ATT2 2nd Relief Selector (OPT)
-
ON/OFF
OFF
ATT2 Valve Selector (OPT)
-
C/V or O/T
O/T
ATT2 Accumulator Change (OPT)
-
ON/OFF
OFF
ATT2 2-Speed Change (OPT)
-
ON/OFF
OFF
ATT3 ATT Type
-
BR PU CR VI Un Non
PU
ATT3 ATT No.
-
1 to 5
1
ATT3 P1 Swash Angle Adjustment
0.5 L/min
52.8 to 105.6 L/min
105.6 L/min
ATT3 P2 Swash Angle Adjustment
0.5 L/min
52.8 to 105.6 L/min
105.6 L/min
ATT3 Engine Speed Adjustment
10 min-1
-500 to 200 min-1
200 min-1
ATT3
ATT3 2nd Relief Selector (OPT)
-
ON/OFF
OFF
ATT3 Valve Selector (OPT)
-
C/V or O/T
C/V
ATT3 Accumulator Change (OPT)
-
ON/OFF
OFF
ATT3 2-Speed Change (OPT)
-
ON/OFF
ON
NOTE: ATT:
BR:
PU:
CR:
VI:
Un:
Non:
Attachment
Breaker
Pulverizer
Crusher
Vibrating hammer
Other attachment
No setting for attachment
T5-3-14
Remark
TROUBLESHOOTING / Dr. ZX
Adjustment Data
Minimum Adjustment
Adjustable Range
Initial Value
-
BR PU CR VI Un Non
CR
ATT4
ATT4 ATT Type
ATT4 ATT No.
-
1 to 5
1
ATT4 P1 Swash Angle Adjustment
0.5 L/min
52.8 to 105.6 L/min
105.6 L/min
ATT4 P2 Swash Angle Adjustment
0.5 L/min
52.8 to 105.6 L/min
105.6 L/min
ATT4 Engine Speed Adjustment
10 min
ATT4 2nd Relief Selector (OPT)
-1
-1
-1
-500 to 200 min
200 min
-
ON/OFF
OFF
ATT4 Valve Selector (OPT)
-
C/V or O/T
C/V
ATT4 Accumulator Change (OPT)
-
ON/OFF
OFF
ATT4 2-Speed Change (OPT)
-
ON/OFF
ON
ATT5 ATT Type
-
BR PU CR VI Un Non
Unregistration
ATT5
ATT5 ATT No.
-
1 to 5
Unregistration
ATT5 P1 Swash Angle Adjustment
0.5 L/min
52.8 to 105.6 L/min
105.6 L/min
ATT5 P2 Swash Angle Adjustment
0.5 L/min
52.8 to 105.6 L/min
105.6 L/min
ATT5 Engine Speed Adjustment
10 min-1
-500 to 200 min-1
0 min-1
ATT5 2nd Relief Selector (OPT)
-
ON/OFF
Unregistration
ATT5 Valve Selector (OPT)
-
C/V or O/T
Unregistration
ATT5 Accumulator Change (OPT)
-
ON/OFF
Unregistration
ATT5 2-Speed Change (OPT)
-
ON/OFF
Unregistration
NOTE: ATT:
BR:
PU:
CR:
VI:
Un:
Non:
Attachment
Breaker
Pulverizer
Crusher
Vibrating hammer
Other attachment
No setting for attachment
T5-3-15
Remark
TROUBLESHOOTING / Dr. ZX
ICF ADJUSTMENT ITEM LIST
Adjustment Item List
Item
Data Range
Information C/U: Initialization
Model Number Setting
Initialization/End
Model
ASCII (4 characters) 0 to 9, A to Z
Machine Nos.
000000 to 999999
Time Setting
Year
Date
Time
2000 to 2100
Month
1 to 12
Day
1 to 31
Hour
0 to 23
Minutes
0 to 59
Control Data: Initialization
Initialization/End
Satellite Terminal: Initialization
Erase/End
Satellite Terminal Serial Number Verification
12 digits from 0 to 9 and A to Z
Check for Communication Status
ICF↔ Satellite Terminal
Satellite Terminal
Connection
Connected/Not-connected
Communication
OK/NG
Power Source
ON/OFF
Satellite
Transmission available/Not available
Communication
Rod Antenna
OK/NG
GPS Antenna
OK/NG
Wave Signal Status
ON/OFF
Number of Unsent Data
0 to 99
Time of Previous Transmission
Satellite Communication, Sent/Stop Setting
YYYY/MM/DD hh:mm:ss
Start/Stop
T5-3-16
TROUBLESHOOTING / Dr. ZX
(Blank)
T5-3-17
TROUBLESHOOTING / Dr. ZX
OPTION CONTROLLER ADJUSTMENT LIST
Adjustment Item List
Item
Left Grip Assignment
Unit
0, 1, 2, 3, 4
Data
Left grip assignment
Backup Operation (Pedal)
Enable/Disable Auxiliary operation enable/disable
Outrigger/Blade Operation (Lever)
Enable/Disable Blade/Outrigger operation enable/disable
Positioning Operation (Pedal)
Enable/Disable Positioning operation enable/disable
Assist Analog (Right Grip)
Enable/Disable Assist operation enable/disable
Assist SW (Right Grip)
Enable/Disable Assist operation enable/disable
Aux (ATT) Ope 1 P/S/V Adjustment
MPa
Adjustment of auxiliary solenoid valve
Aux (ATT) Ope 2 P/S/V Adjustment
MPa
Adjustment of auxiliary solenoid valve
Blade/OR Ope 1 P/S/V Adjustment
MPa
Adjustment of blade/outrigger solenoid valve
Blade/OR Ope 2 P/S/V Adjustment
MPa
Adjustment of blade/outrigger solenoid valve
Positioning Ope 1 P/S/V Adjustment
MPa
Adjustment of positioning solenoid valve
Positioning Ope 2 P/S/V Adjustment
MPa
Adjustment of positioning solenoid valve
Assist Ope 1 P/S/V Adjustment
MPa
Adjustment of assist solenoid valve
Assist Ope 2 P/S/V Adjustment
MPa
Adjustment of assist solenoid valve
Assist Ope 3 P/S/V Adjustment
MPa
Adjustment of assist solenoid valve
Assist Ope 4 P/S/V Adjustment
MPa
Adjustment of assist solenoid valve
Load Alarm Min Bottom Pressure
kgf/cm2
Setting for boom cylinder minimum bottom pressure
Pressure Alarm Dtrmn Empty Load
kgf/cm2
Setting for empty bucket judgment pressure
T5-3-18
TROUBLESHOOTING / Dr. ZX
Adjustment List
Item
Unit
Minimum Adjustment
Adjustable Range
Initial Value
0, 1, 2, 3, 4
-
-
0 (Disable)
Backup Operation (Pedal)
Enable/Disable
-
-
Disable
Outrigger/Blade Operation (Lever)
Enable/Disable
-
-
Enable
Positioning Operation (Pedal)
Enable/Disable
-
-
Enable
Assist Analog (Right Grip)
Enable/Disable
-
-
Disable
Assist SW (Right Grip)
Enable/Disable
-
-
Disable
MPa
0.0196
-0.5 to 0.5
0
Left Grip Assignment
Aux (ATT) Ope 1 P/S/V Adjustment
Aux (ATT) Ope 2 P/S/V Adjustment
MPa
0.0196
-0.5 to 0.5
0
Blade/OR Ope 1 P/S/V Adjustment
MPa
0.0196
-0.5 to 0.5
0
Blade/OR Ope 2 P/S/V Adjustment
MPa
0.0196
-0.5 to 0.5
0
Positioning Ope 1 P/S/V Adjustment
MPa
0.0196
-0.5 to 0.5
0
Positioning Ope 2 P/S/V Adjustment
MPa
0.0196
-0.5 to 0.5
0
Assist Ope 1 P/S/V Adjustment
MPa
0.0196
-0.5 to 0.5
0
Assist Ope 2 P/S/V Adjustment
MPa
0.0196
-0.5 to 0.5
0
Assist Ope 3 P/S/V Adjustment
MPa
0.0196
-0.5 to 0.5
0
Assist Ope 4 P/S/V Adjustment
MPa
0.0196
-0.5 to 0.5
0
Load Alarm Min Bottom Pressure
kgf/cm2
2
-100 to 170
0
Pressure Alarm Dtrmn Empty Load
kgf/cm2
2
0 to 100
80
T5-3-19
TROUBLESHOOTING / Dr. ZX
Dr. ZX OPERATION PROCEDURE
Some examples are explained here. As for other Dr.
ZX Operation Procedure, refer to the extra volume, Dr.
ZX Manual.
Parameter Change (Option Controller)
As for the machine equipped with each attachment of
auxiliary, blade/outrigger, positioning and assist, the
operation item should be selected into Enable/Disable
according to the machine specification. If the operation
item is selected into Enable, the corresponding
attachment can be operated.
IMPORTANT: If the operation item is not selected
into Enable, the corresponding
attachment cannot be operated.
In addition, make the item for the
unnecessary attachment disable.
Example:
• Machine equipped with 2-piece boom, 4 outrigger:
• Backup Operation (Pedal): Disable
• Outrigger/Blade Operation (Lever): Enable
• Positioning Operation (Pedal): Enable
• Assist Analog (Right Grip): Disable
• Assist SW (Right Grip): Disable
• Machine equipped with monoblock boom, auxiliary,
rear blade
• Backup Operation (Pedal): Enable
• Outrigger/Blade Operation (Lever): Enable
• Positioning Operation (Pedal): Disable
• Assist Analog (Right Grip): Disable
• Assist SW (Right Grip): Disable
NOTE: The “backup” of “backup operation” means
the auxiliary circuit.
T5-3-20
TROUBLESHOOTING / Dr. ZX
Example: Outrigger/Blade Operation: Enable
Push Parameter Change of option
controller. Push ESC and return to
Main Menu screen.
Push Outrigger/Blade Operation
(Lever).
Select item
Select item
+
Parameter Change
+
+
ML Parameter Change
+
+
All Parameter
initialize
+
+
ESC
Setup Item Selection Screen
Outrigger/Blade Operation(Lever)
Backup Operation
(Pedal)
Outrigger/Blade
Operation(Lever)
Positioning
Operation(Pedal)
Assist Analog
(Right Grip)
Status:
Enable
ESC
Parameter Change Selection
Screen
Push Exec. Push ESC and return
to Parameter Change Selection
screen.
*Adjust Data Confirm*
Adjusting Deviation Data Name
Outrigger/Blade Operation(Lever)
Adjustment:
Disable
Current:
Enable
Exec
Data has changed
ESC
Push Enable and Push Exec. Push
ESC and return to Parameter
Change Selection screen.
ESC
Adjust Data Confirm Screen
T5-3-21
Disable
Disable
Exec
Setup Selection Screen
ESC
To the
lower
TROUBLESHOOTING / Dr. ZX
Parameter Change (Left Grip Assignment)
The initial setting of the left analog switch is in Disable.
If one of the listed operations on the screen is
assigned to the left analog switch by using Dr. ZX, the
operation can be performed with the left analog switch.
At this time, the originally assigned operation cannot
be performed.
Example: When assigning backup operation:
• Backup operation with left analog switch is
enable.
• Furthermore, the assigned operation cannot be
performed by the electric lever/pedal.
Push Parameter Change of option
controller. Push ESC and return to
Main Menu screen.
As for Parameter Change item,
refer to Adjustment Item List. Items
are displayed by pushing a skip
mark.
Select item
Select item
+
Parameter Change
+
+
ML Parameter Change
+
+
All Parameter
initialize
+
+
Select item
Backup Operation
(Pedal)
Outrigger/Blade
Operation(Lever)
Positioning
Operation(Pedal)
Assist Analog
(Right Grip)
Select assigned operation and
push Exec. Push ESC and return
to Parameter Change Selection
screen.
Left Grip Assignment
Current:
+
+
Assist SW
(Right Grip)
Left Grip
Assignment
To the
lower
+
+
ESC
ESC
Setup Item Selection Screen
Push Left Grip Assignment.
Parameter Change Selection
Screen
ESC
Parameter Change Selection
Screen
Push Exec. Push ESC and return
to Parameter Change Selection
screen.
*Adjust Data Confirm*
0: Disable
Adjusting Deviation Data Name
0: Disable
Left Grip Assignment
1: Backup Operation
Current:
2: Outrigger/Blade Operation
3: Positioning Operation
0: Disable
Data has changed
Adjustment: 1: Backup Operation
4: Assist Operation
Exec
ESC
Operation Selection Screen
Exec
ESC
Adjust Data Confirm Screen
T5-3-22
ESC
TROUBLESHOOTING / ICF
OUTLINE
ICF (Information Controller) saves the input signals
from various sensors and switches of the machine as
data.
Various input signals are recorded as “list of daily report data”, “list of frequency distribution data”, “list of
total operating hours”, “list of alarm” and “list of failure”
in ICF.
The recorded data is downloaded to the personal
computer and is uploaded to the center server via LAN,
so that the data can be used as “e-Service”.
The machine equipped with the satellite communication terminal (optional) sends the data to center server
by using satellite communication. (As for the satellite
communication system, refer to T5-4-24.
T5-4-1
TROUBLESHOOTING / ICF
LIST OF DAILY REPORT DATA
Data which can be downloaded by Palm
Item
Details
Date
Date of daily report data
Time when key switch is first turned ON during a day
Start: Time
(Time is recorded by key switch ON signal.)
Time when key switch is last turned OFF during a day
Stop: Time
(Time is recorded by key switch ON signal.)
The value of the final remained fuel during a day
Fuel Level
(Value is recorded by fuel sensor data from monitor unit.)
The value of fuel used during a day
Fuel Usage Amount
(Value is calculated and recorded by accumulated fuel usage amount
from ECM.)
Hour meter cumulative hours
Machine Hour Meter
(Hours are recorded by hour meter from monitor unit.)
Total engine operating hours selecting HP mode during a day
HP Mode Hours
(Hours are recorded by power mode switch information from MC.)
Engine
Operating
Total engine operating hours selecting P mode during a day
P Mode Hours
Hours
(Hours are recorded by power mode switch information from MC.)
Total engine operating hours selecting E mode during a day
E Mode Hours
(Hours are recorded by power mode switch information from MC.)
Hours when auto-idle switch is turned ON during a day
Auto-Idle Switch ON Time
(Hours are recorded by switch from MC.)
Fast Idle (Hi) Trav- Total operating hours of travel mode (Hi) during a day
(Hours are recorded by travel mode switch information from MC.)
Travel
Operating eling Hours
Hours
Slow Idle (Lo) Trav- Total operating hours of travel mode (Lo) during a day
eling Hours
(Hours are recorded by travel mode switch information from MC.)
Total swing operating hours during a day
Swing Operating Hours
(Hours are recorded by swing pressure sensor information from MC.)
Total operating hours selecting front attachment during a day
Digging Operating Hours
(Hours are recorded by front attachment pressure sensor information
from MC.)
Breaker Operating Total operating hours selecting breaker during a day
Hours
(Hours are recorded by attachment information from MC.)
Secondary Crusher Total operating hours selecting secondary crusher during a day
Operating Hours
(Hours are recorded by attachment information from MC.)
Attachment Operat- Hydraulic Crusher Total operating hours selecting hydraulic crusher during a day
ing Hours
Operating Hours
(Hours are recorded by attachment information from MC.)
Vibrating Hammer Total operating hours selecting vibrating hammer during a day
Operating Hours
(Hours are recorded by attachment information from MC.)
Bucket Operating Total operating hours selecting bucket during a day
Hours or Others
(Hours are recorded by attachment information from MC.)
T5-4-2
TROUBLESHOOTING / ICF
Item
Details
Total machine’s waiting hours during a day
No Load Time
(Hours are recorded by each pressure sensor information from MC.)
The highest radiator coolant temperature during a day
Radiator Coolant Temperature
(Value is recorded from monitor unit.)
The highest hydraulic oil temperature during a day
Hydraulic Oil Temperature
(Value is recorded from MC.)
The highest intake air temperature during a day
Intake Air Temperature
(Value is recorded from ECM.)
Engine operating hour distribution during a day
Engine Operating Hour Distribution Data (Operating hours are recorded only when alternator output signal is
continuously delivered for more than 10 minutes.)
Machine operating hour distribution during a day
Loaded Time Distribution Data
(Operating hours are recorded only when operating pressure is continuously detected for more than 5 minutes while the engine runs.)
NOTE: The daily operation in this table is equivalent to the hours between 0:00 and
23:59:59 counted by the ICX built-in clock.
In case the engine is kept operated beyond
0:00, such data are recorded as those for
the following day.
T5-4-3
TROUBLESHOOTING / ICF
Data which can be sent by Satellite Communication
Item
Details
Date
Date of daily report data
The value of the final remained fuel during a day
Fuel Level
(Value is recorded by fuel sensor data from monitor unit.)
The value of fuel used during a day
Fuel Usage Amount
(Value is calculated and recorded by accumulated fuel usage amount
from ECM.)
Hour meter cumulative hours
Machine Hour Meter
(Hours are recorded by hour meter from monitor unit.)
Total engine operating hours during daily operation
Engine Operating Hours
(Hours are recorded with alternator signal ON.)
Travel Operating Hours
Total travel operating hours during daily operation
Swing Operating Hours
Total swing operating hours during daily operation
Front Attachment Operating Hours
Total front attachment operating hours during daily operation
Attachment Operating Hours
Total attachment operating hours during daily operation
No Load Time
Total machine’s waiting hours during daily operation
Radiator Coolant Temperature
The highest radiator coolant temperature during a day
Hydraulic Oil Temperature
The highest hydraulic oil temperature during a day
Intake Air Temperature
The highest intake air temperature during a day
Engine Operating Hour Distribution Data Engine operating hour distribution during daily operation
(Operating hours are recorded only when alternator output signal is
continuously delivered for more than 10 minutes.)
Loaded Time Distribution Data
Machine operating hour distribution during daily operation
(Operating hours are recorded only when operating pressure is
continuously detected for more than 5 minutes while the engine runs.)
NOTE: The daily operation in this table is equivalent to the hours between 0:00 and
23:59:59 counted by the ICX built-in clock.
In case the engine is kept operated beyond
0:00, such data are recorded as those for
the following day.
T5-4-4
TROUBLESHOOTING / ICF
LIST OF FREQUENCY DISTRIBUTION DATA
Item
Details
Frequency distribution of fuel temperature
Frequency distribution of average pump delivery pressure of pumps 1
Pump Load
and 2
Average Pump Delivery Pressure in Frequency distribution of average delivery pressure from pumps during
Digging Operation
digging operation
Average Pump Delivery Pressure in Frequency distribution of average delivery pressure from pumps during
Travel Operation
travel operation
Radiator Coolant Temperature
Frequency information of coolant temperature
Hydraulic Oil Temperature
Frequency information of hydraulic oil temperature
Radiator Coolant Temperature － Intake Frequency information on temperature in which intake air temperature is
Air Temperature
pulled from coolant temperature
Hydraulic Oil Temperature － Intake Air Frequency information on temperature in which intake air temperature is
Temperature
pulled from hydraulic oil temperature
Frequency information of engine speed and average load rate (average
Pump Load Rate
of pump 1 load rate and pump 2 load rate)
Engine Load Rate
Frequency information of engine speed and engine torque
Radiator Coolant Temperature/Intake Air
Frequency information of coolant temperature and intake air temperature
Temperature
Hydraulic Oil Temperature/Intake Air Frequency information of hydraulic oil temperature and intake air temTemperature
perature
Fuel Temperature
T5-4-5
TROUBLESHOOTING / ICF
LIST OF TOTAL OPERATING HOURS
Item
Details
Inner Hour Meter
Hour meter’s value accumulated inside ICF
Machine Hour Meter
Hour meter’s value accumulated in machine’s monitor
Engine
Hour
Operating
HP Mode Hours
Total engine operating hours selecting HP mode
P Mode Hours
Total engine operating hours selecting P mode
E Mode Hours
Total engine operating hours selecting E mode
Auto-Idle Switch ON Time
Hours when auto-idle switch is turned ON
Fast Idle (Hi) TravelTotal operating hours of travel mode (Hi)
Travel
Operating ing Hours
Hour
Slow Idle (Lo) TravTotal operating hours of travel mode (Lo)
eling Hours
Swing Operating Hour
Total swing operating hours during
Front Attachment Operating Hour
Total front attachment operating hours
Breaker
Operating
Total operating hours selecting breaker during daily operation
Hours
Secondary Crusher Total operating hours selecting secondary crusher during daily operaOperating Hours
tion
Attachment Operat- Hydraulic
Crusher Total operating hours selecting hydraulic crusher during daily operaing Hour
Operating Hours
tion
Vibrating
Hammer Total operating hours selecting vibrating hammer during daily operaOperating Hours
tion
Bucket
Operating
Total operating hours selecting bucket during daily operation
Hours or Others
No Load Time
Total machine’s waiting hours
T5-4-6
TROUBLESHOOTING / ICF
(Blank)
T5-4-7
TROUBLESHOOTING / ICF
HOW TO DOWNLOAD AND UPLOAD DATA
OF ICF
Satellite
Terminal
Rear Console
After the data saved in ICF is downloaded to Palm (Dr.
ZX), is uploaded to the personal Computer, and is uploaded to the center server by using LAN, the data can
be used as “e-Service”.
Dr. ZX
Connector
How to Download Data from Machine to Palm
1. Connect the Dr. ZX connectors in Palm and machine by using the Hot Sync cable and connecting
harness.
2. Turn Palm ON and start downloading the data.
(Refer to the next page.)
ICF
TCJB-05-04-001
Palm
(Dr. ZX)
Hot Sync
Cable
Connecting
Harness
T1V1-05-07-002
T5-4-8
TROUBLESHOOTING / ICF
Data Download
After starting Dr. ZX, push Select
Controller.
Select Function
+
Select failure-diagnosis controller
Self-Diagnostic Result
+
Push OK.
Push ICF Controller.
Select Controller
+
Engine Controller
+
Main Controller
+
Monitor Controller
+
ICF Controller
ESC
・ ICF
controller Ver.: XXYY
・ Satellite terminal Controller
Ver.: XXYY
Is it correct?
ESC
OK
ESC
Function Selection Screen
Controller Selection Screen
ICF Controller Screen
Push Start.
Push Date Download.
While
downloading
data,
Download Screen is displayed.
Select Item
Password
Dr. ZX SerVice Soft
(C)Hitachi Construction
Machinery Co., ltd
Data Download
+
Information C/U: Various
Setup
Data Download
+
Save Data Check
+
Downloading.
Do not turn off the Palm or
disconnect the download cable.
27%
+
Op. Manual
Start
Back
ESC
Cancel
Title Screen
Main Menu Screen
Data Download Screen
When downloading is completed
normally, Normal End Screen is
displayed.
Push OK and return to Main Menu
Screen.
If pushing Cancel on Data
Download Screen, Alarm Screen
is displayed. Push OK and return
to Main Menu Screen.
Push ESC and return to Title
Screen.
Select Item
i
Initialization has been
completed.
The download is completed.
CAUTION
Initialization has been
completed.
The download
has been interrupted.
You may disconnect the
download cable.
No data has been transferred to the Dr. ZX
OK
Normal End Screen
To the
lower
+
Information C/U: Various
Setup
Data Download
+
Save Data Check
+
+
OK
ESC
Alarm Screen
Main Menu Screen
T5-4-9
To the
lower
TROUBLESHOOTING / ICF
How to Upload Data from Palm to Personal
Computer
1. Set Palm to the cradle. Connect the USB cable to
the personal computer.
2. Push the Hot Sync button.
Palm
NOTE: When pushing the Hot Sync button and
uploading the data to the personal computer, the Palm (or CLIE) Desktop software
attached with Palm need to be installed.
Cradle
Hot Sync
Button
T178-05-07-033
T5-4-10
TROUBLESHOOTING / ICF
VARIOUS SETUP OF ICF AND SATELLITE
COMMUNICATION TERMINAL BY USING
Dr. ZX
Before starting satellite communication, installing the
satellite communication terminal and replacing ICF,
perform the following procedures by using Dr. ZX.
ICF Setup Procedures
Start Dr. ZX
1.1 Select Information Controller
1.2 Select Information C/U: Various Setup
1.3 Enter Date and Time
1.4 Enter Model and Serial No.
1.5 Information C/U: Initialize
Communication
No Communication
1.6 Satellite Terminal: Initialize
1.7 Satellite Terminal Serial No. Check
1.8 Satellite Terminal, Communicating State Check
2. Self-Diagnosing
T5-4-11
TROUBLESHOOTING / ICF
1.1 Select Information Controller
1.2 Select Information C/U: Various Setup
1.1 Select Information Controller
After starting Dr. ZX, push Select
Controller.
Push ICF Controller.
Push OK.
Select failure-diagnosis controller
Select Function
+
Self-Diagnostic Result
+
Select Controller
+
Engine Controller
+
Main Controller
+
Monitor Controller
+
ICF Controller
ESC
Function Selection Screen
・ ICF
Controller Ver.: XXYY
・ Satellite Terminal
Controller Ver.: XXYY
To the
lower
Is it correct?
ESC
Controller Selection Screen
OK
ESC
ICF Controller Screen
1.2 Select Information C/U: Various Setup
Push Information C/U: Various
Setup.
Push Start.
Select Item
Password
+
Information C/U: Initialize
+
Information C/U: Various
Setup
Data Download
+
+
Save Data Check
+
Enter Model and Serial
No.
Enter Date and Time
+
Control Data: Initialize
+
Dr. ZX SerVice Soft
(C)Hitachi Construction
Machinery Co., ltd
Select Item
+
Op. Manual
Start
Title Screen
Back
ESC
Main Menu Screen
T5-4-12
ESC
Information C/U: Various Setup
Screen
TROUBLESHOOTING / ICF
1.3 Enter Date and Time
Push Enter Date and Time.
Push ESC and return to Main
Menu Screen.
Push Set and the focused item is
YY.
Push ESC and return to Information C/U: Various Setup Screen.
Enter Date and Time
Select Item
+
Information C/U: Initialize
YY 2004 MM
01
+
HH
01
01
+
Enter Model and Serial
No.
Enter Date and Time
+
Control Data: Initialize
MM
－
Set
ESC
Information C/U: Various Setup
Screen
01
DD
＋
ESC
YY, MM, DD, HH and MM
The focused item is displayed reversely.
At first, the focused item is YY.
YY, MM, DD, HH and MM
Move the focused item.
No repeat input.
Enter Date and Time Screen
－
YY, MM, DD, HH and MM
Value of the focused item is increased or decreased one by one.
In case value is beyond maximum one:
Change value into the minimum one
In case value is below minimum one: Change
value into the maximum one
No repeat input.
Select Item
+
Information C/U: Various
Setup
Data Download
+
Save Data Check
+
＋
+
ESC
Main Menu Screen
T5-4-13
TROUBLESHOOTING / ICF
1.4 Enter Model and Serial No.
Push Enter Model and Serial No.
Select Item
+
Information C/U: Initialize
+
+
Enter Model and Serial
No.
Enter Date and Time
+
Control Data: Initialize
To the
lower
ESC
Information C/U: Various Setup
Screen
After inputting model and serial
No., push OK and return to Enter
Model and Serial No. Screen.
Push ESC and return to Information C/U: Various Setup Screen.
Push Exec, and model and serial
No. can be input.
Push ESC and return to Information C/U: Various Setup Screen.
Enter Model and Serial No.
Model
Enter Model and Serial No.
01J1
Select Item
Model |
Exec
Serial No. 123456
Exec
Push ESC and return to Main
Menu Screen.
ESC
ESC
Ex. Mach.No.(HCM1J1⋅⋅⋅12
3456) Model(01J1)
Serial No.
Ex. Mach.No.(HCM1J1⋅⋅⋅12
3456) Serial No.(123456)
OK
ESC
ESC
OK
+
Information C/U: Initialize
+
+
Enter Model and Serial
No.
Enter Date and Time
+
Control Data: Initialize
ESC
Information C/U: Various Setup
Screen
Enter Model and Serial No.
T5-4-14
TROUBLESHOOTING / ICF
1.5 Information C/U: Initialize
Push Information C/U: Initialize.
Select Item
+
Information C/U: Initialize
+
+
Enter Model and Serial
No.
Enter Date and Time
+
Control Data: Initialize
To the
lower
ESC
Information C/U: Various Setup
Screen
Push Init and the controller operating data is initialized.
Push ESC and return to Information C/U: Various Setup Screen.
Push OK and return to Information C/U: Various Setup Screen.
Information C/U: Initialize
Select Item
Is operation data erased?
Init
i
Initialization has been
completed.
Initialization has been
completed.
ESC
Init
ESC
Push ESC and return to Main
Menu Screen.
OK
+
Information C/U: Initialize
+
+
Enter Model and Serial
No.
Enter Date and Time
+
Control Data: initialize
ESC
Information C/U: Initialize Screen
Information C/U: Various Setup
Screen
T5-4-15
TROUBLESHOOTING / ICF
1.6 Satellite Terminal: Initialize
Display the next screen of Information
C/U:
Various
Setup
Screen.
Push Satellite Terminal: Initialize.
Push ESC and return to Main
Menu Screen.
Select Item
Select Item
+
Information C/U: Initialize
+
+
+
+
Enter Model and Serial
No.
Enter Date and Time
+
Control Data: Initialize
+
+
Information C/U: Various Setup
Screen
Satellite Terminal: Initialize
Satellite Terminal: Initialize
Satellite Terminal No.
Confirmation
Communicating State
Check
Enter Satellite Comm.
Start/Stop
ESC
Push Exec.
Push ESC and return to Information C/U: Various Setup Screen.
ESC
Next Screen of Information C/U:
Various Setup Screen
Is Un-Transmit data erased?
Exec
ESC
Satellite Terminal: Initialize
Push OK and return to Information C/U: Various Setup Screen.
Satellite Terminal: Initialize
Select Item
+
Un-Transmit data is erased.
+
+
+
OK
Select Item
Satellite Terminal: Initialize
Satellite Terminal No.
Confirmation
Communicating State
Check
Enter Satellite Comm.
Start/Stop
+
Information C/U: Various
Setup
Data Download
+
Save Data Check
+
+
ESC
Information C/U: Various Setup
Screen
T5-4-16
ESC
Main Menu Screen
To the
lower
TROUBLESHOOTING / ICF
1.7 Satellite Terminal Serial No. Check
Push Satellite Terminal No. Confirmation.
Push ESC and return to Main
Menu Screen.
Select Item
+
+
+
+
Satellite Terminal: Initialize
Satellite Terminal No.
Confirmation
Communicating State
Check
Enter Satellite Comm.
Start/Stop
Confirm serial no. (12 digits).
Push ESC and return to Information C/U: Various Setup Screen.
Satellite Terminal No. Confirmation
Select Item
+
+
Serial No. 8GBDA701862
+
+
ESC
ESC
Satellite Terminal: Initialize
Satellite Terminal No.
Confirmation
Communicating State
Check
Enter Satellite Comm.
Start/Stop
ESC
Information C/U: Various Setup
Screen
Information C/U: Various Setup
Screen
Select Item
+
Information C/U: Various
Setup
Data Download
+
Save Data Check
+
+
ESC
Main Menu Screen
T5-4-17
TROUBLESHOOTING / ICF
1.8 Satellite
Check
Terminal,
Push
Communicating
State
Check.
Push ESC and return to Main
Menu Screen.
Select Item
+
+
+
+
Satellite Terminal: Initialize
Satellite Terminal No.
Confirmation
Communicating State
Check
Enter Satellite Comm.
Start/Stop
Communicating
State
Check communicating state.
Communicating State Check
ICF⇔Satellite Terminal
UnUn・ Conn
・ Comm.
OK
NG
Satellite Terminal
ON
OFF
・ Power
・ Comm.
Enable
Stop
ESC
Information C/U: Various Setup
Screen
Check the enclosed state.
Uncon: Faulty harness
NG: Faulty harness for Comm.
OFF: Faulty harness, Faulty controller
Stop: 1.9 Enter Satellite Comm. Start/Stop
ESC
Communicating State Check
Rod Aerial
OK
NG
GPS Aerial
OK
NG
Wave State
ON
OFF
Un Transmit Data Number
0
Last Transmitting Time
When electrical wave of the satellite is
caught, the items are turned into OK.
IMPORTANT: Check this with the key of machine ON in outdoor.
According to state of electrical
wave, it may take a little
longer time.
2004/07/01 13：50：00
ESC
Select Item
Select Item
+
+
Information C/U: Various
Setup
Data Download
+
Save Data Check
+
+
+
+
+
ESC
Satellite Terminal: Initialize
Satellite Terminal No.
Confirmation
Communicating State
Check
Enter Satellite Comm.
Start/Stop
ESC
Main Menu Screen
Information C/U: Various Setup
Screen
T5-4-18
TROUBLESHOOTING / ICF
1.9 Enter Satellite Comm. Start/Stop
Push ▼ and move to the next
screen of Information C/U: Various Setup Screen.
Push Enter Satellite Comm.
Start/Stop.
Select Item
+
+
+
+
Satellite Terminal: Initialize
Satellite Terminal No.
Confirmation
Communicating State
Check
Enter Satellite Comm.
Start/Stop
To the
lower
ESC
Information C/U: Various Setup
Screen
When starting Satellite Comm.,
push Start and push Exec.
When stopping Satellite Comm.,
push Stop and push Exec.
Push ESC and return to Information C/U: Various Setup Screen.
Push OK and return to Information C/U: Various Setup Screen.
Enter Satellite Comm. Start/Stop
Satellite Terminal UnTrasmit
State
Stop
Setting has been completed
ESC
Exec
ESC
Select Item
+
+
Exec
Start
Push ESC and return to Main
Menu Screen.
+
+
OK
Satellite Terminal: Initialize
Satellite Terminal No.
Confirmation
Communicating State
Check
Enter Satellite Comm.
Start/Stop
ESC
Information C/U: Various Setup
Screen
T5-4-19
TROUBLESHOOTING / ICF
1.10 Control Data: Initialize
Push Control Data: Initialize.
Select Item
+
Information C/U: Initialize
+
+
Enter Model and Serial
No.
Enter Date and Time
+
Control Data: Initialize
ESC
Information C/U: Various Setup
Screen
Push Init and the controller operating data is initialized.
Push ESC and return to Information C/U: Various Setup Screen.
Push OK and return to Information C/U: Various Setup Screen.
Select Item
Control Data: Initialize
Is control data initialized?
Init
i
Initialization has been
completed.
Initialization has been
completed.
ESC
Init
Push ESC and return to Main
Menu Screen.
ESC
OK
+
Information C/U: Initialize
+
+
Enter Model and Serial
No.
Enter Date and Time
+
Control Data: Initialize
ESC
Information C/U: Various Setup
Screen
Control Data: Initialize Screen
T5-4-20
TROUBLESHOOTING / ICF
(Blank)
T5-4-21
TROUBLESHOOTING / ICF
2. Self-Diagnosing
After starting Dr. ZX,
Self-Diagnostic Result.
Push Fault of ICF Controller. If
there is no trouble, No Problem is
displayed.
push
Self-diagnosing of controllers
below hasn completed.
Select Function
+
Self-Diagnostic Result
+
Select Controller
Engine Controller No Problem
Main Controller
Self-Diagnosing
Fault
To the
lower
Monitor Controller No Problem
ICF Controller
ESC
ESC
ESC
Function Selection Screen
Change the page and
the fault code in back
and forth is displayed.
Push Details, and Details and
Corrective Action are displayed.
Push ESC and Retry B Screen is
Displayed.
Push ESC and Retry B Screen is
Displayed.
ICF Controller
Problem was detected.
14000
Fault
Controller Self-Diagnosing Screen
Push Retry B and return to Controller
Self-Diagnosing Screen after controller
self-diagnsing.
Push ESC and return to Controller
Self-Diagnosing Screen.
Fault Code 14000-2
14001
Details
Details
CAN Communication Error
ESC
Corrective Action
1)Retry B
2)Check Harness
3)
Retry B
Do you want to escape?
ESC
Details
ESC
ESC
Fault Code Screen
Retry B
Retry B Screen
Execute
Retry B
Self-diagnosing of controllers
below hasn completed.
Engine Controller No Problem
Main Controller
ESC
Fault
Monitor Controller No Problem
ICF Controller
Fault
ESC
Controller Self-Diagnosing Screen
T5-4-22
ESC
TROUBLESHOOTING / ICF
LIST OF FAULT CODE
Fault Code
Details
Remedy
14000-2
Abnormal CAN Communication
14001-2
ICF: Flash Memory: Read / Write Execute retry B in self-diagnosing and execute the following
Error
item.
Execute 1.5 Information C/U: Initialize (T5-4-15).
ICF: External RAM: Read / Write Error
14002-2
14003-2
ICF: EEPROM: Sum Check Error
Execute retry B in self-diagnosing.
If this error code is displayed after re-try, check the following
item.
Check the CAN communication line (check the harness).
Execute retry B in self-diagnosing.
If this error code is displayed after re-try, check the following
item.
1. Execute 1.10 Control Data: Initialize (T5-4-20).
2. Execute 1.4 Enter Model and Serial No. (T5-4-14).
Then, execute self-diagnosing and execute retry B.
14006-2
ICF: Satellite Communication Ter- Execute retry B in self-diagnosing.
minal: Communication Error
If this error code is displayed after re-try, check the following
item.
Check the communication line.
Check the power source line of satellite terminal.
Check the fuse.
Then, execute self-diagnosing and execute retry B.
14008-2
14100-2
Execute retry B in self-diagnosing.
If this error code is displayed after re-try, replace the controlSatellite Communication Terminal: ler.
Abnormal EEPROM
ICF: Abnormal Internal RAM
14101-2
Satellite Communication Terminal:
Abnormal IB/OB Queue
14102-2
Satellite Communication Terminal:
Abnormal Local Loup Back
14103-2
Satellite Communication Terminal:
The satellite is not found.
14104-2
Satellite Communication Terminal:
Fail 1 of Remote Loup Back
14105-2
Satellite Communication Terminal:
Fail 2 of Remote Loup Back
14106-2
Satellite Communication Terminal:
Sending and receiving data are unmatched.
T5-4-23
TROUBLESHOOTING / ICF
SATELLITE COMMUNICATION SYSTEM
The satellite communication system is used for maintenance of the machine, “e-Service” by transmitting
various data of the machine regularly via a low earth
orbit satellite.
GPS Aerial
Communication
Aerial
NOTE: Depending on the circumstances of the
machine (ex. in the constructions, in the
tunnel, affected by the surrounding building
and affected of noise), the data transfer
rate may become slower, or the communication might not be established.
The satellite communication system using
a low earth orbit satellite transmits digital
data through the radio wave. If there is excessively noise or use of electrical equipment which causes noise near the machine,
they cause reduces data transfer rate or
communication might not be established at
worst.
T1V1-05-07-003
Satellite
Terminal
Rear Console
The satellite communication system consists of satellite communication terminal, GPS aerial and communication aerial. The mail function of monitor unit becomes effective.
The functions of each equipment are:
• Satellite Communication Terminal
•
•
•
1.
2.
3.
4.
Receives the data from ICF, GPS aerial and
monitor unit, and sends the data to the communication aerial.
GPS Aerial
Receives location information of the machine
from a low earth orbit satellite.
Communication Aerial
Communicates the data with a low earth orbit
satellite.
Monitor Unit
Sends the mail when pushing the key corresponding to requirement.
General Requirement
Fuel Replenishing Requirement
Service Maintenance Requirement
Forwarding Requirement
ICF
TCJB-05-04-001
Monitor Unit
1
T5-4-24
2
3
Mail Screen
4
T1V5-05-01-037
TROUBLESHOOTING / ICF
On the machine equipped with the satellite communication system, the data are sent according to the condition as follows:
Kinds of data sent from the machine by using satellite
communication:
Items
Periodical
Transmission
Kinds of Data
Daily Report Data, Latest Location Information, Fuel Level
Condition
The data are sent once a day. In order to
avoid congested traffic in the communication line, the data is sent randomly
between 0:00 and 02:00.
Transmitting Data at Latest Location Information
The data is sent only when the machine
Engine Start
is moved more than 5 km from the place
where it is recorded lastly.
Emergency
Alarm and Error Information
The transmission starts immediately
Transmission
when the alarm and error occurs.
Hour Meter 100 Hours Frequency Distribution Information
The data is sent when the hour meter
Transmission
exceeds every 100 hours.
Transmission by Mail
General Requirement, Fuel Replenishing The transmission starts when the key on
Requirement, Service Maintenance Re- monitor unit corresponding to requirequirement and Forwarding Requirement
ment is pushed.
T5-4-25
TROUBLESHOOTING / ICF
(Blank)
T5-4-26
TROUBLESHOOTING / Component Layout
MAIN COMPONENT LAYOUT
Upperstructure (1)
1
2
3
4
5
6
7
8
24
23
16
22
21
18
20
15
14
13
TCEB-01-02-002
1 - Rear Camera
7-
Air Cleaner
13 - Oil Cooler
2345-
8910 11 -
Battery
Fuel Cooler
Washer Tank
ECM (Engine Controller)
14 15 16 17 -
12 - Solenoid Valve Unit
(For Electric Lever)
10
17
19
Radiator
Inter Cooler
Reserve Tank
Air Conditioner
Condenser
6 - Receiver Drier
12
11
9
Travel Shockless Valve
Pilot Valve (Left)
Pilot Shut-Off Solenoid Valve
Center Joint
18 - Accumulator Charging Valve
T5-5-1
19 - Auxiliary / Positioning Electric
Lever
20 - Steering Valve
21 - Brake Valve
22 - Travel Pilot Valve
23 - Pilot Valve (Right)
24 - Blade / Outrigger Electric
Lever
TROUBLESHOOTING / Component Layout
Upperstructure (2)
42
41
40
39
38
37
36
35
34
25
33
26
32
27
31
30
28
TCEB-01-02-003
29
25 26 27 28 -
Positioning Control Valve
Shuttle Valve
Signal Control Valve
Heat Circuit Cut Solenoid
Valve
29 - Swing Shockless Valve
30 31 32 33 -
Automatic Fueling Switch
Control Valve
Automatic Fueling Pump
3-Spool Solenoid Valve
Unit
34 - Swing Device
35 36 37 38 -
T5-5-2
Engine Oil Filter
Pump Device
Fuel Pre Filter
Fuel Main Filter
39 40 41 42 -
Solenoid Pump
Steering Filter
Pilot Filter
Engine
TROUBLESHOOTING / Component Layout
Undercarriage
2
1
3
4
5
9
8
6
7
TCEB-01-02-001
1 - Blade Cylinder
2 - Rear Axle
45-
Axle Lock Cylinder
Front Axle
67-
3 - 2-Spool Solenoid Valve
Unit (Blade / Outrigger
Cylinder)
T5-5-3
Outrigger Cylinder
Travel Motor
89-
Transmission
Transmission Changeover
Solenoid Valve
TROUBLESHOOTING / Component Layout
Front Attachment
• 2-Piece Boom
• Monoblock Boom
1
2
3
2
4
7
7
4
1
5
6
6
T1F3-01-02-004
T1F3-01-02-003
1 - Bucket Cylinder
3-
Positioning Cylinder
2 - Arm Cylinder
4-
Boom Cylinder
5-
Hose Rupture Valve
(Positioning)
6 - Hose Rupture Valve
(Boom)
T5-5-4
7-
Hose Rupture Valve (Arm)
TROUBLESHOOTING / Component Layout
ELECTRICAL COMPONENT LAYOUT (Overview)
Pump Device (Refer to T1-2-13.)
・Pump 1 Delivery Pressure Sensor
・Pump 2 Delivery Pressure Sensor
・Pump 1 Control Pressure Sensor
・Pump 2 Control Pressure Sensor
・Pump 1 Maximum Flow Rate Limit
Control Solenoid Valve
・Pump 2 Maximum Flow Rate Limit
Control Solenoid Valve
・Torque Control Solenoid Valve
Filter (Refer to T1-2-15.)
・Steering Pump Delivery Pressure Sensor
Engine (Refer to T1-2-12.)
13
1
12
2
3
4
5
10
9
8
7
6
11
Travel Shockless Valve
(Refer to T1-2-15.)
・Pressure Sensor (Travel Forward)
・Pressure Sensor (Travel Reverse)
Brake Valve (Refer to T1-2-14.)
・Brake Pressure Sensor
・Work Brake Release Switch
・Brake Remain Pressure Sensor
1 - Fresh Air Temperature
Sensor
2 - Starter Relay
5-
Battery
6-
ECM
3 - Battery Relay
7-
Intake Air Temperature
Sensor
8-
Solenoid Valve Unit
(For Electric Lever)
9 - Atmosphere Pressure
Sensor
10 - Air Cleaner Restriction
Switch
4 - Glow Plug Relay
T5-5-5
TCEB-01-02-002
11 - Pilot Shut-Off Solenoid
Valve
12 - Fuel Sensor
13 - Hydraulic Oil Temperature
Sensor (Main)
TROUBLESHOOTING / Component Layout
Swing Device
(Refer to T1-2-13.)
・Pressure Sensor (Front)
14
18
15
16
Control Valve (Refer to T1-2-14.)
・Pressure Sensor (Boom Raise)
・Pressure Sensor (Arm Roll-In)
14 - Horn
16 - Pressure Sensor
(Positioning)
17
TCEB-01-02-003
Signal Control Valve
(Refer to T1-2-13.)
・Pressure Sensor (Swing)
・Pressure Sensor (Auxiliary)
17 - Heat Circuit Cut Solenoid
Valve
15 - Slip Ring
T5-5-6
18 - 3-Spool Solenoid Valve
Unit
TROUBLESHOOTING / Component Layout
ELECTRICAL COMPONENT LAYOUT
(MONITORS AND SWITCHES)
6
5
7
1
2
4
12
3
11
10
TCJB-01-02-006
8
TCJB-01-02-014
22
14
23
15
16
9
24
34
25
13
26
27
28
33
17
18
32
19
31
30
29
TCJB-01-02-007
20
21
TCJB-01-02-008
1-
Monitor Unit
(Refer to T1-2-8.)
2 - Swing Lock Lever
3-
Blade/Outrigger Lever
4-
Pilot Shut-Off Lever
56-
Engine Stop Switch
Combination Switch
･Turn Signal Switch
･Light Switch
･Dimmer Switch
･Passing Switch
7 - Brake Switch
8-
Accelerator Pedal
9-
Brake Pedal
10 - Steering Column Monitor
(Refer to T1-2-9.)
