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TO THE READER
This manual is written for an experienced technician If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using Service Manual
Revision Request Form at the end of this man-
Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition Operation Manual of the Engine
to this manual. Parts Catalog of the Engine
Hitachi Training Material
The 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.
IN-01
INTRODUCTION
PAGE NUMBER
Example : T 1-3-5
This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury. Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights. NOTE:
To avoid injury and damage, be sure to use appropri- Indicates supplementary technical information or
ate lifting techniques and equipment when lifting know-how.
heavy parts.
IN-02
INTRODUCTION
UNITS USED
SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature C F C1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque Nm kgfm 1.0197 mL/rev cc/rev 1.0
Nm lbfft 0.7375
IN-03
INTRODUCTION
(Blank)
IN-04
SAFETY
RECOGNIZE SAFETY INFORMATION
001-E01A-0688
SA-688
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
SA-2
SAFETY
PREPARE FOR EMERGENCIES
004-E01A-0437
005-E01A-0438
SA-3
SAFETY
PROTECT AGAINST NOISE
006-E01A-0434
SA-434
INSPECT MACHINE
Inspect your machine carefully each day or shift by
walking around it before you start it to avoid
personal injury.
In the walk-around inspection be sure to cover all
points described in the PRE-START
INSPECTION chapter in the operators manual.
S007-E01A-0435
SA-435
SA-4
SAFETY
GENERAL PRECAUTIONS FOR CAB
SA-5
SAFETY
USE HANDHOLDS AND STEPS
008-E01B-0439
009-E01A-0378
SA-6
SAFETY
FASTEN YOUR SEAT BELT
010-E01A-0237
011-E01A-0426
SA-7
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
Inappropriate engine starting procedures may
cause the machine to runaway, possibly resulting in
serious injury or death.
Start the engine only when seated in the
operator's seat.
NEVER start the engine while standing on the
track or on ground.
Do not start engine by shorting across starter
terminals.
Before starting the engine, confirm that all control
levers are in neutral.
SA-084
012-E01B-0444
JUMP STARTING
machine.
S013-E01A-0032
SA-8
SAFETY
KEEP RIDERS OFF MACHINE
014-E01B-0379
SA-091
018-E01A-0481
SA-481
017-E01A-0491
SA-092
SA-9
SAFETY
DRIVE MACHINE SAFELY (WORK SITE)
SA-288
019-E05B-0090
SA-10
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.
Place the shift lever in neutral, and put the brake
switch in the P (parking brake) position.
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.
Stop the engine and remove the key from the key
switch.
Pull the pilot control shut-off lever to LOCK posi-
SA-278
tion.
Block both tires and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
Position the machine to prevent rolling.
Park a reasonable distance from other machines.
020-E01A-0270
SA-11
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
If any person is present near the machine when
backing or swinging the upperstructure, the
machine may hit or run over that person, resulting
in serious injury or death.
equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
USE A SIGNAL PERSON WHEN BACKING UP
IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a
signal person.
No machine motions shall be made unless
signals are clearly understood by both signalman SA-384
and operator.
Learn the meanings of all flags, signs, and
markings used on the job and confirm who has
the responsibility for signaling.
Keep windows, mirrors, and lights clean and in
good condition.
Dust, heavy rain, fog, etc., can reduce visibility.
As visibility decreases, reduce speed and use
proper lighting.
Read and understand all operating instructions in
the operators manual.
S021-E01A-0494
SA-12
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF
TIPPING MACHINE---SERIOUS OR FATAL
CRUSHING INJURIES WILL RESULT
To avoid tipping:
Be extra careful before operating on a grade.
Prepare machine operating area flat.
Keep the bucket low to the ground and close to
the machine.
Reduce operating speeds to avoid tipping or
slipping.
Avoid changing direction when traveling on
grades.
NEVER attempt to travel across a grade steeper
than 5 degrees if crossing the grade is
unavoidable. SA-562
S025-E01B-0495
SA-13
SAFETY
AVOID POWER LINES
029-E01A-0381
OBJECT HANDLING
032-E01A-0014
SA-14
SAFETY
PROTECT AGAINST FLYING DEBRIS
031-E01A-0432
SA-432
033-E07B-0093
SA-15
SAFETY
HANDLE FLUIDS SAFELYAVOID FIRES
034-E01A-0496
SA-019
SA-16
SAFETY
SAFETY TRANSPORTING
035-E06A-0395
SA-17
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
SA-18
SAFETY
If a maintenance procedure must be performed
with the engine running, do not leave machine
unattended.
If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
Never work under a machine raised by the boom.
Inspect certain parts periodically and repair or
replace as necessary. Refer to the section
discussing that part in the MAINTENANCE
chapter in the operators manual.
Keep all parts in good condition and properly
installed.
Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
When cleaning parts, always use nonflammable
SA-028
detergent oil. Never use highly frammable oil
such as fuel oil and gasoline to clean parts or
surfaces.
Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
Illuminate your work area adequately but safely.
Use a portable safety light for working inside or
under the machine.
Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
Sufficiently illuminate the work site. Use a
maintence work light when working under or SA-527
S500-E02B-0497
SA-037
SA-19
SAFETY
WARN OTHERS OF SERVICE WORK
SS2045102
502-E01A-0026
SA-026
SA-20
SAFETY
PREVENT PARTS FROM FLYING
503-E03A-0344
SA-344
SA-034
504-E01A-0034
521-E02A-0249
SA-21
SAFETY
PREVENT BURNS
Hot spraying fluids:
After operation, engine coolant is hot and under
pressure. Hot water or steam is contained in the
engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
To avoid possible injury from hot spraying water.
DO NOT remove the radiator cap until the engine
is cool. When opening, turn the cap slowly to the
stop. Allow all pressure to be released before
removing the cap. SA-039
505-E01B-0498 SA-225
S506-E01A-0019
SA-22
SAFETY
AVOID HIGH-PRESSURE FLUIDS
SA-292
507-E03A-0499
SA-044
SA-23
SAFETY
PREVENT FIRES
Check for Oil Leaks:
Fuel, hydraulic oil and lubricant leaks can lead to
fires.
Check for oil leaks due to missing or loose
clamps, kinked hoses, lines or hoses that rub
against each other, damage to the oil-cooler, and
loose oil-cooler flange bolts.
Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts.
Do not bend or strike high-pressure lines.
Never install bent or damaged lines, pipes, or SA-019
hoses.
Clean up Flammables:
Spilled fuel and oil, and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.
Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
SA-24
SAFETY
Check Key Switch:
If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
Always check key switch function before
operating the machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to
confirm that the engine stops.
If any abnormalities are found, be sure to repair
them before operating the machine.
S508-E02B-0019
SA-25
SAFETY
EVACUATING IN CASE OF FIRE
518-E02B-0393
SS-1510
509-E01A-0016
SA-016
SA-26
SAFETY
PRECAUTIONS FOR WELDING AND
GRINDING
Welding may generate gas and/or small fires.
Be sure to perform welding in a well ventilated
and prepared area. Store flammable objects in a
safe place before starting welding.
Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before
starting grinding.
After finishing welding and grinding, recheck that SA-818
SA-27
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
Avoid potentially toxic fumes and dust.
Do all such work outside or in a well-ventilated
area. Dispose of paint and solvent properly.
511-E01A-0029
512-E01C-0032
SA-28
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
If spilled onto skin, refrigerant may cause a cold
contact burn.
Refer to the freon container for proper use when
servicing the air conditioning system.
Use a recovery and recycling system to avoid
venting freon into the atmosphere.
Never let the freon stream make contact with the
skin.
SA-405
513-E01A-0405
S515-E01A-0309
SA-29
SAFETY
DISPOSE OF WASTE PROPERLY
S516-E01A-0226
S517-E01A-0435 SA-435
SA-30
SECTION AND GROUP SECTION 4 OPERATIONAL PER-
CONTENTS FORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
TECHNICAL MANUAL
Group 6 Adjustment
(Troubleshooting) SECTION 5 TROUBLESHOOTING
Group 1 General
Group 2 Component Layout
Group 3 Troubleshooting A
Group 4 Troubleshooting B
Group 5 Troubleshooting C
Group 6 Electrical System Inspection
Group 7 ICX
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Control System Group 5 Travel Device
Group 2 Hydraulic System Group 6 Signal Control Valve
Group 3 Electrical System Group 7 Steering Valve
All information, illustrations and speci- Group 8 Brake Valve
fications in this manual are based on Group 9 Transmission Control Valve
the latest product information available Group 10 Others (Upperstructure)
at the time of publication. The right is Group 11 Others (Undercarriage)
reserved to make changes at any time
without notice.
COPYRIGHT(C)2003
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
WORKSHOP MANUAL
SECTION 1 GENERAL INFORMATION SECTION 3 UNDERCARRIAGE
Group 1 Precautions for Disassem- Group 1 Swing Bearing
bling and Assembling Group 2 Travel Motor
Group 2 Tightening Torque Group 3 Center Joint
Group 3 Painting Group 4 Transmission
Group 4 Bleeding Air from Hydrau- Group 5 Axle
lic Oil Tank Group 6 Axle Lock Cylinder
SECTION 2 UPPERSTRUCTURE Group 7 Check Valve
Group 1 Cab (Axle Lock Cylinder)
Group 2 Counterweight Group 8 Propeller Shaft
Group 3 Main Frame SECTION 4 FRONT ATTACHMENT
Group 4 Pump Device Group 1 Front Attachment
Group 5 Control Valve Group 2 Cylinder
Group 6 Swing Device Group 3 Hose-Rupture Safety Valve
Group 7 Pilot Valve Group 4 Check Valve
Group 8 Pilot Shut-Off Valve (Blade/Stabilizer)
Group 9 Signal Control Valve SECTION 5 ENGINE
Group 10 Travel Shockless Valve
Group 11 Solenoid Valve
Group 12 Pilot Relief Valve
Group 13 Steering Valve
Group 14 Brake Valve
Group 15 Accumulator Charging Valve
Group 16 Transmission 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 Service Brake Function Check .................... T4-4-2
Parking Brake Function Check .................... T4-4-3
Group 2 Standard Swing Speed ................................................ T4-4-4
Operational Performance Swing Function Drift Check ......................... T4-4-5
Standard Table............................................T4-2-1 Swing Motor Leakage .................................. T4-4-6
Main Pump P-Q Diagram .............................T4-2-6 Maximum Swingable Slant Angle ................ T4-4-7
Injection Pump..............................................T4-2-8 Swing Bearing Play...................................... T4-4-8
Dr.ZX Monitor Indicating Hydraulic Cylinder Cycle Time................... T4-4-10
Values .........................................................T4-2-9 Dig Function Drift Check............................ T4-4-12
Sensor Activating Range ............................T4-2-14 Control Lever Operating Force .................. T4-4-14
Control Lever Stroke .................................. T4-4-15
Group 3 Engine Test Combined Boom Raise/Swing
Engine Speed ...............................................T4-3-1 Function Check ........................................ T4-4-16
Engine Compression Pressure ....................T4-3-4
Valve Clearance Adjustment ........................T4-3-6
Nozzle Check ...............................................T4-3-8
Injection Timing ..........................................T4-3-10
Lubricant Consumption ..............................T4-3-12
CCBT-4-1
Group 5 Component Test
Primary Pilot Pressure..................................T4-5-1
Secondary Pilot Pressure.............................T4-5-4
Solenoid Valve Set Pressure........................T4-5-6
Main Pump Delivery Pressure......................T4-5-9
Main Relief Valve Set Pressure..................T4-5-10
Relief Pressure (When relieving Swing) ....T4-5-13
Relief Pressure (When relieving Travel) ....T4-5-14
Overload Relief Valve Set Pressure...........T4-5-15
Main Pump Flow Rate Measurement.........T4-5-18
Regulator Adjustment .................................T4-5-22
Swing Motor Drainage................................T4-5-25
Travel Motor Drainage................................T4-5-27
Steering Valve Relief Valve Set Pressure ..T4-5-30
Brake Pressure (Front and Rear)...............T4-5-32
Brake Accumulate Pressure.......................T4-5-34
Brake Warning Set Pressure (Decrease)...T4-5-36
Brake Warning Set Pressure (Increase) ....T4-5-38
Group 6 Adjustment
Engine Speed Adjustment and Engine
Learning......................................................T4-6-1
Governor Lever and Fuel Cut Lever
Position .......................................................T4-6-4
CCBT-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 300 m (984 ft 3 in), and to
make a full swing with the front attachment ex-
tended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to T105-06-01-003
T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE
STANDARD TABLE
The standard Performance values are listed in the Engine Control Dial : Fast Idle
table below. Refer to the Group T4-3 to T4-5 for Power Mode Switch : P Mode
performance test procedures. Values indicated in Auto-Idle/Acceleration Selector : OFF
parentheses are reference values. Work Mode Switch : Digging Mode
Engine Speed Control Mode Selection Switch:
The following switch positions shall be selected and Dial Mode
the hydraulic oil temperature shall be maintained as Hydraulic Oil Temperature : 505 C (1229 F)
indicated below as the preconditions of performance
tests unless otherwise instructed in each performance
test procedure: NOTE: 1 mm=0.03937 in
ZAXIS180W
Reference
PERFORMANCE TEST DESIGNATION Performance Remarks
Page
Standard
ENGINE SPEED min
-1
T4-3-1
Slow Idle Speed 950+150-100 Value indicated on Dr. ZX.
Fast Idle Speed (P mode) 200050
Fast Idle Speed (P mode Wirh ECO
2150+80-20
deactivated)
Extend the arm cylinder to
Fast Idle Speed (P mode and Relief relieve the arm roll-in
2000+80-20
Operation) circuit.Value indicated on Dr.
ZX.
Fast Idle Speed (E mode) 195070 Value indicated on Dr. ZX.
Extend the arm cylinder to
Fast Idle Speed (HP mode and Relief relieve the arm roll-in
2100 to 2350
Operation) circuit.Value indicated on Dr.
ZX.
Shift Lever: D or L.
Brake Swithch: OFF or Axle
Slow Idle Speed (Pedal Mode) 2100+150-100
Lock.
Value indicated on Dr. ZX.
Shift Lever: N.
Fast Idle Speed (Pedal Mode With Work
220050 Brake Swithch: S.
Brake)
Value indicated on Dr. ZX.
Shift Lever: D.
Brake Swithch: OFF or Axle
Fast Idle Speed (Pedal Mode and Relief Lock. Machine jacked up.
220050
Operation) Keep brake pedal depressed
for travel operation.
Value indicated on Dr. ZX.
Auto-Idle Speed 1200100 Value indicated on Dr. ZX.
Auto-Acceleration Speed 1750100
Warming Up Speed 1150100
ENGINE COMPRESSION PRESSURE After engine warm-up T4-3-4
3.04 (31,440)
(After engine warm-up) 2
MPa (kgf/cm , psi)
VALVE CLEARANCE (IN, EX) 0.4 With the engine cold T4-3-7
NOZZLE INJECTION PRESSURE T4-3-8
2 18.14 (185, 2640)
MPa (kgf/cm , psi)
INJECTION TIMING T4-3-10
9
(Degrees before TDC) deg.
T4-2-1
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZAXIS180W
Reference
PERFORMANCE TEST DESIGNATION Performance Remarks
Page
Standard
LUBRICANT CONSUMPTION Hour meter: 1000 hours or
48 or less T4-3-12
(Rated output) mL/h less
TRAVEL SPEED km/h(100 m) T4-4-1
Engine speed control mode
Fast Speed 27.52.0 selection switch: Pedal
Shift Lever: D
Engine speed control mode
Slow Speed 7.20.5 selection switch: Pedal
Shift Lever: L
Engine speed control mode
Creeper 3.30.3 selection switch: Creeper
Shift Lever: L
TRAVEL SPEED (for Germany) km/h(100 m) T4-4-1
Engine speed control mode
Fast Speed 20.02.0 selection switch: Pedal
Shift Lever: D
Engine speed control mode
Slow Speed 5.20.5 selection switch: Pedal
Shift Lever: L
Engine speed control mode
Creeper 2.60.3 selection switch: Creeper
Shift Lever: L
SERVICE BRAKE FUNCTION CHECK T4-4-2
m
Braking distance at travel speed of 27.5
10.6 or less
km/h
Braking distance at travel speed of 20
6.4 or less
km/h
PARKING BRAKE FUNCTION CHECK T4-4-3
mm/5 min
0
T4-2-2
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZAXIS180W
Reference
PERFORMANCE TEST DESIGNATION Performance Remarks
Page
Standard
HYDRAULIC CYLINDER CYCLE TIME 0.70 m3 (PCSA heaped) T4-4-10
sec bucket, bucket empty.
Mono boom with 2.70 m arm.
2 piece boom with 2.70 m
arm.
Boom Raise (Mono Boom) 3.50.3
Boom Raise (2 Piece Boom) 3.50.3
Boom Lower (Mono Boom) 2.80.3
Boom Lower (2 Piece Boom) 3.00.3
Arm Roll-In 3.50.3
Arm Roll-Out 3.00.3
Bucket Roll-In 2.80.3
Bucket Roll-Out 2.10.3
Positioning Raise 5.80.5
Positioning Lower 3.40.3
Stabilizer Raise 1.80.3
Stabilizer Lower 1.90.3
Blade Raise 1.90.5
Blade Lower 2.00.5
DIG FUNCTION DRIFT CHECK mm/5 min 0.70 m3 (PCSA heaped) T4-4-12
bucket, bucket empty.
Mono boom with 2.70 m arm.
2 piece boom with 2.70 m
arm.
Boom Cylinder
15 or less Bucket loaded
(Maximum Reach Position)
Arm Cylinder
20 or less Bucket loaded
(Maximum Reach Position)
Bucket Cylinder
20 or less Bucket loaded
(Maximum Reach Position)
Positioning Cylinder
(Maximum Reach Position) 10 or less Bucket loaded
T4-2-3
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZAXIS180W
Reference
PERFORMANCE TEST DESIGNATION Performance Remarks
Page
Standard
CONTROL LEVER STROKE mm T4-4-15
Right Hand Lever: Forward/Backward 7410
Right Hand Lever: Right/Left 6210
Left Hand Lever: Forward/Backward 7410
Left Hand Lever: Right/Left 6210
Steering Wheel Turns (lock-to-lock) 5.70.5
COMBINED BOOM RAISE/SWING sec 0.70 m3 (PCSA heaped) T4-4-16
bucket, bucket empty.
3.80.3
2 piece boom with 2.70 m
arm. bucket empty
(Bucket Teeth Height: H) mm 4500 or more
PRIMARY PILOT PRESSURE T4-5-1
(Brake Pilot Pressure) 2
MPa (kgf/cm , psi)
Engine: Fast Idle Accumulator pressure (when
4.5+1.0-0.5
charged): 15 (153, 2180) or
(46 -5, 654+145-73)
+10
higher.
SECONDARY PILOT PRESSURE) 3.3 to 3.9 (34 to Value indicated on Dr. ZX T4-5-4
(Engine: Fast Idle and Slow Idle) 40, 480 to 567) (Lever: Full stroke)
2
MPa (kgf/cm , psi) Travel, extra and blade/out-
riggers: 2.7 to 3.3 (28 to 34,
393 to 480)
SOLENOID VALVE SET PRESSURE Value Indicated On Value Indicated On Dr. ZX T4-5-6
2
MPa (kgf/cm , psi) Dr. ZX
[SE (Brake switch:
OFF): 3.7+1.0-0.5
(38+10-5, 538+145-73)]
MAIN PUMP DELIVERY PRESSURE 1.4 (14, 204) or Value indicated on Dr. ZX T4-5-9
2
MPa (kgf/cm , psi) less
MAIN RELIEF VALVE SET PRESSURE T4-5-10
2
MPa (kgf/cm , psi)
Boom, Arm, and Bucket 34.3+2.0-0.5 Value indicated on Dr. ZX
(350+20-5,
4980+290-73)
RELIEF PRESSURE 34.3+2.3-0 Value indicated on Dr. ZX T4-5-13
2
MPa (kgf/cm , psi)
(When Relieving Swing) (350+25-0,
4980+356-0)
RELIEF PRESSURE 34.8+2.0-0 Value indicated on Dr. ZX T4-5-14
2
MPa (kgf/cm , psi)
(When Relieving Travel) (355+20-0, Travel motor relief set pres-
sure: 40 (408, 5815)
5059+284-0)
RELIEF PRESSURE 2
MPa (kgf/cm , psi) 32.02.0 Value indicated on Dr. ZX
(When Relieving Stabilizer) (raise/lower) (32620,
4652291)
RELIEF PRESSURE 2
MPa (kgf/cm , psi) 32.02.0 Value indicated on Dr. ZX
(When Relieving Blade) (raise/lower) (32620,
4652291)
T4-2-4
OPERATIONAL PERFORMANCE TEST / Standard
NOTE: 1 mm=0.03937 in
ZAXIS180W Reference
PERFORMANCE TEST DESIGNATION Performance Remarks Page
Standard
OVERLOAD RELIEF VALVE SET PRES- (Reference values T4-5-15
SURE MPa (kgf/cm , psi) at 50 L/min)
2
T4-2-5
OPERATIONAL PERFORMANCE TEST / Standard
MAIN PUMP P-Q DIAGRAM
Main Pump 1
L/min Main Pump 2
Flow
Rate
MPa (kgf/cm2)
TCCB-04-02-001
Delivery Pressure
T4-2-6
OPERATIONAL PERFORMANCE TEST / Standard
Pilot Characteristics
(REFERENCE: Measured at Test Stand)
Main Pump P1 Max. Flow Rate
-1
Rated Pump Speed: 2200 min (rpm)
(This pump device is not equipped with a
Main Pump P2 Max. Flow Rate
transmission so that the pump speed is equal to
the engine speed. Therefore, measure the pump
flow rate with the engine running at the rated
pump speed.)
Flow
Hydraulic Oil Temperature: 505 C (1229 F) Rate
T4-2-7
OPERATIONAL PERFORMANCE TEST / Standard
INJECTION PUMP
Test Conditions:
1. Injection pump: PES4AD 101041-8950 7. Test fuel: ISO 4113 or SAE J967d
2. Governor: EP/RSV 105411-2470 8. Transfer pump pressure:
3. Nozzle and nozzle holder assembly: 157 kPa (1.6 kgf/cm2, 33 psi)
105780-8140 (Bosch No. EF8511/9A) 9. Injection pipe: Inner Dia. 2 mmOuter Dia. 6
4. Nozzle: 105780-0000 (Bosch No. DN12SD12T) mm-Length 600 mm (0.0790.236-23.6 in)
5. Nozzle holder: 105780-2080 10. Fuel temperature: 40+5 C (104+9 F)
(Bosch No. EF8511/9) 11. Overflow valve opening pressure:
6. Nozzle opening pressure: 255 kPa (2.6 kgf/cm2, 37 psi)
17.2 MPa (175 kgf/cm2, 2490 psi)
Governor adjustment
Rack Limit
Difference in Rack Posi-
-1
Idle-sub Spring Setting tion between 1100 min
-1
Above 14.0 and 550 min
Boost Compensator
Rack Position Stroke
(mm)
Governor Spring
Setting
-1
Pump Speed min (rpm)
T1F1-04-02-001
T4-2-8
OPERATIONAL PERFORMANCE TEST / Standard
Dr. ZX MONITOR INDICATING VALUES
Unless specified, test under the following conditions.
Engine Control Dial : Fast Idle
NOTE: Items marked ( ) are measurable with the
Power Mode Switch : P Mode built-in diagnosing system.
Auto-Idle/Acceleration Selector : OFF
Items marked ( ) are measurable with the
Work Mode Switch : Digging Mode
built-in diagnosing system. However, it
Engine Control Mode Selector Switch : Dial Mode
may be difficult to read the measured value
Hydraulic Oil Temperature : 505 C (1229 F)
while operating the machine.
T4-2-9
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-10
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-11
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-12
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-13
OPERATIONAL PERFORMANCE TEST / Standard
SENSOR ACTIVATING RANGE
1. Checking Method
T4-2-14
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary
1. Measure the engine speed using the built-in di- 2
agnosing system or Dr. ZX. If the built-in diag-
nosing system or Dr. ZX is not available, use an 1
engine speed meter or a pulse counter. (Refer to
the TROUBLESHOOTING / General group.)
2. Measure the engine speeds in each mode.
3
Preparation:
1. Select the monitor function of the built-in diag-
nosing system (In case of Dr. ZX, connect it first).
When using an engine speed meter, install speed
pickup (2) to injection pipe (1).
When using a pulse counter, disconnect the
N-sensor connector.
2. Warm up the machine until the engine coolant
temperature reaches 50 C (122 F) or more, and
hydraulic oil is 505 C (1229 F).
T4-3-1
OPERATIONAL PERFORMANCE TEST / Engine Test
Measurement: Evaluation:
1. Check engine speeds for auto-warm up (when Refer to T4-2 Operational Performance Standard.
starting the engine), auto-idle, slow idle, fast idle
(when normal), fast idle (when the ECO is deac- Remedy:
tivated), fast idle (in the E mode), fast idle (in the Refer to T5-4 Troubleshooting B.
HP mode) and, slow idle (in the pedal mode), fast
idle (in the pedal mode with work brake) and fast NOTE: ECO stands for the auto engine speed re-
idle in the pedal mode and relief operation. duction system by 100 min-1.
2. Select the switch positions and the test condi-
tions corresponding to the engine speed to be
measured as shown in the table below.
3. When using the pulse counter, read the pulse
counter. Calculate the engine speed using the
following formula: Engine Speed (min-1) =
Pulse Numbers (Hz) 60 / 32
T4-3-2
OPERATIONAL PERFORMANCE TEST / Engine Test
Jacking Up:
Raise the undercarriage with the stabilizer and blade
provided at the front and rear of the undercarriage.
