Zaxis 130 Fallas
Zaxis 130 Fallas
Zaxis 130 Fallas
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
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition The Engine Manual
to this manual. Parts Catalog of the Engine
Hitachi Training Material
The Operators Manual
The Parts Catalog
MANUAL COMPOSITION
This manual consists of three portions: the Techni- Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
Information included in the Technical Manual Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redelivery and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
Each page has a number, located on the center
lower part of the page, and each number contains
the following information:
Example : T 1-3-5
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and CAUTION:
signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
NOTE:
To avoid injury and damage, be sure to use appropri-
Indicates supplementary technical information or
ate lifting techniques and equipment when lifting
know-how.
heavy parts.
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
2
Length mm in 0.03937 Pressure MPa kgf/cm 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
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque Nm kgf m 1.0197 mL/rev cc/rev 1.0
Nm lbf ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
These are the SAFETY ALERT SYMBOLS.
001-E01A-0001
SA-688
002-E01A-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
Carefully read and follow all safety signs on the
machine and all safety messages in this manual.
Safety signs should be installed, maintained and
replaced when necessary.
003-E01B-0003
SA-2
SAFETY
PREPARE FOR EMERGENCIES
Be prepared if a fire starts or if an accident occurs.
004-E01A-0437
005-E01A-0438
SA-3
SAFETY
PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause im-
pairment or loss of hearing.
006-E01A-0434
SA-434
INSPECT MACHINE
Inspect your machine carefully each day or shift by
walking around it before you start it to avoid per-
sonal injury.
007-E01A-0435
SA-435
SA-4
SAFETY
GENERAL PRECAUTIONS FOR CAB
Before entering the cab, thoroughly remove all dirt
and/or oil from the soles of your work boots. If any
controls such as a pedal is operated while with
dirt and/or oil on the soles of the operator's work
boots the operator's foot may slip off the pedal,
possibly resulting in a personal accident.
Do not leave parts and/or tools lying around the
operator's seat. Store them in their specified loca-
tions.
Avoid storing transparent bottles in the cab. Do
not attach any transparent type window decora-
tions on the windowpanes as they may focus
sunlight, possibly starting a fire.
Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab
while operating the machine.
Keep all flammable objects and/or explosives
away from the machine.
After using the ashtray, always cover it to extin-
guish the match and/or tobacco.
Do not leave cigarette lighters in the cab. When
the temperature in the cab increases, the lighter
may explode.
524-E01A-0000
SA-5
SAFETY
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal injury.
008-E01A-0439
SA-439
009-E01A-0462
SA-6
SAFETY
ENSURE SAFETY BEFORE RISING FROM
OR LEAVING OPERATOR'S SEAT
Before rising from the operator's seat to open/close
either side window or to adjust the seat position, be
sure to first lower the front attachment to the ground
and then move the pilot control shut-off lever to the
LOCK position. Failure to do so may allow the ma-
chine to unexpectedly move when a body part un-
intentionally comes in contact with a control lever,
possibly resulting in serious personal injury or death.
010-E01A-0237
SA-7
SAFETY
MOVE AND OPERATE MACHINE SAFELY
Bystanders can be run over.
011-E01A-0398
036-E01A-0293-3
SA-8
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
Inappropriate engine starting procedures may cause
the machine to runaway, possibly resulting in seri-
ous injury or death.
012-E01B-0431
JUMP STARTING
Battery gas can explode, resulting in serious injury.
S013-E01A-0032
SA-9
SAFETY
KEEP RIDERS OFF MACHINE
Riders on machine are subject to injury such as be-
ing struck by foreign objects and being thrown off
the machine.
014-E01B-0427
SA-379
M104-05-015
SA-10
SAFETY
INVESTIGATE JOB SITE BEFOREHAND
When working at the edge of an excavation or on a
road shoulder, the machine could tip over, possibly
resulting in serious injury or death.
Investigate the configuration and ground condi-
tions of the job site beforehand to prevent the
machine from falling and to prevent the ground,
stockpiles, or banks from collapsing.
Make a work plan. Use machines appropriate to
the work and job site.
Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
When working on an incline or on a road shoulder, SA-380
employ a signal person as required.
Confirm that your machine is equipped a FOPS
cab before working in areas where the possibility
of falling stones or debris exist.
When the footing is weak, reinforce the ground
before starting work.
When working on frozen ground, be extremely
alert. As ambient temperatures rise, footing be-
comes loose and slippery.
Beware the possibility of fire when operating the
machine near flammable objects such as dry
grass.
Make sure the worksite has sufficient strength to
firmly support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks po-
sitioned perpendicular to the cliff face with travel
motors at the rear, so that the machine can more
easily evacuate if the cliff face collapses.
If working on the bottom of a cliff or a high bank is
required, be sure to investigate the area first and
confirm that no danger of the cliff or bank collapsing
exists. If any possibility of cliff or bank collapsing
exists, do not work on the area.
Soft ground may collapse when operating the ma-
chine on it, possibly causing the machine to tip over.
When working on a soft ground is required, be sure
to reinforce the ground first using large pieces of
steel plates strong and firm enough to easily support
the machine.
Note that there is always a possibility of machine
tipping over when working on rough terrain or on
slopes. Prevent machine tipping over from occurring.
When operating on rough terrain or on slopes:
Reduce the engine speed.
Select slow travel speed mode.
Operate the machine slowly and be cautious with
machine movements.
SA-11
SAFETY
EQUIPMENT OF HEAD GUARD, ROPS,
FOPS
In case the machine is operated in areas where the
possibility of falling stones or debris exist, equip a
head guard, ROPS, or FOPS according to the poten-
tial hazardous conditions. (The standard cab for this
machine corresponds to ROPS and FOPS.)
SA-490
018-E01A-0481
SA-481
017-E01A-0491
SA-491
SA-12
SAFETY
DRIVE MACHINE SAFELY
Before driving the machine, always confirm that the
travel levers/pedals direction corresponds to the di-
rection you wish to drive.
SA-658
SA-441
SA-442
SA-13
SAFETY
DRIVE MACHINE SAFELY
Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover.
If the direction must be changed, move the ma-
chine to level ground, then, change the direction
to ensure safe operation.
Avoid swinging the upperstructure on slopes.
Never attempt to swing the upperstructure down-
hill. The machine may tip over. If swinging uphill is
unavoidable, carefully operate the upperstructure
and boom at slow speed. Travel Motor
If the engine stalls on a slope, immediately lower
the bucket to the ground. Return the control lev-
M104-05-008
ers to neutral. Then, restart the engine.
Be sure to thoroughly warm up the machine be-
fore ascending steep slopes. If hydraulic oil has
not warmed up sufficiently, sufficient performance
may not be obtained.
Use a signal person when moving, swinging or
operating the machine in congested areas. Coor-
dinate hand signals before starting the machine.
Before moving machine, determine which way to
move travel pedals/levers for the direction you
Arrow-Mark
want to go. When the travel motors are in the rear,
pushing down on the front of the travel pedals or M178-03-001
SA-14
SAFETY
Use wood plates in order not to damage the road
surface. Be careful of steering when operating on
asphalt roads in summer.
When crossing train tracks, use wood plates in
order not to damage them.
Do not make contact with electric wires or
bridges.
When crossing a river, measure the depth of the
river using the bucket, and cross slowly. Do not
cross the river when the depth of the river is
deeper than the upper edge of the upper roller.
When traveling on rough terrain, reduce engine
speed. Select slow travel speed. Slower speed
will reduce possible damage to the machine.
Avoid operations that may damage the track and SA-011
undercarriage components.
During freezing weather, always clean snow and
ice from track shoes before loading and unloading
machine, to prevent the machine from slipping.
SA-15
SAFETY
AVOID INJURY FROM ROLLAWAY ACCI-
DENTS
Death or serious injury may result if you attempt to
mount or stop a moving machine.
To avoid rollaways:
Select level ground when possible to park ma-
chine.
Do not park the machine on a grade.
Lower the bucket and/or other work tools to the
ground.
Turn the auto-idle switch and the H/P mode
switch off.
Run the engine at slow idle speed without load for
5 minutes to cool down the engine. SA-391
Stop the engine and remove the key from the key
switch.
Pull the pilot control shut-off lever to LOCK posi-
tion.
Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
Position the machine to prevent rolling.
Park a reasonable distance from other machines.
SA-392
020-E02A-0493
SA-16
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
If any person is present near the machine when
backing or swinging the upperstructure, the machine
may hit or run over that person, resulting in serious
injury or death.
021-E01A-0494
SA-17
SAFETY
KEEP PERSON CLEAR FROM WORKING
AREA
A person may be hit severely by the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.
022-E01A-0386
SA-386
023-E01A-0487
SA-487
AVOID UNDERCUTTING
In order to retreat from the edge of an excavation if
the footing should collapse, always position the un-
dercarriage perpendicular to the edge of the exca-
vation with the travel motors at the rear.
024-E01A-0488 SA-488
SA-18
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE---SERIOUS OR FATAL CRUSHING IN-
JURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU
CAN JUMP FREE
FASTEN YOUR SEAT BELT
The danger of tipping is always present when oper-
ating on a grade, possibly resulting in serious injury
or death.
To avoid tipping:
Be extra careful before operating on a grade.
SA-012
025-E03B-0463
026-E01A-0519
SA-489
SA-19
SAFETY
DIG WITH CAUTION
Accidental severing of underground cables or gas
lines may cause an explosion and/or fire, possibly
resulting in serious injury or death.
027-E01A-0382
SA-389
028-E01A-0389
SA-20
SAFETY
AVOID POWER LINES
Serious injury or death can result if the machine or
front attachments are not kept a safe distance from
electric lines.
OBJECT HANDLING
If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed under-
neath it, resulting in serious injury or death.
SA-21
SAFETY
PROTECT AGAINST FLYING DEBRIS
If flying debris hit eyes or any other part of the body,
serious injury may result.
031-E01A-0432
SA-432
ards.
Do not incinerate or puncture pressurized con-
tainers.
Do not store oily rags; they can ignite and burn
spontaneously.
Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
SA-22
SAFETY
TRANSPORT SAFELY
Take care the machine may turn over when loading
or unloading the machine onto or off of a truck or
trailer.
035-E07A-0454
SA-23
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
Understand service procedures before starting
work.
Keep the work area clean and dry.
Do not spray water or steam inside cab.
Never lubricate or service the machine while it is
moving.
Keep hands, feet and clothing away from
power-driven parts.
500-E02C-0520
SA-527
SA-24
SAFETY
If a maintenance procedure must be performed
with the engine running, do not leave machine
unattended.
If the machine must be raised, maintain a 90 to
100° angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
Inspect certain parts periodically and repair or re-
place as necessary. Refer to the section discuss-
ing that part in the "MAINTENANCE" chapter of
this manual.
SA-037
Keep all parts in good condition and properly in-
stalled.
Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or de-
bris.
When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such
as fuel oil and gasoline to clean parts or surfaces.
Disconnect battery ground cable (-) before mak-
ing adjustments to electrical systems or before
performing welding on the machine.
Sufficiently illuminate the work site. Use a main-
tenance 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, anti-
freeze fluid, or window washer fluid may catch
fire.
501-E01A-0287
T1J1-01-01-001
SA-25
SAFETY
SUPPORT MACHINE PROPERLY
Never attempt to work on the machine without se-
curing the machine first.
SA-527
519-E01A-0527
502-E01A-0026
SA-026
SA-26
SAFETY
PREVENT PARTS FROM FLYING
Grease in the track adjuster is under high pressure.
Failure to follow the precautions below may result in
serious injury, blindness, or death.
503-E01B-0344
504-E01A-0034
SA-034
SA-27
SAFETY
PREVENT BURNS
Hot spraying fluids:
505-E01B-0498
S506-E01A-0019
SA-28
SAFETY
AVOID HIGH-PRESSURE FLUIDS
Fluids such as diesel fuel or hydraulic oil under
pressure can penetrate the skin or eyes causing se-
rious injury, blindness or death.
507-E03A-0499
SA-292
SA-044
SA-29
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
Clean up Flammables:
Spilled fuel and oil, and trash, grease, debris, ac-
cumulated coal dust, and other flammables may
cause fires.
Prevent fires by inspecting and cleaning the ma-
chine daily and by removing spilled or accumu-
lated flammables immediately.
Check Key Switch:
If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
Always check key switch function before operating
the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to con-
firm that the engine stops.
If any abnormalities are found, be sure to repair
them before operating the machine.
508-E02B-0019
SA-30
SAFETY
EVACUATING IN CASE OF FIRE
If a fire breaks out, evacuate the machine in the fol-
lowing way:
18-E02B-0393
SS-1510
509-E01A-0016
SA-016
523-E01A-0818
SA-31
SAFETY
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
510-E01B-0030
511-E01A-0029
SA-32
SAFETY
BEWARE OF ASBESTOS DUST
Take care not to inhale dust produced in the work
site. Inhalation of asbestos fibers may be the cause
of lung cancer.
512-E01B-0032
SA-33
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
If spilled onto skin, refrigerant may cause a cold
contact burn.
513-E01A-0405
SA-405
mended equipment.
See your authorized dealer for MSDS's (available
only in English) on chemical products used with
your machine.
515-E01A-0309
SA-34
SAFETY
DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the en-
vironment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
516-E01A-0226
S517-E01A-0435
SA-435
SA-35
SAFETY
(Blank)
SA-36
SECTION AND GROUP SECTION 4 OPERATIONAL PER-
CONTENTS FORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
TECHNICAL MANUAL
Group 6 Adjustment
(Troubleshooting) SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Monitor Unit
Group 3 Dr. ZX
Group 4 e-Shovel
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 Travel Device
All information, illustrations and speci- Group 2 Control System Group 6 Signal Control Valve
fications in this manual are based on Group 3 ECM System Group 7 Others (Upperstructure)
the latest product information available Group 4 Hydraulic System Group 8 Others (Undercarriage)
at the time of publication. The right is Group 5 Electrical System
reserved to make changes at any time
without notice. WORKSHOP MANUAL
SECTION 1 GENERAL INFORMA- Group 10 2-Spool Solenoid Valve Unit
TION Group 11 Engine
Group 1 Precautions for Disassem- SECTION 3 UNDERCARRIAGE
bling and Assembling Group 1 Swing Bearing
Group 2 Tightening Torque Group 2 Travel Device
Group 3 Painting Group 3 Center Joint
COPYRIGHT(C)2007
Group 4 Bleeding Air from Hydraulic Group 4 Track Adjuster
Hitachi Construction Machinery Co., Ltd.
Oil Tank Group 5 Front Idler
Tokyo, Japan
SECTION 2 UPPERSTRUCTURE Group 6 Upper and Lower Roller
All rights reserved
Group 1 Cab Group 7 Track
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 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Solenoid
Valve
Group 9 Signal Control Valve
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction Group 4 Excavator Test
Operational Performance Tests ................ T4-1-1 Travel Speed............................................. T4-4-1
Preparation for Performance Tests ........... T4-1-2 Track Revolution Speed ............................ T4-4-2
Mistrack Check ......................................... T4-4-3
Group 2 Standard Travel Parking Leakage ............................ T4-4-4
ZX110-3 Class Operational Swing Speed ............................................. T4-4-5
Performance Standard Table .................. T4-2-1 Swing Function Drift Check....................... T4-4-6
ZX120-3 Class Operational Swing Motor Leakage ............................... T4-4-8
Performance Standard Table .................. T4-2-5 Maximum Swingable Slant Angle ............ T4-4-10
ZX135US-3 Class Operational Swing Bearing Play................................. T4-4-12
Performance Standard Table .................. T4-2-9 Hydraulic Cylinder Cycle Time ................ T4-4-14
Main Pump P-Q Diagram........................ T4-2-13 Dig Function Drift Check ......................... T4-4-16
Sensor Activating Range ........................ T4-2-15 Control Lever Operating Force................ T4-4-19
ZX110-3 Class Dr. ZX Control Lever Stroke ............................... T4-4-21
Monitor Indicating Values...................... T4-2-16 Combined Operation of
ZX120-3 Class Dr. ZX Boom Raise / Swing Function Check .... T4-4-22
Monitor Indicating Values...................... T4-2-21 Combined Operation of Boom Raise
ZX135US-3 Class Dr. ZX / Arm Roll-In Function Check ................ T4-4-24
Monitor Indicating Values...................... T4-2-26
1R7T-4-1
Group 5 Component Test
Primary Pilot Pressure .............................. T4-5-1
Secondary Pilot Pressure ......................... T4-5-3
Solenoid Valve Set Pressure .................... T4-5-5
Main Pump Delivery Pressure .................. T4-5-8
Main Relief Set Pressure .......................... T4-5-9
Relief Pressure
(When Relieving Swing) .................... T4-5-13
Relief Pressure
(When Relieving Travel) .................... T4-5-14
Overload Relief Valve Set Pressure........ T4-5-15
Main Pump Flow Rate Measurement ...... T4-5-18
Swing Motor Drainage ............................ T4-5-26
Travel Motor Drainage ............................ T4-5-28
Group 6 Adjustment
Adjustment ............................................... T4-5-1
Attachment Setting ................................ T4-5-20
1R7T-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedure to quan- The machine performance does not always deterio-
titatively check all system and functions on the ma- rate as the working hours increase. However, the
chine. machine performance is normally considered to re-
duce in proportion to the increase of the operation
Purpose of Performance Tests hours. Accordingly, restoring the machine perform-
1. To comprehensively evaluate each operational ance by repair, adjustment, or replacement shall con-
function by comparing the performance test data sider the number of the machines 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 machines 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
Observe the following rules in order to carry out
performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to
run straight more than 20 m (65 ft 7 in), and to
make a full swing with the front attachment ex-
tended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork-
ers. Once the test is started, be sure to commu-
nicate with each other using these signals, and to
follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid acci-
dents due to landslides or contact with
high-voltage power lines. Always confirm that
there is sufficient space for full swings.
4. Avoid polluting the machine and the ground with T105-06-01-003
T105-06-01-004
T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard
ZX110-3 CLASS OPERATIONAL
PERFORMANCE STANDARD TABLE
The standard performance values are listed in the The following conditions are required for
table below. Refer to T4-3 to T4-6 as for performance measurement.
test procedures. The values indicated in parentheses Engine Control Dial: Fast Idle
are reference values. Power Mode Switch: P Mode
Auto-Idle Switch: OFF
Work Mode: Digging Mode
Hydraulic Oil Temperature: 50 5 C (122 9 F)
Engine Coolant Temperature: 55 C (131 F) or more
ZX110-3 class
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
-1
ENGINE SPEED min T4-3-1
Slow Idle Speed 1050 50 Value indicated on Dr. ZX
Fast Idle Speed (normal) 1700 50 Value indicated on Dr. ZX
Lever in neutral, Pilot shut-off
Fast Idle Speed (with ECO deactivated) 1800 50
lever: UNLOCK position
Fast Idle Speed
1800 50
(during travel single operation)
Fast Idle Speed (during relief operation) 1800 50 Boom raise relief operation
Fast Idle Speed (E mode) 1650 50 Lever in neutral
Relief operation of boom rasie
Fast Idle Speed (HP mode) 2000 50
and arm roll-in
Auto-Idle Speed 1200 50
Hydraulic oil temperature
Warming-Up Speed 1400 100 when engine starts: 0 C or
less
ENGINE COMPRESSION PRESSURE 3.04 0.2 Engine speed: 200min-1 T4-3-3
2
MPa (kgf/cm , psi) (31 2, 442 29)
VALVE CLEARANCE (IN, EX) 0.15 With the engine cold T4-3-4
LUBRICANT CONSUMPTION Hour meter: 2000 hours or T4-3-7
30 or less
(Rated output) mL/h less
TRAVEL SPEED sec/10 m T4-4-1
Fast Speed 6.5 0.6
Slow Speed 11.0 1.2
TRACK REVOLUTION SPEED sec/3 rev T4-4-2
Fast Speed 13.8 1.0 With one side track raised
Slow Speed 21.0 2.0
MISTRACK mm/20 m T4-4-3
200 or less
(With fast and slow travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0 T4-4-4
T4-2-1
OPERATIONAL PERFORMANCE TEST / Standard
ZX110-3 class
Referenc
PERFORMANCE TEST DESIGNATION (Performance Remarks
e Page
Standard)
SWING SPEED sec/3 rev 13.5 1.0 Bucket: empty T4-4-5
2.26 m arm T4-4-6
SWING FUNCTION DRIFT CHECK 3
860 or less 0.45 m (PCSA heaped)
mm/180
bucket, bucket: empty
2.26 m arm T4-4-8
SWING MOTOR LEAKAGE mm/5 min 0 0.45 m3 (PCSA heaped)
bucket, bucket: loaded
MAXIMUM SWINGABLE SLANT ANGLE Bucket: loaded T4-4-10
21 or more
deg.
SWING BEARING PLAY mm 0.2 to 1.25 Allowable limit: 2.0 to 3.05 T4-4-12
HYDRAULIC CYLINDER CYCLE TIME 2.26 m arm T4-4-14
sec 0.45 m3 (PCSA heaped)
bucket, bucket: empty
Boom Raise 2.9 0.3
Boom Lower 2.3 0.3
Arm Roll-In 2.9 0.3
Arm Roll-Out 2.2 0.3
Bucket Roll-In 3.3 0.3
Bucket Roll-Out 2.4 0.3
DIG FUNCTION DRIFT CHECK 2.26 m arm T4-4-16
mm/5 min 0.45 m3 (PCSA heaped)
bucket
Boom Cylinder
(Maximum Reach Position) 10 or less Bucket: loaded
(Arm Roll-In position) 5 or less Bucket: empty
Arm Cylinder
(Maximum Reach Position) 20 or less Bucket: loaded
(Arm Roll-In position) 15 or less Bucket: empty
Bucket Cylinder
(Maximum Reach Position) 15 or less Bucket: loaded
(Arm Roll-In position) 10 or less Bucket: empty
Bucket Bottom
(Maximum Reach Position) 150 or less Bucket: loaded
(Arm Roll-In position) 110 or less Bucket: empty
T4-2-2
OPERATIONAL PERFORMANCE TEST / Standard
ZX110-3 class
Referenc
PERFORMANCE TEST DESIGNATION (Performance Remarks
e Page
Standard)
CONTROL LEVER OPERATING FORCE HITACHI lever pattern T4-4-20
N (kgf, lbf)
Boom Lever 16 (1.6, 3.6) or
less
Arm Lever 13 (1.3, 2.9) or
(ISO Lever Pattern: Swing Lever) less
Bucket Lever 13 (1.3, 2.9) or
less
Swing Lever 16 (1.6, 3.6) or
(ISO Lever Pattern: Arm Lever) less
Travel Lever 28 (2.8, 6.3) or
less
CONTROL LEVER STROKE mm HITACHI lever pattern T4-4-21
Boom Lever 97 10
Arm Lever
82 10
(ISO Lever Pattern: Swing Lever)
Bucket Lever 82 10
Swing Lever 97 10
(ISO Lever Pattern: Arm Lever)
Travel Lever 120 10
COMBINED OPERATION OF BOOM 2.26 m arm T4-4-22
RAISE/SWING sec 3.1 0.4 0.45 m3 (PCSA heaped)
bucket, bucket: empty
Bucket Teeth Height: H mm 5400 or more
COMBINED OPERATION OF BOOM 2.26 m arm T4-4-23
RAISE/ARM ROLL-IN sec 5.3 0.5 0.45 m3 (PCSA heaped)
bucket
HYDRAULIC SYSTEM
PRIMARY PILOT PRESSURE T4-5-1
MPa (kgf/cm2, psi)
Engine: Fast Idle 4.0+1.0-0.5
(40+10-5,
580+142-71)
+1.0
Engine: Slow Idle 3.8 -0.5
+10 +145
(38 -5, 550 -71)
SECONDARY PILOT PRESSURE T4-5-3
MPa (kgf/cm2, psi)
Value indicated on Dr. ZX
3.4 to 4.0
(Engine: Fast Idle (noraml) and Slow (Lever: Full stroke)
(34 to 40, 483 to
Idle)
570)
T4-2-3
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-4
OPERATIONAL PERFORMANCE TEST / Standard
ZX120-3 CLASS OPERATIONAL
PERFORMANCE STANDARD TABLE
The standard performance values are listed in the The following conditions are required for
table below. Refer to T4-3 to T4-6 as for performance measurement.
test procedures. The values indicated in parentheses Engine Control Dial: Fast Idle
are reference values. Power Mode Switch: P Mode
Auto-Idle Switch: OFF
Work Mode: Digging Mode
Hydraulic Oil Temperature: 50 5 C (122 9 F)
Engine Coolant Temperature: 55 C (131 F) or more
ZX120-3 class
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
-1
ENGINE SPEED min T4-3-1
Slow Idle Speed 1050 50 Value indicated on Dr. ZX
Fast Idle Speed (normal) 1700 50 Value indicated on Dr. ZX
Lever in neutral, Pilot shut-off
Fast Idle Speed (with ECO deactivated) 1800 50
lever: UNLOCK position
Fast Idle Speed
1800 50
(during travel single operation)
Fast Idle Speed (during relief operation) 1800 50 Boom raise relief operation
Fast Idle Speed (E mode) 1650 50 Lever in neutral
Relief operation of boom rasie
Fast Idle Speed (HP mode) 2000 50
and arm roll-in
Auto-Idle Speed 1200 50
Hydraulic oil temperature
Warming-Up Speed 1400 100 when engine starts: 0 C or
less
ENGINE COMPRESSION PRESSURE 3.04 0.2 Engine speed: 200min-1 T4-3-3
2
MPa (kgf/cm , psi) (31 2, 442 29)
VALVE CLEARANCE (IN, EX) 0.15 With the engine cold T4-3-4
LUBRICANT CONSUMPTION Hour meter: 2000 hours or T4-3-7
30 or less
(Rated output) mL/h less
TRAVEL SPEED sec/10 m T4-4-1
Fast Speed 6.5 0.6
Slow Speed 11.0 1.2
TRACK REVOLUTION SPEED sec/3 rev T4-4-2
Fast Speed 14.7 1.5 With one side track raised
Slow Speed 23.8 2.0
MISTRACK mm/20 m T4-4-3
200 or less
(With fast and slow travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0 T4-4-4
T4-2-5
OPERATIONAL PERFORMANCE TEST / Standard
ZX120-3 class
Referenc
PERFORMANCE TEST DESIGNATION (Performance Remarks
e Page
Standard)
SWING SPEED sec/3 rev 13.3 1.0 Bucket: empty T4-4-5
2.52 m arm T4-4-6
SWING FUNCTION DRIFT CHECK 3
860 or less 0.5 m (PCSA heaped) bucket,
mm/180
bucket: empty
2.52 m arm T4-4-8
SWING MOTOR LEAKAGE mm/5 min 0 0.5 m3 (PCSA heaped) bucket,
bucket: loaded
MAXIMUM SWINGABLE SLANT ANGLE Bucket: loaded T4-4-10
22 or more
deg.
SWING BEARING PLAY mm 0.2 to 1.25 Allowable limit: 2.0 to 3.05 T4-4-12
HYDRAULIC CYLINDER CYCLE TIME 2.52 m arm T4-4-14
sec 0.5 m3 (PCSA heaped) bucket,
bucket: empty
Boom Raise 3.1 0.3
Boom Lower 2.4 0.3
Arm Roll-In 3.4 0.3
Arm Roll-Out 2.6 0.3
Bucket Roll-In 3.5 0.3
Bucket Roll-Out 2.4 0.3
DIG FUNCTION DRIFT CHECK 2.52 m arm T4-4-16
mm/5 min 0.5 m3 (PCSA heaped) bucket
Boom Cylinder
(Maximum Reach Position) 10 or less Bucket: loaded
(Arm Roll-In position) 5 or less Bucket: empty
Arm Cylinder
(Maximum Reach Position) 20 or less Bucket: loaded
(Arm Roll-In position) 15 or less Bucket: empty
Bucket Cylinder
(Maximum Reach Position) 15 or less Bucket: loaded
(Arm Roll-In position) 10 or less Bucket: empty
Bucket Bottom
(Maximum Reach Position) 150 or less Bucket: loaded
(Arm Roll-In position) 110 or less Bucket: empty
T4-2-6
OPERATIONAL PERFORMANCE TEST / Standard
ZX120-3 class
Referenc
PERFORMANCE TEST DESIGNATION (Performance Remarks
e Page
Standard)
CONTROL LEVER OPERATING FORCE HITACHI lever pattern T4-4-20
N (kgf, lbf)
Boom Lever 16 (1.6, 3.6) or
less
Arm Lever 13 (1.3, 2.9) or
(ISO Lever Pattern: Swing Lever) less
Bucket Lever 13 (1.3, 2.9) or
less
Swing Lever 16 (1.6, 3.6) or
(ISO Lever Pattern: Arm Lever) less
Travel Lever 28 (2.8, 6.3) or
less
CONTROL LEVER STROKE mm HITACHI lever pattern T4-4-21
Boom Lever 97 10
Arm Lever
82 10
(ISO Lever Pattern: Swing Lever)
Bucket Lever 82 10
Swing Lever 97 10
(ISO Lever Pattern: Arm Lever)
Travel Lever 120 10
COMBINED OPERATION OF BOOM 2.52 m arm T4-4-22
RAISE/SWING sec 3.7 0.4 0.5 m3 (PCSA heaped) bucket,
bucket: empty
Bucket Teeth Height: H mm 5000 or more
COMBINED OPERATION OF BOOM 2.52 m arm T4-4-23
RAISE/ARM ROLL-IN sec 5.3 0.5 0.5 m3 (PCSA heaped) bucket
HYDRAULIC SYSTEM
PRIMARY PILOT PRESSURE T4-5-1
MPa (kgf/cm2, psi)
Engine: Fast Idle 4.0+1.0-0.5
(40+10-5,
580+142-71)
+1.0
Engine: Slow Idle 3.8 -0.5
+10 +145
(38 -5, 550 -71)
SECONDARY PILOT PRESSURE T4-5-3
MPa (kgf/cm2, psi)
Value indicated on Dr. ZX
3.4 to 4.0
(Engine: Fast Idle (noraml) and Slow (Lever: Full stroke)
(34 to 40, 483 to
Idle)
570)
T4-2-7
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-8
OPERATIONAL PERFORMANCE TEST / Standard
ZX135US-3 CLASS OPERATIONAL
PERFORMANCE STANDARD TABLE
The standard performance values are listed in the The following conditions are required for
table below. Refer to T4-3 to T4-6 as for performance measurement.
test procedures. The values indicated in parentheses Engine Control Dial: Fast Idle
are reference values. Power Mode Switch: P Mode
Auto-Idle Switch: OFF
Work Mode: Digging Mode
Hydraulic Oil Temperature: 50 5 C (122 9 F)
Engine Coolant Temperature: 75 C (167 F) or more
ZX135US-3 class
Reference
PERFORMANCE TEST DESIGNATION (Performance Remarks
Page
Standard)
-1
ENGINE SPEED min T4-3-1
Slow Idle Speed 1050 50 Value indicated on Dr. ZX
Fast Idle Speed (normal) 1700 50 Value indicated on Dr. ZX
Lever in neutral, Pilot shut-off
Fast Idle Speed (with ECO deactivated) 1800 50
lever: UNLOCK position
Fast Idle Speed
2000 50
(during travel single operation)
Fast Idle Speed (during relief operation) 1800 50 Boom raise relief operation
Fast Idle Speed (E mode) 1650 50 Lever in neutral
Relief operation of boom rasie
Fast Idle Speed (HP mode) 2000 50
and arm roll-in
Auto-Idle Speed 1200 50
Hydraulic oil temperature
Warming-Up Speed 1400 100 when engine starts: 0 C or
less
ENGINE COMPRESSION PRESSURE 3.04 0.2 Engine speed: 200min-1 T4-3-3
2
MPa (kgf/cm , psi) (31 2, 442 29)
VALVE CLEARANCE (IN, EX) 0.15 With the engine cold T4-3-4
LUBRICANT CONSUMPTION Hour meter: 2000 hours or T4-3-7
30 or less
(Rated output) mL/h less
TRAVEL SPEED sec/10 m T4-4-1
Fast Speed 6.5 0.6
Slow Speed 11.0 1.2
TRACK REVOLUTION SPEED sec/3 rev T4-4-2
Fast Speed 23.9 2.0 With one side track raised
Slow Speed 23.9 2.0
MISTRACK mm/20 m T4-4-3
200 or less
(With fast and slow travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0 T4-4-4
T4-2-9
OPERATIONAL PERFORMANCE TEST / Standard
ZX135US-3 class
Referenc
PERFORMANCE TEST DESIGNATION (Performance Remarks
e Page
Standard)
SWING SPEED sec/3 rev 13.3 1.0 Bucket: empty T4-4-5
2.52 m arm T4-4-6
SWING FUNCTION DRIFT CHECK 3
860 or less 0.5 m (PCSA heaped) bucket,
mm/180
bucket: empty
2.52 m arm T4-4-8
SWING MOTOR LEAKAGE mm/5 min 0 0.5 m3 (PCSA heaped) bucket,
bucket: loaded
MAXIMUM SWINGABLE SLANT ANGLE Bucket: loaded T4-4-10
20 or more
deg.
SWING BEARING PLAY mm 0.2 to 1.25 Allowable limit: 2.0 to 3.05 T4-4-12
HYDRAULIC CYLINDER CYCLE TIME 2.52 m arm T4-4-14
sec 0.5 m3 (PCSA heaped) bucket,
bucket: empty
Boom Raise 3.5 0.3
Boom Lower 3.0 0.3
Arm Roll-In 3.4 0.3
Arm Roll-Out 2.6 0.3
Bucket Roll-In 3.5 0.3
Bucket Roll-Out 2.4 0.3
DIG FUNCTION DRIFT CHECK 2.52 m arm T4-4-16
mm/5 min 0.5 m3 (PCSA heaped) bucket
Boom Cylinder
(Maximum Reach Position) 10 or less Bucket: loaded
(Arm Roll-In position) 5 or less Bucket: empty
Arm Cylinder
(Maximum Reach Position) 20 or less Bucket: loaded
(Arm Roll-In position) 15 or less Bucket: empty
Bucket Cylinder
(Maximum Reach Position) 15 or less Bucket: loaded
(Arm Roll-In position) 10 or less Bucket: empty
Bucket Bottom
(Maximum Reach Position) 150 or less Bucket: loaded
(Arm Roll-In position) 110 or less Bucket: empty
T4-2-10
OPERATIONAL PERFORMANCE TEST / Standard
ZX135US-3 class
Referenc
PERFORMANCE TEST DESIGNATION (Performance Remarks
e Page
Standard)
CONTROL LEVER OPERATING FORCE HITACHI lever pattern T4-4-20
N (kgf, lbf)
Boom Lever 16 (1.6, 3.6) or
less
Arm Lever 13 (1.3, 2.9) or
(ISO Lever Pattern: Swing Lever) less
Bucket Lever 13 (1.3, 2.9) or
less
Swing Lever 16 (1.6, 3.6) or
(ISO Lever Pattern: Arm Lever) less
Travel Lever 28 (2.8, 6.3) or
less
CONTROL LEVER STROKE mm HITACHI lever pattern T4-4-21
Boom Lever 97 10
Arm Lever
82 10
(ISO Lever Pattern: Swing Lever)
Bucket Lever 82 10
Swing Lever 97 10
(ISO Lever Pattern: Arm Lever)
Travel Lever 120 10
COMBINED OPERATION OF BOOM 2.52 m arm T4-4-22
RAISE/SWING sec 3.2 0.4 0.5 m3 (PCSA heaped) bucket,
bucket: empty
Bucket Teeth Height: H mm 5200 or more
COMBINED OPERATION OF BOOM 2.52 m arm T4-4-23
RAISE/ARM ROLL-IN sec 5.3 0.5 0.5 m3 (PCSA heaped) bucket
HYDRAULIC SYSTEM
PRIMARY PILOT PRESSURE T4-5-1
MPa (kgf/cm2, psi)
Engine: Fast Idle 4.0+1.0-0.5
(40+10-5,
580+142-71)
+1.0
Engine: Slow Idle 3.8 -0.5
+10 +145
(38 -5, 550 -71)
SECONDARY PILOT PRESSURE T4-5-3
MPa (kgf/cm2, psi)
Value indicated on Dr. ZX
3.4 to 4.0
(Engine: Fast Idle (noraml) and Slow (Lever: Full stroke)
(34 to 40, 483 to
Idle)
570)
T4-2-11
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-12
OPERATIONAL PERFORMANCE TEST / Standard
MAIN PUMP P-Q DIAGRAM
Hydraulic P-Q Control
ZX110-3 Class Points on P-Q Line ZX120-3 Class, 135US-3 Class Points on P-Q Line
Delivery Pressure Flow Rate Delivery Pressure Flow Rate
MPa (kgf/cm2, psi) L/min (gpm) MPa (kgf/cm2, psi) L/min (gpm)
A 3.9 (40, 570) 100 2 (26.4 0.5) A 3.9 (40, 570) 105 2 (27.7 0.5)
B 14.7 (150, 2135) 99+2-4 (26.1+0.5-1.1) B 14.7 (150, 2135) 104+2-4 (27.5+0.5-1.1)
C 19.6 (200, 2850) 88 4 (23.2 1.1) C 19.6 (200, 2850) 88 4 (23.2 1.1)
D 22.7 (232, 3300) [78 (20.6)] D 22.7 (232, 3300) [78 (20.6)]
E 27.0 (275, 3930) 63 4 (16.6 1.1) E 27.0 (275, 3930) 63 4 (16.6 1.1)
F 34.3 (350, 4780) [42 6 (11.1 1.6)] F 34.3 (350, 4780) [42 6 (11.1 1.6)]
The value indicated in parentheses is only a reference The value indicated in parentheses is only a reference
value. value.
L/min A B
D
Flow
Rate
T4-2-13
OPERATIONAL PERFORMANCE TEST / Standard
P-Q Control by Pump Control Pilot Pressure Signal
ZX110-3 Class Points on P-Q Line ZX120-3 Class, 135US-3 Class Points on P-Q Line
Pump Control Flow Rate Pump Control Flow Rate
pressure L/min (gpm) pressure L/min (gpm)
MPa (kgf/cm2, psi) MPa (kgf/cm2, psi)
A - 35 2 (9.2 0.5) A - 35 2 (9.2 0.5)
1.96 0.05 (20 0.5, 61 1 (16.1 0.3) 1.96 0.05 (20 0.5, 61 1 (16.1 0.3)
B B
284 7) 284 7)
C 2.39 (24.4, 350) [85 (22.4)] C 2.39 (24.4, 350) [85 (22.4)]
2.94 0.05 2.94 0.05 0.3
D 0.3
100 2 (26.4 0.5) D 105 2 (27.7 0.5)
(30 0.5 3, 427 7 43) (30 0.5 3, 427 7 43)
The valve indicated in parentheses is only a reference The valve indicated in parentheses is only a reference
valve. valve.