11 - Auxiliary/Positioning Pedal
(Optional)
12 - Horn Switch
13 - Left Analog Switch
(Auxiliary)
14 - Horn Switch
15 - Positioning Pedal Selection
Switch
16 - Auxiliary Pedal Selection
Switch
17 - Hazard Switch
19 - Blade/Outrigger Front-Rear
Selector Switch
20 - Outrigger Left-Right
Selector Switch
21 - Heater Seat Switch
(Optional)
22 - FNR Switch
27 - Engine Speed Control Mode
Selection Switch
28 - Power Mode Switch
29 - Key Switch
23 - Auxiliary
24 - Auxiliary
30 - Blade/Outrigger Selector
Switch
31 - Auto-Idle Switch
32 - Work Light Switch
25 - Engine Control Dial
33 - Wiper/Washer Switch
26 - Travel Speed Mode Switch
34 - Right Analog Switch
(Assist) (Optional)
18 - Electrical Control Main
Switch (Optional)
T5-5-7
TROUBLESHOOTING / Component Layout
Monitor Unit
7
1
2
3
4
5
6
8
9
10
11
12
13
14
15
16
17
18
35
34
21
33
1 - Work Mode Display
2 - Auto-Idle Display
3 - Overload Alarm Display
(Optional)
4 - Auto Axle Lock Display
5 - Auxiliary
6 - Glow Signal Display
7 - Trip Meter
8 - Odometer
9 - Hour Meter
32 31 30 29 28 27 26 25
24
23
22
20
19
TCJB-05-02-043
10 - Parking Brake Display
11 - Work Brake Display
12 - Axle Lock Display
19 - Trip Meter Display
20 - Odometer Display
21 - Hour Meter Display
13 - Work Light Display
14 - Auxiliary 2 (Positioning)
Selection Display
15 - Auxiliary 1 (Attachment)
Selection Display
16 - Blade/Outrigger Settings
and Brake Mode Display
17 - Mail Display (Optional)
18 - Clock
22 - Back Monitor Selection
23 - Menu
28 - Work Mode Display
29 - Auxiliary Selection
30 - Coolant Temperature
Gauge
31 - Work Mode Selection
32 - Return to Primary Screen
24 - Meter Display Selection
33 - Brake Oil Pressure Gauge
25 - Fuel Gauge
34 - Speedometer
26 - Auxiliary
27 - Mail Selection (Optional)
35 - Tachometer
T5-5-8
TROUBLESHOOTING / Component Layout
Steering Column Monitor
1
2
12
3
4
11
5
10
6
9
7
8
TCJB-02-01-008
1 - Travel Forward Indicator
4 - Pilot Cut Indicator
2 - Turn Signal Indicator
(Right)
3 - Neutral Indicator
5 - Travel Reverse Indicator
6 - Hazard Light Indicator
7 - Auto-Cruise Indicator
(Optional)
8 - Travel Slow Speed Indicator
9 - Auxiliary
T5-5-9
10 - Clearance Light Indicator
11 - High Beam Indicator
12 - Turn Signal Indicator (Left)
TROUBLESHOOTING / Component Layout
ELECTRICAL COMPONENT LAYOUT
(CONTROLLERS AND RELAYS)
1
2
7
3
4
6
5
TCJB-01-02-015
1 - MC (Main Controller)
2 - Satellite Communication
Terminal (Optional)
3 - Fuse Box
4 - Dr.ZX Connector
(Use as Download Connector)
T5-5-10
5 - Option Controller
6 - ICF (Information Controller)
7 - Flasher
TROUBLESHOOTING / Component Layout
Relays Position
TCJB-01-02-009
Option Controller
Dr.ZX Connector
1 - High Beam Relay
15 - Stop Light Relay
2 - Clearance Light Relay
(Left)
3 - Clearance Light Relay
(Right)
4 - Head Light Relay (Left)
5 - Head Light Relay (Right)
6 - Travel Slow Selection
Relay
7 - Compressor Relay (A/C)
8 - Heater Relay (A/C)
9 - MAX-Hi Relay (A/C)
16 - Washer Relay
10 - ECM Main Relay
11 - Turn Signal Light Relay
(Left)
12 - Turn Signal Light Relay
(Right)
13 - Wiper Relay
14 - Boom Light Relay
17 - Horn Relay
18 - Load Dump Relay
19 - Pilot Shut-Off Relay
20 - Security Horn Relay
21 - Starter Cut Relay
22 - Security Relay
23 - Travel Fast Selection
Relay
24 - Blade/Outrigger Relay
(Rear)
25 - Blade/Outrigger Relay
(Front)
26 - Blade/Outrigger Relay
(Rear-Right)
27 - Blade/Outrigger Relay
(Rear-Left)
28 - Blade/Outrigger Relay
(Main 2)
29 - Blade/Outrigger Relay
(Front-Right)
30 - Blade/Outrigger Relay
(Front-Left)
31 - Blade/Outrigger Relay
(Main 1)
32 - Auto-Cruise Relay (OP)
33 - Heater Seat Relay (OP)
34 - Room Lamp Controller Relay
(OP)
35 - Assist Relay 1 (OP)
36 - Assist Relay 2 (OP)
37 - Assist Flow Rate Control
Relay (OP)
38 - Blank
39 - Auxiliary/Positioning Selection
Relay 1 (OP)
40 - Auxiliary/Positioning Selection
Relay 2 (OP)
41 - Auxiliary/Positioning Selection
Relay 3 (OP)
42 - Auxiliary/Positioning Selection
Relay 4 (OP)
NOTE: OP: Optional
T5-5-11
Fuse Box
TCJB-01-02-010
43 - Twin Wiper Relay 1 (OP)
44 - Twin Wiper Relay 2 (OP)
45 - Twin Wiper Relay 3 (OP)
46 - Twin Wiper Relay 4 (OP)
47 - Twin Wiper Relay 5 (OP)
48 - Twin Wiper Relay 6 (OP)
49 - Swing Alarm Relay (OP)
50 - Rear Head Light Relay (OP)
51 - Additional Front Head Light
(OP)
52 - Additional Front Head Light
(OP)
53 - Revolving Light Relay (OP)
54 - Immobilizer 1 (OP)
55 - Immobilizer 2 (OP)
56 - Immobilizer 3 (OP)
TROUBLESHOOTING / Component Layout
ENGINE
1
2
T1T1-01-02-005
3
5
4
6
7
8
9
13
12
T1T1-01-02-003
11
10
T1T1-01-02-004
1-
EGR Valve
5-
Overheat Switch
8-
2-
Glow Plug
6-
Injector
9-
34-
Cam Angle Sensor
Coolant Temperature
Sensor
7-
Boost Pressure Sensor
Boost Temperature Sensor
Common Rail Pressure
Sensor
10 - Crank Speed Sensor
T5-5-12
11 - Engine Oil Pressure
Sensor
12 - Fuel Temperature Sensor
13 - Supply Pump Actuator
TROUBLESHOOTING / Component Layout
PUMP DEVICE
5
2
6
1
7
11
10
9
4
3
8
TCEB-03-01-003
SWING DEVICE
TCEB-03-01-001
SIGNAL CONTROL VALVE
13
19
12
14
18
15
17
16
TCEB-01-02-005
TCEB-01-02-004
1 - Pump 1
6-
2 - Pump 2
7-
3 - Pump 1 Delivery
Pressure Sensor
4 - Pump 2 Delivery
Pressure Sensor
5 - Pilot Pump
Steering Pump
Pump 2 Control Pressure
Sensor
8 - Pump 1 Control Pressure
Sensor
9 - Pump 1 Maximum Flow
Rate Limit Control Solenoid
Valve
10 - Torque Control Solenoid
Valve
11 - Pump 2 Maximum Flow Rate
Limit Control Solenoid Valve
12 - Pressure Sensor (Front)
16 - Heat Circuit Cut Solenoid
Valve
17 - Swing Shockless Valve
13 - Signal Control Valve
18 - Pressure Sensor (Swing)
14 - Pressure Sensor (Positioning)
19 - Pressure Sensor
(Auxiliary)
15 - Shuttle Valve
T5-5-13
TROUBLESHOOTING / Component Layout
CONTROL VALVE
BRAKE VALVE
1
4
2
5
8
7
6
3
TCJB-01-02-017
TCGB-01-02-003
3-SPOOL SOLENOID VALVE UNIT
9
10
SOLENOID VALVE UNIT
(FOR ELECTRIC LEVER)
11
20
19
12
18
13
14
17
15
TCGB-03-12-001
16
TCJB-01-02-018
1 - Main Relief Valve
2 - Pressure Sensor
(Arm Roll-In)
3 - Pressure Sensor
(Boom Raise)
4 - Accumulator Charging
Valve
5 - Brake Remain Pressure
Sensor
6-
Stop Light / Work Brake
Release Switch
7 - Brake Pressure Sensor
11 - Solenoid Valve Unit (SI)
8-
Brake Valve
12 - Positioning / Assist
Solenoid Valve
13 - Auxiliary Solenoid Valve
16 - Hydraulic Oil Temperature
Sensor (For Electric Lever)
17 - Blade / Outrigger Solenoid
Valve
18 - Auxiliary Solenoid Valve
9-
Solenoid Valve Unit (SC)
14 - Blade / Outrigger Solenoid
Valve
15 - Travel Make-Up Solenoid
Valve
19 - Positioning / Assist
Solenoid Valve
20 - Swing Parking Brake
Release Solenoid Valve
10 - Solenoid Valve Unit (SF)
T5-5-14
TROUBLESHOOTING / Component Layout
TRAVEL SHOCKLESS VALVE
TRANSMISSION
NOID VALVE
5
1
CHANGEOVER
SOLE-
6
2
3
TCJB-05-07-002
TCJB-01-02-019
4
TRAVEL DEVICE
FILTER
11
7
10
12
13
8
9
TCJB-01-02-020
15
14
TCEB-01-02-006
1 - Pressure Sensor
(Travel Forward)
2 - Travel Forward Pi Cut
Solenoid Valve
3 - Travel Reverse Pi Cut
Solenoid Valve
4 - Pressure Sensor
(Travel Reverse)
5 - Travel Mode Selector
Solenoid Valve
6 - Pressure Reducing Valve
7 - Travel Motor
8 - Transmission
9-
Travel N Sensor
10 - Travel Motor Displacement
Control Solenoid Valve
11 - Steering Pump Delivery
Pressure Sensor
12 - Steering Filter
T5-5-15
13 - Pilot Filter
14 - Fuel Pre Filter
15 - Fuel Main Filter
TROUBLESHOOTING / Component Layout
COMPONENTS IN CONTROL VALVE
1
2
3
4
5
6
7
8
9
10
41
11
40
12
39
13
38
14
37
15
36
35
34
16
17
33
32
18
19
31
30
29
20
28
21
27
26
25 24
23
22
T16W-03-03-018
T5-5-16
TROUBLESHOOTING / Component Layout
11
14
4
41
31
35, 36
Front
38
18
T16W-03-03-030
1-
Load Check Valve
(Blade/Outrigger
Tandem Circuit)
2 - Load Check Valve
(Blade/Outrigger Parallel
Circuit)
3 - Check Valve
(Main Relief Circuit)
4 - Main Relief Valve
56-
789-
10 -
11 -
Auxiliary Flow Combiner
Valve
Check Valve
(Auxiliary Flow
Combiner Circuit)
Check Valve
(Main Relief Circuit)
Check Valve (Flow
Combiner Circuit)
Bucket Flow Rate
Control Valve (Selector
Valve)
Bucket Flow Rate
Control Valve (Poppet
Valve)
Make-Up Valve
(Travel Reverse Side)
12 - Make-Up Valve
(Travel Forward Side)
22 - Load Check Valve
(Arm 2 Tandem Circuit)
32 - Arm Anti-Drift Valve
(Check Valve)
13 - Bucket Regenerative Circuit
23 - Bypass Shut-Out Valve
33 - Arm Anti-Drift Valve
(Selector Valve)
14 - Overload Relief Valve
(Bucket Rod Side)
15 - Overload Relief Valve
(Bucket Bottom Side)
16 - Load Check Valve
(Boom 1 Parallel Circuit)
17 - Boom Regenerative Circuit
24 - Check Valve (Orifice)
(Arm 2 Parallel Circuit)
25 - Load Check Valve (Arm 1
Parallel Circuit)
26 - Load Check Valve
(Arm 1 Tandem Circuit)
27 - Load Check Valve
(Swing Circuit)
34 - Load Check Valve
(Boom 2 Parallel Circuit)
35 - Aux. Flow Rate Control
Valve (Poppet Valve)
36 - Aux. Flow Rate Control
Valve (Selector Valve)
37 - Overload Relief Valve
(Auxiliary)
18 - Overload Relief Valve
(Boom Bottom Side)
19 - Overload Relief Valve
(Boom Rod Side)
20 - Boom Anti-Drift Valve
(Check Valve)
28 - Arm Regenerative Valve
(Selector Valve)
29 - Arm Regenerative Circuit
38 - Overload Relief Valve
(Auxiliary)
39 - Load Check Valve
(Bucket Parallel Circuit)
40 - Overload Relief Valve
(Blade/Outrigger Rod Side)
21 - Boom Anti-Drift Valve
(Selector Valve)
31 - Overload Relief Valve
(Arm Rod Side)
30 - Overload Relief Valve
(Arm Bottom Side)
T5-5-17
41 - Overload Relief Valve
(Blade/Outrigger Bottom
Side)
TROUBLESHOOTING / Component Layout
1
2
3
4
5
6
7
8
9
10
41
11
40
12
39
13
38
14
37
15
36
35
34
16
17
33
32
18
19
31
30
29
20
28
21
27
26
25 24
23
22
T16W-03-03-018
T5-5-18
TROUBLESHOOTING / Component Layout
19
15
9, 10
12
39
6
23
30
37
40
Front
1-
Load Check Valve
(Blade/Outrigger
Tandem Circuit)
2 - Load Check Valve
(Blade/Outrigger Parallel
Circuit)
3 - Check Valve
(Main Relief Circuit)
4 - Main Relief Valve
56-
789-
10 -
11 -
Auxiliary Flow Combiner
Valve
Check Valve
(Auxiliary Flow
Combiner Circuit)
Check Valve
(Main Relief Circuit)
Check Valve (Flow
Combiner Circuit)
Bucket Flow Rate
Control Valve (Selector
Valve)
Bucket Flow Rate
Control Valve (Poppet
Valve)
Make-Up Valve
(Travel Reverse Side)
5
T16W-03-03-031
12 - Make-Up Valve
(Travel Forward Side)
22 - Load Check Valve
(Arm 2 Tandem Circuit)
32 - Arm Anti-Drift Valve
(Check Valve)
13 - Bucket Regenerative Circuit
23 - Bypass Shut-Out Valve
33 - Arm Anti-Drift Valve
(Selector Valve)
14 - Overload Relief Valve
(Bucket Rod Side)
15 - Overload Relief Valve
(Bucket Bottom Side)
16 - Load Check Valve
(Boom 1 Parallel Circuit)
17 - Boom Regenerative Circuit
24 - Check Valve (Orifice)
(Arm 2 Parallel Circuit)
25 - Load Check Valve (Arm 1
Parallel Circuit)
26 - Load Check Valve
(Arm 1 Tandem Circuit)
27 - Load Check Valve
(Swing Circuit)
34 - Load Check Valve
(Boom 2 Parallel Circuit)
35 - Aux. Flow Rate Control
Valve (Poppet Valve)
36 - Aux. Flow Rate Control
Valve (Selector Valve)
37 - Overload Relief Valve
(Auxiliary)
18 - Overload Relief Valve
(Boom Bottom Side)
19 - Overload Relief Valve
(Boom Rod Side)
20 - Boom Anti-Drift Valve
(Check Valve)
28 - Arm Regenerative Valve
(Selector Valve)
29 - Arm Regenerative Circuit
38 - Overload Relief Valve
(Auxiliary)
39 - Load Check Valve
(Bucket Parallel Circuit)
40 - Overload Relief Valve
(Blade/Outrigger Rod Side)
21 - Boom Anti-Drift Valve
(Selector Valve)
31 - Overload Relief Valve
(Arm Rod Side)
30 - Overload Relief Valve
(Arm Bottom Side)
T5-5-19
41 - Overload Relief Valve
(Blade/Outrigger Bottom
Side)
TROUBLESHOOTING / Component Layout
1
2
3
4
5
6
7
8
9
10
41
11
40
12
39
13
38
14
37
15
36
35
34
16
17
33
32
18
19
31
30
29
20
28
21
27
26
25 24
23
22
T16W-03-03-018
T5-5-20
TROUBLESHOOTING / Component Layout
A
B
C
C
D
D
E
E
F
F
G
G
H
H
B
A
Cross Section A-A
T16W-03-03-002
8
Cross Section B-B
13
Travel
Blade/
Outrigger
Bucket
Auxiliary
Boom 2
Boom 1
Arm 2
Arm 1
Swing
28
17
TCHB-03-03-001
29
1-
Load Check Valve
(Blade/Outrigger
Tandem Circuit)
2 - Load Check Valve
(Blade/Outrigger Parallel
Circuit)
3 - Check Valve
(Main Relief Circuit)
4 - Main Relief Valve
56-
789-
10 -
11 -
Auxiliary Flow Combiner
Valve
Check Valve
(Auxiliary Flow
Combiner Circuit)
Check Valve
(Main Relief Circuit)
Check Valve (Flow
Combiner Circuit)
Bucket Flow Rate
Control Valve (Selector
Valve)
Bucket Flow Rate
Control Valve (Poppet
Valve)
Make-Up Valve
(Travel Reverse Side)
T16W-03-03-008
12 - Make-Up Valve
(Travel Forward Side)
22 - Load Check Valve
(Arm 2 Tandem Circuit)
32 - Arm Anti-Drift Valve
(Check Valve)
13 - Bucket Regenerative Circuit
23 - Bypass Shut-Out Valve
33 - Arm Anti-Drift Valve
(Selector Valve)
14 - Overload Relief Valve
(Bucket Rod Side)
15 - Overload Relief Valve
(Bucket Bottom Side)
16 - Load Check Valve
(Boom 1 Parallel Circuit)
17 - Boom Regenerative Circuit
24 - Check Valve (Orifice)
(Arm 2 Parallel Circuit)
25 - Load Check Valve (Arm 1
Parallel Circuit)
26 - Load Check Valve
(Arm 1 Tandem Circuit)
27 - Load Check Valve
(Swing Circuit)
34 - Load Check Valve
(Boom 2 Parallel Circuit)
35 - Aux. Flow Rate Control
Valve (Poppet Valve)
36 - Aux. Flow Rate Control
Valve (Selector Valve)
37 - Overload Relief Valve
(Auxiliary)
18 - Overload Relief Valve
(Boom Bottom Side)
19 - Overload Relief Valve
(Boom Rod Side)
20 - Boom Anti-Drift Valve
(Check Valve)
28 - Arm Regenerative Valve
(Selector Valve)
29 - Arm Regenerative Circuit
38 - Overload Relief Valve
(Auxiliary)
39 - Load Check Valve
(Bucket Parallel Circuit)
40 - Overload Relief Valve
(Blade/Outrigger Rod Side)
21 - Boom Anti-Drift Valve
(Selector Valve)
31 - Overload Relief Valve
(Arm Rod Side)
30 - Overload Relief Valve
(Arm Bottom Side)
T5-5-21
41 - Overload Relief Valve
(Blade/Outrigger Bottom
Side)
TROUBLESHOOTING / Component Layout
1
2
3
4
5
6
7
8
9
10
41
11
40
12
39
13
38
14
37
15
36
35
34
16
17
33
32
18
19
31
30
29
20
28
21
27
26
25 24
23
22
T16W-03-03-018
T5-5-22
TROUBLESHOOTING / Component Layout
Cross Section C-C
Cross Section D-D
Blade/
Travel
Outrigger
4
41
7
11
3
1
2
5
8
6
39
40
T16W-03-03-014
1-
Load Check Valve
(Blade/Outrigger
Tandem Circuit)
2 - Load Check Valve
(Blade/Outrigger Parallel
Circuit)
3 - Check Valve
(Main Relief Circuit)
4 - Main Relief Valve
56-
789-
10 -
11 -
Auxiliary Flow Combiner
Valve
Check Valve
(Auxiliary Flow
Combiner Circuit)
Check Valve
(Main Relief Circuit)
Check Valve (Flow
Combiner Circuit)
Bucket Flow Rate
Control Valve (Selector
Valve)
Bucket Flow Rate
Control Valve (Poppet
Valve)
Make-Up Valve
(Travel Reverse Side)
12
T16W-03-03-013
12 - Make-Up Valve
(Travel Forward Side)
22 - Load Check Valve
(Arm 2 Tandem Circuit)
32 - Arm Anti-Drift Valve
(Check Valve)
13 - Bucket Regenerative Circuit
23 - Bypass Shut-Out Valve
33 - Arm Anti-Drift Valve
(Selector Valve)
14 - Overload Relief Valve
(Bucket Rod Side)
15 - Overload Relief Valve
(Bucket Bottom Side)
16 - Load Check Valve
(Boom 1 Parallel Circuit)
17 - Boom Regenerative Circuit
24 - Check Valve (Orifice)
(Arm 2 Parallel Circuit)
25 - Load Check Valve (Arm 1
Parallel Circuit)
26 - Load Check Valve
(Arm 1 Tandem Circuit)
27 - Load Check Valve
(Swing Circuit)
34 - Load Check Valve
(Boom 2 Parallel Circuit)
35 - Aux. Flow Rate Control
Valve (Poppet Valve)
36 - Aux. Flow Rate Control
Valve (Selector Valve)
37 - Overload Relief Valve
(Auxiliary)
18 - Overload Relief Valve
(Boom Bottom Side)
19 - Overload Relief Valve
(Boom Rod Side)
20 - Boom Anti-Drift Valve
(Check Valve)
28 - Arm Regenerative Valve
(Selector Valve)
29 - Arm Regenerative Circuit
38 - Overload Relief Valve
(Auxiliary)
39 - Load Check Valve
(Bucket Parallel Circuit)
40 - Overload Relief Valve
(Blade/Outrigger Rod Side)
21 - Boom Anti-Drift Valve
(Selector Valve)
31 - Overload Relief Valve
(Arm Rod Side)
30 - Overload Relief Valve
(Arm Bottom Side)
T5-5-23
41 - Overload Relief Valve
(Blade/Outrigger Bottom
Side)
TROUBLESHOOTING / Component Layout
1
2
3
4
5
6
7
8
9
10
41
11
40
12
39
13
38
14
37
15
36
35
34
16
17
33
32
18
19
31
30
29
20
28
21
27
26
25 24
23
22
T16W-03-03-018
T5-5-24
TROUBLESHOOTING / Component Layout
Cross Section E-E
Cross Section F-F
Auxiliary
38
Boom 2 Boom 1
Bucket
14
18
21
20
35
10
34
16
9
36
17
T16W-03-03-012
37
1-
Load Check Valve
(Blade/Outrigger
Tandem Circuit)
2 - Load Check Valve
(Blade/Outrigger Parallel
Circuit)
3 - Check Valve
(Main Relief Circuit)
4 - Main Relief Valve
56-
789-
10 -
11 -
Auxiliary Flow Combiner
Valve
Check Valve
(Auxiliary Flow
Combiner Circuit)
Check Valve
(Main Relief Circuit)
Check Valve (Flow
Combiner Circuit)
Bucket Flow Rate
Control Valve (Selector
Valve)
Bucket Flow Rate
Control Valve (Poppet
Valve)
Make-Up Valve
(Travel Reverse Side)
T16W-03-03-011
15
19
12 - Make-Up Valve
(Travel Forward Side)
22 - Load Check Valve
(Arm 2 Tandem Circuit)
32 - Arm Anti-Drift Valve
(Check Valve)
13 - Bucket Regenerative Circuit
23 - Bypass Shut-Out Valve
33 - Arm Anti-Drift Valve
(Selector Valve)
14 - Overload Relief Valve
(Bucket Rod Side)
15 - Overload Relief Valve
(Bucket Bottom Side)
16 - Load Check Valve
(Boom 1 Parallel Circuit)
17 - Boom Regenerative Circuit
24 - Check Valve (Orifice)
(Arm 2 Parallel Circuit)
25 - Load Check Valve (Arm 1
Parallel Circuit)
26 - Load Check Valve
(Arm 1 Tandem Circuit)
27 - Load Check Valve
(Swing Circuit)
34 - Load Check Valve
(Boom 2 Parallel Circuit)
35 - Aux. Flow Rate Control
Valve (Poppet Valve)
36 - Aux. Flow Rate Control
Valve (Selector Valve)
37 - Overload Relief Valve
(Auxiliary)
18 - Overload Relief Valve
(Boom Bottom Side)
19 - Overload Relief Valve
(Boom Rod Side)
20 - Boom Anti-Drift Valve
(Check Valve)
28 - Arm Regenerative Valve
(Selector Valve)
29 - Arm Regenerative Circuit
38 - Overload Relief Valve
(Auxiliary)
39 - Load Check Valve
(Bucket Parallel Circuit)
40 - Overload Relief Valve
(Blade/Outrigger Rod Side)
21 - Boom Anti-Drift Valve
(Selector Valve)
31 - Overload Relief Valve
(Arm Rod Side)
30 - Overload Relief Valve
(Arm Bottom Side)
T5-5-25
41 - Overload Relief Valve
(Blade/Outrigger Bottom
Side)
TROUBLESHOOTING / Component Layout
1
2
3
4
5
6
7
8
9
10
41
11
40
12
39
13
38
14
37
15
36
35
34
16
17
33
32
18
19
31
30
29
20
28
21
27
26
25 24
23
22
T16W-03-03-018
T5-5-26
TROUBLESHOOTING / Component Layout
Cross Section G-G
Cross Section H-H
Arm 1
33
Swing
Arm 2
31
28
32
22
27
25
26
24
23
29
T16W-03-03-009
30
1-
Load Check Valve
(Blade/Outrigger
Tandem Circuit)
2 - Load Check Valve
(Blade/Outrigger Parallel
Circuit)
3 - Check Valve
(Main Relief Circuit)
4 - Main Relief Valve
56-
789-
10 -
11 -
Auxiliary Flow Combiner
Valve
Check Valve
(Auxiliary Flow
Combiner Circuit)
Check Valve
(Main Relief Circuit)
Check Valve (Flow
Combiner Circuit)
Bucket Flow Rate
Control Valve (Selector
Valve)
Bucket Flow Rate
Control Valve (Poppet
Valve)
Make-Up Valve
(Travel Reverse Side)
T16W-03-03-010
12 - Make-Up Valve
(Travel Forward Side)
22 - Load Check Valve
(Arm 2 Tandem Circuit)
32 - Arm Anti-Drift Valve
(Check Valve)
13 - Bucket Regenerative Circuit
23 - Bypass Shut-Out Valve
33 - Arm Anti-Drift Valve
(Selector Valve)
14 - Overload Relief Valve
(Bucket Rod Side)
15 - Overload Relief Valve
(Bucket Bottom Side)
16 - Load Check Valve
(Boom 1 Parallel Circuit)
17 - Boom Regenerative Circuit
24 - Check Valve (Orifice)
(Arm 2 Parallel Circuit)
25 - Load Check Valve (Arm 1
Parallel Circuit)
26 - Load Check Valve
(Arm 1 Tandem Circuit)
27 - Load Check Valve
(Swing Circuit)
34 - Load Check Valve
(Boom 2 Parallel Circuit)
35 - Aux. Flow Rate Control
Valve (Poppet Valve)
36 - Aux. Flow Rate Control
Valve (Selector Valve)
37 - Overload Relief Valve
(Auxiliary)
18 - Overload Relief Valve
(Boom Bottom Side)
19 - Overload Relief Valve
(Boom Rod Side)
20 - Boom Anti-Drift Valve
(Check Valve)
28 - Arm Regenerative Valve
(Selector Valve)
29 - Arm Regenerative Circuit
38 - Overload Relief Valve
(Auxiliary)
39 - Load Check Valve
(Bucket Parallel Circuit)
40 - Overload Relief Valve
(Blade/Outrigger Rod Side)
21 - Boom Anti-Drift Valve
(Selector Valve)
31 - Overload Relief Valve
(Arm Rod Side)
30 - Overload Relief Valve
(Arm Bottom Side)
T5-5-27
41 - Overload Relief Valve
(Blade/Outrigger Bottom
Side)
TROUBLESHOOTING / Component Layout
Layout of Positioning Control Valve (2-Piece Boom)
1
4
2
3
Positioning
Control Valve
TCEB-03-03-001
T5-5-28
TROUBLESHOOTING / Component Layout
Cross Section X-X
X
4
2
1
3
1-
Load Check Valve
(Positioning Parallel Circuit)
T198-03-03-003
T178-03-03-070
X
2-
Load Check Valve
(Positioning Tandem Circuit)
3-
T5-5-29
Overload Relief Valve
(Positioning: Bottom Side)
4-
Overload Relief Valve
(Positioning: Rod Side)
TROUBLESHOOTING / Component Layout
PILOT PORT
Pilot Valve Side
C
PH
A
E
M
D
H
B
F
SB
G
PI
Pilot Valve Side
N
K
I
SH
J
DF
SA
L
T178-03-06-016
Pilot Valve Side
Port Name
Port A
Port B
Port C
Port D
Port E
Port F
Port G
Port H
Port I
Port J
Port K
Port L
Port M
Port N
Port SA
Port SB
Port PI
Port PH
Port SH
Port DF
Connecting to
Right Pilot Valve
Right Pilot Valve
Swing Shockless Valve (Left Pilot Valve)
Swing Shockless Valve (Left Pilot Valve)
Swing Shockless Valve (Left Pilot Valve)
Swing Shockless Valve (Left Pilot Valve)
Right Pilot Valve
Right Pilot Valve
Travel Shockless Valve (Travel Pilot Valve)
Travel Shockless Valve (Travel Pilot Valve)
Blade/Outrigger Solenoid Valve
Auxiliary Solenoid Valve
Pump 1 Regulator
Pump 2 Regulator
Pilot Shut-Off Solenoid Valve
Pilot Shut-Off Solenoid Valve
Swing Parking Brake
Hydraulic Oil Tank
T5-5-30
Remark
Boom Raise Pilot Pressure
Boom Lower Pilot Pressure
Arm Roll-Out Pilot Pressure
Arm Roll-In Pilot Pressure
Left Swing Pilot Pressure
Right Swing Pilot Pressure
Bucket Roll-In Pilot Pressure
Bucket Roll-Out Pilot Pressure
Plug
Plug
Travel Reverse Pilot Pressure
Travel Forward Pilot Pressure
Blade/Outrigger Pilot Pressure
Auxiliary Pilot Pressure
Pump 1 Control Pressure
Pump 2 Control Pressure
Primary Pilot Pressure
Primary Pilot Pressure (Heat Circuit)
Brake Release Pressure
Returning to Hydraulic Oil Tank
TROUBLESHOOTING / Component Layout
Control Valve Side
3
1
5
Pressure Sensor
(Auxiliary)
13
4
2
SK
SE
8
Pressure Sensor
(Swing)
14
Control
Valve Side
7
9
6
10
SN
SL
11
12
SP
T1F3-03-06-003
Control Valve Side
Port Name
Port 1
Port 2
Port 3
Port 4
Port 5
Port 6
Port 7
Port 8
Port 9
Port 10
Port 11
Port 12
Port 13
Port 14
Port SE
Port SN
Port SP
Port SL
Port SK
Connecting to
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Hydraulic Oil Tank
Control Valve
Control Valve
Hydraulic Oil Tank
Control Valve
Remark
Boom Raise Pilot Pressure
Boom Lower Pilot Pressure
Arm Roll-Out Pilot Pressure
Arm Roll-In Pilot Pressure
Left Swing Pilot Pressure
Right Swing Pilot Pressure
Bucket Roll-In Pilot Pressure
Bucket Roll-Out Pilot Pressure
Returning to Hydraulic Oil Tank
Plug
Travel Reverse Pilot Pressure
Travel Forward Pilot Pressure
Plug
Plug
Plug
Plug
Returning to Hydraulic Oil Tank
Plug
Bucket Flow Rate Control Valve Control Pressure
2-Piece Boom Specification Machine
Port SP
Positioning Solenoid Valve
Pump 1 Control Pressure
T5-5-31
TROUBLESHOOTING / Component Layout
NOTE: Machine with front attachment (pulverizer 1
to 5 and crusher 1 to 5) attached.
Control Valve Side
14
Control
Valve Side
SN
T1F3-03-06-003
Control Valve Side
Port Name
Port 14
Port SN
Connecting to
Auxiliary Flow Combiner Contorl Solenoid
Valve
Pressure Reducing Valve
NOTE: The auxiliary flow combiner control
solenoid valve and pressure reducing valve
are installed only on the machines
equipped with the optional parts.
T5-5-32
Note
Auxiliary
Pressure
Auxiliary
Pressure
Flow
Combiner
Valve
Control
Flow
Combiner
Valve
Control
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault
codes are displayed after diagnosing by using Dr. ZX
or the service menu of monitor unit.
• How to Read Troubleshooting Flow Charts
YES (OK)
・
(2)
(1)
NO (NOT OK)
・
· Key switch: ON
After completing the checking and/or measuring procedures in box (1),
select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
(3)
Instructions, reference, and/or inspection methods and/or measurements are occasionally
described under the box. If incorrectly checked or measured, not only will troubleshooting
be unsuccessful but also damage to the components may result.
・
Refer to “Electrical System Inspection” Group (Group 8) for descriptions in the dotted-line
box.
・
Use Dr. ZX 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: Harness end connector viewed from the
open end side by the all connectors image
shown in this section.
Harness
Harness End
Connector
Open End Side
T6L4-05-03-001
T5-6-1
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE LIST
Controller Hardware Failure
Fault Code
Trouble
Cause
Influenced Control
11000-2
11001-2
11002-2
11003-3
Abnormal EEPROM
Abnormal RAM
Abnormal A/D Conversion
Abnormal Sensor Voltage
Faulty MC
Faulty MC
Faulty MC
Faulty MC
Faulty Sensor
Faulty Harness
All Controls
All Controls
All Controls
All Controls
11004-2
Abnormal CAN Communication
Faulty MC
Faulty CAN Harness
• Heater Control
• Speed Sensing Control
• Attachment Operation Speed
Increase Control
• Attachment Operation Speed
Limit Control
• Pump 1 and 2 Flow Rate Limit
Control
• Attachment Flow Rate Limit
Control (Optional)
• Work Brake Control
• Breaker/Pulverizer/Crusher
Control (Optional)
• Travel Mode Selection Control
• CAN
Cycle
Data
Communication
T5-6-2
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When
Remedy by Dr. ZX
Trouble Occurs.
Retrial B
Retrial B
Retrial B
Although the engine control dial is Retrial B
operated, the engine speed does not
change.
• The machine movement is slow.
• The work brake is not operated.
• The work mode alarm is displayed on
the monitor unit.
Remedy
Replace MC.
Replace MC.
Replace MC.
• Check the sensor connected to MC.
• Check the harness.
• Replace MC.
• Check the CAN harness.
• Replace MC.
Retrial B
T1V1-05-01-102
• The travel speed does not change.
T5-6-3
TROUBLESHOOTING / Troubleshooting A
Engine Failure
Fault Code
Trouble
Cause
Influenced Control
11100-2
Abnormal Engine Speed
Engine Speed: more than Speed Sensing Control
-1
4000 min
11101-3
Abnormal Engine Control Dial Voltage: more than 4.78 V
Sensor High Voltage
Engine Control Dial Control
11101-4
Abnormal Engine Control Dial Voltage: less than 0.22 V
Sensor Low Voltage
Engine Control Dial Control
T5-6-4
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When
Remedy by Dr. ZX
Trouble Occurs.
The machine movement is slow.
Retrial B
(During speed sensing, the torque is
reduced.)
• Trouble condition with the key ON: Retrial B
The engine speed is kept at idle
speed.
• Trouble condition during operation:
The engine speed is kept at the
speed immediately before trouble.
• Trouble condition with the key ON: Retrial B
The engine speed is kept at idle
speed.
• Trouble condition during operation:
The engine speed is kept at the
speed immediately before trouble.
T5-6-5
Remedy
• Check the crank speed sensor.
• Check the cam angle sensor.
• Check the harness.
• Replace the engine control dial.
• Check the harness.
• Replace the engine control dial.
TROUBLESHOOTING / Troubleshooting A
Pump Failure
Fault Code
Trouble
Cause
Influenced Control
11200-3
Abnormal Pump 1 Delivery Voltage: more than 4.5 V
Pressure Sensor High Voltage
• HP Mode Control
• Travel Accelerator Control
• E Mode Control
• Arm Regenerative Control
• Auto-Power Lift Control
11200-4
Abnormal Pump 1 Delivery Voltage: less than 0.25 V
Pressure Sensor Low Voltage
• HP Mode Control
• Travel Accelerator Control
• E Mode Control
• Arm Regenerative Control
• Auto-Power Lift Control
11202-3
Abnormal Pump 2 Delivery Voltage: more than 4.5 V
Pressure Sensor High Voltage
• HP Mode Control
• E Mode Control
• Arm Regenerative Control
11202-4
Abnormal Pump 2 Delivery Voltage: less than 0.25 V
Pressure Sensor Low Voltage
• HP Mode Control
• E Mode Control
• Arm Regenerative Control
11203-3
Abnormal Pump 3 Delivery Voltage: more than 4.5 V
Pressure Sensor High Voltage
• Steering
Pump
Reduction Control
Torque
11203-4
Abnormal Pump 3 Delivery Voltage: less than 0.25 V
Pressure Sensor Low Voltage
• Steering
Pump
Reduction Control
Torque
11206-3
Abnormal Pump 1 Pump Control Voltage: more than 4.75 V
Pressure Sensor High Voltage
• E Mode Control
• Heater Control
11206-4
Abnormal Pump 1 Pump Control Voltage: less than 0.25 V
Pressure Sensor Low Voltage
• E Mode Control
• Heater Control
11208-3
Abnormal Pump 2 Pump Control Voltage: more than 4.75 V
Pressure Sensor High Voltage
• E Mode Control
• Heater Control
11208-4
Abnormal Pump 2 Pump Control Voltage: less than 0.25 V
Pressure Sensor Low Voltage
• E Mode Control
• Heater Control
T5-6-6
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When
Remedy by Dr. ZX
Trouble Occurs.
• Combined operation of arm roll-in and Retrial B
boom raise or combined operation of
arm-roll-in and swing: Arm speed is
slow.
• Single operation of boom raise: Lifting
force is weak.
• Combined operation of arm roll-in and Retrial B
boom raise or combined operation of
arm-roll-in and swing: Arm speed is
slow.
• Single operation of boom raise: Lifting
force is weak.
• Combined operation of arm roll-in and Retrial B
boom raise or combined operation of
arm-roll-in and swing: Arm speed is
slow.
Remedy
• Check the harness.
• Replace the pump
pressure sensor.
1
delivery
• Check the harness.
• Replace the pump
pressure sensor.
1
delivery
• Check the harness.
• Replace the pump
pressure sensor.
2
delivery
• Combined operation of arm roll-in and Retrial B
boom raise or combined operation of
arm-roll-in and swing: Arm speed is
slow.
• The steering pump torque decrease Retrial B
control is inactive.
• Check the harness.
• Replace the pump
pressure sensor.
2
delivery
• The steering pump torque decrease Retrial B
control is inactive.
• Check the harness.
• Replace the steering pump delivery
pressure sensor.
• Check the harness.
• Replace the pump 1 control
pressure sensor.
• Check the harness.
• Replace the steering pump delivery
pressure sensor.
• Although speed normally returns to P Retrial B
speed when lever is operated in E
mode, speed stays at P speed in this
failure.
• Although speed normally returns to P Retrial B
speed when lever is operated in E
mode, speed stays at P speed in this
failure.
• Check the harness.
• Replace the pump
pressure sensor.
1
control
• Although speed normally returns to P Retrial B
speed when lever is operated in E
mode, speed stays at P speed in this
failure.
• Check the harness.
• Replace the pump
pressure sensor.
2
control
• Although speed normally returns to P Retrial B
speed when lever is operated in E
mode, speed stays at P speed in this
failure.
• Check the harness.
• Replace the pump
pressure sensor.
2
control
T5-6-7
TROUBLESHOOTING / Troubleshooting A
Pilot Failure
Fault Code
Trouble
Cause
Influenced Control
11301-3
Abnormal Swing Pilot Pressure Voltage: more than 4.75 V
Sensor High Voltage
• Arm Regenerative Control
• Attachment Flow Rate Control
(Optional)
• Swing Alarm Control (Optional)
11301-4
Abnormal Swing Pilot Pressure Voltage: less than 0.25 V
Sensor Low Voltage
• Arm Regenerative Control
• Attachment Flow Rate Control
(Optional)
• Swing Alarm Control (Optional)
11302-3
Abnormal Boom Raise Pilot Voltage: more than 4.75 V
Pressure Sensor High Voltage
• HP Mode Control
• Arm Regenerative Control
• Auto-Power Lift Control
• Attachment Flow Rate Control
(Optional)
11302-4
Abnormal Boom Raise Pilot Voltage: less than 0.25 V
Pressure Sensor Low Voltage
• HP Mode Control
• Arm Regenerative Control
• Auto-Power Lift Control
• Attachment Flow Rate Control
(Optional)
11303-3
Abnormal Arm Roll-In Pilot Voltage: more than 4.75 V
Pressure Sensor High Voltage
• HP Mode Control
• Arm Regenerative Control
• Auto-Power Lift Control
11303-4
Abnormal Arm Roll-In Pilot Voltage: less than 0.25 V
Pressure Sensor Low Voltage
• HP Mode Control
• Arm Regenerative Control
• Auto-Power Lift Control
T5-6-8
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When
Trouble Occurs.
• Combined operation of arm-roll-in and
swing: Arm speed is slow.
• In case of the machine equipped with
the swing alarm (optional) and when
swing alarm is effective, swing alarm
continues to sound even in no
swinging.
• Combined operation of arm-roll-in and
swing: Arm speed is slow.
• In case of the machine equipped with
the swing alarm (optional) and when
swing alarm is effective, swing alarm
continues to sound even in no
swinging.
• During HP control, engine speed does
not increase in boom raise operation.
• Combined operation of arm roll-in and
boom raise: Arm speed is slow.
• Single operation of boom raise: Lifting
force is weak.
• During HP control, engine speed does
not increase in boom raise operation.
• Combined operation of arm roll-in and
boom raise: Arm speed is slow.
• Single operation of boom raise: Lifting
force is weak.
• During HP control, engine speed does
not increase in arm-roll-in operation.
• Combined operation of arm roll-in and
swing: Arm speed is slow.
Remedy by Dr. ZX
Remedy
Retrial B
• Check the harness.
• Replace the swing pilot pressure
sensor.
Retrial B
• Check the harness.
• Replace the swing pilot pressure
sensor.
Retrial B
• Check the harness.
• Replace the boom
pressure sensor.
raise
pilot
• Check the harness.
• Replace the boom
pressure sensor.
raise
pilot
• Check the harness.
• Replace the arm
pressure sensor.
roll-in
pilot
• Check the harness.
• Replace the arm
pressure sensor.
roll-in
pilot
Retrial B
Retrial B
• During HP control, engine speed does Retrial B
not increase in arm-roll-in operation.
• Combined operation of arm roll-in and
swing: Arm speed is slow.
T5-6-9
TROUBLESHOOTING / Troubleshooting A
Fault Code
Trouble
Cause
11305-3
Abnormal
Travel Voltage: more than 4.75 V
Forward
Pilot
Pressure
Sensor
High Voltage
11305-4
Abnormal
Travel Voltage: less than 0.25 V
Forward
Pilot
Pressure Sensor Low
Voltage
11306-3
Abnormal
Travel Voltage: more than 4.75 V
Reverse
Pilot
Pressure
Sensor
High Voltage
11306-4
Abnormal
Travel Voltage: less than 0.25 V
Reverse
pilot
Pressure Sensor Low
Voltage
T5-6-10
Influenced Control
• Auto-Idle Control
• Idle Speed-Up Control
• ECO Control
• Travel Accelerator Control
• Heater Control
• Speed Sensing Control (Normal)
• Travel Speed Sensing Control
• Pump 1 and 2 Flow Rate Limit Control
• Travel Motor Displacement Angle Control
• Travel Motor Excessive Rotation Control
• Auto Axle Lock Control
• Forward/Reverse Shifting Limit Control
• Attachment Flow Rate Limit Control
• Travel Alarm Control (Optional)
• Auto-Cruise Control (Optional)
• Auto-Idle Control
• Idle Speed-Up Control
• ECO Control
• Travel Accelerator Control
• Heater Control
• Speed Sensing Control (Normal)
• Travel Speed Sensing Control
• Pump 1 and 2 Flow Rate Limit Control
• Travel Motor Displacement Angle Control
• Travel Motor Excessive Rotation Control
• Auto Axle Lock Control
• Forward/Reverse Shifting Limit Control
• Attachment Flow Rate Limit Control
• Travel Alarm Control (Optional)
• Auto-Cruise Control (Optional)
• Auto-Idle Control
• Idle Speed-Up Control
• ECO Control
• Travel Accelerator Control
• Heater Control
• Speed Sensing Control (Normal)
• Travel Speed Sensing Control
• Pump 1 and 2 Flow Rate Limit Control
• Travel Motor Displacement Angle Control
• Travel Motor Excessive Rotation Control
• Auto Axle Lock Control
• Forward/Reverse Shifting Limit Control
• Attachment Flow Rate Limit Control
• Travel Alarm Control (Optional)
• Auto-Idle Control
• Idle Speed-Up Control
• ECO Control
• Travel Accelerator Control
• Heater Control
• Speed Sensing Control (Normal)
• Travel Speed Sensing Control
• Pump 1 and 2 Flow Rate Limit Control
• Travel Motor Displacement Angle Control
• Travel Motor Excessive Rotation Control
• Auto Axle Lock Control
• Forward/Reverse Shifting Limit Control
• Attachment Flow Rate Limit Control
• Travel Alarm Control (Optional)
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When
Remedy by Dr. ZX
Trouble Occurs.
• When traveling forward at idle speed, Retrial B
engine speed does not increase to the idle
speed-up speed.
• When traveling forward, engine speed does
not return from auto idle speed.
• When traveling forward, engine speed does
not return from ECO speed.
• When operating the attachment with
traveling forward, the machine mistracks.
• In case of the machine equipped with the
travel alarm (optional), travel alarm
continues to sound even in no traveling.
Remedy
• Check the harness.
• Replace the travel forward pilot
pressure sensor.
• When traveling forward at idle speed, Retrial B
engine speed does not increase.
• When traveling forward, engine speed does
not return from auto idle speed.
• When traveling forward, engine speed does
not return from ECO speed.
• When operating the attachment with
traveling forward, the machine mistracks.
• In case of the machine equipped with the
travel alarm (optional), travel alarm
continues to sound even in no traveling.
• Check the harness.
• Replace the travel forward pilot
pressure sensor.
• When traveling reverse at idle speed, Retrial B
engine speed does not increase to the idle
speed-up speed.
• When traveling reverse, engine speed does
not return from auto idle speed.
• When traveling reverse, engine speed does
not return from ECO speed.
• When operating the attachment with
traveling reverse, the machine mistracks.
• In case of the machine equipped with the
travel alarm (optional), travel alarm
continues to sound even in no traveling.
• Check the harness.
• Replace the travel reverse pilot
pressure sensor.
• When traveling reverse at idle speed, Retrial B
engine speed does not increase to the idle
speed-up speed.
• When traveling reverse, engine speed does
not return from auto idle speed.
• When traveling reverse, engine speed does
not return from ECO speed.
• When operating the attachment with
traveling reverse, the machine mistracks.
• In case of the machine equipped with the
travel alarm (optional), travel alarm
continues to sound even in no traveling.
• Check the harness.
• Replace the travel reverse pilot
pressure sensor.
T5-6-11
TROUBLESHOOTING / Troubleshooting A
Fault Code
Trouble
Cause
Influenced Control
11307-3
Abnormal Front Attachment Pilot Voltage: more than 4.75 V
Pressure Sensor High Voltage
• Auto-Idle Control
• Idle Speed-Up Control
• ECO Control
• Pump 1 and 2 Flow Rate Limit
Control
• Heater Control
• Parking Brake Alarm Control
11307-4
Abnormal Front Attachment Pilot Voltage: less than 0.25 V
Pressure Sensor Low Voltage
• Auto-Idle Control
• Idle Speed-Up Control
• ECO Control
• Pump 1 and 2 Flow Rate Limit
Control
• Heater Control
• Parking Brake Alarm Control
11310-3
Abnormal
Brake
Sensor High Voltage
Pressure Voltage: more than 4.50 V
11310-4
Abnormal
Brake
Sensor Low Voltage
Pressure Voltage: less than 0.25 V
11311-3
Abnormal Brake Remaining Voltage: more than 4.50 V
Pressure Sensor High Voltage
• Work Brake Control
• Auto-Cruise Control
(Optional)
• Work Brake Control
• Auto-Cruise Control
(Optional)
• Travel Mode Selection Control
11311-4
Abnormal Brake Remaining Voltage: less than 0.25 V
Pressure Sensor Low Voltage
T5-6-12
• Travel Mode Selection Control
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When
Remedy by Dr. ZX
Trouble Occurs.
• When operating the front attachment at Retrial B
idle speed, engine speed does not
increase to the idle speed-up speed.
• When operating the front attachment,
engine speed does not return from
auto idle speed.
• When operating the front attachment,
engine speed does not return from
ECO speed.
• Although the front attachment is
operated while parking brake is
activated, buzzer does not sound.
Remedy
• Check the harness.
• Replace the front pilot pressure
sensor.
• When operating the front attachment at Retrial B
idle speed, engine speed does not
increase to the idle speed-up speed.
• When operating the front attachment,
engine speed does not return from
auto idle speed.
• When operating the front attachment,
engine speed does not return from
ECO speed.
• Although the front attachment is
operated while parking brake is
activated, buzzer does not sound.
• Check the harness.
• Replace the front pilot pressure
sensor.
• Work brake is not does not work.
• Auto-cruise
control
cannot
be
released.
• Work brake is not does not work.
• Auto-cruise
control
cannot
be
released.
• After releasing the parking brake,
shifting fast/slow of the transmission
does not work.
• After releasing the parking brake,
shifting fast/slow of the transmission
does not work.
Retrial B
• Check the harness.
• Replace the brake pressure sensor.
Retrial B
• Check the harness.
• Replace the brake pressure sensor.
Retrial B
• Check the harness.
• Replace the brake
pressure sensor.
• Check the harness.
• Replace the brake
pressure sensor.
Retrial B
T5-6-13
remaining
remaining
TROUBLESHOOTING / Troubleshooting A
Proportional Solenoid Valve Failure
Fault Code
Trouble
11400-2
Abnormal Current Feedback of
Maximum Pump 2 Flow Rate Limit
Control Solenoid Valve
Abnormal Feedback High Current of
Maximum Pump 2 Flow Rate Limit
Control Solenoid Valve
Current: Both of Higher Pump 2 Flow Rate Limit Control
than 920 mA or Less
than 60 mA
Current: Higher than Pump 2 Flow Rate Limit Control
920 mA
Abnormal Feedback Low Current of
Maximum Pump 2 Flow Rate Limit
Control Solenoid Valve
Abnormal Current Feedback of
Torque Control Solenoid Valve
Current: Less than 56 Pump 2 Flow Rate Limit Control
mA
11400-3
11400-4
11401-2
11401-3
Abnormal Feedback High Current of
Torque Control Solenoid Valve
11401-4
Abnormal Feedback Low Current of
Torque Control Solenoid Valve
11403-2
Cause
Current: Both of Higher
than 920 mA or Less
than 60 mA
Current: Higher than
920 mA
Influenced Control
• Speed Sensing Control
• Steering Pump Torque Decrease
Control
• Speed Sensing Control
• Steering Pump Torque Decrease
Control
Current: Less than 56 • Speed Sensing Control
mA
• Steering Pump Torque Decrease
Control
Abnormal Current Feedback of Current: Both of Higher Arm Regenerative Control
Solenoid Valve Unit (SC) (Arm than 920 mA or Less
Regeneration)
than 60 mA
11403-3
Abnormal Feedback High Current of Current: Higher than Arm Regenerative Control
Solenoid Valve Unit (SC) (Arm 920 mA
Regeneration)
11403-4
Abnormal Feedback Low Current of Current: Less than 56 Arm Regenerative Control
Solenoid Valve Unit (SC) (Arm mA
Regeneration)
11404-2
Abnormal Current Feedback of
Solenoid Valve Unit (SG) (Relief
Pressure Control)
Abnormal Feedback High Current of
Solenoid Valve Unit (SG) (Relief
Pressure Control)
Abnormal Feedback Low Current of
Solenoid Valve Unit (SG) (Relief
Pressure Control)
11404-3
11404-4
Current: Both of Higher
than 920mA or Less
than 60 mA
Current: Higher than
920 mA
• Power Digging Control
• Auto-Power Lift Control
• Power Digging Control
• Auto-Power Lift Control
Current: Less than 56 • Power Digging Control
mA
• Auto-Power Lift Control
T5-6-14
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When
Trouble Occurs.
In case the attachment flow rate is
limited, it cannot be limited.
Remedy by Dr. ZX
Remedy
Retrial B
• Check the harness.
Retrial B
• Check the harness.
Retrial B
• Check the harness.
Retrial B
• Check the harness.
Operation during abnormal high current: Retrial B
• The engine is stalled at slow idle.
• Engine speed: Middle to Fast: Engine
stall or large lug down
Operation during abnormal low current: Retrial B
• Machine overall operation is slow.
• Check the harness.
Combined operation of boom raise and Retrial B
arm roll-in with the front attachment
over ground, the boom is not raised
smoothly and the arm roll-in full-speed
is slow.
Operation during abnormal high current: Retrial B
• Digging force (arm) becomes weak.
• Check the harness.
Operation during abnormal low current: Retrial B
• Combined operation of boom raise
and arm roll-in with the front
attachment over ground, the boom is
not raised smoothly and the arm
roll-in full-speed is slow.
Pressure does not increase even if Retrial B
power digging switch is on.
• Check the harness.
Operation during abnormal high current:
• Pressure always increases.
Retrial B
• Check the harness.
Operation during abnormal low current: Retrial B
• Pressure does not increase even if
power digging switch is on.
• Check the harness.
Operation during abnormal high current:
• Travel mistakes.
• Boom raise operation is slow.
• Arm operation is slow.
• Swing operation is slow.
Operation during abnormal low current:
• In case the attachment flow rate is
limited, it cannot be limited.
Machine overall operation is slow.
• Check the harness.
• Check the harness.
• Check the harness.
T5-6-15
TROUBLESHOOTING / Troubleshooting A
Fault Code
Trouble
Cause
Influenced Control
Current: Both of Higher • Pump 1 Flow Rate Limit Control
than 920 mA or Less
When Traveling At Creeper Mode
than 60 mA
• Pump 1 Flow Rate Limit Control
• Attachment Flow Rate Limit
Control
Current: Higher than • Pump 1 Flow Rate Limit Control
920 mA
When Traveling At Creeper Mode
• Pump 1 Flow Rate Limit Control
• Attachment Flow Rate Limit
Control
Current: Less than 56 • Pump 1 Flow Rate Limit Control
mA
When Traveling At Creeper Mode
• Pump 1 Flow Rate Limit Control
• Attachment Flow Rate Limit
Control
Current: Both of Higher • Travel Motor Displacement Angle
than 920 mA or Less
Control
than 60 mA
• Travel Motor Excessive Rotation
Control
Current: Higher than • Travel Motor Displacement Angle
920 mA
Control
• Travel Motor Excessive Rotation
Control
11410-2
Abnormal Current Feedback of
Maximum Pump 1 Flow Rate Limit
Control Solenoid Valve
11410-3
Abnormal Feedback High Current of
Maximum Pump 1 Flow Rate Limit
Control Solenoid Valve
11410-4
Abnormal Feedback Low Current of
Maximum Pump 1 Flow Rate Limit
Control Solenoid Valve
11422-2
Abnormal Current Feedback of
Travel Motor Displacement Angle
Control Solenoid Valve
11422-3
Abnormal Feedback High Current of
Travel Motor Displacement Angle
Control Solenoid Valve
11422-4
Abnormal Feedback Low Current of Current: Less than 56 • Travel Motor Displacement Angle
Travel Motor Displacement Angle mA
Control
Control Solenoid Valve
• Travel Motor Excessive Rotation
Control
Abnormal Current Feedback of Current: Both of Higher
Travel Make-Up Solenoid Valve
than 920 mA or Less
than 60 mA
Abnormal Feedback High Current of Current: Higher than
Travel Make-Up Solenoid Valve
920 mA
11423-2
11423-3
11423-4
Abnormal Feedback Low Current of
Travel Make-Up Solenoid Valve
Current: Less than 56
mA
T5-6-16
-
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When
Trouble Occurs.
In case the attachment flow rate is
limited, it cannot be limited.
Remedy by Dr. ZX
Remedy
Retrial B
• Check the harness.
Operation during abnormal high current:
• Travel mistakes.
• Boom raise operation is slow.
• Arm operation is slow.
• Swing operation is slow.
Operation during abnormal low current:
• In case the attachment flow rate is
limited, it cannot be limited.
Retrial B
• Check the harness.
Retrial B
• Check the harness.
In case the attachment flow rate is
limited, it cannot be limited.
Retrial B
• Check the harness.
Operation during abnormal high current:
• Travel mistakes.
• Boom raise operation is slow.
• Arm operation is slow.
• Swing operation is slow.
Operation during abnormal low current:
• In case the attachment flow rate is
limited, it cannot be limited.
Retrial B
• Check the harness.
Retrial B
• Check the harness.
In case the attachment flow rate is
limited, it cannot be limited.
Retrial B
• Check the harness.
Operation during abnormal high current:
• Travel mistakes.
• Boom raise operation is slow.
• Arm operation is slow.
• Swing operation is slow.
Operation during abnormal low current:
• In case the attachment flow rate is
limited, it cannot be limited.
Retrial B
• Check the harness.
Retrial B
• Check the harness.
T5-6-17
TROUBLESHOOTING / Troubleshooting A
Fault Code
Trouble
11424-2
Abnormal Current Feedback of
Solenoid Valve Unit (SI) (Axle Lock
Selection)
Abnormal Feedback High Current
of Solenoid Valve Unit (SI) (Axle
Lock Selection)
Current: Both of Higher • Auto Axle Lock Control
than 920 mA or Less
than 60 mA
Current: Higher than • Auto Axle Lock Control
920 mA
Abnormal Feedback Low Current
of Solenoid Valve Unit (SI) (Axle
Lock Selection)
Abnormal Current Feedback of
Solenoid Valve Unit (SF) (Work
Brake)
Current: Less than 56 • Auto Axle Lock Control
mA
11424-3
11424-4
11425-2
11425-3
11425-4
Cause
Influenced Control
Current: Both of Higher • ECO Control
than 920 mA or Less • Idle Speed-Up Control
than 60 mA
• Speed Sensing Control
• Brake
Dragging
Prevention
Control
• Work Brake Control
Abnormal Feedback High Current Current: Higher than • ECO Control
of Solenoid Valve Unit (SF) (Work 920 mA
• Idle Speed-Up Control
Brake)
• Speed Sensing Control
• Brake
Dragging
Prevention
Control
• Work Brake Control
Abnormal Feedback Low Current Current: Less than 56 • ECO Control
of Solenoid Valve Unit (SF) (Work mA
• Idle Speed-Up Control
Brake)
• Speed Sensing Control
• Brake
Dragging
Prevention
Control
• Work Brake Control
T5-6-18
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When
Trouble Occurs.
In case the attachment flow rate is
limited, it cannot be limited.
Remedy by Dr. ZX
Remedy
Retrial B
• Check the harness.
Operation during abnormal high current:
• Travel mistakes.
• Boom raise operation is slow.
• Arm operation is slow.
• Swing operation is slow.
Operation during abnormal low current:
• In case the attachment flow rate is
limited, it cannot be limited.
In case the attachment flow rate is
limited, it cannot be limited.
Retrial B
• Check the harness.
Retrial B
• Check the harness.
Retrial B
• Check the harness.
Operation during abnormal high current:
• Travel mistakes.
• Boom raise operation is slow.
• Arm operation is slow.
• Swing operation is slow.
Retrial B
• Check the harness.
Operation during abnormal low current:
• In case the attachment flow rate is
limited, it cannot be limited.
Retrial B
• Check the harness.
T5-6-19
TROUBLESHOOTING / Troubleshooting A
CAN Data Reception Failure
Fault Code
Trouble
Cause
Influenced Control
11910-2
Actual Engine Speed
Sent from: ECM
Faulty harness
• Speed Sensing Control
• Send to ICF
11911-2
Security Signal
Send from: Monitor Unit
Faulty harness
Theft Prevention Engine Speed,
Engine Torque
11914-2
Radiator Coolant Temperature
Sent from: ECM
Faulty harness
Heater Control
11915-2
Gate Lock Signal
Send from: Option Controller
Faulty harness
Heater Control
11918-2
Work Mode
Send from: Monitor Unit
Faulty harness
• Attachment Operation Speed
Increase Control
• Attachment Operation Speed
Limit Control
• Attachment
Pump
Torque
Decrease Control
• Pump 1 and 2 Flow Rate Limit
Control
• Attachment Flow Rate Control
(Optional)
• Breaker/Pulverizer/Crusher
Control (Optional)
11920-2
Fuel Flow Rate
Sent from: ECM
Faulty harness
Fuel Flow Rate
T5-6-20
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When
Trouble Occurs.
Remedy by Dr. ZX
Remedy
Retrial B
• Check the harness.
When theft prevention is ON set by Dr. Retrial B
ZX,
Engine speed = Slow idle
Pump torque = Minimum displacement
angle
Those values are fixed.
• Check the harness.
Heater control is inactive.
Retrial B
• Check the harness.
Heater control is inactive.
Retrial B
• Check the harness.
• Work Mode: Digging mode is fixed.
Retrial B
In case decreasing flow rate and speed
are set in ATT mode, stop this mode
control, or Work mode is not changed
from Digging mode to ATT mode.
• Work Mode Alarm is displayed on the
monitor unit.
• Check the harness.
Machine operation speed is slow.
(During speed sensing, torque is
decreased.)
Engine stall is displayed on e-Service.
T1V1-05-01-102
When fuel rate display is set on
monitor, "---" is displayed.
• Check the harness.
Retrial B
T5-6-21
TROUBLESHOOTING / Troubleshooting A
Other Failures
Fault Code
Trouble
Cause
Influenced Control
*11502-2
Travel Motor Excessive Rotation Transmission rotation keeps
over its threshold value for 2.0
sec.
11901-3
Hydraulic
Oil
Temperature Voltage: more than 4.52 V
Sensor High Voltage
• Auto-Warming Up Control
• Arm Regenerative Control
11901-4
Hydraulic
Oil
Temperature Voltage: less than 0.23 V
Sensor Low Voltage
• Auto-Warming Up Control
• Arm Regenerative Control
11921-2
Incorrect Odometer Value
Faulty MC
Faulty harness
NOTE: *: Fault code 11502 is shown when travel
motor overturns.
Select the MC monitor item on Dr. ZX.
Check the counted travel motor excessive
rotations. (The travel motor is not faulty.)
Select retrial in order to erase the displayed
fault code.
T5-6-22
-
-
TROUBLESHOOTING/ Troubleshooting A
Symptoms in Machine Operation When Trouble
Occurs.
-
Remedy by
Dr. ZX
-
In low temperature (Hydraulic oil temperature is less
than 0 °C (32 °F)), auto-warming up control is
impossible.
Retrial B
• Check the harness.
In low temperature (Hydraulic oil temperature is less
than 0 °C (32 °F)), auto-warming up control is
impossible.
Retrial B
• Check the harness.
Odometer value may increase after the key switch is
OFF.
Retrial B
• Check the harness.
• Replace MC.
T5-6-23
Remedy
-
TROUBLESHOOTING/ Troubleshooting A
ECM FAULT CODE LIST
Sensor System
Fault
Trouble
Code
636-2
Abnormal Cam Angle Sensor (No Signal)
636-2
723-2
723-2
636-7
172-3
Abnormal Cam Angle Sensor (Abnormal
Signal)
Abnormal Crank Speed Sensor (No
Signal)
Abnormal
Crank
Speed
Sensor
(Abnormal Signal)
Phase Mismatch of Cam Angle Sensor
Cause
Although the crank signal is present, the cam signal is
not present.
The pulse of cam signal is not matched.
Although the cam signal is present, the crank signal is
not present.
The pulse of crank signal is not matched.
The right cam pulse is not present at the gap in the
crank.
Abnormal Intake Air Temperature
(Abnormal High Voltage)
Abnormal Intake Air Temperature
(Abnormal Low Voltage)
Abnormal Coolant Temperature
(Abnormal High Voltage)
Abnormal Coolant Temperature
(Abnormal Low Voltage)
Sensor Voltage at the intake air temperature sensor is beyond
4.95 V in 3 minutes after the engine starts.
Sensor Voltage at the intake-air temperature sensor is below
0.1 V.
Sensor Voltage at the coolant temperature sensor is beyond
4.85 V in 3 minutes after the engine starts.
Sensor Voltage at the coolant temperature sensor is below 0.1
V
102-4
Abnormal Boost Pressure
(Abnormal High Voltage)
Sensor
102-3
Abnormal Boost Pressure Sensor Voltage at the boost pressure sensor is below 0.1 V
(Abnormal Low Voltage)
Abnormal EGR Position (Brushless spec.) The condition which the output signal of EGR position
cannot be present in.
172-4
110-3
110-4
10001-3
108-4
108-3
174-3
174-4
Abnormal Atmospheric Pressure
(Abnormal High Voltage)
Abnormal Atmospheric Pressure
(Abnormal Low Voltage)
Abnormal Fuel Temperature
(Abnormal High Voltage)
Abnormal Fuel Temperature
(Abnormal Low Voltage)
Voltage at the boost pressure sensor is beyond 4.9 V.
Sensor Voltage at the atmospheric pressure sensor is beyond
3.8 V.
Sensor Voltage at the atmospheric pressure sensor is below
0.5 V.
Sensor Voltage at the fuel temperature sensor is beyond 4.85
V in 3 minutes after the engine starts.
Sensor Voltage at the fuel temperature sensor is below 0.1 V.
T5-6-24
TROUBLESHOOTING/ Troubleshooting A
Presumptive Symptoms in Real Machine
Operation
• While the engine runs, there is nothing
abnormal with machine operation.
• After the engine is stalled, the re-start is
impossible.
• The output power may decrease, white smoke
may occur and vibration may occur.
• The engine may be stalled. (If the cam senor is
normal, the engine can re-start.)
• While the engine runs, there is nothing
abnormal with machine operation.
• After the engine is stalled, the re-start is
impossible.
Nothing special
Normal temperature: When starting, dark smoke
may occur and engine combustion sound may be
become loud.
While warming up with fresh air in low
temperature: Rough idle, engine stall or while
smoke may be occur.
Dark smoke occurs.
Assumptive Conditions at Backup
Fault Code
(Tech 2)
P0340
While the engine runs, operate according to
standard of the crank sensor. When the engine
stops, the start is impossible (in order to P0341
prevent the engine from damaging).
Operate according to standard of the cam
sensor.
P0335
P0336
The timing chain and the belt does not turn
smoothly but turn in reverse.
P1345
When starting: -10 °C (14 °F) (Start the engine P0113
although what state.)
When operating: 25 °C (77 °F) (Operate P0112
normally.)
When starting: -20 °C (-4 °F) (Start the engine
although what state.)
When operating: 80 °C (176 °F) (Operate
normally.)
P0118
Boost pressure cannot be corrected.
P0238
P0117
P0237
There is influence to exhaust gas.
Dark smoke occurs at high altitude.
Nothing special.
As the sensor input is not certain, it cannot be P0487
controlled. Exhaust gas becomes bad.
Operate the engine with EGR valve fully open.
2
Atmospheric pressure 80 kPa (0.8 kgf/cm , 12 P0108
psi) (2000 m above the sea)
P0107
When starting: -20 °C (-4 °F) (Start the engine
although what state.)
When operating: 70 °C (158 °F) (Operate
normally.)