Work Mode
Switch
Power Mode
Switch
Auto-Idle/Acceleration
Selector
MCBB-01-012
MCBB-01-014
T4-3-3
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders
to check for a decline in engine power.
2. Check exhaust gas color. Keep track of engine oil
consumption.
3. Check for abnormalities in the intake system, in-
cluding the air filter.
Preparation:
1. Confirm that valve clearances are correct.
2. Confirm that the batteries are charged properly.
3. Run the engine until the coolant temperature
gauge reaches the operating range.
4. Stop the engine. Remove glow plugs from each
cylinder.
Measurement:
1. Turn the starter to crank the engine. Record the
compression pressure of each cylinder.
2. Repeat measurement three times for each cylin-
der and calculate the mean values.
Evaluation:
Refer to T4-2 Operational Performance Standard.
Remedy:
Refer to engine shop manual.
T4-3-4
OPERATIONAL PERFORMANCE TEST / Engine Test
(Blank)
T4-3-5
OPERATIONAL PERFORMANCE TEST / Engine Test
VALVE CLEARANCE ADJUSTMENT
Summary:
1. Perform the measurement when the engine is
cold.
2. Before starting work, clean the head cover
mounting area to avoid contamination in the en-
gine.
Preparation:
1. Locate the top dead center (TDC) in the com-
pression stroke. Top Mark
Align the TDC mark on the crank pulley with the
pointer located on the timing gear case as illus-
TDC Mark
trated. Piston No.1 (or piston No.4) is now posi-
tioned at the TDC in its compression stroke.
Timing Gear
Case
NOTE: When rotating the crank pulley, remove the
fan guard. Then, rotate the fan while hold- Crank Pulley
ing the fan belt. If it is difficult to rotate,
remove all glow plugs to release the com-
pression pressure.
T157-05-02-002
2. Remove the head cover.
3. Move push rods for the intake and exhaust
valves on the No.1 cylinder up and down by hand.
If any clearances on the both ends of the push
rods are found, piston No.1 is positioned at TDC
in the compression stroke. (If the exhaust valve
of cylinder No.1 is pushed down, piston No.4 is
positioned at TDC in the compression stroke.
Start measurement from the cylinder (No.1 or
No.4) positioned at TDC in the compression
stroke.
T4-3-6
OPERATIONAL PERFORMANCE TEST / Engine Test
Measurement:
1. Insert a thickness gauge into the clearance be-
tween the rocker arm and the valve stem end to
measure the valve clearance.
Evaluation:
Refer to T4-2 Operational Performance Standard.
Adjustment:
If the measurement results are out of specification,
adjust the valve clearance in the same order of
measurement.
T4-3-7
OPERATIONAL PERFORMANCE TEST / Engine Test
NOZZLE CHECK
Summary:
1. Check the injection pressure and the spray pat-
tern with a nozzle tester.
2. Before starting work, clean the nozzle holder
mounting area to avoid contamination in the en-
gine.
Preparation:
1. Remove the nozzle holders.
Remove all nozzle holders and fuel injection pip-
ings from the engine.
2. Attach a nozzle holder to the nozzle tester.
Measurement:
CAUTION: Never touch spray directly. The
fuel spray from the nozzle may penetrate the
skin, resulting in serious injury. If fuel pene-
trates into the blood stream, it may cause
blood toxication.
1. Injection pressure
After attaching the nozzle holder to the nozzle
tester, strongly make several strokes of the tester
to inject fuel. Then, while operating the tester at T107-06-02-006
approx. 60 time strokes a minute, measure the
fuel injection pressure.
If adjustment is required, loosen the lock nuts
and adjust the adjusting screws. Turn clockwise
to increase the pressure, and counterclockwise
to decrease the pressure.
2. Spray pattern
For this test, turn the pressure tester knob to by-
pass the pressure gauge. Attach the nozzle
holder to the nozzle tester. Strongly make several
strokes of the tester and check the fuel spray pat-
tern.
3. Oil tight condition
Keep the pressure slightly below the injection
pressure. Check for fuel leak from around the
nozzle tip.
T4-3-8
OPERATIONAL PERFORMANCE TEST / Engine Test
Evaluation:
1. Standard Injection Pressure:
Normal
Refer to T4-2 Operational Performance Standard.
2. Spray Pattern
Large-size spray should not be visible to the na-
ked eye.
No stray sideways sprays should be seen.
During initial injection stage, spray size should be
fine and injected intermittently.
There should be no drips found.
Injection spray angle must be normal.
3. Oil Tight Condition
No fuel leaks.
T102-02-11-005
Abnormal
Adjustment:
1. To adjust the injection pressure, loosen the lock
nuts. Adjust the adjusting screw. T102-02-11-006
T107-06-02-007
T4-3-9
OPERATIONAL PERFORMANCE TEST / Engine Test
INJECTION TIMING
Timing Mark
Inspection:
1. Position No.1 piston to the top dead center. Turn Top Mark
the crank pulley in the direction of rotation (clock-
wise as seen from the front of the engine) to set a
TDC Mark
TDC mark on the crank pulley under the Top
mark, located on the timing gear case.
Timing Gear
Case
NOTE: When rotating the crank pulley, remove the
fan guard. Then, rotate the fan while hold- Crank Pulley
ing the fan belt. If it is difficult to rotate,
remove all glow plugs to release the com-
pression pressure.
T157-05-02-002
2. Remove the timing check hole cover on the front
section of the fuel injection pump. Gear Case
Projection
When the mark on the injection pump is set un-
der the projection of the gear case, No.1 piston is
positioned at the top dead center. If the mark is
not set under the projection, keep turning to ad-
just. Check
Hole
4. Remove the delivery valve holder for No.1 cylin- Gear Case
der from the injection pump to pull the delivery Projection
valve and the spring out. Reinstall the delivery
valve holder.
: 39 to 44 Nm
(4 to 4.5 kgfm, 28.9 to 32.6 lbfft)
Injection Pump
Alignment Mark T107-02-12-008
T4-3-10
OPERATIONAL PERFORMANCE TEST / Engine Test
5. Turn the crank pulley at approx. 30 degrees
counterclockwise.
6. While supplying fuel with the feed pump, turn the
crank pulley slowly clockwise just until fuel can-
not be seen from the top of the delivery valve
hole. This is the position where the injection
starts.
7. Check the TDC mark, located on the crank pul-
ley for what degrees the TDC mark indicates.
Adjustment:
1. Turn the crank pulley so that the TDC mark
comes just above the correct timing position on
the timing gear case.
2. Loosen the mounting nuts of the injection pump.
3. When advancing timing, tilt the injection pump
outward against the cylinder block. T107-02-12-009
T4-3-11
OPERATIONAL PERFORMANCE TEST / Engine Test
LUBRICANT CONSUMPTION
Measuring Method
1. Place the machine on level firm ground, and
leave it for at least one hour to let the lubricant
lower to the oil pan.
At this time, confirm that the machine is level,
using a leveler.
2. Record the read-out A (unit: hour) of the hour
meter.
3. Replenish the lubricant up to the high-level
gauge.
4. Operate the machine for at least 100 hours or un-
til the oil level lowers to the low-level gauge.
Evaluation:
Refer to T4-2 Operational Performance Standard.
T4-3-12
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary: Evaluation:
1. Measure the time required for the machine to Refer to the Performance Standard Table in Group
travel a 100 m (328 ft) test track. T4-2.
Preparation: Remedy:
Refer to the Troubleshooting B in Group T5-4.
CAUTION: Be sure to place the swing lock
lever to the LOCK position before traveling.
T4-4-1
OPERATIONAL PERFORMANCE TEST / Excavator Test
SERVICE BRAKE FUNCTION CHECK
Summary:
1. Determine the collective capacity of the hydraulic
pressure circuit, master cylinder and service
brake.
2. The braking capacity test is the maintenance item.
Be sure to perform the capacity test.
Preparation:
CAUTION: Be sure to place the swing lock
lever to the LOCK position before traveling.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-2
OPERATIONAL PERFORMANCE TEST / Excavator Test
PARKING BRAKE FUNCTION CHECK
Summary:
1. Measure the parking brake function on the speci-
fied slope.
2. The braking capacity test is the maintenance item.
Be sure to perform the capacity test.
Preparation:
1. Prepare a flat and solid test slope of 11.31.
2. Position front attachment for travel as instructed
in Operators Manual.
3. Maintain hydraulic oil temperature at 505 C
(1229 F).
Measurement:
1. Climb up the slope, then move the brake switch
to the parking position.
2. Stop the engine. T1F3-04-04-005
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-3
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING SPEED
Summary:
1. Measure the time required to swing three com-
plete turns.
Preparation:
1. Check the lubrication of the swing gear and
swing bearing.
2. Place the machine on flat, solid ground with am-
ple space for swinging. Do not conduct this test
on a slope.
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. The bucket must
be empty. The same height as
the boom foot pin.
4. Maintain the hydraulic oil temperature at 505 C
(1229 F). T1F3-04-04-006
Measurement:
1. Select the following switch positions:
Auto-Idle/
Engine Con- Power Mode Work Mode
Acceleration Brake Switch
trol Dial Switch Switch
Selector
Fast Idle P Digging OFF S (Working)
2. Operate swing control lever fully.
3. Measure the time required to swing 3 turns in
one direction.
4. Operate swing control lever fully in the opposite
direction and measure the time required for 3
turns.
5. Repeat steps 2. to 4. three times and calculate
the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-4
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING FUNCTION DRIFT CHECK
Summary:
1. Measure the swing drift on the bearing outer cir-
cumference when stopping after a 90 full-speed
swing.
Preparation:
1. Check the lubrication of the swing gear and
swing bearing.
2. Place the machine on flat, solid ground with am-
ple space for swinging. Do not conduct this test
on a slope.
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is Two Check Marks T202-07-03-005
the same as the boom foot pin. The bucket must Start the test from the position where the
be empty. upperstructure is rotated 90.
4. Make two chalk marks: one on the swing bearing
and one directly below it on the chassis frame.
5. Swing the upperstructure 90.
6. Maintain the hydraulic oil temperature at 505 C
(1229 F).
CAUTION: Prevent personal injury. Always
make sure that the area is clear and that
co-workers are out of the swing area before
starting the measurement.
Measurement: T1F3-04-04-007
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-5
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING MOTOR LEAKAGE
Summary:
1. Check for upperstructure drift while suspending a
load on a slope.
Preparation:
1. Check the lubrication of the swing gear and
swing bearing.
2. Park the machine on a smooth slope with a
gradient of 26.8 %(15)
3. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
W=1050 kg (2320 lb)
4. With the arm rolled out, and bucket rolled in,
position the arm top pin height to be level with the
boom foot pin.
5. Swing the upperstructure to position it 90 to the
slope. Make aligning marks on the swing bearing
periphery and chassis frame using tape, as T212-07-03-001
illustrated.
6. Maintain the hydraulic oil temperature at 505 C
(1229 F).
Measurement:
1. Select the following switch position:
Auto-Idle/
Engine Con- Power Mode Work Mode Brake
Acceleration
trol Dial Switch Switch Switch
Selector
Slow Idle P Digging OFF S (Working)
2. Maintain the engine at slow idle. After five
minutes, measure the difference between the
marks along the swing bearing periphery and the
chassis frame.
3. Perform the measurement in both right and left Measure Difference Between Marks
swing directions.
4. Perform the measurement three times in each
direction and calculate the average values.
Evaluation:
Refer to the Performance Standard Table in Group Marking on the Chassis Frame
T4-2.
Marking on the Swing Bearing
Remedy:
Refer to the Troubleshooting B in Group T5-4. T105-06-03-010
T4-4-6
OPERATIONAL PERFORMANCE TEST / Excavator Test
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
1. With the upperstructure swung 90 to the slope,
check the maximum slant angle on which the
upperstructure can swing to the uphill side.
Preparation:
1. Check that the swing gear and bearing are well
lubricated.
2. Load bucket fully, In lieu of loading the bucket,
weight (W) of the following specification used.
W=1050 kg (2320 lb)
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin.
4. Climb a slope and swing the upperstructure 90
to the slope.
5. Maintain the hydraulic oil temperature at 505 C
(1229 F).
T212-07-03-001
Measurement:
1. Select the following switch positions:
Auto-Idle/
Engine Con- Power Mode Work Mode
Acceleration Brake Switch
trol Dial Switch Switch
Selector
Fast Idle P Digging OFF S (Working)
2. Operate the swing lever to full stroke to swing the
upperstructure to the uphill side.
3. If the machine can swing, measure the cab floor
slant angle.
4. Increase the slope angle and repeat steps 2. and
3. Check both clockwise and counterclockwise.
5. Perform the measurement three times.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-7
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING BEARING PLAY
Summary:
1. Measure the swing bearing play using a dial
Dial Gauge
gauge to check the wear of bearing races and
balls.
Preparation:
1. Check swing bearing mounting bolts for loose-
ness.
2. Check the lubrication of the swing bearing. Con-
firm that bearing rotation is smooth and without
noise.
3. Install a dial gauge on the chassis frame as
shown, using a magnetic base. Magnetic
4. Position the front attachment to the front of the Base
machine.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race. T202-07-03-008
Measurement:
1. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. Record the dial
gauge reading (h1). Round Frame
2. Lower the bucket to the ground and use it to Chassis
raise the front tires 0.5 m (20 in). Record the dial
gauge reading (h2).
3. Calculate bearing play (H) from this data (h1 and
h2) as follows: Magnetic Dial Gauge T105-06-03-015
H = h2 h1 Base
The same
height as the
boom foot pin
height.
T1F3-04-04-008
T212-07-05-003
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-8
OPERATIONAL PERFORMANCE TEST / Excavator Test
(Blank)
T4-4-9
OPERATIONAL PERFORMANCE TEST / Excavator Test
HYDRAULIC CYLINDER CYCLE TIME
Summary:
1. Measure the cycle time of the boom, arm, bucket,
positioning (if equipped), blade (optional) and Boom Cylinder:
stabilizer (optional) cylinders.
2. The bucket should be empty.
Preparation:
1. Be sure to measure at the position as follows.
To measure the cycle time of the boom cylinders:
With the arm rolled out and the empty bucket
rolled in, lower the bucket to the ground, as T1F3-04-04-009
shown. Arm Cylinder:
To measure the cycle time of the arm cylinder:
With the empty bucket rolled in, position the arm
so that it is vertical to the ground. Lower the
boom until the bucket is 0.5 m (20 in) above the
ground.
To measure the cycle time of the bucket cylinder:
The empty bucket should be positioned at 0.5 m
mid-stroke between roll-in and roll-out, so that
the sideplate edges are vertical to the ground.
To measure the cycle time of the positioning
T1F3-04-04-010
Bucket Cylinder:
cylinder: With the boom raise, arm rolled out and
the empty bucket rolled in, as shown.
To measure the cycle time of the blade cylinder:
Lower the bucket to the ground and use it to lift
the machine to allow the blade cylinder to move
fully upwards and downwards.
To measure the cycle time of the stabilizer
cylinder:
Lower the bucket to the ground and use it to lift
the machine to allow the stabilizer cylinder to
move fully upwards and downwards.
T1F3-04-04-002
T4-4-10
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement: Evaluation:
1. Select the following switch positions: Refer to the Performance Standard Table in Group
Auto-Idle/ T4-2.
Engine Con- Power Mode Work Mode
Acceleration
trol Dial Switch Switch
Selector Remedy:
Fast Idle P Digging OFF Refer to the Troubleshooting B in Group T5-4.
2. To measure cylinder cycle times:
(Cylinder full stroke includes cylinder cushioning
zone.)
Boom cylinders:
Measure the time it takes to raise the boom, and
the time it takes to lower the boom. To do so,
position the boom at one stroke end, then move
the control lever to the other stroke end as
quickly as possible.
Arm cylinder:
Measure the time it takes to roll in the arm, and
the time it takes to roll out the arm. To do so,
position the arm at one stroke end, then move
the control lever to the other stroke end as
quickly as possible.
Bucket cylinder:
Measure the time it takes to roll in the bucket,
and the time it takes to roll out the bucket. To do
so, position the bucket at one stroke end, then
move the control lever to the other stroke end as
quickly as possible.
Positioning cylinder:
Measure the time it takes to raise the positioning,
and the time it takes to lower the positioning. To
do so, position the positioning at one stroke end,
then move the control pedal to the other stroke
end as quickly as possible.
Blade Cylinder:
Measure the time it takes to raise the blade, and
the time it takes to lower the blade. To do so,
position the blade at one stroke end, then move
the control lever to the other stroke end as
quickly as possible.
Stabilizer Cylinder:
Measure the time it takes to raise the stabilizer,
and the time it takes to lower the stabilizer. To do
so, position the stabilizer at one stroke end, then
move the control lever to the other stroke end as
quickly as possible. Move stabilizer cylinders, if
provided at front and/or rear on both sides, one
by one to measure each cycle time.
3. Repeat each measurement three times and
calculate the average values.
T4-4-11
OPERATIONAL PERFORMANCE TEST / Excavator Test
DIG FUNCTION DRIFT CHECK
Preparation:
1. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used. W=1050 kg (2320 lb)
Retracted
2. Position the arm cylinder with the rod 50 mm (2 Distance
in) extended from the fully retracted position.
3. Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position.
4. Position the positioning cylinder with the rod 50
mm (2 in) retracted from the fully extended
position.
5. With the arm rolled out and the bucket rolled in, T1F3-04-04-001
Measurement:
1. Stop the engine. Mark
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the bucket and positioning, as well as the
boom, arm and bucket cylinders.
3. Repeat step 2. three times and calculate the
average values.
T110-06-03-001
Evalution:
Boom, Bucket and Positioning Cylinder Retraction
Refer to the Operational Performance Standard in
Group T4-2. Mark Mark
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T110-06-03-002
T4-4-12
OPERATIONAL PERFORMANCE TEST / Excavator Test
(Blank)
T4-4-13
OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER OPERATING FORCE
Summary:
1. Check the operation of each control lever and the
steering wheel, and measure their operating
force.
2. Measure the maximum operating force of the
control lever for the front attachment and the
steering wheel.
3. Measure the force at the center of the control
lever grip.
Preparation:
Maintain the hydraulic oil temperature at 505 C
(1229 F). T107-06-03-003
Measurement:
1. Measure the force at steering wheel and each
control lever.
MCBB-01-022
2. Select the following switch positions:
Auto-Idle/
Engine Con- Power Mode Work Mode
Acceleration
trol Dial Switch Switch
Selector
Fast Idle P Digging OFF
3. Operate each boom (raise), arm and bucket lever
to the fully and measure the maximum operating
force for each with each actuator relieved.
4. Operate boom (lower) lever and measure the
maximum operating force with the boom (lower)
relieved by jacking up the machine in a safe
area.
5. Operate swing lever and measure the maximum
operating force with swing relieved after securing
the front attachment to prevent swinging.
6. To measure the steering wheel, attach the spring
scale on the knob and measure the maximum
operating force when moving the steering wheel.
7. Repeat steps 3. to 6. three times and calculate
the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-14
OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER STROKE
Summary:
1. Measure each lever stroke at the lever top using
a ruler.
Stroke 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.
Neutral
Preparation:
Maintain the hydraulic oil temperature at 505 C
(1229 F). T1F3-04-04-012
Measurement:
1. Stop the engine.
2. Measure each lever stroke at the lever top from
neutral to the stroke end using a ruler.
3. For steering, measure the rotation frequency
necessary for the right to left stroke end or vice
versa.
4. Repeat step 2. to 3. three times and calculate the
average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-15
OPERATIONAL PERFORMANCE TEST / Excavator Test
COMBINED BOOM RAISE / SWING FUNC-
TION CHECK
Summary:
1. Check boom raise and swing movement and
speeds while operating both functions
simultaneously.
2. Make sure that the cylinders dont hesitate while
operating the cylinder with the engine running at
fast idle.
Preparation:
1. With the arm fully rolled out and bucket fully
rolled in, lower the bucket to the ground. The
bucket must be empty. T212-07-03-005
Measurement:
1. Select the following switch positions:
T212-07-03-006
Auto-Idle/
Engine Con- Power Mode Work Mode
Acceleration
trol Dial Switch Switch
Selector
Fast Idle P Digging OFF
2. Raise the boom and swing simultaneously, both
at full stroke.
3. When the upperstructure rotates 90, release the
control levers to stop both functions. Measure the
time required to swing 90 and the height (H) of
the bucket teeth. (The bucket must be empty.)
4. Repeat steps 2. to 3. three times and calculate
the average values. H
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4. 90 T212-07-03-007
T4-4-16
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
(Including Brake Circuit)
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Disconnect the hose end from the pilot filter inlet or
outlet port Install tee 3/4-16UNF(ST 6477), fitting
(ST 6069), pressure gauge (ST 6314) and cou-
pling (ST 6332).
: 22 mm, 24 mm
Measurement:
1. Select the following switch positions:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Fast Idle P Digging OFF
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-5-1
OPERATIONAL PERFORMANCE TEST / Component Test
Primary Pilot Pressure Adjustment Procedure
T1F3-03-08-002
T4-5-2
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)
T4-5-3
OPERATIONAL PERFORMANCE TEST / Component Test
SECONDARY PILOT PRESSURE
Preparation:
1. Properly shut down the engine.
Signal Control Valve
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Measure pressure at the location between the
pilot valve and the signal control valve:
Disconnect the pilot circuit hose to be measured
from the signal control valve. Connect hose
(9/16-18UNF approx. 400 mm long) to the signal
control valve. Install tee (4351843), adapter (ST
6460) fitting (ST 6069), coupling (ST 6332) and
pressure gauge (ST 6315) between the hoses.
: 17 mm, 19 mm
T4-5-4
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Fast Idle P Digging OFF
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-5-5
OPERATIONAL PERFORMANCE TEST / Component Test
SOLENOID VALVE SET PRESSURE
Solenoid Valve Unit
Measure solenoid valve set pressure with both the
Dr.ZX and the pressure gauge.
SC SE SI SG
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Disconnect line (1) from the solenoid valve to be
measured. Install hose 7/16 ZOUNF (Parts Num-
ber: 4216453), tee (ST 6451), adapter (ST 6461),
and pressure gauge (ST 6942) to the dis-
connected end at the solenoid valve side, as il-
lustrated.
: 17 mm, 19 mm, 22 mm
T1F3-03-10-017
T4-5-6
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Fast Idle P Digging OFF
Slow Idle P Digging OFF
Evaluation:
Refer to the performance Standard Table in Group
T4-2.
T4-5-7
OPERATIONAL PERFORMANCE TEST / Component Test
Solenoid Valve Set Pressure Adjustment Proce-
dure 7
7 8
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-8
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN PUMP DELIVERY PRESSURE
The main pump delivery pressure can also be meas-
ured with Dr.ZX.
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install adapter G1/4 (ST 6069), hose (ST
6943) and pressure gauge (ST 6941) on the port.
: 6 mm
Measurement:
1. Select the following switch positions:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch T157-05-04-005
Selector
Fast Idle P Digging OFF
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-5-9
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN RELIEF VALVE SET PRESSURE
The main relief pressure can also be measured with
Dr.ZX.
Summary:
Measure the main relief valve setting pressure at the
main pump delivery port.
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install adapter G1/4 (ST 6069), hose (ST
6943) and pressure gauge (ST 6941) on the port.
: 6 mm
T157-05-04-005
T4-5-10
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Fast Idle P Digging OFF
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-5-11
OPERATIONAL PERFORMANCE TEST / Component Test
Main Relief Pressure Setting Adjustment Proce-
dure
Adjustment:
1. Loosen lock nut (1). Main Relief
: 17 mm Valve
: 19.5 Nm (2 kgfm, 14.5 lbfft)
T176-03-03-010
Adjusting
Screw
Pressure Pressure
Increase Decrease
T105-06-05-002
T4-5-12
OPERATIONAL PERFORMANCE TEST / Component Test
RELIEF PRESSURE (When relieving
Swing)
Adjust pressure by changing the number of shims (2).
T4-5-13
OPERATIONAL PERFORMANCE TEST / Component Test
RELIEF PRESSURE (When relieving
Travel)
Adjustment
Loosen lock nut (2) to adjust adjusting screw (1).
Pressure Pressure
Increase Decrease
W107-02-05-129
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 pressure of the front functions
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 Preparation:
case a main relief valve designed to leak a small 1. Properly shut down the engine.
quantity of oil before reliving is used, its 2. Press the air release valve on top of the hydraulic
pre-leaking start pressure must be increased oil tank to release any remaining pressure.
more than the overload relief valve set-pressure. 3. Remove the plug from the main pump delivery
However, the pre-leaking start pressure is not al- port. Install adapter (ST 6069), hose (ST 6943)
ways increased more than the overload relief and pressure gauge (ST 6941) on the port.
valve set-pressure as the adjustable upper limit of : 6 mm
the main relief valve set-pressure is provided.
Accordingly, the overload relief valve assembly 4. Connect Dr.ZX to the machine for main pump de-
should be removed from the machine and livery pressure monitoring.
checked on a specified test stand at a correct oil Start the engine. Confirm that no oil leakage is
flow rate. Some overload relief valves come in observed at the pressure gauge connection.
contact with the control valve body to block the oil
passage. When this type of overload relief valve is 5. Maintain the hydraulic oil temperature at 505 C
checked, the control valve body must be precisely (1229 F).
finished as the test unit. Provide one control valve
other than that on the machine as a test kit.