L/min
D
Flow
Rate
T4-2-14
OPERATIONAL PERFORMANCE TEST / Standard
SENSOR ACTIVATING RANGE
1. Checking Method
T4-2-15
OPERATIONAL PERFORMANCE TEST / Standard
ZX110-3 CLASS DR. ZX MONITOR INDI-
CATING VALUES
Unless specified, test under the following conditions. NOTE: Items marked ( ) are measurable by using
Engine Speed: Fast Idle service menu/monitoring in the monitor
Work Mode: Digging Mode unit.
Power Mode Switch: P mode Items marked ( ) are measurable by using
Auto-Idle: OFF service menu/monitoring in the monitor
unit. However, it may be difficult to read the
measured value while operating the ma-
chine.
MC
Reference Measured Value
Item Remarks
Value First Second Third Average
PUMP 1 PRESSURE (MPa)
Control Lever in Neutral 0.9
Boom Raise 36.3 When relieving
Boom Lower -
Arm Roll-in 35.9 When relieving
Arm Roll-Out 35.6 When relieving
Bucket Roll-Out 35.9 When relieving
Bucket Roll-In* 35.9 When relieving
Boom Raise + Arm 35.4 When relieving
Roll-In + Bucket Roll-In
Combined Operation
PUMP 2 PRESSURE (MPa)
Control Lever in Neutral 0.7
Boom Raise 36.1 When relieving
Boom Lower -
Arm Roll-in 35.6 When relieving
Arm Roll-Out 35.4 When relieving
Bucket Roll-Out 0.9 When relieving
Bucket Roll-In 0.7 When relieving
Boom Raise + Arm 35.9 When relieving
Roll-In + Bucket Roll-In
Combined Operation
T4-2-16
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-17
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-18
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-19
OPERATIONAL PERFORMANCE TEST / Standard
ECM
Reference Measured Value
Item Remarks
Value First Second Third Average
Engine Torque ( )*
No load 4
When relieving arm roll-in 63
-1
Actual Engine Speed (min ) *
No load 1700
When relieving arm roll-in 1800
Target Engine Speed (min-1) *
No load 1700
When relieving arm roll-in 1800
Engine Oil Pressure (kPa) *
No load 420
When relieving arm roll-in 430
Fuel Rate (L/h)
No load 2.5
When relieving arm roll-in 12.0
Atmospheric Pressure (kPa) * 100.5
Boost Pressure (kPa) *
No load 122
When relieving arm roll-in 178
Battery Voltage (V) 28.6
T4-2-20
OPERATIONAL PERFORMANCE TEST / Standard
ZX120-3 CLASS DR. ZX MONITOR INDI-
CATING VALUES
Unless specified, test under the following conditions. NOTE: Items marked ( ) are measurable by using
Engine Speed: Fast Idle service menu/monitoring in the monitor
Work Mode: Digging Mode unit.
Power Mode Switch: P mode Items marked ( ) are measurable by using
Auto-Idle: OFF service menu/monitoring in the monitor
unit. However, it may be difficult to read the
measured value while operating the ma-
chine.
MC
Reference Measured Value
Item Remarks
Value First Second Third Average
PUMP 1 PRESSURE (MPa)
Control Lever in Neutral 0.9
Boom Raise 35.9 When relieving
Boom Lower -
Arm Roll-in - When relieving
Arm Roll-Out 36.3 When relieving
Bucket Roll-Out - When relieving
Bucket Roll-In* - When relieving
Boom Raise + Arm - When relieving
Roll-In + Bucket Roll-In
Combined Operation
PUMP 2 PRESSURE (MPa)
Control Lever in Neutral 0.7
Boom Raise 36.3 When relieving
Boom Lower -
Arm Roll-in - When relieving
Arm Roll-Out 36.3 When relieving
Bucket Roll-Out - When relieving
Bucket Roll-In - When relieving
Boom Raise + Arm - When relieving
Roll-In + Bucket Roll-In
Combined Operation
T4-2-21
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-22
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-23
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-24
OPERATIONAL PERFORMANCE TEST / Standard
ECM
Reference Measured Value
Item Remarks
Value First Second Third Average
Engine Torque ( )*
No load 8
When relieving arm roll-in 62
-1
Actual Engine Speed (min ) *
No load 1700
When relieving arm roll-in 1800
Target Engine Speed (min-1) *
No load 1700
When relieving arm roll-in 1800
Engine Oil Pressure (kPa) *
No load 376
When relieving arm roll-in 380
Fuel Rate (L/h)
No load 2.5
When relieving arm roll-in 12.3
Atmospheric Pressure (kPa) * 100
Boost Pressure (kPa) *
No load 126
When relieving arm roll-in 174
Battery Voltage (V) 24.0
T4-2-25
OPERATIONAL PERFORMANCE TEST / Standard
ZX135US-3 CLASS DR. ZX MONITOR IN-
DICATING VALUES
Unless specified, test under the following conditions. NOTE: Items marked ( ) are measurable by using
Engine Speed: Fast Idle service menu/monitoring in the monitor
Work Mode: Digging Mode unit.
Power Mode Switch: P mode Items marked ( ) are measurable by using
Auto-Idle: OFF service menu/monitoring in the monitor
unit. However, it may be difficult to read the
measured value while operating the ma-
chine.
MC
Reference Measured Value
Item Remarks
Value First Second Third Average
PUMP 1 PRESSURE (MPa)
Control Lever in Neutral 0.9
Boom Raise 36.1 When relieving
Boom Lower -
Arm Roll-in 36.3 When relieving
Arm Roll-Out 35.9 When relieving
Bucket Roll-Out 37.3 When relieving
Bucket Roll-In* 36.8 When relieving
Boom Raise + Arm 35.9 When relieving
Roll-In + Bucket Roll-In
Combined Operation
PUMP 2 PRESSURE (MPa)
Control Lever in Neutral 0.7
Boom Raise 36.1 When relieving
Boom Lower -
Arm Roll-in 36.1 When relieving
Arm Roll-Out 36.1 When relieving
Bucket Roll-Out 0.7 When relieving
Bucket Roll-In 0.9 When relieving
Boom Raise + Arm 35.9 When relieving
Roll-In + Bucket Roll-In
Combined Operation
T4-2-26
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-27
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-28
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-29
OPERATIONAL PERFORMANCE TEST / Standard
ECM
Reference Measured Value
Item Remarks
Value First Second Third Average
Engine Torque ( )*
No load 9
When relieving arm roll-in 67
-1
Actual Engine Speed (min ) *
No load 1700
When relieving arm roll-in 1802
Target Engine Speed (min-1) *
No load 1700
When relieving arm roll-in 1800
Engine Oil Pressure (kPa) *
No load 424
When relieving arm roll-in 440
Fuel Rate (L/h)
No load 2.7
When relieving arm roll-in 12.0
Atmospheric Pressure (kPa) * 100.0
Boost Pressure (kPa) *
No load 124
When relieving arm roll-in 178
Battery Voltage (V) 28.8
T4-2-30
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.
Preparation:
1. Select the service menu of the monitor or Dr. ZX.
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: Evaluation:
1. Measure the items as shown in the table below. Refer to Operational Performance Standard in T4-2.
2. When measuring, set the switch and test condi-
tion as shown in the table below in response to Remedy:
the engine speed to be measured. Refer to Troubleshooting B in T5-6.
Auto-Idle Switch
T1V1-05-01-007
T1V1-04-03-001
T4-3-2
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders
and check for a decline in engine power.
2. Check exhaust gas color. Keep track of engine oil
consumption.
3. Check for abnormalities in the intake system, in-
cluding the air filter.
Preparation:
1. Confirm that valve clearances are correct.
2. Confirm that the batteries are charged properly.
3. Run the engine until the coolant temperature
gauge reaches the operating range.
4. Disconnect the negative terminal of the battery.
Disconnect all the glow plugs from each cylinder.
20 N m (2.0 kgf m, 14.8 lbf ft)
1.
Evaluation:
Refer to Operational Performance Standard in T4-2.
Remedy:
Refer to the engine shop manual.
T1T1-04-03-002
T4-3-3
OPERATIONAL PERFORMANCE TEST / Engine Test
VALVE CLEARANCE
Injector
Summary:
1. Perform the measurement when the engine is
cold.
2. Before starting any work, clean the head cover
mounting area and avoid contamination in the
engine.
Preparation:
1. Disconnect the connector of the injector.
2. Disconnect the leak off hose.
3. Remove the head cover.
4. Rotate the crank pulley. Align the top dead center
(TDC) mark on the crank pulley with the top mark
T1T1-04-03-001
located on the timing gear case. Leak Off Hose
NOTE: Move the push rods for the intake and ex-
haust valves on the No.1 cylinder up and
down by hand. If any clearances on the
both ends of the push rods are found, pis- Top Mark
ton No.1 is positioned at TDC in the com-
pression stroke. (If the exhaust valve of T1T1-04-03-003
T4-3-4
OPERATIONAL PERFORMANCE TEST / Engine Test
Measurement:
1. Insert a thickness gauge into the clearance be-
tween rocker arm roller and cam shaft. Measure A
the valve clearance.
A
Evaluation:
Refer to Operational Performance Standard in T4-2.
T1T1-04-03-005
T4-3-5
OPERATIONAL PERFORMANCE TEST / Engine Test
Adjustment:
If the measurement results are out of specification,
adjust the valve clearance in the same order of the
measurement.
Cam Shaft
1. Loosen lock nuts (16 used) and adjusting screws
(16 used), which secure the rocker arm by using
the adjusting nut wrench (Isuzu 5-8840-2822-0).
2. Insert a thickness gauge into the clearance be-
tween rocker arm roller and cam shaft.
3. Tighten the adjusting screw of the rocker arm un- Thickness
Gauge
til condition for the thickness gauge is proper.
4. Tighten the lock nut of the rocker arm.
: 18 N m (1.8 kgf m, 13.2 lbf ft)
5. Check the valve clearance after the lock nuts are
tightened. T1T1-04-03-004
Adjusting Nut Wrench Rocker Arm
T1T1-04-03-005
T4-3-6
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 un-
til the oil level lowers to the low-level gauge.
Evaluation:
Refer to Operational Performance Standard in T4-2.
T4-3-7
OPERATIONAL PERFORMANCE TEST / Engine Test
(Blank)
T4-3-8
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary: Measurement:
Measure the time required for the excavator to travel 1. Measure at both slow and fast travel speeds of
a test track and check the performance of the travel the machine.
drive system (from main pump to travel motor). 2. Select the following switch positions:
Engine Power Mode Auto-Idle
Work Mode
Preparation: Control Dial Switch Switch
1. Adjust the track sag on both tracks equally. Digging
2. Prepare a flat and solid test track 10 m (33 ft) in Fast Idle P Mode OFF
Mode
length with extra length of 3 to 5 m (9.8 to 16 ft)
on both ends for machine acceleration and de- 3. Start traveling the machine in the acceleration
celeration. zone with the travel levers to full stroke.
3. With the arm and the bucket fully extended, hold 4. Measure the time required to travel 10 m (33 ft).
the bucket 0.3 to 0.5 m (12 to 20 in) above the 5. After measuring the forward travel speed, turn
ground. the upperstructure 180 and measure the reverse
4. Maintain the hydraulic oil temperature at 50 5 C travel speed.
(122 9 F). 6. Repeat the measurement three times in each di-
rection and calculate the average values.
Evaluation:
Refer to Operational Performance Standard in T4-2.
Arm Roll-In, Buck Rolled-In
End Remedy:
Bucket Height: 0.3 to 0.5 m Refer to Troubleshooting B in T5-7.
Start
10 m Deceleration
Zone
3 to 5 m
Acceleration
Zone
3 to 5 m
T105-06-03-001
T4-4-1
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRACK REVOLUTION SPEED
Summary: Measurement:
Measure the track revolution cycle time with the 1. Measure on both tracks at slow and fast travel
track raised off ground and check the performance speeds of the machine.
of the travel drive system (from main pump to travel 2. Select the following switch positions:
motor). Engine Power Mode Auto-Idle
Work Mode
Control Dial Switch Switch
Preparation: Digging
Fast Idle P Mode OFF
1. Adjust the track sag of both side tracks equally. Mode
2. On the track to be measured, put the mark on
one shoe by using a piece of chalk or cloth. 3. Operate the travel control lever of the track to be
3. Raise the track to be measured as illustrated. measured to full stroke.
4. Measure the time required for 3 revolutions in
both directions after a constant track revolution
speed is obtained.
5. Repeat the measurement three times and
calculate the average values.
90 to 110
Evaluation:
Refer to Operational Performance Standard in T4-2.
T4-4-2
OPERATIONAL PERFORMANCE TEST / Excavator Test
MISTRACK CHECK
Summary: Measurement:
1. Allow the machine to travel 20 m (65.6 ft). 1. Measure at both slow and fast travel speeds of
Measure the maximum tread deviation from the the machine.
tread chord line drawn between the travel start 2. Select the following switch positions:
and end points and check the performance of the Engine Power Mode Auto-Idle
Work Mode
travel drive system (from main pump to travel Control Dial Switch Switch
motor). Digging
2. If measured on a concrete surface, the tread Fast Idle P Mode OFF
Mode
deviation has a trend to decrease.
3. Start traveling the machine in the acceleration
Preparation: zone with the travel lever to full stroke.
1. Adjust the track sag on both tracks equally. 4. Measure the maximum distance between a
2. Prepare a flat and solid test track 20 m (65.6 ft) in straight 20 m (65.6 ft) tread chord line and the
length with extra length of 3 to 5 m (9.8 to 16 ft) tread made by the machine.
on both ends for machine acceleration and 5. After measuring the tracking in forward travel,
deceleration. turn the upperstructure 180 and measure in
reverse travel.
6. Repeat the measurement three times and
Maximum Distance calculate the average values.
Evaluation:
Acceleration Refer to Operational Performance Standard in T4-2.
Zone:
3 to 5 m
20 m Remedy:
Refer to Troubleshooting B in T5-7.
T105-06-03-022
T4-4-3
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL PARKING LEAKAGE
Summary:
1. Measure the parking brake function on a speci-
fied slope.
2. The surface of test slope shall be even with a
gradient of 20 % (11.31 ).
Preparation:
0.2 to 0.3 m
1. Measure on a flat slope with a gradient of 20 %
(11.31 ).
2. With the arm and the bucket fully extended, hold
the bucket 0.2 to 0.3 m (8 to 12 in) above the
ground.
3. Maintain the hydraulic oil temperature at 50 5 C T105-06-03-004
(122 9 F).
Measurement:
1. Measure the travel parking brake slip amount
while parked.
2. Climb the slope and set the travel lever in neutral.
3. Stop the engine.
4. After the machine stops, put the matching marks
on a track link or a shoe and a track side frame.
5. After 5 minutes, measure the distance between
marks on the track link or the shoe and the track
frame.
Evaluation:
Refer to Operational Performance Standard in T4-2.
Displacement measured
after 5 minutes
T105-06-03-006
T4-4-4
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING SPEED
Summary:
Measure the time required to swing three complete CAUTION: Prevent personal injury. Always
turns and check the performance of the swing drive make sure that the area is clear and that
system (from main pump to swing motor). co-workers are out of the swing area before
starting the measurement.
Preparation:
Measurement:
1. Check lubrication of the swing gear and the
swing bearing. 1. Select the following switch positions:
2. Place the machine on flat, solid ground with Engine Power Mode Auto-Idle
Work Mode
ample space for swinging. Do not conduct this Control Dial Switch Switch
test on slopes. Digging
Fast Idle P Mode OFF
3. With the arm fully retracted and the bucket fully Mode
extended, hold the bucket so that the height of
the arm end pin is the same as the boom foot pin. 2. Operate the swing control lever fully.
The bucket must be empty. 3. Measure the time required to swing 3 turns in
one direction after a constant turning speed is
obtained.
4. Operate swing control lever fully in the opposite
direction and measure the time required for 3
turns.
5. Repeat the measurement three times and
The same height as the
calculate the average values.
boom foot pin height
Evaluation:
T105-06-03-013 Refer to Operational Performance Standard in T4-2.
T178-04-03-001
T4-4-5
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING FUNCTION DRIFT CHECK
Summary:
1. Measure the swing drift on the swing bearing
outer circumference when stopping after a 180
full-speed swing and check the performance of
the swing brake valve.
2. The mechanical brake for the swing parking
brake is equipped for the swing motor.
Preparation:
1. Check lubrication of the swing gear and the Put the matching marks on swing
swing bearing. bearing outer circumference and
track frame. T105-06-03-008
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 fully retracted and the bucket fully
extended, hold the bucket so that the height of
the arm end pin is the same as the boom foot pin.
The bucket must be empty.
4. Put the matching marks on the swing bearing
outer circumference (upperstructure side) and
the track frame by using a tape.
5. Turn the upperstructure 180 .
6. Maintain the hydraulic oil temperature at 50 5 C Before starting the measurement, T105-06-03-009
(122 9 F). swing the upperstructure 180
T4-4-6
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Select the following switch positions:
Engine Power Mode Auto-Idle
Work Mode
Control Dial Switch Switch
Digging
Fast Idle P Mode OFF Measure difference between marks
Mode
Evaluation:
Refer to Operational Performance Standard in T4-2.
Remedy:
Refer to Troubleshooting B in T5-7.
T4-4-7
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING MOTOR LEAKAGE
Summary:
Measure the upperstructure drift while suspending a
load on a specified slope and check the performance
of the swing parking brake. (The mechanical brake
for the swing parking brake is equipped for the swing
device.)
Preparation:
1. Check lubrication of the swing gear and the
swing bearing.
2. Load the bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
ZX110-3 class : 675 kg (1490 lb)
ZX120-3 class/135US-3 class : 750 kg (1650 lb)
3. With the arm fully retracted and the bucket fully
extended, hold the bucket so that the height of
the arm end pin is the same as the boom foot pin.
The bucket must be empty. T105-06-03-011
4. Measure on a flat slope with a gradient of
26.8 1.8 % (15 1 ).
5. Climb the slope and turn the upperstructure to
position it 90 to the slope. Put the matching
marks on the outer circumference of the swing
bearing (upperstructure side) and the track frame
by using a tape.
6. Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
T4-4-8
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Select the following switch position:
Power Mode Auto-Idle
Work Mode
Switch Switch
P Mode OFF Digging Mode Measure difference between marks
Evaluation:
Refer to Operational Performance Standard in T4-2.
Remedy:
Refer to Troubleshooting B in T5-7.
T4-4-9
OPERATIONAL PERFORMANCE TEST / Excavator Test
MAXIMUM SWINGABLE SLANT ANGLE
Summary: Measurement:
With the upperstructure positioned 90 to the slope, 1. Select the following switch positions:
check the maximum slant angle on which the upper- Engine Power Mode Auto-Idle Work
structure can turn to the uphill side. Control Dial Switch Switch Mode
Digging
Preparation: Fast Idle P Mode OFF
Mode
1. Check lubrication of the swing gear and the
swing bearing. 2. Operate the swing control lever to full stroke and
2. Load the bucket fully. In lieu of loading the bucket, turn the upperstructure to the uphill side.
weight (W) of the following specification can be 3. If the machine can turn, measure the cab floor
used. slant angle.
ZX110-3 class : 675 kg (1490 lb) 4. Increase the slope angle and repeat steps 2 and
ZX120-3 class/135US-3 class : 750 kg (1650 lb) 3. Check both clockwise and counterclockwise.
3. With the arm fully retracted and the bucket fully 5. Repeat the measurement three times.
extended, hold the bucket so that the height of
the arm end pin is the same as the boom foot pin. Evaluation:
The bucket must be empty. Refer to Operational Performance Standard in T4-2.
4. Climb the slope and turn the upperstructure to
position 90 to the slope. Remedy:
5. Maintain the hydraulic oil temperature at 50 5 C Refer to Troubleshooting B in T5-7.
(122 9 F).
T105-06-03-011
T4-4-10
OPERATIONAL PERFORMANCE TEST / Excavator Test
(Blank)
T4-4-11
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING BEARING PLAY
Summary:
Measure the swing bearing play and check the wear
of the bearing races and the balls.
Preparation:
1. Check the swing bearing mounting bolts for
looseness.
2. Check lubrication of the swing bearing. Confirm
that bearing rotation is smooth without noise.
3. Secure a dial gauge on the round trunk of the
track frame by using a magnetic base. Magnetic Dial
4. Position the upperstructure so that the boom Base Gauge
T105-06-03-014
aligns with the tracks facing towards the front
idlers.
5. Position the dial gauge so that its needle point
comes into contact with the bottom surface of the
swing bearing outer race.
6. The bucket must be empty.
T105-06-03-015
T4-4-12
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. With the arm fully retracted and the bucket fully
Measurement: (h1)
extended, hold the bucket 100 mm (3.9 in) above
the ground. Record dial gauge reading (h1).
2. Lower the bucket onto the ground and raise the
front idler 0.5 m (20 in) by using the front
attachment. Record dial gauge reading (h2).
3. Calculate bearing play (H) from dial gauge
readings (h1 and h2) as follows:
H=h2-h1 100 mm
Evaluation:
Refer to Operational Performance Standard in T4-2. T105-06-03-007
Measurement: (h2)
T105-06-03-017
T4-4-13
OPERATIONAL PERFORMANCE TEST / Excavator Test
HYDRAULIC CYLINDER CYCLE TIME
Summary:
1. Measure the cycle time of boom, arm, bucket and
blade (optional) cylinders and check the per-
formance of the front attachment drive system
(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 cylin-
der:
With the arm cylinder fully retracted and the
bucket cylinder fully extended, lower the bucket
onto the ground. T105-06-03-018
0.5 m
T1V1-04-05-005
T105-06-03-020
T4-4-14
OPERATIONAL PERFORMANCE TEST / Excavator Test
1-4. Measurement of the cycle time of blade cylin-
der:
Raise the machine by using the front attach-
ment in order to be able to move the blade cyl-
inder to fully stroke.
Measurement:
1. Select the following switch positions:
Engine Power Mode Auto-Idle
Work Mode
Control Dial Switch Switch
Digging
Fast Idle P Mode OFF
Mode
Evaluation:
Refer to Operational Performance Standard in T4-2.
Remedy:
Refer to Troubleshooting B in T5-7.
T4-4-15
OPERATIONAL PERFORMANCE TEST / Excavator Test
DIG FUNCTION DRIFT CHECK
Maximum Reach Position
Summary:
1. Measure dig function drift, which can be caused
by oil leakage in the control valve and boom, arm
and bucket cylinders, with the loaded bucket.
2. When testing the dig function drift just after
cylinder replacement, slowly operate each
cylinder for ten minutes to its stroke end and
bleed air from the cylinder. Extended
Retracted
Distance
Distance
Retracted
Distance
Preparation:
1. Load the bucket fully. In lieu of loading the bucket,
Same Height
weight (W) of the following specification can be
used.
Dig Function
ZX110-3 class : 675 kg (1490 lb) Drift Amount
ZX120-3 class/135US-3 class : 750 kg (1650 lb)
2. With the arm fully retracted and the bucket fully
extended, hold the bucket so that the height of T105-06-03-021
the arm end pin is the same as the boom foot pin.
The bucket must be empty.
Boom and Bucket Cylinder Retraction
3. Position the arm cylinder with the rod 50 mm (2
in) extended from the fully retracted position. Mark Mark
Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position.
4. Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
Measurement:
1. Stop the engine.
2. In five minutes after the engine has been stopped, T110-06-03-002
Remedy:
Refer to Troubleshooting B in T5-7.
T110-06-03-001
T4-4-16
OPERATIONAL PERFORMANCE TEST / Excavator Test
Arm Roll-In Position
Summary:
1. Measure dig function drift, which can be caused
by oil leakage in the control valve and boom, arm
and bucket cylinders.
2. When testing the dig function drift just after
cylinder replacement, slowly operate each
cylinder for ten minutes to its stroke end and
bleed air from the cylinder.
Preparation:
1. The bucket must be empty.
2. With the arm fully extended and the bucket fully
extended, hold the arm end 1 m (40 in) above the
ground.
3. Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position.
4. Maintain the hydraulic oil temperature at 50 5 C 1m
(122 9 F).
T173-04-03-001
Measurement:
1. Stop the engine.
2. In five minutes after the engine has been stopped,
measure the change in position of bottom of the
arm tip, as well as the boom, arm and bucket
cylinders.
3. Repeat the measurement three times and
calculate the average values. Cylinder Retraction
Remedy:
Refer to Troubleshooting B in T5-7.
T110-06-03-002
T4-4-17
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement of Blade Cylinder (Optional)
Measurement:
1. Stop the engine.
2. In five minutes after the engine has been stopped,
measure the change in position of bottom of the
blade tip. Calculate the difference between the
before and after data.
3. Repeat the measurement three times and
calculate the average values.
Evalution:
Refer to Operational Performance Standard in T4-2.
Remedy:
Refer to Troubleshooting B in T5-7.
T4-4-18
OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER OPERATING FORCE
Summary:
1. Measure a play and operating condition of each
control lever.
2. Measure the maximum operating force of the
front attachment control lever.
3. Measure the operating force at the grip center of
each control lever.
Preparation:
Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
T107-06-03-004
T4-4-19
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Measure each control lever.
2. Select the following switch positions:
Engine Power Mode Auto-Idle
Work Mode
Control Dial Switch Switch
Digging
Fast Idle P Mode OFF
Mode
Evalution:
Refer to Orerational Performance Standard in T4-2.
T4-4-20
OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER STROKE
Summary:
1. Check a play and operating condition and
measure each control lever stroke.
2. Measure the lever stroke at the grip center of
each control lever.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both
side lever strokes.
Preparation:
Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
Measurement: T107-06-03-005
Evalution:
Refer to Orerational Performance Standard in T4-2.
T4-4-21
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 if the cylinders do not hesitate while oper-
ating the cylinder with the engine running at fast
idle.
Preparation:
1. With the arm fully retracted and the bucket fully
extended, lower the bucket onto the ground. The
bucket must be empty.
2. Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
T4-4-22
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Select the following switch positions:
Power
Engine Auto-Idle
Mode Work Mode
Control Dial Switch
Switch
Digging
Fast Idle P Mode OFF
Mode
Evalution:
Refer to Operational Performance Standard in T4-2.
Remedy:
Refer to Troubleshooting B in T5-7.
T107-06-03-011
T4-4-23
OPERATIONAL PERFORMANCE TEST / Excavator Test
COMBINED OPERATION OF BOOM RAISE
/ ARM ROLL-IN FUNCTION CHECK
Summary:
1. Check boom raise and arm roll-in movement and
speeds while operating both functions
simultaneously. Arm Mounting
2. Check if the cylinders do not hesitate while oper- Pin
ating the cylinder with the engine running at fast
idle.
Preparation:
1. Retract the arm cylinder fully and extend the
bucket cylinder so that the bucket teeth and arm
mounting pin are on a straight line. Adjust the
boom cylinder so that the bucket tooth tip height
is 0.5 m (1 ft 8 in) above the ground. (The bucket 0.5 m
must be empty.)
2. Maintain the hydraulic oil temperature at 50 5 C T107-06-03-006
(122 9 F).
Measurement:
1. Select the switch positions as follows.
Engine Power Mode Auto-Idle
Work Mode
Control Dial Switch Switch
Digging
Fast Idle P Mode OFF
Mode
Evaluation:
Refer to T4-2 Operational Performance Standard in
T1V1-04-04-001
T4-2.
Remedy:
Refer to Troubleshooting B in T5-7.
T4-4-24
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and bleed air.
3. Remove the plug from the pilot filter. Install the
adapter (ST 6069) and the pressure gauge (ST
6942) to the pressure check port.
: 14 mm
4. Start the engine. Confirm that no oil leakage is Plug
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
T178-03-07-001
Measurement:
1. Select the following switch positions:
Engine Power Mode Auto-Idle
Work Mode
Control Dial Switch Switch
Digging
Fast Idle P Mode OFF
Mode
Digging
Slow Idle P Mode OFF
Mode
Evaluation:
Refer to Operational Performance Standard in 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
T178-03-07-001
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 on top of the hydraulic oil Pilot Valve Signal Control Valve
tank and bleed air.
3. Measure pressure at the location between the pi- Hose
lot valve and the signal control valve. Disconnect
the pilot hose from the circuit to be measured. Nipple
Connect the hose (9/16-18UNF, Length: approx.
400 mm (16 in)) to the signal control valve side.
Install the tee (4351843), the adapter (ST 6460),
the nipple (ST 6069), the coupling (ST 6332) and
the pressure gauge (ST 6315) between the hoses. Pressure
Gauge
: 17 mm, 19 mm
Tee
Adapter
NOTE: When disconnecting the piping from the
signal control valve, use the tool (SNAP-ON
GAN850812B: size 19.05 mm) in order to
easily disconnect.
T4-5-3
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions:
Engine Power Mode Auto-Idle
Work Mode
Control Dial Switch Switch
Digging
Fast Idle P Mode OFF
Mode
Digging
Slow Idle P Mode OFF
Mode
Evaluation:
Refer to Operational Performance Standard in T4-2.
Remedy:
Refer to Troubleshooting B in T5-7.
T4-5-4
OPERATIONAL PERFORMANCE TEST / Component Test
SOLENOID VALVE SET PRESSURE
Solenoid Valve Unit
Measure solenoid valve set pressure by using both Dr.
Pressure Gauge
ZX and a pressure gauge.
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and bleed air.
3. Disconnect the hose from the solenoid valve to be
measured. Install the tee (ST 6451), the hose
(Parts Number: 4216453), the adapter (ST 6461) Hose Tee Adapter T157-05-04-002
T4-5-5
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions:
Engine Power Mode Auto-Idle
Work Mode
Control Dial Switch Switch
Digging
Fast Idle P Mode OFF
Mode
Digging
Slow Idle P Mode OFF
Mode
SC SI
2. Operate the solenoid valve to be measured as
followings.
Solenoid valve SI: Travel, Stop
Solenoid valve SC: Combined operation of boom
raise and arm roll-in.
3. Read the values on both Dr. ZX and the pressure
gauge.
4. Repeat the measurement three times and calcu-
late the average values.
T1R7-03-07-001
Evaluation:
Refer to Operational Performance Standard in T4-2.
T4-5-6
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
T4-5-7
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN PUMP DELIVERY PRESSURE
The main pump delivery pressure can also be meas-
ured by using Dr. ZX.
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and bleed air.
3. Remove the plug of the pressure check port from
the main pump delivery port. Install the adapter
(ST 6069), the hose (ST 6943) and the pressure
gauge (ST 6941).
: 6 mm
Connect Dr. ZX and select the monitoring func-
tion.
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50 5 C
(122 9 F). Pressure Check Pressure Check
Port for Pump 2 Port for Pump 1
Measurement: T1R7-04-05-001
Evaluation:
Refer to Operational Performance Standard in T4-2.
Remedy:
Refer to Troubleshooting B in T5-6.
T4-5-8
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN RELIEF SET PRESSURE
Main Circuit
Summary:
Measure the main relief valve set pressure at the de-
livery port in main pump. (The main relief set pressure
can also be measured by using Dr. ZX.)
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and bleed air.
3. Remove the plug of the pressure check port from
the main pump delivery port. Install the adapter
(ST 6069), the hose (ST 6943) and the pressure
gauge (ST 6941).
: 6 mm
Pressure Check Pressure Check
Connect Dr. ZX and select the monitoring func- Port for Pump 2 Port for Pump 1
tion.
4. Start the engine. Confirm that no oil leakage is
T1R7-04-05-001
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
T4-5-9
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions:
Engine Power Mode Auto-Idle
Work Mode
Control Dial Switch Switch
Digging
Fast Idle P Mode OFF
Mode
Evaluation:
Refer to Operational Performance Standard in T4-2.
T4-5-10
OPERATIONAL PERFORMANCE TEST / Component Test
Blade Circuit (Optional)
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and bleed air.
3. Disconnect the hose from the blade pump. Install
the adapter (ST 6291), the hose (ST 6943) and
the pressure gauge (ST 6941). T1R7-04-05-002
: 24mm, 27 mm
Measurement:
1. Select the following switch positions:
Engine Power Mode Auto-Idle
Work Mode
Control Dial Switch Switch
Digging
Fast Idle P Mode OFF
Mode
Evaluation:
Refer to Operational Performance Standard in T4-2.
T4-5-11
OPERATIONAL PERFORMANCE TEST / Component Test
Adjustment:
W105-02-05-151
1. Loosen the lock nut.
Adjusting
2. Turn the adjustiing screw and adjust the main Screw
relief set pressure.
: 24 mm
: 9.82 N m (1 kgf m, 7.2 lbf ft) Blade Circuit
Adjusting
4. After adjustment, check the set pressure. Screw
Main Circuit
Screw Turns 1/4 1/2 3/4 1
MPa 2.79 5.59 8.36 11.2
Change in
(28.5) (57) (85.2) (114)
Pressure
psi) (405) (811) (1212) (1620) Lock Nut
Screw Turns 1
MPa 13.5 Adjusting
Change in
(138) Screw
Pressure
psi) (1960)
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-12
OPERATIONAL PERFORMANCE TEST / Component Test
RELIEF PRESSURE (WHEN RELIEVING Swing Relief
SWING) Valve
Adjustment
1. Loosen lock nut (1).
: 24 mm
: 49 N m (5 kgf m, 36 lbf ft)
T176-01-02-002
1 2
T176-04-04-004
Adjusting
Screw
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-13
OPERATIONAL PERFORMANCE TEST / Component Test
RELIEF PRESSURE (WHEN RELIEVING
TRAVEL)
Adjustment
1. Remove the travel relief valve.
: 30 mm
3. Install shims (5) between poppet (3) and spring Travel Relief
Valve
guide (4), and adjust the set pressure.
1 2 5
NOTE: Standard Change in Pressure (Reference)
Shim Change in
Thickness Parts No. Pressure
(mm) kPa (kgf/cm2) (psi)
0.5 4305162 785 (8) (114)
3 4
T135-06-04-001
T4-5-14
OPERATIONAL PERFORMANCE TEST / Component Test
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary:
1. The circuit pressure must be increased by apply- 3. If the overload relief valve performance must be
ing an external force while blocking the return cir- checked on the machine, however, measure the
cuit from the control valve. This measuring main relief pressure while releasing each front
method is hazardous and the results obtained with function respective to the measuring overload re-
this method are unreliable. lief valve. And, assume that the overload relief
2. The oil flow rate used to set the overload relief valve is functioning correctly if the obtained main
pressure is far less than that used to set the main relief pressure is within the specified value range.
relief pressure. Therefore, measuring the overload Measure the main relief pressure by using Dr. ZX
pressure in the main circuit by increasing the main as follows:
relief set pressure more than the overload valve
set-pressure is not a proper method. In addition, in
case a main relief valve designed to leak a small Preparation:
quantity of oil before reliving is used, its 1. Stop the engine.
pre-leaking start pressure must be increased 2. Push the air bleed valve on top of the hydraulic oil
more than the overload relief valve set pressure. tank and bleed air.
However, the pre-leaking start pressure is not al- 3. Main circuit:
ways increased more than the overload relief Remove the plug of the pressure check port from
valve set-pressure as the adjustable upper limit of the main pump delivery port. Install the adapter
the main relief valve set-pressure is provided. (ST 6648), the hose (ST 6943) and the pressure
Accordingly, the overload relief valve assembly gauge (ST 6941).
should be removed from the machine and : 6 mm
checked on a specified test stand at a correct oil
Blade circuit (optional):
flow rate. Some overload relief valves come in
Disconnect the delivery piping of the blade pump.
contact with the control valve body to block the oil
Install the adapter (ST 6291), the hose (ST 6943)
passage. When this type of overload relief valve is
and the pressure gauge (ST 6941).
checked, the control valve body must be precisely
: 24 mm, 27 mm
finished as the test unit. Provide one control valve
other than that on the machine as a test kit.
4. Connect Dr.ZX and select the monitoring function.
Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
T4-5-15
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions:
Engine Power Mode Auto-Idle Blade Pump
Work Mode
Control Dial Switch Switch
Digging
Fast Idle P Mode OFF
Mode
Evaluation:
1. Performance of the overload relief valves are
normal if the measured pressures of the bucket,
arm, boom and blade circuits are within the speci-
fied value range of the main relief pressure (in the
main circuit or the blade circuit).
T4-5-16
OPERATIONAL PERFORMANCE TEST / Component Test
Overload Relief Valve Pressure Adjustment
Procedure Main Circuit Adjusting
Lock Nut Screw
Adjustment:
1. Loosen the lock nut.
Main circuit : T176-04-04-003
: 17 mm
: 31.5 N m (3.2 kgf m, 23.1 lbf ft)
Lock Nut Adjusting
Screw
Blade circuit :
: 17 mm
: 19.6 N m (2 kgf m, 14.4 lbf ft)
: 6 mm Pressure Pressure
Increase Decrease
2. Turn the adjustiing screw and adjust the overload
relief set pressure.
T105-06-05-002
3. Tighten the lock nut.
Main Circuit
Adjusting Screw 1/4 1/2 3/4 1
Turns
MPa 2.79 5.59 8.36 11.2
Change in
(28.5) (57) (85.2) (114)
Pressure
psi) (405) (811) (1212) (1620) Adjusting Screw
T198-04-04-008
Blade Circuit
Adjusting Screw 1/4 1/2 3/4 1 Lock Nut
Adjusting Screw
Turns
MPa 4.9 9.9 14.9 19.8
Change in
(50.5) (101.0) (151.4) (201.9)
Pressure
psi) (718) (1436) (2153) (2811)
Pressure Pressure
Increase Decrease
T505-06-04-007
T4-5-17
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN PUMP FLOW RATE MEASUREMENT
P-Q Control (Torque Control)
Summary:
Main pump performance is checked by measuring 5. Install a pressure gauge to the main pump to be
the pump flow rate by using a hydraulic tester in- measured. (Refer to Main Relief Set Pressure.)
stalled at the main pump delivery port (one side) to : 6 mm
be measured. Use Dr. ZX and a pressure gauge at 6. Disconnect pipe (13) from the regulator. Install the
the same time. plug (G 1/4) to port (14). Connect the hose (G 1/4)
to port (13). Connect one side of the hose to the
IMPORTANT: This measurement procedure is a hydraulic oil tank.
simple method. The measured data : 17 mm
will be lower by approx. 5 % than the 7. Remove the vacuum pump. Loosen plug (11) on
accurately measured value. In order top of the pump casing. Bleed air from the casing
to measure accurately, disconnect until oil only comes out.
the return circuit from the control 8. Fully open the loading valve of hydraulic tester (4).
valve and connect it to the hydraulic 9. Start the engine. Confirm that no oil leakage is
oil tank. observed at the pressure gauge connection.
