ZX210W-3 Technical Manual (Troubleshooting)
ZX210W-3 Technical Manual (Troubleshooting)
ZX210W-3 Technical Manual (Troubleshooting)
TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX: 81-29-831-1162
E-mail: [email protected]
• This manual contains the revision information
to the 30, April 2009.
ADDITIONAL REFERENCES
MANUAL COMPOSITION
• This manual consists the Technical Manual and the • Information included in the Workshop Manual:
Workshop Manual. technical information needed for maintenance
and repair of the machine, tools and devices
• Information included in the Technical Manual: needed for maintenance and repair, maintenance
technical information needed for redelivery and standards, and removal/installation and assem-
delivery, operation and activation of all devices ble/disassemble procedures.
and systems, operational performance tests, and
troubleshooting procedures.
PAGE NUMBER
Example : T 1-3-5
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
UNITS USED
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-02
SAFETY
001-E01A-0001
SA-688
002-E01A-1223
SA-1
SAFETY
SA-2
SAFETY
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 SA-435
524-E01A-0000
SA-4
SAFETY
SA-439
008-E01A-0439
009-E01A-0462
SA-5
SAFETY
010-E01A-0237
011-E01A-0398
036-E01A-0293-3
SA-6
SAFETY
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” chap-
ter 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
014-E01B-0427
SA-091
SA-7
SAFETY
M202-05-014
SA-8
SAFETY
SA-9
SAFETY
SA-686
018-E01A-0481
SA-481
SA-092
017-E01A-0491
SA-10
SAFETY
SA-288
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 min-
utes 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.
SA-278
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
020-E02A-0493
SA-11
SAFETY
021-E01A-0494
SA-12
SAFETY
KEEP PERSON CLEAR FROM WORKING AREA
• A person may be hit severely by the swinging front attach-
ment 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 any-
one from entering the work area.
022-E01A-0386
M202-05-014
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 pos-
sible, do not panic. Often, the machine can be secured by
lowering the front attachment, in such cases.
024-E01A-0488 SA-683
SA-13
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MA-
CHINE---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 ma-
SA-088
chine.
• 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.
025-E03B-0463
SA-684
026-E01A-0519
SA-685
SA-14
SAFETY
027-E01A-0382
028-E01A-0389 SA-087
SA-15
SAFETY
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, result-
ing 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 sud-
denly.
• 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
031-E01A-0432
SA-432
034-E01A-0496
SA-019
SA-17
SAFETY
TRANSPORT SAFELY
• Take care the machine may turn over when loading or un-
loading the machine onto or off of a truck or trailer.
• Observe the related regulations and rules for safe trans-
portation.
• 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:
Less than 15°
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the SA-094
machine weight.
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 travel-
ing 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 Less than 15°
sudden bump. Take care when traveling over it.
SA-095
8. Place blocks in front of and behind the tires. Securely
hold the machine to the truck or trailer deck with wire
ropes.
035-E07A-0454
SA-18
SAFETY
500-E02C-0520
SA-19
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
501-E01A-0287
SS3076175 SS2045102
519-E01A-0527
502-E01A-0026
SA-026
SA-20
SAFETY
503-E01B-0344
SA-344
504-E01A-0034 SA-034
521-E02A-0249
SA-21
SAFETY
PREVENT BURNS
Hot spraying fluids:
• 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
S506-E01A-0019
SA-22
SAFETY
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.
508-E02B-0019
508-E02A-0393
SA-24
SAFETY
18-E02B-0393
SS-1510
509-E01A-0016
SA-016
523-E01A-0818
SA-25
SAFETY
FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that contain flam-
mable fluids.
• Clean them thoroughly with nonflammable solvent be-
fore welding or flame cutting them.
510-E01B-0030
511-E01A-0029
SA-26
SAFETY
512-E01B-0032
513-E01A-0405
SA-405
SA-27
SAFETY
515-E01A-0309
516-E01A-0226
SA-28
SAFETY
S517-E01A-0435
SA-435
SA-29
SAFETY
(Blank)
SA-30
SECTION AND GROUP SECTION 4 OPERATIONAL PER-
CONTENTS FORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
TECHNICAL MANUAL
SECTION 5 TROUBLESHOOTING
(Troubleshooting)
Group 1 Diagnosing Procedure
Group 2 Monitor Unit
Group 3 Dr. ZX
Group 4 ICF
Group 5 Component Layout
Group 6 Troubleshooting A
Group 7 Troubleshooting B
Group 8 Electrical System Inspection
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Controller Group 5 Electric Lever
Group 2 Control System Group 6 Transmission
Group 3 ECM System Group 7 Axle
All information, illustrations and speci- Group 4 Hydraulic System Group 8 Travel Motor
fications in this manual are based on Group 5 Electrical System Group 9 Signal Control Valve
the latest product information available Group 10 Steering Valve
at the time of publication. The right is Group 11 Brake Valve
reserved to make changes at any time Group 12 Others (Upperstructure)
without notice. 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 Precautions for Disassem- Group 1 Swing Bearing
bling and Assembling Group 2 Travel Motor
Group 2 Tightening Torque Group 3 Center Joint
Group 3 Painting Group 4 Transmission
Group 4 Bleeding Air from Hydrau- Group 5 Axle
lic Oil Tank Group 6 Axle Lock Cylinder
SECTION 2 UPPERSTRUCTURE Group 7 Operate Check Valve
Group 1 Cab (Axle Lock Cylinder)
Group 2 Counterweight SECTION 4 FRONT ATTACHMENT
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 Solenoid Valve
Group 13 Steering Valve
Group 14 Brake Valve
Group 15 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
Main Pump Delivery Pressure......................T4-5-6
Performance Standard ................................. T4-2-1
Main Relief Set Pressure..............................T4-5-8
Main Pump P-Q Diagram............................. T4-2-6
Relief Pressure (When relieving Swing).... T4-5-10
Sensor Activating Range.............................. T4-2-8
Overload Relief Valve Set Pressure .......... T4-5-12
Group 3 Engine Test 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 Steering Valve Relief Pressure.................. T4-5-26
Valve Clearance ........................................... T4-3-6 Brake Pressure (Front and Rear) .............. T4-5-28
Lubricant Consumption ................................ T4-3-9 Brake Accumulated Pressure .................... T4-5-30
Brake Warning Set Pressure (Decrease) .. T4-5-32
Group 4 Excavator Test
Brake Warning Set Pressure (Increase).... T4-5-34
Travel Speed ................................................ T4-4-1
Brake Control Function ................................ T4-4-3
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
CJBT-4-1
(Blank)
CJBT-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedure to quan- The machine performance does not always deteriorate
titatively check all system and functions on the ma- as the working hours increase. However, the machine
chine. performance is normally considered to reduce in pro-
portion to the increase of the operation hours. Accord-
Purpose of Performance Tests ingly, restoring the machine performance by repair,
1. To comprehensively evaluate each operational adjustment, or replacement shall consider the number
function by comparing the performance test data of the machine’s working hours.
with the standard values.
2. According to the evaluation results, repair, adjust, Definition of “Performance Standard”
or replace parts or components as necessary to 1. Operation speed values and dimensions of the
restore the machine’s performance to the desired new machine.
standard. 2. Operational performance of new components
3. To economically operate the machine under op- adjusted to specifications. Allowable errors will be
timal conditions. indicated as necessary.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the op-
erational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to evalu-
ate the performance test data.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
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 ex-
tended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork- T105-06-01-003
ers. Once the test is started, be sure to commu-
nicate with each other using these signals, and to
follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic
pipings.
T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard
PERFORMANCE STANDARD
The performance standard values are listed in the * The standard measurement conditions are as
table below. follows.
For details including measuring method, refer to T4-3
• Engine Control Dial: Fast Idle
onward.
The value indicated in parentheses is only a • Power Mode Switch: P mode
reference. • 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 Reference
Descriptions Remarks
Standard Page
ENGINE SPEED min−
1
T4-3-1
Slow Idle Speed 800±100 Value indicated on Dr. ZX.
Fast Idle Speed 1550±50 ↑
Fast Idle Speed (with ECO deactivated) 1650±50 ↑
Fast Idle Speed (Relief operation) 1650±50 Arm roll-in relief control. Value
indicated on Dr. ZX.
Fast Idle Speed (E mode) 1500±50 Value indicated on Dr. ZX.
Fast Idle Speed (HP mode, Relief operation) 1850±50 Arm roll-in relief control. Value
indicated on Dr. ZX.
Slow Idle Speed (Pedal mode) 1100±50 Travel speed mode switch:
Fast speed
Brake switch: OFF or Axle lock
Jack up and measure.
Value indicated on Dr. ZX.
Fast Idle Speed (Pedal mode, Working 1850±50 FNR switch: N
accelerator) Brake switch: OFF, Auto axle
lock or Axle lock
Value indicated on Dr. ZX.
Fast Idle Speed (Pedal mode, Relief operation) 2000±50 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.
Auto-Idle Speed 1100±100 Value indicated on Dr. ZX.
Warming-Up Speed 1400±100 ↑
ENGINE COMPRESSION PRESSURE 3.04±0.2 Engine speed: at 200 min-1 T4-3-4
2
MPa (kgf/cm , psi) (31±2, 440)
VALVE CLEARANCE (IN, EX) mm 0.4 With engine cold T4-3-6
LUBRICANT CONSUMPTION 30 or less Hour meter: 2000 hours or less T4-3-9
(Rated Output) mL/h
T4-2-1
OPERATIONAL PERFORMANCE TEST / Standard
Performance Reference
Descriptions Remarks
Standard Page
TRAVEL SPEED km/h (100 m) T4-4-1
Fast 27.5+2.0-3.0 Engine speed control mode
selection switch: Pedal mode,
Travel speed mode switch: Fast
Slow 7.5±0.5 Engine speed control mode
selection switch: Pedal mode,
Travel speed mode switch:
Slow
Creeper 2.8±0.3 Engine speed control mode
selection switch: Creeper mode
SERVICE BRAKE FUNCTION N (kgf) T4-4-2
Service Brake Tire
lock
Parking Brake Tire
lock
PARKING BRAKE FUNCTION mm/5 min (0) T4-4-3
SWING SPEED sec/3 rev 15.3±1.0 Bucket: empty T4-4-4
14.7±1.0
(HRV)
SWING FUNCTION DRIFT mm/90° 860 or less Bucket: empty T4-4-5
SWING MOTOR LEAKAGE mm/5 min 0 Bucket: loaded T4-4-7
MAXIMUM SWINGABEL SLANT 22 or more Bucket: loaded T4-4-8
ANGLE deg.
SWING BEARING PLAY mm 0.2 to 1.25 Allowable limit: 2.0 to 3.05 T4-4-9
HYDRAULIC CYLINDER CYCLE TIME 2.91 m arm T4-4-10
sec 0.8 m3 (PCSA heaped) bucket,
Bucket: empty
Boom Raise (Monoblock Boom) 3.8±0.3
Boom Raise (2-Piece Boom) 4.0±0.3
Boom Lower (Monoblock Boom) 3.2±0.3 With HRV: 3.4±0.3
Boom Lower (2-Piece Boom) 3.0±0.3 With HRV: 3.2±0.3
Arm Roll-In 3.6±0.3 With HRV: 3.9±0.3
Arm Roll-Out 2.7±0.3
Bucket Roll-In 3.4±0.3
Bucket Roll-Out 2.1±0.3
Positioning Extend 8.8±0.5
Positioning Retract 6.7±0.4 With HRV: 7.0±0.4
Blade Raise 1.5±0.3
Blade Lower 2.0±0.3
Outrigger Raise 1.5±0.3
Outrigger Lower 2.0±0.3
NOTE: HRV: Hose Rupture Valve
T4-2-2
OPERATIONAL PERFORMANCE TEST / Standard
Performance Reference
Descriptions Remarks
Standard Page
DIG FUNCTION DRIFT mm/5 min 2.91 m arm T4-4-12
3
(Maximum Reach Position) 0.8 m (PCSA heaped)
bucket, bucket loaded
Boom Cylinder 5 or less
Arm Cylinder 10 or less
Bucket Cylinder 15 or less
Positioning Cylinder 15 or less
Front Drift Amount (Bucket Bottom) 100 or less
CONTROL LEVER OPERATING FORCE T4-4-13
N (kgf)
Right Lever: Forward/Backward 15 (1.5) or less
Right Lever: Right/Left 15 (1.5) or less
Left Lever: Forward/Backward 15 (1.5) or less
Left Lever: Right/Left 15 (1.5) or less
Steering Wheel Turns (lock-to-lock) 20 (2.0) or less
CONTROL LEVER STROKE mm T4-4-14
Right Lever: Forward/Backward 74±10
Right Lever: Right/Left 68±10
Left Lever: Forward/Backward 74±10
Left Lever: Right/Left 68±10
Steering Wheel Turns (lock-to-lock) 6.9±0.5
COMBINED OPERATION OF BOOM 2.91 m arm T4-4-15
3
RAISE/SWING sec 3.6±0.3 0.8 m (PCSA heaped)
bucket, Bucket: empty
Bucket Teeth Height: H mm 6400 or more
T4-2-3
OPERATIONAL PERFORMANCE TEST / Standard
Reference
Descriptions Performance Standard Remarks
Page
HYDRAULIC SYSTEM
PRIMARY PILOT PRESSURE T4-5-1
2
MPa (kgf/cm , psi)
Fast Idle 4.0+1.0-0.5
(41+10-5,581+145-73)
SECONDARY PILOT PRESSURE 3.3 to 3.9 Value indicated on T4-5-3
(For Fast Idle, Slow Idle) 2
MPa (kgf/cm , psi) (34 to 40, Dr. ZX.
480 to 567) (Control lever: Full
stroke)
STEERING PUMP PRESSURE 2.5±1.0
2
MPa (kgf/cm , psi) (25±10, 360±145)
SOLENOID VALVE SET PRESSURE T4-5-4
2
MPa (kgf/cm , psi)
Solenoid Valve Unit Set Pressure (Value of Dr. ZX) ±0.2 Value indicated on
(2, 29) Dr. ZX.
MAIN PUMP DELIVERY PRESSURE 0.8+1.0-0.5 In neutral, Value T4-5-6
2
MPa (kgf/cm , psi) (8+10-5.0,
116+145-73) indicated on Dr. ZX
MAIN RELIEF VALVE RELIEF T4-5-8
PRESSURE 2
MPa (kgf/cm , psi)
Boom, Arm, Bucket (Relief operation for each) 34.3+2.0-0.5 Value indicated on
(350+20-5,
4980+290-73) Dr. ZX.
Power Digging 36.3+2.0-1.0 Value indicated on
(370 -10, 5280+290-145)
+20
Dr. ZX.
RELIEF PRESSURE 2
MPa (kgf/cm , psi)
T4-2-4
OPERATIONAL PERFORMANCE TEST / Standard
Reference
Descriptions Performance Standard Remarks
Page
MAIN PUMP FLOW RATE L/min - Refer to T4-2-6. T4-5-14
SWING MOTOR DRAINAGE L/min
With constant speed 0.2 to 0.3 T4-5-24
With motor relieved (2 to 5)
STEERING VALVE RELIEF PRESSURE 17.5±1.0 T4-5-28
2
MPa kgf/cm , psi) (179±10, 2540±145)
BRAKE PRESSURE (FRONT/REAR) 7.0±1.0 T4-5-30
(including work brake operating pressure) (70±10, 1020±145)
MPa (kgf/cm2, psi)
BRAKE ACCUMULATOR PRESSURE 17.7±1.0 T4-5-32
2
MPa kgf/cm , psi) (181±10, 2570±145)
BRAKE ALARM PRESSURE 2
MPa (kgf/cm , psi)
Decrease 8.3±0.3 T4-5-34
(85±3, 1210±44)
Increase 9.3±0.3 T4-5-36
(95±3, 1350±44)
T4-2-5
OPERATIONAL PERFORMANCE TEST / Standard
MAIN PUMP P-Q DIAGRAM
P-Q Point
Delivery Pressure Flow Rate
2
MPa (kgf/cm , psi) L/min (gpm)
A 3.9 (40, 570) 229±3 (60.4±0.8)
B 13.7 (140, 1990) [227 (59.9)]
C 16.7 (170, 2430) 212±6 (55.9±1.6)
D 20.4 (208, 2970) [166 (43.8)]
E 26.4 (270, 3840) 134±6 (35.4±1.6)
F 34.3 (350, 4990) 94±10 (24.8±2.6)
The value indicated in parentheses is only a reference.
A
L/min B
D
Flow Rate
T4-2-6
OPERATIONAL PERFORMANCE TEST / Standard
• P-Q Control by Pump Control Pilot Pressure
Signal
(NOTE: Measured at Test Stand)
P-Q Point
Pump Control Pressure Flow Rate
2
MPa (kgf/cm , psi) L/min (gpm)
1.9±0.05 123±2
A
(19±0.5, 276±7.3) (32.5±0.5)
3.4±0.05 202±8
B
(35±0.5, 494±7.3) (53.3±2.1)
Pump 1: 229±3
2.9+0.05−0.29 (60.4±0.8)
C
(30 −3, 422+7.3−42.2)
+0.5
Pump 2: 236±3
(62.3±0.8)
L/min
Flow Rate
T4-2-7
OPERATIONAL PERFORMANCE TEST / Standard
SENSOR ACTIVATING RANGE
1. Measuring Method
• Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
• Unless specified:
T4-2-8
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.
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: Remedy:
1. Measure the engine speeds in the "dial mode" Refer to Troubleshooting B in Group T5-7.
and "pedal mode" positions for the engine speed
control mode selection switch.
2. When measuring, set the switch and test NOTE: ECO stands for the auto engine speed
-1
condition as shown in the table below in response reduction system by 100 min .
to the engine speed to be measured.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
T4-3-2
OPERATIONAL PERFORMANCE TEST / Engine Test
• Engine Speed Control Mode Selection Switch: Pedal mode
Accelerator Power Mode Auto-Idle Work
Test Conditions
Pedal Switch Switch Mode
• FNR switch: (F or R)
Not Digging • Brake switch:
Slow Idle P OFF
depressed mode OFF or Axle lock
• Engine control dial: Slow
Max. Digging • FNR switch: N
Fast Idle P OFF
depressing mode • Work brake: Operable
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 each cylinder
to check for a decline in engine power.
2. Check the exhaust gas color. Keep track of engine
oil consumption.
3. Check for any abnormalities in the intake system
including the air filter.
Preparation:
1. Check that the 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) Injector Lower Head Cover
Measurement:
1. Turn the starter and measure compression
pressure for each cylinder.
2. Repeat the measurement three times and
calculate the mean values. T1V1-04-03-005
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Remedy:
Refer to the engine shop manual.
T4-3-4
OPERATIONAL PERFORMANCE TEST / Engine Test
(Blank)
T4-3-5
OPERATIONAL PERFORMANCE TEST / Engine Test
VALVE CLEARANCE
Terminal Nut
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. Remove the head cover.
2. Remove the terminal nut which secures the
harness to the injector. Harness
: 2 N⋅m (0.2 kgf⋅m, 1.5 lbf·ft)
3. Remove the harness assembly from the injector.
4. Remove the leak off pipe.
: 12 N⋅m (1.2 kgf⋅m, 8.9 lbf·ft)
Injector
5. Rotate the crank pulley. Align the top dead center
(TDC) mark on the crank pulley with the top mark T1V1-04-03-008
7. Start measurement from the cylinder No.1 (or Top Mark Crank Pulley
cylinder No.4) positioned at TDC in the
compression stroke.
TDC Mark
T1V1-04-03-004
T4-3-6
OPERATIONAL PERFORMANCE TEST / Engine Test
Measurement:
1. Insert a thickness gauge into the clearance Rocker Arm
between rocker arm and bridge cap end and
measure the valve clearance.
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
T17P-04-03-001
Bridge Cap
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
T4-3-7
OPERATIONAL PERFORMANCE TEST / Engine Test
Adjustment:
Adjusting
If the measurement results are out of specification, Screw Rocker Arm
adjust the valve clearance in the same order of
measurement.
T1V1-04-03-003
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)
[mL].
NOTE: When measuring, use a high-precision
measuring cylinder or the like.
8. Determine lubricant consumption from the
following equation.
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.
T4-4-1
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
CAUTION: Do not measure travel speed
when traveling in reverse. (FNR Switch: F)
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: Evaluation:
1. Check the performance of hydraulic brake circuit Refer to OPERATIONAL PERFORMANCE TEST /
and brake. Standard in Group T4-2.
2. Brake control function is the safety item. Carry out
the performance test of brake certainly. Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B
Preparation: in Group T5-7.
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 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.
3. Position the front attachment as illustrated in the
operator’s manual.
4. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
Stop Position
CAUTION: Do not measure travel speed Stop Distance
when traveling in reverse. (FNR Switch: F)
Brake
1. Measure travel speed in fast idle. Start Position (100 m Position)
T1F3-04-04-004
2. Select the following switch positions:
T4-4-3
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 Height of the boom
foot pin is the
the arm tip pin. (The bucket must be empty.) same as the
4. Maintain hydraulic oil temperature at 50±5 °C arm tip pin
(122±9 °F).
T1F3-04-04-006
Measurement:
1. Select the following switch positions:
Engine Power Mode Work Auto-Idle
Brake Switch Work Brake
Control Dial Switch Mode Switch
Digging Axle lock or
Fast idle P OFF Operable
mode Auto axle lock
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
OPERATIONAL PERFORMANCE TEST / Excavator Test
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.) Put the matching marks on swing
4. Put the matching marks on the swing bearing bearing outer circumference and
T202-07-03-005
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
Brake Switch Work Brake
Control Dial Switch Mode Switch
Digging Axle lock or
Fast idle P OFF Operable
mode Auto axle lock
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 Measure the distance between the marks.
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.
T105-06-03-010
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B
in Group T5-7.
T4-4-7
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Select the following switch positions:
Engine Power Mode Work Auto-Idle
Brake Switch Work Brake
Control Dial Switch Mode Switch
Digging Axle lock or
Slow idle P OFF Operable
mode Auto axle lock
2. Maintain the engine at slow idle. After five minutes,
measure the distance between the marks along
swing bearing outer circumference and chassis. Measure the distance between the marks.
3. Measure on the right and left swing.
4. Repeat the measurements three times. Calculate
the average values.
Mark on Chassis
T105-06-03-010
T4-4-8
OPERATIONAL PERFORMANCE TEST / Excavator Test
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 1200 kg (2650 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
T212-07-03-001
(122±9 °F).
Measurement:
1. Select the following switch positions:
Engine Power Mode Work Auto-Idle
Brake Switch Work Brake
Control Dial Switch Mode Switch
Digging Axle lock or
Fast idle P OFF Operable
mode Auto axle lock
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
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING BEARING PLAY
Summary:
1. Measure the swing bearing play between inner
Dial Gauge
race and outer race and check the wear of swing
bearing races and balls.
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. Magnetic T202-07-03-008
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST / 100 mm
Standard in Group T4-2.
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
Boom Cylinder:
on to the ground.
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: T202-07-03-012
Adjust each cylinder of boom and arm so that
Arm Cylinder:
the center of bucket full stroke is vertical.
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
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:
Operate the outrigger control lever to full stroke. TCJB-04-04-001
Measure the time to raise and lower the NOTE: The illustration shows the rear blade.
outrigger. Measure the time for the cylinders
one by one. Outrigger Cylinder:
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
Remedy: TCJB-04-04-002
Refer to TROUBLESHOOTING / Troubleshooting B
NOTE: The illustration shows the rear outrigger.
in Group T5-7.
T4-4-13
OPERATIONAL PERFORMANCE TEST / Excavator Test
HYDRAULIC CYLINDER DRIFT CHECK
Preparations:
1. Load a specified weight 1200 kg (2650 lb) into the
bucket.
2. With the arm cylinder fully retracted and the
bucket cylinder fully extended, hold the bucket so
Extended Distance
that the height of the boom foot pin is the same as Retracted Distance
the arm tip pin. Retracted
3. Position the arm and buckets cylinders with the Distance
rod 50 mm (2 in) retracted from the fully extended
position. Height of the
boom foot pin is
4. Maintain hydraulic oil temperature at 50±5 °C the same as the arm tip pin.
(122±9 °F).
Drift Amount
Measurement: T1F3-04-04-011
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
T110-06-03-002
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B Arm Cylinder Extension
in Group T5-7.
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).
Measurement:
1. Measure for each control lever.
2. Select the following switch positions: TCJB-04-04-003
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 Stroke Stroke
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.
Neutral
Preparations:
1. Maintain hydraulic oil temperature at 50±5 °C T1F3-04-04-012
(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
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 T212-07-03-005
(122±9 °F).
Measurement: T212-07-03-006
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
T4-4-17
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. Plug
5. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement: T178-03-07-001
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
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) T178-03-07-001
4. After adjustment, check the set pressure.
1
NOTE: Standard Change in Pressure (Reference) 2
Shim Change in Pressure
Thickness
kPa (kgf/cm2) (psi)
(mm)
0.25 78 (0.8) (11)
0.5 157 (1.6) (23)
1.0 304 (3.1) (44)
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 Pilot Valve Signal Control Valve
release any remaining pressure.
3. Measure pressure at the location between pilot Hose
valve and signal control valve. Remove the pilot
hose from the circuit to be measured. Install the Fitting
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. Pressure
Gauge
: 17 mm, 19 mm
Tee
Adapter
NOTE: When removing the lines from signal con-
trol valve, use tool (SNAP-ON
GAN850812B: size 19.05 mm) in order to
easily remove the lines.
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
OPERATIONAL PERFORMANCE TEST / Component Test
SOLENOID VALVE SET PRESSURE
Preparation:
1. Stop the engine.
2. Push the air bleed valve of the oil supply cap and
Solenoid Valve Unit
release any remaining pressure.
3. Remove the line from the solenoid valve to be Pressure Gauge
measured. Install tee (ST 6451), hose (Parts
Number: 4216453), adapter (ST 6461) and pres-
sure 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 Hose Tee Adapter
(122±9 °F). T157-05-04-002
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 SG: SC SF SI SG
Turn the power digging switch ON and OFF.
• 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. T1V1-03-07-007
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
T4-5-4
OPERATIONAL PERFORMANCE TEST / Component Test
Solenoid Valve Adjustment Procedure
7 O-Ring
T1V1-04-05-003
7 8
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-5
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN PUMP DELIVERY 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 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 func-
tion.
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 T157-05-04-005
Digging
Fast idle P OFF
mode
2. Measure pressure with the control levers in neu-
tral 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
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 de-
livery 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 func-
tion.
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 T157-05-04-005
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 up-
perstructure 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.
5. With the power digging switch pushed, slowly op-
erate the bucket, arm and boom control levers to
the stroke ends and relieve each function.
(Measure within 8 seconds after relief.)
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
T4-5-8
OPERATIONAL PERFORMANCE TEST / Component Test
T4-5-9
OPERATIONAL PERFORMANCE TEST / Component Test
RELIEF PRESSURE (WHEN RELIEVING
SWING)
Swing Relief Valve
A B C T178-03-02-005
T4-5-10
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)
T4-5-11
OPERATIONAL PERFORMANCE TEST / Component Test
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary:
1. The circuit pressure must be increased by apply- 5. Maintain hydraulic oil temperature at 50±5 °C
ing an external force while blocking the return cir- (122±9 °F).
cuit from the control valve. This measuring
method is hazardous and the results obtained with Measurement:
this method are unreliable. 1. Select the following switch positions.
2. The oil flow rate used to set the overload relief Engine Power Mode Auto-Idle
Work Mode
pressure is far less than that used to set the main Control Dial Switch Switch
relief pressure. Therefore, measuring the overload Digging
pressure in the main circuit by increasing the main Fast idle P OFF
mode
relief set pressure more than the overload valve
set-pressure is not a proper method. In addition, in 2. Slowly operate the bucket, arm or boom control
case a main relief valve designed to leak a small levers to the stroke ends and relieve each func-
quantity of oil before reliving is used, its tion.
pre-leaking start pressure must be increased 3. Read pressures on the pressure gauge at this
more than the overload relief valve set pressure. time.
However, the pre-leaking start pressure is not al- 4. Perform the measurement for the bucket, arm and
ways increased more than the overload relief boom in that order.
valve set-pressure as the adjustable upper limit of 5. Repeat the measurement three times. Calculate
the main relief valve set pressure is provided. the average value for each.
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 re-
lief 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.
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
T157-05-04-005
main pump delivery port. Install adapter (ST 6069),
hose (ST 6943) and pressure gauge (ST 6941).
: 6 mm
T4-5-12
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.
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-13
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN PUMP FLOW RATE MEASUREMENT
T4-5-14
OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified pump speed by using the following for- Refer to OPERATIONAL PERFORMANCE TEST /
mulas: Standard in Group T4-2.
1, 2 3 4 5 6 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) 5- Hydraulic Tester (ST 6299) 8- Test Hose (ST 6320) 11 - Bolt (ST 6409) (4 Used)
2 - Pipe B (ST 6143) 6- Adapter PF1 × UNF1-7/8 9- Flange (ST 6118) 12 - Plug
(ST 6146)
3 - Test Hose (ST 6145) 7 - Joint (ST 6330) 10 - Split Flange (ST 6130) 13 - Pipe
4 - Adapter PF1 × UNF1-7/8
(ST 6146)
T4-5-15
OPERATIONAL PERFORMANCE TEST / Component Test
• Pilot Pressure Characteristics
Summary:
Main pump performance is checked by measuring 5. Install hose (19) and adapter (20) to port T of
the pump flow rate by using a hydraulic tester in- pressure reducing valve (16). Remove plug L
stalled at the main pump delivery port (one side) to from the return pipe. Install hose (19).
be measured. Use Dr. ZX and a pressure gauge at : 19 mm, 22 mm
the same time. 6. Remove pipe (21) from the regulator. Install plug
(G 1/4) to the mounting hole for pipe (21) in the
IMPORTANT: This measurement procedure is a regulator.
simple method. The measured data : 17 mm
will be lower by approx. 5 % than the 7. Remove the vacuum pump. Loosen the plug from
accurately measured value. In order top of the pump casing. Bleed air from the pump
to measure accurately, disconnect casing until oil only comes out.
the return circuit from the control 8. Fully open the loading valve of hydraulic tester.
valve and connect it to the hydraulic 9. Start the engine. Check the connections for any
oil tank. 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 5 6 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
T L
20
18
P1 P2 19
15
14 17 15 16 15 14 13
T178-04-04-004
1 - Pipe E (ST 6144) 7 - Joint (ST 6330) 12 - Plug M 17 - Tee UNF7/16×UNF7/16×
PF1/4 (ST 6451)
2 - Pipe B (ST 6143) 8 - Test Hose (ST 6320) 13 - Adaptor UNF7/16 18 - Pressure Gauge (ST
×PF1/4 (ST 6069) 6931)
3 - Test Hose (ST 6145) 9 - Flange (ST 6118) 14 - Hose UNF7/16× 19 - Hose UNF7/16×
UNF7/16(4334309) UNF7/16 (4334309)
4 - Adapter PF1 × UNF1-7/8 10 - Split Flange 15 - Adapter PF3/8×UNF7/16 20 - Adapter PF3/8×UNF7/16
(ST 6146) (ST 6130) (4200465) (4200465)
5 - Hydraulic Tester (ST 6299) 11 - Bolt (ST 6409) (4 Uded) 16 - Pressure Reducing Valve 21 - Pipe
(4325439)
6 - Adapter PF1 × UNF1-7/8
(ST 6146)
T4-5-17
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 ex-
ternal 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: 2000 min
Ne : Measured Engine Speed:
Values indicated on Dr. ZX
T4-5-18
OPERATIONAL PERFORMANCE TEST / Component Test
1, 2 3 4 5 6 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
T L
20
18
P1 P2 19
15
14 17 15 16 15 14 13
T178-04-04-004
1 - Pipe E (ST 6144) 7- Joint (ST 6330) 12 - Plug M 17 - Tee UNF7/16×UNF7/16×
PF1/4 (ST 6451)
2 - Pipe B (ST 6143) 8- Test Hose (ST 6320) 13 - Adaptor UNF7/16 18 - Pressure Gauge (ST
×PF1/4 (ST 6069) 6931)
3 - Test Hose (ST 6145) 9- Flange (ST 6118) 14 - Hose UNF7/16× 19 - Hose UNF7/16×
UNF7/16 (4334309) UNF7/16 (4334309)
4 - Adapter PF1 × UNF1-7/8 10 - Split Flange 15 - Adapter PF3/8×UNF7/16 20 - Adapter PF3/8×UNF7/16
(ST 6146) (ST 6130) (4200465) (4200465)
5 - Hydraulic Tester (ST 6299) 11 - Bolt (ST 6409) (4 Used) 16 - Pressure Reducing Valve 21 - Pipe
(4325439)
6 - Adapter PF1 × UNF1-7/8
(ST 6146)
T4-5-19
OPERATIONAL PERFORMANCE TEST / Component Test
Regulator Adjustment
6 5 1
2
10
4 3
7 8
T1V1-03-01-009
1 - Lock Nut (For Minimum 4 - Adjusting Screw (For 7 - Lock Nut (For P-Q 9 - Lock Nut (For P-Q
Flow Rate) Maximum Flow Rate) Control) Control)
2 - Adjusting Screw (For 5 - Lock Nut (For Pilot 8 - Adjusting Screw (For P-Q 10 - Adjusting Screw (For P-Q
Minimum Flow Rate) Pressure Characteristic) Control) Control)
3 - Lock Nut (For Maximum 6 - Adjusting Screw (For Pilot
Flow Rate) Pressure Characteristic)
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 maxi- rate.
mum pump flow rate by 8.22 cm3/rev. In other words, do not turn adjust-
3
(0.5 in /rev). ing screw (4) counterclockwise.
