Ttjbm-en-00.pdf

PART NO. ZX870-5A • 870LC-5A • 890H-5A • 890LCH-5A HYDRAULIC EXCAVATOR TECHNICAL MANUAL TROUBLESHOOTING

URL:http://www.hitachi-c-m.com

TTJBM-EN-00

PRINTED IN JAPAN (K) 2016, 03

TTJBM-EN-00

Technical Manual Troubleshooting

ZX

870-5A 870LC-5A 890H-5A 890LCH-5A

Hydraulic Excavator

Service Manual consists of the following separate Part No. Technical Manual (Operational Principle) : Vol. No.TOJBM-EN Technical Manual (Troubleshooting) : Vol. No.TTJBM-EN Workshop Manual : Vol. No.WJBM-EN Engine Manual : Vol. No.ETJBM-EN,EWJBM-EN

INTRODUCTION To The Reader This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine. The machine specification and description according to destination may be explained on this manual.

 If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.):  Technical Information Center Hitachi Construction Machinery Co., Ltd.  TEL: 81-29-832-7084  FAX: 81-29-831-1162  E-mail: [email protected]

 Be sure to thoroughly read this manual for correct product information and service procedures.

Additional References Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.

Manual Composition  Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures.

This manual consists the Technical Manual, the Workshop Manual and the Engine Manual.  Information included in the Technical Manual: Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.

 Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures.

Page Number Each page has a number, located on the center lower part of the page, and each number contains the following information: Example:  Technical Manual: T 1-3-5 T 1 3 5

 Workshop Manual: W 1-3-2-5 W 1 3 2 5

Technical Manual Section Number Group Number Consecutive Page Number for Each Group

IN-01

Workshop Manual Section Number Group Number Sub Group Number Consecutive Page Number for Each Group

INTRODUCTION Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage.

dCAUTION: Indicates potentially hazardous situation which could, if not avoided, result in personal injury or death.

d This is the safety alert symbol. When you see this

IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

fNOTE: Indicates supplementary technical information or knowhow.

Units Used SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parentheses just behind SI units.

Example: 24.5 MPa (250 kgf/cm2, 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposes.

Quantity

To Convert From

Into

Multiply By

Length

mm

in

0.03937

mm

ft

0.003281

L

US gal

0.2642

L

US qt

1.057

m3

yd3

1.308

Weight

kg

lb

2.205

Force

N

kgf

0.10197

N

lbf

0.2248

Torque

N·m

kgf·m

Pressure

MPa

kgf/cm

MPa

psi

145.0

kW

PS

1.360

kW

HP

1.341

Temperature

°C

°F

°C×1.8+32

Velocity

km/h

mph

0.6214

min

rpm

1.0

L/min

US gpm

0.2642

mL/rev

cc/rev

1.0

Volume

Power

Flow rate

-1

fNOTE:

The numerical value in this manual might be different from the above-mentioned table.

IN-02

0.10197 2

10.197

SYMBOL AND ABBREVIATION Symbol/ Abbreviation TO TT T/M W, W/M MC ECM GSM

GPS CAN

A/C OP, OPT MPDr. A/I WU Li ATT HI, Hi LO, Lo EGR

ML SPN-FMI DTC

Name

Explanation

Technical manual (Operational principle) Technical manual (Troubleshooting) Technical manual Workshop manual

Technical manual (Operational Principle). Technical manual (Troubleshooting). Technical manual. Workshop manual (Removal and Installation, Disassembly and Assembly). Main Controller Main controller. MC controls the engine, pump, and valve according to the machine operating condition. Engine Control Module Engine controller. ECM controls fuel injection amount according to the machine operating condition. Global System for Mobile communications Communication controller. GSM is a type of wireless controller communication system, is used in more than on 100 countries around Europe and Asia, and becomes the factual global standards of the mobile telephone. Global Positioning System Global positioning system. Controller Area Network CAN communication. CAN is a serial communications protocol internationally-standardized by ISO (International Organization for Standardization). Air Conditioner Air conditioner. Option Optional component. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and adjustment. Auto-Idle Auto-idle. Warming-Up Warming-up. Low (Slow) Idle Slow idle engine speed. Attachment Attachment. Attachment is optional parts such as breaker, crusher, and pulverizer in this manual. High Travel fast position. Low Travel slow position. Exhaust Gas Recirculation The EGR control re-circulates a part of exhaust gas in the intake manifold and combines it with intake-air. Therefore, combustion temperature is lowered and generation of oxide of nitrogen (NOx) is controlled. Moment Limiter ML clane. Service Principal Name - Failure Mode ECM fault code(Hitachi Construction Machinery Co.). Identifier Diagnostic Trouble Code ECM fault code(Engine Manufacturer).

SY-1

SYMBOL AND ABBREVIATION (Blank)

SY-2

SAFETY Recognize Safety Information  These are the SAFETY ALERT SYMBOLS.  When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.  Follow recommended precautions and safe operating practices.

SA-688

Understand Signal Words  On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.  DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.  WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.  CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.  DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.  Some safety signs do not use any of the designated signal words above after the safety alert symbol are occasionally used on this machine.  CAUTION also calls attention to safety message in this manual.  To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine. 

NOTE: indicates an additional explanation for an element of information.

SA-1

SA-1223

SAFETY Follow Safety Instructions  Carefully read and follow all safety signs on the machine and all safety messages in this manual.  Safety signs should be installed, maintained and replaced when necessary.  If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).  Learn how to operate the machine and its controls correctly and safely.  Allow only trained, qualified, authorized personnel to operate the machine.  Keep your machine in proper working condition.  Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.  Do not modify any machine parts without authorization. Failure to do so may deteriorate the part safety, function, and/or service life. In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void Hitachi Warranty Policy.  Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void Hitachi Warranty Policy.  The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/ or your authorized dealer before operating or performing maintenance work on the machine.

SA-2

SA-003

SAFETY Prepare for Emergencies  Be prepared if a fire starts or if an accident occurs.  Keep a first aid kit and fire extinguisher on hand.  Thoroughly read and understand the label attached on the fire extinguisher to use it properly.  To ensure that a fire extinguisher can be always used when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fire extinguisher manual.  Establish emergency procedure guidelines to cope with fires and accidents.  Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.

SA-437

Wear Protective Clothing  Wear close fitting clothing and safety equipment appropriate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask Be sure to wear the correct equipment and clothing for the job. Do not take any chances.  Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.  Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.

SA-3

SA-438

SAFETY Protect Against Noise  Prolonged exposure to loud noise can cause impairment or loss of hearing.  Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

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 "Inspect Machine Daily Before Starting" section in the operator’s manual.

SA-435

SA-4

SAFETY General Precautions for Cab  Before entering the cab, thoroughly remove all dirt and/or oil such as mud, grease, soil or stones that may mess up the cab from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots, the operator’s foot may slip off the pedal, possibly resulting in a personal accident.  Do not mess up around the operator’s seat with parts, tools, soil, stones, obstacles that may fold up or turn over, cans or lunch box. The levers or pedals become inoperable if obstacle jams in operation stroke of the travel levers/pedals, pilot control shut-off lever or control levers, which may result in serious injury or death.  Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire.  Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine.  Keep all flammable objects and/or explosives away from the machine.  After using the ashtray, always cover it to extinguish the match and/or tobacco.  Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.  Use proper floor mat dedicated to the machine. If another floor mat is used, it may be displaced and contact with the travel pedals during operation, resulting in serious injury or death.

SA-5

SAFETY Use Handholds and Steps  Falling is one of the major causes of personal injury.  When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.  Do not use any controls as hand-holds.  Never jump on or off the machine. Never mount or dismount a moving machine.  Before getting on or off the machine, check the condition of the steps and handrails for sticking of slippery material like grease or mud. Thoroughly remove such material if stuck. In addition, repair the damage to the steps and/or handrails. Retighten loose bolts.  Never get on and off the machine with tools in your hands.

SA-439

Adjust the Operator's Seat  A poorly adjusted seat for either the operator or the work at hand may quickly fatigue the operator leading to misoperations.  The seat should be adjusted whenever changing the operator for the machine.  The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back.  If not, move the seat forward or backward, and check again.  Adjust the rear view mirror position so that the best rear visibility is obtained from the operator’s seat. If the mirror is broken, immediately replace it with a new one.

SA-6

SA-378

SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat  Before rising from the operator’s seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever and/or pedal, possibly resulting in serious personal injury or death.  Before leaving the machine, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Turn the key switch OFF to stop the engine.  Before leaving the machine, close all windows, doors, and access covers and lock them up.

Fasten Your Seat Belt  If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.  Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine.  Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident.  We recommend that the seat belt is replaced every three years regardless of its apparent condition.

SA-7

SA-237

SAFETY Move and Operate Machine Safely  Bystanders can be run over.  Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine.  Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move.  Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine.  Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it.  Ensure the cab door, windows, doors and covers are securely locked.  Check the mirrors and the monitor in the cab for problems. If there is, replace the problem part(s) or clean the mirror, camera lens and the monitor display. Refer to "Rear View Monitor" section on the cleaning of the camera lens and the monitor display in the operator’s manual.

SA-426

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 the ground.  Do not start engine by shorting across starter terminals.  Before starting the engine, confirm that all control levers are in neutral.  Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders.

SA-8

SA-444

SAFETY Jump Starting  Battery gas can explode, resulting in serious injury.  If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual.  The operator must be in the operator’s seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation.  Never use a frozen battery.  Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine. SA-032

Keep Riders off Machine  Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine.  Only the operator should be on the machine. Keep riders off.  Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.

SA-379

SA-9

SAFETY Precautions for Operations  Investigate the work site before starting operations.  Be sure to wear close fitting clothing and safety equipment appropriate for the job, such as a hard hat, etc. when operating the machine.  Clear all persons and obstacles from the area of operation and machine movement. Do not permit persons other than the operator to enter areas where there is danger such as flying objects. Always beware of the surroundings while operating. When working in a small area surrounded by obstacles, take care not to hit the upperstructure against obstacles.  When loading onto trucks, bring the bucket over the truck beds from the rear side. Take care not to swing the bucket over the cab or over any person.

M178-05-007

SA-10

SAFETY Investigate Job Site Beforehand  When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.  Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles or banks from collapsing.  Make a work plan. Use machines appropriate to the work and job site.  Reinforce ground, edges and road shoulders as necessary. Keep the machine well back from the edges of excavations and road shoulders.  When working on an incline or on a road shoulder, employ a signal person as required.  Confirm that your machine is equipped with a FOPS cab before working in areas where the possibility of falling stones or debris exist.  When the footing is weak, reinforce the ground before starting work.  When working on frozen ground, be extremely alert. As ambient temperatures rise, footing becomes loose and slippery.  Beware the possibility of fire when operating the machine near flammable objects such as dry grass.

SA-11

SA-380

SAFETY  Make sure the worksite has sufficient strength to firmly support the machine. When working close to an excavation or at road shoulders, operate the machine with the tracks positioned perpendicular to the cliff face with travel motors at the rear, so that the machine can more easily evacuate if the cliff face collapses.  If working on the bottom of a cliff or a high bank is required, be sure to investigate the area first and confirm that no danger of the cliff or bank collapsing exists. If any possibility of cliff or bank collapsing exists, do not work on the area.  Soft ground may collapse when operating the machine on it, possibly causing the machine to tip over. When working on soft ground is required, be sure to reinforce the ground first using large pieces of steel plates strong and firm enough to easily support the machine.  Note that there is always a possibility of machine tipping over when working on rough terrain or on slopes. Prevent machine tipping over from occurring. When operating on rough terrain or on slopes:  Reduce the engine speed.  Select slow travel speed mode.  Operate the machine slowly and be cautious with machine movements.

M104-05-016

Install OPG Guard In case the machine is operated in areas where the possibilities of falling stones or debris exist, install the Hitachi OPG guard. Consult your authorized dealer for installing the OPG guard. In order not to impair operator protective structure: Replace damaged OPG guard. Never attempt to repair or modify the guard. OPG: Operator Protective Guard

SA-490

SA-12

SAFETY Restriction of Attachment Installation  Do not install an attachment which exceeds specified weight for the machine structure.

Provide Signals for Jobs Involving Multiple Machines  For jobs involving multiple machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

SA-481

Confirm Direction of Machine to Be Driven  Incorrect travel pedal/lever operation may result in serious injury or death.  Before driving the machine, confirm the position of the undercarriage in relation to the operator’s position. If the travel motors are located in front of the cab, the machine will move in reverse when travel pedals/levers are operated to the front.

SA-491

SA-13

SAFETY Drive Machine Safely  Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the direction you wish to drive.  Be sure to detour around any obstructions.  Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Do not allow personnel to stay around the machine while traveling.

A

SA-657

 Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.  Never attempt to ascend or descend 35 degrees or steeper slopes.  Be sure to fasten the seat belt.  When driving up or down a slope, keep the bucket facing the direction of travel, approximately 0.2 to 0.3 m (A) above the ground.  If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.  Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

A

SA-658

SA-441

WRONG

SA-590

SA-14

SAFETY  Avoid swinging the upperstructure on slopes. Never attempt to swing the upperstructure downhill. The machine may tip over. If swinging uphill is unavoidable, carefully operate the upperstructure and boom at slow speed.  If the engine stalls on a slope, immediately lower the bucket to the ground. Return the control levers to neutral. Then, restart the engine.  Be sure to thoroughly warm up the machine before ascending steep slopes. If hydraulic oil has not warmed up sufficiently, sufficient performance may not be obtained.  Use a signal person when moving, swinging or operating the machine in congested areas. Coordinate hand signals before starting the machine.  Before moving machine, determine which way to move travel pedals/levers for the direction you want to go. When the travel motors are in the rear, pushing down on the front of the travel pedals or pushing the levers forward moves the machine forward, towards the idlers. An arrow-mark seal is stuck on the inside surface of the side frame to indicate the machine front direction.  Select a travel route that is as flat as possible. Steer the machine as straight as possible, making small gradual changes in direction.  Before traveling on them, check the strengths of bridges and road shoulders, and reinforce if necessary.  Use wood plates in order not to damage the road surface. Be careful of steering when operating on asphalt roads in summer.  When crossing train tracks, use wood plates in order not to damage them.  Do not make contact with electric wires or bridges.  When crossing a river, measure the depth of the river using the bucket, and cross slowly. Do not cross the river when the depth of the river is deeper than the upper edge of the upper roller.  When traveling on rough terrain, reduce engine speed. Select slow travel speed. Slower speed will reduce possible damage to the machine.  Avoid operations that may damage the track and undercarriage components.  During freezing weather, always clean snow and ice from track shoes before loading and unloading machine, to prevent the machine from slipping.

SA-15

Travel Motor M104-05-008

Arrow -mark M178-03-001

SA-011

SAFETY Avoid Injury from Rollaway Accidents  Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways:  Select level ground when possible to park the machine.  Do not park the machine on a grade.  Lower the bucket and/or other work tools to the ground.  Turn the auto-idle switch OFF.  Run the engine at slow idle speed without load for 5 minutes to cool down the engine.  Stop the engine and remove the key from the key switch.  Pull the pilot control shut-off lever to LOCK position.  Block both tracks and lower the bucket to the ground. Thrust the bucket teeth into the ground if you must park on a grade.  Position the machine to prevent rolling.  Park at a reasonable distance from other machines.

SA-391

SA-2273

SA-16

SAFETY Avoid Injury from Back-Over and Swing Accidents  If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents:  Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR.  Keep the travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE.  USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. Use hand signals, which conform to your local regulations, when work conditions require a signal person.  No machine motions shall be made unless signals are clearly understood by both signal person and operator.  Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling.  Keep windows, mirrors, and lights clean and in good condition.  Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.  Read and understand all operating instructions in the operator’s manual.

SA-17

SA-383

SA-384

SAFETY Keep Person Clear from Working Area  A person around the operating machine may be hit severely by the swinging front attachment or counterweight, be caught in other objects, and/or be struck by flying objects, resulting in serious injury or death.  Set up barriers and/or put a NO ADMISSION sign at the machine operating site and areas exposed by flying objects to prevent anyone from entering the work area.  Before operating the machine, confirm that there are no obstacles or person other than signal person from working area.

SA-386

Never Position Bucket Over Anyone  Never lift, move, or swing bucket above anyone or a truck cab. Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket.

SA-487

SA-18

SAFETY Avoid Undercutting  In order to retreat from the edge of an excavation if the footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with the travel motors at the rear.  If the footing starts to collapse and if retreat is not possible, do not panic. Often, the machine can be secured by lowering the front attachment, in such cases.

SA-488

Avoid Tipping DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE --- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT  The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death. To avoid tipping:  Be extra careful before operating on a grade.  Prepare machine operating area flat.  Keep the bucket low to the ground and close to the machine.  Reduce operating speeds to avoid tipping or slipping.  Avoid changing direction when traveling on grades.  NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable.  Reduce swing speed as necessary when swinging loads.

SA-012

 Be careful when working on frozen ground.  Temperature increases will cause the ground to become soft and make ground travel unstable.

SA-440

SA-19

SAFETY Never Undercut a High Bank  The edges could collapse or a land slide could occur causing serious injury or death.

SA-489

Dig with Caution  Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.  Before digging check the location of cables, gas lines, and water lines.  Keep the minimum distance required, by law, from cables, gas lines, and water lines.  If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.  Contact your local “diggers hot line” if available in your area , and/or the utility companies directly. Have them mark all underground utilities.

SA-382

Operate with Caution  If the front attachment or any other part of the machine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may result as well.  Take care to avoid hitting overhead obstacles with the boom or arm.

SA-389

SA-20

SAFETY Avoid Power Lines  Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines.  When operating near an electric line, NEVER move any part of the machine or load closer than 3 m plus twice the line insulator length.  Check and comply with any local regulations that may apply.  Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site. SA-381

Precautions for Lightning  Lightning may strike the machine. If lightning comes close, immediately stop the operation, and take the following action.  When you are around the machine or operating cabless machine, evacuate to a safe place far away from the machine.  When you are in the cab, stay in the cab until lightning has passed and safety is secured. Close the cab doors and windows. Lower the bucket to the ground, and stop the engine. Put your hands on your lap to avoid contact with any metal surfaces. Never go out of the cab. SA-1088

If lightning strikes the machine or near the machine, check all of the machine safety devices for any failure after lightning has passed and safety is secured. If any trouble is found, operate the machine only after repairing it.

SA-21

SAFETY Object Handling  If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death.  When using the machine for craning operations, be sure to comply with all local regulations.  Do not use damaged chains or frayed cables, sables, slings, or ropes.  Before craning, position the upperstructure with the travel motors at the rear.  Move the load slowly and carefully. Never move it suddenly.  Keep all persons well away from the load.  Never move a load over a person’s head.  Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground.  Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall.

SA-014

Protect Against Flying Debris  If flying debris hit eyes or any other part of the body, serious injury may result.  Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.  Keep bystanders away from the working area before striking any object.  Always close the front windows, doors, door windows and the overhead window when operating the machine.

SA-432

SA-22

SAFETY Park Machine Safely To avoid accidents:  Park machine on a firm, level surface.  Lower bucket to the ground.  Turn auto-idle switch OFF.  Run engine at slow idle speed without load for 5 minutes.  Turn key switch to OFF to stop engine.  Remove the key from the key switch.  Pull the pilot control shut-off lever to the LOCK position.  Close windows, roof vent, and cab door.  Lock all access doors and compartments. SA-390

Handle Fluids Safely−Avoid Fires  Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.  Do not refuel the machine while smoking or when near open flame or sparks.  Always stop the engine before refueling the machine.  Fill the fuel tank outdoors.  All fuels, most lubricants, and some coolants are flammable.  Store flammable fluids well away from fire hazards.  Do not incinerate or puncture pressurized containers.  Do not store oily rags; they can ignite and burn spontaneously.  Securely tighten the fuel and oil filler caps.

SA-018

SA-019

SA-23

SAFETY Transport Safely  Take care, the machine may turn over when loading or unloading the machine onto or off of a truck or trailer.  Observe the related regulations and rules for safe transportation.  Select an appropriate truck or trailer for the machine to be transported.  Be sure to use a signal person.  Always follow the following precautions for loading or unloading: 1. Select solid and level ground. 2. Always use a ramp or deck strong enough to support the machine weight. 3. Turn auto-idle switch OFF. 4. Always select the slow speed mode with the travel mode switch. 5. Never load or unload the machine onto or off a truck or trailer using the front attachment functions when driving up or down the ramp. 6. Never steer the machine while on the ramp. If the traveling direction must be changed while the ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading again. 7. The top end of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it. 8. Place blocks in front of and behind the tires. Securely hold the machine to the truck or trailer deck with wire ropes. Be sure to further follow the details described in the "TRANSPORTING" chapter in the operator’s manual.

SA-24

SA-395

SAFETY Practice Safe Maintenance To avoid accidents:  Understand service procedures before starting work.  Keep the work area clean and dry.  Do not spray water or steam inside cab.  Never lubricate or service the machine while it is moving.  Keep hands, feet and clothing away from power-driven parts. Before servicing the machine: 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. 4. Run the engine at slow idle speed without load for 5 minutes. 5. Turn the key switch to OFF to stop engine. 6. Relieve the pressure in the hydraulic system by moving the control levers several times.

SA-028

7. Remove the key from the key switch. 8. Attach a “Do Not Operate” tag on the control lever. 9. Pull the pilot control shut-off lever to the LOCK position. 10. Allow the engine to cool.  If a maintenance procedure must be performed with the engine running, do not leave the 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.  Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter in the operator’s manual.  Keep all parts in good condition and properly installed.  Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.  When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces.  Disconnect battery ground cable (−) before making adjustments to electrical systems or before performing welding on the machine.

SA-25

SA-527

SAFETY  Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.  Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

SA-037

Warn Others of Service Work  Unexpected machine movement can cause serious injury.  Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever. This tag is available from your authorized dealer.

SS2045102

Support Machine Properly  Never attempt to work on the machine without securing the machine first.  Always lower the attachment to the ground before you work on the machine.  If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.

SA-26

SA-527

SAFETY Stay Clear of Moving Parts  Entanglement in moving parts can cause serious injury.  To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

SA-026

SA-2294

Prevent Parts from Flying  Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death.  Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY.  Do not attempt to remove grease fitting securing cover.  As pieces may fly off, be sure to keep body and face away from valve.  Never attempt to disassemble the track adjuster. Inadvertent disassembling of the track adjuster may cause the parts such as a spring to fly off, possibly resulting in severe personal injury or death.  Travel reduction gears are under pressure.  As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury.  GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure.

SA-27

SA-344

SAFETY Avoid Injury from Attachment Falling Accident  Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death.  To avoid possible personal injury from attachment falling accident, use a platform when replacing an attachment.  Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.

SA-034

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.  Avoid possible injury from hot spraying water. DO NOT remove the expansion tank cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap.  The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.

SA-039

Hot fluids and surfaces:  Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well.  Wait for the oil and components to cool before starting any maintenance or inspection work.

SA-225

SA-28

SAFETY Replace Rubber Hoses Periodically  Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.  Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual.)  Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.

SA-019

Avoid High-Pressure Fluids  Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death.  Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.  Tighten all connections before applying pressure.  Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.  If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

SA-031

SA-292

SA-044

SA-29

SAFETY Prevent Fires Check for Oil Leaks:  Fuel, hydraulic oil and lubricant leaks can lead to fires.  Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil cooler, and loose oil cooler flange bolts.  Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil cooler and oil cooler flange bolts.  Do not bend or strike high-pressure lines.  Never install bent or damaged lines, pipes, or hoses.  Replace fuel hoses and hydraulic hoses periodically even if there is no abnormality in their external appearance. Check for Shorts:  Short circuits can cause fires.  Clean and tighten all electrical connections.  Check before each shift or after eight (8) to ten (10) hours operation for loose, kinked, hardened or frayed electrical cables and wires.  Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal caps.  DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.  Never attempt to modify electric wirings.

SA-30

SA-019

SAFETY Clean up Flammable Materials:  Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammable materials may cause fires.  Prevent fires by inspecting and cleaning the machine daily, and by removing adhered oil or accumulated flammable materials immediately. Check and clean high temperature parts such as the exhaust outlet and muffler earlier than the normal interval.  Do not wrap high temperature parts such as a muffler or exhaust pipe with oil absorbents.  Do not store oily cloths as they are vulnerable to catching fire.  Keep flammable materials away from open flames.  Do not ignite or crush a pressurized or sealed container.  Wire screens may be provided on openings on the engine compartment covers to prevent flammable materials such as dead leaves from entering. However, flammable materials which have passed through the wire screen may cause fires. Check and clean the machine every day and immediately remove accumulated flammable materials. Check Key Switch:  If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. Always check key switch function before operating the machine every day: 1. Start the engine and run it at slow idle. 2. Turn the key switch to the OFF position to confirm that the engine stops.  If any abnormalities are found, be sure to repair them before operating the machine. Check Heat Shields:  Damaged or missing heat shields may lead to fires.  Damaged or missing heat shields must be repaired or replaced before operating the machine.  If hydraulic hoses are broken while the engine cover is open, splattered oil on the high temperature parts such as muffler may cause fire. Always close the engine cover while operating the machine.

SA-31

SAFETY Evacuating in Case of Fire  If a fire breaks out, evacuate the machine in the following way:  Stop the engine by turning the key switch to the OFF position if there is time.  Use a fire extinguisher if there is time.  Exit the machine.  In an emergency, if the cab door or front window can not be opened, break the front or rear window pane with the emergency evacuation hammer to escape from the cab. Refer to the explanation pages on the Emergency Evacuation Method in the operator’s manual.

SA-393

SS-1510

Beware of Exhaust Fumes  Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.  If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

SA-016

SA-32

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 materials in a safe place before starting welding.  Only qualified personnel should perform welding. Never allow an unqualified person to perform welding.  Turn the battery disconnect switch to the OFF position before operating the machine.  Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding.  After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.

SA-33

SA-818

SAFETY Avoid Heating Near Pressurized Fluid Lines  Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders.  Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.  Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc. SA-030

Avoid Applying Heat to Lines Containing Flammable Fluids  Do not weld or flame cut pipes or tubes that contain flammable fluids.  Clean them thoroughly with nonflammable solvent before welding or flame cutting them.

Precautions for Handling Accumulator and Gas Damper High-pressure nitrogen gas is sealed in the accumulator and the gas damper. Inappropriate handling may cause explosion, possibly resulting in serious injury or death. Strictly comply with the following items:  Do not disassemble the unit.  Keep the units away from open flames and fire.  Do not bore a hole, do not cut by torch.  Avoid giving shocks by hitting or rolling the unit.  Before disposing the unit, sealed gas must be released. Consult your authorized dealer.

SA-34

SAFETY Remove Paint Before Welding or Heating  Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.  Avoid potentially toxic fumes and dust.  Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly.  Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable materials from area. Allow fumes to disperse at least 15 minutes before welding or heating.

SA-029

Beware of Asbestos and Silicon Dust and Other Contamination  Take care not to inhale dust produced in the work site. Inhalation of asbestos fibers may be the cause of lung cancer. Inhalation of silicon dust or other contaminations may cause sickness.  Depending on the work site conditions, the risk of inhaling asbestos fiber, silicon dust or other contaminations may exist. Spray water to prevent asbestos fibers, silicon dust or other contaminations from becoming airborne. Do not use compressed air.  When operating the machine in a work site where asbestos fibers, silicon dust or other contaminations might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos, silicon dust or other contaminations.  Keep bystanders out of the work site during operation.  Asbestos fibers might be present in imitation parts. Use only genuine Hitachi Parts.

SA-35

SA-029

SAFETY Prevent Battery Explosions  Battery gas can explode.  Keep sparks, lighted matches, and flame away from the top of battery.  Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.  Do not charge a frozen battery; it may explode. Warm the battery to 16 ˚C ( 60 ˚F ) first.  Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result.  Loose terminals may produce sparks. Securely tighten all terminals.  Connect terminals to the correct electrical poles. Failure to do so may cause damage to the electrical parts or fire.

SA-032

 Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness.  Be sure to wear eye protection when checking electrolyte specific gravity.

Service Air Conditioning System Safely  If spilled onto skin, refrigerant may cause a cold contact burn.  Refer to the instructions described on the container for proper use when handling the refrigerant.  Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere.  Never touch the refrigerant.

SA-405

SA-36

SAFETY Handle Chemical Products Safely  Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives.  A Safety Data Sheet (SDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.  Check the SDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment.  See your authorized dealer for SDS’s (available only in English) on chemical products used with your machine.

SA-2579

Dispose of Waste Properly  Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.  Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.  Do not pour waste onto the ground, down a drain, or into any water source.  Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.  Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.

SA-37

SA-226

SAFETY Never Ride Attachment Never allow anyone to ride attachments or load. This is an extremely dangerous practice.

Precautions for Communication Terminal Electrical wave transmitted from the communication terminal may cause malfunction of other electronic devices. Inquire the device manufacturer for electrical wave disturbance upon using an electronic device near the communication terminal.

SA-38

SAFETY Precautions for Communication Terminal Equipment This machine has a communication terminal equipment emitting electrical waves installed inside a rear tray which is situated at the back of the operator's seat. There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, would be affected and would malfunction by the electrical waves emitted from the communication terminal equipment. Any person affixed with a medical device such as the above should not use this machine, unless the medical device and the rear tray are at least 22 centimeters (8.7 inches) apart at all times. If such condition cannot be met, please contact your authorized dealer and have the person in charge stop the communication terminal equipment from functioning completely and confirm that it is not emitting electrical waves. Specific Absorption Rate ("SAR") (measured by 10 g per unit) of communication terminal equipments: E-GSM900 0.573 W/Kg (914.80 MHz) DCS-1800 0.130 W/Kg (1710.20 MHz) WCDMA Band I 0.271 W/Kg (1950.00 MHz) *This data was measured by having each type of communication terminal equipment, such as the communication terminal equipment used with this machine, and a human body set apart by 3 cm (1.2 inches). * SAR is a measure of the amount of radio frequency energy absorbed by the body when using a wireless application such as a mobile phone. In Japan: *Under the Japanese Radio Act and other relevant Japanese regulations, the maximum SAR value is 2 W/kg (as of March 2010). In EU Member nation: *Under the "Council Recommendation 1999/519/EC 12 July 1999'; the maximum SAR value is 2 W/kg (as of March 2010).

SA-39

SA-2302

SAFETY  Do not attempt to disassemble, repair, modify and displace of the communication terminal, antenna and cables. Failure to do so may cause damage or fire on the machine and the communication terminal. (Before removing or installing the communication terminal, consult your authorized dealer.)  Do not pinch or forcibly pull cables, cords and connectors. Failure to do so may cause damage or fire on the machine and the communication terminal due to short/broken circuit.

Before Returning the Machine to the Customer  After maintenance or repair work is complete, confirm that:  The machine is functioning properly, especially the safety systems.  Worn or damaged parts have been repaired or replaced.

SA-435

SA-40

4 OPERATIONAL SECTION AND GROUP SECTION PERFORMANCE TEST CONTENTS Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Excavator Test TECHNICAL MANUAL (Troubleshooting)

Group 5 Component Test Group 6 Adjustment

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Monitor Group 3 e-Service Group 4 Component Layout Group 5 Troubleshooting A Group 6 Troubleshooting B Group 7 Air Conditioner

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

COPYRIGHT(C)2016 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved

TECHNICAL MANUAL (Operational Principle)

WORKSHOP MANUAL

SECTION 1 GENERAL Group 1 Specification Group 2 Component Layout Group 3 Component Specifications SECTION 2 SYSTEM Group 1 Controller Group 2 Control System Group 3 ECM System Group 4 Hydraulic System Group 5 Electrical System SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Swing Device Group 3 Control Valve Group 4 Pilot Valve Group 5 Travel Device Group 6 Signal Control Valve Group 7 Others (Upperstructure) Group 8 Others (Undercarriage)

SECTION 1 GENERAL INFORMATION Group 1 Precautions for Disassembling and Assembling Group 2 Tightening Torque Group 3 Painting Group 4 Bleeding Air Group 5 Pressure Release Procedure Group 6 Preparation SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Group 2 Undercarriage Group 3 Attachment SECTION 3 UPPERSTRUCTURE Group 1 Cab Group 2 Counterweight Group 3 Main Frame Group 8 Pump Device Group 9 Control Valve Group 10 Swing Device Group 11 Pilot Valve Group 12 Solenoid Valve Group 13 Signal Control Valve Group 14 Shockless Valve Group 15 Fan Valve Group 16 Fan Moter SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Group 2 Travel Device Group 3 Center Joint Group 4 Track Adjuster Group 5 Front Idler Group 6 Upper and Lower Roller Group 7 Track SECTION 5 ATTACHMENT Group 1 Front Attachment Group 2 Cylinder

SECTION 4

OPERATIONAL PERFORMANCE TEST CONTENTS Group 1 Introduction

Operational Performance Tests....................................... T4-1-1 Preparation for Performance Tests................................ T4-1-2

Group 2 Standard

Group 6 Adjustment

PUMP LEARNING.................................................................. T4-6-1 TORQUE ADJUSTMENT...................................................... T4-6-2 CONNECTION........................................................................ T4-6-3

Operational Performance Standard Table.................. T4-2-1 Main Pump P-Q Diagram.................................................. T4-2-5 Fan Pump P-Q Diagram..................................................... T4-2-6 Fan Pump I-Q Diagram....................................................... T4-2-7 Sensor Activating Range................................................... T4-2-8 MPDr. Monitor Indicating Values (MC)......................... T4-2-9 MPDr. Monitor Indicating Values (ECM).....................T4-2-15

Group 3 Engine Test

Engine Speed........................................................................ T4-3-1 Lubricant Consumption.................................................... T4-3-4

Group 4 Machine Performance Test

Travel Speed.......................................................................... T4-4-1 Track Revolution Speed..................................................... T4-4-2 Mistrack Check...................................................................... T4-4-3 Travel Parking Leakage...................................................... T4-4-4 Swing Speed.......................................................................... T4-4-5 Swing Function Drift Check............................................. T4-4-6 Swing Motor Leakage........................................................ T4-4-8 Maximum Swingable Slant Angle................................T4-4-10 Swing Bearing Play............................................................T4-4-12 Hydraulic Cylinder Cycle Time.......................................T4-4-14 Dig Function Drift Check.................................................T4-4-16 Control Lever Operating Force......................................T4-4-19 Control Lever Stroke.........................................................T4-4-20 Combined Operation of Boom Raise and Swing Function Check................................................T4-4-21

Group 5 Component Test

Primary Pilot Pressure......................................................... T4-5-1 Secondary Pilot Pressure................................................... T4-5-3 4-Spool Solenoid Valve Set Pressure............................. T4-5-4 2-Spool Solenoid Valve Set Pressure............................. T4-5-5 Main Pump Delivery Pressure......................................... T4-5-7 Fan Pump Delivery Pressure............................................ T4-5-8 Main Relief Set Pressure.................................................... T4-5-9 Overload Relief Set Pressure..........................................T4-5-15 Main Pump Flow Rate Measurement.........................T4-5-18 Fan Pump Flow Rate Measurement............................T4-5-20 Swing Motor Drainage.....................................................T4-5-30 Travel Motor Drainage.....................................................T4-5-32

JBMT-4-1

(Blank)

JBMT-4-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Operational Performance Tests Use operational performance test procedure to quantitatively check all system and functions on the machine.

The machine performance does not always deteriorate as the working hours increase. However, the machine performance is normally considered to reduce in proportion to the increase of the operation hours. Accordingly, restoring the machine performance by repair, adjustment, or replacement shall consider the number of the machine’s working hours.

Purpose of Performance Tests 1. To comprehensively evaluate each operational function by comparing the performance test data with the standard values. 2. According to the evaluation results, repair, adjust, or replace parts or components as necessary to restore the machine’s performance to the desired standard.

Definition of “Performance Standard” 1. Operation speed values and dimensions of the new machine. 2. Operational performance of new components adjusted to specifications. Allowable errors will be indicated as necessary.

3. To economically operate the machine under optimal conditions. Kinds of Tests 1. Base machine performance test is to check the operational performance of each system such as engine, travel, swing, and hydraulic cylinders. 2. Hydraulic component unit test is to check the operational performance of each component such as hydraulic pump, motor, and various kinds of valves. Performance Standards “Performance Standard” is shown in tables to evaluate the performance test data. Precautions for Evaluation of Test Data 1. To evaluate not only that the test data are correct, but also in what range the test data are. 2. Be sure to evaluate the test data based on the machine operation hours, kinds and state of work loads, and machine maintenance conditions.

T4-1-1

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Preparation for Performance Tests Observe the following rules in order to carry out performance tests accurately and safely. THE MACHINE 1. Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test. TEST AREA 1. Select a hard and flat surface. 2. Secure enough space to allow the machine to run straight more than 20 m (65 ft 7 in), and to make a full swing with the front attachment extended. 3. If required, rope off the test area and provide signboards to keep unauthorized personnel away. PRECAUTIONS 1. Before starting to test, agree upon the signals to be employed for communication among coworkers. Once the test is started, be sure to communicate with each other using these signals, and to follow them without fail. 2. Operate the machine carefully and always give first priority to safety. 3. While testing, always take care to avoid accidents due to landslides or contact with high-voltage power lines. Always confirm that there is sufficient space for full swings. 4. Avoid polluting the machine and the ground with leaking oil. Use oil pans to catch escaping oil. Pay special attention to this when removing hydraulic pipings.

T105-06-01-003

MAKE PRECISE MEASUREMENT 1. Accurately calibrate test instruments in advance to obtain correct data. 2. Carry out tests under the exact test conditions prescribed for each test item. 3. Repeat the same test and confirm that the test data obtained can be produced repeatedly. Use mean values of measurements if necessary.

T105-06-01-004

T4-1-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Operational Performance Standard Table

The standard measurement conditions are as followings unless instructed in each performance test procedure: Test procedure:  Engine Control Dial: Fast Idle  Power Mode Switch: HP Mode  Auto-Idle Switch: OFF  Work Mode: Digging Mode  Hydraulic Oil Temperature: 50±5 °C

The standard Performance values are listed in the table below. The detailed measurement procedures are explained in T4-3, T4-4, and T4-5. Refer to the reference page. Values indicated in parentheses [ ] are reference values.

Performance Test ENGINE SPEED Slow Idle Speed Fast Idle Speed (HP mode) Fast Idle Speed (PWR mode) Fast Idle Speed (ECO mode)

Performance Standard

Unit min-1

900±50 1650±50 1650±50 1630±50

Fast Idle Speed (HP mode)

1819±50

Auto-Idle Speed

1180±50

ENGINE COMPRESSION PRESSURE VALVE CLEARANCE (IN, EX) LUBRICANT CONSUMPTION (Rated output) TRAVEL SPEED Fast Speed Mode Slow Speed Mode TRACK REVOLUTION SPEED

Remark

2.84 (29) or more

MPa (kgf/cm2)

mm

0.4

mL/h

100 or less

Reference Page T4-3-1

Control Lever: Neutral Control Lever: Neutral Control Lever: Neutral Control Lever: Neutral With boom raise relief operation, Fan maximum speed Control Lever: Neutral Engine speed: 200 min-1

With the engine cold

Refer to Engine Manual Refer to Engine Manual

Hour meter: 2000 hours or less

sec/20 m

T4-4-1 15.5±2.0 22.9±2.0

sec/3 rev

T4-4-2

Fast Speed Mode

28.5±2.0

Slow Speed Mode

42.0±2.0

MISTRACK CHECK (With fast and slow travel speed modes) TRAVEL MOTOR LEAKAGE SWING SPEED SWING FUNCTION DRIFT CHECK

mm/20 m

200 or less

mm/5 min sec/3 rev mm/180 °

0 23.7±1.5 1510 or less

SWING MOTOR LEAKAGE

mm/5 min

0

MAXIMUM SWINGABLE SLANT ANGLE

deg.

15 or more

SWING BEARING PLAY

mm

0.4 to 1.6

T4-2-1

870LC-5A/890LCH-5A: 30.9±2.0 870LC-5A/890LCH-5A: 45.5±2.0 T4-4-3 Bucket: Empty Bucket: Empty Bucket: Loaded Weight: 4650 kg Bucket: Loaded Weight: 4650 kg Allowable limit: 3.6 to 4.8

T4-4-4 T4-4-5 T4-4-6 T4-4-7 T4-4-8 T4-4-10

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test HYDRAULIC CYLINDER CYCLE TIME (Backhoe)

Performance Standard

Unit

sec

Boom Raise Boom Lower Arm Roll-In Arm Roll-Out Bucket Roll-In Bucket Roll-Out DIG FUNCTION DRIFT CHECK (Backhoe) (Maximum Reach Position) Boom Cylinder Arm Cylinder Bucket Cylinder Bucket Bottom RADIATOR FAN MOTOR SPEED OIL COOLER FAN MOTOR SPEED

Remarks

Reference Page

8.4 m Boom 3.7 m Arm 3.5 m3 (PCSA heaped) Bucket, Bucket empty Weight: 4650 kg

T4-4-12

8.4 m Boom 3.7 m Arm 3.5 m3 (PCSA heaped) Bucket, Bucket loaded Weight: 4650 kg

T4-4-14

4.6±0.4 2.9±0.4 4.2±0.4 3.2±0.4 3.4±0.4 2.8±0.4

mm/5 min

min-1 min-1

T4-2-2

5 or less 10 or less 15 or less 100 or less 1110±50 1110±50

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test CONTROL LEVER OPERATING FORCE

Performance Standard

Unit N (kgf )

Right and Left at Left Side Right and Left at Right Side Front and Rear at Left Side Travel Control Lever

Engine: Fast Idle Speed SECONDARY PILOT PRESSURE SOLENOID VALVE SET PRESSURE

Reference Page T4-4-15

16.0 (1.6) or less 13.0 (1.3) or less 13.0 (1.3) or less 16.0 (1.6) or less 28.0 (2.9) or less

Front and Rear at Right Side

CONTROL LEVER STROKE Front and Rear at Right Side Right and Left at Left Side Right and Left at Right Side Front and Rear at Left Side Travel Control Lever COMBINED OPERATION OF BOOM RAISE AND SWING FUNCTION CHECK (The time required to swing the upperstructure 90 degrees) Bucket Teeth Height: H HYDRAULIC SYSTEM PRIMARY PILOT PRESSURE Engine: Slow Idle Speed

Remarks

mm

T4-4-16 97±10 82±10 82±10 97±10 120±10

sec

4.9 or less

mm

7900 or more

8.4 m Boom Backhoe: 3.7 m Arm 3.5 m3 (PCSA heaped) Bucket, Bucket empty

MPa (kgf/cm2)

T4-5-1

3.9±0.5 (40±5) 3.91.00 (40+100) MPa (kgf/cm2) 3.9±0.5 (40±5) (Lever: Full Stroke) MPa (kgf/cm2) 3.9±0.5 (40±5)

T4-5-3 T4-5-4

T4-2-3

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test MAIN RELIEF SET PRESSURE

Performance Standard

Unit MPa (kgf/cm2)

Power Digging MPa (kgf/cm2)

28.4 -0.5 (290+20-5) 34.3+2.0-0.5 (350+20-5)

Relief Operation of Travel MPa (kgf/cm2)

T4-5-15

L/min L/min

35.3+1.00 (360+100) 11.8+2.0−0.5 (120+20−5) -

L/min

0.2 to 0.3

L/min

5 or less

Boom, Arm, and Bucket Boom (Lower) (When operating boom mode selector) MAIN PUMP FLOW RATE FAN PUMP FLOW RATE SWING MOTOR DRAINAGE With constant maximum speed TRAVEL MOTOR DRAINAGE With the track raised off the ground

T4-5-13 +2.0

Relief Operation of Swing

OVERLOAD RELIEF PRESSURE

Reference Page T4-5-9

31.9+2.0−0.5 (325+20−5) 34.3+2.0−0.5 (350+20−5)

Boom Lower, Arm, Bucket

RELIEF PRESSURE

Remarks

T4-2-4

Reference values at 110 L/min Reference values at 210 L/min Refer to page T4-2-5 Refer to page T4-2-6

T4-5-18 T4-5-20 T4-5-30

Allowable limit: 10

T4-5-32

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Main Pump P-Q Diagram Points on P-Q Line Delivery Pressure (P) MPa (kgf/cm2) A 20 (204) B 25 (255) C 30 (306)

 P-Q Control (Torque Control) (REFERENCE: Measured at Test Stand)  Rated Pump Speed: 1956 min-1 (rpm)  Power Mode Switch: HP Mode  Hydraulic Oil Temperature: 50±5 °C

fNOTE:

Flow Rate (Q) L/min Approx. 431 Approx. 341 Approx. 280

Refer to T4-5-20.

L/min 700

600

500 A

Q

400 B 300

C

200

100

0

0

5.0 (51)

10.0 (102)

15.0 (153)

20.0 (204)

P

P-

Delivery Pressure

Q- Flow Rate

T4-2-5

25.0 (255)

30.0 (306)

35.0 (357)

MPa (kgf/cm2) TJBM-04-02-001

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Fan Pump P-Q Diagram Points on P-Q Line Delivery Pressure (P) MPa (kgf/cm2) A 7.8 (80) B 17.0 (173) C 21.6 (220)

 P-Q Control (Torque Control) (REFERENCE: Measured at Test Stand)  Rated Pump Speed: 1800 min-1 (rpm)  Power Mode Switch: HP Mode  Hydraulic Oil Temperature: 50±5 °C

fNOTE:

Flow Rate (Q) L/min Approx. 117 Approx. 114 Approx. 113

Refer to T4-5-26.

L/min 150

125 B

A

C

100

Q

75

50

25

0

0

5.0 (51)

10.0 (102)

15.0 (153)

P

P-

Delivery Pressure

Q- Flow Rate

T4-2-6

20.0 (204)

MPa (kgf/cm2) TJBC-04-02-002

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Fan Pump I-Q Diagram  I-Q Control Fan Pump Control Solenoid Value Operating Signal (I) mA 381+100 590±30

(REFERENCE: Measured at Test Stand)  Rated Pump Speed: 1800 min-1 (rpm)  Power Mode Switch: HP Mode  Hydraulic Oil Temperature: 50±5 °C

A B

Flow Rate (Q) L/min Approx. 117±2 Approx. 15±3

L/min 150

125

A

100

Q 75

50

25 B 0 I-

Fan

200

300 Q- Flow Rate

400

500

I

T4-2-7

600

700

mA TJBC-04-02-003

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Sensor Activating Range 1. Checking Method  Hydraulic Oil Temperature: 50±5 °C  Unless specified: Engine Control Dial

Power Mode

Work Mode

Auto-Idle Switch

Maximum Speed

HP

Digging Mode

OFF

 Monitor each sensor using MPDr.. 2. Sensor Activating Range Sensor Engine Control Dial

Pilot Operation Pressure Sensor

Operation Slow Idle

0.3 to 1.0 V

Fast Idle

4.0 to 4.7 V

Control Lever: Neutral Pilot Shut-Off Lever: LOCK Control Lever: Full Stroke Pilot Shut-Off Lever: UNLOCK Control Lever: Neutral

Pump Regulator Pressure Sensor

Pump Delivery Pressure Sensor

Specification

One Side Track Raised off the ground, Travel Lever: Full Stroke (Jack-up Side)

0 to 0.49 MPa (0 to 5 kgf/cm2) 2.45 to 3.9 MPa (25 to 40 kgf/cm2) Pump 1: *1.05 MPa (11 kgf/cm2) Pump 2: *1.05 MPa (11 kgf/cm2) *3.10 MPa (32 kgf/cm2)

Control Lever: Neutral

*0.2 to 0.7 MPa (2 to 7 kgf/cm2)

When Boom Raise Relieving

34.3+2.0-0.5 MPa (350+20-5 kgf/cm2) *: Reference Value

T4-2-8

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard MPDr. Monitor Indicating Values (MC) The standard measurement conditions are as followings unless instructed in each performance test procedure:  Engine Control Dial: Fast Idle  Work Mode: Digging Mode  Power Mode Switch: HP mode  Auto-Idle Switch: OFF  Hydraulic Oil Temperature: 50±5 °C

Item DEMAND ENGINE SPEED Fast Idle Speed Fast Idle Speed (When operating a control lever)

Unit

Reference Value

Remarks

1600 1700 1800

Fast Idle Speed (PWR Mode) Fast Idle Speed (ECO Mode) Auto-Idle Speed Slow Idle Speed ACTUAL ENGINE SPEED Fast Idle Speed Fast Idle Speed (When operating a control lever)

1600 1580 1030 750

When boom raise relieving

min-1 1650 1750

Fast Idle Speed (HP Mode)

1850

Fast Idle Speed (PWR Mode) Fast Idle Speed (ECO Mode) Auto-Idle Speed

1650 1630 1180

Slow Idle Speed

900

When boom raise relieving

Pilot shut-off lever: UNLOCK position

min-1 50 50

Fast Idle Speed (HP Mode)

50

Fast Idle Speed (PWR Mode) Fast Idle Speed (ECO Mode) Auto-Idle Speed

50 50 150

Slow Idle Speed

150

EC DIAL Slow Idle Fast Idle

Average

min-1

Fast Idle Speed (HP Mode)

ENGINE SPEED DEVIATION Fast Idle Speed Fast Idle Speed (When operating a control lever)

First

Measured Value Second Third

When boom raise relieving

Pilot shut-off lever: LOCK position

V 0.56 4.42

T4-2-9

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Item

Unit

PUMP 1 DELIVERY PRESSURE Control Lever in Neutral Boom Raise Boom Lower Arm Roll-In Arm Roll-Out Bucket Roll-Out Bucket Roll-In Combined operation of boom raise, arm roll-in, and bucket roll-in PUMP 2 DELIVERY PRESSURE Control Lever in Neutral Boom Raise Boom Lower Arm Roll-In Arm Roll-Out Bucket Roll-Out Bucket Roll-In Combined operation of boom raise, arm roll-in, and bucket roll-in

MPa

Reference Value

First

0.4 34.3 31.9 31.9 31.9 31.9

Measured Value Second Third

Average

Remarks

When relieving When relieving When relieving When relieving When relieving

31.9

When relieving

MPa 0.4 34.3 31.9 31.9 31.9 31.9

When relieving When relieving When relieving When relieving When relieving

31.9

When relieving

T4-2-10

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Item

Unit

PUMP 1 CONTROL PRESSURE Control Lever in Neutral Boom Raise Boom Lower Arm Roll-In Arm Roll-Out Bucket Roll-Out Bucket Roll-In Combined operation of boom raise, arm roll-in, and bucket roll-in PUMP 2 CONTROL PRESSURE Control Lever in Neutral Boom Raise Boom Lower Arm Roll-In Arm Roll-Out Bucket Roll-Out Bucket Roll-In Combined operation of boom raise, arm roll-in, and bucket roll-in

MPa

Reference Value

First

Measured Value Second Third

Average

Remarks

1.05 1.12 1.12 1.12 1.12 1.12

When relieving When relieving When relieving When relieving

1.12

When relieving

When relieving

MPa 1.05 1.12 1.12 1.12 1.12 1.12

When relieving When relieving When relieving When relieving

1.12

When relieving

When relieving

T4-2-11

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Item FRONT ATTACHMENT PILOT PRESSURE TRAVEL PILOT PRESSURE BOOM RAISE PILOT PRESSURE BOOM LOWER PILOT PRESSURE ARM ROLL-IN PILOT PRESSURE ARM ROLL-OUT PILOT PRESSURE BUCKET ROLL-OUT PILOT PRESSURE BUCKET ROLL-IN PILOT PRESSURE SWING PILOT PRESSURE LEFT TRAVEL PILOT PRESSURE RIGHT TRAVEL PILOT PRESSURE

Unit

Reference Value

First

Measured Value Second Third

Average

Remarks

MPa

3.9

When relieving

MPa

3.9

When relieving

MPa

3.9

When relieving

MPa

3.9

When relieving

MPa

3.9

When relieving

MPa

3.9

When relieving

MPa

3.9

When relieving

MPa

3.9

When relieving

MPa

3.9

When relieving

MPa

3.9

When relieving

MPa

3.9

When relieving

T4-2-12

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Item FRONT ATTACHMENT PILOT PRESSURE MAIN RELIEF BOOST PRESSURE OUTPUT Power Digging Switch: ON, Lever in Neutral When Boom Raise Relieving TRAVEL MOTOR CONTROL P/S OUTPUT BOOM MODE CONTROL P/S OUTPUT Lever in Neutral Boom Lower ARM 2 FLOW CONTROL P/S OUTPUT When Arm Roll-In Relieving Lever in Neutral (HP Mode) Lever in Neutral (PWR Mode) Lever in Neutral (ECO Mode) SWING FLOW CONTROL P/S OUTPUT When Boom Raise Relieving and Swing

Unit MPa

Reference Value

First

3.9

Measured Value Second Third

Average

Remarks When relieving

MPa 3.9 3.9 MPa

When fast speed traveling Boom mode selector switch: ON

3.9

MPa 0.47 3.92

When relieving

MPa 3.25 1.5 1.5 1.1 MPa 3.0

T4-2-13

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Item PUMP 1 (4 UNITS) P/S OUTPUT FB PUMP 2 (5 UNITS) P/S OUTPUT FB FUN SPEED CONTROL P/S 1 OUTPUT FB ARM 2 FLOW CONTROL P/S OUTPUT FB SWING FLOW CONTROL P/S OUTPUT FB FAN DIRECTION CONTROL P/S 1 OUTPUT FB FAN DIRECTION CONTROL P/S 2 OUTPUT FB

Unit

Reference Value

mA

294

mA

294

First

Measured Value Second Third

Average

Remarks When boom raise relieving When boom raise relieving

mA 381 to 590 mA

523

mA

490

mA

-

mA

-

When arm roll-in relieving When boom raise relieving and swing

T4-2-14

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard MPDr. Monitor Indicating Values (ECM) Unless specified, test under the following conditions.  Engine Control Dial: Fast Idle  Work Mode: Digging Mode  Power Mode Switch: HP mode  Auto-Idle Switch: OFF  Hydraulic Oil Temperature: 50±5 °C

Item ENGINE TORQUE

Reference Value

Unit %

Measured Value First

Second

Third

Average

Remarks

58

When boom raise relieving

ACTUAL ENGINE SPEED

min-1

1850

When boom raise relieving

TARGET ENGINE SPEED

min-1

1800

When boom raise relieving

ENGINE OIL PRESSURE

kPa 420 to 460

When boom raise relieving, When neutral: 440

FUEL FLOW RATE

L/h

-

When boom raise relieving

BOOST PRESSURE

kPa

146

When boom raise relieving

V

28.2

When boom raise relieving

BATTERY VOLTAGE

T4-2-15

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard (Blank)

T4-2-16

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 3 Engine Test Engine Speed Summary: 1. Measure the engine speed by using the monitor unit or MPDr.. 2. Measure the engine speeds in each mode.

fNOTE:

Measure the engine speed before performing all other tests. If the engine speed is not adjusted correctly, all other performance data will be unreliable.

Preparation: 1. Select the service menu of the monitor or MPDr.. In case of MPDr., install MPDr. first. 2. Warm up the machine until the coolant temperature reaches 70 °C or more and the hydraulic oil temperature is 50±5 °C.

T4-3-1

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 3 Engine Test Measurement:

Remedy:

1. Measure the items as shown in the table below.

Refer to Troubleshooting B.

2. When measuring, set the switch and test condition as shown in the table below in response to the engine speed to be measured. Evaluation: Refer to Operational Performance Standard. Item

Engine Control Dial

Power Mode

Auto-Idle Switch

Work Mode

Test Conditions

Slow Idle Speed

Min. Speed

HP

OFF

Pilot shut-off lever: LOCK position

Slow Idle Speed

Min. Speed

HP

OFF

Fast Idle Speed (With ECO deactivated) Fast Idle Speed (Relief operation) Fast Idle Speed (ECO mode) Fast Idle Speed (HP mode) Auto-Idle Speed

Max. Speed

HP

OFF

Digging Mode Digging Mode Digging Mode

Max. Speed

PWR

OFF

Boom raise (Relief operation)

Max. Speed

ECO

OFF

Max. Speed

HP

OFF

Max. Speed

HP

ON

Digging Mode Digging Mode Digging Mode Digging Mode

T4-3-2

Pilot shut-off lever: UNLOCK position, Control lever in neutral Deactivate ECO by MPDr., Control lever in neutral

Boom raise (Relief operation) 3.5 seconds passed after returning the control levers to neutral

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 3 Engine Test Switch Panel:

Monitor: 4

1 2

3 1- 2-

Engine Control Dial Auto-Idle Switch

3- 4-

TDAA-05-02-032 Power Mode Switch Digging Mode

T4-3-3

TDAA-05-02-060

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 3 Engine Test Lubricant Consumption Measuring Method 1. Place the machine on the level, firm ground and leave the machine for at least one hour in order to return the lubricant to the oil pan after the engine stops. At this time, confirm that the machine is level by using a leveler. 2. Record read-out A (unit: hour) of the hour meter. 3. Replenish the lubricant up to the high-level gauge. 4. Operate the machine for at least 100 hours or until the oil level lowers to the low-level gauge. 5. Place the machine on the level, firm ground and leave the machine for at least one hour in order to return the lubricant to the oil pan after the engine stops. At this time, confirm that the machine is level by using a leveler. 6. Record read-out B (unit: hour) of the hour meter. 7. Replenish the lubricant up to the high-level gauge while measuring the oil-replenishing volume C.

fNOTE:

When measuring, use a high-precision measuring cylinder or the like. 8. Determine the lubricant consumption from the following equation:

Oil replenishing volume (C) [mL]/Operating hours (B-A) [hr]

Evaluation: Refer to Operational Performance Standard.