T5-6-25
P0183
P0182
TROUBLESHOOTING/ Troubleshooting A
Fault
Code
157-3
157-3
100-4
100-3
105-3
105-4
Trouble
Abnormal Common Rail Pressure
(Abnormal High Voltage)
Abnormal Common Rail Pressure
(Abnormal Low Voltage)
Abnormal Engine Oil Pressure
(Abnormal High Voltage)
Abnormal Engine Oil Pressure
(Abnormal Low Voltage)
Abnormal Boost Temperature
(Abnormal High Voltage)
Cause
Sensor
Sensor
Sensor
Sensor
Sensor
Abnormal Boost Temperature Sensor
(Abnormal Low Voltage)
Voltage at the common rail pressure sensor is beyond
4.5 V.
Voltage at the common rail pressure sensor is below
0.7 V.
Voltage at the engine oil pressure sensor is beyond
4.85 V.
Voltage at the engine oil pressure sensor is below 0.1
V.
Voltage at the boost temperature sensor is beyond
4.95 V over 5 minutes after the engine starts or when
coolant temperature is beyond 50 °C (122 °F).
Voltage at the boost temperature sensor is below 0.1
V.
T5-6-26
TROUBLESHOOTING/ Troubleshooting A
Presumptive Symptoms in Real Machine
Operation
The engine may be stalled. The output power
decreases.
Assumptive Conditions at Backup
The supply pump can not be controlled.
Fault Code
(Tech 2)
P0193
P0192
There is no influence when operating the
machine.
Nothing special.
P0523
P0522
There is no influence when operating the
machine.
Nothing special.
P1113
P1112
T5-6-27
TROUBLESHOOTING/ Troubleshooting A
Fault Code
636-2
636-2
723-2
723-2
636-7
172-3
172-4
110-3
110-4
102-4
102-3
10001-3
108-4
108-3
174-3
174-4
157-3
157-4
100-4
100-3
Influence to Engine
Performance
(Presumption)
Abnormal Cam Angle Sensor (No No influence during
operating
Signal)
Abnormal Cam Angle Sensor After stopping, the
re-start is impossible.
(Abnormal Signal)
Abnormal Crank Speed Sensor (No No
output
power
Signal)
decrease
Abnormal Crank Speed Sensor
(Abnormal Signal)
Phase Mismatch of Cam Angle No influence during
Sensor
operating
After stopping, the
re-start is impossible.
output
power
Abnormal Intake Air Temperature No
decrease
Sensor (Abnormal High Voltage)
Abnormal Intake Air Temperature
Sensor (Abnormal Low Voltage)
output
power
Abnormal
Coolant
Temperature No
decrease
Sensor (Abnormal High Voltage)
Abnormal
Coolant
Temperature
Sensor (Abnormal Low Voltage)
Abnormal Boost Pressure Sensor No
output
power
(Abnormal High Voltage)
decrease
Abnormal Boost Pressure Sensor
(Abnormal Low Voltage)
Abnormal EGR Position (Brushless No
output
power
spec.)
change
Abnormal Atmospheric Pressure No
output
power
Sensor (Abnormal High Voltage)
decrease
Abnormal Atmospheric Pressure
Sensor (Abnormal Low Voltage)
Abnormal Fuel Temperature Sensor No
output
power
(Abnormal High Voltage)
decrease
Abnormal Fuel Temperature Sensor
(Abnormal Low Voltage)
Abnormal Common Rail Pressure Output
power
Sensor (Abnormal High Voltage)
decrease: 70%
Abnormal Common Rail Pressure
Sensor (Abnormal Low Voltage)
Abnormal Engine Oil Pressure No
output
power
Sensor (Abnormal High Voltage)
change
Abnormal Engine Oil Pressure
Sensor (Abnormal Low Voltage)
Trouble
T5-6-28
Operating Rank
(Current State)
A B C D
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
○
Remedy
TROUBLESHOOTING/ Troubleshooting A
Fault
Code
105-3
105-4
Influence to Engine
Operating Rank
Performance
(Current State)
(Presumption)
output
power
Abnormal Boost Temperature Sensor No
○
change
(Abnormal High Voltage)
Abnormal Boost Temperature Sensor
○
(Abnormal Low Voltage)
Trouble
Operating Rank
A: Digging is operable.
B: Machine can travel with the boom raised.
(Steering is impossible.)
C: The engine only runs. (Travel, digging and
operation are impossible even in light load.)
D: The engine cannot stop / start.
IMPORTANT: When fault code 723-2 (abnormal
crank speed sensor) is displayed
and the engine does not start, the
cam angle sensor is faulty although
fault codes 636-2 (abnormal cam
angle sensor) and 636-7 (phase
mismatch of cam angle sensor) are
not displayed.
T5-6-29
Remedy
TROUBLESHOOTING/ Troubleshooting A
External Device System
Fault Code
Trouble
Cause
10002-2
Abnormal EGR Valve Control
Difference between the target valve lift and actual position is
beyond 20%.
1347-0
Open Circuit in Suction Control Valve The suction control valve drive current is beyond 2400 mA or
Drive System, Shorted Circuit In + B below 50 mA. Or, difference between the tartget current and
or GND
actual current is 1000 mA or more.
651-3
Open Circuit in Injection Nozzle #1 No input signal of injector 1 monitor.
Drive System
652-3
Open Circuit in Injection Nozzle #2 No input signal of injector 2 monitor.
Drive System
653-3
Open Circuit in Injection Nozzle #3 No input signal of injector 3 monitor.
Drive System
654-3
Open Circuit In Injection Nozzle #4 No input signal of injector 4 monitor.
Drive System
T5-6-30
TROUBLESHOOTING/ Troubleshooting A
Presumptive Symptoms in Real Machine
Operation
Assumptive Conditions at Backup
Fault Code
(Tech 2)
There is influence to exhaust gas.
EGR cannot be controlled.
As exhaust gas becomes bad, EGR stops.
P0488
The engine may be stalled and the rotation
speed increases automatically and abnormally
according to open or shorted circuit condition.
Dark smoke occurs. Output power is too large.
The supply pump cannot be controlled.
→ Prevent the engine from increasing the rotation
speed automatically and abnormally (Protect the
engine).
P0090
Vibration of the engine is large, rough idle, #1 injector cannot be controlled.
output power decrease, faulty increasing of → Stop drive pulse output of #1 injector.
rotation speed, output power decrease.
#2 injector cannot be controlled.
→ Stop drive pulse output of #2 injector.
P0201
#3 injector cannot be controlled.
→ Stop drive pulse output of #3 injector.
P0203
#4 injector cannot be controlled.
→ Stop drive pulse output of #4 injector.
P0204
T5-6-31
P0202
TROUBLESHOOTING/ Troubleshooting A
Fuel System
Fault Code
Trouble
Cause
157-0
Abnormal Common Rail Pressure Common rail pressure is beyond 185 MPa.
(First Stage)
157-0
Abnormal Common Rail Pressure
(Second Stage)
The first stage “Abnormal common rail pressure” is approved
common rail pressure is beyond 190 MPa.
157-2
Abnormal Common Rail Pressure
(Pump Over-Pressure)
When duty factor to the suction control valve is 40 % or more,
3
or target pressure to the suction control valve is 90 mm /sec
2
or less, actual rail pressure is 40 MPa (410 kgf/cm , 5820 psi)
higher than the target rail pressure.
633-7
Pressure Limiter Open
The pressure limiter is open.
1240-1
No Pressure to Pump (Fuel Leakage) When duty factor to the suction control valve is 33 % or less,
3
or pressure to the suction control valve is 28000 mm /sec or
-1
more and engine speed is 1200 min , actual rail pressure is
2
50 MPa (510 kgf/cm , 7270 psi) lower than the target rail
pressure.
-1
No Pressure to Pump (Fuel Leakage) When engine speed 900 min , actual rail pressure is 15 MPa
2
(150 kgf/cm , 2180 psi) or less.
1239-1
T5-6-32
TROUBLESHOOTING/ Troubleshooting A
Presumptive Symptoms in Real Machine
Operation
Assumptive Conditions at Backup
Vibration of the engine may be large, rough idle,
output power decrease may occur, faulty
increasing of rotation speed, dark smoke may
occur, output power may be too large.
Prevention the injection system (pump) from
damage
(Protect
the
rail
pressure
sensor
by
over-pressure)
P0088
Vibration of the engine may be large, rough idle, Prevention the injection system from damage
output power decrease may occur, faulty (Pressure is too much as rail is clogged.)
increasing of rotation speed, dark smoke may
occur, output power may be too large.
P0088
Vibration of the engine may be large, rough idle,
output power decrease may occur, faulty
increasing of rotation speed, dark smoke may
occur, output power may be too large.
Prevention the injection system (pump) from
damage
(Protect
the
rail
pressure
sensor
by
over-pressure)
P0089
Output power decrease.
Rail pressure is beyond the allowable pressure.
P1095
Vibration of the engine may be large, rough idle,
output power decrease may occur, faulty
increasing of rotation speed, dark smoke may
occur, output power may be too large.
Fuel leakage is too much.
Difference between target rail pressure and actual
rail pressure is larger than the specification.
(Large deflection)
P1093
Vibration of the engine may be large, rough idle, Fuel leakage is too much.
output power decrease may occur, faulty Actual rail pressure does not increase to the
increasing of rotation speed, dark smoke may required pressure.
occur, output power may be too large.
P0087
T5-6-33
Fault Code
(Tech 2)
TROUBLESHOOTING/ Troubleshooting A
Fault
Code
Influence to Engine
Performance
(Presumption)
Trouble
10002-2 Abnormal EGR Valve Control
1347-0
651-3
652-3
653-3
654-3
655-3
656-3
Fault
Code
157-0
157-0
157-2
633-7
1240-1
1239-1
No output power
change
Open Circuit in Suction Control Valve Output power
Drive System, Shorted Circuit in + B or decrease: 50%
GND
Open Circuit in Injection Nozzle #1 Output power
decrease: 15%
Drive System
Open Circuit in Injection Nozzle #2 (Five cylinders drive.)
Drive System
Open Circuit in Injection Nozzle #3
Drive System
Open Circuit in Injection Nozzle #4
Drive System
Open Circuit in Injection Nozzle #5
Drive System
Open Circuit in Injection Nozzle #6
Drive System
Influence to Engine
Performance
(Presumption)
Trouble
Abnormal Common Rail Pressure (First Output power
Stage)
decrease: 50%
Abnormal Common Rail Pressure
Output power
(Second Stage)
decrease: 50%
Abnormal Common Rail Pressure
Output power
(Pump Over-Pressure)
decrease: 50%
Pressure Limiter Open
Output power
decrease: 50%
No Pressure to Pump (Fuel Leakage)
Output power
decrease: 50%
No Pressure to Pump (Fuel Leakage)
Operating Rank
A: Digging is operable.
B: Machine can travel with boom raised. (Steering is
impossible.)
C: The engine only runs. (Travel, digging and
operation are impossible even in light load.)
D: The engine cannot stop / start.
T5-6-34
Operating Rank
(Current)
A
B
C
Remedy
D
○
○
○
○
○
○
○
○
Operating Rank
(Current)
A
B
○
○
○
○
○
○
C
D
Remedy
TROUBLESHOOTING/ Troubleshooting A
(Blank)
T5-6-35
TROUBLESHOOTING/ Troubleshooting A
Fault Code
Trouble
110-0
Overheating
190-0
Overrunning
Fault code
Cause
Coolant temperature is beyond 120 °C (248 °F) when running
engine.
-1
In case the engine speed is beyond 2500 min .
Trouble
Cause
987-3
Abnormal Check Engine Lamp
No monitor signal of the check engine lamp.
1485-2
Abnormal Main Relay System (ON is Voltage in the main relay system is 1 V or less with the main
impossible.)
relay coil output ON
Although the main relay coil output is OFF, the main relay is
kept ON.
T5-6-36
TROUBLESHOOTING/ Troubleshooting A
Presumptive Symptoms in Real Machine
Fault Code
Assumptive Conditions at Backup
Operation
(Tech 2)
There is no influence when operating the Nothing special (The history of overheating is
P1173
machine.
recorded.)
Engine speed of the excavator may not increase Nothing special
-1
2500 min or more.
Presumptive Symptoms in Real Machine
Assumptive Conditions at Backup
Operation
There is no influence when operating the Nothing special
machine.
The engine cannot start.
P0219
Fault Code
(Tech 2)
P0650
Nothing
Electrical power is kept supplying to the Nothing
machine.
T5-6-37
P1625
TROUBLESHOOTING/ Troubleshooting A
Fault
Code
Influence to Engine
Performance
(Presumption)
Trouble
110-0
Overheating
190-0
Overrunning
No
output
change
No
output
change
power
power
Influence to Engine
Trouble
Performance
(Presumption)
987-3 Abnormal Check Engine Lamp
No
output
power
change
1485-2 Abnormal Main Relay System (ON is The engine stops.
impossible.)
Nothing (The engine
cannot
re-start
according to battery
voltage.)
Fault
Code
Operating Rank
A: Digging is operable.
B: Machine can travel with boom raised. (Steering is
impossible.)
C: The engine only runs. (Travel, digging and
operation are impossible even in light load.)
D: The engine cannot stop / start.
T5-6-38
Operating Rank
(Current)
A
B
C
Remedy
D
○
○
Operating Rank
(Current)
A B C D
○
○
○
○
Remedy
TROUBLESHOOTING/ Troubleshooting A
(Blank)
T5-6-39
TROUBLESHOOTING/ Troubleshooting A
Internal Circuit System
Fault Code
Trouble
Cause
10005-1
Abnormal Charge Circuit
(Bank 1)
In case voltage at bank 1 of charge circuit in ECM is low.
10006-1
Abnormal Charge Circuit
(Bank 2)
In case voltage at bank 2 of charge circuit in ECM is low.
10008-2
Abnormal A/D Conversion
A/D conversion cannot be done.
10007-2
Abnormal CPU
Within 100 msec after the key switch is turned ON, failure of
main CPU is detected by sub CPU.
(Sub CPU resets CPU.)
1077-2
Abnormal IC for CPU Watching
No change of RUN-SUB pulse in 20 msec.
628-2
Abnormal ROM
ROM is broken.
10013-2
Abnormal EEPROM
EEPROM is broken.
1079-2
Abnormal 5 V Power Source 1 When battery voltage is between 16 V and 32 V, voltage of
Voltage
key switch power source is 5.5 V or more or 4.5 V or less.
1080-2
Abnormal 5 V Power Source 2 When battery voltage is between 16 V and 32 V, voltage of
Voltage
key switch power source is 5.5 V or more or 4.5 V or less.
10009-2
Abnormal 5 V Power Source 3 When battery voltage is between 16 V and 32 V, voltage of
Voltage
key switch power source is 5.5 V or more or 4.5 V or less.
10010-2
Abnormal 5 V Power Source 4 When battery voltage is between 16 V and 32 V, voltage of
Voltage
key switch power source is 5.5 V or more or 4.5 V or less.
10011-2
Abnormal 5 V Power Source 5 When battery voltage is between 16 V and 32 V, voltage of
Voltage
key switch power source is 5.5 V or more or 4.5 V or less.
10003-2
Abnormal Injection Nozzle Common No monitor signals of injectors 1, 3, 5.
1 Drive System
Abnormal Injection Nozzle Common No monitor signals of injectors 2, 4, 6.
2 Drive System
10004-2
T5-6-40
TROUBLESHOOTING/ Troubleshooting A
Presumptive Symptoms in Real Machine
Operation
Assumptive Conditions at Backup
Vibration of the engine may be large, rough idle,
output power decrease may occur, faulty
increasing of rotation speed may occur, the
engine may be stalled.
The injector cannot be controlled.
→ Stop output of drive signal at failed common
side
(Protect the engine from damage)
P0612
Output power decrease, dark smoke occurs.
All analogue sensor cannot be used.
P1630
Output power decrease.
CPU is broken.
P0606
The engine cannot start.
Fault Code
(Tech 2)
P0611
P0606
Output power decrease.
Sub CPU is broken.
P0601
The engine stops.
Data of ROM cannot be read.
P1603
There is no influence when operating the Data cannot be written to EEPROM.
machine.
P1631
←
P1632
Same as Abnormal atmospheric and in-take ←
temperature sensors.
P1633
Same as Abnormal coolant temperature, fuel ←
temperature and hydraulic oil pressure sensors.
P1634
Same as Abnormal boost pressure and boost ←
temperature sensors.
P1635
Same as Abnormal rail pressure and EGR ←
position sensors.
P1261
No backup.
Vibration of the engine may be large, rough idle,
output power decrease may occur, faulty
increasing of rotation speed may occur, the
engine may be stalled.
The injector cannot be controlled.
→ Stop output of drive signal at failed common
side
(Protect the engine from damage)
T5-6-41
P1262
TROUBLESHOOTING/ Troubleshooting A
Fault Code
10005-1
10006-1
Trouble
Abnormal Charge Circuit
Abnormal Charge Circuit
10008-2
Abnormal A/D Conversion
10007-2
Abnormal CPU
(Bank 1)
(Bank 2)
1077-2
Abnormal IC for CPU Watching
628-2
10013-2
Abnormal ROM
Abnormal EEPROM
1079-2
1080-2
Abnormal 5 V Power Source 1 Voltage
Abnormal 5 V Power Source 2 Voltage
10009-2
Abnormal 5 V Power Source 3 Voltage
10010-2
Abnormal 5 V Power Source 4 Voltage
10011-2
Abnormal 5 V Power Source 5 Voltage
10003-2
Abnormal Injection Nozzle Common 1
Drive System
Abnormal Injection Nozzle Common 2
Drive System
10004-2
Influence to Engine
Performance
(Presumption)
Output
power
decrease: 60%
(Three cylinders in
operation.)
Output
power
decrease: 50%
Output
power
decrease: 50%
The engine cannot
start.
Output
power
decrease: 50%
The engine stops.
No
output
power
decrease
Idle Speed Operation
No
output
power
decrease
No
output
power
change
No
output
power
decrease
Output
power
decrease: 50%
Output
power
decrease: 60%
(Three cylinders in
operation.)
Operating Rank
A: Digging is operable.
B: Machine can travel with boom raised. (Steering is
impossible.)
C: The engine only runs. (Travel, digging and
operation are impossible even in light load.)
D: The engine cannot stop / start.
T5-6-42
Operating Rank
(Current)
A B C D
○ ○
○ ○
○
○
○
○
○
○
○
○
○
○
○ ○
○ ○
○ ○
Remedy
TROUBLESHOOTING/ Troubleshooting A
(Blank)
T5-6-43
TROUBLESHOOTING / Troubleshooting A
Communication System
Fault Code
639-2
639-3
Trouble
Abnormal CAN Bus Line
Abnormal CAN Time Out
Cause
Detect the Bus Line OFF
In case the CAN data
predetermined time.
T5-6-44
reception
is
impossible
for
TROUBLESHOOTING / Troubleshooting A
Presumptive Symptoms in Real Machine
Operation
The engine runs at idle speed.
Assumptive Conditions at Backup
CAN communication is impossible.
Fault code
(Tech2)
U2104
U2106
T5-6-45
TROUBLESHOOTING / Troubleshooting A
Fault
Code
Trouble
639-2
Abnormal CAN Bus Line
639-3
Abnormal CAN Time Out
Influence to Engine
Performance
(Presumption)
Idle Speed
T5-6-46
Operating Rank
(Current)
A B C D
○
○
Remedy
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-6-47
TROUBLESHOOTING / Troubleshooting A
ICF FAULT CODE LIST
Fault Code
14000-2
14001-2
14002-2
Trouble
Cause
Remedy
Abnormal
CAN Data cannot be received
Communication
due to the noise on the
CAN bus line.
Flash
Memory: The internal memory is
Read / Write Error abnormal when the key is
ON.
Check for CAN communication bus line.
After initializing the information C/U by using Dr.
ZX, retry in the troubleshooting.
If the error code is displayed after retry, ICF may
be broken.
Replace ICF.
NOTE: When initializing the information C/U,
all stored data is deleted.
External
RAM: The internal memory is After initializing the information C/U by using Dr.
Read / Write Error abnormal when the key is ZX, retry in the troubleshooting.
ON.
If the error code is displayed after retrial, ICF may
be broken.
Replace ICF.
14003-2
EEPROM:
Check Error
Sum The internal memory is
abnormal when the key is
ON.
14006-2
Satellite
Communication
Terminal:
Communication
Error
14008-2
Abnormal Internal The internal memory is
RAM
abnormal when the key is
ON.
Communication
to
the
satellite terminal cannot be
done over 30 seconds.
T5-6-48
NOTE: When initializing the information C/U,
all stored data is deleted.
Retry in the troubleshooting by using Dr. ZX.
If the error code is displayed after retrial, ICF may
be broken.
Replace ICF.
Check for the items below.
1. Check if the communication line is abnormal.
2. Check if the electrical power source of
communication terminal is abnormal.
• Electrical power source
• Fuses
3. Check if the satellite terminal is broken.
Retry in the troubleshooting by using Dr. ZX.
If the error code is displayed after retrial, ICF may
be broken.
Replace ICF.
TROUBLESHOOTING / Troubleshooting A
SATELLITE TERMINAL FAULT CODE LIST
Fault Code
14100-2
14101-2
14102-2
14103-2
14104-2
14105-2
14106-2
Trouble
Abnormal EEPROM
Abnormal IB/OB Queue
Abnormal Local Loop Back
Cause
Remedy
Internal memory is abnormal.
Internal memory is abnormal.
Data can not be received from
satellite.
Satellite can not be caught.
Replace the controller.
Replace the controller.
Check
the
communication
antenna for satellite.
Satellite cannot be found.
Check
the
communication
antenna for satellite.
Remote Loop Back Failure 1
Communication with satellite Replace the controller.
base station is impossible.
Remote Loop Back Failure 2
Communication with satellite Replace the controller.
base station is impossible.
Received data is not same with Received data is not same with Replace thecontroller.
sent data.
sent data.
MONITOR UNIT FAULT CODE LIST
Fault Code
Trouble
13303-2
Abnormal Thermistor
Temperature
13304-2
Abnormal REG Input H Level
13306-2
Abnormal EEPROM
13308-2
Abnormal CAN Communication
13310-3
Shorted Circuit in Coolant
Temperature Sensor
Shorted Circuit in Fuel Level
Sensor
Open Circuit in Fuel Level
Sensor
13311-3
13311-4
Cause
Remedy
Thermistor temperature is 85 °C Cool the monitor unit and so on
(185 °F) or more.
until the internal temperature of
monitor unit is less than 85 °C
(185 °F).
REG input level is H.
Refer to the Troubleshooting flow
chart.
EEPROM reading failure occurs. Replace the monitor unit when
displaying the fault code after
retrial.
Bus OFF occurs 5 times or Refer to CAN Harness Check
more.
(T5-6-73 to 104).
Input 105±30 Ω or less continues Check
coolant
temperature
for 60 seconds.
sensor and harness.
Input 3±1 Ω or less continues for Check fuel level sensor and
60 seconds.
harness.
Input 135±20 Ω or less continues Check fuel level sensor and
for 60 seconds.
harness.
T5-6-49
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE LIST
Controller Hardware Failure
Fault Code
15500-4
15501-2
15502-2
15503-2
15504-2
15505-2
15506-3
Trouble
Cause
Abnormal External Reference Faulty controller
Voltage
Abnormal Read Of Initial Setting Faulty controller
Value (EEPROM)
Abnormal EEPROM
Faulty controller
Abnormal RAM
Faulty controller
Abnormal A/D Conversion
Faulty controller
Abnormal CAN Communication Faulty controller
Faulty CAN harness
Abnormal Sensor Voltage
Faulty controller
Faulty sensor
Faulty harness
T5-6-50
Influenced Control
All Controls
All Controls
All Controls
All Controls
All Controls
• All Controls
• Pulverizer/Crusher Control
• CAN Cycle Data Communication
All Controls
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation
When Trouble Occurs.
-
Retrial B
Replace the controller.
-
Retrial B
Replace the controller.
-
Retrial B
Retrial B
Retrial B
Retrial B
Replace the controller.
Replace the controller.
Replace the controller.
Check CAN harness.
Replace the controller.
-
Retrial B
Replace the controller.
Remedy by Dr. ZX
T5-6-51
Remedy
TROUBLESHOOTING / Troubleshooting A
Pilot Pressure Failure
Fault Code
15510-3
15510-4
15511-3
15511-4
15514-3
Trouble
Cause
Abnormal Assist Stroke 1 Sensor Voltage: more than 4.65 V
High Voltage
Abnormal Assist Stroke 1 Sensor Voltage: less than 0.35 V
Low Voltage
Abnormal Assist Stroke 2 Sensor Voltage: more than 4.65 V
High Voltage
Abnormal Assist Stroke 2 Sensor Voltage: less than 0.35 V
Low Voltage
Abnormal Positioning/Auxiliary Voltage: more than 4.55 V
Stroke 1 Sensor High Voltage
Influenced Control
Assist Control
Assist Control
Assist Control
Assist Control
• Auxiliary Selection Switch: ON
Auxiliary Control
• Auxiliary Selection Switch: OFF
Positioning Control
15514-4
Abnormal Positioning/Auxiliary Voltage: less than 0.45 V
Stroke 1 Sensor Low Voltage
• Auxiliary Selection Switch: ON
Auxiliary Control
• Auxiliary Selection Switch: OFF
Positioning Control
15515-3
Abnormal Positioning/Auxiliary Voltage: more than 4.85 V
Stroke 2 Sensor High Voltage
• Auxiliary Selection Switch: ON
Auxiliary Control
• Auxiliary Selection Switch: OFF
Positioning Control
15515-4
Abnormal Positioning/Auxiliary Voltage: less than 0.15 V
Stroke 2 Sensor Low Voltage
• Auxiliary Selection Switch: ON
Auxiliary Control
• Auxiliary Selection Switch: OFF
Positioning Control
T5-6-52
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When Trouble Occurs.
Remedy by
Dr. ZX
• Stop assist operation.
Retrial
• Display "Abnormal assist operation signal warning" on the monitor unit.
• Stop assist operation.
Retrial
• Display "Abnormal assist operation signal warning" on the monitor unit.
• Stop assist operation.
Retrial
• Display "Abnormal assist operation signal warning" on the monitor unit.
• Stop assist operation.
Retrial
• Display "Abnormal assist operation signal warning" on the monitor unit.
• If positioning and auxiliary stroke 2 is neutral, positioning and auxiliary Retrial
operation stops.
• If positioning and auxiliary stroke 2 is not neutral, positioning and auxiliary
operation is active with pressure decreasing by 40%.
• Display "Abnormal attachment operation signal warning" on the monitor
unit.
• Buzzer (intermittent sound) sounds.
• If positioning and auxiliary stroke 2 is neutral, positioning and auxiliary Retrial
operation stops.
• If positioning and auxiliary stroke 2 is not neutral, positioning and auxiliary
operation is active with pressure decreasing by 40%.
• Display "Abnormal attachment operation signal warning" on the monitor
unit.
• Buzzer (intermittent sound) sounds.
• If positioning and auxiliary stroke 1 is neutral, positioning and auxiliary Retrial
operation stops.
• If positioning and auxiliary stroke 1 is not neutral, positioning and auxiliary
operation is active with pressure decreasing by 40%.
• Display "Abnormal attachment operation signal warning" on the monitor
unit.
• Buzzer (intermittent sound) sounds.
• If positioning and auxiliary stroke 1 is neutral, positioning and auxiliary Retrial
operation stops.
• If positioning and auxiliary stroke 1 is not neutral, positioning and auxiliary
operation is active with pressure decreasing by 40%.
• Display "Abnormal attachment operation signal warning" on the monitor
unit.
• Buzzer (intermittent sound) sounds.
T5-6-53
Remedy
B
Check the harness.
B
Check the harness.
B
Check the harness.
B
Check the harness.
B
Check the harness.
B
Check the harness.
B
Check the harness.
B
Check the harness.
TROUBLESHOOTING / Troubleshooting A
Fault Code
Trouble
Cause
Influenced Control
15516-3
Abnormal Positioning/Assist Pi Pressure Voltage: more than 4.60 V
Sensor High Voltage
• Positioning Control
• Assist Control
15516-4
Abnormal Positioning/Assist Pi Pressure Voltage: less than 0.40 V
Sensor Low Voltage
• Positioning Control
• Assist Control
15517-3
Abnormal Outrigger/Blade/Auxiliary
Pressure Sensor High Voltage
Pi Voltage: more than 4.60 V
• Outrigger/Blade Control
• Auxiliary Control
15517-4
Abnormal Outrigger/Blade/Auxiliary
Pressure Sensor Low Voltage
Pi Voltage: less than 0.40 V
• Outrigger/Blade Control
• Auxiliary Control
15518-3
Abnormal Outrigger/Blade
Sensor High Voltage
Stroke
1 Voltage: more than 4.55 V
Outrigger/Blade Control
15518-4
Abnormal Outrigger/Blade
Sensor Low Voltage
Stroke
1 Voltage: less than 0.45 V
Outrigger/Blade Control
15519-3
Abnormal Outrigger/Blade
Sensor High Voltage
Stroke
2 Voltage: more than 4.85 V
Outrigger/Blade Control
15519-4
Abnormal Outrigger/Blade
Sensor Low Voltage
Stroke
2 Voltage: less than 0.15 V.
Outrigger/Blade Control
T5-6-54
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When Trouble Occurs.
Remedy by
Remedy
Dr. ZX
Retrial B
Check the harness.
• All proportional solenoid valve outputs stop by shutting off pilot pressure.
• Display "Abnormal electric lever solenoid valve output warning" on the
monitor unit.
• Buzzer (continuous sound) sounds.
Retrial B
• All proportional solenoid valve outputs stop by shutting off pilot pressure.
• Display "Abnormal electric lever solenoid valve output warning" on the
monitor unit.
• Buzzer (continuous sound) sounds.
Retrial B
• All proportional solenoid valve outputs stop by shutting off pilot pressure.
• Display "Abnormal electric lever solenoid valve output warning" on the
monitor unit.
• Buzzer (continuous sound) sounds.
Retrial B
• All proportional solenoid valve outputs stop by shutting off pilot pressure.
• Display "Abnormal electric lever solenoid valve output warning" on the
monitor unit.
• Buzzer (continuous sound) sounds.
Retrial B
• If outrigger/blade stroke 2 is neutral,
outrigger/blade operation stops.
• If outrigger/blade stroke 2 is not neutral,
outrigger/blade operation is active with pressure decreasing by 40%.
• Display "Abnormal outrigger/blade operation signal warning" on the monitor
unit.
• Buzzer (intermittent sound) sounds.
Retrial B
• If outrigger/blade stroke 2 is neutral,
outrigger/blade operation stops.
• If outrigger/blade stroke 2 is not neutral,
outrigger/blade operation is active with pressure decreasing by 40%.
• Display "Abnormal outrigger/blade operation signal warning" on the monitor
unit.
• Buzzer (intermittent sound) sounds.
Retrial B
• If outrigger/blade stroke 1 is neutral,
outrigger/blade operation stops.
• If outrigger/blade stroke 1 is not neutral,
outrigger/blade operation is active with pressure decreasing by 40%.
• Display "Abnormal outrigger/blade operation signal warning" on the monitor
unit.
• Buzzer (intermittent sound) sounds.
Retrial B
• If outrigger/blade stroke 1 is neutral,
outrigger/blade operation stops.
• If outrigger/blade stroke 1 is not neutral,
outrigger/blade operation is active with pressure decreasing by 40%.
• Display "Abnormal outrigger/blade operation signal warning" on the monitor
unit.
• Buzzer (intermittent sound) sounds.
T5-6-55
Check the harness.
Check the harness.
Check the harness.
Check the harness.
Check the harness.
Check the harness.
Check the harness.
TROUBLESHOOTING / Troubleshooting A
Proportional Solenoid Valve Control Failure
Fault Code
15570-2
15571-2
15572-2
15573-2
15574-3
Trouble
Cause
Abnormal
When meeting the following conditions, •
Outrigger/Blade/Auxiliary outrigger/blade/auxiliary pilot pressure is more •
Neutral
than 1.2 MPa.
(Conditions)
• Outrigger/blade 1 and 2 solenoid valve
output is less than 0.5 MPa
• Auxiliary solenoid valve 1 and 2 output is
less than 0.5 MPa
Abnormal
When meeting either of the following •
Outrigger/Blade/Auxiliary conditions,
outrigger/blade/auxiliary
pilot •
Operation
pressure is less than 1.0 MPa.
(Conditions)
• Outrigger/blade 1 and 2 solenoid valve
output is more than 2.2 MPa
• Auxiliary solenoid valve 1 and 2 output is
more than 2.2 MPa
Abnormal
When meeting the following conditions, •
Positioning/Assist Neutral positioning/assist pilot pressure is more than •
1.2 MPa.
(Conditions)
• Positioning 1 and 2 solenoid valve output is
less than 0.5 MPa
• Assist 1 and 2 solenoid valve output is less
than 0.5 MPa
Abnormal
When meeting either of the following •
Positioning/Assist
conditions, positioning/assist pilot pressure is •
Operation
less than 1.0 MPa.
(Conditions)
• Positioning 1 and 2 solenoid valve output is
more than 2.2 MPa
• Assist 1 and 2 solenoid valve output is more
than 2.2 MPa
Positioning/auxiliary
stroke
1
+•
Abnormal
Positioning/Auxiliary Sum positioning/auxiliary stroke 2 is more than 9.0 •
Signal
Critical
High V
Voltage
Influenced Control
Outrigger/Blade Control
Auxiliary Control
Outrigger/Blade Control
Auxiliary Control
Positioning Control
Assist Control
Positioning Control
Assist Control
Positioning Control
Auxiliary Control
15574-4
Positioning/auxiliary
stroke
1
+ • Positioning Control
Abnormal
Positioning/Auxiliary Sum positioning/auxiliary stroke 2 is less than 0.5 V • Auxiliary Control
Signal
Critical
Low
Voltage
15575-3
Abnormal Outrigger/Blade Outrigger/blade stroke 1 + outrigger/blade Outrigger/Blade Control
Sum Signal Critical High stroke 2 is more than 9.0 V
Voltage
Abnormal Outrigger/Blade Outrigger/blade stroke 1 + outrigger/blade Outrigger/Blade Control
Sum Signal Critical Low stroke 2 is less than 0.5 V
Voltage
15575-4
T5-6-56
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When Trouble Occurs.
• All proportional solenoid valve outputs stop by shutting off pilot pressure.
• Display "Abnormal electric lever solenoid valve output warning" on the
monitor unit.
• Buzzer (continuous sound) sounds.
Remedy by
Remedy
Dr. ZX
Retrial B
Check the harness.
• Outrigger/blade operation is active with pressure decreasing by 40%.
Retrial B
• Positioning and auxiliary 1 operation is active with pressure decreasing by 40%.
Check the harness.
Retrial B
• All proportional solenoid valve outputs stop by shutting off pilot pressure.
• Display "Abnormal electric lever solenoid valve output warning" on the monitor
unit.
• Buzzer (continuous sound) sounds.
Check the harness.
• Positioning 1 operation is active with pressure decreasing by 40%.
• Assist 1 operation is active with pressure decreasing by 40%.
Retrial B
Check the harness.
• Positioning control: Positioning operation stops.
• Auxiliary control: Auxiliary operation stops.
• Display "Abnormal attachment operation signal warning" on the monitor unit.
• Buzzer (intermittent sound) sounds.
Retrial B
Check the harness.
• Positioning control: Positioning operation stops.
• Auxiliary control: Auxiliary operation stops.
• Display "Abnormal attachment operation signal warning" on the monitor unit.
• Buzzer (intermittent sound) sounds.
Retrial B
Check the harness.
• Outrigger/blade operation stops.
Retrial B
• Display "Abnormal outrigger/blade operation signal warning" on the monitor unit.
• Buzzer (intermittent sound) sounds.
• Outrigger/blade operation stops.
Retrial B
• Display "Abnormal outrigger/blade operation signal warning" on the monitor unit.
• Buzzer (intermittent sound) sounds.
Check the harness.
T5-6-57
Check the harness.
TROUBLESHOOTING / Troubleshooting A
Fault Code
Trouble
Cause
Influenced Control
15578-3
Abnormal
Positioning/auxiliary stroke 1 +
• Positioning Control
Positioning/Auxiliary Sum positioning/auxiliary stroke 2 is more than 5.4 • Auxiliary Control
Signal High Voltage
V and less than or equal to 9.0 V
15578-4
Abnormal
Positioning/auxiliary stroke 1 +
Positioning/Auxiliary Sum positioning/auxiliary stroke 2 more than or
Signal Low Voltage
equal to 0.5 V and is less than 4.6 V
15579-3
Abnormal Outrigger/Blade Outrigger/blade stroke 1 + outrigger/blade Outrigger/Blade Control
Sum Signal High Voltage stroke 2 is more than 5.4 V and less than or
equal to 9.0 V
15579-4
Abnormal Outrigger/Blade Outrigger/blade stroke 1 + outrigger/blade Outrigger/Blade Control
Sum Signal Low Voltage stroke 2 more than or equal to 0.5 V and is
less than 4.6 V
20300-2
Abnormal Positioning And Abnormal positioning/auxiliary stroke 1, or
• Auxiliary
Selection
Switch: ON
Auxiliary Operation Signal Abnormal positioning/auxiliary stroke 2, or
Auxiliary Control
Warning
Abnormal sum of positioning/auxiliary 1 and 2
• Auxiliary
Selection
Switch: OFF
Positioning Control
Abnormal Outrigger/Blade Abnormal outrigger/blade stroke 1 or
Outrigger/Blade Control
Operation Signal Warning Abnormal outrigger/blade stroke 2 or
Abnormal sum of outrigger/blade 1 and 2
20301-2
• Positioning Control
• Auxiliary Control
20302-2
Abnormal Warning On Abnormal assist stroke 1 or
Assist Related Operation Abnormal assist stroke 2
Signal
20303-2
Electric Lever Pilot Cut Some electric lever controls are abnormal in All Controls
Warning
monitoring neutral.
T5-6-58
Assist 1 Control
All Electric Lever Control
(Assist 2)
TROUBLESHOOTING / Troubleshooting A
Remedy by
Remedy
Dr. ZX
Check the harness.
• If positioning and auxiliary stroke 2 is not neutral, positioning operation is active Retrial B
with pressure decreasing by 40 %.
• If positioning and auxiliary stroke 2 is neutral, positioning operation stops.
• Display "Abnormal attachment operation signal warning" on the monitor unit.
• Buzzer (intermittent sound) sounds.
Symptoms in Machine Operation When Trouble Occurs.
• If positioning and auxiliary stroke 2 is not neutral, positioning operation is active Retrial B
with pressure decreasing by 40 %.
• If positioning and auxiliary stroke 2 is neutral, positioning operation stops.
• Display "Abnormal attachment operation signal warning" on the monitor unit.
• Buzzer (intermittent sound) sounds.
Check the harness.
• If outrigger/blade stroke 2 is not neutral, outrigger/blade operation is active with Retrial B
pressure decreasing by 40 %.
• If outrigger/blade stroke 2 is neutral, outrigger/blade operation stops.
• Display "Abnormal outrigger/blade operation signal warning" on the monitor unit.
• Buzzer (intermittent sound) sounds.
Check the harness.
• If outrigger/blade stroke 2 is not neutral, outrigger/blade operation is active with Retrial B
pressure decreasing by 40 %.
• If outrigger/blade stroke 2 is neutral, outrigger/blade operation stops.
• Display "Abnormal outrigger/blade operation signal warning" on the monitor unit.
• Buzzer (intermittent sound) sounds.
Check the harness.
• Display "Abnormal attachment operation signal warning" on the monitor unit.
• Buzzer (intermittent sound) sounds.
Retrial B
Check the harness.
• Display "Abnormal outrigger/blade operation signal warning" on the monitor unit. Retrial B
• Buzzer (intermittent sound) sounds.
Check the harness.
• Display "Abnormal assist operation signal warning" on the monitor unit.
Retrial B
Check the harness.
Retrial B
• Front attachment operation completely stops.
• Display "Abnormal electric lever solenoid valve output warning" on the
monitor unit.
• Buzzer (intermittent sound) sounds.
Check the harness.
T5-6-59
TROUBLESHOOTING / Troubleshooting A
Proportional Solenoid Valve Failure
Fault Code
Trouble
Cause
Influenced Control
15520-2
Invalid and Abnormal Current Feedback Current: Both of Higher than Auxiliary Control
Value of Auxiliary 1 Proportional Valve
920 mA or Less than 60 mA
15520-3
Abnormal Feedback Value High Current of Current: Higher than 920 Auxiliary Control
Auxiliary 1 Proportional Valve
mA
15520-4
Abnormal Feedback Value Low Current of Current: Less than 56 mA
Auxiliary Control
Auxiliary 1 Proportional Valve
Invalid and Abnormal Current Feedback Current: Both of Higher than Auxiliary Control
Value of Auxiliary 2 Proportional Valve
920 mA or Less than 60 mA
15521-2
15521-3
Abnormal Feedback Value High Current of Current: Higher than 920 Auxiliary Control
Auxiliary 2 Proportional Valve
mA
15521-4
Abnormal Feedback Value Low Current of Current: Less than 56 mA
Auxiliary 2 Proportional Valve
15522-2
Invalid and Abnormal Current Feedback Current: Both of Higher than Outrigger/Blade Control
Value of Outrigger/Blade 1 Proportional 920 mA or Less than 60 mA
Valve
Abnormal Feedback Value High Current of Current: Higher than 920 Outrigger/Blade Control
Outrigger/Blade 1 Proportional Valve
mA
Abnormal Feedback Value Low Current of Current: Less than 56 mA
Outrigger/Blade Control
Outrigger/Blade 1 Proportional Valve
Invalid and Abnormal Current Feedback Current: Both of Higher than Outrigger/Blade Control
Value of Outrigger/Blade 2 Proportional 920 mA or Less than 60 mA
Valve
15522-3
15522-4
15523-2
Auxiliary Control
15523-3
Abnormal Feedback Value High Current of Current: Higher than 920 Outrigger/Blade Control
Outrigger/Blade 2 Proportional Valve
mA
15523-4
Abnormal Feedback Value Low Current of Current: Less than 56 mA
Outrigger/Blade Control
Outrigger/Blade 2 Proportional Valve
Invalid and Abnormal Current Feedback Current: Both of Higher than • Positioning Control
Value
of
Swing
Parking
Release 920 mA or Less than 60 mA • Assist 1 Control
Proportional Valve
• Assist Switch Control
15524-2
15524-3
Abnormal Feedback Value High Current of Current: Higher than 920 • Positioning Control
Swing Parking Release Proportional Valve mA
• Assist 1 Control
• Assist Switch Control
15524-4
Abnormal Feedback Value Low Current of Current: Less than 56 mA
Swing Parking Release Proportional Valve
T5-6-60
• Positioning Control
• Assist 1 Control
• Assist Switch Control
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When Trouble
Occurs.
Auxiliary operation stops.
Remedy by
Remedy
Dr. ZX
Retrial B
Check the harness.
Auxiliary operation stops.
Retrial B
Check the harness.
Auxiliary operation stops.
Retrial B
Check the harness.
Auxiliary operation stops.
Retrial B
Check the harness.
Auxiliary operation stops.
Retrial B
Check the harness.
Auxiliary operation stops.
Retrial B
Check the harness.
Outrigger/blade operation stops.
Retrial B
Check the harness.
Outrigger/blade operation stops.
Retrial B
Check the harness.
Outrigger/blade operation stops.
Retrial B
Check the harness.
Outrigger/blade operation stops.
Retrial B
Check the harness.
Outrigger/blade operation stops.
Retrial B
Check the harness.
Outrigger/blade operation stops.
Retrial B
Check the harness.
Swing parking release is impossible.
Retrial B
Check the harness.
Swing parking is always released.
Retrial B
Check the harness.
Swing parking release is impossible.
Retrial B
Check the harness.
T5-6-61
TROUBLESHOOTING / Troubleshooting A
Fault Code
15525-2
15525-3
15525-4
15526-2
15526-3
15526-4
15527-2
15527-3
15527-4
15528-2
15528-3
15528-4
Trouble
Cause
Influenced Control
Invalid and Abnormal Current Feedback Current: Both of Higher than 920 Assist 1 Control
Value of Assist 1 Proportional Valve
mA or Less than 60 mA
Abnormal Feedback Value High Current Current: Higher than 920 mA
Assist 1 Control
of Assist 1 Proportional Valve
Abnormal Feedback Value Low Current Current: Less than 56 mA
Assist 1 Control
of Assist 1 Proportional Valve
Invalid and Abnormal Current Feedback Current: Both of Higher than 920 Assist 1 Control
Value of Assist 2 Proportional Valve
mA or Less than 60 mA
Abnormal Feedback Value High Current Current: Higher than 920mA
Assist 1 Control
of Assist 2 Proportional Valve
Abnormal Feedback Value Low Current Current: Less than 56 mA
Assist 1 Control
of Assist 2 Proportional Valve
Invalid and Abnormal Current Feedback Current: Both of Higher than 920 Assist Switch Control
Value of Assist 3 Proportional Valve
mA or Less than 60 mA
Abnormal Feedback Value High Current Current: Higher than 920 mA
Assist Switch Control
of Assist 3 Proportional Valve
Abnormal Feedback Value Low Current Current: Less than 56 mA
Assist Switch Control
of Assist 3 Proportional Valve
Invalid and Abnormal Current Feedback Current: Both of Higher than 920 Assist Switch Control
Value of Assist 4 Proportional Valve
mA or Less than 60 mA
Abnormal Feedback Value High Current Current: Higher than 920 mA
Assist Switch Control
of Assist 4 Proportional Valve
Abnormal Feedback Value Low Current Current: Less than 56 mA
Assist Switch Control
of Assist 4 Proportional Valve
T5-6-62
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When Trouble
Occurs.
Assist 1 operation stops.
Remedy by
Remedy
Dr. ZX
Retrial B
Check the harness.
Assist 1 operation stops.
Retrial B
Check the harness.
Assist 1 operation stops.
Retrial B
Check the harness.
Assist 1 operation stops.
Retrial B
Check the harness.
Assist 1 operation stops.
Retrial B
Check the harness.
Assist 1 operation stops.
Retrial B
Check the harness.
Assist switch operation stops.
Retrial B
Check the harness.
Assist switch operation stops.
Retrial B
Check the harness.
Assist switch operation stops.
Retrial B
Check the harness.
Assist switch operation stops.
Retrial B
Check the harness.
Assist switch operation stops.
Retrial B
Check the harness.
Assist switch operation stops.
Retrial B
Check the harness.
T5-6-63
TROUBLESHOOTING / Troubleshooting A
Fault Code
15529-2
15529-3
15529-4
15530-2
15530-3
15530-4
Trouble
Cause
Influenced Control
Invalid and Abnormal Current Feedback Current: Both of higher than 920 Positioning Control
Value of Positioning 1 Proportional mA or Less than 60 mA
Valve
Abnormal Feedback Value High Current Current: Higher than 920mA
Positioning Control
of Positioning 1 Proportional Valve
Abnormal Feedback Value Low Current Current: Less than 56 mA
Positioning Control
of Positioning1 Proportional Valve
Invalid and Abnormal Current Feedback Current: Both of higher than 920 Positioning Control
Value of Positioning 2 Proportional mA or Less than 60 mA
Valve
Abnormal Feedback Value High Current Current: Higher than 920mA
Positioning Control
of Positioning 2 Proportional Valve
Abnormal Feedback Value Low Current Current: Less than 56 mA
Positioning Control
of Positioning 2 Proportional Valve
T5-6-64
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When Trouble
Occurs.
Positioning operation stops.
Remedy by
Remedy
Dr. ZX
Retrial B
Check the harness.
Positioning operation stops.
Retrial B
Check the harness.
Positioning operation stops.
Retrial B
Check the harness.
Positioning operation stops.
Retrial B
Check the harness.
Positioning operation stops.
Retrial B
Check the harness.
Positioning operation stops.
Retrial B
Check the harness.
T5-6-65
TROUBLESHOOTING / Troubleshooting A
CAN Data Reception Failure
Fault code
Trouble
Cause
Unreceived for 2000 ms
Influenced Control
•
•
•
•
15565-2
Unreceived Work Mode
Sent from: MC
15566-2
Unreceived ATT 1 and 2 Optional Unreceived for 10 sec
Selection
Sent from: MC
15567-2
Unreceived ATT 3 and 4 Optional Unreceived for 10 sec
Selection
Sent from: MC
• Pulverizer Control
• Crusher Control
15568-2
Unreceived ATT 5 Optional Selection
Sent from: MC
Unreceived for 10 sec
• Pulverizer Control
• Crusher Control
15577-2
Unreceived Actual Engine Speed
Sent from: ECM
Unreceived for 10 sec
All Electric Lever Control
T5-6-66
Pulverizer Control
Crusher Control
Pulverizer Control
Crusher Control
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When Trouble Occurs
Work mode control is inactive (Always digging mode).
Remedy by
Remedy
Dr. ZX
Retrial B
Check the harness.
• Secondary pilot relief control solenoid valve: Always Retrial B
OFF
• Selector valve control solenoid valve: Always OFF
• Accumulator control solenoid valve: Always OFF
• Secondary pilot relief control solenoid valve: Always Retrial B
OFF
• Selector valve control solenoid valve: Always OFF
• Accumulator control solenoid valve: Always OFF
• Secondary pilot relief control solenoid valve: Always Retrial B
OFF
• Selector valve control solenoid valve: Always OFF
• Accumulator control solenoid valve: Always OFF
Check the harness.
• Electric lever: Engine stop control
Check the harness.
Retrial B
T5-6-67
Check the harness.
Check the harness.
TROUBLESHOOTING / Troubleshooting A
STEERING COLUMN MONITOR FAULT CODE
Fault Code
16000-2
Trouble
Cause
Abnormal CAN Faulty steering
communication column monitor
Faulty CAN harness
Symptoms in
Influenced
Machine
Remedy
Remedy
Control Operation When by Dr. ZX
Trouble Occurs.
Retrial B Check the CAN
harness.
T5-6-68
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-6-69
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODES 11000 TO 11002
Fault Code
11000-2
11001-2
11002-2
Trouble
Abnormal EEPROM
Abnormal RAM
Abnormal A/D Convesion
Cause
Faulty MC
Faulty MC
Faulty MC
YES
* Faulty MC.
Check if engine and machine
operate normally.
Faulty MC.
NO
* After retrial, if the engine and the machine operate
normally with the fault code shown, the machine can
be operated.
T5-6-70
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11003
Fault Code
11003-3
Trouble
Abnormal Sensor Voltage
Cause
Faulty MC
IMPORTANT: Fault code 11003-3 (Abnormal sensor voltage) is shown with other
fault code, diagnose fault code
11003-3 first.
YES
Disconnect all sensor
connectors for displayed
fault code and retry.
Check if fault code
11003-3 disappears.
NO
Faulty sensor.
Disconnect all connectors at MC side.
Check for continuity
between terminals
#1 and #3 (harness
end) of connector.
· Key switch: OFF
Connector (Harness end of connector viewed from the
open end side)
• Pressure Sensor (Boom Raise, Arm Roll-Out,
(Optional)/Arm Roll-In, Front Attachment, Swing,
Travel Forward/Reverse, Auxiliary (Optional), Positioning (Optional))
• Pump 1 Control Pressure Sensor
• Pump 2 Control Pressure Sensor
YES
Shorted circuit in harness with
continuity between MC and
sensor.
Faulty MC.
NO
• Pump 1 Delivery Pressure Sensor
• Pump 2 Delivery Pressure Sensor
• Steering Pump Delivery Pressure Sensor
T1V1-05-07-101
T1V1-05-07-102
T5-6-71
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11004
Fault Code
11004-2
Trouble
Abnormal CAN Communication
Cause
Faulty MC
Dr.ZX
Satellite Terminal
(Optional)
Monitor Unit
ICF
Option
Controller
MC
CAN Harness
Steering
Column
Monitor
ECM
T1J1-02-01-004
• Check the CAN harness between the controllers.
(Refer to CAN Harness Check on T5-6-73 to 104.)
T5-6-72
TROUBLESHOOTING / Troubleshooting A
CAN HARNESS CHECK
• Check the wiring connections first.
NO
YES Check for continuity in
CAN harness between
MC and ECM.
· Key switch: OFF
· Refer to CAN Harness Continuity
Check on T5-6-78.
Check for continuity in
YES CAN harness between
MC and ICF.
· Key switch: OFF
· Refer to CAN Harness Continuity
Check on T5-6-79.
Retry by using Dr. ZX.
Check if fault code
11004-2 is displayed.
NO
Open circuit in CAN
harness between
MC and ECM.
Check for continuity
in CAN harness between MC and
YES
monitor unit.
· Key switch: OFF
· Refer to CAN Harness Continuity
Check on T5-6-80.
Open circuit in CAN
harness between
MC and ICM.
Normal.
NO
T5-6-73
To A
TROUBLESHOOTING / Troubleshooting A
YES
YES
· Key switch: OFF
· Refer to CAN Harness Continuity
Check on T5-6-82.
Check for continuity in
CAN harness between
YES
MC and steering column monitor.
· Key switch: OFF
· Refer to CAN Harness Continuity
Check on T5-6-81.
A
Check for continuity in
CAN harness between
MC and option controller.
NO
Open circuit in CAN
harness between
MC and option controller.
Open circuit in CAN
harness between
MC and steering
column monitor.
NO
Open circuit in CAN
harness between
MC and monitor unit.
NO
T5-6-74
TROUBLESHOOTING / Troubleshooting A
Shorted circuit in
CAN harness between ground circuit
and CAN circuit.
YES
Disconnect all connectors of MC, ICF,
ECM, monitor unit,
steering column
monitor and option
controller.
Check for continuity
between ground circuit and CAN circuit
of each controller.
· Key switch: OFF
· Refer to Discontinuity
Check between CAN
Circuit and Ground
Circuit on T5-6-84 to
91.
Shorted circuit in
CAN harness between electric power
circuit and CAN circuit.
YES
NO
Check for continuity
between power circuit and CAN circuit
of MC, ICF, ECM,
monitor unit, steering
column monitor and
option controller.
· Key switch: OFF
NO
· Refer to Discontinuity
Check between CAN
Circuit and Power
Circuit on T5-6-92 to
99.
T5-6-75
Check for continuity
between key signal
circuit and CAN circuit of MC, ICF,
ECM, monitor unit,
steering column
monitor and option
controller.
· Key switch: OFF
· Refer to Discontinuity
Check between CAN
Circuit and Key Signal
Circuit on T5-6-100 to
103.
Shorted circuit in
YES CAN harness between electric
key-signal circuit and
CAN circuit.
NO
Check for continuity
between High and
Low sides of CAN
harness.
· Key switch: OFF
· Refer to Discontinuity Check in CAN
Harness on
T5-6-104.
To B
TROUBLESHOOTING / Troubleshooting A
Shorted circuit in
CAN harness.
YES
YES
B
Connect all MC
connectors except
connector MC-C.
Check if resistance
NO between terminals
#C4 and #C15 of
harness end of connector MC-C is within
60±10 Ω.
YES
· Key switch: OFF
NO
C23
Faulty ICF.
YES Faulty ECM.
NO
#C15
Connect ICF connector.
Disconnect ECM
connector.
Check if resistance
between terminals
#18 and #37 of harness end is within
120±10 Ω.
· Key switch: OFF
C10
C1
NO
Connect ECM connector.
Disconnect connector monitor-B in
monitor unit.
Check if resistance
between terminals
#B6 and #B7 of harness end is within
120±10 Ω.
· Key switch: OFF
C31
ICF Connector ICF-C
(Harness end)
#C5
#C11
ECM Connector
(Harness end)
Connect MC connector.
Disconnect connector ICF-C in ICF.
Check if resistance
between terminals
#C5 and #C11 of
harness end is within
60±10 Ω.
· Key switch: OFF
Connector
MC Connector MC-C
(Harness end)
#C4
Faulty MC.
#18
T1V1-05-04-002
Monitor Unit Connector Monitor-B
(Harness end)
#B7
#37
T1GR-05-04-002
T5-6-76
#B6
T183-05-04-013
TROUBLESHOOTING / Troubleshooting A
YES
Faulty monitor unit.
YES
NO
Connect monitor unit
connector.
Disconnect connector 2
in steering column
monitor.
Check if resistance between terminals #1 and
#9 of harness end is
within 60±10 Ω.
· Key switch: OFF
NO
Faulty steering column
monitor.
Connect steering column monitor connector.
Disconnect connector C
in option controller.
Check if resistance between terminals #C10
and #C22 of harness
end is within 60±10 Ω.
YES
Faulty option controller.
Failure in any controller.
NO
· Key switch: OFF
Steering Column Monitor Connector 2
(Harness end)
Option Controller Connector C
(Harness end)
C1
#9
C10
#C10
#C22
#1
TCJB-05-06-001
T5-6-77
C23
C31
TROUBLESHOOTING / Troubleshooting A
CAN Harness Continuity Check
IMPORTANT:
Before continuity check, trun the
key switch OFF.
• Between MC and ECM
• CAN Harness (High Side)
Check for continuity between terminal #C4 (harness end) of connector MC-C in MC and terminal
#18 (harness end) of connector in ECM.
• CAN Harness (Low Side)
Check for continuity between terminal #C15
(harness end) of connector MC-C in MC and terminal #37 (harness end) of connector in ECM.
Connector
MC Connector MC-C
(Harness end)
#C4
#C15
C1
C23
ECM Connector
(Harness end)
C10
C31
#18
#37
T1GR-05-04-002
T5-6-78
TROUBLESHOOTING / Troubleshooting A
• Between MC and ICF
• CAN Harness (High Side)
Check for continuity between terminal #C4 (harness end) of connector MC-C in MC and terminal
#C5 (harness end) of connector ICF-C in ICF.
• CAN Harness (Low Side)
Check for continuity between terminal #C15
(harness end) of connector MC-C in MC and terminal #C11 (harness end) of connector ICF-C in
ICF.