T4-5-15
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Fast Idle P Digging OFF
Evaluation:
1. Performance of the overload relief valves are
normal if the measured main relief pressures are
within the specified value range. T157-05-04-005
T4-5-16
OPERATIONAL PERFORMANCE TEST / Component Test
Overload Relief Valve Set Pressure Adjusting
Procedure
Adjustment:
Adjust the pressure setting of the overload relief valve
using adjusting screw (2) after loosening lock nut (1). 1
W107-02-05-129
T4-5-17
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN PUMP FLOW RATE MEASUREMENT
T4-5-18
OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified pump speed using the following formu- Refer to T4-2 Operational Performance Standard.
las: NOTE: When actually measuring, install pipe (1 or
2) only to the pump to be measured.
Qc = (Ns Q) Ne
1, 2 3 4 5 6 7 8 9 10
T1F3-04-05-010
12
N Sensor
T1GL-03-01-001
11
1 - Pipe E (ST 6144) 5 - Hydraulic Tester (ST 6299) 8- Flange (ST 6118) 11 - Plug
2 - Pipe B (ST 6143) 6 - Adapter G1 UNF1-7/8 9- Split Flange (4085560) 12 - Pipe
(ST 6146)
3 - Test Hose (ST 6145) 7 - Test Hose (ST 6320) 10 - Bolt (J781240) (4 used)
4 - Adapter G1 UNF1-7/8
(ST 6146)
T4-5-19
OPERATIONAL PERFORMANCE TEST / Component Test
Pilot Characteristics
CAUTION: If air is mixed in the brake system, 9. Disconnect the vacuum pump. Loosen plug on
the brake function is reduced, possibly the top of the pump casing. Bleed air from the
resulting in serious hazard. Be sure to bleed pump casing until oil only comes out of the plug.
air from the brake system after disconnecting 10. Fully open the loading valve of the hydraulic
and reconnecting the pipe lines. tester.
Refer to the Troubleshooting B in Group T5-4. 11. Start the engine. Check the line connections for
any oil leaks.
Summary:
Main pump performance is checked by measuring Measurement:
the pump flow rate with a hydraulic tester installed at 1. The pump flow rate in response to the external
the main pump delivery port (one side) to be command pilot pressure is measured.
measured. Use Dr. ZX and a pressure gauge at the 2. Select each switch position as follows:
same time. Auto-Idle /
Engine Power Mode Work Mode
Acceleration
IMPORTANT: This measurement procedure is a Control Dial Switch Switch
Selector
simple method. The measured data Fast Idle P Digging OFF
will be lower by approx. 5 % than the
accurately measured value. To 3. Adjust the reducing valve set-pressure to each
measure accurately, disconnect the pressure point specified along the main pump
return circuit from the control valve P-Q curve. (Pilot Characteristics) (Refer to
and connect it to the hydraulic oil T4-2-7) Measure the flow rates and engine
tank. speeds at the pressure points specified in the P-Q
curve.
Preparation: 4. Repeat each measurement three times and
1. Referring to steps 1 to 4 on page T4-5-20, calculate the average values.
connect a hydraulic tester to the main pump to be
measured. Evaluation:
2. Disconnect the hose from regulator port Pi of the 1. Convert the measured flow rates to those at the
pump to be measured. Connect plug (4174545) specified pump speed using the following
(9/16 UNF) to the disconnected hose. formulas:
: 19 mm
3. Install adapters (15) (3 used) to reducing valve Qc = (Ns Q) / Ne
(16). Disconnect the hose (PE) from P1 port of the
2-unit solenoid valve, and install tee (12), adapter Qc : Converted Flow Rate
(13) and hose (14). Q: Measured Flow Rate
Connect the other end of hose (14) to regulator Ns : Specified Pump Speed (2200 min-1)
port P1 on reducing valve (16). Ne : Measured Engine Speed
: 19 mm Pulse Numbers (Hz)60/34
4. Install tee (17) to port P2 on reducing valve (16).
Connect pressure gauge (18) and hose (14) to 2. Standard Flow Rate
tee (17). Connect hose (14) to the regulator. Refer to T4-2 Operational Performance Standard.
: 19 mm NOTE: Both pipes (1 and 2) are illustrated as if
5. Connect hose (14) and adapter (15) to port T on they are installed. When actually
reducing valve (16). Remove plug L from the measuring, install pipe (1 or 2) only to the
return pipe. Connect hose (14) to the plug L port. pump to be measured.
: 19 mm
6. Disconnect pipe (19) from the regulator. Connect
plug (M141.5) to the disconnected pipe.
: 22 mm
7. Disconnect the N sensor connector. Connect the
pulse counter to the N sensor.
T4-5-20
OPERATIONAL PERFORMANCE TEST / Component Test
1, 2 3 4 5 6 7 8 9 10
Hose(PE) T1F3-04-05-010
19 Port Pi
N Sensor 2-Unit
Solenoid
Valve
11
T1GL-03-01-001
T1GL-01-02-007
Reducing Valve
Port Position
Reducing Return Pipe
Valve
T
L
15
To 2-Unit Solenoid
18 Valve P1 Prt
14
P1 P2
15
To Regulator
Port Pi
14 17 15 16 15 14 13 12
T1F3-04-05-009
T4-5-21
OPERATIONAL PERFORMANCE TEST / Component Test
REGULATOR ADJUSTMENT
6 5 1 2
10
4 3
7 8
T178-03-01-006
1 - Lock Nut (For Minimum 4 - Adjusting Screw (For 7 - Lock Nut 9- Lock Nut
Flow Adjustment) Maximum Flow (For P-Q Line Adjustment) (For P-Q Line Adjustment)
Adjustment)
2 - Adjusting Screw (For 5 - Lock Nut 8 - Adjusting Screw 10 - Adjusting Screw
Minimum Flow Adjustment) (For Pilot Pressure (For P-Q Line Adjustment) (For P-Q Line Adjustment)
Characteristic Adjustment)
3 - Lock Nut (For Maximum 6 - Adjusting Screw
Flow Adjustment) (For Pilot Pressure
Characteristic Adjustment)
Pi
2. Maximum Flow Rate Loosen lock nut (3) and turn 1) Do not turn the adjusting screw more
adjusting screw (4). than two turns.
Q Rotating adjusting screw (4) 1/4 2) Do not increase the maximum flow
a turn clockwise decreases the rate.
maximum pump flow rate by 7.14 In other words, do not turn the
cm3/rev. (0.44 in3/rev). adjusting screw counterclockwise.
: 13 mm Increasing the maximum flow rate
: 9.8 Nm (turning the adjusting screw
(1 kgfm, 7.2 lbfft) counterclockwise), however, will be
required after adjusting the pilot
pressure characteristics.
3) Securely retighten lock nut (3) after
Pd the adjustment.
T4-5-22
OPERATIONAL PERFORMANCE TEST / Component Test
4. P-Q Control A: Loosen lock nut (7) and turn 1) Do not turn the adjusting screws
(Torque Adjustment) adjusting screw (8). more than one turn.
Rotating adjusting screw (8) 2) Rotate the adjusting screws
Q 1/4 a turn clockwise increases watching the engine performance.
the maximum pump flow rate 3) Securely retighten lock nut (7) or (9)
A by 13.43 cm3/rev. after the adjustment.
(0.82 in3/rev.).
B: Loosen lock nut (9) and turn
adjusting screw (10).
Rotating adjusting screw (10)
1/4 a turn clockwise increases
Pd the maximum pump flow rate
by 2.36 cm3/rev. (0.14 in3/rev).
Q
Pd
T4-5-23
OPERATIONAL PERFORMANCE TEST / Component Test
SWING MOTOR DRAINAGE
Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while
swinging the upperstructure.
1
NOTE: The amount of drain oil from the swing
motor will change depending on hydraulic
oil temperature.
Preparation: MCBB-07-025
T178-04-04-005
T4-5-24
OPERATIONAL PERFORMANCE TEST / Component Test
Preconditions for Measurement:
1. Select the following switch positions:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Fast Idle P Digging OFF
Measurement:
1. Amount of Oil Drained While Swinging the
Upperstructure
(1) Fully retract the arm cylinder. Fully extend the
bucket cylinder. Raise the boom so that the The same height as
arm tip pin height is the same as the boom boom foot pin height
foot pin height. Be sure that the bucket is
empty. T212-07-04-001
(2) Start the engine. Operate and hold the swing
lever full stroke. Start draining oil
measurement after the swing speed reaches a
constant maximum speed. The measuring
time should be more than 45 seconds.
(3) Repeat the measurement at least three times
in both clockwise and counterclockwise
directions, and calculate the average values.
T212-07-04-002
T4-5-25
OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation:
Refer to the Operational Performance Standard Table
in Group T4-2.
Q = 60 q / t
Where: T107-06-05-008
T4-5-26
OPERATIONAL PERFORMANCE TEST / Component Test
TRAVEL MOTOR DRAINAGE
Summary:
To check travel motor performance, measure the
amount of oil draining from the travel motor while
rotating the travel motor with the measuring jacked
up.
Be sure to secure the safety of the personnel during
the measurement, and pay good attention to the
safety of the surroundings.
1
Preparation:
1. Main hydraulic oil temperature at 505 C (1229
F). Rotate the travel motor to warm the inside of
the motor.
Brake
Shift Lever
Switch
A
D
(Axle Lock)
T1GL-04-05-002
T4-5-27
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
T4-5-28
OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Q = 60 q / t
Where:
Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-29
OPERATIONAL PERFORMANCE TEST / Component Test
STEERING VALVE RELIEF VALVE SET
PRESSURE
Measure steering valve relief valve set pressure with
both the Dr.ZX and the pressure gauge.
Summary:
The steering circuit has the steering valve relief valve.
When the steering valve relief valve is malfunctioning, 1
the steering wheel may become heavier.
Preparation:
1. Properly shut down the engine.
2. Press the air release valve (1) on top of the hy-
draulic oil tank to release any remaining pressure.
3. Disconnect the hose end from the steering pilot
filter inlet or outlet port. Install tee 3/4-16UNF(ST
6477), fitting (ST 6069) and pressure gauge as-
sembly (ST 6933).
: 22 mm, 24 mm
MCBB-07-025
Measurement:
1. Select the following switch positions:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Fast Idle P Digging OFF
TCCB-02-01-003
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
The steering valve relief valve cannot be adjusted. If
it does not fulfill the standard, replace as a unit.
T4-5-30
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)
T4-5-31
OPERATIONAL PERFORMANCE TEST / Component Test
BRAKE PRESSURE (Front and Rear)
Summary:
Brake pressure is measured on the output side of the
brake valve. Measure the pressure when the brake
pedal is depressed, and that when the working brake
is applied.
Preparation:
TCCB-04-05-002
T4-5-32
OPERATIONAL PERFORMANCE TEST / Component Test
Preconditions for Measurement:
Select the following switch positions:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration Shift Lever Brake Switch
Control Dial Switch Switch
Selector
Fast Idle P Digging OFF N OFF
Measurement:
1. Measure the pressure when fully depressing the
brake pedal to the floor.
2. Measure the pressure when setting the brake
switch to S (working), without depressing the
brake pedal.
3. Repeat the measurement three times, and cal-
culate the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
Normally, the front and rear wheel brake pressures
become equal. If not, malfunction of the brake valve
and dirt caught in the valve are suspected.
T4-5-33
OPERATIONAL PERFORMANCE TEST / Component Test
BRAKE ACCUMLATE PRESSURE
Summary:
The accumulated brake pressure is measured at
output port of the accumulator. The accumulated
brake pressure varies according to operation of the
brake. Record the maximum value.
Preparation:
T4-5-34
OPERATIONAL PERFORMANCE TEST / Component Test
Preconditions for Measurement:
Select the following switch positions:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration Shift Lever Brake Switch
Control Dial Switch Switch
Selector
Fast Idle P Digging OFF N OFF
Measurement:
1. Measure maximum pressure when depressing
the brake pedal slowly.
2. Repeat the measurement three times, and cal-
culate the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-5-35
OPERATIONAL PERFORMANCE TEST / Component Test
BRAKE WARNING SET PRESSURE
(DECREASE)
Summary:
When the warning buzzer sounds by reducing the
accumulated brake pressure, the pressure is meas-
ured at the output port of the accumulator.
Preparation:
T4-5-36
OPERATIONAL PERFORMANCE TEST / Component Test
Preconditions for Measurement:
Select the following switch positions:
Shift Lever Brake Switch
N P (Parking)
Measurement:
1. Properly shut down the engine. Turn key switch to
ON position.
2. Measure the pressure when warning buzzer
sounds by slowly depressing the brake pedal
several times.
3. Repeat the measurement three times, and cal-
culate the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-5-37
OPERATIONAL PERFORMANCE TEST / Component Test
BRAKE WARNING SET PRESSURE
(INCREASE)
Summary:
When sounding of the warning buzzer stops by in-
creasing the accumulated brake pressure, the pres-
sure is measured at the output port of the accumu-
lator.
Preparation:
T4-5-38
OPERATIONAL PERFORMANCE TEST / Component Test
Preconditions for Measurement:
Select the following switch positions:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration Shift Lever Brake Switch
Control Dial Switch Switch
Selector
Minimum P Digging OFF N P (Parking)
Measurement:
1. Properly shut down the engine. Turn key switch to
ON position.
2. Depress the brake pedal several times to make
the warning buzzer sound.
3. Start the engine. Measure the pressure when
sounding of the warning buzzer stops. Notice that
it is difficult to read the gauge because the pres-
sure increases rapidly.
4. Repeat the measurement three times, and cal-
culate the average values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-5-39
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)
T4-5-40
OPERATIONAL PERFORMANCE TEST / Adjustment
ENGINE SPEED ADJUSTMENT AND EN-
GINE LEARNING
After removing and/or replacing the components as
described below for repair and/or inspection, or if error
in engine speed is found, readjust engine speed and
perform engine learning.
5. Loosen the bolt holding the control lever to the EC Holding Bolt
motor output shaft.
Control Lever T157-07-04-015
6. While monitoring the actual engine speed with Dr.
ZX or the engine speed meter, adjust the control
lever so that the minimum speed (slow idle)
matches the specification.
Specification: Refer to T4-2 OPERATIONAL PER
FORMANCE TEST.
T4-6-1
OPERATIONAL PERFORMANCE TEST / Adjustment
Engine Learning:
1. Turn the key switch OFF
Learning
NOTE: In case the engine doesnt stop when the Switch
key switch is turned OFF, pull the handle
located under the seat to stop the engine.
Dr.ZX
2. Disconnect Dr. ZX. Wait for 5 seconds. Connector
to MC
3. Turn the learning switch ON.
Learning Switch is
Turned to Stamp E
Learning Switch
Stamp
T1CC-05-01-001
T4-6-2
OPERATIONAL PERFORMANCE TEST / Adjustment
(Blank)
T4-6-3
OPERATIONAL PERFORMANCE TEST / Adjustment
GOVERNOR LEVER AND FUEL CUT
LEVER POSITION
1 2 3 4
T1F3-05-04-002
T4-6-4
OPERATIONAL PERFORMANCE TEST / Adjustment
Governor Lever Position
T1F3-05-04-002
FULL STOP
T1F3-05-04-002
T4-6-5
OPERATIONAL PERFORMANCE TEST / Adjustment
(Blank)
T4-6-6
MEMO
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SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 General Components in Control Valve ..................T5-2-12
Introduction ............................................... T5-1-1 Signal Control Valve
Diagnosing Procedure .............................. T5-1-2 Port Location .......................................T5-2-26
Built-In Diagnosing System Operation ...... T5-1-6
Built-In Diagnosing Function Group 3 Troubleshooting A
Display List............................................ T5-1-7 Troubleshooting A Procedure ....................T5-3-1
Dr. ZX Operation ....................................... T5-1-8 Fault Code List ..........................................T5-3-2
Dr. ZX Fault Code List (MC).................... T5-1-10 Fault Code 01, 02, 03................................T5-3-3
Dr. ZX Monitoring Item List ..................... T5-1-12 Fault Code 04............................................T5-3-3
Dr. ZX Special Function .......................... T5-1-14 Fault Code 06............................................T5-3-4
Dr. ZX Service Mode............................... T5-1-15 Fault Code 07............................................T5-3-5
Adjustment Data List............................... T5-1-25 Fault Code 10, 11 ......................................T5-3-6
Fault Code 12, 13......................................T5-3-7
Group 2 Component Layout Fault Code 14, 15, 16, 18, 23, 24 ..............T5-3-8
Main Component Layout ........................... T5-2-1 Fault Code 19..........................................T5-3-10
Electrical Component Layout .................... T5-2-4 Fault Code 20.......................................... T5-3-11
(Overview) Fault Code 22..........................................T5-3-12
Electrical System (Relays) ........................ T5-2-5
Electrical System ...................................... T5-2-7
(Monitors and Switches)
Electrical System (Column Box)................ T5-2-8
Pump Device ............................................ T5-2-9
Swing Device ............................................ T5-2-9
Signal Control Valve.................................. T5-2-9
Control Valve .......................................... T5-2-10
Auxiliary control Valve............................. T5-2-10
4-Unit Solenoid Valve Unit ...................... T5-2-10
3-Unit Solenoid Valve Unit ...................... T5-2-10
Travel Shockless Valve /
Accumulator Chrging Valve ................... T5-2-11
Transmission Control Valve .................... T5-2-11
Travel Device .......................................... T5-2-11
Filter ....................................................... T5-2-11
CCBT-5-1
Group 4 Troubleshooting B Malfunction of Overload Alarm
Troubleshooting B Procedure ................... T5-4-1 Indicator (Optional)................................T5-5-20
Relationship between Machine Trouble Malfunction of Auto-Acceleration
Symptoms and Related Parts.................. T5-4-2 Indicator ................................................T5-5-24
Correlation between Trouble Malfunction of Auto-Idle Indicator ............T5-5-26
Symptoms and Part Failures ................. T5-4-26 Malfunction of Digging Mode Indicator
Engine System Troubleshooting ............. T5-4-40 or Attachment Mode Indicator................T5-5-27
All Actuator System Troubleshooting ...... T5-4-66 Malfunction of LCD..................................T5-5-28
Front Attachment System Malfunction of Hour Meter .......................T5-5-29
Troubleshooting .................................... T5-4-72 Malfunction of Blade/Stabilizer
Swing System Troubleshooting ............... T5-4-80 Indicator ................................................T5-5-30
Travel System Troubleshooting............... T5-4-82 Malfunction of Buzzer..............................T5-5-34
Brake System Troubleshooting ............... T5-4-92 Malfunction of Turn Signal Indicator ........T5-5-36
Steering System Troubleshooting ........... T5-4-97 Malfunction of Travel Motor Indicator ......T5-5-37
Other System Troubleshooting................ T5-4-98 Malfunction of Work Light Indicator .........T5-5-38
Exchange Inspection............................. T5-4-114 Malfunction of Shift Lever Indicator .........T5-5-40
Bleeding Air from Transmission............. T5-4-116 Malfunction of Work Brake Indicator........T5-5-42
Bleeding Air from Brake (Axle) .............. T5-4-117 Malfunction of Parking Brake Indicator ....T5-5-44
Emergency Boom Lowering Procedure Malfunction of Axle Lock Indicator ...........T5-5-46
(without Hose-Rupture Safety Valve) .. T5-4-118 Malfunction of Clearance Light
Emergency Boom Lowering Procedure Indicator ................................................T5-5-48
(with Hose-Rupture Safety Valve) ....... T5-4-119 Malfunction of Hazard Light Indicator ......T5-5-49
CCBT-5-2
Group 6 Electrical System Inspection
Precautions for Inspection and
Maintenance ........................................... T5-6-1
Instructions for Disconnecting
Connectors ............................................. T5-6-3
Fuse Inspection ........................................ T5-6-4
Fusible Link Inspection ............................. T5-6-6
Battery Voltage Check .............................. T5-6-7
How to Troubleshoot Alternator
Malfunctions............................................ T5-6-8
Continuity Check..................................... T5-6-10
Voltage and Current Measurement ......... T5-6-13
Check by False Signal ............................ T5-6-17
Test Harness........................................... T5-6-18
Group 7 ICX
Outline ...................................................... T5-7-1
ICX Fault Code List................................... T5-7-6
Fault Code 1 to 6 ...................................... T5-7-7
Fault Code 7 to 10 .................................... T5-7-7
Some Parts of Data in Daily Report,
Frequency Distribution, Cumulative
Operation Hours are not Recorded ......... T5-7-8
CCBT-5-3
(Blank)
CCBT-5-4
TROUBLESHOOTING / General
INTRODUCTION
Refer to the inspection and troubleshooting proce- Troubleshooting B (base machine diagnosis start-
dures after any machine trouble has occurred. The ing with inspection of abnormal operational
inspection and troubleshooting procedures are pre- status)
sented in an orderly fashion in this section to quickly Refer to these procedures when no fault codes
find the cause of the machine trouble and solution. are displayed after diagnosing the machine with
Dr. ZX (or the built-in diagnosing system). Trace
The troubleshooting section in this manual consists of the cause of trouble based on the inspected re-
7 groups; General, Component Layout, Troubleshoot- sult of the abnormal symptom.
ing A (base machine diagnosis using fault codes),
Troubleshooting B (base machine diagnosis starting Example: Even if the engine control dial is oper-
with inspection of abnormal operational status), Trou- ated, engine speed remains unchanged.
bleshooting C (monitor diagnosis), Electrical System
Inspection, and ICX. Troubleshooting C (monitor diagnosis)
Refer to these procedures when gauges and/or
General indicators are malfunctioning.
T5-1-1
TROUBLESHOOTING / General
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient
troubleshooting:
T107-07-01-002
T5-1-2
TROUBLESHOOTING / General
3. Inspect the machine
Before starting the troubleshooting procedure,
check the machines daily maintenance points, as
shown in the operator's manual.
T5-1-3
TROUBLESHOOTING / General
5. Perform troubleshooting
CAUTION: Never attempt to disconnect
harnesses or hydraulic lines while the engine
is running. The machine may malfunction or
pressurized oil may spout, possibly resulting
in personal injury. Be sure to stop the engine
before disconnecting harnesses or hydraulic
lines.
T5-1-4
TROUBLESHOOTING / General
(Blank)
T5-1-5
TROUBLESHOOTING / General
BUILT-IN DIAGNOSING SYSTEM OPERA-
TION
IMPORTANT: This system is to be operated by the
HITACHI Dealer Only. Dont explain
this system function to the cus-
tomer.
T5-1-6
TROUBLESHOOTING / General
BUILT-IN DIAGNOSING FUNCTION DISPLAY LIST
Display
Description Monitored Result Unit Remarks
Order
1 Hour Meter {{{{{ h Standard Mode
2 Trip 1 {{{{{ h Standard Mode (Subtraction)
3 Trip 2 {{{{{ h Standard Mode (Subtraction)
-1
4 Engine Actual Speed n {{{{ min User Mode (Required to set
in the Dr. ZX service mode)
5 Hydraulic Oil Tempera- {{{ C User Mode (Required to set
ture in the Dr. ZX service mode)
6 L1 E Display Purpose Only
7 L2 E Display Purpose Only
8 Fault Code* 0 {{ Possible to display
9 ML Switch** 1 {{ 0: Switch OFF Possible to display
1: Switch ON
10 Pump 1 Delivery Pres- 2 {{ MPa Possible to display
sure
11 Pump 2 Delivery Pres- 3 {{ MPa Possible to display
sure
12 Pump 1 Pump (Flow) 4 {{ MPa Possible to display
Control Pressure
13 Pump 2 Pump (Flow) 5 {{ MPa Possible to display
Control Pressure
-1
14 Engine Target Speed 6 {{ min Possible to display
15 EC Angle 7 {{ V Possible to display
16 Dial Angle 8 {{ V Possible to display
17 Boom Raise Pilot Pres- 9 {{ MPa Possible to display
sure
18 Arm Roll-In Pilot Pres- A {{ MPa Possible to display
sure
19 Swing Control Pilot b {{ MPa Possible to display
Pressure
20 Travel Control Pilot c {{ MPa Possible to display
Pressure
21 Front Att. Operation d {{ 0: Not Operating Possible to display
1: Operating
22 Att. Control Pressure E {{ MPa Possible to display
23 Work Mode F {{ 0: Digging Possible to display
1: Breaker
2: Secondary
Crusher
(Demolisher)
3: Crusher
4: Vibro-Hammer
T5-1-7
TROUBLESHOOTING / General
Dr. ZX OPERATION
Dr. ZX is a troubleshooting tool to diagnose the elec- Rear Console Fuse Box Dr. ZX
Connector
tronic control system including the MC (main Control- (MC)
ler) and ICX (Information Controller). When Dr. ZX is
connected to either the MC or the ICX, it displays
whether the controllers and sensors operate normally
in the form of fault codes (Self-Diagnosing Result Dis-
play Function).
In addition, Dr. ZX can display the inputs from sensors
and switches to the MC and/or the outputs to actua-
tors such as solenoid valves from the MC in real time
while operating the machine (Monitor Display Func-
tion).
Dr. ZX Connector
(ICX)
T1F3-01-02-012
Palm
Dr. ZX
Battery Box
Cable
T178-05-01-167
T5-1-8
TROUBLESHOOTING / General
Operation
1. Connect palm (Dr. ZX) to the diagnosis connec-
tors (MC and ICX) located in the cab, using Hot Start
Sync cable and battery box cable.
Self-diagnostic
Result by control- Enter model
ler is displayed Record
code and serial
No.
