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Hitachi ZAXIS 140W-3 Technical Manual

Wheeled excavator, troubleshooting

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Page 3 13, July 2009. 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: This manual consists the Technical Manual and the Workshop Manual.
Page 4 INTRODUCTION SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS • In this manual, the following safety alert symbol and CAUTION: signal words are used to alert the reader to the Indicated potentially hazardous situation which potential for personal injury of machine damage. could, if not avoided, result in personal injury or death.
Page 5: Recognize Safety Information
SAFETY RECOGNIZE SAFETY INFORMATION • These are the SAFETY ALERT SYMBOLS. • When you see these symbols on your machine or in this manual, be alert to the potential for personal injury. • Follow recommended precautions and safe operating practices. 001-E01A-0001 SA-688 UNDERSTAND SIGNAL WORDS...
Page 6: Follow Safety Instructions
Hitachi Warranty Policy. • Do not use attachments and/or optional parts or equip- ment 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,...
Page 7: Prepare For Emergencies
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. •...
Page 8: Inspect Machine
SAFETY INSPECT MACHINE • Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury. • In the walk-around inspection be sure to cover all points described in the “PRE-START INSPECTION” chapter in the operator’s manual.
Page 9: Use Handholds And Steps
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. •...
Page 10: Fasten Your Seat Belt
SAFETY FASTEN YOUR SEAT BELT • If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the opera- tor may be crushed by the overturning machine, resulting in serious injury or death. • Prior to operating the machine, thoroughly examine web- bing, buckle and attaching hardware.
Page 11: Operate Only From Operator's Seat
SAFETY OPERATE ONLY FROM OPERATOR'S SEAT • Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. • Start the engine only when seated in the operator's seat. • NEVER start the engine while standing on the track or on ground.
Page 12: Precautions For Operations
SAFETY PRECAUTIONS FOR OPERATIONS • Investigate the work site before starting operations. • Be sure to wear close fitting clothing and safety equip- ment appropriate for the job, such as a hard hat, etc. when operating the machine. • Clear all persons and obstacles from area of operation and machine movement.
Page 13: Investigate Job Site Beforehand
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 fall- ing and to prevent the ground, stockpiles, or banks from collapsing.
Page 14: Equipment Of Head Guard, Rops, Fops
SAFETY EQUIPMENT OF HEAD GUARD, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) ROPS: Roll-Over Protective Structure FOPS: Falling Object Protective Structure SA-686...
Page 15: Drive Machine Safely
SAFETY DRIVE MACHINE SAFELY • Before driving the machine, always confirm that the steer- ing wheel/forward/reverse switch direction corresponds to the direction you wish to drive. • Be sure to detour around any obstructions. • Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine.
Page 16: Avoid Injury From Back-Over And Swing Accidents
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: •...
Page 17: Keep Person Clear From Working Area
SAFETY KEEP PERSON CLEAR FROM WORKING AREA • A person may be hit severely by the swinging front attach- ment or counterweight and/or may be crushed against an other object, resulting in serious injury or death. • Keep all persons clear from the area of operation and machine movement.
Page 18: Avoid Tipping
SAFETY AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MA- CHINE---SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT • The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death.
Page 19: Dig With Caution
SAFETY DIG WITH CAUTION • Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death. • Before digging check the location of cables, gas lines, and water lines. • Keep the minimum distance required, by law, from cables, gas lines, and water lines.
Page 20: Avoid Power Lines
SAFETY AVOID POWER LINES • Serious injury or death can result if the machine or front at- tachments 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.
Page 21: Protect Against Flying Debris
SAFETY PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result. • Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. • Keep bystanders away from the working area before strik- ing any object.
Page 22: Transport Safely
SAFETY TRANSPORT SAFELY • Take care the machine may turn over when loading or un- loading the machine onto or off of a truck or trailer. • Observe the related regulations and rules for safe trans- portation. • Select an appropriate truck or trailer for the machine to be transported.
Page 23: Practice Safe Maintenance
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. •...
Page 24: Warn Others Of Service Work
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.
Page 25: Prevent Parts From Flying
SAFETY PREVENT PARTS FROM FLYING • Travel reduction gears are under pressure. • As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury. • GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure.
Page 26: Prevent Burns
SAFETY PREVENT BURNS Hot spraying fluids: • After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. •...
Page 27: Avoid High-Pressure Fluids
SAFETY AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death. • Avoid this hazard by relieving pressure before disconnect- ing hydraulic or other lines. •...
Page 28: Prevent Fires
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.
Page 29: Evacuating In Case Of Fire
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. •...
Page 30: Avoid Heating Near Pressurized Fluid Lines
SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near pres- surized 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.
Page 31: Beware Of Asbestos Dust
• Keep bystanders out of the work site during operation. • Asbestos might be present in imitation parts. Use only SA-029 genuine Hitachi Parts. PREVENT BATTERY EXPLOSIONS • Battery gas can explode. • Keep sparks, lighted matches, and flame away from the top of battery.
Page 32: Handle Chemical Products Safely
• Improperly disposing of waste can threaten the environ- ment 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.
Page 33 SAFETY BEFORE RETURNING THE MACHINE TO THE CUS- TOMER • After maintenance or repair work is complete, confirm that: • The machine is functioning properly, especially the safety systems. • Worn or damaged parts have been repaired or replaced S517-E01A-0435 SA-435 SA-29...
Page 34 SAFETY (Blank) SA-30...
Page 35: Group 1 Introduction
The right is Group 11 Brake Valve reserved to make changes at any time Group 12 Others (Upperstructure) without notice. Group 13 Others (Undercarriage) COPYRIGHT(C)2007 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved...
Page 36 WORKSHOP MANUAL SECTION 1 GENERAL INFORMATION SECTION 3 UNDERCARRIAGE Group 1 Precautions for Disassem- Group 1 Swing Bearing bling and Assembling Group 2 Travel Motor Group 2 Tightening Torque Group 3 Center Joint Group 3 Painting Group 4 Transmission Group 4 Bleeding Air from Hydrau- Group 5 Axle lic Oil Tank Group 6 Axle Lock Cylinder...
Page 37: Table Of Contents
SECTION 4 OPERATIONAL PERFORMANCE TEST CONTENTS Group 1 Introduction Group 5 Component Test Operational Performance Tests ....T4-1-1 Primary Pilot Pressure........T4-5-1 Preparation for Performance Tests ....T4-1-2 Secondary Pilot Pressure......T4-5-3 Solenoid Valve Set Pressure ......T4-5-4 Group 2 Standard Main Pump Delivery Pressure......T4-5-6 Performance Standard .........
Page 38 (Blank) CEBT-4-2...
Page 39: Operational Performance Tests
OPERATIONAL PERFORMANCE TEST / Introduction OPERATIONAL PERFORMANCE TESTS Use operational performance test procedure to quan- The machine performance does not always deteriorate titatively check all system and functions on the ma- as the working hours increase. However, the machine chine. performance is normally considered to reduce in pro- portion to the increase of the operation hours.
Page 40: Preparation For Performance Tests
OPERATIONAL PERFORMANCE TEST / Introduction PREPARATION 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.
Page 41: Group 2 Standard
SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Standard * The standard measurement conditions are as follows. The performance standard values are listed in the table  Engine Control Dial: Fast Idle below.  Power Mode Switch: P mode For details including measuring method, refer to T4-3 ...
Page 42 SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Reference Descriptions Reference Standard Page TRAVEL SPEED T4-4-1 km/h (100 m) Fast Engine speed control mode 35.0 selection switch: Pedal mode, +1.0 -3.0 Travel speed mode switch: Fast Slow Engine speed control mode selection switch: Pedal mode, 8.6±0.5 Travel speed mode switch:...
Page 43 SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Reference Descriptions Remarks Standard Page HYDRAULIC CYLINDER CYCLE TIME 2.52 m arm T4-4-12 0.3 m (PCSA heaped) bucket, Bucket: empty, With HRV Boom Raise (Monoblock Boom) Without bucket: 3.9±0.3 4.1±0.3 Boom Lower (Monoblock Boom) 3.0±0.3 Without bucket: 3.3±0.3 Boom Raise (2-Piece Boom)
Page 44: Performance Standard
SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Reference Descriptions Remarks Standard Page HYDRAULIC SYSTEM PRIMARY PILOT PRESSURE T4-5-1 MPa (kgf/cm , psi) +1.0 Fast Idle -0.5 , 581 +145 SECONDARY PILOT PRESSURE 3.3 to 3.9 Value indicated on Dr. ZX. T4-5-3 (For Fast Idle, Slow Idle) (34 to 40,...
Page 45 SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Reference Descriptions Remarks Standard Page MAIN PUMP FLOW RATE Refer to T4-2-6. T4-5-14 L/min SWING MOTOR DRAINAGE L/min With constant speed 0.2 to 0.3 T4-5-24 With motor relieved (2 to 5) STEERING VALVE RELIEF PRESSURE 17.5±1.0 T4-5-28...
Page 46: Main Pump P-Q Diagram
SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Main Pump P-Q Diagram  Hydraulic P-Q Control (Torque Control) (NOTE: Measured at Test Stand)  Rated Pump Speed: 2200 min (rpm)  Hydraulic Oil Temperature: 50±5 °C (122±9 °F) NOTE: Refer to T4-5-14. P-Q Point Delivery Pressure Flow Rate...
Page 47 SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard  P-Q Control by Pump Control Pilot Pressure Signal (NOTE: Measured at Test Stand)  Rated Pump Speed: 2200 min (rpm)  Hydraulic Oil Temperature: 50±5 °C (122±9 °F) NOTE: Refer to T4-5-16. P-Q Point Pump Control Pressure Flow Rate...
Page 48: Sensor Activating Range
SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Sensor Activating Range 1. Measuring Method  Hydraulic Oil Temperature: 50±5 °C (122±9 °F)  Unless specified: Power Engine Auto-Idle Mode Work Mode Control Dial Switch Switch Fast Idle Digging Speed mode ...
Page 49: Engine Speed
OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE SPEED Summary: 1. Measure the engine speed by using the monitor unit or Dr. ZX. 2. Measure the engine speeds in each mode. NOTE: If the engine speed is not adjusted correctly, all other performance data will be unreliable. Consequently, measure the engine speed before performing all other tests in order to check that the engine speed meets...
Page 50 OPERATIONAL PERFORMANCE TEST / Engine Test Measurement: Remedy: 1. Measure the engine speeds in the "dial mode" and Refer to Troubleshooting B in Group T5-7. "pedal mode" positions for the engine speed control mode selection switch. NOTE: ECO stands for the auto engine speed 2.
Page 51 OPERATIONAL PERFORMANCE TEST / Engine Test • Engine Speed Control Mode Selection Switch: Pedal mode Accelerator Power Mode Auto-Idle Work Test Conditions Pedal Switch Switch Mode • FNR switch: (F or R) • Brake switch: Digging Slow Idle depressed mode OFF or Axle lock •...
Page 52: Engine Compression Pressure
OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE COMPRESSION PRESSURE Summary: 1. Measure compression pressure in the cylinders and check for a decline in engine power. 2. Check exhaust gas color. Keep track of engine oil consumption. 3. Check for abnormalities in the intake system, including the air filter.
Page 53 OPERATIONAL PERFORMANCE TEST / Engine Test (Blank) T4-3-5...
Page 54: Valve Clearance
OPERATIONAL PERFORMANCE TEST / Engine Test VALVE CLEARANCE Injector Summary: 1. Perform the measurement when the engine is cold. 2. Before starting any work, clean the head cover mounting area and avoid contamination in the engine. Preparation: 1. Disconnect the connector of inject. 2.
Page 55 OPERATIONAL PERFORMANCE TEST / Engine Test Measurement: 1. Insert a thickness gauge into the clearance between rocker arm roller and cam shaft and measure the valve clearance. NOTE: The cylinders are aligned from No.1 to No.4 in that order, as viewed from the fan side.
Page 56 OPERATIONAL PERFORMANCE TEST / Engine Test Adjustment: If the measurement results are out of specification, adjust the valve clearance in the same order of measurement. Cam Shaft 1. Loosen the lock nuts (16 used) and adjusting screws (16 used), which secure the rocker arm by using adjust nut wrench (Isuzu 5-8840-2822-0).
Page 57: Lubricant Consumption
OPERATIONAL PERFORMANCE TEST / Engine Test LUBRICANT CONSUMPTION Measuring Method 1. Place the machine on level firm ground and leave the machine for at least one hour in order to let the lubricant lower to the oil pan when the engine stops.
Page 58 OPERATIONAL PERFORMANCE TEST / Engine Test (Blank) T4-3-10...
Page 59: Travel Speed
OPERATIONAL PERFORMANCE TEST / Excavator Test TRAVEL SPEED Summary: 1. Measure the time required for the excavator to travel a 100 m (328 ft) test track and check the performance of travel device systems (from main pump to travel motor). Preparation: CAUTION: Set the swing lock lever to the LOCK position while traveling.
Page 60 OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: CAUTION: Do not measure travel speed when traveling in reverse. (FNR Switch: F) 1. Measure at fast, slow and creeper speed. 2. Select the following switch positions: Engine Travel Speed Engine Speed Control Accelerator Power Mode Auto-Idle...
Page 61: Service Brake Function
OPERATIONAL PERFORMANCE TEST / Excavator Test SERVICE BRAKE FUNCTION Summary: Evaluation: 1. Check the performance of hydraulic brake circuit Refer to OPERATIONAL PERFORMANCE TEST / and brake. Standard in Group T4-2. 2. Brake control function is the safety item. Carry out the performance test of brake certainly.
Page 62 OPERATIONAL PERFORMANCE TEST / Excavator Test PARKING BRAKE FUNCTION Summary: 1. Measure the parking brake function on a specified slope. 2. Brake control function is the safety item. Carry out the performance test of brake certainly. Preparation: 1. The surface of test slope shall be even paved road with a gradient (11.31°).
Page 63: Swing Speed
OPERATIONAL PERFORMANCE TEST / Excavator Test SWING SPEED Summary: Measure the time required to swing three complete turns and check the performance of swing device systems (from main pump to swing motor). Preparation: 1. Check lubrication of the swing gear and swing bearing.
Page 64: Swing Function Drift Check
OPERATIONAL PERFORMANCE TEST / Excavator Test SWING FUNCTION DRIFT CHECK Summary: 1. Measure the swing drift on swing bearing outer circumference when stopping after 90° full-speed swing and check the performance of swing brake valve. 2. The mechanical brake for swing parking brake is equipped for the swing motor.
Page 65 OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Select the following switch positions: Engine Power Mode Work Auto-Idle Brake Switch Work Brake Control Dial Switch Mode Switch Digging Axle lock or Fast idle Operable mode Auto axle lock 2. Operate the swing control lever fully. Return the swing control lever to the neutral position when the mark on upperstructure aligns with that on chassis after swinging 90°.
Page 66: Swing Motor Leakage
OPERATIONAL PERFORMANCE TEST / Excavator Test SWING MOTOR LEAKAGE Summary: Evaluation: 1. Measure the upperstructure drift while keeping the Refer to OPERATIONAL PERFORMANCE TEST / upperstructure with an angle of 90° relative to the Standard in Group T4-2. slope a 15±1° slope and check performance of swing parking brake.
Page 67: Maximum Swingable Slant Angle
OPERATIONAL PERFORMANCE TEST / Excavator Test MAXIMUM SWINGABLE SLANT ANGLE CAUTION: As the machine may turn over during swing operation, turn the brake switch to the Axle Lock or Auto Axle Lock position. Summary: 1. With the upperstructure swing 90° relative to the slope, check the maximum slant angle on which the upperstructure can swing to the uphill side.
Page 68: Swing Bearing Play
OPERATIONAL PERFORMANCE TEST / Excavator Test SWING BEARING PLAY Summary: 1. Measure the swing bearing play between inner Dial Gauge race and outer race and check the wear of swing bearing races and balls. Preparation: 1. Check the swing bearing mounting bolts for looseness.
Page 69 OPERATIONAL PERFORMANCE TEST / Excavator Test (Blank) T4-4-11...
Page 70: Hydraulic Cylinder Cycle Time
OPERATIONAL PERFORMANCE TEST / Excavator Test HYDRAULIC CYLINDER CYCLE TIME Summary: 1. Measure the cycle time of boom, arm, bucket, blade (optional) and outrigger (optional) cylinders and check the performance of front attachment systems (from main pump to each cylinder). 2.
Page 71 OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Select the following switch positions: Engine Power Mode Auto-Idle Work Mode Work Brake Control Dial Switch Switch Digging Fast idle Operable mode 2. Measure the cylinder cycle times as follows. (Cylinder full stroke includes cylinder cushioning Blade Cylinder: zone.) 2-1.
Page 72: Dig Function Drift Check
OPERATIONAL PERFORMANCE TEST / Excavator Test DIG FUNCTION DRIFT CHECK • Maximum Reach Position Summary: 1. Load a specified weight into the bucket. Measure the cylinder rod drift and judge oil leakage in the boom, arm and bucket cylinders, and the control valve.
Page 73: Control Lever Operating Force
OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER OPERATING FORCE Summary: 1. Measure a play and operating condition of each control lever. 2. Measure the maximum operating force of front attachment control lever. 3. Measure the operating force at the grip center of each control lever.
Page 74: Control Lever Stroke
OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER STROKE Summary: 1. Check a play and operating condition of each control lever and measure the stroke. 2. Measure the control lever stroke at the grip center Stroke Stroke of each control lever. 3.
Page 75: Combined Operation Of Boom Raise/Swing Function Check
OPERATIONAL PERFORMANCE TEST / Excavator Test COMBINED OPERATION OF BOOM RAISE / SWING FUNCTION CHECK Summary: 1. Check boom raise and swing movement and speeds while operating both functions simultaneously. 2. Check that the cylinders do not hesitate while operating the cylinder with the engine running at fast.
Page 76 OPERATIONAL PERFORMANCE TEST / Excavator Test (Blank) T4-4-18...
Page 77: Primary Pilot Pressure
OPERATIONAL PERFORMANCE TEST / Component Test PRIMARY PILOT PRESSURE Preparation: 1. Stop the engine. 2. Push the air bleed valve of the oil supply cap and release any remaining pressure. 3. Remove the plug from the pilot filter. Install adapter (ST 6069) and pressure gauge (ST 6942) to the pressure check port.
Page 78 OPERATIONAL PERFORMANCE TEST / Component Test Primary Pilot Pressure Adjustment Procedure Adjustment: Adjust the relief valve set pressure if necessary. Relief Valve 1. Remove plug (1) from the relief valve. : 22 mm 2. Install the estimated number of shims (2). 3.
Page 79: Secondary Pilot Pressure
OPERATIONAL PERFORMANCE TEST / Component Test SECONDARY PILOT PRESSURE Preparation: 1. Stop the engine. 2. Push the air bleed valve of the oil supply cap and Pilot Valve Signal Control Valve release any remaining pressure. 3. Measure pressure at the location between pilot Hose valve and signal control valve.
Page 80: Solenoid Valve Set Pressure
OPERATIONAL PERFORMANCE TEST / Component Test SOLENOID VALVE SET PRESSURE Use both Dr. ZX and a pressure gauge. Preparation: 1. Stop the engine. 2. Push the air bleed valve of the oil supply cap and Solenoid Valve Unit release any remaining pressure. 3.
Page 81 OPERATIONAL PERFORMANCE TEST / Component Test Solenoid Valve Adjustment Procedure O-Ring IMPORTANT: As O-ring is damaged and oil leak- age may cause, do not loosen ad- justing screw (8) excessively. Do not loosen adjusting screw (8) more than 2 turns. 1.
Page 82: Main Pump Delivery Pressure
OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP DELIVERY PRESSURE This pressure can also be measured by using Dr. ZX. Preparation: 1. Stop the engine. 2. Push the air bleed valve of the oil supply cap and release any remaining pressure. 3.
Page 83 OPERATIONAL PERFORMANCE TEST / Component Test (Blank) T4-5-7...
Page 84: Main Relief Set Pressure
OPERATIONAL PERFORMANCE TEST / Component Test MAIN RELIEF SET PRESSURE Summary: Measure the main relief valve set pressure at the de- livery port in main pump. (This pressure can also be measured by using Dr. ZX.) Preparation: 1. Stop the engine. 2.
Page 85 OPERATIONAL PERFORMANCE TEST / Component Test NOTE: If the measure pressures for all functions are lower than the specified range, the probable cause is a decrease of the main Main Relief relief valve setting pressure. Valve If the relief pressure of a particular function is lower, the probable cause is other than main relief valve.
Page 86: Relief Pressure (When Relieving Swing)
OPERATIONAL PERFORMANCE TEST / Component Test RELIEF PRESSURE (WHEN RELIEVING Swing Relief SWING) Valve 1. Loosen lock nut (1). : 24 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 2. Turn adjustiing screw (2) to adjust the swing relief pressure setting referring to the table below. : 8 mm 3.
Page 87 OPERATIONAL PERFORMANCE TEST / Component Test (Blank) T4-5-11...
Page 88: Overload Relief Valve Set Pressure
OPERATIONAL PERFORMANCE TEST / Component Test OVERLOAD RELIEF VALVE SET PRES- SURE Summary: 5. Maintain hydraulic oil temperature at 50±5 °C 1. The circuit pressure must be increased by apply- (122±9 °F). ing an external force while blocking the return cir- cuit from the control valve.
Page 89 OPERATIONAL PERFORMANCE TEST / Component Test Evaluation: 1. Performance of the overload relief valves are normal if the measured main relief pressures are within the specified value range. Refer to OPERATIONAL PERFORMANCE TEST / Standard in Group T4-2. Overload Relief Valve Pressure Adjustment Pro- cedure NOTE: In principle, adjust the overload relief valve pressure on a test stand.
Page 90: Main Pump Flow Rate Measurement
OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP FLOW RATE MEASUREMENT • P-Q Control (Torque Control) Summary: Main pump performance is checked by measuring 5. Install a pressure gauge to the main pump to be the pump flow rate by using a hydraulic tester in- measured.
Page 91 OPERATIONAL PERFORMANCE TEST / Component Test Evaluation: 1. Convert the measured flow rates to those at the 2. Standard Flow Rate specified pump speed by using the following for- Refer to OPERATIONAL PERFORMANCE TEST / mulas: Standard in Group T4-2. Qc = Ns×Q/Ne NOTE: When actually measuring, install pipe (1 or 2) only to the pump to be measured.
Page 92 OPERATIONAL PERFORMANCE TEST / Component Test • Pilot Pressure Characteristics Summary: Main pump performance is checked by measuring 5. Install hose (19) and adapter (20) to port T of the pump flow rate by using a hydraulic tester in- pressure reducing valve (16). Remove plug L stalled at the main pump delivery port (one side) to from the return pipe.
Page 93 OPERATIONAL PERFORMANCE TEST / Component Test 1, 2 Delivery Hose (To Control Valve) T173-04-04-002 Plug M Port Pi T178-03-07-001 TCEB-03-01-001 Pressure Reducing Valve Port Position Pressure Reducing Return Pipe Valve To Regulator To Pilot Filter Port Pi T178-04-04-004 1 - Pipe E (ST 6144) 7 - Joint (ST 6330) 12 - Plug M 17 - Tee UNF7/16×UNF7/16×...
Page 94 OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Maintain hydraulic oil temperature at 50±5 °C (122±9 °F). 2. Measure pump flow rate in response to the ex- ternal command pilot pressure. 3. Select the following switch positions. Power Engine Auto-Idle Mode Work Mode Control Dial...
Page 95 OPERATIONAL PERFORMANCE TEST / Component Test 1, 2 Delivery Hose (To Control Valve) T173-04-04-002 Plug M Port Pi T178-03-07-001 TCEB-03-01-001 Pressure Reducing Valve Port Position Pressure Reducing Valve Return Pipe To Regulator Port Pi To Pilot Filter T178-04-04-004 1 - Pipe E (ST 6144) Joint (ST 6330) 12 - Plug M 17 - Tee UNF7/16×UNF7/16×...
Page 96 OPERATIONAL PERFORMANCE TEST / Component Test Regulator Adjustment T1V1-03-01-009 1 - Lock Nut (For Minimum 4 - Adjusting Screw (For 7 - Lock Nut (For P-Q 9 - Lock Nut (For P-Q Flow Rate) Maximum Flow Rate) Control) Control) 2 - Adjusting Screw (For 5 - Lock Nut (For Pilot 8 - Adjusting Screw (For P-Q 10 - Adjusting Screw (For P-Q...