Connector
MC Connector MC-C
(Harness end)
#C4
#C15
C10
C1
C23
ICF Connector ICF-C
(Harness end)
C31
#C5
#C11
T1V1-05-04-002
T5-6-79
TROUBLESHOOTING / Troubleshooting A
• Between MC and Monitor Unit
• CAN Harness (High Side)
Check for continuity between terminal #C4 (harness end) of connector MC-C in MC and terminal
#B7 (harness end) of connector monitor-B in the
monitor unit.
• CAN Harness (Low Side)
Check for continuity between terminal #C15
(harness end) of connector MC-C in MC and terminal #B6 (harness end) of connector monitor-B
in the monitor unit.
Connector
MC Connector MC-C
(Harness end)
#C4
#C15
C10
C1
C23
C31
Monitor Unit Connector Monitor-B
(Harness end)
#B7
#B6
T183-05-04-013
T5-6-80
TROUBLESHOOTING / Troubleshooting A
• Between MC and Steering Column Monitor
• CAN Harness (High Side)
Check for continuity between terminal #C4 (harness end) of connector MC-C in MC and terminal
#1 (harness end) of connector 2 in the steering
column monitor.
• CAN Harness (Low Side)
Check for continuity between terminal #C15
(harness end) of connector MC-C in MC and terminal #9 (harness end) of connector 2 in the
steering column monitor.
Connector
MC Connector MC-C
(Harness end)
#C4
C1
C23
#C15
C10
C31
Steering Column Monitor Connector 2
(Harness end)
#9
#1
TCJB-05-06-001
T5-6-81
TROUBLESHOOTING / Troubleshooting A
• Between MC and Option Controller
• CAN Harness (High Side)
Check for continuity between terminal #C4 (harness end) of connector MC-C in MC and terminal
#C10 (harness end) of connector C in the option
controller.
• CAN Harness (Low Side)
Check for continuity between terminal #C15
(harness end) of connector MC-C in MC and terminal #C22 (harness end) of connector C in the
option controller.
Connector
MC Connector MC-C
(Harness end)
#C4
#C15
C1
C23
C10
C31
Option Controller Connector C
(Harness end)
C1
C10
#C10
#C22
C23
C31
T5-6-82
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-6-83
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Ground Circuit
IMPORTANT: Before continuity check, turn the key
switch OFF.
In case of continuity, the circuit between CAN circuit and ground circuit is shorted.
In case of discontinuity, the circuit is
normal.
Connector
Connector MC-C
(Harness end)
#C4
C10
C1
C23
C31
• MC
Between CAN Circuit (High Side) and Ground Circuit
• Check for continuity between terminal #C4 (harness end) of connector MC-C and terminal #A2
(harness end) of connector MC-A.
Connector MC-A
(Harness end)
#A2
• Check for continuity between terminal #C4 (harness end) of connector MC-C and terminal #A13
(harness end) of connector MC-A.
#A13
T183-05-04-008
• Check for continuity between terminal #C4 (harness end) of connector MC-C and terminal #B8
(harness end) of connector MC-B.
• Check for continuity between terminal #C4 (har-
Connector MC-B
(Harness end)
#B8
ness end) of connector MC-C and terminal #B18
(harness end) of connector MC-B.
#B18
T183-05-04-021
T5-6-84
TROUBLESHOOTING / Troubleshooting A
• MC
Between CAN Circuit (Low Side) and Ground Circuit
• Check for continuity between terminal #C15
(harness end) of connector MC-C and terminal
#A2 (harness end) of connector MC-A.
• Check for continuity between terminal #C15
Connector
Connector MC-C
(Harness end)
#C15
C10
C1
(harness end) of connector MC-C and terminal
#A13 (harness end) of connector MC-A.
• Check for continuity between terminal #C15
(harness end) of connector MC-C and terminal
#B8 (harness end) of connector MC-B.
• Check for continuity between terminal #C15
C23
C31
Connector MC-A
(Harness end)
#A2
(harness end) of connector MC-C and terminal
#B18 (harness end) of connector MC-B.
#A13
T183-05-04-008
Connector MC-B
(Harness end)
#B8
#B18
T183-05-04-021
T5-6-85
TROUBLESHOOTING / Troubleshooting A
• ECM
Between CAN Circuit (High Side) and Ground Circuit
• Check for continuity between terminals #18 and
#1 (harness end).
ECM Connector
(Harness end)
#18
#43
#4
• Check for continuity between terminals #18 and
#3
#3 (harness end).
• Check for continuity between terminals #18 and
#62
#4 (harness end).
#1
T1GR-05-04-002
• Check for continuity between terminals #18 and
#43 (harness end).
• Check for continuity between terminals #18 and
#62 (harness end).
• ECM
Between CAN Circuit (Low Side) and Ground Circuit
• Check for continuity between terminals #37 and
#1 (harness end).
• Check for continuity between terminals #37 and
#3 (harness end).
• Check for continuity between terminals #37 and
ECM Connector
(Harness end)
#37
#43
#4 (harness end).
#4
#3
• Check for continuity between terminals #37 and
#43 (harness end).
• Check for continuity between terminals #37 and
#62 (harness end).
T5-6-86
#62
#1
T1GR-05-04-002
TROUBLESHOOTING / Troubleshooting A
• ICF
Between CAN Circuit (High Side) and Ground Circuit
• Check for continuity between terminals #C5 and
#C14 (harness end) of connector ICF-C.
ICF Connector ICF-C
(Harness end)
#C5
• Check for continuity between terminals #C5 and
#C15 (harness end) of connector ICF-C.
#C14
T1V1-05-04-002
#C15
• ICF
Between CAN Circuit (Low Side) and Ground Circuit
• Check for continuity between terminals #C11 and
#C14 (harness end) of connector ICF-C.
ICF Connector ICF-C
(Harness end)
• Check for continuity between terminals #C11 and
#C15 (harness end) of connector ICF-C.
#C14
#C15
T1V1-05-04-002
#C11
• Monitor Unit
Between CAN Circuit (High Side) and Ground Circuit
• Check for continuity between terminals #B7 and
#B11 (harness end) of connector monitor unit-B.
Monitor Unit Connector Monitor-B
(Harness end)
#B7
• Monitor Unit
Between CAN Circuit (Low Side) and Ground Circuit
• Check for continuity between terminals #B6 and
#B11 (harness end) of connector monitor unit-B.
#B11
T183-05-04-013
Monitor Unit Connector Monitor-B
(Harness end)
#B6
#B11
T5-6-87
T183-05-04-013
TROUBLESHOOTING / Troubleshooting A
• Steering Column Monitor
Between CAN Circuit (High Side) and Ground Circuit
• Check for continuity between terminal #1 (harness end) of connector 2 and terminal #1 (harness end) of connector 1.
Steering Column Monitor Connector 1
(Harness end)
#7
• Check for continuity between terminal #1 (har-
#1
ness end) of connector 2 and terminal #7 (harness end) of connector 1.
TCJB-05-06-002
• Steering Column Monitor
Between CAN Circuit (Low Side) and Ground Circuit
• Check for continuity between terminal #9 (harness end) of connector 2 and terminal #1 (harness end) of connector 1.
Steering Column Monitor Connector 2
(Harness end)
#9
• Check for continuity between terminal #9 (harness end) of connector 2 and terminal #7 (harness end) of connector 1.
T5-6-88
#1
TCJB-05-06-001
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-6-89
TROUBLESHOOTING / Troubleshooting A
• Option Controller
Between CAN Circuit (High Side) and Ground Circuit
• Check for continuity between terminal #C10
(harness end) of connector C and terminal #A2
(harness end) of connector A.
Connector
Connector C
(Harness end)
C10
C1
#C10
• Check for continuity between terminal #C10
(harness end) of connector C and terminal #A13
(harness end) of connector A.
C23
C31
• Check for continuity between terminal #C10
(harness end) of connector C and terminal #A25
(harness end) of connector A.
Connector A
(Harness end)
#A2
• Check for continuity between terminal #C10
(harness end) of connector C and terminal #B8
(harness end) of connector B.
• Check for continuity between terminal #C10
#A25
(harness end) of connector C and terminal #B18
(harness end) of connector B.
• Check for continuity between terminal #C10
(harness end) of connector C and terminal #B25
(harness end) of connector B.
#A13
T183-05-04-008
Connector B
(Harness end)
#B8
#B25
#B18
T183-05-04-021
T5-6-90
TROUBLESHOOTING / Troubleshooting A
• Option Controller
Between CAN Circuit (Low Side) and Ground Circuit
• Check for continuity between terminal #C22
(harness end) of connector C and terminal #A2
(harness end) of connector A.
Connector
Connector C
(Harness end)
C10
C1
• Check for continuity between terminal #C22
#C22
(harness end) of connector C and terminal #A13
(harness end) of connector A.
C23
C31
• Check for continuity between terminal #C22
(harness end) of connector C and terminal #A25
(harness end) of connector A.
Connector A
(Harness end)
• Check for continuity between terminal #C22
#A2
(harness end) of connector C and terminal #B8
(harness end) of connector B.
• Check for continuity between terminal #C22
(harness end) of connector C and terminal #B18
(harness end) of connector B.
#A25
#A13
T183-05-04-008
• Check for continuity between terminal #C22
(harness end) of connector C and terminal #B25
(harness end) of connector B.
Connector B
(Harness end)
#B8
#B25
#B18
T183-05-04-021
T5-6-91
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Power Circuit
IMPORTANT: Before continuity check, turn the key
switch OFF.
In case of continuity, the circuit between CAN circuit and power circuit
is shorted.
In case of discontinuity, the circuit is
normal.
• MC
Between CAN Circuit (High Side) and Power Circuit
• Check for continuity between terminal #C4 (harness end) of connector MC-C and terminal #A1
(harness end) of connector MC-A.
Connector
Connector MC-C
(Harness end)
#C4
C1
C23
C10
C31
Connector MC-A
(Harness end)
#A1
• Check for continuity between terminal #C4 (harness end) of connector MC-C and terminal #A12
(harness end) of connector MC-A.
#A12
T183-05-04-008
• Check for continuity between terminal #C4 (harness end) of connector MC-C and terminal #B7
(harness end) of connector MC-B.
Connector MC-B
(Harness end)
#B7
• Check for continuity between terminal #C4 (harness end) of connector MC-C and terminal #B17
(harness end) of connector MC-B.
#B17
T183-05-04-021
T5-6-92
TROUBLESHOOTING / Troubleshooting A
• MC
Between CAN Circuit (Low Side) and Power Circuit
• Check for continuity between terminal #C15
(harness end) of connector MC-C and terminal
#A1 (harness end) of connector MC-A.
Connector
Connector MC-C
(Harness end)
#C15
C1
• Check for continuity between terminal #C15
C10
(harness end) of connector MC-C and terminal
#A12 (harness end) of connector MC-A.
C23
C31
• Check for continuity between terminal #C15
(harness end) of connector MC-C and terminal
#B7 (harness end) of connector MC-B.
• Check for continuity between terminal #C15
(harness end) of connector MC-C and terminal
#B17 (harness end) of connector MC-B.
Connector MC-A
(Harness end)
#A1
#A12
T183-05-04-008
Connector MC-B
(Harness end)
#B7
#B17
T183-05-04-021
T5-6-93
TROUBLESHOOTING / Troubleshooting A
• ECM
Between CAN Circuit (High Side) and Power Circuit
• Check for continuity between terminals #18 and
#2 (harness end).
ECM Connector
(Harness end)
#18
#5
• Check for continuity between terminals #18 and
#5 (harness end).
• ECM
Between CAN Circuit (Low Side) and Power Circuit
• Check for continuity between terminals #37 and
#2 (harness end).
• Check for continuity between terminals #37 and
#2
ECM Connector
(Harness end)
#37
T1GR-05-04-002
#5
#5 (harness end).
• ICF
Between CAN Circuit (High Side) and Power Circuit
• Check for continuity between terminals #C5 and
#C1 (harness end) of connector ICF-C.
#2
T1GR-05-04-002
• Check for continuity between terminals #C5 and
#C2 (harness end) of connector ICF-C.
ICF Connector ICF-C
(Harness end)
• ICF
#C2
Between CAN Circuit (Low Side) and Power Circuit
• Check for continuity between terminals #C11 and
#C1 (harness end) of connector ICF-C.
#C5
#C1
T1V1-05-04-002
• Check for continuity between terminals #C11 and
#C2 (harness end) of connector ICF-C.
ICF Connector ICF-C
(Harness end)
#C2
#C1
#C11
T5-6-94
T1V1-05-04-002
TROUBLESHOOTING / Troubleshooting A
• Monitor Unit
Between CAN Circuit (High Side) and Power Circuit
• Check for continuity between terminal #B7 (harness end) of connector monitor-B and terminal
#A16 (harness end) of connector monitor-A.
Monitor Unit Connector Monitor-B
(Harness end)
#B7
T183-05-04-013
Monitor Unit Connector Monitor-A
(Harness end)
• Monitor Unit
Between CAN Circuit (Low Side) and Power Circuit
• Check for continuity between terminal #B6 (harness end) of connector monitor-B and terminal
#A16 (harness end) of connector monitor-A.
T183-05-05-001
#A16
Monitor Unit Connector Monitor-B
(Harness end)
#B6
T183-05-04-013
Monitor Unit Connector Monitor-A
(Harness end)
T183-05-05-001
#A16
T5-6-95
TROUBLESHOOTING / Troubleshooting A
• Steering Column Monitor
Between CAN Circuit (High Side) and Power Circuit
• Check for continuity between terminal #1 (harness end) of connector 2 and terminal #6 (harness end) of connector 1.
Steering Column Monitor Connector 2
(Harness end)
• Check for continuity between terminal #1 (harness end) of connector 2 and terminal #12 (harness end) of connector 1.
#1
TCJB-05-06-001
Steering Column Monitor Connector 1
(Harness end)
#12
#6
• Steering Column Monitor
TCJB-05-06-002
Between CAN Circuit (Low Side) and Power Circuit
• Check for continuity between terminal #9 (harness end) of connector 2 and terminal #6 (harness end) of connector 1.
• Check for continuity between terminal #9 (har-
Steering Column Monitor Connector 2
(Harness end)
ness end) of connector 2 and terminal #12 (harness end) of connector 1.
#9
TCJB-05-06-001
Steering Column Monitor Connector 1
(Harness end)
#12
#6
TCJB-05-06-002
T5-6-96
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-6-97
TROUBLESHOOTING / Troubleshooting A
• Option Controller
Between CAN Circuit (High Side) and Power Circuit
• Check for continuity between terminal #C10
(harness end) of connector C and terminal #A1
(harness end) of connector A.
Connector
Connector C
(Harness end)
C1
• Check for continuity between terminal #C10
C10
#C10
(harness end) of connector C and terminal #A12
(harness end) of connector A.
C23
C31
• Check for continuity between terminal #C10
(harness end) of connector C and terminal #B7
(harness end) of connector B.
• Check for continuity between terminal #C10
(harness end) of connector C and terminal #B17
(harness end) of connector B.
Connector A
(Harness end)
#A1
• Check for continuity between terminal #C10
(harness end) of connector C and terminal #B24
(harness end) of connector B.
#A12
T183-05-04-008
Connector B
(Harness end)
#B7
#B17
#B24
T5-6-98
T183-05-04-021
TROUBLESHOOTING / Troubleshooting A
• Option Controller
Between CAN Circuit (Low Side) and Power Circuit
• Check for continuity between terminal #C22
(harness end) of connector C and terminal #A1
(harness end) of connector A.
Connector
Connector C
(Harness end)
C1
• Check for continuity between terminal #C22
C10
(harness end) of connector C and terminal #A12
(harness end) of connector A.
#C22
C23
• Check for continuity between terminal #C22
(harness end) of connector C and terminal #B7
(harness end) of connector B.
• Check for continuity between terminal #C22
(harness end) of connector C and terminal #B17
(harness end) of connector B.
C31
Connector A
(Harness end)
#A1
• Check for continuity between terminal #C22
(harness end) of connector C and terminal #B24
(harness end) of connector B.
#A12
T183-05-04-008
Connector B
(Harness end)
#B7
#B17
#B24
T5-6-99
T183-05-04-021
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Key Signal Circuit
IMPORTANT: Before continuity check, turn the key
switch OFF.
In case of continuity, the circuit between CAN circuit and key signal
circuit is shorted.
In case of discontinuity, the circuit is
normal.
Connector
Connector MC-C
(Harness end)
#C4
C10
C1
C23
C31
• MC
Between CAN Circuit (High Side) and Key Signal
Circuit
• Check for continuity between terminal #C4 (harness end) of connector MC-C and terminal #B16
(harness end) of connector MC-B.
Connector MC-B
(Harness end)
#B16
T183-05-04-021
• MC
Between CAN Circuit (Low Side) and Key Signal
Circuit
• Check for continuity between terminal #C15
(harness end) of connector MC-C and terminal
#B16 (harness end) of connector MC-B.
Connector
Connector MC-C
(Harness end)
#C15
C1
C23
C10
C31
Connector MC-B
(Harness end)
#B16
T183-05-04-021
T5-6-100
TROUBLESHOOTING / Troubleshooting A
• ECM
Between CAN Circuit (High Side) and Key Signal
Circuit
• Check for continuity between terminals #18 and
#24 (harness end) of connector.
ECM Connector
(Harness end)
#18
#24
T1GR-05-04-002
• ECM
Between CAN Circuit (Low Side) and Key Signal
Circuit
• Check for continuity between terminals #37 and
#24 (harness end) of connector.
ECM Connector
(Harness end)
#37
#24
T1GR-05-04-002
• ICF
Between CAN Circuit (High Side) and Key Signal
Circuit
• Check for continuity between terminals #C5 and
#C7 (harness end) of connector ICF-C.
ICF Connector ICF-C
(Harness end)
#C5
#C7
T1V1-05-04-002
• ICF
Between CAN Circuit (Low Side) and Key Signal
Circuit
• Check for continuity between terminals #C11 and
#C7 (harness end) of connector ICF-C.
ICF Connector ICF-C
(Harness end)
#C7
#C11
T5-6-101
T1V1-05-04-002
TROUBLESHOOTING / Troubleshooting A
• Monitor Unit
Between CAN Circuit (High Side) and Key Signal
Circuit
• Check for continuity between terminal #B7 (harness end) of connector monitor-B and terminal
#A7 (harness end) of connector monitor-A.
Monitor Unit Connector Monitor-B
(Harness end)
#B7
T183-05-04-013
Monitor Unit Connector Monitor-A
(Harness end)
#A7
T183-05-05-001
• Monitor Unit
Between CAN Circuit (Low Side) and Key Signal
Circuit
• Check for continuity between terminal #B6 (harness end) of connector monitor-B and terminal
#A7 (harness end) of connector monitor-A.
Monitor Unit Connector Monitor-B
(Harness end)
#B6
T183-05-04-013
Monitor Unit Connector Monitor-A
(Harness end)
#A7
T183-05-05-001
T5-6-102
TROUBLESHOOTING / Troubleshooting A
• Option Controller
Between CAN Circuit (High Side) and Key Signal
Circuit
• Check for continuity between terminal #C10
(harness end) of connector C and terminal #B16
(harness end) of connector B.
Connector
Connector C
(Harness end)
C1
C10
#C10
C23
C31
Connector B
(Harness end)
#B16
T183-05-04-021
• Option Controller
Between CAN Circuit (Low Side) and Key Signal
Circuit
• Check for continuity between terminal #C22
(harness end) of connector C and terminal #B16
(harness end) of connector B.
Connector
Connector C
(Harness end)
C1
C10
#C22
C23
C31
Connector B
(Harness end)
#B16
T183-05-04-021
T5-6-103
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check in CAN Harness
IMPORTANT: Before continuity check, turn the key
switch OFF.
In case of continuity, the circuit between CAN (High side) circuit and
CAN (Low side) circuit is shorted.
In case of discontinuity, the circuit is
normal.
• Connector MC-C
• Connector Monitor Unit-B
Check for continuity between terminals #C4 and
#C15 (harness end) of connector MC-C in MC.
Check for continuity between terminals #B6 and
#B7 (harness end) of connector monitor B in the
monitor unit.
Monitor Unit Connector Monitor-B
(Harness end)
MC Connector MC-C
(Harness end)
#C4
#B7
#B6
#C15
C10
C1
C23
C31
T183-05-04-013
• Connector 2 of Steering Column Monitor
• Connector ECM
Check for continuity between terminals #1 and #9
(harness end) of connector 2.
Check for continuity between terminals #18 and
#37 (harness end) of connector ECM.
ECM Connector
(Harness end)
Steering Column Monitor Connector 2
(Harness end)
#18
#37
#9
#1
TCJB-05-06-001
T1GR-05-04-002
• Connector C of Option Controller
Check for continuity between terminals #C10 and
#C22 (harness end) of connector C.
• Connector ICF-C
Check for continuity between terminals #C5 and
#C11 (harness end) of connector ICF-C in ICF.
ICF Connector ICF-C
(Harness end)
#C5
Option Controller Connector C
(Harness end)
C1
C10
#C10
#C22
C23
#C11
T1V1-05-04-002
T5-6-104
C31
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11100
Fault Code
Trouble
11100-2 Abnormal Engine Speed
Cause
-1
Engine speed: 4000 min or more
• Actual engine speed which ECM sends by using
CAN bus line.
Diagnose ECM.
T5-6-105
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11101
Fault Code
Trouble
Cause
11101-3 Abnormal Engine Control Dial Voltage: more than 4.78 V
Sensor High Voltage
11101-4 Abnormal Engine Control Dial Voltage: less than 0.22 V
Sensor Low Voltage
Check if voltage between terminals #1 and
YES #3 (harness end) of
connector of switch
panel is 5±0.5 V.
1. With connector of switch
panel connected, insert
a test probe into the
back side of connector
in terminal #2.
When rotating engine
control dial, check if
voltage becomes specification.
Disconnect connector
MC-C of MC.
YES Check for continuity
between terminal #C1
(harness end) of
connector and terminal #2 (harness end)
of switch panel.
Check if voltage between terminal #1
(harness end) of
connector of switch
panel and machine
becomes specification.
· Key switch: ON
NO
2. Disconnect connector of
switch panel. Check if
resistance between terminals #1 and #3 (switch
panel end) of connector
is 5±0.5 kΩ.
To A
Open circuit in harness between MC
YES and engine control
dial (terminal #3).
NO
Connector (Harness end of connector viewed from the
open end side)
A
Check if voltage between
terminal #C1 (harness
end) of connector MC-C
and machine is 0 V.
· Key switch: ON
MC Connector MC-C
#C1
C10
C31
Switch Panel
#3 #2
Open circuit in harness between MC
and engine control
dial (terminal #1).
Faulty engine control
dial.
NO
Specification of Engine Control Dial
Slow Idle
0.3 to 1.0 V
Fast Idle
4.0 to 4.7 V
C23
Open circuit in harness between MC
and engine control
dial.
YES
· Key switch: ON
· Specification: 5±0.5 V
· Specification: Refer to
the following table.
C1
NO
#1
T5-6-106
YES Faulty MC.
NO
Shorted circuit in
harness between MC
and engine control
dial.
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11200
Fault Code
11200-3
11200-4
Trouble
Cause
Abnormal Pump 1 Delivery Pressure Voltage: more than 4.5 V
Sensor High Voltage
Abnormal Pump 1 Delivery Pressure Voltage: less than 0.25 V
Sensor Low Voltage
Switch pump 1 delivery
pressure sensor with
pump 2 delivery pressure sensor and retry.
Check if fault code is
switched.
Disconnect connector
of pump 1 delivery
pressure sensor.
NO Check if voltage between terminals #1 and
#3 (harness end) of
connector is 5±0.5 V.
· Key switch: ON
Disconnect connector
MC-D of MC.
Check for continuity beNO
tween terminal #D10
(harness end) of conYES nector and terminal #2
(harness end) of connector of pump 1 delivery
pressure sensor.
YES
Check if voltage between terminal #1 (harness end) of connector
YES
of pump 1 delivery
pressure sensor and
machine becomes
NO specification.
NO
· Key switch: ON
· Specification: 0.25 V or more,
4.5 V or less
To A
Open circuit in harness between MC
and pump 1 delivery
pressure sensor
(terminal #3).
Open circuit in harness between MC
and pump 1 delivery
pressure sensor
(terminal #1).
Faulty pump 1 delivery pressure sensor.
YES
A
Check if voltage between
terminal #D10 (harness
end) of connector MC-D
and machine is 0 V.
· Key switch: ON
Connector (Harness end of connector viewed from the open end side)
MC Connector MC-D
Open circuit in harness between MC
and pump 1 delivery
pressure sensor.
Pump 1 Delivery Pressure Sensor
#D10
3
2
1
T183-05-04-009
T5-6-107
YES Faulty MC.
NO
Shorted circuit in
harness between MC
and pump 1 delivery
pressure sensor.
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11202
Fault Code
11202-3
11202-4
Trouble
Cause
Abnormal Pump 2 Delivery Pressure Voltage: more than 4.5 V
Sensor High Voltage
Abnormal Pump 2 Delivery Pressure Voltage: less than 0.25 V
Sensor Low Voltage
Disconnect connector
MC-D of MC.
Check for continuity
between terminal #D4
(harness end) of conYES nector and terminal #2
(harness end) of connector of pump 2 delivery pressure sensor.
Switch pump 1 delivery
pressure sensor with
pump 2 delivery pressure sensor and retry.
Check if fault code is
switched.
Disconnect connector
NO of pump 2 delivery
pressure sensor.
Check if the voltage
between terminal #1
and #3 (harness end)
of connector is 5±0.5
V.
NO
To A
YES
Check if voltage between terminal #1
(harness end) of
connector of pump 2
delivery pressure
sensor and machine
becomes specification.
NO
· Key switch: ON
Open circuit in harness between MC
YES and pump 2 delivery
pressure sensor
(terminal #3).
NO
· Key switch: ON
· Specification: 0.25 V or more,
4.5 V or less
Open circuit in harness between MC
and pump 2 delivery
pressure sensor
(terminal #1).
Faulty pump 2 delivery pressure sensor.
YES
A
Check if voltage between
terminal #D4 (harness end)
of connector MC-D and
machine is 0 V.
· Key switch: ON
Connector (Harness end of connector viewed from the open end side)
MC Connector MC-D o
Open circuit in harness between MC
and pump 2 delivery
pressure sensor.
Pump 2 Delivery Pressure Sensor
#D4
3
2
1
T183-05-04-009
T5-6-108
YES Faulty MC.
NO
Shorted circuit in
harness between MC
and pump 2 delivery
pressure sensor.
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11203
Fault Code
11203-3
11203-4
Trouble
Cause
Abnormal Pump 3 Delivery Pressure Voltage: more than 4.5 V
Sensor High Voltage
Abnormal Pump 3 Delivery Pressure Voltage: less than 0.25 V
Sensor Low Voltage
Switch pump 3 delivery
pressure sensor with
pump 2 delivery pressure sensor and retry.
Check if fault code is
switched.
Disconnect connector
of pump 3 delivery
pressure sensor.
NO Check if voltage between terminals #1 and
#3 (harness end) of
connector is 5±0.5 V.
· Key switch: ON
Disconnect connector
MC-D of MC.
Check for continuity
between terminal #D3
(harness end) of conYES
nector and terminal #2
(harness end) of connector of pump 3 delivery pressure sensor.
Check if voltage between terminal #1
(harness end) of connector of pump 3 delivery pressure sensor
and machine becomes
specification.
NO
NO
To A
YES
Open circuit in harness between MC
YES and pump 3 delivery
pressure sensor
(terminal #3).
NO
· Key switch: ON
· Specification: 0.25 V or more,
4.5 V or less
YES
A
Check if voltage between
terminal #D3 (harness end)
of connector MC-D and
machine is 0 V.
· Key switch: ON
Connector (Harness end of connector viewed from the open end side)
MC Connector MC-D
Pump 3 Delivery Pressure
Sensor
#D3
3
2
1
T183-05-04-009
T5-6-109
Open circuit in harness between MC
and pump 3 delivery
pressure sensor.
Open circuit in harness between MC
and pump 3 delivery
pressure sensor
(terminal #1).
Faulty pump 3 delivery pressure sensor.
YES Faulty MC.
NO
Shorted circuit in
harness between MC
and pump 3 delivery
pressure sensor.
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11206
Fault Code
11206-3
11206-4
Trouble
Cause
Abnormal Pump 1 Control Pressure Voltage: more than 4.75 V.
Sensor High Voltage
Abnormal Pump 1 Control Pressure Voltage: less than 0.25 V.
Sensor Low Voltage
Switch pump 1 control
pressure sensor with
pump 2 control pressure
sensor and retry. Check
if fault code is switched.
Disconnect connector
of pump 1 control
pressure sensor.
NO Check if voltage between terminals #1 and
#3 (harness end) of
connector is 5±0.5 V.
· Key switch: ON
Disconnect connector
MC-D of MC.
Check for continuity
between terminal #D11
(harness end) of conYES nector and terminal #2
(harness end) of connector of pump 1 control pressure sensor.
Check if voltage between terminal #1
(harness end) of
connector of pump 1
control pressure
sensor and machine
becomes specification.
NO
NO
To A
YES
Open circuit in harness between MC
YES and pump 1 control
pressure sensor
(terminal #3).
NO
· Key switch: ON
· Specification: 0.25 V or more,
4.75 V or less
YES
A
Check if voltage between
terminal #D11 (harness
end) of connector MC-D
and machine is 0 V.
· Key switch: ON
Connector (Harness end of connector viewed from the open end side)
Pump 1 Control Pressure Sensor
MC Connector MC-D
1
2
3
#D11
T183-05-04-009
T5-6-110
Open circuit in harness between MC
and pump 1 control
pressure sensor.
Open circuit in harness between MC
and pump 1 control
pressure sensor
(Terminal #1).
Faulty pump 1 control
pressure sensor.
YES Faulty MC.
NO
Shorted circuit in
harness between MC
and pump 1 control
pressure sensor.
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11208
Fault Code
11208-3
11208-4
Trouble
Cause
Abnormal Pump 2 Control Pressure Voltage: more than 4.75 V
Sensor High Voltage
Abnormal Pump 2 Control Pressure Voltage: less than 0.25 V
Sensor Low Voltage
Switch pump 1 control
pressure sensor with
pump 2 control pressure
sensor and retry. Check
if fault code is switched.
Disconnect connector
of pump 2 control
pressure sensor.
NO Check if voltage between terminals #1 and
#3 (harness end) of
connector is 5±0.5 V.
· Key switch: ON
Disconnect connector
MC-D of MC.
Check for continuity
between terminal #D14
(harness end) of conYES nector and terminal #2
(harness end) of connector for pump 2 control pressure sensor.
Check if voltage between terminal #1
(harness end) of
connector of pump 2
control pressure
sensor and machine
becomes specification.
NO
NO
To A
YES
Open circuit in harness between MC
YES and pump 2 control
pressure sensor
(terminal #3).
NO
· Key switch: ON
· Specification: 0.25 V or more,
4.75 V or less
Open circuit in harness between MC
and pump 2 control
pressure sensor
(terminal #1).
Faulty pump 2 control
pressure sensor.
YES
A
Check if voltage between
terminal #D14 (harness
end) of connector MC-D
and machine is 0 V.
· Key switch: ON
Connector (Harness end of connector viewed from the open end side)
Pump 2 Control Pressure Sensor
MC Connector MC-D
Open circuit in harness between MC
and pump 2 control
pressure sensor.
#D14
1
2
3
T183-05-04-009
T5-6-111
YES Faulty MC.
NO
Shorted circuit in
harness between MC
and pump 2 control
pressure sensor.
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11301
Fault Code
11301-3
11301-4
Trouble
Abnormal Swing Pilot
Sensor High Voltage
Abnormal Swing Pilot
Sensor Low Voltage
Cause
Pressure Voltage: more than 4.75 V
Pressure Voltage: less than 0.25 V
Disconnect connector
of pressure sensor.
Check if voltage between terminals #1 and
NO
#3 (harness end) of
connector is 5±0.5 V.
Disconnect connector
MC-C of MC.
Check for continuity
between terminal #C13
(harness end) of connector and terminal #2
YES (harness end) of connector of pressure
sensor.
NO
YES
A
To A
Check if voltage between terminal #1
(harness end) of
connector of pressure
sensor and machine
becomes specification.
Open circuit in harness between MC
YES and pressure sensor
(terminal #3).
Open circuit in harness between MC
and pressure sensor
NO
· Key switch: ON
(terminal #1).
· Specification: 0.25 V or more,
4.75 V or less
Faulty pressure sensor.
Check if voltage between
terminal #C13 (harness
end) of connector MC-C
and machine is 0 V.
YES Faulty MC.
Shorted circuit in
harness between MC
and pressure sensor.
· Key switch: ON
Connector (Harness end of connector viewed from the open end side)
MC Connector MC-C
Pressure Sensor (Swing)
#C13
C1
C23
C10
1
2
Open circuit in harness between MC
and pressure sensor.
YES
· Key switch: ON
Switch pressure sensor
with other pressure
sensor and retry. Check
if fault code disappears.
NO
3
C31
T5-6-112
NO
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11302
Fault Code
11302-3
11302-4
Trouble
Cause
Abnormal Boom Raise Pilot Pres- Voltage: more than 4.75 V
sure Sensor High Voltage
Abnormal Boom Raise Pilot Pres- Voltage: less than 0.25 V
sure Sensor Low Voltage
Disconnect connector
of pressure sensor.
Check if voltage between terminal #1 and
NO #3 (harness end) of
connector is 5±0.5 V.
· Key switch: ON
Switch pressure sensor
with other pressure
sensor and retry. Check
if fault code disappears.
Disconnect connector
MC-C of MC.
Check for continuity
YES between terminal #D15
(harness end) of connector and terminal #2
(harness end) of connector of pressure
sensor.
Check if voltage between terminal #1
(harness end) of
connector of pressure
sensor and machine
becomes specificaNO tion.
NO
Open circuit in harness between MC
and pressure sensor.
To A
YES
Open circuit in harYES ness between MC
and pressure sensor
(terminal #3).
Open circuit in harness between MC
and pressure sensor
NO
· Key switch: ON
(terminal #1).
· Specification: 0.25 V or more,
4.75 V or less
Faulty pressure sensor.
YES
A
Check if voltage between
terminal #D15 (harness
end) of connector MC-D
and machine is 0 V.
· Key switch: ON
Connector (Harness end of connector viewed from the open end side)
Pressure Sensor (Boom Raise)
MC Connector MC-D
1
2
3
#D15
T183-05-04-009
T5-6-113
YES Faulty MC.
NO
Shorted circuit in
harness between MC
and pressure sensor.
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11303
Fault Code
11303-3
11303-4
Trouble
Cause
Abnormal Arm Roll-in Pilot Pressure Voltage: more than 4.75 V
Sensor High Voltage
Abnormal Arm Roll-in Pilot Pressure Voltage: less than 0.25 V
Sensor Low Voltage
Disconnect connector
of pressure sensor.
Check if voltage beNO tween terminal #1 and
#3 (harness end) of
connector is 5±0.5 V.
· Key switch: ON
Switch pressure sensor
with other pressure
sensor and retry. Check
if fault code disappears.
Disconnect connector
MC-C of MC.
Check for continuity
YES between terminal #C3
(harness end) of connector and terminal #2
(harness end) of connector of pressure
sensor.
Check if voltage between terminal #1
(harness end) of
connector of pressure
sensor and machine
becomes specificaNO tion.
A
Check if voltage between
terminal #C3 (harness
end) of connector MC-C
and machine is 0 V.
· Key switch: ON
Connector (Harness end of connector viewed from the open end side)
Pressure Sensor
(Arm Roll-In)
#C3
C1
C10
1
C23
Open circuit in harness between MC
and pressure sensor.
To A
YES
Open circuit in harYES ness between MC
and pressure sensor
(terminal #3).
Open circuit in harness between MC
and pressure sensor
NO
· Key switch: ON
(terminal #1).
· Specification: 0.25 V or more,
4.75 V or less
Faulty pressure sensor,
YES
MC Connector MC-C
NO
2
3
C31
T5-6-114
YES Faulty MC,
NO
Shorted circuit in
harness between MC
and pressure sensor.
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11305
Fault Code
11305-3
11305-4
Trouble
Abnormal Travel Forward
Pressure Sensor High Voltage
Abnormal Travel Forward
Pressure Sensor Low Voltage
Cause
Pilot Voltage: more than 4.75 V
Pilot Voltage: less than 0.25 V
Disconnect connector
of pressure sensor.
Check if voltage beNO
tween terminal #1 and
#3 (harness end) of
connector is 5±0.5 V.
Switch pressure sensor
with other pressure
sensor and retry. Check
if fault code disappears.
· Key switch: ON
Disconnect connector
MC-C of MC.
Check for continuity
between terminal #C2
YES
(harness end) of connector and terminal #2
(harness end) of connector of pressure
sensor.
NO
Check if voltage between terminal #1
(harness end) of
connector of pressure
sensor and machine
becomes specification.
A
Check if voltage between
terminal #C2 (harness
end) of connector MC-C
and machine is 0 V.
· Key switch: ON
Connector (Harness end of connector viewed from the open end side)
Pressure Sensor (Travel Forward)
#C2
C1
C10
1
C23
Open circuit in harness between MC
and pressure sensor.
To A
YES
Open circuit in harYES ness between MC
and pressure sensor
(terminal #3).
Open circuit in harness between MC
NO and pressure sensor
· Key switch: ON
(terminal #1).
· Specification: 0.25 V or more,
4.75 V or less
Faulty pressure sensor.
YES
MC Connector MC-C
NO
2
3
C31
T5-6-115
YES Faulty MC.
NO
Shorted circuit in
harness between MC
and pressure sensor.
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11306
Fault Code
11306-3
11306-4
Trouble
Abnormal Travel Reverse
Pressure Sensor High Voltage
Abnormal Travel Reverse
Pressure Sensor Low Voltage
Switch pressure sensor
with other pressure
sensor and retry. Check
if fault code disappears.
Cause
Pilot Voltage: more than 4.75 V
Pilot Voltage: less than 0.25 V
Disconnect connector
MC-C of MC.
Check for continuity
between terminal #C11
(harness end) of conYES nector and terminal #2
(harness end) of connector of pressure
sensor.
Disconnect connector
of pressure sensor.
NO Check if voltage between terminal #1 and
#3 (harness end) of
connector is 5±0.5 V.
Check if voltage between terminal #1
(harness end) of
connector of pressure
sensor and machine
becomes specificaNO tion.
· Key switch: ON
NO
To A
YES
Open circuit in harness between MC
YES
and pressure sensor
(terminal #3).
Open circuit in harness between MC
NO and pressure sensor
· Key switch: ON
(terminal #1).
· Specification: 0.25 V or more,
4.75 V or less
Faulty pressure sensor.
YES
A
Check if voltage between
terminal #C11 (harness end)
of connector MC-C and
machine is 0 V.
· Key switch: ON
Connector (Harness end of connector viewed from the open end side)
MC Connector MC-C
C1
Pressure Sensor (Travel Reverse)
C10
1
2
3
#C11
C23
Open circuit in harness between MC
and pressure sensor.
C31
T5-6-116
YES Faulty MC.
NO
Shorted circuit in
harness between MC
and pressure sensor.
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11307
Fault Code
11307-3
11307-4
Trouble
Cause
Abnormal Front Attachment Pilot Voltage: more than 4.75 V
Pressure Sensor High voltage
Abnormal Front Attachment Pilot Voltage: less than 0.25 V
Pressure Sensor Low voltage
Disconnect connector
of pressure sensor.
Check if voltage between terminal #1 and
NO
#3 (harness end) of
connector is 5±0.5 V.
· Key switch: ON
Switch pressure sensor
with other pressure
sensor and retry. Check
if fault code disappears.
Disconnect connector
MC-C of MC.
Check for continuity
between terminal #C12
YES (harness end) of connector and terminal #2
(harness end) of connector of pressure
sensor.
Check if voltage between terminal #1
(harness end) of connector of pressure
NO sensor and machine
becomes specification.
A
Check if voltage between
terminal #C12 (harness
end) of connector MC-C
and machine.
Check if the voltage is 0 V.
· Key switch: ON
Connector (Harness end of connector viewed from the open end side)
Pressure Sensor (Front Attachment)
#C12
C1
C23
C10
Open circuit in harness between MC
and pressure sensor.
To A
YES
Open circuit in harYES ness between MC
and pressure sensor
(terminal #3).
Open circuit in harness between MC
NO and pressure sensor
· Key switch: ON
(terminal #1).
· Specification: 0.25 V or more,
4.75 V or less
Faulty pressure sensor.
YES
MC Connector MC-C
NO
1
2
3
C31
T5-6-117
YES Faulty MC.
NO
Shorted circuit in
harness between MC
and pressure sensor.
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11310
Fault Code
11310-3
11310-4
Trouble
Cause
Abnormal Brake Pressure Sensor Voltage: more than 4.75 V
High Voltage
Abnormal Brake Pressure Sensor Voltage: less than 0.25 V
Low Voltage
Disconnect the connector of brake pressure
sensor. Check if voltage
NO between terminal #1
and #3 (harness end)
of connectoris 5±0.5 V.
Disconnect connector
MC-C of MC.
Check for continuity
between terminal #D12
YES (harness end) of connector and terminal #2
(harness end) of connector of brake pressure sensor.
· Key switch: ON
Switch brake pressure
sensor with pump 1 delivery pressure sensor
and retry. Check if fault
code is switched.
NO
Check if voltage between terminals #1
(harness end) of connector of brake pressure sensor and machine becomes specification.
NO
To A
YES
Open circuit in harness between MC
YES
and brake pressure
sensor (terminal #3).
NO
· Key switch: ON
· Specification: 0.25 V or more,
4.5 V or less
A
Check if voltage between
terminal #D12 (harness
end) of connector MC-D
and machine is 0 V.
· Key switch: ON
Connector (Harness end of connector viewed from the open end side)
Brake Pressure Sensor
#D12
Open circuit in harness between MC
and brake pressure
sensor (terminal #1).
Faulty brake pressure
sensor.
YES
MC Connector MC-D
Open circuit in harness between MC
and brake pressure
sensor.
3
2
1
T183-05-04-009
T5-6-118
YES Faulty MC.
NO
Shorted circuit in
harness between MC
and brake pressure
sensor.
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11311
Fault Code
11311-3
11311-4
Trouble
Cause
Abnormal Brake Remaining Pres- Voltage: more than 4.75 V
sure Sensor High Voltage
Abnormal Brake Remaining Pres- Voltage: less than 0.25 V
sure Sensor Low Voltage
Disconnect connector
MC-C of MC.
Check for continuity
between terminal #C24
(harness end) of conYES nector and terminal #2
(harness end) of connector of brake remaining pressure sensor.
Disconnect connector
of brake remaining
pressure sensor.
NO Check if voltage between terminals #1 and
#3 (harness end) of
connector is 5±0.5 V.
Replace brake remaining pressure sensor with
pump 1 delivery pressure sensor and retry.
Check if fault code is
switched.
NO
To A
YES
· Key switch: ON
NO
Check if voltage between terminal #1
(harness end) of connector of brake remaining pressure
sensor and machine
becomes specification.
Open circuit in harness between MC
YES and brake remaining
pressure sensor
(terminal #3).
NO
· Key switch: ON
· Specification: 0.25 V or more,
4.5 V or less
A
Check if voltage between
terminal #C24 (harness
end) of connector MC-C
and machine is 0 V.
· Key switch: ON
Connector (Harness end of connector viewed from the open end side)
Brake Remaining Pressure Sensor
C10
C1
3
C23
Open circuit in harness between MC
and brake remaining
pressure sensor
(terminal #1).
Faulty brake remaining pressure sensor.
YES
MC Connector MC-C
Open circuit in harness between MC
and brake remaining
pressure sensor.
2
1
C31
#C24
T5-6-119
YES Faulty MC.
NO
Shorted circuit in
harness between MC
and brake remaining
pressure sensor.
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11400
Fault Code
11400-2
11400-3
11400-4
Trouble
Abnormal Current Feedback of
Maximum Pump 2 Flow Rate Limit
Control Solenoid Valve
Abnormal Feedback High Current of
Maximum Pump 2 Flow Rate Limit
Control Solenoid Valve
Abnormal Feedback Low Current of
Maximum Pump 2 Flow Rate Limit
Control Solenoid Valve
YES
Check for continuity in
harness between MC
and maximum pump 2
flow rate limit control
solenoid valve.
· Between terminal #A22
of connector MC-A in
MC and terminal #1 of
connector in maximum
pump 2 flow rate limit
control solenoid valve.
· Between terminal #A16
of connector MC-A in
MC and terminal #2 of
connector in maximum
pump 2 flow rate limit
control solenoid valve
Cause
Current: Both of Higher than
920 mA or Less than 60 mA
Current: Higher than 920 mA
Current: Less than 56 mA
Switch connectors of
maximum pump 2 flow
rate limit control
solenoid valve and
torque control solenoid
valve.
Check if fault code of
torque control solenoid
valve is displayed.
NO
Faulty maximum pump 2
flow rate limit control
solenoid valve.
Faulty MC.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open end side)
MC
Connector MC-A
#A16
#A22
T183-05-04-008
Maximum Pump 2 Flow Rate
Limit Control Solenoid Valve
T1V1-05-04-003
T5-6-120
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11401
Fault Code
11401-2
11401-3
11401-4
Trouble
Cause
Abnormal Current Feedback of Current: Both of Higher than
Torque Control Solenoid Valve
920 mA or Less than 60 mA
Abnormal Feedback High Current of Current: Higher than 920 mA
Torque Control Solenoid Valve
Abnormal Feedback Low Current of Current: Less than 56 mA
Torque Control Solenoid Valve
YES
Check for continuity in
harness between MC
and torque control
solenoid valve.
· Between terminal #A30
of connector MC-A in
MC and terminal #1 of
connector in torque
control solenoid valve.
· Between terminal #A19
of connector MC-A in
MC and terminal #2 of
connector in torque
control solenoid valve
Switch connectors of
torque control solenoid
valve and maximum
pump 2 flow rate limit
control solenoid valve.
Check if fault code of
maximum pump 2 flow
rate limit control solenoid
valve is displayed.
NO
Faulty torque control
solenoid valve.
Faulty MC.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open end side)
MC
Connector MC-A
#A19
#A30
T183-05-04-008
Torque Control Solenoid Valve
T1V1-05-04-003
T5-6-121
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11403
Fault Code
11403-2
11403-3
11403-4
Trouble
Abnormal Current Feedback of
Solenoid Valve Unit (SC) (Arm
Regeneration)
Abnormal Feedback High Current of
Solenoid Valve Unit (SC) (Arm
Regeneration)
Abnormal Feedback Low Current of
Solenoid Valve Unit (SC) (Arm
Regeneration)
YES
Check for continuity in
harness between MC
and solenoid valve unit
(SC) (arm regeneration).
· Between terminal #A24
of connector MC-A in
MC and terminal #1 of
connector in solenoid
valve unit (SC) (arm
regeneration)
· Between terminal #A18
of connector MC-A in
MC and terminal #2 of
connector in solenoid
valve unit (SC) (arm
regeneration)
Cause
Current: Both of Higher than
920 mA or Less than 60 mA
Current: Higher than 920 mA
Current: Less than 56 mA
Switch connectors of
solenoid valve unit (SC)
(arm regeneration) and
other solenoid valve
unit (SF, SG or SI).
Check if fault code of
switched solenoid valve
unit is displayed.
NO
Faulty solenoid valve unit
(SC) (arm regeneration).
Faulty MC.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open end side)
MC
Connector MC-A
#A24
#A18
T183-05-04-008
Solenoid Valve Unit (SC)
(Arm Regeneration)
T1V1-05-04-003
T5-6-122
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11404
Fault Code
11404-2
11404-3
11404-4
Trouble
Abnormal Current Feedback of
Solenoid Valve Unit (SG) (Relief
Pressure Control)
Abnormal Feedback High Current of
Solenoid Valve Unit (SG) (Relief
Pressure Control)
Abnormal Feedback Low Current of
Solenoid Valve Unit (SG) (Relief
Pressure Control)
Current: Higher than 920 mA
Current: Less than 56 mA
Switch connectors of
solenoid valve unit
(SG) (relief pressure
control) and other
solenoid valve unit (SF,
SC or SI).
Check if fault code of
switched solenoid valve
unit is displayed.
YES
Check for continuity in
harness between MC
and solenoid valve unit
(SG) (relief pressure
control).
· Between terminal #A8
of connector MC-A in
MC and terminal #1 of
connector in solenoid
valve unit (SG) (relief
pressure control)
· Between terminal #A4
of connector MC-A in
MC and terminal #2 of
connector in solenoid
valve unit (SG) (relief
pressure control)
Cause
Current: Both of Higher than
920 mA or Less than 60 mA
NO
Faulty solenoid valve unit
(SG) (relief pressure
control).
Faulty MC.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open end side)
Connector MC-A of MC
#A4
#A8
T183-05-04-008
Solenoid Valve Unit (SG)
(Relief Pressure Control)
T1V1-05-04-003
T5-6-123
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11410
Fault Code
11410-2
11410-3
11410-4
Trouble
Abnormal Current Feedback of
Maximum Pump 1 Flow Rate Limit
Control Solenoid Valve
Abnormal Feedback High Current of
Maximum Pump 1 Flow Rate Limit
Control Solenoid Valve
Abnormal Feedback Low Current of
Maximum Pump 1 Flow Rate Limit
Control Solenoid Valve
YES
Check for continuity in
harness between MC
and maximum pump 1
flow rate limit control
solenoid valve.
· Between terminal #A31
of connector MC-A in
MC and terminal #1 of
connector in maximum
pump 1 flow rate limit
control solenoid valve
· Between terminal #A5
of connector MC-A in
MC and terminal #2 of
connector in maximum
pump 1 flow rate limit
control solenoid valve
Cause
Current: Both of Higher than
920 mA or Less than 60 mA
Current: Higher than 920 mA
Current: Less than 56 mA
Switch connectors of
maximum pump1 flow
rate limit control
solenoid valve and
torque control solenoid
valve.
Check if fault code of
torque control solenoid
valve is displayed.
NO
Faulty maximum pump 1
flow rate limit control
solenoid valve.
Faulty MC.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open side)
MC
Connector MC-A
#A5
#A31
T183-05-04-008
Maximum Pump 1 Flow Rate
Limit Control Solenoid Valve
T1V1-05-04-003
T5-6-124
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11422
Fault Code
11422-2
11422-3
11422-4
Trouble
Abnormal Current Feedback of
Travel Motor Displacement Angle
Control Solenoid Valve
Abnormal Feedback High Current of
Travel Motor Displacement Angle
Control Solenoid Valve
Abnormal Feedback Low Current of
Travel Motor Displacement Angle
Control Solenoid Valve
Current: Higher than 920 mA
Current: Less than 56 mA
Disassemble and check
travel motor displacement
angle control solenoid
valve.
Check for abnormality.
YES
Check for continuity in
harness between MC
and travel motor
displacement angle
control solenoid valve.
· Between terminal #A29
of connector MC-A in
MC and terminal #1 of
connector in travel
motor displacement
angle control solenoid
valve.
· Between terminal #A32
of connector MC-A in
MC and terminal #2 of
connector in travel
motor displacement
angle control solenoid
valve
Cause
Current: Both of Higher than
920 mA or Less than 60 mA
NO
Faulty travel motor
displacement angle
control solenoid valve.
Faulty MC.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open end side)
MC Connector MC-A
#A29
#A32
T183-05-04-008
Travel Motor Displacement Angle Control Solenoid Valve
TCJB-05-06-004
T5-6-125
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11424
Fault Code
11424-2
11424-3
11424-4
Trouble
Abnormal Current Feedback of
Solenoid Valve Unit (SI) (Axle Lock
Selection)
Abnormal Feedback High Current of
Solenoid Valve Unit (SI) (Axle Lock
Selection)
Abnormal Feedback Low Current of
Solenoid Valve Unit (SI) (Axle Lock
Selection)
YES
Check for continuity in
harness between MC
and solenoid valve unit
(SI) (axle lock selection).
· Between terminal #A21
of connector MC-A in
MC and terminal #1 of
connector in solenoid
valve unit (SI) (axle lock
selection).
· Between terminal #A14
of connector MC-A in
MC and terminal #2 of
connector in solenoid
valve unit (SI) (axle lock
selection).
Cause
Current: Both of Higher than
920 mA or Less than 60 mA
Current: Higher than 920 mA
Current: Less than 56 mA
Switch connectors of
solenoid valve unit (SI)
(axle lock selection)
and other solenoid
valve unit (SF, SC or
SG).
Check if fault code of
switched solenoid valve
unit is displayed.
NO
Faulty solenoid valve unit
(SI) (axle lock selection).
Faulty MC.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open end side)
MC Connector MC-A
#A14
#A21
T183-05-04-008
Solenoid Valve Unit (SI)
(Axle Lock Selection)
T1V1-05-04-003
T5-6-126
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11425
Fault Code
11425-2
11425-3
11425-4
Abnormal
Solenoid
Brake)
Abnormal
Solenoid
Brake)
Abnormal
Solenoid
Brake)
Trouble
Cause
Current Feedback of Current: Both of Higher than
Valve Unit (SF) (Work 920 mA or Less than 60 mA
Feedback High Current of Current: Higher than 920 mA
Valve Unit (SF) (Work
Feedback Low Current of Current: Less than 56 mA
Valve Unit (SF) (Work
YES
Check for continuity in
harness between MC
and solenoid valve unit
(SF) (work brake).
· Between terminal #A9
of connector MC-A in
MC and terminal #1 of
connector in solenoid
valve unit (SF) (work
brake).
· Between terminal #A15
of connector MC-A in
MC and terminal #2 of
connector in solenoid
valve unit (SF) (work
brake).
Switch connectors of
solenoid valve unit (SF)
(Work Brake) and other
solenoid valve unit (SC,
SG or SI).
Check if fault code of
switched solenoid valve
unit is displayed.
NO
Faulty solenoid valve unit
(SF) (work brake).
Faulty MC.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open end side)
MC Connector MC-A
#A9
#A15
T183-05-04-008
Solenoid Valve Unit (SF)
(Work Brake)
T1V1-05-04-003
T5-6-127
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODES 11910 TO 11920
Fault Code
11910-2
11911-2
11914-2
11915-2
11918-2
11920-2
Trouble
Actual Engine Speed
Sent from: ECM
Security Signal
Send from: Monitor Unit
Radiator Coolant Temperature
Sent from: ECM
Gate Lock Signal
Send from: Option Controller
Work Mode
Send from: Monitor Unit
Fuel Flow Rate
Sent from: ECM
Cause
Faulty harness
Faulty harness
Faulty harness
Faulty harness
Faulty harness
Faulty harness
NOTE: If fault codes 11910 to 11920 are displayed,
the CAN harness between MC and source
controller may be faulty.
Refer to CAN Harness Check on T5-6-73
to 104 and check the CAN harness.
T5-6-128
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11901
Fault Code
11901-3
11901-4
Trouble
Cause
Hydraulic Oil Temperature Sensor Voltage: more than 4.52 V
High Voltage
Hydraulic Oil Temperature Sensor Voltage: less than 0.23 V
Low Voltage
Disconnect connector of
hydraulic oil temperature
sensor.
Check if resistance at
sensor end connector is
specification.
· Specification: Refer to
the table below.
Connect terminals #1
and #2 (harness end)
of connector in
hydraulic oil
temperature sensor by
YES using a clip.
Disconnect connector
MC-D from MC.
Check for continuity
between terminals #D2
and #D6 (harness end)
of connector MC-D.
Faulty MC.
YES
NO
Connect terminal #D6
(harness end) of
connector MC-D in
MC to machine.
Check for continuity
between terminals #2
(harness end) of
connector in hydraulic
oil temperature
sensor and machine.
Open circuit in harness
YES between MC and
hydraulic oil temperature
sensor (terminal #1).
NO
Faulty hydraulic oil
temperature sensor.
NO
Specification of Hydraulic Oil Temperature Sensor
Resistance (kΩ)
Hydraulic Oil
Temperature
°C (°F)
-20 (-4)
16.2±1.6
0 (32)
(5.88)
20 (68)
2.45±0.24
40 (104)
(1.14)
60 (140)
(0.534)
80 (176)
0
Connector (Harness end of connector viewed from the open end side)
MC Connector MC-D
#D2
Hydraulic Oil Temperature Semsor
1
#D6
Open circuit in harness
between MC and
hydraulic oil temperature
sensor (terminal #2).
T183-05-04-009
T5-6-129
2
TROUBLESHOOTING / Troubleshooting A
ECM FAULT CODES 100 TO 190
NOTE: If ECM fault code is displayed, refer to the
other manual "Engine Troubleshooting
Manual" and check the engine.