Retry B
Select data to
be monitored
Self-diagnostic
Result is displayed Monitored data
is displayed
T5-1-9
TROUBLESHOOTING / General
FAULT CODE LIST (MC)
Fault code Problem Cause
01 Abnormal EEPROM Faulty MC
02 Abnormal RAM
03 Abnormal A/D Conversion
04 Abnormal Sensor Voltage Faulty MC
Faulty Harness
Faulty Sensor
06 Abnormal EC Sensor Faulty MC
Faulty Harness
Faulty EC Sensor
07 Abnormal Engine Control Dial Angle Faulty MC
Faulty Harness
Faulty Engine Control Dial
10 Abnormal Pump 1 Delivery Pressure Faulty MC
11 Abnormal Pump 2 Delivery Pressure Faulty Harness
Faulty Pump Delivery Pressure Sensor
12 Abnormal Pump 1 Pump Control Pressure Faulty MC
13 Abnormal Pump 2 Pump Control Pressure Faulty Harness
Faulty Pump Control Pressure Sensor
14 Abnormal Swing Pilot Pressure Sensor Faulty MC
15 Abnormal Boom Raise Pilot Pressure Sensor Faulty Harness
16 Abnormal Arm Roll-In Pilot Pressure Sensor Faulty Pilot Pressure Sensor
18 Abnormal Travel Pilot Pressure Sensor
19 Abnormal Hydraulic Oil Temperature Faulty MC
Faulty Harness
Faulty Hydraulic Oil Temperature Sensor
20 Abnormal Travel Motor Drain Pressure Sensor Faulty MC
Faulty Harness
Faulty Travel Motor Drain Pressure Sensor
22 Abnormal Travel Motor Faulty MC
Faulty Harness
Faulty Travel Motor Drain Pressure Sensor
23 Abnormal Travel Forward Pilot Pressure Sensor Faulty MC
24 Abnormal Travel Reverse Pilot Pressure Sensor Faulty Harness
Faulty Travel Pilot Pressure Sensor
*26 Travel Motor Over-rev. Travel Motor Over-rev.
T5-1-10
TROUBLESHOOTING / General
(Blank)
T5-1-11
TROUBLESHOOTING / General
Dr. ZX MONITORING ITEM LIST
Dr. ZX displays the input signals from the switches
and sensors to the MC and the control signals to the
actuators from the MC.
T5-1-12
TROUBLESHOOTING / General
Optional
Item Data Unit
Boom Cylinder Bottom Pressure Input signal from pressure sensor (boom raise) MPa
Arm Roll-Out Pilot Pressure Input signal from pressure sensor (arm roll-out) MPa
ATT. Control Pilot Pressure Input signal from pressure sensor (auxiliary) MPa
ATT. P/S Valve Output Control signal to auxiliary flow rate control sole- MPa
noid valve
Tr/Sw/OverLoad Alarm Signal to each alarm Tr, Sw, Load (ON:
Outline Type Font)
T5-1-13
TROUBLESHOOTING / General
Dr. ZX SPECIAL FUNCTION
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS180W.
Fig. A Fig. B
T178-05-01-013 T178-05-01-168
Select ESC to return
to Fig. A.
Special function
Execute Execute
T5-1-14
TROUBLESHOOTING / General
Dr. ZX SERVICE MODE
Dr. ZX Engine
Dr. ZX has three modes, learning value display, pa- Connector (MC) Learning
rameter change, and monitor display information set- Switch
ting.
Parameter Change
Engine speed, pump delivery flow rate, and solenoid
valve output pressure can be adjusted.
this time.
5. Turn Dr. ZX switch ON.
The learning switch is
turned to the stamped
mark E
Learning Switch
Stamped
Mark E
T1CC-05-01-001
T5-1-15
TROUBLESHOOTING / General
Item Data
Learning Data Display
EC Motor Stop Position Display of the engine stop value in engine learning
EC Motor Maximum Speed Position Display of max. engine speed valve in engine learning
Parameter Change
Li Speed Adjustment Adjustment of minimum engine speed
WU Speed Adjustment Adjustment of warming up engine speed
AI Speed Adjustment Adjustment of auto-idle engine speed
E Speed Adjustment Adjustment of E-mode engine speed
P Speed Adjustment Adjustment of P-mode engine speed
Breaker Engine Speed Adjustment Adjustment of breaker operation engine speed
Secondary Crusher (Demolisher) Engine Speed Adjustment of secondary crusher (demolisher) operation
Adjustment engine speed
Crusher Engine Speed Adjustment Adjustment of crusher operation engine speed
Vibro-Hammer Speed Adjustment Adjustment of vibratory hammer operation engine speed
Travel Li Speed Adjustment Adjustment of traveling engine speed
Hyd. Breaker P1 Max. Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in breaker
operation
Secondary Crusher (Demolisher) P1 Max. Adjustment of lowest pump 1 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P1 Max. Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in crusher
operation
Vibro P1 Max. Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in vibratory
hammer operation
Hyd. Breaker P2 Max. Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in breaker
operation
Secondary Crusher (Demolisher) P2 Max. Adjustment of lowest pump 2 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P2 Max. Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in crusher
operation
Vibro P2 Max. Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in vibratory
hammer operation
Pump PQ Base Torque Correction Adjustment of pump P-Q curve
ATT P/S Valve Adjustment Adjustment of optional solenoid valve
ATT. Speed Increase Down Waiting Time Setting of time required for engine speed increase
*Max. ML Crane Speed Adjustment Setting of engine speed in crane mode
Min. Boom CYL. Bottom Pressure Over Balance
Travel Motor Over-rev. Counter Display of the travel motor excessive speed rotation
Front PI Control Adjustment Adjustment of lowest pump 1 max. flow rate in front
operation
T5-1-16
TROUBLESHOOTING / General
(Blank)
T5-1-17
TROUBLESHOOTING / General
Displaying Engine Learning Data and Angle Sensor Correction Valve
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS200.
T5-1-18
TROUBLESHOOTING / General
EC Motor stop position EC Motor Maximum Boom angle sensor correc- Arm angle sensor correction
engine speed position tion value value
T5-1-19
TROUBLESHOOTING / General
Changing Parameters In The Controller
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS200.
Start the service mode on the condition that the engine learning switch is turned on.
To change the parameter, it is necessary to enter the password. To change the password, refer to the Changing the password
section.
The menu will be displayed. Enter the password to change Select the item you want to change. The
Select Parameter Change from the parameter. up- and down-arrow buttons can be
the menu. used to scroll through the item list.
Fig. F
Fig. E T178-05-01-042
T178-05-01-043
Fig. G
Select ESC to return T178-05-01-044
Select ESC to return to Fig. E. Select ESC to return
to Fig. D. to Fig. E.
T5-1-20
TROUBLESHOOTING / General
Enter the new value Confirm the new value Parameter adjustment
result
Enter the new value in the Ad- The new value will be displayed
The adjusted value will be dis-
justment space, and press in the Adjustment space. Select
played.
Execution. Execute to change to this value.
T5-1-21
TROUBLESHOOTING / General
Changing The User Mode Display on The Monitor Panel
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS200.
Start the service mode on the condition that the engine learning switch is turned on.
T5-1-22
TROUBLESHOOTING / General
T5-1-23
TROUBLESHOOTING / General
T5-1-24
TROUBLESHOOTING / General
ADJUSTMENT DATA LIST
T5-1-25
TROUBLESHOOTING / General
(Blank)
T5-1-26
TROUBLESHOOTING / Component Layout
MAIN COMPONENT LAYOUT
Upperstructure
2 3 4 5 6 7 8 9 10 11 27 12
13
14
15
16
17
29
21
28 19
18
26
24 20
25
TCCB-02-01-001
22
T5-2-1
TROUBLESHOOTING / Component Layout
Undercarriage
1
2
TCCB-02-01-002
T5-2-2
TROUBLESHOOTING / Component Layout
Front Attachment
2-Piece Boom Monoblock Boom
1
2
3 2
7 7
4
1
5
6 T1F3-01-02-004
T1F3-01-02-003
1 - Bucket Cylinder 3- Positioning Cylinder 5- Hose-Rupture Safety Valve 7- Hose-Rupture Safety Valve
(Positioning) (Arm)
2 - Arm Cylinder 4- Boom Cylinder 6 - Hose-Rupture Safety Valve
(Boom)
T5-2-3
TROUBLESHOOTING / Component Layout
ELECTRICAL COMPONENT LAYOUT (Overview)
2 Refer to the
Transmission
Control Valve.
(T1-2-11)
Refer to the
Signal Control
Valve. (T1-2-9)
Refer to the
Control Valve.
Refer to the (T1-2-10)
Swing Device. 3
(T1-2-9)
4
14 5
13 Refer to the
Pump Device.
(T1-2-9)
12
TCCB-01-02-004
11 10 9 8 7 6
1 - Service Brake Pressure 5 - EC Motor/EC Sensor 9 - Coolant Temperature 12 - Air Cleaner Restriction
Switch Sensor Switch
2 - Fuel Sensor 6 - Pump Control Solenoid 10 - Battery Relay 13 - Brake Remaining Pressure
Valve Unit Switch
3 - 4-Unit Solenoid Valve Unit 7 - Engine Oil Pressure Switch 11 - Glow Plug Relay 14 - Slip Ring
4 - Hydraulic Oil Temperature 8 - Overheat Switch
Sensor
T5-2-4
TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM (RELAYS)
1 2 3 4 5 6 7
Relay Position
(T1-2-6)
10
T1F3-01-02-012
T5-2-5
TROUBLESHOOTING / Component Layout
Relay Position
T1F3-01-02-012
3
View A
4
30 5
6
29 7
8
28 9
27 10
26 11
25 12
24 13
23 14
22 15
21 16
20
T1F3-01-02-013
19 18 17
1 - Head Lamp Relay 9- Head Lamp Relay 17 - Left Turn Signal Relay 24 - Stop Lamp Relay (R17)
(Left-Lower) (R29) (Right-Lower) (R13) (R15)
2 - Parking Brake Relay 3 10 - Wiper Relay A (R6) 18 - Work Brake Indicator Relay 25 - Travel Reverse Pi Cut
(R30) (R18) Solenoid Valve Relay (R25)
3 - Parking Brake Relay 2 11 - Wiper Relay B-3 (R9) 19 - Neutral Signal Relay (R21) 26 - Parking Brake Alarm Relay
(R11) (R23)
4 - Work Light Relay 2 (R4) 12 - Washer Relay (R2) 20 - Right Turn Signal Relay 27 - Transmission Changeover
(R16) Relay (R20)
5 - High Beam Relay (R14) 13 - Right Clearance Light 21 - Travel Forward Pi Cut 28 - Auto-Acceleration Cancel
Relay (R12) Solenoid Valve Relay (R24) Relay (R26)
6 - Wiper Relay B-1 (R7) 14 - Horn Relay (R5) 22 - Axle Lock Relay (R19) 29 - Parking Brake Relay 1
(R27)
7 - Starter Relay (R10) 15 - Wiper Relay B-2 (R8) 23 - Travel Motor Alarm Relay 30 - Left Clearance Light Relay
(R22) (R28)
8 - Work Light Relay 1 (R3) 16 - Load Damp Relay (R1)
T5-2-6
TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM
(Monitors and Switches)
1
2
19
18
3
17
16 4
15
MCBB-01-022 5
14
6
7
13
20 8
12
21 11
10
MCBB-01-012
22
9
23
24 25
26
MCBB-01-014 M216-01-021
1 - Coolant Temperature 8- Blade/Stabilizer Operation 15 - Digging Mode Indicator 22 - Work Light Switch
Gauge Indicator
2 - Fuel Gauge 9- Overload Alarm Indicator 16 - Attachment Mode 23 - Power Mode Switch
(Optional) Indicator
3 - Display Selection Switch 10 - Hydraulic Oil Filter Restriction 17 - Liquid Crystal Display 24 - Auto-Idle/Acceleration
Indicator (LCD) Selector
4 - Set Switch 11 - Engine Oil Pressure 18 - Auto-Idle Indicator 25 - Brake Switch
Indicator
5 - Work Mode Switch 12 - Preheat Indicator 19 - Auto-Acceleration 26 - Shift Lever
Indicator
6 - Fuel Level Indicator 13 - Air Filter Restriction 20 - Engine Control Dial
Indicator
7 - Alternator Indicator 14 - Overheat Indicator 21 - Engine Speed Control
Mode Selection Switch
T5-2-7
TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM
(Around the Steering Wheel)
8 9 10 11 12 8
1, 2, 3, 4 5 6
13 12
MCBB-01-004
14 15 16 17 18 19 20
MCBB-01-005
22 21
MCBB-01-006
T5-2-8
TROUBLESHOOTING / Component Layout
PUMP DEVICE 5 6
2 1
7
11
10
9
8
TCCB-01-02-005
4 3 T1GL-03-01-001
SWING DEVICE
SIGNAL CONTROL VALVE
13
14
12
T1F3-03-06-003
T178-03-02-001
T5-2-9
TROUBLESHOOTING / Component Layout
CONTROL VALVE AUXILIARY CONTROL VALVE
1
4
T176-01-02-003 T1SM-01-02-007
3
5 6 7 8 T178-01-02-003
TCCB-02-01-003
1 - Pressure Sensor 4- Overload Relief Valve 9- Solenoid Valve Unit (SI) 9- Max. Pump 1 Flow Rate
(Arm Roll-In) (Auxiliary Control Valve) Limit Solenoid Valve
2 - Main Relief Valve 5 - Solenoid Valve Unit (SC) 8- Solenoid Valve Unit (SG)
3 - Pressure Sensor 6 - Solenoid Valve Unit (SE)
(Boom Raise)
T5-2-10
TROUBLESHOOTING / Component Layout
TRAVEL SHOCKLESS VALVE/ TRANSMISSION CONTROL VALVE
ACCUMULATOR CHARGING VALVE 9
10
1
2 3 4 8
5
11
12
T1F3-01-02-006
7 6
T1F3-01-02-005
13
14
18
19
15
16
TCCB-02-01-003
17
T1F3-01-02-009
1 - Travel Shockless Valve 6- Travel Reverse Pi Cut 11 - Accumulator 16 - Travel Motor Drain Pressure
Solenoid Valve (Transmission Circuit) Switch
2 - Pressure Sensor (Travel 7 - Pressure Sensor 12 - Parking Brake Pressure 17 - Pilot Filter
Forward) (Travel Reverse) Switch
3 - Travel Forward Pi Cut 8 - Transmission Control Valve 13 - N sensor (Travel) 18 - Steering Pump Delivery
Solenoid Valve Pressure Sensor
4 - Pressure Sensor (Brake Oil 9- Transmission Changeover 14 - Transmission 19 - Steering Filter
Pressure Gauge) Solenoid Valve
5 - Accumulator Charging 10 - Parking Brake Solenoid 15 - Travel Motor
Valve Valve
T5-2-11
TROUBLESHOOTING / Component Layout
COMPONENTS IN CONTROL VALVE
1 2 3 4 5 6 7 9 10 11
35
12
34 13
33
32
31
14
30
15
16
29
28 17
27
26
25 24 23
22 21 20 19 18
T1F3-03-03-014
T5-2-12
TROUBLESHOOTING / Component Layout
16
26
29
18, 19
7
21
12
9, 10
Front
T176-03-03-038
1 - Load Check Valve (Posi- 11 - Bucket Regenerative Circuit 20 - Load Check Valve 29 - Overload Relief Valve (Arm
tioning Tandem Circuit) (Arm 2 Tandem Circuit) Rod Side)
2 - Load Check Valve (Posi- 12 - Overload Relief Valve (Bucket 21 - Bypass Shut-Out Valve 30 - Arm Anti-Drift Valve (Check
tioning Parallel Circuit) Rod Side) Valve)
3 - Check Valve 13 - Overload Relief Valve (Bucket 22 - Check Valve (Orifice) (Arm 31 - Arm Anti-Drift Valve (Se-
(Main Relief Circuit) Bottom Side) 2 Parallel Circuit) lector Valve)
4 - Main Relief Valve 14 - Load Check Valve (Boom 1 23 - Load Check Valve (Arm 1 32 - Load Check Valve (Boom 2
Parallel Circuit) Parallel Circuit) Parallel Circuit)
5 - Auxiliary Flow Combiner 15 - Boom Regenerative Circuit 24 - Load Check Valve 33 - Aux. Flow Rate Control
Valve (Arm 1 Tandem Circuit) Valve (Poppet Valve)
6 - Check Valve 16 - Overload Relief Valve (Boom 25 - Load Check Valve 34 - Aux. Flow Rate Control
(Auxiliary Flow Combin- Bottom Side) (Swing Circuit) Valve (Selector Valve)
ing Circuit)
7 - Check Valve 17 - Overload Relief Valve (Boom 26 - Arm Regenerative Valve 35 - Load Check Valve (Bucket
(Main Relief Circuit) Rod Side) (Selector Valve) Parallel Circuit)
9 - Bucket Flow Rate Con- 18 - Boom Anti-Drift Valve (Check 27 - Arm Regenerative Circuit
trol Valve (Selector Valve)
Valve)
10 - Bucket Flow Rate Con- 19 - Boom Anti-Drift Valve (Selec- 28 - Overload Relief Valve (Arm
trol Valve (Poppet Valve) tor Valve) Bottom Side)
T5-2-13
TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7 9 10 11
35
12
34 13
33
32
31
14
30
15
16
29
28 17
27
26
25 24 23
22 21 20 19 18
T1F3-03-03-014
T5-2-14
TROUBLESHOOTING / Component Layout
30, 31
33, 34
28
Front
5 17 T176-03-03-036
13
6 35
1- Load Check Valve (Po- 11- Bucket Regenerative Circuit 20- Load Check Valve 29- Overload Relief Valve (Arm
sitioning Tandem Circuit) (Arm 2 Tandem Circuit) Rod Side)
2- Load Check Valve (Po- 12- Overload Relief Valve (Bucket 21- Bypass Shut-Out Valve 30- Arm Anti-Drift Valve (Check
sitioning Parallel Circuit) Rod Side) Valve)
3- Check Valve 13- Overload Relief Valve (Bucket 22- Check Valve (Orifice) (Arm 31- Arm Anti-Drift Valve (Se-
(Main Relief Circuit) Bottom Side) 2 Parallel Circuit) lector Valve)
4- Main Relief Valve 14- Load Check Valve (Boom 1 23- Load Check Valve (Arm 1 32- Load Check Valve (Boom 2
Parallel Circuit) Parallel Circuit) Parallel Circuit)
5- Auxiliary Flow Combiner 15- Boom Regenerative Circuit 24- Load Check Valve 33- Aux. Flow Rate Control
Valve (Arm 1 Tandem Circuit) Valve (Poppet Valve)
6- Check Valve 16- Overload Relief Valve (Boom 25- Load Check Valve 34- Aux. Flow Rate Control
(Auxiliary Flow Combin- Bottom Side) (Swing Circuit) Valve (Selector Valve)
ing Circuit)
7- Check Valve 17- Overload Relief Valve (Boom 26- Arm Regenerative Valve 35- Load Check Valve (Bucket
(Main Relief Circuit) Rod Side) (Selector Valve) Parallel Circuit)
9 - Bucket Flow Rate Con- 18- Boom Anti-Drift Valve (Check 27- Arm Regenerative Circuit
trol Valve (Selector Valve)
Valve)
10 - Bucket Flow Rate Con- 19- Boom Anti-Drift Valve (Selec- 28- Overload Relief Valve (Arm
trol Valve (Poppet Valve) tor Valve) Bottom Side)
T5-2-15
TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7 9 10 11
35
12
34 13
33
32
31
14
30
15
16
29
28 17
27
26
25 24 23
22 21 20 19 18
T1F3-03-03-014
T5-2-16
TROUBLESHOOTING / Component Layout
F
E Cross Section A 4
D
C
B
7
A
35
6
5
a T1F3-03-03-013
T176-03-03-035
1- Load Check Valve (Po- 11- Bucket Regenerative Circuit 20- Load Check Valve 29- Overload Relief Valve (Arm
sitioning Tandem Circuit) (Arm 2 Tandem Circuit) Rod Side)
2- Load Check Valve (Po- 12- Overload Relief Valve (Bucket 21- Bypass Shut-Out Valve 30- Arm Anti-Drift Valve (Check
sitioning Parallel Circuit) Rod Side) Valve)
3- Check Valve 13- Overload Relief Valve (Bucket 22- Check Valve (Orifice) (Arm 31- Arm Anti-Drift Valve (Se-
(Main Relief Circuit) Bottom Side) 2 Parallel Circuit) lector Valve)
4- Main Relief Valve 14- Load Check Valve (Boom 1 23- Load Check Valve (Arm 1 32- Load Check Valve (Boom 2
Parallel Circuit) Parallel Circuit) Parallel Circuit)
5- Auxiliary Flow Combiner 15- Boom Regenerative Circuit 24- Load Check Valve 33- Aux. Flow Rate Control
Valve (Arm 1 Tandem Circuit) Valve (Poppet Valve)
6- Check Valve 16- Overload Relief Valve (Boom 25- Load Check Valve 34- Aux. Flow Rate Control
(Auxiliary Flow Combin- Bottom Side) (Swing Circuit) Valve (Selector Valve)
ing Circuit)
7- Check Valve 17- Overload Relief Valve (Boom 26- Arm Regenerative Valve 35- Load Check Valve (Bucket
(Main Relief Circuit) Rod Side) (Selector Valve) Parallel Circuit)
9- Bucket Flow Rate Con- 18- Boom Anti-Drift Valve (Check 27- Arm Regenerative Circuit
trol Valve (Selector Valve)
Valve)
10- Bucket Flow Rate Con- 19- Boom Anti-Drift Valve (Selec- 28- Overload Relief Valve (Arm
trol Valve (Poppet Valve) tor Valve) Bottom Side)
T5-2-17
TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7 9 10 11
35
12
34 13
33
32
31
14
30
15
16
29
28 17
27
26
25 24 23
22 21 20 19 18
T1F3-03-03-014
T5-2-18
TROUBLESHOOTING / Component Layout
Cross Section B Cross Section C
Travel Positioning Bucket Auxiliary
12
1
10 33
2 34
9
11
13
T1F3-03-03-012
T176-03-03-004
1- Load Check Valve (Po- 11- Bucket Regenerative Circuit 20- Load Check Valve 29- Overload Relief Valve (Arm
sitioning Tandem Circuit) (Arm 2 Tandem Circuit) Rod Side)
2- Load Check Valve (Po- 12- Overload Relief Valve (Bucket 21- Bypass Shut-Out Valve 30- Arm Anti-Drift Valve (Check
sitioning Parallel Circuit) Rod Side) Valve)
3- Check Valve 13- Overload Relief Valve (Bucket 22- Check Valve (Orifice) (Arm 31- Arm Anti-Drift Valve (Se-
(Main Relief Circuit) Bottom Side) 2 Parallel Circuit) lector Valve)
4- Main Relief Valve 14- Load Check Valve (Boom 1 23- Load Check Valve (Arm 1 32- Load Check Valve (Boom 2
Parallel Circuit) Parallel Circuit) Parallel Circuit)
5- Auxiliary Flow Combiner 15- Boom Regenerative Circuit 24- Load Check Valve 33- Aux. Flow Rate Control
Valve (Arm 1 Tandem Circuit) Valve (Poppet Valve)
6- Check Valve 16- Overload Relief Valve (Boom 25- Load Check Valve 34- Aux. Flow Rate Control
(Auxiliary Flow Combin- Bottom Side) (Swing Circuit) Valve (Selector Valve)
ing Circuit)
7- Check Valve 17- Overload Relief Valve (Boom 26- Arm Regenerative Valve 35- Load Check Valve (Bucket
(Main Relief Circuit) Rod Side) (Selector Valve) Parallel Circuit)
9- Bucket Flow Rate Con- 18- Boom Anti-Drift Valve (Check 27- Arm Regenerative Circuit
trol Valve (Selector Valve)
Valve)
10- Bucket Flow Rate Con- 19- Boom Anti-Drift Valve (Selec- 28- Overload Relief Valve (Arm
trol Valve (Poppet Valve) tor Valve) Bottom Side)
T5-2-19
TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7 9 10 11
35
12
34 13
33
32
31
14
30
15
16
29
28 17
27
26
25 24 23
22 21 20 19 18
T1F3-03-03-014
T5-2-20
TROUBLESHOOTING / Component Layout
Cross Section D Cross Section E
Boom 1 Boom 2 Arm 2 Arm 1
19 31
16 29
18 30
14 20 23
32
22
24
27
15
28
17
T176-03-03-006
T176-03-03-005
1- Load Check Valve (Po- 11- Bucket Regenerative Circuit 20- Load Check Valve 29- Overload Relief Valve (Arm
sitioning Tandem Circuit) (Arm 2 Tandem Circuit) Rod Side)
2- Load Check Valve (Po- 12- Overload Relief Valve (Bucket 21- Bypass Shut-Out Valve 30- Arm Anti-Drift Valve (Check
sitioning Parallel Circuit) Rod Side) Valve)
3- Check Valve 13- Overload Relief Valve (Bucket 22- Check Valve (Orifice) (Arm 31- Arm Anti-Drift Valve (Se-
(Main Relief Circuit) Bottom Side) 2 Parallel Circuit) lector Valve)
4- Main Relief Valve 14- Load Check Valve (Boom 1 23- Load Check Valve (Arm 1 32- Load Check Valve (Boom 2
Parallel Circuit) Parallel Circuit) Parallel Circuit)
5- Auxiliary Flow Combiner 15- Boom Regenerative Circuit 24- Load Check Valve 33- Aux. Flow Rate Control
Valve (Arm 1 Tandem Circuit) Valve (Poppet Valve)
6- Check Valve 16- Overload Relief Valve (Boom 25- Load Check Valve 34- Aux. Flow Rate Control
(Auxiliary Flow Combin- Bottom Side) (Swing Circuit) Valve (Selector Valve)
ing Circuit)
7- Check Valve 17- Overload Relief Valve (Boom 26- Arm Regenerative Valve 35- Load Check Valve (Bucket
(Main Relief Circuit) Rod Side) (Selector Valve) Parallel Circuit)
9- Bucket Flow Rate Con- 18- Boom Anti-Drift Valve (Check 27- Arm Regenerative Circuit
trol Valve (Selector Valve)
Valve)
10- Bucket Flow Rate Con- 19- Boom Anti-Drift Valve (Selec- 28- Overload Relief Valve (Arm
trol Valve (Poppet Valve) tor Valve) Bottom Side)
T5-2-21
TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7 9 10 11
35
12
34 13
33
32
31
14
30
15
16
29
28 17
27
26
25 24 23
22 21 20 19 18
T1F3-03-03-014
T5-2-22
TROUBLESHOOTING / Component Layout
Cross Section F
Swing
26
25
21
T176-03-03-007
1- Load Check Valve (Po- 11- Bucket Regenerative Circuit 20- Load Check Valve 29- Overload Relief Valve (Arm
sitioning Tandem Circuit) (Arm 2 Tandem Circuit) Rod Side)
2- Load Check Valve (Po- 12- Overload Relief Valve (Bucket 21- Bypass Shut-Out Valve 30- Arm Anti-Drift Valve (Check
sitioning Parallel Circuit) Rod Side) Valve)
3- Check Valve 13- Overload Relief Valve (Bucket 22- Check Valve (Orifice) (Arm 31- Arm Anti-Drift Valve (Se-
(Main Relief Circuit) Bottom Side) 2 Parallel Circuit) lector Valve)
4- Main Relief Valve 14- Load Check Valve (Boom 1 23- Load Check Valve (Arm 1 32- Load Check Valve (Boom 2
Parallel Circuit) Parallel Circuit) Parallel Circuit)
5- Auxiliary Flow Combiner 15- Boom Regenerative Circuit 24- Load Check Valve 33- Aux. Flow Rate Control
Valve (Arm 1 Tandem Circuit) Valve (Poppet Valve)
6- Check Valve 16- Overload Relief Valve (Boom 25- Load Check Valve 34- Aux. Flow Rate Control
(Auxiliary Flow Combin- Bottom Side) (Swing Circuit) Valve (Selector Valve)
ing Circuit)
7- Check Valve 17- Overload Relief Valve (Boom 26- Arm Regenerative Valve 35- Load Check Valve (Bucket
(Main Relief Circuit) Rod Side) (Selector Valve) Parallel Circuit)
9- Bucket Flow Rate Con- 18- Boom Anti-Drift Valve (Check 27- Arm Regenerative Circuit
trol Valve (Selector Valve)
Valve)
10- Bucket Flow Rate Con- 19- Boom Anti-Drift Valve (Selec- 28- Overload Relief Valve (Arm
trol Valve (Poppet Valve) tor Valve) Bottom Side)
T5-2-23
TROUBLESHOOTING / Component Layout
Auxiliary Control
Valve
2
T1F3-03-03-014
T5-2-24
TROUBLESHOOTING / Component Layout
X
2
T1GL-03-03-004
T1GL-03-03-003
T5-2-25
TROUBLESHOOTING / Component Layout
SIGNAL CONTROL VALVE PORT LOCA-
TION
Pilot Valve Side
PH
C
A
E
M
D
H
B
F
SB
PI G
K N
I
SH
J
DF
SA L
T178-03-06-016
T5-2-26
TROUBLESHOOTING / Component Layout
3
1
Pressure Sensor 5
(Auxiliary)
13
2 4
SK SE
Pressure Sensor 8
(Swing)
14
Control 7
Valve Side
9
6
10
SN
SL
11
T1F3-03-06-003
12 SP
Control Valve Side
Port Name Connecting to Note
Port 1 Control Valve Boom Raise Pilot Pressure
Port 2 Control Valve Boom Lower Pilot Pressure
Port 3 Control Valve Arm Roll-Out Pilot Pressure
Port 4 Control Valve Arm Roll-In Pilot Pressure
Port 5 Control Valve Left Swing Pilot Pressure
Port 6 Control Valve Right Swing Pilot Pressure
Port 7 Control Valve Bucket Roll-In Pilot Pressure
Port 8 Control Valve Bucket Roll-Out Pilot Pressure
Port 9 Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port 10 Plug
Port 11 Control Valve Travel Reverse Pilot Pressure
Port 12 Control Valve Travel Forward Pilot Pressure
Port 13 Pilot Pressure Shift Valve Positioning Raise/Auxiliary Open Pilot Pressure
Port 14 Pilot Pressure Shift Valve Positioning Lower/Auxiliary Close Pilot Pressure
Port SE Plug
Port SN Plug
Port SP Shuttle Valve Pump 1 Flow Rate Control Valve Control Pressure
Port SL Plug
Port SK Control Valve Bucket Flow Rate Control Valve Control Pressure
T5-2-27
TROUBLESHOOTING / Component Layout
Control
Valve Side
SN
T1F3-03-06-004
T5-2-28
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault
codes are displayed after diagnosing the main con-
troller (MC) using Dr. ZX (or the built-in diagnosing
system).