T4-3-4

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Travel Speed Summary: 1. Measure the time required for the machine to travel a test track and check the performance of the travel systems (from main pump to travel motor).

c a

Preparation:

b

1. Adjust track sag of both tracks to the nominal dimension. 2. Provide a flat, solid test yard 10 m in length, with extra length of 3 to 5 m on both ends for machine acceleration and deceleration.

e

d

d

3. With the arm and the bucket cylinders fully extended, hold the bucket 0.3 to 0.5 m above the ground.

TDBC-04-04-001

4. Maintain the hydraulic oil temperature at 50±5 °C. abc-

Measurement:

Bucket Height: 0.3 to 0.5 m Start End

1. Measure in both fast and slow travel modes. 2. Select the following conditions. Travel Mode Switch

Engine Control Power Mode Dial

Auto-Idle Switch

Work Mode

Slow Mode

Fast Idle

HP

OFF

Digging Mode

Fast Mode

Fast Idle

HP

OFF

Digging Mode

3. Start traveling the machine in the acceleration zone with the travel levers to full stroke. 4. Measure the time required to travel between the start and end. 5. After measuring the time when going, swing the upperstructure 180 degrees, and measure the time when coming back in the same way. 6. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

T4-4-1

de-

Acceleration/Deceleration Zone: 3 to 5 m 10 m

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Track Revolution Speed Summary: 1. Measure the track revolution cycle time with the track raised off ground and check the performance of the travel systems (from main pump to travel motor).

a

Preparation: 1. Adjust track sag of both tracks to the nominal dimension. 2. On the track to be measured, put a mark on one shoe by using a piece of chalk or cloth.

M104-07-067 a-

90 to 110 Degrees

3. Raise the track to be measured off the ground as illustrated. Securely support the raised machine dCAUTION: off the ground by using blocks. 4. Maintain the hydraulic oil temperature at 50±5 °C. Measurement: 1. Measure on both tracks at slow and fast travel modes with forward and reverse travel. 2. Select the following conditions. Travel Mode Switch Slow Mode

Engine Control Power Mode Dial Fast Idle HP

Auto-Idle Switch OFF

Work Mode

Fast Mode

Fast Idle

OFF

Digging Mode

HP

3. Operate the travel control lever of the track to be measured to full stroke. 4. Measure the time required for 3 revolutions after a constant track revolution speed is obtained. 5. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard. NOTE: When the measurement data obtained through the track revolution test with the track raised off the ground has wide variations, the evaluation based on the results obtained from the 10 m travel speed check described before is more recommendable.

f

Remedy: Refer to Troubleshooting B.

T4-4-2

Digging Mode

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Mistrack Check Summary: 1. Allow the machine to travel 20 m. Measure the maximum tread deviation from the tread chord drawn between the travel start and end points and check the performance of the travel system (from main pump to travel motor). 2. If measured on a pavement surface, the tread deviation has a trend to decrease. Preparation:

a

1. Adjust track sag of both tracks to the nominal dimension. b

2. Provide a flat, solid test yard 20 m in length, with extra length of 3 to 5 m on both ends for machine acceleration and deceleration.

c

3. With the arm and bucket cylinders fully extended, hold the bucket 0.3 to 0.5 m above the ground. 4. Maintain the hydraulic oil temperature at 50±5 °C. T105-06-03-022

Measurement:

a- b-

1. Measure in both fast and slow travel modes.

Maximum Distance Acceleration/Deceleration Zone: 3 to 5 m

2. Select the following conditions. Travel Mode Switch Slow Mode

Engine Control Power Mode Dial Fast Idle HP

Auto-Idle Switch OFF

Work Mode

Fast Mode

Fast Idle

OFF

Digging Mode

HP

3. Start traveling the machine in the acceleration zone with the travel levers to full stroke. 4. Measure maximum distance (a) between a straight 20 m tread chord and the tread made by the machine. 5. After measuring maximum distance (a) when going, swing the upperstructure 180 degrees, and measure maximum distance (a) when coming back in the same way. 6. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

T4-4-3

Digging Mode

c-

20 m

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Travel Parking Leakage Summary: 1. Measure the parking brake function on a specified slope. 2. Measure on a flat slope with a gradient of 20 % (11.31 degrees). a

Preparation: 1. Measure on a flat slope with a gradient of 20 % (11.31 degrees). 2. With the arm and bucket cylinders fully extended, hold the bucket 0.2 to 0.3 m above the ground. 3. Maintain the hydraulic oil temperature at 50±5 °C.

T105-06-03-004 a-

0.2 to 0.3 m

Measurement: 1. Climb the slope and set the travel control lever in neutral. 2. Stop the engine. 3. After the machine stops, put marks onto the track link or the shoe, and the track side frame. 4. When five minutes passed, measure the distance between marks on the track link or the shoe, and the track frame. Evaluation: Refer to Operational Performance Standard.

b TDAA-04-04-001 b-

T4-4-4

Distance measured when five minutes passed

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Swing Speed Summary: 1. Measure the time required to swing three complete turns and check the performance of the swing system (from main pump to swing motor). Preparation: 1. Check lubrication of the swing gear and the swing bearing. 2. Place the machine on a flat and solid ground with ample space for swinging. Do not conduct this test on a slope.

a

3. Fully retract the arm cylinder. Fully extend the bucket cylinder. Adjust and hold the boom so that the arm end pin height is the same as the boom foot pin height. (Empty the bucket.)

T105-06-03-013 a-

The same height as boom foot pin

fNOTE:

In case a sufficient space for the measurement is difficult to find, carry out the measurement with the boom fully raised and the arm fully rolled-in. 4. Maintain the hydraulic oil temperature at 50±5 °C.

Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers are out of the swing area before starting the measurement. Measurement: 1. Select the following conditions. Engine Control Dial Fast Idle

Power Mode Auto-Idle Switch HP OFF

Work Mode Digging Mode

T178-04-03-001

2. Operate the swing control lever to full stroke and swing the upperstructure. 3. Measure the time required to swing 3 turns when the swing speed is a constant speed. 4. Check the time in both clockwise and counterclockwise directions. 5. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

T4-4-5

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Swing Function Drift Check Summary: 1. Measure the swing drift on the swing bearing outer circumference when stopping after a 180 degrees full-speed swing and check the performance of the swing brake valve. 2. The mechanical brake for the swing parking brake is equipped for the swing motor. Preparation:

a

1. Check lubrication of the swing gear and the swing bearing.

T105-06-03-008 a-

2. Place the machine on a flat and solid ground with ample space for swinging. Do not conduct this test on a slope.

Put the marks on swing bearing outer circumference and track frame.

3. Fully retract the arm cylinder. Fully extend the bucket cylinder. Adjust and hold the boom so that the arm end pin height is the same as the boom foot pin height. (Empty the bucket.) 4. Put marks onto the swing bearing outer circumference (upperstructure side) and the track frame. 5. Swing the upperstructure 180 degrees.

b

6. Maintain the hydraulic oil temperature at 50±5 °C. Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers

T105-06-03-009 b-

are out of the swing area before starting the measurement.

T4-4-6

Before start the measurement, swing the upperstructure 180 degrees.

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Select the following conditions. Engine Control Dial

Power Mode Auto-Idle Switch

Work Mode

Fast Idle

HP

Digging Mode

OFF

a

2. Operate the swing control lever to full stroke and swing the upperstructure 180 degrees. When the mark on upperstructure aligns with that on track frame, return the swing control lever to the neutral position. 3. After stopping the upperstructure, measure the arc length (swing bearing circumference) between the two marks on the swing bearing and track frame. 4. Check the arc length in both clockwise and counterclockwise directions.

b c T105-06-03-010 a- b-

5. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

T4-4-7

Measure arc length (swing bearing circumference). Mark on Track Frame

c-

Mark on Swing Bearing

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Swing Motor Leakage Summary: 1. Set the machine on a specified slope and swing the upperstructure 90 degrees to the slope. Measure the upperstructure drift while suspending a load on a specified slope and check the performance of the swing parking brake. (The mechanical brake for the swing parking brake is equipped for the swing device.) Preparation: 1. Check lubrication of the swing gear and the swing bearing. 2. Load the bucket. (Refer to the Operational performance Standard about the loading weight.)

T105-06-03-011

3. Fully retract the arm cylinder. Fully extend the bucket cylinder. Adjust and hold the boom so that the arm end pin height is the same as the boom foot pin height. (Empty the bucket.) 4. Park the machine on a smooth slope with a gradient of 15±1 degrees. 5. Climb a slope and swing the upperstructure to position it 90 degrees to the slope. Put the marks onto the swing bearing outer circumference (upperstructure side) and the track frame. 6. Maintain the hydraulic oil temperature at 50±5 °C.

T4-4-8

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Select the following conditions. Power Mode

Auto-Idle Switch

Work Mode

HP

OFF

Digging Mode

a

2. Start the engine. When 5 minutes passed at idle speed, measure the arc length (swing bearing circumference) between the two marks on the swing bearing and track frame.

b

3. Check the arc length in both clockwise and counterclockwise directions. 4. Repeat the measurement three times and calculate the mean values. Evaluation:

c T105-06-03-010 a- b-

Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

T4-4-9

Measure arc length (swing bearing circumference). Mark on Track Frame

c-

Mark on Swing Bearing

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Maximum Swingable Slant Angle Summary: 1. With the upperstructure swung 90 degrees to the slope, check the maximum slant angle on which the upperstructure can swing to the uphill side. Preparation: 1. Check lubrication of the swing gear and the swing bearing. 2. Load the bucket. (Refer to the Operational performance Standard about the loading weight.) 3. Fully retract the arm cylinder. Fully extend the bucket cylinder. Adjust and hold the boom so that the arm end pin height is the same as the boom foot pin height. (Empty the bucket.)

T105-06-03-011

4. Climb a slope and swing the upperstructure 90 degrees to the slope. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T4-4-10

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Select the following conditions. Engine Control Dial

Power Mode Auto-Idle Switch

Work Mode

Fast Idle

HP

Digging Mode

OFF

2. Operate the swing control lever to full stroke to swing the upperstructure to a uphill side. 3. If the machine can swing, measure the cab floor slant angle. 4. When the machine can swing, increase the slant angle. Check the slant angle in both clockwise and counterclockwise directions. Evaluation: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

T4-4-11

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Swing Bearing Play Summary: 1. Measure the swing bearing play and check the wear of the swing bearing races and the balls. Preparation: 1. Check the swing bearing mounting bolts for looseness.

1

2 T105-06-03-014

1-

2. Check lubrication of the swing bearing. Confirm that bearing rotation is smooth without noise.

Magnetic Base

2-

Dial Gauge

3. Secure dial gauge (2) on the round trunk (3) side of the track frame by using magnetic base (1). 4. Position the upperstructure so that the boom aligns with the tracks facing towards the front idlers. 5. Position dial gauge (2) so that its needle point comes in contact with the bottom surface of the swing bearing outer race.

3

6. Empty the bucket.

fNOTE:

The measured value will vary depending on where magnetic base (1) is secured. Secure magnet base (1) on the round trunk as close to the swing bearing as possible.

1 1-

T4-4-12

Magnetic Base

T105-06-03-015 3-

Round Trunk

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Fully retract the arm cylinder. Fully extend the bucket cylinder. Adjust the boom so that the arm end pin height is same as the boom foot pin height. Record dial gauge reading (h1) of dial gauge (2). a

T105-06-03-013 a - The arm end pin height is the same as boom foot pin.

2. Lower the bucket onto the ground and raise the front idler 0.5 m off the ground by using the front attachment. Record reading (h2) of dial gauge (2). 3. Calculate bearing play (H) from these data (h1 and h2) as follows: H=h2-h1 T105-06-03-017

Evaluation: Refer to Operational Performance Standard.

T4-4-13

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Hydraulic Cylinder Cycle Time Summary: 1. Measure the cycle time of boom, arm, and bucket cylinders, and check the performance of the front attachment system (from main pump to each cylinder). 2. Empty the bucket. Preparation: 1. Measurement is made for the following positions.  Measurement of the cycle time of the boom cylinder: With the bucket cylinder fully extended and the arm cylinder fully retracted, lower the bucket onto the ground.

T105-06-03-018

 Measurement of the cycle time of the arm cylinder: Retract or extend the bucket cylinder so that the arm and the bucket teeth are vertical to the ground. Set the arm so that the center of arm operation is vertical. The bucket teeth clearance above the ground is 0.5 m.

 Measurement of the cycle time of the bucket cylinder: Adjust the boom and arm cylinders so that the bucket oscillation center faces vertically to the ground. 2. Maintain the hydraulic oil temperature at 50±5 °C.

a

T1V1-04-05-005 a-

0.5 m

T105-06-03-020

T4-4-14

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Select the following conditions. Engine Control Dial Fast Idle

Power Mode Auto-Idle Switch HP OFF

Work Mode Digging Mode

2. Measure the cylinder cycle times as follows: (Cylinder full stroke includes cylinder cushioning zone.)  Measurement of the cycle time of the boom cylinder: Operate the boom control lever to full stroke. Measure the time to raise and lower the boom.  Measurement of the cycle time of the arm cylinder: Operate the arm control lever to full stroke. Measure the time to roll in and roll out the arm.  Measurement of the cycle time of the bucket cylinder: Operate the bucket control lever to full stroke. Measure the time to roll in and roll out the bucket. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

T4-4-15

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Dig Function Drift Check  Maximum Reach Position Summary: 1. Measure dig function drift, which can be caused by oil leakage in the control valve and boom, arm and bucket cylinders, with the bucket loaded.

b

a

a

2. When measuring the drift just after cylinder replacement, slowly operate the cylinder for ten minutes and bleed air from the cylinder. d

Preparation:

c

1. Load the bucket. (Refer to the Operational performance Standard about the loading weight.) 2. Fully retract the arm cylinder. Fully extend the bucket cylinder. Adjust and hold the boom so that the arm end pin height is the same as the boom foot pin height. (Empty the bucket.)

T105-06-03-021 a- b- c-

3. Position the arm cylinder and the bucket cylinder with the rod 50 mm away from the full stroke end position. 4. Maintain the hydraulic oil temperature at 50±5 °C.

T4-4-16

Retracted Distance Extended Distance Dig Function Drift Amount

d-

The arm end pin height is the same as boom foot pin.

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Stop the engine.

a

b

2. When 5 minutes passed, measure the change in position of bottom of the bucket, as well as the boom, arm, and bucket cylinders.

b

Boom and Bucket Cylinders: Retracted Distance: a a=A-B Arm Cylinder: Extended Distance: c c=B-A

T110-06-03-002

3. Repeat the measurement three times and calculate the mean values. Evaluation:

a-

Boom and Bucket Cylinders: Retracted Distance

b-

Mark

c

Refer to Operational Performance Standard. d

d

Remedy: Refer to Troubleshooting B.

TDCY-04-04-001

c-

T4-4-17

Arm Cylinder: Extended Distance

d-

Mark

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test  Arm Roll-In Position Summary: 1. Measure dig function drift, which can be caused by oil leakage in the control valve and boom, arm, and bucket cylinders. 2. When measuring the drift just after cylinder replacement, slowly operate the cylinder for 10 minutes and bleed air from the cylinder. Preparation: 1. Empty the bucket. 2. With the arm fully extended and the bucket fully extended, hold the arm end 1 m above the ground. 3. Position the arm cylinder and the bucket cylinder with the rod 50 mm away from the full stroke end position. 4. Maintain the hydraulic oil temperature at 50±5 °C. a

Measurement: T173-04-03-001

1. Stop the engine. a-

2. When 5 minutes passed, measure the change in position of bottom of the arm tip, as well as the boom, arm and bucket cylinders. Cylinder: Retracted Distance: b b=A-B

1m

b

3. Repeat the measurement three times and calculate the mean values.

c

c

Evaluation: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

T110-06-03-002 b-

T4-4-18

Cylinder: Retracted Distance

c-

Mark

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Control Lever Operating Force Summary: 1. Check a play and operating condition and measure the operating force. 2. Measure the maximum operating force of the front attachment control lever. 3. Measure the lever stroke along the control lever operation from the grip center of each control lever. Preparation: 1. Maintain the hydraulic oil temperature at 50±5 °C. Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers

TABA50-04-04-001

are out of the swing area before starting the measurement. Measurement: 1. Measure the operating force of each control lever. 2. Select the following conditions. Engine Control Dial

Power Mode Auto-Idle Switch

Work Mode

Fast Idle

HP

Digging Mode

OFF

3. In case of boom (raise), arm, and bucket control levers, measure the maximum operating force for each with each actuator relieved.

TABA50-04-04-003

4. In case of boom (lower) control lever, measure the maximum operating force with the boom (lower) relieved by raising the machine in a stable area. 5. In case of swing control lever, engage the bucket teeth with the ground and secure the upperstructure in order to prevent the machine from swinging. Operate the swing control lever and measure the maximum operating force with the swing relieved. 6. In case of travel control lever, raise the track to be measured off the ground. Measure the maximum operating force to be required. 7. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard.

T4-4-19

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Control Lever Stroke Summary: 1. Check a play and operating condition and measure each control lever stroke. 2. Measure the control lever stroke at the grip center of each control lever. 3. In case the lever stroke play is present in the neutral position, add half (1/2) the play present to both side lever strokes. Preparation: 1. Maintain the hydraulic oil temperature at 50±5 °C.

T107-06-03-005

Measurement: 1. Stop the engine. 2. Measure each control lever stroke from neutral to the stroke end of each control lever of boom, arm, bucket, swing, and travel. 3. Measure the chord length from neutral to the stroke end. 4. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard.

T4-4-20

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Combined Operation of Boom Raise and Swing Function Check Summary: 1. Check the boom raise and swing movement and speed while operating both functions simultaneously. 2. Check if the cylinders do not hesitate while operating the cylinder with the engine running at fast idle.

T107-06-03-009

Preparation: 1. With the arm cylinder fully retracted and the bucket cylinder fully extended, lower the bucket onto the ground. Lower the bucket onto the ground. (Empty the bucket.) 2. Maintain the hydraulic oil temperature at 50±5 °C. Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers are out of the swing area before starting the measurement. T107-06-03-010

Measurement: 1. Select the following conditions. Engine Control Dial

Power Mode Auto-Idle Switch

Work Mode

Fast Idle

HP

Digging Mode

OFF

H

2. Raise the boom and swing the upperstructure in full stroke at the same time. 90 Measure the time required to swing the upperstructure 90 degrees and height (H) of the bucket teeth. (The bucket should be empty.) 3. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

T4-4-21

T107-06-03-011

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test (Blank)

T4-4-22

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Primary Pilot Pressure Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Remove plug (1) from the pilot filter. Install adapter (ST 6069) and pressure gauge (ST 6942) to the pressure check port. j : 19 mm 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C. Measurement: 1

1. Select the following conditions. Engine Control Dial Fast Idle

Power Mode Auto-Idle Switch HP OFF

Slow Idle

HP

OFF

Work Mode Digging Mode Digging Mode

2. Measure the pilot pressure without load by using the pressure gauge under each condition above.

T178-03-07-001 1-

3. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard.

T4-5-1

Plug

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Primary Pilot Pressure Adjustment Procedure Adjustment: Adjust the relief valve (1) set pressure if necessary.

1. Remove plug (2) from relief valve (1).

1

j : 22 mm 2. Install the estimated number of shims (3). 3. After the adjustment, tighten plug (2).

T178-03-07-001

m : 25+2 N·m (2.5+0.2 kgf·m)

2

3

4. After the adjustment, check the set pressure.

fNOTE:

Standard Change in Pressure (Reference)

Shim (3) Thickness (mm) 0.25

Change in Pressure kPa (kgf·m) 78 (0.8)

0.5

157

(1.6)

1.0

304

(3.1)

T111-06-04-004 1- 2-

T4-5-2

Relief Valve Plug

3-

Shim

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Secondary Pilot Pressure Preparation:

1

1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air.

8

3. Measure the pilot pressure between pilot valve (1) and signal control valve (2). Disconnect the signal control valve (2) side of pilot hose (3) of the circuit to be measured. Install hose (8), tee (5), adapter (4), adapter (7), and pressure gauge (6) between signal control valve (2) and pilot hose (3).

2

7 6

j : 19 mm, 22 mm 5

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge (6) connection.

4

5. Maintain the hydraulic oil temperature at 50±5 °C. 3

Measurement: 1. Select the following conditions. Engine Control Dial Fast Idle

Power Mode Auto-Idle Switch HP OFF

Slow Idle

HP

OFF

Work Mode Digging Mode Digging Mode

TJAA-04-05-001 1- 2- 3- 4- 5-

2. Operate the control lever to be measured. Measure the pilot pressure by using pressure gauge (6) with the control lever set to the full stroke. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

T4-5-3

Pilot Valve Signal Control Valve Pilot Hose Adapter (ST 6460) Tee (4351843)

6- 7- 8-

Pressure Gauge (ST 6942) Adapter (ST 6069) Hose (9/16-18UNF, Length: approx. 400 mm)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test 4-Spool Solenoid Valve Set Pressure Use MPDr. and a pressure gauge at the same time. 1

Preparation:

2

1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air.

6

3. Disconnect the hose from the solenoid valve to be measured. Install tee (4), hose (5), adapter (3), adapter (6), and pressure gauge (2) between the disconnected hose and the solenoid valve unit (1).

5

4

3

j : 17 mm, 19 mm

T157-05-04-002

Connect MPDr. and select the monitoring function. 1- 2- 3-

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge (2) connection.

Solenoid Valve Unit Pressure Gauge (ST 6942) Adapter (ST 6461)

4- 5- 6-

Tee (ST 6451) Hose (4216453) Adapter (ST 6069)

5. Maintain the hydraulic oil temperature at 50±5 °C. Measurement: 1. Select the following conditions. Engine Control Dial Fast Idle

Power Mode Auto-Idle Switch HP OFF

Slow Idle

HP

OFF

Work Mode SC

SF

SI

SG

Digging Mode Digging Mode

2. Operate as instructed below for each measuring solenoid valve:

Solenoid Valve SG: Single operation of arm roll-in or arm roll-out.



Solenoid Valve SI: Turn ON and OFF the power digging switch.



Solenoid Valve SF: Single operation of bucket roll-in or bucket roll-out.



Solenoid Valve SC: Set the travel mode switch fast speed mode and slow speed mode.

TJAA-01-02-102

3. Read the values on both MPDr. and the pressure gauge. 4. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard.

T4-5-4

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test 2-Spool Solenoid Valve Set Pressure Use MPDr. and a pressure gauge at the same time. 1

Preparation:

2

1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air.

6

3. Disconnect the hose from the solenoid valve to be measured. Install tee (4), hose (5), adapter (3), adapter (6), and pressure gauge (2) between the disconnected hose and the solenoid valve unit (1).

5

4

3

j : 17 mm, 19 mm

T157-05-04-002

Connect MPDr. and select the monitoring function. 1- 2- 3-

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge (2) connection.

Solenoid Valve Unit Pressure Gauge (ST 6942) Adapter (ST 6461)

4- 5- 6-

Tee (ST 6451) Hose (4216453) Adapter (ST 6069)

5. Maintain the hydraulic oil temperature at 50±5 °C. Measurement: 1. Select the following conditions. Engine Control Dial

Power Mode

Auto-Idle Switch

Work Mode

Fast Idle

HP

OFF

Digging Mode

Slow Idle

HP

OFF

Digging Mode

SC

SI

2. Operate as instructed below for each measuring solenoid valve:  Solenoid Valve SI: Combined operation of swing and boom raise, or swing and arm roll-out.  Solenoid Valve SC: Turn ON the boom mode selector switch. Operate boom raise, boom lower, arm roll-in, arm roll-out, bucket roll-in bucket roll-out or swing. 3. Read the values on both MPDr. and the pressure gauge. 4. Repeat the measurement three times and calculate the average values.

TJAA-01-02-103

Evaluation: Refer to the Operational Performance Standard.

T4-5-5

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Solenoid Valve Adjustment Procedure

8

IMPORTANT: If loosening adjusting screw (8) excessively, O-ring (9) is damaged and oil leakage may cause. Do not loosen adjusting screw (8) excessively. Do not loosen adjusting screw (8) more than 2 turns from fully tightened position.

7

9

1. Loosen lock nut (7). Turn adjusting screw (8) in order to adjust the set pressure. a

2. After the adjustment, tighten lock nut (7).

T1V1-04-05-004

j : 13 mm m : 5 N·m (0.5 kgf·m) l : 3 mm

8

7

3. After the adjustment, check the set pressure.

fNOTE:

Standard Change in Pressure (Reference)

Adjusting Screw (8) Turns

1/4

Change in kPa 69 Pressure (kgf/cm2) (0.7)

1/2

3/4

1

137

206

275

(1.4)

(2.1)

(2.8) T1V1-04-05-003

8

7

b

c

W107-02-05-129 a- b-

2.0 mm Pressure Increase

c-

Pressure Decrease

7- 8-

Lock Nut Adjusting Screw

9-

O-Ring

T4-5-6

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Main Pump Delivery Pressure The main pump delivery pressure can be also measured by using MPDr.. Preparation: 1. Stop the engine.

2

1

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Remove the plug from the delivery pressure check port of the main pump to be measured. Install the adapter (ST 6069), the hose (ST 6943), and the pressure gauge (ST 6941) to the delivery pressure check port of the main pump to be measured. j : 19 mm l : 6 mm

Connect MPDr. and select the monitoring function.

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C.

TJBC-04-05-001

1-

Measurement: 1. Select the following conditions. Engine Control Dial Fast Idle

Power Mode Auto-Idle Switch HP OFF

Work Mode Digging Mode

2. Measure the pressure with the control lever set in neutral without load. 3. Repeat the measurement three times and calculate the mean values. Evaluation: Refer to Operational Performance Standard. Remedy: Refer to Troubleshooting B.

T4-5-7

Pump 1 Delivery Pressure Check Port

2-

Pump 2 Delivery Pressure Check Port

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Fan Pump Delivery Pressure Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Remove the plug from delivery pressure check port of the fan pump to be measured. Install adapter (ST 6069), coupling (ST 6333) and pressure gauge (ST 6308) to the fan pump delivery pressure check port (1).

1

j : 19 mm l : 6 mm 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C. Measurement: 1. Select the following conditions. Engine Control Dial

Power Mode

Auto-Idle Switch

Work Mode

Fast Idle

HP

OFF

Digging Mode

TJBA-04-05-002

1-

2. Measure the pressure with the control lever set in neutral without load. 3. Repeat the measurement three times and calculate the average values. Evaluation: Refer to the Operational Performance Standard. Remedy: Refer to the Troubleshooting B.

T4-5-8

Fan Pump Delivery Pressure Check Port

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Main Relief Set Pressure Summary: Measure the main relief valve set pressure at the delivery port in the main pump. The main relief set pressure can be also measured by using MPDr..

2

1

Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and bleed air. 3. Remove the plug from the delivery pressure check port of the main pump to be measured. Install the adapter (ST 6069), the hose (ST 6943), and the pressure gauge (ST 6941) to the delivery pressure check port of the main pump to be measured. TJBC-04-05-001

j : 19 mm l : 6 mm

1-

Connect MPDr. and select the monitoring function.

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C.

T4-5-9

Pump 1 Delivery Pressure Check Port

2-

Pump 2 Delivery Pressure Check Port

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: 1. Select the following conditions. Engine Control Dial

Power Mode Auto-Idle Switch

Work Mode

Fast Idle

HP

Digging ON Mode OFF

OFF

Power Digging Switch

2. Main relief pressure: Perform bucket, arm, boom, or travel operation. Measure the set pressure of main relief valve (1). When measuring the pressure of bucket, arm, and boom, operate each control lever slowly. Operate each cylinder to the stroke end (extend, retract) and relieve the pressure. 3. Swing relief pressure: When measuring the pressure of swing, secure the upperstructure so that it does not swing. Slowly operate the swing control lever and relieve the swing function. In order to judge at which swing device the swing relief pressure is detected, loosen the adjustment plug of the swing device (right).  When the swing relief pressure decreases, the swing relief pressure at the swing device (right) is detected. Further loosen the adjustment plug of the swing device (right). When the swing relief pressure stops decreasing, the pressure is the swing relief pressure at the swing device (left). Return the adjustment plug of the swing device (right) to the original position.  When the swing relief pressure does not decrease, the swing relief pressure at the swing device (left) is detected. Return the adjustment plug of the swing device (right) to the original position. Slowly loosen the adjustment plug of the swing device (left). When the swing relief pressure stops decreasing, the pressure is the swing relief pressure at the swing device (right). Return the adjustment plug of the swing device (left) to the original position. 4. Travel relief pressure: When measuring the pressure of travel, secure the tracks against an immovable object. Slowly operate the travel control lever and relieve the pressure. 5. When measuring the pressure during power digging operation, measure the pressure within 8 seconds after pushing the switch. Evaluation: Refer to Operational Performance Standard.

T4-5-10

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test

fNOTE:

1

If pressures of all circuits are low, the pressure of the main relief valve may decrease.

Main Relief Valve (1) Setting Adjustment Procedure When adjusting the pressure during the power digging operation, adjust the high-pressure side of main relief pressure. When adjusting the normal main relief pressure, adjust the low-pressure side of main relief pressure. When adjusting the high-pressure side of main relief pressure, the low-pressure side of main relief pressure setting is changed accordingly. Therefore, be sure to adjust the low-pressure side of main relief pressure after adjusting the high-pressure side of main relief pressure. High-pressure side of relief pressure adjustment procedure.

TJAA-04-05-003

2

1. Loosen lock nut (3). Lightly tighten plug (2) until plug (2) comes into contact with the end of sleeve (4).



3 4

Tighten lock nut (3).

5

j : 22 mm, 30 mm

6

(Lock Nut (3)) m : 50 to 60 N·m (5 to 6 kgf·m)

2. Loosen lock nut (5). Turn sleeve (4) and adjust the pressure until the specified pressure is obtained. j : 27 mm, 41 mm

(Lock Nut (5)) m : 90 to 100 N·m (9 to 10 kgf·m)

3. After the adjustment has been completed, tighten lock nut (5). 4. After the adjustment, check the set pressure.

T16J-04-04-003 1- 2- 3-

Main Relief Valve Plug Lock Nut

4- 5- 6-

Sleeve Lock Nut Cap

2, 4

b

a

W107-02-05-127 a-

T4-5-11

Pressure Increase

b-

Pressure Decrease

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Low-pressure side of relief pressure adjustment procedure.

2 3

3. Loosen lock nut (3). Turn plug (2) and adjust the pressure until the specified pressure is obtained. After the adjustment has been completed, tighten lock nut (3).

4 5 6

j : 22 mm, 30 mm

(Lock Nut (3)) m : 50 to 60 N·m (5 to 6 kgf·m)

4. After adjustment, check the set pressure.

fNOTE:

Standard chang in Pressure (Reference)

Plug (2), Sleeve (4) Turns

1/4

1/2

3/4

1

Change in Relief Pressure

4.4

8.8

13.2

17.7

(90)

(135)

(180)

MPa

(kgf/cm2) (45)

T16J-04-04-003 2- 3- 4-

Plug Lock Nut Sleeve

5- 6-

Lock Nut Cap

2, 4

b

a

W107-02-05-127 a-

T4-5-12

Pressure Increase

b-

Pressure Decrease

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Swing Relief Valve Set-Pressure Adjustment Procedure

1

Adjust the set pressure of swing relief valve (1) using adjusting plug (2) after loosening lock nut (3). 1. Loosen lock nut (3). j : 38 mm 2. Turn adjusting plug (2) to adjust. j : 30 mm 3. Tighten lock nut (3). j : 38 mm m : 118 N·m (12.0 kgf·m) 4. After adjustment, check the set pressure.

fNOTE:

Standard Change in Pressure (Reference)

Adjusting Plug Turns (2) Change in Pressure

T1JB-04-05-005

1

MPa

10.0

(kgf/cm2)

(102)

3

2

T16J-04-05-001 1- 2-

Swing Relief Valve Adjusting Plug

3-

Lock Nut

2

b

a

T157-05-04-023 a-

T4-5-13

Pressure Increase

b-

Pressure Decrease

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Travel Relief Valve Set-Pressure Adjustment Procedure (Reference) Adjust the set pressure of travel relief valve (1) using adjusting screw (3) after loosening lock nut (2). 1. Loosen lock nut (2). j : 19 mm 2. Turn adjusting screw (3) to adjust the pressure setting, referring to the table below. j : 6 mm 3. Retighten lock nut (2). j : 19 mm m : 34.3 to 44.1 N·m

1

T183-01-02-012

(3.5 to 4.5 kgf·m)

4. After adjustment check the set pressure by the special test device.

fNOTE:

2

Standard Change in Pressure (Reference)

Adjusting Screw (3) Turns

1/4

Change in MPa 1.96 Pressure (kgf/cm2) (20)

1/2

3/4

1

3.92

5.88

7.85

(40)

(60)

(80)

3 T142-05-04-007 1- 2-

Travel Relief Valve Lock Nut

3-

2

Adjusting Screw

3

b

a

W107-02-05-129 a-

T4-5-14

Pressure Increase

b-

Pressure Decrease

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Overload Relief Set Pressure Summary: 1. When measure the overload relif set pressure, the circuit pressure must be increased by applying an external force while blocking the return circuit of the control valve. However, this measuring method is hazardous and the results obtained with this method are unreliable. 2. Accordingly, the overload relief valve assembly should be removed from the machine and checked on a specified test stand at a correct oil flow rate.

Measurement: 1. Select the following conditions. Engine Control Dial

Power Mode Auto-Idle Switch

Work Mode

Fast Idle

HP

Digging Mode

OFF

2. Slowly operate the bucket, arm, or boom control levers. Operate each cylinder to the stroke end (extend, retract) and relieve the main relief valve.

3. Measure the pressure on the machine is not recommended because of above mentioned reasons. If the measurement on the machine is required, please substitute the measurement of the main relief set pressure. The main relief set pressure can be also measured by using MPDr..

3. Read the pressure on the pressure gauge at this time. 4. Perform the measurement for the bucket, arm, and boom in sequence.

Preparation: 1. Stop the engine.

5. Repeat the measurement three times and calculate the mean values.

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air.

Evaluation: The overload relief valves are normal when each main relief set pressure in the measured circuits (bucket, arm, boom) is within the specified value range. Refer to the Operational Performance Standard.

3. Remove the plug from the delivery pressure check port of the main pump to be measured. Install adapter (ST 6069), hose (ST 6943), the pressure gauge (ST 6941) to the delivery pressure check port of the main pump to be measured. j : 19 mm

2

1

l : 6 mm 4. Connect MPDr. and select the monitoring function. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C.

TJBC-04-05-001

1-

T4-5-15

Pump 1 Delivery Pressure Check Port

2-

Pump 2 Delivery Pressure Check Port

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Overload Relief Pressure Adjustment Procedure (Reference)

1

IMPORTANT: Adjust the overload relief valve pressure on a test stand. Loosen lock nut (1) and adjust the set pressure of the overload relief valve by using adjusting screw (2). 1. Loosen lock nut (1). 2

j : 19 mm 2. Turn adjusting screw (2) and adjust the set pressure. l : 6 mm

T162-04-04-004 1-

Lock Nut

2-

Adjusting Screw

3. Tighten lock nut (1). j : 19 mm

1

2

m : 31.5 N·m (3.2 kgf·m) 4. After adjustment check the set pressure by the special test device.

fNOTE:

b

a

Standard Change in Pressure (Reference)

Adjusting Screw (2) Turns

1/4

1/2

3/4

1

Change in MPa 4.9 Pressure (kgf/cm2) (50)

9.8

14.7

19.6

(100)

(150)

(200)

W107-02-05-129 a-

T4-5-16

Pressure Increase

b-

Pressure Decrease

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test (Blank)

T4-5-17

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Main Pump Flow Rate Measurement 6. Disconnect the hose from the port Psv (11). Install plug (ST 6255) (13) to the port Psv.

 P-Q Control (Torque Control) Summary: Install hydraulic tester (5) to the delivery port of the main pump to be measured. Main pump performance is checked by measuring the pump flow rate. Use MPDr. and a hydraulic tester at the same time.

j : 19 mm 7. Remove the vacuum pump. Loosen plug (12) on top of the air bleed port Bleed air from the casing until oil only comes out.

IMPORTANT: This measurement procedure is a simple method. In order to measure accurately, disconnect the return circuit from the control valve and connect it to the hydraulic oil tank.

j : 19 mm 8. Fully open the loading valve of hydraulic tester (5).

Preparation:

9. Start the engine. Confirm that no oil leakage is observed at the hydraulic tester connection. Connect MPDr. and select the monitoring function.

1. Stop the engine. Push the air bleed valve and bleed air. Connect a vacuum pump to the oil filler port.

Measurement:

fNOTE:

Operate the vacuum pump while connecting the pump flow rate test line. 2. Disconnect the delivery hose from the main pump to be measured. Connect pipe (1 or 2) to the delivery port of the main pump with the split flange and bolts of the disconnected hose. j : 41 mm

1. Maintain the hydraulic oil temperature at 50±5 °C. 2. Measure the maximum flow rate. 3. Select the following conditions. Engine Control Dial

Power Mode

Auto-Idle Switch

Work Mode

Fast Idle

HP

OFF

Digging Mode

l : 10 mm 3. Connect pipe (1 or 2) to hydraulic tester (5) by using test hose (3) and adapter (4). Install adapter (6), test hose (7) and flange (8) to hydraulic tester (5). j : 41 mm l : 10 mm

4. Adjust the relief set pressure of main relief valve in control valve to each pressure point specified along the main pump P-Q curve. (Refer to T4-2-5) Slowly restrict the loading valve of hydraulic tester (5) while relieving pressure in the arm roll-in circuit. Measure the flow rates and engine speeds at each pressure point specified in the P-Q curve. 5. Repeat the measurement three times and calculate the average values.

4. Connect the delivery hose to flange (8) with split flanges (9) and bolt (10). l : 10 mm 5. Install a pressure gauge to the main pump to be measured. (Refer to “Main Relief Set Pressure”.) l : 6 mm

T4-5-18

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Evaluation: 1. Convert the measured flow rates to those at the specified pump speed by using the following formula.

2. Standard Flow Rate

Refer to Operational Performance Standard.

fNOTE:

When actually measuring, install pipe (1 or 2) only to the pump to be measured.

Qc = Q × Ns / Ne Qc : Converted Flow Rate Q :

Measured Flow Rate

Ns : Specified Engine Speed:

1800 min-1

Ne : Measured Engine Speed:

Values indicated on MPDr.

1, 2

3

4

5

6

7

8 9 10

Delivery Hose (To Control Valve) TJAA-04-05-004

12

11

TJBG-04-05-001

1- 2- 3- 4-

Pipe F (ST 6138) Pipe D (ST 6132) Test Hose (ST 6145) Adapter G1 × UNF1-7/8 (ST 6146)

5- 6- 7- 8-

Hydraulic Tester (ST 6299) Adapter G1 × UNF1-7/8 (ST 6146) Test Hose (ST 6145) Flange (ST 6140)

13

9- 10- 11- 12- 13-

T4-5-19

Split Flange (4075853) Bolt (J271245) (4 Used) Port P1 Plug Plug (ST 6255)

TJBA-04-05-004

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Fan Pump Flow Rate Measurement Measurement:

 P-Q Control (Torque Control) Summary:

1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Fan pump performance is checked by measuring the pump flow rate by using a hydraulic tester (3) installed at the fan pump delivery port to be measured. Use a hydraulic tester. IMPORTANT: This measurement procedure is a simple method. Preparation:

2. Measure the maximum flow rate. 3. Select the following conditions. Engine Control Dial

Power Mode

Auto-Idle Switch

Work Mode

Fast Idle

HP

OFF

Digging Mode

1. Stop the engine. Push the air bleed valve and bleed air. Connect a vacuum pump to the oil filler port.

fNOTE:

Operate the vacuum pump while connecting the pump flow rate test piping. 2. Disconnect the delivery hose (7) from fan pump. Install the pipe (10) and the test hose (1) to the delivery port. j : 36 mm, 41 mm 3. Connect test hose (1) to hydraulic tester (3) with adapter (2). Install adapter (4), test hose (5) and adapter (6) to hydraulic tester (3). j : 41 mm 4. Connect the delivery hose (7) to adapter (6). j : 41 mm 5. Disconnect the hose from the port Psv (8). Install plug (ST 6204) to the port Psv (8). j : 19 mm 6. Remove the vacuum pump. Loosen plug (9) on top of the pump casing. Bleed air from the casing until oil only comes out. l : 6 mm 7. Fully open the loading valve of hydraulic tester (3). 8. Start the engine. Confirm that no oil leakage is observed at the hydraulic tester (3) connection.

T4-5-20

4. Adjust the set pressure of relief valve in fan valve to each pressure point specified along the fan pump P-Q curve. (Refer to T4-2-6) Slowly restrict the loading valve of hydraulic tester (3). Measure the flow rates and engine speeds at each pressure point specified in the P-Q curve. 5. Repeat the measurement three times and calculate the average values.

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Evaluation:

2. Standard Flow Rate

1. Convert the measured flow rates to those at the specified pump speed by using the following formula.



Refer to Operational Performance Standard.

Qc = Q × Ns / Ne Qc : Converted Flow Rate Q :

Measured Flow Rate

Ns : Specified Engine Speed:1800 min-1 Ne : Measured Engine Speed:

Values indicated on MPDr.

10

1

2

3

4

5

6

Delivery Hose (To Control Valve) TJBG-04-05-005

9 8

9 7

TJBA-04-05-002 1- 2-

Test Hose (ST 6145) Adapter G1 × UNF1-7/8 (ST 6146)

3- 4-

Hydraulic Tester (ST 6299) Adapter G1 × UNF1-7/8 (ST 6146)

5- 6- 7-

T4-5-21

Test Hose (ST 6145) Adapter (ST 6025) Delivery Hose

8- Port Psv 9- Plug 10- Pipe (ST 6142)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Adjustment of Main Pump Maximum Flow Rate When adjusting the main pump maximum flow rate, loosen lock nut (5) on the regulator and turn adjusting screw (6). j : 13 mm : Lock Nut (5) : 1 mm : Adjusting Screw (6)

5

6

a

b

1 2

3 4 5 6 a-

Flow Rate Increase

b-

Flow Rate Decrease

1-

Adjusting Screw (For Minimum Flow Rate) Lock Nut (For Minimum Flow Rate)

3-

Lock Nut (For Flow Rate Control) Adjusting Screw (For Flow Rate Control)

2-

4-

Adjusting Screw (6) Turn

1/4

Flow Rate Change

29.0 L/min

Engine Speed

1800 min-1

5- 6-

TJBA-04-05-007

Lock Nut (For Minimum Flow Rate) Adjusting Screw (For Minimum Flow Rate) Q

I TJAA-04-05-007 I-

T4-5-22

Pump Control Solenoid Valve Signal Current

Q- Pump Delivery Flow Rate

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Adjustment of Main Pump Minimum Flow Rate When adjusting the main pump minimum flow rate, loosen lock nut (2) on the regulator and turn adjusting screw (1). j : 17 mm : Lock Nut (2) : 1.5 mm : Adjusting Screw (1)

b

a

1 2 1 2 3

TJBA-04-05-008

a-

Flow Rate Decrease

b-

Flow Rate Increase

1-

Adjusting Screw (For Minimum Flow Rate) Lock Nut (For Minimum Flow Rate)

3-

Lock Nut (For Flow Rate Control) Adjusting Screw (For Flow Rate Control)

2-

4-

5 6

4

5- 6-

Lock Nut (For Minimum Flow Rate) Adjusting Screw (For Minimum Flow Rate) Q

Adjusting Screw (1) Turn

1/4

Flow Rate Change

32.1 L/min

Engine Speed

1800 min-1

I TJAA-04-05-008 I-

T4-5-23

Pump Control Solenoid Valve Signal Current

Q- Pump Delivery Flow Rate

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Adjustment of Main Pump Flow Rate Control (by Pilot Pressure Characteristics) When adjusting the main pump flow rate control, loosen lock nut (3) on the regulator and turn adjusting screw (4). j : 30 mm : Lock Nut (3) j : 13 mm : Adjusting Screw (4)

4

b

a

1

3

2

3 4 5 6 a-

Flow Rate Increase

b-

Flow Rate Decrease

1-

Adjusting Screw (For Minimum Flow Rate) Lock Nut (For Minimum Flow Rate)

3-

Lock Nut (For Flow Rate Control) Adjusting Screw (For Flow Rate Control)

2-

4-

Adjusting Screw (4) Turn

1/4

Flow Rate Change

54.2 L/min

Engine Speed

1800 min-1

5- 6-

TJBA-04-05-007

Lock Nut (For Minimum Flow Rate) Adjusting Screw (For Minimum Flow Rate) Q

IMPORTANT: When adjusting the flow rate, the maximum flow rate will also be changed. There fore, adjust the maximum flow rate after adjusting the flow rate. I TJAA-04-05-009 I-

T4-5-24

Pump Control Solenoid Valve Signal Current

Q- Pump Delivery Flow Rate

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test (Blank)

T4-5-25

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Adjustment of Fan Pump Maximum Flow Rate When adjusting the radiator fan pump maximum flow rate, loosen lock nut (2) on the the large chamber side end of the servo piston and turn adjusting screw (1). j : 24 mm : Lock Nut (2) j : 10 mm : Adjusting Screw (1)

3 4 1

2

TJBA-04-05-009 1-

Adjusting Screw (For Maximum Flow Rate)

2-

Lock Nut (For Maximum Flow Rate)

Adjusting Screw (1) Turn

1/4

Flow Rate Change

3.1 L/min

Engine Speed

1800 min-1

3-

Lock Nut (For Minimum Flow Rate)

4-

Adjusting Screw (For Minimum Flow Rate)

Q

I TJBA-04-05-010 I-

Fan Pump Control Solenoid Valve Signal Current

Q- Pump Delivery Flow Rate

1

b

a

TJBA-04-05-006 a-

T4-5-26

Flow Rate Decrease

b-

Flow Rate Increase

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Adjustment of Radiator Fan Pump Minimum Flow Rate When adjusting the radiator fan pump minimum flow rate, loosen lock nut (3) on the the small chamber side end of the servo piston and turn adjusting screw (4). j : 19 mm : Lock Nut (3) l : 6 mm : Adjusting Screw (4)

3 4 1

2

TJBA-04-05-009 1-

Adjusting Screw (For Maximum Flow Rate)

2-

Lock Nut (For Maximum Flow Rate)

3-

Lock Nut (For Minimum Flow Rate)

4-

Adjusting Screw (For Minimum Flow Rate)

Q

Adjusting Screw (4) Turn

1/4

Flow Rate Change

2.8 L/min

Engine Speed

1800 min-1

I TJBA-04-05-011 I-

Fan Pump Control Solenoid Valve Signal Current

Q- Pump Delivery Flow Rate

4

b

a

a-

T4-5-27

Flow Rate Increase

b-

W107-02--05-129 Flow Rate Decrease

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Adjustment of Radiator Fan Pump Flow Rate Control The radiator fan pump flow rate control is performed by signal current (I)of pump control solenoid valve. The flow rate control is adjusted by changing the set-force of spring (1)Adjustment: Loosen lock nut (2) and turn adjusting screw (3). j : 17 mm : Lock Nut (2) l: 5 mm : Adjusting Screw (3) 1 2 3

TJBA-04-05-009 1-

Spring

2-

Lock Nut

Adjusting Screw (3) Turn

1/4

Flow Rate Change

9.5 L/min

Engine Speed

1800 min-1

3-

Adjusting Screw Q

IMPORTANT: When adjusting the flow rate, the maximum flow rate will also be changed. There fore, adjust the maximum flow rate after adjusting the flow rate. I TJBA-04-05-012 I-

Fan Pump Control Solenoid Valve Signal Current

Q- Pump Delivery Flow Rate

3

b

a

W107-02--05-129 a-

T4-5-28

Flow Rate Decrease

b-

Flow Rate Increase

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test (Blank)

T4-5-29

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Swing Motor Drainage Summary:

1

A

1. Measure amount of oil draining from the swing motor while swinging the upperstructure and check the swing motor performance. 2. Secure absolute safety for the measuring persons as well as for the surrounding while measuring. 3. The amount of drain oil from the swing motor will change depending on hydraulic oil temperature. Preparation: 1. Maintain hydraulic oil temperature at 50±5 °C (122±9 °F). Rotate the swing motor in order to warm inside of the motor. 2. Stop the engine. Push air bleed valve (1) on top of the hydraulic oil tank and release any remaining pressure. 3. Disconnect right drain hose (1) at right side of tee (A). Install plug (ST 6491) on the tee side. The drain oil at the swing device (right) comes out from the drain hose (1).

Machine Front Side

2

B T1JB-04-05-005

Disconnect drain hose (2) at left side of tee (B). Connect a test drain hose (3/4-16UN) to the motor side and plug (ST 6637) to drain hose (2). The drain oil at the swing device (left) comes out from the test drain hose.

1-

A- Right Side of Tee

j : 27 mm m : 93 N·m (9.5 kgf·m) Preconditions for Measurement: 1. Select the following conditions. Engine Control Dial

Power Mode

Auto-Idle Switch

Work Mode

Fast Idle

HP

OFF

Digging Mode

Drain Hose (Between Swing Motor)

T4-5-30

2-

Drain Hose (Return Hydraulic Oil Tank)

B-

Left Side of Tee

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers are out of the swing area before starting the measurement. Also, take care not to fall off from the machine while measuring. 1. Fully retract the arm cylinder. Fully extend the bucket cylinder. Hold the boom so that the arm tip pin height is the same as the boom foot pin height. Empty the bucket. 2. Start the engine. Operate and hold the swing control lever in the full stroke. After the swing speed reaches a constant maximum speed, start the draining oil measurement when the drain oil starts coming out of the drain hose end. 3. Repeat the measurement at least three times in both clockwise and counterclockwise directions, and calculate the mean values.

a

T105-06-03-013 a-

The same height as boom foot pin

4. The measuring time should be more than 45 seconds. Evaluation: Refer to Operational Performance Standard. * Conversion of amount of measured drain oil into the per-minute value First measure the amount of drain oil by using a calibrated container. Then, convert the measured drain oil into the per-minute value by using the following formula. Q =60×q/t Q : Amount of drain oil per minute (L/min) t : Measured time (seconds) q : Total amount of drain oil (L) T107-06-05-008

T4-5-31

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Travel Motor Drainage Summary: 1. While rotating the travel motor with the track to be measured raised off the ground, measure amount of oil draining from the travel motor and check travel motor performance.

1

2. Secure absolute safety for the measuring persons as well as for the surrounding while measuring. 3. Judge travel motor performance from the results including travel speed, mistrack and so on overall. 4. The amount of drain oil from the travel motor will change depending on hydraulic oil temperature. Keep the hydraulic oil temperature. M183-01-001

Preparation: 1. Adjust track sag.

Track sag specification: 450 to 500 mm

2. Main hydraulic oil temperature at 50±5 °C (122±9 °F). Rotate the travel motor and warm inside of the motor.

2

3. Stop the engine. Push air bleed valve on top of the hydraulic oil tank and release any remaining pressure. 4. Disconnect the drain hose (1) in the travel motor at the travel motor end. Install plug (3) (ST 6637) to the disconnected end. Connect test drain hose (2) (3/416UN) to the travel motor. j : 27 mm T157-05-04-019

m : 93 N·m (9.5 kgf·m) Preconditions for Measurement:

1

1. Select the following conditions. Engine Control Dial

Power Mode

Auto-Idle Switch

Work Mode

Fast Idle

HP

OFF

Digging Mode

3

T183-04-04-011 1- 2-

T4-5-32

Drain Hose Test Drain Hose

3-

Plug

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: When the working around moving dCAUTION: parts is unavoidable, pay special attention to ensure that hands, feet, and clothing do not become entangled. Securely support the raised track off the ground by using the blocks.

a

1. Start the engine. Raise the track to be measured off the ground. 2. Rotate the track to be measured. Start drain oil measurement when drain oil starts coming out of the connected drain hose end.

M104-07-067 a - 90 to 110°

3. Repeat the measurement at least three times in both clockwise and counterclockwise directions, and calculate the mean values. 4. The measuring time should be more than 45 seconds. Evaluation: Refer to Operational Performance Standard. * Conversion of the amount of drain oil measured into the per-minute value First measure the amount of drain oil by using a calibrated container. Then, convert the measured drain oil into the per-minute value by using the following formula. Q =60×q/t Q : Amount of drain oil per minute (L/min) t : Measured time (seconds) q : Total amount of drain oil (L)

T157-05-04-019

T4-5-33

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test (Blank)

T4-5-34

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment PUMP LEARNING (Pump Regulator Pressure Learning) Detects electrical current and pressure, which control the pump regulator, of the pump control solenoid valve, and memorize in MC. (Refer to the T/M (SYSTEM) section.) Therefore, as difference between the signal to pump control solenoid valve from MC and the regulator pressure controlled by the pump control solenoid valve is adjusted, the pump swash angle is controlled correctly. MPDr. displays the pump status during the pump learning and can check if the learning has been done correctly. IMPORTANT: Perform the pump learning if the following work is done.  Replace the pump, pump regulator and pump control solenoid valve  Replace MC  When executing all parameter initialize of MC IMPORTANT: After the learning, turn the learning switch to the OFF position. If the pump learning fails, the adjustment is not done. If the adjustment succeeds and the learning switch is turned by mistake, the learning may fail.

Learning Start Condition MC, ECM: No breakdown, no failure Engine Control Dial: Fast idle Auto-Idle Switch: OFF Power Mode Switch: HP Mode Pressure Sensor: Output zero. (The control lever is in neutral.)  Hydraulic Oil Temperature: 50±5 °C (122±9 °F)  Pilot Shut-Off Lever: LOCK Position  Learning Switch: OFF NOTE: Cancellation during learning:     

f

When the learning switch is turned to the OFF position before finishing the learning, the adjustment is done according to the former learning result.

T4-6-1

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment TORQUE ADJUSTMENT Adjust pump drive torque, sum of main pumps 1, 2, by using MPDr. (Refer to the T/M (SYSTEM) section.) IMPORTANT: These procedures are for only adjustment without repair. When main pump drive torque need to increase or decrease, do these procedures. Adjustment Start Condition:  MC, ECM: No breakdown and No malfunction (by using MPDr.)  Engine output horsepower: Normal  Hydraulic oil temperature: 50±5 °C (122±9 °F)

T4-6-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment CONNECTION 1. Connect MPDr. to the MPDr. connector by using the USB serial cable, the inter link cross cable, and the connecting harness.

MPDr. Connector

1

2. Turn the key switch ON or start the engine. Personal Computer (MPDr.) Inter Link Cross cable

TJAA-01-02-018

USB Serial Cable Connecting Harness T1T1-06-01-001 1-

MPDr. Connector

T4-6-3

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 6 Adjustment (Blank)

T4-6-4

MEMO

MEMO

SECTION 5

TROUBLESHOOTING CONTENTS Group 1 Diagnosing Procedure

Introduction........................................................................... T5-1-1 Diagnosis Procedure........................................................... T5-1-2 Electrical System Inspection............................................ T5-1-5 Precautions for Inspection and Maintenance............ T5-1-6 Instructions for Disconnecting Connectors............... T5-1-8 Fuse Inspection...................................................................T5-1-10 Fusible Link Inspection....................................................T5-1-13 Battery Voltage Check......................................................T5-1-14 Alternator Check................................................................T5-1-15 Continuity Check...............................................................T5-1-16 Voltage and Current Measurement.............................T5-1-18 Check by False Signal.......................................................T5-1-25 Test Wire Harness...............................................................T5-1-26

Group 2 Monitor

Outline..................................................................................... T5-2-1 Operating Procedures of Service Menu....................... T5-2-2 Setting Menu.......................................................................T5-2-39 Inspection of Engine Oil Level, Coolant Level, Hour Meter, and Fuel Gauge...............................................T5-2-41 Fuel Gauge and Coolant Temperature Gauge.........T5-2-42

Group 3 e-Service

Outline..................................................................................... T5-3-1 List of Operation Data........................................................ T5-3-2 Snapshot Data....................................................................... T5-3-6 Communication System.................................................... T5-3-7

Group 4 Component Layout

Main Component................................................................. T5-4-1 Radiator/Oil Cooler/Inter Cooler.................................... T5-4-2 Electrical System (Overview)........................................... T5-4-3 Fuel Pump............................................................................... T5-4-4 Electrical System (Rear Tray)............................................. T5-4-5 Electrical System (Switch Panel)..................................... T5-4-6 Electrical System (Cab Behind Side).............................. T5-4-7 Battery Disconnect Switch............................................... T5-4-8 Around Horn.......................................................................... T5-4-9 Boom Upper Side...............................................................T5-4-10 Electric Grease Gun...........................................................T5-4-10 Engine....................................................................................T5-4-11 Pump Device.......................................................................T5-4-12 Control Valve.......................................................................T5-4-13 Check Valve..........................................................................T5-4-14 Signal Control Valve..........................................................T5-4-14

4-Spool Solenoid Valve Unit...........................................T5-4-17 2-Spool Solenoid Valve Unit...........................................T5-4-17 Layout of Control Valve....................................................T5-4-18 Pilot Port (Signal Control Valve)....................................T5-4-34

Group 5 Troubleshooting A

Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure.................................... T5-5-1 MC Fault Code List............................................................... T5-5-3 ECM Fault Code List...........................................................T5-5-22 Monitor Controller (Monitor) Fault Code List..........T5-5-27 Monitor Controller (Information) Fault Code List...T5-5-28 Air Conditioner Controller Fault Code List................T5-5-31 Communication Terminal Fault Code List.................T5-5-32 MC Fault Codes 11000 to 11002...................................T5-5-33 MC Fault Code 11003.......................................................T5-5-34 MC Fault Codes 11006, 11007,11009 Monitor Controller (Monitor) Fault Codes 13002, 13003, 13005...................................................T5-5-37 CAN0 Harness Check........................................................T5-5-38 MC Fault Codes 11008, 11010 Monitor Controller (Monitor) Fault Codes 13004, 13006, 13007...................................................T5-5-41 CAN1 Harness Check........................................................T5-5-42 MC Fault Code 11100.......................................................T5-5-45 MC Fault Code 11101.......................................................T5-5-46 MC Fault Codes 11200, 11202.......................................T5-5-47 MC Fault Codes 11301, 11302.......................................T5-5-48 MC Fault Code 11303.......................................................T5-5-49 MC Fault Codes 11304, 11325.......................................T5-5-50 MC Fault Code 11405.......................................................T5-5-51 MC Fault Code 11408.......................................................T5-5-52 MC Fault Code 11412.......................................................T5-5-53 MC Fault Code 11428.......................................................T5-5-54 MC Fault Code 11802.......................................................T5-5-55 MC Fault Code 11901.......................................................T5-5-56 MC Fault Codes 11942, 11944.......................................T5-5-57 MC Fault Codes 11945......................................................T5-5-58 MC Fault Code 11948.......................................................T5-5-59 MC Fault Code 11950.......................................................T5-5-60 MC Fault Code 11951.......................................................T5-5-61 MC Fault Code 11953.......................................................T5-5-62 MC Fault Codes 11978, 11979.......................................T5-5-63 MC Fault Code 11981.......................................................T5-5-64 MC Fault Code 11982.......................................................T5-5-65 MC Fault Codes 11985, 11986.......................................T5-5-66

JBMT-5-1

MC Fault Code 11989.......................................................T5-5-67 MC Fault Codes 11992, 11994.......................................T5-5-68 MC Fault Codes 11995, 11997.......................................T5-5-69 MC Fault Code 11998.......................................................T5-5-70 MC Fault Codes 20062......................................................T5-5-71 Monitor Controller (Information) Fault Codes 13304, 13310..................................................................T5-5-72 Monitor Controller (Information) Fault Code 13311................................................................................T5-5-73 Monitor Controller (Information) Fault Codes 20100 to 20104, 20106...............................................T5-5-74 Monitor Controller (Information) Fault Codes 20107, 20109, 20110, 20114, 20146, 20149........T5-5-75 Air Conditioner Controller Fault Codes 11 to 22.....T5-5-76 Air Conditioner Controller Fault Codes 43 to 92.....T5-5-77

Group 6 Troubleshooting B

Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure....................... T5-6-1 Relationship between Machine Trouble Symptoms and Related Parts..................................... T5-6-3 Correlation Between Trouble Symptoms and Part Failures.............................................................................T5-6-29 Engine System Troubleshooting..................................T5-6-47 All Actuator System Troubleshooting.........................T5-6-53 Front Attachment System Troubleshooting.............T5-6-62 Swing System Troubleshooting....................................T5-6-75 Travel System Troubleshooting....................................T5-6-78 Other System Troubleshooting.....................................T5-6-82 Exchange Inspection........................................................T5-6-89 How to Lowering Boom When Emergency and When Engine Stops.....................................................T5-6-92

Group 7 Air Conditioner

Outline..................................................................................... T5-7-1 Functions of Main Parts..................................................... T5-7-4 Troubleshooting................................................................... T5-7-9 Air Conditioner Controller Fault Code List................T5-7-10 Air Conditioner Controller Fault Codes 11 to 22.....T5-7-11 Air Conditioner Controller Fault Codes 43 to 92.....T5-7-12 Work after Replacing Components.............................T5-7-34 Refill Compressor Oil........................................................T5-7-35 Charge Air Conditioner with Refrigerant..................T5-7-36 Hose and Pipe Tightening Torque................................T5-7-44

JBMT-5-2

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Introduction Refer to the inspection and troubleshooting procedures after any machine trouble has occurred. The inspection and troubleshooting procedures are presented in an orderly fashion in this section to quickly find the cause of the machine trouble and solution. The troubleshooting section in this manual consists of seven groups as follows. 5. Troubleshooting A (Base Machine Diagnosis By Using Fault Codes)

1. Diagnosing Procedure This group explains procedures of troubleshooting and precautions and/or information for the electrical system inspection. Example: Fuse Inspection 2. Monitor This group contains the display screen of monitor and the operating procedures of service menu. 3. e-Service

Refer to these procedures if any fault codes are displayed when each controller is diagnosed by using MPDr. (or the service menu of monitor). IMPORTANT: The monitor controller receives and records the electrical signal system malfunction of each controller in the form of fault codes by using the CAN communication. The monitor controller records the electrical signal system malfunction in the form of fault codes by the self-diagnosing function.