Fault Code
100-3
100-4
102-3
102-4
105-3
105-4
108-3
108-4
110-0
110-3
110-4
157-0
157-0
157-2
157-3
157-4
172-3
172-4
174-3
174-4
190-0
Trouble
Abnormal Engine Oil Pressure Sensor (Abnormal Low
Voltage)
Abnormal Engine Oil Pressure Sensor (Abnormal High
Voltage)
Abnormal Boost Pressure Sensor (Abnormal Low Voltage)
Abnormal Boost Pressure Sensor (Abnormal High Voltage)
Abnormal Boost Temperature Sensor (Abnormal High
Voltage)
Abnormal Boost Temperature Sensor (Abnormal Low Voltage)
Abnormal Atmospheric Pressure Sensor (Abnormal Low
Voltage)
Abnormal Atmospheric Pressure Sensor (Abnormal High
Voltage)
Overheating
Abnormal Coolant Temperature Sensor (Abnormal High
Voltage)
Abnormal Coolant Temperature Sensor (Abnormal Low
Voltage)
Abnormal Common Rail Pressure (First stage)
Abnormal Common Rail Pressure (Second stage)
Abnormal Common Rail Pressure (Pump Over-Pressure)
Abnormal Common Rail Pressure Sensor (Abnormal High
Voltage)
Abnormal Common Rail Pressure Sensor (Abnormal Low
Voltage)
Abnormal Intake Air Temperature Sensor (Abnormal High
voltage)
Abnormal Intake Air Temperature Sensor (Abnormal Low
Voltage)
Abnormal Fuel Temperature Sensor (Abnormal High Voltage)
Abnormal Fuel Temperature Sensor (Abnormal Low Voltage)
Overrunning
T5-6-130
Fault Code
(TECH2)
Engine
Troubleshooting
Manual
Reference Page
P0522
1E-393
P0523
1E-399
P0237
P0238
1E-331
1E-339
1E-450
P1113
P1112
1E-443
P0107
1E-228
P0108
1E-235
P1173
1E-456
P0118
1E-261
P0117
1E-255
P0088
P0088
P0089
1E-212
1E-212
1E-217
P0193
1E-287
P0192
1E-281
P0113
1E-247
P0112
1E-241
P0183
P0182
P0219
1E-274
1E-268
1E-329
TROUBLESHOOTING / Troubleshooting A
ECM FAULT CODES 628 TO 1485
Fault Code
Trouble
628-2
633-7
636-2
636-2
636-7
639-2
639-3
651-3
652-3
653-3
654-3
723-2
723-2
987-3
1077-2
1079-2
1080-2
1239-1
1240-1
Abnormal ROM
Pressure Limiter Open
Abnormal Cam Angle Sensor (No Signal)
Abnormal Cam Angle Sensor (Abnormal Signal)
Phase Mismatch of Cam Angle Sensor
Abnormal CAN Bus Line
Abnormal CAN Time Out
Open Circuit in Injection Nozzle #1 Drive System
Open Circuit in Injection Nozzle #2 Drive System
Open Circuit in Injection Nozzle #3 Drive System
Open Circuit in Injection Nozzle #4 Drive System
Abnormal Crank Speed Sensor (No Signal)
Abnormal Crank Speed Sensor (Abnormal Signal)
Abnormal Check Engine Lamp
Abnormal IC for CPU Watching
Abnormal 5 V Power Source 1 Voltage
Abnormal 5 V Power Source 2 Voltage
No pressure to pump (Fuel leakage)
No pressure to pump (Fuel leakage)
Open Circuit in Suction Control Valve Drive System,
Shorted circuit in +B or GND.
Abnormal Main Relay System (ON is impossible.)
1347-0
1485-2
P0601
P1095
P0340
P0341
P1345
U2104
U2106
P0201
P0202
P0203
P0204
P0335
P0336
P0650
P0606
P1631
P1632
P0087
P1093
Engine
Troubleshooting
Manual
Reference Page
1E-407
1E-433
1E-358
1E-365
1E-512
1E-541
1E-546
1E-294
1E-300
1E-306
1E-312
1E-346
1E-352
1E-419
1E-411
1E-526
1E-529
1E-204
1E-424
P0090
1E-222
P1625
1E-517
Fault Code
(TECH2)
IMPORTANT: When fault code 723-2 (abnormal
crank speed sensor) is displayed
and the engine does not start, the
cam angle sensor is faulty although
fault codes 636-2 (abnormal cam
angle sensor) and 636-7 (phase
mismatch of cam angle sensor) are
not displayed.
T5-6-131
TROUBLESHOOTING / Troubleshooting A
ECM FAULT CODES 10001 TO 10013
Fault Code
10001-3
10002-2
10003-2
10004-2
10005-1
10006-1
10007-2
10008-2
10009-2
10010-2
10011-2
10013-2
Fault Code
(TECH2)
Trouble
Abnormal EGR Position (Brushless spec.)
Abnormal EGR Valve Control
Abnormal Injection Nozzle Common 1 Drive System
Abnormal Injection Nozzle Common 2 Drive System
Abnormal Charge Circuit (Bank 1)
Abnormal Charge Circuit (Bank 2)
Abnormal CPU
Abnormal A/D Conversion
5 V Power Source 3 Voltage
5 V Power Source 4 Voltage
5 V Power Source 5 Voltage
Abnormal EEPROM
T5-6-132
P0487
P0488
P1261
P1262
P0611
P0612
P0606
P1630
P1633
P1634
P1635
P0603
Engine Troubleshooting
Manual
Reference Item
1E-381
1E-387
1E-466
1E-476
1E-413
1E-416
1E-411
1E-524
1E-532
1E-535
1E-538
1E-409
TROUBLESHOOTING / Troubleshooting A
ICF FAULT CODES 14000 TO 14003
Fault Code
Trouble
14000-2 Abnormal CAN Communication
14001-2
14002-2
Flash Memory: Read / Write Error
External RAM: Read / Write Error
14003-2
EEPROM: Sum Check Error
Remedy
Execute retry B in self-diagnosing.
If this error code is displayed after retrial, check the following
item.
• Check the CAN communication line (harness).
Execute retry B in self-diagnosing and execute the following
item.
• Execute “Information C/U: Initialize”.
Execute retry B in self-diagnosing.
If this error code is displayed after retrial, check the following
item.
• Execute “Control Data: Initialize”.
• Execute “Enter Model and Serial No.”.
Then, execute self-diagnosing and execute retry B.
T5-6-133
TROUBLESHOOTING / Troubleshooting A
INFORMATION C/U: INITIALIZE
After starting Dr. ZX, push Select
Controller.
Push Information C/U.
Push OK.
To the
lower
Function Selection Screen
T1V7-05-03-001
Controller Selection Screen
Push Information
Setup.
Push Start.
C/U:
T1V7-05-03-009
Various
ICF Controller Screen
T1V7-05-03-024
Push Information C/U: Initialize.
To the
lower
Title Screen
T1V7-05-03-025
Push Init and the controller
operating data is initialied. Push
ESC and return to Information C/U:
Various Setup Screen.
Main Menu Screen
T1V7-05-03-026
Push OK and return to Information
C/U: Various Setup Screen.
Information C/U: Various Setup
Screen
T1V7-05-03-027
Push ESC and return to Main
Menu Screen.
Init
ESC
T1V7-05-03-028
T1V7-05-03-029
Information C/U: Initialize Screen
T1V7-05-03-027
Information C/U: Various Setup
Screen
T5-6-134
TROUBLESHOOTING / Troubleshooting A
CONTROL DATA: INITIALIZE
After starting Dr. ZX, push Select
Controller.
Push OK.
Push Information C/U.
To the
lower
Function Selection Screen
T1V7-05-03-001
T1V7-05-03-009
Push Information
Setup.
Push Start.
C/U:
T1V7-05-03-024
ICF Controller Screen
Controller Selection Screen
Various
Push Control Data: Initialize.
To the
lower
Title Screen
T1V7-05-03-025
Push Init and the controller control
data is initialied. Push ESC and
return to Information C/U: Various
Setup Screen.
T1V7-05-03-026
Main Menu Screen
Information C/U: Various Setup
Screen
Push OK and return to Information
C/U: Various Setup Screen.
Push ESC and return to Main
Menu Screen.
T1V7-05-03-027
Init
ESC
T1V7-05-03-033
T1V7-05-03-034
Control Data: Initialize Screen
T1V7-05-03-027
Information C/U: Various Setup
Screen
T5-6-135
TROUBLESHOOTING / Troubleshooting A
ENTER MODEL AND SERIAL No.
After starting Dr. ZX, push Select
Controller.
Push Information C/U.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1V7-05-03-024
Function Selection Screen
Controller Selection Screen
ICF Controller Screen
Push Start.
Push Information
Setup.
Push Enter Model and Serial No.
C/U:
Various
To the
lower
T1V7-05-03-025
T1V7-05-03-026
Title Screen
Main Menu Screen
Push Exec and model and serial
No. can be input.
Push
ESC
and
return
to
Information C/U: Various Setup
Screen.
Push OK after inputting model and
serial No. and return to Enter
Model and Serial No. Screen.
Push
ESC
and
return
to
Information C/U: Various Setup
Screen.
T1V7-05-03-027
Information C/U: Various Setup
Screen
Push ESC and return to Main
Menu Screen.
ESC
Exes
ESC
OK
T1V7-05-03-030
T1V7-05-03-031
T1V7-05-03-027
Information C/U: Various Setup
Screen
Enter Model and Serial No. Screen
T5-6-136
TROUBLESHOOTING / Troubleshooting A
ICF FAULT CODES 14006, 14008
Fault Code
Trouble
14006-2 ICF: Satellite Communication
Terminal: Communication Error
14008-2
Remedy
Execute retry B in self-diagnosing.
If this error code is displayed after retrial, check the following
item.
• Check the communication line.
• Check the power source line of satellite terminal.
• Check the fuse.
Then, execute self-diagnosing and execute retry B.
Execute retry B in self-diagnosing.
If this error code is displayed after retrial, replace the
controller.
ICF: Abnormal Internal RAM
Fault Code 14006-2
• Check the communication line
1. Check for continuity between terminal #A8
(harness end) of connector ICF-A in ICF and
terminal #10 (harness end) of connector A in
satellite terminal.
2. Check for continuity between terminal #A9
(harness end) of connector ICF-A in ICF and
terminal #20 (harness end) of connector A in
satellite terminal.
3. Check for continuity between terminal #A31
(harness end) of connector ICF-A in ICF and
terminal #2 (harness end) of connector B in
satellite terminal.
Connector (Harness end of connector viewed from the
open end side)
• Check the power source line of satellite terminal
1. Check the battery power
Check if voltage between terminal #2 (harness
end) of connector A in satellite terminal and
machine is 24 V.
2. Check the main power
With the key switch ON, check if voltage between
terminal #1 (harness end) of connector A in
satellite terminal and machine is 24 V.
3. Check the ground circuit
Check for continuity between terminals #11 and
#12 (harness end) of connector A in satellite
terminal.
T5-6-137
ICF
Connector ICF-A
#A8
#A9
#A31
Satellite Terminal
Connector A
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
Satellite Terminal
Connector B
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
TROUBLESHOOTING / Troubleshooting A
SATELLITE TERMINAL FAULT CODES 14100 TO 14106
Fault Code
Trouble
14100-2 Abnormal EEPROM
14101-2 Abnormal IB/OB Queue
Remedy
Execute retry B in self-diagnosing.
If this error code is displayed after retrial, replace the
controller.
Check the communication antenna of satellite terminal.
14102-2
14103-2
14104-2
14105-2
Abnormal Local Loop Back
Satellite cannot be found.
Remote Loop Back Failure 1
Remote Loop Back Failure 2
14106-2
Received data is not same with sent
data.
Execute retry B in self-diagnosing.
If this error code is displayed after retrial, replace the
controller.
Satellite Terminal
• Fault Codes 14102-2 and 14103-2
TCJB-05-04-001
Communication
Antenna
GPS Antenna
T1V1-05-06-004
T5-6-138
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13303
Fault Code
Trouble
13303-2 Abnormal Thermistor Temperature
Remedy
Cool the monitor unit and so on until the internal temperature
of monitor unit is less than 85 °C (185 °F).
• The screen of monitor unit becomes dark.
YES
YES
Normal.
Cool monitor unit. Check
if the screen of monitor
unit becomes normal.
Faulty monitor unit.
Check if temperature
around monitor unit is
high.
NO
Faulty monitor unit.
NO
T5-6-139
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13304
Fault Code
Trouble
13304-2 Abnormal REG Input H Level
• Check the wiring connections first.
Remedy
Refer to the following.
NOTE: *As terminal L in the regulator is a
waterproof type connector, it is difficult to
measure voltage.
Measure voltage at terminal R in starter
relay.
Check for continuity at terminal R in starter
relay and terminal L in the regulator in
advance.
Less than 33.5 V
Less than
33.5 V
Measure voltage at
terminal #C7 of
connector monitor-C.
· Engine: Running
Measure voltage at
terminal L *in
regulator.
33.5 V or higher
Connector (Harness end of connector viewed from the
open end)
Starter Relay
E
R
Monitor Unit
Connector Monitor-C
6
12
Open circuit in harness
between terminal L in
regulator and monitor
unit.
Faulty regulator or faulty
alternator.
33.5 V or higher
S
Faulty monitor unit.
1
7
#C7
T5-6-140
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODES 13306 AND 13308
Fault Code
Trouble
13306-2 Abnormal EEPROM
13308-2
Abnormal CAN Communication
Remedy
Replace the monitor unit when displaying the fault code after
retrial.
Refer to CAN Harness Check (T5-6-73 to 104).
T5-6-141
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13310
Fault Code
Trouble
13310-2 Shorted
Circuit
in
Temperature Sensor
YES
Check if resistance of
coolant temperature
sensor is specification.
Remedy
Coolant Check the coolant temperature sensor and harness.
With terminal of coolant
temperature sensor
disconnected, disconnect
connector monitor-C in
monitor unit.
Check for continuity between
terminal #C8 (harness end) of
connector in monitor unit and
machine.
Shorted circuit in harness
between monitor unit and
sensor.
Faulty monitor unit.
NO
Faulty coolant temperature
sensor.
NO
Coolant Temperature Sensor
Coolant Temperature °C
Resistance
(°F)
(kΩ)
25 (77)
7.6±0.76
40 (104)
4.0±0.35
50 (122)
2.7±0.22
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 of connector viewed from the
open end side)
Monitor Unit
Connector Monitor-C
6
12
YES
1
7
#C8
T5-6-142
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13311
Fault Code
Trouble
13311-3 Shorted Circuit in Fuel Level Sensor
13311-4 Open Circuit in Fuel Level Sensor
Remedy
Check fuel level sensor and harness.
Check fuel level sensor and harness.
Shorted circuit in harness
between monitor unit and
sensor.
YES
With connector of fuel
level sensor
YES disconnected, disconnect
connector monitor-C in
monitor unit.
Check for continuity
between terminal #C2
(harness end) of
connector in monitor unit
and machine.
Check if resistance of
fuel level sensor is
specification.
NO
Connect terminal #1
(harness end) of
connector in fuel level
sensor to machine.
Check for continuity
between terminal #C2
(harness end) of
connector in monitor unit
and machine.
YES Faulty monitor unit.
NO
Open circuit in harness
between monitor unit and
sensor.
Faulty fuel level sensor.
NO
Fuel Sensor
Float Position
Upper Limit (FULL)
3/4
1/2
1/4
Alarm Level
Lower Limit (EMPTY)
Float
FULL
R381.9
257 mm
3/4
Resistance (Ω)
+0
10 -4
26
38±5
53
85±3
+10
90 -0
93 mm
Connector (Harness end of connector viewed from the
open end)
70.5 mm
204 mm
338 mm
1/2
Monitor Unit
Connector Moniter-C
Fuel Sensor
1/4
#C2
EMPTY
T178-05-05-001
T5-6-143
6
12
1
7
1
2
TROUBLESHOOTING / Troubleshooting A
PILOT SHUT-OFF LEVER ALARM
Pilot shut-off lever alarm is displayed on the
monitor unit screen.
YES
Faulty pilot shut-off
switch.
Check if pilot shut-off
switch is bent or
damaged.
Faulty harness.
NO
Pilot Shut-Off
Lever
Pilot Shut-Off
Switch
T1V1-05-06-005
T5-6-144
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODES 15500 TO 15504
Fault Code
Trouble
15500-4
Abnormal External Reference Voltage
15501-2
Abnormal Read of Initial Setting Value
(EEPROM)
15502-2
Abnormal EEPROM
15503-2
Abnormal RAM
15504-2
Abnormal A/D Conversion
Cause
Faulty controller
Faulty controller
Faulty controller
Faulty controller
Faulty controller
YES
* Faulty option controller.
Check if engine and machine
operate normally
Faulty option controller.
NO
* After retrial, if the engine and the machine operate
normally with the fault code shown, the machine
can be operated.
T5-6-145
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15505
Fault Code
15505-2
Trouble
Abnormal CAN Communication
Cause
Faulty controller
Faulty CAN harness
NOTE: If fault code 15505 is displayed, the CAN
harness between MC and source controller
may be faulty.
Refer to CAN Harness Check on T5-6-73
to 104 and check the CAN harness.
T5-6-146
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15506
Fault Code
15506-3
Trouble
Abnormal Sensor Voltage
Cause
Faulty controller
Faulty sensor
Faulty harness
YES
Disconnect all sensor
connectors for displayed
fault code and retry.
Check if fault code
15506-3 disappears.
NO
Faulty sensor.
Disconnect all
connectors at option
controller side.
Check for continuity
between terminals #1
and #3 (harness end) of
connector.
· Key switch: OFF
YES
Shorted circuit in harness with
continuity between MC and
sensor.
Faulty MC.
NO
Connector (Harness end of connector viewed from the
open end side)
• Electric Lever (Blade/Outrigger,
• Pressure Sensor (Positioning) (Optional)
• Pressure Sensor (Auxiliary) (Optional)
Auxiliary/Positioning)
T1V1-05-07-102
TCJB-05-06-005
T5-6-147
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15510
Fault Code
15510-3
15510-4
Trouble
Cause
Abnormal Assist Stroke 1 Sensor High Voltage: more than 4.65 V
Voltage
Abnormal Assist Stroke 1 Sensor Low Voltage: less than 0.35 V
Voltage
YES
Disconnect connector of
right grip.
Check if voltage
between terminals #5
and #7 (harness end) of
connector is 5±0.5 V.
Disconnect connector
C of option controller.
Check for continuity
between terminal #C1
(harness end) of
connector and terminal
#7 (harness end) of
connector of right grip.
YES
Check if voltage
between terminal # C
20 (harness end) of
connector C of option
controller and machine
0 V.
NO
Check if voltage
between terminal #7
(harness end) of
connector for right grip
and machine is
specification.
YES
NO
Connector (Harness end of connector viewed from the open end side)
Option Controller Connector C
Right Grip Connector
#C20
C23
C10
C31
TCJB-05-06-006
T5-6-148
Faulty option
controller.
Shorted circuit in
harness between
option controller and
right grip (assist
switch).
Open circuit in
harness between
option controller and
right grip (assist
switch).
· Key switch: ON
· Specification: 0.25 V or more,
4.75 V or less
#C1 C1
NO
· Key switch: ON
NO
· Key switch: ON
YES
Open circuit in
harness between
option controller and
right grip (assist
switch) (terminal #5).
Open circuit in
harness between
option controller and
right grip (assist
switch) (terminal #7).
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15511
Fault Code
15511-3
15511-4
Trouble
Cause
Abnormal Assist Stroke 2 Sensor High Voltage: more than 4.65 V
Voltage
Abnormal Assist Stroke 2 Sensor Low Voltage: less than 0.35 V
Voltage
YES
YES
Disconnect connector of
right grip.
Check if voltage
between terminals #5
and #7 (harness end) of
connector is 5±0.5 V.
Disconnect connector
C of option controller.
Check for continuity
between terminal #C
(harness end) of
connector and terminal
#7 (harness end) of
connector of right grip.
Check if voltage
between terminal #C6
(harness end) of
connector C of option
controller and machine
is 0 V.
NO
Check if voltage
between terminals #7
(harness end) of
connector of right grip
and machine is
specification.
YES
NO
Connector (Harness end of connector viewed from the open end side)
Option Controller Connector C
Right Grip Connector
#C6
C23
C10
C31
TCJB-05-06-006
T5-6-149
Faulty option
controller.
Shorted circuit in
harness between
option controller and
right grip (assist
switch).
Open circuit in
harness between
option controller and
right grip (assist
switch).
· Key switch: ON
· Specification: 0.25 V or more,
4.75 V or less
#C1 C1
NO
· Key switch: ON
NO
· Key switch: ON
YES
Open circuit in
harness between
option controller and
right grip (assist
switch) (terminal #5).
Open circuit in
harness between
option controller and
right grip (assist
switch) (terminal #7).
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15514
Fault Code
15514-3
15514-4
Trouble
Cause
Abnormal Positioning/Auxiliary Stroke 1 Voltage: more than 4.55 V
Sensor High Voltage
Abnormal Positioning/Auxiliary Stroke 1 Voltage: less than 0.45 V
Sensor Low Voltage
YES
Disconnect connector
of electric lever
(auxiliary/positioning).
Check if voltage
between terminals #2
and #4 (harness end)
of connector is 5±0.5 V.
Disconnect connector C
of option controller.
Check for continuity
between terminal #C1
(harness end) of
connector and terminal
#2 (harness end) of
connector of electric
lever
(auxiliary/positioning).
YES
Check if voltage
between terminal
#C19 (harness end) of
connector C option
controller and machine
0 V.
NO
Check if voltage
between terminal #2
(harness end) of
connector of electric
lever
(auxiliary/positioning)
and machine is
specification.
Connector (Harness end of connector viewed from the open end side)
Option Controller Connector C
Electric Lever (Auxiliary/Positioning)
#C19
C23
C10
C31
TCJB-05-06-005
T5-6-150
Faulty option controller.
Shorted circuit in
harness between
option controller and
electric lever
(auxiliary/positioning).
Open circuit in harness
between option
controller and electric
lever
(auxiliary/positioning).
· Key switch: ON
· Specification: 0.25 V or more,
4.75 V or less
#C1 C1
NO
· Key switch: ON
NO
· Key switch: ON
YES
YES
Open circuit in between
option controller and
electric lever
(auxiliary/positioning)
(terminal #4).
NO
Open circuit in n
harness between
option controller and
electric lever
(auxiliary/positioning)
(terminal #2).
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15515
Fault Code
15515-3
15515-4
Trouble
Cause
Abnormal Positioning/Auxiliary Stroke 2 Voltage: more than 4.85 V
Sensor High Voltage
Abnormal Positioning/Auxiliary Stroke 2 Voltage: less than 0.15 V
Sensor Low Voltage
YES
Disconnect connector
of electric lever
(auxiliary/positioning).
Check if voltage
between terminals #2
and #4 (harness end) of
connector is 5±0.5 V.
Disconnect connector C
of option controller.
Check for continuity
between terminal #C1
(harness end) of
connector and terminal
#2 (harness end) of
connector of electric
lever
(auxiliary/positioning).
YES
Check if voltage
between terminals
#C17 (harness end) of
connector C of option
controller and
machine.
Check if voltage is 0 V.
NO
Check if voltage
between terminal #2
(harness end) of
connector of electric
lever
(auxiliary/positioning)
and machine is
specification.
YES
NO
Connector (Harness end of connector viewed from the open end side)
Option Controller Connector C
Electric Lever (Auxiliary/Positioning)
#C17
C23
C10
C31
TCJB-05-06-005
T5-6-151
Faulty option controller.
Shorted circuit in
harness between
option controller and
electric lever
(auxiliary/positioning).
Open circuit in harness
between option
controller and electric
lever
(auxiliary/positioning).
· Key switch: ON
· Specification: 0.25 V or more,
4.75 V or less
#C1 C1
NO
· Key switch: ON
NO
· Key switch: ON
YES
Open circuit in harness
between option
controller and electric
lever
(auxiliary/positioning)
(terminal #4).
Open circuit in harness
between option
controller and electric
lever
(auxiliary/positioning)
(terminal #2).
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15516
Fault Code
15516-3
15516-4
Trouble
Abnormal Positioning/Assist Pi pressure
Sensor High Voltage
Abnormal Positioning/Assist Pi pressure
Sensor Low Voltage
Disconnect connector
of pressure sensor.
Check if voltage
between terminals #1
NO and #3(harness end) of
connector is 5±0.5 V.
· Key switch: ON
Switch pressure sensor
with other pressure
sensor and retry. Check
if fault code disappears.
Cause
Voltage: more than 4.60 V
Voltage: less than 0.40 V
Disconnect connector C
of option controller.
Check for continuity
YES
between terminal #C16
(harness end) of
connector and terminal
#2 (harness end) of
connector of pressure
sensor.
Check if voltage
between terminal #1
(harness end) of
connector of pressure
sensor and machine is
NO specification.
NO
To A
YES
YES Open circuit in harness
between option
controller and pressure
sensor (terminal #3).
Open circuit in harness
between option
· Key switch: ON
NO controller and pressure
· Specification: 0.25 V or more,
sensor (terminal #1).
4.75 V or less
Faulty pressure
sensor.
YES
A
Check if voltage between
terminal #C16 (harness
end) of connector C and
machine is 0 V.
· Key switch: ON
Connector (Harness end of connector viewed from the open end side)
Option Controller Connector C
Pressure Sensor (Positioning)
#C16
C1
C23
Open circuit in harness
between option
controller and pressure
sensor.
C10
T1V1-05-07-102
C31
T5-6-152
YES Faulty option controller.
NO
Shorted circuit in
harness between
option controller and
pressure sensor.
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15517
Fault Code
15517-3
15517-4
Trouble
Abnormal Outrigger/Blade/Auxiliary
Pressure Sensor High Voltage
Abnormal Outrigger/Blade/Auxiliary
Pressure Sensor Low Voltage
Disconnect connector
of pressure sensor.
Check if voltage
between terminals #1
NO and #3 (harness end)
of connector is 5±0.5
V.
· Key switch: ON
Switch pressure sensor
with other pressure
sensor and retry. Check if
fault code disappears.
Cause
Pi Voltage: more than 4.60 V
Pi Voltage: is less than 0.40 V
Disconnect connector C
of option controller.
Check for continuity
YES
between terminal #C15
(harness end) of
connector and terminal
#2 (harness end) of
connector of pressure
sensor.
Check if voltage
between terminal #1
(harness end) of
connector of pressure
sensor and machine is
NO specification.
NO
To A
YES
Open circuit in harness
between option
YES controller and pressure
sensor (terminal #3).
Open circuit in harness
between option
NO controller and pressure
· Key switch: ON
sensor (terminal #1).
· Specification: 0.25 V or more,
4.75 V or less
Faulty pressure
sensor.
YES
A
Check if voltage between
terminal #C15 (harness
end) of connector C and
machine is 0 V.
· Key switch: ON
Connector (Harness end of connector viewed from the open end side)
Option Controller Connector C
Pressure Sensor (Auxiliary)
#C15
C1
C10
T1V1-05-07-102
C23
Open circuit in harness
between option
controller and pressure
sensor.
C31
T5-6-153
YES Faulty option controller.
NO
Shorted circuit in
harness between
option controller and
pressure sensor.
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15518
Fault Code
15518-3
15518-4
Trouble
Cause
Abnormal Outrigger/Blade Stroke 1 Sensor Voltage: more than 4.55 V
High Voltage
Abnormal Outrigger/Blade Stroke 1 Sensor Voltage: less than 0.45 V
Low Voltage
YES
Disconnect connector
of electric lever
(blade/outrigger).
Check if voltage
between terminals #2
and #4 (harness end) of
connector is 5±0.5 V.
Disconnect connector C
of option controller.
Check for continuity
between terminal #C1
(harness end) of
connector and terminal
#2 (harness end) of
connector of electric
lever (blade/outrigger).
YES
Check if voltage
between terminal
#C18 (harness end) of
connector C of option
controller and machine
is 0 V.
· Key switch: ON
NO
Check if voltage
between terminal #2
(harness end) of
connector of electric
lever (blade/outrigger)
and machine is
specification.
· Key switch: ON
· Specification: 0.25 V or more,
4.75 V or less
Connector (Harness end of connector viewed from the open end side)
Option Controller Connector C
Electric Lever (Blade/Outrigger)
#C18
#C1 C1
C23
C10
C31
TCJB-05-06-005
T5-6-154
Faulty option controller.
NO
Shorted circuit in
harness between option
controller and electric
lever (blade/outrigger).
Open circuit in harness
between option
controller and electric
lever (blade/outrigger).
NO
· Key switch: ON
YES
YES
Open circuit in harness
between option
controller and electric
lever (blade/outrigger)
(terminal #4).
NO
Open circuit in harness
between option
controller and electric
lever (blade/outrigger)
(terminal #2).
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15519
Fault Code
15519-3
15519-4
Trouble
Cause
Abnormal Outrigger/Blade Stroke 2 Sensor Voltage: more than 4.85 V
High Voltage
Abnormal Outrigger/Blade Stroke 2 Sensor Voltage: less than 0.15 V
Low Voltage
YES
Disconnect connector of
electric lever
(blade/outrigger).
Check if voltage
between terminals #2
and #4 (harness end) of
connector is 5±0.5 V.
Disconnect connector C
of option controller.
Check for continuity
between terminal #C1
(harness end) of
connector and terminal
#2 (harness end) of
connector of electric
lever (blade/outrigger).
YES
Check if voltage
between terminal
#C28 (harness end) of
connector C of option
controller and machine
is 0 V.
NO
Option Controller Connector C
Check if voltage
between terminal #2
(harness end) of
connector of electric
lever (blade/outrigger)
and machine is
specification.
YES
· Key switch: ON
· Specification: 0.25 V or more,
4.75 V or less
NO
Electric Lever (Blade/Outrigger)
C10
C23
C31
TCJB-05-06-005
#C28
T5-6-155
Faulty option
controller.
Shorted circuit in
harness between
option controller and
electric lever
(blade/outrigger).
Open circuit in
harness between
option controller and
electric lever
(blade/outrigger).
Connector (Harness end of connector viewed from the open end side)
#C1 C1
NO
· Key switch: ON
NO
· Key switch: ON
YES
Open circuit in
harness between
option controller and
electric lever
(blade/outrigger)
(terminal #4).
Open circuit in
harness between
option controller and
electric lever
(blade/outrigger)
(terminal #2).
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15570
Fault Code
Trouble
Cause
15570-2
Abnormal Outrigger/Blade/Auxiliary Neutral When meeting the any following conditions,
outrigger/blade/auxiliary pilot pressure is
more than 1.2 MPa.
(Conditions)
• Outrigger/blade 1 and 2 solenoid valve
output is less than 0.5 MPa
• Auxiliary solenoid valve 1 and 2 output
is less than 0.5 MPa
YES
YES
Set pilot shut-off lever
to LOCK position and
retry.
Check if fault code
disappears.
Disassemble and check
auxiliary solenoid valve
1 or 2.
Check for abnormality.
· Engine: Running
NO
NO
Faulty blade/outrigger solenoid
valve 1 or 2 (stuck spool).
YES
Faulty pressure sensor.
Switch pressure
sensor with other
pressure sensor and
retry. Check if fault
code disappears.
Faulty option controller.
NO
T5-6-156
Faulty auxiliary solenoid valve
1 or 2 (stuck spool).
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15571
Fault Code
Trouble
15571-2
Abnormal Outrigger/Blade/Auxiliary
Operation
Cause
When meeting either of the any following
condition, outrigger/blade/auxiliary pilot
pressure is less than 1.0 MPa.
(Conditions)
• Outrigger/blade 1 and 2 solenoid valve
output is more than 2.2 MPa
• Auxiliary solenoid valve 1 and 2 output
is more than 2.2 MPa
• All of auxiliary solenoid valves 1, 2 and
blade/outrigger solenoid valves 1, 2 may not
become faulty at the same time.
• Therefore when the fault code is displayed, the
pressure sensor or the controller may be faulty.
• Refer to "FAULT CODE 15517".
T5-6-157
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15572
Fault Code
Trouble
15572-2
Abnormal Positioning/Assist Neutral
Cause
When meeting the any following conditions,
positioning/assist pilot pressure is more than
1.2 MPa.
(Conditions)
• Positioning 1 and 2 solenoid valve
output is less than 0.5 MPa
• Assist 1 and 2 solenoid valve output
is less than 0.5 MPa
YES
YES
Disassemble and check
assist solenoid valve 1
or 2.
Check for abnormality.
Set pilot shut-off lever
to LOCK position and
retry.
Check if fault code
disappears.
· Engine: Running
NO
Switch pressure
sensor with other
pressure sensor and
retry.
Check if fault code
disappears.
T5-6-158
Faulty assist solenoid valve 1
or 2 (stuck spool).
NO
Faulty positioning solenoid
valve 1 or 2 (stuck spool).
YES
Faulty pressure sensor.
Faulty option controller.
NO
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15573
Fault Code
Trouble
15573-2
Abnormal Positioning/Assist Operation
Cause
When meeting either of the following
conditions, positioning/assist pilot pressure
is less than 1.0 MPa.
(Conditions)
• Positioning 1 and 2 solenoid valve
output is more than 2.2 MPa
• Assist 1 and 2 solenoid valve output
is more than 2.2 MPa
• All of assist solenoid valves 1, 2 and positioning
solenoid valves 1, 2 may not become faulty at the
same time.
• Therefore when the fault code is displayed, the
pressure sensor or the controller may be faulty.
• Refer to "FAULT CODE 15516".
T5-6-159
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODES 15574-3 AND 15578-3
Fault Code
Trouble
Cause
15574-3
Abnormal Positioning/Auxiliary Sum Signal Positioning/auxiliary stroke 1 + positioning/
Critical High Voltage
auxiliary stroke 2 is more than 9.0 V
15578-3
Abnormal Positioning/Auxiliary Sum Signal Positioning/auxiliary stroke 1 + positioning/
High Voltage
auxiliary stroke 2 is more than 5.4 V and
less than or equal to 9.0 V
YES
Disconnect connector
of electric lever
(auxiliary/positioning).
Connect terminal #2
and #4 (harness end)
of connector by using a
clip or others and retry.
Check if fault code
disappears.
NO
Faulty electric lever.
Disconnect connector C
of option controller.
Check for continuity
between following
terminals (harness end)
of connector.
YES
· Between terminal #C19 of NO
connector C and terminal #3
of connector of electric lever
· Between terminal #C17 of
connector C and terminal #1
of connector of electric lever
Connector (Harness end of connector viewed from the open end side)
Electric Lever
(Auxiliary/Positioning)
Option Controller Connector C
C1
TCJB-05-06-005
#C17
#C19
C23
C10
C31
T5-6-160
Shorted circuit in harness with
continuity.
Faulty option controller.
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODES 15574-4 AND 15578-4
Fault Code
Trouble
Cause
15574-4
Abnormal Positioning/Auxiliary Sum Signal Positioning/auxiliary stroke 1 + positioning/
Critical Low Voltage
auxiliary stroke 2 is less than 0.5 V
15578-4
Abnormalr Positioning/Auxiliary Sum Signal Positioning/auxiliary stroke 1 + positioning/
Low Voltage
auxiliary stroke 2 is more than or equal to
0.5 V and less than 4.6 V
Disconnect connector of
electric lever
(auxiliary/positioning).
Connect terminals #2 and
#1 (harness end) of
connector by using a clip
or others.
Connect terminals #2 and
#3 (harness end) of
connector by using a clip
or others. Retry and
Check if fault code
disappears.
YES
NO
Faulty electric lever.
Disconnect connector C
of option controller and
connector of electric
lever
(auxiliary/positioning).
Check for continuity
between following
terminals (harness end)
of connector.
· Between terminal #C19
of connector C and
terminal #3 of connector
of electric lever
· Between terminal #C17
of connector C and
terminal #1 of connector
of electric lever
YES
Faulty option controller.
NO
Open circuit in harness without
continuity.
Connector (Harness end of connector viewed from the open end side)
Electric Lever
(Auxiliary/Positioning)
Option Controller Connector C
C1
#C17
#C19
C23
C10
C31
TCJB-05-06-005
T5-6-161
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODES 15575-3 AND 15579-3
Fault Code
Trouble
15575-3 Abnormal Outrigger/Blade
Critical High Voltage
15579-3
Abnormal Outrigger/Blade
High Voltage
Sum
Sum
Cause
Signal Outrigger/blade stroke 1 + outrigger/blade
stroke 2 is more than 9.0 V
Signal Outrigger/blade stroke 1 + outrigger/blade
stroke 2 is more than 5.4 V and less than or
equal to 9.0 V
YES
Disconnect connector
of electric lever
(blade/outrigger).
Connect terminals #2
and #4 (harness end)
of connector by using
a clip or others.
Retry and Check if
fault code disappears.
NO
Faulty electric lever.
Disconnect connector C
of option controller.
Check for continuity
between following
terminals (harness end)
of connector.
YES
· Between terminal #C18 of
connector C and terminal
#3 of connector of electric
lever
· Between terminal #C28 of
connector C and terminal
#1 of connector of electric
lever
NO
Faulty option controller.
Connector (Harness end of connector viewed from the open end side)
Electric Lever
(Blade/Outrigger)
Option Controller Connector C
#C18
C1
C23
TCJB-05-06-005
C10
C31
#C28
T5-6-162
Shorted circuit in with
continuity.
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODES 15575-4 AND 15579-4
Fault Code
Trouble
Cause
15575-4
Abnormal Outrigger/Blade Sum Signal Outrigger/blade stroke 1 + outrigger/blade
Critical Low Voltage
stroke 2 is less than 0.5 V
15579-4
Abnormal Outrigger/Blade Sum Signal Low Outrigger/blade stroke 1 + outrigger/blade
Voltage
stroke 2 is more than or equal to 0.5 V and
less than 4.6 V
Disconnect connector of
electric lever
(blade/outrigger).
Connect terminals #2 and
#1 (harness end) of
connector by using a clip
or others.
Connect terminals #2 and
#3 (harness end) of
connector by using a clip
or others.
Retry and check if fault
code disappears.
YES
NO
Faulty electric lever.
Disconnect connector C
of option controller and
connector of electric
lever (blade/outrigger).
Check for continuity
between following
terminals (harness end)
of connector.
· Between terminal #C18
of connector C and
terminal #3 of connector
of electric lever
· Between terminal #C28
of connector C and
terminal #1 of connector
of electric lever
Connector (Harness end of connector viewed from the open end side)
Electric Lever
(Auxiliary/Positioning)
Option Controller Connector C
#C18
C1
C23
TCJB-05-06-005
C10
C31
#C28
T5-6-163
YES
Faulty option controller.
NO
Open circuit in without
continuity.
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODES 20300 TO 20303
Fault Code
Trouble
Cause
20300-2
Abnormal Positioning/Auxiliary Operation Abnormal positioning/auxiliary stroke 1, or
Signal Warning
Abnormal positioning/auxiliary stroke 2, or
Abnormal sum of positioning/auxiliary 1 and 2
20301-2
Abnormal Outrigger/Blade Operation Abnormal outrigger/blade stroke 1 or
Signal Warning
Abnormal outrigger/blade stroke 2 or
Abnormal sum of outrigger/blade 1 and 2
20302-2
Abnormal Warning on
Abnormal assist stroke 1 or Abnormal assist
Assist Related Operation Signal
stroke 2
20303-2
Electric Lever Pilot
Some electric lever controls are abnormal in
Cut Warning
monitoring neutral.
• If this fault code is displayed, all related fault
codes are displayed at the same time.
• Refer to all fault codes and check them.
T5-6-164
TROUBLEHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15520
Fault Code
Trouble
Cause
15520-2
Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less
Value of Auxiliary 1 Proportional Valve
than 60 mA
15520-3
Abnormal Feedback Value High Current of Current: Higher than 920 mA
Auxiliary 1 Proportional Valve
15520-4
Abnormal Feedback Value Low Current of Current: Less than 56 mA
Auxiliary 1 Proportional Valve
Switch connector of
auxiliary solenoid valve 1
with connector of auxiliary
solenoid valve 2.
Check if fault code for
auxiliary solenoid valve 2
is displayed.
YES
Check for continuity of
harness between option
controller and auxiliary
solenoid valve 1.
· Between terminal #A22
of connector A of option
controller and terminal
#1 of connector of
auxiliary solenoid valve 1
· Between terminal #A19
of connector A of option
controller and terminal
#2 of connector of
auxiliary solenoid valve 1
NO
Faulty auxiliary solenoid
valve 1.
Faulty option controller.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open end side)
Option Controller Connector A
#A19
#A22
T183-05-04-008
Auxiliary Solenoid Valve 1
T1V1-05-04-003
T5-6-165
TROUBLEHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15521
Fault Code
Trouble
Cause
15521-2
Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less
Value of Auxiliary 2 Proportional Valve
than 60 mA
15521-3
Abnormal Feedback Value High Current of Current: Higher than 920 mA
Auxiliary 2 Proportional Valve
15521-4
Abnormal Feedback Value Low Current of Current: Less than 56 mA
Auxiliary 2 Proportional Valve
Switch connector of
auxiliary solenoid valve 2
with connector of auxiliary
solenoid valve 1.
Check if fault code for
auxiliary solenoid valve 1
is displayed.
YES
Check for continuity of
harness between option
controller and auxiliary
solenoid valve 2.
· Between terminal #A23
of connector A of option
controller and terminal #1
of connector of auxiliary
solenoid valve 2
· Between terminal #A15
of connector A of option
controller and terminal #2
of connector of auxiliary
solenoid valve 2
Faulty auxiliary solenoid
valve 2.
Faulty option controller.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open end side)
Option Controller Connector A
#A15
NO
#A23
T183-05-04-008
Auxiliary Solenoid Valve 2
T1V1-05-04-003
T5-6-166
TROUBLEHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15522
Fault Code
Trouble
Cause
15522-2
Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less
Value of Outrigger/Blade 1 Proportional than 60 mA
Valve
15522-3
Abnormal Feedback Value High Current of Current: Higher than 920 mA
Outrigger/Blade 1 Proportional Valve
15522-4
Abnormal Feedback Value Low Current of Current: Less than 56 mA
Outrigger/Blade 1 Proportional Valve
YES
Check for continuity of
harness between option
controller and
blade/outrigger solenoid
valve 1.
· Between terminal #A32 of
connector A of option
controller and terminal #1
of connector of
blade/outrigger solenoid
valve 1
· Between terminal #A7 of
connector A of option
controller and terminal #2
of connector of
blade/outrigger solenoid
valve 1
Switch connector of
blade/outrigger solenoid
valve 1 with connector
of blade/outrigger
solenoid valve 2. Check
if the fault code for
blade/outrigger solenoid
valve 2 is displayed.
NO
Faulty blade/outrigger
solenoid valve 1.
Faulty option controller.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open end side)
Blade/Outrigger Solenoid Valve 1
Option Controller Connector A
#A7
T1V1-05-04-003
#A32
T183-05-04-008
T5-6-167
TROUBLEHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15523
Fault Code
Trouble
Cause
15523-2
Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less
Value of Outrigger/Blade 2 Proportional than 60 mA
Valve
15523-3
Abnormal Feedback Value High Current of Current: Higher than 920 mA
Outrigger/Blade 2 Proportional Valve
15523-4
Abnormal Feedback Value Low Current of Current: Less than 56 mA
Outrigger/Blade 2 Proportional Valve
YES
Check for continuity of
harness between option
controller and
blade/outrigger solenoid
valve 2.
· Between terminal #A24 of
connector A of option
controller and terminal #1
of connector of
blade/outrigger solenoid
valve 2
· Between terminal #A4 of
connector A of option
controller and terminal #2
of connector of
blade/outrigger solenoid
valve 2
Switch connector of
blade/outrigger solenoid
valve 2 with connector of
blade/outrigger solenoid
valve 1.
Check if fault code for
blade/outrigger solenoid
valve 1 is displayed.
NO
Faulty blade/outrigger
solenoid valve 2.
Faulty option controller.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open end side)
Option Controller Connector A
Blade/Outrigger Solenoid Valve 2
#A4
#A24
T1V1-05-04-003
T183-05-04-008
T5-6-168
TROUBLEHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15524
Fault Code
Trouble
Cause
15524-2
Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less
Value
of
Swing
Parking
Release than 60 mA
Proportional Valve
15524-3
Abnormal Feedback Value High Current of Current: Higher than 920 mA
Swing Parking Release Proportional Valve
15524-4
Abnormal Feedback Value Low Current of Current: Less than 56 mA
Swing Parking Release Proportional Valve
YES
Check for continuity of
harness between option
controller and swing
parking brake release
solenoid valve.
· Between terminal #A17 of
connector A of option
controller and terminal #1
of connector of swing
parking brake release
solenoid valve
· Between terminal #A31 of
connector A of option
controller and terminal #2
of connector of swing
parking brake release
solenoid valve
Switch connector of
swing parking brake
release solenoid valve
with connector of
blade/outrigger solenoid
valve 1.
Check if fault code for
blade/outrigger solenoid
valve 1 is displayed.
NO
Faulty swing parking
brake release solenoid
valve.
Faulty option controller.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open end side)
Option Controller Connector A
Swing Parking Brake Release Solenoid Valve
#A17
T1V1-05-04-003
#A31
T183-05-04-008
T5-6-169
TROUBLEHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15525
Fault Code
Trouble
Cause
15525-2
Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less
Value of Assist 1 Proportional Valve
than 60 mA
15525-3
Abnormal Feedback Value High Current of Current: Higher than 920 mA
Assist 1 Proportional Valve
15525-4
Abnormal Feedback Value Low Current of Current: Less than 56 mA
Assist 1 Proportional Valve
YES
Check for continuity of
harness between option
controller and assist
solenoid valve 1.
· Between terminal #A30
of connector A of option
controller and terminal
#1 of connector of
assist solenoid valve 1
· Between terminal #A16
of connector A of option
controller and terminal
#2 of connector of
assist solenoid valve 1
Switch connector of assist
solenoid valve 1 with
connector of assist
solenoid valve 2.
Check if fault code for
assist solenoid valve 2 is
displayed.
NO
Faulty assist solenoid
valve 1.
Faulty option controller.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open end side)
Option Controller Connector A
#A16
#A30
T183-05-04-008
Assist Solenoid Valve 1
T1V1-05-04-003
T5-6-170
TROUBLEHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15526
Fault Code
Trouble
Cause
15526-2
Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less
Value of Assist 2 Proportional Valve
than 60 mA
15526-3
Abnormal Feedback Value High Current of Current: Higher than 920 mA
Assist 2 Proportional Valve
15526-4
Abnormal Feedback Value Low Current of Current: Less than 56 mA
Assist 2 Proportional Valve
Switch connector of assist
solenoid valve 2 with
connector of assist
solenoid valve 1.
Check if fault code for
assist solenoid valve 1 is
displayed.
YES
Check for continuity of
harness between option
controller and assist
solenoid valve 2.
· Between terminal
#A21 of connector A of
option controller and
terminal #1 of
connector of assist
solenoid valve 2
· Between terminal #A5
of connector A of
option controller and
terminal #2 of
connector of assist
solenoid valve 2
Faulty assist solenoid
valve 2.
Faulty option controller.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open end side)
Option Controller Connector A
#A5
NO
#A21
T183-05-04-008
Assist Solenoid Valve 2
T1V1-05-04-003
T5-6-171
TROUBLEHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15527
Fault Code
Trouble
Cause
15527-2
Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less
Value of Assist 3 Proportional Valve
than 60 mA
15527-3
Abnormal Feedback Value High Current of Current: Higher than 920 mA
Assist 3 Proportional Valve
15527-4
Abnormal Feedback Value Low Current of Current: Less than 56 mA
Assist 3 Proportional Valve
YES
Check for continuity of
harness between option
controller and assist
solenoid valve 3.
· Between terminal #A10
of connector A of option
controller and terminal
#1 of connector of
assist solenoid valve 3
· Between terminal #A29
of connector A of option
controller and terminal
#2 of connector of
assist solenoid valve 3
Switch connector of assist
solenoid valve 3 with
connector of assist
solenoid valve 4.
Check if fault code for
assist solenoid valve 4 is
displayed.
NO
Faulty assist solenoid
valve 3.
Faulty option controller.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open end side)
Option Controller Connector A
#A10
#A29
T183-05-04-008
Assist Solenoid Valve 3
T1V1-05-04-003
T5-6-172
TROUBLEHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15528
Fault Code
Trouble
Cause
15528-2
Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less
Value of Assist 4 Proportional Valve
than 60 mA
15528-3
Abnormal Feedback Value High Current of Current: Higher than 920 mA
Assist 4 Proportional Valve
15528-4
Abnormal Feedback Value Low Current of Current: Less than 56 mA
Assist 4 Proportional Valve
Switch connector of assist
solenoid valve 4 with
connector of assist
solenoid valve 3.
Check if fault code for
assist solenoid valve 3 is
displayed.
YES
Check for continuity of
harness between option
controller and assist
solenoid valve 4.
· Between terminal #A8
of connector A of
option controller and
terminal #1 of
connector of assist
solenoid valve 4
· Between terminal
#A14 of connector A of
option controller and
terminal #2 of
connector of assist
solenoid valve 4
NO
Faulty assist solenoid
valve 4.
Faulty option controller.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open end side)
Option Controller Connector A
#A14
#A8
#A29
T183-05-04-008
Assist Solenoid Valve 4
T1V1-05-04-003
T5-6-173
TROUBLEHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15529
Fault Code
Trouble
Cause
Invalid
and
Abnormal
Current
Feedback
Current:
Both
of
Higher
than 920 mA or Less
15529-2
Value of Positioning 1 Proportional Valve
than 60 mA
Abnormal Feedback Value High Current of Current: Higher than 920 mA
15529-3
Positioning 1 Proportional Valve
Abnormal Feedback Value Low Current of Current: Less than 56 mA
15529-4
Positioning 1 Proportional Valve
YES
Check for continuity of
harness between option
controller and
positioning solenoid
valve 1.
· Between terminal #A11 of
connector A of option
controller and terminal #1
of connector of positioning
solenoid valve 1
· Between terminal #A6 of
connector A of option
controller and terminal #2
of connector of positioning
solenoid valve 1
Switch connector of
positioning solenoid
valve 1 with connector of
positioning solenoid
valve 2.
Check if fault code for
positioning solenoid
valve 2 is displayed.
NO
Faulty positioning
solenoid valve 1.
Faulty option controller.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open end side)
Option Controller Connector A
#A6
#A11
T183-05-04-008
Positioning Solenoid Valve 1
T1V1-05-04-003
T5-6-174
TROUBLEHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15530
Fault Code
Trouble
Cause
15530-2
Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less
Value of Positioning 2 Proportional Valve
than 60 mA
15530-3
Abnormal Feedback Value High Current of Current: Higher than 920 mA
Positioning 2 Proportional Valve
15530-4
Abnormal Feedback Value Low Current of Current: Less than 56 mA
Positioning 2 Proportional Valve
YES
Check for continuity of
harness between option
controller and
positioning solenoid
valve 2.
· Between terminal #A9 of
connector A of option
controller and terminal #1
of connector of positioning
solenoid valve 2
· Between terminal #A3 of
connector A of option
controller and terminal #2
of connector of positioning
solenoid valve 2
Switch connector of
positioning solenoid
valve 2 with connector of
positioning solenoid
valve 1.
Check if fault code for
positioning solenoid
valve 1 is displayed.
Faulty positioning
solenoid valve 2.
Faulty option controller.
YES
Open circuit in harness.
NO
Connector (Harness end of connector viewed from the
open end side)
Option Controller Connector A
#A3
NO
#A9
T183-05-04-008
Positioning Solenoid Valve 2
T1V1-05-04-003
T5-6-175
TROUBLEHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODES 15565 TO 15577
Fault Code
Trouble
15565-2
Unreceived Work Mode
Sent from: MC
Cause
Unreceived for 2000 ms
15566-2
Unreceived ATT 1 and 2 Optional Selection Unreceived for 10 sec
Sent from: MC
15567-2
Unreceived ATT 3 and 4 Optional Selection Unreceived for 10 sec
Sent from: MC
15568-2
Unreceived ATT 5 Optional Selection
Sent from: MC
Unreceived for 10 sec
15577-2
Unreceived Actual Engine Speed
Sent from: ECM
Unreceived for 10 sec
NOTE: If fault codes 15565 to 15577 are displayed,
the CAN harness between MC and source
controller may be faulty.
Refer to CAN Harness Check o T5-6-73 to
104 and check the CAN harness.
T5-6-176
TROUBLEHOOTING / Troubleshooting A
STEERING COLUMN MONITOR FAULT CODE 16000
Fault Code
Trouble
16000-2
Abnormal CAN Communication
Cause
Faulty steering column monitor
Faulty CAN harness
NOTE: If fault code 16000-2 is displayed, the CAN
harness between MC and source controller
may be faulty.
Refer to CAN Harness Check on T5-6-73
to 104 and check the CAN harness.
T5-6-177
TROUBLEHOOTING / Troubleshooting A
(Blank)
T5-6-178
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code
is displayed on the service menu (built-in diagnosing
system) in monitor unit and the diagnosing by Dr. ZX
although the machine operation is abnormal. When
the fault code is displayed, refer to the troubleshooting
A group and diagnose.
On the front section pages of this group are the 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 tablesHow to Read the
Troubleshooting Flow Charts
• How to read troubleshooting flowchart
YES (OK)
・
(2)
•
(1)
After checking or measuring item (1), select either YES (OK)
or NO (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO (NOT OK)
•
Special instructions or reference item are indicated in the spaces under the box.
Incorrect measuring or checking methods will render troubleshooting impossible,
and may damage components as well.
•
Explanation of how to use test harness kit required. Refer to “Electrical System
Inspection” Group (Group 8) in this section.
・
•
Use the service menu (built-in diagnosing system) in the monitor unit or the
diagnosing system / monitor function in Dr. ZX.
・
•
Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
・
· Key switch: ON
・
NOTE: For all connector shown in this group,
harness end connector viewed from the
open end side are shown
Harness
Harness End
Connector
Open End Side
T6L4-05-03-001
T5-7-1
TROUBLESHOOTING / Troubleshooting B
RELATIONSHIP
BETWEEN
MACHINE
TROUBLE SYMPTOMS AND RELATED
PARTS
This table indicates the relationship between machine
trouble symptoms and the potential problem parts,
which may cause trouble if failed, and the evaluation
methods of these components.
Parts
Engine Control Dial
Item
•
Instructs engine target
speed.
.
Pump Control Pressure Sensor
•
Monitors pump control pressure
in order to control E mode control.
Pump 1 Delivery
Pressure Sensor
•
Monitors pump
delivery pressure in
order to control HP
mode, auto-power lift
and travel acceleration controls.
If pump delivery
pressure sensor
output is 0 or 5 V, following symptoms will
be presented by
back-up mode function.
HP mode is
inoperable.
Boom raise
power is weak during
digging operation.
During combined operation of
arm roll-in and swing,
arm speed is slow.
Function
•
As below
•
No signals arrive to MC.
•
•
Although operating lever at E
mode, engine speed does not reach
P speed.
•
Symptoms in control
system when trouble
occurs.
•
•
Trouble when starting
engine: Engine speed is kept
at slow idle speed. (Engine
can top by key switch.)
Trouble when running
engine:
Engine speed is kept at
speed just before trouble.
•
•
Symptoms in machine
operation when trouble
occurs.
By Fault Code
Evaluation
11101
11206, 11208
11200
Monitor Item: Requested Engine
Speed, EC Dial Angle (Possible
to display by built-in diagnosing
system)
Monitor Item: Pump 1 Flow Control
Pressure, Pump 2 Flow Control Pressure (Possible to display by built-in diagnosing system)
Monitor Item: Pump 1
Delivery Pressure (Possible to display by
built-in diagnosing system)
By Using Test
Harness
-
-
-
Others
-
By Monitor
Function
NOTE
Descriptions of Control
(Operational Principle
Section in T/M)
-
•
•
-
T2-2
•
Evaluation by Dr. ZX
0.25 or less: open circuit in
harness
4.75 or more: shorted circuit in
harness
T2-2
T5-7-2
-
•
Possible to
judge if sensor is
malfunction or harness is faulty by
switching pump 2
and 3 sensors.
T2-2
TROUBLESHOOTING / Troubleshooting B
Pump 2 Delivery
Pressure Sensor
•
Monitors pump delivery
pressure in order to control HP
mode, and arm regenerative
controls.
•
•
If pump delivery pressure
sensor output is 0 or 5 V, following symptoms will be presented by back-up mode function.
•
•
•
HP mode is inoperable.
During combined operation of arm roll-in and swing,
arm speed is slow.
•
Steering Pump Delivery
Pressure Sensor
Monitors pump delivery
pressure in order to control
steering pump torque decrease
control.
•
•
As below
Engine stalls if pump torque
is increased.
•
•
•
•
•
Pressure Sensor
(Travel Forward)
Monitors travel forward pilot pressure in order to control auto-idle,
idle speed-up, travel
acceleration, speed
sensing, forward/reverse
selection controls.
•
No signals arrive to
•
MC.
Although accelerator
pedal is fully depressed
and machine travels forward, engine speed does
not increase.
Although machine
travels forward with
auto-idle switch ON, engine speed does not increase.
Although operating
pedal with engine speed
control mode selection
switch in pedal position,
engine speed does not increase.
When machine travels at slow idle speed, engine may hunt.
Although machine
travels forward at slow
idle, engine speed does
not increase.
•
•
•
•
•
Pressure Sensor
(Travel Reverse)
Monitors travel forward pilot pressure in order to control auto-idle,
idle speed-up, travel
acceleration, speed
sensing, forward/reverse
selection controls.
No signals arrive to
MC.
Although accelerator
pedal is fully depressed
and machine travels reverse, engine speed does
not increase.
Although machine
travels reverse with
auto-idle switch ON, engine speed does not increase.
Although operating
pedal with engine speed
control mode selection
switch in pedal position,
engine speed does not increase.
When machine travels at slow idle speed, engine may hunt.
Although machine
travels reverse at slow
idle, engine speed does
not increase.
11202
11203
11305
11306
Monitor Item: Pump 2 Delivery
Pressure (Possible to display by
built-in diagnosing system)
Monitor Item: Pump 3 Delivery
Pressure
Monitor Item: Travel Forward
Pilot Pressure (Possible to
display built-in diagnosing
system).