Connect Dr. ZX and select the monitoring func-
tion.
Preparation:
1. Stop the engine. Push the air bleed valve and
bleed air. Install a vacuum pump to the oil filler Measurement:
port. 1. Maintain the hydraulic oil temperature at 50 5 C
NOTE: Operate the vacuum pump while connect- (122 9 F).
ing the pump flow rate test piping. 2. Measure the maximum flow rate.
2. Disconnect the delivery hose from the main pump 3. Select the following switch position:
(one side) to be measured. Connect pipe (1) with Engine Power Mode Auto-Idle
Work Mode
the split flange and the bolt which were used for Control Dial Switch Switch
the disconnected delivery hose. Digging
: 41 mm Fast Idle P Mode OFF
Mode
: 10 mm
3. Connect pipe (1) to hydraulic tester (5) with test
hose (2) and adapter (3). Install adapter (5), joint 4. Adjust the relief set pressure of the main relief
(6), test hose (7) and flange (8) to hydraulic tester valve in the control valve to each pressure point
(4). specified along the main pump P-Q curve. (Refer
: 41 mm to T4-2-13.) Slowly restrict the loading valve of
: 10 mm hydraulic tester (4) while relieving pressure in the
4. Connect the delivery hose to flange (8) with split arm roll-in circuit. Measure the flow rates and the
flange (9) and bolt (10). engine speeds at each pressure point specified in
: 10 mm the P-Q curve.
5. Repeat the measurement three times and calcu-
late the average values.
T4-5-18
OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified engine speed by using the following Refer to Operational Performance Standard in
formulas: T4-2.
NOTE: When actually measuring, connect pipe (1)
Qc = (Ns Q) Ne only to the pump to be measured.
1 2 3 4 5 6 7 8 9 10
Delivery Hose
(To Control Valve)
T173-04-04-002
11
12
14 13
T1R7-04-05-001
1 - Pipe N (ST 6192) 5 - Adapter G1 UNF1-7/8 9- Split Flange (ST 6130) 12 - Pipe
(ST 6146)
2 - Test Hose (ST 6145) 6 - Joint (ST 6330) 10 - Bolt (ST 6409) (4 Used) 13 - Port (G 1/4)
3 - Adapter G1 UNF1-7/8 7 - Test Hose (ST 6320) 11 - Plug 14 - Port (G 1/4)
(ST 6146)
4 - Hydraulic Tester (ST 6299) 8 - Flange (ST 6118)
T4-5-19
OPERATIONAL PERFORMANCE TEST / Component Test
Pilot Characteristics
Summary:
Main pump performance is checked by measuring 5. Install hose (18) and adapter (19) to port T of
the pump flow rate by using a hydraulic tester in- pressure reducing valve (15). Remove plug L
stalled at the main pump delivery port (one side) to from the return piping. Connect hose (18).
be measured. Use Dr. ZX and a pressure gauge at : 19 mm, 22 mm
the same time. 6. Remove the vacuum pump. Loosen the plug on
top of the pump casing. Bleed air from the pump
IMPORTANT: This measurement procedure is a casing until oil only comes out.
simple method. The measured data 7. Disconnect pipe (13) from the regulator. Install the
will be lower by approx. 5 % than the plug (G 1/4) to the pipe (13) mounting hole on the
accurately measured value. In order regulator.
to measure accurately, disconnect : 17 mm
the return circuit from the control 8. Fully open the loading valve of the hydraulic
valve and connect it to the hydraulic tester.
oil tank. 9. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
Preparation:
1. While referring to steps 1 to 4 on T4-5-18. Install a
hydraulic tester to the main pump to be meas-
ured.
2. Disconnect the hose of port Pi from the regulator
at the pump side to be measured. Install the plug
(ST 6213) to the disconnected hose.
: 6 mm, 19 mm
3. Install adapters (14) (3 used) to pressure reducing
valve (15). Remove plug M from the pilot filter.
Install adapter (12) and hose (13) to the pilot filter.
Connect hose (13) to port P1 of the regulator on
pressure reducing valve (15).
: 19 mm
4. Install tee (16) to port P2 of pressure reducing
valve (15). Install pressure gauge (17) and hose
(13) to tee (16). Connect hose (13) to the regula-
tor.
: 19 mm
T4-5-20
OPERATIONAL PERFORMANCE TEST / Component Test
1 2 3 4 5 6 7 8 9 10
Delivery Hose
(To Control Valve)
T173-04-04-002
11
20
Port Pi
T1R7-04-05-001
T L 19
17
18
P1 P2
14
To Regulator To Pilot
Port Pi Filter
13 16 14 15 14 13 12
T178-04-04-004
T178-03-07-001
1 - Pipe N (ST 6192) 6 - Joint (ST6330) 11 - Plug 16 - Tee UNF7/16 UNF7/16 PF1/4
(ST 6451)
2 - Test Hose (ST 6145) 7 - Test Hose (ST 6320) 12 - Adapter UNF7/16 G1/4 17 - Pressure Gauge
(ST 6069) (ST 6931)
3 - Adapter G1 UNF1-7/8 8 - Flange (ST 6118) 13 - Hose UNF7/16 UNF7/16 18 - Hose UNF7/16 UNF7/16
(ST 6146) (4334309) (4334309)
4 - Hydraulic Tester (ST 6299) 9 - Split Flange (ST 6130) 14 - Adapter G3/8 UNF7/16 19 - Adapter G3/8 UNF7/16
(4200465) (4200465)
5 - Adapter G1 UNF1-7/8 10 - Bolt (ST 6409) (4 Used) 15 - Pressure Reducing Valve 20 - Pipe
(ST 6146) (4325439)
T4-5-21
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement: Evaluation:
1. Measure the pump flow rate in response to the 1. Convert the measured flow rates to those at the
external command pilot pressure. specified engine speed by using the following
2. Select the following switch position: formulas:
Engine Power Mode Auto-Idle
Work Mode Qc = (Ns Q) / Ne
Control Dial Switch Switch
Digging Qc : Converted Flow Rate
Fast Idle P Mode OFF
Mode Q: Measured Flow Rate
Ns : Specified Engine Speed: 1800 min-1
3. Adjust the pressure reducing valve set pressure to Ne : Measured Engine Speed:
each pressure point specified along the main Values indicated on Dr. ZX
pump P-Q curve. (Pilot Characteristics) (Refer to
T4-5-18.) Measure the flow rates and the engine 2. Standard Flow Rate
speeds at the pressure points specified in the P-Q Refer to Operational Performance Standard in
curve. T4-2.
4. Repeat the measurement three times and calcu-
late the average values.
T4-5-22
OPERATIONAL PERFORMANCE TEST / Component Test
1 2 3 4 5 6 7 8 9 10
Delivery Hose
(To Control Valve)
T173-04-04-002
11
20
Port Pi
T1R7-04-05-001
T L 19
17
18
P1 P2
14
To Regulator To Pilot
Port Pi Filter
13 16 14 15 14 13 12
T178-04-04-004
T178-03-07-001
1 - Pipe N (ST 6192) 6 - Joint (ST6330) 11 - Plug 16 - Tee UNF7/16 UNF7/16 PF1/4
(ST 6451)
2 - Test Hose (ST 6145) 7 - Test Hose (ST 6320) 12 - Adapter UNF7/16 G1/4 17 - Pressure Gauge
(ST 6069) (ST 6931)
3 - Adapter G1 UNF1-7/8 8 - Flange (ST 6118) 13 - Hose UNF7/16 UNF7/16 18 - Hose UNF7/16 UNF7/16
(ST 6146) (4334309) (4334309)
4 - Hydraulic Tester (ST 6299) 9 - Split Flange (ST 6130) 14 - Adapter G3/8 UNF7/16 19 - Adapter G3/8 UNF7/16
(4200465) (4200465)
5 - Adapter G1 UNF1-7/8 10 - Bolt (ST 6409) (4 Used) 15 - Pressure Reducing Valve 20 - Pipe
(ST 6146) (4325439)
T4-5-23
OPERATIONAL PERFORMANCE TEST / Component Test
Regulator Adjustment
10
4 3
7 8
T178-03-01-006
1 - Lock Nut 4 - Adjusting Screw 7 - Lock Nut 9 - Lock Nut
(For Minimum Flow Rate) (For Maximum Flow Rate) (For P-Q Control) (For P-Q Control)
2 - Adjusting Screw 5 - Lock Nut 8 - Adjusting Screw 10 - Adjusting Screw
(For Minimum Flow Rate) (For Pilot Pressure Characteristic) (For P-Q Control) (For P-Q Control)
3 - Lock Nut 6 - Adjusting Screw
(For Maximum Flow Rate) (For Pilot Pressure Characteristic)
Pi
2. Maximum Flow Rate Loosen lock nut (3) and turn ad- 1) Do not turn adjusting screw (4) more
Q justing screw (4). than two turns.
Turning adjusting screw (4) 1/4 a 2) Do not increase the maximum flow
turn clockwise decreases the rate.
maximum pump flow rate by 2.88 In other words, do not turn adjusting
cm3/rev. (0.18 in3/rev). screw (4) counterclockwise.
: 13 mm 3) Securely tighten lock nut (3) after
: 9.8 N m adjustment.
(1 kgf m, 7.2 lbf ft)
Pd
T4-5-24
OPERATIONAL PERFORMANCE TEST / Component Test
Pd
T4-5-25
OPERATIONAL PERFORMANCE TEST / Component Test
SWING MOTOR DRAINAGE
Summary:
1. Measure amount of oil draining from the swing
motor while turning 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 the 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) or top of
the hydraulic oil tank and bleed air. 1
3. Disconnect drain hose (2) of the swing motor at
the hydraulic oil tank side. Install the plug (ST
6213) to the open end on the hydraulic oil tank
side.
: 22 mm
: 39 N m (4 kgf m, 28.5 lbf·ft)
T176-04-04-005
T4-5-26
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
Q = 60 q / t
Q : Amount of drain oil per minute (L/min)
t : Measured time (seconds)
q : Total amount of drain oil (L)
T107-06-05-008
T4-5-27
OPERATIONAL PERFORMANCE TEST / Component Test
TRAVEL MOTOR DRAINAGE
Summary:
1. While rotating the travel motor with the track to be
measured raised, measure amount of oil draining
from the travel motor and check travel motor per-
formance.
2. Secure absolute safety for the measuring persons
as well as for the surrounding while measuring.
3. Judge travel motor performance from the results
including travel speed, mistrack and so on overall.
1
4. Keep oil temperature constant as the drain
amount from the travel motor is much influenced
by oil temperature.
CAUTION: Prevent personal injury. Always
make sure that the area is clear and that
co-workers are out before starting the meas-
urement.
Also, take care not to fall off the machine
while the measurement.
T157-05-04-014
Preparation:
1. Maintain the hydraulic oil temperature at 50 5 C
(122 9 F). Rotate the travel motor and warm in- 2
side of the motor.
2. Stop the engine. Push air bleed valve (1) on top of
the hydraulic oil tank and bleed air.
3. Remove drain hose (2) in the travel motor at the
travel motor side. Install the plug (ST 6637) to the
disconnected hose. Connect the drain hose
(3/4-16UN) to the travel motor.
: 27 mm
: 78 N m (8.0 kgf m, 58 lbf ft)
T4-5-28
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
CAUTION: When working around moving
parts is unavoidable, pay special attention to
ensure that hands, feet, and clothing do not
become entangled. Securely support the
90 to 110
raised track by using the blocks.
Evaluation:
Refer to Operational Performance Standard in T4-2.
Q = 60 q/t
T4-5-29
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)
T4-5-30
OPERATIONAL PERFORMANCE TEST / Adjustment
ADJUSTMENT
Engine speed, pump delivery flow rate and solenoid valve output pressure can be adjusted by Dr.ZX.
Parameter Change
Item Data Unit
Li Speed Adjustment Adjustment of slow idle engine speed min-1
WU Speed Adjustment Adjustment of auto warming-up engine speed min-1
AI Speed Adjustment Adjustment of auto-idle engine speed min-1
P Speed Adjustment Adjustment of P mode engine speed min-1
Pump PQ Torque Adjustment Adjustment of pump P-Q curve Nm
Boom Dampener Proportional Adjustment of solenoid valve MPa
Valve Adjustment
ATT Proportional Valve Adjustment of optional solenoid valve MPa
Adjustment
ATT Speed Increase Down Setting of time required for engine speed decrease ms
Waiting Time
ATT Torque Down ON/OFF ON/OFF of torque down control when the attachment is ON, OFF
operated
ECO Control Selection ON/OFF of ECO control ON, OFF
HP Control Selection ON/OFF of HP control ON, OFF
ATT Mode Memory ON/OFF ON/OFF of attachment mode memory ON, OFF
Selection
Heater Control Selection ON/OFF of heater control ON, OFF
Engine Control Theft ON/OFF of engine control theft prevention ON, OFF
Prevention Selection
Pump Control Theft Prevention ON/OFF of pump control theft prevention ON, OFF
Selection
Min, Boom CYL. Bottom Setting of minimum boom cylinder bottom pressure over MPa
Pressure Over Balance balance
Radiator Coolant Temperature ON/OFF of radiator coolant temperature WU_B control ON, OFF
WU_B Selection
T4-6-1
OPERATIONAL PERFORMANCE TEST / Adjustment
T4-6-2
OPERATIONAL PERFORMANCE TEST / Adjustment
T4-6-3
OPERATIONAL PERFORMANCE TEST / Adjustment
T4-6-4
OPERATIONAL PERFORMANCE TEST / Adjustment
(Blank)
T4-6-5
OPERATIONAL PERFORMANCE TEST / Adjustment
Adjustment
1. Connect Palm (Dr. ZX) to the diagnosing
connector in the cab by using the Hot Sync cable
and the connecting harness.
2. Turn the key switch ON or start the engine.
3. When turning Palm ON, the following screen is
displayed on the display of Palm.
3-1. Initial Screen
Select Dr. ZX icon.
3-2. Password Setup Screen (When the
password has unset)
Set the password. T1V1-05-07-001
Dr. ZX
3-3. Service Software Selection Screen Connector
Connecting
Harness
Parts No.
3108613
T1V1-05-07-002
T4-6-6
OPERATIONAL PERFORMANCE TEST / Adjustment
Start
Initial Screen
Password Setup Screen
Input Password
Input the former
When the password has unset
Communication password (6 characters
Error or more).
Next time, input the
Check Communication Harness same password in order
Check Fuse to check and push OK.
When the password has set
Service Software
Selection Screen
Self-Diagnostic
Result Function Select Controller
Select
Function
Main Controller Engine Controller ICF Controller Monitor Controller
Self-Diagnostic
Result of Each Record Main Menu Main Menu Main Menu Main Menu
Controller Monitor Display Monitor Display Information C/U Monitoring
Special Function Special Function Various Setup Various Setup
Setup Disp. Record Data Download Password Change
Select Controller Disp. Record Password Change Save Data Check
Password Change Password Change
Op. Manual
Retry B
Self-Diagnostic
Result
T4-6-7
OPERATIONAL PERFORMANCE TEST / Adjustment
Setting
Parameter Change
To the
lower
To the
lower
T4-6-8
OPERATIONAL PERFORMANCE TEST / Adjustment
Parameter Input
Example: Li Speed Adjustment
Input Value = Normal Value
Input the value and push Execution. Check Adjustment and push Execute.
Push ESC and return to Parameter Push ESC and return to Parameter
Push Li Speed Adjustment. Change Selection Screen. Change Selection Screen.
To the
lower
T1V7-05-03-107
T4-6-9
OPERATIONAL PERFORMANCE TEST / Adjustment
Input the value and push Execution. Push Execute. Push ESC and return
Push ESC and return to Parameter to Parameter Change Selection
Push Li Speed Adjustment. Change Selection Screen Screen
To the
lower
T1V7-05-03-107
T4-6-10
OPERATIONAL PERFORMANCE TEST / Adjustment
Input Value > Maximum Value
(Input Value < Minimum Value)
Push Re-Input and return to
Parameter Input Screen. Push Max
Input the value and push Execution. and the maximum value is input.
Push ESC and return to Parameter Push ESC and return to Parameter
Push Li Speed Adjustment. Change Selection Screen. Change Selection Screen.
To the
lower
T1V7-05-03-107
T4-6-11
OPERATIONAL PERFORMANCE TEST / Adjustment
When the input value cannot be divided
To the
lower
T1V7-05-03-107
T4-6-12
OPERATIONAL PERFORMANCE TEST / Adjustment
Status Selection
Example: ATT Torque Reducing On/Off: Off
Push OFF and Push Exec. Push Check OFF and push Execute.
Push ATT Torque Reducing On/Off. ESC and return to Parameter Push ESC and return to Parameter
Change Selection Screen. Change Selection Screen.
To the
lower
T1V7-05-03-107
T4-6-13
OPERATIONAL PERFORMANCE TEST / Adjustment
Attachment Parameter Change
To the
lower
To the
lower
T4-6-14
OPERATIONAL PERFORMANCE TEST / Adjustment
Attachment Parameter Input
Input Value = Normal Value
To the
lower
T1V7-05-03-117 T1V7-05-03-107
T4-6-15
OPERATIONAL PERFORMANCE TEST / Adjustment
Input Value = Current Value
To the
lower
Push Execute. Push ESC and return Push ESC and return to Parameter
to Parameter Change Screen. Change Screen.
T1V7-05-03-118 T1V7-05-03-107
T4-6-16
OPERATIONAL PERFORMANCE TEST / Adjustment
Input Value > Maximum Value
(Input Value < Minimum Value)
To the
lower
T1V7-05-03-119 T1V7-05-03-107
T4-6-17
OPERATIONAL PERFORMANCE TEST / Adjustment
When the input value cannot be divided
To the
lower
T1V7-05-03-120 T1V7-05-03-107
T4-6-18
OPERATIONAL PERFORMANCE TEST / Adjustment
Status Selection
Example: ATT1, ATT No.
To the
lower
T1V7-05-03-168 T1V7-05-03-107
T4-6-19
OPERATIONAL PERFORMANCE TEST / Adjustment
ATTACHMENT SETTING Monitor Unit
T1V1-05-01-104
Pulverizer
T1V1-05-01-105
Crusher
Key 6
T1V5-05-01-001
T1V1-05-01-106
Attachment Specification Screen (Breaker 1)
Vibrating Hammer
T1V1-05-01-107
Work
Others Mode
T1V1-05-02-003
T4-6-20
OPERATIONAL PERFORMANCE TEST / Adjustment
Five kinds attachment can be selected from Breaker 1
to 5, pulverizer 1 to 5, crusher 1 to 5, vibrating hammer
1 to 5 and others 1 to 5.
(Refer to T4-6-2 to 4.)
Attachment 2 Attachment 3
Attachment 4
Attachment 1 Attachment 5
T1V5-05-01-109
T4-6-21
OPERATIONAL PERFORMANCE TEST / Adjustment
Attachment Setting
Example: Set Pulverizer 5 to Attachment 1
Push PU and push Exec. Push
ESC and return to ATT Parameter
Push ATT 1. Push ATT1 ATT Type. Change Selection Screen.
To the
lower
Check PU and push Execute. Push Push ESC and return to ATT
ESC and return to ATT Parameter Parameter Change Selection
Change Selection Screen. Screen. Push ATT 1 ATT Number.
To the
lower
Push 5 and push Exec. Push Check No. and push Execute. Push ESC and return to ATT
ESC and return to ATT Parameter Push ESC and return to ATT Parameter Change Selection
Change Selection Screen. Parameter Change Selection Screen.
T4-6-22
OPERATIONAL PERFORMANCE TEST / Adjustment
When the work mode screen of monitor unit is
displayed, Pulverizer 5 is displayed at Attachment 1.
When pushing key 2, Pulverizer 5 is selected and the
Pulverizer 5 specification screen is displayed.
Attachment 5
T1V5-05-03-004
Key 2
T4-6-23
OPERATIONAL PERFORMANCE TEST / Adjustment
Attachment Non-Setting
IMPORTANT: When the attachment is non-setting,
the attachment cannot be selected on
the monitor unit.
Example: Set Attachment to Non-Setting
Push Non and push Exec. Push
ESC and return to ATT Parameter
Push ATT 1. Push ATT1 ATT Type. Change Selection Screen.
To the
lower
Check Non and push Execute. Push ESC and return to ATT
Push ESC and return to ATT Parameter Change Selection
Parameter Change Selection Screen.
T1V7-05-03-178 T1V7-05-03-107
T4-6-24
OPERATIONAL PERFORMANCE TEST / Adjustment
When the work mode of monitor unit is displayed,
attachment 1 display disappears.
Attachment 5
T1V5-05-03-005
T4-6-25
OPERATIONAL PERFORMANCE TEST / Adjustment
(Blank)
T4-6-26
MEMO
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
MEMO
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 Diagnosing Procedure Group 3 Dr. ZX
Introduction .............................................. T5-1-1 Outline ...................................................... T5-3-1
Diagnosing Procedure .............................. T5-1-2 Select Controller ....................................... T5-3-6
Main Controller ......................................... T5-3-7
Group 2 Monitor Unit Main Menu Monitor Display....................... T5-3-8
Outline...................................................... T5-2-1 Special Function ..................................... T5-3-14
How to Use Screens ............................... T5-2-19 Setting .................................................... T5-3-16
Primary Screen....................................... T5-2-29 Adjustment Data List............................... T5-3-20
Screen Display Attachment Adjustment Data List ............ T5-3-22
When an Alarm is Issued .................... T5-2-30 Attachment Setting.................................. T5-3-38
Contents of Alarms ................................. T5-2-32 Engine Controller .................................... T5-3-47
Troubleshooting...................................... T5-2-34 Main Menu Monitor Display..................... T5-3-49
Controller Version................................... T5-2-36 Special Function Data Upload
Monitoring .............................................. T5-2-38 from ECM.............................................. T5-3-52
Displaying Operating Conditions ............ T5-2-41 Data Download to ECM........................... T5-3-54
Pump 2 Flow Rate Adjustment Write Injection ID Code ........................... T5-3-56
(Only Machines Equipped ECM Data Display................................... T5-3-58
with Optional Parts) .............................. T5-2-42 Actuator Test........................................... T5-3-59
Attachment Selection (Only Machines Example of Engine Speed
Equipped with Optional Parts) .............. T5-2-44 Down & Stop Cylinder Function
Time Set ................................................. T5-2-48 (on a Four-Cylinder Engine) .................. T5-3-62
Fuel Rate Display/No Display ................. T5-2-50 Record Data Display ............................... T5-3-63
Back Monitor Settings............................. T5-2-54 Password Change................................... T5-3-64
Maintenance Settings ............................. T5-2-56 ICF Controller ......................................... T5-3-65
Language Settings.................................. T5-2-62 Main Menu
Mail (Optional) ........................................ T5-2-64 Information C/U Various Setup .............. T5-3-66
List of Monitor Unit Setting Function ....... T5-2-66 Information C/U: Initialize........................ T5-3-67
Enter Model and Serial No. ..................... T5-3-68
Enter Date and Time ............................... T5-3-69
Control Data: Initialize............................. T5-3-70
Satellite Terminal: Initialize ..................... T5-3-71
Satellite Terminal Serial No.
Confirmation ......................................... T5-3-72
1R7T-5-1
Communicating State Check .................. T5-3-73 Group 5 Component Layout
Satellite Comm. Start / Stop Set ............. T5-3-74 Main Components ..................................... T5-5-1
Satellite Comm. Transmitting.................. T5-3-75 Electrical System (Overview) .................... T5-5-3
Date Download ....................................... T5-3-77 Electrical System (In Cab) ........................ T5-5-5
Save Data Check.................................... T5-3-78 Electrical System (Rear Tray) ................... T5-5-7
Password Change .................................. T5-3-79 Electrical System (Switch Panel) .............. T5-5-9
Monitor Controller ................................... T5-3-80 Electrical System (Relays) ...................... T5-5-10
Monitoring .............................................. T5-3-81 Engine .................................................... T5-5-11
Various Settings ..................................... T5-3-85 Pump Device .......................................... T5-5-12
Optional Function Allocation ................... T5-3-86 Swing Device .......................................... T5-5-13
Overload Alarm Enable / Disable Control Valve .......................................... T5-5-13
Selection............................................... T5-3-92 Signal Control Valve................................ T5-5-13
Back Monitor Setting .............................. T5-3-94 2-Spool Solenoid Valve Unit.................... T5-5-13
Operating Condition Enable / Travel Device .......................................... T5-5-14
Disable Selection.................................T5-3-102 Blade Control Valve (Optional) ................ T5-5-14
Time Setting Function Enable /
Disable Selection.................................T5-3-104 Group 6 Troubleshooting A
Maintenance Setting Maintenance Troubleshooting A Procedure .................... T5-6-1
Operation Allow / Not Allow Selection ..T5-3-106 Fault Code List MC ................................... T5-6-2
Notification Function ECM........................................................ T5-6-20
Enable / Disable Selection ...................T5-3-108 ICF.......................................................... T5-6-44
Maintenance Display Item Controller Hardware Failure
On/Off Selection .................................. T5-3-110 MC Fault Code 11000 to 11002............. T5-6-50
Fuel Consumption Gauge Display MC Fault Code 11003 ............................. T5-6-51
Enable / Disable Selection ...................T5-3-114 MC Fault Code 11004 ............................. T5-6-52
Password Change .................................T5-3-116 CAN Harness Check ............................... T5-6-54
Engine Failure
Group 4 e-Shovel MC Fault Code 11100............................ T5-6-73
Outline...................................................... T5-4-1 MC Fault Code 11101 ............................. T5-6-74
List of Daily Report Data........................... T5-4-2 Pump Failure
List of Frequency Distribution Data........... T5-4-5 MC Fault Code 11200 ........................... T5-6-75
List of Total Operating Hours .................... T5-4-6 MC Fault Code 11202 ............................. T5-6-76
How to Download and Upload Data MC Fault Code 11206 ............................. T5-6-77
of ICF...................................................... T5-4-8 MC Fault Code 11208 ............................. T5-6-78
Various Setup of ICF and Pilot Failure
Satellite Communication Terminal MC Fault Code 11301 ........................... T5-6-79
by Using Dr. ZX .....................................T5-4-11 MC Fault Code 11302 ............................. T5-6-80
List of Fault Code ................................... T5-4-23 MC Fault Code 11303 ............................. T5-6-81
Satellite Communication System ............ T5-4-24 MC Fault Code 11304 ............................. T5-6-82
1R7T-5-2
MC Fault Code 11307............................. T5-6-83 ICF, Satellite Terminal Fault Codes
Proportional Solenoid Valve Failure 14006, 14008, 14100 to 14106 ............T5-6-111
MC Fault Code 11400 ........................... T5-6-84 Monitor Unit Fault Code 13303 ............. T5-6-113
MC Fault Code 11401............................. T5-6-85 Monitor Unit Fault Code 13304 ............. T5-6-114
MC Fault Code 11403............................. T5-6-86 Monitor Unit Fault Code 13306, 13308 . T5-6-115
MC Fault Code 11405............................. T5-6-87 Monitor Unit Fault Code 13310 ............. T5-6-116
CAN Data Reception Failure Monitor Unit Fault Code 13311 ............. T5-6-117
MC Fault Codes 11910, 11914, 11920 .. T5-6-88 Pilot Shut-Off Lever Alarm .................... T5-6-118
CAN Harness Check
MC Fault Codes 11910, 11914, 11920 .. T5-6-90 Group 7 Troubleshooting B
MC Fault Codes 11911, 11918................ T5-6-93 Troubleshooting B Procedure ................... T5-7-1
CAN Harness Check Relationship between Machine Trouble
Fault Codes 11911, 11918 .................... T5-6-94 Symptoms and Related Parts.................. T5-7-2
Other Failures Correlation between Trouble
MC Fault Code 11901 ........................... T5-6-97 Symptoms and Part Failures ................. T5-7-40
ECM, Sensor System Engine System Troubleshooting ............. T5-7-56
ECM Fault Codes 100, 102, 105, All Actuator System Troubleshooting ...... T5-7-84
108, 110, 157, 172 ................................ T5-6-98 Front Attachment System
ECM Fault Codes Troubleshooting .................................... T5-7-96
174, 636, 723, 10001............................ T5-6-99 Swing System Troubleshooting ............. T5-7-110
ECM, External Device System Travel System Troubleshooting............. T5-7-112
ECM Fault Codes 651, 652, 653, Other System Troubleshooting.............. T5-7-120
654, 655, 656, 1347, 10002 .................T5-6-100 Exchange Inspection............................. T5-7-140
ECM, Fuel System Emergency Boom Lowering
ECM Fault Codes Procedure ........................................... T5-7-143
157, 633, 1239, 1240...........................T5-6-101 Circuit Pressure Release Procedure ..... T5-7-144
ECM, Engine Protection One Part of Data, Daily Report Data,
ECM Fault Codes 110, 190....................T5-6-102 Distribution Data and Total Operating
ECM, Engine Protection hours is not Recorded........................ T5-7-146
ECM Fault Codes 987, 1485 .................T5-6-103
ECM, Internal Circuit System
ECM Fault Codes 628, 1077, 1079,
1080, 10003, 10004, 10005 .................T5-6-104
ECM Fault Codes 10006, 10007, 10008,
10009, 10010, 10011, 10013 ...............T5-6-105
ECM, Communication System
ECM Fault Codes 639 ...........................T5-6-106
ICF, Satellite Terminal Fault Codes
14000 to 14003....................................T5-6-107
1R7T-5-3
Group 8 Electrical System Inspection
Precautions for Inspection and
Maintenance ........................................... T5-8-1
Instructions for Disconnecting
Connectors ............................................. T5-8-3
Fuse Inspection ........................................ T5-8-4
Fusible Link Inspection ............................. T5-8-5
Battery Voltage Check .............................. T5-8-6
Alternator Check....................................... T5-8-7
Continuity Check ...................................... T5-8-8
Voltage and Current Measurement ......... T5-8-10
Check by False Signal ............................ T5-8-17
Test Harness .......................................... T5-8-18
1R7T-5-4
TROUBLESHOOTING / Diagnosing Procedure
INTRODUCTION
Refer to the inspection and troubleshooting proce-
dures after any machine trouble has occurred. The
inspection and troubleshooting procedures are pre-
sented in an orderly fashion in this section to quickly
find the cause of the machine trouble and solution.
T5-1-1
TROUBLESHOOTING / Diagnosing Procedure
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient
troubleshooting:
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
1 2 3 4 5 6 7 8
22 10
11
12
13
14
15
21 20 19 18 17 16
T1V1-05-01-094
1 - Work Mode Display 7 - Work Mode Display 13 - Fuel Consumption Gauge 18 - Mail Selection (Optional)
2 - Auto-Idle Display 8 - Hour Meter 14 - Clock 19 - *ML Crane Selection
(Optional)
3 - *ML Crane Display or 9 - *ML Crane Display 15 - Back-Screen Selection 20 - Work Mode Selection
Overload Alarm Display (Optional)
(Optional)
4 - Auxiliary 10 - Fuel Gauge 16 - Menu 21 - Return to Primary Screen
5 - Auxiliary 11 - Mail Display (Optional) 17 - Auxiliary Selection 22 - Coolant Temperature
Gauge
6 - Glow Display 12 - Auxiliary
NOTE: *ML crane display and ML crane selection is only available in Japanese domestic market.
T5-2-1
TROUBLESHOOTING / Monitor Unit
Display of Meters
Work Mode 2
Data to be displayed on each meter from are dis-
played on the monitor unit according to the input
signal from sensor, the signal received by using CAN
and the internal data of the monitor unit. 1 3
Items to be displayed
1. Coolant Temperature Gauge (Input signal from the
coolant temperature sensor)
2. Hour Meter (Internal data of the monitor unit)
3. Fuel Consumption Gauge (Input signal from the 4
fuel sensor)
4. Clock (Signal received from ICF by using CAN)
Digging Mode
T1V1-05-01-108
Attachment Mode
Breaker
T1V1-05-01-104
Pulverizer
T1V1-05-01-105
Crusher
T1V1-05-01-106
Vibrating Hammer
T1V1-05-01-107
Others
T1V1-05-02-003
T5-2-2
TROUBLESHOOTING / Monitor Unit
1 3
Auto-Idle Display (1)
When the auto-idle switch on the 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.
T1V1-05-01-008
Overload Alarm
T1V1-05-02-002
T1V1-05-01-128
Fuel Consumption Gauge Display (4)
IMPORTANT: The values on the fuel consumption
gauge are references and different
from the measured values.
Fuel consumption is displayed according to the sig-
nal from ECM, which is received through MC by us-
ing CAN.
T5-2-3
TROUBLESHOOTING / Monitor Unit
Fuel Gauge
Fuel level is displayed on. Fuel Gauge
T1V1-05-01-008
Primary Screen
T1V1-05-02-010
1 or more
Less than 3
T1V1-05-02-012
T5-2-4
TROUBLESHOOTING / Monitor Unit
T1V1-05-02-014
5 or more
Less than 12
T1V1-05-02-016
12 or more
Less than 20
T1V1-05-02-018
20 or more
Less than 30
T1V1-05-02-020
30 or more
Less than 40
T1V1-05-02-022
40 or more
Less than 50
T1V1-05-02-024
T5-2-5
TROUBLESHOOTING / Monitor Unit
T1V1-05-02-026
60 or more
Less than 70
T1V1-05-02-028
70 or more
Less than 80
T1V1-05-02-030
80 or more
Less than 90
T1V1-05-02-032
90 or more
Less than 100
T1V1-05-02-034
100 or more
T1V1-05-02-036
T5-2-6
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-7
TROUBLESHOOTING / Monitor Unit
Coolant Temperature Gauge
Temperature of the engine coolant is displayed. Coolant Temperature Gauge
T1V1-05-01-008
Primary Screen
T1V1-05-02-038
40 C or more
Less than 45 C
T1V1-05-02-040
T5-2-8
TROUBLESHOOTING / Monitor Unit
T1V1-05-02-042
50 C or more
Less than 60 C
T1V1-05-02-045
60 C or more
Less than 80 C
80 C or more
Less than 96 C
T1V1-05-02-047
96 C or more
Less than 98 C
T5-2-9
TROUBLESHOOTING / Monitor Unit
T1V1-05-02-047
99 C
100 C
T1V1-05-02-049
101 C
T1V1-05-02-051
102 C
T1V1-05-02-053
103 C
T1V1-05-02-056
T5-2-10
TROUBLESHOOTING / Monitor Unit
T1V1-05-02-058
105 C or more
Less than 110 C
T1V1-05-02-062
110 C or more
Less than 115 C
T1V1-05-02-066
115 C or more
Less than 120 C
T1V1-05-02-067
120 C or more
T1V1-05-02-068
Overheat SW=ON
T5-2-11
TROUBLESHOOTING / Monitor Unit
Fuel Sensor Error Display Coolant Temperature Fuel Sensor Error
When the fuel sensor is faulty or if the harness be- Sensor Error Display Display
tween fuel sensor and monitor unit is open circuit,
the data is displayed on the fuel gauge.
T1V1-05-01-096
Alarm Display
T1V5-05-01-013
Remedy Display against
Alarm
T5-2-12
TROUBLESHOOTING / Monitor Unit
Troubleshooting
This screen displays the fault codes according to the
signals received from each controller by using CAN.
T1V5-05-01-097
Fault Code Display
Controller Version
This screen displays the version of MC, ICF and the
monitor unit.
NOTE: The version of ECM is not displayed.
Monitoring
This screen displays temperature and pressure data
received from each controller by using CAN.
By the key operation, the displayed data can be
held.
T1V5-05-01-087
Monitoring Screen
Operating Conditions
This screen displays machine operating hour, fuel
usage and fuel consumption rate registered by the
monitor unit.
T1V5-05-01-025
Operating Conditions Screen
T5-2-13
TROUBLESHOOTING / Monitor Unit
Pump 2 Flow Rate Adjustment
(Only machines equipped with optional parts)
When using the attachments, fine adjust flow rate of
pump 2 by keys 1 and 2 operation.
The signals from the monitoring unit are sent to MC
by using CAN.
When breaker 1 or 2 is used, MC adjusts flow rate of
pump 2 while controlling the maximum pump 2 flow
rate limit control solenoid valve. When pulverizer 1
or crusher 1 is used, MC adjusts flow rate of pres-
sure oil that flows from pump 2 to the pulverizer or Key 1
the crusher while controlling the auxiliary flow rate
control solenoid valve. (Refer to Control System.) Key 2
Type of 2-Speed Valve Selector Accumulator Secondary Pump 2 Flow Auxiliary Flow
Attachments Selector Circuit Circuit Circuit Hydraulic Rate Control Rate Control
Relief Selector
Circuit
Breaker 1 OFF to Hydraulic OFF ON ON OFF
Oil Tank
Breaker 2 OFF to Hydraulic ON OFF ON OFF
Oil Tank
Pulverizer 1 ON to Control Valve OFF OFF OFF ON
Crusher 1 ON to Control Valve OFF OFF OFF ON
T5-2-14
TROUBLESHOOTING / Monitor Unit
Attachment Selection
(Only machines equipped with optional parts)
Digging mode and attachment mode set by Dr. ZX
on this screen are selected.
T5-2-15
TROUBLESHOOTING / Monitor Unit
Back Monitor Settings
By the key operation, image display ON and OFF of
Auto-Control for switching image of the back monitor
while traveling can be set.
T1V5-05-01-173
T5-2-16
TROUBLESHOOTING / Monitor Unit
Maintenance Settings
This screen displays the hour meter reading at the
replacement time and the remaining hours until the
next replacement.
As the items to be replaced are displayed in a list,
the performed replacement by selecting an item from
the list is recorded.