: 13 mm 3) Securely tighten lock nut (3) after
: 9.8 N⋅m (1 kgf⋅m, 7.2 lbf·ft) adjustment.
T4-5-20
OPERATIONAL PERFORMANCE TEST / Component Test
Pd
T4-5-21
OPERATIONAL PERFORMANCE TEST / Component Test
Adjustment of Maximum Pump 1 and 2 Flow Rate
Limit Control Solenoid Valve
Torque Control
Solenoid Valve
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. 1
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)
T178-04-04-005
T4-5-24
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
∆Q = 60 × q / t
∆Q : Amount of drain oil per minute (L/min)
T107-06-05-008
t : Measured time (seconds)
q : Total amount of drain oil (L)
T4-5-25
OPERATIONAL PERFORMANCE TEST / Component Test
STEERING VALVE RELIEF PRESSURE
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. 1
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).
MCBB-07-025
Steering Filter
MCBB-07-027
T4-5-26
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, re-
place the steering relief valve as an assembly.
T4-5-27
OPERATIONAL PERFORMANCE TEST / Component Test
BRAKE PRESSURE (FRONT AND REAR)
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 SA-1140
ground after securing the front attachment in
order to prevent running away and an oper-
ating error.
moved hose.
: 19 mm, 22 mm 1
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 Rear
Axle
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).
T1F3-04-05-004
T4-5-28
OPERATIONAL PERFORMANCE TEST / Component Test
Conditions for Measurement
1. Select the following switch positions.
Engine Power Mode Work Mode Auto-Idle FNR Brake
Control Dial Switch Switch Switch Switch
Fast idle P Digging mode OFF N OFF
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.
T4-5-29
OPERATIONAL PERFORMANCE TEST / Component Test
BRAKE ACCUMLATED PRESSURE
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:
T4-5-30
OPERATIONAL PERFORMANCE TEST / Component Test
Conditions for Measurement
1. Select the following switch positions.
Engine Power Mode Work Mode Auto-Idle FNR Brake
Control Dial Switch Switch Switch Switch
Fast idle P Digging mode 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.
T4-5-31
OPERATIONAL PERFORMANCE TEST / Component Test
BRAKE WARNING SET PRESSURE
(DECREASE)
Summary:
When the warning buzzer sounds by reducing the
accumulated brake pressure, measure the pressure
at the output port of accumulator.
Preparation:
T4-5-32
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 posi-
tion.
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.
T4-5-33
OPERATIONAL PERFORMANCE TEST / Component Test
BRAKE WARNING SET PRESSURE
(INCREASE)
Summary:
When sounding of the warning buzzer stops by in-
creasing the accumulated brake pressure, measure
the pressure at the output port of accumulator.
Preparation:
T4-5-34
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Stop the engine. Turn the key switch to ON posi-
tion.
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 in-
creases rapidly.
5. Repeat the measurement three times and calcu-
late 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
(Blank)
T4-5-36
MEMO
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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
Monitor Unit Monitoring List ......................T5-3-6
Outline .....................................................T5-2-1
Steering Column Monitor
How to Use Screens...............................T5-2-17
Monitoring List ........................................T5-3-7
Screen Display When An Alarm
Option Controller Monitoring List ..............T5-3-8
is Issued...............................................T5-2-24
MC Adjustment List ................................T5-3-10
Contents of Alarms .................................T5-2-26
MC Attachment Adjustment List ..............T5-3-12
Time Setting ...........................................T5-2-29
ICF Adjustment Item List ........................T5-3-16
Attachment Adjustment
Option Controller Adjustment List ...........T5-3-18
(Pump 2 Flow Rate Adjustment) ...........T5-2-30
Dr. ZX Operation Procedure ...................T5-3-20
Displaying Operating Conditions.............T5-2-32
Maintenance Settings .............................T5-2-34 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 Upload Data of ICF .................................T5-4-8
Meter Combination Settings ...................T5-2-58 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 Setting Function .......T5-2-75
CJBT-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 MC Fault Code 11301 ........................... T5-6-112
Electrical Component Layout MC Fault Code 11302 ........................... T5-6-113
(Monitors and Switches) .........................T5-5-7 MC Fault Code 11303 ........................... T5-6-114
Electrical Component Layout 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
4-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 ................................................T5-5-32 ECM Fault Codes 628 to 1485 ..............T5-6-131
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
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
CJBT-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 Symptoms and Related Parts .................T5-7-2
Option Controller Fault Code 15515 ..... T5-6-151 Correlation between Trouble
Option Controller Fault Code 15516 ..... T5-6-152 Symptoms and Part Failures.................T5-7-24
Option Controller Fault Code 15517 ..... T5-6-153 Engine System Troubleshooting .............T5-7-42
Option Controller Fault Code 15518 ..... T5-6-154 All Actuator System Troubleshooting ......T5-7-70
Option Controller Fault Code 15519 ..... T5-6-155 Front Attachment System
Option Controller Fault Code 15570 ..... T5-6-156 Troubleshooting ....................................T5-7-79
Option Controller Fault Code 15571 ..... T5-6-157 Swing System Troubleshooting ...............T5-7-98
Option Controller Fault Code 15572 ..... T5-6-158 Travel System Troubleshooting.............T5-7-102
Option Controller Fault Code 15573 ..... T5-6-159 Brake System Troubleshooting ............. T5-7-114
Option Controller Fault Codes Steering System Troubleshooting ......... T5-7-117
15574-3 and 15578-3 ......................... T5-6-160 Other System Troubleshooting ............. T5-7-118
Option Controller Fault Codes Exchange Inspection ............................T5-7-138
15574-4 and 15578-4 ......................... T5-6-161 Bleeding Air from Transmission ............T5-7-142
Option Controller Fault Codes Bleeding Air from Brake (Axle)..............T5-7-143
15575-3 and 15579-3 ......................... T5-6-162 Emergency Boom Lowering Procedure
Option Controller Fault Codes (without Hose Rupture Valve) .............T5-7-144
15575-4 and 15579-4 ......................... T5-6-163 Attachment Circuit Pressure Release
Option Controller Fault Codes Procedure...........................................T5-7-145
20300 to 20303 .................................. T5-6-164 Group 8 Electrical System Inspection
Option Controller Fault Code 15520 ..... T5-6-165 Precautions for Inspection and
Option Controller Fault Code 15521 ..... T5-6-166 Maintenance ...........................................T5-8-1
Option Controller Fault Code 15522 ..... T5-6-167 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
CJBT-5-3
(Blank)
CJBT-5-4
TROUBLESHOOTING / Diagnosing Procedure
INTRODUCTION
T5-1-1
TROUBLESHOOTING / Diagnosing Procedure
DIAGNOSING PROCEDURE
T107-07-01-003
T5-1-2
TROUBLESHOOTING / Diagnosing Procedure
T5-1-3
TROUBLESHOOTING / Diagnosing Procedure
5. Perform troubleshooting
T5-1-4
TROUBLESHOOTING / Diagnosing Procedure
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 20 19
TCJB-05-02-043
33 32 31 30 29 28 27 26 25 24 23 22
1 - Work Mode Display 10 - Parking Brake Display 19 - Trip Meter Display 28 - Work Mode Display
2 - Auto-Idle Display 11 - Work Brake Display 20 - Odometer Display 29 - Auxiliary Selection
3 - Overload Alarm Display 12 - Axle Lock Display 21 - Hour Meter Display 30 - Coolant Temperature
(Optional) Gauge
4 - Auto Axle Lock Display 13 - Work Light Display 22 - Back Monitor Selection 31 - Work Mode Selection
5 - Auxiliary 14 - Auxiliary 2 (Positioning) 23 - Menu 32 - Return to Primary Screen
Selection Display
6 - Glow Signal Display 15 - Auxiliary 1 (Attachment) 24 - Meter Display Selection 33 - Brake Oil Pressure Gauge
Selection Display
7 - Trip Meter 16 - Blade/Outrigger Settings 25 - Fuel Gauge 34 - Speedometer
and Brake Mode Display
8 - Odometer 17 - Mail Display (Optional) 26 - Auxiliary 35 - Tachometer
9 - Hour Meter 18 - Clock 27 - Mail Selection (Optional)
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 18
TCJB-05-02-056
9
TCJB-05-02-042
35 TCJB-05-02-041
T5-2-2
TROUBLESHOOTING / Monitor Unit
• Work Mode Display (1) 1 7
The attachments being used are displayed accord-
ing 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 33 30 25
T1V1-05-01-105
Crusher
T1V1-05-01-106
Vibrating Hammer
T1V1-05-01-107
Others
T1V1-05-02-003
T5-2-3
TROUBLESHOOTING / Monitor Unit
• Auto-Idle Display (2)
2 3 4 6
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.
TCJB-05-02-061
T5-2-4
25
TROUBLESHOOTING / Monitor Unit 30
TCJB-05-02-064
• Speedometer (34)
Travel speed is displayed.
TCJB-05-02-064
35
• Tachometer (35)
Engine speed is displayed.
TCJB-05-02-065
T5-2-5
TROUBLESHOOTING / Monitor Unit
• Parking Brake Display (10)
When the parking brake is applied, the red indicator 4 10 11 12
lights.
(Brake Switch: P (Parking Brake) Position
T5-2-6
TROUBLESHOOTING / Monitor Unit
• Work Light Display (13)
The work light switch is turned ON, the green indi- 15 14
cator lights.
Green indicator
lights.
TCJB-05-02-074
TCJB-05-02-075
TCJB-05-02-102
T5-2-7
TROUBLESHOOTING / Monitor Unit
• Fuel Sensor Error Display Coolant Temperature Fuel Sensor Error
Sensor Error Display Display
TCJB-05-02-104
TCJB-05-02-103
TCJB-05-02-045
Alarm
T5-2-8
TROUBLESHOOTING / Monitor Unit
Main Menu
• Time Setting
Time is set. (Refer to T5-2-29.)
• Operating Conditions
This screen displays machine operating hour, fuel
usage and fuel consumption rate registered by the
monitor unit.
(Refer to T5-2-32.)
T5-2-9
TROUBLESHOOTING / Monitor Unit
• Pump 2 Flow Rate Adjustment (Attachment Adjust- Figure 1
ment)
(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 us-
ing 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) Key 1
(Pump 2 Flow Rate Limit Control)
When pulverizer 1 or crusher 1 is used, MC adjusts Key 2
flow rate of pressure oil that flows from pump 2 to
pulverizer or crusher while controlling the auxiliary When using Breaker 1 T1V5-05-01-111
T5-2-10
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.)
T5-2-11
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.)
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 envi-
ronment. (Refer to T5-2-56.)
TCJB-05-02-068
Meter Combination Setup Screen
TCJB-05-02-016
Unit Setup Screen
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.)
• 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.
• 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
(Only the machines equipped with optional parts) Overload Alarm
T1V1-05-02-004
T5-2-15
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-16
TROUBLESHOOTING / Monitor Unit
HOW TO USE SCREENS
TCJB-05-02-050
Alternator Alarm
T5-2-17
TROUBLESHOOTING / Monitor Unit
Displaying Primary Screen by Password Input
(Optional)
TCJB-05-02-054
Primary Screen
T1V5-05-01-093
Password Input Screen
T5-2-18
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.
T5-2-19
TROUBLESHOOTING / Monitor Unit
In Case of Inputting an Incorrect Password
T1V5-05-01-002
Confirm Key Erase Key
T1V5-05-01-004
Back 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 dis-
play disappears and the buzzer rings for thirty
seconds.
T1V5-05-01-093
Password Input Screen
T5-2-21
TROUBLESHOOTING / Monitor Unit
Extending Password Duration Time
2. While the password duration screen is still dis- Password Duration Screen (Key Switch: OFF)
played, push a relevant key, and password dura-
tion 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
T5-2-22
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-23
TROUBLESHOOTING / Monitor Unit
SCREEN DISPLAY WHEN AN ALARM IS
ISSUED
TCJB-05-02-046
TCJB-05-02-047
TCJB-05-02-048
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.
T1V5-05-01-013
T5-2-25
TROUBLESHOOTING / Monitor Unit
CONTENTS OF ALARMS
M183-01-071
M1CC-01-039
T5-2-26
TROUBLESHOOTING / Monitor Unit
TCJB-05-02-035
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
Menu Key
TCJB-05-02-064
Primary Screen
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
T1V5-05-01-019
Key 1 Key 2 Confirm Key
Back Key
Key 6 T1V5-05-01-022
T5-2-29
TROUBLESHOOTING / Monitor Unit
ATTACHMENT ADJUSTMENT
(PUMP 2 FLOW RATE ADJUSTMENT)
T1V5-05-01-019
Key 1 Key 2 Confirm Key
T5-2-30
TROUBLESHOOTING / Monitor Unit
T1V5-05-01-019
Key 1 Key 2 Confirm Key
T1V5-05-01-024
Key 1 Key 6 Key 2 Back Key
T5-2-31
TROUBLESHOOTING / Monitor Unit
DISPLAYING OPERATING CONDITIONS
Menu Key
TCJB-05-02-064
Primary Screen
T1V5-05-01-019
Key 1 Key 2 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.
Back Key
T1V5-05-01-026
Key 6 Confirm Key
T5-2-32
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-33
TROUBLESHOOTING / Monitor Unit
MAINTENANCE SETTINGS
Menu Key
T1V5-05-01-019
Key 1 Key 2 Confirm Key
T1V5-05-01-049
Key 1 Key 2 Confirm Key
T5-2-34
TROUBLESHOOTING / Monitor Unit
Maintenance Information Display ON/OFF
T5-2-35
TROUBLESHOOTING / Monitor Unit
Change Interval Settings
Key 1
T1V5-05-01-138
Key 2 Confirm Key
Menu Key
T5-2-36
TROUBLESHOOTING / Monitor Unit
Resetting Data
Key 5
T5-2-37
TROUBLESHOOTING / Monitor Unit
Notice
Screen Display when Maintenance Information
Display is ON
NOTE: When pushing the back key while the Maintenance Information Display Screen T1V5-05-01-170
T1V5-05-01-171
Reset Screen
TCJB-05-02-064
Primary Screen
T5-2-38
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 mainte-
nance is required, the primary screen gives notice
of the maintenance item. In three seconds, the
maintenance information display screen is dis-
played automatically.
(In the right example, Hydraulic Oil is displayed.)
Back Key
T5-2-39
TROUBLESHOOTING / Monitor Unit
WORK MODE (ATTACHMENT SELECTION)
Digging
Back Key
Confirm
Key
TCJB-05-02-084
Attachment Specification Screen
T5-2-40
TROUBLESHOOTING / Monitor Unit
Selecting Attachment from Main Menu
Menu Key
TCJB-05-02-064
Primary Screen
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
TCHB-05-02-001
Key 1 Key 2 Confirm Key
Back Key
Confirm
Key
Attachment Specification Screen TCJB-05-02-084
T5-2-41
TROUBLESHOOTING / Monitor Unit
Attachment Specification Screen
T5-2-42
TROUBLESHOOTING / Monitor Unit
TCJB-05-02-083
TCJB-05-02-084
T5-2-43
TROUBLESHOOTING / Monitor Unit
MAIL (Optional)
1 - General Request
2 - Fuel Replenishment Request
3 - Service Maintenance Request
4 - Forwarding Request
T1V5-05-01-037
1 2 3 Mail Screen 4
3. While mail information is sent to ICF, the message
“Mail is being delivered.” is displayed on the
screen.
T1V5-05-01-038
T5-2-44
TROUBLESHOOTING / Monitor Unit
T1V5-05-01-040
T5-2-45
TROUBLESHOOTING / Monitor Unit
METER DISPLAY SELECTION
screen as follows.
Hour Meter → Odometer → Trip Meter
2. Select the meter by using keys 1 and 2. Push the Data Reset
confirm key. (In the right example, Trip Meter is Icon
selected.)
Confirm
Key
Key 6
TCHB-05-02-006
T5-2-46
TROUBLESHOOTING / Monitor Unit
Primary Screen
2. Select HOUR ↔ ODO ↔ TRIP from main menu TCJB-05-02-069
Back Key
NOTE: The contents which are set by the meter Key 2 Confirm
display selection are available until the key Key
switch is turned OFF. When the key switch Key 6
is turned OFF, the contents are reset to Meter Display Selection Screen TCJB-05-02-072
T5-2-47
TROUBLESHOOTING / Monitor Unit
PASSWORD CHANGE (OPTIONAL)
Menu Key
T1V5-05-01-041
Registered Password
3. Input the registered password and push the con-
firm key.
T5-2-48
TROUBLESHOOTING / Monitor Unit
T1V5-05-01-044
Back Key
T1V5-05-01-130
A New Password
T1V5-05-01-131
Confirm Key Erase Key
T5-2-49
TROUBLESHOOTING / Monitor Unit
7. The message “Re-enter password.” appears.
Then, input a new password again and push the
confirm key.
T1V5-05-01-132
T1V5-05-01-043
Key 6
T5-2-50
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-51
TROUBLESHOOTING / Monitor Unit
BACK MONITOR SETTINGS
Auto-Control: ON
Back Key
Back Key
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.
T5-2-53
TROUBLESHOOTING / Monitor Unit
Auto-Control: OFF
Menu Key
TCJB-05-02-064
Primary Screen
Back Key
Key 6
T1V5-05-01-173
T5-2-54
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-55
TROUBLESHOOTING / Monitor Unit
LANGUAGE SETTINGS
Menu Key
TCJB-05-02-064
Primary Screen
TCHB-05-02-003
Key 1 Key 2 Confirm Key Back Key
3. Select a desired language by using keys 1 and 2.
Push the confirm key.
T5-2-56
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
Menu Key
TCJB-05-02-064
Primary Screen
-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.
TCHB-05-02-003
Key 1 Key 2 Confirm Key Back Key
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 2 Confirm
Key
Key 6
Meter Combination Setup Screen TCJB-05-02-068
T5-2-58
TROUBLESHOOTING / Monitor Unit
Speedometer
(km)
TCJB-05-02-069
Tachometer
TCJB-05-02-065
Trip
Meter
• When selecting mph (speedometer) and trip me-
ter
(Unit: When selecting mile)
Speedometer
(mile)
TCJB-05-02-070
T5-2-59
TROUBLESHOOTING / Monitor Unit
UNIT SETTINGS
Menu Key
4. Push key 6, and the primary screen is displayed. Key 1 Back Key
Key 2 Confirm
Key
Key 6
Unit Setup Screen TCJB-05-02-016
T5-2-60
TROUBLESHOOTING / Monitor Unit
NOTE: Examples
• When selecting km
TCJB-05-02-069
TCJB-05-02-070
T5-2-61
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-62
TROUBLESHOOTING / Monitor Unit
SERVICE MENU (BUILT-IN DIAGNOSING
SYSTEM) OPERATION
T5-2-63
TROUBLESHOOTING / Monitor Unit
TROUBLESHOOTING
T1V1-05-01-115
Turn key switch ON while pushing the key
Menu Key
TCJB-05-02-064
Primary Screen
T5-2-64
TROUBLESHOOTING / Monitor Unit
4. Select troubleshooting by using keys 1 and 2.
Push the confirm key. Then, the troubleshooting
screen appears.
5. Results of trouble analyses for each controller are A figure enclosed in ( ) indicates the number of fault codes.
displayed on the screen.
Displayed Controller:
• Main Controller
• Engine Governor Controller
• Monitor Controller
• ICF Controller
• Steering Column Monitor
• Option Controller
T5-2-65
TROUBLESHOOTING / Monitor Unit
MONITORING
T1V1-05-01-115
Turn the key switch ON while pushing the key
Menu Key
TCJB-05-02-064
Primary Screen
T5-2-66
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.
TCHB-05-02-007
Key 1 Key 2 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.
Back Key
T1V5-05-01-088
Key 6 Confirm Key
T5-2-67
TROUBLESHOOTING / Monitor Unit
A List of Items to be Monitored
T5-2-68
TROUBLESHOOTING / Monitor Unit
T5-2-69
TROUBLESHOOTING / Monitor Unit
CONTROLLER VERSION
T1V1-05-01-115
Turn the key switch ON while pushing the key
Menu Key
TCJB-05-02-064
Primary Screen
T5-2-70
TROUBLESHOOTING / Monitor Unit
4. Select controller version by using keys 1 and 2.
Push the confirm key. Then, the controller version
screen appears.
TCHB-05-02-007
Key 1 Key 2 Confirm Key Back Key
TCHB-05-02-008
Key 6 Back Key
T5-2-71
TROUBLESHOOTING / Monitor Unit
BLADE/OUTRIGGER SETTINGS
T1V1-05-01-115
Turn the key switch ON while pushing the key
Menu Key
TCJB-05-02-064
Primary Screen
T5-2-72
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
Back Key
Key 2
Key 6
Blade/Outrigger Setup Screen TCHB-05-02-009
Display the
Selected
Screen
T5-2-73
TROUBLESHOOTING / Monitor Unit
KEYLESS HOUR METER
• Hour Meter
• Odometer
• Fuel Gauge
Hour Meter
Odometer
Fuel Gauge
Back Monitor
Selection Key
T5-2-74
TROUBLESHOOTING / Monitor Unit
LIST OF MONITOR UNIT SETTING FUNC-
TION
Setting Function
Function Item Monitor Default
Dr.ZX
Unit
Alarm Check alarms while trouble occurs ○ ○(Troubleshooting) -
Security Password function Enable/Disable × ○(Security) Disable
Password change ○ × 0000
Permission/no permission of password change on the
× ○(Security) Permission
monitor
Max.
Maximum password digit change × ○(Security)
4 digits
Password check × ○(Security) -
Extending function Enable/Disable × ○(Security) Enable
Selection on extra time ○ × -
Time Setting Time set function Enable/Disable × ○(Monitor Controller) Enable
Time change ○ ○(ICF) -
Operating Operational condition Enable/Disable × ○(Monitor Controller) Enable
Condition Operational condition reset ○ × -
Maintenance Maintenance operation Allow/Not Allow × ○(Monitor Controller) Allow
Setting Maintenance display items ON/OFF × ○(Monitor Controller) ON
Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Engine Oil Change interval ○ × 500 hours
Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
Maintenance display items ON/OFF × ○(Monitor Controller) ON
Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Engine Oil
Change interval ○ × 500 hours
Filter
Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
Maintenance display items ON/OFF × ○(Monitor Controller) ON
Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Hydraulic
Change interval × × 5000 hours
Oil
Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
Maintenance display items ON/OFF × ○(Monitor Controller) ON
Hydraulic Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Oil Pilot Change interval × × 1000 hours
Filter Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
T5-2-75
TROUBLESHOOTING / Monitor Unit
Setting Function
Function Item Monitor Default
Dr.ZX
Unit
Maintenance Maintenance display items ON/OFF × ○(Monitor Controller) ON
Setting Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Hydraulic
Change interval × × 1000 hours
Oil Filter
Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
Maintenance display items ON/OFF × ○(Monitor Controller) ON
Pump Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Transmission Change interval × × 1000 hours
Oil Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
Maintenance display items ON/OFF × ○(Monitor Controller) ON
Swing Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Reduction Change interval × × 1000 hours
Gear Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
Maintenance display items ON/OFF × ○(Monitor Controller) ON
Swing Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Bearing Change interval × × 500 hours
Grease Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
Maintenance display items ON/OFF × ○(Monitor Controller) ON
Hydraulic
Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Oil Brake
Change interval × × 500 hours
Steering
Filter Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
Maintenance display items ON/OFF × ○(Monitor Controller) ON
Travel Device Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Transmission Change interval × × 500 hours
Oil Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
Maintenance display items ON/OFF × ○(Monitor Controller) ON
Axle Gear
Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Oil
Change interval × × 500 hours
(Front, Rear,
each Hub) Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
T5-2-76
TROUBLESHOOTING / Monitor Unit
Setting Function
Function Item Monitor Default
Dr.ZX
Unit
Maintenance Maintenance display items ON/OFF × ○(Monitor Controller) ON
Setting Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Drive Shaft
Change interval × × 500 hours
Greasing
Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
Maintenance display items ON/OFF × ○(Monitor Controller) ON
Front Axle Notification function Enable/Disable ○ ○(Monitor Controller) Enable
King Pin Change interval × × 30 days
Greasing Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
Maintenance display items ON/OFF × ○(Monitor Controller) ON
Front Axle Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Center Pin Change interval × × 250 hours
Greasing Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
Maintenance display items ON/OFF × ○(Monitor Controller) ON
Wheel Nut Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Torque Change interval × × 250 hours
Check Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
Maintenance display items ON/OFF × ○(Monitor Controller) ON
Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Air Filter Change interval × × 1500 hours
Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
Maintenance display items ON/OFF × ○(Monitor Controller) ON
Engine / Air Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Conditioner Change interval × × 1000 hours
V-belt Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
Maintenance display items ON/OFF × ○(Monitor Controller) ON
Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Fuel Filter Change interval × × 500 hours
Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
T5-2-77
TROUBLESHOOTING / Monitor Unit
Setting Function
Function Item Monitor Default
Dr.ZX
Unit
Maintenance Maintenance display items ON/OFF × ○(Monitor Controller) ON
Setting Air Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Conditioner Change interval × × 3000 hours
Filter Remaining hours data reset ○ × -
Previous change Date/Hour Meter check ○ × -
Maintenance display items ON/OFF × × ON
Notification function Enable/Disable ○ × Disable
User Setting
Change interval ○ × 5000 hours
(TRIP 1)
Remaining hours data reset × × -
Previous change Date/Hour Meter check ○ × -
Optional Work mode function Set/Unset × ○(Monitor Controller) Set
Function Mail function Set/Unset × ○(Monitor Controller) Unset
Send the mail ○ × -
Overload
Overload alarm Enable/Disable × ○(Monitor Controller) Disable
Alarm
Back Monitor Back monitor function Enable/Disable × ○(Monitor Controller) Enable
Setting Auto-display/no auto-display of camera image during No auto
○ ×
travel reverse operation (auto-control) display
Back monitor display Normal/Flip Vertical × ○(Monitor Controller) Normal
Selection of NTSC/PAL (image method) × ○(Monitor Controller) NTSC
Meter Setting Meter setup function Enable/Disable × ○(Monitor Controller) Enable
Speedometer
Meter combination setting change ○ × +
Hour Meter
Unit Setting Unit setup function Enable/Disable × ○(Monitor Controller) Enable
Unit Change ○ × km
Language Select language ○ × English
Setting Register/delete language × × -
Registered language check ○ × -
Trouble- Check alarms while trouble occurs ○ ○(Troubleshooting) -
shooting Check alarms which occurred × ○(Troubleshooting) -
Clear fault code (Retry B) × ○(Troubleshooting) -
Monitoring Item order change ○ × -
Reset item order to default ○ × -
Blade / Out-
Blade/Outrigger setting change ○ × 1/12
rigger Setting
T5-2-78
TROUBLESHOOTING / Dr. ZX
OUTLINE
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
Unit Data
Selecting Monitoring
-1
Requested Engine Speed Req. Eng min Input signal from engine control dial
-1
Actual Engine Speed Actual Speed min Input signal from ECM
-1
Engine Speed Deviation Eng Speed Deviat min A value subtracted required engine speed from actual engine speed
Vehicle Speed Vehicle Speed km/h Input value from travel N sensor
Pump 1 Delivery Pressure P1 Delivery Pres MPa Input signal from pump 1 delivery pressure sensor
Pump 1 Flow Control Pressure PC 1 Pressure MPa 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 Control instruction signal to maximum pump 1 flow rate limit control solenoid
valve
Pump 2 Delivery Pressure P2 Delivery Pres MPa Input signal from pump 2 delivery pressure sensor
Pump 2 Flow Control Pressure PC 2 Pressure MPa Input signal from pump 2 control pressure sensor
Pump 2 Flow Rate Limit P/S/V Out P2 P/S Valve MPa Control instruction signal to maximum pump 2 flow rate limit control solenoid
valve
Pump 2 Upper Limit Displacement P2Maxq cm3 Calculation from engine speed and pump 2 delivery pressure
(With attachment only)
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 P Torque P/S/V MPa Control instruction signal to torque control solenoid valve
Pump 3 Delivery Pressure P3 Pressure MPa Input signal from steering pump delivery pressure sensor
Pump 4 Delivery Pressure P4 Pressure MPa Input signal from pump 4 delivery pressure sensor
Front Pilot Pressure Fr Pilot Press MPa Input signal from pressure sensor (front)
Boom Raise Pilot Pressure Boom Raise MPa Input signal from pressure sensor (boom raise)
Arm Roll-In Pilot Pressure Arm Roll-In MPa Input signal from pressure sensor (arm roll-in)
Arm Roll-Out Pilot Pressure Arm Roll-Out MPa Input signal from pressure sensor (arm roll-out)
Swing Pilot Pressure SW Pilot Press MPa Input signal from pressure sensor (swing)
Travel Forward Pilot Pressure Tr F Pilot Press MPa Input signal from pressure sensor (travel forward)
Travel Reverse Pilot Pressure Tr R Pilot Pilot Press MPa Input signal from pressure sensor (travel reverse)
ATT Control Pilot Pressure ATT Pilot Press MPa Input signal from pressure sensor (auxiliary)
EC Dial Angle Dial Angle V Input signal from engine control dial
Boom Bottom Pressure Bm Bottom Press MPa Input signal from boom bottom pressure sensor
Brake Remain Pressure Brake Remain P MPa Input signal from brake remaining pressure sensor
Brake Pressure Brake Pressure MPa Input signal from brake pressure sensor
E/P SW E/P SW E, P Power mode switch selection status
HP Mode SW HP Mode SW ON, OFF Power mode switch selection status
Auto-Idle SW AI SW AI Auto-idle switch selection status
T5-3-2
TROUBLESHOOTING / Dr. ZX
Item
Unit Data
Selecting Monitoring
Power Boost SW Power Boost SW ON, OFF Power digging switch ON/OFF selection status
Key SW Key SW ON, OFF Key switch ON/OFF selection status
Slight Travel SW Slight Travel SW ON, OFF Engine control mode selection switch (creeper) ON/OFF selection
status
Pedal EC SW Pedal EC SW ON, OFF Engine control mode selection switch (pedal) ON/OFF selection
status
Implement Brake Deactive Imp Brk Release ON, OFF Work brake release switch ON/OFF selection status
Parking Brake SW Parking Brake SW ON, OFF Brake switch (parking brake) ON/OFF selection status
Transmission H/L SW T/M H/L SW Lo, Hi Travel speed mode switch ON/OFF selection status
FNR (R) SW FNR (R) SW ON, OFF FNR switch (R) ON/OFF selection status
Arm Regenerative P/S Valve Output Am Regen P/S/V MPa Control instruction signal to solenoid valve unit (SC)
Power Boost Control Pressure PD Ctrl Pressure MPa Control instruction signal to solenoid valve unit (SG)
ATT P/S Valve Output ATT P/S Valve MPa Control instruction signal to auxiliary flow rate control solenoid valve
Pump 1 Flow Rate Limit P/S/V Out FB P1 Flow P/V FB mA Feedback from maximum pump 1 flow rate limit solenoid valve output
Pump 2 Flow Rate Limit P/S/V Out FB P2 Flow P/V FB mA Feedback from maximum pump 2 flow rate limit control solenoid valve
output
Pump Torque P/S/V Output FB P Torque P/V FB mA Feedback from torque control solenoid valve output
ATT P/S Valve Output FB ATT P/S/V FB mA 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 TrM Swash Angle P/V Out MPa Control instruction signal to travel motor displacement angle control
Output solenoid valve
Travel Makeup P/S/V Output Travel Makeup P/S/V Out MPa Control instruction signal to travel make-up solenoid valve
Implement Brake P/S/V Output Implement Brake P/S/V MPa Control instruction signal to solenoid valve unit (SF)
Axle Lock Output Axle Lock Output MPa Control instruction signal to solenoid valve unit (SI)
Travel Motor Swash Angle P/V FB TrM Swash Angle P/V FB mA Feedback from travel motor displacement angle control solenoid
valve output
Travel Makeup P/S/V FB Travel Makeup P/S/V FB mA Feedback from travel make-up solenoid valve output
Axle Lock Output FB Axle Lock Output FB mA Feedback from solenoid valve unit (SI) output
Implement Brake FB Implement Brake FB mA Feedback from solenoid valve unit (SF) output
Travel Alarm Travel Alarm Action/ Action/No Action status of travel alarm
No Action
Swing Alarm Swing Alarm Action/ Action/No Action status of swing alarm
No Action
Hydraulic Oil Temperature (HOT) Hyd Oil Temp. °C Input signal from hydraulic oil temperature sensor
T/M Change (Low Speed) T/M Change (Low Speed) ON, OFF Travel mode selector solenoid valve (slow) ON/OFF selection status
T/M Change (High Speed) T/M Change (High Speed) ON, OFF Travel mode selector solenoid valve (fast) ON/OFF selection status
Axle Lock Control State Axle Lock Control State ON, OFF Brake switch (axle lock) ON/OFF selection status
Implement Brake State Implement Brake State ON, OFF Work brake ON/OFF selection status
Travel Motor Over Rotation Count TrM Over Rotation Count Count Input value from travel N sensor
T5-3-3
TROUBLESHOOTING / Dr. ZX
Item
Unit Data
Selecting Monitoring
Speed Meter Auto Change Flag Speed Meter Auto Change Flag ON, OFF Speed meter auto switch ON/OFF selection status
Current ATT Type Current ATT Type BR, PU, CR, VI, Un Communication from monitor unit
Current ATT No. Current ATT No. 1, 2, 3, 4, 5 Communication from monitor unit
ATT1 Type ATT1 Type BR, PU, CR, VI, Un Communication from monitor unit
ATT1 No. ATT1 No. 1, 2, 3, 4, 5 Communication from monitor unit
ATT2 Type ATT2 Type BR, PU, CR, VI, Un Communication from monitor unit
ATT2 No. ATT2 No. 1, 2, 3, 4, 5 Communication from monitor unit
ATT3 Type ATT3 Type BR, PU, CR, VI, Un Communication from monitor unit
ATT3 No. ATT3 No. 1, 2, 3, 4, 5 Communication from monitor unit
ATT4 Type ATT4 Type BR, PU, CR, VI, Un Communication from monitor unit
ATT4 No. ATT4 No. 1, 2, 3, 4, 5 Communication from monitor unit
ATT5 Type ATT5 Type BR, PU, CR, VI, Un Communication from monitor unit
ATT5 No. ATT5 No. 1, 2, 3, 4, 5 Communication from monitor unit
Trip Meter Trip Meter km Unit setting status for monitor unit
Odo Meter Odo Meter km Unit setting status for monitor unit
(German) Specifications Change SW (German) Specifications Change ON, OFF German specification selection switch ON/OFF selection status
SW
FNR (F) SW FNR (F) SW ON, OFF FNR switch (Forward) ON/OFF selection status
T5-3-4
TROUBLESHOOTING / Dr. ZX
ECM MONITORING LIST
Item
Unit Data
Selecting Monitoring
Engine Torque Engine Torque % Input signal from ECM
Actual Engine Speed
Act. Eng Speed min-1 Input signal from crank speed sensor and cam angle sensor
(Engine Speed)
Target Engine Speed Tar. Eng Speed min-1 Input signal from engine control dial
Glow Signal Glow Signal OFF, ON Glow Plug Relay ON/OFF selection status
Coolant Temperature (Engine) Coolant Temp. °C Input signal from coolant temperature sensor
Fuel Temperature Fuel Temp. °C Input signal from fuel level sensor
Engine Oil Pressure Eng Oil Pressure kPa 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 OFF, ON Communication from monitor unit
Mail SW Mail SW OFF Mail Operation Status
Fuel
Forward
Repair
General
T5-3-6
TROUBLESHOOTING / Dr. ZX
STEERING COLUMN MONITOR MONITORING LIST
Item
Unit Data
Selecting Monitoring
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
Att SW Operation (Proportional SW) Att SW Ope (Prop) V Input signal from attachment switch
Auxiliary Operation (Proportional SW) Aux Ope (Prop SW) V Input signal from attachment switch
Positioning/Att 1 Operation Posn/Att 1 Ope V Input signal from attachment pedal
Positioning/Att 2 Operation Posn/Att 2 Ope V Input signal from attachment 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/Att SW Pilot Monitor Pressure Posn/Att SW P Press MPa Input signal from pressure sensor (positioning, attachment)
Outrgr/Blade/Att Pilot Montr Pressr OR/BL/Att P Press MPa Input signal from pressure sensor (blade/outrigger, auxiliary)
Hydraulic Oil Temperature (OPT) Hyd Oil Temp. °C Input signal from pilot oil temperature sensor
Boom Bottom Pressure Bm Bottom Press MPa Input signal from boom bottom pressure sensor
Gate Lock Signal Gate Lock Signal Up, Down Pilot shut-off lever up/down status (Pilot shut-off switch
ON/OFF selection status)
Att SW & Aux (Main SW) Att SW & Aux (Main SW) ON, OFF Electric operation main switch ON/OFF selection status
Att Selection SW Att Selection SW Aux, Posn Attachment selection switch ON/OFF selection status
Att SW 1 Operation Att SW 1 Operation ON, OFF Attachment switch ON/OFF selection status
Att SW 2 Operation Att SW 2 Operation ON, OFF Attachment 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
Swing Parking Release Swing Parking MPa Control instruction signal to swing parking brake release
solenoid valve
Att 1 P/S/V Att 1 P/S/V MPa Control instruction signal to auxiliary solenoid valve
Att 2 P/S/V Att 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
Att SW 1 P/S/V Att SW 1 P/S/V MPa Control instruction signal to attachment solenoid valve
Att SW 2 P/S/V Att SW 2 P/S/V MPa Control instruction signal to attachment solenoid valve
Att SW 3 P/S/V Att SW 3 P/S/V MPa Control instruction signal to attachment solenoid valve
Att SW 4 P/S/V Att SW 4 P/S/V MPa Control instruction signal to attachment solenoid valve
T5-3-8
TROUBLESHOOTING / Dr. ZX
Item
Unit Data
Selecting Monitoring
Swing Parking Release FB Swing Parking FB mA Feedback from swing parking brake release solenoid valve
output
Att 1 P/S/V FB Att 1 P/S/V FB mA Feedback from auxiliary solenoid valve output
Att 2 P/S/V FB Att 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
Att SW 1 P/S/V FB Att SW 1 P/V FB mA Feedback from attachment solenoid valve output
Att SW 2 P/S/V FB Att SW 2 P/V FB mA Feedback from attachment solenoid valve output
Att SW 3 P/S/V FB Att SW 3 P/V FB mA Feedback from attachment solenoid valve output
Att SW 4 P/S/V FB Att SW 4 P/V FB mA Feedback from attachment 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
selection status
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
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.