Page 97 OPERATIONAL PERFORMANCE TEST / Component Test Adjustment Item Adjustment Procedure Remarks 3. Pilot Pressure Characteristics Loosen lock nut (5) and turn ad- 1) Do not turn adjusting screw (6) more justing screw (6). than one turn. Rotating adjusting screw (6) 1/4 2) When adjusting screw (6) is turned a turn clockwise decreases the clockwise, the maximum flow rate...
Page 98 OPERATIONAL PERFORMANCE TEST / Component Test Adjustment of Maximum Pump 1 and 2 Flow Rate Limit Control Solenoid Valve Maximum Pump 2 Flow Rate Limit Control Solenoid Valve Torque Control Solenoid Valve Maximum Pump 1 Flow Rate Limit Control Solenoid Valve TCEB-03-01-001 Adjustment Item Adjustment Procedure...
Page 99 OPERATIONAL PERFORMANCE TEST / Component Test (Blank) T4-5-23...
Page 100: Swing Motor Drainage
OPERATIONAL PERFORMANCE TEST / Component Test SWING MOTOR DRAINAGE Summary: 1. Measure amount of oil draining from the swing motor while swinging the upperstructure and check the swing motor performance. 2. Secure absolute safety for the measuring persons as well as for the surrounding while measuring. 3.
Page 101 OPERATIONAL PERFORMANCE TEST / Component Test Measurement: CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement. Also, take care not to fall off the machine while the measurement.
Page 102: Steering Valve Relief Pressure
OPERATIONAL PERFORMANCE TEST / Component Test STEERING VALVE RELIEF PRESSURE Use both Dr. ZX and a pressure gauge. CAUTION: If air is mixed in the brake system, the brake function is reduced, and serious hazard may occur. Bleed air from the brake system after removing and installing the pipe lines of steering and brake and replacing hy- draulic oil.
Page 103 OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Select the following switch positions. Engine Power Work Auto-Idle Control Mode Mode Switch Dial Switch Digging Fast idle mode 2. Measure the steering pressure in the handle from right to left stroke end and from left to right stroke end by using a pressure gauge.
Page 104: Brake Pressure (Front And Rear)
OPERATIONAL PERFORMANCE TEST / Component Test BRAKE PRESSURE (FRONT AND REAR) CAUTION: If air is mixed in the brake system, the brake function is reduced and serious hazard may occur. Bleed air from the brake system after removing and installing the pipe lines and replacing hydraulic oil.
Page 105 OPERATIONAL PERFORMANCE TEST / Component Test Conditions for Measurement 1. Select the following switch positions. Engine Power Mode Work Mode Auto-Idle Brake Control Dial Switch Switch Switch Switch Fast idle Digging mode Measurement: 1. Measure the pressure when fully depressing the brake pedal.
Page 106 OPERATIONAL PERFORMANCE TEST / Component Test BRAKE ACCUMLATED PRESSURE CAUTION: If air is mixed in the brake system, the brake function is reduced serious hazard may occur. Bleed air from the brake system after removing and installing the pipe lines and replacing hydraulic oil.
Page 107 OPERATIONAL PERFORMANCE TEST / Component Test Conditions for Measurement 1. Select the following switch positions. Engine Power Mode Work Mode Auto-Idle Brake Control Dial Switch Switch Switch Switch Fast idle Digging mode Measurement: 1. When depressing the brake pedal slowly several times, measure the maximum pressure.
Page 108: Brake Warning Set Pressure (Decrease)
OPERATIONAL PERFORMANCE TEST / Component Test BRAKE WARNING SET PRESSURE (DECREASE) CAUTION: If air is mixed in the brake system, the brake function is reduced serious hazard may occur. Bleed air from the brake system after removing and installing the pipe lines and replacing hydraulic oil.
Page 109 OPERATIONAL PERFORMANCE TEST / Component Test Conditions for Measurement: 1. Select the following switch positions. Forward/Reverse Lever Parking Brake Switch P (Parking Brake) Measurement: 1. Stop the engine. Turn the key switch to ON posi- tion. 2. Measure the pressure when warning buzzer sounds by slowly depressing the brake pedal several times.
Page 110: Brake Warning Set Pressure (Increase)
OPERATIONAL PERFORMANCE TEST / Component Test BRAKE WARNING SET PRESSURE (INCREASE) CAUTION: If air is mixed in the brake system, the brake function is reduced serious hazard may occur. Bleed air from the brake system after removing and installing the pipe lines and replacing hydraulic oil.
Page 111 OPERATIONAL PERFORMANCE TEST / Component Test Conditions for Measurement 1. Select the following switch positions. Engine Power Mode Auto-Idle Brake Work Mode Control Dial Switch Switch Switch Switch Fast idle Digging mode Measurement: 1. Stop the engine. Turn the key switch to ON posi- tion.
Page 112 OPERATIONAL PERFORMANCE TEST / Component Test (Blank) T4-5-36...
Page 113 M E M O ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 114 M E M O ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 115 SECTION 5 TROUBLESHOOTING CONTENTS Group 1 Diagnosing Procedure Group 4 ICF Introduction ................T5-1-1 Outline ..................T5-4-1 Diagnosing Procedure ............T5-1-2 List of Daily Report Data ........... T5-4-2 List of Frequency Distribution Data ......T5-4-5 Group 2 Monitor Unit List of Total Operating Hours .......... T5-4-6 Outline ..................
Page 116 Steering Column Monitor Option Controller Fault Code 15516 ....... T5-6-152 Fault Code ..............T5-6-68 Option Controller Fault Code 15517 ....... T5-6-153 MC Fault Codes 11000 to 11002 ........T5-6-70 Option Controller Fault Code 15518 ....... T5-6-154 MC Fault Code 11003............T5-6-71 Option Controller Fault Code 15519 ....... T5-6-155 MC Fault Code 11004............T5-6-72 Option Controller Fault Code 15570 .......
Page 117 Group 8 Electrical System Inspection Precautions for Inspection and Maintenance ..............T5-8-1 Instructions for Disconnecting Connectors ..............T5-8-3 Fuse Inspection ..............T5-8-4 Fusible Link Inspection ............. T5-8-6 Battery Voltage Check ............T5-8-7 How to Check Alternator ..........T5-8-8 Continuity Check..............T5-8-9 Voltage and Current Measurement ......T5-8-10 Check by False Signal ............T5-8-17 Test Harness ................T5-8-18...
Page 118 (Blank) CEBT-5-4...
Page 119: Introduction
TROUBLESHOOTING / Diagnosing Procedure INTRODUCTION Refer to the inspection and troubleshooting proce- dures after any machine trouble has occurred. The inspection and troubleshooting procedures are pre- sented in an orderly fashion in this section to quickly find the cause of the machine trouble and solution. The troubleshooting section in this manual consists of 8 groups;...
Page 120: Diagnosing Procedure
TROUBLESHOOTING / Diagnosing Procedure DIAGNOSING PROCEDURE These six basic steps are essential for efficient troubleshooting: 1. Study the System Study the machine’s technical manuals. Know the system and how it works, and what the construction, functions and specifications of the system components are.
Page 121 TROUBLESHOOTING / Diagnosing Procedure 4. Operate the machine yourself Try to identify the trouble by operating the machine yourself. If the trouble cannot be confirmed, stop the engine obtain further details malfunction from the operator. Also, check for any incomplete connections of the wire harnesses correponding to the trouble.
Page 122 TROUBLESHOOTING / Diagnosing Procedure 5. Perform troubleshooting CAUTION: Do not disconnect harnesses or hydraulic lines while the engine is running. The machine may malfunction or pressurized oil may spout, possibly resulting in personal injury. Stop the engine before disconnecting harnesses or hydraulic lines. Perform diagnosis by connecting Palm to the machine or by using the service menu of monitor unit.
Page 123 TROUBLESHOOTING / Diagnosing Procedure 6. Trace possible causes Before reaching a conclusion, check the most likely causes again. Try to identify the actual cause of the trouble. Based on your conclusion, make a plan for appropriate repairs avoid consequent malfunctions. T5-1-5...
Page 124 TROUBLESHOOTING / Diagnosing Procedure (Blank) T5-1-6...
Page 125: Outline
TROUBLESHOOTING / Monitor Unit OUTLINE Primary Screen TCJB-05-02-043 1 - Work Mode Display 10 - Parking Brake Display 19 - Trip Meter Display 28 - Work Mode Display 2 - Auto-Idle Display 11 - Work Brake Display 20 - Odometer Display 29 - Auxiliary Selection 3 - Overload Alarm Display 12 - Axle Lock Display...
Page 126 TROUBLESHOOTING / Monitor Unit • Display of Meters Data to be displayed on each meter are displayed on the monitor unit according to the input signal from sensor, the signal received from ICF by using CAN and the internal data of monitor unit. Items to be displayed 7.
Page 127 Attachment Mode Breaker T1V1-05-01-104 Pulverizer TCJB-05-02-057 T1V1-05-01-105 Crusher T1V1-05-01-106 Vibrating Hammer T1V1-05-01-107 Others T1V1-05-02-003 NOTE: The items on monitor unit and HITACHI pattern are same. Monitor Unit HITACHI pattern Breaker1 Hydraulic Breaker1 Breaker2 Hydraulic Breaker2 Pulverizer1 Secondary Crusher1 Crusher1 Primary Crusher1...
Page 128 TROUBLESHOOTING / Monitor Unit • Auto-Idle Display (2) When the auto-idle switch on switch panel is turned ON, the data is displayed. When the key switch is turned ON with the auto-idle switch ON, the data blinks for 10 seconds. •...
Page 129 TROUBLESHOOTING / Monitor Unit • Fuel Gauge (25) The data of fuel level is displayed. • Coolant Temperature Gauge (30) Temperature of engine coolant is displayed. TCJB-05-02-064 • Brake Oil Pressure Gauge (33) Pressure in the brake circuit is displayed. •...
Page 130 TROUBLESHOOTING / Monitor Unit • Parking Brake Display (10) When the parking brake is applied, the red indicator lights. (Brake Switch: P (Parking Brake) Position • Work Brake Display (11) When the work brake is applied (under the work brake control), the red indicator lights. (Refer to the SYSTEM/Control System group.) •...
Page 131 TROUBLESHOOTING / Monitor Unit • Work Light Display (13) The work light switch is turned ON, the green indi- cator lights. • Auxiliary 2 (Positioning) Selection Display (14) When the auxiliary/positioning selection switch is in the Positioning position, the green indicator lights. •...
Page 132 TROUBLESHOOTING / Monitor Unit • Fuel Sensor Error Display Coolant Temperature Fuel Sensor Error Sensor Error Display Display TCJB-05-02-104 When the fuel sensor is faulty or if the harness be- tween fuel sensor and monitor unit is open circuit, the data is displayed on the fuel gauge. •...
Page 133 1 - Digging 2 - Breaker 1 3 - Breaker 2 4 - Pulverizer 1 5 - Crusher 1 T1V5-05-01-109 NOTE: The items on monitor unit and HITACHI Attachment Selection Screen pattern are same. Monitor Unit HITACHI pattern Breaker1 Hydraulic Breaker1...
Page 134 Figure 1 Pulverizer 1 Figure 2 Crusher 1 Figure 2 NOTE: O/T: Hydraulic Oil Tank C/V: Control Valve NOTE: The items on monitor unit and HITACHI pattern are same. Monitor Unit HITACHI pattern Breaker 1 Hydraulic Breaker 1 Breaker 2...
Page 135 TROUBLESHOOTING / Monitor Unit • Maintenance Settings The data; date of the last replacement, hour meter, the remaining hours until the next replacement and the replacement interval are displayed. As the items to be replaced are displayed in a list, record performed replacement by selecting an item from the list.
Page 136 TROUBLESHOOTING / Monitor Unit • Mail (Optional Function) Sends requests such as general, fuel replenishment, service maintenance and forwarding requests in the mail switch screen. Contents of mails are registered in ICF, and are sent to the central server by a satellite terminal. (Refer to T5-2-44.) Mail Switch Screen T1V5-05-01-037...
Page 137 TROUBLESHOOTING / Monitor Unit • Language Settings Select a language to be used in screens from among preset languages, according to work envi- ronment. (Refer to T5-2-56.) Language Setup Screen T1V1-05-01-137 • Meter Combination Settings (km/h↔min Speedometer (km/h), tachometer (min ), hour meter, odometer and trip meter on the primary screen are combined and set respectively.
Page 138 TROUBLESHOOTING / Monitor Unit • Service Menu (Built-In Diagnosing System) • Troubleshooting This screen displays the fault codes according to the signals received from each controller by using CAN. (Refer to T5-2-64.) Fault Code Display T1V5-05-01-097 • Monitoring This screen displays temperature and pressure data received from each controller by using CAN.
Page 139 TROUBLESHOOTING / Monitor Unit • Overload Alarm Overload Alarm (Only the machines equipped with optional parts) IMPORTANT: When using overload alarm, make overload alarm available by using Dr. 1. MC detects load of the suspended load by the signal from the boom bottom pressure sensor. 2.
Page 140 TROUBLESHOOTING / Monitor Unit (Blank) T5-2-16...
Page 141: How To Use Screens
TROUBLESHOOTING / Monitor Unit HOW TO USE SCREENS Displaying Primary Screen IMPORTANT: Start the engine after the primary screen is displayed. When the key switch is turned to the ON position, the starting screen appears for about two seconds and the primary screen appears.
Page 142 TROUBLESHOOTING / Monitor Unit Displaying Primary Screen by Password Input (Optional) IMPORTANT: Before performing this operation, make the password function avail- able by using Dr. ZX. Starting Screen T1V1-05-01-115 1. When the key switch is turned to the ON position, Password the starting screen appears and the primary Icon...
Page 143 TROUBLESHOOTING / Monitor Unit 3. Input a password by using the keys located under the screen. If pushing the confirm key, the monitor unit matches the input password to the registered one. If they match, the primary screen appears. NOTE: When inputting the password again, the entered characters can be erased by pushing the erase key.
Page 144 TROUBLESHOOTING / Monitor Unit In Case of Inputting an Incorrect Password 1. If inputting an incorrect password, the message “Password is incorrect.” appears by pushing the confirm key. Password Input Screen T1V5-05-01-093 T1V5-05-01-002 Confirm Key Erase Key 2. Return to the password input screen by pushing the back key.
Page 145 TROUBLESHOOTING / Monitor Unit 3. If inputting an incorrect password three times, a screen appears informing that the security lock has been applied, and a buzzer rings. While the key switch is turned to the ON position, the buzzer does not stop ringing. When the key switch is turned to the OFF position, the security lock dis- play disappears and the buzzer rings for thirty seconds.
Page 146 TROUBLESHOOTING / Monitor Unit Extending Password Duration Time IMPORTANT: This operation is applicable only to those machines that display the primary screen based upon pass- word input. By using the password duration screen, password duration time can be set. When restarting the machine, a password need not be input within that timeframe.
Page 147 TROUBLESHOOTING / Monitor Unit (Blank) T5-2-23...
Page 148 TROUBLESHOOTING / Monitor Unit SCREEN DISPLAY WHEN AN ALARM IS ISSUED When an alarm is issued, the alarm marks are dis- played at the bottom of screen. • When the number of alarm is three or less TCJB-05-02-046 • When the number of alarm is four to five TCJB-05-02-047 •...
Page 149 TROUBLESHOOTING / Monitor Unit When an alarm is issued, if the key under a relevant alarm mark is pushed, the remedy against the alarm is displayed. Push a Relevant Key TCJB-05-02-046 T1V5-05-01-013 T5-2-25...
Page 150: Contents Of Alarms
TROUBLESHOOTING / Monitor Unit CONTENTS OF ALARMS Display Buzzer Contents of Alarms Remedy Overheat Alarm Temperature of engine coolant is going up abnormally Continuously higher. sounds Stop the work. Run the engine at low idle in order to lower the coolant temperature. M178-01-036 Engine Warning Alarm Failure of the engine or its related parts.
Page 151 TROUBLESHOOTING / Monitor Unit Display Buzzer Contents of Alarms Remedy Brake Pressure Alarm Brake oil pressure is low. Please contact our authorized distributor or dealer. Continuously sounds TCJB-05-02-032 Attachment Operating Attachment pedal operating signal is abnormal. Signal Alarm Please contact our authorized distributor or dealer. Intermittently sounds TCJB-05-02-033...
Page 152 TROUBLESHOOTING / Monitor Unit (Blank) T5-2-28...
Page 153: Time Setting
TROUBLESHOOTING / Monitor Unit TIME SETTING 1. When the primary screen appears, push the menu key and display main menu. Menu Key TCJB-05-02-064 Primary Screen 2. Select time set from main menu by using keys 1 and 2. Push the confirm key. Then, the time setup screen appears.
Page 154: Attachment Adjustment
TROUBLESHOOTING / Monitor Unit ATTACHMENT ADJUSTMENT (PUMP 2 FLOW RATE ADJUSTMENT) NOTE: Only the machines equipped with optional parts. IMPORTANT: This operation is effective when at- tachments are used. When using breaker 1 or breaker 2 1. When the primary screen appears, push the menu key and display main menu.
Page 155 TROUBLESHOOTING / Monitor Unit NOTE: Only the machines equipped with optional parts. IMPORTANT: This operation is effective when at- tachments are used. When using pulverizer or crusher 1. When the primary screen appears, push the menu key and display main menu. 2.
Page 156: Displaying Operating Conditions
TROUBLESHOOTING / Monitor Unit DISPLAYING OPERATING CONDITIONS 1. When the primary screen appears, push the menu key and display main menu. Menu Key TCJB-05-02-064 Primary Screen 2. Select operating conditions from main menu by using keys 1 and 2. Push the confirm key. Then, the operating conditions screen appears.
Page 157 TROUBLESHOOTING / Monitor Unit (Blank) T5-2-33...
Page 158: Maintenance Settings
TROUBLESHOOTING / Monitor Unit MAINTENANCE SETTINGS 1. When the primary screen appears, push the menu key and display main menu. Menu Key Primary Screen TCJB-05-02-064 2. Select maintenance settings from main menu by using keys 1 and 2. Push the confirm key. Then, the maintenance settings screen appears.
Page 159 TROUBLESHOOTING / Monitor Unit Maintenance Information Display ON/OFF Example: Maintenance Information Display OFF→ON When time comes to change, the informa- tion message is displayed on the screen. OFF: No information message is displayed. 1. Select maintenance information display by using Key 1 keys 1 and 2.
Page 160 TROUBLESHOOTING / Monitor Unit Change Interval Settings IMPORTANT: Change interval can only be set when maintenance information dis- play is set to ON. 1. Select change interval by using keys 1 and 2. 2. Set time for change interval by using keys 3 and Key 1 Key 2 Key 3...
Page 161 TROUBLESHOOTING / Monitor Unit Resetting Data If data is reset, push key 5 on the interval ON/OFF setup screen. The message “Reset Data. OK?” appears. Then, push the confirm key. The value of remaining hours is reset to that of change interval.
Page 162 TROUBLESHOOTING / Monitor Unit Notice Screen Display when Maintenance Information Display is ON • When only one item is displayed 1. If the key switch is turned to the ON position, the primary screen appears. At this time, if mainte- nance is required, the primary screen gives notice of the maintenance item.
Page 163 TROUBLESHOOTING / Monitor Unit Notice • When more than two items are displayed 1. If the key switch is turned to the ON position, the primary screen appears. At this time, if mainte- nance is required, the primary screen gives notice of the maintenance item.
Page 164: Work Mode (Attachment Selection)
TROUBLESHOOTING / Monitor Unit WORK MODE (ATTACHMENT SELECTION) NOTE: Only the machines equipped with optional parts. IMPORTANT: Select the attachments from the work mode screen. In order to display the work mode screen, push key F1 after the pri- mary screen appears, or select from main menu.
Page 165 TROUBLESHOOTING / Monitor Unit Selecting Attachment from Main Menu 1. When the primary screen appears, push the menu key and display main menu. Menu Key TCJB-05-02-064 Primary Screen 2. Select work mode from main menu by using keys 1 and 2. Push the confirm key. Then, the work mode screen appears.
Page 166 TROUBLESHOOTING / Monitor Unit Attachment Specification Screen Maximum Pump 2 Flow Rate Maximum Engine Speed Accumulator Control Solenoid Valve: Secondary Hydraulic Relief Selector Control Solenoid Valve: ON Selector Valve Control Solenoid Valve: ON The selector valve is connected to the hydraulic oil tank.
Page 167 TROUBLESHOOTING / Monitor Unit Maximum Pumps 1 and 2 Flow Rate Maximum Engine Speed Accumulator Control Solenoid Valve: Secondary Hydraulic Relief Selector Control Solenoid Valve: OFF Selector Valve Control Solenoid Valve: OFF The selector valve is connected to the control valve.
Page 168: Mail (Optional)
TROUBLESHOOTING / Monitor Unit MAIL (Optional) IMPORTANT: This function is available only to a machine equipped with a satellite terminal. When using the mail function, make the mail function available by using Dr. ZX. 1. When the primary screen appears, push key F3 and display the mail screen.
Page 169 TROUBLESHOOTING / Monitor Unit NOTE: When ICF could not receive the mail, the message “Mail delivery failed.” is displayed on the screen. T1V5-05-01-040 T5-2-45...
Page 170: Meter Display Selection
TROUBLESHOOTING / Monitor Unit METER DISPLAY SELECTION NOTE: The meter display selection screen is dis- played by pushing key F4 or selecting main menu after the primary screen is displayed. Select Meter Display Selection from Key F4 1. After the primary screen is displayed, push key F4. Key F4 Then, the meter display selection screen is dis- played.
Page 171 TROUBLESHOOTING / Monitor Unit NOTE: The meter display selection screen is dis- played by pushing key F4 or selecting main menu after the primary screen is displayed. Select Meter Display Selection from Main Menu 1. After the primary screen is displayed, push the menu key.
Page 172: Password Change (Optional)
TROUBLESHOOTING / Monitor Unit PASSWORD CHANGE (OPTIONAL) 1. After the primary screen is displayed, push the menu key and display main menu. Menu Key Primary Screen TCJB-05-02-064 2. Select password change from main menu by us- ing keys 1 and 2. Push the confirm key. Then, the password change screen appears.
Page 173 TROUBLESHOOTING / Monitor Unit NOTE: If inputting an incorrect password after pushing the confirm key, the message “Password is incorrect.” appears. Push the back key and go back to the pre- vious screen. Input the password again. T1V5-05-01-044 Back Key 5.
Page 174 TROUBLESHOOTING / Monitor Unit 7. The message “Re-enter password.” appears. Then, input a new password again and push the confirm key. 8. If inputting the password again, push the erase key in order to erase the entered characters. T1V5-05-01-132 Confirm Key Erase Key T1V5-05-01-133 9.
Page 175 TROUBLESHOOTING / Monitor Unit (Blank) T5-2-51...
Page 176: Back Monitor Settings
TROUBLESHOOTING / Monitor Unit BACK MONITOR SETTINGS IMPORTANT: Image displayed on the back monitor is of auxiliary nature at best. When the machine is operated, pay thor- ough attention to surrounding situa- tion. Auto-Control: ON When the FNR switch is turned to the R (reverse) position, image on the monitor unit is automatically Menu Key switched to that of the back monitor.
Page 177 TROUBLESHOOTING / Monitor Unit 5. When the FNR switch is turned to the R (reverse) position, image on the monitor unit is switched to rear view image. NOTE: After rear view image is displayed on the monitor unit screen and although the ac- celerator pedal returns to the neutral posi- tion, rear view image is displayed for three seconds.
Page 178 TROUBLESHOOTING / Monitor Unit Auto-Control: OFF When the FNR switch is the R (reverse) position, automatic switching function of images between monitor unit and back monitor is set to OFF. 1. When the primary screen appears, push the menu key and display main menu. Menu Key TCJB-05-02-064 Primary Screen...
Page 179 TROUBLESHOOTING / Monitor Unit (Blank) T5-2-55...
Page 180: Language Settings
TROUBLESHOOTING / Monitor Unit LANGUAGE SETTINGS 1. When the primary screen appears, push the menu key and display main menu. Menu Key TCJB-05-02-064 Primary Screen 2. Select language from main menu by using keys 1 and 2. Push the confirm key. Then, the language settings screen appears.