This group contains as follows. Procedures of downloading and uploading data from the monitor controller. Procedures when starting communication, when installing the communication controller and when replacing the monitor controller. Explanation for the communication system.

Example: Fault Code 11000-2: Abnormal EEPROM 6. Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Refer to troubleshooting B for diagnosis by using trouble symptom. Refer to these procedures when no fault codes are displayed after diagnosing the machine by using MPDr. (or the service menu of monitor).

4. Component Layout

Example: Even if engine control dial is rotated, engine speed does not change. 7. Air Conditioner This group explains air conditioner system, troubleshooting, and procedure of charging refrigerant to the air conditioner.

T5-1-1

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Diagnosis Procedure These six basic steps are essential for efficient troubleshooting: 1. Study the system  Study the machine's technical manuals.  Know the system and how it works, and what the construction, functions and specifications of the system components are. (Construction and functions) 2. Ask the operator Before inspecting, get the full story of malfunctions from the operator below.  Operating condition: How is the machine being used? Find out if the machine is being operated correctly.  Trouble identification: When was the trouble noticed, and what type of work was the machine doing at that time?  Trouble symptom: What are the details of the trouble? Did the trouble slowly get worse, or did it appear suddenly?  Trouble history: Did the machine have any other troubles previously? If so, which parts were repaired before? 3. Inspect the machine Before starting the troubleshooting procedure, check the machine's daily maintenance points, as shown in the operator's manual. Troubles in the electrical system such as low battery voltage, loose connections and blown fuses will result in malfunction of the controllers. Also, troubles in the electrical system will cause total operational failure of the machine. If troubleshooting is started without checking for blown fuses, a wrong diagnosis may result in wasting time. Check for blown fuses before troubleshooting. Even if a fuse looks normal by visual inspection, a fine crack may exist and it is difficult to find. Always use a circuit tester when checking the fuses.

T107-07-01-001

T107-07-01-002

4. Operate the machine yourself Reproduce the trouble on the machine and make sure the actual phenomenon. If the trouble cannot be confirmed, stop the engine and obtain further details of the malfunction from the operator. Also, check for any incomplete connections of the wire harnesses corresponding to the trouble. T107-07-01-003

T5-1-2

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 5. Perform troubleshooting Do not disconnect wire harnesses dCAUTION: or hydraulic lines while the engine is running. The machine may malfunction or pressurized oil may spout out, possibly resulting in personal injury. Stop the engine before disconnecting wire harnesses or hydraulic lines. Perform diagnosis by connecting MPDr. to the machine or by using the service menu of monitor. In case any fault code has been displayed by diagnosis by using MPDr. (or the service menu of monitor), write the fault code. Then, delete the fault code once and retry self-diagnosis again. If the fault code is displayed again, check the cause of the trouble by referring to Troubleshooting A in this section. After the machine trouble has been corrected, the fault code (displayed by the service menu of monitor) will be deleted. Therefore, if there are problems that are not easily re-predicable, check the fault code by using MPDr.. If the fault code is not displayed, check operating condition of each component by referring to Troubleshooting B in this section and by using MPDr. (or the service menu of monitor). NOTE: The controller stores even temporary electrical malfunctions, such as a drop in battery output voltage or disconnection of the switches, sensors, etc., for inspections.

f

T5-1-3

TDCD-05-01-002

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 6. Trace possible causes Before reaching a conclusion, check the most suspect causes again. Try to identify the actual cause of the trouble. Based on your conclusion, make a plan for appropriate repairs to avoid secondary malfunctions.

7. Maintenance mode Before checking the electrical system such as disconnecting the connector, select the maintenance mode on the monitor. (Refer to Monitor.)

T107-07-01-007

T5-1-4

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Electrical System Inspection The precautions and information for the electrical system inspection are explained here. The electrical system inspection contains as follows.          

Precautions for Inspection and Maintenance Instructions for Disconnecting Connectors Fuse Inspection Fusible Link Inspection Battery Voltage Check Alternator Check Continuity Check Voltage and Current Measurement Check by False Signal Test Wire Harness

T5-1-5

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Precautions for Inspection and Maintenance IMPORTANT: Do not turn OFF battery disconnect switch (1) while the engine is running and the key switch is in the position other than OFF. And do not turn OFF battery disconnect switch until more than five minutes past after setting the key switch to the OFF position. Failure to do so may damage the electrical system. 1. Disconnect the power source. Turn OFF battery disconnect switch (1) first when taking off wire harnesses and connectors 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. In addition, even when the key switch is set to the OFF position, the controller may be operated for a specified time. Therefore, turn OFF battery disconnect switch (1) after setting the key switch to the OFF position and waiting five minutes or more. 2. Color coding of wire harnesses. As for the color codes of wire harnesses in the electrical system, refer to the table. If one wire consists of two colors, two or more codes are indicated. The left code stands for base color and the right code stands for marking color. Code Color Code Color

R Red Or Orange

W White Lg Light green

L Blue Br Brown

G Green P Pink

Y Yellow Gr Gray

B Black V Violet

fNOTE:  Code BW indicates a black base wire harness with white fine-line marking.  Initials "O" and "Or" both stand for the color orange.  Longitudinal stripes printed on wires are not color code and indicate the kinds of wires.

T5-1-6

1

MJAC-01-052

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 3. Precautions for connecting and disconnecting terminal connectors  Disconnect the connectors by grasping. Do not pull on the wire harness itself. Release the lock first before attempting to separate the connectors, if a lock is provided. (Refer to Instructions for Disconnecting Connector on T5-1-8.)  The water-resistant connectors keep water out. If water enters them, water will not easily drain from them. When checking the water-resistant connectors, take extra care not to allow water to enter the connectors. In case water should enter the connectors, reconnect only after the connectors are thoroughly dried.  Before connecting the connectors, check that no terminals are bent (3) or coming off (4). In addition, as most terminals are made of brass, check that no terminals are rusting (2).  When connecting connectors provided with a lock, insert them together until the lock "clicks."  Pull lightly the wire harness near the connector in order to check if it is correctly connected.

TDAA-05-08-002

1 2 3

4 TDAA-05-08-003

1- 2-

Normal Rusting

3- 4-

Bent Coming Off

4. Precautions for using a circuit tester  Before using a circuit tester, refer to the instructions in the circuit tester manual. Then, set the circuit tester to meet the object to be measured, voltage range and current polarity.  Before starting the connector test, always check the connector terminal numbers by referring to the circuit diagram. When the connector size is very small, and the standard probe size is too large to be used for testing, wind a fine piece of sharpened wire or a pin around the probe to make the test easier.  When checking the connector by using a circuit tester, do not damage the terminal inside the connector. Insert a tester probe from the wire harness end of the connector.

T5-1-7

TDAA-05-08-004

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Instructions for Disconnecting Connectors  Push, Unlock, and Separate Type (Most connectors are this type.)  The connectors will not be easily separated even if the lock is pushed while being pulled. At first push the lock and pull the connectors.  The lock is located on female side connector (wire harness end side).

T107-04-05-002

 Raise Lock, Pull, and Separate Type

T107-04-05-003

T5-1-8

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure  Pull Lock and Switch the Lever Type

TDAA-05-08-005

 Remove Bolt (1) and Remove Type: (A)  Push Lock and Switch Lever (2) Type: (B)

A

1 2

B

1-

T5-1-9

Bolt (M8)

2-

Lever

TDAA-05-08-006

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fuse Inspection Cracks in a fuse are so fine that it is very difficult or impossible to find by visual inspection. Use a circuit tester in order to correctly inspect fuse continuity by following the instructions described below.

fNOTE:

Check the starter circuit fuse with the key switch set in the START position and follow the procedure in step 3. b

1. Set the key switch to the ON position. When the key switch is in the ON position, current from key switch terminal M turns ON the battery relay so that electric power is supplied to all circuits except the starter circuit. (Refer to the circuit diagram.)

a

b

2. Remove the fuse box cover. Set a circuit tester. (Measurement Range: 0 to 30 V) 3. Ground the negative probe of circuit tester to the body. Touch the terminals located (b) away from center of the fuse box with the positive probe of circuit tester one at a time. When the circuit tester indicates 20 to 25 V (battery voltage), the fuse is normal.

M178-07-034 a-

Terminals connected to the power source

Fuse Box 1

b-

Terminals connected to loads (accessories)

Fuse Box 2

10 9 8 7 6

20 19 18 17 16

30 29 28 27 26

40 39 38 37 36

5 4 3 2 1

15 14 13 12 11

25 24 23 22 21

35 34 33 32 31

M178-07-034

T5-1-10

M178-07-034

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fuse No. Capacity Connected to 1 20 A Work Light Relay 1 2 10 A Washer Relay, Wiper Motor 3 20 A Air Conditioner Unit 4 20 A Pilot Shut-Off Relay, Pilot Shut-Off Solenoid Valve, Security Relay, MC (Solenoid Valve Power) 5 5A Option 1, Travel Alarm (Optional), Option 2, ATT 6 20 A Option 2, OPT-Wiper 7 5A Monitor Controller, ECM 8 30 A ECM Main Relay (Power) 9 10 A Monitor Controller (Backup Power), Switch Panel, Cab Light, Radio (Backup Power), Security Horn (Power), Security Horn Relay (Power), GSM (Power) 10 5A MC (Power), GSM (Power), Wiper/Light Controller (Power) 11 5A Fuel Pump Relay 12 5A Wiper/Light Controller, Radio (Power) 13 10 A Cigar Lighter 14 5A Monitor Controller (Power) 15 10 A Auxiliary (Power) 16 5A Glow Plug Relay 17 5A Buzzer, Engine Stop Switch, Air Conditioner Unit, Work Light Relay 1, Washer Relay, Wiper Relay, GSM, Monitor Controller, ECM, MC, OPT-Wiper 18 5A ACC Cut Relay, Key Switch ON Cut Relay, Auto Shut-Down Relay, Starter Cut Relay 19 10 A Horn Relay (Power) 20 5A Option 3

T5-1-11

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fuse No. Capacity Connected to 21 10 A Seat Heater (Optional) 22 10 A Work Light Relay 3 23 10 A Cab Light Rear Side (Optional) 24 10 A 25 5A Immobilizer (Optional) 26 5A Quick Hitch (Optional) 27 5A 28 10 A 29 20 A Work Light Relay 2 30 10 A Auto Lubrication Relay 31 10 A Seat Compressor (Optional) 32 10 A Cab Light Front Side (Optional) 33 10 A Indicator (Optional) 34 10 A 35 20 A 36 15 A Suction Control Valve 1, Suction Control Valve 2 37 10 A Grease Pump 38 39 40 -

T5-1-12

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Fusible Link Inspection 2

Inspection

3

1

1. Visually inspect fusible link (2, 3). Replacement 1. Turn OFF the battery disconnect switch. 2. Pull out fusible link (2, 3). Replace fusible link (2, 3). 3. Turn ON the battery disconnect switch.

M1JB-07-012

2

T111-04-05-015 1- 2-

T5-1-13

Battery Relay Fusible Link (45 A)

3-

Fusible Link (75 A)

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Battery Voltage Check 1. Turn OFF the key switch. Check the voltage between the battery positive terminal and the body (ground).

Specification: 24 V

fNOTE:

If the voltage is not within the specification, recharge or replace the battery. 2. Start the engine. Check the voltage between the battery positive terminal and the body (ground).

Specification: 26 to 28 V

fNOTE:

If the voltage is not within the specification, check the charging system.

T162-05-06-005

T5-1-14

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Alternator Check Generally, if the alternator has generated electricity, alternator alarm (1) will disappear. If alternator alarm (1) is displayed while the engine is running, the alternator might be defective. How to Check Alternator 1. Set the key switch to the ON position. Confirm that alternator alarm (1) is displayed. 2. Measure voltage between terminals B and E of the alternator. If the measured voltage is around 24 V, the alternator circuit can be considered normal. If the measured voltage is low, a shortage in battery capacity or looseness of the wire connectors between battery and alternator might be the cause of the malfunction. When voltage is 0 V, the ground line of the alternator might be disconnected. 3. Next, start the engine and measure voltage generated while the alternator rotates. As described above, measure voltage between terminals B and E on the alternator side. If voltage is around 28 V, the alternator is operating normally. If the measured voltage is same as the battery voltage (around 24 V), there is some trouble with the alternator or the regulator.

1

MDAA-01-043

B

Connector (L, R)

T16J-05-06-001

T5-1-15

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Continuity Check IMPORTANT: Before continuity check, set the key switch to the OFF position.  Single line continuity check Disconnect both end connectors of the wire harness and check continuity (measure the resistance) between both end terminals:  ∞ Ω = Open circuit  0 Ω = Normal

A

A

 When the one end connector is far apart from the other Connect one end of connector (A) to the body by using a clip. Then, check continuity of the wire harness between terminal (a) and the body.  ∞ Ω = Open circuit  0 Ω = Normal

 Multi line continuity check Disconnect both end connectors of the wire harness, and short circuit two terminals, (A) and (B), at one end connector. Then, check continuity between terminals (a) and (b) at the other connector. If the ohm meter reading is ∞ Ω, either line (A) - (a), or (B) - (b) is in discontinuity, or both lines (A) - (a) and (B) - (b) are in discontinuity. Discontinuity is not limited at only one place. Check discontinuity of the single line for all uncertain wire harnesses.  Multi line short circuit check Disconnect both end connectors of the wire harness, and check continuity between terminals (A) and (B) or (C).  0 Ω = Short circuit exists between the lines.  ∞ Ω = Normal

a

A

 Single line short circuit check Disconnect both end connectors of the wire harness and check continuity between one end connector terminal of the wire harness and the body:  0 Ω = Short circuit  ∞ Ω = Normal

a

a

T107-07-05-003

A B C

a b c

T107-07-05-004

A B C

a b c

T107-07-05-005

T5-1-16

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure (Blank)

T5-1-17

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Voltage and Current Measurement Turn on the switches so that the specified voltage (current) is supplied to the location to be measured. Judge if the circuit is normal by evaluating whether the measured voltage (current) matches the specification. 24-Volt Circuit Start checking the circuit in order up to the location to be measured from either power source or actuator side. Thereby, the faulty location in the circuit will be found.  Black (negative) probe terminal of circuit tester: To the body (to ground)  Red (Positive) probe terminal of circuit tester: To touch the location to be measured Engine Electric Power Circuit Stopped Stopped Stopped Stopped Stopped Stopped

Key Switch

Location to be Measured

Specification

OFF OFF OFF OFF OFF OFF

Between (2) and (1): Between (3) and (2): Between (3) and (1): Between (4) and Ground: Between (5) and Ground: Between (1) and Ground:

One Battery One Battery Two Batteries Battery Power Fusible Link Backup Current *1

10 to 12.5 V 10 to 12.5 V 20 to 25 V 20 to 25 V 20 to 25 V 20 mA or less

Stopped

ON or START

Between (11) and Ground:

Key Switch

20 to 25 V

Stopped

ON or START

Between (7) and Ground:

Glow Plug *2

20 to 25 V

Fast Speed Fast Speed Fast Speed Fast Speed Surge Voltage Prevention Circuit Slow Idle Speed Slow Idle Speed Slow Idle Speed Slow Idle Speed Accessory Circuit

ON ON ON ON

Between (9) and Ground: Between (8) and Ground: Between (17) and Ground: Between (14) and Ground:

Alternator (B), Generating Voltage Battery Relay, Generating Voltage Fuse Box 1, Generating Voltage Monitor Controller (A15)

26 to 30 V 26 to 30 V 26 to 30 V 13 to 30 V

ON ON ON ON

Between (9) and Ground: Between (13) and Ground: Between (10) and Ground: Between (6) and Ground:

Alternator (B) Key Switch ON Cut Relay Load Dump Relay Battery Relay

26 to 30 V 26 to 30 V 26 to 30 V 26 to 30 V

Stopped Stopped Stopped Stopped Stopped Stopped

ON ON ON ON ON ON

Between (12) and Ground: Between (15) and Ground: Between (16) and Ground: Between (18) and Ground: Between (19) and Ground: Between (6) and Ground:

ACC Cut Relay Monitor Controller Wiper/Light Controller, Radio Auxiliary Cigar Lighter Battery Relay

20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V

Preheating Circuit

Charging Circuit

*1 *2

Before measurement, turn OFF the battery disconnect switch. The preheating circuit is operated for the preheating time according to the coolant temperature.

T5-1-18

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

g h

12

13

i

11 1 2 3

4 5

6 c

d

e

j

f

14 n

10

a

k 7 8 19 18

17 16

15

9 b

m l

TJAE-05-01-001 a- b- c- d-

Battery Alternator Fusible Link Battery Relay

e- f- g- h-

Glow Plug Load Dump Relay Key Switch ACC Cut Relay

i- j- k- l-

T5-1-19

Key Switch ON Cut Relay Fuse Box 1 Monitor Controller ECM

m- MC n- Fuse Box 2

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Engine Starting Circuit Started Started Started Started Started Started Started Started Started Started Started Started Started Started

Key Switch START START START START START START START START START START START START START START

Location to be Measured Between (20) and Ground: Between (21) and Ground: Between (22) and Ground: Between (23) and Ground: Between (24) and Ground: Between (25) and Ground: Between (26) and Ground: Between (27) and Ground: Between (28) and Ground: Between (29) and Ground: Between (30) and Ground: Between (31) and Ground: Between (32) and Ground: Between (33) and Ground:

Battery Relay (Coil) Battery Relay (Switch) Starter (B) Starter (C) Starter Relay 1 (B) Starter Cut Relay Fuse Box 1 Key Switch Fuse Box 1 Monitor Controller (A16) MC (E4) ECM (134) ECM Main Relay ECM Main Relay

T5-1-20

Specification 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

e

20

27

26 d

c

28

k a

f

25 22 23

g

21

A16

29

24

b

30

33

h 32 31

E4

j

134 i

TJAE-05-01-001

a- b- c-

Starter Starter Relay 1 Battery Relay

d- e- f-

Starter Cut Relay Key Switch Fuse Box1

g- h- i-

T5-1-21

Monitor Controller ECM Main Relay ECM

j- k-

MC Fuse Box 2

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Engine Pilot Shut-Off Circuit* Stopped Stopped Stopped

Key Switch

Location to be Measured

ON ON ON

Between (34) and Ground: Between (35) and Ground: Between (36) and Ground:

Pilot Shut-Off Solenoid Valve Pilot Shut-Off Relay (Coil) Pilot Shut-Off Relay (Switch)

20 to 25 V 20 to 25 V 20 to 25 V

Stopped Stopped

ON ON

Between (37) and Ground: Between (38) and Ground:

Security Relay Fuse Box 1

20 to 25 V 20 to 25 V

* Before measurement, set the pilot shut-off lever to the UNLOCK position.

T5-1-22

Specification

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

34

b

a

c

d

e

38 35 36

37

TJAE-05-01-001

a- b-

Pilot Shut-Off Solenoid Valve Pilot Shut-Off Relay

c- d-

Security Relay Fuse Box 1

e-

T5-1-23

Fuse Box 2

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 5-Volt Circuit  Voltage between terminal #1 and the body Disconnect the connector with the key switch OFF. Measure voltage between terminal #1 (5 V power supply) on the body harness end connector and the body (ground).

Two Polarities 1

2

 Key Switch: ON  Black (negative) probe terminal of circuit tester: To the body (to ground)  Red (positive) probe terminal of circuit tester: Terminal #1

T107-07-05-006

If the measuring voltage is within 5 ± 0.5 volts, the circuit up to terminal #1 is normal.

Three Polarities 1

 Voltage between terminal #1 and the ground terminal Turn OFF the key switch, and disconnect the sensor connector. Measure the voltage between terminal #1 (5 V power supply) on the body harness end connector and the ground terminal (terminal #2 for two-polarities or terminal #3 for three-polarities connector) under the following conditions.

2

3

T107-07-05-007

Two Polarities 1

2

 Key Switch: ON  Black (negative) probe terminal of circuit tester: To ground terminal (Terminal #2 or #3)  Red (positive) probe terminal of circuit tester: Terminal #1 If the measuring voltage is within 5 ± 0.5 volts, the circuit up to terminal #1 and the ground terminal (terminal #2 or #3) is normal.

T107-07-05-008

Three Polarities 1

2

3

T107-07-05-009

T5-1-24

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Check by False Signal Two Polarities

Turn OFF the key switch. Disconnect the sensor connector. Turn ON the key switch. Connect terminal #1 (power source) of the body harness end connector to terminal #2 (signal). (Power voltage is used as a false signal.) Check this state by using the monitor function of MPDr.. When the maximum value is displayed, MC and the circuit up to the body harness end connector are normal. In case of a pressure switch, it displays "ON" status. IMPORTANT: Do not connect terminal #1 or #2 to terminal #3 or to the body (ground) when checking a three-polarity connector.

1

2

T107-07-05-010

Three Polarities

fNOTE:

1

Some kinds of sensors can be monitored by the service menu of the monitor.

2

3

T107-07-05-011

T5-1-25

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Test Wire Harness

Parts Number 4283594 (ST 7126)

Install a test wire harness between connectors. Check the circuit condition depending on whether the test wire harness lamp lights or extinguishes during operation.  Parts Number 4283594 (ST 7126) Use in order to check a single-line (open circuit and/or voltage). T107-07-05-012

 During Operation: Light is ON. Parts Number (ST 7226)

 Parts Number (ST 7226) Use in order to check the solenoid valve unit circuits.

3 1

 When the corresponding control lever or switch is operated: Light is ON.

2

150

4 50 50

50

2

1 T107-07-06-015

Connect a test wire harness to the wire harness end connector of pressure sensor. Check the state of pressure sensor circuit.  ST 6701 for high-pressure sensor  ST 6703 for low-pressure sensor

TDAA-05-06-003

T5-1-26

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Connecting Procedure of Test Wire Harness

fNOTE:

The connecting procedures of test wire harness of pump 2 delivery pressure sensor (1) are explained. 1. Disconnect the connector of pump 2 delivery pressure sensor (1). 1

2. Connect the male end connector of test wire harness (3) (ST 6701) to wire harness end connector (4) of pump 2 delivery pressure sensor (1).

TJBA-05-01-001

3. Connect dummy sensor (2) equivalent to #4703324 to the female end connector of test wire harness (3) (ST 6701).

2

2

3

TDAA-05-06-002

3

4 TDAA-05-06-003

T5-1-27

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure (Blank)

T5-1-28

SECTION 5 TROUBLESHOOTING Group 2 Monitor Outline Basic Screen

1

2

3

4 5 6 7 8

19 18 17 16 15

9

10

14

11

13

12

MJAE-01-012

12345-

Work Mode Display Auto-Idle Display Power Mode Display Clock, Hour Meter Auto-Lubrication Display (Option)

678910-

Fan Reverse Display (Option) Glow Signal Display Seat Belt Display Fuel Gauge Sub Meter

11- Logo Display/ Operation Display/ No Display/ Rear View Monitor Display 12- Radio Display 13- Air Conditioner Display 14- Coolant Temperature Gauge

T5-2-1

1516171819-

Auxiliary Auxiliary Travel Mode Display Auto Shut-Down Display Auxiliary

SECTION 5 TROUBLESHOOTING Group 2 Monitor Operating Procedures of Service Menu IMPORTANT: The service menu is provided only for service activity. Do not explain this function to your customers. The following items can be displayed on the monitor without using MPDr..  Troubleshooting: Fault code is displayed.  Monitoring: A part of monitor items for MPDr. is displayed.  Controller Version: The controller version is displayed.  Issued Warning Record: Ten alarms which were issued recently are displayed.  Operation: Total operating hours of various hour meters are displayed.  Communication Terminal Status: Information of the communication terminal is displayed.  Machine Setting: The settings are adjusted.  Monitor Setting: All item operations displayed on the monitor are set to enable/disable.  Engine Setting: Fault Code Clear is set.  Maintenance Mode: ON/OFF of the maintenance mode is set. NOTE: Machine Setting and Monitor Setting are not displayed in initialization. When displaying Machine Setting and Monitor Setting, make enable by function settings of MPDr..

f

T5-2-2

SECTION 5 TROUBLESHOOTING Group 2 Monitor How to display service menu

2

1

1. Push select/set switch (3) while pushing 9 on numeric keypad (4) when the basic screen is displayed with the key switch set in the ON position or the engine running. Service Menu (5) is added to the Main Menu screen. (Figure A)

3

2. Turn select/set switch (3) and select Service Menu (5). When pushing select/set switch (3), the Service Menu screen appears. (Figure B) 3. When pushing back switch (1), the previous screen appears. 4. When pushing return to basic screen switch (2), the basic screen appears.

4

fNOTE:

Once the basic screen appears, Service Menu (5) on the Main Menu screen is deleted. If Service Menu (5) is required to display, perform step 1 again.

TDAA-05-02-032 A

B

5

TDC1-05-02-014EN

T5-2-3

TDC1-05-02-010EN

SECTION 5 TROUBLESHOOTING Group 2 Monitor Troubleshooting 1

1. Turn select/set switch (3) and select Troubleshooting (4) on Service Menu. When pushing select/set switch (3), the Troubleshooting screen appears. (Figure A)

2

3

2. Turn select/set switch (3) and select the controller. When pushing select/set switch (3), the selfdiagnostic result of selected controller (fault code) is displayed. (Figure B)

fNOTE:

TDAA-05-02-030

Main (MC) (5) is selected as an example here. A

3. The past fault codes as well as the current ones are displayed at this time. 4. Turn select/set switch (3), select CLEAR (6), and push select/set switch (3).

4 5

5. The past fault codes are deleted and only the current fault codes which have been generated newly can be displayed. (Figure C) 6. When pushing back switch (1), the previous screen appears. 7. When pushing return to basic screen switch (2), the basic screen appears.

TDC1-05-02-010EN B

TDC1-05-02-024EN C

6

TDC1-05-02-025EN

T5-2-4

TDC1-05-02-031EN

SECTION 5 TROUBLESHOOTING Group 2 Monitor (Blank)

T5-2-5

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitoring

1

2

1. Turn select/set switch (3) and select Monitoring (4) on Service Menu. When pushing select/set switch (3), the Monitoring screen appears. (Figure A)

3

2. Turn select/set switch (3) and select the controller for monitoring. When pushing select/set switch (3), the monitoring items for selected controller are displayed. (Figure B) (Refer to List of Monitoring Item.)

TDAA-05-02-030 A

3. Turn select/set switch (3), select the item for monitoring, and push select/set switch (3). (Up to 12 items can be selected.) 4. Push back switch (1) and the Monitoring screen appears. (Figure C)

4

5. Turn select/set switch (3), select START (5), and push select/set switch (3). (Figure C)

fNOTE:

START (5) and CLEAR (HOLD) (6) are displayed only when one or more monitoring items are selected. START (5) and CLEAR (HOLD) (6) are not displayed when no monitoring item is selected.

TDC1-05-02-010EN B

TDC1-05-02-015EN C

5 6

TDAA-05-02-016EN

T5-2-6

TDC1-05-02-017EN

SECTION 5 TROUBLESHOOTING Group 2 Monitor 1

6. The selected monitoring item is started monitoring. (Figure D)

2

7. When pushing select/set switch (3) while monitoring, PAUSE (7) is displayed and the monitoring value can pause (be held). (Figure E)

3

8. When pushing select/set switch (3) again, pause is stopped.

TDAA-05-02-030

fNOTE:

Even if the key switch is set to OFF position, the selected monitoring item has been stored. If the selected monitoring item is required to release, select CLEAR (HOLD) (6) on the Monitoring screen and push select/set switch (3) for a while until START (5) and CLEAR (HOLD) (6) disappear.

D

E

7

9. When pushing back switch (1), the previous screen appears. 10. When pushing return to basic screen switch (2), the basic screen appears. TDC1-05-02-019EN

5 6

TDC1-05-02-017EN

T5-2-7

TDC1-05-02-018EN

SECTION 5 TROUBLESHOOTING Group 2 Monitor List of Monitoring Item Engine Controller (ECM) Item Target Engine Speed Engine Torque Actual Engine Speed Boost Pressure Target Fuel Injection Qty Starter Switch Air Cleaner Restriction SW Engine Stop Switch Common Rail Pressure Directed Engine Speed Starter Cutoff Relay Signal Common Rail Pressure DP Coolant Temperature Fuel Temperature Supply Pump Inlet Press Engine Oil Pressure Atmospheric Pressure Intake Air Temperature Boost Temperature Battery Voltage EGR Opening Amount 1 Coolant Temp (Meter)

Unit min-1 % min-1 kPa mm3/st OFF/ON OFF/ON OFF/ON MPa min-1 OFF/ON MPa ºC ºC kPa kPa kPa ºC ºC V % ºC

Data Target engine speed signal to ECM Input signal from ECM Input signal from crank speed sensor and cam angle sensor Input signal from boost pressure sensor Input signal from ECM Key switch ON/OFF status Clogged air filter status Engine stop switch ON/OFF status Input signal from common rail pressure sensor Input signal from engine control dial Starter cutoff relay ON/OFF status Input signal from common rail pressure sensor Input signal from coolant temperature sensor Input signal from fuel temperature sensor Input signal from suction control valve Input signal from engine oil pressure sensor Input signal from atmospheric pressure sensor Input signal from intake-air temperature sensor Input signal from boost temperature sensor Input signal from ECM Input signal from ECM Input signal from coolant temperature sensor (Coolant Temperature Gauge)

T5-2-8

SECTION 5 TROUBLESHOOTING Group 2 Monitor Main Controller (MC) Item Demand Engine Speed Actual Engine Speed Engine Speed Deviation

Unit min-1 min-1 min-1

EC Dial Hydraulic Oil Temperature Tgt Pump 1 Flow Rate

V ºC L

Tgt Pump 2 Flow Rate

L

Tgt Pump 1 Displacement

cm3

Tgt Pump 2 Displacement

cm3

Pump 1 Load Factor

%

Pump 2 Load Factor

%

Pump 1 Delivery Pressure Pump 2 Delivery Pressure Boom Cyl Bottom Press*1 Boom Raise Pilot Pressure Arm Roll-In Pilot Pressure Bucket Roll-In Pilot Press Travel Pilot Pressure Front ATT Pilot Pressure Swing Pilot Pressure

MPa MPa MPa MPa MPa MPa MPa MPa MPa

fNOTE:

Data Input signal from engine control dial Input signal from ECM Difference between actual engine speed and requested engine speed Input signal from engine control dial Input signal from hydraulic oil temperature sensor Command signal to maximum pump 1 flow rate limit control solenoid valve Command signal to maximum pump 2 flow rate limit control solenoid valve Calculated value from engine speed and input signal from pump 1 delivery pressure sensor Calculated value from engine speed and input signal from pump 2 delivery pressure sensor Calculated value from engine speed and input signal from pump 1 delivery pressure sensor Calculated value from engine speed and input signal from pump 2 delivery pressure sensor Input signal from pump 1 delivery pressure sensor Input signal from pump 2 delivery pressure sensor Input signal from boom cylinder bottom pressure sensor Input signal from pressure sensor (boom raise) Input signal from pressure sensor (arm roll-in) Input signal from pressure sensor (bucket roll-in) Input signal from pressure sensor (travel) Input signal from pressure sensor (front attachment) Input signal from pressure sensor (swing)

*1: Option *2: Unused (The item is only displayed)

T5-2-9

SECTION 5 TROUBLESHOOTING Group 2 Monitor Item ATT 1 Pilot Pressure*1 Arm Roll-Out Pilot Pressure*1 Arm 2 Flw Cont P/S Output Arm 2 Flw Cont P/S O/P FB Digital Input 7 PCSL Lever Switch Power Boost Switch Engine Oil Level Switch Power Mode Switch Travel Mode SW Auto-Idle Switch O/L Warning Buzzer SW*1 Digital Input 8 Digital Input 22 Digital Input 19 Digital Input 18 Digital Input 29 Digital Input 28 Digital Input 27 Digital Input 26 Auto Shut-Down Relay Tgt Clg Fan Pump 1 Flw Tgt Clg Fan Pump 2 Flw

fNOTE:

Unit MPa MPa MPa mA OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON LO/HI OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON L L

Data Input signal from pressure sensor (auxiliary 1) Input signal from pressure sensor (arm roll-out) Control signal to 4-spool solenoid valve unit (SG) Feedback from 4-spool solenoid valve unit (SG) output Pilot shut-off switch ON/OFF status Power digging switch ON/OFF status Engine oil level switch ON/OFF status Power mode switch operating status Travel mode switch selection status Auto-idle switch ON/OFF status Overload alarm switch ON/OFF status Auto shut-down relay ON/OFF status Command signal to fan pump control solenoid valve Command signal to fan pump control solenoid valve

*1: Option *2: Unused (The item is only displayed)

T5-2-10

SECTION 5 TROUBLESHOOTING Group 2 Monitor Item Pump 1 S/A Cont Press Pump 2 S/A Cont Press Pump 1 S/A Cont Press Learning Cond Pump 2 S/A Cont Press Learning Cond Pump 1 S/A Cont Press Learning Stat Pump 2 S/A Cont Press Learning Stat Torque Learning Condition Torque Learning Status Bm Lower Pilot Pressure Bucket Roll-Out Pilot Press Low Pressure Monitor Sensor Auxil 2 Cont Press Snsr (5P) Auxil 1 Cont Press Snsr (4P) Signal C/V SA Port Pressure Signal C/V SB Port Pressure Pump 1 (4 Units) P/S Output Pump 2 (5 units) P/S Output Analog Output 2 Analog Output 3 Travel Mode C/V Output Bypass Cut Cont P/S Swing Flw Cont P/S Output Analog Output 11 4-unit bypass P/S (2Sp)*2 3-Port Valve Control*2 ATT O/L Cont P/S Output*2 Main Relief Boost Press Output Boom Mode Cont P/S O/P

fNOTE:

Unit MPa MPa MPa MPa MPa MPa MPa MPa MPa MPa MPa MPa MPa MPa MPa MPa MPa MPa MPa MPa MPa MPa

Data Command signal to pump 1control solenoid valve Command signal to pump 2control solenoid valve Pump 1 learning condition Pump 2 learning condition Pump 1 learning status Pump 2 learning status Torque learning condition Torque learning status Input signal from pressure sensor (boom lower) Input signal from pressure sensor (bucket roll-out) Input signal from pressure sensor (4-spool side) Input signal from pressure sensor (5-spool side) Control signal to pump 1control solenoid valve Control signal to pump 2control solenoid valve Control signal to 4-spool solenoid valve unit (SC) Control signal to 4-spool solenoid valve unit (SF) Control signal to 2-spool solenoid valve unit (SI) Control signal to 3-spool solenoid valve unit (SA) Control signal to 3-spool solenoid valve unit (SC) Control signal to 3-spool solenoid valve unit (SB) Control signal to 4-spool solenoid valve unit (SI) Control signal to 2-spool solenoid valve unit (SC)

*1: Option *2: Unused (The item is only displayed)

T5-2-11

SECTION 5 TROUBLESHOOTING Group 2 Monitor Item Analog Output 18 Analog Output 19 Analog Output 20 Brk Rel Cont P/S O/P* Pump 1 (4 Units) P/S O/P FB Pump 2 (5 units) P/S O/P FB Analog Output FB 2 Analog Output FB 3 Travel Mode C/V Output FB Fan Sp Cont P/S 1 O/P FB Bypass Cut Cont P/S FB Fan Dir Cont P/S 1 O/P FB Fan Dir Cont P/S 2 O/P FB Swing Flw Cont P/S O/P FB Analog Output FB 11 4-unit bypass P/S (2Sp) FB*2 3-Port Valve Control FB*2 ATT O/L Cont P/S O/P FB*2 Main Relief Boost Press O/P FB Bm Mode Cont P/S O/P FB Fan Sp Cont P/S 2 O/P FB Analog Output FB 18 Analog Output FB 19 Analog Output FB 20 Brk Rel Cont P/S O/P FB*2 Arm 2 Flw Cont Disable SW AG Detn Time Adj Switch

Unit MPa MPa MPa MPa mA mA mA mA mA mA mA mA mA mA mA mA mA mA mA mA mA mA mA mA mA OFF/ON OFF/ON

AG Manual Switch AG Main Switch AG Limit Switch Boom Mode Switch F/M Rotation Dir Cont SW Max Fan Speed Switch Loader Selection Switch Fan Rotation Test Switch Engine Torque Learning

OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON

fNOTE:

*1: Option *2: Unused (The item is only displayed)

T5-2-12

Data Control signal to 3-spool solenoid valve unit (SB) Feedback from pump 1 control solenoid valve Feedback from pump 2 control solenoid valve Feedback from 4-spool solenoid valve unit (SC) Feedback from fan pump control solenoid valve Feedback from 4-spool solenoid valve unit (SF) Feedback from reverse rotation control solenoid valve Feedback from reverse rotation control solenoid valve Feedback from 2-spool solenoid valve unit (SI) Feedback from 3-spool solenoid valve unit (SA) Feedback from 3-spool solenoid valve unit (SC) Feedback from 3-spool solenoid valve unit (SB) Feedback from 4-spool solenoid valve unit (SI) Feedback from 2-spool solenoid valve unit (SC) Feedback from fan pump control solenoid valve Feedback from 3-spool solenoid valve unit (SB) Arm 2 flow rate disable switch status Auto lubrication error time change switch ON/OFF status Auto-lubrication manual switch ON/OFF status Auto-lubrication main switch ON/OFF status Auto-lubrication limit switch ON/OFF status Boom mode selector switch ON/OFF status Reverse switch ON/OFF status Max fan speed switch ON/OFF status Loader selection switch ON/OFF status Fan rotation test switch ON/OFF status Engine torque learning switch ON/OFF status

SECTION 5 TROUBLESHOOTING Group 2 Monitor Item Pump Reg Press Learning SW

Unit OFF/ON

Coolant Level Switch Warning Buzzer*1 Swing Alarm*1 Travel Alarm*1 ON/OFF Valve Output 4 ON/OFF Valve Output 3 ON/OFF Valve Output1 ON/OFF Valve Output 0 ON/OFF Valve Output 11 AG Output ON/OFF Valve Output 9

OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON

fNOTE:

*1: Option *2: Unused (The item is only displayed)

T5-2-13

Data Pump regulator pressure learning switch ON/OFF status Coolant level switch ON/OFF status Warning Buzzer ON/OFF status Swing alarm ON/OFF status Travel alarm ON/OFF status Grease pump ON/OFF status -

SECTION 5 TROUBLESHOOTING Group 2 Monitor Wiper/Light Controller Item Wiper 1 Input Wiper 2 Input Washer 1 Switch Washer 2 Switch Work Light 1 Switch Work Light 2 Switch Cab Light Switch Wiper 1 Output Wiper 2 Output Washer 1 Output Washer 2 Output Work Light 1 Output Work Light 2 Output Cab Light 1 Output Cab Light 2 Output

Unit V V OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON OFF/ON

Data Input signal from wiper switch Input signal from overhead window wiper switch Washer switch ON/OFF status Washer switch ON/OFF status Work light switch 1 ON/OFF status Work light switch 2 ON/OFF status Cab light switch ON/OFF status Wiper relay ON/OFF status Overhead window wiper relay ON/OFF status Washer relay ON/OFF status Washer relay ON/OFF status Work light relay 1 ON/OFF status Work light relay 2 ON/OFF status Cab light ON/OFF status Cab light ON/OFF status

Unit OFF/ON ºC ºC W/m2

Data Compressor operating status Input signal from ambient temperature sensor Input signal from re-circulated air temperature sensor Input signal from solar radiation sensor

Air Conditioner Unit Item Compressor Operation Outdoor Air Temperature Indoor Air Temperature Amount of Insolation

T5-2-14

SECTION 5 TROUBLESHOOTING Group 2 Monitor Controller Version 1

1. Turn select/set switch (3) and select Controller Version (4) on Service Menu.

2

2. When pushing select/set switch (3), the version of each controller appears. (Figure A)

3

3. When pushing back switch (1), the previous screen appears. 4. When pushing return to basic screen switch (2), the basic screen appears.

TDAA-05-02-030 A

4

TDC1-05-02-010EN

T5-2-15

TDC1-05-02-009EN

SECTION 5 TROUBLESHOOTING Group 2 Monitor Issued Warning Record 1

1. Turn select/set switch (3) and select Issued Warning Record (4) on Service Menu. When pushing select/ set switch (3), the Issued Warning Record screen appears. (Figure A)

2

3

2. The logo and trouble of maximum ten alarms which were issued recently are displayed. (Refer To List of Alarm.) 3. Turn select/set switch (3) and select the displayed alarm. When pushing select/set switch (3), the time (ON/OFF) when the selected alarm has occurred/ solved are displayed. (Figure B)

TDAA-05-02-030 A

4. In case of current alarms, the time (---) when the selected alarm has solved is displayed. (Figure C)

fNOTE:

The display of date and time depends on the setting. (Refer to the operator’s manual.) 4

5. When pushing back switch (1), the previous screen appears. 6. When pushing return to basic screen switch (2), the basic screen appears.

TDC1-05-02-010EN B

C

TDC1-05-02-022EN

T5-2-16

TDC1-05-02-021EN

TDC1-05-02-023EN

SECTION 5 TROUBLESHOOTING Group 2 Monitor List of Alarm Logo

Alarm Engine Oil Level Alarm

Trouble Screen Check Engine Oil Level And Add Oil If Required.

Remedy Follow Trouble Screen on the monitor.

Overheat Alarm

Coolant Temperature Is Abnormally High. Stop Refer to Operation. Run The Engine At Slow Idle To Cool Coolant Troubleshooting Temperature. A.

Coolant Level Alarm

Check Coolant Level And Add Coolant If Required.

Overheat Alarm

Coolant Temperature Is Abnormally High. Stop Refer to Operation. Run The Engine At Slow Idle To Cool Coolant Troubleshooting Temperature. A.

Hydraulic Oil Overheat Alarm

Hydraulic Oil Temperature Is Abnormally High. Stop Refer to Operation, Check Hydraulic Oil Level And Any Oil Leaks Troubleshooting From Hydraulic Circuit. A.

Engine Trouble Alarm

Engine Or Accessory Are Abnormal. Contact Your Nearest Authorized Dealer.

M183-01-075

MDAA-01-067

Follow Trouble Screen on the monitor.

MDAA-01-065

MDAA-01-067

MDAA-01-068

MDAA-01-069

T5-2-17

Refer to Engine Troubleshooting Manual.

SECTION 5 TROUBLESHOOTING Group 2 Monitor

Logo

Alarm Trouble Screen *Engine Oil Pressure Alarm Engine Oil Pressure Is Low. Immediately Stop Engine. Check Engine Oil System And Oil Level.

Remedy Refer to Troubleshooting A.

*Engine Start Disabled

Engine Cannot Start If Pilot Shut-Off Lever Is UNLOCK Position.

Set the pilot shut-off lever to the LOCK position.

*Engine Start Disabled

Engine Cannot Start If Engine Shut-Off Switch Is In The OFF Position.

Set the engine stop switch to the ON position.

Alternator Alarm

Electrical System Is Abnormal. Check Alternator And Battery Systems.

Refer to Troubleshooting A.

*Fuel Level Alarm

Fuel Level Is Low.

Refer to Troubleshooting A.

M178-01-037

MDAA-01-028

MDAA-01-028

M183-01-071

M178-01-034

fNOTE:

*: These alarms are not displayed on the Issued Warning Record screen.

T5-2-18

SECTION 5 TROUBLESHOOTING Group 2 Monitor

Logo

Alarm Fuel Temperature Alarm

Trouble Screen Fuel Temperature Is Abnormally High. Stop Operation And Check For Any Abnormality Such As Clogged Fuel Cooler.

Remedy Refer to Troubleshooting A.

Auto-Lubrication Indicator This indicator will light when any trouble occurs in the auto-lubrication system. Replace the grease container or check the piping.

Refer to Troubleshooting A.

Air Cleaner Restriction Alarm

Air Cleaner Is Clogged. Clean Or Replace Air Cleaner Element.

Refer to Troubleshooting A.

Fuel Filter Restriction Alarm

Fuel Filter Is Clogged. Replace Fuel Filter Element.

Refer to Troubleshooting A.

System Failure Alarm

Machine Network System Is Abnormal. Contact Your Nearest Authorized Dealer.

Refer to Troubleshooting A.

Pilot Control Shut-Off Lever Alarm

Pilot Control Shut-Off Lever System Is Abnormal. Contact Your Nearest Authorized Dealer.

Refer to Troubleshooting A.

MDAA-01-032

T1J1-05-01-005

M183-01-067

M1U1-01-116

MDAA-01-034

MDAA-01-036

T5-2-19

SECTION 5 TROUBLESHOOTING Group 2 Monitor Operation 1

1. Turn select/set switch (3) and select Operation (4) on Service Menu. When pushing select/set switch (3), the Operation screen appears. (Figure A)

2

2. The hour meters are displayed.

3

3. When pushing back switch (1), the previous screen appears. 4. When pushing return to basic screen switch (2), the basic screen appears.

TDAA-05-02-030

A

4

TDC1-05-02-010EN

T5-2-20

TDC1-05-02-020EN

SECTION 5 TROUBLESHOOTING Group 2 Monitor Communication Terminal Status 1. Turn select/set switch (3) and select Communication Terminal Status (4) on Service Menu. When pushing select/set switch (3), the Communication Terminal Status screen appears. (Figure A)

1

2

3

2. Each data of the communication terminals is displayed. (Refer To List of Communication Terminal Status.) 3. When pushing back switch (1), the previous screen appears.

TDAA-05-02-030

4. When pushing return to basic screen switch (2), the basic screen appears.

A

4

TDC1-05-02-011EN

T5-2-21

TDC1-05-02-034EN

SECTION 5 TROUBLESHOOTING Group 2 Monitor List of Communication Terminal Status Item Unit GPS Status

Radio Wave Intensity

0 to 2

Data GSM Terminal 0: Uncoupled Connection

0 to 3, 250

1: Incomplete Positioning 2: Positioning State 0: GSM Antenna: 0

Data Transmission Status

0, 1

Comm Module Status

0, 1

Potable Antenna Signal (GSM Antenna Signal)

0 to 31, 99

GPRS Ntwk Conn Status

0, 1

Frequency Band

0 to 3

1: GSM Antenna: 1 2: GSM Antenna: 2 3: GSM Antenna: 3 250: Out of service 0: Uncoupled Connection 1: Connection 0: Correct 1: Incorrect 0 to 1: Out of service 2 to 8: GSM Antenna: 0 9 to 12: GSM Antenna: 1 13 to 17: GSM Antenna: 2 18 to 31: GSM Antenna: 3 99: Not detected 0: Failure 1: Success 0 to 3

fNOTE:

The detail data of radio wave intensity are displayed for GSM Antenna Signal.

fNOTE:

If “--------” is displayed on Radio Wave Intensity, the communication data is abnormal.

T5-2-22

Satellite Terminal (Optional) 0: Uncoupled Connection/ Incomplete Positioning 1: Incomplete Positioning 2: Positioning State 0: Communication not available 1: Communication available

-

-

SECTION 5 TROUBLESHOOTING Group 2 Monitor Machine Setting 1

fNOTE:

Machine Setting is not displayed in initialization. When displaying Machine Setting, make Machine Setting enable with MPDr..

2

3

 Constant Change 1. Turn select/set switch (3) and select Machine Setting (4) on Service Menu. When pushing select/ set switch (3), the Machine Setting screen appears. (Figure A)

TDAA-05-02-030

2. Turn select/set switch (3) and select the item to be adjusted. When pushing select/set switch (3), the adjustment screen for selected item appears. (Figure B) (Refer to List of Setting Item.)

fNOTE:

A

Li Speed (5) is selected as an example here.

3. When pushing select/set switch (3), the color of selected adjustment item data is changed. Turn select/set switch (3), change the data, and push select/set switch (3). (Figure C)

5 4

4. Turn select/set switch (3) and select a check mark. When pushing select/set switch (3), the setting has been completed. 5. When pushing back switch (1), the previous screen appears.

TDC1-05-02-061EN

TDCD-05-02-011EN B

C

6. When pushing return to basic screen switch (2), the basic screen appears.

TDC1-05-02-071EN

T5-2-23

TDC1-05-02-072EN

SECTION 5 TROUBLESHOOTING Group 2 Monitor List of Machine Setting Item (Constant Change) Item ECO Control Suspend

Unit 0, 1

Li Speed AI Speed PWR Mode Speed ECO Mode Selection

min-1 min-1 min-1 0, 1

Power Mode Memory Selection

0, 1

Work Mode Memory Selection

0, 1

Power Mode Selection

0 to 4

Data Setting of ECO control (casual deactivation) 0: Enable 1: Casual Deactivation Adjustment of slow idle engine speed Adjustment of auto-idle engine speed Adjustment of PWR mode fast idle engine speed ON/OFF of ECO control 0: OFF 1: ON Setting of power mode with the key switch ON 0: OFF (Power mode is ECO mode when turning the key switch ON. ) 1: ON (The power mode when turning the key switch OFF is kept.) Setting of attachment mode with the key switch ON 0: OFF (Setting of attachment mode is bucket (digging) mode when turning the key switch ON.) 1: ON (Setting of the attachment mode when turning the key switch OFF is kept.) Setting of power mode selection 0: ECO, PWR mode: Selected 1: ECO mode: Fixed 2: PWR mode: Fixed 3: ECO, PWR, HP mode: Selected 4: HP mode: Fixed

T5-2-24

SECTION 5 TROUBLESHOOTING Group 2 Monitor Item Auto Shut-Down Control

Unit 0 to 2

Auto Shut-Down Set Time Holding

0, 1

Air Conditioner Control Mode

0 to10

ATT Speed Deceleration Waiting Time

ms

Data Setting of auto shut-down control with the key switch ON 0: OFF when starting 1: ON when starting 2: Previous setting is held. The time until starting auto shut-down control is held. 0: Settable 1: Un-settable Selection of air conditioner specification 0: Unused (without an air conditioner) 1: STD cab (middle) (with an air conditioner) 2: STD cab (middle) (without an air conditioner) 3: STD cab (large) (with an air conditioner) 4: STD cab (large) (without an air conditioner) 5: US cab (75US class) (with an air conditioner) 6: US cab (75US class) (without an air conditioner) 7: US cab (135US class) (with an air conditioner) 8: US cab (135US class) (without an air conditioner) 9: US cab (225US class) (with an air conditioner) 10: US cab (225US class) (without an air conditioner) The time when the increased engine speed is held at attachment operation speed increase control

T5-2-25

SECTION 5 TROUBLESHOOTING Group 2 Monitor  List of Adjustment (Constant Change) Item ECO Control Suspend Li Speed AI Speed PWR Mode Speed ECO Control Selection Power Mode Memory Selection Work Mode Memory Selection Power Mode Selection Auto Shut-Down Control Auto Shut-Down Set Time Holding Air Conditioner Control Mode ATT Speed Deceleration Waiting Time

Minimum Adjustment 0, 1 -1 10 min 10 min-1 10 min-1 0, 1 0, 1 0, 1 0 to 4 0 to 2 0, 1 0 to 10 ms 40 Unit

T5-2-26

Adjustable Range

Initial Value

0, 1 0 to 150 -180 to 500 -100 to 0 0, 1 0, 1 0, 1 0 to 4 0 to 2 0, 1 0 to 10 0 to 9600

0 0 0 0 1 0 1 0 0 0 3 9600

SECTION 5 TROUBLESHOOTING Group 2 Monitor 1

 Attachment Constant Change 1. Turn select/set switch (3) and select Machine Setting (4) on Service Menu. When pushing select/ set switch (3), the Machine Setting screen appears. (Figure A)

2 3

2. Turn select/set switch (3) and select the item to be adjusted. When pushing select/set switch (3), the adjustment screen for selected item appears. (Figure B) (Refer to List of Setting Item.)

TDAA-05-02-030 A

fNOTE:

ATT 1 Type (5) is changed as an example here. (Initial setting: Breaker 1) 5

3. When pushing select/set switch (3), the color of selected adjustment item data is changed. Turn select/set switch (3), change the data, and push select/set switch (3). (Figure C)

4

4. Turn select/set switch (3) and select a check mark. When pushing select/set switch (3), the setting has been completed. 5. When pushing back switch (1), the previous screen appears. 6. When pushing return to basic screen switch (2), the basic screen appears.

T5-2-27

TDCD-05-02-011EN B

TDCD-05-02-073EN C

TDAA-05-02-074EN

TDAA-05-02-075EN

TDAA-05-02-026EN

TDAA-05-02-076EN

SECTION 5 TROUBLESHOOTING Group 2 Monitor List of Setting Item (Attachment Constant Change) Item ATT1 Type

Unit 0 to 7

ATT1 No.

1 to 5

ATT1 Pump 1 Maximum Flow Rate

L/min

ATT1 Pump 2 Maximum Flow Rate

L/min

ATT1 Engine Speed ATT1 Relief Valve

min-1 0 to 2

ATT1 Selector Valve*2

0, 1

ATT1 Auxiliary Flow Combiner Valve*1

0, 1

fNOTE:

Data Kinds of attachment 0: Unset 1: Breaker 2: Pulverizer 3: Crusher 4: Vibrating Hammer 5: Others 6: Grapple 7: Clamshell Selection of attachment setting No. 1: 1 2: 2 3: 3 4: 4 5: 5 Adjustment of maximum pump 1 flow rate when using attachment Adjustment of maximum pump 2 flow rate when using attachment Adjustment of engine speed when using attachment Selection of breaker relief solenoid valve, auxiliary overload relief solenoid valve 0: Both are disabled. 1: ATT relief is enabled. 2: Breaker relief is enabled. Selection of return circuit connection of selector valve 0: C/V 1: O/T Setting of auxiliary flow combiner valve selection 0: OFF 1: ON

*1: Option *2: Unused (The item is only displayed)

T5-2-28

SECTION 5 TROUBLESHOOTING Group 2 Monitor  List of Adjustment (Attachment Constant Change) ATT1 Item

Unit

ATT1 Type ATT1 No. ATT1 Pump 1 Maximum Flow Rate ATT1 Pump 2 Maximum Flow Rate ATT1 Engine Speed ATT1 Relief Valve ATT1 Selector Valve*2 ATT1 Auxiliary Flow Combiner Valve*1

0 to 7 1 to 5 L/min L/min min-1 0 to 2 0, 1 0, 1

Minimum Adjustment 0.5 0.5 10 -

Adjustable Range 0 to 7 1 to 5 100 to 542 100 to 542 -500 to 100 0 to 2 0, 1 0, 1

Initial Value

Minimum Adjustment 0.5 0.5 10 -

Adjustable Range 0 to 7 1 to 5 100 to 542 100 to 542 -500 to 100 0 to 2 0, 1 0, 1

Initial Value

1 1 542 260 100 2 1 0

ATT2 Item

Unit

ATT2 Type ATT2 No. ATT2 Pump 1 Maximum Flow Rate ATT2 Pump 2 Maximum Flow Rate ATT2 Engine Speed ATT2 Relief Valve ATT2 Selector Valve*2 ATT2 Auxiliary Flow Combiner Valve*1

0 to 7 1 to 5 L/min L/min min-1 0 to 2 0, 1 0, 1

fNOTE:

*1: Option *2: Unused (The item is only displayed.)