Mail
(Optional Function)
Requests such as general, fuel replenishment, ser-
vice maintenance and forwarding requests in the
mail switch screen are performed.
Contents of mails are registered in ICF, and are sent
to the central server by a satellite terminal.
T5-2-17
TROUBLESHOOTING / Monitor Unit
Overload Alarm
Alarm
(Only machines equipped with optional parts)
T5-2-18
TROUBLESHOOTING / Monitor Unit
HOW TO USE SCREENS
T1V1-05-01-117
Alternator Alarm
T5-2-19
TROUBLESHOOTING / Monitor Unit
Displaying Primary Screen by Password Input
(Optional)
T1V5-05-01-093
Password Input Screen
2. 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.
T1V5-05-01-002
Confirm Key Delete Key
T5-2-20
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-21
TROUBLESHOOTING / Monitor Unit
In Case of Inputting an Incorrect Password
T1V5-05-01-093
Password Input Screen
T1V5-05-01-002
Confirm Key Delete Key
T1V5-05-01-004
Back Key
T1V5-05-01-093
T5-2-22
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 buzzer rings for
thirty seconds.
T1V5-05-01-005
Security Lock Screen
4. After thirty seconds, if the key switch is turned to
the ON position, the starting screen appears and
the password input screen appears again. Then a
password can be input again. If inputting an in-
correct password even once this time, the security
lock screen appears again and a buzzer rings.
While the key switch is turned to the ON position,
the buzzer does not stop ringing. When the key
switch is turned to the OFF position, the buzzer
rings for thirty seconds.
T5-2-23
TROUBLESHOOTING / Monitor Unit
Extending Password Duration Time
T5-2-24
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-25
TROUBLESHOOTING / Monitor Unit
Password Change (Optional)
Menu Key
T1V5-05-01-123
Primary Screen
2. Select Password Change from the main menu by
using keys1 and 2. Push the confirm key. Then,
the password change screen appears.
T1V5-05-01-129
Key 1 Key 2 Confirm Key
T1V5-05-01-041
Registered Password
T1V5-05-01-042
Confirm Key Delete Key
T5-2-26
TROUBLESHOOTING / Monitor Unit
T1V5-05-01-044
Back Key
T1V5-05-01-130
A New Password
T1V5-05-01-131
Confirm Key Erase Key
T5-2-27
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
T1V1-05-01-123
Primary Screen
T5-2-28
TROUBLESHOOTING / Monitor Unit
PRIMARY SCREEN
Machine with Overload Alarm
(Optional) Attached
1 2 3 4 5 6 7 8
22 10
11
12
13
14
15
21 20 19 18 17 16
T1V1-05-01-094
1 - Work Mode Display 7 - Work Mode Display 13 - Fuel Consumption Gauge 18 - Mail Selection (Optional)
2 - Auto-Idle Display 8 - Hour Meter 14 - Clock 19 - *ML Crane Selection
(Optional)
3 - *ML Crane Display or 9 - *ML Crane Display 15 - Screen Selection 20 - Work Mode Selection
Overload Alarm Display (Optional)
(Optional)
4 - Auxiliary 10 - Fuel Gauge 16 - Menu 21 - Return to Primary Screen
5 - Auxiliary 11 - Mail Display (Optional) 17 - Auxiliary Selection 22 - Coolant Temperature
Gauge
6 - Glow Display 12 - Auxiliary
NOTE: *ML crane display and ML crane selection is only available in Japanese domestic market.
T5-2-29
TROUBLESHOOTING / Monitor Unit
SCREEN DISPLAY WHEN AN ALARM IS
ISSUED
When an alarm is issued, the alarm marks are dis-
played at the bottom of the screen.
T1V1-05-01-095
T1V1-05-01-096
T5-2-30
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
T5-2-31
TROUBLESHOOTING / Monitor Unit
CONTENTS OF ALARMS
M183-01-080
M183-01-071
M178-01-034
M1CC-01-039
M183-01-067
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
T5-2-32
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-33
TROUBLESHOOTING / Monitor Unit
TROUBLESHOOTING
1. Displaying Service Menu
Turn the key switch to the ON position while
pushing the key at the upper right corner of the
monitor unit. Therefore, the service menu is
added to the main menu.
T1V1-05-01-115
Turn key switch ON while pushing the key.
Menu Key
T1V1-05-01-123
Primary Screen
T1V5-05-01-114
Key 1 Key 2 Confirm Key Back Key
T5-2-34
TROUBLESHOOTING / Monitor Unit
4. Select Troubleshooting by using keys 1 and 2.
Push the confirm key. Then, the troubleshooting
screen appears.
T1V1-05-01-123
Primary Screen
T5-2-35
TROUBLESHOOTING / Monitor Unit
CONTROLLER VERSION
1. Displaying Service Menu
Turn the key switch to the ON position while
pushing the key at the upper right corner of the
monitor unit. Therefore, the service menu is
added to the main menu.
T1V1-05-01-115
Turn the key switch ON while pushing the key.
Menu Key
T1V1-05-01-123
Primary Screen
T1V5-05-01-114
Key 1 Key 2 Confirm Key Back Key
T5-2-36
TROUBLESHOOTING / Monitor Unit
4. Select Controller Version by using keys 1 and 2.
Push the confirm key. Then, the controller version
screen appears.
T1V5-05-01-083
Key 1 Key 2 Confirm Key Back Key
T1V5-05-01-122
Key 6 Back Key
T1V1-05-01-123
Primary Screen
T5-2-37
TROUBLESHOOTING / Monitor Unit
MONITORING
1. Displaying Service Menu
Turn the key switch to the ON position while
pushing the key at the upper right corner of the
monitor unit. Therefore, the service menu is
added to the main menu.
T1V1-05-01-115
Turn the key switch ON while pushing the key.
Menu Key
T1V1-05-01-123
Primary Screen
T1V5-05-01-114
Key 1 Key 2 Confirm Key Back Key
T5-2-38
TROUBLESHOOTING / Monitor Unit
4. Select Monitoring by using keys 1 and 2. Push the
confirm key. Then, the monitoring screen appears.
As for the items to be monitored, refer to the next
page.
T1V5-05-01-083
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
8. Push key 6, and the primary screen appears.
T1V1-05-01-123
Primary Screen
T5-2-39
TROUBLESHOOTING / Monitor Unit
A List of Items to be Monitored
Items Units
Engine Torque %
Coolant Temperature (E) °C
Fuel Temperature °C
Engine Oil Pressure kPa
Atmospheric Pressure kPa
Intake-Air Temperature °C
Boost Pressure kPa
Boost Temperature °C
Coolant Temperature (M) °C
Target Engine Speed min-1
Actual Engine Speed min-1
Pump 1 Delivery Pressure MPa
Pump 1 Pump Control Pressure MPa
Pump 1 Target Flow Rate L/min
Pump 2 Delivery Pressure MPa
Pump 2 Pump Control Pressure MPa
Pump 2 Target Flow Rate L/min
Front Attachment Control Pilot Pressure MPa
Boom Raise Control Pilot Pressure MPa
Arm Roll-In Control Pilot Pressure MPa
Swing Control Pilot Pressure MPa
Travel Control Pilot Pressure MPa
Attachment Control Pilot Pressure MPa
EC Dial Angle V
Hydraulic Oil Temperature °C
Pump Torque Proportional Valve MPa
Digging Regenerative Valve MPa
Arm Regenerative Valve MPa
Travel Mode Control Pressure MPa
Power Digging Control Pressure MPa
Power Mode -
Travel Mode Switch -
Power Digging Switch -
Radio Signal Strength -
T5-2-40
TROUBLESHOOTING / Monitor Unit
DISPLAYING OPERATING CONDITIONS
1. After the primary screen appears, push the menu
key and display Main Menu.
T1V5-05-01-025
Reset Key Back Key
Back Key
T1V5-05-01-026
Key 6 Confirm Key
T5-2-41
TROUBLESHOOTING / Monitor Unit
PUMP 2 FLOW RATE ADJUSTMENT
(Only Machines Equipped with Optional
Parts)
IMPORTANT: This operation is effective when at-
tachments are used.
T1V5-05-01-019
Key 1 Key 2 Confirm Key
T1V5-05-01-111
Key 1 Key 2 Back Key
T1V5-05-01-024
Key 1 Key 6 Key 2 Back Key
T5-2-42
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-43
TROUBLESHOOTING / Monitor Unit
ATTACHMENT SELECTION
(Only Machines Equipped with Optional
Parts)
IMPORTANT: Select the attachments from the
work mode screen.
In order to display the work mode
screen, push key F1 after the primary
screen appears, or select from Main
Menu.
Back Key
Confirm
Key
T1V5-05-01-028
Attachment Specification Screen
T5-2-44
TROUBLESHOOTING / Monitor Unit
Selecting Attachment from Main Menu
T1V5-05-01-019
Key 1 Key 2 Confirm Key
5. Push the confirm key, and the primary screen
appears.
Digging
Back Key
Back Key
Confirm
Key
Attachment Specification Screen T1V5-05-01-028
T5-2-45
TROUBLESHOOTING / Monitor Unit
Attachment Specification Screen
T5-2-46
TROUBLESHOOTING / Monitor Unit
T1V5-05-01-011
T1V5-05-01-028
T5-2-47
TROUBLESHOOTING / Monitor Unit
TIME SET
1. After the primary screen appears, push the menu
key and display Main Menu.
Menu Key
T1V1-05-01-123
Primary Screen
2. Select Time Set from Main Menu by using keys 1
and 2. Push the confirm key. Then, the time set
screen appears.
Back Key
T1V5-05-01-019
Key 1 Key 2 Confirm Key
Back Key
Key 6 T1V5-05-01-022
T5-2-48
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-49
TROUBLESHOOTING / Monitor Unit
FUEL RATE DISPLAY/NO DISPLAY
IMPORTANT: The values displayed on the fuel
gauge are just for reference and dif-
ferent from actual values.
Menu Key
T1V1-05-01-123
Primary Screen
T1V5-05-01-118
Key 1 Key 2 Confirm Key Back Key
T1V5-05-01-164
Confirm Key
Back Key
T1V5-05-01-119
T5-2-50
TROUBLESHOOTING / Monitor Unit
4. Push key 6, and the fuel gauge is added to the
primary screen.
Key 6 T1V5-05-01-119
T1V1-05-01-007
Fuel Gauge
T5-2-51
TROUBLESHOOTING / Monitor Unit
Fuel Rate No Display
Fuel
Gauge
Menu Key
T1V1-05-01-007
Primary Screen
2. Select Fuel Rate Display/No Display from Main
Menu by using keys 1 and 2. Push the confirm key.
Then, the fuel rate display/no display screen ap-
pears.
Back Key
Back Key
T1V5-05-01-164
T5-2-52
TROUBLESHOOTING / Monitor Unit
4. Push key 6, and return to the primary screen.
Key 6
T1V5-05-01-164
T1V1-05-01-123
Primary Screen
T5-2-53
TROUBLESHOOTING / Monitor Unit
BACK MONITOR SETTINGS
IMPORTANT: Image displayed on the back monitor
is of auxiliary nature at best. When
the machine is operated pay thor-
ough attention to surrounding situa-
tion.
Auto-Control: ON
Back Key
T1V5-05-01-114
Key 1 Key 2 Confirm Key
Back Key
Key 6
T1V5-05-01-174
T5-2-54
TROUBLESHOOTING / Monitor Unit
Auto-Control: OFF
Menu Key
T1V1-05-01-123
Primary Screen
T1V5-05-01-118
Key 1 Key 2 Confirm Key Back Key
Back Key
Key 6
T1V5-05-01-173
T5-2-55
TROUBLESHOOTING / Monitor Unit
MAINTENANCE SETTINGS
1. After the primary screen appears, push the menu
key and display Main Menu.
Menu Key
T1V1-05-01-123
Primary Screen
2. Select Maintenance Settings from Main Menu by
using keys 1 and 2. Push the confirm key. Then,
the maintenance settings screen appears.
T1V5-05-01-019
Key 1 Key 2 Confirm Key
T1V5-05-01-049
Key 1 Key 2 Confirm Key
T5-2-56
TROUBLESHOOTING / Monitor Unit
Maintenance Information Display ON/OFF
Menu Key
T1V1-05-01-123
Primary Screen
T5-2-57
TROUBLESHOOTING / Monitor Unit
Change Interval Settings
Key 1
T1V5-05-01-138
Key 2 Confirm Key
Menu Key
T1V1-05-01-123
Primary Screen
T5-2-58
TROUBLESHOOTING / Monitor Unit
Resetting Data
Key 5
T5-2-59
TROUBLESHOOTING / Monitor Unit
Screen Display when Maintenance Information
Display is ON
3. If data is rest, push the reset key while the main- Reset Key
tenance information display screen is displayed.
The message "Reset Data. OK?" appears. Then, T1V5-05-01-170
push the confirm key. Maintenance Information Display Screen
The value of remaining hours is reset to that of
change interval. The previous change date/hour is
updated with current date and time.
T1V5-05-01-171
Reset Screen
T1V1-05-01-123
Primary Screen
T5-2-60
TROUBLESHOOTING / Monitor Unit
When more than two items are displayed
1. If turning the key switch to the ON position, the
starting screen appears. Then, the scheduled
maintenance screen for the items whose change
interval has expired appears for ten seconds. Fi-
nally the primary screen appears.
T1V5-05-01-169
Scheduled Maintenance Screen
NOTE: When pushing the back key while the
scheduled maintenance screen is displayed,
the primary screen appears.
nance screen.
Back Key
T1V5-05-01-171
Reset Screen
T5-2-61
TROUBLESHOOTING / Monitor Unit
LANGUAGE SETTINGS
1. After the primary screen appears, push the menu
key and display Main Menu.
T1V5-05-01-114
Key 1 Key 2 Confirm Key Back Key
Back Key
T1V1-05-01-137
Key 1 Key 6 Key 2 Confirm Key
T5-2-62
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
T5-2-63
TROUBLESHOOTING / Monitor Unit
MAIL
(Optional)
IMPORTANT: This function is available only to a
machine equipped with a satellite
terminal.
When using the mail function, make
the mail function available by using
Dr. ZX.
T1V5-05-01-038
Back Key
T1V5-05-01-039
T5-2-64
TROUBLESHOOTING / Monitor Unit
T1V5-05-01-040
T5-2-65
TROUBLESHOOTING / Monitor Unit
LIST OF MONITOR UNIT SETTING FUNC-
TION
: with setting function
: without setting function
Setting Function
Factory Set-
Function Item Monitor
Dr. ZX ting
Unit
Alarm The alarm which the trouble occurs on is checked. (Troubleshooting) -
Security Password function is used/ is not used. (Security) Not used
The password is changed. 0000
The password is changed/ is not changed by the
(Security) Changed
monitor.
Max.:
The max. digit quantity of password is changed. (Security)
4 digits
The password is checked. (Security) -
Extension function is used/ is not used. (Security) Used
Extension time is selected. -
Time Setting Time is is changed/ is not changed by the monitor. (Monitor Controller) Changed
Time is is changed. (ICF) -
Operating Machine operating condition is displayed/ is not dis-
(Monitor Controller) Displayed
Condition played on the main menu.
Machine operating condition is reset. -
Maintenance Maintenace setting is operated/ is not operated. (Monitor Controller) Operated
Setting Engine oil is displayed/ is not displayed. (Monitor Controller) Displayed
Information display of engine oil is turned ON/OFF. (Monitor Controller) ON
Replacement interval of engine oil is changed. 500 hours
The engine oil replacement switch is pushed. -
Date/ the hour meter when engine oil was replaced last
-
time are checked.
The engine oil filter is displayed/ is not displayed. (Monitor Controller) Displayed
Information display of engine oil filter is turned
(Monitor Controller) ON
ON/OFF.
Replacement interval of engine oil filter is changed. 500 hours
The engine oil filter replacement switch is pushed. -
Date/ the hour meter when engine oil filter was re-
-
placed last time are checked.
Hydraulic oil is displayed/ is not displayed. (Monitor Controller) Displayed
Information display of hydraulic oil is turned ON/OFF. (Monitor Controller) ON
Replacement interval of hydraulic oil is changed. 5000 hours
The hydraulic oil replacement switch is pushed. -
Date/ the hour meter when hydraulic oil was replaced
-
last time are checked.
T5-2-66
TROUBLESHOOTING / Monitor Unit
Setting Function
Factory Set-
Function Item Monitor
Dr. ZX ting
Unit
Maintenance Hydraulic oil pilot filter is displayed/ is not displayed. (Monitor Controller) Displayed
Setting Information display of hydraulic oil pilot filter is turned
(Monitor Controller) ON
ON/OFF.
Replacement interval of hydraulic oil pilot filter is
1000 hours
changed.
The hydraulic oil pilot filter replacement switch is
-
pushed.
Date/ the hour meter when hydraulic oil pilot filter was
-
replaced last time are checked.
Hydraulic oil full-flow fileter is displayed/ is not dis-
(Monitor Controller) Displayed
played.
Information display of hydraulic oil full-flow filter is
(Monitor Controller) ON
turned ON/OFF.
Replacement interval of hydraulic oil full-flow filter is
1000 hours
changed.
The hydraulic oil full-flow filter replacement switch is
-
pushed.
Date/ the hour meter when hydraulic oil full-flow filter
-
was replaced last time are checked.
Pump transmission oil is displayed/ is not displayed. (Monitor Controller) Not displayed
Information display of pump transmission oil is turned
(Monitor Controller) ON
ON/OFF.
Replacement interval of pump transmission oil is
1000 hours
changed.
The pump transmission oil replacement switch is
-
pushed.
Date/ the hour meter when pump transmission oil was
-
replaced last time are checked.
Travel device oil is displayed/ is not displayed. (Monitor Controller) Displayed
Information display of travel device oil is turned
(Monitor Controller) ON
ON/OFF.
Replacement interval of travel device oil is changed. 2000 hours
The travel device oil replacement switch is pushed. -
Date/ the hour meter when travel device oil was re-
-
placed last time are checked.
Swing device oil is displayed/ is not displayed. (Monitor Controller) Displayed
Information display of swing device oil is turned
(Monitor Controller) ON
ON/OFF.
Replacement interval of swing device oil is changed. 1000 hours
The swing device oil replacement switch is pushed. -
Date/ the hour meter when swing device oil was re-
-
placed last time are checked.
Swing drain filter is displayed/ is not displayed. (Monitor Controller) Not displayed
Information display of swing drain filter is turned
(Monitor Controller) OFF
ON/OFF.
T5-2-67
TROUBLESHOOTING / Monitor Unit
Setting Function
Factory Set-
Function Item Monitor
Dr. ZX ting
Unit
Maintenance Replacement interval of swing drain filter is changed. 4000 hours
Setting The swing drain filter replacement switch is pushed. -
Date/ the hour meter when swing drain filter was re-
-
placed last time are checked.
Swing bearing lubrication is displayed/ is not dis-
(Monitor Controller) Displayed
played.
Information display of swing drain filter is turned
(Monitor Controller) ON
ON/OFF.
Replacement interval of swing bearing lubrication is
500 hours
changed.
The swing bearing lubrication replacement switch is
-
pushed.
Date/ the hour meter when swing bearing lubrication
-
was replaced last time are checked.
The air cleaner filter is displayed/ is not displayed. (Monitor Controller) Displayed
Information display of air cleaner filter is turned
(Monitor Controller) ON
ON/OFF.
Replacement interval of air cleaner filter is changed. 1500 hours
The air cleaner filter replacement switch is pushed. -
Date/ the hourmeter when air cleaner filter was re-
-
placed last time are checked.
The engine/ air conditioner V-belt is displayed/ is not
(Monitor Controller) Not displayed
displayed.
Information display of engine/ air conditioner V-belt is
(Monitor Controller) ON
turned ON/OFF.
Replacement interval of engine/ air conditioner V-belt
1000 hours
is changed.
The engine/ air conditioner V-belt replacement switch
-
is pushed.
Date/ the hourmeter when engine/ air conditioner
-
V-belt was replaced last time are checked.
The fuel filter is displayed/ is not displayed. (Monitor Controller) Displayed
Information display of fuel filter is turned ON/OFF. (Monitor Controller) ON
Replacement interval of fuel filter is changed. 500 hours
The fuel filter replacement switch is pushed. -
Date/ the hourmeter when fuel filter was replaced last
-
time are checked.
The air conditioner filter is displayed/ is not displayed. (Monitor Controller) Displayed
Information display of air conditioner filter is turned
(Monitor Controller) ON
ON/OFF.
Replacement interval of air conditioner filter is
3000 hours
changed.
The air conditioner filter replacement switch is pushed. -
Date/ the hourmeter when air conditioner filter was
-
replaced last time are checked.
T5-2-68
TROUBLESHOOTING / Monitor Unit
Setting Function
Factory Set-
Function Item Monitor
Dr. ZX ting
Unit
Maintenance The user setting (TRIP1) is displayed/ is not displayed. Displayed
Setting Information display of user setting (TRIP1) is turned
ON
ON/OFF.
Replacement interval of user setting (TRIP1) is
5000 hours
changed.
The user setting (TRIP1) replacement switch is
-
pushed.
Date/ the hour meter when user setting (TRIP1) was
-
replaced last time are checked.
The user setting (TRIP2) is displayed/ is not displayed. Displayed
Information display of user setting (TRIP2) is turned
ON
ON/OFF.
Replacement interval of user setting (TRIP2) is
5000 hours
changed.
The user setting (TRIP2) replacement switch is
-
pushed.
Date/ the hourmeter when user setting (TRIP2) was
-
replaced last time are checked.
Optional Work mode function is displayed/ is not displayed. (Monitor Controller) Displayed
Function ML carne function is displayed/ is not displayed. (Monitor Controller) Not displayed
ML crane switch is turned ON/OFF. -
The switch ON/OFF is stored/ is not stored. (Monitor Controller) Stored
Mail function is displayed/ is not displayed. (Monitor Controller) Not displayed
The mail is sent. -
Overload
Overload alarm is displayed/ is not displayed. (Monitor Controller) Not displayed
Alarm
Fuel Rate Fuel rate display/No display is displayed/ is not dis-
(Monitor Controller) Displayed
Display/No played on the main menu.
Display Fuel consumption gauge is turned ON/OFF. OFF
Back Moni- Back monitoring setting is displayed/ is not displayed
(Monitor Controller) Displayed
tor Setting on the main menu.
The camera image is selected/ is not selected auto-
Not selected
matically when the machine travels. (Auto-switch)
The camera image is flipped horizontally. (Display
(Monitor Controller) Normal image
type)
The camera image is flipped vertically. (Display type 2) (Monitor Controller) Flip vertical
NTSC/PAL is selected. (Image type) (Monitor Controller) NTSC
Language The language displayed on the monitor is selected. Japanese
Setting The language is registerd to the monitor / is deleted
-
from the monitor.
The language registered on the monitor is checked. -
Trouble- The fault code which the trouble occurs on is checked. (Troubleshooting) -
shooting The fault code which the trouble occurred is checked. (Troubleshooting) -
The fault code is completed. (Retrial B) (Troubleshooting) -
Monitoring The item order is changed. -
The item order is set to the initialized one. -
T5-2-69
TROUBLESHOOTING / Monitor Unit
(Blank)
T5-2-70
TROUBLESHOOTING / Dr. ZX
OUTLINE
Dr. ZX is used for diagnosis of the electrical system
including MC, EMC, ICF and the monitor unit.
Dr. ZX is connected to ICF and failure of each
controller and each sensor is displayed as a fault code.
(Self-Fiagnostic Result)
T5-3-1
TROUBLESHOOTING / Dr. ZX
Operation
1. Connect Palm (Dr. ZX) to the diagnosing
connector in the cab by using the Hot Sync cable
and the connecting harness.
2. Turn the key switch ON or start the engine.
3. When turning Palm ON, the following screen is
displayed on the display of Palm.
3-1. Initial Screen
Select Dr. ZX icon.
3-2. Password Setup Screen (When the
password has unset)
Set the password.
3-3. Service Software Selection Screen Dr. ZX
T1V1-05-07-001
Connector
+ Select ZX-3 Mid.
3-4. Function Selection Screen
+ Self-Diagnostic Result
+ Select Controller
Palm
Dr. ZX
4. Select Self-Diagnostic Result and operate
according to the instruction under the screen.
Connecting
Harness
Part No.
3108613
T1V1-05-07-002
T5-3-2
TROUBLESHOOTING / Dr. ZX
Start
Initial Screen
Password Setup Screen
Input Password
Input the former
When the password has unset
Communication password (6 characters
Error or more).
Next time, input the
Check Communication Harness same password in order
Check Fuse to check and push OK.
When the password has set
Service Software
Selection Screen
Self-Diagnostic
Result Function Select Controller
Select
Function Engine Monitor
Main Controller ICF
Controller Controller Controller
Self-Diagnostic
Result of Each Record Main Menu Main Menu Main Menu Main Menu
Controller Monitor Display Monitor Display Information C/U Monitoring
Special Function Special Function Various Setup Various Setup
Setup Disp. Record Data Download Password Change
Select Controller Password Change Save Data Check
Disp. Record
Password Change
Password Change
Op. Manual.
Retry B
Self-Diagnostic
Result
T5-3-3
TROUBLESHOOTING / Dr. ZX
Self-Diagnostic Result
The self-diagnostic result of each controller is
displayed.
After starting Dr. ZX, push Self-Diagnostic Results.
T5-3-4
TROUBLESHOOTING / Dr. ZX
Self-Diagnosis
Push Fault of Information C/U. In
After starting Dr. ZX, push case of no faulty, No Fault is
Self-Diagnostic Results. displayed.
To the
lower
Details Retry B
ESC ESC
Retry B Screen
If the message of Details is
long, push the arrow and
change the screen.
Execute B
ESC
T1V7-05-03-002
Controller Self- Diagnosis Screen
T5-3-5
TROUBLESHOOTING / Dr. ZX
SELECT CONTROLLER
Select failure-diagnosis controller.
After starting Dr. ZX, push Select Controller.
T1V7-05-03-001 T1V7-05-03-009
T5-3-6
TROUBLESHOOTING / Dr. ZX
MAIN CONTROLLER
Title Screen
Recorded Data Display
This displays data recorded in MC by one day by using
Dr. ZX.
Password Change
This changes the password input when setting.
Main Menu
Monitor Display
This displays the control signals of MC and the
input signals from each switch and sensor.
Special Function
This makes Special Function disabled. T1V7-05-03-011
Return to Controller
Setup Selection Screen.
Password Disp. Record
This adjusts engine speed, pump delivery flow Change
rate and solenoid valve output pressure. Main Controller Screen
T1V7-05-03-010
Return to Controller
Selection Screen.
Main Menu Screen
T1V7-05-03-012
Monitor Display
Special Function
Setup
T5-3-7
TROUBLESHOOTING / Dr. ZX
MAIN MENU MONITOR DISPLAY
Dr. ZX displays the input signals from switches and
sensors and the control signals from MC.
T5-3-8
TROUBLESHOOTING / Dr. ZX
T5-3-9
TROUBLESHOOTING / Dr. ZX
T5-3-10
TROUBLESHOOTING / Dr. ZX
T5-3-11
TROUBLESHOOTING / Dr. ZX
Monitor Display
To the
lower
To the
lower
Enter Model and Serial No. Screen Display Item Selection Screen Monitor Screen
T5-3-12
TROUBLESHOOTING / Dr. ZX
To the
lower
If Rec. No. has already been If Rec. No. has not been recorded
recorded and push Overwrite, data yet and push Write, data is written Push Comment.
is overwritten. Push ESC and to Recording Screen. Push ESC Push ESC and return to Main
return to Main Menu Screen. and return to Main Menu Screen. Menu Screen.
To the
lower
T5-3-13
TROUBLESHOOTING / Dr. ZX
SPECIAL FUNCTION
Auto-Warming Up Control: Deactivation
To the
lower
To the
lower
Push WU Dectivation. Push Execute. Push ESC and Push ESC and return to WU
Push ESC and return to Main return to WU Deactivation/ECO Deactivation/ECO Deactivation
Menu Screen. Deactivation Selection Screen. Selection Screen.
T5-3-14
TROUBLESHOOTING / Dr. ZX
ECO Control: Deactivation
To the
lower
To the
lower
Push Execute.
Push ECO Deactivation. Push ESC and return to WU Push ESC and return to WU
Push ESC and return to Main Deactivation/ECO Deactivation Deactivation/ECO Deactivation
Menu Screen. Selection Screen. Selection Screen.
T5-3-15
TROUBLESHOOTING / Dr. ZX
SETTING
Engine speed, pump delivery flow rate and solenoid valve output pressure can be adjusted.
Parameter Change
Item Data Unit
Li Speed Adjustment Adjustment of slow idle engine speed min-1
WU Speed Adjustment Adjustment of auto warming-up engine speed min-1
AI Speed Adjustment Adjustment of auto-idle engine speed min-1
P Speed Adjustment Adjustment of P mode engine speed min-1
Pump PQ Torque Adjustment Adjustment of pump P-Q curve Nm
ATT Proportional Valve Adjustment of optional solenoid valve MPa
Adjustment
ATT Speed Increase Down Setting of time required for engine speed decrease ms
Waiting Time
ATT Torque Down ON/OFF ON/OFF of torque down control when the attachment is ON, OFF
operated
ECO Control Selection ON/OFF of ECO control ON, OFF
HP Control Selection ON/OFF of HP control ON, OFF
ATT Mode Memory ON/OFF ON/OFF of attachment mode memory ON, OFF
Selection
Heater Control Selection ON/OFF of heater control ON, OFF
Engine Control Theft ON/OFF of engine control theft prevention ON, OFF
Prevention Selection
Pump Control Theft ON/OFF of pump control theft prevention ON, OFF
Prevention Selection
Min, Boom CYL. Bottom Setting of minimum boom cylinder bottom pressure over MPa
Pressure Over Balance balance
Radiator Coolant ON/OFF of radiator coolant temperature WU_B control ON, OFF
Temperature WU_B
Selection
IMPORTANT: When turning the key switch to the
OFF position with the ATT mode
memory ON/OFF selection OFF, the
selected work mode becomes
ineffective and returns to the digging
mode. Next time, the work mode
should be selected. When turning
the key switch to the OFF position
with the ATT mode memory ON/OFF
selection ON, the selected work
mode becomes effective.
T5-3-16
TROUBLESHOOTING / Dr. ZX
T5-3-17
TROUBLESHOOTING / Dr. ZX
T5-3-18
TROUBLESHOOTING / Dr. ZX
T5-3-19
TROUBLESHOOTING / Dr. ZX
ADJUSTMENT DATA LIST
T5-3-20
TROUBLESHOOTING / Dr. ZX
(Blank)
T5-3-21
TROUBLESHOOTING / Dr. ZX
ATTACHMENT ADJUSTMENT DATA LIST
ZX110-3 class
Min.
Standard
Adjustment Data Adjustment Adjustable Range Remarks
Adjustment
Value
ATT1
ATT1 ATT Type/No. - 0 to 5 Breaker 1
ATT1 P1 Max Swash
0.5 L/min 35 to 100 L/min 100 L/min
Angle Adjustment
ATT1 P2 Max Swash
0.5 L/min 35 to 100 L/min 100 L/min
Angle Adjustment
ATT1 Engine Speed
10 min-1 -500 to 200 min-1 0 min-1
Increase/Decrease
ATT1 Secondary Pilot
- ON/OFF ON
Relief Pressure Selection
ATT1 Selector Valve
- C/V or O/T O/T
Selection
ATT1 Accumulator
- ON/OFF OFF
Selection
ATT1 2-Speed Selection
- ON/OFF OFF
ATT2
ATT2 ATT Type/No. - 0 to 5 Breaker 2
ATT2 P1 Max Swash
0.5 L/min 35 to 100 L/min 100 L/min
Angle Adjustment
ATT2 P2 Max Swash
0.5 L/min 35 to 100 L/min 100 L/min
Angle Adjustment
ATT2 Engine Speed
10 min-1 -500 to 200 min-1 0 min-1
Increase/Decrease
ATT2 Secondary Pilot
- ON/OFF OFF
Relief Pressure Selection
ATT2 Selector Valve
- C/V or O/T O/T
Selection
ATT2 Accumulator
- ON/OFF ON
Selection
ATT2 2-Speed Selection
- ON/OFF OFF
ATT3
ATT3 ATT Type/No. - 0 to 5 Secondary Crusher 1
ATT3 P1 Max Swash
0.5 L/min 35 to 100 L/min 100 L/min
Angle Adjustment
ATT3 P2 Max Swash
0.5 L/min 35 to 100 L/min 100 L/min
Angle Adjustment
ATT3 Engine Speed
10 min-1 -500 to 200 min-1 200 min-1
Increase/Decrease
ATT3 Secondary Pilot
- ON/OFF OFF
Relief Pressure Selection
ATT3 Selector Valve
- C/V or O/T C/V
Selection
ATT3 Accumulator
- ON/OFF OFF
Selection
ATT3 2-Speed Selection
- ON/OFF ON
T5-3-22
TROUBLESHOOTING / Dr. ZX
Min.
Standard
Adjustment Data Adjustment Adjustable Range Remarks
Adjustment
Value
ATT4
ATT4 ATT Type/No. - 0 to 5 Primary Crusher 1
ATT4 P1 Max Swash
0.5 L/min 35 to 100 L/min 100 L/min
Angl4 Adjustment
ATT4 P2 Max Swash
0.5 L/min 35 to 100 L/min 100 L/min
Angle Adjustment
ATT4 Engine Speed
10 min-1 -500 to 200 min-1 200 min-1
Increase/Decrease
ATT4 Secondary Pilot
- ON/OFF OFF
Relief Pressure Selection
ATT4 Selector Valve
- C/V or O/T C/V
Selection
ATT4 Accumulator
- ON/OFF OFF
Selection
ATT4 2-Speed Selection
- ON/OFF ON
ATT5
ATT5 ATT Type/No. - 0 to 5 Unregistration
ATT5 P1 Max Swash
0.5 L/min 35 to 100 L/min 100 L/min
Angle Adjustment
ATT5 P2 Max Swash
0.5 L/min 35 to 100 L/min 100 L/min
Angle Adjustment
ATT5 Engine Speed
10 min-1 -500 to 200 min-1 0 min-1
Increase/Decrease
ATT5 Secondary Pilot
- ON/OFF Unregistration
Relief Pressure Selection
ATT5 Selector Valve
- C/V or O/T Unregistration
Selection
ATT5 Accumulator
- ON/OFF Unregistration
Selection
ATT5 2-Speed Selection
- ON/OFF Unregistration
T5-3-23
TROUBLESHOOTING / Dr. ZX
T5-3-24
TROUBLESHOOTING / Dr. ZX
Min.
Standard
Adjustment Data Adjustment Adjustable Range Remarks
Adjustment
Value
ATT4
ATT4 ATT Type/No. - 0 to 5 Primary Crusher 1
ATT4 P1 Max Swash
0.5 L/min 35 to 105 L/min 105 L/min
Angl4 Adjustment
ATT4 P2 Max Swash
0.5 L/min 35 to 105 L/min 105 L/min
Angle Adjustment
ATT4 Engine Speed
10 min-1 -500 to 200 min-1 200 min-1
Increase/Decrease
ATT4 Secondary Pilot
- ON/OFF OFF
Relief Pressure Selection
ATT4 Selector Valve
- C/V or O/T C/V
Selection
ATT4 Accumulator
- ON/OFF OFF
Selection
ATT4 2-Speed Selection
- ON/OFF ON
ATT5
ATT5 ATT Type/No. - 0 to 5 Unregistration
ATT5 P1 Max Swash
0.5 L/min 35 to 105 L/min 105 L/min
Angle Adjustment
ATT5 P2 Max Swash
0.5 L/min 35 to 105 L/min 105 L/min
Angle Adjustment
ATT5 Engine Speed
10 min-1 -500 to 200 min-1 0 min-1
Increase/Decrease
ATT5 Secondary Pilot
- ON/OFF Unregistration
Relief Pressure Selection
ATT5 Selector Valve
- C/V or O/T Unregistration
Selection
ATT5 Accumulator
- ON/OFF Unregistration
Selection
ATT5 2-Speed Selection
- ON/OFF Unregistration
T5-3-25
TROUBLESHOOTING/ Dr. ZX
Setting
Parameter Change
To the
lower
To the
lower
T5-3-26
TROUBLESHOOTING/ Dr. ZX
Parameter Input
Example: Li Speed Adjustment
Input Value = Normal Value
To the
lower
T1V7-05-03-107
T5-3-27
TROUBLESHOOTING/ Dr. ZX
Input the value and push Push Execute. Push ESC and
Execution. Push ESC and return to return to Parameter Change
Push Li Speed Adjustment. Parameter Change Selection Selection Screen
To the
lower
T1V7-05-03-107
T5-3-28
TROUBLESHOOTING/ Dr. ZX
Input Value > Maximum Value
(Input Value < Minimum Value)
Push Re-Input and return to
Parameter Input Screen. Push Max
Input the value and push and the maximum value is input.
Execution. Push ESC and return to Push ESC and return to Parameter
Push Li Speed Adjustment. Parameter Change Selection Change Selection Screen.
To the
lower
T1V7-05-03-107
T5-3-29
TROUBLESHOOTING/ Dr. ZX
When the input value cannot be divided
To the
lower
T1V7-05-03-107
T5-3-30
TROUBLESHOOTING/ Dr. ZX
Status Selection
Example: ATT Torque Reducing On/Off: OFF
Push OFF and Push Exec. Push Check OFF and push Execute.
Push ATT Torque Reducing On/Off. ESC and return to Parameter Push ESC and return to Parameter
Change Selection Screen. Change Selection Screen.
To the
lower
T1V7-05-03-107
T5-3-31
TROUBLESHOOTING/ Dr. ZX
Attachment Parameter Change
To the
lower
To the
lower
T5-3-32
TROUBLESHOOTING/ Dr. ZX
Attachment Parameter Input
Input Value = Normal Value
To the
lower
T1V7-05-03-117 T1V7-05-03-107
T5-3-33
TROUBLESHOOTING/ Dr. ZX
Input Value = Current Value
To the
lower
Push Execute. Push ESC and return Push ESC and return to Parameter
to Parameter Change Screen. Change Screen.