Page 181 TROUBLESHOOTING / Monitor Unit Lists of Display Languages Display Languages 1 Language Screen Display Japanese T1V1-05-01-141 English T1V1-05-01-142 Chinese T1V1-05-01-143 Taiwanese T1V1-05-01-144 Korean T1V1-05-01-145 Indonesian T1V1-05-01-146 Thai T1V1-05-01-147 Vietnamese T1V1-05-01-148 Myanmarese T1V1-05-01-149 Arabic T1V1-05-01-150 Persian T1V1-05-01-151 Turkish T1V1-05-01-152 Display Languages 2 Language Screen Display English...
Page 182: Meter Combination Settings
TROUBLESHOOTING / Monitor Unit METER COMBINATION SETTINGS 1. After the primary screen is displayed, push the menu key and display main menu. Menu Key TCJB-05-02-064 Primary Screen 2. Select km/h ↔ min from main menu by using keys 1 and 2. Push the confirm key. Then, the meter combination setup screen is displayed.
Page 183 TROUBLESHOOTING / Monitor Unit NOTE: Examples of combination Odometer • When selecting km (speedometer) and odometer Speedometer (km) TCJB-05-02-069 • When selecting min (tachometer) and hour me- Hour Me- Tachometer TCJB-05-02-065 Trip Meter • When selecting mph (speedometer) and trip me- (Unit: When selecting mile) Speedometer (mile)
Page 184: Unit Settings
TROUBLESHOOTING / Monitor Unit UNIT SETTINGS 1. After the primary screen is displayed, push the menu key and display main menu. Menu Key Primary Screen TCJB-05-02-064 2. Select km/h ↔ mile from main menu by using keys 1 and 2. Push the confirm key. Then, the unit combination setup screen is displayed.
Page 185 TROUBLESHOOTING / Monitor Unit NOTE: Examples • When selecting km TCJB-05-02-069 • When selecting mile TCJB-05-02-070 T5-2-61...
Page 186 TROUBLESHOOTING / Monitor Unit (Blank) T5-2-62...
Page 187: Service Menu (Built-In Diagnosing System) Operation
Monitor Unit SERVICE MENU (BUILT-IN DIAGNOSING SYSTEM) OPERATION IMPORTANT: This system is to be operated by the HITACHI dealer only. Do not explain this system function to the cus- tomer. Although Dr.ZX id not used, the following items can be displayed on the monitor unit.
Page 188 TROUBLESHOOTING / Monitor Unit TROUBLESHOOTING 1. Displaying Service Menu Turn the key switch to the ON position while pushing the key at upper right corner of the monitor unit. Therefore, service menu is added to main menu. Turn key switch ON while pushing the key T1V1-05-01-115 2.
Page 189 TROUBLESHOOTING / Monitor Unit 4. Select troubleshooting by using keys 1 and 2. Push the confirm key. Then, the troubleshooting screen appears. Key 1 Key 2 Confirm Key Back Key TCHB-05-02-007 A figure enclosed in ( ) indicates the number of fault codes. 5.
Page 190: Monitoring
TROUBLESHOOTING / Monitor Unit MONITORING 1. Displaying Service Menu Turn the key switch to the ON position while pushing the key at upper right corner of the moni- tor unit. Therefore, service menu is added to main menu. T1V1-05-01-115 Turn the key switch ON while pushing the key 2.
Page 191 TROUBLESHOOTING / Monitor Unit 4. Select monitoring by using keys 1 and 2. Push the confirm key. Then, the monitoring screen appears. As for items to be monitored, refer to the next page. TCHB-05-02-007 Key 1 Key 2 Confirm Key 5.
Page 192 TROUBLESHOOTING / Monitor Unit A List of Items to be Monitored Items Units Remarks Engine Torque °C Coolant Temperature (E) Input signal to the monitor unit from ECM by using CAN °C Fuel Temperature Engine Oil Pressure Atmospheric Pressure °C Intake Air Temperature Boost Pressure °C...
Page 193 TROUBLESHOOTING / Monitor Unit Items Units Remarks Speed km/h Although mile is selected from main menu, travel speed (km/h) is displayed. Travel Motor Over Speed (Count) Brake Pressure Emergency Stop OFF/ON Attachment1/Positioning1 Signal Attachment2/Positioning2 Signal Blade1/Outrigger1 Signal Blade2/Outrigger2 Signal Assist1 Signal Assist2 Signal Assist3 Signal Assist4 Signal...
Page 194: Controller Version
TROUBLESHOOTING / Monitor Unit CONTROLLER VERSION 1. Displaying Service Menu Turn the key switch to the ON position while pushing the key at upper right corner of the moni- tor unit. Therefore, service menu is added to main menu. T1V1-05-01-115 Turn the key switch ON while pushing the key 2.
Page 195 TROUBLESHOOTING / Monitor Unit 4. Select controller version by using keys 1 and 2. Push the confirm key. Then, the controller version screen appears. NOTE: The version of ECM is not displayed. NOTE: When pushing the back key, return to the previous screen.
Page 196: Blade/Outrigger Settings
TROUBLESHOOTING / Monitor Unit BLADE/OUTRIGGER SETTINGS 1. Displaying Service Menu Turn the key switch to the ON position while pushing the key at upper right corner of the moni- tor unit. Therefore, service menu is added to main menu. T1V1-05-01-115 Turn the key switch ON while pushing the key 2.
Page 197 TROUBLESHOOTING / Monitor Unit 4. Select blade/outrigger settings by using keys 1 and 2. Push the confirm key. Then, the blade/outrigger setup screen appears. Key 1 Key 2 Confirm Key TCHB-05-02-007 5. Select the screen corresponded to the combina- tion by using keys 1 and 2. NOTE: When pushing the back key, return to the previous screen.
Page 198: Keyless Hour Meter
TROUBLESHOOTING / Monitor Unit KEYLESS HOUR METER When the key switch is turned OFF, the following items can be displayed on the monitor unit screen. • Hour Meter • Odometer • Fuel Gauge When the back monitor selection key is pushed for one second or more, the keyless hour meter screen is displayed.
Page 199: List Of Monitor Unit Sitting Function
TROUBLESHOOTING / Monitor Unit LIST OF MONITOR UNIT SETTING FUNC- TION ○: with setting function ×: without setting function Setting Function Function Item Default Monitor Dr.ZX Unit Alarm Check alarms while trouble occurs ○ ○(Troubleshooting) － Security Password function Enable/Disable Disable ×...
Page 200 TROUBLESHOOTING / Monitor Unit Setting Function Function Item Default Monitor Dr.ZX Unit Maintenance Maintenance display items ON/OFF ○(Monitor Controller) × Setting Notification function Enable/Disable ○(Monitor Controller) Enable ○ Hydraulic Change interval 1000 hours × × Oil Filter Remaining hours data reset ○...
Page 201 TROUBLESHOOTING / Monitor Unit Setting Function Function Item Default Monitor Dr.ZX Unit Maintenance Maintenance display items ON/OFF ○(Monitor Controller) × Setting Notification function Enable/Disable ○(Monitor Controller) Enable ○ Drive Shaft Change interval 500 hours × × Greasing Remaining hours data reset ○...
Page 202 TROUBLESHOOTING / Monitor Unit Setting Function Function Item Default Monitor Dr.ZX Unit Maintenance Maintenance display items ON/OFF ○(Monitor Controller) × Setting Notification function Enable/Disable ○(Monitor Controller) Enable ○ Conditioner Change interval 3000 hours × × Filter Remaining hours data reset ○...
Page 203: Outline
TROUBLESHOOTING / Dr. ZX OUTLINE Dr. ZX is a tool used for troubleshooting of the electronic control system of MC, ECM, ICF, monitor unit, steering column monitor and option controller. It displays the fault code of each controller or sensor by connecting Dr.
Page 204: Mc Monitoring List
TROUBLESHOOTING / Dr. ZX MC MONITORING LIST Dr. ZX displays the input signals from switches and sensors to MC and the control signals to the actuators from MC. Item Unit Data Selecting Monitoring Requested Engine Speed Req. Eng Input signal from engine control dial Actual Engine Speed Actual Speed Input signal from ECM...
Page 205 TROUBLESHOOTING / Dr. ZX Item Unit Data Selecting Monitoring Power Boost SW Power Boost SW ON, OFF Power digging switch ON/OFF selection status Key SW Key SW ON, OFF Key switch ON/OFF selection status Slight Travel SW Slight Travel SW ON, OFF Engine control mode selection switch (creeper) ON/OFF selection status...
Page 206 TROUBLESHOOTING / Dr. ZX Item Unit Data Selecting Monitoring Speed Meter Auto Change Flag Speed Meter Auto Change Flag ON, OFF Speed meter auto switch ON/OFF selection status Current ATT Type Current ATT Type BR, PU, CR, VI, Un Communication from monitor unit Current ATT No.
Page 207: Ecm Monitoring List
TROUBLESHOOTING / Dr. ZX ECM MONITORING LIST Item Unit Data Selecting Monitoring Engine Torque Engine Torque ％ Input signal from ECM Actual Engine Speed Act. Eng Speed Input signal from crank speed sensor and cam angle sensor (Engine Speed) Target Engine Speed Tar.
Page 208: Monitor Unit Monitoring List
TROUBLESHOOTING / Dr. ZX MONITOR UNIT MONITORING LIST Item Unit Data Selecting Monitoring − Monitor SW Status Check Monitor SW Status Check Monitor unit switch status Coolant Temperature Coolant Temp. °C Input signal from coolant temperature sensor Fuel Level Fuel Level Input signal from fuel level sensor Security Signal Security Signal...
Page 209: Steering Column Monitor Monitoring List
TROUBLESHOOTING / Dr. ZX STEERING COLUMN MONITOR MONITORING LIST Item Unit Data Selecting Monitoring Speed Pulse Speed Pulse Communication from MC Vehicle Speed Pulse Vehicle Speed Pulse Communication from MC T5-3-7...
Page 210: Option Controller Monitoring List
TROUBLESHOOTING / Dr. ZX OPTION CONTROLLER MONITORING LIST Item Unit Data Selecting Monitoring Att SW Operation (Proportional SW) Att SW Ope (Prop) Input signal from attachment switch Auxiliary Operation (Proportional SW) Aux Ope (Prop SW) Input signal from attachment switch Positioning/Att 1 Operation Posn/Att 1 Ope Input signal from attachment pedal...
Page 211 TROUBLESHOOTING / Dr. ZX Item Unit Data Selecting Monitoring Swing Parking Release FB Swing Parking FB Feedback from swing parking brake release solenoid valve output Att 1 P/S/V FB Att 1 P/S/V FB Feedback from auxiliary solenoid valve output Att 2 P/S/V FB Att 2 P/S/V FB Feedback from auxiliary solenoid valve output Blade 1/Outrigger 1 P/S/V FB...
Page 212: Mc Adjustment List
TROUBLESHOOTING / Dr. ZX MC ADJUSTMENT LIST Engine speed, pump delivery flow rate, solenoid valve output pressure and so on can be adjusted. Adjustment Item List Item Unit Data Li Speed Adjustment Adjustment of minimum engine speed Travel Li Speed Adjustment Adjustment of minimum engine speed when traveling WU Speed Adjustment Adjustment of warming up engine speed...
Page 213 TROUBLESHOOTING / Dr. ZX Adjustment List Item Unit Minimum Adjustment Adjustable Range Initial Value Li Speed Adjustment 0 to 400 Travel Li Speed Adjustment 0 to 400 WU Speed Adjustment -600 to 200 AI Speed Adjustment -300 to 400 E Speed Adjustment Temporarily release (valid only when key is ON) P Speed Adjustment...
Page 214: Mc Attachment Adjustment List
TROUBLESHOOTING / Dr. ZX MC ATTACHMENT ADJUSTMENT LIST Adjustment Item List Item Unit Data ATT1 ATT1 ATT Type BR PU CR VI Un Non Attachment selection ATT1 ATT No. 1 2 3 4 5 Attachment setting number selection ATT1 P1 Swash Angle Adjustment L/min Adjustment of lower limit of maximum pump 1 flow rate when using attachment ATT1 P2 Swash Angle Adjustment...
Page 215 TROUBLESHOOTING / Dr. ZX Item Unit Data ATT4 ATT4 ATT Type BR PU CR VI Un Non Attachment selection ATT4 ATT No. 1 2 3 4 5 Attachment setting number selection ATT4 P1 Swash Angle Adjustment L/min Adjustment of lower limit of maximum pump 1 flow rate when using attachment ATT4 P2 Swash Angle Adjustment L/min Adjustment of lower limit of maximum pump 2 flow rate when using attachment...
Page 216 TROUBLESHOOTING / Dr. ZX Adjustment Value List Adjustment Data Minimum Adjustment Adjustable Range Initial Value Remark ATT1 ATT1 ATT Type BR PU CR VI Un Non ATT1 ATT No. 1 to 5 ATT1 P1 Swash Angle Adjustment 0.5 L/min 52.8 to 105.6 L/min 105.6 L/min ATT1 P2 Swash Angle Adjustment 0.5 L/min...
Page 217 TROUBLESHOOTING / Dr. ZX Adjustment Data Minimum Adjustment Adjustable Range Initial Value Remark ATT4 ATT4 ATT Type BR PU CR VI Un Non ATT4 ATT No. 1 to 5 ATT4 P1 Swash Angle Adjustment 0.5 L/min 52.8 to 105.6 L/min 105.6 L/min ATT4 P2 Swash Angle Adjustment 0.5 L/min...
Page 218: Icf Adjustment Item List
TROUBLESHOOTING / Dr. ZX ICF ADJUSTMENT ITEM LIST Adjustment Item List Item Data Range Information C/U: Initialization Initialization/End Model Number Setting Model ASCII (4 characters) 0 to 9, A to Z Machine Nos. 000000 to 999999 Time Setting Year 2000 to 2100 Date Month 1 to 12...
Page 219 TROUBLESHOOTING / Dr. ZX (Blank) T5-3-17...
Page 220: Option Controller Adjustment List
TROUBLESHOOTING / Dr. ZX OPTION CONTROLLER ADJUSTMENT LIST Adjustment Item List Item Unit Data Att Ope 1 P/S/V Adjustment Adjustment of auxiliary solenoid valve Att Ope 2 P/S/V Adjustment Adjustment of auxiliary solenoid valve Blade/OR Ope 1 P/S/V Adjustment Adjustment of blade/outrigger solenoid valve Blade/OR Ope 2 P/S/V Adjustment Adjustment of blade/outrigger solenoid valve Att SW Ope 1 P/S/V Adjustment...
Page 221 TROUBLESHOOTING / Dr. ZX Adjustment List Item Unit Minimum Adjustment Adjustable Range Initial Value Att Ope 1 P/S/V Adjustment 0.0196 -0.5 to 0.5 Att Ope 2 P/S/V Adjustment 0.0196 -0.5 to 0.5 Blade/OR Ope 1 P/S/V Adjustment 0.0196 -0.5 to 0.5 Blade/OR Ope 2 P/S/V Adjustment 0.0196 -0.5 to 0.5...
Page 222: Dr. Zx Operation Procedure
TROUBLESHOOTING / Dr. ZX Dr. ZX OPERATION PROCEDURE Some examples are explained here. As for other Dr. ZX Operation Procedure, refer to the extra volume, Dr. ZX Manual. Parameter Change (Option Controller) As for the machine equipped with each attachment auxiliary, blade/outrigger, positioning and attachment, operation item...
Page 223 TROUBLESHOOTING / Dr. ZX Example: Outrigger/Blade Function: Enable Push Enable and Push Exec. Push Push Parameter Change of option ESC and return to Parameter controller. Push ESC and return to Change Selection screen. Main Menu screen. Push Outrigger/Blade Function. Select item Select item Outrigger/Blade Function...
Page 224 TROUBLESHOOTING / Dr. ZX Parameter Change (Aux Assignment (Proportional SW)) The initial setting of the left proportional switch is in Disable. If one of the listed operations on the screen is assigned to the left proportional switch by using Dr. ZX, the operation can be performed with the left proportional switch.
Page 225: Outline
TROUBLESHOOTING / ICF OUTLINE ICF (Information Controller) saves the input signals from various sensors and switches of the machine as data. Various input signals are recorded as “list of daily re- port data”, “list of frequency distribution data”, “list of total operating hours”, “list of alarm,”...
Page 226: List Of Daily Report Data
TROUBLESHOOTING / ICF LIST OF DAILY REPORT DATA Data which can be downloaded by Palm Item Details Date Date of daily report data Time when key switch is first turned ON during a day Start: Time (Time is recorded by key switch ON signal.) Time when key switch is last turned OFF during a day Stop: Time (Time is recorded by key switch ON signal.)
Page 227 TROUBLESHOOTING / ICF Item Details Total machine’s waiting hours during a day No Load Time (Hours are recorded by each pressure sensor information from MC.) The highest radiator coolant temperature during a day Radiator Coolant Temperature (Value is recorded from monitor unit.) The highest hydraulic oil temperature during a day Hydraulic Oil Temperature (Value is recorded from MC.)
Page 228 TROUBLESHOOTING / ICF Data which can be sent by satellite communication Item Details Date Date of daily report data The value of the final remained fuel during a day Fuel Level (Value is recorded by fuel sensor data from monitor unit.) The value of fuel used during a day Fuel Usage Amount (Value is calculated and recorded by accumulated fuel usage amount...
Page 229: List Of Frequency Distribution Data
TROUBLESHOOTING / ICF LIST OF FREQUENCY DISTRIBUTION DATA Item Details Fuel Temperature Frequency distribution of fuel temperature Frequency distribution of average pump delivery pressure of pumps 1 Pump Load and 2 Average Pump Delivery Pressure in Frequency distribution of average delivery pressure from pumps during Digging Operation digging operation Average Pump Delivery Pressure in...
Page 230: List Of Total Operating Hours
TROUBLESHOOTING / ICF LIST OF TOTAL OPERATING HOURS Item Details Inner Hour Meter Hour meter’s value accumulated inside ICF Machine Hour Meter Hour meter’s value accumulated in machine’s monitor HP Mode Hours Total engine operating hours selecting HP mode Engine Operating P Mode Hours Total engine operating hours selecting P mode...
Page 231 TROUBLESHOOTING / ICF (Blank) T5-4-7...
Page 232: How To Download And Upload Data Of Icf
TROUBLESHOOTING / ICF HOW TO DOWNLOAD AND UPLOAD DATA Satellite OF ICF Rear Console Terminal After the data saved in ICF is downloaded to Palm (Dr. ZX), is uploaded to the personal computer, and is up- loaded to the center server by using LAN, the data can be used as “e-Service”.
Page 233 Information C/U: Various Downloading. Setup Do not turn off the Palm or To the Dr. ZX SerVice Soft Data Download disconnect the download ca- lower (C)Hitachi Construction ble. Machinery Co., ltd Save Data Check Op. Manual Start Back Cancel Title Screen...
Page 234 TROUBLESHOOTING / ICF How to Upload Data from Palm to Personal Computer 1. Set Palm to the cradle. Connect the USB cable to the personal computer. Palm 2. Push the Hot Sync button. NOTE: When pushing the Hot Sync button and uploading the data to the personal com- puter, the Palm (or CLIE) Desktop software with Palm...
Page 235: Various Setup Of Icf And Satellite Communication Terminal By Using Dr. Zx
TROUBLESHOOTING / ICF VARIOUS SETUP OF ICF AND SATELLITE COMMUNICATION TERMINAL BY USING Dr. ZX Before starting satellite communication, installing the satellite communication terminal and replacing ICF, perform the following procedures by using Dr. ZX. ICF Setup Procedures Start Dr. ZX 1.1 Select Information Controller 1.2 Select Information C/U: Various Setup 1.3 Enter Date and Time...
Page 236 Select Item Password Information C/U: Various Information C/U: Initialize Setup Dr. ZX SerVice Soft Data Download Enter Model and Serial (C)Hitachi Construction Machinery Co., ltd Save Data Check Enter Date and Time Control Data: Initialize Op. Manual Start Back Title Screen...
Page 237 TROUBLESHOOTING / ICF 1.3 Enter Date and Time Push Set and the focused item is Push ESC and return to Information Push Enter Date and Time. C/U: Various Setup Screen. Push ESC and return to Main Menu Screen. Enter Date and Time Select Item YY, MM, DD, HH, and MM 2004...
Page 238 TROUBLESHOOTING / ICF 1.4 Enter Model and Serial No. Push Enter Model and Serial No. Select Item Information C/U: Initialize To the Enter Model and Serial lower Enter Date and Time Control Data: Initialize Information C/U: Various Setup Screen After inputting model and serial Push Exec, and model and serial No., push OK and return to Enter No.
Page 239 TROUBLESHOOTING / ICF 1.5 Information C/U: Initialize Push Information C/U: Initialize. Select Item Information C/U: Initialize To the Enter Model and Serial lower Enter Date and Time Control Data: Initialize Information C/U: Various Setup Screen Push Init and the controller oper- ating data is initialized.
Page 240 TROUBLESHOOTING / ICF 1.6 Satellite Terminal: Initialize Push Exec. Push Satellite Terminal: Initialize. Display the next screen of Infor- Push ESC and return to Informa- Push ESC and return to Main mation C/U: Various Setup Screen. tion C/U: Various Setup Screen. Menu Screen.
Page 241 TROUBLESHOOTING / ICF 1.7 Satellite Terminal Serial No. Check Push Satellite Terminal No. Confir- Confirm serial (12 digits). Push mation. ESC and return to Information C/U: Push ESC and return to Main Various Setup Screen. Menu Screen. Select Item Satellite Terminal No. Confirma- Select Item tion Satellite Terminal: Initialize...
Page 242 TROUBLESHOOTING / ICF 1.8 Satellite Terminal, Communicating State Check Push Communicating State Check. Push ESC and return to Main Menu Screen. Check communicating state. Select Item Communicating State Check Check the enclosed state. ICF⇔Satellite Terminal Satellite Terminal: Initialize Satellite Terminal No. ・...
Page 243 TROUBLESHOOTING / ICF 1.9 Enter Satellite Comm. Start/Stop Push ▼ and display to the next screen of Information C/U: Various Setup Screen. Push Enter Satellite Comm. Start/Stop. Select Item Satellite Terminal: Initialize Satellite Terminal No. To the Confirmation lower Communicating State Check Enter Satellite Comm.
Page 244 TROUBLESHOOTING / ICF 1.10 Control Data: Initialize Push Control Data: Initialize. Select Item Information C/U: Initialize To the Enter Model and Serial lower Enter Date and Time Control Data: Initialize Information C/U: Various Setup Screen Push Init and the controller oper- ating data is initialized.
Page 245 TROUBLESHOOTING / ICF (Blank) T5-4-21...
Page 246 TROUBLESHOOTING / ICF 2. Self-Diagnosing Push Fault of ICF Controller. If there is no trouble, No Problem is After starting push displayed. Self-Diagnostic Result. Self-diagnosing of controllers Select Function below hasn completed. Self-Diagnostic Result Engine Controller No Problem To the Select Controller lower Fault...
Page 247: List Of Fault Code
TROUBLESHOOTING / ICF LIST OF FAULT CODE Fault Code Trouble Remedy 14000-2 Abnormal CAN Communication Execute retry B in self-diagnosing. If this fault code is displayed after re-try, check the following item. Check the CAN communication line (check the harness). 14001-2 ICF: Flash Memory: Read / Write Execute retry B in self-diagnosing and execute the following...
Page 248: Satellite Communication System
TROUBLESHOOTING / ICF SATELLITE COMMUNICATION SYSTEM The satellite communication system is used for main- GPS Aerial tenance of the machine, “e-Service” by transmitting Communication various data of the machine regularly via a low earth Aerial orbit satellite. NOTE: Depending on the circumstances of the machine (ex.
Page 249 TROUBLESHOOTING / ICF On the machine equipped with the satellite communi- cation system, the data are sent according to the con- dition as follows: Kinds of data sent from the machine by using satellite communication: Items Kinds of Data Condition Periodical Daily Report Data, Latest Location Infor- The data are sent once a day.
Page 250 TROUBLESHOOTING / ICF (Blank) T5-4-26...
Page 251: Group 5 Component Layout
Section 5 TROUBLESHOOTING Group 5 Component Layout Main Component Layout Upperstructure (1) TCEB-01-02-002 Rear Camera Battery Travel Shockless Valve Steering Valve Radiator Fuel Cooler Pilot Valve (Left) Brake Valve Inter Cooler Washer Tank Pilot Shut-Off Solenoid Valve Travel Pilot Valve Reserve Tank ECM (Engine Controller) Center Joint...