T5-2-29

1 2 542 300 100 2 1 0

SECTION 5 TROUBLESHOOTING Group 2 Monitor ATT3 Item

Unit

ATT3 Type ATT3 No. ATT3 Pump 1 Maximum Flow Rate ATT3 Pump 2 Maximum Flow Rate ATT3 Engine Speed ATT3 Relief Valve ATT3 Selector Valve*2 ATT3 Auxiliary Flow Combiner Valve*1

0 to 7 1 to 5 L/min L/min min-1 0 to 2 0, 1 0, 1

Minimum Adjustment 0.5 0.5 10 -

Adjustable Range 0 to 7 1 to 5 100 to 542 100 to 542 -500 to 100 0 to 2 0, 1 0, 1

Minimum Adjustment 0.5 0.5 10 -

Adjustable Range 0 to 7 1 to 5 100 to 542 100 to 542 -500 to 100 0 to 2 0, 1 0, 1

Initial Value 1 3 542 320 100 2 1 0

ATT4 Item

Unit

ATT4 Type ATT4 No. ATT4 Pump 1 Maximum Flow Rate ATT4 Pump 2 Maximum Flow Rate ATT4 Engine Speed ATT4 Relief Valve ATT4 Selector Valve*2 ATT4 Auxiliary Flow Combiner Valve*1

0 to 7 1 to 5 L/min L/min min-1 0 to 2 0, 1 0, 1

fNOTE:

*1: Option *2: Unused (The item is only displayed.)

T5-2-30

Initial Value 1 4 542 350 100 2 1 0

SECTION 5 TROUBLESHOOTING Group 2 Monitor ATT5 to 11 Item

Unit

ATT5 Type ATT5 No. ATT5 Pump 1 Maximum Flow Rate ATT5 Pump 2 Maximum Flow Rate ATT5 Engine Speed ATT5 Relief Valve ATT5 Selector Valve*2 ATT5 Auxiliary Flow Combiner Valve*1

0 to 7 1 to 5 L/min L/min min-1 0 to 2 0, 1 0, 1

fNOTE:

*1: Option *2: Unused (The item is only displayed.)

T5-2-31

Minimum Adjustment 0.5 0.5 10 -

Adjustable Range 0 to 7 1 to 5 100 to 542 100 to 542 -500 to 100 0 to 2 0, 1 0, 1

Initial Value 0 1 542 542 100 2 1 0

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitor Setting

1

2

fNOTE:

Monitor Setting is not displayed in initialization. When displaying Monitor Setting, make Monitor Setting enable with MPDr..

3

 Operation Permission 1. Turn select/set switch (3) and select Monitor Setting (4) on Service Menu. When pushing select/ set switch (3), the Monitor Setting screen appears. (Figure A)

TDAA-05-02-030 A

2. Turn select/set switch (3) and select Operation Permission. When pushing select/set switch (3), the setting screen for selected item appears. (Figure B) (Refer to List of Monitor Setting Item.) 3. When pushing select/set switch (3), the color of selected item data is changed. Turn select/set switch (3), change the data, and push select/set switch (3). (Figure C)

fNOTE:

4

Setting Value: 1: Operation/Change: Possible

TDC1-05-02-048EN

TDCD-05-02-011EN

0: Operation/Change: Impossible

B

When Operation Permission is set to "0" and each item is selected on Maintenance of Information Menu, RESET (5) of Remains and Maintenance Interval (6) of the maintenance items are not displayed.

C

fNOTE:

Engine Oil is selected as an example here. 4. Turn select/set switch (3) and select a check mark. When pushing select/set switch (3), the setting has been completed. 5. When pushing back switch (1), the previous screen appears. 6. When pushing return to basic screen switch (2), the basic screen appears.

TDC1-05-02-077EN

TDC1-05-02-078EN

5 6

TDC1-05-02-052EN

T5-2-32

TDC1-05-02-051EN

SECTION 5 TROUBLESHOOTING Group 2 Monitor 1

 Maintenance Items 1. Turn select/set switch (3) and select Monitor Setting (4) on Service Menu. When pushing select/ set switch (3), the Monitor Setting screen appears. (Figure A)

2 3

2. Turn select/set switch (3) and select the item to change the setting. When pushing select/set switch (3), the setting screen for selected item appears. (Figure B) (Refer to List of Monitor Setting Item.)

fNOTE:

TDAA-05-02-030 A

Engine Oil is selected as an example here.

3. When pushing select/set switch (3), the color of selected item data is changed. Turn select/set switch (3), change the data, and push select/set switch (3). (Figure C)

fNOTE:

Setting Value:

4

1: Operation/Change: Possible 0: Operation/Change: Impossible

When Engine Oil is set to "0", the item of Engine Oil is deleted on Maintenance of Information Menu. 4. Turn select/set switch (3) and select a check mark. When pushing select/set switch (3), the setting has been completed.

TDC1-05-02-048EN

TDCD-05-02-011EN B

C

5. When pushing back switch (1), the previous screen appears. 6. When pushing return to basic screen switch (2), the basic screen appears.

TDC1-05-02-049EN

TDC1-05-02-079EN

T5-2-33

TDC1-05-02-050EN

TDC1-05-02-080EN

SECTION 5 TROUBLESHOOTING Group 2 Monitor List of Monitor Setting Item Item Startup Screen Image

Startup Screen Control Work Mode Crane Switch Memory Mail Setting Menu Time Setting Breaker Alarm Auto Shut-down Auto-Lubrication Sub Meter Selection Crane

Crane Switch Memory Fuel Gauge Breaker Hour Meter Rear View Camera Monitor

Unit 0: System Starting 1: HITACHI 2: John Deere 3: System Starting (Fixed) 4: REC 0: Auto-Control: OFF 1: Auto-Control: ON 0: Void 1: Exist 0: Non-storable 1: Store 0: Void 1: Exist 0: Void 1: Exist 0: Void 1: Exist 0: Void 1: Exist 0: Void 1: Exist 0:Void 1:Exist 0: Void 1: Exist 0: Void 1: ML Crane 2: Overload Alarm 3: Grapple Load Meter 0: Non-storable 1: Store 0:Void 1:Exist 0:Void 1:Exist 0: Void 1: Exist

fNOTE:

*: Initial values are different according to the factory default specification.

T5-2-34

Details -

Initial Value 1

-

1

with or without function -

1

with or without function with or without function with or without function with or without function with or without function with or without function with or without function with or without function

0

-

0

with or without function with or without function with or without function

0

1

1 1 1 1 1 1 *0

0 0

SECTION 5 TROUBLESHOOTING Group 2 Monitor

Item Display Item Selection Brightness Adjustment Language Unit Selection Main Menu Sequence Change Information Menu Operation Maintenance Operation Permission Engine Oil Engine Oil Filter Hydraulic Oil Pilot Hydraulic Oil Filter Hydraulic Oil Full-Flow Filter Pump Drain Filter Pump Transmission Oil Travel Reduction Gear Oil Swing Reduction Gear Oil Swing Motor Drain Filter

Unit 0: Void 1: Exist 0: Void 1: Exist 0: Void 1: Exist 0: Void 1: Exist 0: Void 1: Exist 0: Void 1: Exist 0: Void 1: Exist 0: Void 1: Exist 0: Inhibited 1: Permission 0: Un-displayed 1: Display 0: Un-displayed 1: Display 0: Un-displayed 1: Display 0: Un-displayed 1: Display 0: Un-displayed 1: Display 0: Un-displayed 1: Display 0: Un-displayed 1: Display 0: Un-displayed 1: Display 0: Un-displayed 1: Display 0: Un-displayed 1: Display

T5-2-35

Details with or without function with or without function with or without function with or without function with or without function with or without function with or without function with or without function -

Initial Value 1

Display

1

Display

1

Display

1

Display

1

Display

1

Display

1

Display

1

Display

1

Display

1

Display

0

1 1 1 1 1 1 1 1

SECTION 5 TROUBLESHOOTING Group 2 Monitor

Item Swing Bearing Grease Air Cleaner Element Fuel Filter Air Conditioner Filter Line Filter Water Separator Filter User Setting 1 User Setting 2 Troubleshooting (Information Menu) Monitoring (Information Menu)

Unit 0: Un-displayed 1: Display 0: Un-displayed 1: Display 0: Un-displayed 1: Display 0: Un-displayed 1: Display 0: Un-displayed 1: Display 0: Un-displayed 1: Display 0: Un-displayed 1: Display 0: Un-displayed 1: Display 0: Void 1: Exist 0: Void 1: Exist

T5-2-36

Details Display

Initial Value 1

Display

1

Display

1

Display

1

Display

1

Display

1

Display

1

Display

1

with or without function with or without function

1 1

SECTION 5 TROUBLESHOOTING Group 2 Monitor Engine Setting 1

1. Turn select/set switch (3) and select Engine Setting (4) on Service Menu. When pushing select/set switch (3), the Engine Setting screen appears. (Figure A)

2

3

2. Turn select/set switch (3) and select the item to change the setting. When pushing select/set switch (3), the setting screen for selected item appears. (Figure B)

fNOTE: here.

TDAA-05-02-030

Fault Code Clear (5) is selected as an example A

3. Turn select/set switch (3) and select a check mark. When pushing select/set switch (3), the setting has been completed.

5

4. When pushing back switch (1), the previous screen appears. 5. When pushing return to basic screen switch (2), the basic screen appears.

4

fNOTE:

When delete ECM fault codes and the engine trouble alarm, operate Fault Code Clear (5). TDBL-05-02-001EN B

TDAA-05-02-054EN

T5-2-37

TDBL-05-02-002EN

SECTION 5 TROUBLESHOOTING Group 2 Monitor Maintenance Mode

1

2

1. Turn select/set switch (3) and select Maintenance Mode (4) on Service Menu. When pushing select/set switch (3), the Maintenance Mode screen appears. (Figure A)

3

2. When pushing select/set switch (3), the color of selected item data is changed. Turn select/set switch (3), change the data, and push select/set switch (3).

TDAA-05-02-030

fNOTE: Setting Value: 1: Maintenance Mode: ON 0: Maintenance Mode: OFF 3. Turn select/set switch (3) and select a check mark. When pushing select/set switch (3), the setting has been completed.

4

4. When Maintenance Mode is ON, maintenance mode alarm (5) is displayed on the basic screen. TDBL-05-02-003EN

5. When pushing back switch (1), the previous screen appears.

A

6. When pushing return to basic screen switch (2), the basic screen appears.

TDC1-05-02-205EN

5

TDBL-05-02-004

T5-2-38

SECTION 5 TROUBLESHOOTING Group 2 Monitor Setting Menu When logging on the service menu, The following items are added to the setting menu. Setting Menu Item Breaker Alarm

During Normal Operation When logging on service menu Un-displayed Display

Attachment Adjust

Pump Flow Rate



fNOTE:

Attachment Adjustment is displayed only when the work mode is attachment mode. (Attachment Adjustment is not displayed when the work mode is digging mode.)

T5-2-39

Data Setting of breaker alarm ON/ OFF and the time until the alarm is operated Adjustment of pump flow rate

SECTION 5 TROUBLESHOOTING Group 2 Monitor Breaker Alarm(Option) 1. Turn select/set switch (3) and select Breaker Alarm (4) on the setting menu. When pushing select/set switch (3), the Breaker Alarm screen appears. (Figure A)

1

2

3

2. Push select/set switch (3) and turn Breaker Alarm ON. 3. Turn select/set switch (3) and select Setting Time (5). Push select/set switch (3).

TDAA-05-02-030

4. Turn select/set switch (3) and set the setting time until Breaker Alarm is activated. When pushing select/set switch (3), the setting is completed.

A

fNOTE:

When ON is selected on the setting screen of Breaker Alarm and the breaker is operated for the setting time continuously, the buzzer sounds. (Refer to SYSTEM/ Control System.)

5. When pushing back switch (1), the previous screen appears.

5 4

6. When pushing return to basic screen switch (2), the basic screen appears. TDAA-05-02-029EN

T5-2-40

TDAA-05-02-013EN

SECTION 5 TROUBLESHOOTING Group 2 Monitor Inspection of Engine Oil Level, Coolant Level, Hour Meter, and Fuel Gauge

1

Inspection of Engine Oil Level 1. If pushing return to basic screen switch (1) for a while with the key switch set in the ON position, engine oil level and coolant level can be checked. 2. If engine oil level alarm (2) and coolant level alarm (5) are green, oil level and coolant level are normal. TDAA-05-02-030

3. If engine oil level alarm (2) and coolant level alarm (5) are red, oil level and coolant level are abnormal. Add or replace engine oil and coolant.

2 5

MJAA-03-001

Inspection of Hour Meter and Fuel Gauge 1. If pushing return to basic screen switch (1) for a while with the key switch set in the OFF position, hour meter (3) and fuel gauge (4) can be checked.

3

4

TDAA-05-02-081EN

T5-2-41

SECTION 5 TROUBLESHOOTING Group 2 Monitor Fuel Gauge and Coolant Temperature Gauge Fuel Gauge B

A

C D E

No. A B C D E F

Fuel Level (%) 100 (FULL) 75 50 25 0 (EMPTY)

Fuel Sensor (Ω) 100-4 19 32±5 49.3 80+12+2

No. A B C D D E F

Coolant Temperature (ºC) 25 40 50 80 95 105 120

Coolant Temperature Sensor (kΩ) 7.6±0.76 4.0±0.35 2.7±0.22 0.92±0.07 0.56±0.04 0.42±0.03 0.28±0.01

F

TDAA-05-02-082

Coolant Temperature Gauge E F

D C

B A

TJBG-05-02-084

T5-2-42

SECTION 5 TROUBLESHOOTING Group 3 e-Service Outline Controller saves the input signals from various sensors and switches of the machine as data. Various input signals are recorded as Operation Data in monitor controller. The recorded data can be downloaded to the personal computer. The downloaded data can be uploaded to the center server via LAN, and can be used as “e-Service”. The machine equipped with the communication terminal (optional) sends the data to the center server by using the communication terminal. (As for the communication system, refer to T5-3-7.)

T5-3-1

SECTION 5 TROUBLESHOOTING Group 3 e-Service List of Operation Data List of Daily Report Data Item Date Time Fuel Level Fuel Usage Amount Machine Hour Meter Engine Operating Hours

HP Mode Hours PWR Mode Hours ECO Mode Hours

Auto-Idle Switch ON Time Travel Operating Hours

Fast (Hi) Traveling Hours Slow (Lo) Traveling Hours Swing Operating Hours Digging Operating Hours

Details Date of daily report data. Final time when the engine is operated during a day. The value of the final remained fuel during a day. (Value is recorded by fuel sensor data from monitor controller.) The value of fuel used during a day. (Value is calculated and recorded by accumulated fuel usage amount from ECM.) Hour meter cumulative hours. (Hours are recorded by hour meter from monitor controller.) Total engine operating hours selecting HP mode during a day. (Hours are recorded by power mode switch information from MC.) Total engine operating hours selecting PWR mode during a day. (Hours are recorded by power mode switch information from MC.) Total engine operating hours selecting ECO mode during a day. (Hours are recorded by power mode switch information from MC.) Hours when auto-idle switch is turned ON during a day. (Hours are recorded by switch from MC.) Total operating hours of travel mode Fast (Hi) during a day. (Hours are recorded by travel mode switch information from MC.) Total operating hours of travel mode Slow (Lo) during a day. (Hours are recorded by travel mode switch information from MC.) Total swing operating hours during a day. (Hours are recorded by swing pressure sensor information from MC.) Total front attachment operating hours during a day. (Hours are recorded by front attachment pressure sensor information from MC.)

T5-3-2

SECTION 5 TROUBLESHOOTING Group 3 e-Service

Item Attachment Operating Hours

Breaker Operating Hours Pulverizer Operating Hours Crusher Operating Hours Vibrating Hammer Operating Hours Bucket Operating Hours or Others

No Load Time Engine Operating Hour Distribution Data Loaded Time Distribution Data

Latitude Longitude

Details Total operating hours selecting breaker during a day. (Hours are recorded by attachment information from MC.) Total operating hours selecting pulverizer during a day. (Hours are recorded by attachment information from MC.) Total operating hours selecting hydraulic crusher during a day. (Hours are recorded by attachment information from MC.) Total operating hours selecting vibrating hammer during a day. (Hours are recorded by attachment information from MC.) Total operating hours selecting bucket during a day. (Hours are recorded by attachment information from MC.) Total machine’s waiting hours during a day. (Hours are recorded by each pressure sensor information from MC.) Engine operating hour distribution during a day. (Operating hours are recorded when the condition that the engine is operated continues over 5 minutes.) Machine operating hour distribution during a day. (Operating hours are recorded only when operating pressure is continuously detected for more than 5 minutes while the engine runs.) Final position during a day. (Signal from GPS antenna.) Final position during a day. (Signal from GPS antenna.)

fNOTE:

The daily operation in this table is equivalent to the hours between 0:00 and 23:59:59 counted by the monitor controller built-in clock. In case the engine is kept operated beyond 0:00, such data are recorded as those for the following day.

T5-3-3

SECTION 5 TROUBLESHOOTING Group 3 e-Service List of Frequency Distribution Data Item Pump Load Average Pump Delivery Pressure in Digging Operation Average Pump Delivery Pressure in Travel Operation Radiator Coolant Temperature (79 °C or less) Radiator Coolant Temperature (80 to 93 °C) Radiator Coolant Temperature (94 to 104 °C) Radiator Coolant Temperature (105 °C or more) Hydraulic Oil Temperature (49 °C or less) Hydraulic Oil Temperature (50 to 89 °C) Hydraulic Oil Temperature (90 to 99 °C) Hydraulic Oil Temperature (100 °C or more)

Details Frequency distribution of average pump delivery pressure of pumps 1 and 2 Frequency distribution of average delivery pressure from pumps during digging operation Frequency distribution of average delivery pressure from pumps during travel operation Total hours when coolant temperature is less than 80 °C during a day. Total hours when coolant temperature is 80 °C or more and less than 94 °C during a day. Total hours when coolant temperature is 94 °C or more and less than 105 °C during a day. Total hours when coolant temperature is 105 °C or more during a day. Total hours when hydraulic oil temperature is less than 50 °C during a day. Total hours when hydraulic oil temperature is 50 °C or more and less than 90 °C during a day. Total hours when hydraulic oil temperature is 90 °C or more and less than 100 °C during a day. Total hours when hydraulic oil temperature is 100 °C or more during a day.

T5-3-4

SECTION 5 TROUBLESHOOTING Group 3 e-Service List of Total Operating Hours Item Hour Meter End Engine HP Mode Hours Operating PWR Mode Hours Hour ECO Mode Hours Auto-Idle Switch ON Time Travel Fast (Hi) Traveling Operating Hours Hour Slow (Lo) Traveling Hours Swing Operating Hour Front Attachment Operating Hour Attachment Breaker Operating Operating Hours Hour Pulverizer Operating Hours Hydraulic Crusher Operating Hours Vibrating Hammer Operating Hours Bucket Operating Hours or Others No Load Time MC Communication Error Time ECM Communication Time Out Time

Details Machine hour meter’s value Total engine operating hours selecting HP mode Total engine operating hours selecting PWR mode Total engine operating hours selecting ECO mode Total hours when auto-idle switch is turned ON Total operating hours of travel mode Fast (Hi) Total operating hours of travel mode Slow (Lo) Total swing operating hours Total front attachment operating hours Total operating hours selecting breaker during daily operation Total operating hours selecting pulverizer during daily operation Total operating hours selecting hydraulic crusher during daily operation Total operating hours selecting vibrating hammer during daily operation Total operating hours selecting bucket during daily operation Total machine’s waiting hours Total hours of MC communication error Total hours of ECM communication time out

T5-3-5

SECTION 5 TROUBLESHOOTING Group 3 e-Service Snapshot Data Item Serial No. Snapshot

Model 1 Model 2 DTC Code Priority Hour Meter Occurrence: Year Occurrence: Date Occurrence: Time SA SPN Version

Details Machine serial no. Difference of large-sized crawler, middle-sized crawler, wheeled excavator, and wheel loader Detail difference on model 1 Fault code and frequency of occurrence Machine hour meter at a time when trouble occurred Year at a time when trouble occurred Date at a time when trouble occurred Time at a time when trouble occurred 001: Version 1 010: Version 2 011: Version 3 100: Version 4 111: Missing version

fNOTE:

The data on machine body system including MC are downloaded as for Snapshot Data Download (Hitachi). The data on engine system including ECM are downloaded as for Snapshot Data Download (Isuzu).

T5-3-6

SECTION 5 TROUBLESHOOTING Group 3 e-Service Communication System The communication system is used for maintenance of the machine: “e-Service” by transmitting various data of the machine regularly via the communication terminal.

fNOTE:

The communication system transmits digital data through the radio wave. Depending on the circumstances of the machine (ex. in a building, in a tunnel, affected by surrounding buildings, and affected of noise), the data transfer rate may become slower, or the communication might not be established. If there is excessively noise or use of electrical equipment which causes noise near the machine, they cause reduces data transfer rate or communication might not be established at worst.

The communication terminal, GPS antenna, and communication antenna are installed to the machine equipped with the communication system. The functions of each equipment are:  Communication Terminal: Receives the data from monitor controller and GPS antenna, and sends the data to the communication antenna.  GPS Antenna: Receives location information of the machine.  Communication Antenna: Communicates the data.

T5-3-7

SECTION 5 TROUBLESHOOTING Group 3 e-Service (Blank)

T5-3-8

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Main Component

1

26 2

3

4

5

6 7

8 9

25

27

24

10 11 12

23

13 22 21 20

12345678-

Arm Cylinder Washer Tank Swing Bearing Center Joint Swing Device Fuel Tank Control Valve Air Cleaner

9101112131415-

Signal Control Valve Oil Cooler Fan Motor Expantion Tank Radiator Fan Motor Engine Pump Device Travel Device

19

18

17

16

14

16- Shockless Valve (Refer to T5-4-2.) 17- Pilot Filter/Pilot Relief Valve 18- Drain Filter 19- Check Valve (Refer to T5-4-14.) 20- Hydraulic Oil Tank 21- Track Adjuster 22- Pilot Shut-Off Solenoid Valve

T5-4-1

MJAE-07-045

15

23- Travel Pilot Valve 24- Front Attachment/Swing Pilot Valve 25- Boom Cylinder 26- Bucket Cylinder 27- Radiator/Oil Cooler/Inter Cooler (Refer to T5-4-2)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Radiator/Oil Cooler/Inter Cooler 2

1

3

TJBM-01-02-002

5

10

4

9

Shockless Valve 6

7

8

TJAA-01-02-008

1- 2- 3-

Inter Cooler Oil Cooler Fuel Cooler

4- 5- 6-

Air Conditioner Condenser Radiator Signal Control Valve

7- 8- 9-

T5-4-2

Control Valve Shocklesss Valve Ambient Temperature Sensor

10- Receiver Tank

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Electrical System (Overview)

3

5

4

6 7

2

8

1

9 10

11

17

16 15

12 13

14

1- 2- 3- 4- 5-

Monitor GPS Aerial Around Horn (Refer to T5-4-9.) Electric Grease Gun (Refer to T5-4-10.) Components Related with Control Valve (Refer to T5-413.)

6-

Components Related with Signal Control Valve (Refer to T5-4-14.) 7- Fuel Sensor 8- Fuel Pump (Refer to T5-4-4.) 9- Air Cleaner Restriction Switch 10- Coolant Level Switch 11- Rear View Camera

12- Components Related with Engine (Refer to T5-4-11.) 13- Components Related with Pump Device (Refer to T5-412.) 14- 4-Spool Solenoid Valve Unit 15- Hydraulic Oil Temperature Sensor

T5-4-3

TJBM-01-02-010

16- Components Related with Check Valve (Refer to T5-4-14.) 17- Electrical System (Cab Behind Side) (Refer to T5-4-7.)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Fuel Pump 2

1

TJBC-01-02-005 1-

Fuel Filter Restriction Sensor

2-

Fuel Pump

T5-4-4

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Electrical System (Rear Tray)

22

23 24 25

2 3

1

4 5 6

TJAA-01-02-004

7

10

11

12

13

9

14

8

15

16

21

1- 2- 3- 4- 5- 6-

Monitor Controller GSM (Option) MC (Main Controller) MPDr. Connector (Download Connector Using Conbinedly) Fuse Box 1 Fuse Box 2

7- 8- 9- 10- 11- 12- 13-

20

19

Wiper/Light Controller Wiper Relay (R6) Work Light Relay 1 (R7) ACC Cut Relay (R12) Work Light Relay 2 (R8) Auto Shut-Down Relay (R11) Washer Relay (R9)

18

14- 15- 16- 17- 18- 19- 20-

T5-4-5

17

Horn Relay (R10) Security Relay (R5) Starter Cut Relay (R4) Key Switch ON Cut Relay (R13) Security Horn Relay (R3) ECM Main Relay (R14) Pilot Shut-Off Relay (R2)

T1V1-01-02-009

21- 22- 23- 24- 25-

Load Damp Relay (R1) Auto Lubrication Relay (R15) Fuel Pump Relay (R16) Work Light Relay 3 (R17) Pump Regulator Pressure Learning Switch

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Electrical System (Switch Panel)

1

2

3

16 4 15 5 6 13

7

14

8 9 24 23 22 21 17 18

19

20

12

11

10

TJAA-01-02-003

1- 2- 3- 4- 5- 6-

Return to Previous Screen Switch (Monitor) Return to Basic Screen Switch (Monitor) Selector/Set Switch (Monitor) AM·FM Switch/Tuning Switch (Radio) Power Switch/Volume Control Switch (Radio) Engine Control Dial

7- 8- 9- 10- 11- 12- 13-

Auto-Idle Switch Travel Mode Switch Work Light Switch Power Mode Switch Key Switch TEN-key Switch Overhead Window Wiper/ Overhead Window Washer Switch (Option) 14- Wiper/Washer Switch

TDAA-05-02-059

15- AUTO/OFF Switch/Blower Switch (Air Conditioner) 16- Temperature Control Switch/ MODE Switch (Air Conditioner) 17- Travel Alarm Cancel Switch (Option) 18- Seat Heat Switch (Option) 19- Boom Mode Selector Switch 20- Auto-Lubrication Switch (Option)

T5-4-6

21- Overload Alarm Switch (Option) 22- Swing Alarm Cancel Switch (Option) 23- Rear Work Light Switch (Option) 24- Beacon Light Switch (Option)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Electrical System (Cab Behind Side) 2

1

TJBG-01-02-005

3

4 8 5

6

7

M1JB-07-012 1- 2-

Atmospheric Pressure Sensor ECM (Engine Control Module)

3- 4-

Battery Fusible Link (45A)

5- 6-

T5-4-7

Glow Plug Relay Starter Relay 1

7- 8-

Battery Relay Fusible Link (75A)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Battery Disconnect Switch

TJBE-01-02-005

1

1

1-

Battery Disconnect Switch

T5-4-8

TJBE-01-02-006

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Around Horn 1

2

T1J7-01-02-004

1-

Horn

3

TJBC-01-02-011

2-

Distribution Valve/Proximity Switch (Optional)

3-

T5-4-9

Boom Bottom Pressure Sensor (Optional)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Boom Upper Side

Electric Grease Gun

2 1

1-

Distribution Valve (Optional)

2-

TJBC-01-02-006

Grease Gun Pump

T5-4-10

TJBC-01-02-007

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Engine

1

4

12

2

3

13

TJBG-01-02-007

14

5

15

6

7

8 11 9 10

1- 2- 3- 4-

Injector Boost Pressure Sensor Boost Temperature Sensor EGR Valve

TJBG-01-02-010

TJBG-01-02-008 5- 6- 7- 8-

Common Rail Pressure Sensor Crank Speed Sensor Engine Oil Pressure Sensor Fuel Temperature Sensor

9- 10- 11- 12-

T5-4-11

Engine Oil Level Switch Supply Pump Cam Angle Sensor Overheat Switch

13- Glow Plug 14- Coolant Temperature Sensor 15- Intake-Air Temperature Sensor

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Pump Device 1

2

3

4

7 6

5 B TJBC-01-02-008

View B 8

9

10

11

TJBC-01-02-009

1- 2- 3- 4-

Pump 1 Fan Pump Fan Pump Control Solenoid Valve Pump 2

5- 6- 7-

Pump 2 Delivery Pressure Sensor Pump 1 Delivery Pressure Sensor Pilot Pump

8-

Pump 1 Control Pressure Sensor 9- Pump 2 Control Pressure Sensor 10- Pump 2 Control Solenoid Valve

T5-4-12

11- Pump 1 Control Solenoid Valve

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Control Valve 1

5 2

3

TJAA-01-02-015

4

6

8

7

TJAG-01-02-101

1- 2-

Main Relief valve Pressure Sensor (Bucket RollOut)

3- 4-

Pressure Sensor (Boom Raise) Pressure Sensor (Arm Roll-out)

5- 6-

T5-4-13

2-Spool Solenoid Valve Unit (Refer to T5-4-17.) Pressure Sensor (Arm Roll-In)

7- 8-

TJAG-01-02-016

Pressure Sensor (Boom Lower) Pressure Sensor (Bucket Roll-In)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Check Valve

1 5 2

TJAA-01-02-017

Signal Control Valve

3

4

TJAA-03-06-003

1- 2-

Pressure Sensor (4-Spool Side) Pressure Sensor (5-Spool Side)

3- 4-

Pressure Sensor Port (Swing) Pressure Sensor Port (Travel)

5-

T5-4-14

Accumulator

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

A A

a

TJAA-03-06-004

Section A-A

1

7

2

6

3

5

4

T178-03-06-002 a-

Pilot Valve Side

1- 2-

Shockless Valve Arm Flow Rate Control Valve Control Spool

3- 4-

Pump 1 Flow Rate Control Valve Flow Combiner Valve Control Spool

5- 6-

T5-4-15

Swing Parking Brake Release Spool Pump 2 Flow Rate Control Valve

7-

Auxiliary

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Swing Device 1

1

TJBG-05-04-007

Travel Device 2

3

M1J1-07-048

1-

Swing Relief Valve

2-

Counterbalance Valve

3-

T5-4-16

Travel Relief Valve

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout 4-Spool Solenoid Valve Unit 1

2

3

2-Spool Solenoid Valve Unit 5

4

TJAA-01-02-103

TJAA-01-02-102 1- 2-

4-Spool Solenoid Valve Unit (SC) 4-Spool Solenoid Valve Unit (SF)

3- 4-

4-Spool Solenoid Valve Unit (SI) 4-Spool Solenoid Valve Unit (SG)

6

5- 6-

T5-4-17

2-Spool Solenoid Valve Unit (SC) 2-Spool Solenoid Valve Unit (SI)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Layout of Control Valve c 1

a 2

3

4

a 5

6

c 7

8

9

52 10 11

51

12

50 49

13

48

14

47 46

15 16 17

45 55 44 43 42

18 19

41

20

40

21

39 38 28 37 36

22 23 24 25

35

26

31 30 34

33

29

32

54

53

T5-4-18

27

TJBM-03-03-001

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout A Side 23

21

24, 25 27

g

15, 16, 17, 18, 19

c

20

26

29

a

14 13 11

7

d

6

10

8

9

TJAG-03-03-002

b a- b-

Machine Upper Side Machine Front Side

c-

1-

Load Check Valve (Travel (Left) Parallel Circuit) Bypass Shut-Out Valve (B side) Check Valve (Bucket Flow Combiner Circuit) Check Valve (Bucket Flow Combiner Circuit) Check Valve (Main Relief Circuit) Flow Combiner Valve Check Valve (Flow Combiner Circuit) Check Valve (Main Relief Circuit) Main Relief valve Load Check Valve (Bucket Parallel Circuit) Bucket Regeneration Cut Valve Bucket Regenerative Valve Overload Relief Valve (Bucket: Rod Side) Overload Relief Valve (Bucket: Bottom Side) Boom Flow Rate Control Valve (Selector Valve)

16- Boom Flow Rate Control Valve (Poppet Valve) 17- Boom Lower Meter-In Cut Valve 18- Boom 1 Anti-Drift Valve (Selector Valve) 19- Boom 1 Anti-Drift Valve (Check Valve) 20- Overload Relief Valve (Boom 1: Bottom Side) 21- Overload Relief Valve (Low Pressure) (Boom 1: Rod Side) 22- Boom Overload Relief Selector Valve 23- Load Check Valve (Arm 2 Tandem Circuit) 24- Arm 2 Flow Rate Control Valve (Selector Valve) 25- Arm 2 Flow Rate Control Valve (Poppet Valve) 26- Check Valve (Arm Make-Up) 27- Bypass Shut-Out Valve (A side) 28- Arm Regenerative Valve 29- Arm Regenerative Cut Valve 30- Check Valve (Auxiliary Flow Combiner Circuit)

2- 3- 4- 5- 6- 7- 8- 9- 10- 11- 12- 13- 14- 15-

Machine Lower Side

d-

Arm Roll-In Pressure Sensor Connecting Position

31- Auxiliary Flow Combiner Valve (Selector Valve) 32- Auxiliary Flow Combiner Valve (Poppet Valve) 33- Swing Flow Rate Control Valve (Selector Valve) 34- Swing Flow Rate Control Valve (Poppet Valve) 35- Arm 1 Flow Rate Control Valve (Selector Valve) 36- Arm 1 Flow Rate Control Valve (Poppet Valve) 37- Load Check Valve (Arm 1 Tandem Circuit) 38- Load Check Valve (Boom 2 Parallel Circuit) 39- Check Valve (Boom 2 Regenerative Circuit) 40- Overload Relief Valve (Arm: Bottom Side) 41- Arm Rod Anti-Drift Valve (Selector Valve) 42- Arm Rod Anti-Drift Valve (Check Valve) 43- Overload Relief Valve (Arm: Rod Side)

T5-4-19

g-

Bucket Roll-In Pressure Sensor Connecting Position

44- Boost Check Valve (Boom Regenerative Back Pressure Valve) 45- Overload Relief Valve (Boom 2: Rod Side) 46- Boom 2 Anti-Drift Valve (Selector Valve) 47- Boom 2 Anti-Drift Valve (Check Valve) 48- Overload Relief Valve (Auxiliary) 49- Load Check Valve (Auxiliary Tandem Circuit) 50- Overload Relief Valve (Auxiliary) 51- Load Check Valve (Auxiliary Parallel Circuit) 52- Load Check Valve (Travel (Left) Tandem Circuit) 53- Pump 1 54- Pump 2 55- Boom Regenerative Valve

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

c 1

a 2

3

4

a 5

6

c 7

8

9

52 10 11

51

12

50 49

13

48

14

47 46

15 16 17

45 55 44 43 42

18 19

41

20

40

21

39 38 28 37 36

22 23 24 25

35

26

31 30 34

33

29

32

54

53

T5-4-20

27

TJBM-03-03-001

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout B Side 37

40

41, 42

33, 34

35, 36

a

40

31

c

e

44

1

50

46, 47

49

52

2

39

45

48

TJAA-03-03-007

b a- b-

Machine Upper Side Machine Front Side

c-

1-

Load Check Valve (Travel (Left) Parallel Circuit) Bypass Shut-Out Valve (B side) Check Valve (Bucket Flow Combiner Circuit) Check Valve (Bucket Flow Combiner Circuit) Check Valve (Main Relief Circuit) Flow Combiner Valve Check Valve (Flow Combiner Circuit) Check Valve (Main Relief Circuit) Main Relief valve Load Check Valve (Bucket Parallel Circuit) Bucket Regeneration Cut Valve Bucket Regenerative Valve Overload Relief Valve (Bucket: Rod Side) Overload Relief Valve (Bucket: Bottom Side) Boom Flow Rate Control Valve (Selector Valve)

16- Boom Flow Rate Control Valve (Poppet Valve) 17- Boom Lower Meter-In Cut Valve 18- Boom 1 Anti-Drift Valve (Selector Valve) 19- Boom 1 Anti-Drift Valve (Check Valve) 20- Overload Relief Valve (Boom 1: Bottom Side) 21- Overload Relief Valve (Low Pressure) (Boom 1: Rod Side) 22- Boom Overload Relief Selector Valve 23- Load Check Valve (Arm 2 Tandem Circuit) 24- Arm 2 Flow Rate Control Valve (Selector Valve) 25- Arm 2 Flow Rate Control Valve (Poppet Valve) 26- Check Valve (Arm Make-Up) 27- Bypass Shut-Out Valve (A side) 28- Arm Regenerative Valve 29- Arm Regenerative Cut Valve 30- Check Valve (Auxiliary Flow Combiner Circuit)

2- 3- 4- 5- 6- 7- 8- 9- 10- 11- 12- 13- 14- 15-

Machine Lower Side

e-

Boom Lower Pressure Sensor Connecting Position

31- Auxiliary Flow Combiner Valve (Selector Valve) 32- Auxiliary Flow Combiner Valve (Poppet Valve) 33- Swing Flow Rate Control Valve (Selector Valve) 34- Swing Flow Rate Control Valve (Poppet Valve) 35- Arm 1 Flow Rate Control Valve (Selector Valve) 36- Arm 1 Flow Rate Control Valve (Poppet Valve) 37- Load Check Valve (Arm 1 Tandem Circuit) 38- Load Check Valve (Boom 2 Parallel Circuit) 39- Check Valve (Boom 2 Regenerative Circuit) 40- Overload Relief Valve (Arm: Bottom Side) 41- Arm Rod Anti-Drift Valve (Selector Valve) 42- Arm Rod Anti-Drift Valve (Check Valve) 43- Overload Relief Valve (Arm: Rod Side)

T5-4-21

44- Boost Check Valve (Boom Regenerative Back Pressure Valve) 45- Overload Relief Valve (Boom 2: Rod Side) 46- Boom 2 Anti-Drift Valve (Selector Valve) 47- Boom 2 Anti-Drift Valve (Check Valve) 48- Overload Relief Valve (Auxiliary) 49- Load Check Valve (Auxiliary Tandem Circuit) 50- Overload Relief Valve (Auxiliary) 51- Load Check Valve (Auxiliary Parallel Circuit) 52- Load Check Valve (Travel (Left) Tandem Circuit) 53- Pump 1 54- Pump 2 55- Boom Regenerative Valve

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

c 1

a 2

3

4

a 5

6

c 7

8

9

52 10 11

51

12

50 49

13

48

14

47 46

15 16 17

45 55 44 43 42

18 19

41

20

40

21

39 38 28 37 36

22 23 24 25

35

26

31 30 34

33

29

32

54

53

T5-4-22

27

TJBM-03-03-001

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

A

Section A-A

B

C C D D E

c

a

E

F

F

G

12

G H

H

6 J

A

B

TJAA-03-03-008

a-

Machine Upper Side

b-

1-

Load Check Valve (Travel (Left) Parallel Circuit) Bypass Shut-Out Valve (B side) Check Valve (Bucket Flow Combiner Circuit) Check Valve (Bucket Flow Combiner Circuit) Check Valve (Main Relief Circuit) Flow Combiner Valve Check Valve (Flow Combiner Circuit) Check Valve (Main Relief Circuit) Main Relief valve Load Check Valve (Bucket Parallel Circuit) Bucket Regeneration Cut Valve Bucket Regenerative Valve Overload Relief Valve (Bucket: Rod Side) Overload Relief Valve (Bucket: Bottom Side) Boom Flow Rate Control Valve (Selector Valve)

16- Boom Flow Rate Control Valve (Poppet Valve) 17- Boom Lower Meter-In Cut Valve 18- Boom 1 Anti-Drift Valve (Selector Valve) 19- Boom 1 Anti-Drift Valve (Check Valve) 20- Overload Relief Valve (Boom 1: Bottom Side) 21- Overload Relief Valve (Low Pressure) (Boom 1: Rod Side) 22- Boom Overload Relief Selector Valve 23- Load Check Valve (Arm 2 Tandem Circuit) 24- Arm 2 Flow Rate Control Valve (Selector Valve) 25- Arm 2 Flow Rate Control Valve (Poppet Valve) 26- Check Valve (Arm Make-Up) 27- Bypass Shut-Out Valve (A side) 28- Arm Regenerative Valve 29- Arm Regenerative Cut Valve 30- Check Valve (Auxiliary Flow Combiner Circuit)

2- 3- 4- 5- 6- 7- 8- 9- 10- 11- 12- 13- 14- 15-

Machine Front Side

b

9 TJAA-03-03-009

c-

Machine Lower Side

31- Auxiliary Flow Combiner Valve (Selector Valve) 32- Auxiliary Flow Combiner Valve (Poppet Valve) 33- Swing Flow Rate Control Valve (Selector Valve) 34- Swing Flow Rate Control Valve (Poppet Valve) 35- Arm 1 Flow Rate Control Valve (Selector Valve) 36- Arm 1 Flow Rate Control Valve (Poppet Valve) 37- Load Check Valve (Arm 1 Tandem Circuit) 38- Load Check Valve (Boom 2 Parallel Circuit) 39- Check Valve (Boom 2 Regenerative Circuit) 40- Overload Relief Valve (Arm: Bottom Side) 41- Arm Rod Anti-Drift Valve (Selector Valve) 42- Arm Rod Anti-Drift Valve (Check Valve) 43- Overload Relief Valve (Arm: Rod Side)

T5-4-23

44- Boost Check Valve (Boom Regenerative Back Pressure Valve) 45- Overload Relief Valve (Boom 2: Rod Side) 46- Boom 2 Anti-Drift Valve (Selector Valve) 47- Boom 2 Anti-Drift Valve (Check Valve) 48- Overload Relief Valve (Auxiliary) 49- Load Check Valve (Auxiliary Tandem Circuit) 50- Overload Relief Valve (Auxiliary) 51- Load Check Valve (Auxiliary Parallel Circuit) 52- Load Check Valve (Travel (Left) Tandem Circuit) 53- Pump 1 54- Pump 2 55- Boom Regenerative Valve

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

c 1

a 2

3

4

a 5

6

c 7

8

9

52 10 11

51

12

50 49

13

48

14

47 46

15 16 17

45 55 44 43 42

18 19

41

20

40

21

39 38 28 37 36

22 23 24 25

35

26

31 30 34

33

29

32

54

53

T5-4-24

27

TJBM-03-03-001

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

Section B-B

Section C-C i

26

37

40

28 55 a

33

c

27

34

TJBA-03-03-006 TJAA-03-03-011

b a-

Machine Upper Side

b-

1-

Load Check Valve (Travel (Left) Parallel Circuit) Bypass Shut-Out Valve (B side) Check Valve (Bucket Flow Combiner Circuit) Check Valve (Bucket Flow Combiner Circuit) Check Valve (Main Relief Circuit) Flow Combiner Valve Check Valve (Flow Combiner Circuit) Check Valve (Main Relief Circuit) Main Relief valve Load Check Valve (Bucket Parallel Circuit) Bucket Regeneration Cut Valve Bucket Regenerative Valve Overload Relief Valve (Bucket: Rod Side) Overload Relief Valve (Bucket: Bottom Side) Boom Flow Rate Control Valve (Selector Valve)

16- Boom Flow Rate Control Valve (Poppet Valve) 17- Boom Lower Meter-In Cut Valve 18- Boom 1 Anti-Drift Valve (Selector Valve) 19- Boom 1 Anti-Drift Valve (Check Valve) 20- Overload Relief Valve (Boom 1: Bottom Side) 21- Overload Relief Valve (Low Pressure) (Boom 1: Rod Side) 22- Boom Overload Relief Selector Valve 23- Load Check Valve (Arm 2 Tandem Circuit) 24- Arm 2 Flow Rate Control Valve (Selector Valve) 25- Arm 2 Flow Rate Control Valve (Poppet Valve) 26- Check Valve (Arm Make-Up) 27- Bypass Shut-Out Valve (A side) 28- Arm Regenerative Valve 29- Arm Regenerative Cut Valve 30- Check Valve (Auxiliary Flow Combiner Circuit)

2- 3- 4- 5- 6- 7- 8- 9- 10- 11- 12- 13- 14- 15-

Machine Front Side

c-

Machine Lower Side

31- Auxiliary Flow Combiner Valve (Selector Valve) 32- Auxiliary Flow Combiner Valve (Poppet Valve) 33- Swing Flow Rate Control Valve (Selector Valve) 34- Swing Flow Rate Control Valve (Poppet Valve) 35- Arm 1 Flow Rate Control Valve (Selector Valve) 36- Arm 1 Flow Rate Control Valve (Poppet Valve) 37- Load Check Valve (Arm 1 Tandem Circuit) 38- Load Check Valve (Boom 2 Parallel Circuit) 39- Check Valve (Boom 2 Regenerative Circuit) 40- Overload Relief Valve (Arm: Bottom Side) 41- Arm Rod Anti-Drift Valve (Selector Valve) 42- Arm Rod Anti-Drift Valve (Check Valve) 43- Overload Relief Valve (Arm: Rod Side)

T5-4-25

i-

Swing

44- Boost Check Valve (Boom Regenerative Back Pressure Valve) 45- Overload Relief Valve (Boom 2: Rod Side) 46- Boom 2 Anti-Drift Valve (Selector Valve) 47- Boom 2 Anti-Drift Valve (Check Valve) 48- Overload Relief Valve (Auxiliary) 49- Load Check Valve (Auxiliary Tandem Circuit) 50- Overload Relief Valve (Auxiliary) 51- Load Check Valve (Auxiliary Parallel Circuit) 52- Load Check Valve (Travel (Left) Tandem Circuit) 53- Pump 1 54- Pump 2 55- Boom Regenerative Valve

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

c 1

a 2

3

4

a 5

6

c 7

8

9

52 10 11

51

12

50 49

13

48

14

47 46

15 16 17

45 55 44 43 42

18 19

41

20

40

21

39 38 28 37 36

22 23 24 25

35

26

31 30 34

33

29

32

54

53

T5-4-26

27

TJBM-03-03-001

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

Section D-D

Section E-E

j

29

k

42

41

18

19

l

44

m

46

20

47 24

38 55

25

23

32 28 36

35

17

16

21

Machine Upper Side Machine Lower Side

j- k-

1-

Load Check Valve (Travel (Left) Parallel Circuit) Bypass Shut-Out Valve (B side) Check Valve (Bucket Flow Combiner Circuit) Check Valve (Bucket Flow Combiner Circuit) Check Valve (Main Relief Circuit) Flow Combiner Valve Check Valve (Flow Combiner Circuit) Check Valve (Main Relief Circuit) Main Relief valve Load Check Valve (Bucket Parallel Circuit) Bucket Regeneration Cut Valve Bucket Regenerative Valve Overload Relief Valve (Bucket: Rod Side) Overload Relief Valve (Bucket: Bottom Side) Boom Flow Rate Control Valve (Selector Valve)

16- Boom Flow Rate Control Valve (Poppet Valve) 17- Boom Lower Meter-In Cut Valve 18- Boom 1 Anti-Drift Valve (Selector Valve) 19- Boom 1 Anti-Drift Valve (Check Valve) 20- Overload Relief Valve (Boom 1: Bottom Side) 21- Overload Relief Valve (Low Pressure) (Boom 1: Rod Side) 22- Boom Overload Relief Selector Valve 23- Load Check Valve (Arm 2 Tandem Circuit) 24- Arm 2 Flow Rate Control Valve (Selector Valve) 25- Arm 2 Flow Rate Control Valve (Poppet Valve) 26- Check Valve (Arm Make-Up) 27- Bypass Shut-Out Valve (A side) 28- Arm Regenerative Valve 29- Arm Regenerative Cut Valve 30- Check Valve (Auxiliary Flow Combiner Circuit)

2- 3- 4- 5- 6- 7- 8- 9- 10- 11- 12- 13- 14- 15-

Arm 2 Arm 1

45 TJBA-03-03-014

TJBA-03-03-013

a- c-

39

l- Boom 1 m- Boom 2 31- Auxiliary Flow Combiner Valve (Selector Valve) 32- Auxiliary Flow Combiner Valve (Poppet Valve) 33- Swing Flow Rate Control Valve (Selector Valve) 34- Swing Flow Rate Control Valve (Poppet Valve) 35- Arm 1 Flow Rate Control Valve (Selector Valve) 36- Arm 1 Flow Rate Control Valve (Poppet Valve) 37- Load Check Valve (Arm 1 Tandem Circuit) 38- Load Check Valve (Boom 2 Parallel Circuit) 39- Check Valve (Boom 2 Regenerative Circuit) 40- Overload Relief Valve (Arm: Bottom Side) 41- Arm Rod Anti-Drift Valve (Selector Valve) 42- Arm Rod Anti-Drift Valve (Check Valve) 43- Overload Relief Valve (Arm: Rod Side)

T5-4-27

44- Boost Check Valve (Boom Regenerative Back Pressure Valve) 45- Overload Relief Valve (Boom 2: Rod Side) 46- Boom 2 Anti-Drift Valve (Selector Valve) 47- Boom 2 Anti-Drift Valve (Check Valve) 48- Overload Relief Valve (Auxiliary) 49- Load Check Valve (Auxiliary Tandem Circuit) 50- Overload Relief Valve (Auxiliary) 51- Load Check Valve (Auxiliary Parallel Circuit) 52- Load Check Valve (Travel (Left) Tandem Circuit) 53- Pump 1 54- Pump 2 55- Boom Regenerative Valve

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

c 1

a 2

3

4

a 5

6

c 7

8

9

52 10 11

51

12

50 49

13

48

14

47 46

15 16 17

45 55 44 43 42

18 19

41

20

40

21

39 38 28 37 36

22 23 24 25

35

26

31 30 34

33

29

32

54

53

T5-4-28

27

TJBM-03-03-001

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

Section F-F

Section G-G

n

11

o

p

50

1

q

13

52

10

12

14

48

49 TJAA-03-03-014

a- c-

Machine Upper Side Machine Lower Side

n- o-

1-

Load Check Valve (Travel (Left) Parallel Circuit) Bypass Shut-Out Valve (B side) Check Valve (Bucket Flow Combiner Circuit) Check Valve (Bucket Flow Combiner Circuit) Check Valve (Main Relief Circuit) Flow Combiner Valve Check Valve (Flow Combiner Circuit) Check Valve (Main Relief Circuit) Main Relief valve Load Check Valve (Bucket Parallel Circuit) Bucket Regeneration Cut Valve Bucket Regenerative Valve Overload Relief Valve (Bucket: Rod Side) Overload Relief Valve (Bucket: Bottom Side) Boom Flow Rate Control Valve (Selector Valve)

16- Boom Flow Rate Control Valve (Poppet Valve) 17- Boom Lower Meter-In Cut Valve 18- Boom 1 Anti-Drift Valve (Selector Valve) 19- Boom 1 Anti-Drift Valve (Check Valve) 20- Overload Relief Valve (Boom 1: Bottom Side) 21- Overload Relief Valve (Low Pressure) (Boom 1: Rod Side) 22- Boom Overload Relief Selector Valve 23- Load Check Valve (Arm 2 Tandem Circuit) 24- Arm 2 Flow Rate Control Valve (Selector Valve) 25- Arm 2 Flow Rate Control Valve (Poppet Valve) 26- Check Valve (Arm Make-Up) 27- Bypass Shut-Out Valve (A side) 28- Arm Regenerative Valve 29- Arm Regenerative Cut Valve 30- Check Valve (Auxiliary Flow Combiner Circuit)

2- 3- 4- 5- 6- 7- 8- 9- 10- 11- 12- 13- 14- 15-

Bucket Auxiliary

TJAA-03-03-015

p- q-

Travel (Right) Travel (Left)

31- Auxiliary Flow Combiner Valve (Selector Valve) 32- Auxiliary Flow Combiner Valve (Poppet Valve) 33- Swing Flow Rate Control Valve (Selector Valve) 34- Swing Flow Rate Control Valve (Poppet Valve) 35- Arm 1 Flow Rate Control Valve (Selector Valve) 36- Arm 1 Flow Rate Control Valve (Poppet Valve) 37- Load Check Valve (Arm 1 Tandem Circuit) 38- Load Check Valve (Boom 2 Parallel Circuit) 39- Check Valve (Boom 2 Regenerative Circuit) 40- Overload Relief Valve (Arm: Bottom Side) 41- Arm Rod Anti-Drift Valve (Selector Valve) 42- Arm Rod Anti-Drift Valve (Check Valve) 43- Overload Relief Valve (Arm: Rod Side)

T5-4-29

44- Boost Check Valve (Boom Regenerative Back Pressure Valve) 45- Overload Relief Valve (Boom 2: Rod Side) 46- Boom 2 Anti-Drift Valve (Selector Valve) 47- Boom 2 Anti-Drift Valve (Check Valve) 48- Overload Relief Valve (Auxiliary) 49- Load Check Valve (Auxiliary Tandem Circuit) 50- Overload Relief Valve (Auxiliary) 51- Load Check Valve (Auxiliary Parallel Circuit) 52- Load Check Valve (Travel (Left) Tandem Circuit) 53- Pump 1 54- Pump 2 55- Boom Regenerative Valve

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

c 1

a 2

3

4

a 5

6

c 7

8

9

52 10 11

51

12

50 49

13

48

14

47 46

15 16 17

45 55 44 43 42

18 19

41

20

40

21

39 38 28 37 36

22 23 24 25

35

26

31 30 34

33

29

32

54

53

T5-4-30

27

TJBM-03-03-001

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

Section H-H

8

7

6

2 TJAA-03-03-016

a-

Machine Upper Side

c-

1-

Load Check Valve (Travel (Left) Parallel Circuit) Bypass Shut-Out Valve (B side) Check Valve (Bucket Flow Combiner Circuit) Check Valve (Bucket Flow Combiner Circuit) Check Valve (Main Relief Circuit) Flow Combiner Valve Check Valve (Flow Combiner Circuit) Check Valve (Main Relief Circuit) Main Relief valve Load Check Valve (Bucket Parallel Circuit) Bucket Regeneration Cut Valve Bucket Regenerative Valve Overload Relief Valve (Bucket: Rod Side) Overload Relief Valve (Bucket: Bottom Side) Boom Flow Rate Control Valve (Selector Valve)

16- Boom Flow Rate Control Valve (Poppet Valve) 17- Boom Lower Meter-In Cut Valve 18- Boom 1 Anti-Drift Valve (Selector Valve) 19- Boom 1 Anti-Drift Valve (Check Valve) 20- Overload Relief Valve (Boom 1: Bottom Side) 21- Overload Relief Valve (Low Pressure) (Boom 1: Rod Side) 22- Boom Overload Relief Selector Valve 23- Load Check Valve (Arm 2 Tandem Circuit) 24- Arm 2 Flow Rate Control Valve (Selector Valve) 25- Arm 2 Flow Rate Control Valve (Poppet Valve) 26- Check Valve (Arm Make-Up) 27- Bypass Shut-Out Valve (A side) 28- Arm Regenerative Valve 29- Arm Regenerative Cut Valve 30- Check Valve (Auxiliary Flow Combiner Circuit)

2- 3- 4- 5- 6- 7- 8- 9- 10- 11- 12- 13- 14- 15-

Machine Lower Side 31- Auxiliary Flow Combiner Valve (Selector Valve) 32- Auxiliary Flow Combiner Valve (Poppet Valve) 33- Swing Flow Rate Control Valve (Selector Valve) 34- Swing Flow Rate Control Valve (Poppet Valve) 35- Arm 1 Flow Rate Control Valve (Selector Valve) 36- Arm 1 Flow Rate Control Valve (Poppet Valve) 37- Load Check Valve (Arm 1 Tandem Circuit) 38- Load Check Valve (Boom 2 Parallel Circuit) 39- Check Valve (Boom 2 Regenerative Circuit) 40- Overload Relief Valve (Arm: Bottom Side) 41- Arm Rod Anti-Drift Valve (Selector Valve) 42- Arm Rod Anti-Drift Valve (Check Valve) 43- Overload Relief Valve (Arm: Rod Side)

T5-4-31

44- Boost Check Valve (Boom Regenerative Back Pressure Valve) 45- Overload Relief Valve (Boom 2: Rod Side) 46- Boom 2 Anti-Drift Valve (Selector Valve) 47- Boom 2 Anti-Drift Valve (Check Valve) 48- Overload Relief Valve (Auxiliary) 49- Load Check Valve (Auxiliary Tandem Circuit) 50- Overload Relief Valve (Auxiliary) 51- Load Check Valve (Auxiliary Parallel Circuit) 52- Load Check Valve (Travel (Left) Tandem Circuit) 53- Pump 1 54- Pump 2 55- Boom Regenerative Valve

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

c 1

a 2

3

4

a 5

6

c 7

8

9

52 10 11

51

12

50 49

13

48

14

47 46

15 16 17

45 55 44 43 42

18 19

41

20

40

21

39 38 28 37 36

22 23 24 25

35

26

31 30 34

33

29

32

54

53

T5-4-32

27

TJBM-03-03-001

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

View J

Section I-I

I I

5 TJAA-03-03-017

a-

Machine Upper Side

c-

1-

Load Check Valve (Travel (Left) Parallel Circuit) Bypass Shut-Out Valve (B side) Check Valve (Bucket Flow Combiner Circuit) Check Valve (Bucket Flow Combiner Circuit) Check Valve (Main Relief Circuit) Flow Combiner Valve Check Valve (Flow Combiner Circuit) Check Valve (Main Relief Circuit) Main Relief valve Load Check Valve (Bucket Parallel Circuit) Bucket Regeneration Cut Valve Bucket Regenerative Valve Overload Relief Valve (Bucket: Rod Side) Overload Relief Valve (Bucket: Bottom Side) Boom Flow Rate Control Valve (Selector Valve)

16- Boom Flow Rate Control Valve (Poppet Valve) 17- Boom Lower Meter-In Cut Valve 18- Boom 1 Anti-Drift Valve (Selector Valve) 19- Boom 1 Anti-Drift Valve (Check Valve) 20- Overload Relief Valve (Boom 1: Bottom Side) 21- Overload Relief Valve (Low Pressure) (Boom 1: Rod Side) 22- Boom Overload Relief Selector Valve 23- Load Check Valve (Arm 2 Tandem Circuit) 24- Arm 2 Flow Rate Control Valve (Selector Valve) 25- Arm 2 Flow Rate Control Valve (Poppet Valve) 26- Check Valve (Arm Make-Up) 27- Bypass Shut-Out Valve (A side) 28- Arm Regenerative Valve 29- Arm Regenerative Cut Valve 30- Check Valve (Auxiliary Flow Combiner Circuit)

2- 3- 4- 5- 6- 7- 8- 9- 10- 11- 12- 13- 14- 15-

T450-03-03-008

Machine Lower Side 31- Auxiliary Flow Combiner Valve (Selector Valve) 32- Auxiliary Flow Combiner Valve (Poppet Valve) 33- Swing Flow Rate Control Valve (Selector Valve) 34- Swing Flow Rate Control Valve (Poppet Valve) 35- Arm 1 Flow Rate Control Valve (Selector Valve) 36- Arm 1 Flow Rate Control Valve (Poppet Valve) 37- Load Check Valve (Arm 1 Tandem Circuit) 38- Load Check Valve (Boom 2 Parallel Circuit) 39- Check Valve (Boom 2 Regenerative Circuit) 40- Overload Relief Valve (Arm: Bottom Side) 41- Arm Rod Anti-Drift Valve (Selector Valve) 42- Arm Rod Anti-Drift Valve (Check Valve) 43- Overload Relief Valve (Arm: Rod Side)

T5-4-33

44- Boost Check Valve (Boom Regenerative Back Pressure Valve) 45- Overload Relief Valve (Boom 2: Rod Side) 46- Boom 2 Anti-Drift Valve (Selector Valve) 47- Boom 2 Anti-Drift Valve (Check Valve) 48- Overload Relief Valve (Auxiliary) 49- Load Check Valve (Auxiliary Tandem Circuit) 50- Overload Relief Valve (Auxiliary) 51- Load Check Valve (Auxiliary Parallel Circuit) 52- Load Check Valve (Travel (Left) Tandem Circuit) 53- Pump 1 54- Pump 2 55- Boom Regenerative Valve

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Pilot Port (Signal Control Valve) Pilot Valve Side Port Name Port A Port B Port C Port D Port E Port F Port G Port H Port I Port J Port K Port L Port M Port N Port SA Port SB Port PI Port PH Port SH Port DF

Connected to Right Pilot Valve Right Pilot Valve Left Pilot Valve Left Pilot Valve Left Pilot Valve Left Pilot Valve Right Pilot Valve Right Pilot Valve Travel Pilot Valve Travel Pilot Valve Travel Pilot Valve Travel Pilot Valve 4-Spool Side Pressure Sensor 5-Spool Side Pressure Sensor Pilot Shut-Off Solenoid Valve Pilot Shut-Off Solenoid Valve Swing Parking Brake Hydraulic Oil Tank

Remark Boom Raise Pilot Pressure Boom Lower Pilot Pressure Arm Roll-Out Pilot Pressure Arm Roll-In Pilot Pressure Swing (Left) Pilot Pressure Swing (Right) Pilot Pressure Bucket Roll-In Pilot Pressure Bucket Roll-Out Pilot Pressure Travel (Left Forward) Pilot Pressure Travel (Left Reverse) Pilot Pressure Travel (Right Forward) Pilot Pressure Travel (Right Reverse) Pilot Pressure Plug Plug Pump 1 Control Pressure Pump 2 Control Pressure Primary Pilot Pressure Primary Pilot Pressure (Heater Circuit) Brake Release Pressure Returning to Hydraulic Oil Tank

T5-4-34

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Pilot Valve Side PH A

C E

M

D H

B SB

F

G

PI

N K

I J

SH

DF

SA

TJAA-03-06-002

L

Control Valve Side SM

3

1

5

13

4

2

SE

SK

8

S3

14 6

7 9

SN

11

10 SL

TR

12

T5-4-35

SP

TJAA-03-06-003

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

Control Valve Side Port Name Port 1 Port 2 Port 3 Port 4 Port 5 Port 6 Port 7 Port 8 Port 9 Port 10 Port 11 Port 12 Port 13 Port 14 Port S3 Port SE Port SM Port SN Port SP Port SL Port SK Port TR

Connected to Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Pressure Sensor (Swing) Control Valve Hydraulic Oil Tank Hydraulic Oil Tank Control Valve Pressure Sensor (Travel)

Remark Boom Raise Pilot Pressure Boom Lower Pilot Pressure Arm Roll-Out Pilot Pressure Arm Roll-In Pilot Pressure Swing (Left) Pilot Pressure Swing (Right) Pilot Pressure Bucket Roll-In Pilot Pressure Bucket Roll-Out Pilot Pressure Travel (Left Forward) Pilot Pressure Travel (Left Reverse) Pilot Pressure Travel (Right Forward) Pilot Pressure Travel (Right Reverse) Pilot Pressure Plug Plug Arm 1 Flow Rate Control Valve Control Pressure Returning to Hydraulic Oil Tank Plug Returning to Hydraulic Oil Tank Flow Combiner Valve Control Pressure Plug -

T5-4-36

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Pilot Valve Side PH A

C E

M

D H

B SB

F

G

PI

N K

I J

SH

DF

SA

TJAA-03-06-002

L

Control Valve Side SM

3

1

5

13

4

2

SE

SK

8

S3

14 6

7 9

SN

11

10 SL

TR

12

T5-4-37

SP

TJAA-03-06-003

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout (Blank)

T5-4-38

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure Refer to troubleshooting A procedure in case any fault codes are displayed after diagnosing by using MPDr. or the service menu of the monitor.

fNOTE:

 Diagnosis Procedure  Check the symptoms in machine operation for each fault code. When the symptoms match the machine operation when trouble occurs, perform the remedy.  In case more than one fault code are displayed at the same time, MC may be faulty or the power/ground of the sensor system may be faulty.  When the MC fault code is displayed with other fault code, replace MC.  When fault code 11003-3 (Abnormal Sensor Voltage) is displayed with other fault code, diagnose for fault code 11003-3 first.  In case more than one fault code other than those described above are displayed at the same time, diagnose for each fault code.  It may be required that the machine is operated or the test harness is connected at inspection. Check the items of preparation and perform inspection according to the procedures when diagnosing.

fNOTE:

All connector images in this section are viewed from the open end side of wire harness end.