T5-3-10
TROUBLESHOOTING / Dr. ZX
Adjustment List
Item Unit Minimum Adjustment Adjustable Range Initial Value
Li Speed Adjustment min-1 10 0 to 400 0
-1
Travel Li Speed Adjustment min 10 0 to 400 0
-1
WU Speed Adjustment min 10 -600 to 200 0
-1
AI Speed Adjustment min 10 -250 to 400 0
-1
E Speed Adjustment min 10 Temporarily release 0
(valid only when key is ON)
-1
P Speed Adjustment min 10 -200 to 200 0
Travel P Speed Adjustment min-1 10 -200 to 200 0
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 0.5 118.0 to 118.0 118.0
Front P1 Control Flow Adjustment cm3 0.5 118.0 to 118.0 118.0
Front P2 Control Flow Adjustment cm3 0.5 118.0 to 118.0 118.0
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
Engine Burglar Proof On/Off ON, OFF - ON/OFF OFF
Pump Burglar Proof On/Off ON, OFF - ON/OFF 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
ATT Speed Increase Down Waiting Time ms 40 0 to 3000 0
Axle Lock Timer s 0.5 0 to 10 0
Travel Motor Over Rotation Count Times 1 0 to 253 0
T5-3-11
TROUBLESHOOTING / Dr. ZX
MC ATTACHMENT ADJUSTMENT LIST
T5-3-12
TROUBLESHOOTING / Dr. ZX
T5-3-13
TROUBLESHOOTING / Dr. ZX
T5-3-14
TROUBLESHOOTING / Dr. ZX
T5-3-15
TROUBLESHOOTING / Dr. ZX
ICF ADJUSTMENT ITEM LIST
T5-3-16
TROUBLESHOOTING / Dr. ZX
(Blank)
T5-3-17
TROUBLESHOOTING / Dr. ZX
OPTION CONTROLLER ADJUSTMENT LIST
T5-3-18
TROUBLESHOOTING / Dr. ZX
Adjustment List
Item Unit Minimum Adjustment Adjustable Range Initial Value
Att Ope 1 P/S/V Adjustment MPa 0.0196 -0.5 to 0.5 0
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
Att SW Ope 1 P/S/V Adjustment MPa 0.0196 -0.5 to 0.5 0
Att SW Ope 2 P/S/V Adjustment MPa 0.0196 -0.5 to 0.5 0
Att SW Ope 3 P/S/V Adjustment MPa 0.0196 -0.5 to 0.5 0
Att SW Ope 4 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
Attachment Function Enable/Disable - - Disable
Outrigger/Blade Function Enable/Disable - - Enable
Positioning Function Enable/Disable - - Enable
Att SW Function (Proportional SW) Enable/Disable - - Disable
Att SW Function Enable/Disable - - Disable
Aux Assignment (Proportional SW) 0, 1, 2, 3, 4 - - 0 (Disable)
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
Example:
• Machine equipped with 2-piece boom, 4 outrigger:
• Attachment Function: Disable
• Outrigger/Blade Function: Enable
• Positioning Function: Enable
• Att SW Function (Proportional SW): Disable
• Att SW Function: Disable
T5-3-20
TROUBLESHOOTING / Dr. ZX
Example: Outrigger/Blade Function: Enable
Push Parameter Change of option Push Enable and Push Exec. Push
controller. Push ESC and return to ESC and return to Parameter
Main Menu screen. Push Outrigger/Blade Function. Change Selection screen.
Setup Item Selection Screen Parameter Change Selection Setup Selection Screen
Screen
Adjustment: Disable
Data has changed
Current: Enable
T5-3-21
TROUBLESHOOTING / Dr. ZX
Parameter Change
(Aux Assignment (Proportional SW))
Setup Item Selection Screen Parameter Change Selection Parameter Change Selection
Screen Screen
T5-3-22
TROUBLESHOOTING / ICF
OUTLINE
T5-4-1
TROUBLESHOOTING / ICF
LIST OF DAILY REPORT DATA
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 con-
tinuously detected for more than 5 minutes while the engine runs.)
T5-4-3
TROUBLESHOOTING / ICF
T5-4-4
TROUBLESHOOTING / ICF
LIST OF FREQUENCY DISTRIBUTION DATA
Item Details
Fuel Temperature 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 tem-
Temperature perature
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
HP Mode Hours Total engine operating hours selecting HP mode
Engine Operating
P Mode Hours Total engine operating hours selecting P mode
Hour
E Mode Hours Total engine operating hours selecting E mode
Auto-Idle Switch ON Time Total hours when auto-idle switch is turned ON
Fast Idle (Hi) Travel-
Total operating hours of travel mode (Hi)
Travel Operating ing Hours
Hour Slow Idle (Lo) Trav-
Total operating hours of travel mode (Lo)
eling Hours
Swing Operating Hour Total swing operating hours
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 opera-
Operating Hours tion
Attachment Operat- Hydraulic Crusher Total operating hours selecting hydraulic crusher during daily opera-
ing Hour Operating Hours tion
Vibrating Hammer Total operating hours selecting vibrating hammer during daily opera-
Operating 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 Satellite
OF ICF Rear Console Terminal
TCJB-05-04-001
Palm
(Dr. ZX)
Hot Sync
Cable
Connecting
Harness
T1V1-05-07-002
T5-4-8
TROUBLESHOOTING / ICF
Data Download
+ ICF Controller
Op. Manual
OK OK ESC
T5-4-9
TROUBLESHOOTING / ICF
How to Upload Data from Palm to Personal
Computer
T178-05-07-033
T5-4-10
TROUBLESHOOTING / ICF
VARIOUS SETUP OF ICF AND SATELLITE
COMMUNICATION TERMINAL BY USING
Dr. ZX
Start Dr. ZX
Communication No Communication
2. Self-Diagnosing
T5-4-11
TROUBLESHOOTING / ICF
1.1 Select Information Controller
1.2 Select Information C/U: Various Setup
+ ICF Controller
Op. Manual
T5-4-12
TROUBLESHOOTING / ICF
1.3 Enter Date and Time
Push Set and the focused item is
YY.
Push Enter Date and Time. Push ESC and return to Information
Push ESC and return to Main C/U: Various Setup Screen.
Menu Screen.
ESC
T5-4-13
TROUBLESHOOTING / ICF
1.4 Enter Model and Serial No.
Select Item
ESC
T5-4-14
TROUBLESHOOTING / ICF
1.5 Information C/U: Initialize
Select Item
+ Information C/U: Initialize
ESC
T5-4-15
TROUBLESHOOTING / ICF
1.6 Satellite Terminal: Initialize
Push Exec.
Display the next screen of Infor- Push Satellite Terminal: Initialize. Push ESC and return to Informa-
mation C/U: Various Setup Screen. Push ESC and return to Main tion C/U: Various Setup Screen.
Menu Screen.
Select Item Select Item Satellite Terminal: Initialize
Information C/U: Various Setup Next Screen of Information C/U: Satellite Terminal: Initialize Screen
Screen Various Setup Screen
OK ESC ESC
T5-4-16
TROUBLESHOOTING / ICF
1.7 Satellite Terminal Serial No. Check
Push Satellite Terminal No. Confir- Confirm serial No. (12 digits). Push
mation. ESC and return to Information C/U:
Push ESC and return to Main Various Setup Screen.
Menu Screen.
Select Item
ESC
T5-4-17
TROUBLESHOOTING / ICF
1.8 Satellite Terminal, Communicating State
Check
Push Communicating State
Check.
Push ESC and return to Main
Menu Screen. Check communicating state.
Select Item Communicating State Check
Satellite Terminal: Initialize ICF⇔Satellite Terminal Check the enclosed state.
+
Satellite Terminal No. ・ Conn Un- Un-
Confirmation Uncon: Faulty harness
+ ・ Comm. OK NG
Communicating State NG: Faulty harness for Comm.
Check Satellite Terminal
+ OFF: Faulty harness, Faulty controller
Enter Satellite Comm. ・ Power ON OFF
Stop: 1.9 Enter Satellite Comm. Start/Stop
+ Start/Stop ・ Comm. Enable Stop
ESC ESC
ESC
Select Item Select Item
ESC ESC
T5-4-18
TROUBLESHOOTING / ICF
1.9 Enter Satellite Comm. Start/Stop
Push ▼ and display the next
screen of Information C/U: Various
Setup Screen.
Push Enter Satellite Comm.
Start/Stop.
Select Item
ESC
T5-4-19
TROUBLESHOOTING / ICF
1.10 Control Data: Initialize
Select Item
+ Information C/U: Initialize
Enter Model and Serial To the
+ lower
No.
+ Enter Date and Time
ESC
T5-4-20
TROUBLESHOOTING / ICF
(Blank)
T5-4-21
TROUBLESHOOTING / ICF
2. Self-Diagnosing
Push Fault of ICF Controller. If
After starting Dr. ZX, push there is no trouble, No Problem is
Self-Diagnostic Result. displayed.
Self-diagnosing of controllers
below hasn completed.
Execute
Engine Controller No Problem
Retry B
Main Controller Fault
ESC
T5-4-22
TROUBLESHOOTING / ICF
LIST OF FAULT CODE
T5-4-23
TROUBLESHOOTING / ICF
SATELLITE COMMUNICATION SYSTEM
1 2 3 4 T1V5-05-01-037
Mail Screen
T5-4-24
TROUBLESHOOTING / ICF
On the machine equipped with the satellite communi-
cation system, the data are sent according to the con-
dition as follows:
T5-4-25
TROUBLESHOOTING / ICF
(Blank)
T5-4-26
TROUBLESHOOTING / Component Layout
MAIN COMPONENT LAYOUT
Upperstructure (1)
1
2
3
8
9
10
11
25 12
24 13
14
23 15
22 16
17
21
20 18
TCJB-01-02-012
19
T5-5-1
TROUBLESHOOTING / Component Layout
Upperstructure (2)
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28 26 TCJB-01-02-013
27
26 - Solenoid Valve Unit 31 - Fuel Main Filter 35 - Shuttle Valve (For Bypass 39 - Pilot Filter
(For Electric Lever) Shut-Out Valve Control)
27 - Automatic Fueling Pump 32 - Solenoid Pump 36 - Control Valve 40 - Engine Oil Filter
28 - Shuttle Valve 33 - Swing Device 37 - 4-Spool Solenoid Valve 41 - Steering Filter
Unit
29 - Automatic Fueling Switch 34 - Shuttle Valve 38 - Pump Device 42 - Engine
30 - Fuel Pre Filter
T5-5-2
TROUBLESHOOTING / Component Layout
Undercarriage
1 2
TCJB-01-02-011
T5-5-3
TROUBLESHOOTING / Component Layout
Front Attachment
3 2
7
4
1
4
7 6 T1GL-01-02-003
5 5 T1F3-01-02-004
1 - Bucket Cylinder 3- Positioning Cylinder 5- Hose Rupture Valve 7- Hose Rupture Valve (Arm)
(Boom)
2 - Arm Cylinder 4- Boom Cylinder 6 - Hose Rupture Valve
(Positioning)
T5-5-4
TROUBLESHOOTING / Component Layout
ELECTRICAL COMPONENT LAYOUT (Overview)
1
8
2
T5-5-5
TROUBLESHOOTING / Component Layout
9 10 11
16
15
14 12
Control Valve (Refer to T1-2-14.)
・Pressure Sensor (Boom Raise) 13
・Pressure Sensor (Arm Roll-In) TCJB-01-02-013
Swing Device
(Refer to T1-2-13.)
・Pressure Sensor (Front)
9- Intake Air Temperature 11 - Air Cleaner Restriction 13 - Solenoid Valve Unit 15 - Hydraulic Oil Temperature
Sensor Switch (For Electric Lever) Sensor (Main)
10 - Atmosphere Pressure 12 - Slip Ring 14 - Pressure Sensor 16 - 4-Spool Solenoid Valve
Sensor (Positioning) Unit
T5-5-6
TROUBLESHOOTING / Component Layout
ELECTRICAL COMPONENT LAYOUT
(MONITORS AND SWITCHES)
6 7
5
2
12
4 3
11 10 9 8 TCJB-01-02-014
TCJB-01-02-006
14 22
23
15 34 24
25
16 13
26
27
33 28
17
18 32
TCJB-01-02-007
19 31 30 29
20
21
TCJB-01-02-008
1- Monitor Unit 10 - Steering Column Monitor 19 - Blade/Outrigger Front-Rear 27 - Engine Speed Control Mode
(Refer to T1-2-8.) (Refer to T1-2-9.) Selector Switch Selection Switch
2 - Swing Lock Lever 11 - Auxiliary/Positioning Pedal 20 - Outrigger Left-Right 28 - Power Mode Switch
(Optional) Selector Switch
3- Blade/Outrigger Lever 12 - Horn Switch 21 - Heater Seat Switch 29 - Key Switch
(Optional)
4- Pilot Shut-Off Lever 13 - Left Analog Switch 22 - FNR Switch 30 - Blade/Outrigger Selector
(Auxiliary) Switch
5- Engine Stop Switch 14 - Horn Switch 23 - Auxiliary 31 - Auto-Idle Switch
6- Combination Switch 15 - Positioning Pedal Selection 24 - Power Digging Switch 32 - Work Light Switch
・Turn Signal Switch Switch
・Light Switch
・Dimmer Switch
・Passing Switch
7 - Brake Switch 16 - Auxiliary Pedal Selection 25 - Engine Control Dial 33 - Wiper/Washer Switch
Switch
8- Accelerator Pedal 17 - Hazard Switch 26 - Travel Speed Mode Switch 34 - Right Analog Switch
(Assist) (Optional)
9- Brake Pedal 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
20 20 19
TCJB-05-02-043
33 32 31 30 29 28 27 26 25 24 23 22
1 - Work Mode Display 10 - Parking Brake Display 19 - Trip Meter Display 28 - Work Mode Display
2 - Auto-Idle Display 11 - Work Brake Display 20 - Odometer Display 29 - Auxiliary Selection
3 - Overload Alarm Display 12 - Axle Lock Display 21 - Hour Meter Display 30 - Coolant Temperature
(Optional) Gauge
4 - Auto Axle Lock Display 13 - Work Light Display 22 - Back Monitor Selection 31 - Work Mode Selection
5 - Auxiliary 14 - Auxiliary 2 (Positioning) 23 - Menu 32 - Return to Primary Screen
Selection Display
6 - Glow Signal Display 15 - Auxiliary 1 (Attachment) 24 - Meter Display Selection 33 - Brake Oil Pressure Gauge
Selection Display
7 - Trip Meter 16 - Blade/Outrigger Settings 25 - Fuel Gauge 34 - Speedometer
and Brake Mode Display
8 - Odometer 17 - Mail Display (Optional) 26 - Auxiliary 35 - Tachometer
9 - Hour Meter 18 - Clock 27 - Mail Selection (Optional)
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 7 - Auto-Cruise Indicator 10 - Clearance Light Indicator
(Optional)
2 - Turn Signal Indicator 5 - Travel Reverse Indicator 8 - Travel Slow Speed 11 - High Beam Indicator
(Right) Indicator
3 - Neutral Indicator 6 - Hazard Light Indicator 9 - Auxiliary 12 - Turn Signal Indicator (Left)
T5-5-9
TROUBLESHOOTING / Component Layout
ELECTRICAL COMPONENT LAYOUT
(CONTROLLERS AND RELAYS)
1 2
6 5
TCJB-01-02-015
T5-5-10
TROUBLESHOOTING / Component Layout
Relays Position
TCJB-01-02-009
Option Controller
TCJB-01-02-010
Dr.ZX Connector Fuse Box
1 - High Beam Relay 15 - Stop Light Relay 29 - Blade/Outrigger Relay 43 - Twin Wiper Relay 1 (OP)
(Front-Right)
2 - Clearance Light Relay 16 - Washer Relay 30 - Blade/Outrigger Relay 44 - Twin Wiper Relay 2 (OP)
(Left) (Front-Left)
3 - Clearance Light Relay 17 - Horn Relay 31 - Blade/Outrigger Relay 45 - Twin Wiper Relay 3 (OP)
(Right) (Main 1)
4 - Head Light Relay (Left) 18 - Load Dump Relay 32 - Auto-Cruise Relay (OP) 46 - Twin Wiper Relay 4 (OP)
5 - Head Light Relay (Right) 19 - Pilot Shut-Off Relay 33 - Heater Seat Relay (OP) 47 - Twin Wiper Relay 5 (OP)
6 - Travel Slow Selection 20 - Security Horn Relay 34 - Room Lamp Controller Relay 48 - Twin Wiper Relay 6 (OP)
Relay (OP)
7 - Compressor Relay (A/C) 21 - Starter Cut Relay 35 - Assist Relay 1 (OP) 49 - Swing Alarm Relay (OP)
8 - Heater Relay (A/C) 22 - Security Relay 36 - Assist Relay 2 (OP) 50 - Rear Head Light Relay (OP)
9 - MAX-Hi Relay (A/C) 23 - Travel Fast Selection 37 - Assist Flow Rate Control 51 - Additional Front Head Light
Relay Relay (OP) (OP)
10 - ECM Main Relay 24 - Blade/Outrigger Relay 38 - Power Digging Relay 52 - Additional Front Head Light
(Rear) (OP)
11 - Turn Signal Light Relay 25 - Blade/Outrigger Relay 39 - Auxiliary/Positioning Selection 53 - Revolving Light Relay (OP)
(Left) (Front) Relay 1 (OP)
12 - Turn Signal Light Relay 26 - Blade/Outrigger Relay 40 - Auxiliary/Positioning Selection 54 - Immobilizer 1 (OP)
(Right) (Rear-Right) Relay 2 (OP)
13 - Wiper Relay 27 - Blade/Outrigger Relay 41 - Auxiliary/Positioning Selection 55 - Immobilizer 2 (OP)
(Rear-Left) Relay 3 (OP)
14 - Boom Light Relay 28 - Blade/Outrigger Relay 42 - Auxiliary/Positioning Selection 56 - Immobilizer 3 (OP)
(Main 2) Relay 4 (OP)
NOTE: OP: Optional
T5-5-11
TROUBLESHOOTING / Component Layout
ENGINE
3 4 5
1
T1V1-01-02-017
T1V1-01-02-016
8 7
9 10 11 12 9
T1V1-01-02-015
13
1- Cam Angle Sensor 5- Fuel Temperature Sensor 8- Engine Oil Pressure 11 - Boost Temperature Sensor
Sensor
2- Overheat Switch 6- Crank Speed Sensor 9 - Injector 12 - Boost Pressure Sensor
3- Coolant Temperature 7- Supply Pump Actuator 10 - EGR (Exhaust Gas Recir- 13 - Glow Plug
Sensor culation) Valve
4 - Common Rail Pressure
Sensor
T5-5-12
TROUBLESHOOTING / Component Layout
PUMP DEVICE
5 6
2 1
7
11
10
9
8
TCEB-03-01-003 TCEB-03-01-001
4 3
13
14
12
T1F3-03-06-003
T178-03-02-001
1 - Pump 1 5- Pilot Pump 9- Pump 1 Maximum Flow Rate 12 - Pressure Sensor (Front)
Limit Control Solenoid Valve
2 - Pump 2 6- Steering Pump 10 - Torque Control Solenoid 13 - Pressure Sensor
Valve (Auxiliary)
3 - Pump 1 Delivery 7- Pump 2 Control Pressure 11 - Pump 2 Maximum Flow Rate 14 - Pressure Sensor (Swing)
Pressure Sensor Sensor Limit Control Solenoid Valve
4 - Pump 2 Delivery 8 - Pump 1 Control Pressure
Pressure Sensor Sensor
T5-5-13
TROUBLESHOOTING / Component Layout
CONTROL VALVE BRAKE VALVE
1 4
3 TCJB-01-02-016
6
TCJB-01-02-017
21
20 13
19 14
15
18
16
T1V1-03-07-007
17
TCJB-01-02-018
1 - Pressure Sensor 7- Brake Pressure Sensor 12 - Solenoid Valve Unit (SG) 17 - Hydraulic Oil Temperature
(Arm Roll-In) Sensor (For Electric Lever)
2 - Main Relief Valve 8- Brake Valve 13 - Positioning / Assist 18 - Blade / Outrigger Solenoid
Solenoid Valve Valve
3 - Pressure Sensor 9- Solenoid Valve Unit (SC) 14 - Auxiliary Solenoid Valve 19 - Auxiliary Solenoid Valve
(Boom Raise)
4 - Accumulator Charging 10 - Solenoid Valve Unit (SF) 15 - Blade / Outrigger Solenoid 20 - Positioning / Assist
Valve Valve Solenoid Valve
5 - Brake Remain Pressure 11 - Solenoid Valve Unit (SI) 16 - Travel Make-Up Solenoid 21 - Swing Parking Brake
Sensor Valve Release Solenoid Valve
6 - Stop Light / Work Brake
Release Switch
T5-5-14
TROUBLESHOOTING / Component Layout
TRAVEL SHOCKLESS VALVE TRANSMISSION CHANGEOVER SOLE-
NOID VALVE
5 6
1
3
TCJB-05-07-002
TCJB-01-02-019
4
11
7 8
12
13
10 9
TCJB-01-02-020
14
TCJB-01-02-021
T5-5-15
TROUBLESHOOTING / Component Layout
COMPONENTS IN CONTROL VALVE
Machine Lower Machine Upper Machine Upper Machine Lower
1 2 3 4 5 6 7 8 9 10 11
46 12
13
45
14
44
15
16
43 17
42 18
41 19
20
40
21
39
22
38
37
36
23
35
24
34
25
26
33 32 31 30 29 28 27
T21W-03-03-001
T5-5-16
TROUBLESHOOTING / Component Layout
4-Spool Section
Arm Roll-In
Pressure Sensor 20 21, 24 15 13
10, 11
25
17, 19
18
7
Boom Raise
T21W-03-03-014
Pressure Sensor 22 16 14
1- Load Check Valve 13 - Make-Up Valve (Travel 25 - Arm 2 Flow Rate Control 36 - Arm Anti-Drift Valve
(Blade / Outrigger Reverse Side) Valve (Switch Valve) (Switch Valve)
Parallel Circuit)
2 - Check Valve (Main 14 - Make-Up Valve (Travel 26 - Load Check Valve (Arm 2 37 - Overload Relief Valve
Relief Circuit) Forward Side) Tandem Circuit) (Arm: Bottom Side)
3 - Main Relief Valve 15 - Overload Relief Valve 27 - Bypass Shut-Out Valve 38 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) Valve)
4- Check Valve (Auxiliary 16 - Overload Relief Valve 28 - Arm 2 Flow Rate Control 39 - Overload Relief Valve
Combiner Valve Circuit) (Bucket: Bottom Side) Valve (Poppet Valve) (Arm: Rod Side)
5 - Auxiliary Flow Combiner 17 - Boom Flow Rate Control 29 - Arm Regenerative Valve 40 - Check Valve (Digging
Valve Valve (Poppet Valve) Regenerative Circuit)
6 - Check Valve (Flow 18 - Boom Lower Meter-In Cut 30 - Unused 41 - Load Check Valve (Boom 2
Combiner Valve Circuit) Valve Parallel Circuit)
7 - Flow Combiner Valve 19 - Boom Flow Rate Control 31 - Load Check Valve (Digging 42 - Auxiliary Flow Rate Control
Valve (Switch Valve) Regenerative Circuit) Valve (Poppet Valve)
8- Load Check Valve 20 - Overload Relief Valve (Boom: 32 - Arm 1 Flow Rate Control 43 - Auxiliary Flow Rate Control
(Orifice) (Bucket) Bottom Side) Valve (Poppet Valve) Valve (Switch Valve)
9- Check Valve (Main 21 - Boom Anti-Drift Valve (Check 33 - Load Check Valve (Swing 44 - Load Check Valve (Blade /
Relief Circuit) Valve) Circuit) Outrigger Tandem Circuit)
10 - Bucket Flow Rate 22 - Overload Relief Valve (Boom: 34 - Arm 1 Flow Rate Control 45 - Overload Relief Valve
Control Valve (Poppet Rod Side) Valve (Switch Valve) (Blade / Outrigger: Rod
Valve) Side)
11 - Bucket Flow Rate 23 - Boom Regenerative Valve 35 - Load Check Valve (Arm 46 - Overload Relief Valve
Control Valve (Switch Regenerative Circuit) (Blade / Outrigger: Bottom
Valve) Side)
12 - Bucket Regenerative 24 - Boom Anti-Drift Valve (Switch
Valve Valve)
T5-5-17
TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7 8 9 10 11
46 12
13
45
14
44
15
16
43 17
42 18
41 19
20
40
21
39
22
38
37
36
23
35
24
34
25
26
33 32 31 30 29 28 27
T21W-03-03-001
T5-5-18
TROUBLESHOOTING / Component Layout
5-Spool Section
3
37 34, 36
30, 32
40, 41 T1V1-03-03-072
28
35
1- Load Check Valve 13 - Make-Up Valve (Travel 25 - Arm 2 Flow Rate Control 36 - Arm Anti-Drift Valve
(Blade / Outrigger Reverse Side) Valve (Switch Valve) (Switch Valve)
Parallel Circuit)
2 - Check Valve (Main 14 - Make-Up Valve (Travel 26 - Load Check Valve (Arm 2 37 - Overload Relief Valve
Relief Circuit) Forward Side) Tandem Circuit) (Arm: Bottom Side)
3 - Main Relief Valve 15 - Overload Relief Valve 27 - Bypass Shut-Out Valve 38 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) Valve)
4- Check Valve (Auxiliary 16 - Overload Relief Valve 28 - Arm 2 Flow Rate Control 39 - Overload Relief Valve
Combiner Valve Circuit) (Bucket: Bottom Side) Valve (Poppet Valve) (Arm: Rod Side)
5 - Auxiliary Flow Combiner 17 - Boom Flow Rate Control 29 - Arm Regenerative Valve 40 - Check Valve (Digging
Valve Valve (Poppet Valve) Regenerative Circuit)
6 - Check Valve (Flow 18 - Boom Lower Meter-In Cut 30 - Unused 41 - Load Check Valve (Boom 2
Combiner Valve Circuit) Valve Parallel Circuit)
7 - Flow Combiner Valve 19 - Boom Flow Rate Control 31 - Load Check Valve (Digging 42 - Auxiliary Flow Rate Control
Valve (Switch Valve) Regenerative Circuit) Valve (Poppet Valve)
8- Load Check Valve 20 - Overload Relief Valve (Boom: 32 - Arm 1 Flow Rate Control 43 - Auxiliary Flow Rate Control
(Orifice) (Bucket) Bottom Side) Valve (Poppet Valve) Valve (Switch Valve)
9- Check Valve (Main 21 - Boom Anti-Drift Valve (Check 33 - Load Check Valve (Swing 44 - Load Check Valve (Blade /
Relief Circuit) Valve) Circuit) Outrigger Tandem Circuit)
10 - Bucket Flow Rate 22 - Overload Relief Valve (Boom: 34 - Arm 1 Flow Rate Control 45 - Overload Relief Valve
Control Valve (Poppet Rod Side) Valve (Switch Valve) (Blade / Outrigger: Rod
Valve) Side)
11 - Bucket Flow Rate 23 - Boom Regenerative Valve 35 - Load Check Valve (Arm 46 - Overload Relief Valve
Control Valve (Switch Regenerative Circuit) (Blade / Outrigger: Bottom
Valve) Side)
12 - Bucket Regenerative 24 - Boom Anti-Drift Valve (Switch
Valve Valve)
T5-5-19
TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7 8 9 10 11
46 12
13
45
14
44
15
16
43 17
42 18
41 19
20
40
21
39
22
38
37
36
23
35
24
34
25
26
33 32 31 30 29 28 27
T21W-03-03-001
T5-5-20
TROUBLESHOOTING / Component Layout
A B 3
Cross Section C-C
C C
D D
E E
F F 4
G G
H H
I I
J J
5
7
TCJB-03-03-005 TCJB-03-03-009
A B
Boom 2 Boom 1
Arm 1 Arm 2
29
31
TCJB-03-03-008 TCJB-03-03-007
1- Load Check Valve 13 - Make-Up Valve (Travel 25 - Arm 2 Flow Rate Control 36 - Arm Anti-Drift Valve
(Blade / Outrigger Reverse Side) Valve (Switch Valve) (Switch Valve)
Parallel Circuit)
2 - Check Valve (Main 14 - Make-Up Valve (Travel 26 - Load Check Valve (Arm 2 37 - Overload Relief Valve
Relief Circuit) Forward Side) Tandem Circuit) (Arm: Bottom Side)
3 - Main Relief Valve 15 - Overload Relief Valve 27 - Bypass Shut-Out Valve 38 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) Valve)
4- Check Valve (Auxiliary 16 - Overload Relief Valve 28 - Arm 2 Flow Rate Control 39 - Overload Relief Valve
Combiner Valve Circuit) (Bucket: Bottom Side) Valve (Poppet Valve) (Arm: Rod Side)
5 - Auxiliary Flow Combiner 17 - Boom Flow Rate Control 29 - Arm Regenerative Valve 40 - Check Valve (Digging
Valve Valve (Poppet Valve) Regenerative Circuit)
6 - Check Valve (Flow 18 - Boom Lower Meter-In Cut 30 - Unused 41 - Load Check Valve (Boom 2
Combiner Valve Circuit) Valve Parallel Circuit)
7 - Flow Combiner Valve 19 - Boom Flow Rate Control 31 - Load Check Valve (Digging 42 - Auxiliary Flow Rate Control
Valve (Switch Valve) Regenerative Circuit) Valve (Poppet Valve)
8- Load Check Valve 20 - Overload Relief Valve (Boom: 32 - Arm 1 Flow Rate Control 43 - Auxiliary Flow Rate Control
(Orifice) (Bucket) Bottom Side) Valve (Poppet Valve) Valve (Switch Valve)
9- Check Valve (Main 21 - Boom Anti-Drift Valve (Check 33 - Load Check Valve (Swing 44 - Load Check Valve (Blade /
Relief Circuit) Valve) Circuit) Outrigger Tandem Circuit)
10 - Bucket Flow Rate 22 - Overload Relief Valve (Boom: 34 - Arm 1 Flow Rate Control 45 - Overload Relief Valve
Control Valve (Poppet Rod Side) Valve (Switch Valve) (Blade / Outrigger: Rod
Valve) Side)
11 - Bucket Flow Rate 23 - Boom Regenerative Valve 35 - Load Check Valve (Arm 46 - Overload Relief Valve
Control Valve (Switch Regenerative Circuit) (Blade / Outrigger: Bottom
Valve) Side)
12 - Bucket Regenerative 24 - Boom Anti-Drift Valve (Switch
Valve Valve)
T5-5-21
TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7 8 9 10 11
46 12
13
45
14
44
15
16
43 17
42 18
41 19
20
40
21
39
22
38
37
36
23
35
24
34
25
26
33 32 31 30 29 28 27
T21W-03-03-001
T5-5-22
TROUBLESHOOTING / Component Layout
46 13
15
10
43 11
16
42
45 14 TCJB-03-03-010
12
TCJB-03-03-011
1- Load Check Valve 13 - Make-Up Valve (Travel 25 - Arm 2 Flow Rate Control 36 - Arm Anti-Drift Valve
(Blade / Outrigger Reverse Side) Valve (Switch Valve) (Switch Valve)
Parallel Circuit)
2 - Check Valve (Main 14 - Make-Up Valve (Travel 26 - Load Check Valve (Arm 2 37 - Overload Relief Valve
Relief Circuit) Forward Side) Tandem Circuit) (Arm: Bottom Side)