Page 252 Section 5 TROUBLESHOOTING Group 5 Component Layout Upperstructure (2) TCEB-01-02-003 25- Positioning Control Valve 30- Automatic Fueling Switch 35- Engine Oil Filter 40- Steering Filter 26- Shuttle Valve 31- Control Valve 36- Pump Device 41- Pilot Filter 27- Signal Control Valve 32- Automatic Fueling Pump 37- Fuel Pre Filter 42- Engine...
Page 253 Section 5 TROUBLESHOOTING Group 5 Component Layout Undercarriage ZX140W-3: Up to serial No 005000 ZX140W-3-AMS: Up to serial No 050000 TCEB-01-02-001 Blade Cylinder 2-Spool Solenoid Valve Unit Front Axle Transmission Rear Axle (Blade / Outrigger Cylinder) Outrigger Cylinder Transmission Changeover Axle Lock Cylinder Travel Motor Solenoid Valve...
Page 254 Section 5 TROUBLESHOOTING Group 5 Component Layout Undercarriage ZX140W-3: Serial No 005001 and up ZX140W-3-AMS: Serial No 050001 and up TCJB-01-02-011 Blade Cylinder 2-Spool Solenoid Valve Unit Front Axle Transmission Rear Axle (Blade / Outrigger Cylinder) Outrigger Cylinder Transmission Changeover Axle Lock Cylinder Travel Motor Solenoid Valve...
Page 255 Section 5 TROUBLESHOOTING Group 5 Component Layout Front Attachment  2-Piece Boom  Monoblock Boom T1F3-01-02-004 T1F3-01-02-003 Bucket Cylinder Positioning Cylinder Hose Rupture Valve Hose Rupture Valve (Boom) Arm Cylinder Boom Cylinder (Positioning) Hose Rupture Valve (Arm) T5-5-5...
Page 256: Electrical Component Layout (Overview)
Section 5 TROUBLESHOOTING Group 5 Component Layout Electrical Component Layout (Overview) Pump Device (Refer to T5-5-14.) · Pump 1 Delivery Pressure Sensor · Pump 2 Delivery Pressure Sensor · Pump 1 Control Pressure Sensor · Pump 2 Control Pressure Sensor Filter (Refer to T5-5-16.) ·...
Page 257 Section 5 TROUBLESHOOTING Group 5 Component Layout Swing Device (Refer to T5-5-14.) · PRESSURE SENSOR (FRONT) Control Valve (Refer to T5-5-15.) · PRESSURE SENSOR (BOOM RAISE) TCEB-01-02-003 · PRESSURE SENSOR (ARM ROLL-IN) Signal Control Valve (Refer to T5-5-14.) · PRESSURE SENSOR (SWING) ·...
Page 258: Electrical Component Layout (Monitors And Switches)
Section 5 TROUBLESHOOTING Group 5 Component Layout Electrical Component Layout (Monitors and Switches) TCJB-01-02-014 TCJB-01-02-006 TCJB-01-02-007 TCJB-01-02-008 Monitor Unit (Refer to T5-5-9.) Brake Pedal Hazard Switch Travel Speed Mode Switch Swing Lock Lever Steering Column Monitor Electrical Control Main Switch Engine Speed Control Mode Blade/Outrigger Lever (Refer to T5-5-10.)
Page 259 Section 5 TROUBLESHOOTING Group 5 Component Layout Monitor Unit TCJB-05-02-043 Work Mode Display Parking Brake Display Mail Display (Optional) Mail Selection (Optional) Auto-Idle Display Work Brake Display Clock Work Mode Display Overload Alarm Display Axle Lock Display Trip Meter Display Auxiliary Selection (Optional) Work Light Display...
Page 260 Section 5 TROUBLESHOOTING Group 5 Component Layout Steering Column Monitor TCJB-02-01-008 Travel Forward Indicator Travel Reverse Indicator Travel Slow Speed Indicator Turn Signal Indicator (Left) Turn Signal Indicator (Right) Hazard Light Indicator Auxiliary Neutral Indicator Auto-Cruise Indicator Clearance Light Indicator Pilot Cut Indicator (Optional) High Beam Indicator...
Page 261: Electrical Component Layout (Controllers And Relays)
Section 5 TROUBLESHOOTING Group 5 Component Layout Electrical Component Layout (Controllers and Relays) TCJB-01-02-015 MC (Main Controller) Fuse Box Option Controller Satellite Communication Dr.ZX Connector (Use as ICF (Information Controller) Terminal (Optional) Download Connector) Flasher T5-5-11...
Page 262 Section 5 TROUBLESHOOTING Group 5 Component Layout Relays Position TCJB-01-02-009 Option Controller TCJB-01-02-010 Dr.ZX Connector Fuse Box High Beam Relay Pilot Shut-Off Relay Heater Seat Relay (OP) Twin Wiper Relay 3 (OP) Clearance Light Relay (Left) Security Horn Relay Room Lamp Controller Relay Twin Wiper Relay 4 (OP) Clearance Light Relay (Right) Starter Cut Relay...
Page 263: Engine
Section 5 TROUBLESHOOTING Group 5 Component Layout Engine T1T1-01-02-005 T1T1-01-02-003 T1T1-01-02-004 EGR Valve Overheat Switch Common Rail Pressure Sensor Supply Pump Actuator Glow Plug Injector Crank Speed Sensor Cam Angle Sensor Boost Pressure Sensor Engine Oil Pressure Sensor Coolant Temperature Sensor Boost Temperature Sensor Fuel Temperature Sensor T5-5-13...
Page 264: Pump Device
Section 5 TROUBLESHOOTING Group 5 Component Layout Pump Device TCEB-03-01-003 TCEB-03-01-001 Signal Control Valve Swing Device TCEB-01-02-005 TCEB-01-02-004 Pump 1 Steering Pump Torque Control Solenoid Valve Heat Circuit Cut Solenoid Valve Pump 2 Pump 2 Control Pressure Pump 2 Maximum Flow Rate Swing Shockless Valve Pump 1 Delivery Pressure Sensor...
Page 265: Control Valve
Section 5 TROUBLESHOOTING Group 5 Component Layout Control Valve Brake Valve TCGB-01-02-003 TCJB-01-02-017 3-Spool Solenoid Valve Unit Solenoid Valve Unit (For Electric Lever) TCGB-03-12-001 TCJB-01-02-018 Main Relief Valve Brake Pressure Sensor Auxiliary Solenoid Valve Blade / Outrigger Solenoid Pressure Sensor (Arm Roll-In) Brake Valve Blade / Outrigger Solenoid Valve...
Page 266: Travel Shockless Valve
Section 5 TROUBLESHOOTING Group 5 Component Layout Travel Shockless Valve Transmission Changeover Solenoid Valve TCJB-01-02-019 TCJB-05-07-002 Travel Device Filter TCJB-01-02-020 TCEB-01-02-006 Pressure Sensor (Travel Pressure Sensor (Travel Transmission Steering Filter Forward) Reverse) Travel N Sensor Pilot Filter Travel Forward Pi Cut Solenoid Travel Mode Selector Solenoid Travel Motor Displacement Fuel Pre Filter...
Page 267 Section 5 TROUBLESHOOTING Group 5 Component Layout (Blank) T5-5-17...
Page 268: Components In Control Valve
Section 5 TROUBLESHOOTING Group 5 Component Layout Components in Control Valve T16W-03-03-018 T5-5-18...
Page 269 Section 5 TROUBLESHOOTING Group 5 Component Layout 35, 36 Front T16W-03-03-030 Load Check Valve (Blade/ Make-Up Valve (Travel Forward Bypass Shut-Out Valve Load Check Valve (Boom 2 Outrigger Tandem Circuit) Side) Check Valve (Orifice) (Arm 2 Parallel Circuit) Load Check Valve (Blade/ Bucket Regenerative Circuit Parallel Circuit) Aux.
Page 270 Section 5 TROUBLESHOOTING Group 5 Component Layout T16W-03-03-018 T5-5-20...
Page 271 Section 5 TROUBLESHOOTING Group 5 Component Layout 9, 10 Front T16W-03-03-031 30 37 Load Check Valve (Blade/ Make-Up Valve (Travel Forward Bypass Shut-Out Valve Load Check Valve (Boom 2 Outrigger Tandem Circuit) Side) Check Valve (Orifice) (Arm 2 Parallel Circuit) Load Check Valve (Blade/ Bucket Regenerative Circuit Parallel Circuit)
Page 272 Section 5 TROUBLESHOOTING Group 5 Component Layout T16W-03-03-018 T5-5-22...
Page 273 Section 5 TROUBLESHOOTING Group 5 Component Layout T16W-03-03-002 Cross Section A-A Cross Section B-B Blade/ Travel Outrigger Auxiliary Bucket Boom 2 Boom 1 Arm 1 Arm 2 Swing T16W-03-03-008 TCHB-03-03-001 Load Check Valve (Blade/ Make-Up Valve (Travel Forward Bypass Shut-Out Valve Load Check Valve (Boom 2 Outrigger Tandem Circuit) Side)
Page 274 Section 5 TROUBLESHOOTING Group 5 Component Layout T16W-03-03-018 T5-5-24...
Page 275 Section 5 TROUBLESHOOTING Group 5 Component Layout Cross Section C-C Cross Section D-D Blade/ Travel Outrigger T16W-03-03-014 T16W-03-03-013 Load Check Valve (Blade/ Make-Up Valve (Travel Forward Bypass Shut-Out Valve Load Check Valve (Boom 2 Outrigger Tandem Circuit) Side) Check Valve (Orifice) (Arm 2 Parallel Circuit) Load Check Valve (Blade/ Bucket Regenerative Circuit...
Page 276 Section 5 TROUBLESHOOTING Group 5 Component Layout T16W-03-03-018 T5-5-26...
Page 277 Section 5 TROUBLESHOOTING Group 5 Component Layout Cross Section E-E Cross Section F-F Boom 2 Boom 1 Auxiliary Bucket T16W-03-03-011 T16W-03-03-012 Load Check Valve (Blade/ Make-Up Valve (Travel Forward Bypass Shut-Out Valve Load Check Valve (Boom 2 Outrigger Tandem Circuit) Side) Check Valve (Orifice) (Arm 2 Parallel Circuit)
Page 278 Section 5 TROUBLESHOOTING Group 5 Component Layout T16W-03-03-018 T5-5-28...
Page 279 Section 5 TROUBLESHOOTING Group 5 Component Layout Cross Section G-G Cross Section H-H Arm 1 Arm 2 Swing T16W-03-03-010 T16W-03-03-009 Load Check Valve (Blade/ Make-Up Valve (Travel Forward Bypass Shut-Out Valve Load Check Valve (Boom 2 Outrigger Tandem Circuit) Side) Check Valve (Orifice) (Arm 2 Parallel Circuit) Load Check Valve (Blade/...
Page 280 Section 5 TROUBLESHOOTING Group 5 Component Layout Layout of Positioning Control Valve (2-Piece Boom) Positioning TCEB-03-03-001 Control Valve T5-5-30...
Page 281 Section 5 TROUBLESHOOTING Group 5 Component Layout Cross Section X-X T178-03-03-070 T198-03-03-003 Load Check Valve (Positioning Load Check Valve (Positioning Overload Relief Valve Overload Relief Valve Parallel Circuit) Tandem Circuit) (Positioning: Bottom Side) (Positioning: Rod Side) T5-5-31...
Page 282: Pilot Port
Section 5 TROUBLESHOOTING Group 5 Component Layout Pilot Port Pilot Valve Side Pilot Valve Side T178-03-06-016 Pilot Valve Side Port Name Connecting to Remark Port A Right Pilot Valve Boom Raise Pilot Pressure Port B Right Pilot Valve Boom Lower Pilot Pressure Port C Swing Shockless Valve (Left Pilot Valve) Arm Roll-Out Pilot Pressure...
Page 283 Section 5 TROUBLESHOOTING Group 5 Component Layout Control Valve Side Pressure Sensor (Auxiliary) Pressure Sensor (Swing) Control Valve Side T1F3-03-06-003 Control Valve Side Port Name Connecting to Remark Port 1 Control Valve Boom Raise Pilot Pressure Port 2 Control Valve Boom Lower Pilot Pressure Port 3 Control Valve...
Page 284 Section 5 TROUBLESHOOTING Group 5 Component Layout NOTE: Machine with front attachment (pulverizer 1 to 5 and crusher 1 to 5) attached. Control Valve Side Control Valve Side T1F3-03-06-003 Control Valve Side Port Name Connecting to Note Port 14 Auxiliary Flow Combiner Contorl Solenoid Valve Auxiliary Flow Combiner Valve Control Pressure Port SN Pressure Reducing Valve...
Page 285 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Remedy by Dr. ZX Remedy Trouble Occurs. Retrial B Replace MC. Retrial B Replace MC. Retrial B Replace MC. • Check the sensor connected to MC. Although the engine control dial is Retrial B •...
Page 286: Mc Fault Code List
TROUBLESHOOTING / Troubleshooting A Engine Failure Fault Code Trouble Cause Influenced Control 11100-2 Abnormal Engine Speed Engine Speed: more than Speed Sensing Control 4000 min 11101-3 Abnormal Engine Control Dial Voltage: more than 4.78 V Engine Control Dial Control Sensor High Voltage 11101-4 Abnormal Engine Control Dial Voltage: less than 0.22 V...
Page 287 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Remedy by Dr. ZX Remedy Trouble Occurs. • Check the crank speed sensor. The machine movement is slow. Retrial B • Check the cam angle sensor. (During speed sensing, the torque is reduced.) •...
Page 288 TROUBLESHOOTING / Troubleshooting A Pump Failure Fault Code Trouble Cause Influenced Control • HP Mode Control 11200-3 Abnormal Pump Delivery Voltage: more than 4.5 V • Travel Accelerator Control Pressure Sensor High Voltage • E Mode Control • Arm Regenerative Control •...
Page 289 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Remedy by Dr. ZX Remedy Trouble Occurs. • Combined operation of arm roll-in and • Check the harness. Retrial B • Replace boom raise or combined operation of pump delivery arm-roll-in and swing: Arm speed is pressure sensor.
Page 290 TROUBLESHOOTING / Troubleshooting A Pilot Failure Fault Code Trouble Cause Influenced Control • Arm Regenerative Control 11301-3 Abnormal Swing Pilot Pressure Voltage: more than 4.75 V • Attachment Flow Rate Control Sensor High Voltage (Optional) • Swing Alarm Control (Optional) •...
Page 291 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Remedy by Dr. ZX Remedy Trouble Occurs. • Combined operation of arm-roll-in and • Check the harness. Retrial B • Replace the swing pilot pressure swing: Arm speed is slow. • In case of the machine equipped with sensor.
Page 292 TROUBLESHOOTING / Troubleshooting A Fault Code Trouble Cause Influenced Control • Auto-Idle Control 11305-3 Abnormal Travel Voltage: more than 4.75 V • Idle Speed-Up Control Forward Pilot • ECO Control Pressure Sensor • Travel Accelerator Control High Voltage • Heater Control •...
Page 293 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Remedy by Dr. ZX Remedy Trouble Occurs. • When traveling forward at idle speed, • Check the harness. Retrial B engine speed does not increase to the idle • Replace the travel forward pilot speed-up speed.
Page 294 TROUBLESHOOTING / Troubleshooting A Fault Code Trouble Cause Influenced Control • Auto-Idle Control 11307-3 Abnormal Front Attachment Pilot Voltage: more than 4.75 V • Idle Speed-Up Control Pressure Sensor High Voltage • ECO Control • Pump 1 and 2 Flow Rate Limit Control •...
Page 295 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Remedy by Dr. ZX Remedy Trouble Occurs. • When operating the front attachment at • Check the harness. Retrial B • Replace the front idle speed, engine speed does not attachment pilot increase to the idle speed-up speed.
Page 296 TROUBLESHOOTING / Troubleshooting A Proportional Solenoid Valve Failure Fault Code Trouble Cause Influenced Control 11400-2 Abnormal Current Feedback of Current: Both of Higher Pump 2 Flow Rate Limit Control Maximum Pump 2 Flow Rate Limit than 920 mA or Less Control Solenoid Valve than 60 mA 11400-3...
Page 297 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Remedy by Dr. ZX Remedy Trouble Occurs. • Check the harness. In case the attachment flow rate is Retrial B limited, it cannot be limited. • Check the harness. Operation during abnormal high current: Retrial B •...
Page 298 TROUBLESHOOTING / Troubleshooting A Fault Code Trouble Cause Influenced Control • Pump 1 Flow Rate Limit Control 11410-2 Abnormal Current Feedback of Current: Both of Higher Maximum Pump 1 Flow Rate Limit than 920 mA or Less When Traveling At Creeper Mode •...
Page 299 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Remedy by Dr. ZX Remedy Trouble Occurs. • Check the harness. In case the attachment flow rate is Retrial B limited, it cannot be limited. • Check the harness. Operation during abnormal high current: Retrial B •...
Page 300 TROUBLESHOOTING / Troubleshooting A Fault Code Trouble Cause Influenced Control • Auto Axle Lock Control 11424-2 Abnormal Current Feedback of Current: Both of Higher Solenoid Valve Unit (SI) (Axle Lock than 920 mA or Less Selection) than 60 mA • Auto Axle Lock Control 11424-3 Abnormal Feedback High Current Current: Higher than...
Page 301 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Remedy by Dr. ZX Remedy Trouble Occurs. • Check the harness. In case the attachment flow rate is Retrial B limited, it cannot be limited. • Check the harness. Operation during abnormal high current: Retrial B •...
Page 302 TROUBLESHOOTING / Troubleshooting A CAN Data Reception Failure Fault Code Trouble Cause Influenced Control • Speed Sensing Control 11910-2 Actual Engine Speed Faulty harness • Send to ICF Sent from: ECM 11911-2 Security Signal Faulty harness Theft Prevention Engine Speed, Engine Torque Sent from: Monitor Unit...
Page 303 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Remedy by Dr. ZX Remedy Trouble Occurs. • Check the harness. Machine operation speed is slow. Retrial B (During speed sensing, torque is decreased.) Engine stall is displayed on e-Service. • Check the harness. When theft prevention is ON set by Dr.
Page 304 TROUBLESHOOTING / Troubleshooting A Other Failures Fault Code Trouble Cause Influenced Control *11502-2 Travel Motor Excessive Rotation Transmission rotation keeps over its threshold value for 2.0 sec. • Auto-Warming Up Control 11901-3 Hydraulic Temperature Voltage: more than 4.52 V • Arm Regenerative Control Sensor High Voltage •...
Page 305 TROUBLESHOOTING/ Troubleshooting A Symptoms in Machine Operation When Trouble Remedy by Remedy Occurs. Dr. ZX • Check the harness. In low temperature (Hydraulic oil temperature is less Retrial B than 0 °C (32 °F)), auto-warming up control is impossible. • Check the harness. In low temperature (Hydraulic oil temperature is less Retrial B than 0 °C (32 °F)), auto-warming up control is...
Page 306: Ecm Fault Code List
TROUBLESHOOTING/ Troubleshooting A ECM FAULT CODE LIST Sensor System Fault Trouble Cause Code 636-2 Abnormal Cam Angle Sensor (No Signal) Although the crank signal is present, the cam signal is not present. 636-2 Abnormal Cam Angle Sensor (Abnormal The pulse of cam signal is not matched. Signal) 723-2 Abnormal Crank Speed Sensor (No...
Page 307 TROUBLESHOOTING/ Troubleshooting A Presumptive Symptoms in Real Machine Fault Code Assumptive Conditions at Backup Operation (Tech 2) • While the engine runs, there is nothing While the engine runs, operate according to P0340 abnormal with machine operation. standard of the crank sensor. When the engine •...
Page 308 TROUBLESHOOTING/ Troubleshooting A Fault Trouble Cause Code 157-3 Abnormal Common Rail Pressure Sensor Voltage at the common rail pressure sensor is beyond (Abnormal High Voltage) 4.5 V. 157-3 Abnormal Common Rail Pressure Sensor Voltage at the common rail pressure sensor is below (Abnormal Low Voltage) 0.7 V.
Page 309 TROUBLESHOOTING/ Troubleshooting A Presumptive Symptoms in Real Machine Fault Code Assumptive Conditions at Backup Operation (Tech 2) The engine may be stalled. The output power The supply pump can not be controlled. P0193 decreases. P0192 There is no influence when operating the Nothing special.
Page 310 TROUBLESHOOTING/ Troubleshooting A Influence to Engine Operating Rank Fault Code Trouble Performance (Current State) Remedy (Presumption) 636-2 Abnormal Cam Angle Sensor (No influence during ○ ○ Signal) operating After stopping, 636-2 Abnormal Angle Sensor ○ ○ re-start is impossible. (Abnormal Signal) 723-2 Abnormal Crank Speed Sensor (No output...
Page 311 TROUBLESHOOTING/ Troubleshooting A Influence to Engine Fault Operating Rank Trouble Performance Remedy Code (Current State) (Presumption) 105-3 Abnormal Boost Temperature Sensor output power ○ (Abnormal High Voltage) change 105-4 Abnormal Boost Temperature Sensor ○ (Abnormal Low Voltage) Operating Rank Digging is operable. Machine can travel with the boom raised.
Page 312 TROUBLESHOOTING/ Troubleshooting A External Device System Fault Code Trouble Cause 10002-2 Abnormal EGR Valve Control Difference between the target valve lift and actual position is beyond 20%. 1347-0 Open Circuit in Suction Control Valve The suction control valve drive current is beyond 2400 mA or Drive System, Shorted Circuit In + B below 50 mA.
Page 313 TROUBLESHOOTING/ Troubleshooting A Presumptive Symptoms in Real Machine Fault Code Assumptive Conditions at Backup Operation (Tech 2) There is influence to exhaust gas. EGR cannot be controlled. P0488 As exhaust gas becomes bad, EGR stops. The engine may be stalled and the rotation The supply pump cannot be controlled.
Page 314 TROUBLESHOOTING/ Troubleshooting A Fuel System Fault Code Trouble Cause 157-0 Abnormal Common Rail Pressure Common rail pressure is beyond 185 MPa. (First Stage) 157-0 Abnormal Common Rail Pressure The first stage “Abnormal common rail pressure” is approved (Second Stage) common rail pressure is beyond 190 MPa. 157-2 Abnormal Common Rail Pressure When duty factor to the suction control valve is 40 % or more,...
Page 315 TROUBLESHOOTING/ Troubleshooting A Presumptive Symptoms in Real Machine Fault Code Assumptive Conditions at Backup Operation (Tech 2) Vibration of the engine may be large, rough idle, Prevention the injection system (pump) from P0088 output power decrease may occur, faulty damage increasing of rotation speed, dark smoke may (Protect rail...
Page 316 TROUBLESHOOTING/ Troubleshooting A Operating Rank Influence to Engine Fault (Current) Trouble Performance Remedy Code (Presumption) 10002-2 Abnormal EGR Valve Control No output power ○ change 1347-0 Open Circuit in Suction Control Valve Output power Drive System, Shorted Circuit in + B or decrease: 50% ○...
Page 317 TROUBLESHOOTING/ Troubleshooting A (Blank) T5-6-35...
Page 318 TROUBLESHOOTING/ Troubleshooting A Fault Code Trouble Cause 110-0 Overheating Coolant temperature is beyond 120 °C (248 °F) when running engine. 190-0 Overrunning In case the engine speed is beyond 2500 min Fault code Trouble Cause 987-3 Abnormal Check Engine Lamp No monitor signal of the check engine lamp.
Page 319 TROUBLESHOOTING/ Troubleshooting A Presumptive Symptoms in Real Machine Fault Code Assumptive Conditions at Backup Operation (Tech 2) There is no influence when operating the Nothing special (The history of overheating is P1173 machine. recorded.) Engine speed of the excavator may not increase Nothing special P0219 2500 min...
Page 320 TROUBLESHOOTING/ Troubleshooting A Operating Rank Influence to Engine (Current) Fault Trouble Performance Remedy Code (Presumption) 110-0 Overheating output power ○ change 190-0 Overrunning output power ○ change Operating Rank Influence to Engine Fault (Current) Trouble Performance Remedy Code (Presumption) 987-3 Abnormal Check Engine Lamp output power...
Page 321 TROUBLESHOOTING/ Troubleshooting A (Blank) T5-6-39...
Page 322 TROUBLESHOOTING/ Troubleshooting A Internal Circuit System Fault Code Trouble Cause 10005-1 Abnormal Charge Circuit (Bank 1) In case voltage at bank 1 of charge circuit in ECM is low. 10006-1 Abnormal Charge Circuit (Bank 2) In case voltage at bank 2 of charge circuit in ECM is low. 10008-2 Abnormal A/D Conversion A/D conversion cannot be done.