1 2

T6L4-05-03-001

1-

Wire Harness End Connector

2-

Wire Harness

T5-5-1

The engine controller (ECM) judges the engine malfunction. After the engine is repaired, select Fault Code Clear on Engine Setting. Then, delete the fault code of engine controller (ECM) on Troubleshooting. (Refer to TROUBLESHOOTING/Monitor.)

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Contents of Diagnosis

Fault Code

Preparation Tools for a diagnosis and contents needing inspection beforehand are explained.

How to Read Table

    

Fault Code

Trouble

(A)

(B)

Inspection Method

Evaluation

Cause

(C)

(D)

(E)

(F)

(G)

(H)

A: Fault code B: Trouble details C, F: Inspection method for trouble cause D, G: Evaluation specification of check results E, H: Trouble cause for the fault code

Procedure: 1. Check an applicable line depending on displayed fault cord (A). 2. After checking or measuring on Inspection Method (C), refer to Evaluation (D) and judge the results. 3. In case the results are satisfied with Evaluation (D), the trouble cause is Cause (E).

In case the results are not satisfied with Evaluation (D), go to the next procedure, Inspection Method (F). Circuit Diagram of Test Harness

A connection point of the test harness and a point to check are explained. (Only Pressure Sensor System Troubleshooting)

T5-5-2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code List Controller Hardware Failure Fault Code Trouble

Cause

11000-2 11001-2 11002-2

Faulty MC. Faulty MC. Faulty MC.

11003-3

Abnormal EEPROM Abnormal RAM Abnormal A/D Converter Abnormal Sensor Voltage

Symptoms in Machine Operation When Trouble Occurs -

Remedy

Replace MC. Replace MC. Replace MC.

Faulty MC. Although the engine control Check the sensor connected Faulty sensor. dial is operated, the engine to MC. Faulty wire harness. speed does not change. Check the wire harness. Replace MC.

T5-5-3

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A CAN Data Reception Failure Fault Code Trouble

Cause

11006-2

(MC) EC Communication Error

Faulty harness.

11007-2

(MC) IC Communication Error 1 (MC) IC Communication Error 2 (MC) Monitor Controller Communication Error 1 (MC) Monitor Controller Communication Error 2

Faulty MC. Faulty CAN0 harness. Faulty MC. Faulty CAN1 harness. Faulty MC. Faulty CAN0 harness.

11008-2

11009-2

11010-2

fNOTE:

Faulty MC. Faulty CAN1 harness.

Symptoms in Machine Operation When Trouble Occurs The machine movement is slow. (The torque is reduced by the speed sensing.) The machine movement is slow.

Auto shut-down is not activated.

The machine movement is slow.

Auto shut-down is not activated.

IC is the Information Control Unit of Monitor Controller.

T5-5-4

Remedy Check the wire harness. Check the CAN0 harness. Check MC. Check the CAN1 harness. Check MC. Check the CAN0 harness. Check MC. Check the CAN1 harness. Check MC.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Engine Failure Fault Code

Trouble

11100-2

Abnormal Engine Speed

11101-3

Abnormal Engine Control Angle Sensor High Input

11101-4

Abnormal Engine Control Angle Sensor Low Input

Cause

Symptoms in Machine Operation When Trouble Occurs Engine speed: 4000 The machine operation speed is slow. (During min-1 or more speed sensing, the torque is decreased.) Voltage: more than Trouble condition with the 4.75 V key switch ON: The engine speed is kept at slow idle speed. Trouble condition during operation: The engine speed is kept at the speed just before trouble occurs. Voltage: less than Trouble condition with the 0.25 V key switch ON: The engine speed is kept at slow idle speed. Trouble condition during operation: The engine speed is kept at the speed just before trouble occurs.

T5-5-5

Remedy

Check the crank speed sensor. Check the cam angle sensor. (Refer to the engine manual.) Check the wire harness. Replace the engine control dial.

Check the wire harness. Replace the engine control dial.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Pump Failure Fault Code

Trouble

Cause

11200-3

Pump 1 Delivery Pressure Sensor Circuit High Input

Voltage: more than 4.75 V

11200-4

Pump 1 Delivery Pressure Sensor Circuit Low Input

Voltage: less than 0.25 V

11202-3

Pump 2 Delivery Pressure Sensor Circuit High Input

Voltage: more than 4.75 V

11202-4

Pump 2 Delivery Pressure Sensor Circuit Low Input

Voltage: less than 0.25 V

Symptoms in Machine Operation When Trouble Occurs Combined operation of arm rollin and boom raise or combined operation of arm roll-in and swing: Arm roll-in speed becomes slow. Single operation of boom raise: Lifting force is weak. Machine is kept to travel at slow speed. Combined operation of arm rollin and boom raise or combined operation of arm roll-in and swing: Arm roll-in speed becomes slow. Single operation of boom raise: Lifting force is weak. Machine is kept to travel at slow speed. Combined operation of arm rollin and boom raise or combined operation of arm roll-in and swing: Arm roll-in speed becomes slow. Machine is kept to travel at slow speed. Combined operation of arm rollin and boom raise or combined operation of arm roll-in and swing: Arm roll-in speed becomes slow. Machine is kept to travel at slow speed.

T5-5-6

Remedy Check the wire harness. Replace the pump 1 delivery pressure sensor.

Check the wire harness. Replace the pump 1 delivery pressure sensor.

Check the wire harness. Replace the pump 2 delivery pressure sensor.

Check the wire harness. Replace the pump 2 delivery pressure sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Pilot Failure Fault Code

Trouble

Cause

11301-3

Swing Pilot Pressure Voltage: more Sensor Circuit High than 4.75 V Input

11301-4

Swing Pilot Pressure Voltage: less Sensor Circuit Low than 0.1 V Input

11302-3

Boom Raise Pilot Pressure Sensor Circuit High Input

Voltage: more than 4.75 V

11302-4

Boom Raise Pilot Pressure Sensor Circuit Low Input

Voltage: less than 0.1 V

11303-3

Arm Roll-in Pilot Pressure Sensor Circuit High Input Arm Roll-in Pilot Pressure Sensor Circuit Low Input

Voltage: more than 4.75 V

11303-4

Voltage: less than 0.1 V

Symptoms in Machine Operation When Trouble Occurs Swing speed becomes slow. Combined operation of swing, arm roll-in, and boom raise: Boom does not raise easily and arm speed becomes fast. Swing alarm (optional) continues to sound. Swing speed becomes slow. Combined operation of swing, arm roll-in, and boom raise: Boom does not raise easily and arm speed becomes fast. Swing alarm (optional) continues to sound. When operating boom raise, engine speed does not increase. Combined operation of swing, arm roll-in, and boom raise: Boom does not raise easily. Single operation of boom raise: Lifting force is weak. When operating boom raise, engine speed does not increase. Combined operation of swing, arm roll-in, and boom raise: Boom does not raise easily. Single operation of boom raise: Lifting force is weak. When operating arm roll-in, engine speed does not increase. Arm speed becomes fast. When operating arm roll-in, engine speed does not increase. Arm speed becomes fast.

T5-5-7

Remedy Check the wire harness. Replace the swing pilot pressure sensor.

Check the wire harness. Replace the swing pilot pressure sensor.

Check the wire harness. Replace the boom raise pilot pressure sensor.

Check the wire harness. Replace the boom raise pilot pressure sensor.

Check the wire harness. Replace the arm roll-in pilot pressure sensor. Check the wire harness. Replace the arm roll-in pilot pressure sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble

11304-3

Travel Pilot Pressure Voltage: more Sensor Circuit High than 4.75 V Input

11304-4

Travel Pilot Pressure Voltage: less Sensor Circuit Low than 0.1 V Input

11325-3

Bucket Roll-In Pilot Pressure Sensor Circuit High Input Bucket Roll-In Pilot Pressure Sensor Circuit Low Input

11325-4

Cause

Voltage: more than 4.75 V

Symptoms in Machine Operation When Trouble Occurs Machine travel speed is slow. When traveling, engine speed does not increase to the specification. When traveling, engine speed does not return from auto-idle speed. When traveling, engine speed does not return from ECO speed. Travel alarm (optional) continues to sound. Machine travel speed is slow. When traveling, engine speed does not increase to the specification. When traveling, engine speed does not return from auto-idle speed. When traveling, engine speed does not return from ECO speed. Travel alarm (optional) continues to sound. When operating light digging, bucket speed becomes slow.

Voltage: less than 0.1 V

When operating light digging, bucket speed becomes slow.

T5-5-8

Remedy Check the wire harness. Replace the travel pilot pressure sensor.

Check the wire harness. Replace the travel pilot pressure sensor.

Check the wire harness. Replace the bucket roll-in pilot pressure sensor. Check the wire harness. Replace the bucket roll-in pilot pressure sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Proportional Solenoid Valve Failure Fault Code

Trouble

Cause

Symptoms in Machine Operation When Trouble Occurs

Remedy

11405-3

Travel Swash Angle P/S Valve FB High Current (4-spool solenoid valve unit (SC))

Current: more than 920 mA

Machine is kept travel at fast speed.

Check the wire harness

11405-4

Travel Swash Angle P/S Valve FB Low Current (4-spool solenoid valve unit (SC))

Current: less than Machine is kept travel at slow speed. 56 mA

T5-5-9

Check the wire harness

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble

Cause

Symptoms in Machine Operation When Trouble Occurs

Remedy

11408-3

Center Bypass Cut P/S Valve FB High Current

Current: more than 920 mA

Machine mistracks. Precise control cannot be performed.

Check the wire harness

11408-4

Center Bypass Cut P/S Valve FB Low Current

Current: less than Bucket operation speed is slow. Check the wire 56 mA During single operation of pulverizer/ harness crusher: Attachment operation speed is slow.

11412-3

Hyd. Fan P/S Valve FB High Current

Current: more than 920 mA

Fan rotation speed is kept at the minimum speed.

Check the wire harness

11412-4

Hyd. Fan P/S Valve FB Low Current

Current: less than Fan rotation speed is kept at the 56 mA maximum speed.

Check the wire harness

fNOTE:

The fault codes 11408-3 and 11408-4 are displayed on MPDr. as follows.



11408-3: Muffler Filter Regenerative (Center Bypass Cut) P/S Valve FB High Current.



11408-4: Muffler Filter Regenerative (Center Bypass Cut) P/S Valve FB Low Current.

T5-5-10

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble

Cause

Symptoms in Machine Operation When Trouble Occurs

Remedy

11428-3

Arm 2 Flow Rate Control P/S Valve FB High Current

Current: more than 920 mA

Arm operation speed becomes slow.

Check the wire harness

11428-4

Arm 2 Flow Rate Control P/S Valve FB Low Current

Current: less than Combined operation of arm roll-in 56 mA and bucket roll-in: Bucket roll-in operation speed is slow.

T5-5-11

Check the wire harness

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Other Failures Fault Code

Trouble

Cause

Symptoms in Machine Remedy Operation When Trouble Occurs

11802-3

Boom Bottom Voltage: more than 4.75 V Pressure Sensor Circuit High Input (Option)

The buzzer sounds.

Check the wire harness Replace the boom bottom pressure sensor

11802-4

Boom Bottom Voltage: less than 0.25 V Pressure Sensor Circuit High Input (Option)

The buzzer sounds.

Check the wire harness Replace the boom bottom pressure sensor

11901-3

Hyd. Oil Temp Sensor Circuit High Input

Voltage: more than 4.35 V

Fan rotation speed is kept at the maximum speed. Pump driving torque is reduced.

Check the wire harness

11901-4

Hyd. Oil Temp Sensor Circuit Low Input

Voltage: less than 0.1 V

Fan rotation speed is kept at the maximum speed. Pump driving torque is reduced.

Check the wire harness

T5-5-12

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble

Cause

Symptoms in Machine Remedy Operation When Trouble Occurs

11942-3

Attachment Pilot Voltage: more than 4.75 V Pressure Sensor Circuit High Input (Option)

When operating attachment, engine speed does not increase. Attachment speed becomes slow.

Check the wire harness Replace the attachment pilot pressure sensor

11942-4

Attachment Pilot Voltage: less than 0.1 V Pressure Sensor Circuit Low Input (Option)

When operating attachment, engine speed does not increase. Attachment speed becomes slow.

Check the wire harness Replace the attachment pilot pressure sensor

11944-3

Signal Control Valve SB-port Pressure Sensor Circuit High Input (5-spool side pilot pressure sensor)

Voltage: more than 4.75 V

Boom operation speed becomes slow. Arm operation speed becomes slow. Swing speed becomes slow. Machine mistracks.

Check the wire harness Replace the signal control valve SB-port pressure sensor

11944-4

Signal Control Valve SB-port Pressure Sensor Circuit Low Input (5-spool side pilot pressure sensor)

Voltage: less than 0.25 V

Boom operation speed becomes slow. Arm operation speed becomes slow. Swing speed becomes slow. Machine mistracks.

Check the wire harness Replace the signal control valve SB-port pressure sensor

T5-5-13

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble

Cause

Symptoms in Machine Remedy Operation When Trouble Occurs

11945-3

Signal Control Valve SA-port Pressure Sensor Circuit High Input (4-spool side pilot pressure sensor)

Voltage: more than 4.75 V

Boom operation speed becomes slow. Arm operation speed becomes slow. Bucket operation speed becomes slow. Machine mistracks.

Check the wire harness Replace the signal control valve SA-port pressure sensor

11945-4

Signal Control Valve SA-port Pressure Sensor Circuit Low Input (4-spool side pilot pressure sensor)

Voltage: less than 0.25 V

Boom operation speed becomes slow. Arm operation speed becomes slow. Bucket operation speed becomes slow. Machine mistracks.

Check the wire harness Replace the signal control valve SA-port pressure sensor

11948-3

Main Relief Pressure Control P/S Valve FB High Current (4-spool solenoid valve unit (SI))

Current: more than 920 mA

Check the wire Pressure always increases. harness Machine is kept travel at fast speed.

11948-4

Main Relief Pressure Control P/S Valve FB Low Current (4-spool solenoid valve unit (SI))

Current: less than 56 mA

Check the wire Pressure increasing is harness impossible. Machine is kept travel at slow speed.

11950-3

Pump 2 P/S Valve FB High Current

Current: more than 920 mA

Pump 2 torque is always maximum. The engine stalls is remarkable at high loaded. The engine lugdown is remarkable at high loaded.

Check the wire harness

11950-4

Pump 2 P/S Valve FB Low Current

Current: less than 56 mA

Pump 2 torque is always minimum. Machine overall operation is slow.

Check the wire harness

T5-5-14

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble

Cause

Symptoms in Machine Remedy Operation When Trouble Occurs

11951-3

Pump 1 P/S Valve FB High Current

Current: more than 920 mA

Pump 1 torque is always maximum. The engine stalls is remarkable at high loaded. The engine lug-down is remarkable at high loaded.

11951-4

Pump 1 P/S Valve FB Low Current

Current: less than 56 mA

Pump 1 torque is always Check the wire minimum. Machine harness overall operation is slow.

T5-5-15

Check the wire harness

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble

Cause

Symptoms in Machine Remedy Operation When Trouble Occurs

11953-3

Swing Flow Rate Control P/S Valve FB High Current (2-spool solenoid valve unit (SI))

Current: more than 920 mA

Swing speed becomes slow.

Check the wire harness

11953-4

Swing Flow Rate Control P/S Valve FB Low Current (2-spool solenoid valve unit (SI))

Current: less than 56 mA

Combined operation of swing and arm roll-out: Arm operation speed becomes slow. Combined operation of swing and boom raise: Boom operation speed becomes slow.

Check the wire harness

T5-5-16

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble

Cause

Symptoms in Machine Remedy Operation When Trouble Occurs

11978-3

Auxiliary 2 Pilot Pressure Sensor Circuit High Input (Option)

Voltage: more than 4.75 V

-

Check the wire harness

11978-4

Auxiliary 2 Pilot Pressure Sensor Circuit Low Input (Option)

Voltage: less than 0.1 V

-

Check the wire harness

11979-3

Auxiliary 1 Pilot Pressure Sensor Circuit High Input (Option)

Voltage: more than 4.75 V

-

Check the wire harness

11979-4

Auxiliary 1 Pilot Pressure Sensor Circuit Low Input (Option)

Voltage: less than 0.1 V

-

Check the wire harness

T5-5-17

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble

Cause

Symptoms in Machine Remedy Operation When Trouble Occurs

11981-3

Fan Reverse Rotation P/S Valve FB 2 High Current

Current: more than 920 mA

Fan does not rotate in reverse.

Check the wire harness

11981-4

Fan Reverse Rotation P/S Valve FB 2 Low Current

Current: less than 56 mA

Fan does not rotate in reverse.

Check the wire harness

11982-3

Fan Reverse Rotation P/S Valve FB 1 High Current

Current: more than 920 mA

Fan does not rotate in reverse.

Check the wire harness

11982-4

Fan Reverse Rotation P/S Valve FB 1 Low Current

Current: less than 56 mA

Fan does not rotate in reverse.

Check the wire harness

T5-5-18

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble

Cause

Symptoms in Machine Remedy Operation When Trouble Occurs

11985-2

Pump 2 Regulator Pressure Calibration Abort

Faulty pump 2 control solenoid valve

Machine overall operation is slow.

Check the wire harness Replace the pump 2 control solenoid valve

11986-2

Pump 1 Regulator Pressure Calibration Abort

Faulty pump 1 control solenoid valve

Machine overall operation is slow.

Check the wire harness Replace the pump 1 control solenoid valve

11989-3

Boom Mode Control P/S Valve FB High Current (2-spool solenoid valve unit (SC))

Current: more than 920 mA

Boom mode selector control is impossible.

Check the wire harness

11989-4

Boom Mode Control P/S Valve FB Low Current (2-spool solenoid valve unit (SC))

Current: less than 56 mA

Boom mode selector control is impossible.

Check the wire harness

T5-5-19

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble

Cause

Symptoms in Machine Operation When Trouble Occurs

Remedy

11992-3

Pump 2 RegPressure Sensor Pressure Sensor Circuit High Input (Pump 2 control pressure sensor)

Voltage: more than 4.75 V

Fast travel cannot be selected easily.

Check the wire harness Replace the pump 2 regpressure sensor

11992-4

Pump 2 RegPressure Sensor Pressure Sensor Circuit Low Input (Pump 2 control pressure sensor)

Voltage: less than 0.25 V

Fast travel cannot be selected easily.

Check the wire harness Replace the pump 2 regpressure sensor

11994-3

Pump 1 RegPressure Sensor Pressure Sensor Circuit High Input (Pump 1 control pressure sensor)

Voltage: more than 4.75 V

Fast travel cannot be selected easily.

Check the wire harness Replace the pump 1 regpressure sensor

11994-4

Pump 1 RegPressure Sensor Pressure Sensor Circuit Low Input (Pump 1 control pressure sensor)

Voltage: less than 0.25 V

Fast travel cannot be selected easily.

Check the wire harness Replace the pump 1 regpressure sensor

T5-5-20

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble

Cause

Symptoms in Machine Remedy Operation When Trouble Occurs

11995-3

Arm Roll-Out Pilot Voltage: more than 4.75 V Pressure Sensor Circuit High Input

When Operating arm roll-out, engine speed does not increase. Arm speed becomes fast.

Check the wire harness Replace the arm roll-out pilot pressure sensor

11995-4

Arm Roll-Out Pilot Voltage: less than 0.1 V Pressure Sensor Circuit Low Input

When Operating arm roll-out, engine speed does not increase. Arm speed becomes fast.

Check the wire harness Replace the arm roll-out pilot pressure sensor

11997-3

Bucket Roll-Out Pilot Voltage: more than 4.75 V Pressure Sensor Circuit High Input

When Operating light digging: Bucket speed becomes slow.

Check the wire harness Replace the bucket roll-out pilot pressure sensor

11997-4

Bucket Roll-Out Pilot Voltage: less than 0.1 V Pressure Sensor Circuit Low Input

When Operating light digging: Bucket speed becomes slow.

Check the wire harness Replace the bucket roll-out pilot pressure sensor

11998-3

Boom Lower Pilot Voltage: more than 4.75 V Pressure Sensor Circuit High Input

When Operating boom lower, engine speed does not increase. Combined operation of swing, arm roll-in, and boom lower: Boom does not lower easily.

Check the wire harness Replace the boom lower pilot pressure sensor

11998-4

Boom Lower Pilot Voltage: less than 0.1 V Pressure Sensor Circuit Low Input

When Operating boom lower, engine speed does not increase. Combined operation of swing, arm roll-in, and boom lower: Boom does not lower easily.

Check the wire harness Replace the boom lower pilot pressure sensor

20062-0

Hydraulic Oil Overheat Hydraulic oil temperature is Alarm high

The alarm is displayed on the monitor.

Check the wire harness. Replace the hydraulic oil temperature sensor.

T5-5-21

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A ECM Fault Code List (Refer to the Engine Manual for ECM Fault Codes.) Fault Code Trouble Cause SPN- DTC FMI 91-2 P2138 Accelerator Pedal Opening amount difference Position Sensor 1-2 between accelerator sensors 1 Correlation and 2 is 45 % or more

91-3

91-3

91-4

91-4

P2123 Accelerator Pedal Position Sensor 1 High Input

Voltage at accelerator sensor 1 is more than 4.9 V

P2128 Accelerator Pedal Position Sensor 2 High Input

Voltage at accelerator sensor 2 is more than 4.9 V

P2122 Accelerator Pedal Position Sensor 1 Low Input

Voltage at accelerator sensor 1 is less than 0.2 V

P2127 Accelerator Pedal Position Sensor 2 Low Input

Voltage at accelerator sensor 2 is less than 0.2 V

100-3 P0523 Engine Oil Pressure Sensor Circuit High Input 100-4 P0522 Engine Oil Pressure Sensor Circuit Low Input 102-3 P0238 Boost Pressure Sensor Circuit High Input 102-4 P0237 Boost Pressure Sensor Circuit Low Input 105-3 P1113 Boost Temperature Sensor Circuit High Input 105-4 P1112 Boost Temperature Sensor Circuit Low Input 108-3 P2229 Atmospheric Pressure Sensor Circuit High Input 108-4 P2228 Atmospheric Pressure Sensor Circuit Low Input 110-0 P0217 Overheat

Voltage at the engine oil pressure sensor is more than 4.9 V Voltage at the engine oil pressure sensor is less than 0.1 V Voltage at the boost pressure sensor is more than 4.9 V Voltage at the boost pressure sensor is less than 0.1 V Voltage at the boost temperature sensor is more than 4.94 V Voltage at the boost temperature sensor is less than 0.1 V Voltage at the atmospheric pressure sensor is more than 4 V Voltage at the atmospheric pressure sensor is less than 0.5 V Coolant temperature is more than 101 °C

Operating Rank A: Digging is operable. B: Machine can travel with the boom raised. C: The engine only runs. (Only operation with light load is possible.) D: The engine cannot stop/start.

T5-5-22

Symptoms in Machine Operation When Trouble Occurs One of the sensor is abnormal: Operating normally Both of the sensors are abnormal: Accelerator opening amount is limited to 0 % One of the sensor is abnormal: Operating normally Both of the sensors are abnormal: Accelerator opening amount is limited to 0 % One of the sensor is abnormal: Operating normally Both of the sensors are abnormal: Accelerator opening amount is limited to 0 % One of the sensor is abnormal: Operating normally Both of the sensors are abnormal: Accelerator opening amount is limited to 0 % One of the sensor is abnormal: Operating normally Both of the sensors are abnormal: Accelerator opening amount is limited to 0 % Nothing special. Nothing special.

Operating Rank A B C D

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 

The output power decreases.



The output power decreases. The rotation speed does not increase. The rotation speed does not increase. The output power decreases. The output power decreases. There is no influence when operating the machine.

     

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code

Trouble

Cause

SPN-FMI DTC 110-3 P0118 Engine Coolant Temperature Circuit High Input 110-4 P0117 Engine Coolant Temperature Circuit Low Input 157-3 P0193 Common Rail Pressure Sensor Circuit High Input 157-4 P0192 Common Rail Pressure Sensor Circuit Low Input 157-15 P0089 Abnormal Common Rail Pressure (Over Pumping)

Voltage at the coolant temperature sensor is more than 4.9 V Voltage at the coolant temperature sensor is less than 0.1 V Voltage at the common rail pressure sensor is more than 4.8 V Voltage at the common rail pressure sensor is less than 0.7 V Actual rail pressure is more than 40 MPa higher than the target rail pressure

158-3

Voltage is more than 32 V

172-3

172-4

174-3

174-4

190-0 628-2 633-7 636-2

636-7

639-2 639-19

P0563 Abnormally High Battery System Voltage P0113 Intake Air Temperature Sensor Circuit High Input P0112 Intake Air Temperature Sensor Circuit Low Input P0183 Combustion Temperature Sensor Circuit High Input P0182 Combustion Temperature Sensor Circuit Low Input P0219 Engine Overrun

Voltage at the intake-air temperature sensor is more than 4.9 V Voltage at the intake-air temperature sensor is less than 0.1 V Voltage at the fuel temperature sensor is more than 4.9 V Voltage at the fuel temperature sensor is less than 0.1 V Engine speed is more than specification (2500 min-1) P0601 Abnormal ROM Check sum is NG P0087 Common Rail Pressure It is judged by rail pressure Limiter Open change pattern P0340 Abnormal Cam Angle The signal from cam sensor Sensor (No Signal) is not present.

P0016 Phase Difference between Cam and Sensor

U0101 Abnormal CAN Timeout U0073 Abnormal CAN Bus

Symptoms in Machine Operation When Trouble Occurs The output power decreases.

 The output power decreases.  The engine may be stalled. The output power decreases.



The engine speed increases automatically and abnormally.



Vibration of the engine may be large, rough idle, output power decrease may occur, faulty increasing of rotation speed, dark smoke may occur, output power may be too large. The battery may be faulty.





The output power decreases.  The output power decreases.  Nothing special.  Nothing special.  Engine speed may not increase  2500 min-1 or more. The engine cannot start. The output power decreases.

While the engine runs, there is nothing abnormal with machine operation. After the engine is stalled, the re-start is impossible. The correct cam pulse is not While the engine runs, there present at the gap in the is nothing abnormal with machine operation. crank After the engine is stalled, the re-start is impossible. TSC1 message from SA=228 The engine runs at idle speed. is not received The bus line OFF is detected The engine runs at idle speed.

T5-5-23

Operating Rank A B C D

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SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code

Trouble

SPN-FMI DTC 651-5 P0201 Cylinder 1 Injector Circuit Open 652-5 P0202 Cylinder 2 Injector Circuit Open 653-5 P0203 Cylinder 3 Injector Circuit Open 654-5 P0204 Cylinder 4 Injector Circuit Open 655-5 P0205 Cylinder 5 Injector Circuit Open 656-5 P0206 Cylinder 6 Injector Circuit Open 723-2 P0335 Crank Position Sensor Failure (No Signal) 723-8

1077-2

1079-2

1080-2

1239-1

P0336

P0606

P0641

P0651

P1093

1239-31 P1093

Cause

Symptoms in Machine Operation When Trouble Occurs

No input signal of injector 1 monitor

Vibration of the engine is large, rough idle, output power decrease, faulty increasing of rotation speed, exhaust gas becomes bad. No input signal of Vibration of the engine is large, rough idle, injector 2 monitor output power decrease, faulty increasing of rotation speed, exhaust gas becomes bad. No input signal of Vibration of the engine is large, rough idle, injector 3 monitor output power decrease, faulty increasing of rotation speed, exhaust gas becomes bad. No input signal of Vibration of the engine is large, rough idle, injector 4 monitor output power decrease, faulty increasing of rotation speed, exhaust gas becomes bad. No input signal of Vibration of the engine is large, rough idle, injector 5 monitor output power decrease, faulty increasing of rotation speed, exhaust gas becomes bad. No input signal of Vibration of the engine is large, rough idle, injector 6 monitor output power decrease, faulty increasing of rotation speed, exhaust gas becomes bad. Even if the cam signal The output power may decrease, white is present, the crank smoke may occur and vibration may occur, signal is not present the engine may be stalled (If the cam senor is normal, the engine can re-start). Crank Position The pulse of crank The output power may decrease, white Sensor Failure signal is not matched smoke may occur and vibration may occur, (Abnormal the engine may be stalled (If the cam senor Signal) is normal, the engine can re-start). Abnormal CPU Failure of main CPU is The output power decreases. detected by sub CPU (Sub CPU resets CPU) Abnormal Voltage of 5 V power  5V-Electric source circuit 1 or 5 is Power Circuit #1 over 5.5 V or less than 4.5 V Abnormal Voltage of 5 V power  5V-Electric source circuit 2 or 5 is Power Circuit #2 over 5.5 V or less than 4.5 V Pressure Actual rail pressure is Vibration of the engine may be large, rough Decline in 50 MPa or more lower idle, output power decrease may occur, Common Rail than the target rail faulty increasing of rotation speed, dark (No Pumping pressure smoke may occur, output power may be Pressure) too large. Pressure Actual rail pressure is Vibration of the engine may be large, rough Decline in 50 MPa or more lower idle, output power decrease may occur, Common Rail than the target rail faulty increasing of rotation speed, dark (No Pumping pressure smoke may occur, output power may be Pressure) too large. - low fuel temperature.

T5-5-24

Operating Rank A B C D 

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SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code SPN-FMI 1240-1

1240-31

1347-3

1347-4

1348-3

1348-4

1381-3

1381-4 1485-5

1485-6

Trouble

Cause

Symptoms in Machine Operation When Trouble Occurs

DTC P0093 Pressure Decline in Common Rail (Lack of Pumping Pressure 2)

Operating Rank A B C D

Actual rail pressure is 50 Vibration of the engine may MPa or more lower than the be large, rough idle, output target rail pressure power decrease may occur, faulty increasing of rotation speed, dark smoke may occur, output power may be too large. P0093 Pressure Decline in Actual rail pressure is 50 Vibration of the engine may Common Rail (Lack of MPa or more lower than the be large, rough idle, output Pumping Pressure 2) target rail pressure power decrease may occur, (Low Fuel Temperature) faulty increasing of rotation speed, dark smoke may occur, output power may be too large. P0092 PCV 1 Drive Circuit + PCV 1 current is 2400 mA or The output power Short Circuit B more, or difference between decreases, there is influence to exhaust gas. PCV 1 current and target current is 1000 mA or more The output power P0091 PCV 1 Drive Circuit PCV 1 current is 50 mA or Open or Short Circuited less, or difference between decreases, there is influence to exhaust gas, the supply to GND PCV 1 current and target current is 1000 mA or more pump can not be controlled, the engine may increase the rotation speed automatically and abnormally. P2296 PCV2 Drive Circuit + PCV2 current is 2400 mA or The output power Short Circuit B more, or difference between decreases, there is influence PCV2 current and target to exhaust gas. current is 1000 mA or more P2295 PCV2 Drive Circuit Open PCV2 current is 50 mA or The output power or Short Circuited to less, or difference between decreases, there is influence GND PCV2 current and target to exhaust gas, the supply current is 1000 mA or more pump can not be controlled, the engine may increase the rotation speed automatically and abnormally. P1294 Fuel Filter Restriction Voltage at the restriction Nothing special.  Sensor Circuit High sensor is more than 4.9 V Input P1293 Fuel Filter Restriction Voltage at the restriction Nothing special.  Sensor Circuit Low Input sensor is less than 0.1 V P0685 Abnormal Main Relay Voltage in the main relay The engine cannot start. Circuit (Inactivation) circuit is 1 V or less with the main relay coil output ON Even if the main relay coil Electrical power is kept P0687 Abnormal Main Relay  output is turned OFF, the supplying to the machine. Circuit (Kept closed) main relay is kept ON

T5-5-25

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SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code SPN-FMI 10001-2

Trouble DTC P0409

10001-13 P1404

10002-2

P0404

10003-2

P2146

10004-2

P2149

10005-2

P1261

10006-2

P1262

10007-2

P0606

10008-2

P060B

10009-2

P0697

10010-2

P1655

10013-2

P1621

10032-2

P0602

10033-2

P0604

Cause

Symptoms in Machine Operation Operating When Trouble Occurs Rank A B C D EGR Position Error The output signal of EGR The output power decreases. (Brushless Type) position sensor is stuck in  a low or high condition for 5 second or more. Abnormal EGR ZeroEGR opening amount The output power decreases. point calibration change is abnormal  during Zero-point calibration The output power decreases. Abnormal EGR Valve Difference between Control Circuit the target valve lift and  actual position is more than 20 % Abnormal Injector Abnormal charge voltage Vibration of the engine may be Common 1 Circuit circuit of injectors 1, 2, 3, large, rough idle, output power  or short circuit in injector decrease may occur, faulty solenoid control circuit of increasing of rotation speed may injectors 1, 2, 3. occur, the engine may be stalled Abnormal Injector Abnormal charge voltage Vibration of the engine may be Common 2 Circuit circuit of injectors 4, 5, 6, large, rough idle, output power  or short circuit in injector decrease may occur, faulty solenoid control circuit of increasing of rotation speed may injectors 4, 5, 6. occur, the engine may be stalled Abnormal Charge Voltage at bank 1 of Vibration of the engine may be Circuit (Bank 1) charge circuit in ECM is large, rough idle, output power  low decrease may occur, faulty increasing of rotation speed may occur, the engine may be stalled Abnormal Charge Voltage at bank 2 of Vibration of the engine may be Circuit (Bank 2) charge circuit in ECM is large, rough idle, output power  low decrease may occur, faulty increasing of rotation speed may occur, the engine may be stalled Abnormal CPU No change of RUN-SUB The output power decreases  Monitor IC pulse in 20 msec Abnormal A/D A/D conversion cannot Output power decrease, dark  Converter be done smoke occurs Abnormal 5V-Electric Voltage of 5 V power   Power Circuit #3 source circuit 3 or 7 is 5.5 V or more or 4.5 V or less Abnormal 5V-Electric Voltage of 5 V power   Power Circuit #4 source circuit 4 is 5.5 V or more or 4.5 V or less Abnormal EEPROM/ Abnormal EEPROM is   Abnormal HDEEPROM detected QR Code Error QR code and Q adjust Combustion sound may change  have not been written Abnormal RAM Abnormal RAM is The engine cannot start  detected

T5-5-26

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller (Monitor) Fault Code List Fault Code 13002-2

13003-2

13004-2

13005-2

13006-2

13007-2

20113-2

Trouble (Monitor Controller) Engine Controller Communication Error (Monitor Controller) Main Controller Communication Error 1 (Monitor Controller) Main Controller Communication Error 2 (Monitor Controller) ICF Communication Error 1 (Monitor Controller) ICF Communication Error 2 (Monitor Controller) Body Controller Communication Error System Failure Alarm

Cause Faulty monitor controller Faulty CAN0 harness

Remedy Check the CAN0 harness. Replace the monitor controller.

Faulty monitor controller Faulty CAN0 harness

Check the CAN0 harness. Replace the monitor controller.

Faulty monitor controller Faulty CAN1 harness

Check the CAN1 harness. Replace the monitor controller.

Faulty monitor controller Faulty CAN0 harness

Check the CAN0 harness. Replace the monitor controller.

Faulty monitor controller Faulty CAN1 harness

Check the CAN1 harness. Replace the monitor controller.

Faulty monitor controller Faulty CAN1 harness

Check the CAN1 harness. Replace the monitor controller.

Faulty CAN communication line.

Check the CAN harness.

T5-5-27

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller (Information) Fault Code List Fault Code 14001-2

14002-2

14003-2

14006-2

14008-2

14021-2

14022-2

14023-2

Trouble ICF: Flash Memory Read/Write Error

Cause The internal memory of monitor controller is abnormal

Remedy After initializing the monitor controller (information) by using MPDr., retry the troubleshooting. If the fault code is displayed after retry, the monitor controller may be broken. Replace the monitor controller. When initializing the monitor controller (information), all stored data is deleted. After initializing the monitor controller (information) by ICF: External RAM The internal Read/Write Error memory of monitor using MPDr., retry the troubleshooting. If the fault code is controller is displayed after retry, the monitor controller may be broken. abnormal Replace the monitor controller. When initializing the monitor controller (information), all stored data is deleted. Abnormal EEPROM The internal Retry the troubleshooting by using MPDr.. If the fault code memory of monitor is displayed after retry, the monitor controller may be controller is broken. Replace the monitor controller. abnormal Check the communication line, power line for ICF: Communication Communication error with communication terminal, and fuses. Then, retry the Terminal: Communication communication troubleshooting by using MPDr.. If the fault code is displayed after retry, the communication equipment may Error equipment be broken. Replace the communication equipment. Retry the troubleshooting by using MPDr.. If the fault code ICF: Abnormal The internal Internal RAM memory of monitor is displayed after retry, the monitor controller may be broken. Replace the monitor controller. controller is abnormal Communication Security failure Check the communication line. Check the GPS antenna. In Terminal Security of mobile case the communication equipment has been replaced, Error communication it may be considered faulty. After disable the checking equipment function for mobile phone number by security setting of MPDr., enable it again. Retry the troubleshooting by using MPDr.. If the fault code is displayed after retry, the communication equipment may be broken. Replace the communication equipment. SIM Card Error Abnormal SIM Retry the troubleshooting by using MPDr.. If the fault code card in mobile is displayed after retry, the communication equipment may communication be broken. Replace the communication equipment. equipment Security Error Communication Check the CAN1 harness. Retry the troubleshooting by error with MC using MPDr.. If the fault code is displayed after retry, MC may be broken. Replace MC.

T5-5-28

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Fault Code

Trouble

Cause

13303-2

Abnormal Thermistor Thermistor Temperature (Monitor temperature: 85 °C or Inside Temperature) more

13304-2

Abnormal REG Input H Level

Alternator generating The alternator alarm voltage: 33.5 V or more is displayed on the monitor.

13310-3

Coolant Temperature Sensor Short Circuit

50 Ω or less continues for 60 seconds

13311-3

Fuel Level Sensor High 1.14±1 Ω or less Input continues for 60 seconds

13311-4

Fuel Level Sensor Low 500±20 Ω or less Input continues for 60 seconds

T5-5-29

Symptoms in Machine Operation When Trouble Occurs The screen of the monitor becomes dark.

The coolant temperature gauge (pointer) on the monitor disappears. The logo becomes to red. The fuel gauge (pointer) on the monitor disappears. The logo becomes to red. The fuel gauge (pointer) on the monitor disappears. The logo becomes to red.

Remedy

Cool the monitor and so on until the temperature inside the monitor is less than 85 °C Replace monitor Check the wire harness Check the battery Check the alternator Check the wire harness Replace the coolant temperature sensor

Check the wire harness Replace the fuel sensor Check the wire harness Replace the fuel sensor

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Fault Code 20100-2

Trouble Overheat Alarm

20101-2

20103-2

Engine Warning Alarm Engine Oil Pressure Alarm Alternator Alarm

20104-2

Fuel Level Alarm

20106-2

Air Cleaner Restriction Alarm Water Separator Alarm Pilot Control ShutOff Lever Alarm

20102-2

20107-2 20109-2

20110-2 20114-2

20146-2 20149-2

Fuel Filter Restriction Alarm Overheat Alarm (Immediately after the key is turned ON) Fuel Temperature Increase Alarm EGR Gas Temperature Alarm

Cause Coolant temperature is high while the engine runs. Faulty engine system.

Remedy Check the wire harness. Replace the overheat switch. Refer to Engine Troubleshooting Manual.

Engine oil pressure decreases.

Check the wire harness. Replace the engine oil pressure sensor. Check the wire harness. Check the batteries. Check the alternator. Check the wire harness. Replace the fuel level sensor. Check the wire harness. Replace the air cleaner restriction switch. Check the wire harness. Replace the water separator alarm switch. Check the wire harness. Replace the pilot shut-off switch restriction switch. Check the wire harness. Replace the fuel filter. Check the wire harness. Replace the overheat switch.

Regulator voltage is high. During the engine stop state, the regulator voltage is high. Fuel level is low. Clogged air cleaner. The water separator is full. Faulty pilot shut-off switch.

Clogged fuel filter. Coolant temperature is high within ten seconds after the engine starts. Fuel temperature increases. EGR gas temperature increases.

T5-5-30

Check the wire harness. Replace the fuel temperature sensor. Check the wire harness. Replace the intake manifold temperature sensor.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Air Conditioner Controller Fault Code List Fault Code

Trouble

11

Open circuit in re-circulated air temperature sensor

12

Short circuit in re-circulated air temperature sensor

13

Open circuit in ambient temperature sensor

14

Short circuit in ambient temperature sensor

18

Short circuit in solar radiation sensor

21

Open circuit in frost sensor

22

Short circuit in frost sensor

43

Abnormal air vent damper servo motor

44

Abnormal air mix damper servo motor

51

Abnormal high/low refrigerant pressure

91

CAN communication error

92

CAN bus off error

Cause

Symptoms in Machine Operation When Trouble Occurs. Voltage: more than Operation is controlled 4.95 V under such circumstance as no re-circulated air temperature sensor is provided. Voltage: less than 0.3 V Operation is controlled under such circumstance as no re-circulated air temperature sensor is provided. Voltage: more than Operation is controlled 4.88 V under such circumstance as no ambient temperature sensor is provided. Voltage: less than Operation is controlled 0.096 V under such circumstance as no ambient temperature sensor is provided. Voltage: more than Operation is controlled 5.04 V under such circumstance as no solar radiation sensor is provided. Voltage: more than The compressor clutch 4.79 V is disengaged. (The compressor stops.) Voltage: less than The compressor clutch 0.096 V is disengaged. (The compressor stops.) Short circuit: Voltage: Air vent damper servo 0V motor becomes inoperable. Open circuit: Voltage: more than 5 V Short circuit: Voltage: Air mix damper servo motor less than 0.2 V becomes inoperable. Open circuit: Voltage: more than 4.8 V Voltage: 0 V The compressor clutch is disengaged. (The compressor stops.) Faulty CAN1 harness Air conditioner stops. between monitor controller and air conditioner controller. Faulty air conditioner Air conditioner stops. controller. Faulty CAN1 harness.

T5-5-31

Remedy

Check the wire harness. Replace the re-circulated air temperature sensor.

Check the wire harness. Replace the re-circulated air temperature sensor.

Check the wire harness. Replace the ambient temperature sensor. Check the wire harness. Replace the ambient temperature sensor. Check the wire harness. Replace the solar radiation sensor. Check the wire harness. Replace the frost sensor. Check the wire harness. Replace the frost sensor. Check the wire harness. Replace the air vent damper servo motor. Check the wire harness. Replace the air mix damper servo motor. Check the wire harness. Replace the high/low pressure switch. Check the CAN1 harness. Replace the air conditioner controller. Check the CAN1 harness. Replace the air conditioner controller.

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Communication Terminal Fault Code List Fault Code 14100-2

Trouble Communication Terminal: Abnormal EEPROM

14101-2

Communication Terminal: Abnormal IB/OB Queue

14102-2

Communication Terminal: Abnormal Local Loop Back Communication Terminal: No Satellite Found Communication Terminal: Remote Loop Back Error 1

14103-2 14104-2

14105-2

Communication Terminal: Remote Loop Back Error 2

14106-2

Communication Terminal: Transmission/Receiving Data Unmatched Communication Terminal: Abnormal GSM Module

14107-2

Cause The internal memory of satellite communication terminal (optional) is abnormal. The internal memory of satellite communication terminal (optional) is abnormal. The results of communication test with the satellite is abnormal. Satellite can not be caught.

Remedy Replace the controller (satellite communication terminal). Replace the controller (satellite communication terminal).

Check the communication antenna for satellite. Check the communication antenna for satellite. The results of communication test Replace the controller (satellite with the satellite and base station communication terminal). are abnormal. The results of communication test Replace the controller (satellite with the satellite and base station communication terminal). are abnormal. Transmission/receiving data with Replace the controller (satellite the satellite is unmatched. communication terminal). Abnormal mobile communication Replace the controller (mobile equipment. communication terminal).

fNOTE:

Fault codes 14100-2 to 14106-2 are for satellite communication terminal. Fault code 14107-2 is for mobile communication terminal.

T5-5-32

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 11000 to 11002 Fault Code 11000-2 11001-2 11002-2

Trouble Abnormal EEPROM Abnormal RAM Abnormal A/D Converter

Cause Faulty MC. Faulty MC. Faulty MC.

fNOTE:

When the engine and the machine is operated normally with the fault code displayed after retrial, the machine can be operated as it is.

T5-5-33

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 11003 IMPORTANT: When fault code 11003-3 (Abnormal Sensor Voltage) is displayed with other fault code, diagnose on fault code 11003-3 first.

Fault Code 11003-3

Trouble Abnormal Sensor Voltage

Inspection Method Disconnect connectors from all sensors and switch panel Retry the troubleshooting by using MPDr. Measure voltage between sensor harness end #1 and body. Check short circuit in wire harness between sensor harness end #1 and #3. -

Evaluation Fault code 11003-3 is not displayed

Cause Faulty sensor

0V

Open circuit in wire harness #1

0Ω

Short circuit in wire harness #1 and #3

Normal in above check

Faulty MC

1

2 3 4 5 6 7 8 9 10 11 12

18 17

16 15 13

1- 2- 3- 4- 5- 6-

MC Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Pressure Sensor (Arm Roll-In) Pressure Sensor (Arm Roll-Out) Pressure Sensor (Bucket Roll-In)

7-

Pressure Sensor (Bucket RollOut) 8- Pressure Sensor (Swing) 9- Pressure Sensor (Travel) 10- Pressure Sensor (4-Spool Side) 11- Pressure Sensor (5-Spool Side)

12- Pressure Sensor (Attachment) (Option) 13- Bottom Pressure Sensor (Option) 15- Pump 1 Delivery Pressure Sensor

T5-5-34

TJBG-05-05-001

16- Pump 1 Control Pressure Sensor 17- Pump 2 Delivery Pressure Sensor 14- Pump 2 Control Pressure Sensor

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Connector (Wire harness end of connector viewed from the open end side)  Pressure Sensor (Boom Raise)  Pressure Sensor (Boom Lower)  Pressure Sensor (Arm Roll-In)  Pressure Sensor (Arm Roll-Out)  Pressure Sensor (Bucket Roll-In)  Pressure Sensor (Bucket Roll-Out)  Pressure Sensor (Swing)  Pressure Sensor (Travel)  Pressure Sensor (4-Spool Side)  Pressure Sensor (5-Spool Side)  Pressure Sensor (Attachment) (Option)  Pump 1 Control Pressure Sensor  Pump 2 Control Pressure Sensor

TJBG-05-05-011

 Pump 1 Delivery Pressure Sensor  Pump 2 Delivery Pressure Sensor  Boom Bottom Pressure Sensor (Option)

TJBG-05-05-010

 Switch Panel (Engine Control Dial)

TJBG-05-05-016

T5-5-35

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A (Blank)

T5-5-36

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 11006, 11007,11009 Monitor Controller (Monitor) Fault Codes 13002, 13003, 13005 Preparation  Check the wiring connections first.  Check the CAN0 harness between the controllers. (Refer to CAN0 Harness Check.) Fault Code 11006-2

11007-2

11009-2

13002-2

13003-2

13005-2

fNOTE:

Trouble (MC) EC Communication Error

Inspection Method Continuity check (open circuit)

(MC) IC Communication Error 1

Continuity check (open circuit)

(MC) Monitor Controller Communication Error 1 (Monitor Controller) Engine Controller Communication Error (Monitor Controller) Main Controller Communication Error 1 (Monitor Controller) ICF Communication Error 1

Discontinuity check

Discontinuity check Continuity check (open circuit) Discontinuity check Continuity check (open circuit) Discontinuity check Continuity check (open circuit) Discontinuity check Continuity check (open circuit) Discontinuity check

Cause Open circuit in wire harness. Short circuit in wire harness. Open circuit in wire harness. Short circuit in wire harness. Open circuit in wire harness. Short circuit in wire harness. Open circuit in wire harness. Short circuit in wire harness. Open circuit in wire harness. Short circuit in wire harness. Open circuit in wire harness. Short circuit in wire harness.

IC and ICF are the Information Control Unit of Monitor Controller.

T5-5-37

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A CAN0 Harness Check Preparation  Before continuity check, set the key switch to the OFF position. Evaluation Continuity check (open circuit) Discontinuity check (short circuit) Inspection Continuity check between MC and each controller Discontinuity check between CAN circuit and ground circuit in each controller

Continuity (0 Ω) Correct Incorrect (short circuit)

Discontinuity (∞ Ω) Incorrect (open circuit) Correct

CAN Harness High side Low side

MC #D2 #D3

ECM #154 #132

Monitor Controller #A24 #A23

High side

#D2-#E1 #D2-#E2 #D2-#F4 #D2-#F5 #D2-#F6 #D3-#E1 #D3-#E2 #D3-#F4 #D3-#F5 #D3-#F6 -

#154-#61 #154-#62 #154-#63 #154-#64 #154-#65 #154-#66 #154-#97 #154-#119 #154-#137 #132-#61 #132-#62 #132-#63 #132-#64 #132-#65 #132-#66 #132-#97 #132-#119 #132-#137

#A24-#A22 #A24-#B35 #A24-#B36 #A23-#A22 #A23-#B35 #A23-#B36 -

Low side

T5-5-38

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Inspection Discontinuity check between CAN circuit and power circuit in each controller

CAN Harness High side

Low side

High side Discontinuity check between CAN circuit and Low side key signal circuit in each controller Discontinuity check between CAN (High side) circuit and CAN (Low side) circuit in each controller

MC #D2-#E5 #D2-#E6 #D2-#F1 #D2-#F2 #D2-#F3 #D3-#E5 #D3-#E6 #D3-#F1 #D3-#F2 #D3-#F3 #D2-#E4

ECM #154-#67 #154-#89 #154-#111 #154-#133 #132-#67 #132-#89 #132-#111 #132-#133 #154-#134

Monitor Controller #A24-#B17 #A24-#B18 #A23-#B17 #A23-#B18 #A24-#A16

#D3-#E4

#132-#134

#A23-#A16

#D2-#D3

#154-#132

#A24-#A23

T5-5-39

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Connector (Wire harness end)  MC-D Connector

 Monitor Controller-A Connector

TDAB-05-06-011

TJBG-05-05-005

 MC-E Connector

 Monitor Controller-B Connector

TJBG-05-05-006

 MC-F Connector

TJBG-05-05-007

 ECM-2 Connector

TJBG-05-05-021

T5-5-40

TJBG-05-05-012

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 11008, 11010 Monitor Controller (Monitor) Fault Codes 13004, 13006, 13007 Preparation  Check the wiring connections first.  Check the CAN1 harness between the controllers. (Refer to CAN1 Harness Check.)