3 - Main Relief Valve 15 - Overload Relief Valve 27 - Bypass Shut-Out Valve 38 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) Valve)
4- Check Valve (Auxiliary 16 - Overload Relief Valve 28 - Arm 2 Flow Rate Control 39 - Overload Relief Valve
Combiner Valve Circuit) (Bucket: Bottom Side) Valve (Poppet Valve) (Arm: Rod Side)
5 - Auxiliary Flow Combiner 17 - Boom Flow Rate Control 29 - Arm Regenerative Valve 40 - Check Valve (Digging
Valve Valve (Poppet Valve) Regenerative Circuit)
6 - Check Valve (Flow 18 - Boom Lower Meter-In Cut 30 - Unused 41 - Load Check Valve (Boom 2
Combiner Valve Circuit) Valve Parallel Circuit)
7 - Flow Combiner Valve 19 - Boom Flow Rate Control 31 - Load Check Valve (Digging 42 - Auxiliary Flow Rate Control
Valve (Switch Valve) Regenerative Circuit) Valve (Poppet Valve)
8- Load Check Valve 20 - Overload Relief Valve (Boom: 32 - Arm 1 Flow Rate Control 43 - Auxiliary Flow Rate Control
(Orifice) (Bucket) Bottom Side) Valve (Poppet Valve) Valve (Switch Valve)
9- Check Valve (Main 21 - Boom Anti-Drift Valve (Check 33 - Load Check Valve (Swing 44 - Load Check Valve (Blade /
Relief Circuit) Valve) Circuit) Outrigger Tandem Circuit)
10 - Bucket Flow Rate 22 - Overload Relief Valve (Boom: 34 - Arm 1 Flow Rate Control 45 - Overload Relief Valve
Control Valve (Poppet Rod Side) Valve (Switch Valve) (Blade / Outrigger: Rod
Valve) Side)
11 - Bucket Flow Rate 23 - Boom Regenerative Valve 35 - Load Check Valve (Arm 46 - Overload Relief Valve
Control Valve (Switch Regenerative Circuit) (Blade / Outrigger: Bottom
Valve) Side)
12 - Bucket Regenerative 24 - Boom Anti-Drift Valve (Switch
Valve Valve)
T5-5-23
TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7 8 9 10 11
46 12
13
45
14
44
15
16
43 17
42 18
41 19
20
40
21
39
22
38
37
36
23
35
24
34
25
26
33 32 31 30 29 28 27
T21W-03-03-001
T5-5-24
TROUBLESHOOTING / Component Layout
39
24
21
41
18
19
17 28
22
23 30 30
TCJB-03-03-012 TCJB-03-03-013
1- Load Check Valve 13 - Make-Up Valve (Travel 25 - Arm 2 Flow Rate Control 36 - Arm Anti-Drift Valve
(Blade / Outrigger Reverse Side) Valve (Switch Valve) (Switch Valve)
Parallel Circuit)
2 - Check Valve (Main 14 - Make-Up Valve (Travel 26 - Load Check Valve (Arm 2 37 - Overload Relief Valve
Relief Circuit) Forward Side) Tandem Circuit) (Arm: Bottom Side)
3 - Main Relief Valve 15 - Overload Relief Valve 27 - Bypass Shut-Out Valve 38 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) Valve)
4- Check Valve (Auxiliary 16 - Overload Relief Valve 28 - Arm 2 Flow Rate Control 39 - Overload Relief Valve
Combiner Valve Circuit) (Bucket: Bottom Side) Valve (Poppet Valve) (Arm: Rod Side)
5 - Auxiliary Flow Combiner 17 - Boom Flow Rate Control 29 - Arm Regenerative Valve 40 - Check Valve (Digging
Valve Valve (Poppet Valve) Regenerative Circuit)
6 - Check Valve (Flow 18 - Boom Lower Meter-In Cut 30 - Unused 41 - Load Check Valve (Boom 2
Combiner Valve Circuit) Valve Parallel Circuit)
7 - Flow Combiner Valve 19 - Boom Flow Rate Control 31 - Load Check Valve (Digging 42 - Auxiliary Flow Rate Control
Valve (Switch Valve) Regenerative Circuit) Valve (Poppet Valve)
8- Load Check Valve 20 - Overload Relief Valve (Boom: 32 - Arm 1 Flow Rate Control 43 - Auxiliary Flow Rate Control
(Orifice) (Bucket) Bottom Side) Valve (Poppet Valve) Valve (Switch Valve)
9- Check Valve (Main 21 - Boom Anti-Drift Valve (Check 33 - Load Check Valve (Swing 44 - Load Check Valve (Blade /
Relief Circuit) Valve) Circuit) Outrigger Tandem Circuit)
10 - Bucket Flow Rate 22 - Overload Relief Valve (Boom: 34 - Arm 1 Flow Rate Control 45 - Overload Relief Valve
Control Valve (Poppet Rod Side) Valve (Switch Valve) (Blade / Outrigger: Rod
Valve) Side)
11 - Bucket Flow Rate 23 - Boom Regenerative Valve 35 - Load Check Valve (Arm 46 - Overload Relief Valve
Control Valve (Switch Regenerative Circuit) (Blade / Outrigger: Bottom
Valve) Side)
12 - Bucket Regenerative 24 - Boom Anti-Drift Valve (Switch
Valve Valve)
T5-5-25
TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7 8 9 10 11
46 12
13
45
14
44
15
16
43 17
42 18
41 19
20
40
21
39
22
38
37
36
23
35
24
34
25
26
33 32 31 30 29 28 27
T21W-03-03-001
T5-5-26
TROUBLESHOOTING / Component Layout
36 20
29
38
26 33
34
25
32
37
TCJB-03-03-015
TCJB-03-03-014
1- Load Check Valve 13 - Make-Up Valve (Travel 25 - Arm 2 Flow Rate Control 36 - Arm Anti-Drift Valve
(Blade / Outrigger Reverse Side) Valve (Switch Valve) (Switch Valve)
Parallel Circuit)
2 - Check Valve (Main 14 - Make-Up Valve (Travel 26 - Load Check Valve (Arm 2 37 - Overload Relief Valve
Relief Circuit) Forward Side) Tandem Circuit) (Arm: Bottom Side)
3 - Main Relief Valve 15 - Overload Relief Valve 27 - Bypass Shut-Out Valve 38 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) Valve)
4- Check Valve (Auxiliary 16 - Overload Relief Valve 28 - Arm 2 Flow Rate Control 39 - Overload Relief Valve
Combiner Valve Circuit) (Bucket: Bottom Side) Valve (Poppet Valve) (Arm: Rod Side)
5 - Auxiliary Flow Combiner 17 - Boom Flow Rate Control 29 - Arm Regenerative Valve 40 - Check Valve (Digging
Valve Valve (Poppet Valve) Regenerative Circuit)
6 - Check Valve (Flow 18 - Boom Lower Meter-In Cut 30 - Unused 41 - Load Check Valve (Boom 2
Combiner Valve Circuit) Valve Parallel Circuit)
7 - Flow Combiner Valve 19 - Boom Flow Rate Control 31 - Load Check Valve (Digging 42 - Auxiliary Flow Rate Control
Valve (Switch Valve) Regenerative Circuit) Valve (Poppet Valve)
8- Load Check Valve 20 - Overload Relief Valve (Boom: 32 - Arm 1 Flow Rate Control 43 - Auxiliary Flow Rate Control
(Orifice) (Bucket) Bottom Side) Valve (Poppet Valve) Valve (Switch Valve)
9- Check Valve (Main 21 - Boom Anti-Drift Valve (Check 33 - Load Check Valve (Swing 44 - Load Check Valve (Blade /
Relief Circuit) Valve) Circuit) Outrigger Tandem Circuit)
10 - Bucket Flow Rate 22 - Overload Relief Valve (Boom: 34 - Arm 1 Flow Rate Control 45 - Overload Relief Valve
Control Valve (Poppet Rod Side) Valve (Switch Valve) (Blade / Outrigger: Rod
Valve) Side)
11 - Bucket Flow Rate 23 - Boom Regenerative Valve 35 - Load Check Valve (Arm 46 - Overload Relief Valve
Control Valve (Switch Regenerative Circuit) (Blade / Outrigger: Bottom
Valve) Side)
12 - Bucket Regenerative 24 - Boom Anti-Drift Valve (Switch
Valve Valve)
T5-5-27
TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7 8 9 10 11
46 12
13
45
14
44
15
16
43 17
42 18
41 19
20
40
21
39
22
38
37
36
23
35
24
34
25
26
33 32 31 30 29 28 27
T21W-03-03-001
T5-5-28
TROUBLESHOOTING / Component Layout
K K
L L
M M
TCJB-03-03-016
8 6
N N
T1V1-03-03-022
TCJB-03-03-003
13 - Load Check Valve 25 - Make-Up Valve (Travel 36 - Arm 2 Flow Rate Control 47 - Arm Anti-Drift Valve
(Blade / Outrigger Reverse Side) Valve (Switch Valve) (Switch Valve)
Parallel Circuit)
14 - Check Valve (Main 26 - Make-Up Valve (Travel 37 - Load Check Valve (Arm 2 48 - Overload Relief Valve
Relief Circuit) Forward Side) Tandem Circuit) (Arm: Bottom Side)
15 - Main Relief Valve 27 - Overload Relief Valve 38 - Bypass Shut-Out Valve 49 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) Valve)
16 - Check Valve (Auxiliary 28 - Overload Relief Valve 39 - Arm 2 Flow Rate Control 50 - Overload Relief Valve
Combiner Valve Circuit) (Bucket: Bottom Side) Valve (Poppet Valve) (Arm: Rod Side)
17 - Auxiliary Flow Combiner 29 - Boom Flow Rate Control 40 - Arm Regenerative Valve 51 - Check Valve (Digging
Valve Valve (Poppet Valve) Regenerative Circuit)
18 - Check Valve (Flow 30 - Boom Lower Meter-In Cut 41 - Unused 52 - Load Check Valve (Boom 2
Combiner Valve Circuit) Valve Parallel Circuit)
19 - Flow Combiner Valve 31 - Boom Flow Rate Control 42 - Load Check Valve (Digging 53 - Auxiliary Flow Rate Control
Valve (Switch Valve) Regenerative Circuit) Valve (Poppet Valve)
20 - Load Check Valve 32 - Overload Relief Valve (Boom: 43 - Arm 1 Flow Rate Control 54 - Auxiliary Flow Rate Control
(Orifice) (Bucket) Bottom Side) Valve (Poppet Valve) Valve (Switch Valve)
21 - Check Valve (Main 33 - Boom Anti-Drift Valve (Check 44 - Load Check Valve (Swing 55 - Load Check Valve (Blade /
Relief Circuit) Valve) Circuit) Outrigger Tandem Circuit)
22 - Bucket Flow Rate 34 - Overload Relief Valve (Boom: 45 - Arm 1 Flow Rate Control 56 - Overload Relief Valve
Control Valve (Poppet Rod Side) Valve (Switch Valve) (Blade / Outrigger: Rod
Valve) Side)
23 - Bucket Flow Rate 35 - Boom Regenerative Valve 46 - Load Check Valve (Arm 57 - Overload Relief Valve
Control Valve (Switch Regenerative Circuit) (Blade / Outrigger: Bottom
Valve) Side)
24 - Bucket Regenerative 36 - Boom Anti-Drift Valve (Switch
Valve Valve)
T5-5-29
TROUBLESHOOTING / Component Layout
Layout of Positioning Control Valve (2-Piece Boom)
4 1
3
2
TCJB-03-03-019
T5-5-30
TROUBLESHOOTING / Component Layout
3
T178-03-03-070
T198-03-03-003
X
1- Load Check Valve 2- Load Check Valve 3- Overload Relief Valve 4- Overload Relief Valve
(Positioning Parallel Circuit) (Positioning Tandem Circuit) (Positioning: Bottom Side) (Positioning: Rod Side)
T5-5-31
TROUBLESHOOTING / Component Layout
PILOT PORT
E
M
D
H
B
F
SB
PI G
K N
I
SH
J
DF
SA L
T178-03-06-016
T5-5-32
TROUBLESHOOTING / Component Layout
3
1
Pressure Sensor 5
(Auxiliary)
13
2 4
SK SE
Pressure Sensor 8
(Swing)
14
Control 7
Valve Side
9
10 6
SN
SL
11
T1F3-03-06-003
12 SP
Control Valve Side
Port Name Connecting to Remark
Port 1 Control Valve Boom Raise Pilot Pressure
Port 2 Control Valve Boom Lower Pilot Pressure
Port 3 Control Valve Arm Roll-Out Pilot Pressure
Port 4 Control Valve Arm Roll-In Pilot Pressure
Port 5 Control Valve Left Swing Pilot Pressure
Port 6 Control Valve Right Swing Pilot Pressure
Port 7 Control Valve Bucket Roll-In Pilot Pressure
Port 8 Control Valve Bucket Roll-Out Pilot Pressure
Port 9 Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port 10 - Plug
Port 11 Control Valve Travel Reverse Pilot Pressure
Port 12 Control Valve Travel Forward Pilot Pressure
Port 13 - Plug
Port 14 - Plug
Port SE Control Valve Arm 1 Flow Rate Control Valve Control Pressure
Port SN - Plug
Port SP Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port SL Control Valve Flow Combiner Valve Control Pressure
Port SK Control Valve Bucket Flow Rate Control Valve Control Pressure
T5-5-33
TROUBLESHOOTING / Component Layout
14
Control
Valve Side
SN
T1F3-03-06-003
T5-5-34
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
YES (OK)
(2)
After completing the checking and/or measuring procedures in box (1),
・ (1) select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
(3)
NO (NOT OK)
・ Refer to “Electrical System Inspection” Group (Group 8) for descriptions in the dotted-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.
Harness
Harness End
Connector
T5-6-1
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE LIST
T5-6-2
TROUBLESHOOTING / Troubleshooting A
T1V1-05-01-102
T5-6-3
TROUBLESHOOTING / Troubleshooting A
Engine Failure
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 Engine Control Dial Control
Sensor High Voltage
11101-4 Abnormal Engine Control Dial Voltage: less than 0.22 V Engine Control Dial Control
Sensor Low Voltage
T5-6-4
TROUBLESHOOTING / Troubleshooting A
T5-6-5
TROUBLESHOOTING / Troubleshooting A
Pump Failure
Fault Code Trouble Cause Influenced Control
11200-3 Abnormal Pump 1 Delivery Voltage: more than 4.5 V • HP Mode Control
Pressure Sensor High Voltage • 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 • HP Mode Control
Pressure Sensor Low Voltage • 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 • HP Mode Control
Pressure Sensor High Voltage • E Mode Control
• Arm Regenerative Control
11202-4 Abnormal Pump 2 Delivery Voltage: less than 0.25 V • HP Mode Control
Pressure Sensor Low Voltage • E Mode Control
• Arm Regenerative Control
11203-3 Abnormal Pump 3 Delivery Voltage: more than 4.5 V • Steering Pump Torque
Pressure Sensor High Voltage Reduction Control
11203-4 Abnormal Pump 3 Delivery Voltage: less than 0.25 V • Steering Pump Torque
Pressure Sensor Low Voltage Reduction Control
11206-3 Abnormal Pump 1 Pump Control Voltage: more than 4.75 V • E Mode Control
Pressure Sensor High Voltage • Heater Control
11206-4 Abnormal Pump 1 Pump Control Voltage: less than 0.25 V • E Mode Control
Pressure Sensor Low Voltage • Heater Control
11208-3 Abnormal Pump 2 Pump Control Voltage: more than 4.75 V • E Mode Control
Pressure Sensor High Voltage • Heater Control
11208-4 Abnormal Pump 2 Pump Control Voltage: less than 0.25 V • E Mode Control
Pressure Sensor Low Voltage • Heater Control
T5-6-6
TROUBLESHOOTING / Troubleshooting A
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 • Arm Regenerative Control
Sensor High Voltage • Attachment Flow Rate Control
(Optional)
• Swing Alarm Control (Optional)
11301-4 Abnormal Swing Pilot Pressure Voltage: less than 0.25 V • Arm Regenerative Control
Sensor Low Voltage • Attachment Flow Rate Control
(Optional)
• Swing Alarm Control (Optional)
11302-3 Abnormal Boom Raise Pilot Voltage: more than 4.75 V • HP Mode Control
Pressure Sensor High Voltage • Arm Regenerative Control
• Auto-Power Lift Control
• Attachment Flow Rate Control
(Optional)
11302-4 Abnormal Boom Raise Pilot Voltage: less than 0.25 V • HP Mode Control
Pressure Sensor Low Voltage • 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 • HP Mode Control
Pressure Sensor High Voltage • Arm Regenerative Control
• Auto-Power Lift Control
11303-4 Abnormal Arm Roll-In Pilot Voltage: less than 0.25 V • HP Mode Control
Pressure Sensor Low Voltage • Arm Regenerative Control
• Auto-Power Lift Control
T5-6-8
TROUBLESHOOTING / Troubleshooting A
T5-6-9
TROUBLESHOOTING / Troubleshooting A
T5-6-10
TROUBLESHOOTING / Troubleshooting A
T5-6-11
TROUBLESHOOTING / Troubleshooting A
11307-4 Abnormal Front Attachment Pilot Voltage: less than 0.25 V • Auto-Idle Control
Pressure Sensor Low Voltage • Idle Speed-Up Control
• ECO Control
• Heater Control
• Parking Brake Alarm Control
11310-3 Abnormal Brake Pressure Voltage: more than 4.50 V • Work Brake Control
Sensor High Voltage • Auto-Cruise Control
(Optional)
11310-4 Abnormal Brake Pressure Voltage: less than 0.25 V • Work Brake Control
Sensor Low Voltage • Auto-Cruise Control
(Optional)
11311-3 Abnormal Brake Remaining Voltage: more than 4.50 V • Travel Mode Selection Control
Pressure Sensor High Voltage
11311-4 Abnormal Brake Remaining Voltage: less than 0.25 V • Travel Mode Selection Control
Pressure Sensor Low Voltage
T5-6-12
TROUBLESHOOTING / Troubleshooting A
T5-6-13
TROUBLESHOOTING / Troubleshooting A
11400-2 Abnormal Current Feedback of Current: Both of Higher Pump 2 Flow Rate Limit Control
Maximum Pump 2 Flow Rate Limit than 920 mA or Less
Control Solenoid Valve than 60 mA
11400-3 Abnormal Feedback High Current of Current: Higher than Pump 2 Flow Rate Limit Control
Maximum Pump 2 Flow Rate Limit 920 mA
Control Solenoid Valve
11400-4 Abnormal Feedback Low Current of Current: Less than 56 Pump 2 Flow Rate Limit Control
Maximum Pump 2 Flow Rate Limit mA
Control Solenoid Valve
11401-2 Abnormal Current Feedback of Current: Both of Higher • Speed Sensing Control
Torque Control Solenoid Valve than 920 mA or Less • Steering Pump Torque Decrease
than 60 mA Control
11401-3 Abnormal Feedback High Current of Current: Higher than • Speed Sensing Control
Torque Control Solenoid Valve 920 mA • Steering Pump Torque Decrease
Control
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 Current: Both of Higher • Power Digging Control
Solenoid Valve Unit (SG) (Relief than 920mA or Less • Auto-Power Lift Control
Pressure Control) than 60 mA
11404-3 Abnormal Feedback High Current of Current: Higher than • Power Digging Control
Solenoid Valve Unit (SG) (Relief 920 mA • Auto-Power Lift Control
Pressure Control)
11404-4 Abnormal Feedback Low Current of Current: Less than 56 • Power Digging Control
Solenoid Valve Unit (SG) (Relief mA • Auto-Power Lift Control
Pressure Control)
T5-6-14
TROUBLESHOOTING / Troubleshooting A
T5-6-15
TROUBLESHOOTING / Troubleshooting A
11410-2 Abnormal Current Feedback of Current: Both of Higher • Pump 1 Flow Rate Limit Control
Maximum Pump 1 Flow Rate Limit than 920 mA or Less When Traveling At Creeper Mode
Control Solenoid Valve than 60 mA • Attachment Flow Rate Limit
Control
11410-3 Abnormal Feedback High Current of Current: Higher than • Pump 1 Flow Rate Limit Control
Maximum Pump 1 Flow Rate Limit 920 mA When Traveling At Creeper Mode
Control Solenoid Valve • Attachment Flow Rate Limit
Control
11410-4 Abnormal Feedback Low Current of Current: Less than 56 • Pump 1 Flow Rate Limit Control
Maximum Pump 1 Flow Rate Limit mA When Traveling At Creeper Mode
Control Solenoid Valve • Attachment Flow Rate Limit
Control
11422-2 Abnormal Current Feedback of Current: Both of Higher • Travel Motor Displacement Angle
Travel Motor Displacement Angle than 920 mA or Less Control
Control Solenoid Valve than 60 mA • Travel Motor Excessive Rotation
Control
11422-3 Abnormal Feedback High Current of Current: Higher than • Travel Motor Displacement Angle
Travel Motor Displacement Angle 920 mA Control
Control Solenoid Valve • Travel Motor Excessive Rotation
Control
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
11423-2 Abnormal Current Feedback of Current: Both of Higher -
Travel Make-Up Solenoid Valve than 920 mA or Less
than 60 mA
11423-3 Abnormal Feedback High Current of Current: Higher than -
Travel Make-Up Solenoid Valve 920 mA
T5-6-16
TROUBLESHOOTING / Troubleshooting A
T5-6-17
TROUBLESHOOTING / Troubleshooting A
11424-2 Abnormal Current Feedback of Current: Both of Higher • Auto Axle Lock Control
Solenoid Valve Unit (SI) (Axle Lock than 920 mA or Less
Selection) than 60 mA
11424-3 Abnormal Feedback High Current Current: Higher than • Auto Axle Lock Control
of Solenoid Valve Unit (SI) (Axle 920 mA
Lock Selection)
11424-4 Abnormal Feedback Low Current Current: Less than 56 • Auto Axle Lock Control
of Solenoid Valve Unit (SI) (Axle mA
Lock Selection)
11425-2 Abnormal Current Feedback of Current: Both of Higher • ECO Control
Solenoid Valve Unit (SF) (Work than 920 mA or Less • Idle Speed-Up Control
Brake) than 60 mA • Speed Sensing Control
• Brake Dragging Prevention
Control
• Work Brake Control
11425-3 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
11425-4 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
T5-6-19
TROUBLESHOOTING / Troubleshooting A
T5-6-20
TROUBLESHOOTING / Troubleshooting A
T1V1-05-01-102
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 • Auto-Warming Up Control
Sensor High Voltage • Arm Regenerative Control
11901-4 Hydraulic Oil Temperature Voltage: less than 0.23 V • Auto-Warming Up Control
Sensor Low Voltage • Arm Regenerative Control
T5-6-22
TROUBLESHOOTING/ Troubleshooting A
In low temperature (Hydraulic oil temperature is less Retrial B • Check the harness.
than 0 °C (32 °F)), auto-warming up control is
impossible.
In low temperature (Hydraulic oil temperature is less Retrial B • Check the harness.
than 0 °C (32 °F)), auto-warming up control is
impossible.
Odometer value may increase after the key switch is Retrial B • Replace MC.
OFF.
T5-6-23
TROUBLESHOOTING/ Troubleshooting A
ECM FAULT CODE LIST
Sensor System
Fault
Trouble Cause
Code
636-2 Abnormal Cam Angle Sensor (No Signal) Although the crank signal is present, the cam signal is
not present.
636-2 Abnormal Cam Angle Sensor (Abnormal The pulse of cam signal is not matched.
Signal)
723-2 Abnormal Crank Speed Sensor (No Although the cam signal is present, the crank signal is
Signal) not present.
723-2 Abnormal Crank Speed Sensor The pulse of crank signal is not matched.
(Abnormal Signal)
636-7 Phase Mismatch of Cam Angle Sensor The right cam pulse is not present at the gap in the
crank.
172-3 Abnormal Intake Air Temperature Sensor Voltage at the intake air temperature sensor is beyond
(Abnormal High Voltage) 4.95 V in 3 minutes after the engine starts.
172-4 Abnormal Intake Air Temperature Sensor Voltage at the intake-air temperature sensor is below
(Abnormal Low Voltage) 0.1 V.
110-3 Abnormal Coolant Temperature Sensor Voltage at the coolant temperature sensor is beyond
(Abnormal High Voltage) 4.85 V in 3 minutes after the engine starts.
110-4 Abnormal Coolant Temperature Sensor Voltage at the coolant temperature sensor is below 0.1
(Abnormal Low Voltage) V
102-4 Abnormal Boost Pressure Sensor Voltage at the boost pressure sensor is beyond 4.9 V.
(Abnormal High Voltage)
102-3 Abnormal Boost Pressure Sensor Voltage at the boost pressure sensor is below 0.1 V
(Abnormal Low Voltage)
10001-3 Abnormal EGR Position (Brushless spec.) The condition which the output signal of EGR position
cannot be present in.
108-4 Abnormal Atmospheric Pressure Sensor Voltage at the atmospheric pressure sensor is beyond
(Abnormal High Voltage) 3.8 V.
108-3 Abnormal Atmospheric Pressure Sensor Voltage at the atmospheric pressure sensor is below
(Abnormal Low Voltage) 0.5 V.
174-3 Abnormal Fuel Temperature Sensor Voltage at the fuel temperature sensor is beyond 4.85
(Abnormal High Voltage) V in 3 minutes after the engine starts.
174-4 Abnormal Fuel Temperature Sensor Voltage at the fuel temperature sensor is below 0.1 V.
(Abnormal Low Voltage)
T5-6-24
TROUBLESHOOTING/ Troubleshooting A
• The output power may decrease, white smoke Operate according to standard of the cam P0335
may occur and vibration may occur. sensor.
• The engine may be stalled. (If the cam senor is P0336
normal, the engine can re-start.)
• While the engine runs, there is nothing The timing chain and the belt does not turn P1345
abnormal with machine operation. smoothly but turn in reverse.
• After the engine is stalled, the re-start is
impossible.
Nothing special When starting: -10 °C (14 °F) (Start the engine P0113
although what state.)
When operating: 25 °C (77 °F) (Operate P0112
normally.)
Normal temperature: When starting, dark smoke When starting: -20 °C (-4 °F) (Start the engine P0118
may occur and engine combustion sound may be although what state.)
become loud. When operating: 80 °C (176 °F) (Operate P0117
While warming up with fresh air in low normally.)
temperature: Rough idle, engine stall or while
smoke may be occur.
Dark smoke occurs. Boost pressure cannot be corrected. P0238
P0237
There is influence to exhaust gas. 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
Dark smoke occurs at high altitude. Atmospheric pressure 80 kPa (0.8 kgf/cm , 12 P0108
psi) (2000 m above the sea)
P0107
Nothing special. When starting: -20 °C (-4 °F) (Start the engine P0183
although what state.)
When operating: 70 °C (158 °F) (Operate P0182
normally.)
T5-6-25
TROUBLESHOOTING/ Troubleshooting A
Fault
Trouble Cause
Code
157-3 Abnormal Common Rail Pressure Sensor Voltage at the common rail pressure sensor is beyond
(Abnormal High Voltage) 4.5 V.
157-3 Abnormal Common Rail Pressure Sensor Voltage at the common rail pressure sensor is below
(Abnormal Low Voltage) 0.7 V.
100-4 Abnormal Engine Oil Pressure Sensor Voltage at the engine oil pressure sensor is beyond
(Abnormal High Voltage) 4.85 V.
100-3 Abnormal Engine Oil Pressure Sensor Voltage at the engine oil pressure sensor is below 0.1
(Abnormal Low Voltage) V.
105-3 Abnormal Boost Temperature Sensor Voltage at the boost temperature sensor is beyond
(Abnormal High Voltage) 4.95 V over 5 minutes after the engine starts or when
coolant temperature is beyond 50 °C (122 °F).
105-4 Abnormal Boost Temperature Sensor Voltage at the boost temperature sensor is below 0.1
(Abnormal Low Voltage) V.
T5-6-26
TROUBLESHOOTING/ Troubleshooting A
P1112
T5-6-27
TROUBLESHOOTING/ Troubleshooting A
T5-6-28
TROUBLESHOOTING/ Troubleshooting A
Influence to Engine
Fault Operating Rank
Trouble Performance Remedy
Code (Current State)
(Presumption)
105-3 Abnormal Boost Temperature Sensor No output power
○
(Abnormal High Voltage) change
105-4 Abnormal Boost Temperature Sensor
○
(Abnormal Low Voltage)
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.
T5-6-29
TROUBLESHOOTING/ Troubleshooting A
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.