Page 323 TROUBLESHOOTING/ Troubleshooting A Presumptive Symptoms in Real Machine Fault Code Assumptive Conditions at Backup Operation (Tech 2) Vibration of the engine may be large, rough idle, The injector cannot be controlled. P0611 → Stop output of drive signal at failed common output power decrease may occur, faulty increasing of rotation speed may occur, the side...
Page 324 TROUBLESHOOTING/ Troubleshooting A Influence to Engine Operating Rank Fault Code Trouble Performance (Current) Remedy (Presumption) 10005-1 Abnormal Charge Circuit (Bank 1) Output power ○ ○ decrease: 60% 10006-1 Abnormal Charge Circuit (Bank 2) (Three cylinders ○ ○ operation.) 10008-2 Abnormal A/D Conversion Output power ○...
Page 325 TROUBLESHOOTING/ Troubleshooting A (Blank) T5-6-43...
Page 326 TROUBLESHOOTING / Troubleshooting A Communication System Fault Code Trouble Cause 639-2 Abnormal CAN Bus Line Detect the Bus Line OFF 639-3 Abnormal CAN Time Out In case the CAN data reception is impossible for predetermined time. T5-6-44...
Page 327 TROUBLESHOOTING / Troubleshooting A Presumptive Symptoms in Real Machine Fault code Assumptive Conditions at Backup Operation (Tech2) The engine runs at idle speed. CAN communication is impossible. U2104 U2106 T5-6-45...
Page 328 TROUBLESHOOTING / Troubleshooting A Operating Rank Influence to Engine Fault (Current) Trouble Performance Remedy Code (Presumption) 639-2 Abnormal CAN Bus Line ○ Idle Speed 639-3 Abnormal CAN Time Out ○ T5-6-46...
Page 329 TROUBLESHOOTING / Troubleshooting A (Blank) T5-6-47...
Page 330: Icf Fault Code List
TROUBLESHOOTING / Troubleshooting A ICF FAULT CODE LIST Fault Code Trouble Cause Remedy 14000-2 Abnormal Data cannot be received Check for CAN communication bus line. Communication due to the noise on the CAN bus line. 14001-2 Flash Memory: The internal memory is After initializing the information C/U by using Dr.
Page 331: Satellite Terminal Fault Code List
TROUBLESHOOTING / Troubleshooting A SATELLITE TERMINAL FAULT CODE LIST Fault Code Trouble Cause Remedy 14100-2 Abnormal EEPROM Internal memory is abnormal. Replace the controller. 14101-2 Abnormal IB/OB Queue Internal memory is abnormal. Replace the controller. 14102-2 Abnormal Local Loop Back Data can not be received from Check communication...
Page 332: Option Controller Fault Code List
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE LIST Controller Hardware Failure Fault Code Trouble Cause Influenced Control 15500-4 Abnormal External Reference Faulty controller All Controls Voltage 15501-2 Abnormal Read Of Initial Setting Faulty controller All Controls Value (EEPROM) 15502-2 Abnormal EEPROM Faulty controller All Controls...
Page 333 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation Remedy by Dr. ZX Remedy When Trouble Occurs. Retrial B Replace the controller. Retrial B Replace the controller. Retrial B Replace the controller. Retrial B Replace the controller. Retrial B Replace the controller. Retrial B Check CAN harness.
Page 334 TROUBLESHOOTING / Troubleshooting A Pilot Pressure Failure Fault Code Trouble Cause Influenced Control 15510-3 Abnormal Assist Stroke 1 Sensor Voltage: more than 4.65 V Assist Control High Voltage 15510-4 Abnormal Assist Stroke 1 Sensor Voltage: less than 0.35 V Assist Control Low Voltage 15511-3 Abnormal Assist Stroke 2 Sensor...
Page 335 TROUBLESHOOTING / Troubleshooting A Remedy by Symptoms in Machine Operation When Trouble Occurs. Remedy Dr. ZX • Stop assist operation. Retrial B Check the harness. • Display "Abnormal assist operation signal warning" on the monitor unit. • Stop assist operation. Retrial B Check the harness.
Page 336 TROUBLESHOOTING / Troubleshooting A Fault Code Trouble Cause Influenced Control • 15516-3 Abnormal Positioning/Assist Pi Pressure Voltage: more than 4.60 V Positioning Control • Sensor High Voltage Assist Control • 15516-4 Abnormal Positioning/Assist Pi Pressure Voltage: less than 0.40 V Positioning Control •...
Page 337 TROUBLESHOOTING / Troubleshooting A Remedy by Symptoms in Machine Operation When Trouble Occurs. Remedy Dr. ZX • All proportional solenoid valve outputs stop by shutting off pilot pressure. Retrial B Check the harness. • Display "Abnormal electric lever solenoid valve output warning" on the monitor unit.
Page 338 TROUBLESHOOTING / Troubleshooting A Proportional Solenoid Valve Control Failure Fault Code Trouble Cause Influenced Control • 15570-2 Abnormal When meeting following conditions, Outrigger/Blade Control • Outrigger/Blade/Auxiliary outrigger/blade/auxiliary pilot pressure is more Auxiliary Control Neutral than 1.2 MPa. (Conditions) • Outrigger/blade 1 and 2 solenoid valve output is less than 0.5 MPa •...
Page 339 TROUBLESHOOTING / Troubleshooting A Remedy by Symptoms in Machine Operation When Trouble Occurs. Remedy Dr. ZX • All proportional solenoid valve outputs stop by shutting off pilot pressure. Retrial B Check the harness. • Display "Abnormal electric lever solenoid valve output warning" on the monitor unit.
Page 340 TROUBLESHOOTING / Troubleshooting A Fault Code Trouble Cause Influenced Control • 15578-3 Abnormal Positioning/auxiliary stroke 1 + Positioning Control • Positioning/Auxiliary Sum positioning/auxiliary stroke 2 is more than 5.4 Auxiliary Control Signal High Voltage V and less than or equal to 9.0 V •...
Page 341 TROUBLESHOOTING / Troubleshooting A Remedy by Symptoms in Machine Operation When Trouble Occurs. Remedy Dr. ZX • If positioning and auxiliary stroke 2 is not neutral, positioning operation is active Retrial B Check the harness. with pressure decreasing by 40 %. •...
Page 342 TROUBLESHOOTING / Troubleshooting A Proportional Solenoid Valve Failure Fault Code Trouble Cause Influenced Control 15520-2 Invalid and Abnormal Current Feedback Current: Both of Higher than Auxiliary Control Value of Auxiliary 1 Proportional Valve 920 mA or Less than 60 mA 15520-3 Abnormal Feedback Value High Current of Current: Higher than 920...
Page 343 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Remedy by Remedy Occurs. Dr. ZX Auxiliary operation stops. Retrial B Check the harness. Auxiliary operation stops. Retrial B Check the harness. Auxiliary operation stops. Retrial B Check the harness. Auxiliary operation stops.
Page 344 TROUBLESHOOTING / Troubleshooting A Fault Code Trouble Cause Influenced Control 15525-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 Assist 1 Control Value of Assist 1 Proportional Valve mA or Less than 60 mA 15525-3 Abnormal Feedback Value High Current Current: Higher than 920 mA Assist 1 Control of Assist 1 Proportional Valve...
Page 345 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Remedy by Remedy Occurs. Dr. ZX Assist 1 operation stops. Retrial B Check the harness. Assist 1 operation stops. Retrial B Check the harness. Assist 1 operation stops. Retrial B Check the harness.
Page 346 TROUBLESHOOTING / Troubleshooting A Fault Code Trouble Cause Influenced Control 15529-2 Invalid and Abnormal Current Feedback Current: Both of higher than 920 Positioning Control Value of Positioning 1 Proportional mA or Less than 60 mA Valve 15529-3 Abnormal Feedback Value High Current Current: Higher than 920mA Positioning Control of Positioning 1 Proportional Valve...
Page 347 TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Remedy by Remedy Occurs. Dr. ZX Positioning operation stops. Retrial B Check the harness. Positioning operation stops. Retrial B Check the harness. Positioning operation stops. Retrial B Check the harness. Positioning operation stops.
Page 348 TROUBLESHOOTING / Troubleshooting A CAN Data Reception Failure Fault code Trouble Cause Influenced Control • 15565-2 Unreceived Work Mode Unreceived for 2000 ms Pulverizer Control • Sent from: MC Crusher Control • 15566-2 Unreceived ATT 1 and 2 Optional Unreceived for 10 sec Pulverizer Control •...
Page 349 TROUBLESHOOTING / Troubleshooting A Remedy by Symptoms in Machine Operation When Trouble Occurs Remedy Dr. ZX Work mode control is inactive (Always digging mode). Retrial B Check the harness. • Secondary pilot relief control solenoid valve: Always Retrial B Check the harness. •...
Page 350: Steering Column Monitor Fault Code
TROUBLESHOOTING / Troubleshooting A STEERING COLUMN MONITOR FAULT CODE Symptoms in Influenced Machine Remedy Fault Code Trouble Cause Remedy Control Operation When by Dr. ZX Trouble Occurs. Abnormal CAN Faulty steering Retrial B Check the CAN 16000-2 communication column monitor harness.
Page 351 TROUBLESHOOTING / Troubleshooting A (Blank) T5-6-69...
Page 352: Mc Fault Codes 11000 To 11002
TROUBLESHOOTING / Troubleshooting A MC FAULT CODES 11000 TO 11002 Fault Code Trouble Cause 11000-2 Abnormal EEPROM Faulty MC 11001-2 Abnormal RAM Faulty MC 11002-2 Abnormal A/D Convesion Faulty MC * Faulty MC. Check if engine and machine operate normally. Faulty MC.
Page 353: Mc Fault Code 11003
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11003 Fault Code Trouble Cause 11003-3 Abnormal Sensor Voltage Faulty MC IMPORTANT: Fault code 11003-3 (Abnormal sen- sor voltage) is shown with other fault code, diagnose fault code 11003-3 first. Faulty sensor. Disconnect all sensor connectors for displayed Shorted circuit in harness with fault code and retry.
Page 354: Mc Fault Code 11004
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11004 Fault Code Trouble Cause 11004-2 Abnormal CAN Communication Faulty MC Dr.ZX Satellite Terminal (Optional) Monitor Unit Option Controller CAN Harness Steering Column Monitor TCJB-02-01-001 • Check the CAN harness between the controllers. (Refer to CAN Harness Check on T5-6-73 to 104.) T5-6-72...
Page 355: Can Harness Check
TROUBLESHOOTING / Troubleshooting A CAN HARNESS CHECK • Check the wiring connections first. Open circuit in CAN harness between MC and ECM. Check for continuity in CAN harness between MC and ECM. Check for continuity in CAN harness be- · Key switch: OFF To A tween MC and ·...
Page 356 TROUBLESHOOTING / Troubleshooting A YES Check for continuity in CAN harness between MC and option con- Open circuit in CAN troller. harness between · Key switch: OFF Check for continuity in MC and option con- · Refer to CAN Har- CAN harness between troller.
Page 357 TROUBLESHOOTING / Troubleshooting A Shorted circuit in CAN harness be- tween ground circuit and CAN circuit. Disconnect all con- nectors of MC, ICF, Shorted circuit in ECM, monitor unit, CAN harness be- steering column tween electric power monitor and option circuit and CAN cir- controller.
Page 358 TROUBLESHOOTING / Troubleshooting A Shorted circuit in CAN harness. Faulty MC. Connect all MC connectors except connector MC-C. Check if resistance between terminals Faulty ICF. #C4 and #C15 of harness end of con- nector MC-C is within Connect MC con- 60±10 Ω.
Page 359 TROUBLESHOOTING / Troubleshooting A Faulty monitor unit. Faulty steering column monitor. Connect monitor unit connector. Disconnect connector 2 in steering column monitor. Connect steering col- Check if resistance be- umn monitor connector. Faulty option control- tween terminals #1 and Disconnect connector C ler.
Page 360 TROUBLESHOOTING / Troubleshooting A CAN Harness Continuity Check IMPORTANT: Before continuity check, trun the key switch OFF. • Between MC and ECM • CAN Harness (High Side) Check for continuity between terminal #C4 (har- ness end) of connector MC-C in MC and terminal #18 (harness end) of connector in ECM.
Page 361 TROUBLESHOOTING / Troubleshooting A • Between MC and ICF • CAN Harness (High Side) Check for continuity between terminal #C4 (har- ness end) of connector MC-C in MC and terminal #C5 (harness end) of connector ICF-C in ICF. • CAN Harness (Low Side) Check for continuity between terminal #C15 (harness end) of connector MC-C in MC and ter- minal #C11 (harness end) of connector ICF-C in...
Page 362 TROUBLESHOOTING / Troubleshooting A • Between MC and Monitor Unit • CAN Harness (High Side) Check for continuity between terminal #C4 (har- ness end) of connector MC-C in MC and terminal #B7 (harness end) of connector monitor-B in the monitor unit. •...
Page 363 TROUBLESHOOTING / Troubleshooting A • Between MC and Steering Column Monitor • CAN Harness (High Side) Check for continuity between terminal #C4 (har- ness end) of connector MC-C in MC and terminal #1 (harness end) of connector 2 in the steering column monitor.
Page 364 TROUBLESHOOTING / Troubleshooting A • Between MC and Option Controller • CAN Harness (High Side) Check for continuity between terminal #C4 (har- ness end) of connector MC-C in MC and terminal #C10 (harness end) of connector C in the option controller.
Page 365 TROUBLESHOOTING / Troubleshooting A (Blank) T5-6-83...
Page 366 TROUBLESHOOTING / Troubleshooting A Discontinuity Check between CAN Circuit and Ground Circuit Connector Connector MC-C IMPORTANT: Before continuity check, turn the key (Harness end) switch OFF. In case of continuity, the circuit be- tween CAN circuit and ground cir- cuit is shorted. In case of discontinuity, the circuit is normal.
Page 367 TROUBLESHOOTING / Troubleshooting A • Between CAN Circuit (Low Side) and Ground Circuit Connector • Check for continuity between terminal #C15 Connector MC-C (harness end) of connector MC-C and terminal (Harness end) #A2 (harness end) of connector MC-A. #C15 • Check for continuity between terminal #C15 (harness end) of connector MC-C and terminal #A13 (harness end) of connector MC-A.
Page 368 TROUBLESHOOTING / Troubleshooting A • Between CAN Circuit (High Side) and Ground Cir- ECM Connector cuit (Harness end) • Check for continuity between terminals #18 and #1 (harness end). • Check for continuity between terminals #18 and #3 (harness end). •...
Page 369 TROUBLESHOOTING / Troubleshooting A • Between CAN Circuit (High Side) and Ground Cir- ICF Connector ICF-C cuit (Harness end) • Check for continuity between terminals #C5 and #C14 (harness end) of connector ICF-C. • Check for continuity between terminals #C5 and #C15 (harness end) of connector ICF-C.
Page 370 TROUBLESHOOTING / Troubleshooting A • Steering Column Monitor Between CAN Circuit (High Side) and Ground Cir- Steering Column Monitor Connector 1 cuit (Harness end) • Check for continuity between terminal #1 (har- ness end) of connector 2 and terminal #1 (har- ness end) of connector 1.
Page 371 TROUBLESHOOTING / Troubleshooting A (Blank) T5-6-89...
Page 372 TROUBLESHOOTING / Troubleshooting A • Option Controller Between CAN Circuit (High Side) and Ground Cir- Connector cuit Connector C • Check for continuity between terminal #C10 (Harness end) (harness end) of connector C and terminal #A2 (harness end) of connector A. #C10 •...
Page 373 TROUBLESHOOTING / Troubleshooting A • Option Controller Between CAN Circuit (Low Side) and Ground Circuit Connector • Check for continuity between terminal #C22 Connector C (harness end) of connector C and terminal #A2 (Harness end) (harness end) of connector A. •...
Page 374 TROUBLESHOOTING / Troubleshooting A Discontinuity Check between CAN Circuit and Power Circuit Connector Connector MC-C IMPORTANT: Before continuity check, turn the key (Harness end) switch OFF. In case of continuity, the circuit be- tween CAN circuit and power circuit is shorted. In case of discontinuity, the circuit is normal.
Page 375 TROUBLESHOOTING / Troubleshooting A • Between CAN Circuit (Low Side) and Power Circuit Connector • Check for continuity between terminal #C15 Connector MC-C (harness end) of connector MC-C and terminal (Harness end) #A1 (harness end) of connector MC-A. #C15 • Check for continuity between terminal #C15 (harness end) of connector MC-C and terminal #A12 (harness end) of connector MC-A.
Page 376 TROUBLESHOOTING / Troubleshooting A • Between CAN Circuit (High Side) and Power Circuit ECM Connector • Check for continuity between terminals #18 and (Harness end) #2 (harness end). • Check for continuity between terminals #18 and #5 (harness end). • T1GR-05-04-002 Between CAN Circuit (Low Side) and Power Circuit •...
Page 377 TROUBLESHOOTING / Troubleshooting A • Monitor Unit Between CAN Circuit (High Side) and Power Circuit Monitor Unit Connector Monitor-B • Check for continuity between terminal #B7 (har- (Harness end) ness end) of connector monitor-B and terminal #A16 (harness end) of connector monitor-A. T183-05-04-013 Monitor Unit Connector Monitor-A (Harness end)
Page 378 TROUBLESHOOTING / Troubleshooting A • Steering Column Monitor Between CAN Circuit (High Side) and Power Circuit Steering Column Monitor Connector 2 • Check for continuity between terminal #1 (har- (Harness end) ness end) of connector 2 and terminal #6 (har- ness end) of connector 1.
Page 379 TROUBLESHOOTING / Troubleshooting A (Blank) T5-6-97...
Page 380 TROUBLESHOOTING / Troubleshooting A • Option Controller Between CAN Circuit (High Side) and Power Circuit Connector • Check for continuity between terminal #C10 Connector C (harness end) of connector C and terminal #A1 (Harness end) (harness end) of connector A. •...
Page 381 TROUBLESHOOTING / Troubleshooting A • Option Controller Between CAN Circuit (Low Side) and Power Circuit Connector • Check for continuity between terminal #C22 Connector C (harness end) of connector C and terminal #A1 (Harness end) (harness end) of connector A. •...
Page 382 TROUBLESHOOTING / Troubleshooting A Discontinuity Check between CAN Circuit and Key Signal Circuit Connector Connector MC-C IMPORTANT: Before continuity check, turn the key (Harness end) switch OFF. In case of continuity, the circuit be- tween CAN circuit and key signal circuit is shorted.
Page 383 TROUBLESHOOTING / Troubleshooting A • Between CAN Circuit (High Side) and Key Signal ECM Connector Circuit (Harness end) • Check for continuity between terminals #18 and #24 (harness end) of connector. T1GR-05-04-002 • ECM Connector Between CAN Circuit (Low Side) and Key Signal (Harness end) Circuit •...
Page 384 TROUBLESHOOTING / Troubleshooting A • Monitor Unit Between CAN Circuit (High Side) and Key Signal Monitor Unit Connector Monitor-B Circuit (Harness end) • Check for continuity between terminal #B7 (har- ness end) of connector monitor-B and terminal #A7 (harness end) of connector monitor-A. T183-05-04-013 Monitor Unit Connector Monitor-A (Harness end)
Page 385 TROUBLESHOOTING / Troubleshooting A • Option Controller Between CAN Circuit (High Side) and Key Signal Connector Circuit Connector C • Check for continuity between terminal #C10 (Harness end) (harness end) of connector C and terminal #B16 (harness end) of connector B. #C10 Connector B (Harness end)
Page 386 TROUBLESHOOTING / Troubleshooting A Discontinuity Check in CAN Harness IMPORTANT: Before continuity check, turn the key switch OFF. In case of continuity, the circuit be- tween CAN (High side) circuit and CAN (Low side) circuit is shorted. In case of discontinuity, the circuit is normal.
Page 387: Mc Fault Code 11100
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11100 Fault Code Trouble Cause 11100-2 Abnormal Engine Speed Engine speed: 4000 min or more • Actual engine speed which ECM sends by using CAN bus line. Diagnose ECM. T5-6-105...
Page 388: Mc Fault Code 11101
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11101 Fault Code Trouble Cause 11101-3 Abnormal Engine Control Dial Voltage: more than 4.78 V Sensor High Voltage 11101-4 Abnormal Engine Control Dial Voltage: less than 0.22 V Sensor Low Voltage Open circuit in har- ness between MC Disconnect connector and engine control...
Page 389: Mc Fault Code 11200
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11200 Fault Code Trouble Cause 11200-3 Abnormal Pump 1 Delivery Pressure Voltage: more than 4.5 V Sensor High Voltage 11200-4 Abnormal Pump 1 Delivery Pressure Voltage: less than 0.25 V Sensor Low Voltage Disconnect connector MC-D of MC.
Page 390: Mc Fault Code 11202
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11202 Fault Code Trouble Cause 11202-3 Abnormal Pump 2 Delivery Pressure Voltage: more than 4.5 V Sensor High Voltage 11202-4 Abnormal Pump 2 Delivery Pressure Voltage: less than 0.25 V Sensor Low Voltage Disconnect connector MC-D of MC.
Page 391: Mc Fault Code 11203
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11203 Fault Code Trouble Cause 11203-3 Abnormal Pump 3 Delivery Pressure Voltage: more than 4.5 V Sensor High Voltage 11203-4 Abnormal Pump 3 Delivery Pressure Voltage: less than 0.25 V Sensor Low Voltage Disconnect connector Open circuit in har- MC-D of MC.
Page 392: Mc Fault Code 11206
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11206 Fault Code Trouble Cause 11206-3 Abnormal Pump 1 Control Pressure Voltage: more than 4.75 V. Sensor High Voltage 11206-4 Abnormal Pump 1 Control Pressure Voltage: less than 0.25 V. Sensor Low Voltage Disconnect connector MC-D of MC.
Page 393: Mc Fault Code 11208
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11208 Fault Code Trouble Cause 11208-3 Abnormal Pump 2 Control Pressure Voltage: more than 4.75 V Sensor High Voltage 11208-4 Abnormal Pump 2 Control Pressure Voltage: less than 0.25 V Sensor Low Voltage Disconnect connector Open circuit in har- MC-D of MC.
Page 394: Mc Fault Code 11301
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11301 Fault Code Trouble Cause 11301-3 Abnormal Swing Pilot Pressure Voltage: more than 4.75 V Sensor High Voltage 11301-4 Abnormal Swing Pilot Pressure Voltage: less than 0.25 V Sensor Low Voltage Disconnect connector MC-C of MC.
Page 395: Mc Fault Code 11302
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11302 Fault Code Trouble Cause 11302-3 Abnormal Boom Raise Pilot Pres- Voltage: more than 4.75 V sure Sensor High Voltage 11302-4 Abnormal Boom Raise Pilot Pres- Voltage: less than 0.25 V sure Sensor Low Voltage Disconnect connector Open circuit in har- MC-C of MC.
Page 396: Mc Fault Code 11303
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11303 Fault Code Trouble Cause 11303-3 Abnormal Arm Roll-in Pilot Pressure Voltage: more than 4.75 V Sensor High Voltage 11303-4 Abnormal Arm Roll-in Pilot Pressure Voltage: less than 0.25 V Sensor Low Voltage Disconnect connector Open circuit in har- MC-C of MC.
Page 397: Mc Fault Code 11305
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11305 Fault Code Trouble Cause 11305-3 Abnormal Travel Forward Pilot Voltage: more than 4.75 V Pressure Sensor High Voltage 11305-4 Abnormal Travel Forward Pilot Voltage: less than 0.25 V Pressure Sensor Low Voltage Disconnect connector Open circuit in har- MC-C of MC.
Page 398: Mc Fault Code 11306
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11306 Fault Code Trouble Cause 11306-3 Abnormal Travel Reverse Pilot Voltage: more than 4.75 V Pressure Sensor High Voltage 11306-4 Abnormal Travel Reverse Pilot Voltage: less than 0.25 V Pressure Sensor Low Voltage Disconnect connector MC-C of MC.
Page 399: Mc Fault Code 11307
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11307 Fault Code Trouble Cause 11307-3 Abnormal Front Attachment Pilot Voltage: more than 4.75 V Pressure Sensor High voltage 11307-4 Abnormal Front Attachment Pilot Voltage: less than 0.25 V Pressure Sensor Low voltage Disconnect connector MC-C of MC.