T1V7-05-03-118 T1V7-05-03-107
T5-3-34
TROUBLESHOOTING/ Dr. ZX
Input Value > Maximum Value
(Input Value < Minimum Value)
To the
lower
T1V7-05-03-119 T1V7-05-03-107
T5-3-35
TROUBLESHOOTING/ Dr. ZX
When the input value cannot be divided
To the
lower
T1V7-05-03-120 T1V7-05-03-107
T5-3-36
TROUBLESHOOTING/ Dr. ZX
Status Selection
Example: ATT1, ATT No.
To the
lower
T1V7-05-03-168 T1V7-05-03-107
T5-3-37
TROUBLESHOOTING / Dr. ZX
ATTACHMENT SETTING Monitor Unit
T1V1-05-01-104
Pulverizer
T1V1-05-01-105
Crusher
Key 6
T1V5-05-01-001
T1V1-05-01-106
Attachment Specification Screen (Breaker 1)
Vibrating Hammer
T1V1-05-01-107
Work
Others Mode
T1V1-05-02-003
T5-3-38
TROUBLESHOOTING / Dr. ZX
Five kinds attachment can be selected from Breaker 1
to 5, Pulverizer 1 to 5, Crusher 1 to 5, Vibrating
Hammer 1 to 5 and Others 1 to 5.
(Refer to T5-3-17 to 19.)
Attachment 2 Attachment 3
Attachment 4
Attachment 1 Attachment 5
T1V5-05-01-109
T5-3-39
TROUBLESHOOTING / Dr. ZX
Attachment Setting
Example: Set Pulverizer 5 to Attachment 1
Push PU and push Exec. Push
ESC and return to Parameter
Push ATT 1. Push ATT1 ATT Type. Change Selection Screen.
To the
lower
Check PU and push Execute. Push Push ESC and return to Parameter
ESC and return to Parameter Change Selection Screen.
Change Selection Screen. Push ATT 1 ATT Number.
To the
lower
Push 5 and push Exec. Push Check No. and push Execute. Push ESC and return to Parameter
ESC and return to Parameter Push ESC and return to Parameter Change Selection Screen.
Change Selection Screen. Change Selection Screen.
T5-3-40
TROUBLESHOOTING / Dr. ZX
When the work mode screen of the monitor unit is
displayed, Pulverizer 5 is displayed at Attachment 1.
When pushing key 2, Pulverizer 5 is selected and the
Pulverizer 5 specification screen is displayed.
Attachment 5
T1V5-05-03-004
Key 2
T5-3-41
TROUBLESHOOTING / Dr. ZX
Attachment Non-Setting
IMPORTANT: When the attachment is
non-setting, the attachment cannot
be selected on the monitor unit.
Example: Set Attachment to Non-Setting
Push Non and push Exec. Push
ESC and return to Parameter
Push ATT 1. Push ATT1 ATT Type. Change Selection Screen.
To the
lower
Check Non and push Execute. Push ESC and return to Parameter
Push ESC and return to Parameter Change Selection Screen.
Change Selection Screen.
T1V7-05-03-178 T1V7-05-03-107
T5-3-42
TROUBLESHOOTING / Dr. ZX
When the work mode of the monitor unit is displayed,
the Attachment 1 display disappears.
Attachment 5
T1V5-05-03-005
T5-3-43
TROUBLESHOOTING / Dr. ZX
Recorded Data Display
To the
lower
T1V7-05-03-124 T1V7-05-03-125
T5-3-44
TROUBLESHOOTING / Dr. ZX
Password Change
To the
lower
Input the registered password and Input the new password and push Input the new password again and
push OK. OK. push OK.
To the
lower
T1V7-05-03-128
T5-3-45
TROUBLESHOOTING / Dr. ZX
(Blank)
T5-3-46
TROUBLESHOOTING / D r. ZX
ENGINE CONTROLLER
Recorded Data Display
Data recorded in ECM is displayed by one day by
using Dr. ZX.
Password Change
The password can be changed.
Main Menu
Monitor Display
Dr. ZX displays the input signals from the sensors and
the control signals of ECM.
Return Controller
Selection Screen.
T1V7-05-03-204
T5-3-47
TROUBLESHOOTING / D r. ZX
Special Function
Data Upload From ECM
This uploads one set of data from ECM to Dr.ZX.
ECM data should be uploaded to Dr.ZX before
exchanging ECM.
Actuator Test
T1V7-05-03-205
T5-3-48
TROUBLESHOOTING / D r. ZX
MAIN MENU
MONITOR DISPLAY
List of Monitor Item
Item
Unit Data
Selecting Monitoring
Engine Torque Engine Torque Input signal from ECM
Actual Engine Speed Actual Engine Input signal from crank speed sensor and cam angle
min-1
(Engine Speed) Speed sensor
Target Engine Speed Target Engine
min-1 Input signal from engine control dial
Speed
Glow Signal Glow Signal OFF, ON Glow relay ON/OFF status
Coolant Temperature Coolant
(Engine Coolant Temperature C Input signal from coolant temperature sensor
Temperature) (E)
Fuel Temperature Fuel
C Input signal from fuel sensor
Temperature
Engine Oil Pressure Engine Oil
kPa Input signal from engine oil pressure sensor
Pressure
Fuel Flow Rate Fuel Flow L/h Input signal from ECM
Atmospheric Pressure Barometric
kPa Input signal from atmospheric pressure sensor
Pressure
Intake-Air Temperature Intake Air
C Input signal from intake-air temperature sensor
(Intake Air Temperature) Temperature
Boost Pressure Boost Pressure kPa Input signal from boost pressure sensor
Boost Temperature Boost
C Input signal from boost temperature sensor
Temperature
Battery Voltage Battery Voltage V Input signal from ECM
Total Amount of Fuel Use Total Used
L Input signal from ECM
Fuel
Common Rail Common Rail Low,
Pressure Judge Press Judge Normal
Supply Pump Supply Pump
kPa
Entrance Pressure P
T5-3-49
TROUBLESHOOTING / D r. ZX
Monitor Display
To the
lower
To the
lower
Push the item for Monitor Display Push HOLD and the monitor is
and push OK. Refer to T5-3-49 as stopped temporarily. When the
Input the model code and serial for the monitor item. monitor is started again, push
No. and push OK. Push ESC and Push ESC and return to Main HOLD again. Push ESC and return
return to Main Menu Screen. Menu Screen. to Display Item Selection Screen.
Start
recoding.
To the
next page
T5-3-50
TROUBLESHOOTING / D r. ZX
To the
lower
If Rec. No. has already been If Rec. No. has not been recorded
recorded and push Overwrite, data yet and push Write, data is written
is overwritten. to Recording Screen. Push Comment.
Push ESC and return to Main Push ESC and return to Main Push ESC and return to Main
Menu Screen. Menu Screen. Menu Screen.
To the
lower
T5-3-51
TROUBLESHOOTING / D r. ZX
SPECIAL FUNCTION
DATA UPLOAD FROM ECM
IMPORTANT: This upload one set of data from
ECM.
ECM data should be uploaded
before removing the ECM when
exchanging it.
To the
lower
Push OK. Push Special Function. Push Data Upload From ECM.
To the
lower
T1V7-05-03-181 T1V7-05-03-182
T5-3-52
TROUBLESHOOTING / D r. ZX
(Blank)
T5-3-53
TROUBLESHOOTING / D r. ZX
DATA DOWNLOAD TO ECM
To the
lower
To the
lower
Push Write.
Push ESC and return to Special It takes 10 to 60 sec. for
Push Next. Function Setup Screen. communication.
To the
next page
T5-3-54
TROUBLESHOOTING / D r. ZX
T1V7-05-03-181 T1V7-05-03-185
T5-3-55
TROUBLESHOOTING / D r. ZX
WRITE INJECTOR ID CODE
Cylinder 1 to 4
To the
lower
To the
lower
Write
ID Code
To the
next page
T5-3-56
TROUBLESHOOTING / D r. ZX
T1V7-05-03-190
T1V1-05-03-007
T5-3-57
TROUBLESHOOTING / D r. ZX
ECM DATA DISPLAY
To the
lower
To the
lower
T5-3-58
TROUBLESHOOTING / D r. ZX
ACTUATOR TEST
Engine Speed Down
To the
lower
To the
lower
T5-3-59
TROUBLESHOOTING / D r. ZX
Engine Speed Down & Stop Cylinder
To the
lower
To the
lower
Push Engine Speed Down & Stop Push Cylinder No. to stop fuel
Cylinder. injection.
Push ESC and return to Special Push ESC and return to Actuator
Function Setup Screen. Test Selection Screen.
To the
next page
T1V7-05-03-195 T1V7-05-03-198
Actuator Test Selection Screen Cylinder Stop Selection Screen
T5-3-60
TROUBLESHOOTING / D r. ZX
T1V7-05-03-200 T1V7-05-03-201
T5-3-61
TROUBLESHOOTING / D r. ZX
EXAMPLE OF ENGINE SPEED DOWN &
STOP CYLINDER FUNCTION (ON A
FOUR-CYLINDER ENGINE)
When fuel cannot be injected on cylinder 1 and the
engine runs with three cylinders.
1. Set the engine control dial to the slow idle postion.
Reduce engine speed to 800 min-1.
2. When cylinder 1 is stopped by operating Engine
Speed Down & Stop Cylinder function, the engine
runs at 600 min-1 with three cylinders for 5
seconds.
The engine sounds like strained.
3. When cylinder 2 is stopped by operating Engine
Speed Down & Stop Cylinder function, the engine
runs at 600 min-1 with two cylinders for 5 seconds.
The engine sounds like strained even worse than
step 2.
4. By sound difference of steps 2 and 3, cylinder 1 is
determined to be faulty.
T5-3-62
TROUBLESHOOTING / D r. ZX
RECORED DATA DISPLAY
To the
lower
Push and select No. Push Execute Push HOLD and the monitor is
and the recorded data is stopped temporarily
regenerated. Push DEL and data When the monitor is started again,
of selected No. is deleted. push HOID again.
Push ESC and return to Main Push ESC and return to Main
Menu Screen. Menu Screen.
T1V7-05-03-124 T1V7-05-03-141
Recorded Data Regeneration
Screen
T5-3-63
TROUBLESHOOTING / D r. ZX
PASSWORD CHANGE
To the
lower
Input the registered password and Input the new password and push Input the new password and push
push OK. OK. OK.
To the
lower
T1V7-05-03-128
T5-3-64
TROUBLESHOOTING / Dr. ZX
ICF CONTROLLER
Title Screen
Save Data Check
Daily report data, frequency distribution data, total
operating hours, alarm and failure are saved in ICF
and can be checked by using Dr. ZX.
Password Change
The password can be changed.
Main Menu
Information C/U Various Setup
Initialization of information C/U, setting of model,
serial No. and time, and initialization of control
data can be done. T1V7-05-03-207
Return to Controller
Data Download Selection Screen.
Daily report data, frequency distribution data, total Password Save Data
Check
operating hours, alarm and failure are recorded in ICF Controller Screen
ICF and can be downloaded to Dr. ZX.
T1V7-05-03-024
T1V7-05-03-208
Information C/U:
Various setup
Data Download
T5-3-65
TROUBLESHOOTING / Dr. ZX
MAIN MENU
INFORMATION C/U VARIOUS SETUP
List of Controller Data Setting Item
T5-3-66
TROUBLESHOOTING / Dr. ZX
INFORMATION C/U: INITIALIZE
To the
lower
To the
lower
Init
ESC
T5-3-67
TROUBLESHOOTING / Dr. ZX
ENTER MODEL AND SERIAL No.
To the
lower
To the
lower
Exec ESC
ESC
OK
T5-3-68
TROUBLESHOOTING / Dr. ZX
ENTER DATE AND TIME
To the
lower
To the
lower
T5-3-69
TROUBLESHOOTING / Dr. ZX
CONTROL DATA: INITIALIZE
To the
lower
To the
lower
Init
ESC
T5-3-70
TROUBLESHOOTING / Dr. ZX
SATELLITE TERMINAL: INITIALIZE
To the
lower
To the
lower
ICF Controller Screen Main Menu Screen Information C/U: Various Setup
Push Exec. Screen
Push ESC and return to
Information C/U: Various Setup Push OK and return to Information
Screen. C/U: Various Setup Screen.
Exec
ESC
Screen
T5-3-71
TROUBLESHOOTING / Dr. ZX
SATELLITE TERMINAL SERIAL No.
CONFIRMATION
To the
lower
To the
lower
ICF Controller Screen Main Menu Screen Information C/U: Various Setup
Screen
T1V7-05-03-037 T1V7-05-03-035
T5-3-72
TROUBLESHOOTING / Dr. ZX
COMMUNICATING STATE CHECK
To the
lower
To the
lower
ICF Controller Screen Main Menu Screen Information C/U: Various Setup
Screen
Check communicating state.
Unconn: Faulty harness Push and move to the next
NG: Faulty harness for Comm. screen. Check communicating
OFF: Faulty harness, Faulty controller state of Rod Aerial and GPS Aerial.
Stop: Enter Satellite Comm. Start/Stop Push ESC and return to
Push ESC and return to Information Information C/U: Various Setup Push ESC and return to Main
C/U: Various Setup Screen. Screen. Menu Screen.
ESC
T5-3-73
TROUBLESHOOTING / Dr. ZX
SATELLITE COMM. START / STOP SET
To the
lower
To the
lower
ICF Controller Screen Main Menu Screen Information C/U: Various Setup
Screen
Exec
ESC
T5-3-74
TROUBLESHOOTING / Dr. ZX
SATELLITE COMM. TRANSMITTING
PLACE SET
To the
lower
To the
lower
ICF Controller Screen Main Menu Screen Information C/U: Various Setup
Screen
T5-3-75
TROUBLESHOOTING / Dr. ZX
T1V7-05-03-147 T1V7-05-03-035
T5-3-76
TROUBLESHOOTING / Dr. ZX
DATE DOWNLOAD
To the
lower
To the
lower
T5-3-77
TROUBLESHOOTING / Dr. ZX
SAVE DATA CHECK
To the
lower
T1V7-05-03-040
Save Data Check Screen
T5-3-78
TROUBLESHOOTING / Dr. ZX
PASSWORD CHANGE
To the
lower
Input the registered password and Input the new password and push Input the new password again and
push OK. OK. push OK.
To the
lower
T1V7-05-03-128
T5-3-79
TROUBLESHOOTING / Dr. ZX
MONITOR CONTROLLER
Main Menu
Monitoring
Dr. ZX displays the control signals of each
controller and the input signals from each sensor.
Various Settings
Dr. ZX can set optional function setting, back
monitor setting, operating condition enable/
disable, time set function enable / disable,
maintenance setting, inner hour meter
synchronization and fuel consumption gauge
display ON/OFF selection.
Password Change
The password can be changed.
T1R7-05-03-030
T5-3-80
TROUBLESHOOTING / Dr. ZX
MONITORING
List of Monitoring Item
Item
Unit Data
Selecting Monitoring
Monitor Switch Switch state of monitor unit
Condition Check
Radiator Coolant Coolant C Input signal from coolant temperature sensor
Temperature Temperature
Fuel Level Fuel Level Input signal from fuel sensor
Security Signal Security Signal OFF, ON Communication from monitor unit
Mail Switch Mail Switch OFF, Fuel, Operating state of mail
Forwarding,
Repair,
General
T1V7-05-03-044
Unit
Switch 1 Switch 7
Switch 8 Switch 14
T5-3-81
TROUBLESHOOTING / Dr. ZX
To the
lower
To the
lower
T1V7-05-03-042 T1V7-05-03-043
T1V7-05-03-025
Main Menu Screen Monitoring Item Selection Screen
Title Screen
Switch 1 Switch 7
Switch 8 Switch 14
T1V7-05-03-044
Monitor Switch Condition Check
Screen
T5-3-82
TROUBLESHOOTING / Dr. ZX
When the key on the monitor unit is pushed, the switch
on Monitor Switch Condition Check Screen related to
the key is turned into black. (Key 3 is pushed here.)
If the switch is not turned into black, check the monitor
unit and the CAN harness.
Monitor Unit
Liquid crystals
screen
ESC
T5-3-83
TROUBLESHOOTING / Dr. ZX
Other Monitoring
To the
lower
To the
lower
T1V7-05-03-045
Monitoring Screen
T5-3-84
TROUBLESHOOTING / Dr. ZX
VARIOUS SETTINGS
List of Various Setup Item
Item Unit
Optional Function M1 (Optional Function 1 Allocate)
M2 (Optional Function 2 Allocate) Unset
M3 (Optional Function 3 Allocate) Work Mode Function
M4 (Optional Function 4 Allocate) Mail Function
M5 (Optional Function 5 Allocate) Auto Lubrication Function
M6 (Optional Function 6 Allocate) Collision Prevention Function
M7 (Optional Function 7 Allocate)
M8 (Optional Function 8 Allocate)
M9 (Optional Function 9 Allocate)
Overload Alarm Enable / Disable Disable/Enable
Back Monitor Setup Back Monitor Function Enable/Disable Disable/Enable
Back Monitor Function Image Display Mirror/Normal
Back Monitor Function Image Format NTSC/PAL
Back Monitor Display Normal/Flip Vertical Flip Vertical/Normal
Operating Condition Enable / Disable Disable/Enable
Time Set Function Enable / Disable Disable/Enable
Maintenance Setup Maintenance Function Enable / Disable Disable/Enable
Notification Function Enable / Disable Disable/Enable
Maintenance Display Item ON/OFF
Engine Oil OFF/ON
Engine Oil Filter OFF/ON
Hydraulic Oil OFF/ON
Hydraulic Oil Pilot Filter OFF/ON
Hydraulic Oil Full-Flow Filter OFF/ON
Pump Transmission OFF/ON
Swing Bearing Grease OFF/ON
Travel Device Oil OFF/ON
Swing Device Oil OFF/ON
Air Cleaner Filter OFF/ON
Engine/Air Conditioner V-belt OFF/ON
Air Conditioner Filter OFF/ON
Fuel Filter OFF/ON
Swing Drain Filter OFF/ON
Fuel Consumption Gauge Display ON/OFF Selection Disable/Enable
T5-3-85
TROUBLESHOOTING / Dr. ZX
OPTIONAL FUNCTION ALLOCATION
Example: Allocate E-mail for Menu 7
To the
lower
To the
lower
T5-3-86
TROUBLESHOOTING / Dr. ZX
To the
lower
T5-3-87
TROUBLESHOOTING / Dr. ZX
To the
lower
To the
lower
To the next
page
T5-3-88
TROUBLESHOOTING / Dr. ZX
To the
lower
T1V7-05-03-154 T1V7-05-03-046
Option Function Allocate Execution Various Setup Item Screen
Screen
Mail
Mail Screen
T5-3-89
TROUBLESHOOTING / Dr. ZX
To the
lower
To the
lower
To the next
page
T5-3-90
TROUBLESHOOTING / Dr. ZX
To the
lower
T1V7-05-03-160 T1V7-05-03-046
Option Function Allocate Execution Various Setup Item Screen
Screen
T1V1-05-03-001
T1V1-05-03-002
T5-3-91
TROUBLESHOOTING / Dr. ZX
OVERLOAD ALARM ENABLE / DISABLE
SELECTION
IMPORTANT: In case ML Crane is set to any one of
Overload Alarm: Enable Menu 1 to 9 of Option Function
Allocate, make ML Crane disable.
To the
lower
To the
lower
T1V7-05-03-161 T1V7-05-03-162
T5-3-92
TROUBLESHOOTING / Dr. ZX
To the
lower
To the
lower
T1V7-05-03-163 T1V7-05-03-164
T5-3-93
TROUBLESHOOTING / Dr. ZX
BACK MONITOR SETTING
Back Monitor Function: Enable
To the
lower
To the
lower
Push Back Monitoring Function Push Enable and push Exec. Push
Enable / Disable. Push ESC and ESC and return to Various Setup Push ESC and return to Various
return to the former screen. Item Screen. Setup Item Screen.
T5-3-94
TROUBLESHOOTING / Dr. ZX
To the
lower
To the
lower
Push Back Monitoring Function Push Disable and push Exec. Push
Enable / Disable. Push ESC and ESC and return to Various Setup Push ESC and return to Various
return to the former screen. Item Screen. Setup Item Screen.
T5-3-95
TROUBLESHOOTING / Dr. ZX
To the
lower
To the
lower
Push Back Monitor Function Image Push Normal and push Exec. Push
Display. Push ESC and return to ESC and return to Various Setup Push ESC and return to Various
the former screen. Item Screen. Setup Item Screen.
T5-3-96
TROUBLESHOOTING / Dr. ZX
To the
lower
To the
lower
Push Back Monitor Function Image Push Mirror and push Exec. Push
Display. Push ESC and return to ESC and return to Various Setup Push ESC and return to Various
the former screen. Item Screen. Setup Item Screen.
T5-3-97
TROUBLESHOOTING / Dr. ZX
To the
lower
To the
lower
Push Back Monitor Function Image Push PAL and push Exec. Push
Format. Push ESC and return to ESC and return to Various Setup Push ESC and return to Various
the former screen. Item Screen. Setup Item Screen.
T5-3-98
TROUBLESHOOTING / Dr. ZX
To the
lower
To the
lower
Push Back Monitor Function Image Push NTSC and push Exec. Push
Format. Push ESC and return to ESC and return to Various Setup Push ESC and return to Various
the former screen. Item Screen. Setup Item Screen.
T5-3-99
TROUBLESHOOTING / Dr. ZX
To the
lower
To the
lower
Push Back Monitor Display Normal Push Normal and push Exec. Push
/ Filip Vartical. Push ESC and ESC and return to Various Setup Push ESC and return to Various
return to the former screen. Item Screen. Setup Item Screen.
T5-3-100
TROUBLESHOOTING / Dr. ZX
To the
lower
To the
lower
T5-3-101
TROUBLESHOOTING / Dr. ZX
OPERATING CONDITION ENABLE /
DISABLE SELECTION
Operating Condition: Enable
To the
lower
To the
lower
T1V7-05-03-059 T1V7-05-03-060
T5-3-102
TROUBLESHOOTING / Dr. ZX
To the
lower
To the
lower
T1V7-05-03-061 T1V7-05-03-062
T5-3-103
TROUBLESHOOTING / Dr. ZX
TIME SETTING FUNCTION ENABLE /
DISABLE SELECTION
Time Setting Function: Enable
To the
lower
To the
lower
T1V7-05-03-064 T1V7-05-03-066
T5-3-104
TROUBLESHOOTING / Dr. ZX
To the
lower
To the
lower
T1V7-05-03-067 T1V7-05-03-068
T5-3-105
TROUBLESHOOTING / Dr. ZX
MAINTENANCE SETTING
MAINTENANCE OPERATION ALLOW /
NOT ALLOW SELECTION
Maintenance Operation: Allow
After starting Dr. ZX, push Select
Controller. Push Monitor Unit. Push OK.
To the
lower
To the
lower
T5-3-106
TROUBLESHOOTING / Dr. ZX
To the
lower
To the
lower
T1V7-05-03-069 T1V7-05-03-072
Maintenance Setup Item Screen
NOTE: Push Not Allow, push ESC
and return to Maintenance T1V7-05-03-073
Setup Item Screen, so that
Maintenance Operation Not
Allow is not set.
T5-3-107
TROUBLESHOOTING / Dr. ZX
NOTIFICATION FUNCTION ENABLE /
DISABLE SELECTION
Notification Function: Enable
After starting Dr. ZX, push Select
Controller. Push Monitor Unit. Push OK.
To the
lower
To the
lower
T5-3-108
TROUBLESHOOTING / Dr. ZX
To the
lower
To the
lower
T5-3-109
TROUBLESHOOTING / Dr. ZX
MAINTENANCE DISPLAY ITEM ON/OFF
SELECTION
Maintenance Display Item: ON
After starting Dr. ZX, push Select
Controller. Push Monitor Unit. Push OK.
To the
lower
To the
lower
Push Maintenance Display Items Push ESC and return to the former
On/Off. screen.
To the
next page
T5-3-110
TROUBLESHOOTING / Dr. ZX
To the
lower
T5-3-111
TROUBLESHOOTING / Dr. ZX
To the
lower
To the
lower
To the
next page
T5-3-112
TROUBLESHOOTING / Dr. ZX
T5-3-113
TROUBLESHOOTING / Dr. ZX
FUEL CONSUMPTION GAUGE DISPLAY
ENABLE / DIABLE SELECTION
IMPORTANT: The valve on the fuel gauge is only
reference and is not equal to the
autual valve.
Fuel Consumption Gauge Display: Enable
After starting Dr. ZX, push Select
Controller. Push Monitor Unit. Push OK.
To the
lower
T1V7-05-03-001 T1V7-05-03-041
T1V7-05-03-009
Function Selection Screen Controller Selection Screen Monitor Controller Screen
Move the item by pushing and
push Fuel cost meter display
Push Start. Push Various setting. Enable/Disable.
To the
lower
T1V7-05-03-025 T1V7-05-03-087
T1V7-05-03-042
Title Screen Various Setup Item Screen
Main Menu Screen
Push Enable and push Exec. Push
ESC and return to the former Push ESC and return to Various
screen. Setup Item Screen.
T1V7-05-03-088
T1V7-05-03-089
NOTE: Push Enable, push ESC and
return to Various Setup Item
Screen, so that Fuel
Consumption Gauge Display
Enable is not set.
T5-3-114
TROUBLESHOOTING / Dr. ZX
To the
lower
T1V7-05-03-001 T1V7-05-03-041
T1V7-05-03-009
Function Selection Screen Controller Selection Screen Monitor Controller Screen
To the
lower
T1V7-05-03-025 T1V7-05-03-087
T1V7-05-03-042
Title Screen Various Setup Item Screen
Main Menu Screen
Push Disable and push Exec. Push
ESC and return to the former Push ESC and return to Various
screen. Setup Item Screen.
T1V7-05-03-090
T1V7-05-03-091
T5-3-115
TROUBLESHOOTING / Dr. ZX
PASSWORD CHANGE
To the
lower
Input the registered password and Input the new password and push
Push Password. push OK. OK.
To the
lower
Input the new password again and Push OK and return to Title
push OK. Screen.
T1V7-05-03-169 T1V7-05-03-128
T5-3-116
TROUBLESHOOTING / e-Shovel
OUTLINE
ICF (Information Controller) saves the input signals
from various sensors and switches of the machine as
data.
Various input signals are recorded as list of daily
report data, list of frequency distribution data, list of
total operating hours, list of alarm and list of failure
in ICF.
T5-4-1
TROUBLESHOOTING / e-Shovel
LIST OF DAILY REPORT DATA
Data which can be downloaded by Dr. ZX (Palm)
Item Details
Date Date of daily report data
Start: Time Time when engine starts is first turned ON during a day
Stop: Time Time when engine starts is last turned OFF during a day
The value of the final remained fuel during a day
Fuel Level
(Value is recorded by fuel sensor data from monitor unit.)
The value of fuel used during a day
Fuel Usage Amount (Value is calculated and recorded by accumulated fuel usage amount
from ECM.)
Hour meter cumulative hours
Machine Hour Meter
(Hours are recorded by hour meter from monitor unit.)
Total engine operating hours selecting HP mode during a day
HP Mode Hours
(Hours are recorded by power mode switch information from MC.)
Engine Operating Total engine operating hours selecting P mode during a day
P Mode Hours
Hours (Hours are recorded by power mode switch information from MC.)
Total engine operating hours selecting E mode during a day
E Mode Hours
(Hours are recorded by power mode switch information from MC.)
Hours when auto-idle switch is turned ON during a day
Auto-Idle Switch ON Hours
(Hours are recorded by switch information from MC.)
Fast Idle (Hi) Total operating hours of travel mode (Hi) during a day
Travel Operating Traveling Hours (Hours are recorded by travel mode switch information from MC.)
Hours Slow Idle (Lo) Total operating hours of travel mode (Lo) during a day
Traveling Hours (Hours are recorded by travel mode switch information from MC.)
Total swing operating hours during a day
Swing Operating Hours
(Hours are recorded by swing pressure sensor information from MC.)
Total operating hours selecting front attachment during a day
Digging Operating Hours (Hours are recorded by front attachment pressure sensor information
from MC.)
Breaker Operating Total operating hours selecting breaker during a day
Hours (Hours are recorded by attachment information from MC.)
Secondary Crusher Total operating hours selecting secondary crusher during a day
Operating Hours (Hours are recorded by attachment information from MC.)
Attachment Primary Crusher Total operating hours selecting primary crusher during a day
Operating Hours Operating Hours (Hours are recorded by attachment information from MC.)
Vibrating Hammer Total operating hours selecting vibrating hammer during a day
Operating Hours (Hours are recorded by attachment information from MC.)
Bucket Operating Total operating hours selecting bucket during a day
Hours or Others (Hours are recorded by attachment information from MC.)
T5-4-2
TROUBLESHOOTING / e-Shovel
Item Details
Total machines waiting hours during a day
No Load Hours
(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 engine is continuously
running for more than 5 minutes.)
Machine operating hour distribution during a day
Loaded Hours Distribution Data (Operating hours are recorded only when operating pressure is
continuously detected for more than 5 minutes while the engine runs.)
NOTE: The daily operation in this table is
equivalent to the hours between 0:00:00
and 23:59:59 counted by the ICX built-in
clock. In case the engine is kept operated
beyond 0:00:00, such data are recorded as
those for the following day.
T5-4-3
TROUBLESHOOTING / e-Shovel
T5-4-4
TROUBLESHOOTING / e-Shovel
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 Frequency information on temperature in which intake air temperature is
Intake-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 andaverage load rate
Pump Load Rate
(average of pump 1 load rate and pump 2 load rate)
Engine Load Rate Frequency information of engine spood and engine torque
Radiator Coolant Frequency information of coolant temperature and intake air
Temperature/Intake-Air Temperature temperature
Hydraulic Oil Temperature/Intake-Air Frequency information of hydraulic oil temperature and intake air
Temperature temperature
T5-4-5
TROUBLESHOOTING / e-Shovel
LIST OF TOTAL OPERATING HOURS
Item Details
Inner Hour Meter Hour meters value accumulated inside ICF
Machine Hour Meter Hour meters value accumulated in machines 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 Hours Hours when auto-idle switch is turned ON
Fast Idle (Hi)
Total operating hours of travel mode (Hi)
Travel Operating Traveling Hours
Hour Slow Idle (Lo)
Total operating hours of travel mode (Lo)
Traveling Hours
Swing Operating Hour Total swing operating hours
Front Attachment Operating Hour Total front attachment and swing operating hours
Breaker Operating
Total operating hours selecting breaker during daily operation
Hours
Secondary Crusher Total operating hours selecting secondary crusher during daily
Operating Hours operation
Attachment Primary Crusher
Total operating hours selecting primary crusher during daily operation
Operating Hour Operating Hours
Vibrating Hammer Total operating hours selecting vibrating hammer during daily
Operating Hours operation
Bucket Operating
Total operating hours selecting bucket during daily operation
Hours or Others
No Load Hours Total machines waiting hours
T5-4-6
TROUBLESHOOTING / e-Shovel
(Blank)
T5-4-7
TROUBLESHOOTING / e-Shovel
HOW TO DOWNLOAD AND UPLOAD DATA
OF ICF Rear Console
Palm
(Dr. ZX)
Hot Sync
Cable
Connecting
Harness
T1V1-05-07-002
T5-4-8
TROUBLESHOOTING / e-Shovel
Data Download
After starting Dr. ZX, push Select
Controller. Push ICF Controller. Push Start.
Select Function Select failure-diagnosis
controller Password
+ Self-Diagnostic Result
+ Engine Controller To the
+ Select Controller Dr. ZX SerVice Soft lower
+ Main Controller (C)Hitachi Construction
Machinery Co., ltd
+ Monitor Controller
+ ICF Controller
Save Data Check
Is it correct?
27%
OK OK ESC
T5-4-9
TROUBLESHOOTING / e-Shovel
How to Upload Data from Palm (Dr. ZX) to
Personal Computer
Cradle
Hot Sync
Button
T178-05-07-033
T5-4-10
TROUBLESHOOTING / e-Shovel
VARIOUS SETUP OF ICF AND SATELLITE
COMMUNICATION TERMINAL BY USING
Dr. ZX
Before starting satellite communication, installing the
satellite communication terminal and replacing ICF,
perform the following procedures by using Dr. ZX.
Start Dr. ZX
Communication No Communication
2. Self-Diagnosing
T5-4-11
TROUBLESHOOTING / e-Shovel
1.1 Select Information Controller
1.2 Select Information C/U: Various Setup
+ ICF Controller
Save Data Check
T5-4-12
TROUBLESHOOTING / e-Shovel
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 / e-Shovel
1.4 Enter Model and Serial No.
Select Item
ESC
Enter Model and Serial No. Screen Information C/U: Various Setup
Screen
T5-4-14
TROUBLESHOOTING / e-Shovel
1.5 Information C/U: Initialize
Select Item
+ Information C/U: Initialize
ESC
T5-4-15
TROUBLESHOOTING / e-Shovel
1.6 Satellite Terminal: Initialize
Push Exec.
Display the next screen of Push Satellite Terminal: Initialize. Push ESC and return to
Information C/U: Various Setup Push ESC and return to Main Information C/U: Various Setup
Screen. Menu Screen. 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 / e-Shovel
1.7 Satellite Terminal Serial No. Check
Push Satellite Terminal No. Confirm serial no. (12 digits). Push
Confirmation. 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 / e-Shovel
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 Conn UnCon
Confirmation Uncon: Faulty harness
+ Comm. OK NG
Communicating State NG: Faulty harness for Communication
Check Satellite Terminal
+ OFF: Faulty harness, Faulty controller
Enter Satellite Comm. Power ON OFF
Stop: 1.9 Enter Satellite Communication
+ Start/Stop Comm. Enable Stop Start/Stop
ESC ESC
ESC
Select Item Select Item
Information C/U: Various Satellite Terminal: Initialize
+ +
Setup Satellite Terminal No.
Data Download Confirmation
+ +
Communicating State
+ Check
Enter Satellite Comm.
+ Start/Stop
ESC ESC
T5-4-18
TROUBLESHOOTING / e-Shovel
1.9 Enter Satellite Comm. Start/Stop
Push and move to the next
screen of Information C/U: Various
Setup Screen.
Push Enter Satellite Comm.
Start/Stop.
Select Item
ESC
T5-4-19
TROUBLESHOOTING / e-Shovel
1.10 Control Data: Initialize
Select Item
+ Information C/U: Initialize
ESC
T5-4-20
TROUBLESHOOTING / e-Shovel
(Blank)
T5-4-21
TROUBLESHOOTING / e-Shovel
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 / e-Shovel
LIST OF FAULT CODE
T5-4-23
TROUBLESHOOTING / e-Shovel
SATELLITE COMMUNICATION SYSTEM
GPS Antenna
The satellite communication system is used for
maintenance of the machine, e-Service by Communication
transmitting various data of the machine regularly via Antenna
a low earth orbit satellite.
T5-4-24
TROUBLESHOOTING / e-Shovel
On the machine with the satellite communication
system equipped, the data are sent according to the
condition as follows:
T5-4-25
TROUBLESHOOTING / e-Shovel
(Blank)
T5-4-26
TROUBLESHOOTING / Component Layout
MAIN COMPONENTS
ZX110-3 class, 120-3 class
3
1
4
5
6
7
8
9
26
10
25
24 11
23 12
22
21 13
20 14
19 15
18 16
17
T1R7-01-02-001
T5-5-1
TROUBLESHOOTING / Component Layout
ZX135US-3 class
1
2
4
5
6
7
8
9
10
22
11
21
20 12
19 13
18
14
17
16 15
T1R7-01-02-002
T5-5-2
TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM (OVERVIEW)
ZX110-3 class, 120-3 class
5
6
4
3
2
Relays
Refer to T5-5-10.
1
7
8
9
10
11
12
17
16 13
15
14
T1R7-01-02-003
T5-5-3
TROUBLESHOOTING / Component Layout
ZX135US-3 class
4 5
3 6
7
1
8
Relays
Refer to T5-5-10.
9
10
18 11
12
13
17
16
14
15 T1R7-01-02-004
T5-5-4
TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM (IN CAB)
ZX110-3 class, 120-3 class
Rear Tray
Refer to T5-5-7.
Switch Panel
Refer to T5-5-9.
T1V1-01-02-011
1
T5-5-5
TROUBLESHOOTING / Component Layout
ZX135US-3 class
Rear Tray
(Refer to T5-5-8.)
Switch Panel
(Refer to T5-5-9.)