Monitor pressure change
while traveling forward.
Monitor Item: Travel Reverse
Pilot Pressure (Possible to
display built-in diagnosing
system).
Monitor pressure change
while traveling reverse.
-
-
-
-
-
-
-
-
•
Possible to judge if sensor is malfunction or harness is
faulty by switching pump 1 and
3 sensors.
T2-2
•
Possible to judge if sensor
is malfunction or harness is faulty
by switching pump 1 and 2 sensors.
T2-2
•
Possible to judge if
pressure sensor is faulty or
port is clogged by switching pressure sensor with
another pressure sensor.
T2-2
T5-7-3
•
Possible to judge if
pressure sensor is faulty or
port is clogged by switching pressure sensor with
another pressure sensor.
T2-2
TROUBLESHOOTING / Troubleshooting B
Parts
Item
Pressure Sensor
(Front Attachment)
• Monitors front attachment
• Monitors swing pilot pressure • Monitors boom raise pilot
• When pressure sensor (front
• No signals arrive to MC.
• No signals arrive to MC.
• Although any front attach-
• During arm level crowding
• Although boom is raised at
pilot pressure in order to
control auto-idle, idle
speed-up and parking brake
alarm controls.
Function
attachment) or harness between pressure sensor and
MC is faulty, MC judges that
pressure sensor (front attachment) is ON.
Symptoms in control
system when trouble
occurs.
•
Symptoms in machine
operation when trouble
occurs.
Pressure Sensor
(Boom Raise)
Pressure Sensor (Swing)
•
ment is operated with
auto-idle switch is ON, engine speed does not increase.
When front attachment is
operated at slow idle speed,
engine may hunt.
When parking brake is applied and when front attachment is operated, buzzer
does not sound.
in order to control arm regenerative control.
operation, arm speed is
slightly slow.
pressure in order to control
HP mode, arm regenerative
and auto power lift controls.
•
•
•
By Fault Code
Evaluation
HP mode, engine speed
does not increase.
Arm speed becomes slightly
slower than normal in boom
raise and arm roll-in operation as arm regenerative
control does not work. (Not
remarkable)
Arm roll-in and boom raise
speeds become slightly
slower at the beginning
stage of arm level crowding
operation.
Boom raise power is weak.
(Not remarkable)
11307
11301
11302
Monitor Item: Front Pilot Pressure (Possible to display built-in
diagnosing system).
Monitor pressure change while
operating front attachment.
Monitor Item: Swing Pilot
Pressure (Possible to display
built-in diagnosing system)
Monitor pressure change while
swinging upper-structure.
Monitor Item: Boom Raise Pilot
Pressure (Possible to display
built-in diagnostic system).
Monitor pressure change while
operating front attachment.
By Using Test
Harness
-
-
-
Others
-
-
-
• Possible to judge if pressure
• Possible to judge if pressure
• Possible to judge if pressure
T2-2
T2-2
T2-2
By Monitor
Function
NOTE
Descriptions of Control
(Operational Principle Section in T/M)
sensor is faulty or port is
clogged by switching pressure sensor with another
pressure sensor.
sensor is faulty or port is
clogged by switching pressure sensor with another
pressure sensor.
T5-7-4
sensor is faulty or port is
clogged by switching pressure sensor with another
pressure sensor.
TROUBLESHOOTING / Troubleshooting B
Pressure Sensor
(Arm Roll-In)
Pressure Sensor
(Positioning) (Optional)
Pressure Sensor
(Auxiliary) (Optional)
Brake Pressure Sensor
• Monitors arm roll-in pilot
• Monitors attachment pilot
• Monitors attachment pilot
• Monitors bake operating
• No signals arrive to MC.
• No signals arrive to MC and
• No signals arrive to option
• No signals arrive to MC.
•
•
•
•
pressure in order to control
HP mode, arm regenerative
and auto power lift controls.
•
Although arm is
rolled-in at HP mode, engine speed does not increase.
Arm speed is slow in
arm level crowding operation.
pressure when attachment is
installed in order to control
attachment operation speed
increase, pump 1 and pump
2 flow rate limit and auxiliary
flow rate controls.
option controller. Electric
lever pilot cut-off control is
done by option controller.
•
•
•
•
controller. Electric lever pilot
cut-off control is done by option controller.
When attachment is
operated, engine speed does
not increase.
When attachment is
operated, operation speed
decreases.
All operations are inoperable except travel operation.
Electric Lever Solenoid
Valve Output Warning is displayed on monitor unit.
Buzzer sounds continuously.
11303
11517
Monitor Item: Arm Roll-In Pilot
Pressure (Possible to displayed built-in diagnosing
system).
Monitor pressure change while
rolling arm in.
Monitor Item: ATT Control Pilot
Pressure (Possible to display
built-in diagnosing system).
Monitor pressure change while
operating attachment.
-
-
•
Possible to judge if
pressure sensor is faulty or
port is clogged by switching
pressure sensor with another pressure sensor.
T2-2
•
•
•
•
•
When positioning or
assist is operated, engine
speed does not increase.
When attachment is
operated, operation speed
decreases.
All operations are inoperable except travel operation.
Electric Lever Solenoid
Valve Output Warning is displayed on monitor unit.
Buzzer sounds continuously.
pressure in order to control
work brake.
11516
Monitor Item: Posn/Assist Pilot
Monitor Pressure (Possible to
display built-in diagnosing system)
Monitor pressure change while
operating attachment.
-
•
Possible to judge if
pressure sensor is faulty or
port is clogged by switching
pressure sensor with another
pressure sensor.
T2-2
T5-7-5
Work brake is inoperable.
11310
Monitor Item: Brake Pressure
(Possible to display built-in diagnosing system)
Monitor pressure change while
depressing brake pedal.
-
Possible to judge if
pressure sensor is faulty or
port is clogged by switching
pressure sensor with another
pressure sensor.
T2-2
pressure when attachment is
installed in order to control
positioning and assist controls
-
•
-
Possible to judge if
pressure sensor is faulty or
port is clogged by switching
brake pressure sensor with
pump 1, 2, 3 delivery pressure sensors.
T2-2
TROUBLESHOOTING / Troubleshooting B
Parts
Item
•
Brake Remaining
Pressure Sensor
Boom Bottom
Pressure Sensor
Solenoid Valve Unit (SF)
•
Monitors Boom cylinder
bottom pressure in order to
control (overload alarm control (optional).
• No signals arrive to MC.
•
No Signal arrive to MC.
• Parking
• Condition is always overload. Abnormal low current:
• Overload alarm is displayed • Work brake does not operate.
Function
Monitors accumulated
pressure of accumulator for
brake in order to control
travel motor selection control.
Symptoms in control
system when trouble
occurs.
•
brake cannot be released.
Travel speed is turned to
fast/slow speed.
• Shifts
bake valve by pilot
pressure in order to control
work brake control.
• If
solenoid valve unit (SF) is
not activated, pressure at
port SE becomes 0 MPa (0
kgf/cm2).
on monitor unit.
• Overload alarm sounds.
Abnormal high current:
• Work brake is kept applied.
• Machine cannot travel.
Symptoms in machine
operation when trouble
occurs.
By Fault Code
Evaluation
By Monitor
Function
11311
11425
-
Monitor Item: Brake Remain
Pressure
Monitor Item: Implement Brake
P/S/V Output
Monitor Item: Boom Bottom
Pressure
• Install
By Using Test
Harness
Others
NOTE
Descriptions of Control
(Operational Principle
Section in T/M)
lamp harness (ST
7226). Check output signals
from MC and harness condition.
Possible to judge if
pressure sensor is faulty or
port is clogged by switching
brake pressure sensor with
pump 1, 2, 3 delivery pressure sensors.
T2-2
•
T2-2
T5-7-6
-
-
-
-
-
T2-2
TROUBLESHOOTING / Troubleshooting B
• Routes return oil from
• Is shifted when axle lock or • When
Max. Pump 2 Flow Rate
Limit Control Solenoid
V l
• Limits maximum
flow rate
• If solenoid valve
• If solenoid valve unit (SI) is
• If
Abnormal low current:
• All operation speeds become
slow.
• Axle lock is not released.
Abnormal high current:
• Arm speed becomes fast as arm
regenerative control is always
operated.
Abnormal high current:
• Axle lock is kept in released
condition.
• Condition when front attachment is operated is unstable.
Solenoid Valve Unit (SC)
arm cylinder rod side to bottom side when
rolling arm in order to increase
arm speed.
unit (SC) is not
activated, pressure at port SC
becomes 0 MPa (0 kgf/cm2). Arm
regenerative control will not operate at this time.
Solenoid Valve Unit (SI)
· If max. pump 1 flow rate limit
not activated, pressure at
port SI becomes 0 MPa (0
kgf/cm2).
Abnormal low current:
11424
Monitor Item: Axle Lock Output
• Install
• Install
T2-2
machine is traveling
in travel creeper mode, or
when attachment and front
attachment are operated,
maximum flow rate of pump
1 is restricted in order to
control pump 1 flow rate
limit control in travel creeper
speed mode, pump 1 flow
rate limit and attachment
flow rate limit control.
auto axle lock is selected by
brake switch. Shifts operating check valve of axle lock
cylinder in order to control
auto axle lock control.
11403
Monitor Item: Arm Regenerative P/S
Valve Output (Possible to display by
built-in diagnosing system)
lamp harness (ST 7226).
Check output signals from MC
and harness condition.
Max. Pump 1 Flow Rate
Limit Control Solenoid Valve
control solenoid valve is not
activated, pressure at output
port becomes 0 MPa (0
kgf/cm2).
Abnormal low current:
attachment, front attachment and superfine
travel are operated, operating speed becomes fast.
• When
Abnormal high current:
bucket, arm and
boom speeds become slow
as maximum flow rate of
pump 1 decreases.
of pump 2 when operating
front attachment.
max. pump 2 flow rate
limit control solenoid valve
is not activated, pressure at
output port becomes 0 MPa
(0 kgf/cm2).
Abnormal low current:
front and front attachment are operated, operating speed becomes
fast.
• When
Abnormal high current:
boom and swing
speeds become slow as
maximum flow rate of pump
2 decreases.
• Travel,
• Arm,
11410
Monitor Item: Pump 1 Flow
Rate Limit P/S/V Out
11400
Monitor Item: Pump 2 Flow
Rate Limit P/S/V Out
-
-
lamp harness (ST
7226). Check output signals
from MC and harness condition.
-
-
-
-
-
-
-
-
T2-2
T2-2
T5-7-7
T2-2
TROUBLESHOOTING / Troubleshooting B
Parts
Item
Pilot Shut-Off
Solenoid Valve
Torque Control
Solenoid Valve
• Supplies
• Opens
• If
• As below
Abnormal low current:
• All operation speeds become
slow.
• All
• When
Solenoid valve is open:
pressure oil is always
supplied to pilot value.
Abnormal high current:
• All operations are inoperable except travel operation.
• Alarm is displayed on
monitor unit and buzzer
sounds.
11401
15520, 15521
-
Monitor Item: Pump Torque P/S
Valve Output (Possible to display
by built-in diagnosing system)
Monitor Item: Posn/Aux 1, 2
Operation, Aux 1, 2 P/S/V
(Possible to display by built-in
diagnosing system)
Monitor voltage and pressure
changes while operating lever.
control pressure to
pumps 1 and 2 in order to do
speed sensing control.
and closes pilot cir-
cuit.
Function
Symptoms in control system when trouble occurs.
Auxiliary Solenoid Valve
torque control solenoid
valve is not activated, output
pressure of solenoid valve is
0 MPa (0 kgf/cm2).
• Is
operated by signal from
option controller and supplies pressure oil from pilot
pump to control valve spool
in order to control auxiliary
control.
• When
trouble occurs, solenoid valve output is 0 by
electric lever pilot cut-off
control.
When operating
auxiliary, operating speed
becomes slow.
Solenoid valve is closed:
actuators are not operated. (Pilot pressure oil is
not supplied to pilot value.)
Abnormal low current:
operating auxiliary,
operating speed becomes
slow.
Abnormal high current:
• Engine may stall while traveling at slow idle speed.
• Pilot
Symptoms in machine operation when trouble occurs.
By Fault Code
Evaluation
By Monitor
Function
By Using Test
Harness
Others
NOTE
Descriptions of Control
(Operational Principle
Section in T/M)
T2-2
-
-
-
-
-
-
-
-
-
-
T2-5
T5-7-8
T2-2
TROUBLESHOOTING / Troubleshooting B
Positioning Solenoid Valve
• Is operated by signal from option • Is
controller and supplies pressure
oil from pilot pump to control
valve spool in order to control
positioning control.
• When
trouble occurs, solenoid
valve output is turned OFF by
electric lever pilot cut-off control.
When operating positioning, operating speed becomes slow.
Abnormal low current:
• When operating positioning, operating speed becomes slow.
Abnormal high current:
• All operations are inoperable
except travel operation.
• Alarm is displayed on monitor
unit and buzzer sounds.
Blade/Outrigger
Solenoid Valve
operated by signal from
option controller and supplies pressure oil from pilot
pump to control valve spool
in
order
to
control
blade/outrigger control.
• When
trouble occurs, solenoid valve output is turned
OFF by electric lever pilot
cut-off control. When operating blade/outrigger, operating speed becomes
slow.
Abnormal low current:
• When
operating
blade/outrigger, operating
speed becomes slow.
Abnormal high current:
operations are inoperable except travel operation.
• Alarm is displayed on
monitor unit and buzzer
sounds.
• All
Swing Parking Brake
Release Solenoid Valve
Assist Solenoid Valve
• Is
• Is
• When
• When
Abnormal low current:
operating assist, operating speed becomes
slow.
• All
operated by signal from
option controller and supplies pressure oil from pilot
pump to control valve spool
in order to control assist
control.
trouble occurs, solenoid valve output is turned
OFF by electric lever pilot
cut-off control. When operating assist, operating
speed becomes slow.
• When
Abnormal high current:
operations are inoperable except travel operation.
• Alarm is displayed on
monitor unit and buzzer
sounds.
• All
operated by signal from
option controller and supplies pressure oil from pilot
pump to control valve spool
in order to control positioning and assist controls.
trouble occurs, solenoid valve output is turned
OFF by electric lever pilot
cut-off control.
•
operations are inoperable except travel operation.
Alarm is displayed on
monitor unit and buzzer
sounds.
15529, 15530
15522, 15523
15525, 15526
15524
Monitor Item: Posn/Aux 1, 2 Operation, Positioning 1, 2 P/S/V (Possible to display by built-in diagnosing
system)
Monitor voltage and pressure
changes while operating lever.
Monitor Item: Outrigger/Blade
1, 2 Operation, Blade 1,
2/Outrigger 1, 2 P/S/V (Possible to display by built-in diagnosing system)
Monitor voltage and pressure
changes while operating lever.
Monitor Item: Assist 1, 2 Operation, Assist 1, 2 P/S/V
(Possible to display by built-in
diagnosing system)
Monitor voltage and pressure
changes while operating lever.
Monitor Item: Swing Parking
Release
Monitor voltage and pressure
change while operating lever.
-
-
-
-
-
-
-
-
-
-
-
-
T2-2
T2-2
T2-2
T5-7-9
T2-2
TROUBLESHOOTING / Troubleshooting B
Parts
Item
Auxiliary Flow Rate Control
Solenoid Valve (Optional)
Auxiliary Flow Combiner
Solenoid Valve (Optional)
Selector Valve Control
Solenoid Valve (Optional)
• Restricts flow rate to auxiliary • Activates during auxiliary op- • Activates
spool during combined operation and improves operability.
when attachment
“selector valve returning to
hydraulic oil tank” is selected
and shifts selector valve
spool.
eration and shifts spool in
auxiliary
flow
combining
valve.
Function
Symptoms in control
system when trouble
occurs.
Symptoms in machine
operation when trouble
occurs.
Evaluation
• If
• If auxiliary flow combiner so- • If
Abnormal low current:
• If valve is bound fully open,
boom does not raise during
3-combined operation of
boom raise.
Abnormal high current:
• If valve is bound fully closed,
attachment speed becomes
slow during single operation.
• Speed
auxiliary flow rate control
solenoid valve is not activated, pressure at output port
becomes 0 MPa (0 kgf/cm2).
lenoid valve is not activated,
pressure at output port becomes 0 MPa (0 kgf/cm2)
when operating attachment.
does not increase
during single operation of attachment.
•
selector valve control solenoid valve is not activated,
pressure at output port becomes 0 MPa (0 kgf/cm2)
when attachment “selector
valve returning to hydraulic
oil tank” is selected.
Breaker stroke becomes few.
By Fault Code
-
-
-
By Monitor
Function
-
-
-
Using Test
Harness
-
-
-
Others
-
-
-
-
When pedal is depressed,
pressure in the right piping hose
occurs.
NOTE
Descriptions of Control
(Operational Principle
Section in T/M)
T2-2
T2-2
T5-7-10
T2-2
TROUBLESHOOTING / Troubleshooting B
Secondary Pilot Relief Pressure
Control Solenoid Valve (Optional)
• Activates
when attachment
“secondary pilot relief pressure ON” is selected and
shifts secondary pilot relief
pressure control valve spool.
• If
•
secondary pilot relief pressure control solenoid valve is
not activated, pressure at
output port becomes 0 MPa
(0 kgf/cm2) when attachment
“secondary pilot relief pressure ON” is selected.
Relief set pressure in auxiliary
circuit does not decrease.
Hydraulic Oil
Temperature Sensor
Travel N Sensor
• Detects
•
travel motor speed
and sends a signal to speed
display meter.
Travel motor speed is detected to activate the superfine travel speed, to prevent
travel motor from excessive
rotation, and/or to restrict
forward/reverse shifting.
• Monitors hydraulic oil tem-
perature in order to control
auto-warming up and arm
regenerative controls.
• Speed display meter does not • If
•
circuit breakage occurs,
system operates as if hydraulic oil temperature is 120 °C
(Dr. ZX or monitor will not indicate 120 °C in diagnosis
operation).
operate.
Travel speed, travel motor
excessive rotation, and/or the
forward/reverse shifting restriction control is inoperable.
• Speed display meter does not • Although
•
operate.
When descending a slope,
engine speed is not reduced.
•
-
• Shifts fast/slow speed selec-
tion solenoid valve by shifting
travel speed mode switch
(Fast/Slow) in order to control
travel speed mode selection
control.
• When open or shorted circuit
occurs in switch, fast/slow
speed selection solenoid
valve is held in either fast or
slow position.
• Although travel speed mode
•
switch is in fast position,
travel speed dose not change
into Fast.
Although travel speed mode
switch is in slow position,
travel speed dose not change
into Slow.
Monitor Item: Vehicle Speed
(Possible to display by built-in
diagnosing system)
11901
Monitor Item: Hydraulic Oil
Temperature (HOT)
(Possible to display by built-in
diagnosing system)
Monitor Item: Transmission H/L
SW
-
-
-
-
-
-
-
-
-
T2-2
oil temperature is
lower
than
0
°C,
auto-warming up control does
not operate so that engine
runs at idle speed when engine is started.
When hydraulic oil temperature is lower than 10 °C, arm
regenerative control is inoperable.
Travel Speed
Mode Switch
T2-2
temperature is extremely
low (below -20°C), control
system is in-operable.
-
• If
T2-2
T5-7-11
-
T2-2
TROUBLESHOOTING / Troubleshooting B
Parts
Item
• Shifts parking brake, axle
• When open or shorted cir-
• Depending on failure of
• Depending on failure of
• Although FNR switch is in N
• Although engine speed
• Although parking brake po-
Pi cut-off solenoid valve by
shifting FNR switch in order
to control travel forward/reverse selection limit
and travel pilot pressure
controls.
cuit occurs in switch, FNR
switch is held in N position.
Symptoms in control
system when trouble
occurs.
•
•
position, indicator (N) on
steering column monitor
does not light.
Although FNR switch is in F
or R position, machine does
not travel.
Although FNR switch is in R
position, back light does not
light.
By Fault Code
Evaluation
By Monitor
Function
mode by operating switch in
order to control engine control dial, accelerator pedal
and travel creeper speed
controls.
switch, engine control mode
is held. (Engine control dial,
pedal and creeper modes)
•
control mode selection
switch is turned to pedal
mode, engine speed cannot
be controlled by accelerator
pedal.
Although engine speed
control mode selection
switch is turned to creeper
mode, travel creeper speed
mode is not operable.
-
NOTE
T2-2
lock, auto axle lock and
OFF operating brake switch.
switch, brake mode is held
(parking brake, axle lock,
auto axle lock and OFF)
•
•
•
sition is selected, the parking brake is not operable.
Although axle lock position
is selected, axle cylinder is
not locked.
Although machine travels in
auto axle lock position, axle
lock cylinder is not released.
Although OFF position is
selected, either parking
brake or axle lock is operable.
-
Monitor Item: Slight Travel SW,
Pedal EC SW
By Using Test
Harness
Others
Descriptions of Control
(Operational Principle
Section in T/M)
Brake Switch
• Shifts travel forward/reverse • Shifts engine speed control
Function
Symptoms in machine
operation when trouble
occurs.
Engine Speed Control
Mode Selection Switch
FNR Switch
Monitor Item: Parking Brake
SW, Axle Lock Control State
Monitor
H/L SW
Item:
-
-
-
-
-
-
-
-
-
T2-2
T5-7-12
T2-2
Transmission
TROUBLESHOOTING / Troubleshooting B
MC
Power Mode Switch
(HP Mode)
Auto-Idle Switch
Power Mode Switch
(E Mode)
• Controls engine, pump and
• Activates auto-idle control.
ON: 0 V → Auto-idle is operable.
OFF: 5 V → Inoperable.
• Activates HP mode.
ON: 0 V → HP mode control
OFF: 5 V → Normal
• Selects E mode.
ON: 0 V → E mode
OFF: 5 V → Normal
• Depending on trouble situa-
• As below
• As below
• As below
valve operation.
tions, control system malfunction may differ. (The following symptoms in machine
operation indicates that MC
logic circuit has failed.)
• Although engine starts, speed
•
stays slow.
As pump displacement is held
at minimum, all actuator
speeds are slow.
Open circuit:
• Auto-idle is inoperable.
Open circuit:
Shorted circuit:
• Although auto-idle switch is
OFF, auto-idle control is always done.
11000, 11001, 11002. Other fault
codes may be displayed.
• Although
HP mode is selected, HP mode is inoperable.
Shorted Circuit:
• Although HP mode switch is
turned OFF, HP mode is not
deactivated.
Attachment
speed increase control (optional) becomes inoperable.
Monitor Item: Auto-Idle SW
Open circuit:
if E mode is selected,
engine speed doesn’t decrease.
Shorted Circuit:
• Engine speed does not increase to the maximum.
Auto-idle control is inoperable.
• Even
Monitor Item: HP Mode SW
Monitor Item: E/P SW
-
-
-
-
-
-
-
-
-
-
-
-
• Before suspecting a failure in
MC, be sure to check fuses in
control system. If any sensor
in 5 V system is shorted, fault
code11003 will be displayed.
T2-1
T2-2
T2-2
T5-7-13
T2-2
TROUBLESHOOTING / Troubleshooting B
Parts
Item
Work Brake Release
Switch
Outrigger Selection
Switch
• Release work brake and
• Shifts blade/outrigger main
• Activates pilot shut-off sole-
• No signals arrive to MC.
• Depending on failure of
• As below
• Although
• When outrigger selection
makes machine travel in order
to control work brake control.
relay 1 and pilot shut-off solenoid valve by shifting switch
in order to control
blade/outrigger, pilot cut-off
controls.
Function
switch, each mode (OFF, pilot
cut-off, ON) is held.
Symptoms in control
system when trouble
occurs.
brake pedal is depressed during work brake
operation, work brake is not
released.
•
Symptoms in machine
operation when trouble
occurs.
Evaluation
By Fault
Code
By Monitor
Function
Using Test
Harness
Others
•
switch is turned to OFF or pilot cut-off position, and when
lever is operated,
blade/outrigger is activated.
When outrigger selection
switch is turned to pilot cut-off
position, and when lever is
operated, front attachment or
blade/outrigger is activated.
When outrigger selection
switch is turned to ON position, blade/outrigger is not activated.
-
T2-2
noid valve.(Turns pilot shut-off
relay ON.)
ON: Pump control (positive control) of pumps 1, 2 is activated.
OFF: Minimum pump flow rate
Open circuit:
shout-off switch is always OFF.
• Pilot shut-off solenoid valve is
not shifted.
• Although lever is operated
with pilot shut-off lever in
UNLOCK position, all actuator
are not operated.
Short Circuit:
• Pilot shout-off switch is always ON.
• Engine does not start.
• If shorted circuit occurs while
starting engine, operate lever
with pilot shut-off lever in
LOCK position so actuator is
operated.
• Pilot
-
Monitor Item: Electric Lever Pilot
Cut
NOTE
Descriptions of Control
(Operational
Principle
Section in T/M)
Pilot Shout-Off
Monitor Item: Gate Lock Signal
Monitor Item: E/P SW
-
-
-
-
-
-
-
-
-
T2-2
T5-7-14
T2-5
TROUBLESHOOTING / Troubleshooting B
Bucket Flow Rate
Control Valve
• Restricts oil flow raise to
bucket during 3-combined
operation of bucket, arm
roll-in and boom raise and
makes boom raise.
Boom Flow Rate
Control Valve
• Is shifted by pilot pressure
•
from boom lower meter-in cut
valve.
Limits flow rate to boom 1
spool during combined
operation and improves
combined operation.
Auxiliary Flow Rate
Control Valve
Boom Regenerative Valve
• Is
shifted by pilot pressure
from auxiliary flow rate control solenoid valve.
• Prevents boom cylinder hesitation by routing return oil
from boom cylinder bottom
side to rod side.
• If switch valve is bound with
• As below
• If spool is bound or spring is • As below
• If
• If valve is fully opened, boom
• If
• If check valve is kept closed,
•
•
•
valve activated, bucket circuit
is always restricted.
•
poppet valve is bound at
fully closed position or if
switch valve is bound when
poppet valve is fully closed,
bucket speed becomes slow.
If poppet valve is bound at
fully opened position or if
switch valve is bound when
poppet valve is fully opened,
boom does not raise during
3-combined operation of
bucket, arm roll-in and boom
raise.
T3-3
broken, orifice
change.
lower speed is fast during
combined operation.
If valve is fully closed,
machine cannot be raised off
ground.
does
not
valve is bound at fully
closed position, attachment
speed becomes slow.
If valve is bound at fully
opened position, boom does
not raise during 3-combined
operation of swing, arm roll-in
and boom raise.
boom is not smoothly lowered.
If check valve is kept open,
machine cannot be raised off
ground.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
T3-3
T3-3
T5-7-15
T3-3
TROUBLESHOOTING / Troubleshooting B
Parts
Item
• Is
• Check valve in arm roll-in re-
• Arm
• As below
• If
• Arm
• If check valve is kept closed, • If check valve is kept closed,
Function
shifted by pilot pressure
from solenoid valve unit (SC).
Increases arm speed by
routing return oil from arm
cylinder rod side to bottom
side.
regenerative function is
inoperable.
Symptoms in control
system when trouble
occurs.
•
Evaluation
speed is extremely slow
during arm level crowding
operation while arm regenerative valve is kept closed.
The lever operated first is
given priority during combined operation of arm roll-in
and swing while arm regenerative valve is kept open.
By Fault
Code
By Monitor
Function
Using Test
Harness
Others
NOTE
Descriptions of Control
(Operational
Principle
Section in T/M)
Arm Anti-Drift Valve
• Prevents
•
Symptoms in machine
operation when trouble
occurs.
Bucket Regenerative
Valve
Arm Regenerative Valve
T3-3
bucket cylinder
hesitation by routing return oil
from bucket cylinder rod side
to bottom side.
•
turn circuit is forcibly opened
and arm move only when arm
is rolled in. Prevents arm from
drifting due to oil leaks in
control valve.
switch valve is bound,
check valve does not open.
bucket is not smoothly rolled
in.
If check valve is kept open,
bucket power is weak.
•
•
arm roll-in speed becomes
slow.
If check valve is kept open,
front attachment drift increases due to oil leaks in
control valve.
Arm moves jerky or arm
speed becomes slow depending on valve bound conditions.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
T3-3
T5-7-16
T3-3
TROUBLESHOOTING / Troubleshooting B
Auxiliary Flow
Combiner Valve
Boom Anti-Drift Valve
• Check
valve in boom lower
return circuit is forcibly
opened and makes boom
move only when boom is
lowered. Prevents boom
from drifting due to oil leaks
in control valve.
• If
switch valve is bound,
check valve does not open.
• Is shifted by pilot pressure from • Supplies
•
•
auxiliary
flow
combiner
solenoid
valve
when
attachment mode (secondary
pulverizer, hydraulic crusher) of
travel speed “ON” is selected.
Supplies pressure oil from
pump 1 to auxiliary spool.
As below
• If check valve is kept closed, • If
•
•
boom does not lower.
If check valve is kept open,
front attachment drift increases due to oil leaks in
control valve.
Boom moves jerky or arm
speed becomes slow depending on valve bound
conditions.
T3-3
•
Pump 1 Flow Rate
Control Valve
Bypass Shut-Out Valve
switch valve is kept closed,
attachment speed does not
become fast during single
auxiliary operation.
If switch valve is kept open,
attachment speed does not
become slow when attachment
mode (HSB breaker, NPK
breaker) of travel speed “OFF”
is selected.
pressure oil from
pump 1 to auxiliary spool
and
positioning
control
valve when auxiliary or positioning is operated.
• Supplies
flow rate control
pressure Pi to pump 1 regulator
in response to lever stroke
when boom (raise/lower), arm
(roll-out/in), bucket (roll-out/in),
travel, auxiliary or positioning is
operated.
• As below
• As below
• If
• If
•
•
•
spool is bound at fully
open position, single attachment operation speed
becomes slow.
If spool is bound at fully
closed position, main relief
valve continues to relieve
with all control levers positioned in neutral.
When all control levers are
in neutral, pump 1 pressure
is higher than pump 2 pressure according to bound
spool conditions.
•
•
spool is bound in fully open
position, although control lever
is in neutral, pump 1 swash
angle is tilted to maximum.
If spool is bound in fully open
position, pump 1 control pressure sensor monitors maximum
pressure.
If spool is bound in fully closed
position, although control lever
is operated, pump 1 swash
angle is held to minimum.
(Bucket speed is very slow.)
If spool is bound in fully open
position, pump 1 control pressure sensor can not monitor
the pump control pressure.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
T3-3
T3-3
T5-7-17
T3-9
TROUBLESHOOTING / Troubleshooting B
Pump 2 Flow Rate
Control Valve
Parts
Item
Swing Parking Brake
Release Spool
Bucket Flow Rate Control
Valve Control Spool
• Supplies
• Is
• Is
• As below
• As below
• As below
• If
• If
• If
•
•
flow rate control
pressure Pi to pump 2 regulator in response to lever stroke
when boom (raise), arm
(roll-out/in), swing (right/left),
auxiliary or blade/outrigger is
operated.
Function
shifted by boom, arm,
bucket, swing, auxiliary or
blade/outrigger pilot pressure.
Supplies swing parking brake
release pressure.
shifted by arm roll-in pilot
pressure. Supplies boom raise
pilot pressure to bucket flow
rate control valve.
Symptoms in control system when trouble
occurs.
Symptoms in machine
operation when trouble
occurs.
•
•
Evaluation
spool is bound in fully open
position, although control lever
is in neutral, pump 2 swash
angle is tilted to maximum.
If spool is bound in fully open
position, pump 2 control
pressure
sensor
monitors
maximum pressure.
If spool is bound in fully closed
position, although control lever
is operated, pump 2 swash
angle is held to minimum.
(Swing speed is very slow.)
If spool is bound in fully open
position, pump 2 control pressure sensor can not monitor
pump control pressure.
By Fault
Code
By Monitor
Function
By Using Test
Harness
Others
NOTE
Descriptions of Control
(Operational
Principle
Section in T/M)
T3-9
•
•
spool is bound in fully open
position, swing parking brake is
kept
released.
(Machine
vibrates while traveling.)
If spool is bound in fully open
position, pressure sensor (front
attachment) is always ON.
Thus, engine speed does not
decrease when control lever is
in neutral during auto-idle
control.
If spool is bound in fully closed
position, swing parking brake is
kept applied. (Dragging is felt.)
If spool is bound in fully closed
position, pressure sensor (front
attachment) is always OFF.
Thus, engine speed does not
increase when control lever is
operated during auto-idle control.
•
spool is bound in fully open
position,
bucket
speed
becomes slow when combined
operation of boom raise and
bucket is made. (Bucket flow
rate control is inoperable.)
If spool is bound in fully closed
position, boom does not raise
during 3-combined operation of
bucket, arm roll-in and boom
raise.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
T3-9
T5-7-18
T3-9
TROUBLESHOOTING / Troubleshooting B
Steering Valve
• Supplies
Accumulator
Charging Valve
Brake Valve
Transmission Control
Solenoid Valve
• Supplies
• Charges
• Shifts parking brake and
• Pressure oil is not supplied to • As below
• Pressure
• As below
pressure oil from
steering pump to steering
cylinder in proportion to
steering wheel rotation.
pressure oil to
front/rear axle brakes in
proportion to brake pedal
depression.
steering cylinder in proportion
to steering wheel rotation.
However, steering valve acts
as a pump, steering cylinder
can be operated.
• Turning
force of
wheel increases.
steering
•
• Although
•
T3-10
pressure oil into
accumulator
provided
in
brake circuit. Holds charged
pressure oil for set period of
time.
brake pedal is
depressed, brake is not
applied.
Although brake pedal is not
operated, brake is applied.
oil is not charged
into accumulator.
Brake circuit oil pressure
stays low.
fast/slow in transmission.
• Service brake is not operable. • If fast/slow speed selection
solenoid valve is bound in
• Service brake does not work
effectively.
•
neutral, parking brake is kept
applied although shift switch
is operated.
If fast/slow speed selection
solenoid valve is bound, Hi/Lo
shifting of transmission is not
achieved although travel
mode switch is operated.
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
T3-11
T2-4, T3-12
T5-7-19
T2-2, T3-13
TROUBLESHOOTING / Troubleshooting B
Parts
Item
Blade/Outrigger Cylinder
Solenoid Valve
Travel Forward Pi Cut
Solenoid Valve
• Releases
• Cut
• Cut
• When
•
•
• Although
• If valve is closed:
• If valve is closed:
•
•
operate check
valve
provided
in
blade/outrigger cylinder.
Function
Symptoms in control system
when trouble occurs.
solenoid valve is
bound, operate check valve
does not open or close.
blade/outrigger
lever or blade/outrigger
switch
is
operated,
blade/outrigger cylinder is
not operated.
Symptoms
operation
occurs.
Evaluation
Travel Reverse Pi Cut
Solenoid Valve
travel forward pilot
pressure
and
prevents
machine from
traveling
forward when FNR switch is
in N or R position in order to
control
forward/reverse
selection limit and travel
pilot
pressure
cut-off
controls.
As below
Although FNR switch is in N
position, machine travels
forward.
If valve is open:
Although FNR switch is in F
position, machine does not
travel forward.
travel reverse pilot
pressure
and
prevents
machine from
traveling
reverse when FNR switch is
in N or F position in order to
control
forward/reverse
selection limit and travel
pilot
pressure
cut-off
controls.
As below
Although FNR switch is in N
position, machine travels
reverse.
If valve is open:
Although FNR switch is in R
position, machine does not
travel reverse.
in
machine
when
trouble
By Fault Code
By Monitor
Function
By Using Test
Harness
Others
NOTE
Descriptions
of
(Operational
Section in T/M)
Control T2-2, T3-12
Principle
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
T2-2
T5-7-20
T2-2
TROUBLESHOOTING / Troubleshooting B
Selector Valve (Optional)
Secondary Pilot Relief Pressure
Control Valve (Optional)
• Is shifted by pilot
• Is
• If
• If spool is bound or spring is broken, relief
• Breaker stroke becomes few.
• Relief
pressure from selector
valve control solenoid valve.
spool is bound or spring is broken,
pressure oil from breaker does not return
to hydraulic oil tank.
T2-2
shifted by pilot pressure from
secondary pilot relief pressure control
solenoid valve.
circuit in breaker is blocked.
set pressure in auxiliary circuit
does not decrease.
-
-
-
-
-
-
-
-
-
-
T2-2
T5-7-21
TROUBLESHOOTING / Troubleshooting B
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine
troubles and parts contributing to the cause of the
trouble if failed.
Engine System Troubleshooting
Trouble Symptom
E-1
Starter does not rotate.
Part
MC
ECM
ICF
Monitor Unit
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pump 1 Control Pressure Sensor
Pump 2 Control Pressure Sensor
Pressure Sensor (Travel)
Pressure Sensor (Front Attachment)
Pressure Sensor (Swing)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Auxiliary)
Hydraulic Oil Temperature Sensor
Coolant Temperature Sensor
Key Switch
Engine Control Dial
Auto-Idle Switch
Power Mode Switch
Torque Control Solenoid Valve
Starter Cut Relay
ECM Main Relay
Battery Relay
Glow Plug Relay
Engine Electrical Equipment
Engine Unit
Pump Regulator
Swing Parking Brake
Release Spool (Signal Control Valve)
z
E-2
E-3
Although starter rotates,
engine does not start.
When engine control dial is
fully rotated, engine stalls.
When engine control dial is
fully rotated, engine speed is
slow.
z
{
{
{
z
z
z
z
z
z
z
Check batteries.
Remark
T5-7-22
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are
described provided that each trouble
occurs independently.
E-4
Although engine control dial is
rotated, engine speed does not
changed.
z
z
In case more than one trouble occurs at the
same time, find out all faulty components
while checking all suspected components
in each trouble symptom.
E-5
E-6
Engine speed does not
increase when engine starts.
Faulty HP mode.
z
z
z
{
E-7
Although key switch is turned
OFF, engine does not stop.
{
z
z
z
z
z
z
z
z
{
z
z
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.
T5-7-23
TROUBLESHOOTING / Troubleshooting B
Trouble Symptom
E-8
E-9
Faulty auto-idle.
Faulty E mode.
z
{
z
{
E-10
When traveling or operating
front attachment at slow
idle, engine hunts.
Part
MC
ECM
ICF
Monitor Unit
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pump 1 Control Pressure Sensor
Pump 2 Control Pressure Sensor
Pressure Sensor (Travel)
Pressure Sensor (Front Attachment)
Pressure Sensor (Swing)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Auxiliary)
Hydraulic Oil Temperature Sensor
Coolant Temperature Sensor
Key Switch
Engine Control Dial
Auto-Idle Switch
Power Mode Switch
Torque Control Solenoid Valve
Starter Cut Relay
ECM Main Relay
Battery Relay
Glow Plug Relay
Engine Electrical Equipment
Engine Unit
Pump Regulator
Swing Parking Brake
Release Spool (Signal Control Valve)
z
{
z
z
z
z
{
{
z
z
{
z
z
Remark
T5-7-24
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are
described provided that each trouble
occurs independently.
In case more than one trouble occurs at the
same time, find out all faulty components
while checking all suspected components
in each trouble symptom.
E-11
E-12
E-13
E-14
Although operating attachment
at attachment mode, engine
speed does not increase.
When attachment mode is
selected, engine speed does not
decrease.
Engine stalls during operation
under adverse condition such as
at high altitude.
Engine is difficult to start at low
temperature.
z
{
z
{
z
z
{
{
z
z
z
z
{
{
z
Check batteries.
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.
T5-7-25
z
z
z
TROUBLESHOOTING / Troubleshooting B
Trouble Symptom
Part
MC (Main Controller)
ECM
Torque Control Solenoid Valve
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pump 1 Control Pressure Sensor
Pump 2 Control Pressure Sensor
Pressure Sensor (Travel Forward)
Pressure Sensor (Travel Reverse)
Pressure Sensor (Front Attachment)
Pressure Sensor (Swing)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Auxiliary)
Travel N Sensor
Hydraulic Oil Temperature Sensor
Coolant Temperature Sensor
Auto-Idle Switch
Power Mode Switch
Brake Switch
FNR Switch
Travel Speed Mode Switch
Engine Speed Control Mode Selection
Switch
Battery Relay
Glow Plug Relay
Engine Electrical Equipment
Engine Unit
Pump Regulator
E-15
E-16
Although depressing
accelerator pedal during
travel operation, engine
speed does not change.
Although depressing
accelerator pedal during
digging operation,
engine speed does not
change.
z
z
{
{
{
{
z
z
{
z
z
z
z
Remark
T5-7-26
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-27
TROUBLESHOOTING / Troubleshooting B
All Actuator System Troubleshooting
Trouble Symptom
A-1
A-2
All actuator speeds are slow.
All
actuators
operated.
Part
MC
ECM
Monitor Unit
Torque Control Solenoid Valve
Pilot Shut-Off Solenoid Valve
Pump 2 Delivery Pressure Sensor
Pressure Sensor (Swing)
Pressure Sensor (Arm Roll-In)
Pilot Shut-Off Lever
Pilot Shut-Off Relay
Security Relay
Spool
Main Relief Valve
Arm 1 Flow Rate Control Valve
Main Pump
Regulator
Pilot Pump
Pilot Valve
Pilot Relief Valve
Pump 1 Flow Rate Control Valve
(Signal Control Valve)
Pump 2 Flow Rate Control Valve
(Signal Control Valve)
Arm 1 Flow Rate Control Valve
Control Spool (Signal Control Valve)
z
{
A-3
are
not
Single
swing
operation
speed becomes slow. Arm
speed is slightly slow during
arm level crowding.
{
z
z
z
z
z
{
z
{
z
z
z
z
z
Remark
T5-7-28
TROUBLESHOOTING / Troubleshooting B
In case more than one trouble occurs at the
same time, find out all faulty components
while checking all suspected components
in each trouble symptom.
NOTE: The trouble symptoms in this table are
described provided that each trouble
occurs independently.
A-4
A-5
A-6
Travel is not operated during
single travel operation. Single
bucket
operation
speed
becomes slow. Boom is not
raised properly during arm level
crowding.
Although control lever is turned
to neutral, actuator does not
stop.
Actuator speed is faster than
normal.
Precise control cannot be
performed.
z
z
z
z
z
z
z
z
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.
T5-7-29
TROUBLESHOOTING / Troubleshooting B
Front Attachment System Troubleshooting
Trouble Symptom
F-1
F-2
F-3
F-4
All front attachment
actuator operations
are weak.
Some cylinder are
not operated or
speeds are slow.
Arm speed is slow
during
combined
operation.
During
combined operation
of boom raise and
arm roll-in, boom
raise speed is slow.
Arm speed is slow
during arm level
crowding.
Bucket is slightly
slow during bucket
roll-in
single
operation.
Bucket does not
move
smoothly
during bucket roll-in
single operation.
Part
MC
Solenoid Valve Unit (SF)
Solenoid Valve Unit (SC)
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pressure Sensor (Swing)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Power Digging Switch
Spool
Main Relief Valve
Overload Relief Valve
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve
Bucket Regenerative Valve
Boom Flow Rate Control Valve
Bucket Flow Rate Control Valve
Boom Anti-Drift Valve
Arm Anti-Drift Valve
Emergency Valve
Shockless Valve
(Signal Control Valve)
z
z
{
{
{
{
{
z
z
z
z
z
z
Shuttle Valve
(Signal Control Valve)
z
{
z
z
Bucket Flow Rate Control Valve Control
Spool (Signal Control Valve)
z
Pilot Valve
Cylinder
Remark
T5-7-30
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are
described provided that each trouble
occurs independently.
In case more than one trouble occurs at the
same time, find out all faulty components
while checking all suspected components
in each trouble symptom.
F-5
F-6
F-7
F-8
When starting to move
during
combined
operation, arm does
not smoothly move.
Arm starts to move
slightly slow during arm
roll-in single operation.
These troubles often
occur
when
temperature is low.
When starting to move
during
combined
operation, boom does
not smoothly move.
Boom starts to move
slightly slow during
boom lower single
operation.
When boom raise or
arm
roll-out
is
operated, boom or arm
starts to move after
slightly
moving
downward.
Front attachment drifts
remarkably.
z
z
z
z
z
z
z
z
z
z
z
{
z
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.
T5-7-31
TROUBLESHOOTING / Troubleshooting B
Front Attachment System Troubleshooting
F-12
F-13
F-14
Attachment speed is
fast during combined
operation of attachment
(optional) and front
attachment
(when
pulverizer or crusher is
used).
Attachment speed is
fast during combined
operation of attachment
(optional) and front
attachment
(when
breaker attached with
auxiliary flow combiner
line is used).
Attachment speed is
fast during combined
operation of attachment
(optional) and front
attachment
(when
vibrating hammer is
used).
z
z
z
z
z
z
z
z
z
Trouble Symptom
Part
MC
Auxiliary Flow Rate Control Solenoid Valve
Auxiliary Flow Combiner Solenoid Valve
Maximum Pump 1 Flow Rate Limit Control Solenoid
Pressure Sensor (Auxiliary)
Pressure Sensor (Travel Forward)
Pressure Sensor (Travel Reverse)
Pressure Sensor (Arm Roll-Out)
Auxiliary Flow Rate Control Valve
Auxiliary Flow Combiner Valve
Remark
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.
NOTE: The trouble symptoms in this table are
described provided that each trouble
occurs independently.
In case more than one trouble occurs at the
same time, find out all faulty components
while checking all suspected components
in each trouble symptom.
T5-7-32
z
z
z
z
z
z
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are
described provided that each trouble
occurs independently.
Swing System Troubleshooting
Trouble Symptom
S-1
Swing is slow or unmoving.
Part
MC (Main Controller)
Torque Control Solenoid Valve
Solenoid Valve Unit (SC)
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pump 1 Control Pressure Sensor
Pump 2 Control Pressure Sensor
Pressure Sensor (Travel)
Pressure Sensor (Swing)
Pressure Sensor (Arm Roll-In)
Pump Device
Spool
Load Check Valve
Arm 1 Flow Rate Control Valve
Swing Parking Brake Release Spool
(Signal Control Valve)
Pump 1 Flow Rate Control Valve
(Signal Control Valve)
Pump 2 Flow Rate Control Valve
(Signal Control Valve)
Arm 1 Flow Rate Control Valve Control
Spool (Signal Control Valve)
Shuttle Valve (Signal Control Valve)
Swing Device
Travel Device
Center Joint
Pilot Valve
z
z
{
z
z
Remark
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.
T5-7-33
In case more than one trouble occurs at the
same time, find out all faulty components
while checking all suspected components
in each trouble symptom.
TROUBLESHOOTING / Troubleshooting B
Travel System Troubleshooting
Trouble Symptom
T-1
Machine does not
travel.
T-2
Machine does not
travel forward or
reverse.
Part
MC
Monitor Unit
Main Pump
Regulator
Solenoid Valve Unit (SF)
Solenoid Valve Unit (SI)
Travel Motor Displacement Angle
Control Solenoid Valve
Travel Mode Selector Solenoid
Valve
Fast Speed Selection Relay
Slow Speed Selection Relay
FNR Switch
Travel Speed Mode Switch
Brake Switch
Engine
Speed
Control
Mode
Selection Switch
Work Brake Release Switch
Brake Pressure Sensor
Brake Remaining Pressure Sensor
Travel N Sensor
Control Valve
Travel Shockless Valve
Accumulator Charging Valve
Brake Valve
Transmission
Front Axle
Rear Axle
Travel Motor
Center Joint
Pilot Valve
Axle Lock Cylinder
Operate Check Valve (Axle Lock
Cylinder)
z
z
T-3
T-4
Forward/reverse
travel speeds are
slow. Travel power is
weak.
When releasing
accelerator pedal,
hydraulic brake is not
applied.
(Macnine runs away.)
z
z
{
{
z
z
z
z
z
{
z
{
{
z
z
z
z
z
z
z
z
z
z
{
{
{
z
z
z
Remark
T5-7-34
z
z
z
{
z
z
TROUBLESHOOTING / Troubleshooting B
T-5
Travel mode (fast/slow)
does not shift.
z
T-6
Axle lock is not
released.
T-7
Axle lock is not
operable.
z
z
z
z
z
z
{
{
z
z
z
z
z
{
z
z
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.
T5-7-35
NOTE: The trouble symptoms in this table are
described provided that each trouble
occurs independently.
In case more than one trouble occurs at the
same time, find out all faulty components
while checking all suspected components
in each trouble symptom.
TROUBLESHOOTING / Troubleshooting B
Brake System Troubleshooting
Trouble Symptom
B-1
B-2
Parking brake is not operable
(not applied).
B-3
Service brake is not operable, Work brake is not work
or is not applied effectively.
operable.
Part
MC
ECM
Monitor Unit
Main Pump
Regulator
Solenoid Valve Unit (SF)
Solenoid Valve Unit (SI)
Travel Mode Selector Solenoid
Valve
FNR Switch
Travel Speed Mode Switch
Brake Switch
Engine Speed Control
Mode Selection Switch
Work Brake Release Switch
Brake Pressure Sensor
Brake Remaining Pressure Sensor
Travel N Sensor
Control Valve
Travel Shockless Valve
Accumulator Charging Valve
Brake Valve
Transmission
Front Axle
Rear Axle
Travel Motor
Center Joint
Pilot Valve
z
z
{
z
z
{
{
z
{
{
{
z
{
z
z
z
z
z
{
{
Remark
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.
T5-7-36
NOTE: The trouble symptoms in this table are
described provided that each trouble
occurs independently.
In case more than one trouble occurs at the
same time, find out all faulty components
while checking all suspected components
in each trouble symptom.
TROUBLESHOOTING / Troubleshooting B
Steering System / Other System Troubleshooting
Trouble Symptom
H-1
H-2
O-1
Although steering wheel
is rotated, steering is
heavy.
Although steering wheel
is rotated, steering is
impossible.
Wiper is not operable.
O-2
Air Conditioner is
faulty.
Part
Steering Pump
Steering Valve
Center Joint
Front Axle
Other Electrical Equipment
z
z
z
z
{
{
z
z
Remark
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.
T5-7-37
NOTE: The trouble symptoms in this table are
described provided that each trouble
occurs independently.
In case more than one trouble occurs at the
same time, find out all faulty components
while checking all suspected components
in each trouble symptom.
TROUBLESHOOTING / Troubleshooting B
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter does not rotate.
IMPORTANT: As electric current from the key
switch is not routed to the starter
relay except with the pilot shut-off
lever in the UNLOCK position and
with the brake switch in the P (parking brake) position, the starter does
not rotate. (Refer to the SYSTEM /
Electrical System group.)
YES Faulty starter cut relay.
• This trouble has nothing to do with the electronic
control system such as MC.
• Check the wiring connections first.
Check if voltages at
YES terminals #5 and #6 in
key switch are 24 V.
Check if primary
screen or password
input screen is displayed on monitor unit.
Switch starter cut relay
with other general relay.
Check if starter rotates.
YES
· Key switch: START
· Monitor unit: Primary
screen
NO
Check for continuity
between positive terminal in battery and
terminal #1 in key
switch.
YES Faulty key switch.
· Key switch: START
· Monitor unit: Primary
screen
NO
Disconnect connector
monitor-A in monitor
YES unit.
Check if voltage between terminal #A7
(harness end) of connector and machine is
24 V or more.
· Key switch: ON
NOTE: As for the
Check if battery voltpassword
age and electrolyte
setup type
density are normal,
machine,
NO
and fusible link (45 A)
the passis not blown.
word input
· Voltage: 24 V or more
screen
is
Density: 1.26 or more
displayed.
Disconnect starter cut
relay.
Check if voltage at
terminals #1 and #3
(harness end) of connector is 24 V.
· Key switch: ON
NO
· Key switch: START
· Monitor unit: Primary
screen
NO
Faulty harness between
battery and key switch.
YES Faulty monitor unit.
NO
Open circuit in harness
between monitor unit
and key switch.
Faulty battery.
Faulty fusible link.
Key Switch:
Battery Relay:
Terminal A
T105-07-04-002
T5-7-38
T178-05-04-001
TROUBLESHOOTING / Troubleshooting B
YES Check if voltage at
terminal A in battery
relay is 24 V.
Disconnect connector
of starter relay 2.
Connect terminal S
(harness end) of conYES nector to machine.
Check for continuity
between terminal #4
(harness end) of connector in starter cut
relay and machine.
Check if voltage at
YES terminal #2 (harness
end) of connector in
starter cut relay is 0
V.
Faulty starter, or faulty
YES harness between starter
and battery relay.
Faulty battery relay.
NO
Shorted circuit in harness
between starter cut relay
and emergency stop
switch.
NO
Open circuit in harness
between starter cut relay
and starter relay.
NO
Open circuit in harness
between key switch and
starter cut relay.
NO
Connector (Harness end of connector viewed from the
open end side)
Monitor Unit
Connector Monitor-A
Starter Cut Relay
Starter Relay
#A7
E
S
T183-05-05-001
T5-7-39
T183-05-04-003
R
TROUBLESHOOTING / Troubleshooting B
E-2 Although starter rotates, engine does not
start.
• Check the wiring connections first.
Faulty ECM main relay.
YES
Switch ECM main
relay with other general relay.
Check if engine
starts.
Disconnect ECM main
relay from connector.
Check if voltage beNO tween terminal #3
(harness end) of connector and machine is
specification.
· Specification: 24V
Connect terminal #5
(harness end) of connector in ECM main relay to machine.
YES Disconnect connector in
ECM.
Check for continuity
between terminals #2,
#5 (harness end) of
connector and machine.
Connect terminal #1
(harness end) of
connector in ECM
main relay to maYES
chine.
Check for continuity
between terminals
#21, #40 (harness
end) of connector in
ECM and machine.
Open circuit in harness
between ECM main relay
NO and ECM.
Open circuit in harness
between key switch and
ECM main relay.
NO
· Check if fuse #8 is
blown.
Connector (Harness end of connector viewed from the
open end side)
ECM Main Relay
ECM Connector
#21
#24
#5
T183-05-04-003
T1GR-05-04-002
#40
T5-7-40
#2
TROUBLESHOOTING / Troubleshooting B
Check if voltage
YES between terminal
#24 (harness
Check for contiend) of connector
nuity between
in ECM and machine is specificaYES terminal #2 (harness end) of contion.
nector in ECM
· Key switch: ON
main relay and
· Specification: 24
machine.
V
Disconnect con- YES Open circuit in harness
between key switch and
nector ICF-C in
monitor unit.
ICF. Check if
voltage
between
YES
Check if fuse #18 is blown.
terminal #C7
Disconnect
(harness end) of
connector MC-B
connector and
Open circuit in harness
in MC.
machine is specibetween key switch and
Check
if
voltage
YES
fication.
NO ICF.
between terminal
· Key switch: ON
#B16 (harness
Check if fuse #18 is blown.
· Specification: 24
end) of connecV
tor and machine
Open circuit in harness
is specification.
between key switch and
· Key switch: ON NO
MC.
· Specification: 24
Check if fuse #18 is blown.
V
Open circuit in harness
between key switch and
ECM.
NO
Check if fuse #18 is blown.
Faulty ground in ECM
main relay.
NO
Open circuit in harness
between ECM main relay
and ECM.
NO
Connector ICF-C
Connector MC-B
#B16
B1
B19
B8
#C7
B25
T5-7-41
T1V1-05-04-002
TROUBLESHOOTING / Troubleshooting B
E-3 When engine control dial is fully rotated, engine stalls.
When engine control dial is fully rotated, engine speed is slow.
Related MC Fault Code: 11003-3, 11004-2
• Check the wiring connections first.
YES
Faulty MC, or faulty CAN
between MC and ECM.
Check if fault code is
displayed.
· MC or ECM cannot
be selected on controller diagnosing by
using Dr. ZX.
Refer to Engine Troubleshooting Manual.
NO
T5-7-42
TROUBLESHOOTING / Troubleshooting B
E-4 Although engine control dial is rotated, engine speed does not change.
Related MC Fault Code: 11004-2, 11101-3, 11101-4
• Check the wiring connections first.
Faulty engine control dial,
or open circuit in harness
between engine control
dial and MC.
YES
Check if fault code 11101-3 or
11101-4 is displayed. Monitor
engine control standard voltage (dial angle) by using Dr.
ZX.
Check if voltage is normal.
· Standard voltage
Slow idle position: 0.3 to 1 V
Fast idle position: 4.0 to 4.7 V
· Possible to display by built-in
diagnosing system.
YES
NO
Faulty CAN between MC
and ECM.
Check if fault code 11004-2 is
displayed at the same time.
· Possible to display on MC
monitor by using Dr. ZX.
Faulty MC.
NO
T5-7-43
TROUBLESHOOTING / Troubleshooting B
E-5 Engine speed does not increase when engine starts.
Related MC Fault Code: 11004-2, 11901-3, 11901-4
• Refer to the pages for the Auto Warming Up Control in the SYSTEM / Control System group in the
T/M (Operational Principle).
• Check the wiring connections first.
0 °C or higher
when starting
Normal.
NO Monitor oil temperature.
Check if fault code
11901-3 or 11901-4
is displayed.
· Monitor item: Hydraulic
oil temperature
· Possible to display by
built-in diagnosing system.
Monitor key switch.
Check if displayed “ky”
is highlighted in re0 °C or lower sponse to key switch
when starting operation.
· Monitor item: Key switch
NO
To A
Faulty hyd. oil temperature sensor, or open circuit in harness between
hyd. oil temperature
sensor and MC.
YES
A
Faulty key switch, or
YES open circuit in harness
between key switch and
MC.
NO
Faulty MC.