Page 400: Mc Fault Code 11310
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11310 Fault Code Trouble Cause 11310-3 Abnormal Brake Pressure Sensor Voltage: more than 4.75 V High Voltage 11310-4 Abnormal Brake Pressure Sensor Voltage: less than 0.25 V Low Voltage Disconnect connector MC-C of MC. Open circuit in har- Check for continuity ness between MC...
Page 401: Mc Fault Code 11311
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11311 Fault Code Trouble Cause 11311-3 Abnormal Brake Remaining Pres- Voltage: more than 4.75 V sure Sensor High Voltage 11311-4 Abnormal Brake Remaining Pres- Voltage: less than 0.25 V sure Sensor Low Voltage Disconnect connector MC-C of MC.
Page 402: Mc Fault Code 11400
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11400 Fault Code Trouble Cause 11400-2 Abnormal Current Feedback Current: Both of Higher than Maximum Pump 2 Flow Rate Limit 920 mA or Less than 60 mA Control Solenoid Valve 11400-3 Abnormal Feedback High Current of Current: Higher than 920 mA Maximum Pump 2 Flow Rate Limit Control Solenoid Valve...
Page 403: Mc Fault Code 11401
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11401 Fault Code Trouble Cause 11401-2 Abnormal Current Feedback Current: Both of Higher than Torque Control Solenoid Valve 920 mA or Less than 60 mA 11401-3 Abnormal Feedback High Current of Current: Higher than 920 mA Torque Control Solenoid Valve 11401-4 Abnormal Feedback Low Current of...
Page 404: Mc Fault Code 11403
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11403 Fault Code Trouble Cause 11403-2 Abnormal Current Feedback Current: Both of Higher than Solenoid Valve Unit (SC) (Arm 920 mA or Less than 60 mA Regeneration) 11403-3 Abnormal Feedback High Current of Current: Higher than 920 mA Solenoid Valve Unit (SC) (Arm Regeneration)
Page 405: Mc Fault Code 11404
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11404 Fault Code Trouble Cause 11404-2 Abnormal Current Feedback Current: Both of Higher than Solenoid Valve Unit (SG) (Relief 920 mA or Less than 60 mA Pressure Control) 11404-3 Abnormal Feedback High Current of Current: Higher than 920 mA Solenoid Valve Unit (SG) (Relief Pressure Control)
Page 406: Mc Fault Code 11410
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11410 Fault Code Trouble Cause 11410-2 Abnormal Current Feedback Current: Both of Higher than Maximum Pump 1 Flow Rate Limit 920 mA or Less than 60 mA Control Solenoid Valve 11410-3 Abnormal Feedback High Current of Current: Higher than 920 mA Maximum Pump 1 Flow Rate Limit Control Solenoid Valve...
Page 407: Mc Fault Code 11422
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11422 Fault Code Trouble Cause 11422-2 Abnormal Current Feedback Current: Both of Higher than Travel Motor Displacement Angle 920 mA or Less than 60 mA Control Solenoid Valve 11422-3 Abnormal Feedback High Current of Current: Higher than 920 mA Travel Motor Displacement Angle Control Solenoid Valve...
Page 408: Mc Fault Code 11424
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11424 Fault Code Trouble Cause 11424-2 Abnormal Current Feedback Current: Both of Higher than Solenoid Valve Unit (SI) (Axle Lock 920 mA or Less than 60 mA Selection) 11424-3 Abnormal Feedback High Current of Current: Higher than 920 mA Solenoid Valve Unit (SI) (Axle Lock Selection)
Page 409: Mc Fault Code 11425
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11425 Fault Code Trouble Cause 11425-2 Abnormal Current Feedback Current: Both of Higher than Solenoid Valve Unit (SF) (Work 920 mA or Less than 60 mA Brake) 11425-3 Abnormal Feedback High Current of Current: Higher than 920 mA Solenoid Valve Unit (SF) (Work Brake)
Page 410: Mc Fault Codes 11910 To 11920
TROUBLESHOOTING / Troubleshooting A MC FAULT CODES 11910 TO 11920 Fault Code Trouble Cause 11910-2 Actual Engine Speed Faulty harness Sent from: ECM 11911-2 Security Signal Faulty harness Sent from: Monitor Unit 11914-2 Radiator Coolant Temperature Faulty harness Sent from: ECM 11915-2 Gate Lock Signal Faulty harness...
Page 411: Mc Fault Code 11901
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11901 Fault Code Trouble Cause 11901-3 Hydraulic Oil Temperature Sensor Voltage: more than 4.52 V High Voltage 11901-4 Hydraulic Oil Temperature Sensor Voltage: less than 0.23 V Low Voltage Connect terminals #1 Faulty MC. and #2 (harness end) of connector in hydraulic oil...
Page 412: Ecm Fault Codes 100 To 190
TROUBLESHOOTING / Troubleshooting A ECM FAULT CODES 100 TO 190 NOTE: If ECM fault code is displayed, refer to the other manual "Engine Troubleshooting Manual" and check the engine. Engine Fault Code Troubleshooting Fault Code Trouble (TECH2) Manual Reference Page Abnormal Engine Oil Pressure Sensor (Abnormal Low 100-3 P0522...
Page 413: Ecm Fault Codes 628 To 1485
TROUBLESHOOTING / Troubleshooting A ECM FAULT CODES 628 TO 1485 Engine Fault Code Troubleshooting Fault Code Trouble (TECH2) Manual Reference Page 628-2 Abnormal ROM P0601 1E-407 633-7 Pressure Limiter Open P1095 1E-433 636-2 Abnormal Cam Angle Sensor (No Signal) P0340 1E-358 636-2 Abnormal Cam Angle Sensor (Abnormal Signal)
Page 414: Ecm Fault Codes 10001 To 10013
TROUBLESHOOTING / Troubleshooting A ECM FAULT CODES 10001 TO 10013 Engine Troubleshooting Fault Code Fault Code Trouble Manual (TECH2) Reference Item 10001-3 Abnormal EGR Position (Brushless spec.) P0487 1E-381 10002-2 Abnormal EGR Valve Control P0488 1E-387 10003-2 Abnormal Injection Nozzle Common 1 Drive System P1261 1E-466 10004-2...
Page 415: Icf Fault Codes 14000 To 14003
TROUBLESHOOTING / Troubleshooting A ICF FAULT CODES 14000 TO 14003 Fault Code Trouble Remedy 14000-2 Abnormal CAN Communication Execute retry B in self-diagnosing. If this error code is displayed after retrial, check the following item. • Check the CAN communication line (harness). 14001-2 Flash Memory: Read / Write Error Execute retry B in self-diagnosing and execute the following...
Page 416: Information C/U: Intialize
TROUBLESHOOTING / Troubleshooting A INFORMATION C/U: INITIALIZE After starting Dr. ZX, push Select Push Information C/U. Push OK. Controller. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-024 ICF Controller Screen Controller Selection Screen Function Selection Screen Push Information C/U: Various Push Start. Push Information C/U: Initialize.
Page 417: Control Data: Intialize
TROUBLESHOOTING / Troubleshooting A CONTROL DATA: INITIALIZE After starting Dr. ZX, push Select Push OK. Push Information C/U. Controller. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-024 Function Selection Screen Controller Selection Screen ICF Controller Screen Push Information C/U: Various Push Start. Push Control Data: Initialize.
Page 418: Enter Model And Serial No
TROUBLESHOOTING / Troubleshooting A ENTER MODEL AND SERIAL No. After starting Dr. ZX, push Select Push Information C/U. Push OK. Controller. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-024 Function Selection Screen Controller Selection Screen ICF Controller Screen Push Information C/U: Various Push Start.
Page 419: Icf Fault Codes 14006, 14008
TROUBLESHOOTING / Troubleshooting A ICF FAULT CODES 14006, 14008 Fault Code Trouble Remedy 14006-2 ICF: Satellite Communication Execute retry B in self-diagnosing. Terminal: Communication Error If this error code is displayed after retrial, check the following item. • Check the communication line. •...
Page 420: Satellite Terminal Fault Codes 14100 To 14106
TROUBLESHOOTING / Troubleshooting A SATELLITE TERMINAL FAULT CODES 14100 TO 14106 Fault Code Trouble Remedy 14100-2 Abnormal EEPROM Execute retry B in self-diagnosing. If this error code is displayed after retrial, replace the 14101-2 Abnormal IB/OB Queue controller. 14102-2 Abnormal Local Loop Back Check the communication antenna of satellite terminal.
Page 421: Monitor Unit Fault Code 13303
TROUBLESHOOTING / Troubleshooting A MONITOR UNIT FAULT CODE 13303 Fault Code Trouble Remedy 13303-2 Abnormal Thermistor Temperature Cool the monitor unit and so on until the internal temperature of monitor unit is less than 85 °C (185 °F). • The screen of monitor unit becomes dark. Normal.
Page 422: Monitor Unit Fault Code 13304
TROUBLESHOOTING / Troubleshooting A MONITOR UNIT FAULT CODE 13304 Fault Code Trouble Remedy 13304-2 Abnormal REG Input H Level Refer to the following. • Check the wiring connections first. NOTE: *As terminal L in the regulator is a waterproof type connector, it is difficult to measure voltage.
Page 423: Monitor Unit Fault Codes 13306 And 13308
TROUBLESHOOTING / Troubleshooting A MONITOR UNIT FAULT CODES 13306 AND 13308 Fault Code Trouble Remedy 13306-2 Abnormal EEPROM Replace the monitor unit when displaying the fault code after retrial. 13308-2 Abnormal CAN Communication Refer to CAN Harness Check (T5-6-73 to 104). T5-6-141...
Page 424: Monitor Unit Fault Code 13310
TROUBLESHOOTING / Troubleshooting A MONITOR UNIT FAULT CODE 13310 Fault Code Trouble Remedy 13310-2 Shorted Circuit Coolant Check the coolant temperature sensor and harness. Temperature Sensor With terminal of coolant Shorted circuit in harness temperature sensor between monitor unit and disconnected, disconnect sensor.
Page 425: Monitor Unit Fault Code 13311
TROUBLESHOOTING / Troubleshooting A MONITOR UNIT FAULT CODE 13311 Fault Code Trouble Remedy 13311-3 Shorted Circuit in Fuel Level Sensor Check fuel level sensor and harness. 13311-4 Open Circuit in Fuel Level Sensor Check fuel level sensor and harness. Shorted circuit in harness between monitor unit and sensor.
Page 426: Pilot Shut-Off Lever Alarm
TROUBLESHOOTING / Troubleshooting A PILOT SHUT-OFF LEVER ALARM Pilot shut-off lever alarm is displayed on the monitor unit screen. Faulty pilot shut-off switch. Check if pilot shut-off switch is bent or damaged. Faulty harness. Pilot Shut-Off Pilot Shut-Off Switch Lever T1V1-05-06-005 T5-6-144...
Page 427: Option Controller Fault Codes 15500 To 15504
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODES 15500 TO 15504 Fault Code Trouble Cause 15500-4 Abnormal External Reference Voltage Faulty controller 15501-2 Abnormal Read of Initial Setting Value Faulty controller (EEPROM) 15502-2 Abnormal EEPROM Faulty controller 15503-2 Abnormal RAM Faulty controller 15504-2 Abnormal A/D Conversion...
Page 428: Option Controller Fault Code 15505
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15505 Fault Code Trouble Cause 15505-2 Abnormal CAN Communication Faulty controller Faulty CAN harness NOTE: If fault code 15505 is displayed, the CAN harness between MC and source controller may be faulty. Refer to CAN Harness Check on T5-6-73 to 104 and check the CAN harness.
Page 429: Option Controller Fault Code 15506
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15506 Fault Code Trouble Cause 15506-3 Abnormal Sensor Voltage Faulty controller Faulty sensor Faulty harness Faulty sensor. Disconnect all sensor connectors for displayed fault code and retry. Check if fault code Disconnect all Shorted circuit in harness with 15506-3 disappears.
Page 430: Option Controller Fault Code 15510
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15510 Fault Code Trouble Cause 15510-3 Abnormal Assist Stroke 1 Sensor High Voltage: more than 4.65 V Voltage 15510-4 Abnormal Assist Stroke 1 Sensor Low Voltage: less than 0.35 V Voltage Check if voltage between terminal # C Faulty option 20 (harness end) of...
Page 431: Option Controller Fault Code 15511
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15511 Fault Code Trouble Cause 15511-3 Abnormal Assist Stroke 2 Sensor High Voltage: more than 4.65 V Voltage 15511-4 Abnormal Assist Stroke 2 Sensor Low Voltage: less than 0.35 V Voltage Check if voltage between terminal #C6 Faulty option (harness end) of...
Page 432: Option Controller Fault Code 15514
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15514 Fault Code Trouble Cause 15514-3 Abnormal Positioning/Auxiliary Stroke 1 Voltage: more than 4.55 V Sensor High Voltage 15514-4 Abnormal Positioning/Auxiliary Stroke 1 Voltage: less than 0.45 V Sensor Low Voltage Check if voltage Faulty option controller.
Page 433: Option Controller Fault Code 15515
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15515 Fault Code Trouble Cause 15515-3 Abnormal Positioning/Auxiliary Stroke 2 Voltage: more than 4.85 V Sensor High Voltage 15515-4 Abnormal Positioning/Auxiliary Stroke 2 Voltage: less than 0.15 V Sensor Low Voltage Check if voltage Faulty option controller.
Page 434: Option Controller Fault Code 15516
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15516 Fault Code Trouble Cause 15516-3 Abnormal Positioning/Assist Pi pressure Voltage: more than 4.60 V Sensor High Voltage 15516-4 Abnormal Positioning/Assist Pi pressure Voltage: less than 0.40 V Sensor Low Voltage Open circuit in harness Disconnect connector C between option of option controller.
Page 435: Option Controller Fault Code 15517
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15517 Fault Code Trouble Cause 15517-3 Abnormal Outrigger/Blade/Auxiliary Voltage: more than 4.60 V Pressure Sensor High Voltage 15517-4 Abnormal Outrigger/Blade/Auxiliary Voltage: is less than 0.40 V Pressure Sensor Low Voltage Open circuit in harness Disconnect connector C between option of option controller.
Page 436: Option Controller Fault Code 15518
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15518 Fault Code Trouble Cause 15518-3 Abnormal Outrigger/Blade Stroke 1 Sensor Voltage: more than 4.55 V High Voltage 15518-4 Abnormal Outrigger/Blade Stroke 1 Sensor Voltage: less than 0.45 V Low Voltage Check if voltage Faulty option controller.
Page 437: Option Controller Fault Code 15519
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15519 Fault Code Trouble Cause 15519-3 Abnormal Outrigger/Blade Stroke 2 Sensor Voltage: more than 4.85 V High Voltage 15519-4 Abnormal Outrigger/Blade Stroke 2 Sensor Voltage: less than 0.15 V Low Voltage Check if voltage Faulty option between terminal controller.
Page 438: Option Controller Fault Code 15570
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15570 Fault Code Trouble Cause 15570-2 Abnormal Outrigger/Blade/Auxiliary Neutral When meeting the any following conditions, outrigger/blade/auxiliary pilot pressure is more than 1.2 MPa. (Conditions) • Outrigger/blade 1 and 2 solenoid valve output is less than 0.5 MPa •...
Page 439: Option Controller Fault Code 15571
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15571 Fault Code Trouble Cause 15571-2 Abnormal Outrigger/Blade/Auxiliary When meeting either of the any following Operation condition, outrigger/blade/auxiliary pilot pressure is less than 1.0 MPa. (Conditions) • Outrigger/blade 1 and 2 solenoid valve output is more than 2.2 MPa •...
Page 440: Option Controller Fault Code 15572
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15572 Fault Code Trouble Cause 15572-2 Abnormal Positioning/Assist Neutral When meeting the any following conditions, positioning/assist pilot pressure is more than 1.2 MPa. (Conditions) • Positioning 1 and 2 solenoid valve output is less than 0.5 MPa •...
Page 441: Option Controller Fault Code 15573
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15573 Fault Code Trouble Cause 15573-2 Abnormal Positioning/Assist Operation When meeting either of the following conditions, positioning/assist pilot pressure is less than 1.0 MPa. (Conditions) • Positioning 1 and 2 solenoid valve output is more than 2.2 MPa •...
Page 442: Option Controller Fault Codes 15574-3 And 15578-3
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODES 15574-3 AND 15578-3 Fault Code Trouble Cause 15574-3 Abnormal Positioning/Auxiliary Sum Signal Positioning/auxiliary stroke 1 + positioning/ Critical High Voltage auxiliary stroke 2 is more than 9.0 V 15578-3 Abnormal Positioning/Auxiliary Sum Signal Positioning/auxiliary stroke 1 + positioning/ High Voltage auxiliary stroke 2 is more than 5.4 V and...
Page 443: Option Controller Fault Codes 15574-4 And 15578-4
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODES 15574-4 AND 15578-4 Fault Code Trouble Cause 15574-4 Abnormal Positioning/Auxiliary Sum Signal Positioning/auxiliary stroke 1 + positioning/ Critical Low Voltage auxiliary stroke 2 is less than 0.5 V 15578-4 Abnormalr Positioning/Auxiliary Sum Signal Positioning/auxiliary stroke 1 + positioning/ Low Voltage auxiliary stroke 2 is more than or equal to...
Page 444: Option Controller Fault Codes 15575-3 And 15579-3
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODES 15575-3 AND 15579-3 Fault Code Trouble Cause 15575-3 Abnormal Outrigger/Blade Signal Outrigger/blade stroke 1 + outrigger/blade Critical High Voltage stroke 2 is more than 9.0 V 15579-3 Abnormal Outrigger/Blade Signal Outrigger/blade stroke 1 + outrigger/blade High Voltage stroke 2 is more than 5.4 V and less than or equal to 9.0 V...
Page 445: Option Controller Fault Codes 15575-4 And 15579-4
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODES 15575-4 AND 15579-4 Fault Code Trouble Cause 15575-4 Abnormal Outrigger/Blade Signal Outrigger/blade stroke 1 + outrigger/blade Critical Low Voltage stroke 2 is less than 0.5 V 15579-4 Abnormal Outrigger/Blade Sum Signal Low Outrigger/blade stroke 1 + outrigger/blade Voltage stroke 2 is more than or equal to 0.5 V and...
Page 446: Option Controller Fault Codes 20300 To 20303
TROUBLESHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODES 20300 TO 20303 Fault Code Trouble Cause 20300-2 Abnormal Positioning/Auxiliary Operation Abnormal positioning/auxiliary stroke 1, or Signal Warning Abnormal positioning/auxiliary stroke 2, or Abnormal sum of positioning/auxiliary 1 and 2 20301-2 Abnormal Outrigger/Blade Operation Abnormal outrigger/blade stroke 1 or...
Page 447: Option Controller Fault Code 15520
TROUBLEHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15520 Fault Code Trouble Cause 15520-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less Value of Auxiliary 1 Proportional Valve than 60 mA 15520-3 Abnormal Feedback Value High Current of Current: Higher than 920 mA Auxiliary 1 Proportional Valve 15520-4...
Page 448: Option Controller Fault Code 15521
TROUBLEHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15521 Fault Code Trouble Cause 15521-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less Value of Auxiliary 2 Proportional Valve than 60 mA 15521-3 Abnormal Feedback Value High Current of Current: Higher than 920 mA Auxiliary 2 Proportional Valve 15521-4...
Page 449: Option Controller Fault Code 15522
TROUBLEHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15522 Fault Code Trouble Cause 15522-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less Value of Outrigger/Blade 1 Proportional than 60 mA Valve 15522-3 Abnormal Feedback Value High Current of Current: Higher than 920 mA Outrigger/Blade 1 Proportional Valve 15522-4...
Page 450: Option Controller Fault Code 15523
TROUBLEHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15523 Fault Code Trouble Cause 15523-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less Value of Outrigger/Blade 2 Proportional than 60 mA Valve 15523-3 Abnormal Feedback Value High Current of Current: Higher than 920 mA Outrigger/Blade 2 Proportional Valve 15523-4...
Page 451: Option Controller Fault Code 15524
TROUBLEHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15524 Fault Code Trouble Cause 15524-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less Value Swing Parking Release than 60 mA Proportional Valve 15524-3 Abnormal Feedback Value High Current of Current: Higher than 920 mA Swing Parking Release Proportional Valve 15524-4...
Page 452: Option Controller Fault Code 15525
TROUBLEHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15525 Fault Code Trouble Cause 15525-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less Value of Assist 1 Proportional Valve than 60 mA 15525-3 Abnormal Feedback Value High Current of Current: Higher than 920 mA Assist 1 Proportional Valve 15525-4...
Page 453: Option Controller Fault Code 15526
TROUBLEHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15526 Fault Code Trouble Cause 15526-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less Value of Assist 2 Proportional Valve than 60 mA 15526-3 Abnormal Feedback Value High Current of Current: Higher than 920 mA Assist 2 Proportional Valve 15526-4...
Page 454: Option Controller Fault Code 15527
TROUBLEHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15527 Fault Code Trouble Cause 15527-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less Value of Assist 3 Proportional Valve than 60 mA 15527-3 Abnormal Feedback Value High Current of Current: Higher than 920 mA Assist 3 Proportional Valve 15527-4...
Page 455: Option Controller Fault Code 15528
TROUBLEHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15528 Fault Code Trouble Cause 15528-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less Value of Assist 4 Proportional Valve than 60 mA 15528-3 Abnormal Feedback Value High Current of Current: Higher than 920 mA Assist 4 Proportional Valve 15528-4...
Page 456: Option Controller Fault Code 15529
TROUBLEHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15529 Fault Code Trouble Cause Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less 15529-2 Value of Positioning 1 Proportional Valve than 60 mA Abnormal Feedback Value High Current of Current: Higher than 920 mA 15529-3 Positioning 1 Proportional Valve...
Page 457: Option Controller Fault Code 15530
TROUBLEHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODE 15530 Fault Code Trouble Cause 15530-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less Value of Positioning 2 Proportional Valve than 60 mA 15530-3 Abnormal Feedback Value High Current of Current: Higher than 920 mA Positioning 2 Proportional Valve 15530-4...
Page 458: Option Controller Fault Codes 15565 To 15577
TROUBLEHOOTING / Troubleshooting A OPTION CONTROLLER FAULT CODES 15565 TO 15577 Fault Code Trouble Cause 15565-2 Unreceived Work Mode Unreceived for 2000 ms Sent from: MC 15566-2 Unreceived ATT 1 and 2 Optional Selection Unreceived for 10 sec Sent from: MC 15567-2 Unreceived ATT 3 and 4 Optional Selection Unreceived for 10 sec...
Page 459: Steering Column Monitor Fault Code 16000
TROUBLEHOOTING / Troubleshooting A STEERING COLUMN MONITOR FAULT CODE 16000 Fault Code Trouble Cause 16000-2 Abnormal CAN Communication Faulty steering column monitor Faulty CAN harness NOTE: If fault code 16000-2 is displayed, the CAN harness between MC and source controller may be faulty.
Page 460 TROUBLEHOOTING / Troubleshooting A (Blank) T5-6-178...
Page 461: Troubleshooting B Procedure
TROUBLESHOOTING / Troubleshooting B TROUBLESHOOTING B PROCEDURE Apply troubleshooting B procedure when no fault code is displayed on the service menu (built-in diagnosing system) in monitor unit and the diagnosing by Dr. ZX although the machine operation is abnormal. When the fault code is displayed, refer to the troubleshooting A group and diagnose.
Page 462 TROUBLESHOOTING / Troubleshooting B RELATIONSHIP BETWEEN MACHINE TROUBLE SYMPTOMS AND RELATED PARTS This table indicates the relationship between machine trouble symptoms and the potential problem parts, which may cause trouble if failed, and the evaluation methods of these components. Parts Pump 1 Delivery Engine Control Dial Pump Control Pressure Sensor...
Page 463 TROUBLESHOOTING / Troubleshooting B Pump 2 Delivery Steering Pump Delivery Pressure Sensor Pressure Sensor Pressure Sensor Pressure Sensor (Travel Forward) (Travel Reverse) • • • • Monitors pump delivery Monitors pump delivery Monitors travel for- Monitors travel for- pressure in order to control HP pressure in order to control ward pilot pressure in or- ward pilot pressure in or-...
Page 464 TROUBLESHOOTING / Troubleshooting B Parts Pressure Sensor Pressure Sensor Pressure Sensor (Swing) Item (Front Attachment) (Boom Raise) • • • Monitors front attachment Monitors swing pilot pressure Monitors boom raise pilot pilot pressure in order to in order to control arm re- pressure in order to control control auto-idle, idle generative control.