Fault Code 11008-2

11010-2

13004-2

13006-2

13007-2

fNOTE:

Trouble (MC) IC Communication Error 2

Inspection Method Continuity check (open circuit)

(MC) Monitor Controller Communication Error 2 (Monitor Controller) Main Controller Communication Error 2 (Monitor Controller) ICF Communication Error 2

Continuity check (open circuit)

Discontinuity check

Discontinuity check Continuity check (open circuit) Discontinuity check Continuity check (open circuit) Discontinuity check

(Monitor Controller) Continuity check (open circuit) Body Controller Communication Discontinuity check Error

Cause Open circuit in wire harness. Short circuit in wire harness. Open circuit in wire harness. Short circuit in wire harness. Open circuit in wire harness. Short circuit in wire harness. Open circuit in wire harness. Short circuit in wire harness. Open circuit in wire harness. Short circuit in wire harness.

IC and ICF are the Information Control Unit of Monitor Controller.

T5-5-41

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A CAN1 Harness Check Preparation  Before continuity check, set the key switch to the OFF position. Evaluation Continuity check (open circuit) Discontinuity check (shorted circuit) Inspection

Continuity (0 Ω) Correct

Discontinuity (∞ Ω) Incorrect (open circuit) Correct

Incorrect (short circuit) CAN Harness

Continuity check High side between MC and Low side each controller Discontinuity check High side between CAN circuit and ground circuit in each controller

Low side

MC

Monitor Controller

Radio

A/C

#A26 #A25

Wiper/ Light Controller #B1 #B11

#D4 #D5

#4 #12

#9(A/C2) #10(A/C2)

#D4-#E1 #D4-#E2 #D4-#F4 #D4-#F5 #D4-#F6 #D5-#E1 #D5-#E2 #D5-#F4 #D5-#F5 #D5-#F6

#A26-#A22 #A26-#B35 #A26-#B36 #A25-#A22 #A25-#B35 #A25-#B36 -

#B1-#A8 #B11-#A8 -

#4-#15 #12-#15 -

#9(A/C2)-#1(A/C1) #10(A/C2)-#1(A/C1) -

T5-5-42

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A

Inspection

CAN Harness

Discontinuity check High side between CAN circuit and power circuit in each controller

Low side

Discontinuity High side check between CAN circuit and key Low side signal circuit in each controller Discontinuity check between CAN (High side) circuit and CAN (Low side) circuit in each controller

MC

Monitor Controller

Radio

A/C

#A26-#B17 #A26-#B18 #A25-#B17 #A25-#B18 #A26-#A16

Wiper/ Light Controller #B1-#A4 #B11-#A4 #B1-#B19

#D4-#E5 #D4-#E6 #D4-#F1 #D4-#F2 #D4-#F3 #D5-#E5 #D5-#E6 #D5-#F1 #D5-#F2 #D5-#F3 #D4-#E4

#4-#8 #12-#8 #4-#16

#9(A/C2)-#2(A/C1) #9(A/C2)-#3(A/C1) #10(A/C2)-#2(A/C1) #10(A/C2)-#3(A/C1) #9(A/C2)-#4(A/C1)

#D5-#E4

#A25-#A16

#B11-#B19

#12-#16

#10(A/C2)-#4(A/C1)

#D4-#D5

#A26-#A25

#B1-#B11

#4-#12

#9(A/C2)-#10(A/C2)

T5-5-43

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Connector (Wire harness end)  MC-D Connector

 Wiper/ Light Controller-A Connector

TDAB-05-06-018 TJBG-05-05-005

 MC-E Connector

 Wiper/ Light Controller-B Connector

TDAB-05-06-019 TJBG-05-05-006

 MC-F Connector

 Radio Connector

TDAB-05-06-010 TJBG-05-05-007

 Monitor Controller-A Connector

 A/C1 Connector

TDAB-05-06-011

 Monitor Controller-B Connector

TDAB-05-06-008

 A/C2 Connector

TJBG-05-05-012

T5-5-44

TDAB-05-06-009

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 11100 Preparation  Check the wiring connections first.  The actual engine speed which ECM sends by using the CAN bus line is abnormal. Diagnose ECM. Fault Code 11100-2

Trouble Abnormal Engine Speed

Cause Engine speed: 4000 min-1 or more

T5-5-45

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 11101 Preparation  Check the wiring connections first. Fault Code 11101-3

11101-4

Trouble Engine Control Dial Sensor Circuit High Input

Inspection Method Measure resistance between switch panel end #4 and #5. -

Engine Control Dial Measure resistance Sensor Circuit Low Input between switch panel end #4 and #5. Measure voltage between switch panel harness end #4 and body. Measure voltage between switch panel harness end #4 and #6. -

Connector (Wire harness end of connector viewed from the open end side). Switch Panel (Engine control dial)

TJBG-05-05-016

T5-5-46

Evaluation 0Ω

Cause Faulty engine control dial

Normal in above check ∞Ω

Short circuit in wire harness #4 and #5 Faulty engine control dial

0V

Open circuit in wire harness #4

0V

Open circuit in wire harness #6

Normal in above check

Open circuit in wire harness #5

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 11200, 11202 Preparation  Check the wiring connections first.  Connect the test harness (ST 6701) and dummy sensor equivalent to #4703324.  Before inspection, set the key switch to the ON position. Fault Code 11200-3

11200-4

11202-3

11202-4

Trouble Pump 1 Delivery Pressure Sensor Circuit High Input Pump 1 Delivery Pressure Sensor Circuit Low Input

Pump 2 Delivery Pressure Sensor Circuit High Input Pump 2 Delivery Pressure Sensor Circuit Low Input

Inspection Method Retry by using MPDr.. Measure voltage between B and body. Retry by using MPDr.. Measure voltage between A and body. Measure voltage between A and C (GND). Retry by using MPDr.. Measure voltage between B and body. Retry by using MPDr.. Measure voltage between A and body. Measure voltage between A and C (GND). -

C

B

Evaluation Un-displayed fault code Voltage: more than 4.5 V Un-displayed fault code 0V 0V Normal in above check Un-displayed fault code Voltage: more than 4.5 V Un-displayed fault code 0V 0V Normal in above check

Cause Faulty sensor Short circuit in wire harness #1 and #2 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2 Faulty sensor Short circuit in wire harness #1 and #2 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2

A

TDAA-05-06-003

T5-5-47

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 11301, 11302 Preparation  Check the wiring connections first.  Connect the test harness (ST 6703) and dummy sensor equivalent to #4436535.  Before inspection, set the key switch to the ON position. Fault Code 11301-3

11301-4

Trouble Swing Pilot Pressure Sensor Circuit High Input Swing Pilot Pressure Sensor Circuit Low Input

Inspection Method Retry by using MPDr.. Measure voltage between B and body. Retry by using MPDr.. Measure voltage between A and body. Measure voltage between A and C (GND). -

11302-3

11302-4

Boom Raise Pilot Pressure Sensor Circuit High Input Boom Raise Pilot Pressure Sensor Circuit Low Input

Retry by using MPDr.. Measure voltage between B and body. Retry by using MPDr.. Measure voltage between A and body. Measure voltage between A and C (GND). -

C

B

Evaluation Un-displayed fault code Voltage: more than 4.5 V Un-displayed fault code 0V 0V Normal in above check Un-displayed fault code Voltage: more than 4.5 V Un-displayed fault code 0V 0V Normal in above check

Cause Faulty sensor Short circuit in wire harness #1 and #2 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2 Faulty sensor Short circuit in wire harness #1 and #2 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2

A

TDAA-05-06-003

T5-5-48

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 11303 Preparation  Check the wiring connections first.  Connect the test harness (ST 6703) and dummy sensor equivalent to #4436535.  Before inspection, set the key switch to the ON position. Fault Code 11303-3

11303-4

Trouble Arm Roll-In Pilot Pressure Sensor Circuit High Input Arm Roll-In Pilot Pressure Sensor Circuit Low Input

Inspection Method Retry by using MPDr.. Measure voltage between B and body. Retry by using MPDr.. Measure voltage between A and body. Measure voltage between A and C (GND). -

C

B

Evaluation Un-displayed fault code Voltage: more than 4.5 V Un-displayed fault code 0V 0V Normal in above check

Cause Faulty sensor Short circuit in wire harness #1 and #2 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2

A

TDAA-05-06-003

T5-5-49

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 11304, 11325 Preparation  Check the wiring connections first.  Connect the test harness (ST 6703) and dummy sensor equivalent to #4436535.  Before inspection, set the key switch to the ON position. Fault Code 11304-3

11304-4

Trouble Travel Pilot Pressure Sensor Circuit High Input Travel Pilot Pressure Sensor Circuit Low Input

Inspection Method Retry by using MPDr.. Measure voltage between B and body. Retry by using MPDr.. Measure voltage between A and body. Measure voltage between A and C (GND). -

11325-3

11325-4

Bucket Roll-In Pilot Pressure Sensor Circuit High Input Bucket Roll-In Pilot Pressure Sensor Circuit Low Input

Retry by using MPDr.. Measure voltage between B and body. Retry by using MPDr.. Measure voltage between A and body. Measure voltage between A and C (GND). -

C

B

Evaluation Un-displayed fault code Voltage: more than 4.5 V Un-displayed fault code 0V 0V Normal in above check Un-displayed fault code Voltage: more than 4.5 V Un-displayed fault code 0V 0V Normal in above check

Cause Faulty sensor Short circuit in wire harness #1 and #2 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2 Faulty sensor Short circuit in wire harness #1 and #2 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2

A

TDAA-05-06-003

T5-5-50

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 11405 Preparation  Check the wiring connections first. Fault Code 11405-3

11405-4

Trouble Travel Swash Angle P/S Valve FB High Current (4-spool solenoid valve unit (SC))

Inspection Method Measure resistance between solenoid valve #1 and #2. -

Travel Swash Angle P/S Valve FB Low Current (4-spool solenoid valve unit (SC))

Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Travel Mode C/V Output FB.

Connector (Wire harness end)  Solenoid Valve Connector

TJBG-05-05-003

T5-5-51

Evaluation 0Ω (Specification: 22 Ω) Normal in above check. ∞Ω (Specification: 22 Ω) 0V

Cause Faulty solenoid valve

0 mA

Open circuit in wire harness #2

Short circuit in wire harness #1 and #2 Faulty solenoid valve

Open circuit in wire harness #1

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 11408 Preparation  Check the wiring connections first. Fault Code 11408-3

11408-4

Trouble Center Bypass Cut P/S Valve FB High Current

Center Bypass Cut P/S Valve FB Low Current

Inspection Method Measure resistance between solenoid valve #1 and #2. Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Muf/Filtr Regen P/S O/P FB.

fNOTE:

The fault codes 11408-3 and 11408-4 are displayed on MPDr. as follows.



11408-3: Muffler Filter Regenerative (Center Bypass Cut) P/S Valve FB High Current.



11408-4: Muffler Filter Regenerative (Center Bypass Cut) P/S Valve FB Low Current. Connector (Wire harness end)  Solenoid Valve Connector

TJBG-05-05-003

T5-5-52

Evaluation 0Ω (Specification: 22 Ω) Normal in above check. ∞Ω (Specification: 22 Ω) 0V

0 mA

Cause Faulty solenoid valve

Short circuit in wire harness #1 and #2 Faulty solenoid valve

Open circuit in wire harness #1 Open circuit in wire harness #2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 11412 Preparation  Check the wiring connections first. Fault Code 11412-3

11412-4

Trouble Hyd. Fan P/S Valve FB High Current

Hyd. Fan P/S Valve FB Low Current

Inspection Method Measure resistance between solenoid valve #1 and #2. Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Hyd Fan Rot P/S O/P FB.

Connector (Wire harness end)  Solenoid Valve Connector

TJBG-05-05-003

T5-5-53

Evaluation 0Ω (Specification: 22 Ω) Normal in above check. ∞Ω (Specification: 22 Ω) 0V

0 mA

Cause Faulty solenoid valve

Short circuit in wire harness #1 and #2 Faulty solenoid valve

Open circuit in wire harness #1 Open circuit in wire harness #2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 11428 Preparation  Check the wiring connections first. Fault Code 11428-3

11428-4

Trouble Arm 2 Flow Rate Control P/S Valve FB High Current

Inspection Method Measure resistance between solenoid valve #1 and #2. -

Evaluation 0Ω (Specification: 22 Ω) Normal in above check. ∞Ω (Specification: 22 Ω) 0V

Arm 2 Flow Rate Control Measure resistance P/S Valve FB Low Current between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Arm 2 Flw Cont P/S 0 mA O/P FB.

Connector (Wire harness end)  Solenoid Valve Connector

TJBG-05-05-003

T5-5-54

Cause Faulty solenoid valve

Short circuit in wire harness #1 and #2 Faulty solenoid valve

Open circuit in wire harness #1 Open circuit in wire harness #2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 11802 Preparation  Check the wiring connections first.  Connect the test harness (ST 6701) and dummy sensor equivalent to #4703324.  Before inspection, set the key switch to the ON position. Fault Code 11802-3

11802-4

Trouble Boom Bottom Pressure Sensor Circuit High Input (Option)

Inspection Method Retry by using MPDr.. Measure voltage between B and body. Retry by using MPDr..

Boom Bottom Pressure Sensor Circuit Low Input (Option) Measure voltage between A and body. Measure voltage between A and C (GND). -

C

B

Evaluation Un-displayed fault code Voltage: more than 4.5 V Un-displayed fault code 0V 0V Normal in above check

Cause Faulty sensor Short circuit in wire harness #1 and #2 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2

A

TDAA-05-06-003

T5-5-55

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 11901 Preparation  Check the wiring connections first. Fault Code 11901-3

11901-4

Trouble Hyd. Oil Temp Sensor Circuit High Input

Hyd. Oil Temp Sensor Circuit Low Input

Inspection Method Measure resistance between sensor #1 and #2. Measure resistance between sensor #1 and #2. Measure voltage between sensor harness end #1 and body. -

fNOTE:

Specification of Hydraulic Oil Temperature Sensor. ( ) is a reference value.

Hydraulic Oil Temperature (°C) -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120

Resistance (kΩ) (24.5) 15.04+1.29-1.20 (9.16) (5.74) (3.70) 2.45+0.14-0.13 (1.66) (1.15) (0.811) (0.584) (0.428) 0.318±0.008 (0.240) (0.1836) 0.1417±0.0018 (0.1108)

Connector (Wire harness end)  Hydraulic Oil Temperature Sensor

TDAB-05-06-023

T5-5-56

Evaluation 0Ω

Cause Faulty sensor

Normal in above check ∞Ω

Short circuit in wire harness #1 Faulty sensor

0V

Open circuit in wire harness #1

Normal in above check

Open circuit in wire harness #2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 11942, 11944 Preparation  Check the wiring connections first.  Connect the test harness (ST 6703) and dummy sensor equivalent to #4436535.  Before inspection, set the key switch to the ON position. Fault Code 11942-3

11942-4

11944-3

11944-4

Trouble Attachment Pilot Pressure Sensor Circuit High Input (Option) Attachment Pilot Pressure Sensor Circuit Low Input (Option)

Signal Control Valve SB-port Pressure Sensor Circuit High Input (5-spool side pilot pressure sensor) Signal Control Valve SB-port Pressure Sensor Circuit Low Input (5-spool side pilot pressure sensor)

Inspection Method Retry by using MPDr.. Measure voltage between B and body. Retry by using MPDr.. Measure voltage between A and body. Measure voltage between A and C (GND). Retry by using MPDr.. Measure voltage between B and body. Retry by using MPDr.. Measure voltage between A and body. Measure voltage between A and C (GND). -

C

B

Evaluation Un-displayed fault code Voltage: more than 4.75 V Un-displayed fault code 0V 0V

Cause Faulty sensor Short circuit in wire harness #1 and #2 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2 Faulty sensor

Normal in above check Un-displayed fault code Voltage: more than Short circuit in wire 4.75 V harness #1 and #2 Un-displayed fault code 0V 0V Normal in above check

Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2

A

TDAA-05-06-003

T5-5-57

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 11945 Preparation  Check the wiring connections first.  Connect the test harness (ST 6703) and dummy sensor equivalent to #4436535.  Before inspection, set the key switch to the ON position. Fault Code 11945-3

11945-4

Trouble Signal Control Valve SA-Port Pressure Sensor Circuit High Input (4-spool side pressure sensor) Signal Control Valve SA-Port Pressure Sensor Circuit Low Input (4-spool side pressure sensor)

Inspection Method Retry by using MPDr.. Measure voltage between B and body. Retry by using MPDr.. Measure voltage between A and body. Measure voltage between A and C (GND). -

C

B

Evaluation Un-displayed fault code Voltage: more than 4.5 V

Cause Faulty sensor

Un-displayed fault code 0V

Faulty sensor

0V Normal in above check

Short circuit in wire harness #1 and #2

Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2

A

TDAA-05-06-003

T5-5-58

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 11948 Preparation  Check the wiring connections first. Fault Code 11948-3

11948-4

Trouble Main Relief Pressure Control P/S Valve FB High Current (4-spool solenoid valve unit (SI))

Inspection Method Measure resistance between solenoid valve #1 and #2. -

Main Relief Pressure Control P/S Valve FB Low Current (4-spool solenoid valve unit (SI))

Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Pressure Boost P/S Output FB.

Connector (Wire harness end)  Solenoid Valve Connector

TJBG-05-05-003

T5-5-59

Evaluation 0Ω (Specification: 22 Ω) Normal in above check ∞Ω (Specification: 22 Ω) 0V

0 mA

Cause Faulty solenoid valve

Short circuit in wire harness #1 and #2 Faulty solenoid valve

Open circuit in wire harness #1 Open circuit in wire harness #2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 11950 Preparation  Check the wiring connections first. Fault Code 11950-3

11950-4

Trouble Pump 2 P/S Valve FB High Current

Pump 2 P/S Valve FB Low Current

Inspection Method Measure resistance between solenoid valve #1 and #2. Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Pump 2 (5 units) P/S O/P FB.

Connector (Wire harness end)  Solenoid Valve Connector

TJBG-05-05-003

T5-5-60

Evaluation 0Ω (Specification: 22 Ω) Normal in above check ∞Ω (Specification: 22 Ω) 0V

0 mA

Cause Faulty solenoid valve

Short circuit in wire harness #1 and #2 Faulty solenoid valve

Open circuit in wire harness #1 Open circuit in wire harness #2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 11951 Preparation  Check the wiring connections first. Fault Code 11951-3

11951-4

Trouble Pump 1 P/S Valve FB High Current

Pump 1 P/S Valve FB Low Current

Inspection Method Measure resistance between solenoid valve #1 and #2. Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Pump 1 (4 Units) P/S O/P FB.

Connector (Wire harness end)  Solenoid Valve Connector

TJBG-05-05-003

T5-5-61

Evaluation 0Ω (Specification: 22 Ω) Normal in above check ∞Ω (Specification: 22 Ω) 0V

0 mA

Cause Faulty solenoid valve

Short circuit in wire harness #1 and #2 Faulty solenoid valve

Open circuit in wire harness #1 Open circuit in wire harness #2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 11953 Preparation  Check the wiring connections first. Fault Code 11953-3

11953-4

Trouble Swing Flow Rate Control P/S Valve FB High Current (2-spool solenoid valve unit (SI))

Inspection Method Measure resistance between solenoid valve #1 and #2. -

Swing Flow Rate Control P/S Valve FB Low Current (2-spool solenoid valve unit (SI))

Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Swing Flw Cont P/S O/P FB.

Connector (Wire harness end)  Solenoid Valve Connector

TJBG-05-05-003

T5-5-62

Evaluation 0Ω (Specification: 22 Ω) Normal in above check ∞Ω (Specification: 22 Ω) 0V

0 mA

Cause Faulty solenoid valve

Short circuit in wire harness #1 and #2 Faulty solenoid valve

Open circuit in wire harness #1 Open circuit in wire harness #2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 11978, 11979 Preparation  Check the wiring connections first.  Connect the test harness (ST 6701) and dummy sensor equivalent to #4436271.  Before inspection, set the key switch to the ON position. Fault Code 11978-3

11978-4

11979-3

11979-4

Trouble Inspection Method Auxiliary 2 Pilot Pressure Retry by using MPDr.. Sensor Circuit High Input (Option) Measure voltage between B and body. Auxiliary 2 Pilot Pressure Retry by using MPDr.. Sensor Circuit Low Input (Option) Measure voltage between A and body. Measure voltage between A and C (GND). Auxiliary 1 Pilot Pressure Retry by using MPDr.. Sensor Circuit High Input (Option) Measure voltage between B and body. Auxiliary 1 Pilot Pressure Retry by using MPDr.. Sensor Circuit Low Input (Option) Measure voltage between A and body. Measure voltage between A and C (GND). -

C

B

Evaluation Un-displayed fault code Voltage: more than 4.5 V Un-displayed fault code 0V 0V Normal in above check Un-displayed fault code Voltage: more than 4.5 V Un-displayed fault code 0V 0V Normal in above check

Cause Faulty sensor Short circuit in wire harness #1 and #2 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2 Faulty sensor Short circuit in wire harness #1 and #2 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2

A

TDAA-05-06-003

T5-5-63

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 11981 Preparation  Check the wiring connections first. Fault Code 11981-3

11981-4

Trouble Inspection Method Fan Reverse Rotation P/S Measure resistance Valve 2 FB High Current between solenoid valve #1 and #2. Fan Reverse Rotation P/S Measure resistance Valve 2 FB Low Current between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Fan Dir Cont P/S 2 O/P FB.

Connector (Wire harness end)  Solenoid Valve Connector

TJBG-05-05-003

T5-5-64

Evaluation 0Ω (Specification: 22 Ω) Normal in above check ∞Ω (Specification: 22 Ω) 0V

0 mA

Cause Faulty solenoid valve

Short circuit in wire harness #1 and #2 Faulty solenoid valve

Open circuit in wire harness #1 Open circuit in wire harness #2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 11982 Preparation  Check the wiring connections first. Fault Code 11982-3

11982-4

Trouble Inspection Method Fan Reverse Rotation P/S Measure resistance Valve 1 FB High Current between solenoid valve #1 and #2. Fan Reverse Rotation P/S Measure resistance Valve 1 FB Low Current between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Fan Dir Cont P/S 2 O/P FB.

Connector (Wire harness end)  Solenoid Valve Connector

TJBG-05-05-003

T5-5-65

Evaluation 0Ω (Specification: 22 Ω) Normal in above check ∞Ω (Specification: 22 Ω) 0V

0 mA

Cause Faulty solenoid valve

Short circuit in wire harness #1 and #2 Faulty solenoid valve

Open circuit in wire harness #1 Open circuit in wire harness #2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 11985, 11986 Preparation  Check the wiring connections first. Fault Code 11985-2

11986-2

Trouble Pump 2 Regulator Pressure Calibration Abort

Pump 1 Regulator Pressure Calibration Abort

Inspection Method Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Pump 2 (5 units) P/S O/P FB. Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Pump 1 (4 Units) P/S O/P FB. -

Connector (Wire harness end)  Solenoid Valve Connector

TJBG-05-05-003

T5-5-66

Evaluation 0/∞ Ω (Specification: 22 Ω) 0V

Cause Faulty solenoid valve

0 mA

Open circuit in wire harness #2 Short circuit in wire harness #1 and #2 Faulty solenoid valve

Normal in above check. 0/∞ Ω (Specification: 22 Ω) 0V

0 mA Normal in above check.

Open circuit in wire harness #1

Open circuit in wire harness #1 Open circuit in wire harness #2 Short circuit in wire harness #1 and #2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 11989 Preparation  Check the wiring connections first. Fault Code 11989-3

11989-4

Trouble Boom Mode Control P/S Valve FB High Current (2-spool solenoid valve unit (SC))

Inspection Method Measure resistance between solenoid valve #1 and #2. -

Boom Mode Control P/S Valve FB Low Current (2-spool solenoid valve unit (SC))

Measure resistance between solenoid valve #1 and #2. Measure voltage between solenoid valve harness end #1 and body. Monitor Bm Mode Cont P/S 0 mA O/P FB.

Connector (Wire harness end)  Solenoid Valve Connector

TJBG-05-05-003

T5-5-67

Evaluation 0Ω (Specification: 22 Ω) Normal in above check ∞Ω (Specification: 22 Ω) 0V

Cause Faulty solenoid valve

Short circuit in wire harness #1 and #2 Faulty solenoid valve

Open circuit in wire harness #1 Open circuit in wire harness #2

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 11992, 11994 Preparation  Check the wiring connections first.  Connect the test harness (ST 6703) and dummy sensor equivalent to #4436535.  Before inspection, set the key switch to the ON position. Fault Code 11992-3

11992-4

11994-3

11994-4

Trouble Pump 2 Reg-Pressure Sensor Circuit High Input (Pump 2 control pressure sensor) Pump 2 Reg-Pressure Sensor Circuit Low Input (Pump 2 control pressure sensor)

Pump 1 Reg-Pressure Sensor Circuit High Input (Pump 1 control pressure sensor) Pump 1 Reg-Pressure Sensor Circuit Low Input (Pump 1 control pressure sensor)

Inspection Method Retry by using MPDr.. Measure voltage between B and body. Retry by using MPDr.. Measure voltage between A and body. Measure voltage between A and C (GND). Retry by using MPDr.. Measure voltage between B and body. Retry by using MPDr.. Measure voltage between A and body. Measure voltage between A and C (GND). -

C

B

Evaluation Un-displayed fault code Voltage: more than 4.5 V Un-displayed fault code 0V 0V Normal in above check Un-displayed fault code Voltage: more than 4.5 V Un-displayed fault code 0V 0V Normal in above check

Cause Faulty sensor Short circuit in wire harness #1 and #2 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2 Faulty sensor Short circuit in wire harness #1 and #2 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2

A

TDAA-05-06-003

T5-5-68

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 11995, 11997 Preparation  Check the wiring connections first.  Connect the test harness (ST 6703) and dummy sensor equivalent to #4436535.  Before inspection, set the key switch to the ON position. Fault Code 11995-3

11995-4

11997-3

11997-4

Trouble Arm Roll-Out Pilot Pressure Sensor Circuit High Input Arm Roll-Out Pilot Pressure Sensor Circuit Low Input

Bucket Roll-Out Pilot Pressure Sensor Circuit High Input Bucket Roll-Out Pilot Pressure Sensor Circuit Low Input

Inspection Method Retry by using MPDr.. Measure voltage between B and body. Retry by using MPDr.. Measure voltage between A and body. Measure voltage between A and C (GND). Retry by using MPDr.. Measure voltage between B and body. Retry by using MPDr.. Measure voltage between A and body. Measure voltage between A and C (GND). -

C

B

Evaluation Un-displayed fault code Voltage: more than 4.5 V Un-displayed fault code 0V 0V Normal in above check Un-displayed fault code Voltage: more than 4.5 V Un-displayed fault code 0V 0V Normal in above check

Cause Faulty sensor Short circuit in wire harness #1 and #2 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2 Faulty sensor Short circuit in wire harness #1 and #2 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2

A

TDAA-05-06-003

T5-5-69

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Code 11998 Preparation  Check the wiring connections first.  Connect the test harness (ST 6703) and dummy sensor equivalent to #4436535.  Before inspection, set the key switch to the ON position. Fault Code 11998-3

11998-4

Trouble Boom Lowering Pilot Pressure Sensor Circuit High Input Boom Lowering Pilot Pressure Sensor Circuit Low Input

Inspection Method Retry by using MPDr.. Measure voltage between B and body. Retry by using MPDr.. Measure voltage between A and body. Measure voltage between A and C (GND). -

C

B

Evaluation Un-displayed fault code Voltage: more than 4.5 V Un-displayed fault code 0V 0V Normal in above check.

Cause Faulty sensor Short circuit in wire harness #1 and #2 Faulty sensor Open circuit in wire harness #1 Open circuit in wire harness #3 Open circuit in wire harness #2

A

TDAA-05-06-003

T5-5-70

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A MC Fault Codes 20062 Fault Code 20062-0

Trouble Hydraulic Oil Overheat Alarm

Inspection Method Perform troubleshooting from other fault code.

T5-5-71

Evaluation -

Cause -

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller (Information) Fault Codes 13304, 13310 Fault Code 13304-2

13310-3

Trouble Abnormal REG Input H Level

Coolant Temperature Sensor Short Circuit

Inspection Method Measure voltage between monitor controller harness end #A15 and body. Measure voltage at alternator terminal L. -

Evaluation 13 to 33.5 V

Cause Faulty monitor controller

13 to 33.5 V

Open circuit in wire harness Faulty alternator.

Normal in above check. 0Ω

Measure resistance between sensor and body. Normal in above check.

Faulty sensor Short circuit in wire harness

Connector (Wire harness end)  Monitor Controller-A Connector

TDAB-05-06-011

fNOTE: Coolant Temperature Gauge E F

D

No. A B C D D E F

Coolant Temperature (ºC) 25 40 50 80 95 105 120

C

B A

TJBG-05-02-084

T5-5-72

Coolant Temperature Sensor (kΩ) 7.6±0.76 4.0±0.35 2.7±0.22 0.92±0.07 0.56±0.04 0.42±0.03 0.28±0.01

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller (Information) Fault Code 13311 Fault Code 13311-3

Trouble Fuel Level Sensor Circuit High Input

13311-4

Inspection Method Measure resistance between sensor #1 and #2. Measure voltage between sensor harness end #1 and body. -

Fuel Level Sensor Circuit Low Input

Evaluation 0Ω

Cause Faulty sensor

0V

Open circuit in wire harness #1

Normal in above check ∞Ω

Open circuit in harness #2 Faulty sensor

Measure resistance between sensor #1 and #2. Normal in above check

Short circuit in wire harness #1 and #2

fNOTE: Fuel Gauge B

A

C D E

No. A

Fuel Level (%) 100 (FULL)

Fuel Sensor (Ω) 100-4

B C D E F

75 50 25 6 0 (EMPTY)

19 32±5 49.3 80+12+2

F

TDAA-05-02-082

Connector (Wire harness end)  Fuel Sensor TDCD-05-06-010

T5-5-73

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller (Information) Fault Codes 20100 to 20104, 20106 Fault Code 20100-2

Trouble Overheat Alarm

20101-2

Engine warning Alarm

20102-2

Engine Oil Pressure Alarm

20103-2

Alternator Alarm

20104-2

20106-2

Fuel Level Alarm

Air Cleaner Restriction Alarm

Inspection Method Disconnect a connector from the overheat switch and retry by using MPDr..

Diagnose on fault codes of ECM. Diagnose on fault codes of ECM. Measure voltage between monitor controller harness end #A15 and body. Measure voltage at alternator terminal L. Disconnect a connector from the fuel level sensor and retry by using MPDr..

Evaluation Displayed fault code

Un-displayed fault code -

Cause Faulty monitor controller or short circuit in wire harness Faulty overheat switch -

-

-

13 V to 33.5 V

Faulty monitor controller

13 V to 33.5 V

Open circuit in wire harness Faulty alternator

Normal in above check Displayed fault code

Un-displayed fault code Displayed fault code

Disconnect a connector from air cleaner restriction switch and retry by using MPDr.. Un-displayed fault code

Connector (Wire harness end)  Monitor Controller-A Connector

TDAB-05-06-011

T5-5-74

Faulty monitor controller or short circuit in wire harness Faulty fuel level sensor Faulty monitor controller or short circuit in wire harness Faulty air cleaner restriction switch

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Monitor Controller (Information) Fault Codes 20107, 20109, 20110, 20114, 20146, 20149 Fault Code 20107-2

Trouble Water Separator Alarm

Inspection Method Disconnect a connector from the water separator alarm switch. Retry by using MPDr..

Evaluation Displayed fault code

Un-displayed fault code -

Cause Faulty monitor controller or shorted circuit in wire harness Faulty water separator alarm switch Faulty wire harness Faulty pilot shut-off switch Fanlty wire harness, Diagnose on fault codes of ECM. Faulty fuel filter restriction sensor Faulty monitor controller or short circuit in wire harness Faulty coolant overheat switch -

-

-

Un-displayed fault code Normal Abnormal

20109-2

Pilot Control Shut-Off Lever Alarm

Check the pilot shut-off switch.

20110-2

Fuel Filter Restriction Alarm

Check fuel filter restriction Normal sensor Abnormal

20114-2

20146-2 20149-2

Overheat Alarm Disconnect a connector (Immediately after the key from the coolant overheat is turned ON) switch and retry by using MPDr.. Fuel Temperature Increase Alarm EGR Gas Temperature Alarm

Diagnose on fault codes of ECM. Diagnose on fault codes of ECM.

T5-5-75

Displayed fault code

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Air Conditioner Controller Fault Codes 11 to 22 Preparation  Check the wiring connections first.  Before inspection, set the key switch to the ON position. Fault Code 11

12

13

14

18

21

22

Trouble Open Circuit in Re-circulated Air Temperature Sensor

Short Circuit in Re-circulated Air Temperature Sensor

Inspection Method Measure resistance between sensor #25H and #6B. Measure voltage between sensor harness end #25H and body. Measure resistance between sensor #25H and #6B. -

Open Circuit in Ambient Measure resistance Temperature Sensor between sensor #25H and #6B. Measure voltage between sensor harness end #25H and body. Short Circuit in Ambient Temperature Sensor

Short Circuit in Solar Radiation Sensor

Open Circuit in Frost Sensor

Short Circuit in Frost Sensor

Measure resistance between sensor #25H and #6B. Continuity check between sensor harness end #25H and #6B. Measure resistance between sensor #25H and #6B. Measure voltage between sensor harness end #25H and body. Measure resistance between sensor #25H and #6B. -

T5-5-76

Evaluation Cause ∞ Ω (Normal value: Faulty sensor 300 to 430 kΩ) 0V

Open circuit in wire harness #25H

Normal in above check. 0 Ω (Normal value: 300 to 430 kΩ)

Open circuit in wire harness #6B Faulty sensor

Normal in above Short circuit in wire check. harness #25H and #6B ∞ Ω (Normal value: Faulty sensor 100 to 210 kΩ) 0V

Open circuit in wire harness #25H

Normal in above check. 0 Ω (Normal value: 100 to 210 kΩ)

Open circuit in wire harness #6B Faulty sensor

Normal in above check. 0Ω

Short circuit in wire harness #25H and #6B Short circuit in wire harness #25H and #6B

Normal in above Faulty sensor check. ∞ Ω (Normal value: Faulty sensor 100 to 115 kΩ) 0V

Open circuit in wire harness #25H

Normal in above check. 0 Ω (Normal value: 100 to 115 kΩ)

Open circuit in wire harness #6B Faulty sensor

Normal in above check.

Short circuit in wire harness #25H and #6B

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A Air Conditioner Controller Fault Codes 43 to 92 Preparation  Check the wiring connections first.  Before inspection, set the key switch to the ON position. Fault Code 43

Trouble Abnormal Air Vent Damper Servo Motor

44

Abnormal Air Mix Damper Servo Motor

51

Abnormal High/ Low Refrigerant Pressure

91

CAN Communication Error CAN Bus Off Error

92

Inspection Method Measure voltage between servo motor harness end 7C and body. (AUTO/OFF switch/blower switch: ON) Measure voltage between servo motor harness end 7C and 25D. (AUTO/OFF switch/blower switch: ON) -

Evaluation 0V

0V

Normal in above check. Measure voltage between servo 0 V motor harness end 7D and body. (AUTO/OFF switch/blower switch: ON) Measure voltage between servo 0 V motor harness end 7D and 25E. (AUTO/OFF switch/blower switch: ON) Normal in above check. Measure voltage between high/ 0 V low pressure switch harness end A211 and A052. (AUTO/OFF switch/blower switch: ON) Normal in above check. Continuity check in CAN1 Normal harness. Abnormal Continuity check in CAN1 harness.

T5-5-77

Normal Abnormal

Cause Faulty controller or open circuit in wire harness between controller and air vent damper servo motor Faulty controller or open circuit in wire harness between controller and air vent damper servo motor Faulty air vent damper servo motor Faulty controller or open circuit in wire harness between controller and air mix damper servo motor Faulty controller or open circuit in wire harness between controller and air mix damper servo motor Faulty air mix damper servo motor Faulty controller or open circuit in wire harness between controller and high/low pressure switch Faulty high/low pressure switch Faulty controller Faulty CAN1 harness Faulty controller Faulty CAN1 harness

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting A (Blank)

T5-5-78

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure Refer to troubleshooting B procedures for diagnosis by using trouble symptom when no fault codes are displayed.  Diagnosis Procedure  Perform diagnosis by using MPDr. or the service menu of monitor first.  When the fault code is displayed, refer to the troubleshooting A group and diagnose.  In case any fault code has not been displayed by diagnosis, perform inspection according to the procedures in this group when diagnosing.  On the front section pages of this group, there are the tables indicating the relationship between machine trouble symptoms and related parts which may cause such trouble if failed. Start the troubleshooting with more probable causes selected by referring to these tables. NOTE: All connector images in this section are viewed from the open end side of wire harness end.

f

1

2

T6L4-05-03-001 1-

Wire Harness End Connector

2-

Wire Harness

T5-6-1

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Contents of Diagnosis

Trouble Symptom Preparation Viewpoints for a diagnosis and contents needing inspection beforehand are explained.

How to Read Table Procedure (A) (F)

Inspection Method (B) (G)

Condition

Evaluation

Cause

(C) (H)

(D) (I)

(E) (J)

 A, F: Inspection order  B, G: Inspection method for trouble cause  C, H: Conditions for inspection  D, I: Evaluation specification of check results  E, J: Trouble cause for trouble symptom

Procedure: 1. Perform inspection according to Inspection Method (B) and Condition (C) of Procedure (A). 2. In case the results are applied to Evaluation (D), the trouble cause is Cause (E).

In case the results are not applied to Evaluation (D), go to the next, Procedure (F).

T5-6-2

SECTION 5 TROUBLESHOOTING Group 6 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 MC (Main Controller) Item Function

MC controls the engine, pump, and valve.

Symptoms in control system when trouble occurs

Depending on trouble situations, control system malfunction may differ. (The following symptoms in machine operation indicate that MC logic circuit has failed.) Symptoms Even if engine starts, engine in machine speed remains in slow idle speed. operation As pump displacement is held at when trouble minimum, all actuator speeds are occurs slow.

Evaluation by 11000, 11001, 11002, 11003 Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions of Control (Operational Principle Section in T/M)

Engine Control Dial

Auto-Idle Switch

Engine control dial instructs target This switch activates auto-idle engine speed. control. ON: 0 VAuto-idle control is activated. OFF: 5 VAuto-idle control is not activated. Even if engine control dial is Open circuit: Auto-idle is not operated, engine speed does not activated. change. Short circuit: Even if auto-idle switch is in OFF position, autoidle control is always activated. -1 Engine speed is fixed at 1200 min . Same as shown above (Auto-idle is operated.) In case of open circuit or shorted circuit, target engine speed is fixed at 1200 min-1. Engine can stop by using the key switch. 11101 -

-

MC: Demand Engine Speed, Engine MC: Auto-Idle Switch Control Dial ECM: Target Engine Speed -

T2-2

T2-2

T2-2

T5-6-3

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Power Mode Switch (ECO Mode) Item Function

This switch shifts power mode switch to ECO mode. ON: 0 VECO mode control is operated. OFF: 5 VNormal. Symptoms Open circuit: Even if ECO mode is in control selected, engine speed does not system when decrease with the control lever in trouble occurs neutral. Short circuit: Even if power mode is set to PWR mode or HP mode from ECO mode with the control lever in neutral and the engine control dial in fast idle position, engine speed does not increase. Same as shown above Symptoms in machine operation when trouble occurs Evaluation by Fault Code Evaluation by MC: Power Mode Switch Monitoring Evaluation by using Test Harness Note Descriptions T2-2 of Control (Operational Principle Section in T/M)

Travel Mode Switch

Boom Mode Selector Switch

This switch shifts 4-spool solenoid valve unit (SC) and changes travel speed.

This switch reduces overload relief pressure at the boom cylinder rod side.

Open circuit: Travel speed remains unchanged in slow speed. Short circuit: Even if travel mode switch is in slow idle position, machine travels at fast speed.

Open circuit: Boom mode selector control is not performed. Short circuit: Overload relief pressure at the boom cylinder rod side remains low constantly and machine cannot be raised off the ground with front attachment.

Same as shown above

Same as shown above

-

-

MC: Travel Mode SW

MC: Boom Mode Switch

-

-

T2-2

T2-2

T5-6-4

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Digging Regenerative Control Item Function

This switch shifts 4-spool solenoid valve unit (SI) and activates power digging. ON: 0 VPressure increases. OFF: 5 VPressure does not increase. Open circuit: Pressure does not Symptoms in control increase. system when Short circuit: Pressure increase trouble occurs only for 8 seconds after the key switch is turned ON. Symptoms Same as shown above in machine operation when trouble occurs

Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions of Control (Operational Principle Section in T/M)

MC: Power Boost Switch

Pump Regulator Pressure Learning Switch This switch starts pump learning. ON: 0 VPerform pump learning OFF: 5 VNormal Control

Pump learning cannot be performed.

Open circuit or the switch continuity failure: The machine is operated normally. (Only the learning cannot be done.) Short circuit: The pump learning cannot be done even if pushing the learning switch after turning the key switch ON. -

-

MC: Pump Regulator Pressure, Learning SW -

T2-2

T2-2

T5-6-5

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pilot Shut-Off Switch (Pilot ShutOff Lever) Item Function

This switch shifts pilot shut-off solenoid valve. Symptoms Open circuit: Pilot shout-off in control switch is always OFF. Pilot shutsystem when off solenoid valve is not shifted. trouble occurs Even if lever is operated with pilot shut-off lever in UNLOCK position, all actuator are not operated. Short circuit: Pilot shout-off switch is always ON. Engine does not start. If short circuit occurs while engine running and a lever is operated with pilot shutoff lever in the LOCK position, actuator is operated. Same as shown above Symptoms in machine operation when trouble occurs Evaluation by Fault Code Evaluation by MC: Pilot Control Shut-Off Lever Monitoring Switch Evaluation by using Test Harness Note Descriptions T2-5 of Control (Operational Principle Section in T/M)

T5-6-6

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Auto-Lubrication ON/OFF Switch Proximity Switch (AutoLubrication Device) Item Function

This switch activates the autolubrication function. (AutoLubrication Control) ON: 0 VOperate. OFF: 5 VDoes not operate. No signal is input to MC.

This switch detects operation number of times of the distribution valve to set the lubrication time. (AutoLubrication Control) No signal is input to MC.

-

As the pump keeps operating until generation of the autolubrication error, grease is discharged a lot. When the error judgment time is reached, the auto-lubrication alarm is displayed on the monitor unit. -

MC: Auto-Lubrication Main SW

MC: Auto-Lubrication Limit SW

-

-

T2-2

T2-2

Symptoms in control system when trouble occurs Symptoms The auto-lubrication does not in machine operate both for open and short operation circuit. when trouble occurs

Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions of Control (Operational Principle Section in T/M)

T5-6-7

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pilot Shut-Off Solenoid Valve Item Function

This valve opens and closes pilot circuit. Symptoms When close: All actuators are not in control activated. (Pilot pressure oil is not system when supplied to pilot valve.) trouble occurs When open: Pilot pressure oil is always supplied to pilot valve. Symptoms Same as shown above in machine operation when trouble occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T2-5 of Control (Operational Principle Section in T/M)

Hydraulic Oil Temperature Sensor

This sensor monitors hydraulic oil temperature. MC recognizes that hydraulic oil temperature is 120 °C when an open circuit occurs. (Hydraulic oil temperature: 120 °C is not displayed on monitoring.) The fan speed is fixed to the maximum value.

11901 MC: Hydraulic Oil Temperature -

T2-2

T5-6-8

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pump 1 Delivery Pressure Sensor Item Function Symptoms in control system when trouble occurs Symptoms in machine operation when trouble occurs

This sensor detects pump 1 delivery pressure. When output is 0 V or 5 V, the following symptoms occur.

HP Mode cannot be set. As the pump 1 delivery flow rate is restricted, operation speed of the boom, arm, and bucket becomes slower. The engine becomes easily stalled. As the machine is kept to travel at slow speed, speed does not change into fast. Evaluation by 11200 Fault Code Evaluation by MC: Pump 1 Delivery Pressure Monitoring Evaluation by using Test Harness Note Possible to judge if sensor or harness is faulty by switching pressure sensor with other delivery pressure sensor. Descriptions T2-2 of Control (Operational Principle Section in T/M)

Pump 2 Delivery Pressure Sensor

This sensor detects pump 2 delivery pressure. When output is 0 V or 5 V, the following symptoms occur.

HP Mode cannot be set. As the pump 2 delivery flow rate is restricted, operation speed of the boom, arm, and swing becomes slower. The engine becomes easily stalled. As the machine is kept to travel at slow speed, speed does not change into fast. 11202 MC: Pump 2 Delivery Pressure -

Possible to judge if sensor or harness is faulty by switching pressure sensor with other delivery pressure sensor. T2-2

T5-6-9

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pump 1 Control Pressure Sensor Item Function Symptoms in control system when trouble occurs Symptoms in machine operation when trouble occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note

Descriptions of Control (Operational Principle Section in T/M)

Pump 2 Control Pressure Sensor

This sensor detects pump control pressure of pump 1. When output is 0 V or 5 V, the following symptoms occur.

This sensor detects pump control pressure of pump 2. When output is 0 V or 5 V, the following symptoms occur.

Engine speed does not decrease when operating bucket and travel (right) at ECO mode. Fast travel cannot be selected easily when travering. 11994

Engine speed does not decrease when operating travel (left) at ECO mode. Fast travel cannot be selected easily when travering. 11992

MC: Pump 1 Control Pressure

MC: Pump 2 Control Pressure

-

-

Possible to judge if sensor or wire harness is faulty by switching pressure sensor with other pump control pressure sensor. T2-2

Possible to judge if sensor or wire harness is faulty by switching pressure sensor with other pump control pressure sensor. T2-2

T5-6-10

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pressure Sensor (Boom Raise) Item Function Symptoms in control system when trouble occurs Symptoms in machine operation when trouble occurs

Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note

Descriptions of Control (Operational Principle Section in T/M)

Pressure Sensor (Boom Lower)

Pressure Sensor (Arm Roll-In)

This sensor monitors boom raise pilot pressure. When output is 0 V or 5 V, the following symtoms occur.

This sensor monitors Boom Lower pilot pressure. When output is 0 V or 5 V, the following symtoms occur.

This sensor monitors arm roll-in pilot pressure. When output is 0 V or 5 V, the following symtoms occur.

Engine speed is difficult to increase when performing digging operation. Arm roll-in speed is slow during combined operation of arm rollin and boom raise. During boom raise single operation, power is weak. Boom raise speed is slow during combined operation of swing, arm roll-in, and boom raise.

Engine speed is difficult to increase when performing digging operation. Boom lower speed is slow when performing combined operation of swing, arm roll-in, and boom lower.

11302

11998

Engine speed is difficult to increase when performing digging operation. Arm roll-in speed is slow during combined operation of arm rollin and boom raise. Arm roll-in speed is fast during arm level crowding operation. Attachment and boom raise speed are slow when performing combined operation of arm rollin, boom raise, and attachment. 11303

MC: Boom Raise Pilot Pressure

MC: Bm Lower Pilot Pressure

MC: Arm Roll-In Pilot Pressure

-

-

-

Possible to judge if pressure sensor is faulty or port is clogged by switching pressure sensor with other pressure sensor. T2-2

Possible to judge if pressure sensor is faulty or port is clogged by switching pressure sensor with other pressure sensor. T2-2

Possible to judge if pressure sensor is faulty or port is clogged by switching pressure sensor with other pressure sensor. T2-2

T5-6-11

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pressure Sensor (Arm Roll-Out) Item Function Symptoms in control system when trouble occurs Symptoms in machine operation when trouble occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note

Descriptions of Control (Operational Principle Section in T/M)

Pressure Sensor (Bucket Roll-In)

Pressure Sensor (Bucket Roll-Out)

This sensor monitors arm roll-out pilot pressure. When output is 0 V or 5 V, the following symtoms occur.

This sensor monitors bucket rollin pilot pressure. When output is 0 V or 5 V, the following symtoms occur.

This sensor monitors bucket rollout pilot pressure. When output is 0 V or 5 V, the following symtoms occur.

Engine speed is difficult to increase when performing arm roll-out operation. Arm roll-out speed is slow.

Bucket speed is slow when performing light digging operation.

11995

Engine Speed is difficult to increase when performing digging operation. Bucket speed is slow when performing light digging operation. 11325

11997

MC: Arm Roll-Out Pilot Pressure

MC: Bucket Roll-In Pilot Pressure

MC: Bucket Roll-Out Pilot Pressure

-

-

-

Possible to judge if pressure sensor is faulty or port is clogged by switching pressure sensor with other pressure sensor. T2-2

Possible to judge if pressure sensor is faulty or port is clogged by switching pressure sensor with other pressure sensor. T2-2

Possible to judge if pressure sensor is faulty or port is clogged by switching pressure sensor with other pressure sensor. T2-2

T5-6-12

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pressure Sensor (Travel) Item Function Symptoms in control system when trouble occurs Symptoms in machine operation when trouble occurs

This sensor monitors travel pilot pressure. When output is 0 V or 5 V, the following symtoms occur.

Even if the machine travels, engine speed is kept at auto-idle speed. Even if the machine travels with the engine running at slow idle speed, engine speed does not increase. As the machine is kept to travel at slow speed, speed does not change into fast. When performing combined operation of attachment and travel, the machine mistracks. Travel alarm (option) continues to sound. Evaluation by 11304 Fault Code Evaluation by MC: Travel Pilot Pressure Monitoring Evaluation by using Test Harness Note Possible to judge if pressure sensor is faulty or port is clogged by switching pressure sensor with other pressure sensor. Descriptions T2-2 of Control (Operational Principle Section in T/M)

Pressure Sensor (Swing)

This sensor monitors swing pilot pressure. When output is 0 V or 5 V, the following symtoms occur.

When performing combined operation of swing and boom raise, engine speed does not increase. Boom raise speed is slow and arm roll-in speed is fast when performing combined operation of swing, arm roll-in, and boom raise. Swing speed acceleration becomes bad and swing operation at constant speed is slow. Swing alarm (option) continues to sound. 11301 MC: Swing Pilot Pressure -

Possible to judge if pressure sensor is faulty or port is clogged by switching pressure sensor with other pressure sensor. T2-2

T5-6-13

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pressure Sensor (4-spool Side) Item Function Symptoms in control system when trouble occurs Symptoms in machine operation when trouble occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note

Descriptions of Control (Operational Principle Section in T/M)

Pressure Sensor (5-spool Side)

This sensor monitors control valve 4-spool side pilot pressure. When output is 0 V ro 5 V, the following symptoms occur.

This sensor monitors control valve 5-spool side pilot pressure. When output is 0 V ro 5 V, the following symptoms occur.

Boom operation speed is slow. Arm operation speed is slow. Bucket operation speed is slow. The machine mistracks.

Boom operation speed is slow. Arm operation speed is slow. Swing speed is slow. The machine mistracks.

-

-

MC: Signal C/V SA Port Pressure

MC: Signal C/V SB Port Pressure

11945

11944

Possible to judge if pressure sensor is faulty or port is clogged by switching pressure sensor with other pressure sensor. T2-2

Possible to judge if pressure sensor is faulty or port is clogged by switching pressure sensor with other pressure sensor. T2-2

T5-6-14

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pressure Sensor (Attachment) (Option) Item Function Symptoms in control system when trouble occurs Symptoms in machine operation when trouble occurs

This sensor monitors attachment pilot pressure. When output is 0 V or 5 V, the following symptoms occur.

Even if engine speed of attachment is set to faster (+) speed and the attachment is operated, engine speed does not increase. Attachment speed is slow. Evaluation by 11942 Fault Code Evaluation by MC: ATT 1 Pilot Pressure Monitoring Evaluation by using Test Harness Note Possible to judge if pressure sensor is faulty or port is clogged by switching pressure sensor with other pressure sensor. Descriptions T2-2 of Control (Operational Principle Section in T/M)

T5-6-15

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pump 1 Control Solenoid Valve Item Function

This valve changes pump 1 displacement angle Symptoms High current: Pump 1 in control displacement angle is held at system when maximum. The engine stalls or trouble occurs engine lug-down is remarkable at high loaded. Low current: Pump 1 displacement angle is held at minimum. Machine overall operation is slow Same as shown above Symptoms in machine operation when trouble occurs Evaluation by 11951 Fault Code Evaluation by MC: Pump 1 (4 Units) P/S Output, Monitoring Pump 1 (4 Units) P/S O/P FB Evaluation by using Test Harness Note Descriptions T2-2 of Control (Operational Principle Section in T/M)

Pump 2 Control Solenoid Valve

This valve changes pump 2 displacement angle High current: Pump 2 displacement angle is held at maximum. The engine stalls or engine lug-down is remarkable at high loaded. Low current: Pump 2 displacement angle is held at minimum. Machine overall operation is slow. Same as shown above

11950 MC: Pump 2 (5 Units) P/S Output, Pump 2 (5 Units) P/S O/P FB -

T2-2

T5-6-16

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Fan Speed Control Solenoid Valve Reverse Rotation Control Solenoid Valve 1 (Option) Item Function

This fan controls fan rotation speed. Symptoms High current: The fan speed is in control fixed to the minimum value. system when Low current: The fan speed is trouble occurs fixed to the maximum value.

Symptoms in machine operation when trouble occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions of Control (Operational Principle Section in T/M)

Reverse Rotation Control Solenoid Valve 2 (Option)

Same as shown above

This fan controls fan rotation direction. High current: The fan rotation direction is fixed to the normal direction. Low current: The fan rotation direction is fixed to the normal direction. Same as shown above

This fan controls fan rotation direction. High current: The fan rotation direction is fixed to the normal direction. Low current: The fan rotation direction is fixed to the normal direction. Same as shown above

11412

11982

11981

MC: Fan Sp Cont P/S 2 O/P, Fan Sp MC: Fan Dir Cont P/S 1 O/P, Fan Cont P/S 2 O/P FB Dir Cont P/S 1 O/P FB -

MC: Fan Sp Cont P/S 2 O/P, Fan Sp Cont P/S 2 O/P FB -

T2-2

T2-2

T2-2

T5-6-17

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts 4-Spool Solenoid Valve Unit (SI)

4-Spool Solenoid Valve Unit (SG)

This valve temporally increase main relief valve relief pressure. Symptoms High current: Pressure increases in control constantly. system when Low current: Pressure does not trouble occurs increase constantly.

Same as shown above

This valve shifts selector valve of arm 2 flow rate control valve. High current: As arm 2 flow rate control valve (selector valve) is restricted constantly, the arm speed becomes slow. Low current: As arm 2 flow rate control valve (selector valve) is opened constantly, operability of arm combined operation becomes worse. Same as shown above

11948

11428

MC: Main Relief Boost Press Output, Main Relief Boost Press O/P FB Install light harness (ST 7226). Check output signals from MC and wire harness condition. T2-2

MC: Arm 2 Flw Cont P/S Output, Arm 2 Flw Cont P/S O/P FB

Item Function

Symptoms in machine operation when trouble occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions of Control (Operational Principle Section in T/M)

Install light harness (ST 7226). Check output signals from MC and wire harness condition. T2-2

T5-6-18

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts 4-Spool Solenoid Valve Unit (SC)

2-Spool Solenoid Valve Unit (SC)

2-Spool Solenoid Valve Unit (SI)

This valve shifts boom overload relief valve.

This valve shifts swing flow rate control valve.

Same as shown above

High current: Shifts boom overload relief selector valve constantly. Machine cannot raise the track off the ground. Low current: Since boom overload relief selector does not shift, Machine may be able to raise the track off the ground. Same as shown above

High current: Shifts swing flow rate control valve constantly. Swing speed becomes slow. Low current: As swing flow rate control valve does not shift, boom raise speed is slow when performing combined operation of swing and boom raise. Same as shown above

11405

11989

11953

MC: Travel Mode C/V Output, Travel Mode C/V Output FB Install light harness (ST 7226). Check output signals from MC and wire harness condition. T2-2

MC: Boom Mode Cont P/S O/P, Boom Mode Cont P/S O/P FB Install light harness (ST 7226). Check output signals from MC and wire harness condition. T2-2

MC: Swing Flw Cont P/S Output, Swing Flw Cont P/S O/P FB Install light harness (ST 7226). Check output signals from MC and wire harness condition. T2-2

Item Function

This valve decreases angle of travel motor to the minimum and increases travel speed. Symptoms High current: Machine is kept to in control travel at fast speed. system when Low current: Machine is kept to trouble occurs travel at slow speed.

Symptoms in machine operation when trouble occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions of Control (Operational Principle Section in T/M)

T5-6-19

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts 4-Spool Solenoid Valve Unit (SF) Item Function

This valve shifts bypass shut-out valve.

Main Relief Valve

Symptoms in control system when trouble occurs

High current: Machine mistracks to the right when performing travel operation. Low current: Bucket speed is slow when performing bucket single operation.

Symptoms in machine operation when trouble occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions of Control (Operational Principle Section in T/M)

Same as shown above

This valve prevent pressure in pump 1 and 2 circuits from exceeding the set pressure when the control lever is operated. If valve is stuck in fully closed position, hose of front attachment may be damaged. If valve is stuck in fully open position, power is weak when performing digging and climbing operation. Same as shown above

11408

-

Bypass Cut Cout P/S, Bypass Cut cout P/S FB Install light harness (ST 7226). Check output signals from MC and wire harness condition. T2-2

-

T3-3

T5-6-20

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Overload Relief Valve Item Function

Symptoms in control system when trouble occurs

Symptoms in machine operation when trouble occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions of Control (Operational Principle Section in T/M)

Boom Anti-Drift Valve

Arm Anti-Drift Valve (Rod Side)

If valve is stuck in fully closed position, hose of front attachment may be damaged by external force. If valve is stuck in fully open position, power is weak when performing digging operation. Same as shown above

This valve forcibly opens the check valve in boom lower return circuit and lowers boom, only when performing boom lower operation. The valve prevents boom from drifting due to oil leaks in control valve. If check valve is kept closed, boom does not lower smoothly. If check valve is kept open, machine cannot be raised off the ground.

This valve forcibly opens check valve in arm roll-in return circuit and rolls arm in only when performing arm roll-in operation. The valve prevents arm from drifting due to oil leaks in control valve. If check valve is kept closed, arm roll-in speed becomes slow. If check valve is kept open, front attachment drift increases due to oil leaks in control valve.