1 T1V1-01-02-034
T5-5-6
TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM (REAR TRAY)
ZX110-3 class, 120-3 class 1
T1V1-01-02-007
5 4
8 9 10 11
7
12
6
13
14
T1V1-01-02-009
19 18 17 16 15
1- MC (Main Controller) 6- Security Relay (R5) 11 - Pilot Shut-Off Relay (R12) 16 - Light Relay 2 (R8)
2- Fuse Box 7- Starter Cut Relay (R4) 12 - Load Damp Relay (R1) 17 - ECM (Engine Control
Module) Main Relay (R14)
3- Dr. ZX Connector 8- OFF Relay (Air 13 - Wiper Relay (R6) 18 - Washer Relay (R9)
(Download Connector Conditioner) (R12)
Using Combinedly)
4 - ICF (Information 9- Security Horn Relay (R3) 14 - Light Relay 1 (R7) 19 - Horn Relay (R10)
Controller)
5 - Satellite Communication 10 - Air Conditioner Relay 15 - MAX HI Relay (Air
Terminal (Optional) (R11) Conditioner) (R13)
T5-5-7
TROUBLESHOOTING / Component Layout
ZX135US-3 class
T1V1-01-02-035
18
5
17
6
16
7
15
8
14
9
13
10
12 11
T1V1-01-02-036
1- Satellite Communication 6 - Light Relay 1 (R7) 11 - Horn Relay (R10) 15 - Security Horn Relay (R3)
Terminal (Optional)
2 - Dr. ZX Connector (Download 7 - MAX HI Relay (Air 12 - Security Relay (R5) 16 - Air Conditioner Relay (R11)
Connector Using Combinedly) Conditioner) (R13)
3 - Fuse Box 8 - Light Relay 2 (R8) 13 - Starter Cut Relay (R4) 17 - Pilot Shut-Off Relay (R2)
4 - ICF (Information Controller) 9 - ECM (Engine Control 14 - OFF Relay (Air 18 - Load Damp Relay (R1)
Module) Main Relay Conditioner) (R12)
(R14)
5- Wiper Relay (R6) 10 - Washer Relay (R9)
T5-5-8
TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM (SWITCH PANEL)
2
1 6
9 8 7 T1V1-01-02-037
Wiper / Washer Switch 4 - Auto-Idle Switch 6- Travel Mode Switch 8- Overhead Window Washer
Switch (Optional)
Working Light Switch 5 - Power Mode Switch 7- Key Switch 9 - Overhead Window Wiper Switch
(Optional)
Engine Control Dial
T5-5-9
TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM (RELAYS)
4 6
3
2 7
T1R7-01-02-008
T5-5-10
TROUBLESHOOTING / Component Layout
ENGINE
T1T1-01-02-005
5 6
3 4
7
8
9
13
12
T1T1-01-02-003
11 10
T1T1-01-02-004
1 - EGR (Exhaust Gas 5 - Overheat Switch 8 - Boost Temperature Sensor 11 - Hydraulic Oil Pressure
Recirculation) Valve Sensor
2 - Glow Plug 6 - Injector 9 - Common Rail Pressure 12 - Fuel Temperature Sensor
Sensor
3 - Cam Angle Sensor 7 - Boost Pressure Sensor 10 - Crank Speed Sensor 13 - Supply Pump Actuator
4 - Coolant Temperature
Sensor
T5-5-11
TROUBLESHOOTING / Component Layout
PUMP DEVICE
1 2 3
T1R7-01-02-005
7 6 5 4 T1R7-04-05-001 8 9
1 2 3
T1R7-01-02-006
10 7 6 5 4 8 9
T1R7-04-05-002
1 - Pilot Pump 4 - Pump 1 Control Pressure 7 - Pump 2 Control Pressure 9 - Pump 1 Delivery Pressure
Sensor Sensor Sensor
2 - Pump 2 5 - Torque Control Solenoid 8 - Pump 2 Delivery Pressure 10 - Blade Pump (Optional)
Valve Sensor
3 - Pump 1 6 - Maximum Pump 2 Flow
Rate Limit Control Solenoid
Valve
T5-5-12
TROUBLESHOOTING / Component Layout
SWING DEVICE CONTROL VALVE
2 3
1
4
T176-01-02-003
T176-01-02-002
8
7 9
T1R7-01-02-007
T178-03-06-015
1 - Pressure Sensor 4- Main Relief Valve 6- Pressure Sensor (Swing) 8- Solenoid Valve Unit (SC)
(Front Attachment)
2 - Swing Relief Valve 5- Pressure Sensor 7- Pressure Sensor (Travel) 9- Solenoid Valve Unit (SI)
(Boom Raise)
3 - Pressure Sensor
(Arm Roll-In)
T5-5-13
TROUBLESHOOTING / Component Layout
TRAVEL DEVICE BLADE CONTROL VALVE (OPTIONAL)
2 T155-01-01-006
3
T1SM-01-02-007
T5-5-14
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault
codes are displayed after diagnosing by using Dr. ZX
or the service menu of monitor unit.
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
Open End
Side
Harness End Connector
T158-05-03-001
T5-6-1
TROUBLESHOOTING / Troubleshooting A
FAULT CODE LIST
MC
Controller Hardware Failure
Fault Trouble Cause Influenced Control
Code
11000-2 Abnormal EEPROM Faulty MC All control
11001-2 Abnormal RAM Faulty MC All control
11002-2 Abnormal A/D conversion Faulty MC All control
11003-3 Abnormal sensor voltage Faulty MC All control
T5-6-2
TROUBLESHOOTING / Troubleshooting A
T1V1-05-01-102
T5-6-3
TROUBLESHOOTING / Troubleshooting A
Engine Failure
Fault Trouble Cause Influenced Control
Code
11100-2 Abnormal engine speed Engine speed: more than 4000 Speed sensing control
min-1
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 Trouble Cause Influenced Control
Code
11200-3 Abnormal pump 1 delivery Voltage: more than 4.5 V HP mode control
pressure sensor high voltage Travel HP mode control
E mode control
Travel torque-up control
Arm regenerative control
Travel motor displacement angle
control
11200-4 Abnormal pump 1 delivery Voltage: less than 0.25 V HP mode control
pressure sensor low voltage Travel HP mode control
E mode control
Travel torque-up control
Arm regenerative control
Travel motor displacement angle
control
11202-3 Abnormal pump 2 delivery Voltage: more than 4.5 V HP mode control
pressure sensor high voltage Travel HP mode control
E mode control
Travel torque-up control
Arm regenerative control
Travel motor displacement angle
control
11202-4 Abnormal pump 2 delivery Voltage: less than 0.25 V HP mode control
pressure sensor low voltage Travel HP mode control
E mode control
Travel torque-up control
Arm regenerative control
Travel motor displacement angle
control
11206-3 Abnormal pump 1 pump con- Voltage: more than 4.75 V E mode control
trol pressure sensor high Heater control
voltage Travel motor displacement angle
control
11206-4 Abnormal pump 1 pump con- Voltage: less than 0.25 V E mode control
trol pressure sensor low Heater control
voltage Travel motor displacement angle
control
11208-3 Abnormal pump 2 pump con- Voltage: more than 4.75 V E mode control
trol pressure sensor high Heater control
voltage Travel motor displacement angle
control
11208-4 Abnormal pump 2 pump con- Voltage: less than 0.25 V E mode control
trol pressure sensor low Heater control
voltage Travel motor displacement angle
control
T5-6-6
TROUBLESHOOTING / Troubleshooting A
T5-6-7
TROUBLESHOOTING / Troubleshooting A
Pilot Failure
Fault Trouble Cause Influenced Control
Code
11301-3 Abnormal swing pilot pressure Voltage: more than 4.75 V Arm regenerative control
sensor high voltage Attachment flow rate control
swing alarm control
11301-4 Abnormal swing pilot pressure Voltage: less than 0.25 V Arm regenerative control
sensor low voltage Attachment flow rate control
swing alarm control
11302-3 Abnormal boom raise pilot Voltage: more than 4.75 V HP mode control
pressure sensor high voltage Arm regenerative control
Attachment flow rate control
11302-4 Abnormal boom raise pilot Voltage: less than 0.25 V HP mode control
pressure sensor low voltage Arm regenerative control
Attachment flow rate control
11303-3 Abnormal arm roll-in pilot pres- Voltage: more than 4.75 V HP mode control
sure sensor high voltage Arm regenerative control
11303-4 Abnormal arm roll-in pilot Voltage: less than 0.25 V HP mode control
pressure sensor low voltage Arm regenerative control
T5-6-8
TROUBLESHOOTING / Troubleshooting A
T5-6-9
TROUBLESHOOTING / Troubleshooting A
11304-4 Abnormal travel pilot pressure Voltage: less than 0.25 V Auto-idle control
sensor low voltage ECO control
Travel HP mode control
Heater control
Travel torque-up control
Pump 1 flow rate limit control
Pump 2 flow rate limit control
Travel motor displacement angle
control
Attachment flow rate control
Travel alarm control
11307-3 Abnormal front attachment pilot Voltage: more than 4.75 V Auto-idle control
pressure sensor high voltage ECO control
Travel HP mode control
Heater control
Travel motor displacement angle
control
11307-4 Abnormal front attachment pilot Voltage: less than 0.25 V Auto-idle control
pressure sensor low voltage ECO control
Travel HP mode control
Heater control
Travel motor displacement angle
control
T5-6-10
TROUBLESHOOTING / Troubleshooting A
When traveling, speed does not return Retrial B Check the harness.
from auto idle speed. Replace the travel pilot pres-
When traveling, speed does not return sure sensor.
from ECO speed.
Travel: Slow speed is kept.
When operating ATT, the machine mis-
tracks.
In case of the machine with the travel
alarm (optional) equipped, travel alarm
continues to sound.
T5-6-11
TROUBLESHOOTING / Troubleshooting A
Proportional Solenoid Valve Failure
Fault Trouble Cause Influenced Control
Code
11400-2 Abnormal current feedback of Current: both of more Pump 2 flow rate limit control
maximum pump 2 flow rate limit than 920mA or less
control solenoid valve than 60 mA
11400-3 Abnormal feedback high current of Current: moroe than Pump 2 flow rate limit control
maximum pump 2 flow rate limit 920mA
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 torque Current: both of more Speed sensing control
control solenoid valve than 920mA or less Travel torque-up control
than 60 mA Attachment pump torque de-
crease control
11401-3 Abnormal feedback high current of Current: more than 920 Speed sensing control
torque control solenoid valve mA Travel torque-up control
Attachment pump torque de-
crease control
11401-4 Abnormal feedback low current of Current: less than 56 Speed sensing control
torque control solenoid valve mA Travel torque-up control
Attachment pump torque de-
crease control
11403-2 Abnormal current feedback of sole- Current: both of more Arm regenerative control
noid valve unit (SC) (arm than 920mA or less
regeneration) than 60 mA
11403-3 Abnormal feedback high current of Current: more than Arm regenerative control
solenoid valve unit (SC) (arm regen- 920mA
eration)
11403-4 abnormal feedback low current of Current: less than 56 Arm regenerative control
solenoid valve unit (SC) (arm regen- mA
eration)
T5-6-12
TROUBLESHOOTING / Troubleshooting A
Actual operation of proportional valve during high current: Retrial B Check the harness.
Travel mistakes.
Boom raise operation is slow.
Arm operation is slow.
Swing operation is slow.
Actual operation of proportional valve during low current: Retrial B Check the harness.
In case ATT flow rate is limited, it cannot be limited.
Actual operation of proportional valve during high current: Retrial B Check the harness.
The engine is stalled at Li speed.
Engine speed: middle to fast: engine stall or large lug down
Actual operation of proportional valve during low current: Retrial B Check the harness.
Machine overall operation is slow.
Combined operation of boom raise and arm roll-in with the front Retrial B Check the harness.
attachment over ground, the boom is not raised smoothly and the
arm roll-in full-speed is slow.
Actual operation of proportional valve during high current: Retrial B Check the harness.
Digging force (arm) becomes weak.
Actual operation of proportional valve during low current: Retrial B Check the harness.
Combined operation of boom raise and arm roll-in with the front
attachment over ground, the boom is not raised smoothly and
the arm roll-in full-speed is slow.
T5-6-13
TROUBLESHOOTING / Troubleshooting A
T5-6-14
TROUBLESHOOTING / Troubleshooting A
Operation of proportional valve during high current: Retrial B Check the harness.
Travel motor is always slow.
Operation of proportional valve during low current: Retrial B Check the harness.
Travel motor is always slow.
T5-6-15
TROUBLESHOOTING / Troubleshooting A
CAN Data Reception Failure
Fault Trouble Cause Influenced Control
Code
11910-2 Actual engine speed Faulty harness Speed sensing control
sent from ECM Send to ICF
T5-6-16
TROUBLESHOOTING / Troubleshooting A
T1V1-05-01-102
In case theft prevention is turned ON by Dr. ZX, engine Retrial B Check the harness.
speed is kept at Minimum speed and pump torque is kept
Minimum.
When the monitor setting is displayed fuel consumption at Retrial B Check the harness.
moment, engine display at moment is ----.
Heater control is ineffective. Retrial B Check the harness.
T5-6-17
TROUBLESHOOTING / Troubleshooting A
Other Failures
Fault Trouble Cause Influenced Control
Code
11901-3 Hydraulic oil temperature sen- Voltage: more than 4.52 V Auto-warming up control
sor high voltage
11901-4 Hydraulic oil temperature sen- Voltage: less than 0.23 V Auto-warming up control
sor low voltage
11905-3 Abnormal boom bottom pres- Voltage: more than 4.5 V Overload alarm
sure sensor high voltage
(optional)
11905-4 Abnormal boom bottom pres- Voltage: less than 0.25 V Overload alarm
sure sensor low voltage
(optional)
T5-6-18
TROUBLESHOOTING / Troubleshooting A
When temperature is low (hydraulic oil temperature is less Retrial B Check the harness.
than 0 C), the auto-warming up control is inoperable.
T1V1-05-02-002
T1V1-05-02-002
T5-6-19
TROUBLESHOOTING / Troubleshooting A
ECM
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 signal) Although the cam signal is present, the crank signal is
not present.
723-2 Abnormal crank speed sensor (abnormal The pulse of crank signal is not matched.
signal)
636-7 Phase mismatch of cam angle sensor The correct 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 be-
(abnormal high voltage) yond 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.
110-4 Abnormal coolant temperature sensor Voltage at the coolant temperature sensor is below
(abnormal low voltage) 0.1 V.
102-4 Abnormal boost pressure sensor (ab- Voltage at the boost pressure sensor is beyond 4.9 V.
normal high voltage)
102-3 Abnormal boost pressure sensor (ab- Voltage at the boost pressure sensor is below 0.1 V.
normal 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 (ab- Voltage at the fuel temperature sensor is beyond 4.85
normal high voltage) V in 3 minutes after the engine starts.
174-4 Abnormal fuel temperature sensor (ab- Voltage at the fuel temperature sensor is below 0.1 V.
normal low voltage)
T5-6-20
TROUBLESHOOTING / Troubleshooting A
The output power may decrease, white smoke Operate according to standard of the cam sen- P0335
may occur and vibration may occur. sor.
The engine may be stalled. (If the cam senor is P0336
normal, the engine can re-start.)
While the engine runs, there is nothing abnor- The timing chain and the belt does not turn P1345
mal with machine operation. smoothly but turn in reverse.
After the engine is stalled, the re-start is im-
possible.
Nothing special When starting: -10 C (14 F) (Start the engine P0113
although what state.)
When operating: 25 C (77 F) (Operate nor- P0112
mally.)
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) P0117
While warming up with fresh air in low tempera-
ture: 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.
Dark smoke occurs at high altitude. Atmospheric pressure 80 kPa (0.8 kgf/cm2, 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 nor- P0182
mally.)
T5-6-21
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.
T5-6-22
TROUBLESHOOTING / Troubleshooting A
P1112
T5-6-23
TROUBLESHOOTING/ Troubleshooting A
T5-6-24
TROUBLESHOOTING/ Troubleshooting A
Influence to Engine
Fault Operating Rank
Trouble Performance Remark
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 boom raised. (Steering is
impossible.)
C: The engine only runs. (Travel, digging and opera-
tion with light load are impossible.)
D: The engine cannot stop / start.
T5-6-25
TROUBLESHOOTING/ Troubleshooting A
10002-2 Abnormal EGR valve control Difference between the target valve lift and the actual position
is beyond 20%.
1347-0 Open circuit in suction control valve The suctioncontrol valve drive current is beyond 2400 mA or
drive system, shorted circuit in + B or below 50 mA. Or, difference between the tartget current and
GND the actual current is 1000 mA or more.
651-3 Open circuit in injection nozzle #1 No monitor input signal of injector #1.
drive system
652-3 Open circuit in injection nozzle #2 No monitor input signal of injector #2.
drive system
653-3 Open circuit in injection nozzle #3 No monitor input signal of injector #3.
drive system
654-3 Open circuit in injection nozzle #4 No monitor input signal of injector #4.
drive system
T5-6-26
TROUBLESHOOTING/ Troubleshooting A
Vibration of the engine is large, Rough idle, Injector #1 cannot be controlled. P0201
output power decrease, faulty increasing of Stop drive pulse output of injector #1.
rotation speed, output power decrease.
Injector #2 cannot be controlled. P0202
Stop drive pulse output of injector #2.
Injector #3 cannot be controlled. P0203
Stop drive pulse output of injector #3.
Injector #4 cannot be controlled. P0204
Stop drive pulse output of injector #4.
T5-6-27
TROUBLESHOOTING/ Troubleshooting A
Fuel System
157-0 Abnormal common rail pressure Common rail pressure is beyond 185 MPa.
(first stage)
157-0 Abnormal commo rail pressure The first stage Abnormal common rail presure is ap-
(second stage) proveand commonrail pressure is beyond 190 MPa.
157-2 Abnormal commonrail pressure When DUTY to the suction control valve is 40 % or more, or
(pump over-pressure) target pressure to the suction control valve is 90 mm3/sec or
less, actual rail pressure is 40 MPa (410 kgf/cm2, 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 to the suction control valve is 33 % or less, or
pressure to the suction control valve is 28000 mm3/sec or
more and 1200 min-1, actual rail pressure is 50 MPa (510
kgf/cm2, 7270 psi) lower than the target rail pressure.
1239-1 No pressure to pump (fuel leakage) When pressure to the suction control valve is 900 min-1, ac-
tual rail pressure is 15 MPa (150 kgf/cm2, 2180 psi) or less.
T5-6-28
TROUBLESHOOTING/ Troubleshooting A
Vibration of the engine may be large, Rough idle, Prevent the injection system from damage. P0088
output power decrease may occur, faulty in- (Pressure is too much as PR is clogged.)
creasing of rotation speed, dark smoke may oc-
cur, output power may be too large.
Vibration of the engine may be large, Rough idle, Prevent the injection system (pmp) from damage. P0089
output power decrease may occur, faulty in- (The RP sensor is protected by over-pressure.)
creasing of rotation speed, dark smoke may oc-
cur, output power may be too large.
Output power decreases. 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 in- Difference between target rail pressure and actual
creasing of rotation speed, dark smoke may oc- rail pressure is larger than the specification. (large
cur, output power may be too large. deflection)
Vibration of the engine may be large, Rough idle, Fuel leakage is too much. P0087
output power decrease may occur, faulty in- Actual rail pressure does not increase to the re-
creasing of rotation speed, dark smoke may oc- quired pressure.
cur, output power may be too large.
T5-6-29
TROUBLESHOOTING/ Troubleshooting A
Operating Rank
Influence to Engine (Current)
Fault
Trouble Performance Remark
Code
(Presumption) A B C D
157-0 Abnormal common rail pressure (first Output power de-
stage) crease: 50%
157-0 Abnormal commo rail pressure Output power de-
(second stage) crease: 50%
157-2 Abnormal commonrail pressure Output power de-
(pump over-pressure) crease: 50%
633-7 Pressure limiter open Output power de-
crease: 50%
1240-1 No pressure to pump (fuel leakage) Output power de-
1239-1 No pressure to pump (fuel leakage) crease: 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 opera-
tion with light load are impossible.)
D: The engine cannot stop / start.
T5-6-30
TROUBLESHOOTING/ Troubleshooting A
(Blank)
T5-6-31
TROUBLESHOOTING/ Troubleshooting A
987-3 Abnormal check engine lamp No monitor signal of the check engine lamp
1485-2 Abnormal main relay system Voltage in the main relay system is 1 V or less with the main
relay coil output ON.
Although the main relay coil output is turned OFF, the main
relay is kept ON.
T5-6-32
TROUBLESHOOTING/ Troubleshooting A
Engine speed of the excavator may not increase Nothing special P0219
2500 min-1 or more.
P1625
Electrical power is kept supplying to the ma- Nothing
chine.
T5-6-33
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 opera-
tion with light load are impossible.)
D: The engine cannot stop / start.
T5-6-34
TROUBLESHOOTING/ Troubleshooting A
(Blank)
T5-6-35
TROUBLESHOOTING/ Troubleshooting A
10005-1 Abnormal charge circuit (bank 1) Voltage at bank 1 of charge circuit in ECM is low.
10006-1 Abnormal charge circuit (bank 2) Voltage at bank 2 of charge circuit in ECM is low.
1079-2 Abnormal 5 V power source 1 volt- When battery voltage is between 16 V and 32 V, voltage of
age IGKEY power source is 5.5 V or more or 4.5 V or less.
1080-2 Abnormal 5 V power source 2 volt- When battery voltage is between 16 V and 32 V, voltage of
age IGKEY power source is 5.5 V or more or 4.5 V or less.
10009-2 Abnormal 5 V power source 3 volt- When battery voltage is between 16 V and 32 V, voltage of
age IGKEY power source is 5.5 V or more or 4.5 V or less.
10010-2 Abnormal 5 V power source 4 volt- When battery voltage is between 16 V and 32 V, voltage of
age IGKEY power source is 5.5 V or more or 4.5 V or less.
10011-2 Abnormal 5 V power source 5 volt- When battery voltage is between 16 V and 32 V, voltage of
age IGKEY power source is 5.5 V or more or 4.5 V or less.
10003-2 Abnormal injection nozzle common No monitor siganals of injectors #1, #4
#1 drive system
10004-2 Abnormal injection nozzle common No monitor siganals of injectors #2, #3
#2 drive system
T5-6-36
TROUBLESHOOTING/ Troubleshooting A
Output power decrease, dark smoke occur. All analogue sensor cannot be used. P1630
Output power decreases. CPU is broken. P0606
No backup P1631
T5-6-37
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 opera-
tion with light load are impossible.)
D: The engine cannot stop / start.
T5-6-38
TROUBLESHOOTING/ Troubleshooting A
(Blank)
T5-6-39
TROUBLESHOOTING/ Troubleshooting A
Communication System
639-2 Abnormal CAN bus line The bus line off is detected.
639-3 Abnormal CAN time out The CAN data reception is not approved in prescribedtime.
T5-6-40
TROUBLESHOOTING/ Troubleshooting A
U2106
T5-6-41
TROUBLESHOOTING/ Troubleshooting A
T5-6-42
TROUBLESHOOTING/ Troubleshooting A
(Blank)
T5-6-43
TROUBLESHOOTING/ Troubleshooting A
ICF
14000-2 Abnormal CAN communication Data cannot be received due to the noise on the CAN bus
line.
14001-2 ICF: flash memory: read / write error The internal memory is abnormal when the key is turned ON.
14002-2 ICF: external RAM: read / write error The internal memory is abnormal when the key is turned ON.
14003-2 ICF: EEPROM: sum check error The internal memory is abnormal when the key is turned ON.
14006-2 ICF: communication terminal: com- Communication to the satellite terminal cannot be done over
munication error 30 seconds.
14008-2 ICF: abnormal internal RAM The internal memory is abnormal when the key is turned ON.
T5-6-44
TROUBLESHOOTING/ Troubleshooting A
14001-2 After initializing the information C/U by using Dr. ZX, re-try in the troubleshooting.
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.
14002-2 After initializing the information C/U by using Dr. ZX, re-try in the troubleshooting.
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 As ICF may be broken, replace ICF.
T5-6-45
TROUBLESHOOTING/ Troubleshooting A
Satellite Terminal
14100-2 Satellite communication terminal: Data cannot be received due to the noise on the CAN bus
abnormal EEPROM line.
14101-2 Satellite communication terminal: The internal memory is abnormal when the key is turned ON.
abnormal IB/OB queue
14102-2 Satellite communication terminal: The internal memory is abnormal when the key is turned ON.
abnormal local loup back
14103-2 Satellite communication terminal: The internal memory is abnormal when the key is turned ON.
The satellite is not found.
14104-2 Satellite communication terminal: fail Communication to the satellite terminal cannot be done over
1 of remote loup back 30 seconds.
14105-2 Satellite communication terminal: fail The internal memory is abnormal when the key is turned ON.
2 of remote loup back
14106-2 Satellite communication terminal: Sending and receiving data are unmatched.
Sending and receiving data are un-
matched.
T5-6-46
TROUBLESHOOTING/ Troubleshooting A
T5-6-47
TROUBLESHOOTING/ Troubleshooting A
Monitor Unit
T5-6-48
TROUBLESHOOTING / Troubleshooting A
13303-2 Cool the monitor unit and so on until temperature inside the monitor unit is less than 85 C
(185 F).
13304-2 (Refer to the Troubleshooting flow chart.)
13306-2 If this fault code is displayed after retrial, replace the monitor unit.
T5-6-49
TROUBLESHOOTING / Troubleshooting A
CONTROLLER HARDWARE FAILURE
MC FAULT CODE 11000 to 11002
Faulty MC.
NO
T5-6-50
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11003
1 2 3
T5-6-51
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11004
Dr.ZX
Satellite
Terminal
CAN Harness
MC
ECM
T1V1-02-01-050
T5-6-52
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-6-53
TROUBLESHOOTING / Troubleshooting A
CAN HARNESS CHECK
Check the wiring connections first.
Normal.
NO
T5-6-54
TROUBLESHOOTING / Troubleshooting A
T5-6-55
TROUBLESHOOTING / Troubleshooting A
NO Check the
Connect connector connection of MC
YES in MC. and connector.
A Check if fault code
Connect all 11004-2 is
connectors except displayed. Faulty MC.
connector MC-C in YES
MC. · Key switch: ON
Check if resistance
between terminals NO Check the
Connect connector connection of ICF
#C4 and #C15 of in ICF.
NO harness end of YES and connector.
Connect connector in Check if fault code
connector MC-C is MC. Disconnect 11004-2 is
within 60 10 . connector ICF-C in displayed. Faulty ICF.
ICF. YES
· Key switch: OFF · Key switch: ON
Check if resistance
between terminals
#C5 and #C11 of Connect connector
NO harness end of Connect connector in YES in ECM. Check if
connector is within ICF. fault code 11004-2
60 10 . Disconnect is displayed.
connector ECM-1 in
· Key switch: OFF ECM. · Key switch: ON
Check if resistance
between terminals
NO #18 and #37 of
Connector Connect connector
harness end of
connector is within ECM-1 in ECM.
MC 120 10 . Disconnect
Connector MC-C connector monitor-B
(Harness end) · Key switch: OFF NO in monitor unit.
#C4 #C15 Check if resistance
C1 C10
between terminals
#B6 and #B7 of
harness end of
connector is within
120 10 .
C23 C31
· Key switch: OFF
ICF
Connector ICF-C
(Harness end)
#C5
T1V1-05-04-002
#C11
Monitor Unit
ECM Connector Monitor-B
Connector ECM-1 (Harness end)
(Harness end) #18 #37 #B7 #B6
T1GR-05-04-002
T183-05-04-013
T5-6-56
TROUBLESHOOTING / Troubleshooting A
Faulty ECM.
YES
T5-6-57
TROUBLESHOOTING / Troubleshooting A
Continuity Check in CAN Harness
Connector
MC
Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
ECM
Connector ECM-1
(Harness end)
#18 #37
T1GR-05-04-002
T5-6-58
TROUBLESHOOTING / Troubleshooting A
Between MC and ICF
CAN Harness (High Side)
Check for continuity between terminal #C4 of
harness end of connector MC-C in MC and
terminal #C5 of harness end of connetor ICF-C in
ICF.
Connector
MC
Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
ICF
Connector ICF-C
(Harness end)
#C5
#C11 T1V1-05-04-002
T5-6-59
TROUBLESHOOTING / Troubleshooting A
Between MC and Monitor Unit
CAN Harness (High Side)
Check for continuity between terminal #C4 of
harness end of connector MC-C in MC and
terminal #B7 of harness end of connetor
monitor-B in the monitor unit.
Connector
MC
Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
Monitor Unit
Connector Monitor-B
(Harness end)
#B7 #B6
T183-05-04-013
T5-6-60
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Ground Circuit Connector
IMPORTANT: Before continuity check, turn the key Connector MC-C
(Harness end)
switch OFF.
In case of continuity, the circuit
#C4
between CAN circuit and ground C1 C10
circuit is shorted.
In case of discontinuity, the circuit is
normal.
C23 C31
MC
Between CAN Circuit (High Side) and Ground Connector MC-A
Circuit (Harness end)
Check for continuity between terminal #C4 of
harness end of connector MC-C and terminal #A2 #A2
of harness end of connetor MC-A.
#B8
Check for continuity between terminal #C4 of
harness end of connector MC-C and terminal
#B18 of harness end of connetor MC-B.
#B18
T183-05-04-021
T5-6-61
TROUBLESHOOTING / Troubleshooting A
Between CAN Circuit (Low Side) and Ground
Circuit Connector
Check for continuity between terminal #C5 of
harness end of connector MC-C and terminal #A2
Connector MC-C
of harness end of connetor MC-A. (Harness end)
#A13
T183-05-04-008
Connector MC-B
(Harness end)
#B8
#B18
T183-05-04-021
T5-6-62
TROUBLESHOOTING / Troubleshooting A
ECM
Between CAN Circuit (High Side) and Ground
Circuit ECM
Check for continuity between terminals #18 and Connector ECM-1
#1 of harness end of connector. (Harness end)
#18 #43
Check for continuity between terminals #18 and
#4
#3 of harness end of connector.
#3
Check for continuity between terminals #18 and
#4 of harness end of connector.
T1GR-05-04-002
#62 #1
Check for continuity between terminals #18 and
#43 of harness end of connector.
T5-6-63
TROUBLESHOOTING / Troubleshooting A
ICF
Between CAN Circuit (High Side) and Ground ICF
Circuit Connector ICF-C
Check for continuity between terminals #C5 and (Harness end)
#C14 of harness end of connector ICF-C.
#C5
Check for continuity between terminals #C5 and
#C15 of harness end of connector ICF-C.
T1V1-05-04-002
#C14 #C15
T183-05-04-013
#B11
T183-05-04-013
#B11
T5-6-64
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Power Circuit Connector
IMPORTANT: Before continuity check, turn the key Connector MC-C
switch OFF. (Harness end)
In case of continuity, the circuit
#C4
between CAN circuit and power C1 C10
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 of (Harness end)
harness end of connector MC-C and terminal #A1
of harness end connector MC-A. #A1
#B17
T183-05-04-021
T5-6-65
TROUBLESHOOTING / Troubleshooting A
Between CAN Circuit (Low Side) and Power
Circuit Connector
Check for continuity between terminal #C15 of
harness end of connector MC-C and terminal #A2 Connector MC-C
of harness end connector MC-A. (Harness end)
#C15
Check for continuity between terminal #C15 of C1 C10
harness end of connector MC-C and terminal
#A12 of harness end connector MC-A.
#A12
T183-05-04-008
Connector MC-B
(Harness end)
#B7
#B17
T183-05-04-021
T5-6-66
TROUBLESHOOTING / Troubleshooting A
ECM
Between CAN Circuit (High Side) and Power
ECM
Circuit Connector ECM-1
Check for continuity between terminals #18 and (Harness end)
#2 of harness end of connector. #18 #5
T1GR-05-04-002
#2
T1GR-05-04-002
#2
ICF
ICF
Between CAN Circuit (High Side) and Power Connector ICF-C
Circuit (Harness end)
Check for continuity between terminals #C5 and
#C1 of harness end of connector ICF-C. #C5
#C2
Check for continuity between terminals #C5 and #C1
#C2 of harness end of connector ICF-C.
T1V1-05-04-002
T1V1-05-04-002
#C11
T5-6-67
TROUBLESHOOTING / Troubleshooting A
Monitor Unit
Between CAN Circuit (High Side) and Power
Circuit Monitor Unit
Connector Monitor-A
Check for continuity between terminal #B7 of (Harness end)
harness end of connector in the monitor unit and
terminal #A16 of harness end of connector
monitor-A in the monitor unit.
#A16
T183-05-05-001
Monitor Unit
Connector Monitor-B
(Harness end)
#B7
T183-05-04-013
#A16
T183-05-05-001
Monitor Unit
Connector Monitor-B
(Harness end)
#B6
T183-05-04-013
T5-6-68
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Key Signal Circuit Connector
IMPORTANT: Before continuity check, turn the key Connector MC-C
switch OFF. (Harness end)
In case of continuity, the circuit between #C4
CAN circuit and key signal circuit is C1 C10
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 of #B16
harness end of connector MC-C and terminal
#B16 of harness end of connector MC-B.
T183-05-04-021
C23 C31
Connector MC-B
(Harness end)
#B16
T183-05-04-021
T5-6-69
TROUBLESHOOTING / Troubleshooting A
ECM
Between CAN Circuit (High Side) and Key Signal ECM
Circuit Connector ECM-1
Check for continuity between terminals #18 and (Harness end)
#24 of harness end of connector. #18 #24
T1GR-05-04-002
T1GR-05-04-002
ICF
ICF
Between CAN Circuit (High Side) and Key Signal Connector ICF-C
Circuit (Harness end)
Check for continuity between terminals #C5 and #C5
#C7 of harness end of connector ICF-C.
#C7
T1V1-05-04-002
T1V1-05-04-002
#C11
T5-6-70
TROUBLESHOOTING / Troubleshooting A
Monitor Unit
Between CAN Circuit (High Side) and Power
Monitor Unit
Circuit Connector Monitor-A
Check for continuity between terminal #B7 of (Harness end)
harness end of connector in the monitor unit and
terminal #A7 of harness end of connector #A7
monitor-A in the monitor unit.
T183-05-05-001
Monitor Unit
Connector Monitor-B
(Harness end)
#B7
T183-05-04-013
T183-05-05-001
Monitor Unit
Connector Monitor-B
(Harness end)
#B6
T183-05-04-013
T5-6-71
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check in CAN Harness
C23 C31
Connector ECM-1
T183-05-04-013
Check for continuity between terminals #18 and
#37 of harness end of connector ECM-1 in
ECM.
ECM
Connector ECM-1
(Harness end)
#18 #37
T1GR-05-04-002
Connector ICF-C
Check for continuity between terminals #C5 and
#C11 of harness end of connector ICF-C in ICF.
ICF
Connector ICF-C
(Harness end)
#C5
#C11 T1V1-05-04-002
T5-6-72
TROUBLESHOOTING / Troubleshooting A
ENGINE FAILURE
MC FAULT CODE 11100
T5-6-73
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11101
MC
Connector MC-C
#C1
C1 C10
C23 C31
Switch Panel
#3 #2 #1
T5-6-74
TROUBLESHOOTING / Troubleshooting A
PUMP FAILURE
MC FAULT CODE 11200
3 2 1
T183-05-04-009
T5-6-75
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11202
Disconnect connector
MC-D of MC. YES Open circuit in harness
Check for continuity in between MC and pump 2
harnes between delivery pressure sensor.
YES terminal #D4 of
harness end of
Disconnect connector
connector MC-D in MC
of pump 2 delivery To A
and terminal #2 in
pressure sensor. NO
pump 2 delivery
Check if voltage
NO pressure sensor.
between terminals #1
and #3 of harness end
of connector is 5 0.5
Check if voltage YES Open circuit in harness
between terminal #1 of between MC and pump 2
V. harness end of delivery pressure sensor
Switch pump 1 delivery
pressure sensor with connector in pump 2 (terminal #3).
· Key switch: ON
pump 2 delivery NO delivery pressure
pressure sensor and sensor and body is Open circuit in harness
retry. specification. between MC and pump 2
NO delivery pressure sensor
Check if fault code is · Key switch: ON
switched. (terminal #1).
· Specification:
0.25 V or more,
4.5 V or less Faulty pump 2 delivery
YES pressure sensor.
3 2 1
T183-05-04-009
T5-6-76
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11206
Disconnect connector
MC-D of MC.
Check for continuity in Open circuit in
YES harness between MC
harnes between
terminal #D11 of and pump 1 control
YES harness end of pressure sensor.
connector MC-D in MC
and terminal #2 in
Disconnect connector pump 1 control To A
of pump 1 control pressure sensor. NO
pressure sensor. Check
NO if voltage between Open circuit in
terminals #1 and #3 of harness between MC
Check if voltage
harness end of between terminal #1 of YES and pump 1 control
connector is 5 0.5 V. pressure sensor
harness end of
Switch pump 1 control (terminal #3).
connector in pump 1
pressure sensor with · Key switch: ON control pressure
NO Open circuit in
pump 2 control pressure sensor and body is
sensor and retry. Check specification. harness between MC
if fault code is switched. NO and pump 1 control
· Key switch: ON pressure sensor
· Specification: (terminal #1).
0.25 V or more,
4.5 V or less Faulty pump 1 control
YES pressure sensor.
#D11
1 2 3
T183-05-04-009
T5-6-77
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11208
Disconnect connector
MC-D of MC. Open circuit in harness
Check for continuity in YES between MC and pump 2
harnes between control pressure sensor.
terminal #D14 of
YES harness end of
connector MC-D in MC
Disconnect connector
and terminal #2 in
of pump 2 control
pump 2 control To A
pressure sensor. NO
pressure sensor.
Check if voltage
NO between terminals #1
and #3 of harness end
of connector is 5 0.5 Check if voltage YES Open circuit in harness
between terminal #1 of between MC and pump 2
V. control pressure sensor
harness end of
Switch pump 1 control · Key switch: ON (terminal #3).
connector in pump 2
pressure sensor with
NO control pressure
pump 2 control pressure
sensor and body is Open circuit in harness
sensor and retry.
specification. between MC and pump 2
Check if fault code is NO control pressure sensor
switched. · Key switch: ON
(terminal #1).
· Specification:
0.25 V or more,
4.5 V or less
#D14
1 2 3
T183-05-04-009
T5-6-78
TROUBLESHOOTING / Troubleshooting A
PILOT FAILURE
MC FAULT CODE 11301
Disconnect connector
MC-C of MC. Open circuit in harness
YES
Check for continuity in between MC and
harnes between pressure sensor.
YES
terminal #C13 of
harness end of
connector MC-C in MC
and terminal #2 in To A
Disconnect connector NO
of pressure sensor. pressure sensor.
Check if voltage
NO between terminals #1
and #3 of harness end
of connector is 5 0.5
V. Open circuit in harness
Check if voltage YES between MC and
between terminal #1 of pressure sensor (terminal
· Key switch: ON harness end of #3).
Switch pressure sensor connector in pressure
with other pressure NO sensor and body is
sensor and retry. specification. Open circuit in harness
Check if fault code between MC and
disappears. · Key switch: ON NO pressure sensor (terminal
· Specification:
#1).
0.25 V or more,
4.5 V or less
Faulty pressure sensor.
YES
#C13
C1 C10
1 2 3
C23 C31
T5-6-79
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11302
1 2 3
#D15
T183-05-04-009
T5-6-80
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11303
#C3
C1 C10
1 2 3
C23 C31
T5-6-81
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11304
Connector (Harness end of connector viewed from the YES Faulty MC.
Check if voltage
open side) between terminal #C2
MC Pilot Pressure Sensor (Travel) A of harness end of
Connector MC-C connector MC-C and
#C2 body is 0 V. Shorted circuit in
harness between MC
C1 C10 NO
· Key switch: ON and pressure sensor.
1 2 3
C23 C31
T5-6-82
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11307
1 2 3
C23 C31
T5-6-83
TROUBLESHOOTING / Troubleshooting A
PROPORTIONAL SOLENOID VALVE FAILURE
MC FAULT CODE 11400
Switch connectors of
NO Faulty maximum pump 2
maximum pump 2 flow
flow rate limit control
rate limit control
solenoid valve.
YES solenoid valve and
torque control solenoid
valve.