Page 465 TROUBLESHOOTING / Troubleshooting B Pressure Sensor Pressure Sensor Pressure Sensor Brake Pressure Sensor (Arm Roll-In) (Auxiliary) (Optional) (Positioning) (Optional) • • • • Monitors arm roll-in pilot Monitors attachment pilot Monitors attachment pilot Monitors bake operating pressure in order to control pressure when attachment is pressure when attachment is pressure in order to control...
Page 466 TROUBLESHOOTING / Troubleshooting B Parts Brake Remaining Boom Bottom Solenoid Valve Unit (SF) Item Pressure Sensor Pressure Sensor • • • Monitors accumulated Monitors Boom cylinder Shifts bake valve by pilot pressure of accumulator for bottom pressure in order to pressure in order to control brake in order to control control (overload alarm con-...
Page 467 TROUBLESHOOTING / Troubleshooting B Max. Pump 1 Flow Rate Max. Pump 2 Flow Rate Solenoid Valve Unit (SC) Solenoid Valve Unit (SI) Limit Control Solenoid Valve Limit Control Solenoid • • • • Routes return oil from arm cylin- Is shifted when axle lock or When machine is traveling Limits maximum flow rate der rod side to bottom side when...
Page 468 TROUBLESHOOTING / Troubleshooting B Pilot Shut-Off Parts Torque Control Auxiliary Solenoid Valve Solenoid Valve Solenoid Valve Item • • • Supplies control pressure to Opens and closes pilot cir- Is operated by signal from pumps 1 and 2 in order to do cuit.
Page 469 TROUBLESHOOTING / Troubleshooting B Swing Parking Brake Blade/Outrigger Positioning Solenoid Valve Assist Solenoid Valve Release Solenoid Valve Solenoid Valve • • • • Is operated by signal from option Is operated by signal from Is operated by signal from Is operated by signal from controller and supplies pressure option controller and sup- option controller and sup-...
Page 470 TROUBLESHOOTING / Troubleshooting B Parts Auxiliary Flow Combiner Auxiliary Flow Rate Control Selector Valve Control Solenoid Valve (Optional) Item Solenoid Valve (Optional) Solenoid Valve (Optional) • • • Restricts flow rate to auxiliary Activates during auxiliary op- Activates when attachment spool during combined op- eration and shifts spool in “selector valve returning to...
Page 471 TROUBLESHOOTING / Troubleshooting B Hydraulic Oil Travel Speed Secondary Pilot Relief Pressure Travel N Sensor Temperature Sensor Mode Switch Control Solenoid Valve (Optional • • • • Activates when attachment Detects travel motor speed Monitors hydraulic oil tem- Shifts fast/slow speed selec- “secondary pilot relief pres- and sends a signal to speed perature in order to control...
Page 472 TROUBLESHOOTING / Troubleshooting B Parts Engine Speed Control FNR Switch Brake Switch Item Mode Selection Switch • • • Shifts travel forward/reverse Shifts engine speed control Shifts parking brake, axle Pi cut-off solenoid valve by mode by operating switch in lock, auto axle lock and shifting FNR switch in order order to control engine con-...
Page 473 TROUBLESHOOTING / Troubleshooting B Power Mode Switch Power Mode Switch Auto-Idle Switch (HP Mode) (E Mode) • • • • Controls engine, pump and Activates auto-idle control. Activates HP mode. Selects E mode. ON: 0 V → Auto-idle is operable. ON: 0 V →...
Page 474 TROUBLESHOOTING / Troubleshooting B Parts Work Brake Release Outrigger Selection Pilot Shout-Off Item Switch Switch • • • Release work brake and Shifts blade/outrigger main Activates pilot shut-off sole- makes machine travel in order relay 1 and pilot shut-off so- noid valve.(Turns pilot shut-off to control work brake control.
Page 475 TROUBLESHOOTING / Troubleshooting B Bucket Flow Rate Boom Flow Rate Auxiliary Flow Rate Boom Regenerative Valve Control Valve Control Valve Control Valve • • • • Restricts oil flow raise to Is shifted by pilot pressure Is shifted by pilot pressure Prevents boom cylinder hesi- bucket during 3-combined from boom lower meter-in cut...
Page 476 TROUBLESHOOTING / Troubleshooting B Parts Bucket Regenerative Arm Regenerative Valve Arm Anti-Drift Valve Valve Item • • • Is shifted by pilot pressure Prevents bucket cylinder Check valve in arm roll-in re- from solenoid valve unit (SC). hesitation by routing return oil turn circuit is forcibly opened •...
Page 477 TROUBLESHOOTING / Troubleshooting B Auxiliary Flow Pump 1 Flow Rate Boom Anti-Drift Valve Bypass Shut-Out Valve Combiner Valve Control Valve • • • • Check valve in boom lower Is shifted by pilot pressure from Supplies pressure oil from Supplies flow rate control...
Page 478 TROUBLESHOOTING / Troubleshooting B Pump 2 Flow Rate Parts Swing Parking Brake Bucket Flow Rate Control Control Valve Item Release Spool Valve Control Spool • • • Supplies flow rate control shifted boom, arm, Is shifted by arm roll-in pilot pressure Pi to pump 2 regula- bucket, swing,...
Page 479 TROUBLESHOOTING / Troubleshooting B Accumulator Transmission Control Steering Valve Brake Valve Charging Valve Solenoid Valve • • • • Supplies pressure oil from Supplies pressure Charges pressure oil into Shifts parking brake and steering pump to steering front/rear axle brakes accumulator provided fast/slow in transmission.
Page 480 TROUBLESHOOTING / Troubleshooting B Parts Blade/Outrigger Cylinder Travel Forward Pi Cut Travel Reverse Pi Cut Item Solenoid Valve Solenoid Valve Solenoid Valve • • • Releases operate check travel forward pilot travel reverse pilot valve provided pressure prevents pressure prevents blade/outrigger cylinder.
Page 481 TROUBLESHOOTING / Troubleshooting B Secondary Pilot Relief Pressure Selector Valve (Optional) Control Valve (Optional) • • Is shifted by pilot pressure from selector shifted pilot pressure from valve control solenoid valve. secondary pilot relief pressure control solenoid valve. • • If spool is bound or spring is broken, If spool is bound or spring is broken, relief pressure oil from breaker does not return...
Page 482: Correlation Between Trouble Symptoms And Part Failures
TROUBLESHOOTING / Troubleshooting B CORRELATION BETWEEN TROUBLE SYMPTOMS AND PART FAILURES This table indicates the relationship between machine troubles and parts contributing to the cause of the trouble if failed. Engine System Troubleshooting Trouble Symptom Starter does not rotate. Although starter rotates, When engine control dial is...
Page 483 TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are In case more than one trouble occurs at the described provided that each trouble same time, find out all faulty components occurs independently. while checking all suspected components in each trouble symptom.
Page 484 TROUBLESHOOTING / Troubleshooting B E-10 Trouble Symptom Faulty auto-idle. Faulty E mode. When traveling or operating front attachment at slow idle, engine hunts. Part Monitor Unit Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Control Pressure Sensor Pressure Sensor (Travel) Pressure Sensor (Front Attachment)
Page 485 TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are In case more than one trouble occurs at the described provided that each trouble same time, find out all faulty components occurs independently. while checking all suspected components in each trouble symptom.
Page 486 TROUBLESHOOTING / Troubleshooting B E-15 E-16 Trouble Symptom Although depressing Although depressing accelerator pedal during accelerator pedal during travel operation, engine digging operation, speed does not change. engine speed does not Part change. MC (Main Controller) Torque Control Solenoid Valve Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Pressure Sensor...
Page 487 TROUBLESHOOTING / Troubleshooting B (Blank) T5-7-27...
Page 488 TROUBLESHOOTING / Troubleshooting B All Actuator System Troubleshooting Trouble Symptom All actuator speeds are slow. actuators Single swing operation operated. speed becomes slow. Arm speed is slightly slow during arm level crowding. Part Monitor Unit Torque Control Solenoid Valve Pilot Shut-Off Solenoid Valve Pump 2 Delivery Pressure Sensor Pressure Sensor (Swing) Pressure Sensor (Arm Roll-In)
Page 489 TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are In case more than one trouble occurs at the described provided that each trouble same time, find out all faulty components occurs independently. while checking all suspected components in each trouble symptom.
Page 490 TROUBLESHOOTING / Troubleshooting B Front Attachment System Troubleshooting Trouble Symptom All front attachment Some cylinder are Arm speed is slow Bucket slightly actuator operations operated during combined slow during bucket are weak. speeds are slow. operation. During roll-in single combined operation operation.
Page 491 TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are In case more than one trouble occurs at the described provided that each trouble same time, find out all faulty components occurs independently. while checking all suspected components in each trouble symptom.
Page 492 TROUBLESHOOTING / Troubleshooting B Front Attachment System Troubleshooting F-12 F-13 F-14 Trouble Symptom Attachment speed is Attachment speed is Attachment speed is fast during combined fast during combined fast during combined operation of attachment operation of attachment operation of attachment (optional) front (optional)
Page 493 TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are In case more than one trouble occurs at the described provided that each trouble same time, find out all faulty components occurs independently. while checking all suspected components in each trouble symptom.
Page 494 TROUBLESHOOTING / Troubleshooting B Travel System Troubleshooting Trouble Symptom Machine does not Machine does not Forward/reverse When releasing travel. travel forward or travel speeds are accelerator pedal, reverse. slow. Travel power is hydraulic brake is not weak. applied. Part (Macnine runs away.) Monitor Unit Main Pump Regulator...
Page 495 TROUBLESHOOTING / Troubleshooting B Travel mode (fast/slow) Axle lock is not Axle lock is not does not shift. released. operable. Related, required to check NOTE: The trouble symptoms in this table are : Related. However, in case this component fails, other trouble described provided that each trouble symptom will be more noticeable so that this component will not be the direct cause of the trouble concerned.
Page 496 TROUBLESHOOTING / Troubleshooting B Brake System Troubleshooting Trouble Symptom Parking brake is not operable Service brake is not operable, Work brake is not work (not applied). or is not applied effectively. operable. Part Monitor Unit Main Pump Regulator Solenoid Valve Unit (SF) Solenoid Valve Unit (SI) Travel Mode Selector Solenoid Valve...
Page 497 TROUBLESHOOTING / Troubleshooting B Steering System / Other System Troubleshooting Trouble Symptom Although steering wheel Although steering wheel Wiper is not operable. Air Conditioner is is rotated, steering is is rotated, steering is faulty. impossible. heavy. Part Steering Pump Steering Valve Center Joint Front Axle Other Electrical Equipment...
Page 498: Engine System Troubleshooting
TROUBLESHOOTING / Troubleshooting B ENGINE SYSTEM TROUBLESHOOTING E-1 Starter does not rotate. IMPORTANT: As electric current from the key switch is not routed to the starter relay except with the pilot shut-off lever in the UNLOCK position and with the brake switch in the P (park- ing brake) position, the starter does not rotate.
Page 499 TROUBLESHOOTING / Troubleshooting B Faulty starter, or faulty harness between starter and battery relay. Check if voltage at terminal A in battery relay is 24 V. Check if voltage at Faulty battery relay. terminal #2 (harness end) of connector in Disconnect connector starter cut relay is 0 of starter relay 2.
Page 500 TROUBLESHOOTING / Troubleshooting B E-2 Although starter rotates, engine does not start. • Check the wiring connections first. Faulty ECM main relay. Connect terminal #1 (harness end) of connector in ECM Switch ECM main main relay to ma- Connect terminal #5 relay with other gen- chine.
Page 501 TROUBLESHOOTING / Troubleshooting B Open circuit in harness Disconnect con- between key switch and nector ICF-C in monitor unit. ICF. Check if voltage between Check if fuse #18 is blown. terminal #C7 Disconnect (harness end) of connector MC-B connector and Open circuit in harness in MC.
Page 502 TROUBLESHOOTING / Troubleshooting B E-3 When engine control dial is fully rotated, en- gine stalls. When engine control dial is fully rotated, en- gine speed is slow. Related MC Fault Code: 11003-3, 11004-2 • Check the wiring connections first. Faulty MC, or faulty CAN between MC and ECM.
Page 503 TROUBLESHOOTING / Troubleshooting B E-4 Although engine control dial is rotated, en- gine speed does not change. Related MC Fault Code: 11004-2, 11101-3, 11101-4 • Check the wiring connections first. Faulty engine control dial, or open circuit in harness between engine control dial and MC.
Page 504 TROUBLESHOOTING / Troubleshooting B E-5 Engine speed does not increase when en- gine starts. Related MC Fault Code: 11004-2, 11901-3, 11901-4 • Refer to the pages for the Auto Warming Up Con- trol in the SYSTEM / Control System group in the T/M (Operational Principle).
Page 505 TROUBLESHOOTING / Troubleshooting B (Blank) T5-7-45...
Page 506 TROUBLESHOOTING / Troubleshooting B E-6 Faulty HP mode • Even if power mode switch is turned to the HP mode position, HP mode is not operated. (General mode normally operates.) Related MC Fault Codes: 11004-2, 11200-3, 11200-4, 11202-3, 11202-4, 11302-3, 11302-4, 11303-3, 11303-4 •...
Page 507 TROUBLESHOOTING / Troubleshooting B • Although the power mode switch is not turned to HP mode, HP mode is operated. • Boom raise and arm roll-in must be operated when the average delivery pressures of pump 1 and 2 are high, if HP mode control is performed. The sensors related to this condition may not be faulty at the same time.
Page 508 TROUBLESHOOTING / Troubleshooting B E-7 Although key switch is turned OFF, engine does not stop. (If the engine does not stop, stop engine by turning the emergency stop switch ON located under the seat stand. Then, begin inspection.) • Probably the symptoms such as “Engine speed is slower than specification in all operating ranges”...
Page 509 TROUBLESHOOTING / Troubleshooting B (Blank) T5-7-49...
Page 510 TROUBLESHOOTING / Troubleshooting B E-8 Faulty auto-idle system • Although control lever is turned to neutral, auto-idle is not operated. Related MC Fault Code: 11004-2, 11304-3, 11304-4, 11307-3, 11307-4 Related ECM Fault Code: 639-2, 639-3 • • If trouble symptoms E1 to E8 are recognized, Refer to the pages for Auto-Idle Control in the perform the troubleshooting of these troubles SYSTEM / Control System group in the T/M (Op-...
Page 511 TROUBLESHOOTING / Troubleshooting B Refer to fault code 11004 in Trouble- shooting A. Refer to Engine Troubleshooting Manual. Check if fault code 639-2 or 639-3 is displayed. Faulty corresponding sensor, or open cir- cuit in harness be- tween MC and sen- sor.
Page 512 TROUBLESHOOTING / Troubleshooting B • Although auto-idle switch is turned OFF, auto-idle is operated. Shorted circuit in harness between MC Disconnect connector and auto-idle switch. MC-B in MC and con- nector in switch panel. Check for continuity between terminal #B6 Refer to fault code (harness end) of con- 11004 in Trouble-...
Page 513 TROUBLESHOOTING / Troubleshooting B (Blank) T5-7-53...
Page 514 TROUBLESHOOTING / Troubleshooting B E-9 Faulty E mode • Although power mode switch is turned to the E mode position, engine speed does not change. (En- gine speed does not decrease.) Related MC Fault Code: 11004-2, 11200-3, 11200-4, 11202-3, 11202-4, 11206-3, 11206-4, 11208-3, 11208-4...
Page 515 TROUBLESHOOTING / Troubleshooting B • Although power mode switch is not turned to E mode, engine speed decreases. • Required engine speed from the engine control dial must be beyond 1800 min when the pump control pressures of pump 1 and 2 are low or the average delivery pressures of pump 1 and 2 are high, if E mode control is performed.
Page 516 TROUBLESHOOTING / Troubleshooting B E-10 When traveling or operating front attach- ment at slow idle, engine hunts. Related MC Fault Code: 11004-2, 11304-3, 11304-4, 11307-3, 11307-4 • Although the failure in pressure sensors (travel forward/reverse and front attachment) may have relevance to malfunction of idle speed-up control.
Page 517 TROUBLESHOOTING / Troubleshooting B E-11 Although operating attachment at attach- ment mode, engine speed does not in- crease. Related MC Fault Code: 11004-2, 11918-2 • Refer to the pages for Attachment Operation • In case trouble symptoms E-1 to E-11 are recog- Speed Increase Control in the SYSTEM / Control nized, perform the troubleshooting of these trou- System group in the T/M (Operational Principle).
Page 518 TROUBLESHOOTING / Troubleshooting B E-12 When attachment mode is selected, engine speed does not decrease. Related MC Fault Code: 11004-2, 11918-2 • If trouble symptoms E-1 to E-11 are recognized, perform the troubleshooting of these troubles be- forehand. • Refer to the pages for Attachment Operation Speed Limit Control in the SYSTEM / Control System group in the T/M (Operational Principle).
Page 519 TROUBLESHOOTING / Troubleshooting B (Blank) T5-7-59...
Page 520 TROUBLESHOOTING / Troubleshooting B E-13 Engine stalls during operation under ad- Test Harness (ST 7226) verse condition such as at high altitude. When operating corresponding control lever and switch: ON Related MC Fault Code: 11004-2, 11100-2, 11910-2, 11401-2, 11401-3, 11401-4 •...
Page 521 TROUBLESHOOTING / Troubleshooting B Faulty torque control so- lenoid valve. Open circuit in harness between torque control solenoid valve and MC. T5-7-61...
Page 522 TROUBLESHOOTING / Troubleshooting B E-14 Engine is difficult to start at low tempera- ture. (During cold weather or in cold dis- tricts, engine is difficult to start or does not start even if pre-heated.) Related MC Fault Code: None • •...
Page 523 TROUBLESHOOTING / Troubleshooting B ∞ Ω Faulty glow plug. Faulty glow plug relay, or faulty harness between glow plug relay and glow Connect connector in plug. glow plug relay. Connect terminal #4 (harness end) of connector to machine. Check if voltage at glow plug is 20 to 24 V.
Page 524 TROUBLESHOOTING / Troubleshooting B E-15 Although depressing accelerator pedal Connector (Harness end of connector viewed from the during travel operation, engine speed does open end side) not change. • Check that: Switch Panel Brake Switch: OFF or Axle Lock Position ●...
Page 525 TROUBLESHOOTING / Troubleshooting B E-16 Although depressing accelerator pedal during digging operation, engine speed Connector (Harness end of connector viewed from the does not change. open end side) • Check that: Switch Panel Work Brake: Operable FNR Switch: N Position ●...
Page 526: All Actuator System Troubleshooting
TROUBLESHOOTING / Troubleshooting B ALL ACTUATOR SYSTEM TROUBLE- SHOOTING A-1 All actuator speeds are slow. Related MC Fault Code: 11004-2, 11100-2, 11910-2, 11401-2, 11401-3, 11401-4 • Although speed is satisfactory, and when power is • Reduction in pump 1 and 2 flow rate due to some weak, refer to the troubleshooting for faulty main reasons or faulty pilot system (A-2) may cause relief valve (F-1).
Page 527 TROUBLESHOOTING / Troubleshooting B A-2 All actuator are not operated. • • The pilot shut-off circuit or the electric lever circuit When the key switch is turned to the START posi- may be faulty. tion with the engine stop switch in the ON position, •...
Page 528: Troubleshooting B
TROUBLESHOOTING / Troubleshooting B Check for continuity between terminal #2 (harness end) of connector in security relay and machine. Check for continuity between terminal #3 (harness end) of Connect terminal #5 connector in security (harness end) of con- relay and machine. nector in pilot shut-off Faulty ground in security relay to machine.
Page 529 TROUBLESHOOTING / Troubleshooting B Faulty monitor unit, or shorted circuit in harness between monitor unit and security relay. Faulty pilot shut-off sole- Connect connector noid valve. monitor-B. Check for continuity between terminal #2 (harness end) of connector in pilot shut-off relay and Faulty monitor unit.
Page 530 TROUBLESHOOTING / Troubleshooting B A-3 Single swing operation speed becomes slow. Arm speed is slightly slow during arm level crowding. (All problems occur at the same time.) Related MC Fault Code: None • The pump 2 flow rate is minimized (approx. 20 L/min) due to some reasons.
Page 531 TROUBLESHOOTING / Troubleshooting B A-4 Travel is operated during single travel op- eration. Single bucket operation speed be- comes slow. Boom is not raised properly during arm level crowding. (All problems occur at the same time.) Related MC Fault Code: None •...
Page 532 TROUBLESHOOTING / Troubleshooting B A-5 Although control lever is turned to neutral, actuator does not stop. • Bound spool in the pilot valve or bound main spool in the control valve is suspected. Faulty pilot valve. · When control lever is in neu- tral, pilot pressure is routed to spool end in control valve.
Page 533 TROUBLESHOOTING / Troubleshooting B A-6 Actuator speed is faster than normal Precise control cannot be performed. Related MC Fault Code: None • The pump 1 or 2 flow rate is maximized due to some reasons. Therefore, the maximum flow rate is supplied and actuator speed is faster though the control lever does not reach the full stroke.
Page 534: Front Attachment System Troubleshooting
TROUBLESHOOTING / Troubleshooting B FRONT ATTACHMENT SYSTEM TROU- BLESHOOTING F-1 All front attachment actuator operations are weak. • If operating speeds are extremely slow, pump control may be malfunctioning (A-3, A-4). Faulty pilot system may also cause this trouble. 34.3 to 36.3 MPa Main relief valve should be nor- (350 to 370 kgf/cm , 4990 to 5280 psi)
Page 535 TROUBLESHOOTING / Troubleshooting B F-2 Some cylinders are not operated or speeds are slow. • When other actuators (travel and swing) operate normally, the pilot pump (primary pilot pressure) is considered to be normal. • If single bucket operation speed is slow, refer to F-4.
Page 536 TROUBLESHOOTING / Troubleshooting B F-4 Arm speed is slow during combined opera- tion. Arm speed is slow during arm level crowding. • Related MC Fault Code: 11202-3, 11202-4, 11301-3, Refer to the pages for the SYSTEM / Control 11301-4, 11302-3, 11302-4, 11303-3, 11303-4, System group / Arm Regenerative Control in the 11403-2, 11403-3, 11403-4 T/M (Operational Principle).
Page 537 TROUBLESHOOTING / Troubleshooting B F-4 Bucket is slightly slow during bucket roll-in single operation. Bucket does not move smoothly during bucket roll-in single opera- tion. • Bucket flow rate control valve or bucket regen- erative valve may be faulty. • Refer to the COMPONENT OPERATION / Control Valve group in the T/M (Operational Principle).
Page 538 TROUBLESHOOTING / Troubleshooting B F-5 When starting to move during combined operation, arm does not smoothly move. Arm starts to move slightly slow during arm roll-in single operation. These troubles often occur when temperature is low. • Refer to the COMPONENT OPERATION / Control Valve group in the T/M (Operational Principle).
Page 539 TROUBLESHOOTING / Troubleshooting B F-7 When boom raise or arm roll-out is operated, boom or arm starts to move after moving slightly downward. Faulty anti-drift valve. Check if anti-drift valves (arm and boom) are bound or scored. Check if load check valve in Oil leaks in cylinder.
Page 540 TROUBLESHOOTING / Troubleshooting B F-8 Front attachment drifts remarkably. Normal. Correctly adjust emer- gency valve and lock it Check if emergency Check if each front valve at boom 1 sec- attachment cylin- der drift is within tion in control valve Check if symptom is 4-spool side is cor- specification.
Page 541 TROUBLESHOOTING / Troubleshooting B Emergency Valve Scored control valve spool, broken spring, or loose spool end. Check if oil leaks in cylinders. Faulty cylinder. (Replace seal kit.) Faulty overload relief T16W-03-03-032 valve. TCGB-05-07-001 Adjustment Procedure: Loosen screw (1) fully and tighten lock nut (2). : 4 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) T5-7-81...
Page 542 TROUBLESHOOTING / Troubleshooting B F-9 Attachment speed is fast during combined operation of attachment (optional) and front attachment. When pulverizer or crusher is used. Open circuit in har- • Check the wiring connections first. ness between MC and pressure sensor (aux- Disconnect connec- iliary).
Page 543 TROUBLESHOOTING / Troubleshooting B Check if voltage be- Disconnect connec- tween terminal #D9 tor MC-D in MC. To A (harness end) of Check for continuity connector MC-D and between terminal machine is 0 V. #D9 (harness end) of Disconnect connec- connector and ter- tor in pressure sen- ·...