T5-6-30
TROUBLESHOOTING/ Troubleshooting A
Vibration of the engine is large, rough idle, #1 injector cannot be controlled. P0201
output power decrease, faulty increasing of → Stop drive pulse output of #1 injector.
rotation speed, output power decrease.
#2 injector cannot be controlled. P0202
→ Stop drive pulse output of #2 injector.
#3 injector cannot be controlled. P0203
→ Stop drive pulse output of #3 injector.
#4 injector cannot be controlled. P0204
→ Stop drive pulse output of #4 injector.
T5-6-31
TROUBLESHOOTING/ Troubleshooting A
Fuel System
157-0 Abnormal Common Rail Pressure Common rail pressure is beyond 185 MPa.
(First Stage)
157-0 Abnormal Common Rail Pressure The first stage “Abnormal common rail pressure” is approved
(Second Stage) common rail pressure is beyond 190 MPa.
157-2 Abnormal Common Rail Pressure When duty factor to the suction control valve is 40 % or more,
3
(Pump Over-Pressure) 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
1239-1 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.
T5-6-32
TROUBLESHOOTING/ Troubleshooting A
Vibration of the engine may be large, rough idle, Prevention the injection system from damage P0088
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.
Vibration of the engine may be large, rough idle, Prevention the injection system (pump) from P0089
output power decrease may occur, faulty damage
increasing of rotation speed, dark smoke may (Protect the rail pressure sensor by
occur, output power may be too large. over-pressure)
Output power decrease. Rail pressure is beyond the allowable pressure. P1095
Vibration of the engine may be large, rough idle, Fuel leakage is too much. P1093
output power decrease may occur, faulty Difference between target rail pressure and actual
increasing of rotation speed, dark smoke may rail pressure is larger than the specification.
occur, output power may be too large. (Large deflection)
Vibration of the engine may be large, rough idle, Fuel leakage is too much. P0087
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.
T5-6-33
TROUBLESHOOTING/ Troubleshooting A
Operating Rank
Influence to Engine (Current)
Fault
Trouble Performance Remedy
Code
(Presumption) A B C D
157-0 Abnormal Common Rail Pressure (First Output power
○
Stage) decrease: 50%
157-0 Abnormal Common Rail Pressure Output power
○
(Second Stage) decrease: 50%
157-2 Abnormal Common Rail Pressure Output power
○
(Pump Over-Pressure) decrease: 50%
633-7 Pressure Limiter Open Output power
○
decrease: 50%
1240-1 No Pressure to Pump (Fuel Leakage) Output power ○
1239-1 No Pressure to Pump (Fuel Leakage) decrease: 50% ○
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
TROUBLESHOOTING/ Troubleshooting A
(Blank)
T5-6-35
TROUBLESHOOTING/ Troubleshooting A
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
P1625
Electrical power is kept supplying to the Nothing
machine.
T5-6-37
TROUBLESHOOTING/ Troubleshooting A
Operating Rank
Influence to Engine (Current)
Fault
Trouble Performance Remedy
Code
(Presumption) A B C D
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
TROUBLESHOOTING/ Troubleshooting A
(Blank)
T5-6-39
TROUBLESHOOTING/ Troubleshooting A
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.
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.
T5-6-40
TROUBLESHOOTING/ Troubleshooting A
Output power decrease, dark smoke occurs. All analogue sensor cannot be used. P1630
Output power decrease. CPU is broken. P0606
There is no influence when operating the Data cannot be written to EEPROM. P1631
machine.
No backup. ← P1632
T5-6-41
TROUBLESHOOTING/ Troubleshooting A
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
TROUBLESHOOTING/ Troubleshooting A
(Blank)
T5-6-43
TROUBLESHOOTING / Troubleshooting A
Communication System
Fault Code Trouble Cause
639-2 Abnormal CAN Bus Line Detect the Bus Line OFF
639-3 Abnormal CAN Time Out In case the CAN data reception is impossible for
predetermined time.
T5-6-44
TROUBLESHOOTING / Troubleshooting A
U2106
T5-6-45
TROUBLESHOOTING / Troubleshooting A
T5-6-46
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-6-47
TROUBLESHOOTING / Troubleshooting A
ICF FAULT CODE LIST
14000-2 Abnormal CAN Data cannot be received Check for CAN communication bus line.
Communication due to the noise on the
CAN bus line.
14001-2 Flash Memory: The internal memory is After initializing the information C/U by using Dr.
Read / Write Error abnormal when the key ZX, retry in the troubleshooting.
switch is ON. 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.
14002-2 External RAM: The internal memory is After initializing the information C/U by using Dr.
Read / Write Error abnormal when the key ZX, retry in the troubleshooting.
switch is ON. If the error code is displayed after retrial, ICF may
be broken.
Replace ICF.
NOTE: When initializing the information C/U,
all stored data is deleted.
14003-2 EEPROM: Sum The internal memory is Retry in the troubleshooting by using Dr. ZX.
Check Error abnormal when the key If the error code is displayed after retrial, ICF may
switch is ON. be broken.
Replace ICF.
14006-2 Satellite Communication to the Check for the items below.
Communication satellite terminal cannot be 1. Check if the communication line is abnormal.
Terminal: done over 30 seconds. 2. Check if the electrical power source of
Communication communication terminal is abnormal.
Error • Electrical power source
• Fuses
3. Check if the satellite terminal is broken.
14008-2 Abnormal Internal The internal memory is Retry in the troubleshooting by using Dr. ZX.
RAM abnormal when the key If the error code is displayed after retrial, ICF may
switch is ON. be broken.
Replace ICF.
T5-6-48
TROUBLESHOOTING / Troubleshooting A
SATELLITE TERMINAL FAULT CODE LIST
13303-2 Abnormal Thermistor Thermistor temperature is 85 °C Cool the monitor unit and so on
Temperature (185 °F) or more. until the internal temperature of
monitor unit is less than 85 °C
(185 °F).
13304-2 Abnormal REG Input H Level REG input level is H. Refer to the Troubleshooting flow
chart.
13306-2 Abnormal EEPROM EEPROM reading failure occurs. Replace the monitor unit when
displaying the fault code after
retrial.
13308-2 Abnormal CAN Communication Bus OFF occurs 5 times or Refer to CAN Harness Check
more. (T5-6-73 to 104).
13310-3 Shorted Circuit in Coolant Input 105±30 Ω or less continues Check coolant temperature
Temperature Sensor for 60 seconds. sensor and harness.
13311-3 Shorted Circuit in Fuel Level Input 3±1 Ω or less continues for Check fuel level sensor and
Sensor 60 seconds. harness.
13311-4 Open Circuit in Fuel Level Input 135±20 Ω or less continues Check fuel level sensor and
Sensor for 60 seconds. harness.
T5-6-49
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE LIST
T5-6-50
TROUBLESHOOTING / Troubleshooting A
T5-6-51
TROUBLESHOOTING / Troubleshooting A
Pilot Pressure Failure
Fault Code Trouble Cause Influenced Control
15510-3 Abnormal Assist Stroke 1 Sensor Voltage: more than 4.65 V Assist Control
High Voltage
15510-4 Abnormal Assist Stroke 1 Sensor Voltage: less than 0.35 V Assist Control
Low Voltage
15511-3 Abnormal Assist Stroke 2 Sensor Voltage: more than 4.65 V Assist Control
High Voltage
15511-4 Abnormal Assist Stroke 2 Sensor Voltage: less than 0.35 V Assist Control
Low Voltage
15514-3 Abnormal Positioning/Auxiliary Voltage: more than 4.55 V • Auxiliary Selection Switch: ON
Stroke 1 Sensor High Voltage Auxiliary Control
• Auxiliary Selection Switch: OFF
Positioning Control
15514-4 Abnormal Positioning/Auxiliary Voltage: less than 0.45 V • Auxiliary Selection Switch: ON
Stroke 1 Sensor Low Voltage Auxiliary Control
• Auxiliary Selection Switch: OFF
Positioning Control
15515-3 Abnormal Positioning/Auxiliary Voltage: more than 4.85 V • Auxiliary Selection Switch: ON
Stroke 2 Sensor High Voltage Auxiliary Control
• Auxiliary Selection Switch: OFF
Positioning Control
15515-4 Abnormal Positioning/Auxiliary Voltage: less than 0.15 V • Auxiliary Selection Switch: ON
Stroke 2 Sensor Low Voltage Auxiliary Control
• Auxiliary Selection Switch: OFF
Positioning Control
T5-6-52
TROUBLESHOOTING / Troubleshooting A
Remedy by
Symptoms in Machine Operation When Trouble Occurs. Remedy
Dr. ZX
• Stop assist operation. Retrial B Check the harness.
• Display "Abnormal assist operation signal warning" on the monitor unit.
• Stop assist operation. Retrial B Check the harness.
• Display "Abnormal assist operation signal warning" on the monitor unit.
• Stop assist operation. Retrial B Check the harness.
• Display "Abnormal assist operation signal warning" on the monitor unit.
• Stop assist operation. Retrial B Check the harness.
• Display "Abnormal assist operation signal warning" on the monitor unit.
• If positioning and auxiliary stroke 2 is neutral, positioning and auxiliary Retrial B Check the harness.
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 B Check the harness.
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 B Check the harness.
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 B Check the harness.
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
TROUBLESHOOTING / Troubleshooting A
15516-4 Abnormal Positioning/Assist Pi Pressure Voltage: less than 0.40 V • Positioning Control
Sensor Low Voltage • Assist Control
15518-3 Abnormal Outrigger/Blade Stroke 1 Voltage: more than 4.55 V Outrigger/Blade Control
Sensor High Voltage
15518-4 Abnormal Outrigger/Blade Stroke 1 Voltage: less than 0.45 V Outrigger/Blade Control
Sensor Low Voltage
15519-3 Abnormal Outrigger/Blade Stroke 2 Voltage: more than 4.85 V Outrigger/Blade Control
Sensor High Voltage
15519-4 Abnormal Outrigger/Blade Stroke 2 Voltage: less than 0.15 V. Outrigger/Blade Control
Sensor Low Voltage
T5-6-54
TROUBLESHOOTING / Troubleshooting A
Remedy by
Symptoms in Machine Operation When Trouble Occurs. Remedy
Dr. ZX
• All proportional solenoid valve outputs stop by shutting off pilot pressure. Retrial B Check the harness.
• Display "Abnormal electric lever solenoid valve output warning" on the
monitor unit.
• Buzzer (continuous sound) sounds.
• All proportional solenoid valve outputs stop by shutting off pilot pressure. Retrial B Check the harness.
• Display "Abnormal electric lever solenoid valve output warning" on the
monitor unit.
• Buzzer (continuous sound) sounds.
• All proportional solenoid valve outputs stop by shutting off pilot pressure. Retrial B Check the harness.
• Display "Abnormal electric lever solenoid valve output warning" on the
monitor unit.
• Buzzer (continuous sound) sounds.
• All proportional solenoid valve outputs stop by shutting off pilot pressure. Retrial B Check the harness.
• Display "Abnormal electric lever solenoid valve output warning" on the
monitor unit.
• Buzzer (continuous sound) sounds.
• If outrigger/blade stroke 2 is neutral, Retrial B Check the harness.
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.
• If outrigger/blade stroke 2 is neutral, Retrial B Check the harness.
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.
• If outrigger/blade stroke 1 is neutral, Retrial B Check the harness.
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.
• If outrigger/blade stroke 1 is neutral, Retrial B Check the harness.
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
TROUBLESHOOTING / Troubleshooting A
Proportional Solenoid Valve Control Failure
Fault Code Trouble Cause Influenced Control
15570-2 Abnormal When meeting the following conditions, • Outrigger/Blade Control
Outrigger/Blade/Auxiliary outrigger/blade/auxiliary pilot pressure is more • Auxiliary Control
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
15571-2 Abnormal When meeting either of the following • Outrigger/Blade Control
Outrigger/Blade/Auxiliary conditions, outrigger/blade/auxiliary pilot • Auxiliary Control
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
15572-2 Abnormal When meeting the following conditions, • Positioning Control
Positioning/Assist Neutral positioning/assist pilot pressure is more than • Assist Control
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
15573-2 Abnormal When meeting either of the following • Positioning Control
Positioning/Assist conditions, positioning/assist pilot pressure is • Assist Control
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
15574-3 Abnormal Positioning/auxiliary stroke 1 +• Positioning Control
Positioning/Auxiliary Sum positioning/auxiliary stroke 2 is more than 9.0 • Auxiliary Control
Signal Critical High V
Voltage
15574-4 Abnormal Positioning/auxiliary stroke 1 + • Positioning Control
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
15575-4 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
T5-6-56
TROUBLESHOOTING / Troubleshooting A
Remedy by
Symptoms in Machine Operation When Trouble Occurs. Remedy
Dr. ZX
• All proportional solenoid valve outputs stop by shutting off pilot pressure. Retrial B Check the harness.
• Display "Abnormal electric lever solenoid valve output warning" on the
monitor unit.
• Buzzer (continuous sound) sounds.
• Outrigger/blade operation is active with pressure decreasing by 40%. Retrial B Check the harness.
• Positioning and auxiliary 1 operation is active with pressure decreasing by 40%.
• All proportional solenoid valve outputs stop by shutting off pilot pressure. Retrial B Check the harness.
• Display "Abnormal electric lever solenoid valve output warning" on the monitor
unit.
• Buzzer (continuous sound) sounds.
• Positioning 1 operation is active with pressure decreasing by 40%. Retrial B Check the harness.
• Assist 1 operation is active with pressure decreasing by 40%.
T5-6-57
TROUBLESHOOTING / Troubleshooting A
T5-6-58
TROUBLESHOOTING / Troubleshooting A
Remedy by
Symptoms in Machine Operation When Trouble Occurs. Remedy
Dr. ZX
• If positioning and auxiliary stroke 2 is not neutral, positioning operation is active Retrial B Check the harness.
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.
• If positioning and auxiliary stroke 2 is not neutral, positioning operation is active Retrial B Check the harness.
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.
• If outrigger/blade stroke 2 is not neutral, outrigger/blade operation is active with Retrial B Check the harness.
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.
• If outrigger/blade stroke 2 is not neutral, outrigger/blade operation is active with Retrial B Check the harness.
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.
• Display "Abnormal attachment operation signal warning" on the monitor unit. Retrial B Check the harness.
• Buzzer (intermittent sound) sounds.
• Display "Abnormal outrigger/blade operation signal warning" on the monitor unit. Retrial B Check the harness.
• Buzzer (intermittent sound) sounds.
• Display "Abnormal assist operation signal warning" on the monitor unit. Retrial B 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
15521-2 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
15521-3 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 Control
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
15522-3 Abnormal Feedback Value High Current of Current: Higher than 920 Outrigger/Blade Control
Outrigger/Blade 1 Proportional Valve mA
15522-4 Abnormal Feedback Value Low Current of Current: Less than 56 mA Outrigger/Blade Control
Outrigger/Blade 1 Proportional Valve
15523-2 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
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
15524-2 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
15524-3 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 • Positioning Control
Swing Parking Release Proportional Valve • Assist 1 Control
• Assist Switch Control
T5-6-60
TROUBLESHOOTING / Troubleshooting A
T5-6-61
TROUBLESHOOTING / Troubleshooting A
T5-6-62
TROUBLESHOOTING / Troubleshooting A
T5-6-63
TROUBLESHOOTING / Troubleshooting A
T5-6-64
TROUBLESHOOTING / Troubleshooting A
T5-6-65
TROUBLESHOOTING / Troubleshooting A
15567-2 Unreceived ATT 3 and 4 Optional Unreceived for 10 sec • Pulverizer Control
Selection • Crusher Control
Sent from: MC
15568-2 Unreceived ATT 5 Optional Selection Unreceived for 10 sec • Pulverizer Control
Sent from: MC • Crusher Control
15577-2 Unreceived Actual Engine Speed Unreceived for 10 sec All Electric Lever Control
Sent from: ECM
T5-6-66
TROUBLESHOOTING / Troubleshooting A
Remedy by
Symptoms in Machine Operation When Trouble Occurs Remedy
Dr. ZX
Work mode control is inactive (Always digging mode). Retrial B Check the harness.
• Secondary pilot relief control solenoid valve: Always Retrial B Check the harness.
OFF
• Selector valve control solenoid valve: Always OFF
• Accumulator control solenoid valve: Always OFF
• Secondary pilot relief control solenoid valve: Always Retrial B Check the harness.
OFF
• Selector valve control solenoid valve: Always OFF
• Accumulator control solenoid valve: Always OFF
• Secondary pilot relief control solenoid valve: Always Retrial B Check the harness.
OFF
• Selector valve control solenoid valve: Always OFF
• Accumulator control solenoid valve: Always OFF
• Electric lever: Engine stop control Retrial B Check the harness.
T5-6-67
TROUBLESHOOTING / Troubleshooting A
STEERING COLUMN MONITOR FAULT CODE
Symptoms in
Influenced Machine Remedy
Fault Code Trouble Cause Remedy
Control Operation When by Dr. ZX
Trouble Occurs.
16000-2 Abnormal CAN Faulty steering - - Retrial B Check the CAN
communication column monitor harness.
Faulty CAN harness
T5-6-68
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-6-69
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODES 11000 TO 11002
T5-6-70
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11003
T1V1-05-07-101
T1V1-05-07-102
T5-6-71
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11004
Dr.ZX
Satellite Terminal
(Optional)
Monitor Unit
ICF
Option MC
Controller
CAN Harness
Steering
Column ECM
Monitor
TCJB-02-01-001
T5-6-72
TROUBLESHOOTING / Troubleshooting A
CAN HARNESS CHECK
Normal.
NO
T5-6-73
TROUBLESHOOTING / Troubleshooting A
YES
YES Check for continuity in
CAN harness between
MC and option con-
troller. Open circuit in CAN
harness between
Check for continuity in · Key switch: OFF MC and option con-
NO
CAN harness between · Refer to CAN Har- troller.
YES ness Continuity
MC and steering col-
umn monitor. Check on T5-6-82.
T5-6-74
TROUBLESHOOTING / Troubleshooting A
Shorted circuit in
CAN harness be-
YES tween ground circuit
and CAN circuit.
Disconnect all con-
nectors of MC, ICF,
ECM, monitor unit, Shorted circuit in
steering column CAN harness be-
YES
monitor and option tween electric power
controller. circuit and CAN cir-
Check for continuity cuit.
Check for continuity
between power cir-
between ground cir-
cuit and CAN circuit
cuit and CAN circuit NO Shorted circuit in
of each controller. of MC, ICF, ECM,
Check for continuity YES CAN harness be-
monitor unit, steering
column monitor and between key signal tween electric
· Key switch: OFF option controller. circuit and CAN cir- key-signal circuit and
· Refer to Discontinuity cuit of MC, ICF, CAN circuit.
Check between CAN · Key switch: OFF NO ECM, monitor unit,
Circuit and Ground · Refer to Discontinuity steering column
Check between CAN Check for continuity
Circuit on T5-6-84 to monitor and option
Circuit and Power between High and
91. controller.
Low sides of CAN To B
Circuit on T5-6-92 to NO
99. · Key switch: OFF harness.
· Refer to Discontinuity
Check between CAN · Key switch: OFF
Circuit and Key Signal · Refer to Discontinu-
Circuit on T5-6-100 to ity Check in CAN
103. Harness on
T5-6-104.
T5-6-75
TROUBLESHOOTING / Troubleshooting A
Connect all MC
connectors except
connector MC-C.
Check if resistance
NO between terminals YES Faulty ICF.
#C4 and #C15 of
harness end of con-
nector MC-C is within
Connect MC con-
60±10 Ω.
nector.
· Key switch: OFF Disconnect connec-
tor ICF-C in ICF.
NO Check if resistance YES Faulty ECM.
between terminals
#C5 and #C11 of Connect ICF con-
harness end is within nector.
60±10 Ω. Disconnect ECM
connector.
Check if resistance Connect ECM con-
· Key switch: OFF NO nector.
Connector between terminals
#18 and #37 of har- Disconnect connec-
MC Connector MC-C tor monitor-B in
ness end is within
(Harness end) 120±10 Ω. monitor unit.
#C4 #C15 NO Check if resistance
· Key switch: OFF between terminals
C1 C10
#B6 and #B7 of har-
ness end is within
120±10 Ω.
#C11 T1V1-05-04-002
Monitor Unit Connector Monitor-B
(Harness end)
ECM Connector
#B7 #B6
(Harness end) #18 #37
T1GR-05-04-002 T183-05-04-013
T5-6-76
TROUBLESHOOTING / Troubleshooting A
YES
Faulty monitor unit.
YES
Faulty steering column
Connect monitor unit monitor.
connector.
Disconnect connector 2
in steering column
NO monitor.
Connect steering col-
Check if resistance be- YES
umn monitor connector. Faulty option control-
tween terminals #1 and
Disconnect connector C ler.
#9 of harness end is
in option controller.
within 60±10 Ω.
Check if resistance be-
NO tween terminals #C10
· Key switch: OFF
and #C22 of harness
end is within 60±10 Ω. Failure in any control-
NO
ler.
· Key switch: OFF
C1 C10
#9 #C10
#1 #C22
TCJB-05-06-001
C23 C31
T5-6-77
TROUBLESHOOTING / Troubleshooting A
CAN Harness Continuity Check
Connector
MC Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
ECM Connector
(Harness end)
#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 (har-
ness end) of connector MC-C in MC and terminal
#C5 (harness end) of connector ICF-C in ICF.
Connector
MC Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
T1V1-05-04-002
#C11
T5-6-79
TROUBLESHOOTING / Troubleshooting A
• Between MC and Monitor Unit
• CAN Harness (High Side)
Check for continuity between terminal #C4 (har-
ness end) of connector MC-C in MC and terminal
#B7 (harness end) of connector monitor-B in the
monitor unit.
Connector
MC Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
#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 (har-
ness end) of connector MC-C in MC and terminal
#1 (harness end) of connector 2 in the steering
column monitor.
Connector
MC Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
#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 (har-
ness end) of connector MC-C in MC and terminal
#C10 (harness end) of connector C in the option
controller.
Connector
MC Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
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 Connector
Connector MC-C
IMPORTANT: Before continuity check, turn the key (Harness end)
switch OFF.
#C4
In case of continuity, the circuit be- C1 C10
tween CAN circuit and ground cir-
cuit is shorted.
In case of discontinuity, the circuit is
normal. C23 C31
• MC
Between CAN Circuit (High Side) and Ground Cir- Connector MC-A
cuit (Harness end)
• Check for continuity between terminal #C4 (har- #A2
ness end) of connector MC-C and terminal #A2
(harness end) of connector MC-A.
#B18
T183-05-04-021
T5-6-84
TROUBLESHOOTING / Troubleshooting A
• MC
Between CAN Circuit (Low Side) and Ground Circuit Connector
• Check for continuity between terminal #C15 Connector MC-C
(harness end) of connector MC-C and terminal (Harness end)
#A2 (harness end) of connector MC-A.
#C15
• Check for continuity between terminal #C15 C1 C10
(harness end) of connector MC-C and terminal
#A13 (harness end) of connector MC-A.
#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 Cir- ECM Connector
cuit (Harness end)
• Check for continuity between terminals #18 and #18 #43
#1 (harness end).
#4
#4 (harness end).
• ECM
Between CAN Circuit (Low Side) and Ground Circuit
• Check for continuity between terminals #37 and
#1 (harness end).
#3
• Check for continuity between terminals #37 and
#43 (harness end).
T1GR-05-04-002
• Check for continuity between terminals #37 and #62 #1
#62 (harness end).
T5-6-86
TROUBLESHOOTING / Troubleshooting A
• ICF
Between CAN Circuit (High Side) and Ground Cir- ICF Connector ICF-C
cuit (Harness end) #C5
• Check for continuity between terminals #C5 and
#C14 (harness end) of connector ICF-C.
• ICF
Between CAN Circuit (Low Side) and Ground Circuit ICF Connector ICF-C
• Check for continuity between terminals #C11 and (Harness end)
#C14 (harness end) of connector ICF-C.
• Monitor Unit
Between CAN Circuit (High Side) and Ground Circuit Monitor Unit Connector Monitor-B
• Check for continuity between terminals #B7 and (Harness end)
#B11 (harness end) of connector monitor unit-B.
#B7
#B6
T183-05-04-013
#B11
T5-6-87
TROUBLESHOOTING / Troubleshooting A
• Steering Column Monitor
Between CAN Circuit (High Side) and Ground Cir- Steering Column Monitor Connector 1
cuit (Harness end)
• Check for continuity between terminal #1 (har-
ness end) of connector 2 and terminal #1 (har-
ness end) of connector 1.
#7
T5-6-88
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-6-89
TROUBLESHOOTING / Troubleshooting A
• Option Controller
Between CAN Circuit (High Side) and Ground Cir- Connector
cuit Connector C
• Check for continuity between terminal #C10 (Harness end)
(harness end) of connector C and terminal #A2
(harness end) of connector A. C1 C10
#C10
• Check for continuity between terminal #C10
(harness end) of connector C and terminal #A13
(harness end) of connector A. C23 C31
#B25
#B18
T183-05-04-021
T5-6-90
TROUBLESHOOTING / Troubleshooting A
• Option Controller
Between CAN Circuit (Low Side) and Ground Circuit Connector
• Check for continuity between terminal #C22 Connector C
(harness end) of connector C and terminal #A2 (Harness end)
(harness end) of connector A.
C1 C10
• Check for continuity between terminal #C22
(harness end) of connector C and terminal #A13 #C22
(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.
#B25
#B18
T183-05-04-021
T5-6-91
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Power Circuit Connector
Connector MC-C
IMPORTANT: Before continuity check, turn the key (Harness end)
switch OFF. #C4
In case of continuity, the circuit be- C1 C10
tween CAN circuit and power circuit
is shorted.
In case of discontinuity, the circuit is
normal. C23 C31
• MC
Between CAN Circuit (High Side) and Power Circuit Connector MC-A
• Check for continuity between terminal #C4 (har- (Harness end)
ness end) of connector MC-C and terminal #A1
(harness end) of connector MC-A. #A1
#B17
T183-05-04-021
T5-6-92
TROUBLESHOOTING / Troubleshooting A
• MC
Between CAN Circuit (Low Side) and Power Circuit Connector
• Check for continuity between terminal #C15 Connector MC-C
(harness end) of connector MC-C and terminal (Harness end)
#A1 (harness end) of connector MC-A. #C15
C1 C10
• Check for continuity between terminal #C15
(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. Connector MC-A
(Harness end)
• Check for continuity between terminal #C15
(harness end) of connector MC-C and terminal #A1
#B17 (harness end) of connector MC-B.
#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 ECM Connector
• Check for continuity between terminals #18 and (Harness end)
#2 (harness end). #18 #5
• ECM #2
T1GR-05-04-002
• ICF
Between CAN Circuit (High Side) and Power Circuit
• Check for continuity between terminals #C5 and #2
T1GR-05-04-002
#C1
T1V1-05-04-002
#C11
T5-6-94
TROUBLESHOOTING / Troubleshooting A
• Monitor Unit
Between CAN Circuit (High Side) and Power Circuit Monitor Unit Connector Monitor-B
• Check for continuity between terminal #B7 (har- (Harness end)
ness end) of connector monitor-B and terminal
#A16 (harness end) of connector monitor-A. #B7
T183-05-04-013
• Monitor Unit
Between CAN Circuit (Low Side) and Power Circuit T183-05-05-001
#B6
T183-05-04-013
T183-05-05-001
#A16
T5-6-95
TROUBLESHOOTING / Troubleshooting A
• Steering Column Monitor
Between CAN Circuit (High Side) and Power Circuit Steering Column Monitor Connector 2
• Check for continuity between terminal #1 (har- (Harness end)
ness end) of connector 2 and terminal #6 (har-
ness end) of connector 1.
#12
#6
• Steering Column Monitor TCJB-05-06-002
TCJB-05-06-001
#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 Connector
• Check for continuity between terminal #C10 Connector C
(harness end) of connector C and terminal #A1 (Harness end)
(harness end) of connector A.
C1 C10
• Check for continuity between terminal #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.
Connector A
• Check for continuity between terminal #C10 (Harness end)
(harness end) of connector C and terminal #B17
(harness end) of connector B. #A1
Connector B
(Harness end)
#B7
#B17
#B24 T183-05-04-021
T5-6-98
TROUBLESHOOTING / Troubleshooting A
• Option Controller
Between CAN Circuit (Low Side) and Power Circuit Connector
• Check for continuity between terminal #C22 Connector C
(harness end) of connector C and terminal #A1 (Harness end)
(harness end) of connector A.
C1 C10
• Check for continuity between terminal #C22
(harness end) of connector C and terminal #A12 #C22
(harness end) of connector A.
C23 C31
• Check for continuity between terminal #C22
(harness end) of connector C and terminal #B7
(harness end) of connector B. Connector A
(Harness end)
• Check for continuity between terminal #C22
(harness end) of connector C and terminal #B17
(harness end) of connector B. #A1
Connector B
(Harness end)
#B7
#B17
#B24 T183-05-04-021
T5-6-99
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Key Signal Circuit Connector
Connector MC-C
IMPORTANT: Before continuity check, turn the key (Harness end)
switch OFF. #C4
In case of continuity, the circuit be- C1 C10
tween CAN circuit and key signal
circuit is shorted.
In case of discontinuity, the circuit is
normal. C23 C31
• MC
Between CAN Circuit (High Side) and Key Signal Connector MC-B
Circuit (Harness end)
• Check for continuity between terminal #C4 (har- #B16
ness end) of connector MC-C and terminal #B16
(harness end) of connector MC-B.
T183-05-04-021
• MC Connector
Between CAN Circuit (Low Side) and Key Signal Connector MC-C
Circuit (Harness end)
• Check for continuity between terminal #C15 #C15
(harness end) of connector MC-C and terminal C1 C10
#B16 (harness end) of connector MC-B.
C23 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 ECM Connector
Circuit (Harness end)
#18 #24
• Check for continuity between terminals #18 and
#24 (harness end) of connector.
T1GR-05-04-002
T1GR-05-04-002
• ICF
Between CAN Circuit (High Side) and Key Signal ICF Connector ICF-C
Circuit (Harness end) #C5
• Check for continuity between terminals #C5 and
#C7 (harness end) of connector ICF-C. #C7
T1V1-05-04-002
• ICF
Between CAN Circuit (Low Side) and Key Signal ICF Connector ICF-C
Circuit (Harness end)
• Check for continuity between terminals #C11 and
#C7
#C7 (harness end) of connector ICF-C.
T1V1-05-04-002
#C11
T5-6-101
TROUBLESHOOTING / Troubleshooting A
• Monitor Unit
Between CAN Circuit (High Side) and Key Signal Monitor Unit Connector Monitor-B
Circuit (Harness end)
• Check for continuity between terminal #B7 (har-
ness end) of connector monitor-B and terminal #B7
#A7 (harness end) of connector monitor-A.
T183-05-04-013
#A7
T183-05-05-001
• Monitor Unit
Between CAN Circuit (Low Side) and Key Signal Monitor Unit Connector Monitor-B
Circuit (Harness end)
• Check for continuity between terminal #B6 (har-
ness end) of connector monitor-B and terminal #B6
#A7 (harness end) of connector monitor-A.
T183-05-04-013
#A7
T183-05-05-001
T5-6-102
TROUBLESHOOTING / Troubleshooting A
• Option Controller
Between CAN Circuit (High Side) and Key Signal Connector
Circuit Connector C
• Check for continuity between terminal #C10 (Harness end)
(harness end) of connector C and terminal #B16
(harness end) of connector B. C1 C10
#C10
C23 C31
Connector B
(Harness end)
#B16
T183-05-04-021
C23 C31
Connector B
(Harness end)
#B16
T183-05-04-021
T5-6-103
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check in CAN Harness
#1
TCJB-05-06-001
#C22
C23 C31
T1V1-05-04-002
#C11
T5-6-104
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11100
T5-6-105
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11101
C23 C31
Switch Panel
#3 #2 #1
T5-6-106
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11200
Disconnect connector
MC-D of MC. Open circuit in har-
Check for continuity be- ness between MC
NO
tween terminal #D10 and pump 1 delivery
(harness end) of con- pressure sensor.
YES nector and terminal #2
(harness end) of con-
nector of pump 1 delivery
Disconnect connector pressure sensor. To A
of pump 1 delivery YES
pressure sensor. Check if voltage be-
NO Check if voltage be- Open circuit in har-
tween terminal #1 (har-
tween terminals #1 and ness end) of connector ness between MC
#3 (harness end) of YES and pump 1 delivery
of pump 1 delivery
connector is 5±0.5 V. pressure sensor and pressure sensor
Switch pump 1 delivery (terminal #3).
pressure sensor with machine becomes
pump 2 delivery pres- NO specification.
sure sensor and retry. · Key switch: ON Open circuit in har-
Check if fault code is ness between MC
switched. · Key switch: ON NO and pump 1 delivery
· Specification: 0.25 V or more, pressure sensor
4.5 V or less (terminal #1).
Connector (Harness end of connector viewed from the open end side)
#D10
3 2 1
T183-05-04-009
T5-6-107
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11202
Disconnect connector
MC-D of MC.