YES(OK)
(2)
(1) After completing the checking and/or measuring procedures in box
(1) (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
(3)
NO(NOT OK)
described under the box. If incorrectly checked or measured, not only will troubleshooting
Key switch: ON be unsuccessful but also damage to the components may result.
Refer to Electrical System Inspection Group (Group 6) for descriptions in the dotted-line
box.
Use Dr. ZX (or the built-in diagnosing system) for descriptions in the double-line box.
Causes of machine problems are stated in the thick-line box. Scanning quickly through the
thick-line boxes allows you to estimate the possible causes before actually following the
flow chart.
Harness
Open End
Side
Harness End Connector
T158-05-03-001
T5-3-1
TROUBLESHOOTING / Troubleshooting A
FAULT CODE LIST
Fault code Problem Cause
01 Abnormal EEPROM Faulty MC
02 Abnormal RAM
03 Abnormal A/D Conversion
04 Abnormal Sensor Voltage Faulty MC
Faulty Harness
Faulty Sensor
06 Abnormal EC Sensor Faulty MC
Faulty Harness
Faulty EC Sensor
07 Abnormal Engine Control Dial Angle Faulty MC
Faulty Harness
Faulty Engine Control Dial
10 Abnormal Pump 1 Delivery Pressure Faulty MC
11 Abnormal Pump 2 Delivery Pressure Faulty Harness
Faulty Pump Delivery Pressure Sensor
12 Abnormal Pump 1 Pump Control Pressure Faulty MC
13 Abnormal Pump 2 Pump Control Pressure Faulty Harness
Faulty Pump Control Pressure Sensor
14 Abnormal Swing Pilot Pressure Sensor Faulty MC
15 Abnormal Boom Raise Pilot Pressure Sensor Faulty Harness
16 Abnormal Arm Roll-In Pilot Pressure Sensor Faulty Pilot Pressure Sensor
18 Abnormal Travel Pilot Pressure Sensor
19 Abnormal Hydraulic Oil Temperature Faulty MC
Faulty Harness
Faulty Hydraulic Oil Temperature Sensor
20 Abnormal Travel Motor Drain Pressure Sensor Faulty MC
Faulty Harness
Faulty Travel Motor Drain Pressure Sensor
22 Abnormal Travel Motor Faulty MC
Faulty Harness
Faulty Travel Motor Drain Pressure Sensor
23 Abnormal Travel Forward Pilot Pressure Sensor Faulty MC
24 Abnormal Travel Reverse Pilot Pressure Sensor Faulty Harness
Faulty Travel Pilot Pressure Sensor
*26 Travel Motor Over-rev. Travel Motor Over-rev.
T5-3-2
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 01 (ABNORMAL EEPROM)
FAULT CODE 02 (ABNORMAL RAM)
FAULT CODE 03
(ABNORMAL A/D CONVERSION)
Faulty MC.
NO
Refer to T4-6-1.
* Even if any fault codes are still displayed after re-
trying, as long as the engine and machine operate
normally, the machine can be operated as it is.
FAULT CODE 04
(ABNORMAL SENSOR VOLTAGE)
T5-3-3
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 06
(ABNORMAL EC SENSOR)
C23 C31
#18
EC Sensor
1 2 3
T5-3-4
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 07
(ABNORMAL ENGINE CONTROL DIAL
ANGLE)
Engine Control Dial Specification Connector (Harness End Connector Viewed from the
Minimum Speed 0.3 to 1.0 V Open End Side)
Maximum Speed 4.0 to 4.7 V
MC Connector C
#6
C1 C10
C23 C31
Switch Panel
#4 #3 #2
T5-3-5
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 10
(ABNORMAL PUMP 1 DELIVERY PRES-
SURE)
FAULT CODE 11
(ABNORMAL PUMP 2 DELIVERY PRES-
SURE)
Checking Instruction
Both pump 1 and pump 2 delivery pressure sen-
sors seldom fail at the same time. Accordingly, if
both fault codes 10 and 11 are displayed simulta- Faulty harness be-
neously, faulty harness may be the cause of this Check harness be- tween MC and pump
problem. tween MC connector C delivery pressure
(31P) harness end sensor.
YES
terminal #1 (pump 1)
or #4 (pump 2) and
YES pump delivery pres-
sure sensor terminal
#2 for breakage or
Faulty MC.
short circuit.
Disconnect pump de- NO
livery pressure sensor.
Check if voltage be- Refer to T4-6-1.
tween harness end
NO connector terminals #1 Broken harness be-
and #3 is 50.5 V. tween MC and pump
Check if voltage be- delivery pressure
Check if fault codes are tween pump delivery YES sensor terminal #3.
switched after switching pressure sensor har-
pump 1 delivery pres- ness end connector
Key switch: ON
sure sensor with pump 2 terminal #1 and vehi-
delivery pressure sensor cle frame matches
NO Broken harness be-
and retrying. specification. tween MC and pump
delivery pressure
NO sensor terminal #1.
Key switch: ON
Specification: 50.5 V Faulty pump delivery
pressure sensor.
YES
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#1 #4
C1 C10
C23 C31
3 2 1
T5-3-6
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 12
(ABNORMAL PUMP 1 CONTROL PRES-
SURE)
FAULT CODE 13
(ABNORMAL PUMP 2 CONTROL PRES-
SURE)
Checking Instruction
Both pump 1 and pump 2 control pressure sen-
sors seldom fail at the same time. Accordingly, if
both fault codes 12 and 13 are displayed simul-
taneously, faulty harness may be the cause of Check harness be- Faulty harness be-
this problem. tween MC connector C tween MC and pump
(31P) harness end control pressure sen-
terminal #7 (pump 1) sor.
YES
or #13 (pump 2) and
pump control pressure
YES sensor terminal #2 for
breakage or short cir-
cuit.
Key switch: ON
Specification: 50.5 V
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#13 #7
C1 C10
C23 C31
1 2 3
T5-3-7
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 14
(ABNORMAL SWING PILOT PRESSURE)
FAULT CODE 15
(ABNORMAL BOOM RAISE PILOT
PRESSURE) NOTE: Fault code 18 (abnormal travel pilot pres-
FAULT CODE 16 sure sensor) will be displayed together
(ABNORMAL ARM ROLL-IN PILOT with fault code (23 or 24) simultaneously in
PRESSURE) case either the travel forward pilot pres-
FAULT CODE 18 sure sensor or the travel reverse pilot
(ABNORMAL TRAVEL PILOT PRESSURE) pressure sensor is abnormal.
FAULT CODE 23
(ABNORMAL TRAVEL FORWARD PILOT
PRESSURE)
FAULT CODE 24
(ABNORMAL TRAVEL REVERSE PILOT
PRESSURE)
Check harness between MC
connector C (31P) harness
Checking Instruction end each corresponding
All pressure sensors seldom fail at the same time. YES terminal and pressure sen-
Accordingly, if fault codes 14, 15, 16, 18, 23 and sor terminal #2 for breakage
24 are displayed simultaneously, faulty harness or short circuit.
may be the cause of this problem.
Connector C Terminal:
#14: Pressure Sensor (Swing)
#2: Pressure Sensor (Boom Raise)
Disconnect pressure #5: Pressure Sensor (Arm Roll-In)
sensor. Check if voltage #17: Pressure Sensor (Travel Forward)
NO between harness end #23: Pressure Sensor (Travel Reverse)
connector terminals #1
and #3 is 50.5 V.
Check if fault code dis-
appears after switching
pressure sensor with Check if voltage between
Key switch: ON
another pressure sensor pressure sensor harness
and retrying. end connector terminal
#1 and vehicle frame
NO matches specification.
Fault Code:
14: Pressure Sensor (Swing)
15: Pressure Sensor (Boom Raise)
16: Pressure Sensor (Arm Roll-In) Key switch: ON
23: Pressure Sensor (Travel Forward) Specification: 50.5 V
24: Pressure Sensor (Travel Reverse)
YES
T5-3-8
TROUBLESHOOTING / Troubleshooting A
Faulty MC.
NO
Refer to T4-6-1.
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C Pilot Pressure Sensor
#2 #5
C1 C10
1 2 3
C23 C31
T5-3-9
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 19
(ABNORMAL HYDRAULIC OIL
TEMPERATURE)
Connect hydraulic oil
temperature sensor Faulty MC.
YES
harness end connector
terminal #1 to #2 with a
clip. Remove connec- Refer to T4-6-1.
tor B (25P) and
connector C (31P) Broken harness be-
Connect MC con- tween MC and
YES from MC. Check for
nector B (25P) YES hydraulic oil tem-
continuity between
harness end terminal perature sensor
connector B harness
#22 to vehicle frame. terminal #1.
end terminal #22 and
Check for continuity
connector C terminal
Disconnect hydraulic oil between hydraulic oil
#24.
temperature sensor. NO temperature sensor
Check if sensor side harness end con- Broken harness be-
connector resistance nector terminal #2 tween MC and
matches specification. and vehicle frame. hydraulic oil tem-
NO perature sensor
terminal #2.
Specification: Refer to
the table below.
Faulty hydraulic oil
temperature sensor.
NO
Connector (Harness End Connector Viewed from the Open End Side)
Oil Temperature Specification
Oil Temperature Resistance MC Connector B
(C) (k)
B1 B8
20 16.21.6
0 (5.88)
20 2.450.24
40 (1.14) B19 B25
60 (0.534) #22
80 0.322
MC Connector C
C1 C10
C23 C31
#24
1 2
T5-3-10
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 20 (ABNORMAL TRAVEL
MOTOR DRAIN PRESSURE SENSOR)
Connector (Harness End Connector Viewed from the Open End Side)
C1 C10
1 2 3
C23 C31
T5-3-11
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 22 (ABNORMAL TRAVEL
MOTOR)
This fault code is displayed when input signal
value from the travel motor drain pressure sensor
is more than 1.6 MPa and when this status con-
tinues for longer than 50 ms. Faulty travel motor or
MC may be the cause of this trouble.
T5-3-12
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code
is displayed on the Dr.ZX (or the built-in diagnosing
system) although the machines operation is
abnormal.
On the front section pages of this group T5-4, are
tables indicating the relationship between machine
trouble symptoms and related parts which may cause
such trouble if failed.
Start the troubleshooting with more probable causes
selected by referring to these tables.
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
Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
T5-4-1
TROUBLESHOOTING / Troubleshooting B
RELATIONSHIP BETWEEN MACHINE
TROUBLE SYMPTOMS AND RELATED
PARTS
This table indicates the relationship between machine
trouble symptoms and the potential problem parts,
which may cause trouble if failed, and the evaluation
methods of these components.
Parts
EC Motor EC Sensor
Moves governor. Detects minimum governor speed position
(2.5 V) only when key switch is turned ON.
Detects minimum and maximum speed posi-
tion when engine learning is conducted.
Function
Governor lever doesnt move. Engine speed is controlled based on idle posi-
tion set when key switch is turned ON. There-
fore, engine speed is always controlled with
Symptoms in control sys- error in idle position setting if set incorrectly.
tem when trouble occurs.
Even if engine control dial is turned, engine Error in setting will seldom occur so that
speed doesnt increase from slow idle speed. change in machine operation will not be no-
Engine start may be difficult though starter ticed.
rotates. In case error is set on lower side, engine
Engine will stall if discontinuity occurs in EC speed changes but runs slower than normal
motor while engine is running at more than a through the full range when engine control dial
specified speed. is turned. (Note: In case error is set on upper
Engine will become uncontrollable if disconti- side, EC motor is driven so that it runs faster
nuity occurs in EC motor while engine is run- than the control range. However, motor, a
ning at lower than a specified speed. Engine worm gear type, holds governor lever at
cannot be stopped with key switch. maximum constant position, preventing en-
Symptoms in machine gine stall. When engine control dial is turned
operation when trouble to minimum speed position, governor lever is
returned to idle position.)
occurs. When starting engine, engine speed fluctu-
ates.
Starting engine is occasionally difficult.
T5-4-2
TROUBLESHOOTING / Troubleshooting B
Engine Control Dial Pump Control Pressure Sensor Pump 1 Delivery Pressure Sensor
Indicates governor lever position (engine Monitors pump control pressure to con- Monitors pump delivery pressure to con-
target speed). trol auto-acceleration system. trol HP mode, auto-acceleration and
forward/reverse travel pedal.
Engine speed doesnt change even if No signals arrive to MC If pump delivery pressure sensor output
engine control dial is turned. is 0 or 5 V, following symptoms will be
If discontinuity or short circuit occurs in presented by back-up mode function.
engine control dial, slow idle is used as
back-up value.
Engine speed is kept unchanged from Auto-acceleration control is inoperable HP mode is inoperable.
slow idle. (Engine can be stopped by (but not noticeable). Auto-acceleration control is inoperable.
key switch.) When the machine travels, the engine
speed doesnt increase.
Fault code 07 is displayed. Fault codes 12 and 13 are displayed. Fault code 10 is displayed.
Monitor Item: Engine Target Speed, Dial Monitor Item: Pump 1 and 2 Pump Flow Monitor Item: Pump 1 Delivery Pressure
Angle (Displayed by built-in diagnosing Control Pressure (Displayed by built-in di- (Displayed by built-in diagnostic system)
system) agnostic system)
Evaluation by Dr. ZX
Broken Circuit: 0.25 V or less
Short Circuit: 0.75 V or more
T5-4-3
TROUBLESHOOTING / Troubleshooting B
Function
If pump delivery pressure sensor output is 0 or Engine stalls if pump torque is increased.
5 V, following symptoms will be presented by
Symptoms in control sys- back-up mode function.
tem when trouble occurs.
NOTE
T5-4-4
TROUBLESHOOTING / Troubleshooting B
No signals arrive to MC No signals arrive to MC When the pressure sensor (front attach-
ment) or the harness between the pres-
sure sensor and the MC is faulty, the MC
judges that the pressure sensor (front
attachment) is ON.
Engine speed doesnt increase even if Engine speed doesnt increase even if Engine speed doesnt increase even if
auto-idle/auto-acceleration selector is auto-idle/auto-acceleration selector is any front attachment actuator is operated
auto-idle position. auto-idle position. with auto-idle/auto-acceleration selector
Even if the pedal is stepped on with the Even if the pedal is stepped on with the is auto-idle position.
engine speed control mode selection engine speed control mode selection Occasionally, engine speed hunts while
switch in the pedal position, the engine switch in the pedal position, the engine operating front attachment at slow idle.
speed doesnt increase. speed doesnt increase. When the parking brake is applied or
Occasionally, engine speed hunts while Occasionally, engine speed hunts while when the front attachment is operated,
traveling at slow idle. traveling at slow idle. the buzzer doesnt sound.
Even though the machine is driven with Even though the machine is driven with
the forward/reverse travel pedal fully the forward/reverse travel pedal fully
stepped on, the engine speed doesnt in- stepped on, the engine speed doesnt in-
crease. crease.
Even though the machine travels forward Even though the machine travels reverse
with the auto-acceleration switch ON, the with the auto-acceleration switch ON, the
engine speed doesnt increase. engine speed doesnt increase.
Fault codes 18 and 23 are displayed. Fault codes 18 and 24 are displayed.
Monitor Item: Forward Travel Control Pilot Monitor Item: Reverse Travel Control Pilot Monitor Item: Front ATT. Operation (Dis-
Pressure (Displayed built-in diagnostic sys- Pressure (Displayed built-in diagnostic sys- played built-in diagnostic system).
tem) tem) Monitor pressure change while operating
Monitor pressure change while traveling Monitor Pressure change while traveling front attachment.
forward. reverse.
Judge if pressure sensor is faulty or port Judge if pressure sensor is faulty or port Judge if pressure sensor is faulty or port
is clogged by switching pressure sensor is clogged by switching pressure sensor is clogged by switching pressure sensor
with another pressure sensor. with another pressure sensor. with another pressure sensor.
T5-4-5
TROUBLESHOOTING / Troubleshooting B
Function
During arm level crowding operation, arm speed Even if boom is raised with HP mode
is slightly slow. switch ON, engine speed doesnt in-
crease.
Even if boom is raised with
auto-idle/auto-acceleration selector is
auto-acceleration position, engine speed
doesnt increase.
Arm roll-in speed becomes slightly slower
Symptoms in machine op- than normal in boom raise and arm roll-in
combined operation as arm regenerative
eration when trouble occurs. system doesnt work. (Not remarkable)
Arm roll-in and boom raise speeds be-
come slightly slower at the beginning
stage of arm level crowd operation.
By Monitor Monitor Item: Swing Control Pilot Pressure (Dis- Monitor Item: Boom Raise Pilot Pressure
played built-in diagnosing system) (Displayed built-in diagnosing system).
Function Monitor pressure change while swinging upper- Monitor pressure change while raising
structure. boom.
Evalua-
tion
Using Test Har-
ness
Others
Judge if pressure sensor is faulty or port is Judge if pressure sensor is faulty or port
clogged by switching pressure sensor with an- is clogged by switching pressure sensor
other pressure sensor. with another pressure sensor.
NOTE
T5-4-6
TROUBLESHOOTING / Troubleshooting B
Even if arm is rolled-in with HP mode When the MC judges that the sensor is ab- Engine speed doesnt increase when
switch ON, engine speed doesnt in- normal, the MC displays any stored fault attachment is operated.
crease. codes (indicator light) and continues to control When attachment is operated, opera-
Even if arm is rolled-in with the machine operation normally using the tion speed increases.
auto-idle/auto-acceleration selector is backup value (0 MPa).
auto-acceleration position, engine speed
doesnt increase.
Arm speed is slow in arm level crowd
operation.
Judge if pressure sensor is faulty or port Judge if pressure sensor is faulty or port is Judge if pressure sensor is faulty or
is clogged by switching pressure sensor clogged by switching pressure sensor with port is clogged by switching pressure
with another pressure sensor. another pressure sensor. sensor with another pressure sensor.
T5-4-7
TROUBLESHOOTING / Troubleshooting B
Parts
Torque Control Solenoid Valve Solenoid Valve Unit (SE)
Supplies control pressure to pumps 1 and 2 to Releases the operate check valve provided in
control speed sensing. the axle lock cylinder
Function
Iftorque control solenoid valve is not acti- When the solenoid valve is seized, the oper-
vated, output pressure from solenoid valve is ate check valve doesnt open (close).
2
0 MPa (0 kgf/cm ).
Symptoms in control sys-
tem when trouble occurs.
Occasionally the engine stalls during travel The axle lock is not released even though the
operation. brake switch is turned OFF.
The axle lock cylinder is not locked even
though the brake switch is turned to the axle
lock position.
By Fault Code
Monitor Item: Pump Torque P/S Valve Output
By Monitor
Evalua-
Function
tion
Using Test
Harness
Others
NOTE
T2-1 T2-1
Descriptions of Control
(Operational Principle Sec-
tion in T/M)
T5-4-8
TROUBLESHOOTING / Troubleshooting B
Solenoid Valve Unit (SG) Solenoid Valve Unit (SC) Solenoid Valve Unit (SI)
When the work mode is selected with Routes return oil from arm cylinder rod side The valve is shifted when the superfine
the brake switch, the valve is shifted so to bottom side when rolling arm in to in- travel mode is selected so that the travel
that the pilot pressure shifts the brake crease arm speed. motor displacement angle is increased
valve (work brake control). to the maximum (superfine travel speed
control).
When descending a slope, the travel
motor displacement angle is increased
to apply the hydraulic brake.
In case solenoid valve unit (SG) is not In case solenoid valve unit (SC) is not ac- In case solenoid valve unit (SI) is not
activated, pressure at port SE becomes tivated, pressure at port SC becomes 0 activated, pressure at port SI becomes
2 2 2
0 MPa (0 kgf/cm ). MPa (0 kgf/cm ). Arm regenerative valve 0 MPa (0 kgf/cm ).
will not operate at this time.
Solenoid valve unit (SG) is closed: Solenoid valve unit (SC) is closed: Solenoid valve unit (SI) is closed:
The work brake doesnt operate. Arm speed is slow in arm level crowd op- Even of the super fine travel mode is
eration. selected, the travel speed is not re-
Solenoid valve unit (SG) is open: duced.
The work brake is kept apply so that the Solenoid valve unit (SC) is open:
machine cannot travel. Arm speed is fast as the arm regeneration Solenoid valve unit (SI) is open:
is always operated. Since the travel motor displacement an-
gle is constantly kept at the maximum,
the travel speed doesnt increase.
Monitor Item: Working Brake P/S Valve Monitor Item: Arm Regenerative P/S Valve Monitor Item: Travel Motor Tilt P/S Valve
Output Output Output
Install lamp harness (ST 7226) to check Install lamp harness (ST 7226) to check Install lamp harness (ST 7226) to check
output signals from MC and harness output signals from MC and harness con- output signals from MC and harness
condition. dition. condition.
T5-4-9
TROUBLESHOOTING / Troubleshooting B
In case max. pump 1 flow rate limit solenoid In case max. pump 2 flow rate limit so-
valve is not activated, pressure at output lenoid valve is not activated, pressure at
2 2
port becomes 0 MPa (0 kgf/cm ). output port becomes 0 MPa (0 kgf/cm ).