YES
Refer to fault code 11004
in Troubleshooting A.
Check if fault code
11004-2 is displayed at the same
time.
T5-7-44
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-45
TROUBLESHOOTING / Troubleshooting B
E-6 Faulty HP mode
• Even if power mode switch is turned to the HP
mode position, HP mode is not operated. (General
mode normally operates.)
Related MC Fault Codes: 11004-2, 11200-3,
11200-4, 11202-3, 11202-4, 11302-3, 11302-4,
11303-3, 11303-4
• The sensors detect the conditions necessary to
• Refer to the pages for HP Mode Control in the
operate HP mode. Therefore, if any of these sensors fails, HP mode becomes ineffective.
• Pressure sensors (arm roll-in and boom raise)
and pump 1 and 2 delivery pressure sensors are
also engaged in the HP mode control. However, if
these sensors fail, other operating functions will
be also affected.
SYSTEM / Control System group in the T/M (Operational Principle).
• Check the wiring connections first.
NO
NO
Check if fault code is
displayed.
Monitor power mode
switch.
Check if indication is
changed when power
mode switch is turned
to HP mode.
Faulty power mode
switch or open circuit in
harness between power
mode switch and MC.
Faulty MC.
· Monitor item: HP mode
SW
· Possible to display by
built-in diagnosing
system.
YES
NO
Faulty corresponding
sensor, or open circuit in
harness between MC and
sensor.
Check if fault code
11004-2 is displayed at
YES the same time.
YES
T5-7-46
Refer to fault code 11004
in Troubleshooting A.
TROUBLESHOOTING / Troubleshooting B
• Although the power mode switch is not turned to HP
mode, HP mode is operated.
• 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
faulty at the same time.
Shorted circuit in harness
between MC and power
mode switch.
YES
Monitor power mode
switch.
Check if “HP” is displayed.
· Monitor item: HP
mode SW
· Possible to display by
built-in diagnosing
system.
· Power mode switch:
P mode
YES
NO
Faulty ECM.
Check if fault code
11004-2 is displayed.
Faulty MC.
NO
T5-7-47
TROUBLESHOOTING / Troubleshooting B
E-7 Although key switch is turned OFF, engine
does not stop. (If the engine does not stop,
stop engine by turning the emergency stop
switch ON located under the seat stand.
Then, begin inspection.)
• Probably the symptoms such as “Engine speed is
slower than specification in all operating ranges”
or “Although engine control dial is rotated, engine
speed does not change” may come up. Perform
troubleshooting for these symptoms.
YES
Faulty key switch.
Check if voltage at
terminal #5 in key
switch is 24 V.
· Key switch: OFF
NO
Disconnect connector
in ECM.
Check if voltage between terminal #24
NO (harness end) of connector and machine is
0 V.
· Key switch: OFF
Shorted circuit in
harness between key
switch and ECM.
Faulty ECM.
YES
Key Switch
ECM Connector
(Harness end)
#24
T1GR-05-04-002
T105-07-04-002
T5-7-48
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-49
TROUBLESHOOTING / Troubleshooting B
E-8 Faulty auto-idle system
• Although control lever is turned to neutral, auto-idle
is not operated.
Related MC Fault Code: 11004-2, 11304-3, 11304-4,
11307-3, 11307-4
Related ECM Fault Code: 639-2, 639-3
• If trouble symptoms E1 to E8 are recognized,
• Refer to the pages for Auto-Idle Control in the
perform the troubleshooting of these troubles
first.
• Although failure in pressure sensors (travel forward/reverse and front attachment) may have
relevance to malfunction of the auto-idle control.
However, if these sensors fail, other operating
functions will also be affected.
SYSTEM / Control System group in the T/M (Operational Principle).
• Check the wiring connections first.
YES
YES
YES
Check if auto-idle is
displayed on monitor
unit.
Monitor auto-idle
switch.
Check if ON/OFF is
shifted when
auto-idle switch is
shifted.
Faulty MC.
NO
· Monitor item:
Auto-idle SW
· Auto-idle switch: ON
NO
Check if fault code
for MC or ECM is
displayed.
Check if fault code
11004-2 is displayed.
NO
Disconnect connector monitor-B in
monitor unit.
Check for continuity
between terminal
#B18 (harness end)
of connector and
machine.
YES
NO
· Auto-idle switch: ON
Connector (Harness end of connector viewed from the
open end side)
Connector Monitor-B
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
#B18
T5-7-50
Open circuit in harness between
auto-idle switch and
MC.
Faulty auto-idle
switch.
Open circuit in harness between
auto-idle switch and
monitor unit.
TROUBLESHOOTING / Troubleshooting B
Refer to fault code
11004 in Troubleshooting A.
YES
Refer to Engine
Troubleshooting
Manual.
YES
NO
Check if fault code
639-2 or 639-3 is
displayed.
Faulty corresponding
sensor, or open circuit in harness between MC and sensor.
NO
T5-7-51
TROUBLESHOOTING / Troubleshooting B
• Although auto-idle switch is turned OFF, auto-idle is
operated.
Disconnect connector
MC-B in MC and connector in switch panel.
Check for continuity
between terminal #B6
(harness end) of connector MC-B and machine.
Shorted circuit in
harness between MC
and auto-idle switch.
YES
YES
NO
· Auto-idle switch: OFF
Check if fault code
11004-2 is displayed.
Refer to fault code
11004 in Troubleshooting A.
Faulty MC.
NO
Connector (Harness end of connector viewed from the
open end side)
Connector MC-B
#B6
B1
B8
B19
B25
T5-7-52
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-53
TROUBLESHOOTING / Troubleshooting B
E-9 Faulty E mode
• Although power mode switch is turned to the E
mode position, engine speed does not change. (Engine speed does not decrease.)
Related MC Fault Code: 11004-2, 11200-3, 11200-4,
11202-3, 11202-4, 11206-3, 11206-4, 11208-3,
11208-4
• If trouble symptoms E-1 to E-9 are recognized,
• Pump 1, 2 control pressure sensors and pump 1,
perform the troubleshooting of these troubles
first.
• The sensors detect the conditions necessary to
operate E mode. Therefore, if any of these sensors fails, E mode becomes ineffective.
2 delivery pressure sensors are also engaged in
the E mode control. However, if these sensors fail,
other operating functions will be also affected.
• Refer to the pages for E Mode Control in the
SYSTEM / Control System group in the T/M (Operational Principle).
• Check the wiring connections first.
NO
NO
Monitor power mode
switch.
When power mode
switch is turned to E
mode, check if indication is changed.
· Monitor item: E/P SW
· Possible to display by
built-in diagnosing
system.
Check if fault code is
displayed.
Faulty MC.
YES
NO
YES
Faulty power mode
switch, or open circuit in
harness between power
mode switch and MC.
Faulty corresponding
sensor, or open circuit in
harness between MC and
sensor.
Check if fault code
11004-2 is displayed.
YES
T5-7-54
Refer to fault code 11004
in Troubleshooting A.
TROUBLESHOOTING / Troubleshooting B
• Although power mode switch is not turned to E
mode, engine speed decreases.
• Required engine speed from the engine control
-1
dial must be beyond 1800 min when the pump
control pressures of pump 1 and 2 are low or the
average delivery pressures of pump 1 and 2 are
high, if E mode control is performed. The sensors
related to this condition may not be faulty at the
same time.
Shorted circuit in harness
between MC and power mode
switch, or faulty power mode
switch.
NO
Monitor power mode switch.
Check if “E” is displayed.
· Monitor item: E/P SW
· Possible to display by built-in
diagnosing system.
· Power mode switch: P mode
YES
YES
Refer to fault code 11004 in
Troubleshooting A.
Check if fault code
11004-2 is displayed.
Faulty MC.
NO
T5-7-55
TROUBLESHOOTING / Troubleshooting B
E-10 When traveling or operating front attachment at slow idle, engine hunts.
Related MC Fault Code: 11004-2, 11304-3, 11304-4,
11307-3, 11307-4
• Although the failure in pressure sensors (travel
forward/reverse and front attachment) may have
relevance to malfunction of idle speed-up control.
However, if these sensors fail, other operating
functions will also be affected. (Refer to the relationship between machine trouble symptom and
related part on page T5-7-2.)
• Refer to the pages for Idle Speed-Up Control in
the SYSTEM / Control System group in the T/M
(Operational Principle).
YES
Faulty engine unit or
faulty ECM.
· Set idle speed increasing
in MC by using Dr. ZX.
Set engine control dial to Min.
Check if engine speed is
faster than increased idle
speed.
· Monitor item:
Requested engine speed
· Possible to display by built-in
diagnosing system.
YES
NO
Refer to fault code 11004
in Troubleshooting A.
Check if fault code
11004-2 is displayed.
Faulty MC.
NO
· Set idle speed increasing
in MC by using Dr. ZX.
T5-7-56
TROUBLESHOOTING / Troubleshooting B
E-11 Although operating attachment at attachment mode, engine speed does not increase.
Related MC Fault Code: 11004-2, 11918-2
• Refer to the pages for Attachment Operation
• In case trouble symptoms E-1 to E-11 are recog-
Speed Increase Control in the SYSTEM / Control
System group in the T/M (Operational Principle).
• Check the wiring connections first.
nized, perform the troubleshooting of these troubles first.
• Although the failure in pressure sensor (auxiliary)
and power mode switch may have relevance to
the malfunction of attachment operation speed
increase control. However, if these sensor and
switches fail, other operating functions will also be
affected.
NO
NO
Check if attachment
speed adjustment
has been set to “Increase (+)” on “Parameter Change” in
Dr. ZX.
Check if attachment
speed adjustment
has been set to “Decrease (-)” on “Parameter Change” in
Dr. ZX.
YES
Monitor attachment
control pilot pressure.
Check if pressure
varies in response to
lever stroke.
· Monitor item: ATT
control pilot pressure
YES
NO
To A
Faulty auxiliary pressure
sensor.
Normal (If P speed is set
to decrease, this control
system is deactivated.)
YES
YES
A
Normal (Set to “Increase
(+)”.)
Refer to fault code 11004
in Troubleshooting A.
Fault code 11004-2 or
11918-2 is displayed.
Faulty MC.
NO
T5-7-57
TROUBLESHOOTING / Troubleshooting B
E-12 When attachment mode is selected, engine
speed does not decrease.
Related MC Fault Code: 11004-2, 11918-2
• If trouble symptoms E-1 to E-11 are recognized,
perform the troubleshooting of these troubles beforehand.
• Refer to the pages for Attachment Operation
Speed Limit Control in the SYSTEM / Control
System group in the T/M (Operational Principle).
• Check the wiring connections first.
YES
YES
Refer to fault code 11004
in Troubleshooting A.
Check if fault code
11004-2 or 11918-2 is
displayed.
Faulty MC.
NO
Check if attachment
speed adjustment has
been set to “Decrease
(-)” on “Parameter
Change” in Dr. ZX.
Normal (Set to “Decrease
(-)”.)
NO
T5-7-58
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-59
TROUBLESHOOTING / Troubleshooting B
E-13 Engine stalls during operation under adverse condition such as at high altitude.
Test Harness (ST 7226)
When operating corresponding control lever and
switch: ON
Related MC Fault Code: 11004-2, 11100-2, 11910-2,
11401-2, 11401-3, 11401-4
• If speed sensing control is not operated, the en-
4
gine will stall under adverse operating conditions.
• Check the wiring connections first.
3
1
2
150
50
50
50
2
1
T107-07-06-015
YES
Check if fault code
NO
11401-2, 11401-3 or
11401-4 is displayed.
NO
Monitor actual engine
speed.
Check if engine speed
is abnormal.
Faulty torque control
solenoid valve.
Monitor torque control
solenoid valve output.
Install pressure gauge
to output port so that
pressure is measured
by pressure gauge and
Dr. ZX.
Check if both measured pressure values
by pressure gauge and
Dr. ZX vary identically.
Disconnect harness of
torque control solenoid valve.
NO Connect test harness
(ST 7226) between
solenoid valve and
harness.
Check if test harness
lamp lights.
Disassemble and
YES check regulator.
· Monitor item: Pump
torque P/S valve output
· Refer to the Operational Performance
Test section.
· Monitor item:
Actual engine speed
· Possible to display by
built-in diagnosing system.
Refer to fault code
11004 in Troubleshooting A.
YES
Check if fault code
11004-2 or 11100-2 is
YES displayed.
YES Refer to Engine Troubleshooting Manual.
Check if fault code
NO 11910-2 is displayed.
Faulty MC.
NO
T5-7-60
TROUBLESHOOTING / Troubleshooting B
YES
Faulty torque control solenoid valve.
Open circuit in harness
between torque control
solenoid valve and MC.
NO
T5-7-61
TROUBLESHOOTING / Troubleshooting B
E-14 Engine is difficult to start at low temperature. (During cold weather or in cold districts, engine is difficult to start or does not
start even if pre-heated.)
Related MC Fault Code: None
• Check if electricity is routed to the glow plugs.
Check the glow plugs for any abnormality.
• The pre-heat system operates only when coolant
temperature is below 20 °C (68 °F).
• Check the battery.
• Check the wiring connections first.
Faulty sensor.
YES
Disconnect connector of
coolant temperature sensor.
Check if voltage at glow plug
is 20 to 24 V.
Faulty ECM.
YES
· Key switch: ON
NO
Disconnect connector in
ECM. Connect terminal #4
(harness end) of connector
to machine. Check if problem is corrected.
· Connect to machine from
the back of connector by
using a clip with the connector connected.
NO
Measure each glow plug
resistance.
· 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: 10 Ω or less
Specification: 20 to 24 V
T105-07-04-006
T5-7-62
T105-07-04-007
TROUBLESHOOTING / Troubleshooting B
∞Ω
Faulty glow plug.
NO
YES
Connect connector in
glow plug relay. Connect
terminal #4 (harness end)
of connector to machine.
Check if voltage at glow
plug is 20 to 24 V.
· Key switch: ON
YES
Faulty glow plug relay, or
faulty harness between
glow plug relay and glow
plug.
Open circuit in harness
between glow plug relay
and ECM.
Disconnect connector in
glow plug relay.
Check if voltages at termi10 Ω or less nals #1 and #3 (harness
end) of connector in glow
plug relay are 20 to 24 V.
If terminal #1 is 0 V, open
circuit in harness between glow plug relay
and battery. If terminal #3
is 0 V, open circuit in
harness between glow
plug relay and terminal M
in key switch.
· Key switch: ON
NO
· Check if fuse #16 is
blown.
T5-7-63
TROUBLESHOOTING / Troubleshooting B
E-15 Although depressing accelerator pedal
during travel operation, engine speed does
not change.
Connector (Harness end of connector viewed from the
open end side)
• Check that:
Switch Panel
Brake Switch: OFF or Axle Lock Position
Engine Speed Control Mode Selection Switch:
Pedal Mode Position
FNR Switch: F or R Position
• Faulty pressure sensor (travel forward/reverse)
may be the cause of this problem. In this case,
other functions should become abnormal.
●
#1
Faulty MC.
YES
YES Monitor FNR (R)
switch. Check if ON
is displayed.
· FNR switch: R
Check if neutral
indicator on steering
column monitor
lights.
· Key switch: ON
· FNR switch: F or R
Faulty FNR switch.
NO
YES
YES
NO
Monitor parking
brake switch. Check
if ON is displayed.
· Brake switch:
except P (parking
brake)
Monitor pedal EC
switch. Check if ON
is displayed.
· Engine speed control
mode selection switch:
Pedal
NO
Disconnect connector in switch panel.
Check if voltage between terminal #1
(harness end) of
connector and machine is 5 V.
· Key switch: ON
T5-7-64
Faulty brake switch, or
shorted circuit in harness
between MC and terminal
#3 in brake switch.
Faulty MC.
NO
YES
Faulty engine speed control mode selection switch.
NO
Open circuit in harness
between MC and engine
speed control mode selection switch.
TROUBLESHOOTING / Troubleshooting B
E-16 Although depressing accelerator pedal
during digging operation, engine speed
does not change.
Connector (Harness end of connector viewed from the
open end side)
• Check that:
Switch Panel
Work Brake: Operable
FNR Switch: N Position
Engine Speed Control Mode Selection Switch:
Pedal Mode Position
• Faulty pressure sensor (travel forward/reverse)
may be the cause of this problem. In this case,
other functions should become abnormal.
●
#11
Faulty FNR switch, or
faulty harness between
MC and FNR switch.
NO
Monitor FNR (F) switch and FNR (R)
switch.
Check if OFF is displayed.
YES
YES
FNR switch: N
Monitor pedal EC
switch.
YES Check if ON is displayed.
· Engine speed control
mode selection switch:
Pedal
NO
Monitor implement
brake state.
Check if ON is displayed.
Faulty brake switch, or
shorted circuit in harness
between MC and terminal
#3 in brake switch.
Faulty MC.
· Brake switch:
Axle lock or Auto axle
lock
NO
Disconnect connector in switch panel.
Check if voltage between terminal #11
(harness end) of
connector and machine is 5V.
YES
Faulty engine speed control mode selection switch.
NO
Open circuit in harness
between MC and engine
speed control mode
switch.
· Key switch: ON
T5-7-65
TROUBLESHOOTING / Troubleshooting B
ALL ACTUATOR SYSTEM TROUBLESHOOTING
A-1 All actuator speeds are slow.
Related MC Fault Code: 11004-2, 11100-2, 11910-2,
11401-2, 11401-3, 11401-4
• Although speed is satisfactory, and when power is
• Reduction in pump 1 and 2 flow rate due to some
weak, refer to the troubleshooting for faulty main
relief valve (F-1).
• Check the wiring connections first.
reasons or faulty pilot system (A-2) may cause
this trouble.
• Check fuse of the torque control solenoid valve.
Faulty torque control solenoid valve, or open
circuit in harness between MC and torque
control solenoid valve.
YES
YES
Check if fault code
11401-2, 11401-3 or
11401-4 is displayed.
YES
NO
Check if primary pilot
pressure is normal.
· Fully boom raised or fully
arm rolled-in
· Monitor item:
Boom raise pilot pressure, Arm roll-in pilot
pressure
Check if fault code
11004-2, 11100-2 or
11910-2 is displayed.
YES
NO
Adjust, disassemble
and clean pilot relief
valve.
Check if same symptom appears.
NO
T5-7-66
Faulty CAN between MC
and ECM, or faulty MC.
Faulty pump device.
NO
Faulty pilot pump, or
clogged pilot filter.
End.
TROUBLESHOOTING / Troubleshooting B
A-2 All actuator are not operated.
• The pilot shut-off circuit or the electric lever circuit
• When the key switch is turned to the START posi-
may be faulty.
• If the alarm is displayed on the monitor unit, refer
to Troubleshooting A.
• When the key switch is turned to the START position with the pilot shut-off lever in the LOCK position, the starter does not rotate.
• Check the wiring connections first.
tion with the engine stop switch in the ON position,
the starter rotates.
Refer to the pages for the Electrical System group
/ SYSTEM in the T/M (Operational Principle).
Faulty pilot shut-off relay.
YES
Switch pilot shut-off
relay with other general relay.
Check if actuator can
be operated.
· Pilot shut-off lever:
LOCK position
YES
Faulty security relay.
NO
Connect terminal #2
(harness end) of connector in pilot shut-off
solenoid valve to machine.
Disconnect connector
in pilot shut-off relay.
Check for continuity
between terminal #2
(harness end) of connector and machine.
Switch security relay
with other general
relay.
NO Check if actuator can
be operated.
YES
· Pilot shut-off lever:
LOCK position
Disconnect connector in pilot shut-off
solenoid valve.
Check if voltage between terminal #1
(harness end) of
connector and machine is 24 V.
· Key switch: ON
NO
To A
Open circuit in harness
between pilot shut-off
solenoid valve and battery relay.
· Check if fuse #4 is
blown.
· Check if fusible link 65
A is blown.
Connector (Harness end of connector viewed from the
open end side)
Pilot Shut-Off Solenoid Valve
Pilot Shut-Off Relay
Security Relay
#1
T183-05-04-003
T5-7-67
#2
T1V1-05-04-103
TROUBLESHOOTING / Troubleshooting B
A
Check if voltage
YES between terminal
#1 (harness end) of
connector in pilot
shut-off relay and
machine is 24 V.
Connect terminal #5
(harness end) of connector in pilot shut-off
relay to machine.
YES Disconnect security
relay.
Check for continuity
between terminal #4
(harness end) of connector and machine.
Check for continuity
between terminal #3
YES
(harness end) of
connector in security
relay and machine.
NO
Check for continuity
between terminal #2
YES (harness end) of
connector in security
relay and machine.
Faulty ground in security
NO relay.
Open circuit in harness
between pilot shut-off
relay and security relay.
Open circuit in harness
between pilot shut-off
relay and battery relay.
NO
Open circuit in harness
between pilot shut-off
solenoid valve and pilot
shut-off relay.
NO
T5-7-68
TROUBLESHOOTING / Troubleshooting B
Faulty monitor unit, or
shorted circuit in harness
between monitor unit and
security relay.
YES
NO
Connect terminal #2
(harness end) of connector in pilot shut-off
relay to machine.
Disconnect connector
monitor-B in monitor
unit.
Check for continuity
between terminal #2
(harness end) of connector and machine.
Check for continuity
YES between terminals
#B12 and #B19
(harness end) of
connector monitor-B.
Connect connector
monitor-B.
Check for continuity
YES between terminal #2
(harness end) of
connector in pilot
shut-off relay and
machine.
YES Faulty pilot shut-off solenoid valve.
Faulty monitor unit.
NO
· Pilot shut-off lever:
UNLOCK position
Open circuit in harness
between terminals #B12
and #B19 (harness end)
of connector monitor-B,
or faulty pilot shut-off
lever.
NO
Open circuit in harness
between pilot shut-off
relay and monitor unit.
NO
Connector (Harness end of connector viewed from the
open end side)
Pilot Shut-Off Relay
Connector Monitor-B
#B2
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T183-05-04-003
#B19
T5-7-69
#B12
TROUBLESHOOTING / Troubleshooting B
A-3 Single swing operation speed becomes slow.
Arm speed is slightly slow during arm level
crowding. (All problems occur at the same
time.)
Related MC Fault Code: None
• The pump 2 flow rate is minimized (approx. 20
L/min) due to some reasons. Accordingly, the
swing motors, which are driven by pressure oil
from pump 2, moves very slow.
• Pressure oil from pump 1 is also routed to the arm
and boom cylinders so that the arm and boom can
move at a slightly slow speed in single operation.
However, during level crowding 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).
YES
Faulty pump 2 regulator.
NO
Bound pump 2 flow rate
control valve in signal control valve.
Monitor pump 2 flow
control pressure.
Check if pressure increases in proportion to
swing lever stroke.
· Monitor item: Pump 2
flow control pressure
· Possible to display by
built-in diagnosing system.
T5-7-70
TROUBLESHOOTING / Troubleshooting B
A-4 Travel is operated during single travel operation. Single bucket operation speed becomes slow. Boom is not raised properly
during arm level crowding. (All problems
occur at the same time.)
Related MC Fault Code: None
• The pump 1 flow rate is minimized (approx. 20
L/min) due to some reasons. Accordingly, the
travel motor and bucket cylinder, which are actuated by pressure oil from pump 1, moves very
slow.
• Pressure oil from pump 2 is also routed to the arm
and boom cylinders so that the arm and boom can
move at a slightly slow speed in single operation.
However, in level crowd operation, pressure oil is
routed to the arm prior to the boom so that boom
is scarcely raised.
• Refer to the SYSTEM / Hydraulic System group in
the T/M (Operational Principle).
YES
Faulty pump 1 regulator.
NO
Bound pump 1 flow rate
control valve in signal control
valve.
Monitor pump 1 flow
control pressure.
Check if pressure increases in proportion to
accelerator pedal stroke.
· Monitor item: Pump 1 flow
control pressure
· Possible to display by
built-in diagnosing system.
T5-7-71
TROUBLESHOOTING / Troubleshooting B
A-5 Although control lever is turned to neutral,
actuator does not stop.
• Bound spool in the pilot valve or bound main
spool in the control valve is suspected.
Faulty pilot valve.
YES
· When control lever is in neutral, pilot pressure is routed to
spool end in control valve.
Check if actuator stops when
pilot shut-off lever is turned to
LOCK position.
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.
T5-7-72
TROUBLESHOOTING / Troubleshooting B
A-6 Actuator speed is faster than normal
Precise control cannot be performed.
Related MC Fault Code: None
• The pump 1 or 2 flow rate is maximized due to
some reasons.
Therefore, the maximum flow rate is supplied and
actuator speed is faster though the control lever
does not reach the full stroke.
• Refer to the SYSTEM / Hydraulic System group in
the T/M (Operational Principle).
YES
Faulty pump regulator.
NO
Bound pump flow rate control
valve in signal control valve.
Monitor pump control pressures
of pump 1 and 2.
Check if pressure changes in
response to lever operation.
· Pump 1: Bucket operation
· Pump 2: Swing operation
· Monitor item:
Pump 1 flow control pressure
Pump 2 flow control pressure
· Possible to display by built-in
diagnosing system.
T5-7-73
TROUBLESHOOTING / Troubleshooting B
FRONT ATTACHMENT SYSTEM TROUBLESHOOTING
F-1 All front attachment actuator operations are
weak.
• If operating speeds are extremely slow, pump
control may be malfunctioning (A-3, A-4). Faulty
pilot system may also cause this trouble.
34.3 to 36.3 MPa
2
(350 to 370 kgf/cm , 4990 to 5280 psi)
Main relief valve should be normal.
Find out cause of trouble by
tracing other trouble symptoms.
Monitor pump 1 and 2 delivery pressures.
· Monitor item: Pump 1 and 2 delivery pressures
· Possible to display by built-in
diagnosing system.
· Relieve boom, arm and bucket
circuits.
· Power mode switch: P
· Work mode: Digging
Adjust main relief valve.
Less than 34.3 MPa
2
(Less than 350 kgf/cm , 4990 psi)
T5-7-74
TROUBLESHOOTING / Troubleshooting B
F-2 Some cylinders are not operated or speeds
are slow.
• When other actuators (travel and swing) operate
normally, the pilot pump (primary pilot pressure) is
considered to be normal.
• If single bucket operation speed is slow, refer to
F-4.
• If single arm roll-in operation speed is slow, refer
to F-5.
• If single boom lower operation speed is slow, refer
to F-6.
YES
Bound control valve
spool, or faulty cylinder
(faulty seal kit).
YES Check if overload
relief pressure is normal.
YES
Measure or monitor
secondary pilot
pressure.
Check if secondary
pilot pressure is
normal.
· Secondary pilot
pressure:
Refer to the Operational Performance
Test section.
· Monitor item:
Boom raise pilot
pressure, arm roll-in
pilot pressure.
· Possible to display by
built-in diagnosing
system.
Monitor pump control
pressure.
Check if pump control pressure
changes smoothly
while moving control
lever slowly.
· Monitor item:
Pump 1 flow pressure, pump 2 flow
pressure
· Possible to display
by built-in diagnosing system.
NO
NO
YES
Check if secondary
pilot pressure at inlet
NO port to signal control
valve.
· In case cylinders
other than boom are
abnormal, skip this
step and go NO.
Faulty overload relief
valve.
Faulty shuttle valve in
signal control valve.
Bound shockless valve
spool in signal control
valve.
Faulty pilot valve.
NO
T5-7-75
TROUBLESHOOTING / Troubleshooting B
F-4 Arm speed is slow during combined operation. Arm speed is slow during arm level
crowding.
• Refer to the pages for the SYSTEM / Control
Related MC Fault Code: 11202-3, 11202-4, 11301-3,
11301-4, 11302-3, 11302-4, 11303-3, 11303-4,
11403-2, 11403-3, 11403-4
System group / Arm Regenerative Control in the
T/M (Operational Principle).
NO
NO
Monitor solenoid valve
unit (SC) output. Install
pressure gauge to port
SC.
Check if both measured
values by pressure
gauge and Dr. ZX vary
identically.
· Monitor item: Arm regenerative P/S valve output
· Combined operation of
boom raise and arm
roll-in
· Measurement: Refer to
the Operational performance Test section.
Check if fault code
is displayed.
Disconnect harness in
solenoid valve unit (SC).
Connect test harness
(ST 7226) between solenoid valve unit (SC)
and harness. Check if
lamp lights.
YES
NO
Faulty solenoid valve
unit (SC).
Open circuit in harness
between solenoid valve
unit (SC) and MC.
· Combined operation of
boom raise and arm
roll-in.
YES
Check if arm regenerative valve at 5-spool side
YES in control valve is scored
or bound.
NO
Faulty arm regenerative
valve.
Find out cause of trouble by tracing other
trouble symptoms.
Faulty corresponding
sensor, or faulty MC.
Open circuit in harness
between MC and sensor.
YES
T5-7-76
TROUBLESHOOTING / Troubleshooting B
F-4 Bucket is slightly slow during bucket roll-in
single operation. Bucket does not move
smoothly during bucket roll-in single operation.
• Bucket flow rate control valve or bucket regenerative valve may be faulty.
• Refer to the COMPONENT OPERATION / Control
Valve group in the T/M (Operational Principle).
YES
NO
Check if bucket flow
rate control valve in
control valve is
bound or scored.
Install pressure gauge
to hose SK connecting
signal control valve to
bucket flow rate control
valve in control valve.
When relieving during
3-combined operation
of boom raise, arm
roll-in and bucket
roll-in, check if pressure is 3.9 MPa (40
2
kgfcm ).
Check if bucket reYES generative valve in
bucket spool is
bound or scored.
NO
Faulty bucket regenerative valve. (Disassemble,
clean or replace.)
Find out cause of trouble
by tracing other trouble
symptoms.
Bound bucket flow rate
control valve control
spool in signal control
valve.
NO
Faulty bucket flow rate
control valve. (Disassemble, clean or replace.)
YES
Signal Control Valve (Control Valve Side)
Hose SK
T178-03-06-015
T5-7-77
Bucket Flow Rate
Control Valve
T16W-03-03-032
TROUBLESHOOTING / Troubleshooting B
F-5 When starting to move during combined
operation, arm does not smoothly move.
Arm starts to move slightly slow during arm
roll-in single operation. These troubles often
occur when temperature is low.
• Refer to the COMPONENT OPERATION / Control
Valve group in the T/M (Operational Principle).
Faulty arm regenerative
valve. (Disassemble,
clean or replace.)
YES
NO
Check if arm regenerative valve is bound or
scored.
Find out cause of trouble
by tracing other trouble
symptoms.
NO
Check if arm anti-drift valve is
bound or scored.
Faulty arm anti-drift valve.
(Disassemble, clean or
replace.)
YES
F-6 When starting to move during combined
operation, boom does not move smoothly.
Boom starts to move slightly slow during
boom lower single operation.
• Refer to the COMPONENT OPERATION / Control
Valve group in the T/M (Operational Principle).
Faulty boom lower meter-in cut valve. (Disassemble, clean or replace.)
NO
NO
Check if boom
anti-drift valve is
bound or scored.
Check if boom lower
meter-in cut valve is
bound or scored.
NO
YES
Check if boom regenerative valve is
bound or scored.
Find out cause of trouble
by tracing other trouble
symptoms.
Faulty boom regenerative
valve. (Disassemble,
YES clean or replace.)
Faulty boom anti-drift
valve. (Disassemble,
clean or replace.)
YES
T5-7-78
TROUBLESHOOTING / Troubleshooting B
F-7 When boom raise or arm roll-out is operated,
boom or arm starts to move after moving
slightly downward.
YES Check if anti-drift valves
(arm and boom) are
bound or scored.
Check if load check valve in
control valve is normal.
YES
Faulty anti-drift valve.
Oil leaks in cylinder.
NO
· Disassemble / Visual
Inspection
Faulty load check valve.
NO
NOTE: 1. During the initial stage of operation, oil
pressure and flow rate from the pump is
low. Therefore, if the load check valve is
malfunctioning, the oil in the bottom side
of the boom cylinder flows back into the
circuit through the load check valve so
that the boom cylinder temporarily is retracted.
2. As oil pressure and flow rate from the
pump is low, if oil leaks from bottom side
(A) to rod side (B) due to faulty boom
cylinder piston or cylinder barrel, the
boom cylinder is temporarily retracted
during the initial stage of operation. In
addition, cylinder force is reduced. The
cylinder drift increases in this case.
(B)
When Load Check
Valve is Faulty:
(A)
T105-07-04-012
T5-7-79
TROUBLESHOOTING / Troubleshooting B
F-8 Front attachment drifts remarkably.
YES
Normal.
NO
Check if each front
attachment cylinder drift is within
specification.
NO
NO
Check if emergency
valve at boom 1 section in control valve
4-spool side is correctly adjusted.
YES
Check if cylinder drift
is reduced when pilot
shut-off lever is
turned to LOCK position.
Correctly adjust emergency valve and lock it
up.
Check if symptom is
deleted when overload
relief valve is temporarily switched with
another overload relief
valve.
Faulty pilot valve.
YES
• Boom Cylinder Internal Leakage Check
1. With the bucket cylinder fully retracted and the
arm cylinder slightly extended from the fully retracted position, lower the bucket tooth tips onto
the ground.
2. Remove the hoses from the boom cylinder rod
side. Drain oil from the hoses and cylinders. (Plug
the disconnected hose ends.)
3. Retract the arm cylinder and lift the bucket off the
ground. If oil flows out of the hose removed 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 removed pipe ends but the
boom cylinders are retracted, oil leaks in the control valve.
T5-7-80
T216-05-04-001
TROUBLESHOOTING / Troubleshooting B
Emergency Valve
NO
Scored control valve
spool, broken spring, or
loose spool end.
NO Check if oil leaks
in cylinders.
YES
YES
Faulty cylinder. (Replace
seal kit.)
Faulty overload relief
valve.
T16W-03-03-032
1
2
TCGB-05-07-001
Adjustment Procedure:
Loosen screw (1) fully and tighten lock nut (2).
: 4 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
T5-7-81
TROUBLESHOOTING / Troubleshooting B
F-9 Attachment speed is fast during combined
operation of attachment (optional) and front
attachment.
When pulverizer or crusher is used.
• Check the wiring connections first.
NO
NO
Disconnect connector
in pressure sensor
(auxiliary).
Check if voltage between terminals #1
and #3 (harness end)
of connector is 5±0.5
V.
Disconnect connector MC-D in MC.
YES Check for continuity
between terminal
#D5 (harness end) of
connector and terminal #2 (harness
end) of connector in
pressure sensor
(auxiliary).
YES
Open circuit in harness between MC and
pressure sensor (auxiliary).
Check if voltage between terminal #D5
(harness end) of connector MC-D and
machine is 0 V.
· Key switch: ON
· Key switch: ON
Switch pressure
sensor (auxiliary)
with other pressure
sensor.
Check if fault code
for switched pressure sensor is displayed.
Check if voltage between terminal #1
(harness end) of
connector in presNO sure sensor (auxiliary) and machine is
between 0.25 and
4.75 V.
· Key switch: ON
YES
NO
Open circuit in harness between MC and
pressure sensor (auxiliary) (terminal #3).
Open circuit in harness between MC and
pressure sensor (auxiliary) (terminal #1).
Faulty pressure sensor (auxiliary).
YES
Connector (Harness end of connector viewed from the
open end side)
Pilot Pressure Sensor (Auxiliary)
Pilot Pressure Sensor (Arm Roll-Out)
MC
Connector MC-A
#A7
#A23
T1V1-05-07-102
Auxiliary Flow Rate Control
Solenoid Valve
MC
Connector MC-D
#D5
T183-05-04-008
T1V1-05-04-003
#D9
T5-7-82
T183-05-04-009
TROUBLESHOOTING / Troubleshooting B
NO
Switch pressure
sensor (arm roll-out)
with other pressure
YES sensor.
Check if fault code
for switched pressure sensor is displayed.
Disconnect connector in pressure sensor (arm roll-out).
Check if voltage between terminals #1
and #3 (harness end)
of connector is 5±0.5
V.
· Key switch: ON
Disconnect connector MC-D in MC.
Check for continuity
between terminal
YES #D9 (harness end) of
connector and terminal #2 (harness
end) of connector in
pressure sensor (arm
roll-out).
Check if voltage between terminal #1
(harness end) of
connector in pressure
NO sensor (arm roll-out)
and machine is between 0.25 and 4.75
V.
· Key switch: ON
Check if voltage beYES tween terminal #D9
To A
(harness end) of
connector MC-D and
machine is 0 V.
· Key switch: ON
Open circuit in harness
between MC and pressure
NO
sensor (arm roll-out).
Open circuit in harness
YES between MC and pressure
sensor (arm roll-out) (terminal #3).
Open circuit in harness
between MC and pressure
NO sensor (arm roll-out) (terminal #1).
Faulty pressure sensor
(arm roll-out).
YES
Shorted circuit in harness
between MC and pressure
sensor (auxiliary).
NO
Faulty auxiliary flow rate
control solenoid valve.
YES
Check if auxiliary flow
YES rate control solenoid
valve is bound or
scored.
Check for continuity in
harness between MC
YES and auxiliary flow rate
control solenoid valve.
· Between terminal
#A23 of connector
MC-A in MC and terminal #1 of connector
in auxiliary flow rate
control solenoid valve
· Between terminal #A7
of connector MC-A in
MC and terminal #2 of
connector in auxiliary
flow rate control solenoid valve
A
Check if auxiliary
flow rate control
valve in control
NO valve is bound or
scored.
YES
Faulty auxiliary flow rate
control valve in control
valve.
Faulty MC.
NO
Open circuit in harness
between MC and auxiliary
flow rate control solenoid
valve.
NO
Shorted circuit in harness
between MC and pressure sensor (arm
roll-out).
NO
T5-7-83
TROUBLESHOOTING / Troubleshooting B
F-10 Attachment speed is fast during combined
operation of attachment (optional) and front
attachment.
When breaker attached with auxiliary flow combiner line is used.
NO
• Check the wiring connections first.
NO
Switch pressure
sensor (auxiliary)
with other pressure
sensor.
Check if fault code
for switched pressure sensor is displayed.
Disconnect connector
in pressure sensor
(auxiliary).
Check if voltage between terminals #1
and #3 (harness end)
of connector is 5±0.5
V.
· Key switch: ON
Disconnect connector MC-D in MC.
YES Check if voltage between terminal #D5
(harness end) of
connector and machine is 0 V.
YES
· Key switch: ON
YES
Check if voltage between terminals #1
(harness end) of
connector in presNO sure sensor (auxiliary) and machine is
between 0.25 and
4.25 V.
NO
Shorted circuit in harness between MC and
pressure sensor (auxiliary).
Switch pressure sensor (arm roll-out) with
other pressure sensor.
Check if fault code for
switched pressure
sensor is displayed.
Open circuit in harness between MC and
pressure sensor (auxiliary) (terminal #3).
Open circuit in harness between MC and
pressure sensor (auxiliary) (terminal #1).
· Key switch: ON
Faulty pressure sensor (auxiliary).
YES
Connector (Harness end of connector viewed from the open
end side)
・ Pilot Pressure Sensor (Auxiliary)
・ Pilot Pressure Sensor (Arm Roll-Out)
MC
Connector MC-A
#A7
#A23
T1V1-05-07-102
Auxiliary Flow Combiner Solenoid Valve
MC
Connector MC-D
T183-05-04-008
#D5
T1V1-05-04-003
#D9
T5-7-84
T183-05-04-009
TROUBLESHOOTING / Troubleshooting B
NO
Disconnect connector
in pressure sensor
(arm roll-out).
NO Check if voltage between terminals #1
and #3 (harness end)
of connector is 5±0.5
V.
Disconnect connector
MC-D in MC. Check if
YES
voltage between terminal #D9 (harness
end) of connector and
machine is 0 V.
· Key switch: ON
NO
Check if voltage between terminal #1
(harness end) of connector in pressure
sensor (arm roll-out)
and machine is between 0.25 and 4.75
V.
· Key switch: ON
Disconnect connector
MC-B in MC and connector in auxiliary flow
combiner solenoid
valve.
Check for continuity
YES between terminals #1
and #2 (harness end)
of connector in auxiliary flow combiner
solenoid valve.
YES
NO
Shorted circuit in harness
between MC and pressure sensor (arm
roll-out).
Check if auxiliary flow
NO combiner solenoid
valve is bound or
scored.
To A
Shorted circuit in harness
between MC and auxilYES iary flow combiner solenoid valve.
Open circuit in harness
between MC and pressure sensor (arm roll-out)
(terminal #3).
Open circuit in harness
between MC and pressure sensor (arm roll-out)
(terminal #1).
Faulty pressure sensor
(arm roll-out).
YES
Faulty auxiliary flow
combiner solenoid valve.
YES
A
Check if auxiliary flow
combiner valve in
NO control valve is bound
or scored.
Faulty auxiliary flow
combiner valve.
YES
Faulty MC.
NO
T5-7-85
TROUBLESHOOTING / Troubleshooting B
F-11 Attachment speed is fast during combined
operation of attachment (optional) and front
attachment.
When vibrating hammer is used.
• Check the wiring connections first.
Disconnect connector
in pressure sensor
(auxiliary).
Check if voltage between terminals #1
and #3 (harness end)
of connector is between 5±0.5.
NO
Switch pressure
sensor (auxiliary)
with other pressure
sensor.
Check if fault code
for switched pressure sensor is displayed.
· Key switch: ON
Disconnect connector MC-D in MC.
Check for continuity
YES between terminal
#D5 (harness end) of
connector and terminal #2 (harness
end) of connector in
pressure sensor.
NO
YES
Open
MC
と圧力センサ(予
circuit in harness
備)間のハーネス断線
between
MC and pressure sensor (auxiliary).
Checkコネクタのハー
MC-D
if voltage beネス側コネクタ#D5端
tween
terminal #D5
子と本体間の電圧を測
(harness
end) of con定するMC-D and
nector
電圧は 0Visか
machine
between 0
1V.
· キースイッチ:
Key switch: ONON
Check if voltage between terminal #1
(harness end) of
connector in presNO sure sensor (auxiliary) and machine is
between 0.25 and
4.75 V.
· Key switch: ON
YES
NO
Open
MC
と圧力センサ(予
circuit in harness
備)(#3 端子)間のハー
between
MC and presネス断線
sure
sensor (auxiliary)
(terminal #3).
Open circuit in harness
MC
と圧力センサ(予
between
MC and pres備)(#1
端子)間のハー
sure sensor
(auxiliary)
ネス断線
(terminal #1).
1
Faulty pressure sensor
(auxiliary).
YES
Connector (Harness end of connector viewed from the
open end side)
Pilot Pressure Sensor (Auxiliary)
Pilot Pressure Sensor (Travel Forward)
MC
Connector MC-A
MC
Connector MC-C
#A5
T1V1-05-07-102
Maximum Pump 1 Flow Rate Limit
Control Solenoid Valve
MC
Connector MC-D
#A31
T183-05-04-008
#D5
T1V1-05-04-003
T183-05-04-009
T5-7-86
T1V1-05-07-103
TROUBLESHOOTING / Troubleshooting B
YES
Switch pressure sensor (travel forward)
YES with other pressure
sensor.
Check if fault code for
switched pressure
sensor is displayed.
Disconnect connector
in pressure sensor
(travel forward).
NO Check if voltage between terminals #1
and #3 (harness end)
of connector is 5±0.5
V.
· Key switch: ON
Check if voltage beYES tween terminal #C2
(harness end) of connector MC-C and
machine is 0 V.
· Key switch: ON
Check if voltage between terminal #1
(harness end) of connector in pressure
NO sensor (travel forward)
and machine is between 0.25 and 4.75
V.
· Key switch: ON
Shorted circuit in harness
between MC and presNO sure sensor (travel forward).
Open circuit in harness
YES between MC and pressure sensor (travel forward) (terminal #3).
Open circuit in harness
between MC and presNO sure sensor (travel forward) (terminal #1).
Faulty pressure sensor
(travel forward).
YES
Shorted circuit in harness
between MC and pressure sensor (auxiliary).
NO
A
To A
Check for continuity in
harness between MC
and maximum pump 1
flow rate limit control
solenoid valve.
Disconnect connector
in maximum pump 1
flow rate limit control
solenoid valve.
YES Check if current between terminals #1
and #2 (harness end)
of connector is between 56 mA and 920
mA.
· Key switch: ON
YES
Faulty maximum pump 1
flow rate limit control
solenoid valve.
Faulty MC.
NO
· Between terminal
#A31 of connector
MC-A in MC and terNO
minal #1 of connector
in maximum pump 1
flow rate limit control
solenoid valve
· Between terminal #A5
of connector MC-A in
MC and terminal #2 of
connector in maximum pump 1 flow rate
limit control solenoid
valve
Open circuit in harness
between MC and maximum pump 1 flow rate
limit control solenoid
valve.
T5-7-87
TROUBLESHOOTING / Troubleshooting B
SWING SYSTEM TROUBLESHOOTING
S-1 Swing is slow or unmoving.
• Check whether the pilot system is faulty or the
• If left travel speed is also slow, refer to A-3.
main circuit is faulty.
• If other functions (front attachment and travel)
operate normally, the pilot pump is considered to
be normal. If the pilot system is displaying a
problem, the cause of trouble may exist in the
circuit after pilot valve.
Check if parking brake
YES release pressure is
approx. 3.9 MPa (40
2
kgf/cm ).
· Relieve arm circuit.
· Monitor item:
Front pilot pressure
· Possible to display by
built-in diagnosing system.
Monitor pump control
pressure.
YES While slowly operating
swing lever, check if
pump control pressure
varies smoothly.
Monitor secondary
pilot pressure.
Check if secondary
pilot pressure is normal.
· Specification:
Refer to the Operational Performance
Test section.
· Monitor item:
NO
Swing pilot pressure
· Possible to display by
built-in diagnosing system.
· Monitor item:
Pump 2 flow control
pressure
· Possible to display by
built-in diagnosing system.
NO
Check if swing motor
YES parking brake release
valve is scored or
bound.
Faulty swing parking
brake release spool in
NO signal control valve.
Bound pump 2 flow rate
control valve in signal
control valve.
Faulty pilot valve.
T5-7-88
TROUBLESHOOTING / Troubleshooting B
YES
Faulty swing reduction
gear.
YES Check if swing motor drain
oil amount is normal.
NO
· Measurement:
Refer to the Operational
Performance Test section.
Check if swing relief
pressure is normal.
· Relieve swing circuit.
· Monitor item: Pump 2
delivery pressure
· Possible to display by
built-in diagnosing system.
· Specification:
Refer to the Operational Performance
Test section.
Faulty swing motor.
NO
Faulty swing relief valve.
NO
Faulty swing motor parking brake release valve.
YES
T5-7-89
TROUBLESHOOTING / Troubleshooting B
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Machine does not travel.
• The travel system is inoperable unless the fol-
• Air mixing in the transmission hydraulic circuit
lowing conditions are met.
FNR Switch: F or R position
Brake Switch: OFF, Auto Axle Lock or Axle Lock
position
• Failure in the transmission and/or axle (front
and/or rear) may be the cause of the trouble.
Check if a noise is emitted from each section.
• Check if parking brake indicator (P), work brake
indicator (S) in the monitor unit and neutral indicator (N) in the steering column monitor are OFF.
may cause the parking brake to drag. Bleed air
from the transmission by referring to T5-7-130.
• When other actuators (front attachment and
swing) operate normally, the pilot pump, pilot filter
and pilot relief valve are considered to be normal.
• Check the wiring connections first.
YES
NO
Monitor pump 1 delivery pressure by using
Dr. ZX.
Check if pressure increases according to
travel operation.
· Monitor item: Pump 1
delivery pressure
· Specification: Refer to
the Operational Performance Test section.
Disconnect connectors in
travel forward/reverse Pi cut
solenoid valve.
Check if symptoms disappear.
YES
Monitor implement
brake state.
Check if ON is displayed.
NO
Faulty control valve
(bound spool).
YES
Faulty MC.
Monitor FNR switch.
Check if indication is
changed by shifting
switch.
· Monitor item:
FNR (F) SW,
FNR (R) SW
Faulty FNR switch.
NO
T5-7-90
TROUBLESHOOTING / Troubleshooting B
YES
YES
YES
Monitor work brake
release switch.
Check if ON is displayed.
· Monitor item:
Implement brake deactive
Disconnect connector in
solenoid valve unit (SF).
Check if symptoms disappear.
Faulty MC.
NO
Faulty solenoid valve unit
(SF) (bound).
NO
Faulty Travel mode selection
solenoid valve (bound).
YES
NO
Monitor fast/slow selection relays.
Check if OFF is displayed.
· Monitor item:
T/M change (high speed)
T/M change (low speed)
· FNR switch: N
YES
NO
Faulty work brake release
switch.
Faulty brake switch.
Monitor parking brake
switch.
Check if ON is displayed.
· Brake switch: except
P (parking brake)
Faulty MC.
NO
T5-7-91
TROUBLESHOOTING / Troubleshooting B
T-2 Machine does not travel forward and reverse.
• Failure in the transmission and/or axle (front
and/or rear) may be the cause of the trouble.
Check if a noise is emitted from each section.
• When other actuators (front attachment and
swing) operate normally, the pilot pump, pilot filter
and pilot relief valve are considered to be normal.
• Check the wiring connections first.
YES
Monitor pump 1 delivery
pressure by using Dr. ZX.
Check if travel forward/reverse relief pressure is normal.
Switch relief valves at
NO forward and reverse
sides in travel motor.
Check if symptoms are
switched.
· Refer to the Operational
Performance Test section.
Monitor FNR switch.
Check if ON is displayed when turning
FNR switch to F or R.
NO Check travel spool in
control valve for abnormality.
Faulty travel motor relief
YES valve.
YES
Faulty travel shockless
valve.
· Monitor item:
FNR (F) SW,
FNR (R) SW
Faulty FNR switch, or
open circuit in harness
between MC and FNR
switch.
NO
T5-7-92
TROUBLESHOOTING / Troubleshooting B
Faulty counterbalance
valve.
YES
NO
Check counterbalance
valve in travel motor for
abnormality.
YES Faulty make-up valve.
NO
Check make-up valve for
abnormality.
Faulty center joint.
NO
Faulty control valve
(bound spool).
YES
T5-7-93
TROUBLESHOOTING / Troubleshooting B
T-3 Forward/reverse travel speeds are slow.
Travel power is weak.
• If the travel motor displacement angle control so-
• When other actuators (front attachment and
lenoid valve is faulty, fault code 11422 is displayed.
• Failure in the transmission and/or axle (front
and/or rear) may be the cause of the trouble.
Check if a noise is emitted from each section.
• Air mixing in the transmission hydraulic circuit
may cause the parking brake to drag. Bleed air
from the transmission by referring to T5-7-130.
swing) operate normally, the pilot pump, pilot filter
and pilot relief valve is considered to be normal.
• Pump 1 flow rate reduction may be the cause of
this trouble when bucket single operation speed is
slow. Refer to A-3.
• Check the wiring connections first.
NO
NO
Check travel spool in
control valve for abnormality.
Faulty control valve.
YES
Monitor slight travel SW
NO by using Dr. ZX.
Check if ON is displayed.
· Engine speed control
mode selection switch:
Pedal or Dial
YES
Check if fault code
11422 is displayed.
Disconnect connector
in switch panel.
Monitor slight travel
SW by using Dr. ZX.
Check if ON is displayed.
NO Faulty engine speed control
mode selection switch.
Faulty MC, or shorted circuit
in harness between MC and
YES engine speed control mode
selection switch.
Refer to Troubleshooting A.
YES
T5-7-94
TROUBLESHOOTING / Troubleshooting B
YES
Faulty center joint.
Measure drain amount
from travel motor.
Check if drain amount
is normal.
· Refer to the Operational Performance
Test section.
Faulty travel motor.
NO
T5-7-95
TROUBLESHOOTING / Troubleshooting B
T-4 When releasing accelerator pedal, hydraulic
brake is not applied. (Machine runs away.)
• If the travel motor displacement angle control solenoid valve is faulty, fault code 11422 is displayed.
• Similar symptom may appear when the travel pilot
valve, travel shuttle valve and/or travel spool is
faulty.
NO Faulty control valve.
Check if counterbalNO ance valve in travel
motor is abnormal.
Faulty counterbalance valve.
Switch relief valves at
YES forward and reverse
sides in travel motor.
Check if symptoms are
switched.
YES
YES
Monitor vehicle speed.
Check if speed is
changed according to
accelerator pedal operation.
Faulty travel motor relief
valve.
Faulty travel N sensor, or
faulty harness between MC
and travel N sensor.
NO
T5-7-96
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-97
TROUBLESHOOTING / Troubleshooting B
T-5 Travel mode (fast/slow) does not shift.
• Air mixed in the transmission hydraulic circuit
Travel Mode Selection
Solenoid Valve
may prevent the transmission from being shifted.
Bleed air from the transmission by referring to
T5-7-130.
• Set the FNR switch in the F or R position. Set the
brake switch in the position other than the parking
position. Perform the troubleshooting.
• Check the wiring connections first.
Port B
Port K
TCJB-05-07-003
NO
Install pressure gauge to
ports B and K in transmission changeover solenoid
valve.
YES Check if pressure at each
port varies as shown below when travel speed
mode switch is operated.
· Travel speed mode switch: Slow
→Pressure at port B: 0 MPa
→Pressure at port K: 3.0 MPa
Faulty transmission.
· Travel speed mode switch: Fast
→Pressure at port B: 3.0 MPa YES
→Pressure at port K: 0 MPa
Monitor fast speed
selection relay and
slow speed selection
YES relay.
When shifting travel
speed mode switch,
check if ON is displayed respectively.
· Monitor item:
T/M selection (Fast)
T/M selection (Slow)
When shifting travel
speed mode switch,
check if slow speed
indicator in steering
column monitor is
ON/OFF normally.
NO
Faulty fast/slow speed selection relay.
· Travel speed mode
switch: Slow
→Indicator: ON
· Travel speed mode
switch: Fast
→Indicator: OFF
Faulty travel speed mode
switch, or faulty harness between MC and travel speed
mode switch.
NO
T5-7-98
TROUBLESHOOTING / Troubleshooting B
Open circuit in harness between
travel mode selection solenoid
valve and fast/slow speed
selection relay.
NO
Disconnect connector
in travel mode
selection solenoid
valve.
Check if voltage at
terminal #2 (each
harness end) of
connector is 24 V.
· Travel speed mode
switch: Slow
→Green-yellow line
· Travel speed mode
switch: Fast
→Brown-white line
YES
Faulty travel mode selection
solenoid valve (bound spool).
NO
Open ground circuit in harness
to travel mode selection
solenoid valve.
With connector in travel
mode selection solenoid
valve disconnected, check
YES for continuity between
terminal #1 (harness end) of
connector and machine.
Connector (Harness end of connector viewed from the open
end side)
Travel Mode
Selection Solenoid
Valve
Travel Mode Selection Solenoid Valve
Fast Speed Side
TCJB-05-07-002
First Speed Side Slow Speed Side
Brown-White
Line
T5-7-99
TCJB-05-06-004
Slow Speed Side
Yellow-Green
Line
TCJB-05-06-004
TROUBLESHOOTING / Troubleshooting B
T-6 Axle lock is not released.
• Check that the brake switch is in the OFF position
first.
• Check the wiring connections first.
Related MC Fault Code: 11424-2, 11424-3, 11424-4
YES
Refer to troubleshooting A.
Faulty operate check valve (axle
YES lock cylinder), or open circuit in
harness between MC and solenoid
value unit (SI).
Check if fault code is
11424 is displayed.
· Brake switch:
Auto axle lock
or Axle lock
NO
Monitor brake switch.
Check if OFF is
displayed.
· Monitor item:
Parking brake SW
Axle lock control state
NO
T5-7-100
Faulty brake switch, or shorted
circuit in harness between MC and
brake switch.
TROUBLESHOOTING / Troubleshooting B
T-7 Axle lock is not operable.
• Check that the brake switch is in the auto axle lock
or axle lock position first.
• Check the wiring connections first.
Related MC Fault Code: 11424-2, 11424-3, 11424-4
YES
Refer to troubleshooting A.
YES
Check if fault code is
11424 is displayed.
Faulty operate check valve (axle
lock cylinder), or shorted circuit in
harness between MC and solenoid
value unit (SI).
· Brake switch:
Auto axle lock
or Axle lock
Monitor brake switch.
NO Check if OFF is
displayed.
· Monitor item:
Axle lock control state
· Brake switch:
Auto axle lock or Axle
lock
T5-7-101
NO
Faulty brake switch, or open circuit
in harness between MC and brake
switch.
TROUBLESHOOTING / Troubleshooting B
BRAKE SYSTEM TROUBLESHOOTING
B-1 Parking brake is not operable (not applied).
• Bleed air from the transmission by referring to
T5-7-130 before starting troubleshooting.
• If the fast/slow speeds do not change, refer to “T-5
Travel mode (fast/slow) does not shift”.
• Check the wiring connections first.
YES
Faulty MC.
Monitor parking brake
switch.
Check if ON is
displayed.
· Brake switch:
P (parking brake) position
NO
YES
Faulty brake switch.
NO
Open circuit in harness
between MC and brake
switch.
Disconnect connector
in brake switch.
Connect terminals #3
and #6 (harness end)
of connector.
Monitor parking brake
switch.
Check if ON is
displayed.
Connector (Harness end of connector viewed from the
open end side)
Brake Switch
TCJB-05-07-004
T5-7-102
TROUBLESHOOTING / Troubleshooting B
B-2 Service brake is not operable, or is not
applied effectively.
• The front and rear wheel service brake circuits are
independently designed each other. When either
the front or the rear wheel brake circuit fails,
overall service brake system will not operate
properly.