Open circuit in har-
Check for continuity
NO ness between MC
between terminal #D4
and pump 2 delivery
(harness end) of con-
pressure sensor.
YES nector and terminal #2
(harness end) of con-
nector of pump 2 deliv-
ery pressure sensor. To A
Disconnect connector YES
NO of pump 2 delivery Check if voltage be- Open circuit in har-
pressure sensor. tween terminal #1 ness between MC
Check if the voltage (harness end) of YES and pump 2 delivery
between terminal #1 connector of pump 2 pressure sensor
and #3 (harness end) delivery pressure (terminal #3).
Switch pump 1 delivery of connector is 5±0.5 sensor and machine
pressure sensor with V. NO becomes specifica- Open circuit in har-
pump 2 delivery pres- tion. ness between MC
sure sensor and retry. · Key switch: ON
NO and pump 2 delivery
Check if fault code is
· Key switch: ON pressure sensor
switched.
· Specification: 0.25 V or more, (terminal #1).
4.5 V or less
Faulty pump 2 deliv-
YES ery pressure sensor.
#D4
3 2 1
T183-05-04-009
T5-6-108
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11203
Disconnect connector
MC-D of MC. Open circuit in har-
Check for continuity NO ness between MC
between terminal #D3 and pump 3 delivery
(harness end) of con- pressure sensor.
YES
nector and terminal #2
(harness end) of con-
Disconnect connector nector of pump 3 deliv- To A
of pump 3 delivery ery pressure sensor. YES
pressure sensor.
NO Check if voltage be- Check if voltage be- Open circuit in har-
tween terminals #1 and tween terminal #1 ness between MC
Switch pump 3 delivery (harness end) of con-
pressure sensor with #3 (harness end) of YES and pump 3 delivery
connector is 5±0.5 V. nector of pump 3 de- pressure sensor
pump 2 delivery pres- livery pressure sensor
sure sensor and retry. (terminal #3).
and machine becomes
Check if fault code is · Key switch: ON NO specification. Open circuit in har-
switched.
ness between MC
and pump 3 delivery
NO
· Key switch: ON pressure sensor
· Specification: 0.25 V or more, (terminal #1).
4.5 V or less
Faulty pump 3 deliv-
ery pressure sensor.
YES
Connector (Harness end of connector viewed from the open end side)
3 2 1
T183-05-04-009
T5-6-109
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11206
Disconnect connector
MC-D of MC. Open circuit in har-
Check for continuity NO ness between MC
between terminal #D11 and pump 1 control
(harness end) of con- pressure sensor.
YES nector and terminal #2
(harness end) of con-
Disconnect connector nector of pump 1 con-
of pump 1 control trol pressure sensor. To A
pressure sensor. YES
NO Check if voltage be- Check if voltage be- Open circuit in har-
tween terminals #1 and tween terminal #1 ness between MC
#3 (harness end) of (harness end) of YES and pump 1 control
connector is 5±0.5 V. connector of pump 1 pressure sensor
Switch pump 1 control control pressure (terminal #3).
pressure sensor with sensor and machine
pump 2 control pressure · Key switch: ON
NO becomes specifica- Open circuit in har-
sensor and retry. Check tion. ness between MC
if fault code is switched. and pump 1 control
NO pressure sensor
· Key switch: ON (Terminal #1).
· Specification: 0.25 V or more,
4.75 V or less
Faulty pump 1 control
YES pressure sensor.
1 2 3
#D11
T183-05-04-009
T5-6-110
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11208
Disconnect connector
MC-D of MC. Open circuit in har-
Check for continuity ness between MC
NO
between terminal #D14 and pump 2 control
(harness end) of con- pressure sensor.
YES nector and terminal #2
(harness end) of con-
Disconnect connector nector for pump 2 con- To A
of pump 2 control trol pressure sensor.
pressure sensor. YES
NO Check if voltage be- Check if voltage be- Open circuit in har-
Switch pump 1 control tween terminals #1 and ness between MC
tween terminal #1
pressure sensor with #3 (harness end) of YES and pump 2 control
(harness end) of
pump 2 control pressure connector is 5±0.5 V. pressure sensor
connector of pump 2
sensor and retry. Check control pressure (terminal #3).
if fault code is switched. · Key switch: ON sensor and machine
NO becomes specifica- Open circuit in har-
tion. ness between MC
and pump 2 control
NO pressure sensor
· Key switch: ON
· Specification: 0.25 V or more, (terminal #1).
4.75 V or less
Faulty pump 2 control
YES pressure sensor.
Connector (Harness end of connector viewed from the open end side)
#D14
1 2 3
T183-05-04-009
T5-6-111
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11301
Disconnect connector
MC-C of MC.
Check for continuity
between terminal #C13 Open circuit in har-
NO ness between MC
(harness end) of con-
nector and terminal #2 and pressure sensor.
YES (harness end) of con-
nector of pressure
sensor.
Disconnect connector To A
of pressure sensor. YES
Check if voltage be-
tween terminals #1 and
NO
#3 (harness end) of Check if voltage be-
connector is 5±0.5 V. tween terminal #1 Open circuit in har-
(harness end) of ness between MC
· Key switch: ON connector of pressure YES and pressure sensor
sensor and machine (terminal #3).
Switch pressure sensor becomes specifica-
with other pressure tion.
sensor and retry. Check NO Open circuit in har-
if fault code disappears.
ness between MC
and pressure sensor
· Key switch: ON NO
(terminal #1).
· Specification: 0.25 V or more,
4.75 V or less
Faulty pressure sen-
YES sor.
C23 C31
T5-6-112
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11302
Connector (Harness end of connector viewed from the open end side)
1 2 3
#D15
T183-05-04-009
T5-6-113
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11303
Connector (Harness end of connector viewed from the open end side)
1 2 3
C23 C31
T5-6-114
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11305
Connector (Harness end of connector viewed from the open end side)
C23 C31
T5-6-115
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11306
Connector (Harness end of connector viewed from the open end side)
C1 C10
1 2 3
#C11
C23 C31
T5-6-116
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11307
Disconnect connector
MC-C of MC. Open circuit in har-
Check for continuity NO ness between MC
between terminal #C12 and pressure sensor.
YES (harness end) of con-
nector and terminal #2
(harness end) of con-
Disconnect connector nector of pressure To A
of pressure sensor. sensor. YES
Check if voltage be-
tween terminal #1 and
NO
#3 (harness end) of
connector is 5±0.5 V.
Open circuit in har-
Check if voltage be-
· Key switch: ON YES ness between MC
tween terminal #1 and pressure sensor
(harness end) of con- (terminal #3).
nector of pressure
Switch pressure sensor NO sensor and machine
with other pressure becomes specification. Open circuit in har-
sensor and retry. Check ness between MC
if fault code disappears. NO and pressure sensor
· Key switch: ON
· Specification: 0.25 V or more, (terminal #1).
4.75 V or less
Faulty pressure sen-
YES sor.
Connector (Harness end of connector viewed from the open end side)
MC Connector MC-C Pressure Sensor (Front Attachment)
#C12
C1 C10
1 2 3
C23 C31
T5-6-117
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11310
Disconnect connector
MC-C of MC. Open circuit in har-
Check for continuity NO
ness between MC
between terminal #D12 and brake pressure
YES (harness end) of con- sensor.
nector and terminal #2
(harness end) of con-
Disconnect the connec- nector of brake pres- To A
tor of brake pressure sure sensor. YES
sensor. Check if voltage
NO between terminal #1
and #3 (harness end) Check if voltage be- Open circuit in har-
of connectoris 5±0.5 V. tween terminals #1 ness between MC
YES
(harness end) of con- and brake pressure
nector of brake pres- sensor (terminal #3).
· Key switch: ON sure sensor and ma-
Switch brake pressure
sensor with pump 1 de- NO chine becomes speci-
livery pressure sensor fication. Open circuit in har-
and retry. Check if fault ness between MC
NO and brake pressure
code is switched. · Key switch: ON sensor (terminal #1).
· Specification: 0.25 V or more,
4.5 V or less
Faulty brake pressure
YES sensor.
Connector (Harness end of connector viewed from the open end side)
#D12
3 2 1
T183-05-04-009
T5-6-118
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11311
Connector (Harness end of connector viewed from the open end side)
C1 C10
3 2 1
C23 C31
#C24
T5-6-119
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11400
#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
MC
Connector MC-A
#A19
#A30
T183-05-04-008
T1V1-05-04-003
T5-6-121
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11403
Switch connectors of
solenoid valve unit (SC) NO Faulty solenoid valve unit
(arm regeneration) and (SC) (arm regeneration).
YES other solenoid valve
unit (SF, SG or SI).
Check if fault code of Faulty MC.
switched solenoid valve
unit is displayed. 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
Open circuit in harness.
connector in solenoid
valve unit (SC) (arm NO
regeneration)
· Between terminal #A18
of connector MC-A in
MC and terminal #2 of
connector in solenoid
valve unit (SC) (arm
regeneration)
MC
Connector MC-A
#A24
#A18
T183-05-04-008
T1V1-05-04-003
T5-6-122
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11404
Connector MC-A of MC
#A4 #A8
T183-05-04-008
T1V1-05-04-003
T5-6-123
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11410
#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
MC Connector MC-A
T183-05-04-008
#A29 #A32
TCJB-05-06-004
T5-6-125
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11424
Switch connectors of
solenoid valve unit (SI) Faulty solenoid valve unit
NO
(axle lock selection) (SI) (axle lock selection).
and other solenoid
YES valve unit (SF, SC or
SG).
Check if fault code of Faulty MC.
switched solenoid valve YES
Check for continuity in unit is displayed.
harness between MC
and solenoid valve unit
(SI) (axle lock selection).
· Between terminal #A21
of connector MC-A in
MC and terminal #1 of
Open circuit in harness.
connector in solenoid
valve unit (SI) (axle lock NO
selection).
· Between terminal #A14
of connector MC-A in
MC and terminal #2 of
connector in solenoid
valve unit (SI) (axle lock
selection).
MC Connector MC-A
#A14
#A21 T183-05-04-008
T1V1-05-04-003
T5-6-126
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11425
Switch connectors of
solenoid valve unit (SF) NO Faulty solenoid valve unit
(Work Brake) and other (SF) (work brake).
YES solenoid valve unit (SC,
SG or SI).
Check if fault code of Faulty MC.
Check for continuity in switched solenoid valve
unit is displayed. YES
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
Open circuit in harness.
valve unit (SF) (work
brake). NO
· Between terminal #A15
of connector MC-A in
MC and terminal #2 of
connector in solenoid
valve unit (SF) (work
brake).
MC Connector MC-A
#A9
#A15
T183-05-04-008
T1V1-05-04-003
T5-6-127
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODES 11910 TO 11920
T5-6-128
TROUBLESHOOTING / Troubleshooting A
Connect terminals #1
YES Faulty MC.
and #2 (harness end)
of connector in
hydraulic oil
temperature sensor by Connect terminal #D6
YES using a clip. Open circuit in harness
(harness end) of YES between MC and
Disconnect connector connector MC-D in
MC-D from MC. hydraulic oil temperature
MC to machine. sensor (terminal #1).
Check for continuity Check for continuity
Disconnect connector of between terminals #D2
hydraulic oil temperature NO between terminals #2
and #D6 (harness end) (harness end) of
sensor. Open circuit in harness
of connector MC-D.
Check if resistance at connector in hydraulic between MC and
oil temperature NO hydraulic oil temperature
sensor end connector is
specification. sensor and machine. sensor (terminal #2).
· Specification: Refer to
the table below. Faulty hydraulic oil
NO temperature sensor.
Connector (Harness end of connector viewed from the open end side)
MC Connector MC-D
#D2
1 2
#D6 T183-05-04-009
T5-6-129
TROUBLESHOOTING / Troubleshooting A
ECM FAULT CODES 100 TO 190
Engine
Fault Code Troubleshooting
Fault Code Trouble
(TECH2) Manual
Reference Page
Abnormal Engine Oil Pressure Sensor (Abnormal Low
100-3 P0522 1E-393
Voltage)
Abnormal Engine Oil Pressure Sensor (Abnormal High
100-4 P0523 1E-399
Voltage)
102-3 Abnormal Boost Pressure Sensor (Abnormal Low Voltage) P0237 1E-331
102-4 Abnormal Boost Pressure Sensor (Abnormal High Voltage) P0238 1E-339
Abnormal Boost Temperature Sensor (Abnormal High 1E-450
105-3 P1113
Voltage)
105-4 Abnormal Boost Temperature Sensor (Abnormal Low Voltage) P1112 1E-443
Abnormal Atmospheric Pressure Sensor (Abnormal Low
108-3 P0107 1E-228
Voltage)
Abnormal Atmospheric Pressure Sensor (Abnormal High
108-4 P0108 1E-235
Voltage)
110-0 Overheating P1173 1E-456
Abnormal Coolant Temperature Sensor (Abnormal High
110-3 P0118 1E-261
Voltage)
Abnormal Coolant Temperature Sensor (Abnormal Low
110-4 P0117 1E-255
Voltage)
157-0 Abnormal Common Rail Pressure (First stage) P0088 1E-212
157-0 Abnormal Common Rail Pressure (Second stage) P0088 1E-212
157-2 Abnormal Common Rail Pressure (Pump Over-Pressure) P0089 1E-217
Abnormal Common Rail Pressure Sensor (Abnormal High
157-3 P0193 1E-287
Voltage)
Abnormal Common Rail Pressure Sensor (Abnormal Low
157-4 P0192 1E-281
Voltage)
Abnormal Intake Air Temperature Sensor (Abnormal High
172-3 P0113 1E-247
voltage)
Abnormal Intake Air Temperature Sensor (Abnormal Low
172-4 P0112 1E-241
Voltage)
174-3 Abnormal Fuel Temperature Sensor (Abnormal High Voltage) P0183 1E-274
174-4 Abnormal Fuel Temperature Sensor (Abnormal Low Voltage) P0182 1E-268
190-0 Overrunning P0219 1E-329
T5-6-130
TROUBLESHOOTING / Troubleshooting A
ECM FAULT CODES 628 TO 1485
Engine
Fault Code Troubleshooting
Fault Code Trouble
(TECH2) Manual
Reference Page
628-2 Abnormal ROM P0601 1E-407
633-7 Pressure Limiter Open P1095 1E-433
636-2 Abnormal Cam Angle Sensor (No Signal) P0340 1E-358
636-2 Abnormal Cam Angle Sensor (Abnormal Signal) P0341 1E-365
636-7 Phase Mismatch of Cam Angle Sensor P1345 1E-512
639-2 Abnormal CAN Bus Line U2104 1E-541
639-3 Abnormal CAN Time Out U2106 1E-546
651-3 Open Circuit in Injection Nozzle #1 Drive System P0201 1E-294
652-3 Open Circuit in Injection Nozzle #2 Drive System P0202 1E-300
653-3 Open Circuit in Injection Nozzle #3 Drive System P0203 1E-306
654-3 Open Circuit in Injection Nozzle #4 Drive System P0204 1E-312
723-2 Abnormal Crank Speed Sensor (No Signal) P0335 1E-346
723-2 Abnormal Crank Speed Sensor (Abnormal Signal) P0336 1E-352
987-3 Abnormal Check Engine Lamp P0650 1E-419
1077-2 Abnormal IC for CPU Watching P0606 1E-411
1079-2 Abnormal 5 V Power Source 1 Voltage P1631 1E-526
1080-2 Abnormal 5 V Power Source 2 Voltage P1632 1E-529
1239-1 No pressure to pump (Fuel leakage) P0087 1E-204
1240-1 No pressure to pump (Fuel leakage) P1093 1E-424
Open Circuit in Suction Control Valve Drive System,
1347-0 P0090 1E-222
Shorted circuit in +B or GND.
1485-2 Abnormal Main Relay System (ON is impossible.) P1625 1E-517
T5-6-131
TROUBLESHOOTING / Troubleshooting A
ECM FAULT CODES 10001 TO 10013
Engine Troubleshooting
Fault Code
Fault Code Trouble Manual
(TECH2)
Reference Item
10001-3 Abnormal EGR Position (Brushless spec.) P0487 1E-381
10002-2 Abnormal EGR Valve Control P0488 1E-387
10003-2 Abnormal Injection Nozzle Common 1 Drive System P1261 1E-466
10004-2 Abnormal Injection Nozzle Common 2 Drive System P1262 1E-476
10005-1 Abnormal Charge Circuit (Bank 1) P0611 1E-413
10006-1 Abnormal Charge Circuit (Bank 2) P0612 1E-416
10007-2 Abnormal CPU P0606 1E-411
10008-2 Abnormal A/D Conversion P1630 1E-524
10009-2 5 V Power Source 3 Voltage P1633 1E-532
10010-2 5 V Power Source 4 Voltage P1634 1E-535
10011-2 5 V Power Source 5 Voltage P1635 1E-538
10013-2 Abnormal EEPROM P0603 1E-409
T5-6-132
TROUBLESHOOTING / Troubleshooting A
ICF FAULT CODES 14000 TO 14003
T5-6-133
TROUBLESHOOTING / Troubleshooting A
INFORMATION C/U: INITIALIZE
To the
lower
To the
lower
Init
ESC
T5-6-134
TROUBLESHOOTING / Troubleshooting A
CONTROL DATA: INITIALIZE
To the
lower
To the
lower
Init
ESC
T5-6-135
TROUBLESHOOTING / Troubleshooting A
ENTER MODEL AND SERIAL No.
To the
lower
To the
lower
Exec ESC
ESC
OK
T5-6-136
TROUBLESHOOTING / Troubleshooting A
ICF FAULT CODES 14006, 14008
Fault Code 14006-2 Connector (Harness end of connector viewed from the
• Check the communication line open end side)
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. ICF
Connector ICF-A
2. Check for continuity between terminal #A9 #A8
(harness end) of connector ICF-A in ICF and #A9
terminal #20 (harness end) of connector A in
satellite terminal.
#A31
3. Check for continuity between terminal #A31
(harness end) of connector ICF-A in ICF and Satellite Terminal
Connector A
terminal #2 (harness end) of connector B in
satellite terminal.
10 9 8 7 6 5 4 3 2 1
• Check the power source line of satellite terminal 20 19 18 17 16 15 14 13 12 11
1. Check the battery power
Check if voltage between terminal #2 (harness Satellite Terminal
end) of connector A in satellite terminal and Connector B
machine is 24 V.
2. Check the main power 8 7 6 5 4 3 2 1
With the key switch ON, check if voltage between 16 15 14 13 12 11 10 9
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
TROUBLESHOOTING / Troubleshooting A
SATELLITE TERMINAL FAULT CODES 14100 TO 14106
TCJB-05-04-001
Communication
Antenna
GPS Antenna
T1V1-05-06-004
T5-6-138
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13303
YES Normal.
T5-6-139
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13304
E
S R
Monitor Unit
Connector Monitor-C
6 1
12 7
#C7
T5-6-140
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODES 13306 AND 13308
T5-6-141
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13310
Monitor Unit
Connector Monitor-C
6 1
12 7
#C8
T5-6-142
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13311
Fuel Sensor
1/4
338 mm
1 2
#C2
EMPTY
T178-05-05-001
6 1
12 7
T5-6-143
TROUBLESHOOTING / Troubleshooting A
PILOT SHUT-OFF LEVER ALARM
T1V1-05-06-005
T5-6-144
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODES 15500 TO 15504
T5-6-145
TROUBLESHOOTING / Troubleshooting A
T5-6-146
TROUBLESHOOTING / Troubleshooting A
T1V1-05-07-102
TCJB-05-06-005
T5-6-147
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15510
Check if voltage
between terminal # C YES Faulty option
20 (harness end) of controller.
YES connector C of option
Disconnect connector controller and machine
C of option controller. 0 V. Shorted circuit in
Check for continuity harness between
YES between terminal #C1 NO option controller and
(harness end) of · Key switch: ON right grip (assist
connector and terminal switch).
#7 (harness end) of
connector of right grip. Open circuit in
Disconnect connector of harness between
right grip. option controller and
Check if voltage NO
right grip (assist
between terminals #5 switch).
and #7 (harness end) of
connector is 5±0.5 V. Open circuit in
Check if voltage
between terminal #7 YES harness between
· Key switch: ON
(harness end) of option controller and
connector for right grip right grip (assist
and machine is switch) (terminal #5).
NO specification.
Open circuit in
harness between
· Key switch: ON option controller and
NO
· Specification: 0.25 V or more, right grip (assist
4.75 V or less switch) (terminal #7).
Connector (Harness end of connector viewed from the open end side)
#C20
#C1 C1 C10
C23 C31
TCJB-05-06-006
T5-6-148
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15511
Check if voltage
between terminal #C6 YES Faulty option
(harness end) of controller.
YES connector C of option
controller and machine
Disconnect connector
is 0 V. Shorted circuit in
C of option controller.
Check for continuity harness between
YES between terminal #C NO option controller and
· Key switch: ON right grip (assist
(harness end) of
connector and terminal switch).
#7 (harness end) of
connector of right grip. Open circuit in
Disconnect connector of harness between
right grip. option controller and
Check if voltage NO
right grip (assist
between terminals #5 switch).
and #7 (harness end) of
connector is 5±0.5 V.
Check if voltage Open circuit in
· Key switch: ON between terminals #7 YES harness between
(harness end) of option controller and
connector of right grip right grip (assist
and machine is switch) (terminal #5).
NO specification.
Open circuit in
harness between
· Key switch: ON NO option controller and
· Specification: 0.25 V or more, right grip (assist
4.75 V or less switch) (terminal #7).
Connector (Harness end of connector viewed from the open end side)
#C6
#C1 C1 C10
C23 C31
TCJB-05-06-006
T5-6-149
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15514
Check if voltage
YES Faulty option controller.
between terminal
#C19 (harness end) of
Disconnect connector C YES connector C option
of option controller. controller and machine Shorted circuit in
Check for continuity 0 V. harness between
between terminal #C1 option controller and
YES (harness end) of NO electric lever
· Key switch: ON (auxiliary/positioning).
connector and terminal
#2 (harness end) of
Disconnect connector connector of electric Open circuit in harness
of electric lever lever between option
(auxiliary/positioning). (auxiliary/positioning). controller and electric
Check if voltage NO lever
between terminals #2 (auxiliary/positioning).
and #4 (harness end)
of connector is 5±0.5 V. Check if voltage Open circuit in between
between terminal #2 option controller and
(harness end) of YES electric lever
· Key switch: ON
connector of electric (auxiliary/positioning)
lever (terminal #4).
(auxiliary/positioning)
and machine is
NO
specification. Open circuit in n
harness between
· Key switch: ON NO option controller and
· Specification: 0.25 V or more, electric lever
4.75 V or less (auxiliary/positioning)
(terminal #2).
Connector (Harness end of connector viewed from the open end side)
#C19
#C1 C1 C10
C23 C31
TCJB-05-06-005
T5-6-150
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15515
Check if voltage
between terminals YES Faulty option controller.
#C17 (harness end) of
Disconnect connector C YES connector C of option
of option controller. controller and Shorted circuit in
Check for continuity machine. harness between
between terminal #C1 Check if voltage is 0 V. option controller and
YES (harness end) of NO electric lever
connector and terminal · Key switch: ON (auxiliary/positioning).
#2 (harness end) of
Disconnect connector connector of electric Open circuit in harness
of electric lever lever between option
(auxiliary/positioning). (auxiliary/positioning). controller and electric
Check if voltage NO lever
between terminals #2 (auxiliary/positioning).
and #4 (harness end) of
Check if voltage
connector is 5±0.5 V. Open circuit in harness
between terminal #2
(harness end) of between option
· Key switch: ON connector of electric YES controller and electric
lever lever
(auxiliary/positioning) (auxiliary/positioning)
and machine is (terminal #4).
NO specification.
Open circuit in harness
between option
· Key switch: ON NO controller and electric
· Specification: 0.25 V or more,
lever
4.75 V or less
(auxiliary/positioning)
(terminal #2).
Connector (Harness end of connector viewed from the open end side)
#C17
#C1 C1 C10
T5-6-151
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15516
Faulty pressure
YES sensor.
Connector (Harness end of connector viewed from the open end side)
#C16
C1 C10
T1V1-05-07-102
C23 C31
T5-6-152
TROUBLESHOOTING / Troubleshooting A
T1V1-05-07-102
C23 C31
T5-6-153
TROUBLESHOOTING / Troubleshooting A
Check if voltage
between terminal YES Faulty option controller.
#C18 (harness end) of
Disconnect connector C YES connector C of option
of option controller. controller and machine Shorted circuit in
Check for continuity is 0 V. harness between option
between terminal #C1 controller and electric
YES (harness end) of NO lever (blade/outrigger).
connector and terminal · Key switch: ON
#2 (harness end) of
connector of electric
Disconnect connector lever (blade/outrigger). Open circuit in harness
of electric lever between option
(blade/outrigger). NO controller and electric
Check if voltage lever (blade/outrigger).
between terminals #2
and #4 (harness end) of Open circuit in harness
connector is 5±0.5 V. Check if voltage
between terminal #2 between option
· Key switch: ON (harness end) of YES controller and electric
connector of electric lever (blade/outrigger)
lever (blade/outrigger) (terminal #4).
and machine is
NO specification.
Open circuit in harness
between option
· Key switch: ON NO controller and electric
· Specification: 0.25 V or more, lever (blade/outrigger)
4.75 V or less (terminal #2).
Connector (Harness end of connector viewed from the open end side)
#C18
#C1 C1 C10
T5-6-154
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15519
Check if voltage
YES Faulty option
between terminal
#C28 (harness end) of controller.
YES connector C of option
Disconnect connector C
of option controller. controller and machine Shorted circuit in
Check for continuity is 0 V. harness between
between terminal #C1 option controller and
YES NO electric lever
(harness end) of · Key switch: ON
connector and terminal (blade/outrigger).
#2 (harness end) of
connector of electric Open circuit in
Disconnect connector of lever (blade/outrigger). harness between
electric lever option controller and
(blade/outrigger). NO electric lever
Check if voltage (blade/outrigger).
between terminals #2
and #4 (harness end) of Open circuit in
connector is 5±0.5 V. harness between
Check if voltage YES option controller and
· Key switch: ON between terminal #2 electric lever
(harness end) of (blade/outrigger)
connector of electric (terminal #4).
lever (blade/outrigger)
NO
and machine is Open circuit in
specification. harness between
· Key switch: ON NO option controller and
· Specification: 0.25 V or more, electric lever
4.75 V or less (blade/outrigger)
(terminal #2).
Connector (Harness end of connector viewed from the open end side)
#C1 C1 C10
T5-6-155
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15570
T5-6-156
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15571
T5-6-157
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15572
T5-6-158
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15573
T5-6-159
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODES 15574-3 AND 15578-3
Connector (Harness end of connector viewed from the open end side)
#C17 #C19
C1 C10
TCJB-05-06-005
C23 C31
T5-6-160
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODES 15574-4 AND 15578-4
Connector (Harness end of connector viewed from the open end side)
C23 C31
TCJB-05-06-005
T5-6-161
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODES 15575-3 AND 15579-3
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 Disconnect connector C YES Shorted circuit in with
fault code disappears. of option controller. continuity.
Check for continuity
between following
NO terminals (harness end)
of connector.
Faulty option controller.
· Between terminal #C18 of NO
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)
C23 C31
TCJB-05-06-005 #C28
T5-6-162
TROUBLESHOOTING / Troubleshooting A
Connector (Harness end of connector viewed from the open end side)
C23 C31
TCJB-05-06-005
#C28
T5-6-163
TROUBLESHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODES 20300 TO 20303
T5-6-164
TROUBLEHOOTING / Troubleshooting A
OPTION CONTROLLER FAULT CODE 15520
#A19 #A22
T183-05-04-008
T1V1-05-04-003
T5-6-165
TROUBLEHOOTING / Troubleshooting A
#A15 #A23
T183-05-04-008
T1V1-05-04-003
T5-6-166
TROUBLEHOOTING / Troubleshooting A
Switch connector of
NO Faulty blade/outrigger
blade/outrigger solenoid solenoid valve 1.
valve 1 with connector
YES of blade/outrigger
solenoid valve 2. Check
if the fault code for Faulty option controller.
blade/outrigger solenoid
valve 2 is displayed. YES
Check for continuity of
harness between option
controller and
blade/outrigger solenoid
valve 1.
· Between terminal #A32 of
connector A of option Open circuit in harness.
controller and terminal #1
of connector of NO
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
#A7
T1V1-05-04-003
#A32
T183-05-04-008
T5-6-167
TROUBLEHOOTING / Troubleshooting A
#A4
#A24 T1V1-05-04-003
T183-05-04-008
T5-6-168
TROUBLEHOOTING / Troubleshooting A
#A17
T1V1-05-04-003
#A31 T183-05-04-008
T5-6-169
TROUBLEHOOTING / Troubleshooting A
#A16
#A30 T183-05-04-008
T1V1-05-04-003
T5-6-170
TROUBLEHOOTING / Troubleshooting A
#A5 #A21
T183-05-04-008
T1V1-05-04-003
T5-6-171
TROUBLEHOOTING / Troubleshooting A
#A10
#A29 T183-05-04-008
T1V1-05-04-003
T5-6-172
TROUBLEHOOTING / Troubleshooting A
#A14 #A8
#A29 T183-05-04-008
T1V1-05-04-003
T5-6-173
TROUBLEHOOTING / Troubleshooting A
#A6
#A11
T183-05-04-008
T1V1-05-04-003
T5-6-174
TROUBLEHOOTING / Troubleshooting A
#A3 #A9
T183-05-04-008
T1V1-05-04-003
T5-6-175
TROUBLEHOOTING / Troubleshooting A
T5-6-176
TROUBLEHOOTING / Troubleshooting A
T5-6-177
TROUBLEHOOTING / Troubleshooting A
(Blank)
T5-6-178
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
(3)
NO (NOT OK)
• Special instructions or reference item are indicated in the spaces under the box.
・ Incorrect measuring or checking methods will render troubleshooting impossible,
and may damage components as well.
· Key switch: ON
• 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.
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 Pump 1 Delivery
Item Engine Control Dial Pump Control Pressure Sensor
Pressure Sensor
• Instructs engine target • Monitors pump control pressure in • Monitors pump de-
speed. order to control E mode control. livery pressure in
order to control HP
mode, auto-power lift
Function and travel accelera-
tion controls.
T5-7-2
TROUBLESHOOTING / Troubleshooting B
• HP mode is inoperable. • Engine stalls if pump torque is • Although accelerator pedal • Although accelerator pedal
• During combined operation of increased. is fully depressed and is fully depressed and
arm roll-in and swing, arm machine travels forward, machine travels reverse,
speed is slow. engine speed does not in- engine speed does not in-
crease. crease.
• Although machine travels • Although machine travels
forward with auto-idle reverse with auto-idle
switch ON, engine speed switch ON, engine speed
does not increase. does not increase.
• Although operating pedal • Although operating pedal
with engine speed control with engine speed control
mode selection switch in mode selection switch in
pedal position, engine pedal position, engine
speed does not increase. speed does not increase.
• When machine travels at • When machine travels at
slow idle speed, engine slow idle speed, engine
may hunt. may hunt.
• Although machine travels • Although machine travels
forward at slow idle, en- reverse at slow idle, en-
gine speed does not in- gine speed does not in-
crease. crease.
11202 11203 11305 11306
Monitor Item: Pump 2 Delivery Monitor Item: Pump 3 Delivery Monitor Item: Travel Forward Monitor Item: Travel Reverse
Pressure (Possible to display by Pressure Pilot Pressure (Possible to Pilot Pressure (Possible to
built-in diagnosing system) display built-in diagnosing display built-in diagnosing
system). system).
Monitor pressure change Monitor pressure change
while traveling forward. while traveling reverse.
- - - -
- - - -
• Possible to judge if sensor is • Possible to judge if sensor is • Possible to judge if pres- • Possible to judge if pres-
malfunction or harness is faulty malfunction or harness is faulty sure sensor is faulty or sure sensor is faulty or
by switching pump 1 and 3 by switching pump 1 and 2 sen- port is clogged by switch- port is clogged by switch-
sensors. sors. ing pressure sensor with ing pressure sensor with
another pressure sensor. another pressure sensor.
T2-2 T2-2 T2-2 T2-2
T5-7-3
TROUBLESHOOTING / Troubleshooting B
• When pressure sensor (front • No signals arrive to MC. • No signals arrive to MC.
attachment) or harness be-
Symptoms in control tween pressure sensor and
system when trouble MC is faulty, MC judges that
pressure sensor (front at-
occurs. tachment) is ON.
• Although any front attach- • During arm level crowding • Although boom is raised at
ment is operated with operation, arm speed is HP mode, engine speed
auto-idle switch is ON, en- slightly slow. does not increase.
gine speed does not in- • Arm speed becomes slightly
crease. slower than normal in boom
• When front attachment is raise and arm roll-in opera-
operated at slow idle speed, tion as arm regenerative
engine may hunt. control does not work. (Not
• When parking brake is ap- remarkable)
Symptoms in machine plied and when front at- • Arm roll-in and boom raise
operation when trouble tachment is operated, buzzer speeds become slightly
occurs. does not sound. slower at the beginning
stage of arm level crowding
operation.