Max. pump 1 flow rate limit solenoid valve is Max. pump 2 flow late limit solenoid valve
closed: is closed:
Travel, bucket, arm and boom speeds are Arm, boom and swing speeds are slow
slow as maximum flow rate of pump 1 de- as maximum flow rate of pump 2 de-
creases. creases.
Max. pump 1 flow rate limit solenoid valve is Max. pump 2 flow rate limit solenoid valve
open: is open:
When operating attachment or front attach- When operating attachment, operating
ment, operating speed increase. speed increases.
Even though the creeper mode is selected,
Symptoms in machine operation the travel speed increase.
when trouble occurs.
By Fault Code
NOTE
T5-4-10
TROUBLESHOOTING / Troubleshooting B
Speed sensing control is inoperable. The speed display meter doesnt operate.
The superfine travel speed, travel motor
excessive rotation, and/or the for-
ward/reverse shifting restriction control is
inoperable.
Engine stalls under adverse operating The speed display meter doesnt operate.
conditions such as at high altitude. When descending a slope, the engine
speed is not reduced.
Monitor Item: Actual engine speed (If N
sensor fails, engine speed is not meas-
ured.)
Even if signals from N sensor are not
delivered due to broken circuit or poor
sensor installation, few changes in op-
erational performance occur, making
troubleshooting difficult. Use monitor
function.
T2-1 T2-1
T5-4-11
TROUBLESHOOTING / Troubleshooting B
Parts
Hydraulic Oil Temperature Sensor Engine Learning Switch
Monitors hydraulic oil temperature to control Starts engine learning.
auto-warming up and arm regenerative con- ON: 0 VLearning
trol. OFF: 5 VNormal Control
Function
By Monitor Monitor Item: Hydraulic Oil Temperature Monitor Item: Engine Learning Control
Evalua-
tion Function
Using Test
Harness
Others
In case temperature is extremely low (below
-20C), the control system is inoperable.
NOTE
T5-4-12
TROUBLESHOOTING / Troubleshooting B
When broken or short circuit occurs in Depending on failure of the switch, the Depending on failure of the switch, the
the switch, the Hi/Low solenoid valve is engine control mode may not be se- brake mode may not be selected. (Work
held in either Hi or Low position. lected. (Engine control dial, pedal, su- brake, parking brake, axle lock, and
perfine travel speed) OFF)
Even if the shift lever is placed in the D Even though the engine control mode Even though the work brake is selected,
position, the fast travel speed mode is switch is turned to the pedal position, the work brake isnt operable.
not selected. the engine speed cannot be controlled Even though the parking brake is se-
Even if the shift lever is placed in the L with the travel pilot valve. lected, the parking brake isnt operable.
position, the slow travel speed mode is Even though the engine control mode Even though the axle lock is selected,
not selected. switch is turned to the superfine posi- the axle cylinder is not locked.
Even though the shift lever is placed to tion, the superfine travel speed mode Even though the OFF position is se-
neutral, indicator (N) on the column box isnt operable. lected, either the work brake, parking
doesnt light. brake, or axle lock isnt operable.
Monitor Item: Neutral Switch, Mission Monitor Item: Creeper Mode Switch, Pedal Monitor Item: Working/Parking Switch
Switch EC Switch
T2-1
T5-4-13
TROUBLESHOOTING / Troubleshooting B
Symptoms in control
system when trouble oc-
curs.
Even if key switch is turned ON, step motor Same as described above.
will not move to the START position so that
engine cannot start. Even though engine
Symptoms in machine starts, speed stays slow.
operation when trouble Since pump displacement is held at minimum,
all actuator speeds are slow.
occurs.
T5-4-14
TROUBLESHOOTING / Troubleshooting B
Monitor Item: Auto-Idle/Auto-Accel Switch Monitor Item: E/P/HP Mode Switch Monitor Item: E/P/HP Mode Switch
T5-4-15
TROUBLESHOOTING / Troubleshooting B
By Fault Code
By Monitor Monitor Item: Work Mode Switch Monitor Item: Work Mode Switch
Evalua- Function
tion Using Test Har-
ness
Others
NOTE
T5-4-16
TROUBLESHOOTING / Troubleshooting B
In response to operation of the auxil- If switch valve is bound with valve activated, If spool is bound or spring is broken,
iary valve, engine speed related to bucket circuit is always restricted. orifice doesnt vary.
the attachment is controlled.
Even if auxiliary valve is operated, If poppet valve is bound at fully closed posi- If bound at fully closed position, attach-
engine speed doesnt increase. tion or if switch valve is bound when poppet ment speed becomes slow.
Even if attachment mode is selected, valve is fully closed, bucket speed becomes If bound at fully opened position, boom
maximum engine speed doesnt de- slow. doesnt move during 3-combined opera-
crease. If poppet valve is bound at fully opened posi- tion of swing, arm roll-in, and boom
tion or if switch valve is bound when poppet raise.
valve is fully opened, boom doesnt move
during 3-combined operation of bucket, arm
roll-in, and boom raise.
T5-4-17
TROUBLESHOOTING / Troubleshooting B
Parts
Boom Regenerative Valve Arm Regenerative Valve
Prevents boom cylinder hesitation by routing To be shifted by pilot pressure from solenoid
return oil from boom cylinder bottom side to valve unit (SC).
rod side. Increases arm speed by routing return oil
from arm cylinder rod side to bottom side.
Function
If check valve is kept closed, boom is not Arm regenerative function is inoperable.
smoothly lowered.
If check valve is kept open, machine cannot
be raised off ground with front attachment.
Same as described above. Arm speed is extremely slow during arm level
crowd operation while arm regenerative
valve is kept closed.
The lever operated first is given priority dur-
ing combined operation of arm roll-in and
swing while arm regenerative valve is kept
Symptoms in machine op- open.
eration when trouble occurs.
By Fault Code
By Monitor
Evalua- Function
tion Using Test Har-
ness
Others
NOTE
T5-4-18
TROUBLESHOOTING / Troubleshooting B
If check valve is kept closed, bucket is not If switch valve is bound, check valve If switch valve is bound, check valve
smoothly rolled in. doesnt open. doesnt open.
If check valve is kept open, bucket power is
weak.
Same as described above. If check valve is kept closed, boom If check valve is kept closed, arm roll-in
doesnt lower. speed becomes slow.
If check valve is kept open, front attach- If check valve is kept open, front at-
ment drift increases due to oil leaks in tachment drift increases due to oil
control valve. leaks in control valve.
Boom moves jerky or arm speed be- Arm moves jerky or arm speed be-
comes slow depending on valve bound comes slow depending on valve bound
conditions. conditions.
T5-4-19
TROUBLESHOOTING / Troubleshooting B
Parts
Auxiliary Flow Combiner Valve Bypass Shut-Out Valve
Supplies pressure oil from pump 1 to auxiliary Supplies pressure oil from pump 1 to aux-
spool when auxiliary spool is operated. iliary spool when auxiliary spool is oper-
ated.
Function
Ifcontrol valve is kept closed, operating speed If spool is bound in the fully open position,
doesnt increase in single auxiliary operation. single attachment operation speed be-
comes slow.
If spool is bound in the fully closed posi-
tion, main relief valve continues to relieve
with all control levers positioned in neutral.
If spool is bound in opened position, when
all control levers are in neutral, pump 1
pressure is higher than pump 2 pressure.
By Fault Code
By Monitor
Evalua- Function
tion Using Test Har-
ness
Others
NOTE
T5-4-20
TROUBLESHOOTING / Troubleshooting B
If spool is bound in the fully open posi- If spool is bound in the fully open position, If spool is bound in the fully open posi-
tion, even if control lever is in neutral, even if control lever is in neutral, pump 2 tion, swing parking brake is kept re-
pump 1 swash angle is tilted to maxi- swash angle is tilted to maximum. leased. (Machine vibrates while travel-
mum. If spool is bound in the fully open position, ing.)
If spool is bound in the fully open posi- pump 2 control pressure sensor monitors If spool is bound in the fully open posi-
tion, pump 1 control pressure sensor the maximum pressure. tion, the pressure sensor (front) is al-
monitors the maximum pressure. If spool is bound in the fully closed position, ways turned into ON.
If spool is bound in the fully closed posi- even if control lever is operated, pump 2 Thus, engine speed doesnt decrease
tion, even if control lever is operated, swash angle is held to minimum. (Swing when the control lever is in neutral dur-
pump 1 swash angle is held to mini- speed is very slow.) ing auto-idle/acceleration control.
mum. (Bucket speed is very slow.) If spool is bound in the fully open position, If spool is bound in the fully closed posi-
If spool is bound in the fully open posi- pump 2 control pressure sensor cant tion, swing parking brake is kept ap-
tion, pump 1 control pressure sensor monitor the pump control pressure. plied. (Dragging is felt.)
cant monitor the pump control pres- If spool is bound in the fully closed posi-
sure. tion, the pressure sensor (front) is al-
ways turned into OFF.
Thus, engine speed doesnt increase
when the control lever is operated dur-
ing auto-idle/acceleration control.
T5-4-21
TROUBLESHOOTING / Troubleshooting B
If spool is bound in the fully open position, Even though the blade/stabilizer lever is op-
bucket speed becomes slow when boom raise erated, the pilot oil pressure is not supplied
and bucket combined operation is made. to the 2-unit solenoid valve.
(Bucket flow rate control is inoperable.)
If spool is bound in the fully closed position,
boom doesnt move during 3-combined opera-
tion of bucket, arm roll-in, and boom raise.
By Fault Code
By Monitor
Evalua- Function
tion Using Test Har-
ness
Others
NOTE
T5-4-22
TROUBLESHOOTING / Troubleshooting B
Accumulator
Steering Valve Brake Valve
Charging Valve
Supplies the pressure oil from the Supplies the pressure oil to the front and Charges the pressure oil into the accu-
steering pump to the steering cylinder rear axle brakes corresponding to the mulator provided in the brake circuit and
corresponding to the steering wheel ro- brake pedal operating stroke. holds the charged pressure oil for the
tation. set period of time.
The pressure oil is not supplied to the Even though the brake pedal is stepped on, The pressure oil is not charged into the
steering cylinder in proportion to the the brake is not applied. accumulator.
steering wheel rotation. However, the Even though the brake pedal is not oper- The brake circuit oil pressure stays low.
steering valve acts as a pump, the ated, the brake is applied.
steering cylinder can operate.
Turning force of the steering wheel in- The same as described above. The service brake isnt operable.
creases. The service brake doesnt work effec-
tively.
T5-4-23
TROUBLESHOOTING / Troubleshooting B
If the parking brake solenoid valve is seized, Travel forward Pi cut solenoid valve is
the parking brake doesnt operate (or is kept closed:
applied) even if the brake switch is operated. Even though the shift lever is in neutral, the
If the transmission changeover solenoid valve machine travels forward.
is seized, shifting of the transmission is not Travel forward Pi cut solenoid valve is
achieved even if the travel mode switch is op- open:
erated. Even when the shift lever is in position L or
D, the machine doesnt travel forward.
By Fault Code
By Monitor Monitor Item: Fw/Bk Cut Relay
Evalua- Function
tion Using Test Har-
ness
Others
NOTE
T5-4-24
TROUBLESHOOTING / Troubleshooting B
Monitor Item: Fw/Bk Cut Relay
T2-1
T5-4-25
TROUBLESHOOTING / Troubleshooting B
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine z : 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 (Main Controller) z z
QOS Controller
EC Motor z
EC Sensor { z
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pressure Sensor (Travel)
Pressure Sensor (Front Attachment)
Pressure Sensor (Swing)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Auxiliary)
N Sensor (Engine Speed Sensor)
Hyd. Oil Temperature Sensor
Coolant Temperature Sensor
Key Switch z
Engine Control Dial
Auto-Idle/Acceleration Selector
Power Mode Switch
Work Mode Switch
Auxiliary Mode Switch
Engine Learning Switch z
Battery Relay z
Grow Plug Relay
Starter Relay z
Engine Electrical Equipment z
Engine Unit z z
Governor z z
Check batteries. Check fuel system Check fuel cut-off handle and engine control
(filters and piping). cable. Be sure to perform engine learning after
Remarks replacing engine.
T5-4-26
TROUBLESHOOTING / Troubleshooting B
z z z { z z
z { {
{ {
{
{
{
{
{
{
{ {
z
z
z { z
z {
z {
T5-4-27
TROUBLESHOOTING / Troubleshooting B
Parts
MC (Main Controller) z z z
QOS Controller
Torque Control Solenoid Valve
Pump 1 Delivery Pressure Sensor {
Pump 2 Delivery Pressure Sensor {
Pump 1 Control Pressure Sensor {
Pump 2 Control Pressure Sensor {
Pressure Sensor (Travel Forward) {
Pressure Sensor (Travel Reverse) {
Pressure Sensor (Front Attachment)
Pressure Sensor (Swing) {
Pressure Sensor (Boom Raise) {
Pressure Sensor (Arm Roll-In) {
Pressure Sensor (Auxiliary) z
N Sensor (Engine Speed Sensor)
Hyd. Oil Temperature Sensor
Coolant Temperature Switch
Parking Brake Pressure Switch
Auto-Idle/Acceleration Selector z
Power Mode Switch
Work Mode Switch z
Auxiliary Mode Switch z
Engine Learning Switch
Brake Switch
Shift Lever
Engine Speed Control Mode Selection Switch
z
Grow Plug Relay
Engine Unit z
Governor
Pump Regulator
Remarks
T5-4-28
TROUBLESHOOTING / Troubleshooting B
z z z z
z
z
{ {
{
z
{ {
z
z
z
z z
z
z z
z
z
{
Check fuel system Check batteries.
for clogging.
T5-4-29
TROUBLESHOOTING / Troubleshooting B
Parts
MC (Main Controller) z z z
Torque Control Solenoid Valve z
Pump 2 Delivery Pressure Sensor
Pilot Pump z
Pilot Valve
Pilot Relief Valve z
Pump 1 Flow Rate Control Valve
z
(Signal Control Valve)
Pump 2 Flow Rate Control Valve
z
(Signal Control Valve)
Remarks
NOTE: The trouble symptoms in this table are de- z : Related, required to check
{ : Related. However, in case this component fails, other trouble
scribed provided that each trouble occurs 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.
T5-4-30
TROUBLESHOOTING / Troubleshooting B
A-4 A-5
Actuator doesnt stop Actuator speed is faster
even if control lever is than normal.
returned to neutral. Precise control can not
be performed.
T5-4-31
TROUBLESHOOTING / Troubleshooting B
Parts
MC (Main Controller) z
Solenoid Valve Unit (SC) z
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor {
Pressure Sensor (Swing) {
Pressure Sensor (Boom Raise) {
Pressure Sensor (Arm Roll-In) {
Spool z
Main Relief Valve z
Overload Relief Valve z
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve z
Bucket Regenerative Valve
Bucket Flow Rate Control Valve
Boom Anti-Drift Valve
Arm Anti-Drift Valve
Emergency Valve
Shockless Valve (Signal Control Valve) z
Shuttle Valve (Signal Control Valve) z
Pilot Valve z
Cylinder
Remarks
T5-4-32
TROUBLESHOOTING / Troubleshooting B
z
z
z
z
z
z
z z z
z z z
z
z z
T5-4-33
TROUBLESHOOTING / Troubleshooting B
Parts
MC (Main Controller)
Torque Control Solenoid Valve
Solenoid Valve Unit (SC)
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pump 1 Control Pressure Sensor
Pump 2 Control Pressure Sensor
Pressure Sensor (Travel)
Pressure Sensor (Swing)
Pressure Sensor (Arm Roll-In)
Shift Lever
Pump Device
Spool
Load Check Valve
Swing Parking Brake Release Spool
z
(Signal Control Valve)
Pump 1 Flow Control Valve
(Signal Control Valve)
Pump 2 Flow Control Valve
z
(Signal Control Valve)
Shuttle Valve (Signal Control Valve) {
Swing Device z
Travel Device
Center Joint
Pilot Valve z
Remarks
T5-4-34
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-35
TROUBLESHOOTING / Troubleshooting B
Parts
MC (Main Controller) z z z
Monitor Controller
Solenoid Valve Unit (SG) z
Solenoid Valve Unit (SI) z
Max. Pump 1 Flow Rate
Shift Solenoid Valve
Parking Brake Solenoid Valve
Transmission Changeover Solenoid
Valve
Transistor Unit 2 z z
Relay z
Shift Lever
Brake Switch
Engine Speed Control Mode Selection
z
Switch
Control Valve z z z
Travel Shockless Valve z
Transmission Control Valve
Accumulator Charging Valve
Brake Valve
Transmission z {
Front Axle z {
Rear Axle z {
Travel Motor z z z
Center Joint z z
Pilot Valve z
Remarks
T5-4-36
TROUBLESHOOTING / Troubleshooting B
z
z z
z
{ z z
z z z
z
z z
z
z
z z z
z
z z
z
T5-4-37
TROUBLESHOOTING / Troubleshooting B
Parts
Steering Pump z
Steering Valve z z
Center Joint z
Front Axle { {
Other Electrical Equipment z z
Remarks
T5-4-38
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-39
TROUBLESHOOTING / Troubleshooting B
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter Does Not Rotate.
T5-4-40
TROUBLESHOOTING / Troubleshooting B
Faulty starter.
Faulty battery.
V ST G1 ACC
B G2 M
T105-07-04-002
T5-4-41
TROUBLESHOOTING / Troubleshooting B
E-2 Although starter rotates, engine doesnt
start.
1 2 3 4
T1F3-05-04-002
1- Governor Cable (From EC Motor)
2- Governor Lever
3- Fuel Cut-Off Cable (Fuel Cut-Off Handle)
4- Fuel Cut Lever
T5-4-42
TROUBLESHOOTING / Troubleshooting B
Governor Lever Position
T1F3-05-04-002
T5-4-43
TROUBLESHOOTING / Troubleshooting B
E-3 When engine control dial is fully rotated,
engine stalls.
Occasionally engine stalls during operation
with engine control dial fully rotated and
auto-idle ON.
Engine speed is slower than specification in
all operating ranges.
Idle speed is faster or slower than specifica-
tion.
In case engine learning has not been performed Refer to pages for Engine Learning in the SYS-
or engine learning has been incorrectly per- TEM/Control System group in the T/M (Opera-
formed, engine speed becomes slower than tional Principle).
specification across the operating range. Check for loose harness connections before-
In case the EC sensor is faulty, engine speed is hand.
controlled based on the governor lever position,
which is judged as the idle position when the key
switch is turned ON. Accordingly, discrepancies
in engine speed from specification will result.
Depending on where the governor lever is posi-
tioned when the key switch is turned ON, dis-
crepancy will differ, causing this trouble to be not
reproducible.
T5-4-44
TROUBLESHOOTING / Troubleshooting B
Refer to T4-6-1.
T5-4-45
TROUBLESHOOTING / Troubleshooting B
E-4 Even if engine control dial is rotated, engine
speed remains unchanged.
Refer to T4-6-1.
T5-4-46
TROUBLESHOOTING / Troubleshooting B
E-5 Engine speed doesnt increase after engine
is started.
When starting
engine, oil tem-
perature is over
0C or below
-20C. Normal.
T5-4-47
TROUBLESHOOTING / Troubleshooting B
E-6 Faulty HP mode
Sensors detect the conditions necessary to oper- Refer to the pages for HP Mode Control in the
ate the HP mode. Therefore, if any of these sen- SYSTEM / Control System group in the T/M (Op-
sor fails, the HP mode becomes inoperable. erational Principle).
Pressure sensors (arm roll-in and boom raise) Check for loose harness connections before-
and pump 1 and 2 delivery pressure sensors are hand.
also engaged in the HP mode control. However, if
these sensors fail, other operating functions will
be also affected. (Refer to the relationship be-
tween machine trouble symptoms and related
parts on page T5-4-2.)
Faulty power mode
switch or broken
harness between
NO power mode switch
and MC.
Monitor power mode
switch. Check if indica-
tion HP is highlighted
when power mode
NO switch is turned to HP Check if the symptom
mode. disappears after com- YES End.
pleting engine learn-
ing.
YES
Check if any fault Faulty MC or faulty
codes are displayed. Monitor item: E/P/HP engine.
mode switch NO
Refer to T4-6-1.
Faulty corresponding
sensor or broken
harness between
sensor and MC.
YES
Fault codes:
Pump 1 delivery pressure sensor: 10
Pump 2 delivery pressure sensor: 11
Pilot pressure sensor (boom raise): 15
Pilot pressure sensor (arm roll-in): 16
T5-4-48
TROUBLESHOOTING / Troubleshooting B
T5-4-49
TROUBLESHOOTING / Troubleshooting B
E-7 Even if key switch is turned OFF, engine
doesnt stop. (In case the engine doesnt
stop, stop the engine by pulling the engine
stop handle located under the seat stand.
Then, begin inspection.)
T5-4-50
TROUBLESHOOTING / Troubleshooting B
E-8 Faulty auto-idle system
In case trouble symptoms E1 to E7 are recog- Refer to the pages for Auto-Idle Control in the
nized, perform the troubleshooting of these trou- SYSTEM / Control System group in the T/M (Op-
bles beforehand. erational Principle).
Although the failure in pressure sensors (travel Check for loose harness connections before-
and front attachment) will have relevance to mal- hand.
function of the auto-idle control. However, if these
sensors fail, other operating functions will also be
affected. (Refer to the relationship between ma-
chine trouble symptoms and related parts on
page T5-4-2.)
Faulty MC or harness
YES between the MC and
the front attachment
Check, on monitor, if pressure sensor.
Fr (outline type
font) is displayed Refer to T4-6-1.
when pressure
YES sensor (front at-
tachment) is acti- Faulty pressure sen-
vated. YES sor (front attachment).
Check if symptom is
corrected when
Engine: Running pressure sensor
Monitor auto-idle switch. Monitor item: (front attachment) is
Check if displayed AI is Front attachment NO
replaced with an-
turned OFF or ON in re- operation other sensor. Bound swing parking
sponse to auto-idle /
brake release spool in
auto- acceleration selec-
NO the signal control
tor operation.
valve.
T5-4-51
TROUBLESHOOTING / Troubleshooting B
Faulty MC.
Monitor item: Auto-idle / NO
auto-accel switch
Auto-idle / Refer to T4-6-1.
auto-acceleration selec-
tor: OFF
T5-4-52
TROUBLESHOOTING / Troubleshooting B
E-9 Faulty E mode
Faulty MC.
YES
Monitor item: Refer to T4-6-1.
E/P/HP mode switch
Faulty MC.
Monitor item: E/P/HP switch NO
Power mode switch: P mode
Refer to T4-6-1.
T5-4-53
TROUBLESHOOTING / Troubleshooting B
E-10 Faulty auto-acceleration system
Related Fault Code: 10, 11, 12, 13, 14, 15, 16, and
18
The auto-acceleration system doesnt operate if Although the failure in pressure sensors (travel,
the following conditions are not met. swing, boom raise, and arm roll-in), pump 1 and
Engine Speed Control Mode Selection Switch: 2 delivery pressure sensors, and pump 1 and 2
Dial or Creeper Position control pressure sensors will have relevance to
Auto-Idle/Auto-Acceleration Selector: malfunction of the auto-acceleration control.
Auto-Acceleration Position However, if these sensors fail, other operating
Power Mode Switch: functions will also be affected. (Refer to the rela-
HP or P Position tionship between machine trouble symptoms and
In case trouble symptoms E-1 to E-9 are recog- related parts on page T5-4-2.)
nized, perform the troubleshooting of these trou- Refer to the pages for Auto-Acceleration Control
bles beforehand. in the SYSTEM / Control System group in the
T/M (Operational Principle).
T5-4-54
TROUBLESHOOTING / Troubleshooting B
Faulty MC.
Monitor item: Auto-idle / NO
auto-accel switch
Auto-idle / auto-acceleration se- Refer to T4-6-1.
lector:
Auto-idle position
T5-4-55
TROUBLESHOOTING / Troubleshooting B
E-11 When traveling or operating front attach-
ment with engine running at slow idle, en-
gine hunts.
Faulty MC.
Monitor item: NO
Engine target speed
Possible to display with built-in Refer to T4-6-1.
diagnosing system
T5-4-56
TROUBLESHOOTING / Troubleshooting B
E-12 Engine speed doesnt increase even if at-
tachment is operated in attachment mode.
In case trouble symptoms E-1 to E-11 are recog- Refer to the pages for Attachment Operation
nized, perform the troubleshooting of these trou- Speed Increase Control in the SYSTEM / Control
bles beforehand. System group in the T/M (Operational Principle).
Although the failure in pressure sensor (auxiliary) Check for loose harness connections before-
and power mode switch will have relevance to hand.
the malfunction of the attachment operation
speed increase control. However, if these sensor
and switches fail, other operating functions will
also be affected. (Refer to the relationship be-
tween machine trouble symptoms and related
parts on page T5-4-2.)
Set to Increase (+).
NO
Check if attachment
speed adjustment
has been set to In-
NO crease (+) in Dr. ZX Monitor attachment
service mode. pilot pressure. Check YES
if pressure varies in To A
response to lever
Check if P speed ad-
stroke.
justment has been YES
set to Decrease in Faulty auxiliary pres-
Dr. ZX service mode. sure sensor.
NO
T5-4-57
TROUBLESHOOTING / Troubleshooting B
E-13 When attachment mode is selected, engine
speed doesnt decrease.
NO
T5-4-58
TROUBLESHOOTING / Troubleshooting B
E-14 Engine stalls within several seconds after
engine has started.
T5-4-59
TROUBLESHOOTING / Troubleshooting B
E-15 Engine stalls during operation under ad-
verse condition such as at high altitude.
Disassemble to check
regulator.