Check if fault code in Faulty MC.
torque control solenoid YES
Check for continuity in
valve is displayed.
harness between MC
and maximum pump2
flow rate limit control
solenoid valve.
· Between terminal #A22
of connector MC-A in
MC and terminal #1 of Open circuit in harness.
connector in maximum NO
pump 2 flow rate limit
control solenoid valve.
· Between terminal #A16
of connector MC-A in
MC and terminal #2 of
connector in maximum
pump 2 flow rate limit
control solenoid valve
#A16 #A22
T183-05-04-008
Maximum Pump 2 Flow Rate
Limit Control Solenoid Valve
T1V1-05-04-003
T5-6-84
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11401
MC
Connector MC-A
#A19
#A30
T183-05-04-008
T1V1-05-04-003
T5-6-85
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
(SI).
Check if fault code in 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 #A10
of connector MC-A in
MC and terminal #1 of
connector in solenoid Open circuit in harness.
valve unit (SC) (arm NO
regeneration)
· Between terminal #A6
of connector MC-A in
MC and terminal #2 of
connector in solenoid
valve unit (SC) (arm
regeneration)
MC
Connector MC-A
#A6 #A10
T183-05-04-008
T1V1-05-04-003
T5-6-86
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11405
Switch connectors of
Faulty solenoid valve unit
solenoid valve unit (SI) NO
(SI) (travel motor fast
(travel motor fast speed
speed selection).
selection) and other
YES
solenoid valve unit (SC).
Check if fault code in
switched solenoid valve Faulty MC.
Check for continuity in unit is displayed. YES
harness between MC
and solenoid valve unit
(SI) (travel motor fast
speed selection).
· Between terminal #A31
of connector MC-A in
MC and terminal #1 of Open circuit in harness.
connector in solenoid NO
valve unit (SI) (travel
motor fast speed
selection)
· Between terminal #A5
of connector MC-A in
MC and terminal #2 of
connector in solenoid
valve unit (SI) (travel
motor fast speed
selection)
Connector (Harness end of connector viewed from the
open side)
MC
Connector MC-A
#A5
#A31 T183-05-04-008
T1V1-05-04-003
T5-6-87
TROUBLESHOOTING / Troubleshooting A
CAN DATA RECEPTION FAILURE
MC FAULT CODES 11910, 11914, 11920
Dr. ZX
Satellite
Terminal
CAN Harness
MC
ECM
T1V1-02-01-051
T5-6-88
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-6-89
TROUBLESHOOTING / Troubleshooting A
CAN HARNESS CHECK
(MC FAULT CODES 11910, 11914, 11920)
Normal.
NO
T5-6-90
TROUBLESHOOTING / Troubleshooting A
C23 C31
ECM
Connector ECM-1
(Harness end)
#18 #37
T1GR-05-04-002
T5-6-91
TROUBLESHOOTING / Troubleshooting A
Connector
ICF Monitor Unit
Connector ICF-C Connector Monitor-B
(Harness end) (Harness end)
#C5
#B7 #B6
#C11 T1V1-05-04-002
T183-05-04-013
T5-6-92
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODES 11911, 11918
Dr. ZX
Satellite Terminal
CAN Harness
MC
ECM
T1V1-02-01-052
T5-6-93
TROUBLESHOOTING / Troubleshooting A
CAN HARNESS CHECK
FAULT CODES 11911, 11918
Disconnect all
connectors of MC, ICF, YES Open circuit in CAN
ECM and monitor unit. harness between ground
YES Check for continuity circuit and CAN circuit.
between ground circuit
(MC, ICF, ECM, Check for continuity
monitor unit) and CAN between power
circuit. circuit (MC, ICF,
Check for continuity in NO ECM, monitor unit)
· Key switch: OFF and CAN circuit.
YES CAN harness between · Refer to
MC and monitor unit. Discontinuity Check · Key switch: OFF
· Key switch: OFF between CAN Circuit · Refer to Discontinuity
· Refer to Continuity and Ground Circuit Check between CAN
Check in CAN on T5-6-61 to 64. Circuit and Power
Harness on T5-6-60. Circuit on T5-6-65 to 68.
Retry by using Dr. ZX.
Check if fault code Open circuit in CAN
11004-2 is displayed. harness between MC and
NO monitor unit.
Normal.
NO
T5-6-94
TROUBLESHOOTING / Troubleshooting A
#C4 #C15
C1 C10
C23 C31
Monitor Unit
Connector Monitor-B
(Harness end)
#B7 #B6
T183-05-04-013
T5-6-95
TROUBLESHOOTING / Troubleshooting A
Connector
ECM ICF
Connector ECM-1 Connector ICF-C
(Harness end) #18 #37 (Harness end) #C5
#C11 T1V1-05-04-002
T1GR-05-04-002
T5-6-96
TROUBLESHOOTING / Troubleshooting A
OTHER FAILURES
MC FAULT CODE 11901
Connect terminals #1
YES Faulty MC.
and #2 of harness end
of connector in
hydraulic oil
temperature sensor by Connect terminal #D6
YES using a clip. Open circuit in harness
of harness end of YES between MC and
Disconnect connector connector MC-D in
MC-D from MC. hydraulic oil temperature
MC to body. Check sensor (terminal #1).
Check for continuity for continuity between
Disconnect connector of between terminals #D2
hydraulic oil temperature NO terminals #2 of
and #D6 of harness harness end of
sensor. Open circuit in harness
end of connector connector in hydraulic
Check if resistance at between MC and
MC-D. oil temperature NO
sensor end connector is hydraulic oil temperature
specification. sensor and body. sensor (terminal #2).
· Specification: Refer to
the table below. Faulty hydraulic oil
NO temperature sensor.
MC
Connector MC-D
#D2
#D6 T183-05-04-009
1 2
T5-6-97
TROUBLESHOOTING / Troubleshooting A
ECM, SENSOR SYSTEM
ECM FAULT CODES 100, 102, 105, 108, 110, 157, 172
T5-6-98
TROUBLESHOOTING / Troubleshooting A
ECM FAULT CODES 174, 636, 723, 10001
T5-6-99
TROUBLESHOOTING / Troubleshooting A
ECM, EXTERNAL DEVICE SYSTEM
ECM FAULT CODES 651, 652, 653, 654, 655, 656, 1347, 10002
T5-6-100
TROUBLESHOOTING / Troubleshooting A
ECM, FUEL SYSTEM
ECM FAULT CODES 157, 633, 1239, 1240
T5-6-101
TROUBLESHOOTING / Troubleshooting A
ECM, ENGINE PROTECTION
ECM FAULT CODES 110, 190
T5-6-102
TROUBLESHOOTING / Troubleshooting A
ECM, ENGINE PROTECTION
ECM FAULT CODES 987, 1485
T5-6-103
TROUBLESHOOTING / Troubleshooting A
ECM, INTERNAL CIRCUIT SYSTEM
ECM FAULT CODES 628, 1077, 1079, 1080, 10003, 10004, 10005
T5-6-104
TROUBLESHOOTING / Troubleshooting A
ECM FAULT CODES 10006, 10007, 10008, 10009, 10010, 10011, 10013
T5-6-105
TROUBLESHOOTING / Troubleshooting A
ECM, COMMUNICATION SYSETEM
ECM FAULT CODE 639
T5-6-106
TROUBLESHOOTING / Troubleshooting A
ICF, SATELLITE TERMINAL FAULT CODES 14000 to 14003
T5-6-107
TROUBLESHOOTING / Troubleshooting A
Information C/U: Initialize
To the
lower
To the
lower
Init
ESC
T5-6-108
TROUBLESHOOTING / Troubleshooting A
Control Data: Initialize
To the
lower
To the
lower
Init
ESC
T5-6-109
TROUBLESHOOTING / Troubleshooting A
Enter Model And Serial No.
To the
lower
To the
lower
Exec ESC
ESC
OK
T5-6-110
TROUBLESHOOTING / Troubleshooting A
ICF, SATELLITE TERMINAL FAULT CODES 14006, 14008, 14100 to 14106
Fault Code Trouble Remedy
14006-2 ICF: communication terminal: Execute retry B in self-diagnosing.
communication error If this error code is displayed after retrial, check the following
item.
Check the communication line.
Check the power source line of the satellite terminal.
Check the fuse.
T5-6-111
TROUBLESHOOTING / Troubleshooting A
Communication
Antenna
(GPS Antenna)
Satellite T1V1-05-07-001
Terminal
Communication
Antenna
(GPS Antenna)
T1V1-05-06-004
T5-6-112
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13303
13303-2 Abnormal thermister temperature Cool the monitor unit until temperature inside the monitor unit
becomes less than 85 C.
YES Normal.
T5-6-113
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13304
Monitor Unit
Connector Monitor-C
6 1
12 7
#C7
T5-6-114
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODES 13306, 13308
13306-2 Abnormal EEPROM If this error code is displayed after retrial, replace the monitor
unit.
13308-2 Abnormal CAN communication Refer to Check CAN Harness on T5-6-54.
T5-6-115
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13310
13310-3 Shorted circuit in coolant Check the coolant temperature sensor and the harness.
temperature sensor
Monitor Unit
Connector Monitor-C
·
6 1
12 7
#C8
T5-6-116
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13311
13311-3 Shorted circuit in fuel level sensor Check the fuel level sensor and the harness.
13311-4 Open circuit in fuel level sensor Check the fuel level sensor and the harness.
70.5 mm
Connector (Harness end of connector viewed from the
1/2 open side)
204 mm
Monitor Unit
Connector Moniter-C Fuel Sensor
1/4
338 mm
·
6 1
1 2
12 7
EMPTY
T178-05-05-001
T5-6-117
TROUBLESHOOTING / Troubleshooting A
PILOT SHUT-OFF LEVER ALARM
Pilot shut-off lever alarm is displayed on the
monitor unit screen.
T1V1-05-06-005
T5-6-118
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code
is displayed on the service menu in the monitor unit
and the diagnosing by Dr. ZX although the machine
operation is abnormal.
On the front section pages of this group are the tables
indicating the relationship between machine trouble
symptoms and related parts which may cause such
trouble if failed.
Start the troubleshooting with more probable causes
selected by referring to these tables.
YES(OK)
(2)
After checking or measuring item (1), select either YES (OK) or
(1) NO (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO(NOT OK)
Special instructions or reference item are indicated in the spaces under the box.
Incorrect measuring or checking methods will render troubleshooting impossible,
· Key switch: ON and may damage components as well.
Explanation of how to use test harness kit required. Refer to Electrical System
Inspection (Group 8) in this section.
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.
Item Symptoms in control Symptoms in machine
Parts Function system when trouble operation when trouble
occurs. occurs.
Engine Control Dial This dial instructs engine Engine speed is kept at idling Engine speed is kept at idling
target speed. speed when trouble occurs speed when trouble occurs
with key ON. with key ON.
Engine speed is kept at Engine speed is kept at speed
speed just before trouble just before trouble occurred
occurred when trouble occurs when trouble occurs during
during operation. operation.
Pump Control Pressure This sensor detects pump E mode control E mode control
control pressure in order to In normal, P speed is re- In normal, P speed is returned
Sensor control travel motor dis- turned whenever operating. P whenever operating. P speed
placement angle control. speed is not returned when is not returned when this
this trouble opccurs. trouble opccurs.
Heater Control As the machine is kept to
Heater control is ineffective. travel at slow speed, speed
Travel motor displacement does not change into fast
angle control automatically.
The machine travels at slow
speed.
Pump 1 Delivery Pres- This sensor detects pump HP mode control During combined operation of
sure Sensor delivery pressure in order to Engine speed does not in- boom raise and arm roll-in or
control HP mode, slow speed crease. of arm roll-in and swing, arm
torque increase, and travel Travel HP mode control speed is slow.
motor displacement angle This control is operated by As the machine is kept to
controls. pressure except P1. travel at slow speed, speed
P-Q torque correction does not change into fast.
Torque does not increase.
Travel torque-up control
The machine may mistrack.
Arm regeneration control
Arm regeneration control is
ineffective.
Travel motor displacement
angle control
The machine is kept to travel
at slow speed.
T5-7-2
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
11101-3, 11101-4 Monitor Item: Target T2-2
engine speed, Dial angle
(Possible to display by
service menu and moni-
- -
toring in monitor unit)
- -
T5-7-3
TROUBLESHOOTING / Troubleshooting B
Pump 3 Delivery Pres- This sensor detects pump Engine stalls if pump 3 is Engine stalls if pump 3 is
sure Sensor (Optional) delivery pressure in order to loaded (pump torque is loaded (pump torque is
control pump 3 torque de- increased). increased).
crease control.
T5-7-4
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
11202-3, 11202-4 Monitor Item: Pump 2 T2-2
pressure (Possible to dis-
play by service menu and
monitoring in monitor unit)
- -
T2-2
- - - -
T5-7-5
TROUBLESHOOTING / Troubleshooting B
T5-7-6
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
11304-3, 11304-4 Monitor Item: Travel con- Judge if pressure T2-2
trol pressure (Possible to sensor is faulty or
display by service menu port is clogged by
and monitoring in monitor switching pressure
unit) sensor with other
Monitor pressure change pressure sensor.
while traveling machine.
T5-7-7
TROUBLESHOOTING / Troubleshooting B
Pressure Sensor (Swing) This sensor detects swing Arm regeneration control Arm speed is slow during
pilot pressure in order to During combined operation of combined operation of arm
control arm regeneration arm roll-in and swing, arm roll-in and swing.
control. regeneration is reduced. The swing alarm is kept to
Swing alarm (optional) con- sound when swing alarm is
trol effective as for the machine
Swing alarm is kept ON. equipped with swing alarm
(optional).
T5-7-8
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
11307-3, 11307-4 Monitor Item: Front at- Judge if pressure T2-2
tachment operation (Pos- sensor is faulty or
sible to display by service port is clogged by
menu and monitoring in switching pressure
monitor unit) sensor with other
Monitor pressure change pressure sensor.
while operating front at-
tachment.
T5-7-9
TROUBLESHOOTING / Troubleshooting B
T5-7-10
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
11302-3, 11302-4 Monitor Item: Boom raise Judge if pressure T2-2
pilot pressure (Possible to sensor is faulty or
display by service menu port is clogged by
and monitoring in monitor switching pressure
unit) sensor with other
Monitor pressure change pressure sensor.
while raising boom.
T5-7-11
TROUBLESHOOTING / Troubleshooting B
Pressure Sensor This sensor detects attach- Attachment Open part: During combined operation of
(Auxiliary) (Optional) ment pilot pressure when at- Maximum attachment and front attach-
tachment is installed in order Pump 1, 2 flow rate limits are ment, front attachment speed
to control attachment opera- ineffective. is slow.
tion speed increase, pump 1 Pump 1, 2 flow rates are not
flow rate limit, pump 2 flow limited at attachment mode.
rate limit and auxiliary flow
rate controls.
Torque Control Solenoid This valve supplies control High current: Pump torque is High current: If pump torque is
Valve pressure to pumps 1 and 2 in kept maximum. The engine maximum at low idle, the en-
order to control speed sens- stalls or llug-down is re- gine stalls or lug-down occurs.
ing and slow speed torque markable at high loaded. Low current: The machine
increase controls. Low current: Pump torque is operation is totally slow.
kept minimum.
T5-7-12
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
11303-3, 11303-4 Monitor Item: Arm roll-In Judge if pressure T2-2
pilot pressure (Possible to sensor is faulty or
display by service menu port is clogged by
and monitoring in monitor switching pressure
unit) sensor with other
Monitor pressure change pressure sensor.
while rolling arm in.
T5-7-13
TROUBLESHOOTING / Troubleshooting B
T5-7-14
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
11403-2, 11403-3, Monitor Item: Arm regen- Install lamp harness (ST T2-2
erative proportional sole- 7226). Check output signals
11403-4 from MC and harness condi-
noid valve output
tion.
-
T5-7-15
TROUBLESHOOTING / Troubleshooting B
Max. Pump 1 Flow Rate This valve limits maximum High current: Pump 1 flow High current: The machine
Limit Solenoid Valve (Op- pump 1 flow rate when rate becomes minimum. mistracks. Boom raise
tional)
operating attachment. Low current: Pump 1 flow operation speed is slow. Arm
rate does not decrease. roll-out and roll-in operation
Pump 1 attachment flow rate speeds are slow. Bucket
cannot be controlled. roll-in and roll-put operation
speeds are slow.
Low current: Attachment flow
rate cannot be controlled.
Max. Pump 2 Flow Rate This valve limits maximum High current: Pump 2 flow High current: The machine
Limit Solenoid Valve pump 2 flow rate when rate becomes minimum. mistracks. Boom raise
operating attachment. Low current: Pump 2 flow operation speed is slow. Arm
rate does not decrease. roll-out and roll-in operation
speeds are slow. Swing
operation speed is slow.
Low current: Attachment flow
rate cannot be controlled.
T5-7-16
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
11405-2, 11405-3, Install lamp harness (ST T2-2
7226). Check output signals
11405-4 from MC and harness condi-
- tion. -
T2-2
- - - -
- - -
T5-7-17
TROUBLESHOOTING / Troubleshooting B
Auxiliary Flow Combiner This valve activates during If auxiliary flow combiner Speed does not increase
Solenoid Valve (Optional) auxiliary operation and shifts solenoid valve is not during single operation of
spool in auxiliary flow activated, pressure at output attachment.
combining valve. port becomes 0 MPa (0
kgf/cm2) when operating
attachment.
Selector Valve Control This valve activates when If selector valve control Breaker stroke becomes few.
Solenoid Valve (Optional) attachment selector valve solenoid valve is not
returning to hydraulic oil tank activated, pressure at output
is selected and shifts selector port becomes 0 MPa (0
valve spool. kgf/cm2) when attachment
selector valve returning to
hydraulic oil tank is selected.
Accumulator Control So- This valve activates when If accumulator control When NPK breaker is used,
lenoid Valve (Optional) attachment accumulator ON solenoid valve is not hydraulic pulsation (hose
is selected and shifts activated, pressure at output vibration) becomes big.
accumulator control valve port becomes 0 MPa (0
spool. kgf/cm2) when attachment
accumulator ON is
selected.
T5-7-18
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
T2-2
- - - -
T2-2
- - - -
T2-2
- - - -
T5-7-19
TROUBLESHOOTING / Troubleshooting B
Hydraulic Oil Tempera- This sensor detects hydraulic Auto-warming up control When hydraulic oil
ture Sensor oil temperature in order to Auto-warming up control is temperature is lower than 0
control auto-warming up ineffective. C, auto-warming up control
control. is not operated.
Travel Mode Switch This switch shifts travel Open circuit in switch: Travel Even if travel mode switch is
mode. speed remains unchanged in turned to the FAST position,
slow mode (5V). fast travel mode cannot be
Fast mode: 0V Shorted circuit in switch: selected.
Slow mode: 5V Travel speed remains Even if travel mode switch is
unchanged in auto-second turned to the SLOW position,
gear (0 V). travel mode is turned to the
auto-second gear.
MC This controls engine, pump Depending on trouble Even if engine starts, engine
and valve operations. situations, control system speed remains in idle speed.
malfunction may differ. (The As pump displacement is
following symptoms in kept at minimum, all
machine operation indicates operation speeds are slow.
that MC logic circuit has
failed.)
T5-7-20
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
T2-2
- - - -
- -
- - -
T5-7-21
TROUBLESHOOTING / Troubleshooting B
Power Mode Switch This switch activates HP Open circuit: Even if HP Open circuit: Even if HP
(HP Mode) mode control. mode is selected, HP mode mode is selected, HP mode
is not operated. is not operated.
ON: 0 V HP mode control Shorted circuit: Even if HP Shorted circuit: Even if HP
is operated. mode switch is turned OFF, mode switch is turned OFF,
OFF: 5 V Normal HP mode is continued. HP mode is continued.
Attachment speed increase Attachment speed increase
control (optional) becomes control (optional) becomes
ineffective. ineffective.
Power Mode Switch This switch selects E mode. Open circuit: Even if E mode Open circuit: Even if E mode
(E Mode) is selected, engine speed is selected, engine speed
ON: 0 V E mode does not decrease with the does not decrease with the
OFF: 5 V Normal control lever in neutral. When control lever in neutral. When
E mode is selected and E mode is selected and
engine is operated at full engine is operated at full
speed with light load, engine speed with light load, engine
speed does not increase. speed does not increase.
Shorted circuit: When the Shorted circuit: When the
control lever is in neutral and control lever is in neutral and
the engine control dial is at the engine control dial is at
FAST idle position and even FAST idle position and even
if the power mode switch is if the power mode switch is
shifted from E mode to P shifted from E mode to P
mode, engine speed does mode, engine speed does
not increase. not increase.
T5-7-22
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
T2-2
- - - -
- - -
- - -
T5-7-23
TROUBLESHOOTING / Troubleshooting B
Bucket Flow Rate Control This valve restricts oil flow to If selector valve is bound with If poppet valve is bound at
Valve bucket during 3-combined selector valve activated, fully closed position or if
operation of bucket, arm bucket circuit is always selector valve is bound when
roll-in and boom raise, and restricted. poppet valve is fully closed,
allows boom to raise. bucket speed becomes slow.
If poppet valve is bound at
fully open position or if
selector valve is bound when
poppet valve is fully open,
boom does not raise during
3-combined operation of
bucket, arm roll-in and boom
raise.
T5-7-24
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
T3-3
- - - -
T3-3
- - - -
T5-7-25
TROUBLESHOOTING / Troubleshooting B
Arm Regenerative Valve This valve is shifted by pilot Arm regenerative function is Arm speed is extremely slow
pressure from solenoid valve not operated. during arm level crowd
unit (SC). operation while arm
This valve routes returning oil regenerative valve is kept
from arm cylinder rod side to closed.
bottom side and increases The lever operated first is
arm speed. given priority during
combined operation of arm
roll-in and swing while arm
regenerative valve is kept
open.
T5-7-26
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
T3-3
- - - -
T3-3
- - - -
T5-7-27
TROUBLESHOOTING / Troubleshooting B
Boom Anti-Drift Valve This valve forcibly opens If switch valve is bound, If check valve is kept closed,
check valve in boom lower check valve does not open. boom does not lower.
returning circuit and allows If check valve is kept open,
boom to move only when front attachment drift
boom is lowered. This valve increases due to oil leaks in
prevents boom from drifting control valve.
due to oil leaks in control Boom moves jerky or boom
valve. speed becomes slow
depending on valve bound
conditions.
T5-7-28
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
T3-3
- - - -
T3-3
- - - -
T5-7-29
TROUBLESHOOTING / Troubleshooting B
T5-7-30
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
T3-3
- - - -
T5-7-31
TROUBLESHOOTING / Troubleshooting B
T5-7-32
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
T3-6
- - - -
T5-7-33
TROUBLESHOOTING / Troubleshooting B
Flow Combiner Valve This spool is shifted by right If spool is bound at fully If spool is bound at fully
Control Spool travel pilot pressure and open, when boom, arm, open, when boom, arm,
supplies control pressure to bucket or swing is operated, bucket or swing is operated,
flow combiner valve in flow combiner valve is flow combiner valve is
control valve. shifted. shifted.
If spool is bound at fully If spool is bound at fully
closed, when combined closed, when combined
operation of travel and operation of travel and
front/swing is made, machine front/swing is made, machine
mistracks to the left. (Left mistracks to the left. (Left
travel speed becomes slow.) travel speed becomes slow.)
T5-7-34
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
T3-6
- - - -
T3-6
- - - -
T5-7-35
TROUBLESHOOTING / Troubleshooting B
Bucket Flow Rate Control This spool is shifted by arm If spool is bound at fully open, If spool is bound at fully open,
Valve Control Spool roll-in pilot pressure and bucket speed becomes slow bucket speed becomes slow
supplies boom raise pilot during combined operation of during combined operation of
pressure to bucket flow rate boom raise and bucket. boom raise and bucket.
control valve as control (Bucket flow rate control is (Bucket flow rate control is
pressure. ineffective.) ineffective.)
If spool is bound at fully If spool is bound at fully
closed, boom does not raise closed, boom does not raise
during 3-combined operation during 3-combined operation
of bucket, arm roll-in and of bucket, arm roll-in and
boom raise. boom raise.
T5-7-36
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
T3-3
- - - -
T3-3
- - - -
T5-7-37
TROUBLESHOOTING / Troubleshooting B
Selector Valve (Optional) This valve is shifted by pilot If spool is bound or spring is Breaker stroke becomes few.
pressure from selector valve broken, pressure oil from
control solenoid valve. breaker does not return to
hydraulic oil tank.
Accumulator Control This valve is shifted by pilot If spool is bound or spring is When NPK breaker is used,
Valve (Optional) pressure from accumulator broken, accumulator shifting hydraulic pulsation (hose
control solenoid valve. is turned OFF. vibration) becomes big.
Secondary Pilot Relief This valve is shifted by pilot If spool is bound or spring is Relief set-pressure in
Pressure Control Valve pressure from secondary broken, relief circuit in auxiliary circuit does not
pilot relief pressure control breaker is blocked. decrease.
(Optional) solenoid valve.
T5-7-38
TROUBLESHOOTING / Troubleshooting B
Descriptions of Control
Evaluation by Evaluation by Moni- Evaluation by using
NOTE (Operational Principle
MC Fault Code tor Function Test Harness
Section in T/M)
T3-3
- - - -
T2-2
- - - -
T2-2
- - - -
T2-2
- - - -
T5-7-39
TROUBLESHOOTING / Troubleshooting B
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine : Related, required to check
: Related. However, in case this component fails, other trouble
troubles and parts contributing to the cause of the symptom will be more noticeable so that this component will not
trouble if failed. be the direct cause of the trouble concerned.
Parts
MC
ECM
ICF
Monitor Unit
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pump 1 Control Pressure Sensor
Pump 2 Control Pressure Sensor
Pressure Sensor (Travel)
Pressure Sensor (Front Attachment)
Pressure Sensor (Swing)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Auxiliary)
Hyd. Oil Temperature Sensor
Coolant Temperature Sensor
Key Switch
Engine Control Dial
Auto-Idle Switch
Power Mode Switch
Travel Mode Switch
Torque Control Solenoid Valve
Starter Cut Relay
ECM Main Relay
Battery Relay
Glow Relay
Engine Electrical Equipment
Engine Unit
Pump Regulator
Swing Parking Brake Release Spool
(Signal Control Valve)
Check batteries.
Remarks
T5-7-40
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
T5-7-41
TROUBLESHOOTING / Troubleshooting B
: Related, required to check
: Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will not
be the direct cause of the trouble concerned.
Parts
MC
ECM
ICF
Monitor Unit
Pump 1 Delivery Pressure
Sensor
Pump 2 Delivery Pressure
Sensor
Pump 1 Control Pressure
Sensor
Pump 2 Control Pressure
Sensor
Pressure Sensor (Travel)
Pressure Sensor (Front Attach-
ment)
Pressure Sensor (Swing)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Auxiliary)
Hyd. Oil Temperature Sensor
Coolant Temperature Sensor
Key Switch
Engine Control Dial
Auto-Idle Switch
Power Mode Switch
Travel Mode Switch
Torque Control Solenoid Valve
Starter Cut Relay
ECM Main Relay
Battery Relay
Glow Relay
Engine Electrical Equipment
Engine Unit
Pump Regulator
Swing Parking Brake Release
Spool (Signal Control Valve)
Remarks
T5-7-42
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
T5-7-43
TROUBLESHOOTING / Troubleshooting B
E-14 E-15
Engine stalls during operation Engine is difficult to start at low
Trouble under adverse condition such as temperature.
Symptom at high altitude.
Parts
MC
ECM
ICF
Monitor Unit
Pump 1 Delivery Pressure
Sensor
Pump 2 Delivery Pressure
Sensor
Pump 1 Control Pressure
Sensor
Pump 2 Control Pressure
Sensor
Pressure Sensor (Travel)
Pressure Sensor (Front
Attachment)
Pressure Sensor (Swing)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Auxiliary)
Hyd. Oil Temperature Sensor
Coolant Temperature Sensor
Key Switch
Engine Control Dial
Auto-Idle Switch
Power Mode Switch
Travel Mode Switch
Torque Control Solenoid Valve
Starter Cut Relay
ECM Main Relay
Battery Relay
Glow Relay
Engine Electrical Equipment
Engine Unit
Pump Regulator
Swing Parking Brake Release
Spool (Signal Control Valve)
Check batteries.
Remarks
T5-7-44
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-45
TROUBLESHOOTING / Troubleshooting B
Parts
MC
ECM
Monitor Unit
Torque Control Solenoid Valve
Pilot Shut-Off Solenoid Valve
Pump 2 Delivery Pressure
Sensor
Pressure Sensor (Swing)
Pressure Sensor (Arm Roll-In)
Pilot Shut-Off Lever
Pilot Shut-Off Relay
Security Relay
Spool
Main Relief Valve
Main Pump
Regulator
Pilot Pump
Pilot Valve
Pilot Relief Valve
Pump 1 Flow Rate Control
Valve (Signal Control Valve)
Pump 2 Flow Rate Control
Valve (Signal Control Valve)
Remarks
NOTE: The trouble symptoms in this table are de- : Related, required to check
scribed provided that each trouble occurs : Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will not
independently. In case more than one trou- be the direct cause of the trouble concerned.
ble occurs at the same time, find out all
faulty components while checking all sus-
pected components in each trouble symp-
tom.
T5-7-46
TROUBLESHOOTING / Troubleshooting B
T5-7-47
TROUBLESHOOTING / Troubleshooting B
A-7
Engine lug down is large when
Trouble actuator in maximum flow rate
Symptom gear pump (optional) is oper-
ated.
Parts
MC
ECM
Monitor Unit
Torque Control Solenoid Valve
Pilot Shut-Off Solenoid Valve
Pump 2 Delivery Pressure
Sensor
Pressure Sensor (Swing)
Pressure Sensor (Arm Roll-In)
Pilot Shut-Off Lever
Pilot Shut-Off Relay
Security Relay
Spool
Main Relief Valve
Main Pump
Regulator
Pilot Pump
Pilot Valve
Pilot Relief Valve
Pump 1 Flow Rate Control
Valve (Signal Control Valve)
Pump 2 Flow Rate Control
Valve (Signal Control Valve)
Pump 3 Delivery Pressure
Sensor (Optional)
Remarks
T5-7-48
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-49
TROUBLESHOOTING / Troubleshooting B
Parts
MC
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)
Spool
Main Relief Valve
Overload Relief Valve
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve
Bucket Regenerative Valve
Bucket Flow Rate Control Valve
Boom Anti-Drift Valve
Arm Anti-Drift Valve
Emergency Valve
Shockless Valve (Signal Control Valve)
Shuttle Valve (Signal Control Valve)
Bucket Flow Rate Control Valve Con-
trol Spool (Signal Control Valve)
Pilot Valve
Cylinder
Remarks
T5-7-50
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
F-3 F-4 F-5 F-6
Arm speed is slow during Bucket is slightly slow When starting to move When starting to move
combined operation. during bucket roll-in sin- during combined opera- during combined opera-
During combined opera- gle operation. Bucket tion, arm does not tion, boom does not
tion with boom raise and does not move smoothly smoothly move. Arm smoothly move. Boom
arm roll-in, boom raise during bucket roll-in sin- starts to move slightly starts to move slightly
speed is slow. Arm gle operation. slow during arm roll-in slow during boom lower
speed is slow during arm single operation. These single operation.
level crowding. troubles often occur
when temperature is low.
T5-7-51
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
F-7 F-8
When boom Front attach-
Trouble raise or arm ment drifts
Symptom roll-out is op- remarkably.
erated, boom
or arm starts
to move after
slightly mov-
ing downward.
MC
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)
Spool
Main Relief Valve
Overload Relief Valve
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve
Bucket Regenerative Valve
Bucket Flow Rate Control Valve
Boom Anti-Drift Valve
Arm Anti-Drift Valve
Emergency Valve
Shockless Valve (Signal Control
V l ) Valve (Signal Control Valve)
Shuttle
Bucket Flow Rate Control Valve
Control Spool (Signal Control Valve)
Pilot Valve
Cylinder
Remarks
T5-7-52
TROUBLESHOOTING / Troubleshooting B
MC
Auxiliary Flow Rate Control Solenoid Valve
Auxiliary Flow Combiner Solenoid Valve
Remarks
T5-7-53
TROUBLESHOOTING / Troubleshooting B
Parts
MC (Main Controller)
Torque Control Solenoid Valve
Solenoid Valve Unit (SC)
Solenoid Valve Unit (SI)
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)
Travel Mode Switch
Pump Device
Spool
Load Check Valve
Flow Combiner Valve
Swing Parking Brake Release Spool
(Signal Control Valve)
Pump 1 Flow Rate Control Valve
(Signal Control Valve)
Pump 2 Flow Rate Control Valve
(Signal Control Valve)
Flow Combiner Valve Control Spool
(Signal Control Valve)
Shuttle Valve (Signal Control Valve)
Swing Device
Travel Device
Center Joint
Pilot Valve
Refer to T-5. In case either bucket
or swing is also slow,
Remarks refer to A-3 or A-4.
T5-7-54
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
T-3 T-4 T-5 O-1 O-2
Machine mistracks during Occasionally, machine Fast travel is not selected. Wiper is not operated. Air Conditioner is faulty.
combined operation of may mistrack when trav- Travel mode does not
travel and front attach- eling with engine running change from slow mode
ment. at slow speed. to fast mode.
T5-7-55
TROUBLESHOOTING / Troubleshooting B
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter does not rotate.
Related MC Fault Code: None
T178-05-04-001
T105-07-04-002
T5-7-56
TROUBLESHOOTING / Troubleshooting B
Monitor Unit
Starter Cut Relay Starter Relay 1
Connector Monitor-A
#A7
E
S R
T183-05-05-001 T183-05-04-003
T5-7-57
TROUBLESHOOTING / Troubleshooting B
E-2 Even if starter rotates, engine does not start.
Connect terminal #1
of harness end of
connector in ECM
Switch ECM main main relay to body.
relay with other gen- Connect terminal #5 of YES
Check for continuity
eral relay. harness end of connec- between terminals
Check if engine tor in ECM main relay to #21, #40 of harness
starts. body. end of connector in
YES Disconnect connector ECM and body.
ECM-1 in ECM.
Disconnect ECM main Check for continuity
relay from connector. between terminals #2,
Check if voltage be- #5 of harness end of Open circuit in harness
between ECM main relay
NO tween terminal #3 of connector and body. NO and ECM.
harness end of con-
nector and body 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
T5-7-58
TROUBLESHOOTING / Troubleshooting B
B1 B8
T1V1-05-04-002
#C7
B19 B25
T5-7-59
TROUBLESHOOTING / Troubleshooting B
E-3 When engine control dial is fully rotated,
engine stalls.
When engine control dial is fully rotated,
engine speed is slow.
T5-7-60
TROUBLESHOOTING / Troubleshooting B
E-4 Even if engine control dial is rotated, engine
speed remains unchanged.
T5-7-61
TROUBLESHOOTING / Troubleshooting B
E-5 Engine speed does not increase when en-
gine starts.
0 C or higher
when starting Normal.
NO
Faulty MC.
Check if fault code
A 11004-2 is dis-
played at the same
time.
T5-7-62
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-63
TROUBLESHOOTING / Troubleshooting B
E-6 HP mode is faulty.
The sensors detect the conditions necessary to Refer to HP Mode Control in SYSTEM / Control
operate HP mode. Therefore, if any of these sen- System in T/M (Operational Principle).
sors fails, HP mode becomes ineffective. Check the wiring connections first.
Pressure sensors (arm roll-in and boom raise)
and pump 1 and 2 delivery pressure sensors are
also engaged in the HP mode control. However, if
these sensors fail, other operating functions will
be also affected.
T5-7-64
TROUBLESHOOTING / Troubleshooting B
Even if the power mode switch is not turned to HP
mode, HP mode is operated.
Faulty MC.
NO
T5-7-65
TROUBLESHOOTING / Troubleshooting B
E-7 Travel HP mode is faulty.
The sensors detect the conditions necessary to Refer to Travel HP Mode Control in SYSTEM /
operate travel HP mode. Therefore, if any of Control System in T/M (Operational Principle).
these sensors fails, travel HP mode becomes in- Check the wiring connections first.
effective.
Pressure sensor (travel) and pump 1 and 2 de-
livery pressure sensors are also engaged in the
HP mode control. However, if these sensors fails,
other operating functions will be also affected.
T5-7-66
TROUBLESHOOTING / Troubleshooting B
Even if the travel mode switch is not turned to FAST,
travel mode becomes fast idle.
Travel must be operated when the average de-
livery pressures of pump 1 and 2 are high, if
travel HP mode control is performed. The
sensors related to this condition may not be faulty
at the same time.
Faulty MC.
NO
T5-7-67
TROUBLESHOOTING / Troubleshooting B
E-8 Even if key switch is turned OFF, engine
does not stop. (In case 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.
NO Shorted circuit in
· Key switch: OFF Disconnect connector harness between
ECM-1 in ECM. key switch and ECM.
Check if voltage be-
tween terminal #24 of
NO harness end of con-
nector and body is 0 V.
Faulty ECM.
· Key switch: OFF YES
Key Switch:
#24
Connector ECM-1
(Harness end)
T1GR-05-04-002
T105-07-04-002
T5-7-68
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-69
TROUBLESHOOTING / Troubleshooting B
E-9 Auto-idle system is faulty.
In case trouble symptoms E1 to E8 are recog- Refer to Auto-Idle Control in SYSTEM / Control
nized, perform the troubleshooting of these trou- System in T/M (Operational Principle).
bles first. Check the wiring connections first.
Even if failure in pressure sensors (travel and
front attachment) may have relevance to mal-
function 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
T5-7-70
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.
· Fault code:
11304-3, 11304-4: Pilot pressure sensor (travel)
11307-3, 11307-4: Pilot pressure sensor (front attachment)
T5-7-71
TROUBLESHOOTING / Troubleshooting B
Even if auto-idle switch is turned OFF, auto-idle is op-
erated.
Shorted circuit in
YES harness between
Disconnect connector
MC-B in MC and con- MC and auto-idle
nector in switch panel.
Check for continuity
between terminal #B6 Refer to fault code
YES
of harness end of 11004 in Trouble-
connector MC-B and shooting A.
body. Check if fault code
NO 11004-2 is displayed.
· Auto-idle switch: OFF
Faulty MC.