• Boom raise power is weak.
(Not remarkable)
By Using Test
Harness - - -
Others - - -
• Possible to judge if pressure • Possible to judge if pressure • Possible to judge if pressure
sensor is faulty or port is sensor is faulty or port is sensor is faulty or port is
NOTE clogged by switching pres- clogged by switching pres- clogged by switching pres-
sure sensor with another sure sensor with another sure sensor with another
pressure sensor. pressure sensor. pressure sensor.
T5-7-4
TROUBLESHOOTING / Troubleshooting B
• Although arm is rolled-in at • When attachment is oper- • When positioning or assist is • Work brake is inoperable.
HP mode, engine speed ated, engine speed does not operated, engine speed does
does not increase. increase. not increase.
• Arm speed is slow in arm • When attachment is oper- • When attachment is oper-
level crowding operation. ated, operation speed de- ated, operation speed de-
creases. creases.
• All operations are inoperable • All operations are inoperable
except travel operation. except travel operation.
• Electric Lever Solenoid Valve • Electric Lever Solenoid Valve
Output Warning is displayed Output Warning is displayed
on monitor unit. on monitor unit.
• Buzzer sounds continuously. • Buzzer sounds continuously.
- - - -
- - - -
• Possible to judge if pressure • Possible to judge if pressure • Possible to judge if pressure • Possible to judge if pressure
sensor is faulty or port is sensor is faulty or port is sensor is faulty or port is sensor is faulty or port is
clogged by switching pres- clogged by switching pres- clogged by switching pres- clogged by switching brake
sure sensor with another sure sensor with another sure sensor with another pressure sensor with pump 1,
pressure sensor. pressure sensor. pressure sensor. 2, 3 delivery pressure sen-
sors.
T2-2 T2-2 T2-2 T2-2
T5-7-5
TROUBLESHOOTING / Troubleshooting B
• No signals arrive to MC. • No Signal arrive to MC. • If solenoid valve unit (SG) is
not activated, pressure at
Symptoms in control port SG becomes 0 MPa (0
system when trouble kgf/cm2).
occurs.
• Parking brake cannot be re- • Condition is always overload. Abnormal low current:
leased. • Overload alarm is displayed • Relief pressure stays at nor-
• Travel speed is turned to on monitor unit. mal 34 MPa (350 kfg/cm2).
fast/slow speed. • Overload alarm sounds. Although power digging
switch is pressed, relief
pressure does not increase.
Power does not increase.
Others - - -
• Possible to judge if pressure • Proportional solenoid valve is
sensor is faulty or port is used as an ON/OFF valve.
clogged by switching brake Therefore, although power
pressure sensor with pump digging switch is pressed or
NOTE 1, 2, 3 delivery pressure
-
released, lamp will come ON
sensors. when normal. In case lamp
goes OFF, harness is
shorted.
T2-2 T2-2 T2-2
Descriptions of Control
(Operational Principle
Section in T/M)
T5-7-6
TROUBLESHOOTING / Troubleshooting B
Abnormal low current: Abnormal low current: Abnormal low current: Abnormal low current:
• Work brake does not oper- • All operation speeds become • Axle lock is not released. • When attachment, front at-
ate. slow. tachment and superfine
Abnormal high current: travel are operated, operat-
Abnormal high current: Abnormal high current: • Axle lock is kept in released ing speed becomes fast.
• Work brake is kept applied. • Arm speed becomes fast as arm condition.
• Machine cannot travel. regenerative control is always • Condition when front at- Abnormal high current:
operated. tachment is operated is un- • Travel, bucket, arm and
stable. boom speeds become slow
as maximum flow rate of
pump 1 decreases.
- - - -
T5-7-7
TROUBLESHOOTING / Troubleshooting B
By Monitor
-
Evalua- Function
tion
By Using Test
- - -
Harness
Others - - -
NOTE - - -
T5-7-8
TROUBLESHOOTING / Troubleshooting B
Blade/Outrigger
Auxiliary Solenoid Valve Positioning Solenoid Valve Assist Solenoid Valve
Solenoid Valve
• Is operated by signal from • Is operated by signal from option • Is operated by signal from • Is operated by signal from
option controller and sup- controller and supplies pressure option controller and sup- option controller and sup-
plies pressure oil from pilot oil from pilot pump to control plies pressure oil from pilot plies pressure oil from pilot
pump to control valve valve spool in order to control pump to control valve spool pump to control valve spool
spool in order to control positioning control. in order to control in order to control assist
auxiliary control. blade/outrigger control. control.
• When trouble occurs, so- • When trouble occurs, solenoid • When trouble occurs, sole- • When trouble occurs, sole-
lenoid valve output is 0 by valve output is turned OFF by noid valve output is turned noid valve output is turned
electric lever pilot cut-off electric lever pilot cut-off control. OFF by electric lever pilot OFF by electric lever pilot
control. When operating When operating positioning, op- cut-off control. When op- cut-off control. When op-
auxiliary, operating speed erating speed becomes slow. erating blade/outrigger, op- erating assist, operating
becomes slow. erating speed becomes speed becomes slow.
slow.
Abnormal low current: Abnormal low current: Abnormal low current: Abnormal low current:
• When operating auxiliary, • When operating positioning, op- • When operating • When operating assist, op-
operating speed becomes erating speed becomes slow. blade/outrigger, operating erating speed becomes
slow. speed becomes slow. slow.
Abnormal high current:
Abnormal high current: • All operations are inoperable Abnormal high current: Abnormal high current:
• All operations are inoper- except travel operation. • All operations are inoper- • All operations are inoper-
able except travel opera- • Alarm is displayed on monitor able except travel opera- able except travel opera-
tion. unit and buzzer sounds. tion. tion.
• Alarm is displayed on • Alarm is displayed on • Alarm is displayed on
monitor unit and buzzer monitor unit and buzzer monitor unit and buzzer
sounds. sounds. sounds.
- - - -
- - - -
- - - -
T5-7-9
TROUBLESHOOTING / Troubleshooting B
Parts Swing Parking Brake Auxiliary Flow Rate Control Auxiliary Flow Combiner
Item Release Solenoid Valve Solenoid Valve (Optional) Solenoid Valve (Optional)
• Is operated by signal from • Restricts flow rate to auxiliary • Activates during auxiliary op-
option controller and supplies spool during combined op- eration and shifts spool in
pressure oil from pilot pump eration and improves oper- auxiliary flow combining
to control valve spool in order ability. valve.
to control positioning and as-
Function sist controls.
• When trouble occurs, sole- • Ifauxiliary flow rate control • If auxiliary flow combiner so-
noid valve output is turned solenoid valve is not acti- lenoid valve is not activated,
Symptoms in control OFF by electric lever pilot vated, pressure at output port pressure at output port be-
system when trouble cut-off control. becomes 0 MPa (0 kgf/cm2). comes 0 MPa (0 kgf/cm2)
when operating attachment.
occurs.
• All operations are inoperable Abnormal low current: • Speed does not increase
except travel operation. • If valve is bound fully open, during single operation of at-
• Alarm is displayed on monitor boom does not raise during tachment.
unit and buzzer sounds. 3-combined operation of
boom raise.
Abnormal high current:
• If valve is bound fully closed,
attachment speed becomes
slow during single operation.
Symptoms in machine
operation when trouble
occurs.
NOTE - - -
T5-7-10
TROUBLESHOOTING / Troubleshooting B
• If selector valve control sole- • If accumulator control sole- • If secondary pilot relief pres- • Speed display meter does not
noid valve is not activated, noid valve is not activated, sure control solenoid valve is operate.
pressure at output port be- pressure at output port be- not activated, pressure at • Travel speed, travel motor
comes 0 MPa (0 kgf/cm2) comes 0 MPa (0 kgf/cm2) output port becomes 0 MPa excessive rotation, and/or the
when attachment “selector when attachment “accumu- (0 kgf/cm2) when attachment forward/reverse shifting re-
valve returning to hydraulic oil lator ON” is selected. “secondary pilot relief pres- striction control is inoperable.
tank” is selected. sure ON” is selected.
• Breaker stroke becomes few. • When NPK breaker is used, • Relief set pressure in auxiliary • Speed display meter does not
hydraulic pulsation (hose vi- circuit does not decrease. operate.
bration) becomes big. • When descending a slope,
engine speed is not reduced.
- - - -
Monitor Item: Vehicle Speed
(Possible to display by built-in
- - -
diagnosing system)
- - - -
- - - -
When pedal is depressed,
pressure in the right piping hose
occurs. - - -
T5-7-11
TROUBLESHOOTING / Troubleshooting B
• If circuit breakage occurs, • Open circuit: Pressure does • When open or shorted cir-
system operates as if hy- not increase. cuit occurs in switch,
Symptoms in control draulic oil temperature is • Shorted circuit: Pressure in- fast/slow speed selection
system when trouble 120 °C (Dr. ZX or monitor creases for 8 seconds after solenoid valve is held in ei-
will not indicate 120 °C in turning key switch and stops ther fast or slow position.
occurs. diagnosis operation). increasing.
• Although oil temperature is • Power digging control does • Although travel speed mode
lower than 0 °C, not operate if open circuit or switch is in fast position,
auto-warming up control shorted circuit occurs. travel speed dose not
does not operate so that en- change into Fast.
gine runs at idle speed when • Although travel speed mode
engine is started. switch is in slow position,
• When hydraulic oil tem- travel speed dose not
perature is lower than 10 °C, change into Slow.
arm regenerative control is
Symptoms in machine inoperable.
operation when trouble
occurs.
T5-7-12
TROUBLESHOOTING / Troubleshooting B
• When open or shorted circuit • Depending on failure of • Depending on failure of • Depending on trouble situa-
occurs in switch, FNR switch switch, engine control mode switch, brake mode is held tions, control system mal-
is held in N position. is held. (Engine control dial, (parking brake, axle lock, auto function may differ. (The fol-
pedal and creeper modes) axle lock and OFF) lowing symptoms in machine
operation indicates that MC
logic circuit has failed.)
• Although FNR switch is in N • Although engine speed con- • Although parking brake posi- • Although engine starts, speed
position, indicator (N) on trol mode selection switch is tion is selected, the parking stays slow.
steering column monitor does turned to pedal mode, engine brake is not operable. • As pump displacement is held
not light. speed cannot be controlled • Although axle lock position is at minimum, all actuator
• Although FNR switch is in F or by accelerator pedal. selected, axle cylinder is not speeds are slow.
R position, machine does not • Although engine speed con- locked.
travel. trol mode selection switch is • Although machine travels in
• Although FNR switch is in R turned to creeper mode, auto axle lock position, axle
position, back light does not travel creeper speed mode is lock cylinder is not released.
light. not operable. • Although OFF position is se-
lected, either parking brake or
axle lock is operable.
- - - -
- - - -
• 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.
T2-2 T2-2 T2-2 T2-1
T5-7-13
TROUBLESHOOTING / Troubleshooting B
By Fault
- - -
Code
By Monitor Monitor Item: Auto-Idle SW Monitor Item: HP Mode SW Monitor Item: E/P SW
Evalua-
tion Function
Using Test
- - -
Harness
Others - - -
NOTE - - -
T5-7-14
TROUBLESHOOTING / Troubleshooting B
• Although brake pedal is de- • When outrigger selection Open circuit: • If valve is fully opened: Swing
pressed during work brake switch is turned to OFF or • Pilot shout-off switch is al- power is weak.
operation, work brake is not pilot cut-off position, and ways OFF. • If valve is fully closed: Arm
released. when lever is operated, • Pilot shut-off solenoid valve is speed is slow during arm
blade/outrigger is activated. not shifted. level crowding operation.
• When outrigger selection • Although lever is operated
switch is turned to pilot cut-off with pilot shut-off lever in
position, and when lever is UNLOCK position, all actua-
operated, front attachment or tor are not operated.
blade/outrigger is activated. Short Circuit:
• When outrigger selection • Pilot shout-off switch is al-
switch is turned to ON posi- ways ON.
tion, blade/outrigger is not • Engine does not start.
activated. • If shorted circuit occurs while
starting engine, operate lever
with pilot shut-off lever in
LOCK position so actuator is
operated.
- - - -
Monitor Item: Implement Brake Monitor Item: Electric Lever Pilot Monitor Item: Gate Lock Signal
Deactive Cut -
- - - -
- - - -
- - - -
T5-7-15
TROUBLESHOOTING / Troubleshooting B
Parts Arm 2 Flow Rate Bucket Flow Rate Boom Flow Rate
Item Control Valve Control Valve Control Valve
• Is shifted by pilot pressure • Restricts oil flow raise to • Is shifted by pilot pressure
from solenoid valve unit (SC). bucket during 3-combined from boom lower meter-in cut
• Ensures boom raise speed operation of bucket, arm valve.
Function during combined operation of roll-in and boom raise and • Limits flow rate to boom 1
boom and arm. makes boom raise. spool during combined
operation and improves
combined operation.
• If spool is bound or spring is • If switch valve is bound with • As below
broken, orifice does not valve activated, bucket circuit
Symptoms in control charge. is always restricted.
system when trouble
occurs.
• If valve is fully opened: Boom • If poppet valve is bound at • If valve is fully opened, boom
raise speed is slow. fully closed position or if lower speed is fast during
• If valve is fully closed: Arm switch valve is bound when combined operation.
roll-in speed is slow during poppet valve is fully closed, • If valve is fully closed,
arm level crowding operation. bucket speed becomes slow. machine cannot be raised off
• If poppet valve is bound at ground.
fully opened position or if
switch valve is bound when
poppet valve is fully opened,
Symptoms in machine boom does not raise during
operation when trouble 3-combined operation of
bucket, arm roll-in and boom
occurs. raise.
By Fault
- - -
Code
Evalua- By Monitor - - -
tion Function
Using Test - - -
Harness
Others - - -
NOTE - - -
T5-7-16
TROUBLESHOOTING / Troubleshooting B
• If valve is bound at fully • If check valve is kept closed, • Arm speed is extremely slow • If check valve is kept closed,
closed position, attachment boom is not smoothly low- during arm level crowding bucket is not smoothly rolled
speed becomes slow. ered. operation while arm regen- in.
• If valve is bound at fully • If check valve is kept open, erative valve is kept closed. • If check valve is kept open,
opened position, boom does machine cannot be raised off • The lever operated first is bucket power is weak.
not raise during 3-combined ground. given priority during com-
operation of swing, arm roll-in bined operation of arm roll-in
and boom raise. and swing while arm regen-
erative valve is kept open.
- - - -
- - - -
- - - -
- - - -
- - - -
T5-7-17
TROUBLESHOOTING / Troubleshooting B
• If check valve is kept closed, • If check valve is kept closed, • If valve is kept closed, as boom
arm roll-in speed becomes boom does not lower. flow rate control valve is not
slow. • If check valve is kept open, shifted, boom lower speed
• If check valve is kept open, front attachment drift in- becomes fast during combined
front attachment drift in- creases due to oil leaks in operation.
creases due to oil leaks in control valve. • If valve is kept open, as boom
control valve. • Boom moves jerky or arm flow rate control valve is
• Arm moves jerky or arm speed becomes slow de- shifted, pressure oil from pump
speed becomes slow de- pending on valve bound 1 does not flow to boom 1
Symptoms in machine pending on valve bound conditions. spool. Therefore, machine
operation when trouble conditions. cannot be raised off ground.
occurs.
By Fault
- - -
Code
Evalua- By Monitor - - -
tion Function
By Using Test - - -
Harness
Others - - -
NOTE - - -
T5-7-18
TROUBLESHOOTING / Troubleshooting B
• If switch valve is kept closed, • If spool is bound at fully open • If spool is bound in fully open • If spool is bound in fully open
attachment speed does not position, single attachment position, although control position, although control
become fast during single operation speed becomes lever is in neutral, pump 1 lever is in neutral, pump 2
auxiliary operation. slow. swash angle is tilted to swash angle is tilted to
• If switch valve is kept open, • If spool is bound at fully maximum. maximum.
attachment speed does not closed position, main relief • If spool is bound in fully open • If spool is bound in fully open
become slow when valve continues to relieve position, pump 1 control position, pump 2 control
attachment mode (HSB with all control levers posi- pressure sensor monitors pressure sensor monitors
breaker, NPK breaker) of tioned in neutral. maximum pressure. maximum pressure.
travel speed “OFF” is • When all control levers are in • If spool is bound in fully • If spool is bound in fully
selected. neutral, pump 1 pressure is closed position, although closed position, although
higher than pump 2 pressure control lever is operated, control lever is operated,
according to bound spool pump 1 swash angle is held pump 2 swash angle is held
conditions. to minimum. (Bucket speed is to minimum. (Swing speed is
very slow.) very slow.)
• If spool is bound in fully open • If spool is bound in fully open
position, pump 1 control position, pump 2 control
pressure sensor can not pressure sensor can not
monitor the pump control monitor pump control pres-
pressure. sure.
- - - -
- - - -
- - - -
- - - -
- - - -
T5-7-19
TROUBLESHOOTING / Troubleshooting B
• If spool is bound in fully open • If spool is bound in fully open • If spool is bound at fully
position, swing parking position, bucket speed open, arm speed decreases
brake is kept released. becomes slow when during single arm operation.
(Machine vibrates while combined operation of boom (Arm flow rate control is
traveling.) raise and bucket is made. always operated.)
• If spool is bound in fully open (Bucket flow rate control is • If spool is bound at fully
position, pressure sensor inoperable.) closed, swing power
(front attachment) is always • If spool is bound in fully becomes insufficient during
ON. closed position, boom does combined operation of swing
Thus, engine speed does not raise during 3-combined and arm roll-in. (Arm flow
not decrease when control operation of bucket, arm rate control is not operated.)
Symptoms in machine lever is in neutral during roll-in and boom raise.
operation when trouble auto-idle control.
occurs. • 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.
By Fault Code - - -
By Monitor - - -
Function
Evaluation
By Using Test - - -
Harness
Others - - -
NOTE - - -
T5-7-20
TROUBLESHOOTING / Troubleshooting B
• Pressure oil is not supplied to • As below • Pressure oil is not charged • As below
steering cylinder in proportion into accumulator.
to steering wheel rotation. • Brake circuit oil pressure
However, steering valve acts stays low.
as a pump, steering cylinder
can be operated.
• Turning force of steering • Although brake pedal is • Service brake is not operable. • If fast/slow speed selection
wheel increases. depressed, brake is not • Service brake does not work solenoid valve is bound in
applied. effectively. neutral, parking brake is kept
• Although brake pedal is not applied although shift switch
operated, brake is applied. 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.
- - - -
- - - -
- - - -
- - - -
- - - -
T5-7-21
TROUBLESHOOTING / Troubleshooting B
Symptoms in machine
operation when trouble
occurs.
By Fault Code - - -
By Monitor - - -
Function
Evaluation
By Using Test - - -
Harness
Others - - -
NOTE - - -
T5-7-22
TROUBLESHOOTING / Troubleshooting B
• If spool is bound or spring is broken, • Ifspool is bound or spring is broken, • If spool is bound or spring is broken, relief
pressure oil from breaker does not return accumulator shifting is turned OFF. circuit in breaker is blocked.
to hydraulic oil tank.
• Breaker stroke becomes few. • When NPK breaker is used, hydraulic • Reliefset pressure in auxiliary circuit
pulsation (hose vibration) becomes big. does not decrease.
- - -
- - -
- - -
- - -
- - -
T5-7-23
TROUBLESHOOTING / Troubleshooting B
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
MC z z
ECM { z
ICF {
Monitor Unit z {
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 z
Engine Control Dial
Auto-Idle Switch
Power Mode Switch
Torque Control Solenoid Valve
Starter Cut Relay z
ECM Main Relay
Battery Relay z
Glow Plug Relay
Engine Electrical Equipment
Engine Unit z z
Pump Regulator
Swing Parking Brake
Release Spool (Signal Control Valve)
Check batteries.
Remark
T5-7-24
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are In case more than one trouble occurs at the
described provided that each trouble same time, find out all faulty components
occurs independently. while checking all suspected components
in each trouble symptom.
z z z {
z z { z
z
z
z
z
z {
z
T5-7-25
TROUBLESHOOTING / Troubleshooting B
Remark
T5-7-26
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are In case more than one trouble occurs at the
described provided that each trouble same time, find out all faulty components
occurs independently. while checking all suspected components
in each trouble symptom.
z z z
{ { z z
{ {
z
{ z
{ z
z
Check batteries.
T5-7-27
TROUBLESHOOTING / Troubleshooting B
E-15 E-16
Trouble Symptom
Although depressing Although depressing
accelerator pedal during accelerator pedal during
travel operation, engine digging operation,
speed does not change. engine speed does not
Part change.
MC (Main Controller) z z
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 z z
FNR Switch z z
Travel Speed Mode Switch {
Engine Speed Control Mode Selection
Switch
z z
Battery Relay
Glow Plug Relay
Engine Electrical Equipment
Engine Unit
Pump Regulator
Remark
T5-7-28
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-29
TROUBLESHOOTING / Troubleshooting B
MC z
ECM {
Monitor Unit {
Torque Control Solenoid Valve z
Pilot Shut-Off Solenoid Valve z
Pump 2 Delivery Pressure Sensor
Pressure Sensor (Swing)
Pressure Sensor (Arm Roll-In)
Pilot Shut-Off Lever z
Pilot Shut-Off Relay z
Security Relay z
Spool
Main Relief Valve {
Arm 1 Flow Rate Control Valve
Main Pump z z
Regulator { z
Pilot Pump z
Pilot Valve
Pilot Relief Valve z
Pump 1 Flow Rate Control Valve
(Signal Control Valve)
Pump 2 Flow Rate Control Valve
(Signal Control Valve)
z
Arm 1 Flow Rate Control Valve
Control Spool (Signal Control Valve)
Remark
T5-7-30
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are In case more than one trouble occurs at the
described provided that each trouble same time, find out all faulty components
occurs independently. while checking all suspected components
in each trouble symptom.
z
z
z z
z z
T5-7-31
TROUBLESHOOTING / Troubleshooting B
MC z z
Solenoid Valve Unit (SG) z
Solenoid Valve Unit (SF)
Solenoid Valve Unit (SC) z
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 z
Spool z
Main Relief Valve z z
Overload Relief Valve z z
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve z
Bucket Regenerative Valve
Boom Flow Rate Control Valve
Arm 1 Flow Rate Control Valve z
Arm 2 Flow Rate Control Valve z
Bucket Flow Rate Control Valve
Boom Lower Meter-In Cut Valve
Boom Anti-Drift Valve
Arm Anti-Drift Valve
Emergency Valve
Shockless Valve
(Signal Control Valve) z
Shuttle Valve
(Signal Control Valve) z
Bucket Flow Rate Control Valve Control
Spool (Signal Control Valve)
Arm 1 Flow Rate Control Valve
Control Spool z
(Signal Control Valve)
Pilot Valve z
Cylinder
Remark
T5-7-32
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are In case more than one trouble occurs at the
described provided that each trouble same time, find out all faulty components
occurs independently. while checking all suspected components
in each trouble symptom.
z
z
z
z
z
z
z
T5-7-33
TROUBLESHOOTING / Troubleshooting B
MC
Solenoid Valve Unit (SG)
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 z
Main Relief Valve
Overload Relief Valve z
Load Check Valve z
Boom Regenerative Valve
Arm Regenerative Valve
Bucket Regenerative Valve
Boom Flow Rate Control Valve z z
Arm 1 Flow Rate Control Valve
Arm 2 Flow Rate Control Valve
Bucket Flow Rate Control Valve
Boom Lower Meter-In Cut Valve z z
Boom Anti-Drift Valve z z
Arm Anti-Drift Valve z z
Emergency Valve {
Shockless Valve
(Signal Control Valve)
Shuttle Valve
(Signal Control Valve)
Bucket Flow Rate Control Valve Control
Spool (Signal Control Valve)
Arm 1 Flow Rate Control Valve
Control Spool z
(Signal Control Valve)
Pilot Valve
Cylinder z
Remark
T5-7-34
TROUBLESHOOTING / Troubleshooting B
MC z z z
Auxiliary Flow Rate Control Solenoid Valve z
Auxiliary Flow Combiner Solenoid Valve z
Maximum Pump 1 Flow Rate Limit Control Solenoid z
Pressure Sensor (Auxiliary) z z z
Pressure Sensor (Travel Forward) z
Pressure Sensor (Travel Reverse) z
Pressure Sensor (Arm Roll-Out) z z
Auxiliary Flow Rate Control Valve z
Auxiliary Flow Combiner Valve z
Remark
T5-7-35
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are In case more than one trouble occurs at the
described provided that each trouble same time, find out all faulty components
occurs independently. while checking all suspected components
in each trouble symptom.
Swing System Troubleshooting
S-1 S-2
Trouble Symptom
Swing is slow or unmoving. Swing is slow (weak in power)
during combined operation of
swing and arm roll-in. Swing
does not start smoothly. Swing
power is weak.
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 z
Swing Parking Brake Release Spool
(Signal Control Valve)
z
Pump 1 Flow Rate Control Valve
(Signal Control Valve)
Pump 2 Flow Rate Control Valve
(Signal Control Valve)
z
Arm 1 Flow Rate Control Valve Control
Spool (Signal Control Valve)
z
Shuttle Valve (Signal Control Valve) {
Swing Device z
Travel Device
Center Joint
Pilot Valve z
Remark
T5-7-36
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-37
TROUBLESHOOTING / Troubleshooting B
MC z z z z
Monitor Unit
Main Pump {
Regulator {
Solenoid Valve Unit (SF) z
Solenoid Valve Unit (SI)
Travel Motor Displacement Angle
Control Solenoid Valve
z z
Travel Mode Selector Solenoid
Valve
z z
Fast Speed Selection Relay
Slow Speed Selection Relay
FNR Switch { z
Travel Speed Mode Switch {
Brake Switch {
Engine Speed Control Mode
Selection Switch
z
Work Brake Release Switch z
Brake Pressure Sensor
Brake Remaining Pressure Sensor
Travel N Sensor {
Control Valve z z z z
Travel Shockless Valve z z
Accumulator Charging Valve
Brake Valve
Transmission z {
Front Axle z {
Rear Axle z {
Travel Motor z z z z
Center Joint z z
Pilot Valve z
Axle Lock Cylinder
Operate Check Valve (Axle Lock
Cylinder)
Remark
T5-7-38
TROUBLESHOOTING / Troubleshooting B
z z z
z z
z
z
z
{
z
z z
{ {
z z
T5-7-39
TROUBLESHOOTING / Troubleshooting B
Part
MC z z
ECM {
Monitor Unit
Main Pump
Regulator
Solenoid Valve Unit (SF) z z
Solenoid Valve Unit (SI)
Travel Mode Selector Solenoid
Valve
{
FNR Switch {
Travel Speed Mode Switch
Brake Switch z
Engine Speed Control
Mode Selection Switch
Work Brake Release Switch {
Brake Pressure Sensor z
Brake Remaining Pressure Sensor {
Travel N Sensor {
Control Valve
Travel Shockless Valve
Accumulator Charging Valve z
Brake Valve z z
Transmission {
Front Axle z {
Rear Axle z {
Travel Motor
Center Joint
Pilot Valve
Remark
T5-7-40
TROUBLESHOOTING / Troubleshooting B
Steering Pump z
Steering Valve z z
Center Joint z
Front Axle { {
Other Electrical Equipment z z
Remark
T5-7-41
TROUBLESHOOTING / Troubleshooting B
ENGINE SYSTEM TROUBLESHOOTING
Key Switch:
Battery Relay:
Terminal A
T105-07-04-002
T178-05-04-001
T5-7-42
TROUBLESHOOTING / Troubleshooting B
E
S R
T183-05-05-001 T183-05-04-003
T5-7-43
TROUBLESHOOTING / Troubleshooting B
E-2 Although starter rotates, engine does not
start.
Connect terminal #1
(harness end) of
connector in ECM
Switch ECM main main relay to ma-
relay with other gen- Connect terminal #5 YES
chine.
eral relay. (harness end) of con- Check for continuity
Check if engine nector in ECM main re- between terminals
starts. lay to machine. #21, #40 (harness
YES Disconnect connector in end) of connector in
ECM. ECM and machine.
Disconnect ECM main Check for continuity
relay from connector. between terminals #2,
Check if voltage be- #5 (harness end) of Open circuit in harness
connector and machine. between ECM main relay
NO tween terminal #3 NO and ECM.
(harness end) of con-
nector and machine is
specification. Open circuit in harness
· Specification: 24V between key switch and
NO
ECM main relay.
· Check if fuse #8 is
blown.
T183-05-04-003
T1GR-05-04-002
#40 #2
T5-7-44
TROUBLESHOOTING / Troubleshooting B
B1 B8
T1V1-05-04-002
#C7
B19 B25
T5-7-45
TROUBLESHOOTING / Troubleshooting B
E-3 When engine control dial is fully rotated, en-
gine stalls.
When engine control dial is fully rotated, en-
gine speed is slow.
T5-7-46
TROUBLESHOOTING / Troubleshooting B
E-4 Although engine control dial is rotated, en-
gine speed does not change.
T5-7-47
TROUBLESHOOTING / Troubleshooting B
E-5 Engine speed does not increase when en-
gine starts.
0 °C or higher
when starting Normal.
NO Faulty MC.
T5-7-48
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-49
TROUBLESHOOTING / Troubleshooting B
E-6 Faulty HP mode
• 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 sen- SYSTEM / Control System group in the T/M (Op-
sors fails, HP mode becomes ineffective. erational Principle).
• Pressure sensors (arm roll-in and boom raise) • Check the wiring connections first.
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.
T5-7-50
TROUBLESHOOTING / Troubleshooting B
• Although the power mode switch is not turned to HP
mode, HP mode is operated.
T5-7-51
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.)
Check if voltage at
terminal #5 in key
switch is 24 V. Shorted circuit in
NO
· Key switch: OFF harness between key
Disconnect connector
switch and ECM.
in ECM.
Check if voltage be-
tween terminal #24
NO (harness end) of con-
nector and machine is
0 V.
Faulty ECM.
· Key switch: OFF YES
Key Switch
#24
ECM Connector
(Harness end)
T1GR-05-04-002
T105-07-04-002
T5-7-52
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-53
TROUBLESHOOTING / Troubleshooting B
E-8 Faulty auto-idle system
• If trouble symptoms E1 to E8 are recognized, • Refer to the pages for Auto-Idle Control in the
perform the troubleshooting of these troubles SYSTEM / Control System group in the T/M (Op-
first. erational Principle).
• Although failure in pressure sensors (travel for- • Check the wiring connections first.
ward/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.
Connector Monitor-B
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
#B18
T5-7-54
TROUBLESHOOTING / Troubleshooting B
Refer to Engine
YES
Troubleshooting
Manual.
Check if fault code
639-2 or 639-3 is
NO displayed. Faulty corresponding
sensor, or open cir-
NO cuit in harness be-
tween MC and sen-
sor.
T5-7-55
TROUBLESHOOTING / Troubleshooting B
• Although auto-idle switch is turned OFF, auto-idle is
operated.
Shorted circuit in
YES harness between MC
Disconnect connector
MC-B in MC and con- and auto-idle switch.
nector in switch panel.
Check for continuity
between terminal #B6 Refer to fault code
(harness end) of con- YES
11004 in Trouble-
nector MC-B and ma- shooting A.
chine. Check if fault code
NO 11004-2 is displayed.
· Auto-idle switch: OFF
Faulty MC.
NO
Connector MC-B
#B6
B1 B8
B19 B25
T5-7-56
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-57
TROUBLESHOOTING / Troubleshooting B
E-9 Faulty E mode
• 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 2 delivery pressure sensors are also engaged in
first. the E mode control. However, if these sensors fail,
• The sensors detect the conditions necessary to other operating functions will be also affected.
operate E mode. Therefore, if any of these sen- • Refer to the pages for E Mode Control in the
sors fails, E mode becomes ineffective. SYSTEM / Control System group in the T/M (Op-
erational Principle).
• Check the wiring connections first.
T5-7-58
TROUBLESHOOTING / Troubleshooting B
• Although power mode switch is not turned to E
mode, engine speed decreases.
T5-7-59
TROUBLESHOOTING / Troubleshooting B
E-10 When traveling or operating front attach-
ment at slow idle, engine hunts.
T5-7-60
TROUBLESHOOTING / Troubleshooting B
E-11 Although operating attachment at attach-
ment mode, engine speed does not in-
crease.
Faulty MC.
NO
T5-7-61
TROUBLESHOOTING / Troubleshooting B
E-12 When attachment mode is selected, engine
speed does not decrease.
Faulty MC.
Check if attachment NO
speed adjustment has
been set to “Decrease
(-)” on “Parameter
Change” in Dr. ZX.
T5-7-62
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-63
TROUBLESHOOTING / Troubleshooting B
E-13 Engine stalls during operation under ad- Test Harness (ST 7226)
verse condition such as at high altitude. When operating corresponding control lever and
switch: ON
Related MC Fault Code: 11004-2, 11100-2, 11910-2,
11401-2, 11401-3, 11401-4
T107-07-06-015
Disconnect harness of
Check if fault code torque control sole-
NO
11401-2, 11401-3 or noid valve.