YES
Monitor actual engine
speed. Check if engine
speed is abnormal. Monitor item: Pump torque
proportional solenoid valve
output
Refer to the Operational Per-
Monitor item: formance Test section.
Engine actual speed Faulty N sensor, or faulty
harness between N
sensor and MC.
YES
A
Broken harness be-
tween torque control so-
lenoid valve and MC.
NO
T5-4-60
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-61
TROUBLESHOOTING / Troubleshooting B
E-16 Engine is difficult to start at low tempera-
ture. (During cold weather or in cold dis-
tricts, the engine is difficult to start or
doesnt start although pre-heated.)
Check if electricity is routed to the glow plugs. Check battery at the same time.
Check the glow plugs for any abnormality. Check for loose harness connections before-
The pre-heat system operates only when coolant hand.
temperature is below 10 C (50 F). When cool-
ant temperature is higher than 10 C (50 F), the
pre-heat system doesnt operate.
Remove
the
copper
plate.
Specification: 20 to 24 V
Specification: Below 10
T105-07-04-006
T105-07-04-007
T5-4-62
TROUBLESHOOTING / Troubleshooting B
Connector (Harness End Connector Viewed from the Open End Side)
1 2 3 1
4
4 5 6 3
2
T5-4-63
TROUBLESHOOTING / Troubleshooting B
E-17 The engine speed remains unchanged Connector (Harness End Connector Viewed from the Open
even though the pedal is stepped on dur- End Side
ing traveling.
MC: Connector B
B1 B8
Check that: #9
Brake switch: OFF or Axle Lock Position
Engine Speed Control Mode Selection Switch:
Pedal Position B19 B25
Shift Lever: D or L Position
Faulty pressure sensor (travel forward and re-
verse) may be the cause of this problem. In this
case, other functions should become abnormal.
T5-4-64
TROUBLESHOOTING / Troubleshooting B
E-18 The engine speed remains unchanged
even though the pedal is stepped on dur- Connector (Harness End Connector Viewed from the Open
ing excavation. End Side
MC: Connector B
Related Fault Code: 18, 23
#3
Check that: B1 B8
Brake switch: Work Position #9
Engine Speed Control Mode Selection Switch:
Pedal Position
Shift Lever: N Position B19 B25
Faulty pressure sensor (travel forward and re-
verse) may be the cause of this problem. In this
case, other functions should become abnormal.
YES Faulty MC
Check if continuity
between harness Refer to T4-6-1.
Wk/Pk is
displayed. end terminal #9 and
vehicle frame exists
when MC connector Faulty brake switch or
B is removed. short-circuited harness
NO between MC and brake
switch.
Monitor working /
parking switch with
Faulty travel system, or
Dr. ZX.
parking brake system.
YES Refer to the travel system
troubleshooting and the
Check if column box brake system trouble-
parking brake indi- shooting.
Pk (outline type cator is ON.
font) is displayed. Short-circuited harness
Check if continuity YES
between MC and parking
between harness
brake pressure switch.
end terminal #3 and
NO vehicle frame exists
when MC connector Faulty MC
B is removed. NO
Refer to T4-6-1.
Refer to T4-6-1.
Monitor neutral
PEC (outline type switch with Dr. ZX. Faulty shift lever or broken
font) is displayed. harness between MC and
N is shift lever.
displayed.
T5-4-65
TROUBLESHOOTING / Troubleshooting B
ALL ACTUATOR SYSTEM TROUBLE-
SHOOTING
A-1 All actuator speeds are slow.
Reduction in pump 1 and 2 flow rate due to some Although speed is satisfactory, in case power is
reasons or faulty pilot system may cause this weak, refer to the troubleshooting for faulty relief
trouble. valve (F-1).
Also, check for fuse of the torque control solenoid Check for loose harness connections before-
valve. hand.
End.
NO
Check if primary pilot
pressure is normal.
YES Faulty N sensor or broken
harness in N sensor cir-
Fully boom raised or arm cuit.
roll-in
Monitor item: Boom raise Monitor actual engine
pilot pressure, arm roll-in speed. Check if ab-
pilot pressure normal speed is indi-
cated.
YES
YES
Monitor item: NO
Pump Torque P/S
Valve
Measurement: Refer
to the Operational
Performance Test
Section.
T5-4-66
TROUBLESHOOTING / Troubleshooting B
Torque Control Solenoid Valve Connector (Harness End Connector from the Open End Side)
MC: Connector A
#5 #6
A1 A11
A25 A32
Refer to T4-6-1.
T5-4-67
TROUBLESHOOTING / Troubleshooting B
A-2 Positioning cylinder and swing single op-
eration speeds are slow. Arm speed be-
comes slightly slow in level crowding op-
eration. (All these symptoms occur at the
same time.)
T5-4-68
TROUBLESHOOTING / Troubleshooting B
A-3 Travel is inoperable during single travel op-
eration. Single bucket operation speed is
slow. Boom is not raised properly during
arm level crowding. (All problems occur at
the same time.)
T5-4-69
TROUBLESHOOTING / Troubleshooting B
A-4 Actuator doesnt stop even if control lever
is returned to neutral.
NO
Although pilot pressure is not
routed to spool end in control
valve, spool is kept opened
due to binding of spool.
T5-4-70
TROUBLESHOOTING / Troubleshooting B
A-5 Actuator speed is faster than normal
Machine mistracks when travel lever is op-
erated at half stroke. Precise control cannot
be performed.
T5-4-71
TROUBLESHOOTING / Troubleshooting B
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
F-1 All front attachment actuator power is weak.
T5-4-72
TROUBLESHOOTING / Troubleshooting B
F-2 Some cylinders are inoperable or speeds
are slow.
T5-4-73
TROUBLESHOOTING / Troubleshooting B
F-3 Arm speed is slow in a combined operation.
Arm speed is slow during arm level crowd-
ing.
T5-4-74
TROUBLESHOOTING / Troubleshooting B
F-4 Bucket is slow in bucket roll-in single op-
eration. Bucket doesnt move smoothly in
bucket roll-in single operation.
Hose (SK)
Bucket Flow
Rate Control
Valve
T1GL-05-04-002
T5-4-75
TROUBLESHOOTING / Troubleshooting B
F-5 When starting to move in combined opera-
tion, arm doesnt smoothly move. Arm starts
to move slightly slow in arm roll-in single
operation. These troubles often occur when
oil temperature is low.
T5-4-76
TROUBLESHOOTING / Troubleshooting B
F-7 When boom raise or arm roll-out is operated,
boom or arm starts to move after moving
slightly downward.
Disassemble / Visual
Inspection Faulty load check valve.
NO
T5-4-77
TROUBLESHOOTING / Troubleshooting B
F-8 Front attachment drifts remarkably.
Normal.
YES
Correctly adjust
emergency valve and
Check if each front lock it up.
attachment cylin- NO
der drift is within Check if emergency
specification. valve at boom 1 sec-
NO
tion in control valve Check if symptom is
4-spool block is cor- deleted when overload
rectly adjusted. relief valve is tempo-
Check if cylinder drift YES rarily switched with
is reduced when pilot another overload relief
NO shut-off valve is valve.
closed.
T5-4-78
TROUBLESHOOTING / Troubleshooting B
Emergency
Valve
Scored control
valve spool, broken
NO spring, or loose
spool end.
NO Check if oil
leaks in cylin-
ders. Faulty cylinder. T155-06-04-001
T5-4-79
TROUBLESHOOTING / Troubleshooting B
SWING SYSTEM TROUBLESHOOTING
S-1 Swing is slow or unmoving.
T5-4-80
TROUBLESHOOTING / Troubleshooting B
T5-4-81
TROUBLESHOOTING / Troubleshooting B
TRAVEL SYSTEM TROUBLESHOOTING
The travel system is inoperable unless the fol- Air mixing in the transmission hydraulic circuit
lowing conditions are met. may cause the parking brake to drag. Bleed air
Shift Lever: D or L position from the transmission by referring to T5-4-116.
Brake Switch: OFF or Axle Lock Position When other actuators (front attachment and
In case the travel motor fails, it can be deter- swing motor) operate normally, the pilot pump,
mined by means of the indicator in the column pilot filter and pilot relief valve are considered to
box and the buzzer. be normal.
Failure in the transmission and/or axle (front Check for loose harness connections before-
and/or rear) may be the cause of the trouble. hand.
Check if a noise is emitted from each section.
Check if the parking brake indicator is OFF.
T5-4-82
TROUBLESHOOTING / Troubleshooting B
#9 B1 B8
7 1
#1 B19 B25
#2
T5-4-83
TROUBLESHOOTING / Troubleshooting B
T-2 The machine doesnt travel in both forward
and reverse directions or moves slowly.
T5-4-84
TROUBLESHOOTING / Troubleshooting B
Faulty MC or
YES
Short-circuited harness
between MC and tran-
sistor unit 2.
Refer to T4-6-1.
Transistor Unit 2
7 1
#1
#2
T5-4-85
TROUBLESHOOTING / Troubleshooting B
T-3 Travel speed is slow and travel power is
weak in both forward and reverse directions.
In case the travel motor fails, it can be deter- When other actuators (front attachment and
mined by means of the indicator in the column swing motor) operate normally, the pilot pump,
box and the buzzer. pilot filter and pilot relief valve is considered to be
Failure in the transmission and/or axle (front normal.
and/or rear) may be the cause of the trouble. Pump 1 flow rate reduction may be the cause of
Check if a noise is emitted from each section. this trouble when bucket single operation speed
Air mixing in the transmission hydraulic circuit is slow. Refer to A-3.
may cause the parking brake to drag. Bleed air Check for loose harness connections before-
from the transmission by referring to T5-4-116. hand.
NO
NO Faulty MC.
Disconnect connector C
from MC. Check if con- Refer to T4-6-1.
tinuity between harness
YES end connector terminal
#8 and vehicle frame
exists. Faulty engine speed control
mode selection switch or
short-circuited harness be-
YES tween MC and engine speed
control mode selection
switch.
T5-4-86
TROUBLESHOOTING / Troubleshooting B
Check by measuring if
drain amount from
travel motor is normal.
Refer to the Opera- Faulty travel motor.
tional Performance NO
Test section.
MC Connector C
#8
C1 C10
C23 C31
T5-4-87
TROUBLESHOOTING / Troubleshooting B
T-4 Even though foot is left from the travel pilot
valve, the hydraulic brake doesnt operate
(the machine continues to runaway).
T5-4-88
TROUBLESHOOTING / Troubleshooting B
T-5 Maximum travel speed is slow (traction
force is normal).
Check by monitoring
the vehicle speed with
YES Dr. ZX if the speed me-
ter on column box indi- Faulty harness between
column box and MC.
cates the same vehicle NO
speed.
MC: Connector A
A1 A11
A25 A32
#19 #20
T5-4-89
TROUBLESHOOTING / Troubleshooting B
T-6 Travel mode (Hi/Low) doesnt shift.
Machine
Front Side
T1F3-05-04-001
T5-4-90
TROUBLESHOOTING / Troubleshooting B
T5-4-91
TROUBLESHOOTING / Troubleshooting B
BRAKE SYSTEM TROUBLESHOOTING
T1F3-03-03-002
Shift Lever: D or L
position Faulty transmission.
Brake Switch: Position YES
other than parking
IMPORTANT:
Accumulators are pro-
vided in the circuit con-
nected to port M. Suffi-
ciently relieve the circuit
pressure before installing
the pressure gauge.
T5-4-92
TROUBLESHOOTING / Troubleshooting B
Monitor
Controller
From Fusible
Link (45A)
Column Box
From Fusible (Brake Switch)
Link (65A)
Parking Brake
Relay 3 Parking Parking
Brake Brake
Relay 1 Relay 2
Parking Brake
Solenoid Valve T1GL-05-04-001
T5-4-93
TROUBLESHOOTING / Troubleshooting B
B-2 Parking brake doesnt operate (is not ap-
plied).
Port M
T1F3-03-03-002
T5-4-94
TROUBLESHOOTING / Troubleshooting B
Monitor
Controller
From Fusible
Link (45A)
Column Box
From Fusible (Brake Switch)
Link (65A)
Parking Brake
Relay 3 Parking Parking
Brake Brake
Relay 1 Relay 2
Parking Brake
Solenoid Valve T1GL-05-04-001
T5-4-95
TROUBLESHOOTING / Troubleshooting B
B-3 Service brake doesnt operate, or is not ap-
plied effectively.
T5-4-96
TROUBLESHOOTING / Troubleshooting B
STEERING SYSTEM TROUBLESHOOTING
T5-4-97
TROUBLESHOOTING / Troubleshooting B
OTHER SYSTEM TROUBLESHOOTING
O-1 Wiper is inoperable or not retracted.
Checking Instructions
The wiper is driven by electric power routed via If the front window is open, the wiper wont oper-
the relay circuit controlled by the monitor assem- ate. Check that the front window is securely
bly. In case the wiper is inoperable, first check closed.
the wiper motor and links for any abnormality us-
ing an auxiliary electric power and the test har-
ness.
Faulty front window
open/close switch or
short-circuited harness
between front window
YES open/close switch and
monitor.
T5-4-98
TROUBLESHOOTING / Troubleshooting B
Lamp S
M B S
L E
Ground
T178-05-04-004
Retracted Position
Operating Range
T178-05-04-005
Lamp S
T157-07-04-004
T5-4-99
TROUBLESHOOTING / Troubleshooting B
O-2 Air Conditioner Malfunction
first. LCD
T5-4-100
TROUBLESHOOTING / Troubleshooting B
T5-4-101
TROUBLESHOOTING / Troubleshooting B
Change Displayed Fault Code
1. When displaying more than one fault code, press Temperature
either the upper or bottom side of the tempera- Control Switch
ture control switch key. The following fault code is
displayed.
NOTE: Each time the displayed fault code is
changed, the buzzer sounds. In case only
one fault code exists, the displayed fault
code remains unchanged.
M178-01-017
LCD
M178-01-017
Fan Switch
T5-4-102
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-103
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
Uncontrollable vent hole
Before replacing the control amplifier, be sure to
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
T5-4-104
TROUBLESHOOTING / Troubleshooting B
T5-4-105
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
doesnt 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.
T5-4-106
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 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 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.
T5-4-107
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.
T5-4-108
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.
Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in
L mode for more than 10 minutes, flush smell out by condensed water.
T5-4-109
TROUBLESHOOTING / Troubleshooting B
Compressor
Inoperable
cooling Clutch terminal voltage is low.
system.
T5-4-110
TROUBLESHOOTING / Troubleshooting B
Oil and refrigerant leaks from front housing, and/or cylinder block joint. Replace.
No leaks (normal).
Replace.
Blown gasket (Refer to NOTE 3 on page T5-4-113.)
T5-4-111
TROUBLESHOOTING / Troubleshooting B
Compressor
Trouble other than compressor. Refer to the Cooling Circuit Troubleshooting Ta-
ble on page T5-4-106.
Abnormal
noise
T5-4-112
TROUBLESHOOTING / Troubleshooting B
Loose screws.
Broken valve.
Replace.
Blown gasket.
NOTE:
1. Dont quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A
slight oil seepage will appear due to the seal construction. However, this oil seepage will not
cause malfunction. Be sure to accurately check whether oil is leaking or seeping only.
2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose sur-
face may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
high-pressure side and low-pressure side is 0.49 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.
T5-4-113
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, using this switch-check Section) Section)
method, faulty part /component, and/or harness can
be easily found.
PP2 PP1
Example: Abnormal pump 1 delivery pressure (Fault
code: 10)
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 the pump 2 delivery pressure is abnormal
(fault code 11), the pump 1 delivery pressure sensor
is considered to be faulty.
Pump 2 Pump 1
In case the pump 1 delivery pressure is abnormal (4-Spool
(5-Spool
(fault code 10), the pump 1 delivery pressure sensor Section) Section)
harness is considered to be faulty.
PP1 PP2
Figure B T157-07-04-006
T5-4-114
TROUBLESHOOTING / Troubleshooting B
T5-4-115
TROUBLESHOOTING / Troubleshooting B
BLEEDING AIR FROM TRANSMISSION 1
(working) position.
NOTE: Air is not bled when the brake switch is in
the P (parking) position. 1
4 MCBB-01-010
T5-4-116
TROUBLESHOOTING / Troubleshooting B
BLEEDING AIR FROM BRAKE (AXLE)
IMPORTANT: If air is mixed in the brake system,
the brake function is reduced, pos- 1
sibly resulting in serious hazard. Be
sure to bleed air from the brake
system after disconnecting and re-
connecting the pipe lines, or
changing the hydraulic oil. Bleed air
until hydraulic oil of approx. 500 mL
(0.13 US gal.) is drained from each
wheel (4 places) after air bubbles
disappear.
MCBB-01-008
T5-4-117
TROUBLESHOOTING / Troubleshooting B
EMERGENCY BOOM LOWERING PRO- Rear
CEDURE (without hose-rupture safety
1 Boom 1
valve)
1
5. Loosen socket-head screw (6) clockwise using
5
an allen wrench (4 mm) while closely watching
the boom lower. Note that the loosened degree of
screw (6) determines the boom lowering speed. 7
Adjust the boom lowering speed with the allen
wrench as required. 2
Take care not to remove snap ring (3) and
washer (4) at this time. Also, do not loosen screw 8
(6) excessively or cause washer (4) to be
deformed.
T5-4-118
TROUBLESHOOTING / Troubleshooting B
EMERGENCY BOOM LOWERING PRO-
CEDURE (with hose-rupture safety valve) Hose-Rupture
Safety Valve
1 2
NOTE: Never loosen screw (2) more than 1.5
turns. Adjusting screw (2) may come off.
M1G6-05-014
T5-4-119
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-120
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C (TROUBLE-
SHOOTING FOR MONITOR) PROCEDURE
Use troubleshooting C when any monitors, such as
gauges or indicators malfunction.
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,
and may damage components as well.
Key switch: ON
Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
Harness End
Connector
Harness
T6L4-05-03-001
Open End Side
T5-5-1
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF COOLANT TEM-
PERATURE GAUGE
Disconnect coolant
Gauge pointer temperature sensor.
swings over Check if pointer returns Short-circuited harness be-
scale. YES tween monitor and sensor.
to zero.
Remove connector B (20P)
from monitor. Check if voltage
Key switch: ON at monitor harness end ter-
NO minal #18 is 5 V.
Faulty monitor.
NO
T5-5-2
TROUBLESHOOTING / Troubleshooting C
M178-01-104
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-3
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF FUEL GAUGE
T5-5-4
TROUBLESHOOTING / Troubleshooting C
Fuel Sensor
Fuel Gauge
Float Upper Limit
FULL 1/2
R381.9 mm
257 mm 3/4
Lower Limit
93 mm
70.5 mm M178-01-105
1/2
204 mm
1/4
338 mm
EMPTY
T178-05-05-001
NOTE: 1 mm = 0.03937 in
10 9 8 7 6 5 4 3 2 1
1 2
20 19 18 17 16 15 14 13 12 11
T5-5-5
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF INDICATOR LIGHT
CHECK SYSTEM
Conduct troubleshooting of
each indicator, which does
not light.
NO
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-6
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF PREHEAT INDICATOR
The preheat system operates only when coolant In case the preheat system malfunctions, refer to
temperature is below 10 C (50 F), lighting the the troubleshooting B for E-16 Engine is difficult to
preheat indicator for 8 seconds. (Refer to the start at low temperature.
SYSTEM /Electrical Circuit group.) Check for loose harness connections beforehand.
Without discon-
necting connector,
ground connector to
vehicle frame using
Connector (Harness end connector terminals seen jumper wire such as
from the open end side) clip from the back of
connector.
Monitor Connector B (20P) QOS Controller
10 9 8 7 6 5 4 3 2 1 1 2 3
20 19 18 17 16 15 14 13 12 11 4 5 6
T5-5-7
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF OVERHEAT INDICA-
TOR
Key switch: ON
Indicator doesnt Check if indicator
light even if engine lights when key Key switch: ON
overheats. switch is turned ON. Without disconnecting connector,
ground connector to vehicle frame
using such jumper wire as clip from
Key switch: ON the back of connector.
Faulty monitor.
NO
Check if indicator
Indicator lights even goes OFF when
if coolant tempera- overheat switch is Short-circuited harness be-
ture is low. disconnected. tween monitor and overheat
YES
Check if indicator goes switch.
OFF when connector B
Key switch: ON (20P) is disconnected
Engine: Stopped NO from monitor.
Faulty monitor.
Key switch: ON NO
T5-5-8
TROUBLESHOOTING / Troubleshooting C
Overheat Switch
Coolant Temperature Operation
Lower than 105 C OFF
(221 F)
105 C (221 F) or ON
higher
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-9
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF AIR FILTER RESTRIC-
TION INDICATOR
Key switch: ON
A
Broken harness between
monitor and air filter restriction
NO switch.
T5-5-10
TROUBLESHOOTING / Troubleshooting C
Pressure Operation
5.1 kPa (520 mmH2O) OFF
6.2 kPa (630 mmH2O) ON
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-11
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF FUEL LEVEL INDICA-
TOR
YES
NO
YES
Disconnect fuel
Indicator comes ON sensor. Check if
even if fuel still re- indicator goes
mains. OFF.
YES
Key switch: ON
NO
T5-5-12
TROUBLESHOOTING / Troubleshooting C
10 9 8 7 6 5 4 3 2 1
Short-circuited harness be- 20 19 18 17 16 15 14 13 12 11
tween monitor controller and
fuel sensor.
T5-5-13
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ALTERNATOR INDI-
CATOR
Check for loose harness connections beforehand. NOTE: *Regulator terminals L are water-resistant
type connectors so that it is not practical to
measure voltage at these terminals. Meas-
ure voltage at starter relay terminal R in-
stead. Check for continuity between starter
relay terminal R and regulator terminal L
beforehand.
Alternator indicator
stays ON after en- Measure voltage at
Engine: Running
gine is started. regulator terminal L.*
Engine: Running
Less than 12 V or
higher than 35 V
Although alternator
output is low, alter- Check if indicator
nator indicator lights when key switch
doesnt light. is turned ON. NO
Key switch: ON
NO
E
8 7 6 5 4 3 2 1
S R 16 15 14 13 12 11 10 9
T5-5-14
TROUBLESHOOTING / Troubleshooting C
Between 12 V
and 35 V Faulty monitor.
Between 12 V
and 35 V Faulty monitor.
Between 12 V Measure voltage at
and 35 V monitor connector A
(16P) terminal #2.
Broken harness between regula-
Less than 12 V or tor terminal L and monitor.
Engine: Running higher than 35 V
Faulty regulator.
Less than 12 V or
higher than 35 V
Go to the troubleshooting B (en-
gine troubleshooting).
T5-5-15
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE OIL PRES-
SURE INDICATOR
Check for loose harness connections beforehand. NOTE: During one or two minutes after the engine
is stopped, engine oil pressure may still
exist. When the engine is restarted under
this condition, the indicator may not light.
Faulty monitor.
NO
Faulty monitor.
NO
Key switch: ON
T5-5-16
TROUBLESHOOTING / Troubleshooting C
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-17
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HYDRAULIC OIL FIL-
TER INDICATOR (OPTIONAL)
NO
YES
Check if indicator goes
OFF when hydraulic oil
Although hydraulic filter restriction switch at
oil filter is not plug receptacle with white
clogged, indicator and blue cable is discon-
lights. nected.
Check if indicator goes OFF
when connector C (20P) is
disconnected from monitor.
Key switch: ON NO
Engine: Stopped
Key switch: ON
T5-5-18
TROUBLESHOOTING / Troubleshooting C
Faulty monitor.
NO
Connector (Harness end connector terminals seen
from the open end side)
Faulty monitor.
NO
T5-5-19
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF OVERLOAD ALARM
INDICATOR (OPTIONAL) Connector (Harness end connector terminals seen
from the open end side)
By bulb blow inspection, check that bulb is not Monitor Connector C (20P)
blown.
Check that cancellation switch is at ON position 10 9 8 7 6 5 4 3 2 1
(cancellation release position). 20 19 18 17 16 15 14 13 12 11
Check for loose harness connections beforehand.
Connector (Monitor end connector terminals seen from
Alarm indicator does not go ON even when lifting the open end side)
a load over the setting.
Connector (1)
1 2 3 4
5 6 7 8 9 10
Disconnect monitor
connector C (20P) and
connector (1).
Check for continuity YES
between monitor harness
YES end connector terminal
#20 and connector (1)
terminal #8. NO
Check if alarm buzzer
YES YES
sounds.
Boom raise
Check if alarm indicator
(When relieving)
goes ON when overload
alarm relay and work light
NO relay 2 (R4).
Disconnect overload
alarm relay connector.
Check if alarm
Key switch: ON indicator goes ON
Using Dr. ZX, monitor when connecting relay
boom bottom pressure and NO terminal #2 to the
overload alarm. body.
Check if the following
conditions are met:
NO
T5-5-20
TROUBLESHOOTING / Troubleshooting C
Monitor
Connector (1)
MC
Boom Bottom
Pressure Sensor
Diode
Faulty Monitor.
Refer to T4-6-1.
T5-5-21
TROUBLESHOOTING / Troubleshooting C
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
Connector (1)
1 2 3 4
5 6 7 8 9 10
YES
T5-5-22
TROUBLESHOOTING / Troubleshooting C
Monitor
Connector (1)
MC
Boom Bottom
Pressure Sensor
Diode
Cancellation Switch
Transistor Unit
Overload Alarm Relay
T1GL-05-05-001
Refer T4-6-1.
YES Faulty overload alarm relay.
Faulty monitor.
NO
T5-5-23
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF
AUTO-ACCELERATION INDICATOR
YES
Auto-acceleration Disconnect monitor end
indicator does not go connector B (20P).