Same as shown above

Same as shown above

-

-

-

-

-

-

-

-

-

T3-3

T3-3

T3-3

This valve prevents actuator circuit pressure generated by external force from exceeding the set pressure with the control lever set in neutral.

T5-6-21

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Flow Combiner Valve Item Function

This valve supplies pressure oil to both right and left travel spools from pump 1 when performing combined operation of travel and front attachment/swing. Symptoms If valve is stuck in fully closed in control position, machine mistracks system when to the left when performing trouble occurs combined operation of travel and front attachment/swing. If valve is stuck in fully open position, machine mistracks to the right when performing travel single operation. Same as shown above Symptoms in machine operation when trouble occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T3-3 of Control (Operational Principle Section in T/M)

T5-6-22

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Arm Regenerative Valve Item Function

This valve supplies returning oil from arm cylinder rod side to bottom side and prevents cylinder hesitation.

Bucket Regenerative Valve

This valve supplies returning oil from bucket cylinder rod side to bottom side and prevents cylinder hesitation.

Bucket Regeneration Cut Valve

This valve decreases pressure in bucket cylinder rod side and improves digging force when performing bucket roll-in operation at heavy load. If valve is kept closed, arm If check valve is kept closed, If valve is stuck in fully closed Symptoms regeneration is not done and arm bucket digging speed becomes position, power is weak when in control system when roll-in speed becomes slow. slow, or bucket cylinder performing bucket digging trouble occurs If valve is kept open, oil from hesitation occurs. operation. pump 2 flow back through arm If check valve is kept open, power If valve is stuck in fully open 2 spool, and arm roll-in speed is weak. position, bucket digging speed becomes slow. becomes slow. Symptoms Same as shown above Same as shown above Same as shown above in machine operation when trouble occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T3-3 T3-3 T3-3 of Control (Operational Principle Section in T/M)

T5-6-23

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Arm 1 Flow Rate Control Valve Item Function

This valve is shifted by swing pilot pressure. The valve restricts arm 1 circuit and secures swing speed when performing combined operation of swing and arm rollin.

Arm 2 Flow Rate Control Valve

This valve is shifted by pilot pressure from 4-spool solenoid valve unit (SG). The valve restricts arm 2 circuit and keeps bucket speed when performing combined operation of arm rollin and bucket.

Swing Flow Rate Control Valve

This valve is shifted by pilot pressure from 2-spool solenoid valve unit (SI). The valve restricts swig circuit and secures boom or arm speed when performing combined operation of swing and boom raise or swing and arm roll-out. If poppet valve or selector valve is If poppet valve or selector valve is If poppet valve or selector valve Symptoms stuck in fully closed position, arm stuck in fully closed position, arm is stuck in fully closed position, in control system when roll-in speed becomes slow. roll-in speed becomes slow. swing speed becomes slow. trouble occurs If poppet valve or selector valve If poppet valve or selector valve If poppet valve or selector valve is stuck in fully open position, is stuck in fully open position, is stuck in fully closed position, swing speed becomes slow when bucket roll-in speed becomes boom raise or arm roll-out speed performing combined operation slow when performing combined becomes slow when performing combined operation of swing of swing and arm roll-in. operation of arm roll-in and and boom raise or swing and arm bucket roll-in. roll-out. Same as shown above Same as shown above Same as shown above Symptoms in machine operation when trouble occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T3-3 T3-3 T3-3 of Control (Operational Principle Section in T/M)

T5-6-24

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Boom Flow Rate Control Valve Item Function

Auxiliary Flow Combiner Valve (Option)

This valve is shifted by boom lower pilot pressure. It restricts boom 1 circuit to prioritize other actuators.

This valve is shifted by pilot pressure from auxiliary flow combiner solenoid valve (option). Supplies pressure oil from pump to auxiliary spool. Symptoms If poppet valve or selector valve If valve is stuck in fully closed position, attachment speed does in control is stuck in fully closed position, not increase when performing system when boom lower speed becomes trouble occurs fast when performing combined combined operation of operation. attachment. If poppet valve or selector valve If valve is stuck in fully open is stuck in fully open position, the position, travel speed becomes track can not be raised off the slow when performing combined ground. operation of attachment and travel. Same as shown above Same as shown above Symptoms in machine operation when trouble occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T3-3 T3-3 of Control (Operational Principle Section in T/M)

T5-6-25

Bypass Shut-Out Valve

This valve is shifted by pilot pressure from 4-spool solenoid valve unit (SF) and increases pressure of pump 2 circuit. If valve is stuck in fully closed position, main relief valve (P2) continues to be relieved with all control levers set in neutral.

Same as shown above

-

T3-3

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Boom Lower Meter-In Cut Valve Item Function

This valve is shifted by returning oil from boom cylinder bottom side. The valve lowers boom due to own weight by the boom regenerative circuit when performing boom lower operation above ground, and gives priority to operate other actuators. When machine is raised off the ground, the valve gives priority to operate boom and increses the force to raise the machine. Symptoms If valve is stuck in fully closed in control position, boom lower speed system when becomes fast when performing trouble occurs combined operation. If valve is stuck in fully open position, machine cannot be raised off ground.

Symptoms in machine operation when trouble occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions of Control (Operational Principle Section in T/M)

Travel Motor Displacement Angle Pump 1 Flow Rate Control Valve Control Valve This valve is shifted by pilot pressure from 5-spool solenoid valve unit (SC). The valve shifts travel speed.

This valve supplies flow rate control pressure Pi according to lever stroke to pump 1 regulator when operating boom, arm, bucket , travel (right).

If valve is stuck in fully closed position, machine is kept to travel at slow speed. If valve is stuck in fully open position, machine travels at fast speed with travel mode switch set in slow speed position.

Same as shown above

Same as shown above

If valve is stuck in fully closed position, pump 1 displacement angle is held at minimum when operating control lever. Travel (right) is not operated when performing travel single operation. Bucket speed becomes extremely slow. If valve is stuck in fully open position, pump 1 displacement angle is held at maximum with control lever in neutral. Machine mistracks to the left when travel control lever is operated at half stroke. Pump 1 control pressure sensor detects maximum pressure. Same as shown above

-

-

-

-

-

-

-

-

-

T3-3

T3-5

T3-6

T5-6-26

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Pump 2 Flow Rate Control Valve

Arm Flow Rate Control Valve Control Spool

Swing Parking Brake Release Spool

This valve supplies flow rate control pressure according to pilot pressure to pressure sensor when operating boom, arm, swing and travel (left). Symptoms If valve is stuck in fully closed in control position, pump 2 displacement system when angle is held at minimum trouble occurs when operating control lever. Travel (left) is not operated when performing travel single operation. If valve is stuck in fully open position, pump 2 displacement angle is held at maximum with control lever in neutral. Machine mistracks to the right when travel control lever is operated at half stroke. Pump 2 control pressure sensor detects maximum pressure.

This valve is shifted by arm roll-in pilot pressure. The valve supplies swing pilot pressure to arm 1 flow rate control valve in control valve. If valve is stuck in fully closed position, swing speed is slow when performing combined operation of swing and arm rollin. If valve is stuck in fully open position, swing speed is slow when performing combined operation of swing and arm rollout

This spool is shifted by pilot pressure of boom, arm, bucket or swing. The spool supplies release pressure to swing parking brake.

Symptoms in machine operation when trouble occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions of Control (Operational Principle Section in T/M)

Same as shown above

Same as shown above

If spool is stuck in fully closed position, swing parking brake is kept applied. (Dragging is felt.) Even if control lever is operated at auto-idle control, engine speed does not increase as pressure sensors (boom, arm, and bucket) are always OFF. If spool is stuck in fully open position, swing parking brake is kept released. (Machine vibrates when traveling.) Even if control lever is set to neutral with autoidle switch ON, engine speed does not decrease as pressure sensors (boom, arm, and bucket) are always ON. Same as shown above

-

-

-

-

-

-

-

-

-

T3-6

T3-6

T3-6

Item Function

T5-6-27

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Parts Flow Combiner Valve Control Spool Item Function

This spool is shifted by travel (right) pilot pressure. The spool supplies selection pressure to flow combiner valve in control valve. If valve is stuck in fully closed Symptoms position, machine mistracks in control system when to the left when performing trouble occurs combined operation of travel and front attachment/swing. Travel (left) speed becomes slow. If valve is stuck in fully open position, flow combiner valve is shifted when performing combined operation of travel and front attachment/swing. Same as shown above Symptoms in machine operation when trouble occurs Evaluation by Fault Code Evaluation by Monitoring Evaluation by using Test Harness Note Descriptions T3-6 of Control (Operational Principle Section in T/M)

T5-6-28

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Correlation Between Trouble Symptoms and Part Failures This table indicates the relationship between machine troubles and parts contributing to the cause of the trouble if failed. The trouble symptoms in this table are described based on the conditions that other operations are normal and only one particular trouble symptom occures. In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom. The marks / in this table indicate the influence to trouble symptom. : Related, required to check : Related. However, in case this component fails, fault code is displayed, or other trouble symptom will be more noticeable. Thus, this component will not be the direct cause of the trouble concerned.

T5-6-29

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Engine System Troubleshooting Trouble Symptom E-1 Starter does not rotate. Parts MC ECM Monitor Controller Monitor Key Switch Engine Control Dial Auto-Idle Switch Power Mode Switch Travel Mode Switch Pilot Shut-Off Relay Starter Cut Relay Security Relay Auto Shut-Down Relay ACC Cut Relay Key Switch ON Cut Relay ECM Main Relay Engine Stop Switch Fuse Box 1 Pilot Shut-Off Switch MPDr. Battery Starter Relay 1 Battery Relay Engine Unit Starter Overheat Switch Coolant Temperature Sensor Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Control Pressure Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Pressure Sensor (Arm Roll-In) Pressure Sensor (Arm Roll-Out) Pressure Sensor (Bucket Roll-In) Pressure Sensor (Bucket Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel) Pressure Sensor (4-spool side) Pressure Sensor (5-spool side) Pressure Sensor (Attachment) (OP) Remark

E-2 Even if starter rotates, engine does not start.

E-3 Even if power mode switch is operated, power mode is not shifted. 





  



   

   (#8, #17) 

   (#17) 

    

T5-6-30

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Engine System Troubleshooting Trouble Symptom E-4 ECO mode is faulty. Parts MC ECM Monitor Controller Monitor Key Switch Engine Control Dial Auto-Idle Switch Power Mode Switch Travel Mode Switch Pilot Shut-Off Relay Starter Cut Relay Security Relay Auto Shut-Down Relay ACC Cut Relay Key Switch ON Cut Relay ECM Main Relay Engine Stop Switch Fuse Box 1 Pilot Shut-Off Switch MPDr. Battery Starter Relay 1 Battery Relay Engine Unit Starter Overheat Switch Coolant Temperature Sensor Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Control Pressure Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Pressure Sensor (Arm Roll-In) Pressure Sensor (Arm Roll-Out) Pressure Sensor (Bucket Roll-In) Pressure Sensor (Bucket Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel) Pressure Sensor (4-spool side) Pressure Sensor (5-spool side) Pressure Sensor (Attachment) (OP) Remark

 

 (ECO)

   

T5-6-31

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom E-5 E-6 Auto-idle system is faulty. Auto shut-down is not activated Parts MC ECM Monitor Controller Monitor Key Switch Engine Control Dial Auto-Idle Switch Power Mode Switch Travel Mode Switch Pilot Shut-Off Relay Starter Cut Relay Security Relay Auto Shut-Down Relay ACC Cut Relay Key Switch ON Cut Relay ECM Main Relay Engine Stop Switch Fuse Box 1 Pilot Shut-Off Switch MPDr. Battery Starter Relay 1 Battery Relay Engine Unit Starter Overheat Switch Coolant Temperature Sensor Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Control Pressure Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Pressure Sensor (Arm Roll-In) Pressure Sensor (Arm Roll-Out) Pressure Sensor (Bucket Roll-In) Pressure Sensor (Bucket Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel) Pressure Sensor (4-spool side) Pressure Sensor (5-spool side) Pressure Sensor (Attachment) (OP) Remark

     

 

  

    (#17, #18)    

 

       



T5-6-32

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B All Actuator System Troubleshooting Trouble Symptom A-1 All actuators do not work.

Parts MC ECM Monitor Controller Key Switch Engine Control Dial Pilot Shut-Off Relay Security Horn Relay Starter Cut Relay Security Relay Key Switch ON Cut Relay Fuse Box 1 Pilot Shut-Off Switch Pilot Shut-Off Solenoid Valve Hydraulic Oil Temperature Sensor Battery Starter Relay 1 Main Pump 1 Main Pump 2 Pilot Pump Pump 1 Regulator Pump 2 Regulator

A-2 All actuator speed is slow.

A-3 Travel (right) operation speed is slow when performing travel single operation. Bucket single operation speed is slow.

         (#4)  



      



Pump 1 Control Solenoid Valve





Pump 2 Control Solenoid Valve



Spool Pilot Valve Pump 1 Flow Rate Control Valve Pump 2 Flow Rate Control Valve Shuttle Valve (Signal Control Valve) Pilot Filter Pilot Relief Valve Remark

     

T5-6-33





SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom Parts MC ECM Monitor Controller Key Switch Engine Control Dial Pilot Shut-Off Relay Security Horn Relay Starter Cut Relay Security Relay Key Switch ON Cut Relay Fuse Box 1 Pilot Shut-Off Switch Pilot Shut-Off Solenoid Valve Hydraulic Oil Temperature Sensor Battery Starter Relay 1 Main Pump 1 Main Pump 2 Pilot Pump Pump 1 Regulator Pump 2 Regulator Pump 1 Control Solenoid Valve Pump 2 Control Solenoid Valve Spool Pilot Valve Pump 1 Flow Rate Control Valve Pump 2 Flow Rate Control Valve Shuttle Valve (Signal Control Valve) Pilot Filter Pilot Relief Valve Remark

A-5

A-4

Travel (left) operation speed is slow Actuator does not stop even if control lever is set to neutral. when performing travel single operation.



    

T5-6-34

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom A-6 Parts MC ECM Monitor Controller Monitor Key Switch Engine Control Dial Pilot Shut-Off Relay Security Relay Key Switch ON Cut Relay Fuse Box 1 Pilot Shut-Off Switch Pilot Shut-Off Solenoid Valve Hydraulic Oil Temperature Sensor Battery Air Conditioner Reverse Rotation Control Solenoid Valve 1 Reverse Rotation Control Solenoid Valve 2 Coolant Temperature Sensor Main Pump 1 Main Pump 2 Pilot Pump Fan Pump Pump 1 Regulator Pump 2 Regulator Fan Pump Regulator Pump 2 Delivery Pressure Sensor Pump 2 Control Solenoid Valve Fan Reverse Switch Fan Motor Fan Pump Control Solenoid Valve Bypass Shut-Out Valve Spool Pilot Valve 4-Spool Solenoid Valve Unit (SF) Pilot Filter Pilot Relief Valve Remark

Fan rotation speed does not change.  

A-7

A-8

Oil cooler fan rotation reverse does not change.

Radiator fan rotation reverse does not change.



 





  

T5-6-35



SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Front Attachment System Troubleshooting Trouble Symptom F-1 All front attachment actuator power is weak. Parts MC Power Mode Switch Power Digging Switch Main Pump 1 Main Pump 2 Pilot Pump Pump 1 Regulator Pump 2 Regulator Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Solenoid Valve Pump 2 Control Solenoid Valve Main Relief Valve Boom Anti-Drift Valve Arm Anti-Drift Valve (Rod Side) Arm Regenerative Valve Bucket Regenerative Valve Bucket Regeneration Cut Valve Arm 1 Flow Rate Control Valve Arm 2 Flow Rate Control Valve Bypass Shut-Out Valve Boom Lower Meter-In Cut Valve Boom Overload Relief Selection Valve Load Check Valve Spool Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Pressure Sensor (Arm Roll-In) Pressure Sensor (Arm Roll-Out) Pressure Sensor (Bucket Roll-In) Pressure Sensor (Bucket Roll-Out) Cylinder Pilot Valve Shockless Valve (Signal Control Valve) Shuttle Valve (Signal Control Valve) Pressure Sensor (Travel) Pressure Sensor (Swing) Pressure Sensor (4-Spool Side) Pressure Sensor (5-Spool Side) Swing Flow Rate Control Valve 4-Spool Solenoid Valve Unit (SG) 4-Spool Solenoid Valve Unit (SI) 4-Spool Solenoid Valve Unit (SF) 4-Spool Solenoid Valve Unit (SC) 2-Spool Solenoid Valve Unit (SC) 2-Spool Solenoid Valve Unit (SI) Pilot Filter Pilot Relief Valve Remark

F-2

F-3

Even if power digging switch is pushed, power does not increase. Boom raise power is weak when performing digging operation.

Some cylinders are not operated or speeds are slow.





  

   

 

 







 

       



  (Only Boom) 





 

 

T5-6-36

 

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-4 Trouble Symptom Bucket roll-in speed is slow and power is weak when performing digging operation.

F-5

F-6

Even if the boom mode selector switch is pushed, machine is raised off the ground.

Boom raise speed is slow when performing combined operation of swing and boom raise. Arm roll-out speed is slow when performing combined operation of swing and arm roll-out.  

Parts MC Power Mode Switch Power Digging Switch Boom Mode Selector Switch Main Pump 1 Main Pump 2 Pilot Pump Pump 1 Regulator Pump 2 Regulator Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Solenoid Valve Pump 2 Control Solenoid Valve Main Relief Valve Boom Anti-Drift Valve Arm Anti-Drift Valve (Rod Side) Arm Anti-Drift Valve (Bottom Side) Bucket Regenerative Valve Bucket Regeneration Cut Valve Arm 1 Flow Rate Control Valve Arm 2 Flow Rate Control Valve Bypass Shut-Out Valve Boom Lower Meter-In Cut Valve Boom Overload Relief Selection Valve Load Check Valve Spool Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Pressure Sensor (Arm Roll-In) Pressure Sensor (Arm Roll-Out) Pressure Sensor (Bucket Roll-In) Pressure Sensor (Bucket Roll-Out) Cylinder Pilot Valve Shockless Valve (Signal Control Valve) Shuttle Valve (Signal Control Valve) Pressure Sensor (Travel) Pressure Sensor (Swing) Pressure Sensor (4-Spool Side) Pressure Sensor (5-Spool Side) Swing Flow Rate Control Valve 4-Spool Solenoid Valve Unit (SG) 4-Spool Solenoid Valve Unit (SI) 4-Spool Solenoid Valve Unit (SD) 4-Spool Solenoid Valve Unit (SC) 2-Spool Solenoid Valve Unit (SC) 2-Spool Solenoid Valve Unit (SI) Pilot Filter Pilot Relief Valve Remark



 

    

  

   

 

  

     

 

 







   

T5-6-37

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom F-7

Parts MC Power Mode Switch Power Digging Switch Main Pump 1 Main Pump 2 Pilot Pump Pump 1 Regulator Pump 2 Regulator Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Solenoid Valve Pump 2 Control Solenoid Valve Main Relief Valve Boom Anti-Drift Valve Arm Anti-Drift Valve (Rod Side) Arm Regenerative Valve Bucket Regenerative Valve Bucket Regeneration Cut Valve Arm 1 Flow Rate Control Valve Arm 2 Flow Rate Control Valve Bypass Shut-Out Valve Boom Lower Meter-In Cut Valve Boom Overload Relief Selection Valve Load Check Valve Spool Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Pressure Sensor (Arm Roll-In) Pressure Sensor (Arm Roll-Out) Pressure Sensor (Bucket Roll-In) Pressure Sensor (Bucket Roll-Out) Cylinder Pilot Valve Shockless Valve (Signal Control Valve) Shuttle Valve (Signal Control Valve) Pressure Sensor (Travel) Pressure Sensor (Swing) Pressure Sensor (4-Spool Side) Pressure Sensor (5-Spool Side) Swing Flow Rate Control Valve 4-Spool Solenoid Valve Unit (SG) 4-Spool Solenoid Valve Unit (SI) 4-Spool Solenoid Valve Unit (SF) 4-Spool Solenoid Valve Unit (SC) 2-Spool Solenoid Valve Unit (SC) 2-Spool Solenoid Valve Unit (SI) Pilot Filter Pilot Relief Valve Remark

When performing combined operation, arm does not start to move smoothly. Arm starts to move slightly slow when performing arm single operation. These troubles often occur when temperature is low.

F-8

F-9

When performing combined operation, boom does not start to move smoothly. Boom starts to move slightly slow during boom lower single operation.

When boom raise or arm roll-out is operated, boom or arm starts to move after moving slightly down.



 

 

 

T5-6-38

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom F-10 Front attachment drifts remarkably.

Parts MC Power Mode Switch Pilot Shut-Off Solenoid Valve Main Pump 1 Main Pump 2 Pilot Pump Pump 1 Regulator Pump 2 Regulator Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Solenoid Valve Pump 2 Control Solenoid Valve Main Relief Valve Boom Anti-Drift Valve Arm Anti-Drift Valve (Rod Side) Arm Regenerative Cut Valve Bucket Regenerative Valve Bucket Regeneration Cut Valve Arm 1 Flow Rate Control Valve Arm 2 Flow Rate Control Valve Bypass Shut-Out Valve Boom Lower Meter-In Cut Valve Boom Overload Relief Selection Valve Load Check Valve Spool Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Pressure Sensor (Arm Roll-In) Pressure Sensor (Arm Roll-Out) Pressure Sensor (Bucket Roll-In) Pressure Sensor (Bucket Roll-Out) Cylinder Pilot Valve Shockless Valve (Signal Control Valve) Shuttle Valve (Signal Control Valve) Pressure Sensor (Travel) Pressure Sensor (Swing) Pressure Sensor (4-Spool Side) Pressure Sensor (5-Spool Side) Swing Flow Rate Control Valve 4-Spool Solenoid Valve Unit (SG) 4-Spool Solenoid Valve Unit (SI) 4-Spool Solenoid Valve Unit (SF) 4-Spool Solenoid Valve Unit (SC) 2-Spool Solenoid Valve Unit (SC) 2-Spool Solenoid Valve Unit (SI) Pilot Filter Pilot Relief Valve Remark

F-11

F-12

Boom lower speed above ground is faster than other actuators when performing combined operation. Machine cannot be raised off the ground.

Arm speed is slow when performing arm level crowding operation. Arm power is weak when performing digging operation. 

  

 

  

 



 



 

 



 

 



 

T5-6-39

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom F-13

Parts MC Power Mode Switch Power Digging Switch Main Pump 1 Main Pump 2 Pilot Pump Pump 1 Regulator Pump 2 Regulator Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Solenoid Valve Pump 2 Control Solenoid Valve Main Relief Valve Boom Anti-Drift Valve Arm Anti-Drift Valve (Rod Side) Arm Regenerative Cut Valve Bucket Regenerative Valve Bucket Regeneration Cut Valve Arm 1 Flow Rate Control Valve Arm 2 Flow Rate Control Valve Bypass Shut-Out Valve Boom Lower Meter-In Cut Valve Boom Overload Relief Selection Valve Load Check Valve Spool Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Pressure Sensor (Arm Roll-In) Pressure Sensor (Arm Roll-Out) Pressure Sensor (Bucket Roll-In) Pressure Sensor (Bucket Roll-Out) Cylinder Pilot Valve Shockless Valve (Signal Control Valve) Shuttle Valve (Signal Control Valve) Pressure Sensor (Travel) Pressure Sensor (Swing) Pressure Sensor (4-Spool Side) Pressure Sensor (5-Spool Side) Swing Flow Rate Control Valve 4-Spool Solenoid Valve Unit (SG) 4-Spool Solenoid Valve Unit (SI) 4-Spool Solenoid Valve Unit (SF) 4-Spool Solenoid Valve Unit (SC) 2-Spool Solenoid Valve Unit (SC) 2-Spool Solenoid Valve Unit (SI) Pilot Filter Pilot Relief Valve Remark

Bucket roll-in speed is slow when performing combined operation of arm roll-in and bucket roll-in. 

 

 





 



 

T5-6-40

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Swing System Troubleshooting

Parts

S-2 S-1 Trouble Symptom Swing is slow or unmoving. When starting swing operation, swing speed is fast.

MC Monitor Controller Engine Control Dial Pilot Shut-Off Solenoid Valve Main Pump 1 Main Pump 2 Pilot Pump Pump 1 Regulator Pump 2 Regulator Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Control Pressure Sensor Pump 1 Control Solenoid Valve Swing Motor Swing Parking Brake Pilot Valve Swing Parking Brake Release Spool Shuttle Valve (Signal Control Valve) Arm Flow Rate Control Valve (Signal Control Valve) Arm 1 Flow Rate Control Valve Pressure Sensor (Swing) Pressure Sensor (Boom Lower) Pressure Sensor (Arm Roll-In) Pressure Sensor (Bucket Roll-In) Pressure Sensor (Bucket Roll-Out) 2-Spool Solenoid Valve Unit (SI) Pilot Filter Pilot Relief Valve Remark

S-3 Swing speed is slow when performing combined operation of swing and arm roll-in.



 

 







 

  





         

T5-6-41

 

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Travel System Troubleshooting Trouble Symptom T-1 Both of right and left travels are not operated or travel speed is slow.

Parts MC Monitor Controller Monitor Engine Control Dial Travel Mode Switch Main Pump 1 Main Pump 2 Pilot Pump Pump 1 Regulator Pump 2 Regulator Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Control Pressure Sensor Flow Combiner Valve Auxiliary Flow Combiner Valve Bypass Shut-Out Valve Spool Center Joint Travel Device Pilot Valve Flow Combiner Valve Control Spool Shuttle Valve (Signal Control Valve) Pressure Sensor (Travel) 4-Spool Solenoid Valve Unit (SC) Pilot Filter Pilot Relief Valve Remark

T-2 One side travel is not operated or travel speed is slow. Machine mistracks.

  

T-3 Machine mistracks when performing combined operation of travel and front attachment.

  



   

    





  



T5-6-42

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom T-4 Fast travel is can not be selected. Travel mode does not change from slow speed mode to fast speed Parts mode. MC  Monitor Controller Monitor Engine Control Dial Travel Mode Switch  (Fast Speed) MPDr. Main Pump 1  Main Pump 2  Pilot Pump  Pump 1 Regulator Pump 2 Regulator Pump 1 Delivery Pressure Sensor  Pump 2 Delivery Pressure Sensor  Pump 1 Control Pressure Sensor  Pump 2 Control Pressure Sensor  Flow Combiner Valve Auxiliary Flow Combiner Valve Bypass Shut-Out Valve Spool Center Joint Travel Device Pilot Valve Flow Combiner Valve Control Spool Shuttle Valve (Signal Control Valve) Pressure Sensor (Travel)  4-Spool Solenoid Valve Unit (SC)  Pilot Filter  Pilot Relief Valve  Remark

T5-6-43

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Other System Troubleshooting Trouble Symptom O-1 Work light does not light.

Parts MC Monitor Controller Wiper/Light Controller Monitor Work Light Switch Wiper/Washer Switch Wiper Relay Work Light Relay 1 Work Light Relay 2 Washer Relay Wiper Motor Fuse Box 1 MPDr. Door Open/Close Switch Cab Light Switch Washer Motor Work Light Boom Light Cab Light Remark

O-2 Boom light does not light.

   

   

O-3 Cab light does not light.



 

 (#1, #17)

 (#1, #17)

 (#9)  

  

T5-6-44

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom O-4 Parts Wiper does not operate. MC Monitor Controller  Wiper/Light Controller  Monitor  Work Light Switch Wiper/Washer Switch  Wiper Relay  Work Light Relay 1 Work Light Relay 2 Washer Relay Wiper Motor  Fuse Box 1  (#2, #17) MPDr. Door Open/Close Switch Cab Light Switch Washer Motor Work Light Boom Light Remark

O-5 Washer does not operate.

T5-6-45





  (#2, #17)



SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Trouble Symptom O-6 Parts Auto lubrication is faulty. MC  Monitor Controller  Auto-Lubrication Switch  Auto-Lubrication Relay  Distribution Valve  Grease Pump  Remark

T5-6-46

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Engine System Troubleshooting E-1 Starter does not rotate. Preparation  In case the radio with the key switch set in the ACC position and the horn with the key switch set in the OFF position are operated normally, the wire harness between battery and key switch terminal B is considered normal.

 Check that the pilot shut-off lever is in the LOCK position.  This trouble is not related to the electronic control system such as MC.  Check the wiring connections first. Procedure Inspection Method 1 Measure battery voltage and electrolyte density.

2

3

4

5

6 7 8 9

Condition -

Evaluation Cause The measured Faulty battery values are out of the specification. (Specification: Voltage: 24 V or more, Electrolyte density: 1.26 or more) The starter rotates. Faulty starter cut relay

Switch the starter cut relay Set the key switch to with other general relay. START after switching relays. 0V Measure voltage at starter Key Switch: START cut relay harness end #1 and #3. Measure voltage at starter Key Switch: START 0V relay 1 harness end terminal S. Measure voltage at starter Key Switch: ON 0V cut relay harness end #2. Measure voltage at battery relay terminal A. Measure voltage at starter terminal S. Check continuity between key switch #1 and #6. -

Key Switch: ON

0V

Open circuit in wire harness between key switch and starter cut relay Open circuit in wire harness between starter cut relay and starter relay 1 Short circuit in wire harness between starter cut relay and engine stop switch Faulty battery relay

Key Switch: START

0V

Faulty starter relay 1

Key Switch: START

∞Ω

Faulty key switch

-

The check mentioned above is normal.

Faulty starter

 Starter Cut Relay

 Starter Relay

b

TJAE-05-06-001 b-

 Key Switch

Terminals

TJAE-05-06-002

 Starter

TJAE-05-06-003

T5-6-47

TJAE-05-06-004

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-2 Even if starter rotates, engine does not start. Preparation  Check that the engine stop switch is in the OFF position.  Check that fuses #8 and #17 are normal.  Check the wiring connections first. Procedure Inspection Method Condition 1 Switch the ECM main relay Set the key switch to with other general relay. START after switching relays. 2 Monitor Engine Stop Engine Stop Switch: Switch. OFF 3 -

Evaluation The engine starts.

Cause Faulty ECM main relay

ON is displayed.

Faulty engine stop switch

The check mentioned above is normal.

Faulty ECM or engine unit (Refer to Engine Manual)

T5-6-48

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-3 Even if power mode switch is operated, power mode is not shifted. Preparation  Check the wiring connections first. Procedure Inspection Method 1 Monitor Power Mode Switch.

Condition Power Mode Switch: ON

Evaluation OFF is displayed.

2

-

The check mentioned above is normal.

-

T5-6-49

Cause Faulty power mode switch or open circuit in wire harness between power mode switch and MC Faulty MC

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-4 ECO mode is faulty.

Fast Idle Speed (ECO mode)

Specification (min−1) 1730±50

Remark

Preparation  In case other trouble symptoms occur, perform troubleshooting of these troubles first.  The sensors detect the conditions necessary to operate ECO mode. Therefore, if any of these sensors fails, ECO mode becomes ineffective.

Procedure Inspection Method 1 Check continuity between MC harness end #F9 and body. 2 Monitor Power Mode Switch and operate the power mode switch. 3 -

 Pump 1, 2 control pressure sensors, pump 1, 2 delivery pressure sensors are also related to the ECO mode control. However, if these sensors fail, other operating functions will be also affected.  Refer to SYSTEM/Control System/ECO Mode Control.  Check the wiring connections first.

Condition Power Mode Switch: ON

Evaluation ∞Ω

Key Switch: ON

OFF is displayed.

-

The check mentioned above is normal.

MC-F Connector

TJBG-05-05-007

T5-6-50

Cause Open circuit in wire harness between power mode switch and MC Faulty power mode switch

Faulty MC

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-5 Auto-idle system is faulty.

Auto-Idle Speed

Specification (min−1) 1180±50

Remark

 Even if the control lever is set to neutral, auto-idle system is not operated. Preparation  In case other trouble symptoms occur, perform troubleshooting of these troubles first.  Failure in pressure sensors (boom raise, boom lower, arm roll-in, arm roll-out, bucket roll-in, bucket roll-out, swing, travel, 4-spool side, 5-spool side, attachment (option)) may related to malfunction of the auto-idle control. However, if these sensors fail, other operating functions will be also affected. Procedure Inspection Method 1 Check continuity between MC harness end #F7 and body. 2 Monitor Auto-Idle Switch and turn ON the auto-idle switch. 3 -

 Refer to SYSTEM/Control System/Auto-Idle Control.  Check the wiring connections first.

Condition Evaluation Auto-Idle Switch: ON ∞ Ω

Key Switch: ON

OFF is displayed.

-

The check mentioned above is normal.

Cause Open circuit in wire harness between auto-idle switch and MC Faulty auto-idle switch

Faulty MC

 Even if the auto-idle switch is in the OFF position, autoidle system is operated. Preparation  Check the wiring connections first. Procedure Inspection Method 1 Check continuity between MC harness end #F7 and body. 2 Monitor Auto-Idle Switch and turn OFF the auto-idle switch. 3 -

Condition Evaluation Auto-Idle Switch: OFF 0 Ω

Key Switch: ON

ON is displayed.

-

The check mentioned above is normal.

MC-F Connector

TJBG-05-05-007

T5-6-51

Cause Short circuit in wire harness between auto-idle switch and MC Faulty auto-idle switch

Faulty MC

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B E-6 Auto shut-down is not activated. Preparation  Refer to SYSTEM/Control System and SYSTEM/ Electric System/Auto Shut-Down Control.  Check the wiring connections first. Procedure Inspection Method 1 Switch auto shut-down relay with other general relay. 2 Switch key switch ON cut relay with other general relay. 3 Switch ACC cut relay with other general relay. 4 Monitor Pilot Control ShutOFF Lever Switch. 5 -

Condition -

Evaluation The symptom disappears.

Cause Faulty auto shut-down relay

-

The symptom disappears.

Faulty key switch ON cut relay

-

The symptom disappears. ON is displayed.

Faulty ACC cut relay

The check mentioned above is normal.

Faulty MC

Pilot Shut-Off Lever: UNLOCK Position -

T5-6-52

Faulty pilot shut-off switch

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B All Actuator System Troubleshooting A-1 All actuators do not work. Preparation  The pilot shut-off circuit may be faulty.  Even if the key switch is set to the START position with the pilot shut-off lever in the UNLOCK position, the starter does not rotate.  Even if the key switch is set to the START position with the engine stop switch is in the ON position and the pilot shut-off lever is in the UNLOCK position, the starter rotates. Procedure Inspection Method 1 Monitor Pilot Control ShutOFF Lever Switch. 2 Switch the pilot shut-off relay with other general relay. 3 Switch the security relay with other general relay. 4 Measure resistance between solenoid valves #1 and #2. 5 Measure voltage between pilot shut-off solenoid valve harness end #1 and body. 6 Measure voltage between pilot shut-off relay harness end #1 and body. 7 Check continuity between pilot shut-off relay harness end #3 and body. 8

9

10

11

 Refer to SYSTEM/Electric System.  Check the wiring connections first.

Condition Pilot Shut-Off Lever: UNLOCK Position Pilot Shut-Off Lever: UNLOCK Position

Evaluation OFF is displayed.

Cause Faulty pilot shut-off switch

The symptom disappears.

Faulty pilot shut-off relay

Pilot Shut-Off Lever: UNLOCK Position -

The symptom disappears. 0/∞ Ω (Specification: 49 Ω)

Faulty security relay

Key Switch: ON

0V

Key Switch: ON

0V

Open circuit in wire harness between pilot shut-off solenoid valve and battery relay Open circuit in wire harness between pilot shut-off relay and battery relay Open circuit in wire harness between pilot shut-off solenoid valve and pilot shutoff relay Open circuit in wire harness between pilot shut-off relay and security relay

∞Ω Connect pilot shutoff solenoid valve harness end terminal #2 to the body. Check continuity between Connect pilot shut∞Ω security relay harness end off relay harness end #4 and body. terminal #5 to the body. Check continuity between ∞Ω security relay harness end #3 and body. Check continuity between 0Ω security relay harness end #2 and body. The check mentioned above is normal.

T5-6-53

Faulty pilot shut-off solenoid valve

Faulty ground in security relay Short circuit in wire harness between monitor controller and security relay Faulty monitor controller

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B  Pilot Shut-Off Solenoid Valve

 Security Relay

T1V1-05-04-003

 Pilot Shut-Off Relay TDC1-05-06-001

TDC1-05-06-005

T5-6-54

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-2 All actuator speed is slow.

Primary Pilot Pressure

Specification (MPa) 3.9+1.0-0

Remark Engine Control Dial: Fast Idle

Preparation  Decrease of pump 1, 2 flow rate due to some reasons or faulty pilot system (A-1) may cause this trouble.  Even if speed is satisfactory, in case power is weak, refer to the troubleshooting for faulty main relief valve (F-1).  Check the wiring connections first. Procedure Inspection Method 1 Monitor Boom Raise Pilot Pressure and relieve the boom raise circuit.

Condition -

2

-

-

Evaluation The measured values are out of the specification. (Specification: 3.4-4.0 MPa) The check mentioned above is normal.

T5-6-55

Cause Faulty pilot relief valve or clogged pilot filter

Faulty pump device

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-3 Travel (right) operation speed is slow when performing travel single operation. Bucket single operation speed is slow. (All problems occur at the same time.) Preparation  The pump 1 flow rate is minimized due to some reasons. Travel (right) and bucket, which are driven by pressure oil from pump 1, move very slowly.  Refer to SYSTEM /Control System, Hydraulic System. Procedure Inspection Method 1 Monitor Pump 1 S/A Cont Pressure. 2

-

Condition Evaluation Operate travel (right) Pressure does not control lever. increase according to control lever stroke. The check mentioned above is normal.

T5-6-56

Cause Stuck pump 1 control solenoid valve Faulty pump 1 regulator

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-4 Travel (left) operation speed is slow when performing travel single operation. Preparation  The pump 2 flow rate is minimized due to some reasons. Travel (left) which is driven by pressure oil from pump 2, move very slowly.  Refer to SYSTEM/Control System, Hydraulic System. Procedure Inspection Method 1 Monitor Pump 2 S/A Cont Pressure.

Condition Operate travel (left) control lever.

2

-

-

Evaluation Pressure does not increase according to control lever stroke. The check mentioned above is normal.

T5-6-57

Cause Stuck pump 2 control solenoid valve Faulty pump 2 regulator

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-5 Actuator does not stop even if control lever is set to neutral. Preparation  Stuck spool in the pilot valve or stuck main spool in the control valve is suspected. Procedure Inspection Method 1 Set the pilot shut-off lever to the LOCK position. 2 -

Condition -

Evaluation The actuator stops.

-

The check mentioned above is normal.

T5-6-58

Cause Faulty pilot valve (stuck spool) Faulty control valve (stuck spool)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-6 Fan rotation speed does not change. Preparation  Check the wiring connections first. Procedure Inspection Method 1 Monitor Fan Sp Con P/S 1 O/P FB.

Condition Air conditioner switch: ON

2

-

-

Evaluation Fan Speed Control P/S 1 output FB does not change according to the engine control dial. The check mentioned above is normal.

T5-6-59

Cause Faulty fan pump control solenoid valve or faulty MC

Faulty fan pump regulator

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-7 Oil cooler fan rotation reverse does not change. Preparation  Refer to SYS TEM/Control System/Oil Cooler Fan Reverse Control.  Refer to SYS TEM/Hydraulic System/Oil Cooler Fan Reverse Control Circuit.  Check the wiring connections first. Procedure Inspection Method 1 Monitor F/M Rotation Dir Cont Switch

Condition Fan Reverse Switch: ON

2

Monitor Fan Dir Cont P/S 1 Fan Reverse Switch: O/P FB ON

3

-

-

Evaluation OFF is displayed

Cause Faulty fan reverse switch Open circuit in harness between reverse switch and MC Bound fan reverse rotation control solenoid valve

The reverse rotation control solenoid valve out put does not change The check mentioned Faulty oil fan valve above is normal

T5-6-60

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B A-8 Radiator fan rotation reverse does not change. Preparation  Refer to SYS TEM/Control System/Radiator Fan Reverse Control.  Refer to SYS TEM/Hydraulic System/Radiator Fan Reverse Control Circuit.  Check the wiring connections first. Procedure Inspection Method 1 Monitor F/M Rotation Dir Cont SW

Condition Fan Reverse Switch: ON

2

Monitor Fan Dir Cont P/S 2 Fan Reverse Switch: O/P FB ON

3

-

-

Evaluation OFF is displayed

Cause Faulty fan reverse switch Open circuit in harness between reverse switch and MC Bound fan reverse rotation control solenoid valve

The reverse rotation control solenoid valve out put does not change The check mentioned Faulty oil fan valve above is normal

T5-6-61

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Front Attachment System Troubleshooting F-1 All front attachment actuator power is weak. Main Relief Valve Specification (MPa) Remark Set Pressure Boom Raise, Arm, 31.9+2.0−0.5 Bucket (Relief operation for each) Preparation  If operating speeds are extremely slow, pump control may be faulty (A-3, A-4). Faulty pilot system may also cause this trouble. Procedure Inspection Method 1 Monitor Pump 1 Delivery Pressure, and Pump 2 Delivery Pressure. 2 -

Condition When relieving arm

-

Evaluation The measured values are out of the specification. The check mentioned above is normal.

T5-6-62

Cause Faulty main relief valve (readjust) Find out cause of trouble by tracing other trouble symptoms.

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-2 Even if power digging switch is pushed, power does not increase or boom raise power is weak when performing digging operation. Main Relief Valve Set Pressure Power Digging

Specification (MPa) Remark 35.3+2.0−0.5

Preparation  Refer to SYSTEM/Control System/Power Digging Control and Auto-Power Lift Control.  Check the wiring connections first. Procedure Inspection Method 1 Monitor Power Boost Switch.

Condition Power Digging Switch: ON

Evaluation OFF is displayed.

2

Monitor Pump 1 Delivery Pressure, and Pump 2 Delivery Pressure.

Relieve boom raise circuit.

3

-

-

The measured values are out of the specification. (Specification: 33.8-36.3 MPa) The check mentioned Faulty MC above is normal.

T5-6-63

Cause Faulty power digging switch, or open circuit in wire harness between power digging switch and MC Faulty main relief valve

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-3 Some cylinders are not operated or speeds are slow. Overload Relief Valve Set Pressure Boom, Arm, Bucket Boom Lower

Specification (MPa) 36.3+1.0−0

Remark

11.8

Boom Mode Selector Switch: ON

Preparation  When other actuators (travel and swing motors) are operated normally, the pilot pump (primary pilot pressure) is considered to be normal. Procedure Inspection Method 1 Monitor Boom Raise Pilot Pressure and Arm Roll-In Pilot Pressure.

Condition Fully operate boom raise and arm roll-in.

2

Slowly operate the control lever.

3

4

Monitor Pump 1 S/A Cont Pressure and Pump 2 S/A Cont Pressure. Switch overload relief valves, of which the set pressure are same. -

-

-

Evaluation The measured values are out of the specification. (Specification: 3.4-4.0 MPa) Pump displacement angle control pressure changes smoothly. Symptom is reversed.

Cause Faulty pilot valve or stuck spool of shockless valve in signal control valve (only boom raise)

The check mentioned above is normal.

Stuck control valve spool, or faulty cylinder (faulty seal kit)

T5-6-64

Faulty shuttle valve in signal control valve Faulty overload relief valve

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-4 Bucket roll-in speed is slow and power is weak when performing digging operation. Preparation  Refer to SYSTEM/Hydraulic System/Bucket

Regenerative Cut Circuit.

 Check the wiring connections first. Procedure Inspection Method 1 Disassemble and inspect the bucket regeneration cut valve. 2 Disassemble and inspect the bucket regenerative valve. 3 -

Condition -

Evaluation There is abnormality.

Cause Faulty bucket regeneration cut valve

-

There is abnormality.

Faulty bucket regenerative valve

-

The check mentioned above is normal.

Find out cause of trouble by tracing other trouble symptoms.

T5-6-65

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-5 Even if the boom mode selector switch is pushed, machine is raised off the ground. Preparation  Refer to SYSTEM/Control System/Boom Mode

Selector Control

 Check the wiring connections first. Procedure Inspection Method 1 Monitor Boom Mode Switch.

Condition Evaluation Boom Mode Selector OFF is displayed. Switch: ON

2

-

There is abnormality.

-

The check mentioned above is normal.

3

Disassemble and inspect the boom overload relief selection valve. -

T5-6-66

Cause Faulty boom mode selector switch, or open circuit in wire harness between boom mode selector switch and MC Faulty boom overload relief selection valve Find out cause of trouble by tracing other trouble symptoms.

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-6 Boom raise speed is slow when performing combined operation of swing and boom raise. Arm roll-out speed is slow when performing combined operation of swing and arm roll-out Preparation  In case other trouble symptoms occur, perform troubleshooting of these troubles first.  Refer to SYSTEM/Hydraulic System/Swing Flow Rate Control Circuit. Procedure Inspection Method Condition 1 Disassemble and inspect the swing flow rate control valve. 2 -

Evaluation There is abnormality.

Cause Faulty digging swing flow rate control valve

The check mentioned above is normal.

Find out cause of trouble by tracing other trouble symptoms.

T5-6-67

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-7 When performing combined operation, arm does not start to move smoothly. Arm starts to move slightly slow when performing arm single operation. These troubles often occur when temperature is low. Preparation  Refer to COMPONENT OPERATION/Control Valve Procedure Inspection Method 1 Disassemble and inspect the arm anti-drift valve. 2 Disassemble and inspect the arm regenerative valve. 3 -

Condition -

Evaluation There is abnormality.

Cause Faulty arm anti-drift valve

-

There is abnormality.

Faulty arm regenerative valve

-

The check mentioned above is normal.

Find out cause of trouble by tracing other trouble symptoms.

T5-6-68

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-8 When performing combined operation, boom does not start to move smoothly. Boom starts to move slightly slow when performing boom lower single operation. Preparation  Refer to COMPONENT OPERATION/Control Valve Procedure Inspection Method 1 Disassemble and inspect the boom anti-drift valve. 2 Disassemble and inspect the boom lower meter-in cut valve. 3 -

Condition -

Evaluation There is abnormality.

Cause Faulty boom anti-drift valve

-

There is abnormality.

Faulty boom lower meter-in cut valve

-

The check mentioned above is normal.

Find out cause of trouble by tracing other trouble symptoms.

T5-6-69

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-9 When boom raise or arm roll-out is operated, boom or arm starts to move after moving slightly down.

When the load check valve is faulty:

Preparation (B)

 When start to operate control lever, oil pressure and flow rate from the pump is low. Therefore, if the load check valve is faulty, the load on the boom cylinder is applied, the oil in the bottom side of the boom cylinder flows back into the circuit through the load check valve. Therefore, the boom cylinder is temporarily retracted.  As oil pressure and flow rate from the pump is low, if oil leaks from bottom side (A) to rod side (B) due to faulty boom cylinder piston or cylinder tube, the boom cylinder is temporarily retracted when performing the initial stage of operation. The cylinder becomes the lack of force. The cylinder drift increases in this case. Procedure Inspection Method 1 Disassemble and inspect the load check valve. 2 Disassemble and inspect the anti-drift valves (boom, arm). 3 -

(A)

T105-07-04-012

Condition -

Evaluation There is abnormality.

Cause Faulty load check valve

-

There is abnormality.

Faulty anti-drift valve

-

The check mentioned above is normal.

Faulty cylinder (seal kit)

T5-6-70

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-10 Front attachment drifts remarkably.  Boom Cylinder Internal Leakage Check 1. With the bucket cylinder fully retracted and the arm cylinder slightly extended from the fully retracted position, lower the bucket tooth tips onto the ground. 2. Disconnect the hoses from the boom cylinder rod side. Drain oil from the hoses and cylinders. (Plug the disconnected hose ends.) 3. Retract the arm cylinder and lift the bucket off the ground. If oil flows out of the hose disconnected piping ends and the boom cylinders are retracted at this time, oil leaks in the boom cylinders. If no oil flows out of the hose disconnected piping ends but the boom cylinders are retracted, oil leaks in the control valve. Procedure Inspection Method 1 Set the pilot shut-off lever to the LOCK position. 2 Switch overload relief valves. 3 Disassemble and inspect the anti-drift valves (boom, arm). 4 Disassemble and inspect the emergency valve. 5 Disassemble and inspect the cylinder. 6 -

Condition -

T105-07-04-009

Cause Faulty pilot valve

-

Evaluation The symptom disappears. The symptom disappears. There is abnormality.

-

There is abnormality.

Faulty emergency valve

-

There is abnormality.

Faulty cylinder (seal kit)

-

The check mentioned above is normal.

Scored control valve spool, broken spring, or loose spool end

-

T5-6-71

Faulty overload relief valve Faulty anti-drift valve

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-11 Boom lower speed above ground is faster than other actuators when performing combined operation. Machine cannot be raised off the ground. Preparation  The boom lower meter-in cut valve or boom flow rate control valve may be faulty.  Refer to SYSTEM/Hydraulic System and COMPONENT OPERATION/Control Valve.  In case boom lower single operation speed is slow, also refer to F-8.  In case machine cannot be raised off the ground, also check boom mode selector control (F-5). Procedure Inspection Method 1 Disassemble and inspect the boom lower meter-in cut valve. 2 Disassemble and inspect the bypass shut-out valve. 3 -

Condition -

Evaluation There is abnormality.

Cause Faulty boom lower meter-in cut valve

-

There is abnormality.

Faulty bypass shut-out valve

-

The check mentioned above is normal.

Find out cause of trouble by tracing other trouble symptoms.

T5-6-72

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-12 Arm speed is slow when performing arm level crowding operation. Arm power is weak when performing digging operation. Preparation  Refer to SYSTEM/Hydraulic System/Arm Regenerative Cut Circuit. Procedure Inspection Method 1 Disassemble and inspect the arm regenerative cut valve. 2 -

Condition -

Evaluation There is abnormality.

Cause Faulty arm regenerative cut valve

-

The check mentioned above is normal.

Find out cause of trouble by tracing other trouble symptoms.

T5-6-73

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B F-13 Bucket roll-in speed is slow when performing combined operation of arm roll-in and bucket roll-in. Preparation  Refer to SYSTEM/Control System/Arm 2 Flow

Rate Control.

Procedure Inspection Method 1 Measure pressure at port SG of 4-spool solenoid valve unit.

2

3

Condition Combined operation of arm roll-in and bucket roll-in

Disassemble and inspect the arm 2 flow rate control valve. -

Evaluation The measured values are out of the specification. (Specification: approx. 4.0 MPa) There is abnormality.

Cause Stuck spool in 4-spool solenoid valve unit SG

The check mentioned above is normal.

Find out cause of trouble by tracing other trouble symptoms.

T5-6-74

Faulty arm 2 flow rate control valve

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Swing System Troubleshooting S-1 Swing is slow or unmoving.

Swing Speed

Specification (sec/3 rev) 23.7±1.5

Remark The bucket should be empty

Preparation  Check whether the pilot system is faulty or the main circuit is faulty.  If other functions (front attachment and travel) are operated normally, the pilot pump (primary pilot pressure) and pump flow rate control are considered to be normal. If the pilot system is faulty, the cause of trouble may exist in the circuit downstream of the pilot valve. Procedure Inspection Method 1 Monitor Swing Pilot Pressure.

Condition Fully swing

2

Monitor Front ATT Pilot Pressure.

When relieving arm

3

Disassemble and inspect the parking brake release valve in the swing motor. Monitor Pump 2 Delivery Pressure.

-

4

5 6

Measure the swing motor drainage. -

Evaluation The measured values are out of the specification. (Specification: 3.4-4.0 MPa) The measured values are out of the specification. (Specification: 3.4-4.0 MPa) There is abnormality.

Cause Faulty pilot valve

Faulty swing parking brake release spool in signal control valve

Faulty swing parking brake release valve

When relieving swing The measured Faulty swing relief valve values are out of the specification. (Specification: 28.9-31.4 MPa) With constant speed Refer to T4-5 Swing Faulty swing motor Motor Drainage. The check mentioned Faulty swing reduction gear above is normal.

T5-6-75

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B S-2 When starting swing operation, swing speed is fast. Preparation  Refer to SYSTEM/Control System/Swing High Pressure Power Decrease Control. Procedure Inspection Method 1 Monitor Swing Pilot Pressure.

2

3

4

5

Monitor Pump 1 Delivery Pressure.

Condition Combined operation of Fully swing and boom lower. Combined operation of Fully swing and bucket. When relieving bucket.

Evaluation The measured values are out of the specification. (Specification: 3.4-4.0 MPa)

The measured values are out of the specification. (Specification: 31.4-33.9 MPa) Monitor Pump 2 Delivery When relieving The measured Pressure. swing. values are out of the specification. (Specification: 31.4-33.9 MPa) Measure pressure at port Combined operation The measured SI of 2-spool solenoid valve of swing and arm values are out of unit. roll-out. the specification. (Specification: 3.4-4.0 MPa) The check mentioned above is normal.

T5-6-76

Cause Faulty pilot valve

Faulty pump 1 regulator

Faulty pump 2 regulator

Stuck spool in 2-spool solenoid valve unit (SI)

Find out cause of trouble by tracing other trouble symptoms.

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B S-3 Swing speed is slow when performing combined operation of swing and arm roll-in. Preparation  In case other trouble symptoms occur, perform troubleshooting of these troubles first.  Refer to SYSTEM/Hydraulic System/Arm 1 Flow Rate Control Circuit. Procedure Inspection Method 1 Monitor Swing Pilot Pressure.

Condition Fully swing.

2

Measure pressure at port SE of signal control Valve.

Fully swing.

3

Disassemble and inspect the arm 1 flow rate control valve. -

4

Evaluation The measured values are out of the specification. (Specification: 3.4-4.0 MPa) The measured values are out of the specification. (Specification: 31.9 MPa) There is abnormality.

Cause Faulty pilot valve

The check mentioned above is normal.

Find out cause of trouble by tracing other trouble symptoms.

a

b

TJAA-05-07-002 a-

Control Valve Side

b-

Port SE

T5-6-77

Faulty arm flow rate control valve control spool in signal control valve Faulty arm 1 flow rate control valve

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Travel System Troubleshooting T-1 Both of right and left travels are not operated or travel speed is slow. Travel Speed Fast Speed Slow Speed

Specification (sec/20 m) 15.5±2.0 22.9±2.0

Remark

Preparation  Both right and left pilot valves, travel motors, and/or control valve spools are unlikely to be faulty at the same time.  If both travel systems are not operated, the pilot system, which is applied to both side travel motors, may be faulty. If the primary pilot pressure is lower than specification, the front attachment operating speed becomes slow as well. Refer to A-2.  If the fast travel mode cannot be selected, refer to T-4.

T5-6-78

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-2 One side travel is not operated or travel speed is slow. Machine mistracks. Track Revolution Speed Fast Speed

Specification (sec/3 rev) 28.5±2.0

Slow Speed

42.0±2.0

Remark 870LC, 890LCH: 30.9±2.0 870LC, 890LCH: 45.5±2.0  In only one side track does not rotate, the pilot valve, the control valve, the travel motor, or the center joint may be faulty.

Preparation  Check that both side track sags are equally adjusted.  Faulty pump control will cause the machine to mistrack. Refer to A-3 or A-4. Procedure Inspection Method 1 Monitor Travel Pilot Pressure.

2

3

4

5

6 7

8

Condition Operate the control lever alternately.

Evaluation The measured values are out of the specification. (Specification: 3.4-4.0 MPa) Symptom is reversed.

Switch right and left travel line hoses each other on the top of center joint. Monitor Pump 1 Delivery When relieving travel The measured values are out of Pressure and Pump 2 the specification. Delivery Pressure. (Specification: approx. 32.3 MPa) Symptom is reversed. Switch forward travel relief valve with reverse travel one, or right travel relief valve with left one. Measure the travel motor With the motor The measured drainage. relieved values are out of the specification. (Specification: less than 5 L/min) Disassemble and inspect There is abnormality. the counterbalance valve. Disassemble and inspect There is abnormality. the travel motor servo piston. The check mentioned above is normal.

T5-6-79

Cause Faulty pilot valve

Stuck control valve spool

Faulty travel relief valve

Faulty center joint

Faulty travel motor

Faulty counterbalance valve Faulty travel motor servo piston. Faulty travel reduction gear

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-3 Machine mistracks when performing combined operation of travel and front attachment. Procedure Inspection Method 1 Measure pressure at port SL of signal control valve.

Condition Combined operation of travel and front attachment.

2

Disassemble and inspect the flow combiner valve. Disassemble and inspect the load check valve. -

3 4

Cause Faulty flow combiner valve control spool in signal control valve

-

Evaluation The measured values are out of the specification. (Specification: 3.4-4.0 MPa) There is abnormality.

-

There is abnormality.

Faulty load check valve

-

The check mentioned above is normal.

Find out cause of trouble by tracing other trouble symptoms.

a

b

TJAA-05-07-002 a-

Control Valve Side

b-

Port SL

T5-6-80

Faulty flow combiner valve

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B T-4 Fast travel can not be selected. Travel mode does not change from slow speed mode to fast speed mode. Preparation  Refer to SYSTEM/Control System/Travel Motor Displacement Angle Control.  Check the wiring connections first. Procedure Inspection Method 1 Monitor Travel Mode Switch.

2

Monitor Travel Pilot Pressure.

3

Measure pressure at port SC of 4-spool solenoid valve

4

Disassemble and inspect the travel motor displacement angle control valve. -

5

Condition Evaluation Cause Shift the travel mode HI/LO of travel mode are Faulty travel mode switch or switch. not shifted. open circuit in wire harness between travel mode switch and MC Operate travel Pressure does not Faulty pressure sensor (travel) function. change according to control lever stroke. Stuck spool in 4-spool valve Travel Mode Switch: The measured unit (SC) Fast Speed values are out of the specification. (Specification: approx 4.0 MPa) There is abnormality. Faulty travel motor displacement angle control valve -

The check mentioned above is normal.