11401-4 is displayed. Monitor torque control NO Connect test harness
solenoid valve output. (ST 7226) between
Install pressure gauge solenoid valve and
to output port so that harness.
pressure is measured Check if test harness
by pressure gauge and lamp lights.
Dr. ZX.
NO
Monitor actual engine Check if both meas-
speed. ured pressure values
Check if engine speed by pressure gauge and
is abnormal. Dr. ZX vary identically. Disassemble and
· Monitor item: Pump YES check regulator.
· Monitor item: torque P/S valve output
Actual engine speed · Refer to the Opera-
· Possible to display by tional Performance
built-in diagnosing sys- Test section.
tem.
YES Refer to fault code
11004 in Trouble-
shooting A.
Check if fault code
11004-2 or 11100-2 is
YES displayed. YES Refer to Engine Trou-
bleshooting Manual.
Check if fault code
NO 11910-2 is displayed.
Faulty MC.
NO
T5-7-64
TROUBLESHOOTING / Troubleshooting B
T5-7-65
TROUBLESHOOTING / Troubleshooting B
E-14 Engine is difficult to start at low tempera-
ture. (During cold weather or in cold dis-
tricts, engine is difficult to start or does not
start even if pre-heated.)
Disconnect connector of
coolant temperature sensor.
Check if voltage at glow plug YES Faulty ECM.
is 20 to 24 V.
· Key switch: ON Disconnect connector in
ECM. Connect terminal #4
(harness end) of connector
NO to machine. Check if prob-
lem is corrected.
· Connect to machine from Measure each glow plug
the back of connector by NO resistance.
using a clip with the con-
nector connected. · Key switch: OFF
· Before measuring, re-
move copper plates
connecting each glow
plug.
Remove
the
copper
plate.
T105-07-04-006 T105-07-04-007
T5-7-66
TROUBLESHOOTING / Troubleshooting B
T5-7-67
TROUBLESHOOTING / Troubleshooting B
E-15 Although depressing accelerator pedal
during travel operation, engine speed does Connector (Harness end of connector viewed from the
not change. open end side)
Check if neutral
indicator on steering Faulty brake switch, or
YES shorted circuit in harness
column monitor
lights. between MC and terminal
Monitor parking #3 in brake switch.
· Key switch: ON YES brake switch. Check
· FNR switch: F or R if ON is displayed.
· Brake switch: Faulty MC.
except P (parking NO
Monitor pedal EC brake)
switch. Check if ON
NO is displayed. Disconnect connec-
YES Faulty engine speed con-
tor in switch panel. trol mode selection switch.
· Engine speed control Check if voltage be-
mode selection switch: tween terminal #1
Pedal (harness end) of
NO connector and ma- Open circuit in harness
chine is 5 V. between MC and engine
NO speed control mode selec-
· Key switch: ON tion switch.
T5-7-68
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) #11
may be the cause of this problem. In this case,
other functions should become abnormal.
T5-7-69
TROUBLESHOOTING / Troubleshooting B
ALL ACTUATOR SYSTEM TROUBLE-
SHOOTING
• Reduction in pump 1 and 2 flow rate due to some • Although speed is satisfactory, and when power is
reasons or faulty pilot system (A-2) may cause weak, refer to the troubleshooting for faulty main
this trouble. relief valve (F-1).
• Check fuse of the torque control solenoid valve. • Check the wiring connections first.
T5-7-70
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. tion with the engine stop switch in the ON position,
• If the alarm is displayed on the monitor unit, refer the starter rotates.
to Troubleshooting A. Refer to the pages for the Electrical System group
• When the key switch is turned to the START posi- / SYSTEM in the T/M (Operational Principle).
tion with the pilot shut-off lever in the LOCK posi-
tion, the starter does not rotate.
• Check the wiring connections first.
T1V1-05-04-103
#1 #2
T183-05-04-003
T5-7-71
TROUBLESHOOTING / Troubleshooting B
T5-7-72
TROUBLESHOOTING / Troubleshooting B
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 #B12
T5-7-73
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.)
T5-7-74
TROUBLESHOOTING / Troubleshooting B
A-4 Travel is not 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.)
T5-7-75
TROUBLESHOOTING / Troubleshooting B
A-5 Although control lever is turned to neutral,
actuator does not stop.
T5-7-76
TROUBLESHOOTING / Troubleshooting B
A-6 Occasionally, swing or arm roll-in speed
becomes slow during combined operation
of swing and arm roll-in.
Control Valve
Hose SE
T1V1-05-04-004
T178-03-06-015
T5-7-77
TROUBLESHOOTING / Troubleshooting B
A-7 Actuator speed is faster than normal
Precise control cannot be performed.
T5-7-78
TROUBLESHOOTING / Troubleshooting B
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
T5-7-79
TROUBLESHOOTING / Troubleshooting B
F-2 Although power digging switch is pushed,
power does not increase. Boom raise power
is weak during digging operation.
T5-7-80
TROUBLESHOOTING / Troubleshooting B
F-3 Some cylinders are not operated or speeds
are slow.
T5-7-81
TROUBLESHOOTING / Troubleshooting B
F-4 Arm speed is slow during combined opera-
tion. During combined operation of boom
raise and arm roll-in, boom raise speed is
slow. Arm speed is slow during arm level
crowding.
Related MC Fault Code: 11200-3, 11200-4, 11202-3, • Refer to the pages for the SYSTEM / Control
11202-4, 11303-3, 11303-4, 11301-3, 11301-4, System group / Arm Regenerative Control in the
11302-3, 11302-4, 11403-2, 11403-3, 11403-4 T/M (Operational Principle).
Hose SE
T1V1-05-04-004
Arm 1 Flow Rate
T178-03-06-015 Control Valve
T5-7-82
TROUBLESHOOTING / Troubleshooting B
Section A-A
A
B B
Arm Regenerative
Valve
T1V1-03-03-002 T1V1-03-03-026
A
Section B-B
T5-7-83
TROUBLESHOOTING / Troubleshooting B
F-5 Bucket is slightly slow during bucket roll-in
single operation. Bucket does not move
smoothly during bucket roll-in single opera-
tion.
T178-03-06-015
T1V1-05-04-005
T5-7-84
TROUBLESHOOTING / Troubleshooting B
F-6 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.
T5-7-85
TROUBLESHOOTING / Troubleshooting B
F-8 When boom raise or arm roll-out is operated,
boom or arm starts to move after moving
slightly downward.
T105-07-04-012
T5-7-86
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-87
TROUBLESHOOTING / Troubleshooting B
F-9 Front attachment drifts remarkably.
YES Normal.
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 T216-05-04-001
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 con-
trol valve.
T5-7-88
TROUBLESHOOTING / Troubleshooting B
Emergency
Valve
T1V1-05-04-005
TCJB-05-07-001
Adjustment Procedure:
Tighten (1) and tighten (2).
Tightening Torque:
(1) - 13 N⋅m (1.3 kgf⋅m, 9.6 lbf⋅ft)
(2) - 7 N⋅m (0.7 kgf⋅m, 5.2 lbf⋅ft)
T5-7-89
TROUBLESHOOTING / Troubleshooting B
F-10 Boom lower above ground is faster than
other actuators during combined operation.
T1V1-03-03-026
Boom Flow Rate
Control Valve T1V1-05-04-005
T5-7-90
TROUBLESHOOTING / Troubleshooting B
F-11 Machine cannot be raised off ground.
Bypass Shut-Out
Valve
Boom Lower Me-
ter-In Cut Valve
T1V1-03-03-026
T5-7-91
TROUBLESHOOTING / Troubleshooting B
F-12 Attachment speed is fast during combined
operation of attachment (optional) and front
attachment.
T1V1-05-07-102
T1V1-05-04-003
T183-05-04-009
#D9
T5-7-92
TROUBLESHOOTING / Troubleshooting B
Disconnect connec- Check if voltage be-
tor MC-D in MC. YES tween terminal #D9
Check for continuity (harness end) of To A
between terminal connector MC-D and
Disconnect connec- YES #D9 (harness end) of machine is 0 V.
tor in pressure sen- connector and ter- · Key switch: ON
sor (arm roll-out). minal #2 (harness
NO Check if voltage be- end) of connector in Open circuit in harness
Switch pressure tween terminals #1 pressure sensor (arm between MC and pressure
sensor (arm roll-out) and #3 (harness end) roll-out). NO
sensor (arm roll-out).
with other pressure of connector is 5±0.5
YES sensor.
V.
Check if fault code
for switched pres- · Key switch: ON Open circuit in harness
Check if voltage be- YES between MC and pressure
sure sensor is dis- tween terminal #1
played. sensor (arm roll-out) (ter-
(harness end) of minal #3).
connector in pressure
NO sensor (arm roll-out)
and machine is be-
tween 0.25 and 4.75 Open circuit in harness
V. between MC and pressure
NO sensor (arm roll-out) (ter-
· Key switch: ON minal #1).
T5-7-93
TROUBLESHOOTING / Troubleshooting B
F-13 Attachment speed is fast during combined
operation of attachment (optional) and front
attachment.
When breaker attached with auxiliary flow com- Shorted circuit in har-
biner line is used. NO ness between MC and
• Check the wiring connections first. pressure sensor (aux-
Disconnect connec- iliary).
tor MC-D in MC.
YES Check if voltage be- Switch pressure sen-
tween terminal #D5 sor (arm roll-out) with
(harness end) of other pressure sen-
Disconnect connector connector and ma- YES sor.
in pressure sensor chine is 0 V. Check if fault code for
(auxiliary). · Key switch: ON switched pressure
NO Check if voltage be- sensor is displayed.
tween terminals #1
and #3 (harness end)
Switch pressure of connector is 5±0.5 Open circuit in har-
sensor (auxiliary) V. YES ness between MC and
with other pressure · Key switch: ON pressure sensor (aux-
sensor. Check if voltage be- iliary) (terminal #3).
Check if fault code tween terminals #1
for switched pres- (harness end) of
sure sensor is dis- connector in pres- Open circuit in har-
played. NO sure sensor (auxil- ness between MC and
iary) and machine is pressure sensor (aux-
NO
between 0.25 and iliary) (terminal #1).
4.25 V.
· Key switch: ON
T1V1-05-07-102
Connector MC-D
#D5
T1V1-05-04-003
T183-05-04-009
#D9
T5-7-94
TROUBLESHOOTING / Troubleshooting B
T5-7-95
TROUBLESHOOTING / Troubleshooting B
F-14 Attachment speed is fast during combined
operation of attachment (optional) and front
attachment.
#A5
T1V1-05-07-102
T1V1-05-04-003
T183-05-04-009
T5-7-96
TROUBLESHOOTING / Troubleshooting B
YES
To A
Check if voltage be-
Disconnect connector YES tween terminal #C2
in pressure sensor (harness end) of con-
(travel forward). nector MC-C and
NO Check if voltage be- machine is 0 V. Shorted circuit in harness
tween terminals #1 · Key switch: ON between MC and pres-
Switch pressure sen- and #3 (harness end) NO sure sensor (travel for-
sor (travel forward) of connector is 5±0.5 ward).
YES with other pressure V.
sensor. · Key switch: ON
Check if fault code for Open circuit in harness
switched pressure Check if voltage be- YES between MC and pres-
sensor is displayed. tween terminal #1 sure sensor (travel for-
(harness end) of con- ward) (terminal #3).
nector in pressure
NO sensor (travel forward)
and machine is be- Open circuit in harness
tween 0.25 and 4.75 between MC and pres-
V.
NO sure sensor (travel for-
· Key switch: ON ward) (terminal #1).
Disconnect connector
in maximum pump 1 YES Faulty maximum pump 1
flow rate limit control flow rate limit control
solenoid valve. solenoid valve.
YES Check if current be-
tween terminals #1
and #2 (harness end)
of connector is be-
Check for continuity in
tween 56 mA and 920
harness between MC
mA.
A and maximum pump 1
Faulty MC.
flow rate limit control · Key switch: ON
solenoid valve. NO
· Between terminal
#A31 of connector Open circuit in harness
MC-A in MC and ter- between MC and maxi-
NO mum pump 1 flow rate
minal #1 of connector
in maximum pump 1 limit control solenoid
flow rate limit control valve.
solenoid valve
· Between terminal #A5
of connector MC-A in
MC and terminal #2 of
connector in maxi-
mum pump 1 flow rate
limit control solenoid
valve
T5-7-97
TROUBLESHOOTING / Troubleshooting B
SWING SYSTEM TROUBLESHOOTING
• 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.
T5-7-98
TROUBLESHOOTING / Troubleshooting B
T5-7-99
TROUBLESHOOTING / Troubleshooting B
S-2 Swing is slow (weak in power) during com-
bined operation of swing and arm roll-in.
Swing does not start smoothly.
Swing power is weak.
Faulty corresponding
YES sensor, or faulty MC.
Open circuit in harness
between MC and sensor.
Hose SE
T5-7-100
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-101
TROUBLESHOOTING / Troubleshooting B
TRAVEL SYSTEM TROUBLESHOOTING
• The travel system is inoperable unless the fol- • Air mixing in the transmission hydraulic circuit
lowing conditions are met. may cause the parking brake to drag. Bleed air
FNR Switch: F or R position from the transmission by referring to T5-7-142.
Brake Switch: OFF, Auto Axle Lock or Axle Lock • When other actuators (front attachment and
position swing) operate normally, the pilot pump, pilot filter
• Failure in the transmission and/or axle (front and pilot relief valve are considered to be normal.
and/or rear) may be the cause of the trouble. • Check the wiring connections first.
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 indi-
cator (N) in the steering column monitor are OFF.
Monitor implement
YES brake state.
Check if ON is dis-
played.
· Monitor item:
FNR (F) SW,
FNR (R) SW
Faulty FNR switch.
NO
T5-7-102
TROUBLESHOOTING / Troubleshooting B
T5-7-103
TROUBLESHOOTING / Troubleshooting B
T-2 Machine does not travel forward and re-
verse.
T5-7-104
TROUBLESHOOTING / Troubleshooting B
Check counterbalance
NO
valve in travel motor for
abnormality. YES Faulty make-up valve.
T5-7-105
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 dis- swing) operate normally, the pilot pump, pilot filter
played. and pilot relief valve is considered to be normal.
• Failure in the transmission and/or axle (front • Pump 1 flow rate reduction may be the cause of
and/or rear) may be the cause of the trouble. this trouble when bucket single operation speed is
Check if a noise is emitted from each section. slow. Refer to A-3.
• Air mixing in the transmission hydraulic circuit • Check the wiring connections first.
may cause the parking brake to drag. Bleed air
from the transmission by referring to T5-7-142.
NO
Refer to Troubleshooting A.
YES
T5-7-106
TROUBLESHOOTING / Troubleshooting B
T5-7-107
TROUBLESHOOTING / Troubleshooting B
T-4 When releasing accelerator pedal, hydraulic
brake is not applied. (Machine runs away.)
Check if counterbal-
NO ance valve in travel
motor is abnormal.
T5-7-108
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-109
TROUBLESHOOTING / Troubleshooting B
T-5 Travel mode (fast/slow) does not shift.
Travel Mode Selection
• Air mixed in the transmission hydraulic circuit Solenoid Valve
may prevent the transmission from being shifted. Port B Port K
Bleed air from the transmission by referring to
T5-7-142.
• 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.
TCJB-05-07-003
NO
Install pressure gauge to
ports B and K in transmis-
sion changeover solenoid
valve.
YES Check if pressure at each
port varies as shown be-
low when travel speed
mode switch is operated.
Monitor fast speed · Travel speed mode switch: Slow
selection relay and →Pressure at port B: 0 MPa
slow speed selection →Pressure at port K: 3.0 MPa Faulty transmission.
YES relay. · Travel speed mode switch: Fast
When shifting travel →Pressure at port B: 3.0 MPa YES
speed mode switch, →Pressure at port K: 0 MPa
check if ON is dis-
played respectively.
· Monitor item:
T/M selection (Fast)
T/M selection (Slow)
When shifting travel
speed mode switch, Faulty fast/slow speed selec-
check if slow speed tion relay.
indicator in steering NO
column monitor is
ON/OFF normally.
T5-7-110
TROUBLESHOOTING / Troubleshooting B
TCJB-05-07-002
Brown-White TCJB-05-06-004
Yellow-Green TCJB-05-06-004
T5-7-111
TROUBLESHOOTING / Troubleshooting B
T-6 Axle lock is not released.
YES
Refer to troubleshooting A.
· Monitor item:
Parking brake SW
Axle lock control state
Faulty brake switch, or shorted
circuit in harness between MC and
NO brake switch.
T5-7-112
TROUBLESHOOTING / Troubleshooting B
T-7 Axle lock is not operable.
YES
Refer to troubleshooting A.
· Brake switch:
Auto axle lock
or Axle lock
Monitor brake switch.
NO Check if OFF is
displayed.
· Monitor item:
Axle lock control state Faulty brake switch, or open circuit
· Brake switch: in harness between MC and brake
NO switch.
Auto axle lock or Axle
lock
T5-7-113
TROUBLESHOOTING / Troubleshooting B
BRAKE SYSTEM TROUBLESHOOTING
Disconnect connector
in brake switch.
Connect terminals #3
and #6 (harness end)
NO of connector.
Monitor parking brake
switch.
Check if ON is
displayed. Open circuit in harness
between MC and brake
NO switch.
Brake Switch
TCJB-05-07-004
T5-7-114
TROUBLESHOOTING / Troubleshooting B
B-2 Service brake is not operable, or is not
applied effectively.
T5-7-115
TROUBLESHOOTING / Troubleshooting B
B-3 Work brake is not operable.
Monitor implement
YES brake state.
Check if ON is
displayed.
T5-7-116
TROUBLESHOOTING / Troubleshooting B
STEERING SYSTEM TROUBLESHOOTING
T5-7-117
TROUBLESHOOTING / Troubleshooting B
OTHER SYSTEM TROUBLESHOOTING
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 operated.
the monitor unit. In case the wiper is not operated, Check that the front window is closed securely.
first check if the wiper relay is activated. Next,
check if electric power is routed to the wiper mo-
tor.
YES
Switch wiper relay with Faulty wiper relay.
NO other general relay. Disconnect connector YES
Check if wiper is oper- monitor-A in monitor Faulty monitor unit.
ated. unit.
· Key switch: ON Connect terminal #A2
NO (harness end) of con-
nector to machine. Open circuit in harness
Disconnect wiper relay. between wiper relay and
Check for continuity NO monitor unit.
Check if wiper relay between terminal #A2
is turned ON/OFF (harness end) of con-
according to INT. nector and machine.
position of wiper
switch. YES
Close front window. Faulty wiper motor.
· Key switch: ON Disconnect connector
· Wiper switch: INT YES in wiper motor.
Open front window. Check if voltage be-
tween terminals B and Open circuit in harness
Check if voltage be-
L (harness end) of between window con-
tween terminals B NO
connector is 24 V. tact and wiper motor.
YES and L at window
contact in cab end is · Key switch: ON
24 V. · Wiper switch: ON
· Key switch: ON Open circuit in harness
· Wiper switch: ON NO between wiper relay and
window contact.
T5-7-118
TROUBLESHOOTING / Troubleshooting B
T183-05-05-001
Main
Window Contact ↑
T1V1-05-07-004
T5-7-119
TROUBLESHOOTING / Troubleshooting B
O-2 Air Conditioner is faulty
Normal Operation
Push lower side fan switch. Push upper side fan switch.
Keep pushing OFF switch STEP 1
for more than 3 seconds. Display Function
Confirmation
Push lower side fan switch. Push upper side fan switch.
Keep pushing OFF switch STEP 2
for more than 3 seconds. Present Trouble
Diagnosing
Push lower side fan switch. Push upper side fan switch.
Push lower side fan switch. Push upper side fan switch.
Keep pushing OFF switch
for more than 3 seconds. 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 Push AUTO Push A/C Push A/C switch and
lower side fan switch. Switch and switch and upper side fan switch.
upper side lower side
fan switch. fan switch.
Keep pushing OFF switch STEP 6-1 STEP 6-2
for more than 3 seconds. Correction of the Set Selection of Celsius and Fahrenheit
Temperature Temperature Indication
Keep pushing OFF switch
for more than 3 seconds.
Self-Diagnosis
T5-7-120
TROUBLESHOOTING / Troubleshooting B
Self-Diagnostic System Activation
Fan Switch LCD Air Conditioner Switch
Turn the key switch ON while pushing the air condi-
tioner switch and mode switch on air conditioner con-
trol panel.
T5-7-121
TROUBLESHOOTING / Troubleshooting B
STEP 2 Present Trouble Diagnosing
The LCD indicates the fault codes for present ab-
Fan Switch LCD
normalities of the mix door, mode encoder, and/or
sensors.
T5-7-122
TROUBLESHOOTING / Troubleshooting B
STEP 3 Past Trouble Diagnosing
The LCD indicates the fault codes for past abnor-
Fan Switch LCD Air Conditioner Switch
malities of the mix door, mode encoder, and/or sen-
sors.
The past stored fault codes are deleted.
T5-7-123
TROUBLESHOOTING / Troubleshooting B
STEP 4 Sensing Temperature Display Fan Mark
The LCD indicates the sensing temperature detected
Fan Switch LCD Air Conditioner Switch
by each temperature sensor (excluding the insulation
sensor).
T5-7-124
TROUBLESHOOTING / Troubleshooting B
STEP 5 Component Operation Check Air Conditioner
Fan Switch LCD Switch AUTO Switch
Each component operation is checked by performing
pattern operation.
Table 1
Component Indication Operation Pattern Remarks
on LCD
Air Mix Damper 51 Controls opening extent of air mix 0%, 50%, 100%: “C”, “5” and “H” are in-
damper: 0% (fully closed) → dicated next to the decimal point respec-
50%*→ 100% (fully opened) tively.
Fan 52 Controls air flow volume: Lo → Indicators corresponding to air flow vol-
M(Lo) → M(Hi) → Hi ume light.
Air Vent Location 53 Selects air vent: Front*→ Indicator corresponding to selected air
Front/Rear → Front/Foot → Foot vent lights.
Fresh / Circulation 54 Select Ventilation Mode: Circula- Indicator corresponding to selected
Air Vent Selection tion* → Fresh mode light.
Air Conditioner 55 Turns air conditioner switch: ON* ON: Indicator lights.
→ OFF OFF: Indicator is extinguished.
T5-7-125
TROUBLESHOOTING / Troubleshooting B
STEP 6-1 Correction of the Set Temperature
Fine correction of the set temperature. Temperature
Fan Switch LCD Control Switch AUTO Switch
T5-7-126
TROUBLESHOOTING / Troubleshooting B
STEP 6-2 Selection of Celsius and Fahrenheit
Temperature Indication
Fan Switch LCD Air Conditioner Switch
Selection of Celsius and Fahrenheit Temperature In-
dication.
• Each time when the fresh air vent switch is pushed,
Celsius or Fahrenheit temperature may be dis-
played alternately.
• Temperature is displayed at the top of LCD window
as follows.
(C: Celsius, F: Fahrenheit) T178-05-08-001
T5-7-127
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.
T5-7-128
TROUBLESHOOTING / Troubleshooting B
Refrigerant Quantity....................... 900±50 g
3
Compressor Oil Quantity................ 210 cm
T5-7-129
TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Refrigerant pressure Bubbles can be seen in sight Piping and/or parts are stained with oil,
in both high and glass. respond to gas detector.
low-pressure sides is
low.
No oil stain is found or gas detector
does not respond. Refrigerant has not
been refilled for longer than one sea-
son.
No bubbles are seen in sight
glass.
Refrigerant pressure
in low-pressure side Bubbles can be seen in sight Compressor cylinder is extremely hot,
Insuffi- is high. glass. emitting a smell.
cient
Cooling
Power
Refrigerant pressure in Compressor cylinder is extremely hot,
high-pressure side is low. emitting a smell.
Refrigerant pressure
in high-pressure side Bubbles can be seen in sight Refrigerant pressure in low-pressure
is high. glass. side is low.
Even if condenser is sprayed with water, few bubbles appear. Receiver dryer tem-
perature is low.
Thermistor cools.
T5-7-130
TROUBLESHOOTING / Troubleshooting B
Gas leaks from pipe joints and/or parts. Re-tighten or replace parts.
Improper adjustment (excessive restriction) of expansion valve. Readjust or replace expansion valve.
Frozen expansion valve or water in circuit. After evacuation, refill refrigerant and/or replace re-
ceiver 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.
Clogged high-pressure circuit before receiver dryer. Remove clog, or replace parts.
Clean Condenser.
Gas leaks from case. Seal gaps by using vinyl tape or packing compound.
Even if function and performance are normal, when Instruct user on correct air-conditioner operation.
air-conditioner is kept operated for a long time with thermistor (Reset thermistor to either minimum or middle cooling
in max. cooling position and air flow in M or L mode, frost may position or increase air flow.)
form.
T5-7-131
TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Gas blowing sound (roaring). Gas vibration noise (compressor discharge and/or suc-
tion gas noise).
Expansion valve connection, whistle Abnormal noise from expansion valve (Expansion
Noise sound, gas blowing sound. valve is normally functioning.).
Noisy compressor.
Compressor rotating sound.
Vibration and/or loose screws due to excessive drive
belt looseness.
T5-7-132
TROUBLESHOOTING / Troubleshooting B
Repair or replace.
Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.
Replace.
Repair or replace.
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.
T5-7-133
TROUBLESHOOTING / Troubleshooting B
Compressor
Inoperable
cooling Clutch terminal voltage is low.
system.
T5-7-134
TROUBLESHOOTING / Troubleshooting B
Oil and refrigerant leaks from front housing, and/or cylinder block joint. Replace.
No leaks (normal).
Replace.
Blown gasket (Refer to NOTE 3 on page T5-7-137.)
T5-7-135
TROUBLESHOOTING / Troubleshooting B
Compressor
Trouble other than compressor. Refer to the Cooling Circuit Troubleshooting Ta-
ble on page T5-7-130.
Abnormal
noise
T5-7-136
TROUBLESHOOTING / Troubleshooting B
Loose screws.
Broken valve.
Replace.
Blown gasket.
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 sur-
face may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
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 dis-
appear within about 10 seconds.
T5-7-137
TROUBLESHOOTING / Troubleshooting B
EXCHANGE INSPECTION
Check Method:
1. Switch two delivery pressure sensors located as
Figure A
shown in figure A to figure B.
2. Retry troubleshooting. T157-07-04-006
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.
Pump 2 Pump 1
(5-Spool (4-Spool
In case abnormal pump 1 delivery pressure sensor Section) Section)
high voltage (MC fault code 11200-3) is displayed, the
pump 1 delivery pressure sensor harness is consid-
ered to be faulty. PP1 PP2
Figure B T157-07-04-006
T5-7-138
TROUBLESHOOTING / Troubleshooting B
Applicability of Switch-Check Method
T5-7-139
TROUBLESHOOTING / Troubleshooting B
T5-7-140
TROUBLESHOOTING / Troubleshooting B
T5-7-141
TROUBLESHOOTING / Troubleshooting B
BLEEDING AIR FROM TRANSMISSION
Slow Speed
TCJB-04-03-001
T5-7-142
TROUBLESHOOTING / Troubleshooting B
BLEEDING AIR FROM BRAKE (AXLE)
MCBB-01-008
T5-7-143
TROUBLESHOOTING / Troubleshooting B
EMERGENCY BOOM LOWERING
PROCEDURE (WITHOUT HOSE RUPTURE
VALVE)
T5-7-144
TROUBLESHOOTING / Troubleshooting B
ATTACHMENT CIRCUIT PRESSURE
RELEASE PROCEDURE
Pilot Shut-Off
Solenoid Valve
Control Valve
Accumulator
Pilot Pump
Engine TCJB-05-07-005
T5-7-145
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-146
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
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 Correct Incorrect
wire itself. Release the lock first before
attempting to separate connectors, if a lock is
provided. (Refer to Instructions for
Disconnecting Connectors on T5-8-3.)
• The water-resistant connectors keep water out. T107-07-06-001
T5-8-2
TROUBLESHOOTING / Electrical System Inspection
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
T107-04-05-004
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 NOTE: All terminals located along the lengthwise
impossible to find by visual inspection. Use a tester in centerline of the fuse box are connected to
order to correctly inspect fuse continuity by following the power source, while terminals located
the instructions described below. away from center of the fuse box are
connected to loads (accessories).
1. Turn the key switch ON. Therefore, test all fuses in the same
When the key switch is turned ON, current from method except for the glow relay circuit
key switch terminal M activates the battery relay fuse. Check the glow relay circuit fuse with
so that electric power is supplied to all circuits the key switch turned to the ON position
except the glow plug relay circuit. (Refer to the and follow the procedure in step 3.
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).
30 40
10 20
29 39
9 19
28 38
8 18
27 37
7 17
26 36
6 16
25 35
5 15
24 34
4 14
23 33
3 13
22 32
2 12
21 31
1 11
M178-07-034
M178-07-034
T5-8-4
TROUBLESHOOTING / Electrical System Inspection
T5-8-5
TROUBLESHOOTING / Electrical System Inspection
FUSIBLE LINK INSPECTION
Battery Relay
Inspection
Replacement
Fusible Link
T111-04-05-015
T5-8-6
TROUBLESHOOTING / Electrical System Inspection
BATTERY VOLTAGE CHECK
Normal Voltage: 24 V
Normal Voltage: 26 to 28 V
T162-05-06-005
T5-8-7
TROUBLESHOOTING / Electrical System Inspection
HOW TO CHECK ALTERNATOR Monitor Unit
T157-07-06-003
T5-8-8
TROUBLESHOOTING / Electrical System Inspection
CONTINUITY CHECK Harness
Short-circuit between
NOTE: By conducting the multi-line continuity harnesses
check twice, it is possible to find out which
line is discontinued. With terminals (A) and A a
(C) short-circuited, check continuity B X
b
between terminals (a) and (c). C c
If the ohm-meter reading is:
0 Ω = Line (B) - (b) has discontinuity.
∞ Ω = Line (A) - (a) has discontinuity.
T5-8-9
TROUBLESHOOTING / Electrical System Inspection
VOLTAGE AND CURRENT
MEASUREMENT
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
T5-8-10
TROUBLESHOOTING / Electrical System Inspection
Key Switch
Fuse
Box
5
1 2 3 4 6
17
Load
Damp
Relay
Battery Relay
Battery
13 10 14 15 16
9
Starter
Relay
11
8 7
Glow Plug Relay
Alternator
Glow
Plug
12
C7
Monitor
Unit
TCJB-05-08-001
T5-8-11
TROUBLESHOOTING / Electrical System Inspection
T5-8-12
TROUBLESHOOTING / Electrical System Inspection
25 26 18
Starter
Cut Relay
19
Battery
20 24 Fuse
Starter Box
21
Starter
Relay 22
23
32
ECM
Main
Relay
33
Option
ECM MC Monitor Unit ICF Controller
24 B16 A7 C7 B16
TCJB-05-08-001
30 29 28 27 31
T5-8-13
TROUBLESHOOTING / Electrical System Inspection
Key
Engine Location to be Measured Specification
Switch
Pilot Shut-Off Circuit
Stopped ON Between (34) and (E): Fuse Box 20 to 25 V
Stopped ON Between (35) and (E): Pilot Shut-Off Relay 20 to 25 V
Stopped ON Between (36) and (E): Pilot Shut-Off Solenoid Valve 20 to 25 V
Stopped ON Between (37) and Ground: Pilot Shut-Off Relay 20 to 25 V
Stopped ON Between (38) and (E): Security Relay 20 to 25 V
T5-8-14
TROUBLESHOOTING / Electrical System Inspection
34
Battery
Battery Relay
Fuse Box
36
Pilot
Shut-Off
Solenoid
Security Pilot
Relay Shut-Off
Relay
38 37 35
CJB-05-08-001
T5-8-15
TROUBLESHOOTING / Electrical System Inspection
5 Voltage Circuit
Power Signal or
• Voltage between terminal #1 and the vehicle Two Polarities Source Ground
frame 1 2
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 V
• Tester black terminal (negative):
Connected to the vehicle frame (ground)
• Tester red terminal (positive):
Connected to terminal #1
T107-07-05-006
Power
Evaluation: Three Polarities
Source Signal Ground
If the measuring voltage is within 5±0.5 volts, the 1 2 3
circuit up to terminal #1 is normal.
T107-07-05-009
T5-8-16
TROUBLESHOOTING / Electrical System Inspection
Connect
T107-07-05-011
T5-8-17
TROUBLESHOOTING / Electrical System Inspection
TEST HARNESS
T5-8-18
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162
REPLY:
3. CONNECTORS
CAB HARNESS
(ZX210W-3: Up to serial No.002539/ ZX210W-3-AMS: Up to serial No.020140/ ZX220W-3M: Up to serial
No.041128/ ZX220W-3DH: Up to serial No.001110)
5. ENGINE HARNESS
FLOOR HARNESS
6. MONITOR HARNESS
CHASSIS HARNESS