ON even when Check if voltage at
Check if indicator goes YES
selecting monitor end connector
auto-acceleration. terminal #11 is 5 V. ON when exchanging
auto-acceleration
cancellation relay (R26)
Engine speed control NO with parking brake alarm Disconnect switch box
mode selection switch: relay (R23). connector.
Dial or Creeper position Check if indicator goes
ON when connecting
NO harness end connector
terminal #9 to the body.
T5-5-24
TROUBLESHOOTING / Troubleshooting C
Faulty auto-acceleration
cancellation relay (R26).
7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8 20 19 18 17 16 15 14 13 12 11
T5-5-25
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF AUTO-IDLE
INDICATOR
Switch Box
7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 8
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-26
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF DIGGING MODE
INDICATOR OR ATTACHMENT MODE
INDICATOR
T5-5-27
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF LCD
Display
Description Cause of Trouble
Order
1 Hour Meter Refer to the next page.
2 Trip 1 Faulty Monitor.
3 Trip 2
4 Actual Engine Speed In case Dr. ZX can display data, monitor is abnormal or communication
5 Hydraulic Oil between monitor and MC is interrupted. In case Dr. ZX doesnt display
Temperature data, corresponding signal sensor is faulty. (The machine must have
any abnormality in the control system. Refer to Troubleshooting B.)
8 Fault Code* In case Dr. ZX can display data, monitor is abnormal or communication
9 ML Switch** between monitor and MC is interrupted. In case Dr. ZX doesnt display
10 Pump 1 Delivery data, corresponding signal sensor is faulty. (The machine must have
Pressure any abnormality in the control system. Refer to Troubleshooting B.)
11 Pump 2 Delivery
Pressure
12 Pump 1 Pump (Flow)
Control Pressure
13 Pump 2 Pump (Flow)
Control Pressure
14 Engine Target Speed
15 EC Angle
16 Dial Angle
17 Boom Raise Pilot
Pressure
18 Arm Roll-In Pilot
Pressure
19 Swing Pilot Pressure
20 Travel Pilot Pressure
21 Front Attachment
Operation
22 Attachment Pilot
Pressure
23 Work Mode Position
T5-5-28
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HOUR METER
Lower than
Faulty regulator or
12 V
alternator.
8 7 6 5 4 3 2 1 E
16 15 14 13 12 11 10 9 S R
T5-5-29
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF BLADE/STABILIZER
INDICATOR
Connector (Harness end connector terminals seen
Check that indicator bulb is not blown. from the open end side)
Check for loose harness connections beforehand.
Monitor Connector C (16P) Connector (1)
8 7 6 5 4 3 2 1 2 1
16 15 14 13 12 11 10 9 4 3
1 2 3 1 2 3 1 2 3
4 5 6 4 5 6 4 5 6
YES
Check if voltage at
YES diode (D2) terminal
#1 is 12 V. Disconnect connector (1).
Check if voltage at monitor
end connector terminal #2
is 12 V.
NO
T5-5-30
TROUBLESHOOTING / Troubleshooting C
Monitor
Front/Rear Left/Right
Blade/Stabilizer Selection Selection
Selection Switch Switch Switch
Diode (D2)
Connector (1)
T1GL-05-05-002
T5-5-31
TROUBLESHOOTING / Troubleshooting C
8 7 6 5 4 3 2 1 2 1
16 15 14 13 12 11 10 9 4 3
1 2 3 1 2 3 1 2 3
4 5 6 4 5 6 4 5 6
YES
Check if continuity
Check if indicator between left/right
Indicator goes ON goes OFF when selection switch harness
even if blade/stabilizer disconnecting blade/ end connector terminal
selection switch is stabilizer selection YES #5 and blade/stabilizer
OFF. switch connector. selection switch harness
end connector terminal
#1.
T5-5-32
TROUBLESHOOTING / Troubleshooting C
Monitor
Front/Rear Left/Right
Blade/Stabilizer Selection Selection
Selection Switch Switch Switch
Diode (D2)
Connector (1)
T1GL-05-05-002
T5-5-33
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF BUZZER
Check for loose harness connections beforehand. NOTE: *Regulator terminals L are water-resistant
type connectors so that it is not practical to
measure voltage at these terminals.
Measure voltage at starter relay terminal R
instead. Check for continuity between
starter relay terminal R and regulator
terminal L beforehand.
T5-5-34
TROUBLESHOOTING / Troubleshooting C
8 7 6 5 4 3 2 1 E
16 15 14 13 12 11 10 9 S R
Lower than 12 V or
more than 35 V Faulty regulator and
alternator.
T5-5-35
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF TURN SIGNAL INDI-
CATOR
Check for loose harness connections before-
hand.
If turn signal does not flash, MALFUNCTION of
flasher relay is suspected.
T5-5-36
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF TRAVEL MOTOR IN-
DICATOR
Connector (Harness end connector terminals seen
from the open end side)
Malfunction of travel motor can be found by
buzzer and indicator.
Notice that buzzer does not sound, and indicator Column Box: Connector D (12P)
does not go ON if both column box buzzer circuit
and travel motor indicator circuit are faulty, even
in the case of malfunction of travel motor. 2 3 4 5
In this case, make judgment depending on trav- 6 7 8 9 10 11 12
eling conditions. Refer to troubleshooting B T-1
The machine doesnt travel and T-3 Travel
speed is slow and travel power is weak in both
forward and reverse directions.
Check for loose harness connections before-
hand.
A
Broken harness between
travel motor alarm relay
NO (R22) and column box.
T5-5-37
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF WORK LIGHT INDI-
CATOR
T5-5-38
TROUBLESHOOTING / Troubleshooting C
2 3 4 5 7 6 5 4 3 2 1
6 7 8 9 10 11 12 16 15 14 13 12 11 10 9 8
T5-5-39
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF SHIFT LEVER INDI-
CATOR
T5-5-40
TROUBLESHOOTING / Troubleshooting C
Reconnect disconnected
connector. Disconnect YES Faulty column box.
column box connector D
(12P). Check if voltage at
YES
harness end connector
Check if there is continuity terminal #5 is 24 V. Broken harness between neutral
between shift lever con- relay (R21) and column box.
YES nector end terminals #1 NO
and #5.
Faulty shift lever.
NO
2 3 4 5 1 2 3
6 7 8 9 10 11 12 4 5 6
T5-5-41
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF WORK BRAKE INDI-
CATOR
Reconnect discon-
nected connector.
Check if indicator goes Faulty work brake indicator
YES (R18).
OFF when work brake
YES indicator relay (R18) and
left turn signal relay
Check if indicator (R15) are exchanged. Short-circuited harness be-
Indicator goes ON even tween work brake indicator
goes OFF when col-
if brake switch is not at S (R18) and brake switch.
umn box connector B NO
(work) position.
(9P) is disconnected.
YES
Disconnect brake
switch connector.
Indicator does not go ON Check if indicator goes
even if brake switch is at ON when harness end
S (work) position. connector #3 is con-
nected to body.
2 3
4 5 6
7 8 9
T5-5-42
TROUBLESHOOTING / Troubleshooting C
T5-5-43
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF PARKING BRAKE IN-
DICATOR
YES
Check if indicator goes
Indicator goes ON even OFF when parking brake
if brake switch is not at P pressure switch connec-
(parking) position. tor is disconnected. YES
Check if indicator goes
OFF when diode (D19)
is removed.
NO
NO
2 3
4 5 6
7 8 9
T5-5-44
TROUBLESHOOTING / Troubleshooting C
T5-5-45
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF AXLE LOCK INDICA-
TOR
YES
Check if indicator
goes OFF when axle
Indicator goes ON lock relay (R19) and Disconnect brake switch
even if brake switch is right turn signal relay connector. Check if con-
OFF position. (R16) are ex- tinuity between brake
YES switch end connector
changed.
Check if indicator terminal #4 and #6.
goes OFF when
Brake switch: OFF connector B (9P) is
position disconnected from
NO column box.
NO
T5-5-46
TROUBLESHOOTING / Troubleshooting C
2 3
1 2 3
4 5 6
4 5 6
7 8 9
T5-5-47
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF CLEARANCE LIGHT
INDICATOR
2 3
4 5 6
7 8 9
T5-5-48
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HAZARD LIGHT INDI-
CATOR
The hazard light indicator comes ON when light-
ing signal is inputted to the logic circuit in the col-
umn box from both left and right turn signals.
Therefore, the hazard light indicator does not
come ON when the signal is coming from only
one side. If the hazard light indicator does not
come ON even if both turn signals are lighting or
blinking, blown bulb, broken wiring within column
box, or failure in logic circuit may be suspected. If
only one side of turn signal indicator comes
ON/blinks, refer to Troubleshooting Malfunction
of Turn Signal Indicator.
Check for loose harness connections before-
hand.
T5-5-49
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HIGH-BEAM INDICA-
TOR
T5-5-50
TROUBLESHOOTING / Troubleshooting C
Reconnect disconnected
connector. Disconnect YES Broken harness between high-beam
column box connector B relay (R14) and column box.
(9P). Check if voltage at
Check if there is conti- YES harness end connector
nuity between light terminal #2 is 0 V.
Faulty logic circuit in column box or
switch end connector blown bulb.
NO terminals #2 and #5. NO
2 3
1 2
4 5 6
3 4 5 6
7 8 9
T5-5-51
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF BUZZER IN COLUMN
BOX
If buzzer in column box sounds, travel motor in- NOTE: An example of travel motor indicator is
dicator, parking brake indicator or brake oil indi- described below.
cator must go ON at the same time.
If buzzer sounds even though each indicator is
not ON, or if buzzer does not sound even though
each indicator is ON, Check buzzer circuit and
each indicator circuit. (Refer to Malfunction of
Indicator.)
Check for loose harness connections before-
hand.
NO
T5-5-52
TROUBLESHOOTING / Troubleshooting C
Connector (Column box end connector terminals seen Connector (Harness end connector terminals seen
from the open end side) from the open end side)
2 2 3
4 5 6
7 8 9
T5-5-53
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF BRAKE OIL PRES-
SURE GAUGE
Key switch: ON NO
Disconnect pressure
sensor connector.
Check if pointer swings YES Faulty pressure sensor.
Pressure toward upper limit when
gauge pointer harness end connector
fluctuates. terminals #1 and #2 are Short-circuited harness
Check if the pointer re-
connected. turns toward lower lim- YES between pressure sensor
and column box.
iter when column box
connector B (9P) is
NO disconnected.
Faulty column box.
Key switch: ON
Connection is made NO
using clip.
T5-5-54
TROUBLESHOOTING / Troubleshooting C
2 3
4 5 6
7 8 9
MCBB-01-006
Pressur Sensor
Pressure and Voltage of Pressure Gauge (Brake Oil Pressure Sensor)
Standard Pressure
bar 0 90 160 200
(MPa) (0) (9) (16) (20) 1 2 3
(kgf/cm2) (0) (92) (163) (204)
Voltage (V) 0.5 1.23 1.81 2.13
Tolerance 3.75 7.5 3.75
T5-5-55
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF SPEED METER
Reconnect disconnected
connectors. Check if YES Faulty N sensor.
speed meter works
Disconnect ring connector and normally when faulty N
brush connector of slip ring. YES sensor is replaced with a
Check if there is continuity be- sound one.
tween brush terminal #1 and
Speed meter ring terminal #1 of slip ring, and
pointer fluctu- Faulty column box.
between brush terminal #4 and
ates. ring terminal #4 of slip ring. NO
T5-5-56
TROUBLESHOOTING / Troubleshooting C
Speed Meter
Column Box: Connector C (6P)
2 3
4 5 6
1 2 3 4 4 3 2 1
5 6 7 8 8 7 6 5
T5-5-57
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF BRAKE OIL PRES-
SURE INDICATOR
2 3
1 2 3
4 5 6
7 8 9
T5-5-58
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.
Be sure to remove the negative terminals from
the batteries first when taking wire harnesses
and connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses, and fusible links and, in some
cases, cause fire due to short circuiting.
2. Color coding of wire harnesses. Code Color Code Color
The color codes of the wire harnesses in the R Red W White
electrical system are shown in the table on the L Blue G Green
right. Or Orange Lg Light
In cases on the design sheet where two colors green
are indicated for one wire, the left initial stands Y Yellow B Black
for the base color, while the right initial stands for Br Brown P Pink
the marking color.
Gr Gray V Violet
T5-6-1
TROUBLESHOOTING / Electrical System Inspection
3. Precautions for connecting and disconnecting
terminal connectors.
1) When disconnecting harnesses, grasp them
Right Wrong
by their connectors. Do not pull on the wire
itself. Be sure to release the lock first before
attempting to separate connectors, if a lock
is provided. (Refer to Instructions for
Disconnecting Connector on page T5-6-3.)
2) Water-resistant connectors keep water out T107-07-06-001
T5-6-2
TROUBLESHOOTING / Electrical System Inspection
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
Push to Unlock and Separate Type
T107-04-05-003
T5-6-3
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 to centerline of the fuse box are connected to
correctly inspect fuse continuity by following the in- the power source, while terminals located
structions described below. away from the center of the fuse box are
connected to loads (accessories). There-
1. Turn Key Switch ON fore, test all fuses in the same method ex-
When the key switch is turned ON, current from cept for the glow plug relay circuit fuse.
key switch terminal M activates the battery relay Check the glow plug relay circuit fuse with
so that electric power is supplied to all circuits the key switch turned to the ON position
except the glow plug relay circuit. (Refer to the then follow the procedure in step 3.
circuit diagram.)
2. Remove the fuse box cover. Set the tester volt-
age to meet the circuit specification to be meas-
ured. (Measurement Range: 0 to 30 V)
3. Ground the negative probe of the tester to the
vehicle frame. Touch the terminals located away
from the center of the fuse box with the positive
probe of the tester one at a time. When normal
continuity of a fuse is intact, the tester will indi-
cate 20 to 25 V (battery voltage).
T5-6-4
TROUBLESHOOTING / Electrical System Inspection
10 20 30 40
9 19 29 39
8 18 38
28
7 17 27 37
26
6 16 36
25
5 15 35
24
4 14 34
23
3 13 33
22
2 12 32
21
1 11 31
M178-07-034 M178-07-034
Fuse Fuse
Capacity Connected to Capacity Connected to
No. No.
1 5A Radio, Monitor, ICX (Backup Power) 21 10 A Right Clearance Light Relay
2 5A MC (Main Power) 22 10 A Head Light Relay (Right-Lower)
3 10 A MC (EC Motor Power) 23 10 A High-Beam Relay
4 10 A MC (Solenoid Valve Power) 24 10 A Flasher Relay, Turn Signal Relay
(Left and Right)
5 5A Monitor 25 15 A Stop Lamp Relay
6 5A MC, ICX (Power ON Signal), Park- 26 10 A Reverse Light (Reverse Light is
ing Brake Relay 3 only available in Japanese do-
mestic market.)
7 5A Air Conditioner Unit 27 10 A Column Box (Power ON Signal)
8 5A Optional 1 28 10 A Starter Relay, Work Brake Indica-
tor Relay, Neutral Signal Relay,
Axle Lock Relay
9 10 A Optional 2 29 10 A Blade/Stabilizer Circuit (Optional)
10 5A Optional 3 30 10 A Assist Circuit (Optional)
11 20 A Work Light Relays 1 and 2 31 10 A Left Clearance Light Relay
12 10 A Wiper Relays A, B-1, B-2 and B-3, 32 10 A Head Light Relay (Left-Lower)
Wiper Motor, Washer Relay
13 20 A Heater (Air Conditioner Unit) 33 10 A Heater Seat (Optional)
14 10 A Horn Relay 34 10 A Seat Compressor (Optional)
15 5A Radio 35 15 A Warning Lamp (Optional)
16 10 A Cigarette Lighter 36 10 A Rear Cab Lamp (Optional)
17 5A Room Lamp 37 10 A Front Cab Lamp (Optional)
18 10 A Auxiliary 38 5A Quick Hitch (Optional)
19 5A QOS Controller, Glow Plug Relay 39 5A Auxiliary 2
20 10 A Parking Brake Relay 1, Travel Motor 40 10 A Auxiliary 3
Alarm Relay, Parking Brake Alarm
Relay, Transistor Units 1 and 2,
Travel Forward/Reverse Pi Cut Re-
lay, Auto-Acceleration Cancel Relay
T5-6-5
TROUBLESHOOTING / Electrical System Inspection
FUSIBLE LINK INSPECTION Battery Relay
Inspection
Replacement
T1GL-05-06-001
T5-6-6
TROUBLESHOOTING / Electrical System Inspection
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between
the battery positive terminal and the vehicle
frame.
Normal Voltage: 24 V
Normal Voltage: 26 to 28 V
T157-07-06-007
T5-6-7
TROUBLESHOOTING / Electrical System Inspection
HOW TO TROUBLESHOOT ALTERNATOR
MALFUNCTIONS
In general, the alternator indicator remains off when
the alternator is generating power.
If the alternator indicator comes on while the engine is
running, the alternator might be defective.
T5-6-8
TROUBLESHOOTING / Electrical System Inspection
(Blank)
T5-6-9
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
T5-6-10
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).
T107-07-05-005
T5-6-11
TROUBLESHOOTING / Electrical System Inspection
(Blank)
T5-6-12
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
actuator side. Thereby, the faulty location in the
circuit will be found.
Black Probe (Minus) of Tester : To ground to the vehi-
cle frame
Red Probe (Plus) of Tester : To touch the location
to be measured
T5-6-13
TROUBLESHOOTING / Electrical System Inspection
T5-6-14
TROUBLESHOOTING / Electrical System Inspection
Key Switch
Battery
6 8
1 2 3 5 4 9
15
Battery Relay
Fuse
10 Box
Starter
18 Load
Damp
Relay
11
12 23 22 21 20 19 17
13 Monitor
Starter Relay
16
Alternator
Glow
Plug
Relay
14
Glow Plug
T178-05-06-001
T5-6-15
TROUBLESHOOTING / Electrical System Inspection
5 Voltage Circuit
Power Signal or
Voltage between terminal #1 and the vehicle Two Polarities Source Ground
frame (ground) 1 2
With the key switch turned OFF, disconnect the
sensor connector.
Measure the voltage between terminal #1 on the
machine harness side connector and the vehicle
(ground) under the following conditions.
V
Key switch position: ON
Tester black terminal (negative):
Connected to the vehicle (ground)
Tester red terminal (positive):
T107-07-05-006
Connected to terminal #1
Power
Three Polarities
Source Signal Ground
Evaluation: 1 2 3
If the measuring voltage is within 50.5 volts, the
circuit up to terminal #1 is normal.
terminal
With the key switch turned OFF, disconnect the Two Polarities
1 2
sensor connector.
Measure the voltage between terminal #1 on the
machine harness side connector and the ground
terminal (terminal #2 for two polarities, or terminal
#3 for three polarities) under the following V
conditions.
T107-07-05-009
T5-6-16
TROUBLESHOOTING / Electrical System Inspection
CHECK BY FALSE SIGNAL
Two Polarities
Turn the key switch OFF. After disconnecting the sen- (Hydraulic Oil
sor connector, turn the key switch ON. Then, connect Temperature Sensor)
(Fuel Sensor) 1 2
machine side harness end connector terminal #1 (N Sensor)
(power) to terminal #2 (signal). (Power voltage is used
as a false signal.) Check the controller using Dr. ZX
monitor function under this condition. When the
maximum value is displayed, the MC and the circuit
up to the machine side harness end connector are
normal. When the pressure switch circuits are normal, Connect
Dr. ZX displays ON.
Connect
T107-07-05-011
T5-6-17
TROUBLESHOOTING / Electrical System Inspection
TEST HARNESS
With a test harness installed between connectors, the
circuit condition is checked depending on whether the
test harness lamp lights or extinguishes during opera-
tion.
T107-07-06-015
Parts Number (ST 7226)
T5-6-18
TROUBLESHOOTING / Electrical System Inspection
Parts Number 4284347 (ST 7129)
Use to measure the EC sensor circuit signal line
voltage (between terminals #2 and #3).
(Red)
(Refer to T5-3-4.)
(Black)
T5-6-19
TROUBLESHOOTING / Electrical System Inspection
(Blank)
T5-6-20
TROUBLESHOOTING / ICX
OUTLINE
The ICX (information controller) stores signals from
various kinds of sensors and switches provided on the
machine as data. The various input signals are
grouped into Daily Report Data List, Frequency Dis-
tribution Data List, Cumulative Operation Hour List,
Alarm List, and Trouble List and are recorded in
the ICX.
T5-7-1
TROUBLESHOOTING / ICX
Daily Report Data List
Data Details
1 Key Switch ON Time Time when key switch is first turned ON during daily operation
(Time is recorded by key switch ON signal.)
2 Key Switch OFF Time Time when key switch is last turned OFF during daily operation
(Time is recorded by key switch ON signal.)
3 Engine Start Time Time when engine is first started during daily operation
(Time is recorded by alternator output signal.)
4 Engine Stop Time Time when engine is last stopped during daily operation
(Time is recorded by alternator output signal.)
5 Hour Meter Hour meter cumulative hours
(Hours are recorded by hour meter signal from monitor.)
6 Remaining fuel level Remaining fuel level at the end of daily operation (Level is re-
corded by fuel sensor signal from monitor.)
7 Engine Operating Hours Total engine operating hours during daily operation
(Hours are recorded by alternator output signal.)
8 Travel Operating Hours Total travel operating hours during daily operation
(Hours are recorded by signals from travel pressure sensor.)
9 Front Attachment Operating Hours Total front attachment operating hours during daily operation
(Hours are recorded by signals from front attachment pressure
sensor.)
10 *ML Operating Hours Total *ML crane operating hours during daily operation
(Hours are recorded by signals from crane mode switch.)
11 Engine Operating Hour Distribution Engine operating hour distribution during daily operation
(Operating hours are recorded only when alternator output sig-
nal is continuously delivered for more than 10 minutes.)
T5-7-2
TROUBLESHOOTING / ICX
Frequency Distribution Data List
Data Details
1 Coolant Temperature in Radiator Frequency distribution of coolant temperature
(Temperatures are recorded by signals from coolant tempera-
ture sensor.)
Data Details
1 Engine Operation Hour Cumulative engine operation hours
(Hours are recorded by alternator output signal.)
2 Travel Operation Hour Cumulative travel operation hours
(Hours are recorded by signals from travel pressure sensor.)
3 Front Attachment Operation Hour Cumulative front attachment operation hours
(Hours are recorded by signals from front attachment pressure
sensor.)
4 *ML Operation Hour Cumulative *ML operation hours
(Hours are recorded by signals from crane mode switch.)
T5-7-3
TROUBLESHOOTING / ICX
Alarm List
T5-7-4
TROUBLESHOOTING / ICX
Trouble List
Fault
Trouble Details
Code
01 Abnormal EEPROM Occurrence time and date of fault code 01
02 Abnormal RAM Occurrence time and date of fault code 02
03 Abnormal A/D Conversion Occurrence time and date of fault code 03
04 Abnormal Sensor Voltage Occurrence time and date of fault code 04
06 Abnormal EC Sensor Occurrence time and date of fault code 06
07 Abnormal Engine Control Dial Occurrence time and date of fault code 07
18 Abnormal Travel Lever Stroke Occurrence time and date of fault code 18
64 MC Communication Error Time and date when communication error between MC
and ICX occurred.
65 Monitor Communication Error Time and date when communication error between
monitor and ICX occurred.
66 Satellite Terminal Communication Error Time and date when communication error between sat-
ellite terminal and ICX occurred.
T5-7-5
TROUBLESHOOTING / ICX
ICX FAULT CODE LIST
Fault
Trouble Remarks
Code
1 Abnormal Internal Ram In case of SAM error
2 Abnormal Flush Memory In case of SAM error
3 Abnormal Exterior In case of SAM error or read-write error
4 Abnormal EEPROM In case of SAM error
5 Overwritten Data Save Area In case data save area was overwritten.
6 Abnormal Time In case RTC data was other than figures.
7 MC Communication Timeout In case MC communication lasted for less than 100 ms.
8 Monitor Communication Timeout In case monitor communication didnt last for more than
12 seconds.
9* MC Communication Timeout In case MC communication didnt last for more than 20
seconds.
10 Satellite Terminal Communication Timeout In case satellite communication didnt last for more than
20 seconds.
T5-7-6
TROUBLESHOOTING / ICX
FAULT CODE 1 TO 6
Faulty ICX
NO
FAULT CODE 7 TO 10
T5-7-7
TROUBLESHOOTING / ICX
SOME PARTS OF DATA IN DAILY REPORT,
FREQUENCY DISTRIBUTION, CUMULA-
TIVE OPERATION HOURS ARE NOT RE-
CORDED
All necessary data signals may not be input into
the ICX. Individual signals are utilized to record
more than one data. While referring to the table
below, check the corresponding system for any
abnormality.
Engine start and stop time, Engine operating hours (Daily report and cu- Alternator
mulative operation hour), Engine operating hour distribution
Hour meter Monitor controller
Remaining fuel level (detected at regular data sending time) Fuel level sensor
Travel operating hours (Daily report and cumulative operation hour), Av- Travel pressure sensor
erage pump delivery pressure distribution in travel operation
Front attachment operating hours (Daily report and cumulative operation Front attachment pressure sensor
hour)
*ML operating hours (Daily report and cumulative operation hour) Crane mode switch
T5-7-8
TROUBLESHOOTING / ICX
T5-7-9
TROUBLESHOOTING / ICX
DOWNLOADING FROM AND UPLOADING
TO THE ICX
The data stored in the ICX is downloadable by the
PALM using the MIC Download program or the Dr.
ZX program. Downloading using each program as
well as uploading to a PC are explained below. For
uploading of the downloaded data to a server using
the e-Service, refer to the e-Service Manual.
T5-7-10
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162
REPLY:
ZAXIS130W/160W/180W/210W CONNECTORS