T5-6-81

Faulty travel motor or travel reduction gear

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Other System Troubleshooting O-1 Work light does not light. Preparation  Check that the work lights are not broken.  Refer to SYSTEM/Electrical System.  Check the wiring connections first. Procedure Inspection Method 1 Monitor Work Light 1 Output.

Condition Work Light Switch: 1 position

Evaluation OFF is displayed.

2

Monitor Work Light 1 Switch.

Work Light Switch: 1 position

OFF is displayed.

3

-

-

The check mentioned above is normal.

T5-6-82

Cause Faulty work light relay 1 or open circuit in wire harness between work light relay 1 and wiper/light controller Faulty work light switch or open circuit in wire harness between work light switch and wiper/light controller Faulty wiper/light controller

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-2 Boom light does not light. Preparation  Check that the boom lights are not broken.  Refer to SYSTEM/Electrical System.  Check the wiring connections first. Procedure Inspection Method 1 Monitor Work Light 2 Output.

Condition Work Light Switch: 2 position

Evaluation OFF is displayed.

2

Monitor Work Light 2 Switch.

Work Light Switch: 2 position

OFF is displayed.

3

-

-

The check mentioned above is normal

T5-6-83

Cause Faulty work light relay 2 or open circuit in wire harness between work light relay 2 and wiper/light controller Faulty work light switch or open circuit in wire harness between work light switch and wiper/light controller Faulty wiper/light controller

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-3 Cab light does not light. Preparation  Refer to SYSTEM/Electrical System.  Check the wiring connections first. Procedure Inspection Method 1 Monitor Cab Light Switch.

Condition Door Open/Close Switch: ON

Evaluation OFF is displayed.

2

Monitor Cab Light 1 Output.

Cab Light Switch: Door Position

OFF is displayed.

3

Monitor Cab Light 2 Output.

Cab Light Switch: ON OFF is displayed. Position

4

-

-

The check mentioned above is normal.

T5-6-84

Cause Faulty door open/close switch or open circuit in wire harness between door open/ close switch and wiper/light controller Faulty cab light switch (Door Interlocking Position) or open circuit in wire harness between cab light switch and wiper/light controller Faulty cab light switch (ON Position) or open circuit in wire harness between cab light switch and wiper/light controller Faulty wiper/light controller

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-4 Wiper is not operated. Preparation  The wiper is driven by electric power routed via the relay circuit. The relay circuit is controlled by the wiper/light controller.  When the wiper is not operated, first check if the wiper relay is activated. Next, check if electric power is routed to the wiper motor. Procedure Inspection Method 1 Switch the wiper relay with other general relay. 2 Monitor Wiper 1 Input (or Wiper 2 Input).

3

4

5

6

 When the front window is open, the wiper is not operated. Check that the front window is closed securely.  When the washer is also not operated, check fuse #2.

Condition Key Switch: ON

Wiper Switch: ON Position (or Overhead Window Wiper Switch: ON Position) Monitor Wiper 1 Output (or Wiper Switch: ON Wiper 2 Output). Position (or Overhead Window Wiper Switch: ON Position) Measure voltage between Key Switch: ON window contact (cab side) Wiper Switch: ON terminals B and L. Measure voltage between Key Switch: ON Wiper Switch: ON window contact (wiper motor side) terminals B and L. -

Evaluation The wiper is operated.

Cause Faulty wiper relay

OFF is displayed.

Faulty wiper switch or open circuit in wire harness between wiper switch and wiper/light controller

OFF is displayed.

Open circuit in wire harness between wiper relay and wiper/light controller

0V

Open circuit in wire harness between wiper relay and window contact Open circuit in wire harness between window contact and wiper motor

0V

The check mentioned above is normal.

Faulty wiper motor

Wiper Driving Circuit 1

2

3 1-

Wiper Motor

2-

Wiper Relay

3-

T5-6-85

Window Contact

T1V1-05-07-004

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-5 Washer is not operated. Preparation  Refer to SYSTEM/Electrical System.  Check the wiring connections first. Procedure Inspection Method 1 Switch the washer relay with other general relay. 2 Monitor Washer 1 Switch (or Washer 2 Switch).

3

Monitor Washer 1 Output (or Washer 2 Output).

4

-

Condition Key Switch: ON

Evaluation Cause The washer is operated. Faulty washer relay

Washer Switch: ON OFF is displayed. Position (or Overhead Window Washer Switch: ON Position) Washer Switch: ON OFF is displayed. Position (or Overhead Window Washer Switch: ON Position) The check mentioned above is normal.

T5-6-86

Faulty washer switch or open circuit in wire harness between washer switch and wiper/light controller Open circuit in wire harness between washer relay and wiper/light controller Faulty washer motor

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B O-6 Auto lubrication is faulty. Preparation  Refer to SYSTEM/Control System/Auto-Lubrication Control.  Check the wiring connections first.  Even if the auto lubrication switch is ON, autolubrication is inoperable.  Interval: 90 minutes (variable between 10 and 90 minutes), Lubrication time: 5 minutes Procedure Inspection Method 1 Switch the auto-lubrication relay with other general relay. 2 Monitor AG Main Switch.

Condition Auto-lubrication Switch: ON

Evaluation The grease pump is operated.

Cause Faulty auto-lubrication relay

Auto-lubrication Switch: ON

OFF is displayed.

3

Monitor AG Limit Switch.

Auto-lubrication Switch: ON

ON/OFF does not display alternately.

4

Monitor AG Output.

Auto-lubrication Switch: ON

OFF is displayed.

5

Check continuity between Auto-lubrication auto-lubrication relay #2 Switch: ON and machine. -

Faulty auto-lubrication switch or open circuit in wire harness between auto-lubrication switch and MC Faulty proximity switch Open circuit in wire harness between proximity switch and MC or open circuit in wire harness between proximity switch and auto-lubrication relay Faulty grease pump or open circuit in wire harness between grease pump and auto-lubrication relay Open circuit in wire harness between auto-lubrication relay and MC Damaged lubrication pipings between grease pump and distribution valve or faulty distribution valve

6

0Ω

The check mentioned above is normal.

T5-6-87

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B  Auto-lubrication does not start even lubrication time is passed. Even if auto-lubrication switch is OFF, auto-lubrication does not stop.  Interval: 60 minutes (variable between 10 to 90 minutes), lubrication time: 5 minutes.

Procedure Inspection Method 1 Switch the auto-lubrication relay with other general relay. 2 Monitor AG Main Switch.

Condition Evaluation Auto-lubrication ON/ Grease pump operates. OFF Switch: OFF

Cause Faulty auto-lubrication relay

Auto-lubrication ON/ ON OFF Switch: OFF

3

-

Faulty auto-lubrication switch or short circuit in wire harness between auto-lubrication switch and MC Short circuit in wire harness between auto-lubrication relay and MC or faulty MC

-

The check mentioned above is normal.

 When auto-lubrication stops, auto-lubrication alarm is generated.  Shortage of grease or faulty proximity switch may be the cause. Inspect the following items. 1. Grease level in the cartridge 2. Air mixture in the circuit 3. Plug is installed to the grease cartridge 4. Faulty proximity switch

T5-6-88

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Exchange Inspection Exchange inspection method is a troubleshooting method to find the trouble location by exchanging the suspected part/component with another part / component having identical characteristics. Many sensors and solenoid valves used on this machine are identical. Therefore, by using this switch-check method, faulty part /component, and/or harness can be easily found. Ex.) Abnormal pump 1 delivery pressure high voltage (MC fault code: 11200-3) 1

2

Check Method: 1. Switch connectors of pump 1 delivery pressure sensor and pump 2 delivery pressure sensor.

TJBA-04-05-001

1-

2. Retry troubleshooting. Result: In case abnormal pump 2 delivery pressure high voltage (MC fault code 11202-3) is displayed, the pump 1 delivery pressure sensor is considered to be faulty. In case abnormal pump 1 delivery pressure high voltage (MC fault code 11200-3) is displayed, the pump 1 delivery pressure sensor harness is considered to be faulty.

T5-6-89

Pump 1 Delivery Pressure Sensor

2-

Pump 2 Delivery Pressure Sensor

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Applicability of Switch-Check Method Fault Code Trouble 11200-3 Pump 1 Delivery Pressure Sensor Circuit High Input 11200-4 Pump 1 Delivery Pressure Sensor Circuit Low Input 11202-3 Pump 2 Delivery Pressure Sensor Circuit High Input 11202-4 Pump 2 Delivery Pressure Sensor Circuit Low Input 11994-3 Pump 1 Reg-Pressure Sensor Circuit High Input 11994-4 Pump 1 Reg-Pressure Sensor Circuit Low Input 11992-3 Pump 2 Reg-Pressure Sensor Circuit High Input 11992-4 Pump 2 Reg-Pressure Sensor Circuit Low Input 11301-3 Swing Pilot Pressure Sensor Circuit High Input 11301-4 Swing Pilot Pressure Sensor Circuit Low Input 11302-3 Boom Raise Pilot Pressure Sensor Circuit High Input 11302-4 Boom Raise Pilot Pressure Sensor Circuit Low Input 11303-3 Arm Roll-In Pilot Pressure Sensor Circuit High Input 11303-4 Arm Roll-In Pilot Pressure Sensor Circuit Low Input 11304-3 Travel Pilot Pressure Sensor Circuit High Input 11304-4 Travel Pilot Pressure Sensor Circuit Low Input 11325-3 Bucket Roll-In Pilot Pressure Sensor Circuit High Input 11325-4 Bucket Roll-In Pilot Pressure Sensor Circuit Low Input 11942-3 Attachment Pilot Pressure Sensor Circuit Hign Input (Option) 11942-4 Attachment Pilot Pressure Sensor Circuit Low Input (Option) 11944-3 Signal Control Valve SB-Port Pressure Sensor Circuit High Input (5-Spool Side Pilot Pressure Sensor) 11944-4 Signal Control Valve SB-Port Pressure Sensor Circuit Low Input (5-Spool Side Pilot Pressure Sensor) 11945-3 Signal Control Valve SA-Port Pressure Sensor Circuit High Input (4-Spool Side Pilot Pressure Sensor) 11945-4 Signal Control Valve SA-Port Pressure Sensor Circuit Low Input (4-Spool Side Pilot Pressure Sensor) 11995-3 Arm Roll-Out Pilot Pressure Sensor Circuit High Input 11995-4 Arm Roll-Out Pilot Pressure Sensor Circuit Low Input 11997-3 Bucket Roll-Out Pilot Pressure Sensor Circuit High Input 11997-4 Bucket Roll-Out Pilot Pressure Sensor Circuit Low Input 11998-3 Boom Lowering Pilot Pressure Sensor Circuit High Input 11998-4 Boom Lowering Pilot Pressure Sensor Circuit Low Input

T5-6-90

Remedy Applicable (Wire Harness/Sensor)

Applicable (Wire Harness/Sensor)

Applicable (Wire Harness/Sensor)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B Fault Code 11950-3 11950-4 11951-3 11951-4 11405-3 11405-4 11408-3 11408-4 11428-3 11428-4 11948-3 11948-4 11953-3 11953-4 11989-3 11989-4

Trouble Pump 2 P/S Valve FB High Current Pump 2 P/S Valve FB Low Current Pump 1 P/S Valve FB High Current Pump 1 P/S Valve FB Low Current Travel Swash Angle P/S Valve FB High Current (4-Spool Solenoid Valve Unit (SC)) Travel Swash Angle P/S Valve FB Low Current (4-Spool Solenoid Valve Unit (SC)) Center Bypass Cut P/S Valve FB High Current Center Bypass Cut P/S Valve FB Low Current Arm 2 Flow Rate Control P/S Valve FB High Current Arm 2 Flow Rate Control P/S Valve FB Low Current Main Relief Pressure Control P/S Valve FB High Current (4-Spool Solenoid Valve Unit (SI)) Main Relief Pressure Control P/S Valve FB Low Current (4-Spool Solenoid Valve Unit (SI)) Swing Flow Rate Control P/S Valve FB High Current (2-Spool Solenoid Valve Unit (SI)) Swing Flow Rate Control P/S Valve FB Low Current (2-Spool Solenoid Valve Unit (SI)) Boom Mode Control P/S Valve FB High Current (2-Spool Solenoid Valve Unit (SC)) Boom Mode Control P/S Valve FB Low Current (2-Spool Solenoid Valve Unit (SC))

T5-6-91

Remedy Applicable (Wire Harness/ Solenoid Valve)

Applicable (Wire Harness/ Solenoid Valve)

Applicable (Wire Harness/ Solenoid Valve)

SECTION 5 TROUBLESHOOTING Group 6 Troubleshooting B How to Lowering Boom When Emergency and When Engine Stops

3

Prevent personal injury. Confirm dCAUTION: that no one is under the front attachment before starting the procedure below.

If the engine stalls and cannot be restarted, lower the boom to the ground referring to the following procedure. 1. Loosen lock nut (1) of emergency valve (3). Loosen screw (2) 1/2 turn. The boom lowering speed can be somewhat adjusted by loosening screw (2) more. 2. After the boom is lowered, tighten screw (2) and tighten lock nut (1) to the specifications below.

TJAA-04-05-003

Lock Nut (1) j : 10 mm

3-

Emergency Valve

m : 15 N·m (1.5 kgf·m)

2

Screw (2)

1

l : 3 mm m : 6.0 N·m (0.6 kgf·m)

fNOTE:

Excessive leakage may result if the screw and lock nut are tightened insufficiently. Tighten the screw and lock nut with above-mentioned tightening torque.

TJAA-05-07-001 1-

T5-6-92

Lock Nut

2-

Screw

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Outline Configuration layout of the air conditioning system is illustrated below. Either fresh or re-circulated air is induced into the air conditioner unit by operating fresh/re-circulated air damper servo motor (6). The induced air flows out of the vents through evaporator (5) or heater (15) by blower motor (11). Evaporator (5) is a device used to cool the air. Heater (15) is a device used to warm the air. In the air conditioning system, after the refrigerant is compressed by the compressor, it is sent to evaporator (5) in which the refrigerant expands to cool the air. Heater (15) warms air by absorbing heat from warmed engine coolant. The temperature is kept at the set temperature by adjusting evaporator (5) and heater (15).

The vents (operator’s front/rear vent, foot vent, and the front window) can be simultaneously or independently selected by air vent damper servo motor (1) in accordance with the set-ventilation mode. The front widow and operator’s front vents are manually selectable. The air conditioning controller controls the air conditioning system. The air conditioner controller controls the damper operation by corresponding to the job site conditions such as atmospheric and cab inside air temperatures, coolant temperature, operator’s settemperature, and the set-ventilation mode. In addition, the air conditioning controller displays the air conditioner system operation status on the monitor.

8

7

6 1

5 2

10

3

9

4

16

15 12345-

Air Vent Damper Servo Motor Defroster Vent Rear Vent Front Vent Evaporator

678-

14

13

Fresh/Re-circulated Air Damper Servo Motor Re-circulated Air Temperature Sensor Fresh Air Induction Port

12

9- Re-circulated Air Filter 10- Re-circulated Air Induction Port 11- Blower Motor 12- Power Transistor

T5-7-1

TDAA-05-07-001

11 13141516-

Frost Sensor Air Mix Damper Servo Motor Heater Core Foot Vent

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Component Layout 2

1

3

4 5

6 7

10

9 8 TDAA-05-07-027

11

12

27 TJBA-05-07-001

14 1- 2- 3-

TJBM-05-07-001

13

Solar Radiation Sensor Monitor Temperature Control Switch/ Mode Switch

4- 5- 6- 7-

AUTO/OFF Switch / Blower Switch Engine Control Dial Key Switch Monitor Controller

8- 9- 10- 11- 12-

T5-7-2

Air Conditioner Unit Fresh Air Filter Air Conditioner Controller Ambient Temperature Sensor High/Low Pressure Switch

13- Air Conditioner Condenser 14- Receiver Tank 27- Compressor

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner

19

17

18

16 15

20 21

22 23 24 25

TDAA-05-07-028

26

15- Re-circulated Air Filter 16- Compressor Relay 17- Re-circulated Air Temperature Sensor

18- Fresh/Re-circulated Air Damper Servo Motor 19- Frost Sensor 20- Evaporator

21- 22- 23- 24-

T5-7-3

Heater Core Air Mix Damper Servo Motor Air Vent Damper Servo Motor Blower Motor Relay

25- Power Transistor 26- Blower Motor

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Functions of Main Parts The functions of the main parts for the air conditioner are described below. The connector number. is shown in the parentheses after the part name.  Controller The controller controls the air conditioning system. The controller has the following functions.  The operator’s instructions are input by the switches.  The air and coolant temperature are detected by the sensors.  Input the air conditioner unit conditions.  The blower motor and compressor are controlled by operating the relays.  The air conditioner operating conditions are displayed on the monitor panel.

TDC1-05-07-002

 Power Transistor (CN7) The power transistor is an electric switch to control blower motor voltage.

TDC1-05-07-003

 Blower Motor Relay (CN3) The blower motor relay supplies 24 volts power to the blower motor when the air conditioner is operated. The blower motor relay is turned ON when excited by the current from terminal #30B in controller. TDC1-05-07-004

 Compressor Relay (CN4) The compressor relay supplies 24 volts power to the compressor clutch when the air conditioner is operated. The compressor relay is turned ON when excited by the current from terminal #29B in controller. TDC1-05-07-005

T5-7-4

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Frost Sensor (CN12) When the air conditioner is operated the frost sensor detects the fin temperature which is cooled by the evaporator. When the temperature is higher than 3 °C (approx. 4.2 kΩ), the controller turns ON the compressor relay. When the temperature is 2 °C (approx. 4.5 kΩ) or less, the controller turns OFF the compressor relay. Therefore, the evaporator in the air conditioner unit is prevented from freezing. The electrical resistance in the frost sensor is 100 Ω to 115 kΩ.

TDC1-05-07-006

 High/Low Pressure Switch (CN14) The high/low pressure switch controls the compressor clutch solenoid while detecting the compressor circuit pressure. The high/low pressure switch consists of a pressure gauge and a switch. The pressure gauge detects the low pressure range (0.196 MPa to 0.216 MPa) and the surge pressure range (2.55 MPa to 3.14 MPa). When the circuit pressure decreases to the low pressure range or increases to the surge pressure range, the pressure gauge turns OFF the switch. Therefore, the compressor operation stops. If the pressure decreases to the low range, a lack of refrigerant is suspected. Therefore, damage to the compressor due to a lack of refrigerant is prevented. When the pressure increases to the surge range, damage to the air conditioner circuit parts due to excessively high circuit pressure is prevented.

 Re-circulated Air Temperature Sensor (CN11) The re-circulated air temperature sensor detects the temperatures (0 to 25 °C) around the re-circulated air inlet as the interior air temperatures and converts them to the electrical resistance values. The temperatures 0 °C to 25 °C corresponds to a resistance of 1.645 kΩ (0 °C) to 5 kΩ (25 °C) respectively. The electrical resistance in the re-circulated air temperature sensor is 300 Ω to 430 kΩ.

 Ambient Temperature Sensor (CN15) The ambient temperature sensor detects the temperature at the side of the air conditioner condenser as the ambient temperature, and converts the temperature to the electrical resistance value. The electrical resistance in the ambient temperature sensor is 100 Ω to 210 kΩ.

T5-7-5

TDC1-05-07-007

TDAA-05-07-014

TDC1-05-07-008

TDC1-05-07-009

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Solar Radiation Sensor (CN16) The solar radiation sensor converts the amount of solar radiation (illumination intensity) at the cab front to the current values.

TDC1-05-07-010

 Fresh/Re-circulated Air Damper Servo Motor (CN10) The fresh/re-circulated air damper servo motor opens or closes the fresh/re-circulated air selection door. This servo motor consists of a motor, link mechanism, and position sensing switch. The motor opens or closes the fresh/recirculated air selection door via the link mechanism.

TDC1-05-07-011

T5-7-6

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Air Mix Damper Servo Motor (CN9) The air mix damper servo motor controls opening/closing of the air mixing door in response to the set temperature. This servo motor consists of a motor, link mechanism, and potentiometer. The motor opens or closes the air mixing door via the link mechanism. The potentiometer converts the link movements (the mixing door strokes) to the voltage. Both ends of the potentiometer are energized by 5 V from terminals #7D (+) and #25E (-) in controller. The voltage (0.5 to 4.5 V) corresponding to the link movement is output from the center terminal of the potentiometer, and is input to terminal #19B in controller. The set temperature is determined by temperature UP/ DOWN signal from the controller. The controller calculates voltage (Vr) corresponding the link position for the set temperature. Then, the controller checks the air mixing door position by voltage (Vf ) from the potentiometer. The controller decides the motor rotational direction (polarity of motor) based on the differential voltage between Vr and VP. The controller sends out the current from terminals #15B and #16B. The controller drives the motor until voltage (Vf ) becomes equal to voltage (Vr).

T5-7-7

TDC1-05-07-012

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Air Vent Damper Servo Motor (CN8) The air vent damper servo motor opens or closes the front and rear air vent, foot vent, and defroster vent doors. This servo motor damper consists of a motor, link mechanism, and potentiometer. The motor opens or closes vent louvers via the link mechanism. The potentiometer converts the link movements (vent doors strokes) to the voltage. Both ends of the potentiometer are energized by 5 V from terminals #7C (+) and #25D (-) in controller. The voltage (0.5 to 4.5 V) corresponding to the link movement is output from the center terminal of the potentiometer, and is input to terminal #20B in controller. Depending on the MODE switch set position, vent doors are operated as shown below:  Front Air Vent: Open, Rear Air Vent: Close, Foot Air Vent: Close  Front Air Vent: Open, Rear Air Vent: Open, Foot Air Vent: Close  Front Air Vent: Open, Rear Air Vent: Open, Foot Air Vent: Open  Front Air Vent: Close, Rear Air Vent: Close, Foot Air Vent: Open The controller calculates the doors position of front and rear vent that are corresponding to selected switch position as the voltage (Vr) of potentiometer. Then, The controller checks the vent louvers positions by receiving voltage (Vf ) from the potentiometer. The controller decides the motor rotational direction (polarity of motor) based on the differential voltage between Vr and Vf. The controller sends out the current from terminals #31B and #32B. The controller drives the motor until voltage (Vf ) becomes equal to voltage (Vr).

T5-7-8

TDC1-05-07-013

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Troubleshooting IMPORTANT:  When replacing the compressor due to the breakage of compressor from internal lock, sufficiently clean the air conditioner circuit or replace all the parts.  When cleaning is insufficient or all the parts are not replaced, the air conditioner may be broken due to contaminants remaining in the circuit.  Using deteriorated LLC (coolant) or lowconcentration LLC, the heater core will receive a bad influence and it may lead water leaks and shorten the service life of machine. Replace coolant and manage LLC concentration according to the Operator's Manual.

fNOTE:

The fault code of the air conditioner controller is displayed only on the monitor. It is not displayed on MPDr..

T5-7-9

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Air Conditioner Controller Fault Code List Fault Code

Trouble

Cause

11

Open circuit in re-circulated air temperature sensor

Voltage: more than 4.95 V

12

Short circuit in re-circulated air temperature sensor

Voltage: less than 0.3 V Operation is controlled under such circumstances as no recirculated air temperature sensor is provided.

13

Open circuit in Voltage: more than ambient temperature 4.88 V sensor

14

Short circuit in Voltage: less than ambient temperature 0.096 V sensor

18

Short circuit in solar radiation sensor

Voltage: more than 5.04 V

21

Open circuit in frost sensor

Voltage: more than 4.79 V

The compressor clutch is disengaged. (The compressor stops.)

22

Short circuit in frost sensor

Voltage: less than 0.096 V

The compressor clutch is disengaged. (The compressor stops.)

43

Abnormal air vent damper servo motor

Air vent damper servo motor stops.

44

Abnormal air mix damper servo motor

51

Abnormal high/low refrigerant pressure

Short circuit: Voltage: 0V Open circuit: Voltage: more than 5 V Short circuit: Voltage: less than 0.2 V Open circuit: Voltage: more than 4.8 V Voltage: 0 V

91

CAN communication Faulty CAN1 harness error between monitor controller and air conditioner controller CAN bus off error Faulty air conditioner controller Faulty CAN1 harness

92

Symptoms in Machine Operation When Trouble Occurs. Operation is controlled under such circumstances as no recirculated air temperature sensor is provided.

Operation is controlled under such circumstance as no ambient temperature sensor is provided. Operation is controlled under such circumstance as no ambient temperature sensor is provided. Operation is controlled under such circumstance as no solar radiation sensor is provided.

Air mix damper servo motor servo motor stops.

The compressor clutch is disengaged. (The compressor stops.) Air conditioner stops.

Air conditioner stops.

T5-7-10

Remedy Check the wire harness. Replace the recirculated air temperature sensor. Check the wire harness. Replace the recirculated air temperature sensor. Check the wire harness. Replace the ambient temperature sensor. Check the wire harness. Replace the ambient temperature sensor. Check the wire harness. Replace the solar radiation sensor. Check the wire harness. Replace the frost sensor. Check the wire harness. Replace the frost sensor. Check the wire harness. Replace the air vent damper servo motor. Check the wire harness. Replace the air mix damper servo motor. Check the wire harness. Replace the high/low pressure switch. Check the CAN1 harness. Replace the air conditioner controller. Check the CAN1 harness. Replace the air conditioner controller.

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Air Conditioner Controller Fault Codes 11 to 22 Preparation  Check the wire harness connections first.  Before inspection, set the key switch to the ON position. Fault Code 11

12

13

14

18

21

Trouble Open circuit in re-circulated air temperature sensor

Procedure Inspection Method 1 Measure resistance between sensor #25H and #6B 2 Measure voltage between sensor harness end #25H and the body.

Evaluation Cause ∞ Ω (Normal value: YES: Faulty sensor 300 to 430 kΩ) NO: Go to Procedure No. 2

Short circuit in re-circulated air temperature sensor Open circuit in ambient temperature sensor

1

Measure resistance between sensor #25H and #6B

0 Ω (Normal value: 300 to 430 kΩ)

1

Measure resistance ∞ Ω (Normal value: between sensor #A251 100 to 210 kΩ) and #A41 Measure voltage 0V between sensor harness end #A251 and the body.

Short circuit in ambient temperature sensor Short circuit in solar radiation sensor Open circuit in frost sensor

1

Measure resistance between sensor #A251 and #41

0 Ω (Normal value: 100 to 210 kΩ)

1

Check continuity between sensor harness end #A71 and #A31. Measure resistance between sensor #25C and #5B Measure voltage between sensor harness end #25C and the body.

0Ω

YES: Short circuit in wire harness #A71 and #31 NO: Faulty sensor ∞ Ω (Normal value: YES: Faulty sensor 100 to 115 kΩ) NO: Go to Procedure No. 2

Measure resistance between sensor #25C and #5B

0 Ω (Normal value: 100 to 115 kΩ)

2

1

2

22

Short circuit in frost sensor

1

T5-7-11

0V

0V

YES: Open circuit in wire harness #25H NO: Open circuit in wire harness #6B YES: Faulty sensor NO: Short circuit in wire harness #25H and #6B YES: Faulty sensor NO: Go to Procedure No. 2 YES: Open circuit in wire harness #A251 NO: Open circuit in wire harness #A41 YES: Faulty sensor NO: Short circuit in wire harness #A251 and #A41

YES: Open circuit in wire harness #25C NO: Open circuit in wire harness #5B YES: Faulty sensor NO: Short circuit in wire harness #25C and #5B

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Air Conditioner Controller Fault Codes 43 to 92 Preparation  Check the wire harness connections first.  Before inspection, set the key switch to the ON position. Fault Code 43

44

Trouble Abnormal air vent damper servo motor

Abnormal air mix damper servo motor

Procedure Inspection Method Evaluation 1 Measure voltage between 0 V air vent damper servo motor harness end 7C and the body. (AUTO/OFF switch / blower switch: ON) 2 Measure voltage between 0 V air vent damper servo motor harness end 7C and 25D. (AUTO/OFF switch / blower switch: ON) 1

0V Measure voltage between air mix damper servo motor harness end 7D and the body. (AUTO/ OFF switch / blower switch: ON) Measure voltage between 0 V air mix damper servo motor harness end 7D and 25E. (AUTO/OFF switch / blower switch: ON)

Cause YES: Faulty controller or open circuit in wire harness between controller and air vent damper servo motor NO: To Procedure No. 2 YES: Faulty controller or open circuit in wire harness between controller and air vent damper servo motor NO: Faulty air vent damper servo motor YES: Faulty controller or open circuit in wire harness between controller and air mix damper servo motor NO: To Procedure No. 2

51

Abnormal high/ low refrigerant pressure

1

Measure voltage between 0 V high/low pressure switch harness end A211 and A052. (AUTO/OFF switch / blower switch: ON)

91

CAN communication error CAN bus off error

1

Check continuity in CAN1 Normal harness.

YES: Faulty controller or open circuit in wire harness between controller and air mix damper servo motor NO: Faulty air mix damper servo motor YES: Faulty controller or open circuit in harness between controller and high/low pressure switch NO: Faulty high/low pressure switch YES: Faulty controller NO: Faulty CAN1 harness

1

Check continuity in CAN1 Normal harness.

YES: Faulty controller NO: Faulty CAN1 harness

2

92

T5-7-12

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner (Blank)

T5-7-13

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (1) Condition:  Fault code: Un-displayed  Airflow volume: faulty Blower motor rotates

Normal speed

Slow speed

Clogged re-circulated air filter Clogged fresh air filter Obstacles are found in inlet area Deformation or breakage of blower Frosted evaporator Adhered dirt on evaporator surface Power source voltage decreases

Poor battery terminal contact Faulty blower motor Faulty power transistor Blower motor Faulty blower motor relay does not rotate Faulty blower motor Faulty power transistor Blower interferes with case Faulty controller Faulty ground in body Faulty wire harness, disconnection of connector Blowout of power transistor thermal fuse due to locked motor Blowout of fuse Replace with the Blower motor is locked same capacity fuse Faulty wire harness Short circuit

T5-7-14

Filter cleaning Filter cleaning Remove obstacles Replace the blower Go to A Evaporator surface cleaning Check the battery charging system Repair Replace Replace Replace Replace Replace Repair Replace the controller Make sure to ground Check the wire harness Replace the motor Replace the blower motor Refer to wire harness diagram and check Check the wire harness

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner A: Frosted evaporator Frosted evaporator Stop air conditioner and melt ice With voltage applied to Faulty magnet clutch magnet clutch circuit Faulty wire harness of frost sensor Faulty frost sensor characteristics Frost sensor is out of evaporator (faulty sensitivity) No voltage applied to magnet clutch

T5-7-15

Check of clutch circuit

Replace the clutch relay

Short circuit check

Repair

Characteristic check

Replace the frost sensor. Reinsert (floating distance from evaporator is 3 mm or less) Faulty magnet clutch

Replace the magnet clutch

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (2) Condition:  Fault Code: Un-displayed  Airflow volume: Normal  Compressor: Compressor rotates normally  Compressor pressure: Normal Fresh air enters

Disconnection of Air Mix link

Close the window and door. Readjust the fresh/re-circulated air selection damper. Set the link again.

T5-7-16

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner (Blank)

T5-7-17

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (3) Condition:  Fault Code: Un-displayed  Airflow volume: Normal  Compressor: Compressor rotates normally  Compressor pressure: Abnormal Pressure on lowpressure side is too high (approx. 0.29 MPa or more)

Pressure on highpressure side is too low (pressure is not approx. 0.98 MPa or more)

Pressure on lowpressure side is too low (pressure is approx. 0.05 MPa or less) Pressure is high on both sides of highpressure and lowpressure Pressure is low on both sides of highpressure and lowpressure

Overcharge of air Remove refrigerant thoroughly and recharge refrigerant to proper conditioner with refrigerant level after purging Faulty compressor Breakage of head gasket Replace the compressor. Breakage of inlet valve Replace the compressor. Foreign matter is caught in inlet Replace the compressor. valve Excessive open of Faulty valve Replace the valve. expansion valve Abnormally low ambient temperature Lack of refrigerant To B Faulty compressor Swash plate shoe is locked Replace the compressor. Piston is locked Replace the compressor. Faulty suction discharge valve Replace the compressor. Faulty expansion valve Clogged valve (foreign matter) Replace the valve Temporary clogged due to freezing Thoroughly perform purging valve (moisture in the system) after replacing valve and receiver. Abnormally low ambient temperature Lack of refrigerant Go to B Clogged in refrigeration cycle Go to C Faulty expansion valve Go to D Frosted evaporator Go to A Lack of condenser cooling Clogged fin with dirt or mud Cleaning of fin (washing) Overcharge of air Discharge refrigerant thoroughly and recharge refrigerant to proper conditioner with refrigerant level after purging. Lack of refrigerant

T5-7-18

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner A: Frosted evaporator Frosted evaporator Stop air conditioner and melt ice. With voltage applied to Faulty magnet clutch magnet clutch circuit Faulty wiring of frost sensor Faulty frost sensor characteristics Frost sensor is out of evaporator (faulty sensitivity) No voltage applied to magnet clutch

Check of clutch circuit

Replace the clutch relay

Short circuit check

Repair

Characteristic check

Replace the frost sensor

Reinsert (floating distance from evaporator is 3 mm or less) Faulty magnet clutch

Replace the magnet clutch.

B: Lack of refrigerant Lack of refrigerant

Lack of refrigerant quantity Gas leak

Charge refrigerant to proper level. Check leak and charge with refrigerant after repairing faulty.

Clogged receiver dryer Clogged foreign matter in piping

Replace Replace

C: Clogged in refrigeration cycle Clogged in refrigeration cycle

D: Faulty expansion valve Faulty expansion valve

Clogged valve (foreign matter) Replace the valve. Temporary clogged due to freezing valve Thoroughly perform purging after (moisture in the system) replacing valve and receiver.

T5-7-19

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (4) Condition:  Fault Code: Un-displayed  Airflow volume: Normal  Compressor: Compressor does not rotate normally Broken V belt or slipping Faulty compressor (locked) Faulty magnet Repair or clutch replace

Clutch does not operate due to faulty electrical system

Check wiring

Replace V belt. Replace Open circuit in stator coil Replace Air gap between rotor and stator is too large Repair or Replacement Clutch slipping Slip caused by key breakage or inserting no key Replace the key. Greasy clutch surface Remove oil. Layer short of coil Replace Battery voltage drop Charge Caught foreign matter between rotor and stator Overhaul Faulty controller Replace the controller. Faulty compressor clutch relay Replace Faulty frost sensor Replace Faulty high/low refrigerant pressure switch Replace Abnormal high Too high Abnormally high ambient temperature pressure (2.54 MPa or Lack of Clogged fin with Cleaning of fin more) condenser dirt or mud (washing) cooling Overcharge air Discharge refrigerant thoroughly and conditioner with recharge refrigerant to proper level refrigerant after purging. Air mixed in Discharge refrigerant thoroughly and refrigeration recharge refrigerant to proper level cycle after purging. Too low Abnormally low ambient temperature (0.98 MPa or Lack of refrigerant Go to B less) Clogged during refrigeration cycle Go to C Faulty expansion valve Go to D Frosted evaporator Go to A

T5-7-20

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner A: Frosted evaporator Frosted evaporator Stop air conditioner and melt ice. With voltage applied to Faulty magnet clutch magnet clutch circuit Faulty wiring of frost sensor Faulty frost sensor characteristics Frost sensor is out of evaporator (faulty sensitivity) No voltage applied to magnet clutch

Check of clutch circuit

Replace the clutch relay

Short circuit check

Repair

Characteristic check

Replace the frost sensor

Reinsert (floating distance from evaporator is 3 mm or less). Faulty magnet clutch

Replace the magnet clutch.

B: Lack of refrigerant Lack of refrigerant

Lack of refrigerant quantity Gas leak

Charge refrigerant to proper level. Check leak and charge with refrigerant after repairing faulty.

Clogged receiver dryer Clogged foreign matter in piping

Replace Replace

C: Clogged in refrigeration cycle Clogged in refrigeration cycle

D: Faulty expansion valve Faulty expansion valve

Clogged valve (foreign matter) Replace the valve. Temporary clogged due to freezing valve Thoroughly perform purging after (moisture in the system) replacing valve and receiver.

T5-7-21

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (5) Condition:  Fault Code: 44 (Abnormal air mix damper servo motor) Faulty wiring, open circuit, disconnection of connector Faulty servo motor Caught foreign matter

Wirings inspection

Replace Remove foreign matter.

Condition:  Fault Code: 51 (Abnormal high/low refrigerant pressure) High pressure cut is operated

Low pressure cut is operated

Abnormally high ambient temperature Lack of condenser Clogged fin with dirt or mud Cleaning of fin (washing) cooling Overcharge air Discharge refrigerant thoroughly and recharge refrigerant to conditioner with proper level after purging refrigerant Air mixed in refrigeration Discharge refrigerant thoroughly and recharge refrigerant to cycle proper level after purging Abnormally low ambient temperature Lack of refrigerant Lack of refrigerant quantity Charge refrigerant to proper level. Gas leak Check leak and charge with refrigerant after repairing faulty. Faulty compressor Swash plate shoe is locked Replace the compressor. Piston is locked Replace the compressor. Faulty suction discharge valve Replace the compressor. Faulty expansion valve Clogged valve (foreign matter) Replace the valve. Temporary clogged due to Thoroughly perform purging freezing valve (moisture in the after replacing valve and system) receiver.

T5-7-22

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner (Blank)

T5-7-23

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty heating (1) Condition:  Fault code: Un-displayed Faulty air flow volume

Blower motor rotates.

Normal speed

Clogged re-circulated air filter Clogged fresh air filter Obstacles are found in inlet area Deformation or breakage of blower Frosted evaporator Adhered dirt on evaporator surface

Filter cleaning Filter cleaning Remove obstacles. Replacement of blower Go to A Evaporator surface cleaning Slow speed Power source decreases. Check battery charging system. Poor battery terminal contact Repair Faulty blower motor Replace Faulty power transistor Replace Blower motor Blowout of fuse Replace with the Blower motor is Replace the blower does not rotate. same capacity fuse, locked, motor. Faulty wire harness Refer to wire harness diagram and check. Short circuit Check the wire harness. Faulty blower motor relay Replace Faulty blower motor Replace Faulty power transistor Replace Blower interferes with case Repair Faulty controller Replace the controller. Faulty ground in body Make sure to ground. Faulty wire harness, disconnection of connector Check the wire harness. Blowout of power transistor thermal fuse due to locked Replace the motor. motor Air flow volume Coolant temperature is low. is normal Coolant Disconnection of air mix damper link Set the link again. temperature is Air incorporation in hot-water circuit Bleed air from the circuit. normal. Clogging, breakage, and bending of piping Repair or replace Extremely low ambient temperature Lack of engine coolant Charge engine coolant to proper level. Broken heater core Replace the heater core.

T5-7-24

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner A: Frosted evaporator Frosted evaporator Stop air conditioner and melt ice With voltage applied to Faulty magnet clutch magnet clutch circuit Faulty wiring of frost sensor Faulty the frost sensor characteristics Frost sensor is out of evaporator (faulty sensitivity) No voltage applied to magnet clutch

T5-7-25

Check of clutch circuit Short circuit check

Replace the clutch relay. Repair

Characteristic check

Replace the frost sensor. Reinsert (floating distance from evaporator is 3 mm or less) Faulty magnet clutch

Replace the magnet clutch.

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty heating (2) Condition:  Fault Code: 44 (Abnormal air mix damper servo motor) Caught foreign matter Faulty wire harness, open circuit, disconnection of connector Faulty air mix damper servo motor

Remove foreign matter. Check the wire harness. Replace

T5-7-26

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Others  Faulty air vent switch Fault code is un-displayed. Disconnection of link Fault code 43 (Abnormal air vent damper Faulty wire harness, open circuit, servo motor) disconnection of connector Faulty servo motor Caught foreign matter

Set the link again. Check the wire harness. Replace Remove foreign matter.

 Faulty fresh / re-circulated air selection Fault code is un-displayed.

Disconnection of link Faulty wire harness, open circuit, disconnection of connector Faulty servo motor Caught foreign matter

Set the link again. Check the wire harness. Replace Remove foreign matter.

 Ambient temperature is higher or lower than set temperature Fault code 11 (Open circuit in recirculated air temperature sensor) Fault code 12 (Short circuit in recirculated air temperature sensor) Fault code is un-displayed. (Normal recirculated air temperature sensor)

Open circuit in wire harness, disconnection of connector Open circuit in air circulation sensor Short circuit in wire harness Short circuit in air circulation sensor Faulty cooling, faulty heating

T5-7-27

Check the wire harness. Replace Check the wire harness. Replace Check by referring to the items of faulty cooling and faulty heating.

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Noise Related parts of case Related parts of blower fan motor

Gas blowing sound (roaring) Expansion valve connection, Whistle sound, Gas blowing sound. Clutch disengaging sound

Compressor rotating sound

Louver resonance Fan contacts case, Foreign matter enters case Brush friction noise, metal and/or thrust washer contact Gas vibration noise (compressor discharge and/or suction gas noise) Abnormal noise from expansion valve, Expansion valve is normally functioning Faulty clutch bearing, and/or idle pulley bearing Contact of clutch amature due to resonance. Loose belt, Loose screws Noisy compressor Vibration due to V belt looseness, Loose screws

Repair or replace. Remove foreign matter. Readjust fan motor location. Slight noise is unavoidable. Replace if loud. No functional problem exists. Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard. Replace Repair or replace the clutch. Re-tighten screws. Repair or replace Re-adjust the belt. Re-tighten screws.

 Others Water leak, Water splash

Abnormal smell

Broken heater core, Broken hose Clogged case drain port and/or drain hose Absorbed cigarette and dust smell on evaporator fins

T5-7-28

Replace Clean Clean the 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.

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner (Blank)

T5-7-29

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Blower motor does not operate. Preparation  Check the wire harness connections first. Procedure Inspection Method 1 Switch compressor relay with blower motor relay.

Condition Key Switch: ON Blower Switch: ON

2

Measure voltage between terminal #41B of blower motor relay harness end and the body.

Key Switch: ON

3

Measure voltage between terminal #43A of blower motor harness end and the body.

Key Switch: ON Blower Switch: ON

4

Check continuity between terminals #43B and #44A of blower motor harness end. Key Switch: ON Measure voltage between terminal #44B of power transistor Blower Switch: ON harness end and the body.

5

6

Measure voltage between terminal #9B of power transistor harness end and the body.

Key Switch: ON Blower Switch: ON

Connector (Wire harness end)  Blower Motor Relay

Evaluation Cause (check point) Blower motor YES: Faulty blower motor does not operate. relay NO: Go to Procedure No. 2 0V YES: Open circuit in wire harness between fuse #3 and blower motor relay NO: Go to Procedure No. 3 0V YES: Open circuit in wire harness between blower motor relay and blower motor NO: Go to Procedure No. 4 0Ω YES: Faulty blower motor NO: Go to Procedure No. 5 0V

0V

YES: Open circuit in wire harness between blower motor and power transistor NO: Go to Procedure No. 6 YES: Faulty air conditioner controller NO: Faulty power transistor

 Blower Motor

TDC1-05-07-014

 Power Transistor

TDAB-05-07-028

T5-7-30

TDAB-05-07-027

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Compressor clutch does not operate. Preparation  Check that outdoor air temperature is 0 °C or more first. When outdoor air temperature is less than 0 °C, the air conditioner controller turns OFF the compressor clutch in order to protect the compressor.  Check that fault code 21 or 22 (abnormal frost sensor) is not displayed. When the frost sensor is abnormal, the compressor clutch does not operate.  Check the wire harness connections first. Procedure Inspection Method 1 Switch compressor relay with blower motor relay.

Condition Key Switch: ON Blower Switch: ON

2

Key Switch: ON Measure voltage between terminal #48A of compressor relay harness end and the body.

3

Key Switch: ON Measure voltage between Blower Switch: ON terminal #42B of compressor clutch harness end and the body.

Connector (Wire harness end)  Compressor Relay

Evaluation Cause (check point) Compressor is not YES: Faulty compressor operable. relay NO: Go to Procedure No. 2 0V YES: Open circuit in wire harness between fuse #3 and compressor relay NO: Go to Procedure No. 3 0V YES: Open circuit in wire harness between compressor relay and compressor clutch NO: Faulty compressor clutch

 Compressor Clutch

TDAB-05-07-019

T5-7-31

TDAB-05-07-024

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Cooling circuit check by using manifold gauge Condition:  Engine Speed: 1500 min-1  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool  Fresh/re-circulated air selection: Re-circulated Air  Air conditioner inlet temperature: 30 to 35 °C 1. In normal  Low-pressure side pressure: 0.15 to 0.25 MPa  High-pressure side pressure: 1.37 to 1.57 MPa NOTE: The reading of manifold gauge may depend on conditions.

f

TDAA-05-07-018

2. Lack of refrigerant quantity Trouble

Pressure is low on both sides of high-pressure and low-pressure. Cooling performance is low. Cause Lack of refrigerant quantity Gas leak. Remedy Check and repair of gas leak. Charge air conditioner with refrigerant. TDAA-05-07-019

3. Excessive refrigerant, lack of condenser cooling Trouble

Pressure is high on both sides of highpressure and low-pressure. Cooling performance is low. Cause Overcharge air conditioner with refrigerant. Lack of condenser cooling. Remedy Adjust refrigerant quantity. Clean condenser. Check for machine cooling system. TDAA-05-07-020

4. Water incorporation in circuit. Trouble

After using a certain period of time, lowpressure side gradually indicates negative pressure. Cause Water is mixed in circuit. Remedy Replace receiver tank. Thoroughly perform purging before charging refrigerant to remove water. TDAA-05-07-021

T5-7-32

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner 5. Faulty compression of compressor Trouble

Low-pressure side is high and high-pressure side is low. High-pressure becomes equal to low-pressure immediately after stopping the air conditioner. Cause Faulty compressor. Remedy Check and repair of compressor. TDAA-05-07-022

6. Refrigerant does not circulate (clogged circuit) Trouble

When absolutely clogging, low-pressure side indicates negative pressure quickly. When slightly clogging, low-pressure side gradually indicates negative pressure. Cause Dirt or water adheres or freezes to expansion valves, refrigerant does not flow. Remedy Replace receiver tank. Perform purging.

TDAA-05-07-023

7. Air mixed in circuit Trouble

Pressure is high on both sides of highpressure and low-pressure. When touching low-pressure piping, it is not cold. Cause Air is mixed in system. Remedy Replace refrigerant. Perform purging. TDAA-05-07-024

8. Excessive open of expansion valve Trouble

Pressure is high on both sides of highpressure and low-pressure. Frost (dew) adheres to low-pressure piping. Cause Faulty expansion valve. Remedy Check for installation of thermal cylinder. TDAA-05-07-025

T5-7-33

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Work after Replacing Components The following work is required after replacing compressor, high pressure hose, low pressure hose, condenser, receiver tank, liquid hose, and air conditioner unit. The same work is required when a large amount of gas leakage has occured. 1. Refill Compressor Oil 2. Charge Air Conditioner with Refrigerant    

Purging Charge air conditioner with refrigerant Warm-up operation Inspection

T5-7-34

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Refill Compressor Oil When replacing the refrigeration circuit parts, refill compressor oil to the specified level. Replacement Compressor parts

Condenser

Evaporator

Receiver

D hose (between compressor and condenser)

L hose (between condenser and unit)

S hose (between unit and compressor)

Refill oil quantity

40 cm3

40 cm3

20 cm3

6 to 9 cm3/m

2 to 4 cm3/m

8 to 11 cm3/m

Refer to the following.

 When of replacing compressor New compressor (1) is charged with oil required for refrigeration circuit. When replacing to new compressor (1), drain excess oil from new compressor (1). Adjust oil level so that oil in new compressor (1) is the same level as oil (B) in compressor (2) to be replaced.

fNOTE:

 Compressor oil refill container Oil type ND-OIL8

Part No 4422696

Quantity 40 cm3

Compressor oil quantity: 160 cm3

1

2

TDAA-05-07-015

1-

New Compressor

2-

Replacing Compressor

T5-7-35

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Charge Air Conditioner with Refrigerant Necessity of Purging The following problems can arise if air or other gases remain in the air conditioner circuit. Be sure to perform purging the air conditioner circuit with a vacuum pump before charging with refrigerant (R134a). 1. Pressure rise in the high pressure side If air remains in the air conditioner circuit, this disturbs the heat exchange between refrigerant and air in the condenser. This causes pressure to rise in the high pressure side (compressor side). Refrigerant gas is easily liquefied, but air cannot be liquefied and remains as a gas in the condenser because the temperature at which air liquefies is extremely low. Therefore, liquefaction of the refrigerant gas in the condenser decreases by the amount of air in the circuit, and the gas pressure in the high pressure side increases accordingly.

W115-02-10-001

2. Metal corrosion If air remains in the air conditioner circuit, a chemical reaction between refrigerant and moisture in the air takes place, and as a result, hydrochloric acid is produced. Hydrochloric aid corrodes metals such as aluminum, copper and iron.

W115-02-10-002

3. Plugging of the expansion valve by moisture When high pressure refrigerant gas passes through the expansion valve, gas pressure decreases and temperature drops. Moisture included in high pressure refrigerant gas in the air conditioner circuit freezes at the expansion valve orifice, plugging refrigerant flow. Operation of the air conditioner becomes unstable and cooling efficiency lowers.

W115-02-10-003

T5-7-36

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Procedures for charging air conditioner with refrigerant

1

IMPORTANT: Do not mistake the charge hose connections. 1. Close high pressure valve (2) and low pressure valve (7) of manifold gauge (1). Connect high-pressure side charge hose (3) and low-pressure side charge hose (6) of manifold gauge (1) to the high-pressure side charge valve (“D” marked) and to the lowpressure side charge valve (“S” marked) located on the compressor respectively. Connect charge hose (5) located on the center of manifold gauge (1) to vacuum pump (4).

7 6 2 3 5 4

W115-02-10-005

2. Open high pressure valve (2) and low pressure valve (7) of manifold gauge (1). Perform purging for over 10 minutes by operating vacuum pump (4).

1 7

2

4

W115-02-10-005

T5-7-37

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner IMPORTANT: If the pointer of the low pressure gauge returns to 0, retighten the line connections and perform purging again. 3. When the low pressure gauge reading falls below -0.1 MPa (-750 mm Hg), close high pressure valve (2) and low pressure valve (7) and stop vacuum pump (4). Wait for approximately five minutes and confirm that the pointer of the low pressure gauge does not return to 0.

7

2

4

W115-02-10-005

4. With high pressure valve (2) and low pressure valve (7) on manifold gauge (1) closed, connect charge hose (5) to refrigerant container (8).

7

1

 Refrigerant Specification R134a

Part No. 4333767 4454005 4351827

Volume (g) 200 250 300

2

5

8

5. Open valve (9) of refrigerant container (8). Push air bleed valve (10) on manifold gauge (1) to purge air in charge hose (5) with the refrigerant pressure. When draining refrigerant, immediately release air bleed valve (10).

W115-02-10-007

10

9

1

5

8

W115-02-10-007

T5-7-38

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner IMPORTANT:  Always stop the engine when charging the air conditioner with refrigerant.  Do not position the refrigerant container upside down during charging operation.  When changing the refrigerant container during charging operation, be sure to perform the procedure in step 10.  Charge the low-pressure side hose first. 6. Fully tighten charge hose (5) to manifold gauge (1). Open high pressure valve (2) and valve (9) of refrigerant container (8). Charge with refrigerant (R134a). Close high pressure valve (2) and valve (9) of refrigerant container (8) when high pressure gauge (11) reading reaches 98 kPa.

W115-02-10-008

fNOTE:

Use warm water of 40 °C or less to warm refrigerant container (8) to aid in charging operation.

1

11 2

5 9

IMPORTANT: Use the leak tester for R134a. 7. After charging, check the line connections for gas leaks using the leak tester.

8

W115-02-10-007

T5-7-39

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner 8. Confirm that high pressure valve (2) and low pressure valve (7) on gauge manifold (1) and valve (9) of refrigerant container (8) are closed. Start the engine and operate the air conditioner.

1 7

Operating Conditions of the Air Conditioner  Engine Speed: Slow Idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool

2

9 8

W115-02-10-007

IMPORTANT: Do not open high pressure valve (2) on manifold gauge (1). 9. Open low pressure valve (7) on manifold gauge (1) and valve (9) of refrigerant container (8) to charge with refrigerant.

fNOTE:

1 7

Required refrigerant quantity: 850±50 g 2

10. If refrigerant container (8) becomes empty during the charging work, replace refrigerant container (8) with a new refrigerant container as follows:  Close high pressure valve (2) and low pressure valve (7) on manifold gauge (1).  Replace the empty container with new refrigerant container (8).  Tighten, then slightly loosen refrigerant container (8) joint.  Slightly open low pressure valve (7) on manifold gauge (1).  When refrigerant container (8) joint starts to leak, immediately tighten refrigerant container (8) joint and close low pressure valve (7) on manifold gauge (1). 11. After charging, close low pressure valve (7) on manifold gauge (1) and valve (9) of refrigerant container (8), and stop the engine.

T5-7-40

9 8

W115-02-10-007

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner IMPORTANT: If the air conditioner is operated with very low level of refrigerant, it will cause the damage of the compressor. If the air conditioner is overcharged with refrigerant, cooling efficiency will lower and abnormal high pressure will arise in the air conditioner circuit, causing danger. 12. Start the engine and operate the air conditioner again. Check that cold air blows out from the vents. Operating Conditions of the Air Conditioner  Engine Speed: Slow Idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool When disconnecting the high pressure dCAUTION: side charge hose, refrigerant and compressor oil may spout. Disconnect the high pressure side charge hose after the high pressure side pressure drops to less than 980 kPa. 13. After checking that cold air blows out, disconnect the charge hoses. Disconnect the low pressure side charge hose first. Wait for the high pressure side pressure to drop to less than 980 kPa. Disconnect the high pressure side charge hose.

T5-7-41

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Warm-up Operation After charging air conditioner with specified volume of refrigerant, carry out warm-up operation for five minutes to lubricate system with compressor oil. Operating Conditions of the Air Conditioner  Engine Speed: Slow Idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool Inspection After warm-up operation, carry out gas leak check and performance check. Refrigerant will produce poisonous dCAUTION: material if exposed to heat of 1000 °C or more. Never bring refrigerant close to a fire. 1. Check the air conditioner for gas leaks using a leak tester.  Perform checking under well-ventilated conditions.  Thoroughly wipe off dust from the charge hose connections of the compressor.  Pay special attention to check the piping connections.  If any gas leaks are found, retighten the piping connections. 2. Carry out performance check of the air conditioner after checking each air conditioner component.     

W115-02-10-013

Check each component for abnormalities. Carry out ON-OFF check of the compressor clutch. Check compressor fan belt tension. Check the coolant level in the radiator. Operate the air conditioner and check the performance.

W115-02-10-014

T5-7-42

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner 3. Check before the summer season  Check each air conditioner component for abnormalities.  Check the piping connections for oil leaks.  Check refrigerant quantity.  Check the engine cooling circuit.  Check V belt for wear. Replace if necessary.  Check for clogged condenser. 4. Maintenance during off-season  During off-season, operate the idler pulley and compressor pulley at least once a month for a short time to check for any abnormal sounds.  Do not remove the compressor belts during offseason. Operate the compressor occasionally at slow speed for 5 to 10 minutes with the belt slightly loosened in order to lubricate the compressor.

fNOTE:

When the machine is in normal and the air conditioner is operated with the following conditions, air vent temperature decrease approx. 20 °C or less. (it may be different under special environment.)

Operating Conditions of the Air Conditioner  Engine Speed: Fast Idle  Cab Window: Fully closed  Airflow volume: Maximum  Temperature Control Switch: Maximum cool  Fresh/re-circulated air selection: Re-circulated Air  Season: Summer

T5-7-43

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Hose and Pipe Tightening Torque

A

Use the following tightening torque values when connecting the pipes. Joint Location

Nut type (Fig. A)

Block joint (Fig. B)

Tube or Bolt Size Tightening Torque N·m (kgf·m) Pipe with dia. 8 12 to 15 (1.2 to 1.5) Pipe with D1/2 20 to 25 (2.0 to 2.5) Pipe with D5/8 30 to 35 (3.0 to 3.5) M6 Bolt (4T) for 4.0 to 7.0 receiver (0.4 to 0.7) M6 Bolt (6T) 8.0 to 12 for other than (0.8 to 1.2) Receiver

TDAA-05-07-016 B

TDAA-05-07-017

T5-7-44

MEMO

MEMO

Hitachi Construction Machinery Co., Ltd. Attn: Technical Information Center Tel: 81-29-832-7084 Fax: 81-29-831-1162 E-mail: [email protected]

Hitachi Ref. No.

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The Attached Diagram List The following diagrams are attached to this manual. 1. ELECTRICAL CIRCUIT DIAGRAM AIR CONDITIONER CIRCUIT DIAGRAM 2. CONNECTORS 3. CAB HARNESS MAIN HARNESS 4. ENGINE HARNESS PUMP HARNESS 5. CONTROL VALVE HARNESS 6. MONITOR HARNESS KEY SWITCH HARNESS 7. OIL COOLER FAN REVERSE ROTATION SWITCH HARNESS ENGINE STOP SWITCH HARNESS 8. PILOT SHUT-OFF SOLENOID VALVE HARNESS 9. GSM (MOBILE COMMUNICATION TERMINAL) HARNESS SATELLITE COMMUNICATION HARNESS 10. AUTO LUBRICATION ON/OFF SWITCH HARNESS CAMERA HARNESS 11. BOOM MODE SWITCH AND SEAT HEATER SWITCH HARNESS (OPTION) 12. WORK LIGHT (ON THE CAB ROOF) HARNESS 1 (OPTION) WORK LIGHT (ON THE CAB ROOF) HARNESS 2 (OPTION) 13. HYDRAULIC CIRCUIT DIAGRAM