• Check the brake lining and the accumulator for
any abnormalities, and bleed air from the brake
system by referring to operator’s manual and
T5-7-131 before starting the troubleshooting.
• When other actuators (front attachment, travel
and swing) operate normally, the pilot pump is
considered to be normal.
• Check the wiring connections first.
NO
Faulty accumulator charging
valve.
Monitor brake remain
pressure.
Check if pressure is
12.7 MPa or more.
YES
YES
Monitor brake pressure.
Check if pressure is 6 MPa or
more.
· Brake pedal: Fully operated
· Possible to display by built-in
diagnosing system.
T5-7-103
Faulty brake system at axle
side.
Faulty brake valve.
NO
TROUBLESHOOTING / Troubleshooting B
B-3
Work brake is not operable.
• Check if the brake switch is in the auto axle lock or
axle lock position first.
• When the brake switch is in the auto axle lock or
axle lock position, the work brake is applied.
When the brake switch is in the auto axle lock or
axle lock position and if the work brake is not
applied, the circuit in harness between MC and
brake switch may be open.
• When the speedometer is normal, the travel N
sensor may be normal.
• When other actuators (front attachment, travel
and swing) operate normally, the pilot pump is
considered to be normal.
• Check the wiring connections first.
Related MC Fault Code: 11310-3, 11310-4, 11425-2,
11425-3, 11425-4.
YES Faulty solenoid valve
unit (SI).
YES Monitor implement
brake state.
Check if ON is
displayed.
Faulty MC.
YES Monitor brake
pressure. Check if
pressure is 6.0 MPa or
more.
· Depress brake pedal
fully.
· Possible to display by
built-in diagnosing
system.
Monitor axle lock
control state.
Check if ON is
displayed.
NO
Faulty brake valve.
NO
· Brake switch: Auto axle
lock or Axle lock
Faulty brake switch.
NO
T5-7-104
TROUBLESHOOTING / Troubleshooting B
STEERING SYSTEM TROUBLESHOOTING
H-1 Although steering wheel is rotated, steering
is heavy.
• Check the steering filter first.
Faulty steering pump.
YES
Disconnect hoses from
delivery ports of steering
pump and pilot pump.
Connect hoses each
other to the other side.
Check if symptoms are
improved.
NO
YES
Faulty steering valve.
NO
Faulty relief valve in steering
valve.
Monitor steering pump by
using Dr. ZX.
Check if pressure is normal.
· Monitor item: Pump 3 delivery
pressure
H-2 Although steering wheel is rotated, steering
is impossible.
• Although the steering valve does not have enough
pressure oil from the steering pump, the machine
can turn the left and right.
• If the machine cannot turn the left and right, center
joint maybe faulty.
• If only one side (left or right) can turn, the center
joint or the overload relief valve in the steering
valve maybe faulty.
T5-7-105
TROUBLESHOOTING / Troubleshooting B
OTHER SYSTEM TROUBLESHOOTING
O-1 Wiper is not operated.
Checking Instructions
• The wiper is driven by electric power routed via
• When the front window is open, the wiper is not
the relay circuit. The relay circuit is controlled by
the monitor unit. In case the wiper is not operated,
first check if the wiper relay is activated. Next,
check if electric power is routed to the wiper motor.
Switch wiper relay with
NO other general relay.
Check if wiper is operated.
· Key switch: ON
Check if wiper relay
is turned ON/OFF
according to INT.
position of wiper
switch.
· Key switch: ON
· Wiper switch: INT
Open front window.
Check if voltage between terminals B
YES and L at window
contact in cab end is
24 V.
· Key switch: ON
· Wiper switch: ON
operated.
Check that the front window is closed securely.
YES
Faulty wiper relay.
Disconnect connector
monitor-A in monitor
unit.
Connect terminal #A2
NO (harness end) of connector to machine.
Disconnect wiper relay.
Check for continuity
between terminal #A2
(harness end) of connector and machine.
Close front window.
Disconnect connector
YES in wiper motor.
Check if voltage between terminals B and
L (harness end) of
connector is 24 V.
YES
NO
YES
NO
Faulty monitor unit.
Open circuit in harness
between wiper relay and
monitor unit.
Faulty wiper motor.
Open circuit in harness
between window contact and wiper motor.
· Key switch: ON
· Wiper switch: ON
NO
T5-7-106
Open circuit in harness
between wiper relay and
window contact.
TROUBLESHOOTING / Troubleshooting B
Window Contact (Cab end)
INT. Position
Slow Speed
Middle Speed
Fast Speed
Connector
Wiper Motor (Harness end)
Setting Time
8 seconds
6 seconds
3 seconds
Monitor Unit
Connector Monitor-A (Harness end)
T1V1-05-07-005
B
L
S
E
#A2
T183-05-05-001
Wiper Driving Circuit
Wiper Motor
Wiper Relay
Main
Window Contact ↑
T1V1-05-07-004
T5-7-107
TROUBLESHOOTING / Troubleshooting B
O-2 Air Conditioner is faulty
The air conditioner operation system has a
self-diagnosing function. This system performs the
diagnosis by 8-steps as shown in the flow chart below: Check Model Confirmation, Display Function
Confirmation, Present Trouble Diagnosing, Past
Trouble Diagnosing, Sensing Temperature Display,
and Component Operation Check, Correction of the
Set Temperature and Selection of Celsius and Fahrenheit Temperature Indication.
Normal Operation
Turn key switch ON while pushing air
conditioner switch and mode switch.
Keep pushing OFF switch
for more than 3 seconds.
STEP 0
Check Model Confirmation
Push lower side fan switch.
Keep pushing OFF switch
for more than 3 seconds.
Push upper side fan switch.
STEP 1
Display Function
Confirmation
Push lower side fan switch.
Keep pushing OFF switch
for more than 3 seconds.
Push upper side fan switch.
STEP 2
Present Trouble
Diagnosing
Push lower side fan switch.
Push upper side fan switch.
STEP 3
Past Trouble
Diagnosing
Keep pushing OFF switch
for more than 3 seconds.
Push lower side fan switch.
Keep pushing OFF switch
for more than 3 seconds.
Keep pushing air conditioner
switch for more than 3 seconds.
Push upper side fan switch.
STEP 4
Sensing Temperature
Display
Push lower side fan switch.
Push upper side fan switch.
Keep pushing OFF switch
for more than 3 seconds.
STEP 5
Component Operation Check
Push AUTO switch and
lower side fan switch.
Keep pushing OFF switch
for more than 3 seconds.
Push AUTO
Switch and
upper side
fan switch.
Push A/C
switch and
lower side
fan switch.
STEP 6-1
Correction of the Set
Temperature
Keep pushing OFF switch
for more than 3 seconds.
Self-Diagnosis
T5-7-108
Push A/C switch and
upper side fan switch.
STEP 6-2
Selection of Celsius and Fahrenheit
Temperature Indication
TROUBLESHOOTING / Troubleshooting B
Self-Diagnostic System Activation
Fan Switch
Turn the key switch ON while pushing the air conditioner switch and mode switch on air conditioner control panel.
LCD
Air Conditioner Switch
STEP 0 Check Model Confirmation
The liquid crystal display (LCD) indicates the machine model name this system can diagnose.
• The LCD will indicate “Sd” as the check model
name.
• Select next step in order to be performed by operating the switch as described below.
• Upper side fan switch: To proceed to Step 1
• Keep pressing OFF switch for more than 3 seconds: To return to normal operation
NOTE: The system operation will automatically
proceed to STEP 1 after 5 seconds have
pushed after the check model is displayed.
STEP 1 Display Function Confirmation
Turn all indicators ON in order to check indicator
bulbs.
• The LCD panel and all switch indicators light.
• Select the next step in order to be performed by operating the switches as follows:
• Push the upper side of fan switch: To proceed to
“STEP 2.”
• Push the lower side of fan switch: To return to
“STEP 0.”
• Keep pushing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed.)
T5-7-109
T178-05-08-001
Mode Switch
OFF Switch
TROUBLESHOOTING / Troubleshooting B
STEP 2 Present Trouble Diagnosing
The LCD indicates the fault codes for present abnormalities of the mix door, mode encoder, and/or
sensors.
Fan Switch
LCD
• In case any abnormalities are present, the LCD indicates the fault codes. If more than one fault code
is detected, the following fault code is displayed after flashing (0.5 seconds) twice.
Fault Code
Open Circuit
Shorted Circuit
Mix Door
21
−21
Mode Encoder
22
In-Cab Ambient
23
−23
Temperature
Sensor
Outdoor Ambient
24
−24
Temperature
Sensor
Coolant Tem25
−25
perature Sensor
∗
Solar Radiation
26
−26
Sensor
∗
: When solar radiation is shaded, the solar radiation
sensor indicates the fault code of open circuit.
• Select the next step in order to be performed by operating the switches as follows:
• Push the upper side of fan switch: To proceed to
“STEP 3.”
• Push the lower side of fan switch: To return to
“STEP 1.”
• Keep pushing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed)
T5-7-110
T178-05-08-001
OFF Switch
TROUBLESHOOTING / Troubleshooting B
STEP 3 Past Trouble Diagnosing
The LCD indicates the fault codes for past abnormalities of the mix door, mode encoder, and/or sensors.
The past stored fault codes are deleted.
Fan Switch
LCD
Air Conditioner Switch
• In case any abnormalities occurred in the past, the
LCD indicates the fault codes. If more than one fault
code is detected, the following fault code is displayed after flashing (0.5 seconds) twice.
Fault Code
Open circuit
Shorted Circuit
Mix Door
21
−21
Mode Encoder
22
In-Cab Ambient
Temperature
23
−23
Sensor
Outdoor Ambient
Temperature
24
−24
Sensor
Coolant Tem25
−25
perature Sensor
Solar Radiation
−26
Sensor
• When the air conditioner switch is kept pushing for
more than 3 seconds, the failure records are deleted. After this operation, the air conditioner switch
indicator flashes 5 times. Then, the self-diagnosing
system is deactivated. (Normal functions are resumed.)
• Select the next step in order to be performed by operating the switches as follows:
• Push the upper side of fan switch: To proceed to
“STEP 4.”
• Push the lower side of fan switch: To return to
“STEP 2.”
• Keep pushing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed.)
T5-7-111
T178-05-08-001
OFF Switch
TROUBLESHOOTING / Troubleshooting B
STEP 4 Sensing Temperature Display
The LCD indicates the sensing temperature detected
by each temperature sensor (excluding the insulation
sensor).
Fan Mark
Fan Switch
LCD
Air Conditioner Switch
• The sensing temperature detected by the in-cab
ambient temperature sensor, outdoor ambient temperature sensor and coolant temperature sensor are
displayed on the LCD in real time. (Figures less
than the decimal point are not displayed.)
NOTE: The coolant temperature sensor indicates
“H” when coolant temperature is more than
21 °C (70 °F) and “L” when coolant temperature is less than 21 °C (70 °F).
• Sensing temperature detected by each sensor is
automatically displayed on the LCD and is cycled at
an interval of 3 seconds with the timer. The timer is
turned ON or OFF by operating the fresh air vent
switch.
• Referring to the fan mark can check which sensing
temperature is displayed.
• Select the next step in order to be performed by operating the switches as follows:
• Push the upper side of fan switch: To proceed to
“STEP 5.”
• Push the lower side of fan switch: To return to
“STEP 3.”
• Keep pushing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed.)
T5-7-112
T178-05-08-001
Fresh Air Vent Switch
OFF Switch
TROUBLESHOOTING / Troubleshooting B
STEP 5 Component Operation Check
Each component operation is checked by performing
pattern operation.
Fan Switch
LCD
Air Conditioner
Switch
AUTO Switch
• Each time the fresh air vent switch is pushed, the
component to be checked is selected in order.
Check which component has been selected by referring to No. indicated on the LCD. (Refer to table
1.)
• Operating pattern of the selected component is
shifted at an interval of 10 seconds. Operating pattern is cycled. (Refer to table 1.)
T178-05-08-001
Fresh Air Vent switch
OFF Switch
NOTE: The components other than selected operate under the standard conditions (shown
by marks* in table 1).
• Select the next step in order to be performed by operating the switches as follows:
• Push the AUTO switch and upper side of fan
switch: To proceed to “STEP 6-1”.
• Push the A/C switch and upper side of fan switch:
To proceed to “STEP 6-2”.
• Push the lower side of fan switch: To return to
“STEP 4.”
• Keep pushing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed.)
Table 1
Component
Air Mix Damper
Indication
on LCD
51
Fan
52
Air Vent Location
53
Fresh / Circulation
Air Vent Selection
Air Conditioner
54
55
Operation Pattern
Remarks
Controls opening extent of air mix
damper: 0% (fully closed) →
50%*→ 100% (fully opened)
Controls air flow volume: Lo →
M(Lo) → M(Hi) → Hi
Selects air vent: Front*→
Front/Rear → Front/Foot → Foot
Select Ventilation Mode: Circulation* → Fresh
Turns air conditioner switch: ON*
→ OFF
0%, 50%, 100%: “C”, “5” and “H” are indicated next to the decimal point respectively.
Indicators corresponding to air flow volume light.
Indicator corresponding to selected air
vent lights.
Indicator corresponding to selected
mode light.
ON: Indicator lights.
OFF: Indicator is extinguished.
T5-7-113
TROUBLESHOOTING / Troubleshooting B
STEP 6-1 Correction of the Set Temperature
Fine correction of the set temperature.
Fan Switch
LCD
Temperature
Control Switch
AUTO Switch
• Each time when the top or bottom of temperature
control switch is pushed, temperature correction,
displayed on the LCD window, can be changed.
• Actually controlled temperature is the normally set
temperature plus the set temperature correction.
For instance, when the normally set temperature is
25°C (77 °F) and set temperature correction is -1°C
(-34 °F), the actually controlled temperature becomes 24°C (75 °F).
• Select the next step in order to be performed by operating the switches as follows:
• Push the AUTO switch and lower side of fan
switch: To return to “STEP 5.”
• Keep pushing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed.)
T5-7-114
T178-05-08-001
OFF Switch
TROUBLESHOOTING / Troubleshooting B
STEP 6-2 Selection of Celsius and Fahrenheit
Temperature Indication
Selection of Celsius and Fahrenheit Temperature In-
Fan Switch
LCD
Air Conditioner Switch
dication.
• Each time when the fresh air vent switch is pushed,
Celsius or Fahrenheit temperature may be displayed alternately.
• Temperature is displayed at the top of LCD window
as follows.
(C: Celsius, F: Fahrenheit)
C
T178-05-08-001
Fresh Air Vent Switch
F
• Select the next step in order to be performed by operating the switches as follows:
• Push the Air Conditioner Switch and lower side of
fan switch: To return to “STEP 5.”
• Keep pushing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed.)
T5-7-115
OFF Switch
TROUBLESHOOTING / Troubleshooting B
ÄPlease fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to the related post / after experiencing a problem with
your machine’s air conditioning system.
< AIR CONDITIONER TROUBLE REPORT >
File No.
(1) What
Checked by:
Model
(Serial No.
)
Operation Type
Manual
Semi-Auto
Full-Auto
Delivery Date
Year
Month
(2) When
Date
Year
Month
Day
Operating Hour (
h)
Time
Morning
Daytime
Evening
Night
Frequency
Every Day
Once a Week
Once a Month
Times per
(3) Where
Job Site Address
State
County
Town
Access Road Condition
Paved
Not Paved (Gravel
Sand
Soil)
(4) How (Operating Conditions)
Weather
Fine
Cloudy
Rain
Snow
Atmospheric Temperature
Very Hot
Hot
Cold
Very Cold
Operating Conditions
Parking
Traveling
Working
Temperature Control
Paint blanks equal to red indicators. / Fill in set-temperature when
full-auto operation
A/C
ON
OFF
Air Induction
Re-Circulation
Fresh Air Circulation
Control
Panel
AUTO
ON
OFF
Not Available
Fill following items when operated in manual mode or when manual control type unit is used.
Vent Position
Front
Front / Rear
Foot
Front / Rear and Foot
Fan
First
Second
Third
Fourth
Fifth
Sixth
(5) How (Problem Symptom)
Abnormal Compressor Operation
<Check Result>
Symptom
Not turned ON
(1) Is problem reproducible ?
Not turned OFF
Reproducible
Others
Not reproducible
Uncontrollable air temperature
(2) Pressure (To be measured at gauge manifold)
Symptom
No cool air
Low Pressure
No warm air
High Pressure
Others
(3) Which parts have been replaced ?
Uncontrollable air volume
1
Symptom
Air flows in Hi mode only
No air flows
2
Small air volume
Others
∗ Before replacing the control amplifier, be sure to
Uncontrollable vent hole
check that the connectors are correctly connected
Symptom
Vent hole isn’t selected
while repeatedly disconnecting and reconnecting
Others
connectors.
Abnormal panel indication
Faulty Indica- Vent Hole
tor
A/C
AUTO
Fresh Air Circulation
Fan OFF
Fan (Lo •
••
Hi)
Temperature Control
Symptom
Stays OFF
Stays ON
Blinks
Others
T5-7-116
TROUBLESHOOTING / Troubleshooting B
Refrigerant Quantity....................... 900±50 g
3
Compressor Oil Quantity................ 210 cm
T5-7-117
TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Refrigerant pressure
in both high and
low-pressure sides is
low.
Bubbles can be seen in sight
glass.
No bubbles are seen in sight
glass.
Piping and/or parts are stained with oil,
respond to gas detector.
No oil stain is found or gas detector
does not respond. Refrigerant has not
been refilled for longer than one season.
After cooling at fast speed continuously, cooling power is reduced. Air
flow volume remains unchanged.
Air flow volume is reduced.
Insufficient
Cooling
Power
Refrigerant pressure
in low-pressure side
is high.
Bubbles can be seen in sight
glass.
Compressor cylinder is extremely hot,
emitting a smell.
Refrigerant pressure in
high-pressure side is low.
Compressor cylinder is extremely hot,
emitting a smell.
Heater unit emits hot air.
Refrigerant pressure
in high-pressure side
is high.
Bubbles can be seen in sight
glass.
Refrigerant pressure in low-pressure
side is low.
Condenser is stained and clogged.
Even if condenser is sprayed with water, few bubbles appear. Receiver dryer temperature is low.
After cooling at fast speed continuously, cooling power is reduced. Air
flow volume is reduced.
Frost forms.
Thermistor does not cool.
Thermistor cools.
T5-7-118
TROUBLESHOOTING / Troubleshooting B
Gas leaks from pipe joints and/or parts.
Re-tighten or replace parts.
Normal leakage of refrigerant from hoses.
Refill refrigerant.
Improper adjustment (excessive restriction) of expansion valve.
Readjust or replace expansion valve.
Clogged expansion valve.
Remove clog, or replace receiver and/or expansion
valve.
Clogged low-pressure circuit and/or evaporator.
Remove clog, or replace parts.
Frozen expansion valve or water in circuit.
After evacuation, refill refrigerant and/or replace receiver dryer.
Gas leaks from case.
Seal gaps by using vinyl tape or packing compound.
Poor contact of expansion valve temperature sensing cylinder.
Make good contact. Replace temperature sensing
stay.
Improper adjustment (excessive open) of expansion valve.
Readjust or replace.
Insufficient compressor discharge (faulty gasket and/or valve).
Replace.
Improper water stop valve wire adjustment and/or faulty stop
valve.
Check and readjust or replace.
Poor airtight fitting of outside air damper (outside air induction
type).
Repair.
Clogged high-pressure circuit before receiver dryer.
Remove clog, or replace parts.
Clean Condenser.
Excessive refrigerant.
Remove excessive refrigerant to proper level.
Air is mixed in system.
After evacuation, refill refrigerant and/or replace receiver dryer.
Incorrect thermistor location.
Correct thermistor location.
Gas leaks from case.
Seal gaps by using vinyl tape or packing compound.
Faulty thermistor (stays ON).
Disconnected thermistor cord.
Even if function and performance are normal, when
air-conditioner is kept operated for a long time with thermistor
in max. cooling position and air flow in M or L mode, frost may
form.
Instruct user on correct air-conditioner operation.
(Reset thermistor to either minimum or middle cooling
position or increase air flow.)
T5-7-119
TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Case connection.
Louver resonance.
Fan contacts case, or foreign matter enters case.
Blower fan connection.
Noise
Brush friction noise, metal and/or thrust washer contact
noise.
Gas blowing sound (roaring).
Gas vibration noise (compressor discharge and/or suction gas noise).
Expansion valve connection, whistle
sound, gas blowing sound.
Abnormal noise from expansion valve (Expansion
valve is normally functioning.).
Faulty clutch bearing, and/or idle pulley bearing.
Clutch disengaging sound.
Contact of clutch amature due to resonance, or loose
belt and/or screws.
Noisy compressor.
Compressor rotating sound.
Vibration and/or loose screws due to excessive drive
belt looseness.
Broken heater core and/or hose.
Water leak and/or splash.
Clogged case drain port and/or drain hose.
Others
Absorbed cigarette and dust smell on evaporator fins.
Abnormal smell.
T5-7-120
TROUBLESHOOTING / Troubleshooting B
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.
-1
Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min in L
mode for more than 10 minutes, flush smell out by condensed water.
T5-7-121
TROUBLESHOOTING / Troubleshooting B
Compressor
Compressor does not rotate.
Clutch terminal voltage is normal 24 V.
Inoperable
cooling
system.
Clutch terminal voltage is low.
Clutch terminal voltage is 0 V.
Bubbles exist even after refrigerant is refilled.
Both high and
low side
pressures are
low.
Both compressor and
blower motor rotate.
Check for oil and refrigerant leaks from parts other than
compressor and pipe joints by using gas detector.
Check for oil and refrigerant leaks from compressor (no
leaks from parts other than compressor) by using gas
detector.
(Refer to NOTE 1, 2
on page T5-7-125.)
Stain on exterior.
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 compressor in liquid form.)
High pressure side is
slightly low and low pressure side is high.
No refrigerant returns in liquid form. High pressure side is low.
Bubbles can be seen through
sight glass.
Others
High pressure side is high.
Refer to the Cooling Circuit Troubleshooting
Table on page T5-7-118.
Temperature is not cooled when compressor is
operated at fast speed continuously.
Air flow from blower is insufficient.
T5-7-122
TROUBLESHOOTING / Troubleshooting B
Seized clutch.
Replace.
Improper gap between amature and rotor (improper air gap).
Replace.
Open or shorted circuit in core cable.
Shaft does not rotate (internally locked).
Replace.
Faulty Electrical System.
Faulty Electrical System.
Oil leaks from mechanical seal, gasket, and/or charge valve.
Replace.
Oil leaks from oil plug.
Oil and refrigerant leaks from front housing, and/or cylinder block joint.
Normal leaks from hoses.
Replace.
Charge
refrigerant.
No leaks (normal).
Refer to the Cooling Circuit Troubleshooting Table on page T5-7-118.
Broken valve (Refer to NOTE 3 on page T5-7-125.)
Replace.
Blown gasket (Refer to NOTE 3 on page T5-7-125.)
Check and adjust
oil level.
Excessive oil.
T5-7-123
TROUBLESHOOTING / Troubleshooting B
Compressor
Compressor rotation is abnormally draggy.
Overheating
is susceptible
to occur.
Trouble other than compressor.
Noise is heard when clutch is OFF.
Abnormal
noise
Noise is heard when clutch is ON.
T5-7-124
Refer to the Cooling Circuit Troubleshooting Table on page T5-7-118.
TROUBLESHOOTING / Troubleshooting B
Broken clutch bearing due to overly tightened belt.
Replace.
Shaft does n’o rotate.
Replace.
Shaft rotates draggy.
Broken clutch bearing.
Replace.
Contact or slip due to poor air gap.
Faulty idle pulley bearing.
Refer to the Cooling Circuit
Troubleshooting Table on
page T5-7-120.
Saggy belt.
Loose screws.
Broken valve.
Replace.
Blown gasket.
Abnormal internal noise.
Replace.
Vibration due to saggy belt.
Refer to the Cooling Circuit
Troubleshooting Table on
page T5-7-120.
Loose screws.
NOTE:
1. Do not 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. Accurately check whether oil is leaking or seeping only.
2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose surface may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
2
high-pressure side and low-pressure side is 0.5 MPa (5 kgf/cm ) 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.
T5-7-125
TROUBLESHOOTING / Troubleshooting B
EXCHANGE INSPECTION
Exchange inspection method is a troubleshooting
method to find the trouble location by exchanging the
suspected part/component with another part
/component having identical characteristics.
Many sensors and solenoid valves used on this machine are identical. Therefore, by using this
switch-check method, faulty part/component, and/or
harness can be easily found.
Example: Abnormal pump 1 delivery pressure sensor
high voltage (MC fault code: 11200-3)
Check Method:
1. Switch two delivery pressure sensors located as
shown in figure A to figure B.
2. Retry troubleshooting.
Result:
In case abnormal pump 2 delivery pressure sensor
high voltage is displayed (MC fault code 11202-3), the
pump 1 delivery pressure sensor is considered to be
faulty.
In case abnormal pump 1 delivery pressure sensor
high voltage (MC fault code 11200-3) is displayed, the
pump 1 delivery pressure sensor harness is considered to be faulty.
Pump 2
(5-Spool
Section)
PP2
PP1
Figure A
T157-07-04-006
Pump 2
(5-Spool
Section)
PP1
Figure B
T5-7-126
Pump 1
(4-Spool
Section)
Pump 1
(4-Spool
Section)
PP2
T157-07-04-006
TROUBLESHOOTING / Troubleshooting B
Applicability of Switch-Check Method
Fault Code
11000-2
11001-2
11002-2
11003-3
11004-2
11100-2
11101-3
11101-4
11200-3
11200-4
11202-3
11202-4
11203-3
11203-4
11206-3
11206-4
11208-3
11208-4
11301-3
11301-4
11302-3
11302-4
11303-3
11303-4
11305-3
11305-4
11306-3
11306-4
11307-3
11307-4
11310-3
11310-4
11311-3
11311-4
Trouble
Abnormal EEPROM
Abnormal RAM
Abnormal A/D Conversion
Abnormal Sensor Voltage
CAN Communication Error
Abnormal Engine Speed
Abnormal Engine Control Dial Sensor High Voltage
Abnormal Engine Control Dial Sensor Low Voltage
Abnormal Pump 1 Delivery Pressure Sensor High Voltage
Abnormal Pump 1 Delivery Pressure Sensor Low Voltage
Abnormal Pump 2 Delivery Pressure Sensor High Voltage
Abnormal Pump 2 Delivery Pressure Sensor Low Voltage
Abnormal Pump 3 Delivery Pressure Sensor High Voltage
Abnormal Pump 3 Delivery Pressure Sensor Low Voltage
Abnormal Pump 1 Control Pressure Sensor High Voltage
Abnormal Pump 1 Control Pressure Sensor Low Voltage
Abnormal Pump 2 Control Pressure Sensor High Voltage
Abnormal Pump 2 Control Pressure Sensor Low Voltage
Abnormal Swing Pilot Pressure Sensor High Voltage
Abnormal Swing Pilot Pressure Sensor Low Voltage
Abnormal Boom Raise Pilot Pressure Sensor High Voltage
Abnormal Boom Raise Pilot Pressure Sensor Low Voltage
Abnormal Arm Roll-In Pilot Pressure Sensor High Voltage
Abnormal Arm Roll-In Pilot Pressure Sensor Low Voltage
Abnormal Travel Forward Pilot Pressure Sensor High Voltage
Abnormal Travel Forward Pilot Pressure Sensor Low Voltage
Abnormal Travel Reverse Pilot Pressure Sensor High Voltage
Abnormal Travel Reverse Pilot Pressure Sensor Low Voltage
Abnormal Front Attachment Pilot Pressure Sensor High Voltage
Abnormal Front Attachment Pilot Pressure Sensor Low Voltage
Abnormal Brake Pressure Sensor High Voltage
Abnormal Brake Pressure Sensor Low Voltage
Abnormal Brake Remaining Pressure Sensor High Voltage
Abnormal Brake Remaining Pressure Sensor Low Voltage
T5-7-127
Applicability
Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable
Applicable
(Harness/Sensor)
Applicable
(Harness/Sensor)
Applicable
(Harness/Sensor)
Applicable
(Harness/Sensor)
TROUBLESHOOTING / Troubleshooting B
Fault Code
11400-2
11400-3
11400-4
11401-2
11401-3
11401-4
11410-2
11410-3
11410-4
11403-2
11403-3
11403-4
11424-2
11424-3
11424-4
11425-2
11425-3
11425-4
11422-2
11422-3
11422-4
11423-2
11423-3
11423-4
Trouble
Abnormal Feedback Current of Maximum Pump 2 Flow Rate Limit
Control Solenoid Valve
Abnormal Feedback High Voltage of Maximum Pump 2 Flow Rate
Limit Control Solenoid Valve
Abnormal Feedback Low Voltage of Maximum Pump 2 Flow Rate
Limit Control Solenoid Valve
Abnormal Feedback Current of Torque Control Solenoid Valve
Abnormal Feedback High Voltage of Torque Control Solenoid Valve
Abnormal Feedback Low Voltage of Torque Control Solenoid Valve
Abnormal Feedback Current of Maximum Pump 1 Flow Rate Limit
Control Solenoid Valve
Abnormal Feedback High Voltage of Maximum Pump 1 Flow Rate
Limit Control Solenoid Valve
Abnormal Feedback Low Voltage of Maximum Pump 1 Flow Rate
Limit Control Solenoid Valve
Abnormal Feedback Current of Solenoid Valve Unit (SC)
Abnormal Feedback High Voltage of Solenoid Valve Unit (SC)
Abnormal Feedback Low Voltage of Solenoid Valve Unit (SC)
Abnormal Feedback Current of Solenoid Valve Unit (SI)
Abnormal Feedback High Voltage of Solenoid Valve Unit (SI)
Abnormal Feedback Low Voltage of Solenoid Valve Unit (SI)
Abnormal Feedback Current of Solenoid Valve Unit (SF)
Abnormal Feedback High Voltage of Solenoid Valve Unit (SF)
Abnormal Feedback Low Voltage of Solenoid Valve Unit (SF)
Abnormal Feedback Current of Travel Motor Displacement Angle
Control Solenoid Valve
Abnormal Feedback High Voltage of Travel Motor Displacement
Angle Control Solenoid Valve
Abnormal Feedback Low Voltage of Travel Motor Displacement
Angle Control Solenoid Valve
Abnormal Feedback Current of Travel Make-Up Solenoid Valve
Abnormal Feedback High Voltage of Travel Make-Up Solenoid
Valve
Abnormal Feedback Low Voltage of Travel Make-Up Solenoid Valve
T5-7-128
Applicability
Applicable (Harness)
Applicable
(Harness/Solenoid Valve)
Not Applicable
Applicable
(Harness/Solenoid Valve)
TROUBLESHOOTING / Troubleshooting B
Fault Code
11910-2
11911-2
11914-2
11915-2
11918-2
11920-2
11502-2
11901-3
11901-4
11921-2
Trouble
Actual Engine Speed
Security Signal
Radiator Coolant Temperature
Gate Lock Signal
Word Mode
Fuel Flow Rate
Travel Motor Excessive Rotation
Abnormal Hydraulic Oil Temperature Sensor High Voltage
Abnormal Hydraulic Oil Temperature Sensor Low Voltage
Incorrect Odometer Value
T5-7-129
Applicability
Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable
TROUBLESHOOTING / Troubleshooting B
BLEEDING AIR FROM TRANSMISSION
2
1
IMPORTANT: Release any pressure in the
transmission after removing/installing
the pipe lines or hoses, or changing
the hydraulic oil. If air is mixed in the
transmission
gearshift
circuit,
malfunction of the transmission may
result.
NOTE: Bleed air by two or more persons.
TCJB-01-02-020
1. Start the engine. Park the machine on level firm
ground. Lower the bucket onto the ground.
2. Perform the following steps. Apply the work
brake.
• Set the brake switch to the auto axle lock or axle
lock position.
• Depress the brake pedal fully.
3
NOTE: If the brake switch is the P (parking brake)
position, air bleeding work cannot be
performed.
3. Insert transparent vinyl tube (3) at the end of air
bleed plugs (1, 2) of the transmission. Put the
other one end into transparent container (4) filled
with hydraulic oil.
4. Switch travel speed mode switch (5) fast
speed/slow speed 4 to 5 times.
5. Fast speed side:
Set travel speed mode switch (5) to the fast
speed position. Loosen air bleed plug (1).
Slow speed side:
Set travel speed mode switch (5) to the slow
speed position. Loosen air bleed plug (2).
6. Discharge air in hydraulic oil. Tighten the air
bleed plug after 15 to 20 seconds.
7. Repeat steps 4 to 5 until air bubbles stop coming
out with the hydraulic oil. (About 4 to 5 times)
8. Tighten the air bleed plug.
4
M202-07-023
Fast Speed
5
Slow Speed
TCJB-04-03-001
T5-7-130
TROUBLESHOOTING / Troubleshooting B
BLEEDING AIR FROM BRAKE (AXLE)
IMPORTANT: If air is mixed in the brake system,
the brake function is reduced,
possibly resulting in serious hazard.
Be sure to bleed air from the brake
system after disconnecting and
reconnecting the pipe lines, or
changing the hydraulic oil. Bleed air
until hydraulic oil of approx. 500 mL
(0.13 US gal.) is drained from each
wheel (4 places) after air bubbles
disappear.
1
NOTE: Bleed air by two or more persons.
1. Set the brake switch in the steering column
monitor to the P (parking) position. Start the
engine. Increase the brake pressure.
2. Insert transparent vinyl tube (2) at the end of air
bleed plug (1). Put the other one end into
transparent container (3) filled with hydraulic oil.
3. Depress brake pedal (4) repeatedly several times.
Then, depress and hdd brake pedal (4) fully.
4. In step 3, loosen air bleed plug (1) and drain the
hydraulic oil with air for several seconds.
5. Tighten air bleed plug (1).
6. Repeat steps 3 to 5 until air bubbles stop coming
out with the hydraulic oil.
MCBB-07-044
1
2
NOTE: Although hydraulic oil of 500 mL (0.13 US
gal.) is drained, if air bubbles are still
remaining in the hydraulic oil, continuously
repeat steps 3 to 5.
7. Repeat steps 3 to 5 for the other 3 places.
3
IMPORTANT: After bleeding air from all four
places, bleed air from all four places
once more. After bleeding air by
steps 3 to 5 twice, make sure that air
is completely bled.
M202-07-023
MCBB-01-008
4
T5-7-131
TROUBLESHOOTING / Troubleshooting B
EMERGENCY
BOOM
LOWERING
PROCEDURE (WITHOUT HOSE RUPTURE
VALVE)
CAUTION: Do not stay under the boom
during operation.
2
Boom 1
1
If the engine stalls and cannot be restarted, lower the
boom to lower the bucket to the ground referring to
the emergency boom lowering procedure stated
below.
1. Remove rubber caps (1, 2) from the boom 1
section at 4-spool side in the control valve.
2. Attach a ring spanner or spanner onto lock nut (8).
Rotate to the left and remove lock nut (8).
: 17 mm
3. Put hexagonal wrench into screw (7). Rotate to
the right until screw (7) stops.
: 4 mm
4. Attach a ring spanner or spanner onto lock nut (5).
Rotate to the left and loosen lock nut (5) slightly.
: 17 mm
5. Put hexagonal wrench into screw (6). Rotate
screw (6) to the right and lower the boom while
adjusting the lowering speed.
: 4 mm
6. Do not remove snap ring (3) and washer (4) at
this time. Do not rotate screw (6) too strong, or
washer (4) may be deformed.
7. After the boom is lowered onto the ground, rotate
screws (6, 7) to the left into the position that are
pulled completely. Rotate screw (7) to 1/8 turn
right. Tighten lock nuts (5, 8).
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
T16W-03-03-032
1
3
6
4
2
5
7
8
NOTE: If not tightening securely, leakage may
increase. Tighten completely with the
torque specifications.
8. Do not install rubber caps (1, 2) to the different
place.
NOTE: Install screws (7, 6) in this order.
TCGB-05-07-001
T5-7-132
TROUBLESHOOTING / Troubleshooting B
ATTACHMENT
CIRCUIT
RELEASE PROCEDURE
PRESSURE
As for the machine, attached with the attachment, the
accumulator is equipped between the pilot pump and
the pilot valve.
Set the pilot shut-off lever to the UNLOCK position.
After stopping the engine with the engine stop switch
and when operating the control lever, the accumulator
will perform pressure release procedure in the pilot
circuit.
Travel Pilot
Valve
Left Pilot Valve
Right Pilot Valve
Pilot Shut-Off
Solenoid Valve
Control Valve
Accumulator
Pilot Pump
Engine
TCJB-05-07-005
T5-7-133
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-134
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.
Remove the harness from the negative terminal
side in battery 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.
As for the color codes of wire harnesses in the
electrical system, refer to the table below.
In cases on the design sheet where two colors are
indicated for one wire, the left initial stands for
base color, while the right initial stands for marking
color.
Code
R
L
Or
Color
Red
Blue
Orange
Code
W
G
Lg
Y
Br
Gr
Yellow
Brown
Gray
B
P
V
Color
White
Green
Light
green
Black
Pink
Violet
NOTE: • Code BW indicates a black base wire
with white fine-line marking.
• Initials “O” and “Or” both stand for the
color orange.
• Wires with longitudinal stripes printed on
them are not color coded. Do not
confuse them with color coded wires.
T5-8-1
TROUBLESHOOTING / Electrical System Inspection
3. Precautions for connecting and disconnecting
terminal connectors.
• When disconnecting the harnesses, grasp
them by their connectors. Do not pull on the
wire itself. Release the lock first before
attempting to separate connectors, if a lock is
provided.
(Refer
to
“Instructions
for
Disconnecting Connectors on page T5-8-3.)
• The water-resistant connectors keep water out.
If water enters them, water will not easily drain
from them. When checking the water-resistant
connectors, take extra care not to allow water
to enter the connectors. In case water should
enter the connectors, reconnect only after the
connectors are thoroughly dried.
• Before connecting terminal connectors, check
that no terminals are bent or coming off. In
addition, as most connectors are made of brass,
check that no terminals are rusting.
• When connecting terminal connectors provided
with a lock, insert them together until the lock
“clicks.”
• Pull the harness near the connector in order to
check if it is correctly connected.
4. Precaution for using a circuit tester.
• Before using a circuit tester, refer to the
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object to
be measured, voltage range and current
polarity.
• 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.
• When checking the connector by using a tester,
insert a tester probe from the harness end of
connector in order not to damage the terminal
inside connector.
T5-8-2
Incorrect
Correct
T107-07-06-001
Correct
Rust
Incorrect
(Deformation)
Incorrect
(Separation)
T107-07-06-002
Wind a Piece of Wire
Tester Probe
Sharpen the end of the Wire
T107-07-06-003
TROUBLESHOOTING / Electrical System Inspection
INSTRUCTIONS
CONNECTORS
FOR
DISCONNECTING
• Push, Unlock and Separate Type
NOTE: 1. Connectors will not be easily separated
even if the lock is pushed while being
pulled. Push the lock first before pulling
the connectors.
2 The lock is located on female side
connector (harness end side).
T107-04-05-002
• Raise Lock, Pull and Separate Type
Locations of This Type Connector
Starter Relay
• Pull and Separate Type
T107-04-05-003
IMPORTANT: Before pulling and separating,
release the lock of connector in the
solenoid valve by using a pair of
pincers.
Locations of This Type Connector
Hydraulic Oil Temperature Sensor
Dr. ZX
T107-04-05-004
• Push, Unlock, and Switch the Lever Type
Locations of This Type Connector
Cab Harness to Main Harness
ECM
T1J1-05-08-003
T5-8-3
TROUBLESHOOTING / Electrical System Inspection
FUSE INSPECTION
Cracks in a fuse are so fine that it is very difficult or
impossible to find by visual inspection. Use a tester in
order to correctly inspect fuse continuity by following
the instructions described below.
1. Turn the key switch ON.
When the key switch is turned ON, current from
key switch terminal M activates the battery relay
so that electric power is supplied to all circuits
except the glow plug relay circuit. (Refer to the
circuit diagram.)
2. Remove the fuse box cover. Set the tester.
(Measurement Range: 0 to 30 V)
3. Ground the negative probe of tester to the vehicle
frame. Touch the terminals located away from
center of the fuse box with the positive probe of
tester one at a time. When normal continuity of a
fuse is intact, the tester will indicate 20 to 25 V
(battery voltage).
10
20
9
19
8
18
7
17
6
16
5
15
4
3
14
13
2
12
1
11
M178-07-034
T5-8-4
NOTE: All terminals located along the lengthwise
centerline of the fuse box are connected to
the power source, while terminals located
away from center of the fuse box are
connected
to
loads
(accessories).
Therefore, test all fuses in the same
method except for the glow relay circuit
fuse. Check the glow relay circuit fuse with
the key switch turned to the ON position
and follow the procedure in step 3.
30
40
29
39
28
38
27
37
26
36
25
35
24
23
34
33
22
32
21
31
M178-07-034
TROUBLESHOOTING / Electrical System Inspection
Fuse No.
1
2
Capacity
20 A
10 A
3
20 A
4
10 A
5
5A
6
7
10 A
10 A
Connected to
Boom Light Relay
Wiper Relay, Washer Relay,
Wiper Motor
Compressor Relay, Heater
Relay
Pilot Shut-Off Solenoid Valve,
Pilot Shut-Off Relay, Security
Relay, MC Solenoid Valve
Power
Optional 1, Travel Alarm,
Auxiliary Power
Optional 2
−
Fuse No.
21
22
Capacity
10 A
10 A
8
30 A
9
23
10 A
High-Beam Relay
24
10 A
Flasher, Turn Signal Light
Relay (Left) / (Right), Hazard
Switch
25
15 A
Stop Light Relay
26
27
10 A
10 A
ECM Main Relay
28
10 A
10 A
Security Horn, Security Horn
Relay, Radio (Backup Power)
29
10 A
10
5A
MC/ICF Backup Power
30
10 A
11
12
13
14
15
16
17
10 A
10 A
10 A
10 A
10 A
5A
5A
31
32
33
34
35
36
37
10 A
10 A
10 A
10 A
15 A
10 A
10 A
18
5A
38
10 A
Front Cab Light (Optional)
19
10 A
Horn Relay
Cab Light, Radio Power
Cigarette Lighter
Fuel Pump
Auxiliary
Glow Plug Relay
Air Conditioner Unit Power,
Compressor Relay, Heater
Relay, Blower Hi Relay
MC/ECM/ICF/Monitor Unit/
Option Controller/
Satellite
Communication
Terminal Power ON Signal
Monitor Unit Backup Power,
Buzzer Power
−
Steering
Column
Monitor
Power
Slow Speed Selection Relay,
Fast Speed Selection Relay,
Condenser
(Pulse
Signal
Conversion), Travel N Sensor
Outrigger Main Relay 1, Travel
Forward Pi Cut Solenoid Valve,
Travel
Reverse
Pi
Cut
Solenoid Valve
Assist
(Optional),
Power
Digging Relay
Clearance Light Relay (Left)
Head Light Relay (Left)
Heater Seat (Optional)
Seat Compressor (Optional)
Rotary Beacon Light (Optional)
Rear Cab Light (Optional)
Option Controller Power
39
10 A
20
5A
Optional 3
40
10 A
Option Controller/
Satellite Communication
Terminal Backup Power
Front Cab Light
T5-8-5
Connected to
Clearance Light Relay (Right)
Head Light Relay (Right)
TROUBLESHOOTING / Electrical System Inspection
FUSIBLE LINK INSPECTION
Battery Relay
Inspection
1. Visually inspect the fusible link.
Replacement
1. Remove the negative cable from the battery.
2. Pull out the fusible link. Replace the fusible link.
3. Install the negative cable to the battery.
Fusible Link
M178-07-049
Fusible Link
T111-04-05-015
T5-8-6
TROUBLESHOOTING / Electrical System Inspection
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between
the battery positive terminal and the vehicle frame.
Normal Voltage: 24 V
NOTE: If voltage is abnormal, recharge or replace
the battery.
To Battery Relay
2. Start the engine. Check voltage between the
battery positive terminal and the vehicle frame.
Normal Voltage: 26 to 28 V
NOTE: If voltage is abnormal, check the charging
system.
T162-05-06-005
T5-8-7
TROUBLESHOOTING / Electrical System Inspection
HOW TO CHECK ALTERNATOR
Monitor Unit
Generally, if the alternator has generated electricity,
alternator alarm will disappear.
If the alternator alarm displays while the engine is
running, the alternator might be defective.
How to Check Alternator
1. Turn the key switch to the ON position. Confirm
that the alternator alarm is displayed.
2. Measure voltage between terminals B and E 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 alternator circuit might be the cause
of the malfunction.
When voltage is 0 V, the wiring between fuse box
and alternator might be loose or disconnected.
Also, the alternator cannot generate electricity if
the ground line is disconnected.
Alternator Alarm
3. Next, start the engine and measure voltage
generated while as the alternator rotates. As
described above, measure voltage between
terminals B and E on the side of alternator.
If voltage is around 28 V, the alternator is
operating normally.
If the rated voltage is not being generated (around
24V), there is some trouble with the alternator or
the regulator.
TCJB-05-02-050
B
E
T157-07-06-003
T5-8-8
TROUBLESHOOTING / Electrical System Inspection
CONTINUITY CHECK
Harness
Single-line continuity check
Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity
NOTE: When the one end connector is far apart
from the other, connect one end of
connector (A) to the machine chassis using
a clip. Then, check continuity of the
harness through the vehicle frame as
illustrated.
a
A
Ω
a
A
Connect to the
machine.
Ω
To machine
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity
A
Single-line short-circuit check
Disconnect both end connectors of the harness and
check continuity between one end connector of the
harness and the vehicle frame:
If the ohm-meter reading is:
0 Ω = Short circuit is present.
∞ Ω = No short circuit is present.
Short-circuit
between the
harness and
the machine.
x
a
Ω
T107-07-05-003
Multi-line continuity check
Disconnect both end connectors of the harness, and
short-circuit two terminals, (A) and (B), at one end
connector, as illustrated. Then, check continuity
between terminals (a) and (b) at the other connector.
If the ohm-meter reading is ∞ Ω, either line (A) - (a),
or (B) - (b) is in discontinuity. To find out which line is
discontinued, conduct the single line continuity
check on both lines individually, or, after changing
the short-circuit terminals from (A) - (B) to (A) - (C),
check continuity once more between terminals (a)
and (c).
NOTE: By conducting the multi-line continuity
check twice, it is possible to find out which
line is discontinued. With terminals (A) and
(C) short-circuited, check continuity
between terminals (a) and (c).
If the ohm-meter reading is:
0 Ω = Line (B) - (b) has discontinuity.
∞ Ω = Line (A) - (a) has discontinuity.
Multi-line short-circuit check
Disconnect both end connectors of the harness, and
check continuity between terminals (A) and (B) or
(C).
If the ohm-meter reading is:
0 Ω = Short-circuit exists between the lines.
∞ Ω = No short-circuit exists between the lines.
T5-8-9
First short-circuit (Clip)
a
b
c
A
B
C
Second
short-circuit
Ω
T107-07-05-004
Short-circuit between
harnesses
A
B
C
X
a
b
c
Ω
T107-07-05-005
TROUBLESHOOTING / Electrical System Inspection
VOLTAGE AND CURRENT
MEASUREMENT
Turn key switch ON so that the specified voltage
(current) is supplied to the location to be measured.
Judge if the circuit is normal by evaluating whether the
measured voltage (current) matches the specification.
24-Volt Circuit
Start checking the circuit in order up to the
location to be measured from either power
source or actuator side. Thereby, the faulty
location in the circuit will be found.
Black Probe (Negative) of Tester:
To ground to the vehicle frame
Red Probe (Positive) of Tester:
To touch the location to be measured
Engine
Power Circuit
Stopped
Stopped
Stopped
Stopped
Stopped
Stopped
Preheating Circuit
Stopped
Stopped
Charging Circuit
Fast Speed
Key Switch
Location to be Measured
One Battery
One Battery
Two Batteries
Battery Power
Fusible Link
Backup Current*
Specification
10 to 12.5 V
10 to 12.5 V
20 to 25 V
20 to 25 V
20 to 25 V
6 mA
OFF
OFF
OFF
OFF
OFF
OFF
Between (2) and (1):
Between (3) and (2):
Between (3) and (1):
Between (4) and (E):
Between (5) and (E):
Between (1) and (E):
ON or START
ON or START
Between (6) and (E): Key Switch
Between (7) and (E): Glow Plug
20 to 25 V
20 to 25 V
ON
26 to 30 V
Fast Speed
ON
Fast Speed
ON
Fast Speed
Fast Speed
Surge Voltage
Prevention Circuit
Idle Speed
Idle Speed
Idle Speed
Idle Speed
Accessory Circuit
Stopped
Stopped
Stopped
Stopped
ON
ON
Between (8) and (E): Alternator (B) / Generating
Voltage
Between (9) and (E): Battery Relay / Generating
Voltage
Between (10) and (E): Fuse Box / Starter Relay (R)
/ Generating Voltage
Between (11) and (E): Generating Voltage
Between (12) and (E): Monitor Unit (C7)
ON
ON
ON
ON
Between (8) and (E): Alternator (B)
Between (11) and (E): Starter Relay (R)
Between (13) and (E): Load Damp Relay
Between (9) and (E): Battery Relay
26 to 30 V
13 to 30 V
26 to 30 V
26 to 30 V
ON
ON
ON
ON
Between (14) and (E): Auxiliary
Between (15) and (E): Cigarette Lighter
Between (16) and (E): Radio, Cab Light
Between (17) and (E): Battery Relay
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
*Before measurement, disconnect the negative cable from the battery.
T5-8-10
26 to 30 V
26 to 30 V
13 to 30 V
13 to 30 V
TROUBLESHOOTING / Electrical System Inspection
Key Switch
Fuse
Box
5
1
2
3
6
4
17
Load
Damp
Relay
Battery Relay
Battery
10
13
9
14 15 16
Starter
Relay
11
8
Alternator
7
Glow Plug Relay
Glow
Plug
12
C7
Monitor
Unit
TCJB-05-08-001
T5-8-11
TROUBLESHOOTING / Electrical System Inspection
Engine
Starting Circuit
Started
Started
Started
Started
Started
Started
Started
Started
Started
Started
Started
Started
Started
Started
Started
Started
Key Switch
START
START
START
START
START
START
START
START
START
START
START
START
START
START
START
START
Location to be Measured
Between (18) and (E):
Between (19) and (E):
Between (20) and (E):
Between (21) and (E):
Between (22) and (E):
Between (23) and (E):
Between (24) and (E):
Between (25) and (E):
Between (26) and (E):
Between (27) and (E):
Between (28) and (E):
Between (29) and (E):
Between (30) and (E):
Between (31) and (E):
Between (32) and (E):
Between (33) and (E):
Key Switch
Battery Relay (Coil)
Battery Relay (Switch)
Starter (B)
Starter (C)
Starter Relay (S)
Starter Cut Relay
Fuse Box
Fuse Box
ICF(C7)
Monitor Unit (A7)
MC(B16)
ECM(24)
Option Controller (B16)
ECM Main Relay
ECM Main Relay
*Before measurement, disconnect the negative cable from the battery.
T5-8-12
Specification
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
5V
20 to 25 V
TROUBLESHOOTING / Electrical System Inspection
25
18
Starter
Cut Relay
19
Battery
24
20
Starter
26
Fuse
Box
21
Starter
Relay
22
23
32
ECM
Main
Relay
33
30
ECM
MC
Monitor Unit
ICF
Option
Controller
24
B16
A7
C7
B16
29
28
T5-8-13
27
31
TCJB-05-08-001
TROUBLESHOOTING / Electrical System Inspection
Engine
Pilot Shut-Off Circuit
Stopped
Stopped
Stopped
Stopped
Stopped
Key
Switch
ON
ON
ON
ON
ON
Location to be Measured
Between (34) and (E):
Between (35) and (E):
Between (36) and (E):
Between (37) and Ground:
Between (38) and (E):
Fuse Box
Pilot Shut-Off Relay
Pilot Shut-Off Solenoid Valve
Pilot Shut-Off Relay
Security Relay
*Before measurement, disconnect the negative cable from the battery.
T5-8-14
Specification
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
TROUBLESHOOTING / Electrical System Inspection
34
Battery
Battery
Relay
Fuse Box
36
Pilot
Shut-Off
Solenoid
Security
Relay
Pilot
Shut-Off
Relay
38 37
35
TCJB-05-08-001
T5-8-15
Fuse
TROUBLESHOOTING / Electrical System Inspection
5 Voltage Circuit
• Voltage between terminal #1 and the vehicle
Signal or
Ground
Power
Source
1
Two Polarities
frame
Disconnect the connector with the key switch OFF.
Measure voltage between terminal #1 on the
machine harness end connector and the vehicle
frame (ground).
• Key switch: ON
• Tester black terminal (negative):
2
V
Connected to the vehicle frame (ground)
• Tester red terminal (positive):
Connected to terminal #1
T107-07-05-006
Evaluation:
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal #1 is normal.
Power
Source Signal Ground
1
2
3
Three Polarities
V
• Voltage between terminal #1 and the ground
terminal
Disconnect the sensor connector with the key switch
OFF.
Measure voltage between terminal #1 on the
machine harness end connector and the ground
terminal (terminal #2 for two polarities, or terminal
#3 for three polarities).
T107-07-05-007
Two Polarities
1
2
V
• Key switch: ON
• Tester black terminal (negative):
Connected to the ground terminal
(terminal #2 or #3)
• Tester red terminal (positive):
Connected to terminal #1
T107-07-05-008
Evaluation:
If the measured voltage is within 5±0.5 volt, the
circuit up to terminal #1 or the ground terminal
(terminal #2 or #3) is normal.
Three Polarities
1
2
3
V
T107-07-05-009
T5-8-16
TROUBLESHOOTING / Electrical System Inspection
CHECK BY FALSE SIGNAL
Two Polarities
Turn the key switch OFF. Disconnect the sensor
connector. Turn the key switch ON. Connect terminal
#1 (power source) of machine harness end connector
to terminal #2 (signal). (Power voltage is used as a
false signal.) Check this state by using the monitor
function of Dr. ZX. When the maximum value is
displayed, MC and the circuit up to the machine
harness end connector are normal. If “ON” is displayed,
the pressure switch circuits are normal.
IMPORTANT: Do not connect terminal #1 or #2 to
terminal #3 or to the vehicle frame
(ground)
when
checking
a
three-polarity connector.
NOTE: Some kinds of sensors can be monitored
by the service menu of monitor (the built-in
diagnosing system).
(Hydraulic Oil Temperature Sensor)
(Fuel Sensor)
1
2
Connect
T107-07-05-010
Three Polarities
(Pressure Sensor)
(Pump Delivery Pressure Sensor)
(Pump Control Pressure Sensor)
(Brake Pressure Sensor)
(Brake Remaining Pressure Sensor)
(Boom Bottom Pressure Sensor)
1
2
3
Connect
T107-07-05-011
T5-8-17
TROUBLESHOOTING / Electrical System Inspection
TEST HARNESS
Install a test harness between connectors. Check the
circuit condition depending on whether the test
harness lamp lights or extinguishes during operation.
Parts Number 4283594 (ST 7126)
Use in order to check a single-line (discontinuity
and/or voltage).
During Operation: Lamp is ON.
To Measuring Point.
Parts Number 4283594 (ST 7126)
To Ground
T107-07-05-012
Parts Number (ST 7226)
Use in order to check the solenoid valve unit circuits.
4
When the corresponding control lever or switch is
operated: Lamp is ON.
3
1
2
150
50
50
Parts Number (ST 7226)
T5-8-18
50
2
1
T107-07-06-015
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
MEMO
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
....................................................................................................................................................................
Hitachi Construction Machinery Co. Ltd
Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162
Hitachi Ref. No.
SERVICE MANUAL REVISION REQUEST FORM
NAME OF COMPANY:
MODEL:
PUBLICATION NO.:
YOUR NAME:
DATE:
FAX:
(Located at the right top corner in the cover page)
PAGE NO.:
(Located at the bottom center in the page. If two or more revisions are requested, use the comment column)
YOUR COMMENTS / SUGGESTIONS:
Attach photo or sketch if required.
If your need more space, please use another sheet.
REPLY:
(Copy this form for usage)
THE ATTACHED DIAGRAM LIST
(The following diagrams are attached to this manual.)
1. ELECTRICAL CIRCUIT DIAGRAM (STANDARD)
ELECTRICAL CIRCUIT DIAGRAM (OPTIONAL)
2. CONNECTORS
3. CAB HARNESS
4. ENGINE HARNESS
FLOOR HARNESS
5. MONITOR HARNESS
CHASSIS HARNESS
6. LEFT CONSOLE HARNESS
AUXILIARY / POSITIONING SELECT HARNESS
7. BLADE / OUTRIGGER HARNESS
LICENSE PLATE HARNESS
8. POSITIONING HARNESS
PRESSURE SENSOR (POSITIONING) HARNESS
9. SWING PARKING BRAKE RELEASE HARNESS
10. ENGINE SUB HARNESS (1)
ENGINE SUB HARNESS (2)
11. HYDRAULIC CIRCUIT DIAGRAM (2-PIECE BOOM, FULLY OPTIONAL)
HYDRAULIC CIRCUIT DIAGRAM (MONOBLOCK BOOM, FULLY OPTIONAL)
NOTE: As for the optional harness diagram, refer
to “e-Cabinet”.