Page 544 TROUBLESHOOTING / Troubleshooting B F-10 Attachment speed is fast during combined operation of attachment (optional) and front attachment. When breaker attached with auxiliary flow com- Shorted circuit in har- biner line is used. ness between MC and • pressure sensor (aux- Check the wiring connections first.
Page 545 TROUBLESHOOTING / Troubleshooting B Shorted circuit in harness between MC and pres- sure sensor (arm roll-out). Disconnect connector Disconnect connector MC-D in MC. Check if MC-B in MC and con- voltage between ter- Check if auxiliary flow Disconnect connector nector in auxiliary flow minal #D9 (harness combiner solenoid in pressure sensor...
Page 546 TROUBLESHOOTING / Troubleshooting B F-11 Attachment speed is fast during combined operation of attachment (optional) and front attachment. When vibrating hammer is used. Disconnect connec- MC と圧力センサ(予 Open circuit in harness • Check the wiring connections first. tor MC-D in MC. between MC and pres- 備)間のハーネス断線...
Page 547 TROUBLESHOOTING / Troubleshooting B To A Check if voltage be- Disconnect connector tween terminal #C2 (harness end) of con- in pressure sensor (travel forward). nector MC-C and Shorted circuit in harness machine is 0 V. Check if voltage be- between MC and pres- tween terminals #1 ·...
Page 548: Swing System Troubleshooting
TROUBLESHOOTING / Troubleshooting B SWING SYSTEM TROUBLESHOOTING S-1 Swing is slow or unmoving. • • Check whether the pilot system is faulty or the If left travel speed is also slow, refer to A-3. main circuit is faulty. • If other functions (front attachment and travel) operate normally, the pilot pump is considered to be normal.
Page 549 TROUBLESHOOTING / Troubleshooting B Faulty swing reduction gear. Check if swing motor drain oil amount is normal. Faulty swing motor. · Measurement: Check if swing relief Refer to the Operational pressure is normal. Performance Test section. · Relieve swing circuit. ·...
Page 550: Travel System Troubleshooting
TROUBLESHOOTING / Troubleshooting B TRAVEL SYSTEM TROUBLESHOOTING T-1 Machine does not travel. • • The travel system is inoperable unless the fol- Air mixing in the transmission hydraulic circuit lowing conditions are met. may cause the parking brake to drag. Bleed air FNR Switch: F or R position from the transmission by referring to T5-7-130.
Page 551 TROUBLESHOOTING / Troubleshooting B Faulty work brake release switch. Monitor work brake release switch. Check if ON is dis- played. · Monitor item: Disconnect connector in Implement brake de- Faulty MC. solenoid valve unit (SF). active Check if symptoms dis- appear.
Page 552 TROUBLESHOOTING / Troubleshooting B T-2 Machine does not travel forward and re- verse. • Failure in the transmission and/or axle (front and/or rear) may be the cause of the trouble. Check if a noise is emitted from each section. • When other actuators (front attachment and swing) operate normally, the pilot pump, pilot filter and pilot relief valve are considered to be normal.
Page 553 TROUBLESHOOTING / Troubleshooting B Faulty counterbalance valve. Check counterbalance valve in travel motor for Faulty make-up valve. abnormality. Check make-up valve for abnormality. Faulty center joint. Faulty control valve (bound spool). T5-7-93...
Page 554 TROUBLESHOOTING / Troubleshooting B T-3 Forward/reverse travel speeds are slow. Travel power is weak. • • If the travel motor displacement angle control so- When other actuators (front attachment and lenoid valve is faulty, fault code 11422 is dis- swing) operate normally, the pilot pump, pilot filter played.
Page 555 TROUBLESHOOTING / Troubleshooting B Faulty center joint. Measure drain amount from travel motor. Check if drain amount is normal. · Refer to the Opera- Faulty travel motor. tional Performance Test section. T5-7-95...
Page 556 TROUBLESHOOTING / Troubleshooting B T-4 When releasing accelerator pedal, hydraulic brake is not applied. (Machine runs away.) • If the travel motor displacement angle control so- lenoid valve is faulty, fault code 11422 is dis- played. • Similar symptom may appear when the travel pilot valve, travel shuttle valve and/or travel spool is faulty.
Page 557 TROUBLESHOOTING / Troubleshooting B (Blank) T5-7-97...
Page 558 TROUBLESHOOTING / Troubleshooting B T-5 Travel mode (fast/slow) does not shift. Travel Mode Selection • Air mixed in the transmission hydraulic circuit Solenoid Valve may prevent the transmission from being shifted. Port B Port K Bleed air from the transmission by referring to T5-7-130.
Page 559 TROUBLESHOOTING / Troubleshooting B Open circuit in harness between travel mode selection solenoid valve and fast/slow speed selection relay. Disconnect connector in travel mode selection solenoid valve. Faulty travel mode selection solenoid valve (bound spool). Check if voltage at terminal #2 (each With connector in travel harness end) of mode selection solenoid...
Page 560 TROUBLESHOOTING / Troubleshooting B T-6 Axle lock is not released. • Check that the brake switch is in the OFF position first. • Check the wiring connections first. Related MC Fault Code: 11424-2, 11424-3, 11424-4 Refer to troubleshooting A. Faulty operate check valve (axle lock cylinder), or open circuit in Check if fault code is harness between MC and solenoid...
Page 561 TROUBLESHOOTING / Troubleshooting B T-7 Axle lock is not operable. • Check that the brake switch is in the auto axle lock or axle lock position first. • Check the wiring connections first. Related MC Fault Code: 11424-2, 11424-3, 11424-4 Refer to troubleshooting A.
Page 562: Brake System Troubleshooting
TROUBLESHOOTING / Troubleshooting B BRAKE SYSTEM TROUBLESHOOTING B-1 Parking brake is not operable (not applied). • Bleed air from the transmission by referring to T5-7-130 before starting troubleshooting. • If the fast/slow speeds do not change, refer to “T-5 Travel mode (fast/slow) does not shift”. •...
Page 563 TROUBLESHOOTING / Troubleshooting B B-2 Service brake is not operable, or is not applied effectively. • The front and rear wheel service brake circuits are independently designed each other. When either the front or the rear wheel brake circuit fails, overall service brake system will not operate properly.
Page 564 TROUBLESHOOTING / Troubleshooting B B-3 Work brake is not operable. • Check if the brake switch is in the auto axle lock or axle lock position first. • When the brake switch is in the auto axle lock or axle lock position, the work brake is applied. When the brake switch is in the auto axle lock or axle lock position and if the work brake is not applied, the circuit in harness between MC and...
Page 565: Steering System Troubleshooting
TROUBLESHOOTING / Troubleshooting B STEERING SYSTEM TROUBLESHOOTING H-1 Although steering wheel is rotated, steering is heavy. • Check the steering filter first. Faulty steering pump. Disconnect hoses from delivery ports of steering pump and pilot pump. Connect hoses each other to the other side. Faulty steering valve.
Page 566: Other System Troubleshooting
TROUBLESHOOTING / Troubleshooting B OTHER SYSTEM TROUBLESHOOTING O-1 Wiper is not operated. Checking Instructions • • The wiper is driven by electric power routed via When the front window is open, the wiper is not the relay circuit. The relay circuit is controlled by operated.
Page 567 TROUBLESHOOTING / Troubleshooting B Window Contact (Cab end) Connector Wiper Motor (Harness end) INT. Position Setting Time Slow Speed 8 seconds Middle Speed 6 seconds Fast Speed 3 seconds T1V1-05-07-005 Monitor Unit Connector Monitor-A (Harness end) T183-05-05-001 Wiper Driving Circuit Wiper Motor Wiper Relay Main...
Page 568 TROUBLESHOOTING / Troubleshooting B O-2 Air Conditioner is faulty conditioner operation system self-diagnosing function. This system performs the diagnosis by 8-steps as shown in the flow chart be- low: Check Model Confirmation, Display Function Confirmation, Present Trouble Diagnosing, Past Trouble Diagnosing, Sensing Temperature Display, and Component Operation Check, Correction of the Set Temperature and Selection of Celsius and Fahr- enheit Temperature Indication.
Page 569 TROUBLESHOOTING / Troubleshooting B Self-Diagnostic System Activation Fan Switch Air Conditioner Switch Turn the key switch ON while pushing the air condi- tioner switch and mode switch on air conditioner con- trol panel. STEP 0 Check Model Confirmation The liquid crystal display (LCD) indicates the ma- chine model name this system can diagnose.
Page 570 TROUBLESHOOTING / Troubleshooting B STEP 2 Present Trouble Diagnosing The LCD indicates the fault codes for present ab- Fan Switch normalities of the mix door, mode encoder, and/or sensors. • In case any abnormalities are present, the LCD in- dicates the fault codes. If more than one fault code is detected, the following fault code is displayed af- ter flashing (0.5 seconds) twice.
Page 571 TROUBLESHOOTING / Troubleshooting B STEP 3 Past Trouble Diagnosing The LCD indicates the fault codes for past abnor- Fan Switch Air Conditioner Switch malities of the mix door, mode encoder, and/or sen- sors. The past stored fault codes are deleted. •...
Page 572 TROUBLESHOOTING / Troubleshooting B STEP 4 Sensing Temperature Display Fan Mark The LCD indicates the sensing temperature detected Fan Switch Air Conditioner Switch by each temperature sensor (excluding the insulation sensor). • The sensing temperature detected by the in-cab ambient temperature sensor, outdoor ambient tem- perature sensor and coolant temperature sensor are displayed on the LCD in real time.
Page 573 TROUBLESHOOTING / Troubleshooting B Air Conditioner STEP 5 Component Operation Check Switch Fan Switch AUTO Switch Each component operation is checked by performing pattern operation. • Each time the fresh air vent switch is pushed, the component to be checked is selected in order. Check which component has been selected by re- ferring to No.
Page 574 TROUBLESHOOTING / Troubleshooting B STEP 6-1 Correction of the Set Temperature Temperature Fine correction of the set temperature. Control Switch Fan Switch AUTO Switch • Each time when the top or bottom of temperature control switch is pushed, temperature correction, displayed on the LCD window, can be changed.
Page 575 TROUBLESHOOTING / Troubleshooting B STEP 6-2 Selection of Celsius and Fahrenheit Temperature Indication Fan Switch Air Conditioner Switch Selection of Celsius and Fahrenheit Temperature In- dication. • Each time when the fresh air vent switch is pushed, Celsius or Fahrenheit temperature may be dis- played alternately.
Page 576 TROUBLESHOOTING / Troubleshooting B Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to the related post / after experiencing a problem with your machine’s air conditioning system. < AIR CONDITIONER TROUBLE REPORT > File No. (1) What Checked by: Model (Serial No.
Page 577 TROUBLESHOOTING / Troubleshooting B Refrigerant Quantity....... 900±50 g Compressor Oil Quantity....210 cm T5-7-117...
Page 578 TROUBLESHOOTING / Troubleshooting B Cooling Circuit Piping and/or parts are stained with oil, Bubbles can be seen in sight Refrigerant pressure respond to gas detector. glass. in both high and low-pressure sides is low. No oil stain is found or gas detector does not respond.
Page 579 TROUBLESHOOTING / Troubleshooting B Re-tighten or replace parts. Gas leaks from pipe joints and/or parts. Normal leakage of refrigerant from hoses. Refill refrigerant. Improper adjustment (excessive restriction) of expansion valve. Readjust or replace expansion valve. Remove clog, or replace receiver and/or expansion Clogged expansion valve.
Page 580 TROUBLESHOOTING / Troubleshooting B Cooling Circuit Case connection. Louver resonance. Fan contacts case, or foreign matter enters case. Blower fan connection. Brush friction noise, metal and/or thrust washer contact noise. Gas blowing sound (roaring). Gas vibration noise (compressor discharge and/or suc- tion gas noise).
Page 581 TROUBLESHOOTING / Troubleshooting B Repair or replace. Remove foreign matter. Readjust fan motor location. Slight noise is unavoidable. Replace if loud. No functional problem exists. Provide silencer if intolerable. Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard. Replace.
Page 582 TROUBLESHOOTING / Troubleshooting B Compressor Compressor does not rotate. Clutch terminal voltage is normal 24 V. Inoperable Clutch terminal voltage is low. cooling system. Clutch terminal voltage is 0 V. Bubbles exist even after refrigerant is refilled. Both high and Check for oil and refrigerant leaks from parts other than low side compressor and pipe joints by using gas detector.
Page 583 TROUBLESHOOTING / Troubleshooting B Seized clutch. Replace. Improper gap between amature and rotor (improper air gap). Replace. Open or shorted circuit in core cable. Shaft does not rotate (internally locked). Replace. Faulty Electrical System. Faulty Electrical System. Oil leaks from mechanical seal, gasket, and/or charge valve. Replace.
Page 584 TROUBLESHOOTING / Troubleshooting B Compressor Compressor rotation is abnormally draggy. Overheating is susceptible to occur. Refer to the Cooling Circuit Troubleshooting Ta- Trouble other than compressor. ble on page T5-7-118. Noise is heard when clutch is OFF. Abnormal noise Noise is heard when clutch is ON. T5-7-124...
Page 585 TROUBLESHOOTING / Troubleshooting B Broken clutch bearing due to overly tightened belt. Replace. Shaft does n’o rotate. Replace. Shaft rotates draggy. Broken clutch bearing. Replace. Contact or slip due to poor air gap. Faulty idle pulley bearing. Refer to the Cooling Circuit Saggy belt.
Page 586: Exchange Inspection
TROUBLESHOOTING / Troubleshooting B EXCHANGE INSPECTION Exchange inspection method is a troubleshooting method to find the trouble location by exchanging the suspected part/component with another part /component having identical characteristics. Pump 2 Pump 1 Many sensors and solenoid valves used on this ma- (5-Spool (4-Spool chine...
Page 587 TROUBLESHOOTING / Troubleshooting B Applicability of Switch-Check Method Fault Code Trouble Applicability 11000-2 Abnormal EEPROM Not Applicable 11001-2 Abnormal RAM 11002-2 Abnormal A/D Conversion 11003-3 Abnormal Sensor Voltage Not Applicable 11004-2 CAN Communication Error Not Applicable 11100-2 Abnormal Engine Speed Not Applicable 11101-3 Abnormal Engine Control Dial Sensor High Voltage...
Page 588 TROUBLESHOOTING / Troubleshooting B Fault Code Trouble Applicability 11400-2 Abnormal Feedback Current of Maximum Pump 2 Flow Rate Limit Applicable (Harness) Control Solenoid Valve 11400-3 Abnormal Feedback High Voltage of Maximum Pump 2 Flow Rate Limit Control Solenoid Valve 11400-4 Abnormal Feedback Low Voltage of Maximum Pump 2 Flow Rate Limit Control Solenoid Valve 11401-2...
Page 589 TROUBLESHOOTING / Troubleshooting B Fault Code Trouble Applicability 11910-2 Actual Engine Speed Not Applicable 11911-2 Security Signal Not Applicable 11914-2 Radiator Coolant Temperature Not Applicable 11915-2 Gate Lock Signal Not Applicable 11918-2 Word Mode Not Applicable 11920-2 Fuel Flow Rate Not Applicable 11502-2 Travel Motor Excessive Rotation...
Page 590: Bleeding Air From Transmission
TROUBLESHOOTING / Troubleshooting B BLEEDING AIR FROM TRANSMISSION IMPORTANT: Release pressure transmission after removing/installing the pipe lines or hoses, or changing the hydraulic oil. If air is mixed in the transmission gearshift circuit, malfunction of the transmission may result. NOTE: Bleed air by two or more persons. TCJB-01-02-020 1.
Page 591: Bleeding Air From Brake (Axle)
TROUBLESHOOTING / Troubleshooting B BLEEDING AIR FROM BRAKE (AXLE) IMPORTANT: If air is mixed in the brake system, brake function reduced, possibly resulting in serious hazard. Be sure to bleed air from the brake system after disconnecting reconnecting the pipe lines, or changing the hydraulic oil.
Page 592: Emergency Boom Lowering Procedure (Without Hose Rupture Valve)
TROUBLESHOOTING / Troubleshooting B EMERGENCY BOOM LOWERING PROCEDURE (WITHOUT HOSE RUPTURE VALVE) CAUTION: Do not stay under the boom during operation. Boom 1 If the engine stalls and cannot be restarted, lower the boom to lower the bucket to the ground referring to the emergency boom lowering procedure stated below.
Page 593 TROUBLESHOOTING / Troubleshooting B ATTACHMENT CIRCUIT PRESSURE RELEASE PROCEDURE As for the machine, attached with the attachment, the accumulator is equipped between the pilot pump and the pilot valve. Set the pilot shut-off lever to the UNLOCK position. After stopping the engine with the engine stop switch and when operating the control lever, the accumulator will perform pressure release procedure in the pilot circuit.
Page 594 TROUBLESHOOTING / Troubleshooting B (Blank) T5-7-134...
Page 595: Precautions For Inspection And Maintenance
TROUBLESHOOTING / Electrical System Inspection PRECAUTIONS FOR INSPECTION AND MAINTENANCE 1. Disconnect the power source. Remove the harness from the negative terminal side in battery first when taking wire harnesses and connectors off for repair or replacement work. Failure to do so can result in damage to the wire harnesses, fuses and fusible links and, in some cases, cause fire due to short circuiting.
Page 596 TROUBLESHOOTING / Electrical System Inspection 3. Precautions for connecting and disconnecting terminal connectors. • When disconnecting the harnesses, grasp them by their connectors. Do not pull on the Correct Incorrect wire itself. Release the lock first before attempting to separate connectors, if a lock is provided.
Page 597: Instructions For Disconnecting Connectors
TROUBLESHOOTING / Electrical System Inspection INSTRUCTIONS DISCONNECTING CONNECTORS • Push, Unlock and Separate Type NOTE: 1. Connectors will not be easily separated even if the lock is pushed while being pulled. Push the lock first before pulling the connectors. 2 The lock is located on female side connector (harness end side).
Page 598: Fuse Inspection
TROUBLESHOOTING / Electrical System Inspection FUSE INSPECTION Cracks in a fuse are so fine that it is very difficult or NOTE: All terminals located along the lengthwise impossible to find by visual inspection. Use a tester in centerline of the fuse box are connected to order to correctly inspect fuse continuity by following the power source, while terminals located the instructions described below.
Page 599 TROUBLESHOOTING / Electrical System Inspection Fuse No. Capacity Connected to Fuse No. Capacity Connected to 20 A Boom Light Relay 10 A Clearance Light Relay (Right) 10 A Wiper Relay, Washer Relay, 10 A Head Light Relay (Right) Wiper Motor 20 A Compressor Relay,...
Page 600: Fusible Link Inspection
TROUBLESHOOTING / Electrical System Inspection FUSIBLE LINK INSPECTION Battery Relay Inspection 1. Visually inspect the fusible link. Replacement 1. Remove the negative cable from the battery. 2. Pull out the fusible link. Replace the fusible link. 3. Install the negative cable to the battery. Fusible Link M178-07-049 Fusible Link...
Page 601: Battery Voltage Check
TROUBLESHOOTING / Electrical System Inspection BATTERY VOLTAGE CHECK 1. Turn the key switch OFF. Check voltage between the battery positive terminal and the vehicle frame. Normal Voltage: 24 V NOTE: If voltage is abnormal, recharge or replace To Battery Relay the battery.
Page 602: How To Check Alternator
TROUBLESHOOTING / Electrical System Inspection HOW TO CHECK ALTERNATOR Monitor Unit Generally, if the alternator has generated electricity, alternator alarm will disappear. If the alternator alarm displays while the engine is running, the alternator might be defective. How to Check Alternator 1.
Page 603: Continuity Check
TROUBLESHOOTING / Electrical System Inspection CONTINUITY CHECK Harness Single-line continuity check Disconnect both end connectors of the harness and check continuity between both ends: If the ohm-meter reading is: 0 Ω = Continuity ∞ Ω = Discontinuity Ω NOTE: When the one end connector is far apart from the other, connect one end of connector (A) to the machine chassis using Connect to the...
Page 604: Voltage And Current Measurement
TROUBLESHOOTING / Electrical System Inspection VOLTAGE AND CURRENT MEASUREMENT Turn key switch ON so that the specified voltage (current) is supplied to the location to be measured. Judge if the circuit is normal by evaluating whether the measured voltage (current) matches the specification. 24-Volt Circuit Start checking the circuit in order up to the location to be measured from either power...
Page 605 TROUBLESHOOTING / Electrical System Inspection Key Switch Fuse Load Damp Relay Battery Relay Battery Starter Relay Glow Plug Relay Alternator Glow Plug Monitor Unit TCJB-05-08-001 T5-8-11...
Page 606 TROUBLESHOOTING / Electrical System Inspection Engine Key Switch Location to be Measured Specification Starting Circuit Started START Between (18) and (E): Key Switch 20 to 25 V Started START Between (19) and (E): Battery Relay (Coil) 20 to 25 V Started START Between (20) and (E): Battery Relay (Switch)
Page 607 TROUBLESHOOTING / Electrical System Inspection Starter Cut Relay Battery Fuse Starter Starter Relay Main Relay Option Monitor Unit Controller TCJB-05-08-001 T5-8-13...
Page 608 TROUBLESHOOTING / Electrical System Inspection Engine Location to be Measured Specification Switch Pilot Shut-Off Circuit Stopped Between (34) and (E): Fuse Box 20 to 25 V Stopped Between (35) and (E): Pilot Shut-Off Relay 20 to 25 V Stopped Between (36) and (E): Pilot Shut-Off Solenoid Valve 20 to 25 V Stopped...
Page 609 TROUBLESHOOTING / Electrical System Inspection Battery Battery Relay Fuse Box Pilot Shut-Off Solenoid Security Pilot Relay Shut-Off Relay 38 37 TCJB-05-08-001 T5-8-15 Fuse...
Page 610 TROUBLESHOOTING / Electrical System Inspection 5 Voltage Circuit Signal or Power • Ground Voltage between terminal #1 and the vehicle Source Two Polarities frame Disconnect the connector with the key switch OFF. Measure voltage between terminal #1 on the machine harness end connector and the vehicle frame (ground).
Page 611: Check By False Signal
TROUBLESHOOTING / Electrical System Inspection CHECK BY FALSE SIGNAL Two Polarities Turn the key switch OFF. Disconnect the sensor (Hydraulic Oil Temperature Sensor) (Fuel Sensor) connector. Turn the key switch ON. Connect terminal #1 (power source) of machine harness end connector to terminal #2 (signal).
Page 612: Test Harness
TROUBLESHOOTING / Electrical System Inspection TEST HARNESS Install a test harness between connectors. Check the circuit condition depending on whether the test harness lamp lights or extinguishes during operation. Parts Number 4283594 (ST 7126) Use in order to check a single-line (discontinuity and/or voltage).
Page 613 M E M O ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 614 M E M O ........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 615 Hitachi Construction Machinery Co. Ltd Hitachi Ref. No. Attn: Publications, Marketing & Product Support Fax: 81-29-831-1162 SERVICE MANUAL REVISION REQUEST FORM NAME OF COMPANY: MODEL: PUBLICATION NO.: (Located at the right top corner in the cover page) YOUR NAME: PAGE NO.: DATE: (Located at the bottom center in the page.
Page 616 THE ATTACHED DIAGRAM LIST (The following diagrams are attached to this manual.) 1. ELECTRICAL CIRCUIT DIAGRAM (STANDARD) (ZX140W-3: Up to serial No.002747/ ZX140W-3-AMS: Up to serial No.021417) ELECTRICAL CIRCUIT DIAGRAM (STANDARD) (ZX140W-3: Serial No.002748 and up/ ZX140W-3-AMS: Serial No.021418 and up) 2.
Page 617 THE ATTACHED DIAGRAM LIST 9. BLADE / OUTRIGGER HARNESS LICENSE PLATE HARNESS 10. POSITIONING HARNESS PRESSURE SENSOR (POSITIONING) HARNESS 11. SWING PARKING BRAKE RELEASE HARNESS 12. ENGINE SUB HARNESS (1) ENGINE SUB HARNESS (2) 13. BACK LAMP RELAY HARNESS (ZX140W-3: Up to serial No.002747/ ZX140W-3-AMS: Up to serial No.021417) BACK LAMP RELAY HARNESS (ZX140W-3: Serial No.002748 and up/ ZX140W-3-AMS: Serial No.021418 and up) 14.