NO
Connector MC-B
#B6
B1 B8
B19 B25
T5-7-72
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-73
TROUBLESHOOTING / Troubleshooting B
E-10 E mode is faulty.
In case trouble symptoms E-1 to E-9 are recog- Pump 1, 2 control pressure sensors and pump 1,
nized, perform the troubleshooting of these trou- 2 delivery pressure sensors are also engaged in
bles first. the E mode control. However, if these sensors
The sensors detect the conditions necessary to fail, other operating functions will be also af-
operate E mode. Therefore, if any of these sen- fected.
sors fails, E mode becomes ineffective. Refer to E Mode Control in SYSTEM / Control
System in T/M (Operational Principle).
Check the wiring connections first.
T5-7-74
TROUBLESHOOTING / Troubleshooting B
Even if power mode switch is not turned to E mode,
engine speed decreases.
T5-7-75
TROUBLESHOOTING / Troubleshooting B
E-11 When traveling or operating front attach-
ment with engine running at slow idle, en-
gine hunts.
T5-7-76
TROUBLESHOOTING / Troubleshooting B
E-12 Engine speed does not increase even if
attachment is operated in attachment
mode.
Faulty MC.
NO
T5-7-77
TROUBLESHOOTING / Troubleshooting B
E-13 When attachment mode is selected, engine
speed does not decrease.
Faulty MC.
Check if attachment NO
speed adjustment has
been set to Decrease
(-) in on Parameter
Change in Dr. ZX.
T5-7-78
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-79
TROUBLESHOOTING / Troubleshooting B
E-14 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 comes ON.
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
YES check regulator.
· Monitor item: Pump torque
· Monitor item:
proportional solenoid valve
Engine actual speed
output
· Possible to display by
· Refer to Operational Per-
service menu and
formance Test.
monitoring in monitor
unit. Refer to fault code
YES
11004 in Trouble-
shooting A.
Faulty MC.
NO
T5-7-80
TROUBLESHOOTING / Troubleshooting B
T5-7-81
TROUBLESHOOTING / Troubleshooting B
E-15 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
ECM-1 in ECM. Connect
terminal #4 of harness end
NO of connector to body. Check
if problem is corrected.
· Connect to body from the Measure each glow plug
back of connector by using NO resistance.
a clip with the connector
connected. · Key switch: OFF
· Before measuring, re-
move copper plates
connecting each glow
plug.
Resistance Check
Remove
the
copper
plate.
Specification: 20 to 24 V
T105-07-04-006
Specification: 10 or less
T105-07-04-007
T5-7-82
TROUBLESHOOTING / Troubleshooting B
1
4
3
2
T1GR-05-04-002
T5-7-83
TROUBLESHOOTING / Troubleshooting B
ALL ACTUATOR SYSTEMS TROUBLE-
SHOOTING
A-1 All actuator speeds are slow.
T5-7-84
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-85
TROUBLESHOOTING / Troubleshooting B
A-2 All actuator are not operated.
T1V1-05-04-103
#1 #2
T183-05-04-003
T5-7-86
TROUBLESHOOTING / Troubleshooting B
T5-7-87
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
T5-7-88
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-89
TROUBLESHOOTING / Troubleshooting B
A-3 Left travel is not operated during single
travel operation. Single swing operation
speed becomes slow. Arm speed is slightly
slow during arm level crowding. (All prob-
lems occur at the same time.)
T5-7-90
TROUBLESHOOTING / Troubleshooting B
A-4 Right travel is operated during single travel
operation. Single bucket operation speed
becomes slow. Boom is not raised properly
during arm level crowding. (All problems
occur at the same time.)
T5-7-91
TROUBLESHOOTING / Troubleshooting B
A-5 Actuator does not stop even if control lever
is turned to neutral.
T5-7-92
TROUBLESHOOTING / Troubleshooting B
A-6 Actuator speed is faster than normal. Ma-
chine mistracks when travel lever is oper-
ated at half stroke. Precise control cannot
be performed.
T5-7-93
TROUBLESHOOTING / Troubleshooting B
A-7 Engine lug down is large when actuator in
maximum flow rate gear pump (optional) is
operated.
T1V1-05-07-101
#A30 T183-05-04-008
Connector MC-D
#D3 Torque Control Solenoid Valve
T1V1-05-04-003
T183-05-04-009
T5-7-94
TROUBLESHOOTING / Troubleshooting B
Switch connectors of
torque control solenoid YES Faulty torque control
valve and maximum solenoid valve.
YES pump 2 flow rate limit
control solenoid valve.
Check if fault code for Faulty MC.
pump 2 flow rate limit
control solenoid valve is NO
displayed.
T5-7-95
TROUBLESHOOTING / Troubleshooting B
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
F-1 All front attachment actuator power is weak.
T5-7-96
TROUBLESHOOTING / Troubleshooting B
F-2 Some cylinders are not operated or speeds
are slow.
T5-7-97
TROUBLESHOOTING / Troubleshooting B
F-3 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. Refer to Arm Regenerative Control in SYSTEM /
Control System in T/M (Operational Principle).
Related MC Fault Codes: 11200-3, 11200-4,
11202-3, 11202-4, 11303-3, 11303-4, 11301-3,
11301-4, 11302-3, 11302-4, 11403-2, 11403-3,
11403-4
· Fault code
11200-3, 11200-4: YES Faulty arm regenerative
Pump 1 delivery pressure valve.
sensor Check if arm regenera-
11202-3, 11202-4: tive valve at 4-spool side
Pump 2 delivery pressure NO in control valve is scored
sensor or bound.
11303-3, 11303-4: Find out cause of trouble
Pressure sensor (arm by tracing other trouble
NO
roll-in) symptoms.
11301-3, 11301-4:
Pressure sensor (swing)
11302-3, 11302-4:
Pressure sensor (boom
raise)
11403-2, 11403-3,
11403-4: Solenoid valve
unit (SC)
Control Valve
B B
Arm Regenerative
Valve T1V1-03-03-026
A
T1V1-03-03-002
T5-7-98
TROUBLESHOOTING / Troubleshooting B
F-4 Bucket is slightly slow during bucket roll-in
single operation. Bucket does not move
smoothly during bucket roll-in single opera-
tion.
Hose SK
T1V1-05-04-005
T178-03-06-015
T5-7-99
TROUBLESHOOTING / Troubleshooting B
F-5 When starting to move during combined
operation, arm does not smoothly move.
Arm starts to move slightly slow during arm
roll-in single operation. These troubles often
occur when temperature is low.
T5-7-100
TROUBLESHOOTING / Troubleshooting B
F-7 When boom raise or arm roll-out is oper-
ated, boom or arm starts to move after
moving slightly downward.
T5-7-101
TROUBLESHOOTING / Troubleshooting B
F-8 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
time, oil leaks in the boom cylinders. In case no
oil flows out of the hose disconnected piping
ends but the boom cylinders are retracted, oil
leaks in the control valve.
T5-7-102
TROUBLESHOOTING / Troubleshooting B
Emergency
Valve
T1V1-05-04-005
Emergency
Valve
T178-05-04-003
Adjustment Procedure:
Tighten (1) and tighten (2).
Tightening Torque:
(1)- 13 N m (1.3 kgf m, 9.4 lbf·ft)
(2)- 7 N m (0.7 kgf m, 5.1 lbf·ft)
T5-7-103
TROUBLESHOOTING / Troubleshooting B
F-9 Attachment speed is fast during combined
operation of attachment (optional) and front
attachment (when secondary crusher or
primary crusher is used).
T1V1-05-07-102
T1V1-05-04-003
T183-05-04-009
#D9
T5-7-104
TROUBLESHOOTING / Troubleshooting B
Disconnect connec- Check if voltage be-
tor MC-D in MC. YES tween terminals #D9
Check for continuity of harness end of To A
between terminal connector MC-D and
Disconnect connec- YES #D9 of harness end body is 0 V.
tor in pressure sen- of connector and · Key switch: ON
sor (arm roll-out). terminal #2 of har-
NO Check if voltage be- ness end of connec- Open circuit in harness
Switch pressure tween terminals #1 tor in pressure sen- between MC and pressure
sensor (arm roll-out) and #3 of harness sor (arm roll-out). NO
sensor (arm roll-out).
with other pressure end of connector is
YES sensor. 5 0.5 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 terminals #1 of
played. sensor (arm roll-out) (ter-
harness end of con- minal #3).
nector in pressure
NO sensor (arm roll-out)
and body is between
0.25 and 4.75 V. Open circuit in harness
between MC and pressure
NO sensor (arm roll-out) (ter-
· Key switch: ON minal #1).
T5-7-105
TROUBLESHOOTING / Troubleshooting B
F-10 Attachment speed is fast during combined
operation of attachment (optional) and front
attachment (when breaker attached with
auxiliary flow combining piping attached is
used).
T1V1-05-07-102
T183-05-04-008
Connector MC-D
Auxiliary Flow Combiner Solenoid Valve
#D5
T1V1-05-04-003
T183-05-04-009
#D9
T5-7-106
TROUBLESHOOTING / Troubleshooting B
T5-7-107
TROUBLESHOOTING / Troubleshooting B
F-11 Attachment speed is fast during combined
operation of attachment (optional) and front
attachment (when vibrating hammer is
used).
#A3 #A20
T1V1-05-07-102
T183-05-04-008 T1V1-05-07-103
Maximum Pump 1 Flow Rate Limit Connector MC-D
Control Solenoid Valve (Optional)
#D5
T1V1-05-04-003
T183-05-04-009
T5-7-108
TROUBLESHOOTING / Troubleshooting B
YES
To A
Check if voltage be-
Disconnect connector YES tween terminals #C2
in pressure sensor of harness end of
(travel). connector MC-C and
NO Check if voltage be- body is 0 V.
tween terminals #1 Shorted circuit in har-
· Key switch: ON ness between MC and
and #3 of harness end NO pressure sensor (travel).
Switch pressure sen- of connector is 5 0.5
YES sor (travel) with other V.
pressure 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 terminals #1 of sure sensor (travel) (ter-
harness end of con- minal #3).
nector in pressure
NO sensor (travel) and
body is between 0.25 Open circuit in harness
and 4.75 V. between MC and pres-
· Key switch: ON NO sure sensor (travel) (ter-
minal #1).
Disconnect connector
in maximum pump 1 Faulty maximum pump 1
YES
flow rate limit control flow rate limit control
solenoid valve. solenoid valve.
YES Check if current be-
tween terminals #1
and #2 of 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
#A20 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 #A7
of connector MC-A in
MC and terminal #2 of
connector in maxi-
mum pump 1 flow rate
limit control solenoid
valve
T5-7-109
TROUBLESHOOTING / Troubleshooting B
SWING SYSTEM TROUBLESHOOTING
S-1 Swing is slow or unmoving.
T5-7-110
TROUBLESHOOTING / Troubleshooting B
T5-7-111
TROUBLESHOOTING / Troubleshooting B
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Both right and left tracks do not rotate or
rotate slowly.
T5-7-112
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-113
TROUBLESHOOTING / Troubleshooting B
T-2 One side track does not rotate or rotates
slowly. Machine mistracks.
Check that both side track sags are equally ad- In one side track only does not rotate, the pilot
justed. valve, control valve, travel motor, or center joint
Faulty pump control will cause the machine to may be faulty.
mistrack. In this case, other trouble symptoms
such as slow bucket or swing single operation
speed, or slow arm roll-in and boom raise speed Check if travel motor
YES drain oil amount is
in level crowd operation will occur at the same
time. If both mistrack and other symptoms as normal.
described above occurs at the same time, refer · Measurement: Refer
to A-3 and A-4. NO Check if travel relief to Operational Per-
pressure in slow speed formance Test.
side is normal.
· Relieve travel circuit.
· Monitor item: Pump 1
Check if symptom is and 2 delivery pressures Switch forward travel
· Possible to display by relief valve with re-
YES reversed when right and service menu and verse travel one, or
left travel line hoses are
switched each other at monitoring in monitor right travel relief valve
unit. NO with left one.
the top of center joint.
· Measurement: Check if symptom is
Refer to Operational reversed.
Performance Test.
Check if secondary
travel pilot pressure is
normal. Bound control valve
· Monitor item: Travel con- YES spool.
trol pressure
2 2
3
3 Left Travel Right
(Reverse) Travel
(Reverse)
4
4 Left Travel 5 Right
(Forward) Travel
(Forward)
5 6
7
6 T105-07-04-015
External Oil
7 Leak
T5-7-114
TROUBLESHOOTING / Troubleshooting B
Piping Layout
Front
1 2
5 4
W157-03-03-003
T5-7-115
TROUBLESHOOTING / Troubleshooting B
T-3 Machine mistracks during combined opera-
tion of travel and front attachment.
Flow Combiner
Hose (SL) T178-03-06-015 Valve
T1V1-05-04-005
T5-7-116
TROUBLESHOOTING / Troubleshooting B
T-4 Occasionally, machine may mistrack when
traveling with engine running at slow speed.
T5-7-117
TROUBLESHOOTING / Troubleshooting B
T-5 Fast travel is not operated.
Travel mode does not change from slow
mode to fast mode.
Refer to Travel Motor Displacement Angle Con- If the maximum speed cannot reach at the fast
trol in SYSTEM / Control System in T/M (Opera- mode, the engine speed automatic increase con-
tional Principle). trol at travel may be faulty. Refer to E-6 HP
Check the wiring connections first. mode is faulty.
Faulty travel mode switch, or
NO open circuit in harness be-
tween travel mode switch and
MC.
Monitor travel mode Check if symptom is re-
switch. NO versed when pressure sen-
NO Check if displayed indi- sor (travel) is switched with
cation is highlighted in other pressure sensor.
response to travel mode
switch operation.
· Monitor item: Travel fast
speed Monitor pressure sen-
· Possible to display by sor (travel).
service menu and moni- Check if pressure var-
YES ies in response to travel
toring by monitor unit.
lever operation.
· Monitor item: Travel
Check if fault code is
control pressure
displayed.
· Possible to display by
service menu and Check if travel motor dis-
· Fault Code:
monitoring by monitor placement angle control
11200-3, 11200-4:
it YES valve is bound or scored.
Pump 1 delivery pres-
sure sensor
11202-3, 11202-4:
Pump 2 delivery pres-
sure sensor
11206-3, 11206-4:
Pump 1 control pres-
sure sensor
11208-3, 11208-4: Faulty corresponding sensor,
Pump 2 control pres- or open circuit in harness be-
sure sensor tween MC and sensor.
11304-3, 11304-4: Faulty solenoid valve unit (SI),
YES
Pressure sensor or open circuit in harness be-
(travel) tween solenoid valve unit (SI)
11307-3, 11307-4: and MC.
Pressure sensor (front
attachment)
11405-2, 11405--3,
11405-4: Solenoid
valve unit (SI)
T5-7-118
TROUBLESHOOTING / Troubleshooting B
T5-7-119
TROUBLESHOOTING / Troubleshooting B
OTHER SYSTEM TROUBLESHOOTING
O-1 Wiper is not operated.
Checking Instructions
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 of harness end of con-
nector to body. Dis- Open circuit in harness
connect wiper relay. between wiper relay
Check for continuity NO and monitor unit.
Check if wiper relay between terminal #A2
is turned ON/OFF of harness end of con-
according to INT. nector and body.
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
L of harness end of between window con-
between 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.
T183-05-05-001
T5-7-120
TROUBLESHOOTING / Troubleshooting B
Main
Window Contact
T1V1-05-07-004
T5-7-121
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 for STEP 1
more than 3 seconds. Display Function Con-
firmation
Push lower side fan switch. Push upper side fan switch.
Keep pushing OFF switch for STEP 2
more than 3 seconds. Present Trouble
Diagnosing
Push lower side fan switch. Push upper side fan switch.
Keep pushing OFF switch for STEP 3 Keep pushing air conditioner
more than 3 seconds. Past Trouble Di- switch for more than 3 seconds.
agnosing
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 lower Push AUTO Push A/C Push A/C switch and
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
T5-7-122
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
control panel.
T5-7-123
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.
T5-7-124
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.
T5-7-125
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).
NOTE: The coolant temperature sensor indicates Fresh Air Vent Switch OFF Switch
H when coolant temperature is more than
21 C (70 F) and L when coolant tem-
perature is less than 21 C (70 F).
Sensing temperature detected by each sensor is
automatically displayed on the LCD and is cycled at
an interval of 3 seconds with the timer. The timer is
turned ON or OFF by operating the fresh air vent
switch.
Referring to the fan mark can check which sensing
temperature is displayed.
Select the next step in order to be performed by
operating the switches as follows:
Push the upper side of fan switch: Proceed to
STEP 5.
Push the lower side of fan switch: Return to
STEP 3.
Keep pushing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed.)
T5-7-126
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.
T5-7-127
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
T5-7-128
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
T5-7-129
TROUBLESHOOTING / Troubleshooting B
Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to Hitachi Tsuchiura Works Quality Assurance Dept. after
experiencing a problem with your machines air conditioning system.
AIR CONDITIONER TROUBLE REPORT File No
(1) What Checked by:
Model (Serial No. )
Operation Type Manual Semi-Auto Full-Auto
Delivery Date Year Month
(2) When
Date Year Month Day Operating Hour ( h)
Time Morning Daytime Evening Night
Frequency Every Day Once a Week Once a Month Times per
(3) Where
Job Site Address State County Town
Access Road Condition Paved Not Paved (Gravel Sand Soil)
(4) How (Operating Conditions)
Weather Fine Cloudy Rain Snow
Atmospheric Temperature Very Hot Hot Cold Very Cold
Operating Conditions Parking Traveling Working
Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when
full-auto operation
A/C ON OFF
Control Air Induction Re-Circulation Fresh Air Circulation
Panel AUTO ON OFF Not Available
Fill following items when operated in manual mode or when manual control type unit is used.
Vent Position Front Front / Rear Foot Front / Rear and Foot
Fan First Second Third Fourth Fifth Sixth
(5) How (Problem Symptom)
Abnormal Compressor Operation
Symptom Not turned ON Check Result
Not turned OFF (1) Is problem reproducible ?
Others Reproducible
Uncontrollable air temperature Not reproducible
(2) Pressure (To be measured at gauge manifold)
Symptom No cool air
Low Pressure
No warm air
High Pressure
Others
(3) Which parts have been replaced ?
Uncontrollable air volume
1
Symptom Air flows in Hi mode only
No air flows
2
Small air volume
Others
Before replacing the control amplifier, be sure to
Uncontrollable vent hole
check that the connectors are correctly connected
Symptom Vent hole isnt selected
while repeatedly disconnecting and reconnecting
Others connectors.
Abnormal panel indication
Faulty Indicator Vent Hole
A/C
AUTO
Fresh Air Circulation
Fan OFF
Fan (Lo Hi)
Temperature Control
Symptom Stays OFF
Stays ON
Blinks
Others
T5-7-130
TROUBLESHOOTING / Troubleshooting B
T5-7-131
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.
T5-7-132
TROUBLESHOOTING / Troubleshooting B
Gas leaks from pipe joints and/or parts. Re-tighten or replace parts.
Frozen expansion valve or water in circuit. After evacuation, refill refrigerant and/or replace re-
ceiver dryer.
Gas leaks from case. Seal gaps 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.
T5-7-133
TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Gas blowing sound (roaring). Gas vibration noise (compressor discharge and/or
suction gas noise).
Expansion valve connection, whistle Abnormal noise from expansion valve (Expansion
Noise sound, gas blowing sound. valve is normally functioning.).
Noisy compressor.
Compressor rotating sound.
Vibration and/or loose screws due to excessive drive
belt looseness.
T5-7-134
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.
T5-7-135
TROUBLESHOOTING / Troubleshooting B
Compressor
Inoperable
cooling Clutch terminal voltage is low.
system.
T5-7-136
TROUBLESHOOTING / Troubleshooting B
Oil and refrigerant leaks from front housing, and/or cylinder block joint. Replace.
No leaks (normal).
T5-7-137
TROUBLESHOOTING / Troubleshooting B
Compressor
Trouble other than compressor. Refer to the Cooling Circuit Troubleshooting Ta-
ble on page T5-7-124.
Abnormal
noise
T5-7-138
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
high-pressure side and low-pressure side is 0.5 MPa (5 kgf/cm2) or less. When the clutch is
turned OFF, the pressure difference between high-pressure side and low-pressure side will dis-
appear within about 10 seconds.
T5-7-139
TROUBLESHOOTING / Troubleshooting B
EXCHANGE INSPECTION
Exchange inspection method is a troubleshooting
method to find the trouble location by exchanging the
suspected part / component with another part
/component having identical characteristics.
Pump 2 Pump 1
Many sensors and solenoid valves used on this ma- (5-Spool (4-Spool
chine are identical. Therefore, by using this Side) Side)
switch-check method, faulty part /component, and/or
harness can be easily found.
PP2 PP1
Example: Abnormal pump 1 delivery pressure high
voltage (MC fault code: 11200-3)
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 high volt-
age is displayed (MC fault code 11202-3), the pump 1
delivery pressure sensor is considered to be faulty.
Pump 2 Pump 1
In case abnormal pump 1 delivery pressure high volt- (4-Spool
(5-Spool
age is displayed (MC fault code 11200-3), the pump 1 Side) Side)
delivery pressure sensor harness is considered to be
faulty.
PP1 PP2
Figure B T157-07-04-006
T5-7-140
TROUBLESHOOTING / Troubleshooting B
Applicability of Switch-Check Method
Fault Code Trouble Applicability
11000-2 Abnormal EEPROM Not applicable
11001-2 Abnormal RAM
11002-2 Abnormal A/D conversion
11003-2 Abnormal sensor voltage
11004-2 Can communication error Not applicable
11100-2 Abnormal engine speed Not applicable
11101-3 Abnormal engine control dial sensor high Not applicable
voltage
11101-4 Abnormal engine control dial sensor low Not applicable
voltage
11200-3 Abnormal pump 1 delivery pressure sensor Applicable (harness)
high voltage
11200-4 Abnormal pump 1 delivery pressure sensor Applicable (harness)
low voltage
11202-3 Abnormal pump 2 delivery pressure sensor Applicable (harness)
high voltage
11202-4 Abnormal pump 2 delivery pressure sensor Applicable (harness)
low voltage
11206-3 Abnormal pump 1 control pressure sensor Applicable (harness)
high voltage
11206-4 Abnormal pump 1 control pressure sensor Applicable (harness)
low voltage
11208-3 Abnormal pump 2 control pressure sensor Applicable (harness)
high voltage
11208-4 Abnormal pump 2 control pressure sensor Applicable (harness)
low voltage
11301-3 Abnormal swing pilot pressure sensor high Applicable (harness/ sensor)
voltage
11301-4 Abnormal swing pilot pressure sensor low Applicable (harness/ sensor)
voltage
11302-3 Abnormal boom raise pilot pressure sensor Applicable (harness/ sensor)
high voltage
11302-4 Abnormal boom raise pilot pressure sensor Applicable (harness/ sensor)
low voltage
11303-3 Abnormal arm roll-in pilot pressure sensor Applicable (harness/ sensor)
high voltage
11303-4 Abnormal arm roll-in pilot pressure sensor Applicable (harness/ sensor)
low voltage
11304-3 Abnormal travel pilot pressure sensor high Applicable (harness/ sensor)
voltage
11304-4 Abnormal travel pilot pressure sensor low Applicable (harness/ sensor)
voltage
11307-3 Abnormal front attachment pilot pressure Applicable (harness/ sensor)
sensor high voltage
11307-4 Abnormal front attachment pilot pressure Applicable (harness/ sensor)
sensor low voltage
11400-2 Abnormal feedback current of maximum Applicable (harness)
pump 2 flow rate limit control solenoid
valve
11400-3 Abnormal feedback high voltage of maxi- Applicable (harness)
mum pump 2 flow rate limit control solenoid
valve
T5-7-141
TROUBLESHOOTING / Troubleshooting B
T5-7-142
TROUBLESHOOTING / Troubleshooting B
EMERGENCY BOOM LOWERING PRO-
CEDURE
Screw (2)
: 4 mm (Hexagonal wrench) 1
: 6.9 N m (0.7 kgf m, 5.0 lbf ft)
2
NOTE: Excessive leakage may result if the screw
and the lock nut are tightened insufficiently.
Retighten the screw and the lock nut to
specifications.
T178-05-04-003
T5-7-143
TROUBLESHOOTING / Troubleshooting B
CIRCUIT PRESSURE RELEASE PROCE-
DURE
As for the attachment spec machine, the accumulator
is equipped between the pilot pump and the pilot
valve.
To Control Valve
Accumulator
Pilot Pump
T1R7-05-07-001
Engine
T5-7-144
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-145
TROUBLESHOOTING / Troubleshooting B
ONE PART OF DATA, DAILY REPORT
DATA, DISTRIBUTION DATA AND TO-
TAL OPERATING HOURS IS NOT RE-
CORDED
Fuel Usage Amount Value is calculated and recorded by accumulated fuel us-
age amount from ECM.
T5-7-146
TROUBLESHOOTING / Troubleshooting B
Communication line between ECM and ICF (CAN Check for continuity between terminals #C5 of connector ICF-C in
bus line) ICF and terminals #18 of connector in ECM. (Refer to T5-7-150.)
Check for continuity between terminals #C11 of connector ICF-C in
ICF and terminals #37 of connector in ECM. (Refer to T5-7-150.)
Check for discontinuity between CAN circuit in ground circuit. (Re-
fer to T5-6-62.)
Check for discontinuity between CAN circuit in power circuit. (Re-
fer to T5-6-65.)
Check for discontinuity between CAN circuit in key signal circuit.
(Refer to T5-6-68.)
Check for discontinuity in CAN harness. (Refer to T5-6-70.)
Communication line between monitor unit and ICF Check for continuity between terminals #C5 of connector ICF-C in
(CAN bus line) ICF and terminals #B7 of connector monitor-B in monitor unit.
(Refer to T5-7-151.)
Check for continuity between terminals #C11 of connector ICF-C in
ICF and terminals #B6 of connector monitor-B in monitor unit.
(Refer to T5-7-151.)
Check for discontinuity between CAN circuit in ground circuit. (Re-
fer to T5-6-62.)
Check for discontinuity between CAN circuit in power circuit. (Re-
fer to T5-6-65.)
Check for discontinuity between CAN circuit in key signal circuit.
(Refer to T5-6-68.)
Check for discontinuity in CAN harness. (Refer to T5-6-70.)
T5-7-147
TROUBLESHOOTING / Troubleshooting B
Travel Operating Hours Fast Idle (Hi) Traveling Hours Travel mode switch information sent from MC
Slow Idle (Lo) Traveling Hours Travel mode switch information sent from MC
Swing Operating Hours Swing pressure sensor (swing) information sent from MC
Digging Operating Hours Front attachment pressure sensor (front attachment) in-
formation sent from MC
Attachment Operating Hours Breaker Operating Hours Attachment information sent from MC
T5-7-148
TROUBLESHOOTING / Troubleshooting B
Communication line between MC and ICF (CAN Check for continuity between terminals #C5 of connector ICF-C in
bus line) ICF and terminals #C4 of connector MC-C in MC. (Refer to
T5-6-57.)
Check for continuity between terminals #C11 of connector ICF-C in
ICF and terminals #C15 of connector MC-C in MC. (Refer to
T5-6-57.)
Check for discontinuity between CAN circuit in ground circuit. (Refer
to T5-6-62.)
Check for discontinuity between CAN circuit in power circuit. (Refer
to T5-6-65.)
Check for discontinuity between CAN circuit in key signal circuit.
(Refer to T5-6-68.)
Check for discontinuity in CAN harness. (Refer to T5-6-70.)
T5-7-149
TROUBLESHOOTING / Troubleshooting B
T5-7-150
TROUBLESHOOTING / Troubleshooting B
T5-7-151
TROUBLESHOOTING / Troubleshooting B
Discontinuity Check in CAN Harness
Connector
ECM
Connector ECM-1
(Harness end)
#18 #37
T1GR-05-04-002
ICF
Connector ICF-C
(Harness end)
#C5
T1V1-05-04-002
#C11
T5-7-152
TROUBLESHOOTING / Troubleshooting B
Between Monitor Unit and ICF
CAN Harness (High Side)
Check for continuity between terminal #B7 of
harness end of connector monitor-B in the moni-
tor unit and terminal #C5 of harness end of con-
nector ICF-C in ICF.
Connector
Monitor Unit
Connector Monitor-B
(Harness end)
#B7 #B6
T183-05-04-013
ICF
Connector ICF-C
(Harness end)
#C5
#C11 T1V1-05-04-002
T5-7-153
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-154
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.
Disconnect the harness from the negative
terminal side in the battery first when
disconnecting the wire harnesses and the
connectors for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, the fuses and the fusible links and, in
some cases, cause fire due to short circuiting.
2. Color coding of wire harnesses.
As for the color codes of the wire harnesses in
the electrical system, refer to the table below.
In cases on the design sheet where two colors
are indicated for one wire, the left initial stands
for base color, while the right initial stands for
marking color.
T5-8-1
TROUBLESHOOTING / Electrical System Inspection
3. Precautions for connecting and disconnecting
terminal connectors.
1) When disconnecting the harnesses, grasp
Correct Incorrect
them by their connectors. Do not pull on the
wire itself. Release the lock first before
attempting to separate connectors, if a lock
is provided. (Refer to Instructions for
Disconnecting Connector on T5-8-3.)
2) The water-resistant connectors keep water T107-07-06-001
T5-8-2
TROUBLESHOOTING / Electrical System Inspection
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
Push, Unlock and Separate Type
T107-04-05-004
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 con-
nected to loads (accessories). Therefore,
1. Turn the key switch ON. test all fuses in the same method except
When the key switch is turned ON, current from for the glow relay circuit fuse. Check the
key switch terminal M activates the battery relay glow relay circuit fuse with the key switch
so that electric power is supplied to all circuits turned to the ON position and follow the
except the glow plug relay circuit. (Refer to 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 the tester to the 10 20
body. Touch the terminals located away from cen- 9 19
ter of the fuse box with the positive probe of the
tester one at a time. When normal continuity of a 8 18
fuse is intact, the tester will indicate 20 to 25 V 7 17
(battery voltage).
6 16
5 15
4 14
3 13
2 12
1 11
M178-07-034
Fuse Fuse
Capacity Connected to Capacity Connected to
No. No.
1 20 A Working Light Relays 1 and 2 11 10 A Horn Relay
2 10 A Wiper Relay, Wiper Motor, 12 5A Radio, Cab Light
Washer Relay
3 20 A Heater (Air Conditioner Unit) 13 10 A Cigarette Lighter
4 10 A MC (Solenoid Valve Power), 14 5A Fuel Pump
Pilot Shut-Off Relay, Security
Relay, Pilot Shut-Off Solenoid
Valve
5 5A Optional 1 15 10 A Auxiliary
6 10 A Optional 2 16 5A Glow Plug Relay
7 10 A Empty 17 5A Air Conditioner Unit
8 30 A ECM Main Relay 18 5A MC, ECM, ICF, Monitor Unit
(Power ON Signal)
9 10 A Security Horn, Security Horn 19 5A Monitor Unit (Main Power)
Relay (Power), Radio (Backup)
10 5A MC, ICF (Main Power) 20 5A Optional 3
T5-8-4
TROUBLESHOOTING / Electrical System Inspection
FUSIBLE LINK INSPECTION Battery Relay
Inspection
Replacement
Cable Screw M6
T107-04-05-008
T5-8-5
TROUBLESHOOTING / Electrical System Inspection
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between
the battery positive terminal and the body
(ground).
Normal Voltage: 24 V
Normal Voltage: 26 to 28 V
T157-07-06-007
T5-8-6
TROUBLESHOOTING / Electrical System Inspection
ALTERNATOR CHECK
In general, the alternator indicator remains off when
the alternator is generating power.
If the alternator indicator comes on while the engine is
running, the alternator may be faulty.
T157-07-06-003
T5-8-7
TROUBLESHOOTING / Electrical System Inspection
CONTINUITY CHECK
Harness
Single-line continuity check A a
Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 Continuity
Discontinuity
T107-07-05-003
T5-8-8
TROUBLESHOOTING / Electrical System Inspection
Multi-line continuity check
Disconnect both end connectors of the harness, First short-circuit
and short-circuit two terminals, (A) and (B), at one
end connector, as illustrated. Then, check continuity
A a
between terminals (a) and (b) at the other connector. B b
If the ohm-meter reading is , either line (A) - (a), C c
or (B) - (b) is in discontinuity. To find out which line
is discontinued, conduct the single line continuity Second short-circuit
check on both lines individually, or, after changing
the short-circuit terminals from (A) - (B) to (A) - (C),
check continuity once more between terminals (a)
and (c).
A a
B b
C c
T107-07-05-005
T5-8-9
TROUBLESHOOTING / Electrical System Inspection
VOLTAGE AND CURRENT MEASURE-
MENT
Turn key switch ON so that the specified voltage (cur-
rent) is supplied to the location to be measured.
Judge if the circuit is normal by evaluating whether
the measured voltage (current) matches the specifica-
tion.
24-Volt Circuit
Start checking the circuit in order up to the loca-
tion to be measured from either power source or
the actuator side. Thereby, the faulty location in
the circuit will be found.
Black Probe (Negative) of Tester:
To ground to the body
Red Probe (Positive) of Tester:
To touch the location to be measured
Engine Key Switch Location to be Measured Specification
Power Source
Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (2): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Battery Power 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (1) and Ground: Backup Current* 6 mA
Preheat Circuit
Stopped ON or START Between (6) and Ground: Key Switch 20 to 25 V
Stopped ON or START Between (7) and Ground: Glow Plug 20 to 25 V
Charging Circuit
Fast Speed ON Between (8) and Ground: Alternator (B) / Generating 26 to 30 V
Voltage
Fast Speed ON Between (9) and Ground: Battery Relay / Generating 26 to 30 V
Voltage
Fast Speed ON Between (10) and Ground: Fuse Box / Generating Voltage 26 to 30 V
Fast Speed ON Between (12) and Ground: Monitor Unit (C7) 13 to 30 V
Surge Voltage
Prevention Circuit
Idle Speed ON Between (8) and Ground: Alternator (B) 26 to 30 V
Idle Speed ON Between (13) and Ground: Load Damp Relay 26 to 30 V
Idle Speed ON Between (9) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (14) and Ground: Auxiliary 20 to 25 V
Stopped ON Between (15) and Ground: Cigarette Lighter 20 to 25 V
Stopped ON Between (16) and Ground: Radio, Cab Light 20 to 25 V
Stopped ON Between (17) and Ground: Battery Relay 20 to 25 V
T5-8-10
TROUBLESHOOTING / Electrical System Inspection
Power Source Circuit
Preheat Circuit
Charging Circuit
Surge Voltage Prevention Circuit
Accessory Circuit
Key Switch
Battery
1 2 3 5 4 17 10
Starter 9
B
C
13 Load Damp
Relay
B
Fuse
S Box
E
Starter R 16 15 14
Relay 1
Alternator 12
Glow Plug C7
B Relay
L
8
7
Glow Plug
T5-8-11
TROUBLESHOOTING / Electrical System Inspection
NOTE: *Before measurement, disconnect the negative cable from the battery.
T5-8-12
TROUBLESHOOTING / Electrical System Inspection
Starting Circuit
Key Switch
Starter Cut
19 20 Relay
26
18
Battery
Battery 25
Relay
Starter
21
22 24
23
Starter R
Relay 1
27
C7
ECM Main
Relay
31
28
32
ECM MC Monitor
Unit A7
B16
1-24
30 29
T1R7-05-08-002
T5-8-13
TROUBLESHOOTING / Electrical System Inspection
NOTE: *Before measurement, disconnect the negative cable from the battery.
T5-8-14
TROUBLESHOOTING / Electrical System Inspection
33
#6
Battery
Battery
Relay
Starter
Fuse
Box
Starter
Relay 1
Security
Pilot
Relay 37
Shut-Off
Lever
Pilot
Shut-Off
Relay
36
35 34
Pilot
Shut-Off
Solenoid
Valve
T1R7-05-08-003
T5-8-15
TROUBLESHOOTING / Electrical System Inspection
5-Voltage Circuit
Power Signal or
Voltage between terminal #1 and the body Two Polarities Source Ground
Disconnect the connector with the key switch OFF. 1 2
Measure voltage between terminal #1 on the body
harness end connector and the body (ground).
Key switch: ON
Tester black terminal (negative):
Connected to the body (ground) V
Tester red terminal (positive):
Connected to terminal #1
Evaluation:
T107-07-05-006
If the measuring voltage is within 5 0.5 volts, the
Power
circuit up to terminal #1 is normal. Three Polarities
Source Signal Ground
1 2 3
V
Voltage between terminal #1 and the ground
terminal
Disconnect the sensor connector with the key
switch OFF. T107-07-05-007
Key switch: ON
Tester black terminal (negative): V
Connected to the ground terminal
(terminal #2 or #3)
Tester red terminal (positive):
Connected to terminal #1
Evaluation: T107-07-05-008
If the measured voltage is within 5 0.5 volt, the
circuit up to terminal #1 or the ground terminal Three Polarities
(terminal #2 or #3) is normal. 1 2 3
T107-07-05-009
T5-8-16
TROUBLESHOOTING / Electrical System Inspection
CHECK BY FALSE SIGNAL
Two Polarities
Turn the key switch OFF. Disconnect the sensor con- (Hydraulic Oil Tem-
nector. Turn the key switch ON. Connect terminal #1 perature Sensor)
1 2
(power source) of the body harness end connector to
terminal #2 (signal). (Power voltage is used as a false
signal.) Check this state by using the monitor function
of Dr. ZX. When the maximum value is displayed, MC
and the circuit up to the body harness end connector
are normal. If ON is displayed, the pressure switch
circuits are normal. Connect
connector.
(Pressure Sensor)
(Pump Delivery Pressure Sensor)
NOTE: Some kinds of sensors can be monitored (Pump Control Pressure Sensor) 1 2 3
by the service mode of the monitor (the
built-in diagnosing system). (Refer to
TROUBLESHOOTING / Diagnosing Pro-
cedure.)
Connect
T107-07-05-011
T5-8-17
TROUBLESHOOTING / Electrical System Inspection
TEST HARNESS
Connect a test harness between the connectors.
Check the circuit condition depending on whether the
test harness lamp lights or extinguishes during opera-
tion.
T107-07-06-015
Parts Number (ST 7226)
T5-8-18
MEMO
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
MEMO
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
........................................................................................................................................................................
Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162
REPLY: