t05 PDF

SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 General Group 3 Troubleshooting A
Introduction ..............................................T5-1-1 Troubleshooting A Procedure ...................T5-3-1
Diagnosing Procedure ..............................T5-1-2 Fault Code List .........................................T5-3-2
Built-In Diagnosing System Operation ......T5-1-4 Fault Code 01, 02, 03 ...............................T5-3-3
Built-In Diagnosing Function Display List ..T5-1-5 Fault Code 04...........................................T5-3-3
Dr. EX Operation ......................................T5-1-6 Fault Code 06...........................................T5-3-4
Dr. EX Fault Code List ..............................T5-1-7 Fault Code 07...........................................T5-3-5
Dr. EX Monitoring Item List.......................T5-1-8 Fault Code 10, 11 .....................................T5-3-6
Dr. EX Special Function..........................T5-1-10 Fault Code 12, 13 .....................................T5-3-7
Dr. EX Service Mode ..............................T5-1-12 Fault Code 14, 15, 16, 18 .........................T5-3-8
Adjustment Data List ..............................T5-1-22 Fault Code 19...........................................T5-3-9
Sensor Activating Range ........................T5-3-10
Group 2 Component Layout
Main Component Layout...........................T5-2-1 Group 4 Troubleshooting B
Electrical Component Layout (Overview) ..T5-2-2 Troubleshooting B Procedure ...................T5-4-1
Electrical System (Relays)........................T5-2-3 Relationship between Machine Trouble
Electrical System Symptoms and Related Parts..................T5-4-2
(Monitors and Switches) .........................T5-2-4 Correlation between Trouble
Engine......................................................T5-2-5 Symptoms and Part Failures .................T5-4-16
Pump Device............................................T5-2-5 Engine System Troubleshooting .............T5-4-27
Swing Device ...........................................T5-2-5 All Actuator System Troubleshooting ......T5-4-46
Control Valve............................................T5-2-6 Front Attachment System
Solenoid Valve Unit ..................................T5-2-6 Troubleshooting ....................................T5-4-52
Travel Device ...........................................T5-2-6 Swing System Troubleshooting...............T5-4-66
Shockless Valve .......................................T5-2-6 Travel System Troubleshooting...............T5-4-69
Components in Control Valve ...................T5-2-8 Other System Troubleshooting ...............T5-4-76
Engine Speed Adjustment and
Engine Learning ...................................T5-4-94
Exchange Inspection ..............................T5-4-96
Emergency Boom Lowering Procedure ...T5-4-98
1HHT-5-1
Group 5 Troubleshooting C Group 7 ICX
Troubleshooting C Procedure ...................T5-5-1 Outline .....................................................T5-7-1
Malfunction of Coolant ICX Fault Code List ..................................T5-7-6
Temperature Gauge................................T5-5-2 Satellite Terminal Fault Code List .............T5-7-6
Malfunction of Fuel Gauge .......................T5-5-4 Fault Code 1 to 4 and 6 ............................T5-7-7
Malfunction of Indicator Light Fault Code 7 to 10 ....................................T5-7-7
Check System ........................................T5-5-6 Some Parts of Data in Daily Report,
Malfunction of Preheat Indicator ...............T5-5-7 Frequency Distribution, Cumulative
Malfunction of Engine Oil Level Operation Hours are not Recorded .........T5-7-8
Indicator .................................................T5-5-8 Troubleshooting and Setting of ICX and
Malfunction of Coolant Level Satellite Terminal Using Dr. EX .............T5-7-10
Indicator ...............................................T5-5-10 Satellite Communication System ............T5-7-27
Malfunction of Alternator Indicator ..........T5-5-12
Malfunction of Engine Oil Pressure
Indicator ...............................................T5-5-14
Malfunction of Overheat Indicator ...........T5-5-16
Malfunction of Air Filter Restriction
Indicator ...............................................T5-5-18
Malfunction of Buzzer .............................T5-5-20
Malfunction of LCD.................................T5-5-22
Malfunction of Hour Meter ......................T5-5-23
Malfunction of Hydraulic Oil Filter
Indicator (Optional) ...............................T5-5-24
Group 6 Electrical System Inspection

Precautions for Inspection and
Maintenance ...........................................T5-6-1
Instructions for Disconnecting
Connectors .............................................T5-6-3
Fuse Inspection........................................T5-6-4
Fusible Link Inspection .............................T5-6-5
Battery Voltage Check ..............................T5-6-6
How to Troubleshoot Alternator
Malfunctions ...........................................T5-6-7
Continuity Check ......................................T5-6-8
Voltage and Current Measurement .........T5-6-10
Check by False Signal ............................T5-6-13
Test Harness ..........................................T5-6-14
1HHT-5-2
TROUBLESHOOTING / General
INTRODUCTION
Refer to the inspection and troubleshooting procedures

after any machine trouble has occurred. The inspec-
tion and troubleshooting procedures are presented in
an orderly fashion in this section to quickly find the
cause of the machine trouble and solution.
The troubleshooting section in this manual consists of

7 groups; General, Component Layout, Troubleshoot-
ing A (base machine diagnosis using fault codes),
Troubleshooting B (base machine diagnosis starting
with inspection of abnormal operational status), Trou-
bleshooting C (monitor diagnosis), Electrical System
Inspection, and ICX.
• General • Electrical System Inspection

Refer to this group when required to obtain pre-
• Component Layout cautions and/or information for the electrical sys-
tem inspection.
• Troubleshooting A (base machine diagnosis using
fault codes) Example: Fuse Inspection
Refer to these procedures if any fault codes are
displayed when the main controller (MC) is diag- • ICX
nosed with Dr. EX. (or the built-in diagnosing sys- Refer to these procedures after any fault code is
tem) displayed after diagnosing ICX (Information Con-
(MC self-diagnosing function retains a record of troller) or the satellite terminal (optional) with Dr.
the electrical signal system malfunction in the EX. (The controller self-diagnosing function re-
form of fault codes.) tains a record of the electrical signal system mal-
function in the form of fault codes.)
Example: Fault Code 06: Abnormal EC Sensor
Example: ICX Fault Code 7: MC Communication
• Troubleshooting B (base machine diagnosis start- Time Out
ing with inspection of abnormal operational status)
Refer to these procedures when no fault codes In addition, information on the following items is
are displayed after diagnosing the machine with described in this group.
Dr. EX (or the built-in diagnosing system). Trace (1) Trouble shooting and setting procedures of
the cause of trouble based on the inspected result ICX and satellite terminal using Dr. EX.
of the abnormal symptom. (2) Information on the satellite communication
system
Example: Even if the engine control dial is oper-
ated, engine speed remains unchanged.
• Troubleshooting C (monitor diagnosis)

Refer to these procedures when gauges and/or
indicators are malfunctioning.
Example: Malfunction of fuel gauge
T5-1-1
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient trou-

bleshooting:
1. Study the System

Study the machine’s technical manuals. Know the
system and how it works, and what the construc-
tion, functions and specifications of the system
components are.
2. Ask the operator T107-07-01-001

Before inspecting, get the full story of malfunc-
tions from your star witnessΆthe operator.
(a) How is the machine being used? (Find out if

the machine is being operated correctly)
(b) When was the trouble noticed, and what

types of work the machine doing at that time?
(c) What are the details of the trouble? Is the

trouble getting worse, or did it appear sud-
denly for the first time?
(d) Did the machine have any other troubles pre-

viously? If so, which parts were repaired be-
fore?
T107-07-01-002
3. Inspect the machine

Before starting the troubleshooting procedure,
check the machine’s daily maintenance points, as
shown in the operator's manual.
Also, check the electrical system, including the

batteries, as troubles in the electrical system such
as low battery voltage, loose connections and
blown fuses will result in malfunction of the con-
trollers, causing total operational failure of the
machine.
If troubleshooting is started without checking for
blown fuses, a wrong diagnosis may result, wast-
ing time. Be sure to check for blown fuses before
troubleshooting. Even if a fuse looks normal by
visual inspection, a fine crack is difficult to find.
Always use a tester when checking the fuses.
T107-07-01-003
T5-1-2
4. Operate the machine yourself
Try to identify the trouble by operating the ma-
chine yourself.
If the trouble cannot be confirmed, stop the en-
gine and obtain further details of the malfunction
from the operator.
Also, check for any incomplete connections of the
wire harnesses.
5. Perform troubleshooting
CAUTION: Never attempt to disconnect har-
nesses or hydraulic lines while the engine is
running. The machine may malfunction or T107-07-01-005
pressurized oil may spout, possibly resulting

in personal injury. Be sure to stop the engine
before disconnecting harnesses or hydraulic
lines.
Perform self-diagnosis by connecting Dr. EX to

the machine or by operating the built-in diagnos-
ing system. In case any fault code has been dis-
played by diagnosis using Dr. EX (or the built-in
diagnosing system), delete the fault code once
and retry self-diagnosis again. If the fault code is
displayed again, check the cause of the trouble by
referring to Troubleshooting A in this section. After
the machine trouble has been corrected, the fault
code (displayed by the built-in diagnosing func-
tion) will be deleted. Therefore, in case problems T107-07-01-006
which are not easily re-predicable are encoun-
tered, use Dr. EX to display the fault code. In case
no fault codes are displayed, check all related
parts/component operating condition using the
monitor function of Dr. EX (or the built-in diagnos-
ing system) while referring to troubleshooting B in
this section.
ҰNote that the fault codes displayed do not nec-

essarily indicate machine trouble. The controller
stores even temporary electrical malfunctions,
such as a drop in battery output voltage or dis-
connections of the switches, sensors, etc., for in-
spections. T107-07-01-007
For this reason, the “RETRIAL” is required to
erase the accumulated fault codes from the con-
troller memory and to confirm if any fault codes
are indicated after the “RETRIAL”.
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 appro-
priate repairs to avoid consequent malfunctions.
T5-1-3
BUILT-IN DIAGNOSING SYSTEM OPERA-
TION
IMPORTANT: This system is to be operated by the
HITACHI Dealer Only. Don’t explain
this system function to the cus-
tomer.
In the service mode, the monitor LCD displays the

diagnosing items, fault codes and monitored results
(not all of them) without using Dr. EX.
Built-In Diagnosing System Activation

1. While pressing the monitor SET switch, turn the
key switch ON.
Display Selection
NOTE: Even if the engine is running, the built-in Switch
diagnosing system is operable.
SET Switch
System Operation
1. Each time the display selection switch is pressed,
the displayed item will be changed as shown on
next page.
LCD
NOTE: The fault code is indicated in the display
order 8. All fault codes (refer to Dr. EX fault
code list) can be indicated. In case more
than one fault code is indicated, they will be
displayed with an interval of 1 second in or-
der. After the machine malfunction has
been repaired, the fault codes are auto-
matically deleted. Accordingly, if any trouble,
which is not reproducible, is encountered, it
T178-01-02-008
is recommended to use Dr. EX.
• The built-in diagnosing system displays only the item
No. on the left and the monitored result on the right.
The item description is not displayed.
T5-1-4
BUILT-IN DIAGNOSING FUNCTION DIS-
PLAY LIST
Display
Description Monitored Result Unit Remarks
Order
1 Hour Meter {{{{{ h Standard Mode
2 Trip 1 {{{{{ h Standard Mode (Subtraction)
3 Trip 2 {{{{{ h Standard Mode (Subtraction)
-1
4 Engine Actual Speed n {{{{ min User Mode (Required to set in
the Dr. EX service mode)
5 Hydraulic Oil Tempera- {{{ °C User Mode (Required to set in
ture the Dr. EX service mode)
6 L1 {{{ − Display Purpose Only
7 Overload Alarm L2 {{{ % European Spec. Only
8 Fault Code* 0 {{ − Possible to display
9 ML Switch** 1 {{ 0: Switch OFF Possible to display
1: Switch ON
10 Pump 1 Delivery Pres- 2 {{ MPa Possible to display
sure
11 Pump 2 Delivery Pres- 3 {{ MPa Possible to display
sure
12 Pump 1 Pump (Flow) 4 {{ MPa Possible to display
Control Pressure
13 Pump 2 Pump (Flow) 5 {{ MPa Possible to display
Control Pressure
-1
14 Engine Target Speed 6 {{ min Possible to display
15 EC Angle 7 {{ V Possible to display
16 Dial Angle 8 {{ V Possible to display
17 Boom Raise Pilot Pres- 9 {{ MPa Possible to display
sure
18 Arm Roll-In Pilot Pres- A {{ MPa Possible to display
sure
19 Swing Control Pilot b {{ MPa Possible to display
Pressure
20 Travel Control Pilot c {{ MPa Possible to display
Pressure
21 Front Att. Operation d {{ 0: Not Operating Possible to display
1: Operating
22 Att. Control Pressure E {{ MPa Possible to display
23 Work Mode F {{ 0: Digging Possible to display
1: Breaker
2: Secondary
Crusher
(Demolisher)
3: Crusher
4: Vibro-Hammer
NOTE: * Refer to T5-1-7 for the Fault Codes.

** ML specification is only available in Japanese domestic market.
T5-1-5
Dr. EX OPERATION
Rear Console
Dr. EX is a troubleshooting tool to diagnose the elec- Fuse Box
tronic control system including the MC (main Control-
ler) and ICX (Information Controller). When Dr. EX is
Dr. EX Connector
connected to either the MC or the ICX, it displays (MC)
whether the controllers and sensors operate normally
in the form of fault codes (Diagnosing Result Display
Function).
In addition, Dr. EX can display the inputs from sensors
and switches to the MC and/or the outputs to actuators
such as solenoid valves from the MC in real time while
operating the machine (Monitor Display Function).
NOTE: This group describes how to operate Dr. EX

connected to the MC. Refer to Group 7
“ICX” for operation of Dr. EX connected to
the ICX. Dr. EX Connector
(ICX)
Operation
1. Connect the Dr. EX harness to the diagnosis con- T178-01-02-006
nector in the cab.
IMPORTANT: The Dr. EX harness functions the Start
diagnosing switch so that be sure to
use the specified one.
2. Turn the key switch ON, or start the engine.
3. When the Dr. EX power is turned ON, Dr. EX dis- Title Screen
plays the following screens in order.
3-1. Title Screen
3-2. Model Name Screen
Model Name
(Example) Model: ZX330 Cannot Confirmation
3-3. Function Selection Screen Communicate
F1: Diagnosing Result
· Check harness.
F2: Monitor Display NOT OK
· Check fuse.
F3: Special Functions OK ?
NOTE: Special functions allow the ECO and WU OK

Replace software.
deactivation. (Refer to T5-1-10)
4. Select F1. Then, continue to operate Dr. EX by Self-Diagnosing

following instructions to be displayed at the screen Result Display Special
bottom hereafter. Function Select Monitor Function
function.
NOTE: Refer to the Dr. EX Operation Manual for
the detailed operation of Dr. EX. Self-diagnosing
result by controller Select data to
is displayed. Record.
be monitored.
Monitored data
Retry B is displayed.
Self-diagnosing
result is displayed.
T5-1-6
Dr. EX FAULT CODE LIST
Fault Code Trouble Cause

01 Abnormal EEPROM • Faulty MC
02 Abnormal RAM
03 Abnormal A/D Conversion
04 Abnormal Sensor Voltage • Faulty MC
• Faulty Harness
• Faulty Sensor
06 Abnormal EC Sensor • Faulty MC
• Faulty Harness
• Faulty EC Sensor
07 Abnormal Engine Control Dial Angle • Faulty MC
• Faulty Harness
• Faulty Engine Control Dial
10 Abnormal Pump 1 Delivery Pressure • Faulty MC
11 Abnormal Pump 2 Delivery Pressure • Faulty Harness
• Faulty Pump Delivery Pressure Sensor
12 Abnormal Pump1 Pump Control Pressure • Faulty MC
13 Abnormal Pump2 Pump Control Pressure • Faulty Harness
• Faulty Pump Control Pressure Sensor
14 Abnormal Swing Pilot Pressure • Faulty MC
15 Abnormal Boom Raise Pilot Pressure • Faulty Harness
16 Abnormal Arm Roll-In Pilot Pressure • Faulty Pilot Pressure Sensor
18 Abnormal Travel Pilot Pressure
19 Abnormal Hydraulic Oil Temperature Sen- • Faulty MC
sor • Faulty Harness
• Faulty Hydraulic Oil Temperature Sensor
T5-1-7
Dr. EX MONITORING ITEM LIST
Dr. EX displays the input signals from the switches and

sensors to the MC and the control signals to the actua-
tors from the MC.
Item Data Unit

Pump 1 Delivery Pressure Input signals from pump 1 delivery pressure sensor MPa
Pump 1 Pump (Flow) Con- Input signals from pump 1 control pressure sensor MPa
trol Pressure
Pump 2 Delivery Pressure Input signals from pump 2 delivery pressure sensor MPa
Pump 2 Pump (Flow) Con- Input signals from pump 2 control pressure sensor MPa
trol Pressure
3
Pump 2 Max. Displacement cm
-1 -1
Engine Target Speed Target speed when loaded. Approx. 150 min differs min
from speed when unloaded.
-1
Engine Actual Speed Input signal from N sensor min
-1
Deviation in Engine Speed Calculated Value min
(Engine Speed Differential) ( Target Engine Speed - Actual Engine Speed)
EC Angle Input signal from EC sensor V
Dial Angle Input signal from engine control dial V
Boom Raise Pilot Pressure Input signal from pressure sensor (boom raise) MPa
Arm Roll-In Pilot Pressure Input signal from pressure sensor (Arm Roll-In) MPa
Swing Control Pressure Input signal from pressure sensor (swing) MPa
Travel Control Pressure Input signal from pressure sensor (travel) MPa
Front Att. Operation Input signal from pressure sensor (front att.) FR
Hydraulic Oil Temperature Input signal from oil temperature sensor °C
E/P/HP Mode Switch Power mode switch selection status E, P, HP
Auto-Idle/Auto-Accel Switch Auto-Idle/Acceleration selection status AI, AA
Travel Mode Travel mode switch selection status Lo, Hi
Power Digging (Boost) Power digging switch status Pd
Switch
Key Switch Key switch selection status Ky
Work mode Work mode switch selection status
ATT. Mode
Engine Learning Status Done, Undone,
Aborted Ky
Pump 2 Proportional Sole- Control signal to max. pump 2 flow rate limit solenoid MPa
noid Valve Output valve
Pump Torque Proportional Control signal to torque control solenoid valve MPa
Solenoid Valve Output
Arm Regenerative Propor- Control signal to solenoid valve SC MPa
tional Solenoid Valve Out-
put
Power Digging (Boost) Con- Control signal to solenoid valve SG MPa
trol Pressure
Travel Motor Control Pres- Control signal to solenoid valve SI MPa
sure
EC Motor Position step
T5-1-8
Optional
Item Data Unit
Optional Pump 3 Delivery Pressure Input signal from pump 3 delivery pressure sensor MPa
Boom Cylinder Bottom Pressure MPa
Boom Cylinder Rod Pressure MPa
ATT. Control Pressure Input signal from pressure sensor (auxiliary) MPa
Boom Angle V
Arm Angle V
3
Pump 1 Max. Displacement cm
Pump 1 Proportional Solenoid Valve Control signal to pump 1 flow rate control solenoid MPa
Output valve
Travel/Swing/Overload Alarm Tr, Sw, Load
Initial ML Setting Unf, Done, Abrt,
Und
Initial Boom-Angle Setting Unf, Done, Abrt,
Und
NOTE: ML specification is only available in Japa-

nese domestic market.
T5-1-9
Dr. EX SPECIAL FUNCTION
HITACHI
Special function related to Dr.EX screen panels,
Dr.EX
beginning with the start screen, are shown along
VER
**** with the corresponding Dr.EX key operations.
However, Dr.EX screen panels which are not
related to the Dr.EX key operation are excluded.
(C)Hitachi Construction
Machinery Co.,Ltd. 1996
F1: Start F10: Model Menu
F1 Press
(Example) Model : ZX200
(Example) Ver : 0400
Is model correct?
F1: Correct F10: ESC
F1 Press
Special Functions NOTE: Refer to T4-2-2.
F6: WU Deactivation
F7: ECO Deactivation 2
F8:
F5: ESC
F7 Press
T5-1-10
1 2
ECO Deactivation?
Push key F1 or F5
F5 Press
F1: Execute F5: ESC
F1 Press
ECO Deactivated.
F5 Press
F5: ESC
T5-1-11
Dr. EX SERVICE MODE
Dr. EX has three (3) modes, learning value display,

parameter change, and monitor display information
setting.
Learning Value Display

Displays the values set by learning function.
Parameter Change
Engine speed, pump delivery flow rate, and solenoid
valve output pressure can be adjusted. Fuse Box
Rear Console
Monitor Display Information Setting

Engine
Items to be displayed on the monitor LCD can be Learning
added. Switch
• Accessing Service Mode

1. After turning the key switch OFF, wait for more
than 10 seconds.
2. Connect Dr. EX to the connector on the base ma-
chine.
3. Turn the engine learning switch to the learning
position (E side).
4. Turn the key switch ON. Don’t start the engine at
this time.
5. Turn Dr. EX switch ON.
T178-01-02-006
T5-1-12
Item Data
Learning Data Display
EC Motor Stop Position Display of the engine stop value in engine learning
EC Motor Maximum Speed Position Display of max. engine speed valve in engine learning
Boom Angle Sensor Correction Value Display of boom angle sensor correction value
Arm Angle Sensor Correction Value Display of arm angle sensor correction value
Parameter Change
Li Speed Adjustment Adjustment of minimum engine speed
WU Speed Adjustment Adjustment of warming up engine speed
AI Speed Adjustment Adjustment of auto-idle engine speed
E Speed Adjustment Adjustment of E-mode engine speed
P Speed Adjustment Adjustment of P-mode engine speed
Breaker Engine Speed Adjustment Adjustment of breaker operation engine speed
Secondary Crusher (Demolisher) Engine Adjustment of secondary crusher (demolisher) operation en-
Speed Adjustment gine speed
Crusher Engine Speed Adjustment Adjustment of crusher operation engine speed
Vibro-Hammer Speed Adjustment Adjustment of vibratory hammer operation engine speed
Hyd. Breaker P1 Max Swash Angle Adjust- Adjustment of lowest pump 1 max. flow rate in breaker opera-
ment tion
Secondary Crusher (Demolisher) P1 Max Adjustment of lowest pump 1 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P1 Max Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in crusher opera-
tion
Vibro P1 Max Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in vibratory ham-
mer operation
Hyd. Breaker P2 Max Swash Angle Adjust- Adjustment of lowest pump 2 max. flow rate in breaker opera-
ment tion
Secondary Crusher (Demolisher) P2 Max Adjustment of lowest pump 2 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P2 Max Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in crusher opera-
tion
Vibro P2 Max Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in vibratory ham-
mer operation
Pump PQ Base Torque Correction Adjustment of pump P-Q curve
ATT Speed Increase Down Waiting Time Setting of time required for engine speed increase
Min, Boom CYL. Bottom Pressure Over Bal-
ance
Monitor Display Change
Engine Actual Speed Display/Non-display Monitor setting of display/no-display of actual engine speed
Hydraulic Oil Temperature Display/No-display Monitor setting of display/no-display of hydraulic oil tempera-
ture
Hydraulic Oil Filter LED Display/No-display Monitor setting of ON/OFF of hydraulic oil filter LED.
NOTE: ML specification is only available in Japanese domestic market.
T5-1-13
HITACHI
Service mode related to Dr.EX screen panels,
Dr.EX
beginning with the start screen, are shown along
VER
**** with the corresponding Dr.EX key operations.
However, Dr.EX screen panels which are not
related to the Dr.EX key operation are excluded.
(C)Hitachi Construction
Machinery Co.,Ltd. 1996
F1: Start F10: Model Menu
F1 Press
(Example) Model : ZX200
(Example) Ver : 0400
Is model correct?
F1: Correct F10: ESC
F1 Press
Service mode selected.
In service mode, self-diagnostic

operation and/or monitor display
will not be conducted.
F1: Rechecked F5: ESC
F1 Press
T5-1-14
Select Functions
F3: Special Functions
4
F5: ESC
F8 Press
F3 Press
Select Functions Select item

F6: EC Motor Stop
F6: Learning Data Display Position
F6 Press F7: EC Motor Maximum
F7: Parameter Change Speed Position
F8: Boom Angle Sensor
F8: Monitor Display Correction Value
F5: ESC F3: Next F5: ESC
F7 Press F6 Press F5 Press
Select item EC Motor Stop Position

F6: Li Speed Adjustment
Refer to Learning data
F7: WU Speed Adjustment adjustment data −200 digit is displayed
list.
F8: AI Speed Adjustment
F3: Next F5: ESC F5: ESC
F3 Press
Select item
F6: Hyd. Breaker P1 Max.
Swash Angle Adj.
F7: Vibro P1 Max Swash An example of “F6: Hyd. Breaker P1 Max. Swash Angle
Angle Adjustment Adj” operation is shown on the next page.
F8: Demolisher P1 Max.
Swash Angle Adj.
F3: Next F4: Prev. F5: ESC
F6 Press
T5-1-15
Hyd. Breaker P1 Max. Hyd. Breaker P1 Max.

Swash Angle Adj. Swash Angle Adj. HELP
Adjustable range in HELP F7 Press Adjustable range:
3
+51.0 to +112.8 cm
3
Input the adjusting Initial: +112.8 cm
deviation you want. F5 Press Minimum Adjusting Deviation:
3
+0.6 cm
F3: Next F5: ESC F7: HELP F5: ESC
F3 Press
Hyd. Breaker P1 Max.

Swash Angle Adj.
F7 Press
123
3
Current : +112.8 cm
3
Adjustment : cm
F1: Execution F2: Corr F5 Press

F4: Prev. F5: ESC F7: HELP
“-100” is entered as an example here.
4 Press
5 Press
F1 Press
∗ Adjusting Deviation ∗
∗ Data Confirmation ∗
Adjusting Deviation Data Name:

Swash Angle Adj.
F3: Next F5: ESC
F3 Press F4 Press
3
Current : +27.0 cm
3
Adjustment : 45 cm
F1: Execute
F4: Prev. F5: ESC
F1 Press
T5-1-16
Adjustment was made as follows:
Adjusting Deviation Data Name:

Swash Angle Adj.
F3: Next
F1 Press
3
Current : +27.0 cm
3
Adjustment : 45 cm The last screen for the “Hyd. Breaker P1 Max.
Swash Angle Adj.” will be displayed.
F4: Prev. F5: ESC
Turn off Dr.EX
End
T5-1-17
Select item
F6: Engine Actual Speed
F7: Hydraulic Oil Temp
F8: Hyd. Oil Filter LED
F3: Next F5: ESC

6
F6 Press F8 Press
Engine Actual Speed 5
F5
Press
F1: Disp F2: No Disp
F5: ESC
7
F1 Press F2 Press
∗∗∗ Data Sent ∗∗∗ ∗∗∗ Data Sent ∗∗∗
Engine Actual Speed Engine Actual Speed
Monitor: Disp Monitor: No Disp
F1: Execute F5: ESC F1: Execute F5: ESC
F1 Press F5 Press F1 Press F5 Press
Engine Actual Speed 7 Engine Actual Speed 7
Monitor: Disp Monitor: No Disp
F5: ESC F5: ESC
F5 Press F5 Press
6 6
T5-1-18
Hyd. Oil Filter LED
F1: ON F2: OFF

F5: ESC
8
F1 Press F2 Press
∗∗∗ Data Sent ∗∗∗ ∗∗∗ Data Sent ∗∗∗
Hyd. Oil Filter LED Hyd. Oil Filter LED
LED : ON LED : OFF
F1: Execute F5: ESC F1: Execute F5: ESC
F1 Press F5 Press F1 Press F5 Press
Hyd. Oil Filter LED 8 Hyd. Oil Filter LED 8
LED : ON LED : ON
F5: ESC F5: ESC
F5 Press F5 Press
6 6
T5-1-19
• Operational Performance Check After Adjustment
(Check that pump flow rate and engine speed
have been changed.)
IMPORTANT: After adjusting the engine speed and

flow rate to the attachment, turn the
engine learning switch to neutral. If
the engine is started with the engine
learning switch in the engine learn-
ing position, the MC will not control
the engine, pumps, and valves so
that change in the pump flow rate
and the engine speed cannot be
checked.
1. Turn the key switch OFF.

2. Wait approx. 10 seconds.
3. Turn the engine learning switch to neutral.
4. Disconnect the Dr. EX. connector (When monitor-
ing with Dr. EX, pass this step.)
5. Turn the key switch ON.
6. Start the engine.
7. Check operational performances of the machine.
T5-1-20
(Blank)
T5-1-21
ADJUSTMENT DATA LIST
Min. Adjust- Adjustable Range Standard

Adjustment Data Remarks
ment Value Model Range Adjustment
-1 -1
Li Speed 10 min ZX330 0 to 120 0 min
-1 -1
WU Speed 10 min ZX330 -120 to 120 0 min
-1 -1
AI Speed 10 min ZX330 -120 to 120 0 min
-1 -1
E Speed 10 min ZX330 -120 to 120 0 min
-1 -1
P Speed 10 min ZX330 -120 to 120 0 min
-1 -1
Breaker Speed 10 min ZX330 -500 to 100 0 min
Secondary Crusher -1 -1
10 min ZX330 -500 to 100 100 min
(Demolisher) Speed
-1 -1
Crusher Speed 10 min ZX330 -500 to 100 100 min
-1 -1
Vibro-Hammer Speed 10 min ZX330 -500 to 100 0 min
Hyd. Breaker P1 Max 3 3
1 cm /rev ZX330 73 to 145 145 cm /rev
Swash Angle
Secondary (Demolisher) P1 3 3
1 cm /rev ZX330 73 to 145 145 cm /rev
Max Crusher Swash Angle
Crusher P1 Max Swash 3 3
1 cm /rev ZX330 73 to 145 145 cm /rev
Angle
3 3
Vibro Swash Angle 1 cm /rev ZX330 73 to 145 145 cm /rev
Hyd. Breaker P2 Max 3 3
1 cm /rev ZX330 73 to 145 145 cm /rev
Swash Angle
Secondary Crusher
3 3
(Demolisher) P2 Max 1 cm /rev ZX330 73 to 145 145 cm /rev
Swash Angle
Crusher P2 Max Swash 3 3
1 cm /rev ZX330 73 to 145 145 cm /rev
Angle
3 3
Vibro P2 Max Swash Angle 1 cm /rev ZX330 73 to 145 145 cm /rev
Pump PQ Base Torque
2.45 N⋅m ZX330 -78.4 to 0 0 N⋅m
Adjustment
ATT Speed Increase Down
50 ms ZX330 0 to 3000 3000 ms
Wait Time
Min Boom CYL Bottom
0.1 MPa ZX330 -9.81 to 9.81 0 MPa
Pressure Over Balance
2
NOTE: 1 MPa=10.197 kgf/cm
2
1 kgf/cm =0.098 MPa
T5-1-22
TROUBLESHOOTING / Component Layout
MAIN COMPONENT LAYOUT
1
3
4
5
6
7
8
9
21
10
11
12
13
20 14
15
19 16
18 17 T1HH-01-02-001
1- Bucket Cylinder 7- Fuel Tank 13- Intercooler 19- Pilot Shut-Off Valve
2- Arm Cylinder 8- Hydraulic Oil Tank 14- Radiator 20- Travel Pilot Valve
3- Boom Cylinder 9- Control Valve 15- Oil Cooler 21- Front Attachment/Swing
Pilot Valve
4- Center Joint 10- Pilot Filter and Pilot Relief Valve 16- Battery
5- Swing Bearing 11- Pump Device 17- Travel Device
6- Swing Device 12- Engine 18- Shockless Valve
T5-2-1
ELECTRICAL COMPONENT LAYOUT
(Overview)
1 2
• Pressure Sensor
(Front Attachment)
• Pressure Sensor
(Travel)
Refer to the Control Valve
group.
6, 7
15
14
13
• Pump 1 Delivery Pressure Sensor
• Pump 2 Delivery Pressure Sensor
• N Sensor
12 Refer to the Pump Device group.
8
11
• Coolant Temperature Switch
(Engine Preheat Circuit)
• Engine Oil Pressure Switch
• Engine Oil Level Switch
• Coolant Temperature Sensor
• Overheat Switch
10 Refer to the Engine group
9
T1HH-01-02-002
1 - Wiper Motor 5 - Pump 1 Control Pressure 9 - Battery Relay 13 - Starter Relay

Sensor (4-Spool Side)
2 - Horn 6 - EC Motor 10 - Ambient Temperature Sensor 14 - Air Cleaner Restriction Switch
3 - Work Light 7 - EC Sensor 11 - Coolant Level Switch 15 - Pressure Sensor (Boom Raise)
4 - Fuel Sensor 8 - Pump 2 Control Pressure 12 - Battery Pressure Sensor (Arm Roll-In)
Sensor (5-Spool Side) Pressure Sensor (Swing)
Torque Control Solenoid Valve
Pump 2 Flow Rate Control
Solenoid Valve
T5-2-2
ELECTRICAL SYSTEM (Relays)
Rear Deck
5
4
3 6
2
8
9
10
T178-01-02-006
15
14
19
18 13
17 12
16 11
T178-01-02-007
1 - Mail ON/OFF Switch 6 - Fuse Box 11 - Load Damp Relay (R1) 16 - Wiper Relay A (R6)
(Satellite Navigation System
Equipped Machines only)
2 - QOS Controller 7 - Learning Switch 12 - Washer Relay (R2) 17 - Wiper Relay B1 (R7)
3 - ICX (Information Controller) 8 - Dr. EX Connector to MC 13 - Work Light Relay 2 (R3) 18 - Wiper Relay B2 (R8)
4 - MC (Main Controller) 9 - Download Connector 14 - Work Light Relay 1 (R4) 19 - Wiper Relay B3 (R9)
(Not connected to Satellite
Terminal equipped machines)
5 - Satellite Terminal (Optional) 10 - Dr. EX Connector to ICX 15 - Horn Relay (R5)
T5-2-3
ELECTRICAL SYSTEM
(Monitors and Switches)
1 2
20
19
21
18
3
17
22
16 4
15
23
5
14 24
6
13 7
12 8
25
11
9
10
T178-01-01-003
T178-01-01-004
1 - Coolant Temperature 8 - Alternator Indicator 14 - Overheat Indicator 20 - Engine Control Dial

Gauge
2 - Fuel Gauge 9 - Hydraulic Oil Filter 15 - Digging Mode Indicator 21 - Auto-Idle/Acceleration
Indicator (Optional) Selector
3 - Display Selection Switch 10 - Coolant Level Indicator 16 - Attachment Mode Indicator 22 - Power Mode Switch
4 - SET Switch 11 - Engine Oil Level Indicator 17 - Liquid Crystal Display 23 - Travel Mode Switch
5 - Work Mode Switch 12 - Engine Oil Pressure 18 - Auto-Idle Indicator 24 - Work Light Switch
Indicator
6 - Fuel Level Indicator 13 - Preheat Indicator 19 - Auto-Acceleration Indicator 25 - Wiper/Washer Switch
7 - Air Filter Restriction
Indicator
T5-2-4
ENGINE
1 2
3 4
M1HH-07-001
5
M1HH-07-012
PUMP DEVICE SWING DEVICE
7 8 9
6
10 14
11
13
12 T1HH-01-02-003
T1HH-01-02-004
1 - Coolant Temperature Switch 5 - Engine Oil Level Switch 9 - N Sensor 12 - Pump 1 Delivery Pressure
(Engine Preheat Circuit) Sensor
2 - Engine Oil Pressure Switch 6 - Regulator (Pump 2) 10 - Regulator (Pump 1) 13 - Pump 2 Delivery Pressure
Sensor
3 - Overheat Switch 7 - Pump 2 11 - Pump 1 14 - Swing Relief Valve
4 - Coolant Temperature Sensor 8 - Pilot Pump
T5-2-5
CONTROL VALVE TRAVEL DEVICE
(ZAXIS330, ZAXIS350H)
1 2
T1HH-01-02-005
4
T1HH-01-02-006
TRAVEL DEVICE SOLENOID VALVE UNIT

(ZAXIS370MTH) 3
6
7
T1HH-01-02-008
T183-01-02-012
SHOCKLESS VALVE
9 10
8
T173-03-06-001
1 - Pressure Sensor (Front) 4 - Travel Relief Valve 7 - Solenoid Valve Unit (SG) 9 - Pressure Sensor (Boom Raise)
2 - Pressure Sensor (Travel) 5 - Solenoid Valve Unit (SC) 8 - Pressure Sensor 10 - Pressure Sensor (Swing)
3 - Counterbalance Valve 6 - Solenoid Valve Unit (SI) (Arm Roll-In)
T5-2-6
(Blank)
T5-2-7
COMPONENTS IN CONTROL VALVE
1 2 3 4 5 6 7
Travel Motor (Left)
Travel Motor (Right)
8
9
39
10
38
11
Bucket
Cylinder
37 12
36 13
35 14
Arm
Cylinder 34
Boom
Cylinder
15
16
17
33 32 31 30 18
19
20
29 28 27 26 25 24 23 22 21
Swing Motor
Pump 2 Pump 1
T1HH-03-03-001
1 - Pump Control Valve 11 - Overload Relief Valve 21 - Load Check Valve 31 - Arm Anti-Drift Valve:
(In 5-Spool Section) (Bucket) (Arm 2 Tandem Passage) Bottom Side (Switch Valve)
2 - Check Valve 12 - Load Check Valve 22 - Needle Valve 32 - Arm Anti-Drift Valve:
(Main Relief Circuit) (Boom 1 Parallel Passage) Bottom Side (Check Valve)
3 - Main Relief Valve 13 - Boom Regenerative Valve 23 - Boom Anti-Drift Valve 33 - Arm Anti-Drift Valve:
(Switch Valve) Bottom Side (Relief Valve)
4 - Check Valve 14 - Boom Anti-Drift Valve 24 - Orifice 34 - Overload Relief Valve
(Main Relief Circuit) (Check Valve) (Arm)
5 - Flow Combiner Valve 15 - Overload Relief Valve 25 - Load Check Valve 35 - Arm Anti-Drift Valve:
(Boom) (Arm 2 Parallel Passage) Rod Side (Check Valve)
6 - Check Valve (Flow 16 - Arm Regenerative Valve 26 - Load Check Valve 36 - Load Check Valve
Combiner Valve Circuit) (Arm 1 Parallel Passage) (Boom 2 Parallel Passage)
7 - Check Valve With Orifice 17 - Check Valve (Arm 27 - Orifice 37 - Load Check Valve
(Bucket Combination) Regenerative Valve Circuit) (Aux. Parallel Passage)
8 - Bucket Flow Rate Control 18 - Bucket Flow Rate Control 28 - Load Check Valve 38 - Travel Flow Rate Control
Valve (Poppet Valve) Valve (Switch Valve A) (Arm 1 Tandem Passage) Valve
9 - Bucket Flow Rate Control 19 - Bypass Shut-Out Valve 29 - Load Check Valve (Swing) 39 - Load Check Valve
Valve (Switch Valve B) (Travel Tandem Passage)
10 - Bucket Regenerative Valve 20 - Pump Control Valve 30 - Arm Anti-Drift Valve:
(In 4-Spool Section) Rod Side (Switch Valve)
T5-2-8
34 22 Machine Front
23 Machine Front
11 15
20 3 30
9
35
29
7 27
32
14 33
24, 25 36
12 38
21 39 T173-03-03-051
T173-03-03-050 1
Machine Front
A
B
C
T1HH-03-03-002
Section A Section B Section C
Travel (Left) Travel (Right)
5
6 1
4
2
38
39
3 7
T1HH-03-03-003
T1HH-03-03-004
T5-2-9
1 2 3 4 5 6 7
Travel Motor (Left)
Travel Motor (Right)
8
9
39
10
38
11
Bucket
Cylinder
37 12
36 13
35 14
Arm
Cylinder 34
Boom
Cylinder
15
16
17
33 32 31 30 18
19
20
29 28 27 26 25 24 23 22 21
Swing Motor
Pump 2 Pump 1
T1HH-03-03-001
1 - Pump Control Valve 11 - Overload Relief Valve 21 - Load Check Valve 31 - Arm Anti-Drift Valve:
(In 5-Spool Section) (Bucket) (Arm 2 Tandem Passage) Bottom Side (Switch Valve)
2 - Check Valve 12 - Load Check Valve 22 - Needle Valve 32 - Arm Anti-Drift Valve:
(Main Relief Circuit) (Boom 1 Parallel Passage) Bottom Side (Check Valve)
3 - Main Relief Valve 13 - Boom Regenerative Valve 23 - Boom Anti-Drift Valve 33 - Arm Anti-Drift Valve:
(Switch Valve) Bottom Side (Relief Valve)
4 - Check Valve 14 - Boom Anti-Drift Valve 24 - Orifice 34 - Overload Relief Valve
(Main Relief Circuit) (Check Valve) (Arm)
5 - Flow Combiner Valve 15 - Overload Relief Valve 25 - Load Check Valve 35 - Arm Anti-Drift Valve:
(Boom) (Arm 2 Parallel Passage) Rod Side (Check Valve)
6 - Check Valve (Flow 16 - Arm Regenerative Valve 26 - Load Check Valve 36 - Load Check Valve
Combiner Valve Circuit) (Arm 1 Parallel Passage) (Boom 2 Parallel Passage)
7 - Check Valve With Orifice 17 - Check Valve (Arm 27 - Orifice 37 - Load Check Valve
(Bucket Combination) Regenerative Valve Circuit) (Aux. Parallel Passage)
8 - Bucket Flow Rate Control 18 - Bucket Flow Rate Control 28 - Load Check Valve 38 - Travel Flow Rate Control
Valve (Poppet Valve) Valve (Switch Valve A) (Arm 1 Tandem Passage) Valve
9 - Bucket Flow Rate Control 19 - Bypass Shut-Out Valve 29 - Load Check Valve (Swing) 39 - Load Check Valve
Valve (Switch Valve B) (Travel Tandem Passage)
10 - Bucket Regenerative Valve 20 - Pump Control Valve 30 - Arm Anti-Drift Valve:
(In 4-Spool Section) Rod Side (Switch Valve)
T5-2-10
Section E 22
Section D
Boom 2 Boom 1
Auxiliary Bucket
23
11 15
8
37 14
9
36 12
9
13
10
11 15
T1HH-03-03-005 T1HH-03-03-006
Section F Section G
Arm 1 Arm 2 Swing

19
30
34
20
35 16
26 17
32 31
27 24, 25
29
21
34
T1HH-03-03-008
33 28 18
T1HH-03-03-007
T5-2-11
(Blank)
T5-2-12
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault

codes are displayed after diagnosing the main control-
ler (MC) using the built-in diagnosing system or Dr. EX.
• How to Read Troubleshooting Flow Charts
YES(OK)
Ё2Ђ
After completing the checking and/or measuring procedures in box (1),
Ȁ
ȀО Ё1Ђ select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
Ё3Ђ
NO(NOT OK)
Ȁ Instructions, reference, and/or inspection methods and/or measurements are occasionally

ȀО
described under the box. If incorrectly checked or measured, not only will troubleshooting
· Key switch: ON be unsuccessful but also damage to the components may result.
Refer to “Electrical System Inspection” Group (Group 6) for descriptions in the dotted-line
ȀȀ
О
box.
ȀȀ
О Use Dr. EX (or the built-in diagnosing system) for descriptions in the double-line box.
ȀȀ
О Causes of machine problems are stated in the thick-line box. Scanning quickly through the
thick-line boxes allows you to estimate the possible causes before actually following the flow
chart.
NOTE: All harness end connectors are seen from

the open end side.
Harness
Open End
Side
Harness End Connector
T158-05-03-001
T5-3-1
FAULT CODE LIST
Fault code Problem Cause
01 Abnormal EEPROM • Faulty MC
02 Abnormal RAM
04 Abnormal Sensor Voltage • Faulty MC
• Faulty Harness
• Faulty Sensor
06 Abnormal EC Sensor • Faulty MC
• Faulty Harness
• Faulty EC Sensor
07 Abnormal Engine Control Dial Angle • Faulty MC
• Faulty Harness
• Faulty Engine Control Dial
10 Abnormal Pump 1 Delivery Pressure • Faulty MC
11 Abnormal Pump 2 Delivery Pressure • Faulty Harness
• Faulty Pump Deliver Pressure Sensor
12 Abnormal Pump1 Pump Control Pressure • Faulty MC
13 Abnormal Pump2 Pump Control Pressure • Faulty Harness
• Faulty Pump Control Pressure Sensor
14 Abnormal Swing Lever Stroke • Faulty MC
15 Abnormal Boom Raise Lever Stroke • Faulty Harness
16 Abnormal Arm Roll-In Lever Stroke • Faulty Pilot Pressure Sensor
18 Abnormal Travel Lever Stroke
19 Abnormal Oil Temperature • Faulty MC
• Faulty Harness
• Faulty Oil Temperature Sensor
Ȁ
NOTE: In case all fault codes from 06 to 19 are
displayed, one of the sensors may be
short-circuited. Disconnect all sensors.
Then, reconnect sensors one at a time.
When the connected sensor is normal, the
corresponding fault code will disappear.
When the short-circuited sensor is recon-
nected, all fault codes are displayed again
thus revealing the faulty sensor.
T5-3-2
FAULT CODE 01 (ABNORMAL EEPROM)
FAULT CODE 02 (ABNORMAL RAM)
FAULT CODE 03
(ABNORMAL A/D CONVERSION)
YES * Faulty MC.
Check if engine and machine

actuators operate normally.
Faulty MC.
NO
· Refer to T5-4-94.
* Even if any fault codes are still displayed after retry-
ing, as long as the engine and machine operate
normally, the machine can be operated as it is.
FAULT CODE 04
(ABNORMAL SENSOR VOLTAGE)
YES Faulty MC.

Check if voltage at regulator
terminal L is normal.
Check which code of 06, 07,
10, 11, 12, 13, 14, 15, 16, 18 Faulty sensor indicates ab-
and 19 is indicated. normal code.
NO Short or between MC and
sensor.
T5-3-3
FAULT CODE 06
(ABNORMAL EC SENSOR) YES Faulty harness be-
Check harness be-
tween MC and EC
tween MC connector
sensor.
YES C (31P) terminal #18
and EC sensor termi-
nal #2 for breakage or
short circuit. Faulty MC.
Disconnect EC sen- NO
sor. Check if voltage
Disconnect EC sensor. YES between harness end · Refer to T5-4-94.
Check if resistance be- connectors #1 and #3
tween sensor side is 5±0.5 V. Check if voltage be- YES Broken harness be-
tween MC and EC
connector terminals #1 tween EC sensor
· Key switch: ON sensor terminal #3.
and #3 is less than harness end connec-
2.0±0.4 kΩ. Connect test tor terminal #1 and
harness between EC NO vehicle frame
sensor and base ma- Broken harness be-
matches specification.
chine side harness. tween MC and EC
· Key switch: ON NO sensor terminal #1.
Check if voltage changes
in accordance with speci- · Specification: 5±0.5 V
fications when engine
control dial is rotated. Faulty EC sensor.
· Test Harness: ST 7129 NO
· Specification: See table be- · Refer to T5-4-94.
low.
EC Sensor Specification
Minimum Speed 2.5 to 2.7 V
Maximum Speed (HP 3.3 to 3.7 V
mode Switch: OFF)
Maximum Speed (HP Voltage at Maximum Speed
mode Switch: ON) (HP Mode Switch: OFF) plus
0.2 V or more
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
C1 C10
C23 C31
#18
EC Sensor
1 2 3
T5-3-4
FAULT CODE 07
(ABNORMAL ENGINE CONTROL DIAL
ANGLE) Faulty harness be-
Check harness be- YES
tween MC connector C tween MC and engine
(31P) harness end ter- control dial.
YES minal #6 and switch
panel terminal #3 for
breakage or short cir- Faulty MC.
Disconnect switch cuit.
NO
panel. Check if voltage · Refer to T5-4-94.
YES between harness end
Disconnect switch panel. connector terminals #2 Broken harness be-
Check if resistance be- and #4 is 5±0.5 V. YES tween MC and engine
Check if voltage be-
tween switch panel side control dial terminal
· Key switch: ON tween switch panel
connector terminals #2 and #4.
harness end connec-
#4 is 5±0.5 kΩ. tor terminal #2 and
Reconnect switch panel. NO Broken harness be-
vehicle frame
Insert tester probe into tween MC and engine
matches specification.
connector terminal #3 from NO control dial terminal
the reverse side. Check if · Key switch: ON #2.
voltage varies as specified · Specification: 5±0.5 V
when engine control dial is
turned. Faulty engine control
· Specification: See table NO dial.
below.
Engine Control Dial Specification

Maximum Speed 4.0 to 4.7 V
MC Connector C
#6
C1 C10
C23 C31
Switch Panel
#4 #3 #2
T5-3-5
FAULT CODE 10
(ABNORMAL PUMP 1 DELIVERY PRES-
SURE)
FAULT CODE 11
(ABNORMAL PUMP 2 DELIVERY PRES-
SURE)
Checking Instruction
• Both pump 1 and pump 2 delivery pressure sensors
seldom fail at the same time. Accordingly, if both
fault codes 10 and 11 are displayed simultaneously,
faulty harness may be the cause of this problem.
Faulty harness be-
Check harness be-
YES tween MC and pump
tween MC connector C
delivery pressure
(31P) harness end ter-
sensor.
YES minal #1 (pump 1) or #4
(pump 2) and pump de-
livery pressure sensor
Faulty MC.
Disconnect pump deliv- terminal #2 for break-
ery pressure sensor. age or short circuit. NO
NO Check if voltage be- · Refer to T5-4-94.
tween harness end
connector terminals #1 Broken harness be-
and #3 is 5±0.5 V Check if voltage be- YES tween MC and pump
tween pump delivery delivery pressure
Check if fault codes are pressure sensor har-
switched after switching ness end connector
pump 1 delivery pressure NO terminal #1 and vehi-
sensor with pump 2 de- Broken harness be-
cle frame matches tween MC and pump
livery pressure sensor specification.
and retrying. NO delivery pressure
· Specification: 5±0.5 V
Faulty pump delivery
YES pressure sensor.
MC Connector C
#1 #4
C1 C10
C23 C31
Pump Delivery Pressure Sensor
3 2 1
T5-3-6
FAULT CODE 12
(ABNORMAL PUMP 1 CONTROL PRES-
SURE)
FAULT CODE 13
(ABNORMAL PUMP 2 CONTROL PRES-
SURE)
Checking Instruction
• Both pump 1 and pump 2 control pressure sen-
sors seldom fail at the same time. Accordingly, if
both fault codes 12 and 13 are displayed simulta-
neously, faulty harness may be the cause of this
problem.
Check harness be- Faulty harness be-

tween MC connector C YES tween MC and pump
(31P) harness end ter- control pressure sen-
sor.
YES minal #7 (pump 1) or
#13 (pump 2) and
pump control pressure
Disconnect pump con- sensor terminal #2 for Faulty MC.
breakage or short cir- NO
trol pressure sensor. · Refer to T5-4-94.
cuit.
NO Check if voltage be-
tween harness end Broken harness be-
connector terminals #1 tween MC and pump
Check if voltage be- YES
and #3 is 5±0.5 V control pressure sen-
tween pump control
· Key switch: ON pressure sensor har- sor terminal #3.
Check if fault codes are ness end connector
switched after switching NO terminal #1 and vehicle Broken harness be-
pump 1 control pressure frame matches specifi- tween MC and pump
sensor with pump 2 con- cation. NO control pressure sen-
trol pressure sensor and sor terminal #1.
· Key switch: ON
retrying. · Specification: 5±0.5 V
Faulty pump control
YES pressure sensor.
MC Connector C
#13 #7
C1 C10
C23 C31
Pump Control Pressure Sensor
1 2 3
T5-3-7
FAULT CODE 14
(ABNORMAL SWING PILOT PRESSURE)
FAULT CODE 15
(ABNORMAL BOOM RAISE PILOT
PRESSURE)
FAULT CODE 16
(ABNORMAL ARM ROLL-IN PILOT
PRESSURE) Check harness be- Faulty harness be-
FAULT CODE 18 tween MC connector C
YES tween MC and
(ABNORMAL TRAVEL PILOT PRESSURE) (31P) harness end pressure sensor.
YES each corresponding
Checking Instruction terminal and pressure
sensor terminal #2 for
• All pressure sensors seldom fail at the same time. Faulty MC.
breakage or short cir-
Accordingly, if fault codes 14, 15, 16, and 18 are cuit. NO
displayed simultaneously, faulty harness may be · Refer to T5-4-94.
Connector C Terminal:
the cause of this problem. #14: Pressure Sensor (Swing)
#2: Pressure Sensor
Disconnect pressure (Boom Raise)
sensor. Check if voltage #5: Pressure Sensor
NO between harness end
(Arm Roll-In)
connector terminals #1 #3: Pressure Sensor
and #3 is 5±0.5 V. (Travel)
· Key switch: ON
Broken harness be-
Check if fault code dis- tween MC and
appears after switching Check if voltage be- YES
pressure sensor ter-
pressure sensor with an- tween pressure
minal #3.
other pressure sensor sensor harness end
and retrying. connector terminal #1
NO and vehicle frame Broken harness be-
Fault Code: matches specification. tween MC and
14: Pressure Sensor (Swing) NO pressure sensor ter-
· Key switch: ON minal #1.
15: Pressure Sensor · Specification: 5±0.5 V
(Boom Raise)
16: Pressure Sensor
(Arm Roll-In) Faulty pressure sen-
18: Pressure Sensor YES sor.
(Travel)
ʝ
MC Connector C
#2 #3 #5
C1 C10
C23 C31
#14
Ȁ
Pilot Pressure Sensor
1 2 3
T5-3-8
FAULT CODE 19
(ABNORMAL OIL TEMPERATURE)
Connect oil tempera-

YES Faulty MC.
ture sensor harness
end connector terminal
#1 to #2 with a clip. · Refer to T5-4-94.
Remove connector B
YES (25P) and connector C Connect MC connec- Broken harness be-
(31P) from MC. Check tor B (25P) harness YES tween MC and oil
for continuity between end terminal #22 to temperature sensor
connector B harness vehicle frame. Check terminal #1.
end terminal #22 and for continuity between
Disconnect oil tempera-
connector C terminal NO oil temperature sensor
ture sensor. Check if Broken harness be-
#24. harness end connec-
sensor side connector tween MC and oil
tor terminal #2 and
resistance matches NO temperature sensor
vehicle frame.
specification. terminal #2.
· Specification: See table
below.
Faulty oil temperature
NO sensor.
Oil Temperature Specification

Oil Temperature Resistance
(°C) (kΩ)
−20 16.2±1.6
0 (5.88)
20 2.45±0.24
40 (1.14)
60 (0.534)
80 0.322
MC Connector B
B1 B8
B19 B25
#22
MC Connector C
C1 C10
C23 C31
#24
Oil Temperature Sensor
1 2
T5-3-9
SENSOR ACTIVATING RANGE
1. Checking Method
• Hydraulic Oil Temperature: 50 ± 5 °C

• Unless specified:
Auto-Idle
Engine Power
Work Mode Switch/Auto-
Control Mode
Switch Acceleration
Dial Switch
Selector
Maximum Digging
OFF OFF
Speed Mode
Ȁ
• Monitor each sensor using Dr. EX.
2. Sensor Activating Range
Sensor Operation Specification

Engine Control Dial
Maximum Speed 4.0 to 4.7 V
Maximum Speed (HP Mode Switch: OFF) 3.3 to 3.7 V
EC Sensor
Maximum Speed (HP Mode Switch: ON) Maximum Speed
(Mode Switch: OFF) +0.2 V or more
2
Control Lever: Neutral 2.0 ± 1.0 MPa (20 ± 10 kgf/cm )
Pump Delivery +2.0 +20 2
Arm Roll-In: Relief 31.4 -0.5 MPa (320 -5 kgf/cm )
Pressure Sensor +2.0 +20 2
Boom Raise: Relief 34.3 -1.0 MPa (350 -10 kgf/cm )
2
Pressure Sensor Control Lever: Neutral 0 to 0.1 MPa (0 to 1.0 kgf/cm )
Pilot Control Shut-Off Lever: LOCK
2
Control Lever: Full Stroke 3.3 to 3.9 MPa (34 to 40 kgf/cm )
Pilot Control Shut-Off Lever: UNLOCK
2
Pump Control Control Lever: Neutral 1 to 1.6 MPa (10 to 16 kgf/cm )
Pressure Sensor
2
Jack-Up + Travel (Only one side): 2.9 to 3.9 MPa (30 to 40 kgf/cm )
Full Stroke
T5-3-10
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code

is displayed on the Dr.EX (or the built-in diagnosing
system) although the machine’s operation is abnormal.
On the front section pages of this group T5-4, are ta-
bles indicating the relationship between machine trou-
ble symptoms and related parts which may cause such
trouble if failed.
Start the troubleshooting with more probable causes
selected by referring to these tables.
• How to Read the Troubleshooting Flow Charts
YES(OK)
(2)
• After checking or measuring item (1), select either YES (OK) or
О (1) NO (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO(NOT OK)
О • Special instructions or reference item are indicated in the spaces under the box.
Incorrect measuring or checking methods will render troubleshooting impossible,
· Key switch: ON and may damage components as well.
• Explanation of how to use test harness kit required. Refer to “Electrical System
О
Inspection” Group (Group 6) in this section.
О • Use Dr.EX (or the built-in diagnosing system) function.
О • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
T5-4-1
RELATIONSHIP BETWEEN MACHINE
TROUBLE SYMPTOMS AND RELATED
PARTS
This table indicates the relationship between machine
trouble symptoms and the potential problem parts,
which may cause trouble if failed, and the evaluation
methods of these components.
Parts
EC Motor EC Sensor Engine Control Dial
• Moves governor. • Detects minimum governor • Indicates governor lever posi-
speed position (2.5 V) only tion (engine target speed).
when key switch is turned ON.
• Detects minimum and maxi-
Function mum speed position when en-
gine learning is conducted.
• Governor lever doesn’t move. • Engine speed is controlled • Engine speed doesn’t change
based on idle position set even if engine control dial is
Symptoms in control when key switch is turned ON. turned.
system when trouble Therefore, engine speed is • If discontinuity or short circuit
always controlled with error in occurs in engine control dial,
occurs. idle position setting if set in- target speed of 1600 min-1 is
correctly. used as back-up value.
• Even if engine control dial is • Error in setting will seldom • Engine speed is kept un-
turned, engine speed doesn’t occur so that change in ma- changed from 1600 min-1.
increase from slow idle speed. chine operation will not be no- (Auto-idle system functions.
• Engine start may be difficult ticed. Engine can be stopped by key
though starter rotates. • In case error is set on lower switch.)
• Engine will stall if discontinuity side, engine speed changes
occurs in EC motor while en- but runs slower than normal
gine is running at more than a through the full range when
specified speed. engine control dial is turned.
• Engine will become uncontrol- (Note: In case error is set on
lable if discontinuity occurs in upper side, EC motor is driven
Symptoms in machine EC motor while engine is run- so that it runs faster than the
operation when trou- ning at lower than a specified control range. However, mo-
speed. Engine cannot be tor, a worm gear type, holds
ble occurs. stopped with key switch. governor lever at maximum
constant position, preventing
engine stall. When engine
control dial is turned to mini-
mum speed position, governor
lever is returned to idle posi-
tion.)
• When starting engine, engine
speed fluctuates.
• Starting engine is occasionally
difficult.
By Fault Code Fault code 06 is displayed. Fault code 07 is displayed.


Monitor Item: EC Angle Monitor Item: Engine Target
By Monitor (Displayed by built-in diagnosing Speed, Dial Angle (Displayed by
 system) built-in diagnosing system)
Eval-
Function
uation • Install lamp harness (ST
Using Test 7125) to check EC output sig-
nal and harness for any ab-  
Harness
normality.
Others   
• Engine is stopped by EC mo- • If EC sensor is faulty, engine
tor. (Engine stop motor is not learning is not performed.
NOTE provided.) 
Fuel cut-off cable is provided.
Descriptions of Control T2-1 T2-1 T2-1
(Operational Principle
Section in T/M)
T5-4-2
Pump Control Pressure Pump 1 Delivery Pres- Pump 2 Delivery Pres- Pump 3 Delivery Pres-
Sensor sure Sensor sure Sensor sure Sensor (Optional)
• Monitors pump control pres- • Monitors pump delivery • Monitors pump delivery • Monitors pump delivery
sure to control auto- pressure to control HP pressure to control HP pressure to control pump 3
acceleration system and mode, auto-acceleration, mode, auto-acceleration, torque decrease control.
travel motor swash angle slow speed torque increase, slow speed torque increase,
controls. auto power lift and travel mo- arm regenerative and travel
tor swash angle controls. motor swash angle control.
• No signals arrive to MC • If pump delivery pressure • If pump delivery pressure • Engine stalls if pump torque
sensor output is 0 or 5 V, fol- sensor output is 0 or 5 V, fol- is increased.
lowing symptoms will be pre- lowing symptoms will be pre-
sented by back-up mode sented by back-up mode
function. function.
• Auto-acceleration control is • HP mode is inoperable. • HP mode is inoperable. • Engine stalls if pump torque
inoperable (but not notice- • Auto-acceleration control is • Auto-acceleration control is is increased.
able). inoperable. inoperable.
• Travel speed is kept in slow • Machine mistakes occasion- • Machine mistakes occasion-
mode, not allowing to auto- ally when traveling at slow ally when traveling at slow
matically change to fast idle speed. idle speed.
mode. • Boom raise power is weak • Arm is slow when arm roll-in
during digging operation. and swing combined opera-
• Travel speed is kept in slow tion is made.
mode, not allowing to auto- • Travel speed is kept in slow
matically change to fast mode, not allowing to auto-
mode. matically change to fast
mode.
Fault codes 12 and 13 are dis- Fault codes 10 is displayed. Fault codes 11 is displayed.
played.

Monitor Item: Pump 1 and 2 Monitor Item: Pump 1 delivery Monitor Item: Pump 2 delivery
pump control pressure pressure (Displayed by built-in pressure (Displayed by built-in
(Displayed by built-in diagnos- diagnosing system) diagnosing system) 
ing system)
   
   
• Evaluation by Dr. EX
Broken Circuit: 0.25 V or less
Short Circuit: 4.75 V or more   
T2-1 T2-1 T2-1 T2-1
T5-4-3
Parts Pressure Sensor

Pressure Sensor (Travel) Pressure Sensor (Swing)
(Front Attachment)
• Monitors travel pilot pressure • Monitors front attachment pilot • Monitors swing pilot pressure
to control auto-idle, auto- pressure to control auto-idle, to control arm regenerative
acceleration, idle speed-up, and idle speed-up systems. system.
slow speed torque increase,
Function and travel motor swash angle
controls.
Symptoms in control • No signals arrive to MC • No signals arrive to MC • No signals arrive to MC

system when trouble
occurs.
• Engine speed doesn’t in- • Engine speed doesn’t in- • Since arm regenerative func-
crease even if auto-idle/auto- crease even if any front at- tion is inoperable, when
acceleration selector is auto- tachment actuator is operated swing/arm roll-in combined
idle position. with auto-idle/auto- operation is made, initial arm
• Engine speed doesn’t in- acceleration selector is auto- moving speed is slow. (Not
crease even if auto-idle/auto- idle position. remarkable)
acceleration selector is auto- • Occasionally, engine speed • During arm level crowding
acceleration position. hunts while operating front at- operation, arm speed is
• Occasionally, engine speed tachment at slow idle. slightly slow.
Symptoms in machine hunts while traveling at slow
operation when trou- idle.
ble occurs. • If there is a difference in deliv-
ery flow rate between pumps 1
and 2, machine may mistrack
when traveling at minimum
speed. (Not remarkable)
• Fast travel mode cannot be
selected even if travel mode
switch is turned to the FAST
position.
By Fault Code Fault code 18 is displayed.  Fault code 14 is displayed.

Monitor Item: Travel Control Monitor Item: Front Attachment Monitor Item: Swing Control
Pressure (displayed built-in diag- Operation (displayed built-in di- Pressure (displayed built-in diag-
By Monitor nosing system). agnosing system). nosing system).
Function Monitor pressure change while Monitor pressure change while Monitor pressure change while
Eval-
traveling machine. operating front attachment. swinging upperstructure.
uation
Using Test
  
Harness
Others   
• Judge if pressure sensor is • Judge if pressure sensor is • Judge if pressure sensor is
faulty or port is clogged by faulty or port is clogged by faulty or port is clogged by
switching pressure sensor with switching pressure sensor with switching pressure sensor with
NOTE another pressure sensor. another pressure sensor. another pressure sensor.
Descriptions of Con- T2-1 T2-1 T2-1

trol (Operational Prin-
ciple Section in T/M)
T5-4-4
Pressure Sensor Pressure Sensor Pressure Sensor Torque Control Solenoid

(Boom Raise) (Arm Roll-In) (Auxiliary) (Optional) Valve
• Monitors boom raise pilot • Monitors arm roll-in pilot • Monitors attachment pilot • Supplies control pressure to
pressure to control HP pressure to control HP pressure when attachment is pumps 1 and 2 to control
mode, auto-acceleration, mode, auto-acceleration, installed to control attach- speed sensing and slow
arm regenerative, and auto- and arm regenerative con- ment operation speed in- speed torque increase con-
power lift controls. trols. crease, and pump 1 and trols.
pump 2 flow rate limit.
• No signals arrive to MC • No signals arrive to MC • No signals arrive to MC • If torque control solenoid

valve is not activated, output
pressure from solenoid valve
is 0 MPa (0 kgf/cm2).
• Even if boom is raised with • Even if arm is rolled in with • Engine speed doesn’t in- • Even if speed sensing sys-
HP mode switch ON, engine HP mode switch ON, engine crease when attachment is tem doesn’t work, upper limit
speed doesn’t increase. speed doesn’t increase. operated. power is restricted so that
• Even if boom is raised with • Even if arm is rolled in with • When attachment is oper- machine is operable.
auto-idle/auto-acceleration auto-idle/auto-acceleration ated, operation speed in- • Machine may occasionally
selector is auto-acceleration selector is auto-acceleration creases. mistrack when traveling at
position, engine speed position, engine speed slow idle speed.
doesn’t increase. doesn’t increase.
• Arm roll-in speed becomes • Arm speed is slow in arm
slightly slower than normal in level crowd operation.
boom raise and arm roll-in
combined operation as arm
regenerative system doesn’t
work. (Not remarkable)
• Arm roll-in and boom raise
speeds become slightly
slower at the beginning stage
of arm level crowd operation.
• Boom raise power is weak.
(Not remarkable)
Fault Code 15 is displayed. Fault code 16 is displayed.  

Monitor Item: Boom Raise Pilot Monitor Item: Arm Roll-In Pilot Monitor Item: ATT Control Monitor Item: Pump Torque
Pressure (displayed built-in Pressure (displayed built-in Pressure (displayed built-in Proportional Solenoid Valve
diagnosing system). diagnosing system). diagnosing system). Output
Monitor pressure change while Monitor pressure change while Monitor pressure change while
raising boom. rolling arm in. operating attachment.
   
   
• Judge if pressure sensor is • Judge if pressure sensor is • Judge if pressure sensor is
faulty or port is clogged by faulty or port is clogged by faulty or port is clogged by
switching pressure sensor switching pressure sensor switching pressure sensor
with another pressure sen- with another pressure sen- with another pressure sen-

sor. sor. sor.
T2-1 T2-1 T2-1 T2-1
T5-4-5
Parts
Solenoid Valve Unit (SG) Solenoid Valve Unit (SC) Solenoid Valve Unit (SI)
• Temporarily increases main • Routes return oil from arm • When pump delivery pres-
relief valve set-pressure cylinder rod side to bottom sure is low in fast travel
when operating machine ei- side when rolling arm in to in- mode, travel motor swash
ther in power digging and crease arm speed. angle is reduced to increase
auto-power lift mode. travel speed.
Function
• In case solenoid valve unit • In case solenoid valve unit • Fast travel mode cannot be
Symptoms in control (SG) is not activated, pres- (SC) is not activated, pressure selected.
sure at port SG becomes 0 at port SC becomes 0 MPa (0
system when trouble MPa (0 kgf/cm2). kgf/cm2). Arm regenerative
occurs. valve will not operate at this
time.
In case solenoid valve unit In case solenoid valve unit (SC) In case solenoid valve unit (SI)
(SG) is closed: is closed: is closed:
• Relief pressure stays at • Arm speed is slow in arm level • Even if travel mode switch is
normal 31.4 MPa (320 crowd operation. turned to FAST position, fast
kfg/cm2). Even if power dig- In case solenoid valve unit (SC) travel mode cannot be se-
ging switch is pressed, relief is open: lected.
pressure doesn’t increase. • Arm speed is fast because In case solenoid valve unit (SI)
Power doesn’t increase. arm regeneration is always is open:
Symptoms in machine operated. • Fast travel mode is always
operation when trou- In case solenoid valve unit selected.
ble occurs. (SG) is open:
• The pressure always in-
creases, all operation
makes the force increase.
By Fault Code   
By Monitor Monitor Item: Power Digging Monitor Item: Arm Regenerative Monitor Item: Travel Motor Con-
(Boost) Control Pressure Proportional Sol. Valve Output trol Pressure
Function
Eval- • Install lamp harness (ST • Install lamp harness (ST 7123) • Install lamp harness (ST
uation Using Test 7123) to check output sig- to check output signals from 7123) to check output signals
Harness nals from MC and harness MC and harness condition. from MC and harness condi-
condition. tion.
Others   
• Proportional solenoid valve
is used as an ON/OFF
valve. Therefore, even if
power digging switch is
pressed or released, lamp
NOTE will come ON when normal.  
In case lamp goes OFF, it
may be due to broken har-
ness.

T5-4-6
Max. Pump 1 Flow Rate Limit Max. Pump 2 Flow Rate Hydraulic Oil Temperature
Solenoid Valve (Optional) Limit Solenoid Valve N Sensor
Sensor
• When operating attachment, • When operating attach- • Monitors engine speed to • Monitors hydraulic oil tem-
limits maximum pump 1 flow ment, limits maximum pump operate engine speed sens- perature to control auto-
rate. 2 flow rate. ing control. warming up and arm regen-
erative control.
• In case max. pump 1 flow rate • In case max. pump 2 flow • Speed sensing control is • If circuit breakage occurs,
limit solenoid valve is not acti- rate limit solenoid valve is inoperable. system operates as if hydrau-
vated, pressure at output port not activated, pressure at lic oil temperature is 40 °C
becomes 0 MPa (0 kgf/cm2). output port becomes 0 MPa (Dr. EX or monitor will not in-
(0 kgf/cm2). dicate 40 °C in diagnosis op-
eration).
In case max. pump 1 flow rate In case max. pump 2 flow rate • Engine stalls under adverse • Even if oil temperature is
limit solenoid valve is closed: limit solenoid valve is closed: operating conditions such lower than 0 °C, auto-warming
• When operating attachment, • When operating attach- as at high altitude. up control doesn’t operate so
operating speed doesn’t de- ment, operating speed that engine runs at idle speed
crease. doesn’t decrease. when engine is started.
In case max. pump 1 flow rate In case max. pump 2 flow rate • When oil temperature is lower
limit solenoid valve is open: limit solenoid valve is open: than 10 °C, arm regenerative
• Right travel, bucket, arm and • Left travel, arm, boom and control is inoperable.
boom speeds are slow be- swing speeds are slow be-
cause maximum flow rate of cause maximum flow rate of
pump 1 decrease. pump 2 decreases.
• Machine mistracks to the right • Machine mistracks to the
when traveling. left when traveling.
   Fault code 19 is displayed.

Monitor Item: Actual engine
Monitor Item: Hydraulic Oil Tem-
  speed (If N sensor fails, engine
perature
speed is not measured.)
   
   
• Even if signals from N sen-
sor are not delivered due to
broken circuit or poor sen-
sor installation, few changes
in operational performance
  occur, making troubleshoot- 
ing difficult. Use monitor
function.
T2-1 T2-1 T2-1 T2-1
T5-4-7
Parts
Engine Learning Switch Power Digging Switch Travel Mode Selector
• Starts engine learning. • Activates power digging con- • Changes travel mode.
ON: 0V→Learning trol. Fast Mode: 0V
OFF: 5V→Normal Control ON: 0V→Increasing Pressure Slow Mode: 5V
OFF: 5V→ Not Increasing
Function Pressure
• Engine learning is not per- • Broken Circuit: Pressure • Broken Circuit in Switch:
formed. doesn’t increase. Travel speed remains un-
Symptoms in control • Short Circuit: Pressure in- changed in slow mode (5V).
system when trouble creases for 8 seconds after • Short Circuit in Switch:
turning key switch and stops Travel speed remains un-
occurs. increasing. changed in fast mode (0V).
• Machine will operate normally • Power digging control doesn’t • Even if travel mode selector is
problem is caused by broken operate if broken circuit or turned to the FAST position,
circuit or discontinuity of short circuit occurs. fast travel mode cannot be se-
switch. (Only learning cannot lected.
be performed.) • Even if travel mode selector is
• If short circuit occurs, learning turned to the SLOW position,
mode operation starts when fast travel mode is operated.
key switch is turned ON.
Symptoms in machine Therefore, engine will stall at 2
second or 20 seconds after
operation when trou- engine starts.
ble occurs.
Monitor Item: Engine Learning Monitor Item: Power Digging Monitor Item: Travel Mode
Eval-
By Monitor (Boost) Switch
uation
Function
Using Test   
Harness
Others   
NOTE   

T5-4-8
Auto-Idle/Auto-Acceleration Auto-Idle/Auto-Acceleration Power Mode Switch

MC Selector (Auto-Idle) Selector (Auto-Acceleration) (HP Mode)
• Controls engine, pump, and • Activates auto-idle control. • Activates auto-acceleration • Activates HP mode control.
valve operation. ON: 0 V → Auto-idle is oper- control. ON: 0 V → HP mode is op-
able. ON: 0 V → Auto-acceleration erable.
OFF: 5 V → Inoperable. is operable. OFF: 5 V → Inoperable.
OFF: 5 V → Inoperable.
• Depending on trouble situa- • Broken Circuit: Auto-idle • Broken Circuit: Auto- • Broken Circuit: Even if HP
tions, control system mal- system is inoperable. acceleration control is inop- mode is selected, HP mode
function may differ. (The fol- • Short Circuit: Even if auto- erable. is inoperable.
lowing symptoms in machine idle/auto-acceleration selec- • Short Circuit: Even if auto- • Short Circuit: Even if HP
operation indicates that MC tor is OFF, auto-idle control idle/auto-acceleration selec- mode switch is turned OFF,
logic circuit has failed.) is always performed. tor is OFF, auto-acceleration HP mode system is not de-
control is always performed. activated. Attachment speed
• Even if key switch is turned • Same as described above. • Same as described above. • Same as described above.
ON, EC motor will not move
to the START position so that
engine cannot start. Even
though engine starts, speed
stays slow.
• Since pump displacement is
held at minimum, all actuator
speeds are slow.
Fault codes 01, 02, and 03 are

displayed. Other fault codes   
may be displayed.
Monitor Item: Auto-Idle/Auto- Monitor Item: Auto-Idle/Auto- Monitor Item: E/P/HP Mode
 Accel Switch Accel Switch Switch
   
   
• Before suspecting a failure in
MC, be sure to check the
fuses in control system. If
any sensor in 5 V system is
short-circuited, all sensor   
fault codes will be displayed.
T2-1 T2-1 T2-1 T2-1
T5-4-9
Parts Power Mode Switch Work Mode Switch Work Mode Switch
(E Mode) (Digging Mode) (Attachment Mode)
• Selects E mode. • Allows normal control to be • Functions only when optional
ON: 0 V → E mode performed. attachment kit is equipped.
OFF: 5 V → Normal (Attachment operation speed
Function increase/limit control)
• Broken Circuit: Even if E mode • When operating attachment,

is selected, engine speed engine speed is not con-
doesn’t decrease. trolled.
Symptoms in control • Short Circuit: Engine speed
doesn’t increase to the maxi-
system when trouble mum. Auto-idle control is inop- ;
occurs. erable.
• Same as described above • Even if auxiliary valve is oper-

ated, engine speed doesn’t
increase.
• Even if attachment mode is
selected, maximum engine
speed doesn’t decrease.
Symptoms in machine
operation when trou- ;
ble occurs.
By Monitor Monitor Item: E/P/HP Mode Switch Monitor Item: Work Mode Switch Monitor Item: Work Mode Switch
Eval- Function
uation Using Test   
Harness
Others   
NOTE   

T5-4-10
Auxiliary Mode Switch Travel Flow Control Bucket Flow Control

(Optional) Flow Combiner Valve
Valve Valve
• Functions only when optional • Supplies hydraulic oil to both ОTo ensure pressure oil to ОTo restrict the bucket
attachment kit is equipped. right and left travel spools raise boom when travel and circuit to assist boom to
(Attachment operation speed from pump 1 during com- boom raise functions are raise when a combined
increase/limit control) bined operation of travel and operated at the same time. operation of bucket, arm
front/swing. roll-in, and boom raise is
made.
• When operating attachment, • During combined operation ОOil flow is not restricted ОAlways restrict the bucket
engine speed is not con- of travel and front/swing, in- properly. circuit if switch valve is
trolled. sufficient oil is supplied to left seized in operation.
travel spool.
• Even if auxiliary valve is • While traveling, when ОȀI f fully closed, shock ОȀB ucket speed decreases if
operated, engine speed front/swing lever is operated, increases when travel poppet valve is seized or
doesn’t increase. machine mistracks to the combined operation is switch valve is seized so
• Even if attachment mode is left. made. that the poppet valve is
selected, maximum engine ОȀI f fully opened, boom is not closedȎ
speed doesn’t decrease. raised when the combined ОBoom does not rise when
operation of travel down a the combined operation of
slope and boom raise with bucket, arm roll-in, and
bucket loaded is made. boom raise is made with
(Boom raise single poppet valve fully opened,
operation can be or if switch valve is seized
achieved.) so that poppet valve is fully
opened.
   
   
   
   
; ;  
T2-1 T3-3 T3-3 T3-3
T5-4-11
Parts Boom Regenerative Arm Regenerative Bucket Regenerative

Control Valve Control Valve Valve
ОTo prevent boom cylinder ОȀW hen the valve is switched by • To prevent bucket cylinder
hesitation by allowing the pilot pressure oil led from hesitation by allowing the re-
return oil from the boom solenoids valve unit (SC). turn oil from the bucket cylin-
cylinder bottom side to flow der rod side to flow into the
Function ОȀTo increase arm speed by
into the boom cylinder rod bucket cylinder bottom side.
allowing the return oil from the
side. arm cylinder rod side to flow
into the arm cylinder bottom
side.
ОThe same as described ОArm regenerative function • The same as described be-
below. does not operate. low.
Symptoms in control
system when trouble
occurs.
ОIf check valve is kept closed, ОArm speed is very slow when • If check valve is kept closed,
boom lower speed leveling. bucket is not smoothly rolled
decreases. in.
ОIf check valve is kept • If check valve is kept opened,
opened, jacking up the bucket power is weak.
machine using the front
attachment is difficult.
Symptoms in machine
operation when trou-
ble occurs.
   
   
Eval
-
uatio    
n
   
NOTE   

T5-4-12
Arm Anti-Drift Valve Arm Anti-Drift Valve

Boom Anti-Drift Valve Bypass Shut-Off Valve
(Rod Side) (Bottom Side)
ОTo prevent the arm drift ОTo prevent the arm drift ОTo prevent the boom drift • Supplies pressure oil from
caused by inner leakage of caused by inner leakage of caused by inner leakage of pump 1 to auxiliary spool
hydraulic oil in control hydraulic oil in control hydraulic oil in control when auxiliary spool is oper-
valve. Only when arm is valve. Only when arm is valve. Only when boom is ated.
rolled in, anti-drift valve rolled out, anti-drift valve lowered, anti-drift valve
(check valve) in the arm (check valve) in the arm (check valve) in the boom
cylinder return circuit is cylinder return circuit is cylinder return circuit is
forcibly opened so that arm forcibly opened so that arm forcibly opened so that
ОCheck valve does not open ОCheck valve does not open ОCheck valve does not open ОThe same as described
if switch valve is seized. if switch valve is seized. if switch valve is seized. below.
ОIf check valve does not ОȀI f check valve does not ОIf check valve does not • If spool is bound in the fully
open, arm roll-in speed open, arm roll-out speed open, boom is not lowered. opened position, single at-
decreases. decreases. ОȀI f check valve is kept tachment operation speed
ОIf check valve is kept ОȀI f check valve is kept opened, boom drift becomes slow.
opened, arm drift increases opened, arm drift increases increases due to the • If spool is bound in the fully
due to the control valve due to the control valve control valve inner closed position, main relief
inner leakage. inner leakage. leakage. valve continues to relieve
ОAccording to the degree of ОȀA ccording to the degree of ОȀA ccording to the degree of with all control levers posi-
seizure in check valve, arm seizure in check valve, arm seizure in check valve, tioned in neutral.
roll-in operation becomes roll-out operation becomes boom lower operation • If pump 1 control pressure is
jerky, or slower. jerky, or slower. becomes jerky, or slower. monitored, it indicates the
maximum value.
• If spool is bound in opened
position, when all control
levers are in neutral, pump 1
pressure is higher than pump
2 pressure.
   
Monitor Item: Pump 1 Delivery
   Pressure, Pump 1 Control
Pressure.
   
   
   
T3-3 T3-3 T3-3 T3-3
T5-4-13
Parts Pump Control Valve Pump Control Valve Swing Parking Brake
(4-Spool Side) (5-Spool Side) Release Spool
• Operating boom raise/lower, • Operating boom raise/lower • Supplies swing parking brake
arm roll-in/out, bucket roll- arm roll-in/out, swing right/left release pressure when shifted
in/out, right travel and auxil- and left travel, flow rate con- by boom, arm, bucket, or
iary, flow rate control pressure trol pressure Pi is supplied to swing pilot pressure.
Function Pi is supplied to pump 1 regu- pump 2 regulator in response
lator in response to the opera- to the operation.
tion.
• Pump control pressure of • Pump control pressure of • If spool is bound in the fully
pump 1 doesn’t change if pump 2 doesn’t change if opened position, swing park-
pump control valve (4-spool pump control valve (5-spool ing brake is kept released.
side) spools are seized and side) spool are seized and the (Machine vibrates while travel-
the spring is broken. spring is broken. ing.)
• If spool is bound in the fully
Symptoms in control closed position, swing parking
system when trouble brake is kept applied.
(Dragging is felt.)
occurs.
• Seized in neutral, pump 1 is • Seized in neutral, pump 2 is • Same as described above.

turned the maximum swash turned the maximum swash
angle though the control lever angle though the control lever
is in neutral. (If the travel lever is in neutral. (If the travel lever
is kept at half stroke, the ma- is kept at half stroke, the ma-
chine mistracks to the left.) chine mistracks to the right.)
• Seized in neutral, pump 1 • Seized in neutral, pump 2
Symptoms in machine control pressure sensor indi- control pressure sensor indi-
operation when trou- cates the maximum pressure. cates the maximum pressure.
• Seized with pump control • Seized with pump control
ble occurs. valve operated, pump 1 is valve operated, pump 2 is
kept at the minimum swash kept at the minimum swash
angle, operating the control angle, operating the control
lever. lever.
(Right travel is in operable in (Left travel is inoperable in
single travel operation. Bucket single travel operation. Swing
speed is very slow.) speed is very slow.)
By Monitor Monitor Item: Pump 1 Control Monitor Item: Pump 2 Control Monitor Item: Pump 2 Control
Pressure. Pressure. Pressure.
Eval- Function
uation Using Test   
Harness
Others   
NOTE   

T5-4-14
Bucket Flow Rate Control Bucket Flow Rate Control Valve

Valve (Switch Valve A Spool) (Switch Valve B Spool)
• Supplies boom raise pilot pressure • Reduces flow rate to bucket cylinder
to the switch valve B of bucket flow when shifted by boom raise pilot
rate control valve when shifted by pressure.
arm roll-in pilot pressure.
• If spool is bound in the fully opened • If spool is bound in the fully opened
position, bucket speed becomes position, boom doesn’t raise during
slow when boom raise and bucket 3-combined operation of bucket,
combined operation is made. arm roll-in and boom raise.
(Bucket flow rate control is inoper- • If spool is bound in the fully closed
able.) position, bucket speed becomes
• If spool is bound in the fully closed slow in bucket single operation.
position, boom doesn’t raise during (Bucket flow rate control is always
3-combined operation of bucket, effective.)
arm roll-in, and boom raise.
• Same as described above. • Same as described above.
 
 
 
 
 
T5-4-15
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
E-1 E-2 E-3 E-4
Starter doesn’t rotate Although starter ro- When engine control dial is Even if engine control
Trouble tates, engine doesn’t fully rotated, engine stalls. dial is rotated, engine
Symptom start. Occasionally engine stalls speed remains un-
during operation with engine changed.
control dial fully rotated and
auto-idle ON. Engine speed
is slower than specification
in all operating range. Idle
speed is faster or slower
Parts than specification.
MC (Main Controller) z z
QOS Controller
EC Motor z z
EC Sensor { z
Pump 1 Delivery Pressure
Sensor
Sensor
Pump 1 Control Pressure
Sensor
Sensor
Pressure Sensor (Travel)
Pressure Sensor (Front At-
tachment)
Pressure Sensor (Swing)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Auxiliary)
N Sensor
Hyd. Oil Temperature Sensor
Coolant Temperature Sensor
Key Switch z
Engine Control Dial z
Auto-Idle/Acceleration Selector
Power Mode Switch
Work Mode Switch
Auxiliary Mode Switch
Engine Learning Switch z
Battery Relay z
Glow Relay
Engine Electrical Equipment z
Engine Unit z z z
Governor z z z
Check batteries. Check fuel system Check fuel cut-off handle Check engine control
(filters and piping). and engine control cable. cable.
Remarks Be sure to perform engine
learning after replacing en-
gine.
T5-4-16
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at the
scribed provided that each trouble occurs same time, find out all faulty components
independently. while checking all suspected components
in each trouble symptom.
E-5 E-6 E-7 E-8 E-9

Engine speed doesn’t Faulty HP mode. Even if key switch is Faulty auto-idle system. Faulty E mode.
increase after engine is turned OFF, engine
started. doesn’t stop.
z z { z z
{ {
{ {
{
{
z {
z
z { z
{
{
z : Related, required to check { : Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will not
be the direct cause of the trouble concerned.
T5-4-17
E-10 E-11 E-12 E-13

Faulty auto-acceleration When traveling or oper- Engine speed doesn’t When attachment mode
Trouble system. ating front attachment increase even if at- is selected, engine
Symptom with engine running at tachment is operated in speed doesn’t de-
slow idle, engine hunts. attachment mode. crease.
Parts
MC (Main Controller) z z z z
QOS Controller
EC Motor
EC Sensor
{
Sensor
{
Sensor
{
Sensor
{
Sensor
Pressure Sensor (Travel) {
Pressure Sensor (Front At-
tachment)
Pressure Sensor (Swing) {
Pressure Sensor (Boom
{
Raise)
Pressure Sensor (Arm Roll-In) {
Pressure Sensor (Auxiliary) z
N Sensor
Hyd. Oil Temperature Sensor
Coolant Temperature Switch
Key Switch
Engine Control Dial
Auto-Idle/Acceleration Selec-
z
tor
Power Mode Switch
Work Mode Switch z z
Auxiliary Mode Switch z z
Engine Learning Switch
Battery Relay
Glow Relay
Engine Electrical Equipment
Engine Unit z
Governor
Pump Regulator
Remarks
T5-4-18
E-14 E-15 E-16

Engine stalls within Engine stalls during Engine is difficult to
several seconds after operation under ad- start at low temperature.
engine has started. verse condition such as
at high altitude.
z
z
{
Check fuel system for Check batteries.
clogging.
z : Related, required to check

{ : Related. However, in case this component fails, other trouble
T5-4-19
All Actuator System Troubleshooting

A-1 A-2 A-3 A-4
All actuator speeds are Left travel is inoper- Right travel is inoper- Actuator doesn’t stop
Trouble slow. able during single able during single even if control lever is
Symptom travel operation. Single travel operation. Single returned to neutral.
swing operation speed bucket operation
is slow. Arm is slightly speed is slow. Boom is
slow during arm level not raised properly
crowding. during arm level crowd-
ing.
Parts
MC (Main Controller) z
Torque Control Solenoid Valve {
N Sensor {
Spool z
Main Relief Valve {
Main Pump z z z
Regulator { z z
Pilot Pump z
Pilot Valve z
Pilot Relief Valve z
Pump Control Valve (4-Spool Side) z
Remarks
T5-4-20
NOTE: The trouble symptoms in this table are de-

scribed provided that each trouble occurs
independently. In case more than one trou-
ble occurs at the same time, find out all
faulty components while checking all sus-
pected components in each trouble symp-
tom.
A-5
Actuator speed is faster
than normal. Machine
mistracks when travel
lever is operated at the
half stroke.
Precise control can not
be performed.
z
z

T5-4-21
Front Attachment System Troubleshooting

F-1 F-2 F-3 F-4 F-5
All front attach- Even if power dig- Some cylinders During the com- Arm speed is slow
Trouble ment actuator ging switch is are inoperable or bined operation of in a combined
Symptom power is weak. pressed, power speeds are slow. travel and boom operation. Arm
doesn’t increase. raise, boom does speed is slow dur-
Boom raise power not rise. ing arm level
is weak when dig- crowding.
ging.
Parts
MC (Main Controller) z
Solenoid Valve Unit (SG) z
Solenoid Valve Unit (SC) z
Sensor
{
Sensor
Pressure Sensor (Swing) {
Pressure Sensor (Boom
{
Raise)
Pressure Sensor (Arm Roll-In) {
Oil Temperature Sensor
Power Digging Switch z
Spool z
Main Relief Valve z z
Overload Relief Valve z z
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve z
Bucket Regenerative Valve
Travel Flow Rate Control Valve z
Bucket Flow Rate Control
Valve
Boom Anti-Drift Valve
Arm Anti-Drift Valve
Needle Valve
Shockless Valve z
Pilot Valve z
Cylinder z
Remarks
T5-4-22
F-6 F-7 F-8 F-9 F-10

Bucket is slow in bucket When starting to move in Boom starting speed is When operating the con- Front attachment cylin-
roll-in single operation. combined operation, arm slow and/or jerky during trol lever to raise boom der drift is large.
Bucket doesn’t move doesn’t smoothly move. combined operations. or to roll-out arm, boom
smoothly in bucket roll-in Arm starts to move slow During boom lower sin- or arm starts to move
single operation. slightly in arm roll-in gle operation, boom after slightly moving in
single operation. These speed is slightly slow. the reverse direction.
troubles often occur
when oil temperature is
low.
z
z
z
z
z
z z z
z z z
z
z
z z

T5-4-23
Swing/Travel/Other System Troubleshooting

S-1 T-1 T-2 T-3 T-4
Swing speed is Both right and left When a com- One side track During a com-
Trouble slow or swing travel side tracks bined operation does not move or bined operation of
Symptom function does not do not move or with boom raise is move slowly, or travel and front
operate. move slowly. made, a large the machine can- function, the ma-
shock is felt. not travel straight chine mistracks.
(Mistracks).
Parts
MC (Main Controller)
Solenoid Valve Unit (SI)
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pump 1 Control Pressure Sensor
Pump 2 Control Pressure Sensor
Pressure Sensor (Travel)

Pressure Sensor (Swing)
Pressure Sensor (Arm Roll-In)
Travel Mode Switch
Pump Device
Spool z
Load Check Valve z
Travel Flow Rate Control Valve z
Swing Relief Valve z
Flow Combiner Valve z
Pump Control Valve (4-Spool Side)
Swing Device z
Travel Device z
Center Joint z
Pilot Valve z z
Also, refer to T-7 In case either
bucket or swing is
Remarks also slow, refer to
A-2 or A-3.
T5-4-24
T-5 T-6 T-7 O-1 O-2
Occasionally, machine No steering force and no Fast travel is inoperable. Wiper is inoperable or Air Conditioner mal-
mistracks when traveling gradeability when travel Travel mode does not not retracted. function
with engine running at mode is fast. change from slow mode
slow speed. to fast mode.
z
z
z z
{ {
{ {
{ {
z
z

T5-4-25
(Blank)
T5-4-26
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter doesn’t rotate.
Related Fault Code: None
• This trouble has nothing to do with the electronic

control system such as the MC.
• Check for loose harness connections beforehand.
Faulty starter or
YES faulty harness
between starter
Check if voltage at and battery relay.
YES battery relay
terminal A is 24 V.
Faulty battery
NO relay.
Check if both voltages
YES at key switch terminal
#5 and #6 are 24 V.
· Key switch: START YES Faulty key switch.
Check for
Check if battery
continuity between
voltage and
battery positive
electrolyte density NO terminal and key
is normal, and Faulty harness
switch terminal #1.
fusible link (40 A) is between battery
not blown. NO and key switch.
· Voltage: More than
24 V
Density: More than
1.26 Faulty battery or
NO fusible link.
Key Switch Battery Relay

Terminal A
T178-05-04-001
T105-07-04-002
T5-4-27
E-2 Although starter rotates, engine doesn’t
start.
• Check the fuel cut lever position during cranking.

If the position is normal, the engine unit and/or
fuel system may have trouble.
YES Faulty engine.
· Refer to Engine Shop Manual.
Check if governor lever moves

to the START position when
key switch is turned ON.
· Key switch: ON
Check EC motor drive

NO circuit.
· Test Harness: 4274589
(ST 7125)
• Governor Lever and Fuel Cut Lever

2
1
T1HH-04-02-002
4 3
1 - Governor Cable (From EC

Motor)
2 - Fuel Cut-Off Cable
(Fuel Cut-Off Handle)
3 - Fuel Cut Lever
4 - Governor Lever
T5-4-28
• Governor Lever Position
A - Key Switch OFF (Engine Stop Position)

B - Key Switch ON (Engine Start Position)
B
FULL
A: STOP
FULL
STOP
T1HH-04-02-002
• Fuel Cut Lever Position
A - Fuel Cut-Off Handle Pulled Position

B - Fuel Cut-Off Handle Returned Position
B A
T1HH-04-02-002
T5-4-29
E-3 When engine control dial is fully rotated,
engine stalls.
Occasionally engine stalls during operation
with engine control dial fully rotated and
auto-idle ON.
Engine speed is slower than specification in
all operating ranges.
Idle speed is faster or slower than
specification.
Related Fault Code: 06
• In case engine learning has not been performed

or engine learning has been incorrectly performed,
engine speed becomes slower than specification
across the operating range.
• In case the EC sensor is faulty, engine speed is
controlled based on the governor lever position,
which is judged as the idle position when the key
switch is turned ON. Accordingly, discrepancies in
engine speed from specification will result.
Depending on where the governor lever is
positioned when the key switch is turned ON,
discrepancy will differ, causing this trouble to be
not reproducible.
• Refer to pages for Engine Learning in the
SYSTEM/Control System group in the T/M
(Operational Principle).
Return fuel cut

YES lever to original
position.
Check if fuel cut YES Faulty EC sensor.

lever has been
moved up to half
way stroke. · Refer to T5-4-94.
Check if fault code

NO 06 is displayed. YES End
Check if problem is
corrected after
NO engine learning.
· Refer to T5-4-94 for Monitor engine
engine learning NO learning status.
procedures.
· Monitor item:
Engine learning
status
T5-4-30
YES Faulty engine and/or fuel

system.
OK Check if governor lever comes
in contact with stopper when
performing engine learning. Faulty control cable and/or
incorrectly adjusted engine
NO governor lever.
Ë ⏠
· Adjust engine speed.
(Refer to T5-4-94.)
Faulty MC, faulty learning

switch, or broken harness
NOT OK between learning switch and
MC.
T5-4-31
E-4 Even if engine control dial is rotated, engine
speed remains unchanged.
• If the EC fails, the engine will not stop with the key
switch ON.
Faulty engine control dial or

YES broken harness between
engine control dial and MC.
Check if fault code 07 is
displayed. Using Dr. EX,
monitor engine control dial
angles (standard voltages). YES Faulty EC motor.
Check if voltages are normal.
Install test harness (ST 7125)
· Standard Voltages to EC motor. Check if lamp · Refer to T5-4-94.
Minimum Speed Position: comes ON while turning
0.3 to 1 V NO engine control dial.
Maximum Speed Position: Faulty MC or broken harness
4.4 to 4.7 V between MC and EC motor.
· Possible to display with built-in NO
diagnosing system · Refer to T5-4-94.
E-5 Engine speed doesn’t increase after engine

is started.
• Refer to the pages for the Auto Warming Up

Control in the SYSTEM / Control System group in
the T/M (Operational Principle).
More than 0 °C
when starting Normal.
NO Monitor oil Faulty key switch

temperature. YES or broken harness
Monitor key switch. between key
· Monitor item: switch and MC.
Hydraulic oil Check if displayed
“ky” is highlighted
temperature Lower than 0 °C
· Possible to display when starting in response to key
Check if fault code switch operation. Faulty MC.
with built-in
19 is displayed. diagnosing system NO
· Monitor item:
Key switch
Faulty hyd. oil

temperature
sensor or broken
YES harness between
oil temperature
sensor and MC.
T5-4-32
E-6 Faulty HP mode
• Even if power mode switch is turned to the HP mode

position, HP mode is inoperable. (General mode
normally operates.)
Related Fault Codes: 10, 11, 15, and 16
• Sensors detect the conditions necessary to • Refer to the pages for HP Mode Control in the
operate the HP mode. Therefore, if any of these SYSTEM / Control System group in the T/M
sensor fails, the HP mode becomes inoperable. (Operational Principle).
• Pressure sensors (arm roll-in and boom raise) • Check for loose harness connections beforehand.
and pump 1 and 2 delivery pressure sensors are
also engaged in the HP mode control. However, if
these sensors fail, other operating functions will
be also affected. (Refer to the relationship Faulty power mode
between machine trouble symptoms and related switch or broken
NO harness between
parts on page T5-4-2.)
Monitor power mode power mode switch
switch. Check if and MC.
indication HP is
NO
highlighted when
YES Faulty engine.
power mode switch
is turned to “HP Check if governor
mode”. lever comes in
· Monitor item: E/P/HP YES contact with full-side
mode switch stopper while
Check if any fault Faulty MC.
relieving boom raise
codes are NO
circuit pressure.
displayed. · Refer to T5-4-94.
Faulty
corresponding
sensor or broken
YES harness between
sensor and MC.
• Although the power mode switch isn’t turned to the · Fault Codes:
HP mode position, HP mode is operable. Pump 1 delivery pressure sensor: 10
Pump 2 delivery pressure sensor: 11
Pilot pressure sensor (boom raise): 15
• Boom raise and arm roll-in must be operated Pilot pressure sensor (arm roll-in): 16
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
Short circuited harness
broken at the same time. between MC and power
YES
mode switch.
Monitor the power YES End.

mode switch. Check if the
Check if “HP” is YES symptom disappears
displayed. Check if the governor
lever comes in contact after completing Faulty MC.
with full side stopper engine learning.
· Monitor item: E/P/HP NO
mode switch when the key switch is
· Power mode switch: NO turned ON (engine not
P mode running) and the
engine control dial is Faulty engine.
turned to Fast Idle. NO
T5-4-33
E-7 Even if key switch is turned OFF, engine
doesn’t stop. (In case the engine doesn’t
stop, stop the engine by pulling the engine
stop handle located under the seat stand.
Then, begin inspection.)
Related Fault Codes: 06 and 07
• Probably symptoms such as “Engine speed is

slower than specification in all operating ranges”
or “Even if engine control dial is rotated, engine
speed remains unchanged” will come up. Perform
troubleshooting for these symptoms.
T5-4-34
E-8 Faulty auto-idle system
• Even if control lever is turned to neutral. Auto-idle

system is inoperable.
• In case trouble symptoms E1 to E7 are • Refer to the pages for Auto-Idle Control in the
recognized, perform the troubleshooting of these SYSTEM / Control System group in the T/M
troubles beforehand. (Operational Principle).
• Although the failure in pressure sensors (travel • Check for loose harness connections beforehand.
and front attachment) will have relevance to
malfunction of the auto-idle control. However, if
these sensors fail, other operating functions will
also be affected. (Refer to the relationship Normal (Turn power
between machine trouble symptoms and related YES mode switch to a
position other than
parts on page T5-4-2.) the E mode).
YES Check if power mode

switch is in the E
mode position.
Monitor auto-idle
switch. Check if Faulty MC.
displayed “AI” is NO
turned OFF or ON
in response to · Refer to T5-4-94.
auto-idle / auto-
acceleration
selector operation.
Faulty auto-idle /
· Monitor item: auto- acceleration
Auto-idle / auto-accel selector or broken
NO
switch harness between
auto-idle switch and
MC.
• Although the auto-idle / auto-acceleration selector is

turned OFF, the auto-idle control is operated.
• Be sure to separated auto-idle control from auto-

acceleration control.
YES Short circuited harness

between MC and auto-idle /
Monitor auto-idle / auto-acceleration selector.
auto-acceleration
selector. Check if
“AI” is displayed.
· Monitor item: Auto-idle / Faulty MC.

auto-accel switch NO
· Auto-idle / auto-
acceleration selector:
OFF
T5-4-35
E-9 Faulty E mode
• Even if power mode switch is turned to the E mode

position, engine speed remains unchanged. (Engine
speed doesn’t decrease.)
• In case trouble symptoms E-1 to E-8 are

recognized, perform the troubleshooting of these
troubles beforehand.
• Refer to the pages for E Mode Control in the
SYSTEM / Control System group in the T/M
Faulty power mode switch or
NO
broken harness between
Monitor power mode switch. power mode switch and MC.
Check if displayed “E Mode” is
turned OFF or ON in response
to power mode switch
operation. Faulty MC.
· Monitor item: YES
E/P/HP mode switch · Refer to T5-4-94.
• Although power mode switch isn’t turned into E

mode, engine speed decrease.
YES Short circuited harness

between MC and power mode
switch.
Monitor power mode switch.
Check if “E” is displayed.
· Monitor item: E/P/HP Faulty MC.

switch NO
· Power mode switch: P
mode
T5-4-36
E-10 Faulty auto-acceleration system
• Auto-acceleration system is inoperable.
Related Fault Code: 10, 11, 12, 13, 14, 15, 16, and
18

• Although the failure in pressure sensors (travel,
swing, boom raise, and arm roll-in), pump 1 and 2
delivery pressure sensors, and pump 1 and 2
control pressure sensors will have relevance to
malfunction of the auto-acceleration control.
However, if these sensors fail, other operating
functions will also be affected. (Refer to the
relationship between machine trouble symptoms
and related parts on page T5-4-2.)
• Refer to the pages for Auto-Acceleration Control
in the SYSTEM / Control System group in the T/M
(Operational Principle). Faulty auto-idle / auto-
NO acceleration selector or
Monitor auto-idle / auto- auto-acceleration switch and
acceleration selector. Check if MC.
displayed “AA” is turned OFF
or ON in response to auto-
acceleration switch operation. Faulty MC.
· Monitor item: YES
Auto-idle/auto-accel · Refer to T5-4-94.
switch
• Although auto-idle / acceleration selector is turned

OFF, the auto-idle acceleration control is operated.
• Be sure to separate the auto-idle control from the

auto-acceleration control.
Short circuited harness

YES
between MC and auto-idle /
Monitor auto-idle / auto-acceleration selector.
acceleration selector.
Check if “AA” is displayed.
· Monitor item: Auto-idle / auto-

accel switch Faulty MC.
· Auto-idle / auto-acceleration NO
selector: Auto-idle position
T5-4-37
E-11 When traveling or operating front
attachment with engine running at slow
idle, engine hunches.
• Although the failure in pressure sensors (travel

and front attachment) will have relevance to
malfunction of the engine speed increase control.
However, if these sensors fail, other operating
functions will also be affected. (Refer to the
relationship between machine trouble symptoms
and related parts on page T5-4-2.)
• Refer to the pages for Idle Speed-Up Control in
the SYSTEM / Control System group in the T/M
YES Faulty engine.
Check if engine speed is · Refer to the Engine Shop

faster than increased idle Manual.
speed.
· Monitor item: Faulty MC.
Engine target speed NO
· Possible to display with built-in · Refer to T5-4-94.
diagnosing system
T5-4-38
E-12 Engine speed doesn’t increase even if
attachment is operated in attachment
mode.

• Although the failure in pressure sensor (auxiliary)
and power mode switch will have relevance to the
malfunction of the attachment operation speed
increase control. However, if these sensor and
switches fail, other operating functions will also be
affected. (Refer to the relationship between
machine trouble symptoms and related parts on
page T5-4-2.)
• Refer to the pages for Attachment Operation
Speed Increase Control in the SYSTEM / Control
System group in the T/M (Operational Principle).
NO Normal (Set to
“Increase(+)”).
Check if attachment
NO speed adjustment
has been set to YES
“Increase(+)” in Dr. Monitor attachment To A
EX service mode. pilot pressure. Check
if pressure varies in
Check if P speed YES response to lever
adjustment has stroke. Faulty auxiliary
been set to NO pressure sensor.
“Decrease” in Dr. · Monitor item: Att.
EX service mode. control pressure
Normal (If set to

“Decrease”, this
control system is
YES
deactivated).
YES Faulty MC.
Monitor work mode

switch. Check if · Refer to T5-4-94.
display is turned
A On or OFF in
response to work
mode switch
operation. Faulty work mode
NO switch.
· Monitor item: Work
mode
T5-4-39
E-13 When attachment mode is selected, engine
speed doesn’t decrease.

• Refer to the pages for Attachment Operation
Speed Limit Control in the SYSTEM / Control
System group in the T/M (Operational Principle).
YES Faulty MC.
Monitor work mode

switch. Check if
YES display is turned ON
or OFF in response
to work mode switch
operation. Faulty work mode
Check if
attachment speed · Monitor item: Work switch.
NO
adjustment has mode
been set to
“Decrease (-)” in
Dr. EX service
mode.
Normal (Set to
“Increase (+)”.)
NO
T5-4-40
E-14 Engine stalls within several seconds after
engine has started.
• Refer to the pages for Engine Learning Control in

the SYSTEM / Control System group in the T/M
• If the engine learning switch is turned to the
learning position, the engine will stall in 5 seconds
after the engine starts.
YES Normal (Return switch

to neutral).
Check if engine
learning switch is
turned to the learning Faulty learning switch,
position. or short-circuited
harness between
learning switch and MC,
NO
or check fuel system for
clogging.
T5-4-41
E-15 Engine stalls during operation under
adverse condition such as at high altitude.
• If speed sensing control is inoperable, the engine

will stall under adverse operating conditions.
Monitor torque control Disconnect torque

solenoid valve output. control solenoid valve.
Install pressure gauge NO Connect test harness
to output port so that (ST 7123) between
pressure can be solenoid valve and
measured by pressure harness. Check if test
gauge and Dr. EX. harness lamp comes
NO Check if both ON.
measured pressure
values by pressure
gauge and Dr. EX vary
identically.
Disassemble to check
Monitor actual engine · Monitor item: Pump YES regulator.
speed. Check if engine Torque Proportional
speed is abnormal. Solenoid Valve Output
· Refer to the Operational
· Monitor item: Performance Test
Engine Actual Speed section.
Faulty N sensor, or
faulty harness
YES between N sensor
and MC.
T5-4-42
YES Faulty torque control

solenoid valve.
Broken harness
between torque
NO control solenoid valve
and MC.
T5-4-43
E-16 Engine is difficult to start at low
temperature. (During cold weather or in
cold districts, the engine is difficult to start
or doesn’t start although pre-heated.)
• Check if electricity is routed to the glow plugs.

Check the glow plugs for any abnormality.
• The pre-heat system operates only when coolant
temperature is below 10 °C (50 °F). When coolant
temperature is higher than 10 °C (50 °F), the pre-
heat system doesn’t operate.
• Check battery at the same time.
YES Faulty coolant temperature

switch.
Disconnect coolant
temperature switch. Check if
voltage at glow plug is 20 to 24
YES Faulty QOS controller.
V.
· Key switch: ON
Disconnect QOS controller.
Ground harness end connector
NO terminal #4 to vehicle frame.
Check if problem is corrected.
· Using a clip, ground from the Measure each glow plug

reverse side of the connector NO resistance.
without disconnecting.
· Key switch: ON
· Before measuring, remove
copper plates connecting
each glow plug.
• Measurement of Glow Plug Voltage and Resistance

Voltage Check Resistance Check
Remove
the
copper
plate.
Specification: 20 to 24 V Specification: Below 10 Ω

T105-07-04-006 T105-07-04-007
T5-4-44
∞Ω Faulty glow plug.
NO Faulty glow relay, or broken

harness between glow relay
and glow plug.
Connect glow relay.
YES Connect harness end
connector terminal #4 to
vehicle frame. Check if
voltage at glow plug is 20
to 24 V. Broken harness between glow
relay and QOS controller, or
Disconnect glow relay. · Key switch: ON YES faulty engine unit.
Check if voltage at glow
relay harness end · Refer to the Engine Shop Manual.
Below 10 Ω connector terminals #1 or
#3 is 20 to 24 V.
In case voltage at terminal #1
· Key switch: ON is 0 V, harness between glow
relay and batteries is broken.
In case voltage at terminal #3
NO is 0 V, harness between glow
relay and key switch terminal
M is broken.
· Verify that fuse #19 is normal.
T5-4-45
ALL ACTUATOR SYSTEM TROUBLE-
SHOOTING
A-1 All actuator speeds are slow.
• Reduction in pump 1 and 2 flow rate due to some

reasons or faulty pilot system may cause this trou-
ble.
• Also, check for fuse of the torque control solenoid
valve.
• Although speed is satisfactory, in case power is
weak, refer to the troubleshooting for faulty relief
valve (F-1).
YES Faulty pilot pump or

clogged pilot filter.
Check if same
NO symptom still ap-
pears after disas-
sembling, cleaning,
and adjusting pilot End.
relief valve. NO
Check if primary
pilot pressure is Faulty N sensor or
normal. YES broken harness in N
sensor circuit.
· Fully boom raised or arm
roll-in
· Monitor item: Boom raise
pilot pressure, arm roll-in Monitor actual en-
pilot pressure gine speed. Check
if abnormal speed Install pressure YES
YES
is indicated. gauge to torque
control solenoid
· Monitor item: Engine valve output port.
actual speed Check if pressure
· Possible to display in is 0 MPa when
built-in diagnosing NO
control levers are
system in neutral.
· Engine: Running
NO
T5-4-46
Faulty pump device.
YES Faulty MC.

Disconnect torque
control solenoid
valve. Check if
symptom is cor-
rected.
· Engine: Running Faulty torque control solenoid

NO valve.
T5-4-47
A-2 Left travel is inoperable during single travel
operation. Single swing operation speed is
slow. Arm is slightly slow during arm level
crowding. (All problems occur at the same
time.)
• The pump 2 flow rate is minimized (approx. 20

L/min) due to some reasons. Accordingly, the left
travel and swing motors, which are driven by pres-
sure oil from pump 2, moves very slow.
• Pressure oil from pump 1 is also routed to the arm
and boom cylinders so that the arm and boom can
move at a slightly slow speed in single operation.
However, in level crowd operation, pressure oil is
routed to the boom prior to the arm so that arm
speed becomes very slow.
• Refer to the SYSTEM / Hydraulic System group in
YES Faulty pump 2 regula-

tor.
Monitor pump 2
pump control pres-
sure. Check if
pressure increases
in proportion to left
travel lever stroke. Seized pump control
· Monitor item: Pump valve (5-spool side)
NO spool in control valve.
2 pump flow control
pressure
· Possible to display
with built-in diagnos-
ing system.
T5-4-48
A-3 Right travel is inoperable during single travel
operation. Single bucket operation speed is
slow. Boom is not raised properly during
arm level crowding. (All problems occur at
the same time.)
• The pump 1 flow rate is minimized (approx. 20

L/min) due to some reasons. Accordingly, the right
travel motor and bucket cylinder, which are actu-
ated by pressure oil from pump 1, moves very slow.
• Pressure oil from pump 2 is also routed to the arm
and boom cylinders so that the arm and boom can
move at a slightly slow speed in single operation.
However, in level crowd operation, pressure oil is
routed to the arm prior to the boom so that boom is
scarcely raised.
YES Faulty pump 1 regula-

tor.
Monitor pump 1
pump control pres-
sure. Check if
pressure increases
in proportion to
right travel lever
Seized pump control
stroke.
valve (4-spool side)
· Monitor item: Pump NO spool in control valve.
1 pump flow control
pressure
with built-in diag-
nosing system.
T5-4-49
A-4 Actuator doesn’t stop even if control lever is
returned to neutral.
• Bound spool in the pilot valve or bound main spool

in the control valve is suspected.
YES Faulty pilot valve.
· When control lever is in neu-

Check if actuator stops when tral, pilot pressure is routed to
pilot control shut-off lever is spool end in control valve.
raised.
Faulty control valve.

NO
· Although pilot pressure is not
routed to spool end in control
valve, spool is kept opened
due to binding of spool.
T5-4-50
A-5 Actuator speed is faster than normal
Machine mistracks when travel lever is oper-
ated at half stroke. Precise control can not
be performed.
• 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
doesn’t reach the full stroke.
• The pressure oil from pump 1 makes right travel
perform, and the pressure oil from pump 2 makes
left travel. Perform on the single travel operation.
Different flow rates between pump 1 and pump 2
occur, and the machine mistracks. When the
travel lever is operated at half stroke.
YES Faulty pump regulator.
Monitor pump control pressure

of pump 1 and 2. Check if the
pressure changes in response
to the lever operation.
Bound pump control valve
· Pump 1: Bucket operation
NO spool in control valve.
· Pump 2: Swing operation
· Monitor item: Pump 1 and 2
pump control pressures
· Possible to display with built-
in diagnosing system.
T5-4-51
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
F-1 All front attachment actuator power is weak.
• In case operating speeds are extremely slow,

pump control may be malfunctioning (A-2 and/or
A-3). Faulty pilot system may also cause this trou-
ble.
+2.0
31.4 -0.5 MPa Main relief valve should be
+20 2
(320 -5 kgf/cm ) normal. Find out cause of
trouble by tracing other trou-
ble symptoms.
Monitor pump 1 and 2 delivery
pressures.
· Monitor item: Pump 1 and 2 de- Adjust main relief valve.
livery pressure Less than 31.4 MPa
2
· Possible to display with built-in (320 kgf/cm )
diagnosing system.
· Relieve boom, arm, and bucket
circuits.
· Power mode switch: OFF
· Work mode: Digging
F-2 Even if power digging switch is pressed,

power doesn’t increase. Boom raise power is
weak when digging.
Related fault Code: None
• Refer to the pages for the Power Digging Control

and the Auto-Power Lift Control in the SYSTEM /
Control System group in the T/M (Operational
Principle).
Pressure Increases.
2
Less than 31.4 MPa (320 kgf/cm ) Normal (Possibly, Faulty power digging
Ҵ NO switch or broken har-
2 HP mode is taken for
34.3 MPa (350 kgf/cm ) power digging ness between power
mode.) digging switch and MC.
Monitor pump 1
and 2 delivery
pressures. Monitor power dig-
· Monitor item: ging switch. Check
Remains unchanged.
Pump 1 and 2 deliv- if indication “Pd” is
Pressure turned ON or OFF
ery pressure Check pressure at so-
doesn’t in response to
· Possible to display lenoid valve unit (SG)
increase. power digging
with built-in diagnos- YES port.
ing system. switch operation.
· Check pump delivery · Check pressure
· Monitor item: change while pressing
pressure change Power digging (Boost)
while pressing power power digging switch.
switch · Measurement: Refer to
digging switch. · Proceed to YES if boom Changes.
the Operational Per- 2
raise power is weak in formance Test section. Less than 0.49 MPa (5 kgf/cm )
digging operation. Ҵ
2
Less than 0.98 MPa (10 kgf/cm )
T5-4-52
Disconnect solenoid YES Faulty solenoid valve unit

valve unit (SG). Con- (SG).
nect test harness (ST
7123) between sole-
noid valve unit and
harness. Check if test
harness lamp comes Faulty harness between sole-
ON. NO noid valve unit (SG) and MC.
· Power Digging Switch:
ON
Faulty main relief valve.
T5-4-53
F-3 Some cylinders are inoperable or speeds are
slow.
• When other actuators (travel and swing motors)

operate normally, the pilot pump (primary pilot
pressure) is considered to be normal.
• In case single bucket operation speed is slow, re-
fer to F-6.
• In case single arm roll-in operation speed is slow,
refer to F-7.
• In case single boom lower operation speed is slow,
YES Faulty cylinder (faulty
refer to F-8.
seal kit).
Monitor pump control YES Check if overload
pressure. Check if relief pressure is
pump control pres- normal.
sure changes Faulty overload relief
YES smoothly while mov- NO valve.
Monitor or meas- ing control lever
ure secondary pilot slowly.
pressure. Check if · Monitor item: Seized control valve
secondary pilot Pump 1 flow control NO spool.
pressure is normal. pressure, pump 2 flow
· Secondary pilot pres- control pressure
sure: · Possible to display with
Refer to Operational built-in diagnosing sys-
tem. YES Faulty pilot valve.
Performance Test Sec-
tion. Check if secondary
· Monitor item: Boom pilot pressure is cor-
raise pilot pressure, arm NO rect at the inlet port of
roll-in pilot pressure the shockless valve. Seized shockless
· Possible to display with NO valve spool.
built-in diagnosing sys- · Check only when
tem arm is not rolled-
· In case of boom lower, out. In case cylin-
bucket roll-out/in and ders other than arm
arm roll-out, connect roll-out are abnor-
the pressure gauge to mal, skip this step
the pilot port in control and proceed to the
valve. NO line.
Shockless Valve
2 1
3
4
5
6 1- From Swing Left Pilot Valve
7 2- From Swing Right Pilot Valve
3- From Bucket Roll-Out Pilot Valve
8 4- From Bucket Roll-In Pilot Valve
5- From Boom Raise Pilot Valve
6- From Boom Lower Pilot Valve
7- From Arm Roll-Out Pilot Valve
8- From Arm Roll-In Pilot Valve
T1HH-03-06-001
T5-4-54
F-4 During the Combined Operation of Travel
and Boom Raise, Boom does not Rise.

• During the combined operation of travel and boom
raise, the travel flow rate control valve supplies
the pump flow rate for boom raise. If the boom
does not rise during the combined operation of
travel and boom raise, faulty travel flow rate con-
trol valve may be the cause of the trouble.
• Refer to the COMPONENT OPERATION/Control
Valve group in the T/M (Operational Principle).
T5-4-55
F-5 Arm speed is slow in a combined operation.
Arm speed is slow during arm level crowd-
ing.
• Refer to the pages for the Arm Regenerative Con-

trol in the SYSTEM / Control System group in the
T/M (Operational Principle).
Disconnect solenoid
valve unit (SC). Con- YES Faulty solenoid valve
nect test harness (ST unit (SC).
7123) between sole-
NO noid valve unit (SC)
Monitor output from
solenoid valve unit and harness. Check if Broken harness be-
(SC). Install pressure test harness lamp tween solenoid valve
gauge to port SC. comes ON. NO unit (SC) and MC.
NO Compare pressure · Perform boom raise and
measured by Dr. EX arm roll-in combined
with that measured by operation.
pressure gauge. Check
if both pressure values
vary identically.
YES
· Monitor item:
Arm Regenerative Propor-
tional Solenoid Valve
Output
Check if any fault · Perform boom raise and
codes are dis- arm roll-in combined op-
played. eration.
· Refer to the Operational
· Fault Codes: Performance Test.
11: Pump 2 Delivery
Pressure Sensor
14: Pressure Sensor
(Swing)
15: Pressure Sensor Faulty corresponding
(Boom Raise) sensor or faulty MC, or
16: Pressure Sensor YES broken harness be-
(Arm Roll-In) tween MC and sensor.
NOTE: In case other fault

codes are displayed,
perform troubleshoot-
ing corresponding to
the displayed fault
code.
T5-4-56
YES Faulty arm regen-

erative valve.
Check if arm regen-

erative valve in 4- YES Faulty check valve
spool section of con- and orifice (4-spool).
trol valve is scored or
bound. Check if check valve YES Faulty orifice
and orifice in control (5-spool).
NO valve (4-spool) parallel
circuit are scored, Check if orifice in con-
seized or blocked. trol valve (5-spool) arm
1 parallel circuit is
NO blocked.
Find out cause of
trouble by tracing
NO other trouble symp-
toms.
T5-4-57
F-6 Bucket is slow in bucket roll-in single opera-
tion. Bucket doesn’t move smoothly in
bucket roll-in single operation.
• Faulty bucket flow rate control valve or bucket re-

generative valve may cause this trouble.
• Refer to the COMPONENT OPERATION / Control Faulty bucket regen-
YES
Valve group in the T/M (Operational Principle). erative valve
(Disassemble and
Check if bucket re- clean, or replace.)
Disconnect pipe SL and
YES generative valve in
adapter connected bucket flow
rate control valve (switch valve bucket spool is
B) in the control valve from bound or scored. Find out cause of trou-
bucket flow rate control valve ble by tracing other
(switch valve A). Connect NO trouble symptoms.
NO adapters (PF 1/4) (2 used),
hoses (2 used), a tee and a
pressure gauge between
bucket flow rate control valve
(switch valve A and B).
Check if bucket flow Bound bucket flow rate
Check if relief pressure is ap-
rate control valve 2 control valve (switch
prox. 3.9 MPa (40 kgf/cm )
(switch valve B) in NO valve A) control spool
while performing 3-function
control valve is in signal control valve.
combined operation of boom
bound or scored. raise, arm roll-in, and bucket
roll-in.
Faulty bucket flow rate
control valve (switch
YES valve B). (Disassemble
and clean, or replace.)
Bucket Flow Rate

Control Valve
(Switch Valve B)
T1HH-05-04-001
Pipe (SL) Bucket Flow Rate

Control Valve
(Switch Valve A)
T5-4-58
F-7 When starting to move in combined opera-
tion, arm doesn’t smoothly move. Arm starts
to move slightly slow in arm roll-in single
operation. These troubles often occur when
oil temperature is low.
• Refer to the COMPONENT OPERATION / Control

Valve group in the T/M (Operational Principle).
Faulty arm regenerative valve

YES
(Disassemble to clean, or re-
place.)
NO Check if arm regenera-
tive valve is bound or
scored. Find out cause of trouble by
Check if arm anti-drift valve is tracing other trouble symp-
NO toms.
bound or scored.
· Be sure to check both rod Faulty arm anti-drift valve
side and bottom side. YES (Disassemble to clean, or re-
place.)
T5-4-59
F-8 Boom Starting Speed is Slow and/or Jerky
During Combined Operations. During Boom
Lower Single Operation, Boom Speed is
Slightly Slow.

• Refer to the boom regenerative valve and the
boom anti-drift valve in COMPONENT OPERA-
TION / Control Valve group in T/M (Operational
Principle).
Trace the cause of the

NO trouble by checking other
symptoms.
Check if boom regen-
NO erative valve is seized
or scored. Faulty boom regenera-
tive valve. (Clean or re-
Check if boom anti- YES place boom regenerative
drift valve is seized valve.)
or scored.
Faulty boom anti-drift
valve. (Clean or replace
YES boom anti-drift valve.)
T5-4-60
(Blank)
T5-4-61
F-9 When Operating the Control Lever to Raise
Boom or to Roll-out Arm, Boom or Arm
Starts to Move after Slightly Moving in the
Reverse Direction.
YES Faulty anti-drift valve.
Check if anti-drift valve for

YES arm or boom is seized or
scored.
Cylinder internal leakage.
Check if load check valve NO
in control valve operates
correctly.
· Disassemble and visu-
ally check. Faulty load check valve.
NO
T5-4-62
NOTE: 1. During the initial stage of operation, oil

pressure and flow rate from the pump is
low. Therefore, if the load check valve is (B)
malfunctioning, the oil in the bottom side
of the boom cylinder flows back into the When the load check
circuit through the load check valve, valve is malfunctioning:
(A)
causing the boom cylinder to
temporarily retract.
2. If the clearance between the piston and
the cylinder barrel is poor, oil pressure in
the bottom side (A) leaks to rod side (B).
As oil pressure and flow rate from the
pump is low during the initial stage of
operation, and if the amount of oil
leaking through the gap between the T105-07-04-012
piston and the barrel is large, the

cylinder is temporarily retracted. In
addition, cylinder force is reduced. In
this case, the cylinder drift is also
increased.
T5-4-63
F-10 Front Attachment Cylinder Drift is Large.
YES Normal.
NO Close needle valve.

Check if each front
attachment cylin-
der drift is within Check if needle valve
the specified value. NO in boom 1 section in 4-
spool control valve is Check if the symptom
completely closed. is deleted when the
overload valve is tem-
Check if the cylinder porarily switched with
drift is reduced when YES
one in an other cylinder
NO pilot shut-off valve is circuit.
closed.
Faulty pilot valve.

YES
Needle Valve
Lock Nut
M1HH-05-001
T5-4-64
Scored spool or dam-

NO aged spring in control
valve or loose spool end.
NO Check if internal leak-

age exists in cylinder.
Faulty cylinder. (Replace seal

NO Check if boom or arm
YES kit.)
anti-drift valve is seized
or clogged.
Faulty anti-drift valve. (Clean

YES or replace anti-drift valve.)
Faulty overload relief valve.

YES
• Boom Cylinder Internal Leakage Check
1. With the bucket cylinder fully retracted and the

arm cylinder slightly extended from the fully
retracted position, lower the bucket tooth tips onto
the ground.
2. Disconnect hoses to the boom cylinder rod side.

Then, drain oil from hoses and cylinders. (Plug the
disconnected hose ports.)
3. Retract the arm cylinder to lift the bucket above

the ground.
T105-07-04-009
At this time, if oil flows out of the pipes from which
the hoses were disconnected and the boom
cylinder is retracted, internal leakage in the boom
cylinder exists.
If no oil flows out of the pipes from which the
hoses were disconnected but the boom cylinder is
retracted, internal leakage in the control valve
exists.
T5-4-65
SWING SYSTEM TROUBLESHOOTING
S-1 Swing Speed is Slow or Swing Function
Does not Operate.

• Check whether the pilot system is malfunctioning
or the main hydraulic system is malfunctioning.
• If other functions (front attachment or travel)
operate normally, the pilot pump is considered to
be normal. If the pilot system is malfunctioning,
the cause of the trouble may exist in the pilot
system after the pilot valve.
• When the left travel speed is also slow, refer to A-
2.
Check if swing motor

YES
oil drain amount is
normal.
· Measurement: Refer
to Operational Per-
YES Check if swing relief formance Test sec-
pressure is normal. tion.
Monitor the pump con- · Swing relief pressure

trol pressure. While · Monitor item: Faulty swing relief
slowly operating the Pump 2 delivery pressure NO valve.
YES · Specification:
control lever, check if
the pump control pres- Refer to Operational Per-
sure changes smoothly. formance Test section.
· Possible to display with
built-in diagnosing system.
Check if the pilot Seized pump control
· Monitor item:
secondary pressure valve (5-spool) spool in
Pump 2 pump control NO
is normal. control valve.
pressure
· Specification: · Possible to display
Refer to Operational with built-in diagnosing
Performance Test system. Faulty pilot valve.
section. NO
· Monitor item: Swing
control pressure
ing system.
T5-4-66
NO Faulty swing reduction

device.
Check if the switch
YES valve for swing motor
parking brake release
is scored or seized. Faulty the switch valve
for swing motor parking
YES brake release.
Faulty swing motor.

NO
T5-4-67
(Blank)
T5-4-68
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Both Right and Left Travel Side Tracks Do
Not Move or Move Slowly.
Checking Instructions
• Pilot valves, travel motors, control valve spools in

both right and left travel systems are unlikely to be
faulty at the same time.
• If both travel systems do not operate, the pilot
system, which is applied to both side travel motors,
may be faulty. If the pilot primary pump delivery
pressure is lower than specification, the front
attachment does not operate as well. Refer to A-1.
• If the travel doesn’t change into the fast speed,
refer to T-7.
T-2 When a Combined Operation with Boom

Raise is Made, a Large Shock is Felt.
• Travel flow control valve might be seized.

• Refer to the Travel Flow Rate Control Vavle in
COMPONENT OPERATION / Control Valve group
in T/M (Operational Principle).
T5-4-69
T-3 One Side Track does not Move or Move
Slowly, or the Machine cannot Travel
Straight (Mistracks).
• Check if the slack of both track is epual.
• If one side system only does not operate, pilot
valve, control valve, travel motor, or center joint YES Check if travel motor oil
might be faulty. drain amount is normal.
• Mistracks occur due to faulty pump control. In this
case, a symptom such as bucket or swing · Specification: Refer to
Check if travel relief Operational Perform-
function speed is slow in single operation, or arm ance Test section.
roll-in or boom raise speed is slow is recognized. NO pressure in slow speed
side system is normal.
Refer to A-2 and A-3 if a symptom and mistracks
occur at the same time.
· Relieve travel system.
· Monitor item: Pump 1
Check if the symptom is and 2 delivery pres-
reversed when right sure Switch rear and front or
YES and left travel line · Specification: Refer to right and left travel relief
hoses connected to top Operational Perform- valves with each other.
of center joint are ance Test section.
Check if travel pilot NO Check if symptom is
switched with each · Possible to display
secondary pressure reversed.
other. with built-in diagnosing
is normal. system.
· Monitor item: Travel Seized control valve
control pressure YES spool.
ing system. Faulty pilot valve.
NO
Seal Position
Relation between Faulty Seal Position and
Mistrack Derection
Seal
Traveling Pivot Turn
No.
External oil 1
1
leakage
←
2 2
Left Travel 3
(Reverse)
3 Right Travel
(Reverse)
Left Travel 4
(Forward) 5
4
Right Travel
(Forward)
6
5
7
T105-07-04-015
6
External oil
7 ←
leakage
T5-4-70
NO Faulty travel motor.
YES Faulty travel reduction

Disassemble and clean gear.
YES travel motor servo pis-
ton. Check if same
Disassemble and clean problem occurs again.
Faulty travel motor
travel motor counterbal- servo piston.
ance. Check if same NO
YES problem occurs again.
Faulty counterbalance
NO valve.
NO Faulty center joint.
Faulty travel relief

YES valve.
Pipe Layout
1 2 Front
5 4 W157-03-03-003
1 - Left Travel (Forward) 3 - Pilot 5 - Left Travel (Reverse) 6 - Drain

2 - Right Travel (Forward) 4 - Right Travel (Reverse)
T5-4-71
T-4 During a Combined Operation of Travel and
Front Function, the Machine Mistracks.

YES Faulty load check valve.
YES Check if load check

valve is normal.
Trace the cause of the
Check if flow com- trouble by checking other
biner valve in con- NO symptoms.
trol valve is normal.
Faulty flow combiner valve.
NO
T-5 Occasionally, machine mistracks when trav-

eling with engine running at slow speed.
Related Fault Codes: 10, 11, and 18
• Refer to the pages for the Slow Speed Torque In-

crease Control in the SYSTEM / Control System
group in the T/M (Operational Principle).
Faulty corresponding
YES sensor or broken har-
ness between MC and
corresponding sensor.
Monitor output pres-
sure from torque con-
Check is any fault
trol solenoid valve. YES
code is displayed. Faulty pump device.
Install pressure gauge
· Fault Codes: to torque control sole-
10: Pump 1 Deliv- noid valve output port.
ery Pressure Sen- Check if both pres-
sures measured by Faulty torque control
sor solenoid valve or MC, or
11: Pump 2 Deliv- NO pressure gauge and YES broken harness between
ery Pressure Sen- Dr. EX varies identi- Monitor travel pilot
cally by approx. 1.5 torque control solenoid
sor 2 pressure. Check if valve and MC.
18: Pressure Sen- MPa (15 kgf/cm ) pressure varies in
sor (Travel) when travel operation NO response to travel
· Possible to display is made. lever operation. Faulty pressure sensor
with built-in diag- (travel).
· Monitor item: NO
nosing system · Monitor item:
Pump Torque Propor-
tional Solenoid Valve Travel Control Pilot
Output Pressure
· Engine:
Running at slow idle
speed
T5-4-72
T-6 No steering force and no gradeability when
travel mode is Fast.
Monitor travel motor swash NO Find out cause of trouble

angle control. by other symptoms.
Connect a pressure gauge to
port SI in solenoid valve unit
and operate travel and travel
relief. Seized solenoid valve unit
Check if the pressure changes (SI).
YES
with both pressures of Dr.EX
and the pressure gauge are
equal.
· Monitor item: Travel motor con-

trol pressure
· Travel mode: Fast
· How to Travel: Refer to Opera-
tional Performance Test.
T5-4-73
T-7 Fast travel is inoperable.
Travel mode doesn’t change from slow mode
to fast mode.
• Refer to the pages for the Travel Motor Swash

Angle Control in the SYSTEM / Control section in
NO Faulty travel mode switch or
travel mode switch and MC.
Monitor travel mode Check if symptom is re-

switch. Check if dis- versed when pressure
NO
NO played indication is sensor (travel) is switched
highlighted in response with another pressure sen-
to travel mode switch sor.
operation.
· Monitor: Travel mode
Monitor pressure sen-
sor (travel). Check if
pressure varies in re- Monitor travel motor swash
YES sponse to travel lever angle. Install pressure
operation. gauge to solenoid valve
unit (SI) output port. Check
Check if any fault · Monitor: Travel control if pressure measured by
codes are displayed. pressure Dr. EX varies identically
· Possible to display with with pressure measured by
built-in diagnosing sys- pressure gauge while re-
tem. YES peating to travel and stop.
· Monitor:
Travel motor control pres-
sure
· Travel mode: Fast
· Measurement: Refer to
OPERATIONAL PER-
FORMANCE TEST section.
Faulty corresponding sen-

sor or broken harness be-
YES tween MC and sensor.
· Fault Codes:
10: Pump 1 Delivery Pressure Sensor
11: Pump 2 Delivery Pressure Sensor
12: Pump 1 Control Pressure Sensor
(4-Spool)
13: Pump 2 Control Pressure Sensor
(5-Spool)
NOTE: In case other fault codes

are displayed, perform
troubleshooting corre-
sponding to the displayed
fault code.
T5-4-74
YES Faulty pressure sensor

(travel).
Broken harness between

travel pressure sensor
NO
(travel) and MC.
Disconnect solenoid
valve unit (SI). Connect YES Faulty solenoid valve unit
test harness (ST 7123) (SI).
NO between solenoid valve
unit (SI) and harness.
Check if test harness Broken harness between
lamp comes ON. solenoid valve and MC.
NO
· Travel Mode: Fast
YES Faulty travel motor swash

Check if travel motor angle control valve.
swash angle control
YES valve is bound or
scored. Faulty travel motor or travel
NO reduction gear.
T5-4-75
OTHER SYSTEM TROUBLESHOOTING
O-1 Wiper is inoperable or not retracted.
• The wiper is driven by electric power routed via

the relay circuit controlled by the monitor assem-
bly. In case the wiper is inoperable, first check the
wiper motor and links for any abnormality using an
auxiliary electric power and the test harness.
• If the front window is open, the wiper won’t oper-
ate. Check that the front window is securely
closed.
Faulty front window

open/close switch or
YES
short-circuited harness
between front window
open/close switch and
monitor.
Disconnect front
window open / close YES Faulty wiper relay.
Remove test harness
switch. Check if and reconnect circuit to
wiper operate. YES the original position.
Connect test harness
· Key switch: ON (ST 7227) between Replace wiper relay
auxiliary electric one at a time to see if
power (fuse box #19) wiper operates. To A
NO
NO
and wiper motor as · KeyÔswitch:
ࡗƱ ON
illustrated to the right. ʝ
Check if wiper oper- Faulty wiper motor or
ate. links.
NO or test har-
· Key switch: ON ness lamp doesn’t
light normally.
NOTE: When the wiper motor
is normal, lamp S lights
while the wiper is mov-
ing within the operating
range. Both lamps B YES End (Faulty monitor).
and S light for a mo-
ment at the same time
Replace monitor as-
only when the wiper
A sembly to see if wiper
reaches the intermittent
operates.
stop position. Faulty cab harness.
NO
T5-4-76
Test Harness Application Circuit

Fuse Box #19
Lamp S
M B S
Lamp B Wiper Motor
L E
Ground
T178-05-04-004
Wiper Operating Range Intermittent Stop Position
Retracted Position
Operating Range
T178-05-04-005
Test Harness Connection Method
Wiper Motor Lamp B
Lamp S
Test Harness Fuse Box
T157-07-04-004
T5-4-77
O-2 Air Conditioner Malfunction
The air conditioner operation system has a self-

diagnosing function. This system performs the diag-
nosis by 6-steps as shown in the flow chart below:
Check Model Confirmation, Display Function Confir-
mation, Present Trouble Diagnosing, Past Trouble
Diagnosing, Sensing Temperature Display, and Com-
ponent Operation Check.
Normal Operation
Turn key switch ON while pressing air

conditioner switch and mode switch.
Keep pressing OFF switch

for more than 3 seconds. STEP 0
Check Model
Confirmation
Press lower side fan switch. Press upper side fan switch.
Display Function
Confirmation
Present Trouble
Diagnosing
Keep pressing OFF switch Keep pressing air conditioner
STEP 3 switch for more than 3 seconds.
for more than 3 seconds.
Past Trouble
Diagnosing
Keep pressing OFF switch STEP 4
for more than 3 seconds. Sensing Tem-
perature Display
Component Op-
eration Check
Self-Diagnosis
T5-4-78
Self-Diagnostic System Activation
Fan Switch LCD Air Conditioner Switch
Turn the key switch ON while pressing 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 machine
model name this system can diagnose. T178-05-08-001
Mode Switch OFF Switch

• The LCD will indicate “5d” as the check model
name.
(ZAXIS330, 350H, 350K and 370MTH)
• Select next step to be performed by operating the
switch as described below.
• Upper side fan switch: To proceed to Step 1
• Keep pressing OFF switch for more than 3 sec-
onds: To return to normal operation
NOTE: The system operation will automatically
proceed to STEP 1 after 5 seconds have
passed after the check model is displayed.
STEP 1 Display Function Confirmation

Turn all indicators ON to check indicator bulbs.
• The LCD panel and all switch indicators light.

• Select the next step to be performed by operating
the switches as follows:
• Press the upper side of the fan switch: To proceed
to “STEP 2.”
• Press the lower side of the fan switch: To return to
“STEP 0.”
• Keep pressing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed)
T5-4-79
STEP 2 Present Trouble Diagnosing
The LCD indicates the fault codes for present abnor-
Fan Switch LCD
malities of the mix door, mode encoder, and/or sen-
sors.
• In case any abnormalities are present, the LCD indi-

cates the fault codes. If more than one fault code is
detected, the following fault code is displayed after
flashing (0.5 seconds) twice.
Fault Code T178-05-08-001
Breakage Short Circuit OFF Switch
Mix Door 21 −21
Mode Encoder 22
In-Cab Ambient 23 −23
Temperature Sen-
sor
Outdoor Ambient 24 −24
Temperature Sen-
sor
Coolant Tempera- 25 −25
ture Sensor
∗
Solar Radiation 26 −26
Sensor
∗
: When solar radiation is shaded, the solar radiation
sensor indicates the fault code of breakage.
to “STEP 3.”
“STEP 1.”
T5-4-80
STEP 3 Past Trouble Diagnosing
The LCD indicates the fault codes for past abnormali-
ties of the mix door, mode encoder, and/or sensors.
The past stored fault codes are deleted.
• In case any abnormalities occurred in the past, the

LCD indicates the fault codes. If more than one fault
code is detected, the following fault code is dis-
played after flashing (0.5 seconds) twice.
Fault Code T178-05-08-001
Breakage Short Circuit OFF Switch
Mix Door 21 −21
Mode Encoder 22
In-Cab Ambient
Temperature Sen- 23 −23
sor
Outdoor Ambient
Temperature Sen- 24 −24
sor
Coolant Tempera- 25 −25
ture Sensor
Solar Radiation −26
Sensor
• When the air conditioner switch is kept pressed for
more than 3 seconds, failure records are deleted. Af-
ter this operation, the air conditioner switch indicator
flashes 5 times. Then, the self-diagnosing system is
deactivated. (Normal functions are resumed.)Ж
the switches as follows:Ж
to “STEP 4.”
“STEP 2.”
T5-4-81
STEP 4 Sensing Temperature Display Fan Mark
The LCD indicates the sensing temperature detected
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. (Figures less
than the decimal point are not displayed.) T178-05-08-001
NOTE: The coolant temperature sensor indicates Fresh Air Vent Switch OFF Switch
“H” when coolant temperature is more than
21 °C (70 °F) and “L” when coolant tem-
perature is less than 21 °C (70 °F).
• Sensing temperature detected by each sensor is
automatically displayed on the LCD and is cycled at
an interval of 3 seconds with the timer. The timer is
turned ON or OFF by operating the fresh air vent
switch.
• Referring to the fan mark can check which sensing
temperature is displayed.
to “STEP 5.”
“STEP 3.”
T5-4-82
STEP 5 Component Operation Check
Fan Switch LCD
Each component operation is checked by performing
pattern operation.
• Each time the fresh air vent switch is pressed, the

component to be checked is selected in order.
Check which component has been selected by refer-
ring to No. indicated on the LCD. (See table 1.)
• Operating pattern of the selected component is T178-05-08-001
shifted at an interval of 10 seconds. Operating pat-
Fresh Air Vent switch OFF Switch
tern is cycled. (See table 1.)
NOTE: The components other than selected oper-
ate under the standard conditions (shown
by marks* in table 1).
“STEP 4.”
Table 1
Component Indication Operation Pattern Remarks
on LCD
Air Mix Damper 51 Controls opening extent of air mix 0%, 50%, 100%: “C”, “5”, and “H” are
damper: 0% (fully closed) → indicated next to the decimal point re-
50%*→ 100% (fully opened) spectively.
Fan 52 Controls air flow volume: Lo → Indicators corresponding to air flow vol-
M(Lo) → M(Hi) → Hi ume light.
Air Vent Location 53 Selects air vent: Front*→ Indicator corresponding to selected air
Front/Rear → Front/Foot → Foot vent lights.
Fresh/Circula- 54 Select Ventilation Mode: Circula- Indicator corresponding to selected
tion Air Vent Se- tion* → Fresh mode light.
lection
Air Conditioner 55 Turns air conditioner switch: ON* ON: Indicator lights.
→ OFF OFF: Indicator is extinguished.
T5-4-83
Ұ Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to Hitachi Tsuchiura Works Quality Assurance Dept. after
experiencing a problem with your machine’s air conditioning system.
< AIR CONDITIONER TROUBLE REPORT >ȀȀȀȀȀȀȀȀȀȀ File NoȎ
(1) What
Checked by:
Model (Serial No. )
Operation Type Manual Semi-Auto Full-Auto
Delivery Date Year Month
(2) When
Date Year Month Day Operating Hour ( h)
Time Morning Daytime Evening Night
Frequency Every Day Once a Week Once a Month Times per
(3) Where
Job Site Address State County Town
Access Road Condition Paved Not Paved (Gravel Sand Soil)
(4) How (Operating Conditions)
Weather Fine Cloudy Rain Snow
Atmospheric Temperature Very Hot Hot Cold Very Cold
Operating Conditions Parking Traveling Working
Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when
full-auto operation
A/C ON OFF
Air Induction Re-Circulation Fresh Air Circulation
Control
AUTO ON OFF Not Available
Panel
Fill following items when operated in manual mode or when manual control type unit is used.
Vent Position Front Front / Rear Foot Front / Rear and Foot
Fan First Second Third Fourth Fifth Sixth
(5) How (Problem Symptom)
Abnormal Compressor Operation
Symptom Not turned ON <Check Result>
Not turned OFF (1) Is problem reproducible ?
Others ȀReproducible
Uncontrollable air temperature ȀNot reproducible
Symptom No cool air (2) Pressure (To be measured at gauge manifold)
No warm air ȀLow Pressure
Others ȀHigh Pressure
Uncontrollable air volume (3) Which parts have been replaced ?
Symptom Air flows in Hi mode only 1
No air flows
2
Small air volume
∗ Before replacing the control amplifier, be sure to
Others
check that the connectors are correctly connected
Uncontrollable vent hole while repeatedly disconnecting and reconnecting
Symptom Vent hole isn’t selected connectors.
Others
Abnormal panel indication
Faulty Indica- Vent Hole
tor A/C
AUTO
Fresh Air Circulation
Fan OFF
Fan (Lo • •• Hi)
Temperature Control
Symptom Stays OFF

Stays ON
Blinks
Others
T5-4-84
Refrigerant Quantity....................... 1100±50 g

3
Compressor Oil Quantity................ 210 cm
T5-4-85
Cooling Circuit
Refrigerant pressure Piping and/or parts are stained with

in both high and low Bubbles can be seen in sight oil, respond to gas detector.
pressure sides is low. glass.
No oil stain is found or gas detector
doesn’t respond. Refrigerant has not
been refilled for longer than one sea-
son.
No bubbles are seen in sight
glass.
After cooling at fast speed continu-

ously, cooling power is reduced. Air
flow volume remains unchanged.
Air flow volume is reduced.

Refrigerant pres-
sure in low pressure Bubbles can be seen in sight Compressor cylinder is extremely hot,
side is high. glass. emitting a smell.
Insuff-
icient
Cooling Refrigerant pressure in high Compressor cylinder is extremely hot,
Power pressure side is low. emitting a smell.
Heater unit emits hot air.
Refrigerant pres- Bubbles can be seen in sight Refrigerant pressure in low pressure
sure in high pres- glass. side is low.
sure side is high.
Condenser is stained and clogged.
Even if condenser is sprayed with water, few bubbles appear. Receiver dryer tem-
perature is low.
After cooling at fast speed continu-

ously, cooling power is reduced. Air Frost Thermistor doesn’t cool.
flow volume is reduced. forms.
Thermistor cools.
T5-4-86
Gas leaks from pipe joints and/or parts. Re-tighten or replace parts.
Normal leakage of refrigerant from hoses. Refill refrigerant.
Improper adjustment (excessive restriction) of Readjust or replace expansion valve.

expansion valve.
Remove clog, or replace receiver and/or expan-
Clogged expansion valve. sion valve.
Clogged low pressure circuit and/or evaporator. Remove clog, or replace parts.
Frozen expansion valve or water in circuit. After evacuation, refill refrigerant and/or replace
receiver dryer.
Gas leaks from case.
Seal gaps using vinyl tape or packing compound.
Poor contact of expansion valve temperature Make good contact. Replace temperature sensing
sensing cylinder. stay.
Improper adjustment (excessive open) of expan-
Readjust or replace.
sion valve.
Insufficient compressor discharge (faulty gasket Replace.

and/or valve).
Improper water stop valve wire adjustment and/or Check and readjust or replace.
faulty stop valve.
Repair.
Poor airtight fitting of outside air damper (outside
air induction type).
Remove clog, or replace parts.

Clogged high pressure circuit before receiver
dryer.
Clean Condenser.
Excessive refrigerant. Remove excessive refrigerant to proper level.
After evacuation, refill refrigerant and/or replace

Air is mixed in system. receiver dryer.
Incorrect thermistor location. Correct thermister location.
Gas leaks from case. Seal gaps using vinyl tape or packing compound.
Faulty thermistor (stays ON). Disconnected thermister cord.
Even if function and performance are normal, Instruct user on correct air-conditioner operation.
when air-conditioner is kept operated for a long (Reset thermistor to either minimum or middle
time with thermistor in max. cooling position and cooling position or increase air flow.)
air flow in M or L mode, frost may form.
T5-4-87
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 con-
tact noise.
Gas blowing sound (roaring). Gas vibration noise (compressor discharge and/or
suction gas noise).
Expansion valve connection, whistle Abnormal noise from expansion valve (Expansion
Noise sound, gas blowing sound. valve is normally functioning.).
Faulty clutch bearing, and/or idle pulley bearing.
Clutch disengaging sound.

Contact of clutch amature due to resonance, or loose
belt and/or screws.
Noisy compressor.
Compressor rotating sound.
Vibration and/or loose screws due to excessive drive
belt looseness.
Broken heater core and/or hose.

Water leak and/or splash.
Clogged case drain port and/or drain hose.
Others
Absorbed cigarette and dust smell on evaporator fins.

Abnormal smell.
T5-4-88
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.
Repair or replace clutch. Re-tighten screws.
Repair or replace.
Re-adjust drive belt.
Replace.
Clean.
-1
Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min in
L mode for more than 10 minutes, flush smell out by condensed water.
T5-4-89
Compressor
Compressor doesn’t 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.
Check for oil and refrigerant leaks from parts other than
Both high and low side
compressor and pipe joints using gas detector.
pressures are low.
Both com-
pressor
and blower
motor ro- Check for oil and
tate. refrigerant leaks
from compressor Refer to NOTE 1 and 2 on page T5-4-93.
(no leaks from
Refrigerant has not been refilled for longer
parts other than
than one season.
compressor) using
gas detector.
Stain Refrigerant is discharged within 1 to 2
on months after being recharged. Check for
exterior. refrigerant leaks using gas detector.
Refrigerant is kept charged for longer than

2 years.
Compressor cylinder is not hot. (Refrigerant returns to com-

High pressure side is pressor in liquid form.)
slightly low and low pres-
sure side is high. No refrigerant returns in liquid form. High pressure side is low.
Bubbles can be seen through
ӸOthers
sight glass.
High pressure side is high.

Refer to the Cooling Circuit Troubleshoot-
ing Table on page T5-4-86.
Temperature is not cooled when compressor is
operated at fast speed continuously.
Air flow from blower is insufficient.
Compressor rotation is abnormally draggy.

Overheating
is susceptible
to occur.
Trouble other than compressor. Refer to the Cooling Circuit Troubleshooting Table on page
T5-4-86.
T5-4-90
Seized clutch. Replace.
Improper gap between amature and rotor (improper air gap).

Replace.
Broken or short-circuited core cable.
Shaft doesn’t rotate (internally locked). Replace.
Faulty Electrical System.
Faulty Electrical System.
Faulty mechanical seal, gasket, and/or charge valve.

Replace.
Oil leaks from oil plug.
Oil and refrigerant leaks from front housing, and/or cylinder block joint. Replace.
Normal leaks from hoses. Charge

refrigerant.
No leaks (normal).
Refer to the Cooling Circuit Troubleshooting Table on page T5-4-86.
Broken valve (See NOTE 3 on page T5-4-93.)

Replace.
Blown gasket (See NOTE 3 on page T5-4-93.)
Excessive oil. Check and

adjust oil level.
Broken clutch bearing due to overly tightened belt. Replace.
Shaft doesn’t rotate.

Replace.
Shaft rotates draggy.
T5-4-91
Compressor
Noise is heard when clutch is OFF.
Abnormal
noise
Noise is heard when clutch is ON.
T5-4-92
Broken clutch bearing.

Replace.
Contact or slip due to poor air gap.
Faulty idle pulley bearing.
Saggy belt. Refer to the Cooling Circuit

Troubleshooting Table on
page T5-4-86.
Loose screws.
Broken valve.
Replace.
Blown gasket.
Abnormal internal noise. Replace.
Vibration due to saggy belt.

Refer to the Cooling Circuit
Loose screws. Troubleshooting Table on
page T5-4-86.
NOTE:
1. Don’t quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A
slight oil seepage will appear due to the seal construction. However, this oil seepage will not
cause malfunction. Be sure to accurately check whether oil is leaking or seeping only.
2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose sur-
face may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
2
high pressure side and low pressure side is 0.49 MPa (5 kgf/cm ) or less. When the clutch is
turned OFF, the pressure difference between high pressure side and low pressure side will disap-
pear within about 10 seconds.
T5-4-93
ENGINE SPEED ADJUSTMENT AND EN-
GINE LEARNING
After removing and/or replacing the components as
described below for repair and/or inspection, or if error
in engine speed is found, readjust engine speed and
perform engine learning.
• Removal of the engine, engine control cable, or

EC motor
• Replacement of MC
Adjustment of Engine Speed:

1. Turn the key switch to the START position to start
the engine.
NOTE: Turn the air conditioner OFF.
2. Rotate the engine control dial to the minimum
speed position. (The output voltage from the EC
sensor is 2.5 V.)
3. Deactivate the auto warming up and ECO control
systems by Dr. EX.
4. When Dr. EX is not available, keep the engine
running for about 15 minutes to warm coolant
temperature to more than 30 °C (86 F°) until the
auto warming up control system is deactivated.
5. Loosen the bolt holding the control lever to the EC
motor output shaft. Holding Bolt
6. While monitoring the actual engine speed with Dr.
EX or the engine speed meter, adjust the control T157-07-04-015
Control Lever
lever so that the minimum speed (slow idle)
matches the specification.
Specification: See the OPERATIONAL PER
FORMANCE TEST section.
7. Tighten the lever holding bolt to secure the control
lever to the motor output shaft.
: 13 N⋅m (1.3 kgf⋅m, 9.4 lbf⋅ft)
NOTE: Don’t lubricate the motor output shaft.
8. Perform engine learning.
T5-4-94
Engine Learning:
Rear Console
1. Turn the key switch OFF Fuse Box
NOTE: In case the engine doesn’t stop when the
key switch is turned OFF, pull the handle Engine
located under the seat to stop the engine. Learning
2. Disconnect Dr. EX. Wait for 5 seconds. Switch
3. Turn the engine learning switch ON.
4. Turn the key switch ON. Wait for 5 seconds.
5. Turn the key switch OFF. Wait for 5 seconds.
6. Turn the engine learning switch OFF.
7. Check the engine speed.
T178-01-02-006
T5-4-95
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
(5-Spool (4-Spool
Many sensors and solenoid valves used on this ma- Section) Section)
chine are identical. Therefore, using this switch-check
method, faulty part /component, and/or harness can be
easily found. PP2 PP1
Example: Abnormal pump 1 delivery pressure (Fault

code:10)
Check Method:
Figure A
1. Switch two delivery pressure sensors located as
shown in figure A to figure B. T157-07-04-006
2. Retry troubleshooting.
Result:
In case the pump 2 delivery pressure is abnormal (fault
code 11), the pump 1 delivery pressure sensor is con-
sidered to be faulty.
Pump 2 Pump 1
(5-Spool (4-Spool
In case the pump 1 delivery pressure is abnormal (fault Section) Section)
code 10), the pump 1 delivery pressure sensor har-
ness is considered to be faulty.
PP1 PP2
Figure B T157-07-04-006
T5-4-96
Applicability of Switch-Check Method

Fault Code Trouble Applicability
01 Abnormal EEPROM Not Applicable
02 Abnormal RAM
04 Abnormal Sensor Voltage
06 Abnormal EC Angle Sensor Not Applicable
07 Abnormal EC Dial Not Applicable
10 Abnormal Pump 1 Delivery Pressure Applicable (Harness)
11 Abnormal Pump 2 Delivery Pressure
12 Abnormal Pump 1 Control Pressure Applicable (Harness)
13 Abnormal Pump 2 Control Pressure
14 Abnormal Swing Pilot Pressure Applicable (Harness/Sensor)
15 Abnormal Boom Raise Pilot Pressure
16 Abnormal Arm Roll-In Pilot Pressure
18 Abnormal Travel Pilot Pressure
19 Abnormal Hydraulic Oil Temperature Not Applicable
Sensor
T5-4-97
EMERGENCY BOOM LOWERING PRO-
CEDURE 2
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.
1. Loosen lock nut (1).

: 17 mm
CAUTION: Gradually loosen the needle valve

checking the front attachment, otherwise the
boom falls down.
Be sure not to loosen it more than 4 turns, or
the hydraulic oil spurts.
2. Gradually loosen needle valve (2) checking the Front
front attachment. Attachment Side
: 6 mm T1HH-01-02-005
3. After the front attachment is lowered completely, 2 1

tighten needle valve (2).
: 6 mm
: 7.9 N⋅m (0.8 kgf⋅m, 5.8 lbf⋅ft)
4. Tighten lock nut (1).

: 17 mm
: 41 N⋅m (4.2 kgf⋅m, 30 lbf⋅ft)
M1HH-05-001
T5-4-98
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C
(TROUBLESHOOTING FOR MONITOR)
PROCEDURE
Use troubleshooting C when any monitors, such as

gauges or indicators malfunction.
• How to Read Troubleshooting Flow Charts
YES(OK)
(2)
After completing the checking and/or measuring procedures in box
О (1) (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
(3)
NO(NOT OK)
О Instructions, reference, and/or instruction methods on inspection and/or measurements

are occasionally described under the box. If incorrectly checked or measured, not only
· Key switch: ON will troubleshooting be unsuccessful but also damage to components may result.
О Causes of machine problems are stated in the thick-line box. Scanning quickly through
the thick-line boxes, allows you to estimate the possible causes before actually following
the flow chart.
NOTE: All harness end connector are seen from the

open end side.
Wire Harness Side
Open End
Side Harness End Connector
T158-05-03-001
T5-5-1
MALFUNCTION OF COOLANT TEMPERA-
TURE GAUGE
YES
Disconnect coolant temperature

Gauge pointer doesn’t move sensor. Ground harness end
Without connecting coolant
at all. terminal to vehicle frame. Check
temperature sensor, remove
if pointer swings to (H) side.
connector B (20P) from moni-
· Key switch: ON tor. Check for continuity be-
NO tween monitor harness end
connector terminal #18 and
coolant temperature sensor
terminal.
YES
Disconnect coolant tempera-

Gauge pointer swings over ture sensor. Check if pointer
scale. Without connecting coolant
returns to zero.
temperature sensor, remove
· Key switch: ON connector B (20P) from moni-
tor. Check for continuity be-
NO tween monitor harness end
terminal #18 and vehicle
frame.
YES
Disconnect coolant tempera-

ture sensor. Ground harness
Gauge pointer keeps moving end terminal to vehicle frame,
unstably. Check if pointer swings and is
stabilized to (H) side.
· Key switch: ON
NO
T5-5-2
Coolant Temperature Gauge Board
105 ńC
(95 ńC)
Faulty coolant temperature
sensor.
70 ńC
YES Faulty monitor.
T157-07-05-001

NO monitor and sensor.
Coolant Temperature Sensor

Coolant Temperature Resistance (kΩ)
°C (°F)
25 (77) 7.6±0.76
Faulty coolant temperature 40 (104) 4.0±0.35
sensor. 50 (122) 2.7±0.22
80 (176) 0.92±0.07
95 (203) 0.56±0.04
YES Short-circuited harness be- 105 (221) 0.42±0.03
tween monitor and sensor. 120 (248) 0.28±0.01
Faulty monitor.
NO
Connector (Harness end connector terminals seen

Faulty coolant temperature from the open end side)
sensor. Monitor Connector B (20P)
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
Faulty monitor.
T5-5-3
MALFUNCTION OF FUEL GAUGE
YES
Disconnect fuel sensor. Con-

nect harness end connector
Fuel gauge pointer doesn’t terminal #1 to terminal #2 using
move at all. jumper wire such as clip. Check
Without connecting fuel sensor,
if pointer swings to (FULL) side.
remove connector B (20P) from
· Key switch: ON monitor. Check for continuity
NO between monitor terminal #19
and fuel sensor terminal 1.
YES
Fuel gauge pointer swings over Disconnect fuel sensor. Check

scale. if pointer returns to zero.
Without connecting fuel sensor,
· Key switch: ON remove connector B (20P) from
monitor. Check for continuity
NO between monitor harness end
terminal #19 and vehicle frame.
YES
Disconnect fuel sensor. Con-

nect harness end connector
Fuel gauge pointer keeps mov- terminal #1 to terminal #2 using
ing unstably. jumper wire such as clip. Check
if pointer swings and is stabi-
lized to (FULL) side.
· Key switch: ON NO
T5-5-4
Fuel Sensor
Float
Faulty fuel sensor.
FULL
R370
YES Faulty monitor. 257 mm 3/4
93 mm
Broken harness between 70.5 mm

NO monitor and sensor.
204 mm 1/2
1/4
338 mm
EMPTY
Faulty fuel sensor. T178-05-05-001
NOTE: 1 mm = 0.03937 in
Float Position Resistance (Ω)
YES Short-circuited harness be- Upper Limit (FULL)
+0
10 -4
tween monitor and sensor.
3/4 26
1/2 38±5
1/4 53
Faulty monitor.
Warning Level 85±3
NO +10
Lower Limit (EMPTY) 90 -0

from the open end side)
Faulty fuel sensor.
Monitor Connector B (20P) Fuel Sensor
10 9 8 7 6 5 4 3 2 1
1 2
20 19 18 17 16 15 14 13 12 11
Faulty monitor.
T5-5-5
MALFUNCTION OF INDICATOR LIGHT
CHECK SYSTEM
Check power line.
• Check for loose harness connections beforehand. ⋅ Fuse
YES ⋅ Remove connector C (20P)
from monitor. Check for con-
tinuity between harness end
terminal #1 and fuse terminal
Indicator doesn’t light when #5.
Check if all indicators don’t
indicator light check operation
light.
is performed.
Troubleshoot unlit indicator

NO individually.
Monitor Connector C (20P)
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-6
MALFUNCTION OF PREHEAT INDICATOR
• The preheat system operates only when coolant

temperature is below 10 °C (50 °F), lighting the
preheat indicator for 8 seconds. (Refer to the
SYSTEM /Electrical Circuit group.)
• In case the preheat system malfunctions, refer to
the troubleshooting B for E-16 Engine is difficult to
start at low temperature.
YES Faulty coolant

temperature
Remove connector switch.
Preheat indicator (with black and
lights even though white cables) from YES
coolant tempera- Faulty QOS con-
preheat system troller.
doesn’t operate ture switch. Check
(coolant tempera- if indicator goes
ture is more than OFF by grounding
harness end con- Without connecting
10 °C (50 °F)). Disconnect QOS QOS controller,
Short-circuited
nector to vehicle YES harness between
controller. Check if remove connector
frame. QOS controller
· Key switch: ON NO indicator goes B (20P) from moni-
OFF. and monitor.
tor. Check for con-
· Key switch: ON NO tinuity between
monitor harness
end connector Faulty monitor.
terminal #20 and NO
vehicle frame.
YES Faulty coolant

temperature
switch.
Preheat indicator Remove connector
doesn’t light al- (with black and YES Faulty QOS con-
though preheat white cables) from troller.
system operates coolant tempera-
(coolant temperature switch. Check
Disconnect QOS
ture is lower than if indicator comes
controller. Check if
10 °C (50 °F)). ON.
indicator comes YES Broken harness
· Key switch: ON ON by grounding Ground monitor between QOS con-
NO harness end con- connector B (20P) troller and monitor.
nector terminal #6 terminal #20 to
to vehicle frame. NO vehicle frame.
Check if indicator
· Key switch: ON Faulty monitor.
comes ON.
NO
· Without discon-
necting connector,
ground connector
to vehicle frame us-
Connector (Harness end connector terminals seen ing jumper wire
from the open end side) such as clip from
reverse side of
Monitor Connector B (20P) QOS Controller connector.
10 9 8 7 6 5 4 3 2 1 1 2 3
20 19 18 17 16 15 14 13 12 11 4 5 6
T5-5-7
MALFUNCTION OF ENGINE OIL LEVEL
INDICATOR
• Check that indicator light is not burned out.

• Check that all other indicators work correctly.
• Check that machine is parked on level surface.
Without connecting
connector to engine oil YES
level switch, remove
connector B (20P)
NO from monitor. Check
for continuity between
Check if indicator monitor harness end
Indicator doesn’t lights by removing connector terminal #8
light even if engine NO
connector (with and vehicle frame.
oil level is lower black and white
than specification. cable) from engine
oil level switch.
YES
Without connecting
connector to engine oil
connector B (20P)
Remove connector for continuity between
Lower than 3.5 mm (with black and white
below LOW level mark monitor harness end
cables) from engine oil connector terminal #8
on oil level gauge level switch. Check if and engine oil level
indicator goes OFF by switch connector.
grounding harness
end connector to vehi-
Indicator comes ON
cle frame.
even if engine oil Check oil level with YES
level matches oil level gauge.
specification.
Above 3.5 mm
below LOW level mark
on oil level gauge
T5-5-8
Engine Oil Level Switch

Short-circuited harness be-
tween engine oil level switch
and monitor. Oil Level
Gauge Engine Oil Level
Switch
Faulty monitor. ON
H A (Indicator ON)
L
(Indicator OFF)
Faulty engine oil level switch.
OFF
A: 3.5mm
T107-04-03-010
YES Faulty monitor.
Broken harness between en- Connector (Harness end connector terminals seen
gine oil level switch and moni- from the open end side)
NO tor.
Monitor Connector B (20P)
Faulty engine oil level switch.

10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
Normal (Lack of engine oil).
T5-5-9
MALFUNCTION OF COOLANT LEVEL IN-
DICATOR
• Check that indicator light is not burned out.

• Check that all other indicators work correctly.
• Check that machine is parked on level surface.
Without connecting
connector to coolant YES
connector B (20P)
NO
from monitor. Check
for continuity between
Check if indicator monitor harness end
Indicator doesn’t
lights by removing connector terminal #9 NO
light even if coolant
connector (with gray and vehicle frame.
level is lower than
cable) from coolant
specification.
level switch.
YES
Without connecting
connector to coolant
connector B (20P)
Remove connector for continuity between
(with gray cables) from monitor harness end
coolant level switch. connector terminal #9
No Check if indicator goes and coolant level
OFF by grounding switch connector.
harness end connec-
Indicator comes ON Check if coolant tor terminal #1 to vehi-
even if coolant level level in coolant res- cle frame.
YES
matches specifica- ervoir is lower than
tion. LOW mark.
Yes
T5-5-10
Short-circuited harness be- Coolant Level Switch

tween coolant level switch and
monitor.
Reservoir
ON
Faulty monitor.
FULL
LOW
Faulty coolant level switch.

Radiator OFF
Coolant Level Switch

T107-04-03-012
YES Faulty monitor.
Broken harness between Connector (Harness end connector terminals seen

coolant level switch and moni-
NO tor. from the open end side)
Ӹ
Coolant Level Switch
Faulty coolant level switch.
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 1 2
Normal (Lack of coolant).
T5-5-11
MALFUNCTION OF ALTERNATOR INDI-
CATOR
NOTE: *Regulator terminals L are water-resistant

type connectors so that it is not practical to
measure voltage at these terminals. Meas-
ure voltage at starter relay terminal R in-
stead. Check for continuity between starter
relay terminal R and regulator terminal L
beforehand.
Between 13 V
and 33.5 V
Between 13 V
and 33.5 V Measure voltage at
monitor connector A
(16P) terminal #2.
Alternator indicator Measure voltage at · Engine: Running Less than 13 V or
stays ON after en- regulator terminal L.
∗
higher than 33.5 V
gine is started.
· Engine: Running
Less than 13 V or
higher than 33.5 V
Between 10 V
and 33.5 V
YES Measure voltage at

regulator terminal L.
· Key switch: ON
Although alternator · Engine: Stopped
Check if indicator Less than 10 V or
output is low, alter-
lights when key higher than 33.5 V
nator indicator
switch is turned ON.
doesn’t light.
· Key switch: ON
NO
T5-5-12

Faulty monitor. from the open end side)
Starter Relay
Broken harness between E

regulator terminal L and moni-
S R
tor.
Faulty regulator or alternator.

Monitor Connector A (16P)
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
Faulty monitor.
Faulty regulator.
Burned indicator light.
T5-5-13
MALFUNCTION OF ENGINE OIL PRES-
SURE INDICATOR
NOTE: During one or two minutes after the engine

is stopped, engine oil pressure may still ex-
ist. When the engine is restarted under this
condition, the indicator may not light.
YES
Disconnect engine oil
pressure switch. Check
if indicator light when
YES
harness end connector
terminal #1 (white and Reconnect engine oil pres-
red cable) is grounded sure switch. Check if indica-
to vehicle frame. tor lights when monitor con-
Indicator doesn’t Check if indicator · Key switch: ON NO nector C (20P) terminal #18
light even if engine lights when key is grounded to vehicle frame.
oil pressure is low. switch is turned ON.
· Key switch: ON
· Key switch: ON · Without disconnecting con-
· Engine: Stopped nector, ground connector to
vehicle frame using such
jumper wire as clip from re-
verse side of connector.
NO
YES
Check if indicator
Indicator stays ON goes OFF when
after engine is engine oil pressure YES
Reconnect engine oil
started. switch is discon-
pressure switch and
nected.
· Check oil filter for remove connector C
clogging. · Key switch: ON (20P) from monitor.
· Engine: Stopped NO Check for continuity
between harness end
connector terminal #18
and vehicle frame.
NO
T5-5-14
Engine Oil Pressure Switch

Pressure Operation
Approx. 98 kPa
2
Faulty engine oil pressure (1.0 kgf/cm , 14.22 psi) ON
switch. or less
Approx. 98 kPa
2
(1.0 kgf/cm , 14.22 psi) OFF
YES Broken harness between
monitor and engine oil pres-
or higher
sure switch.
Faulty monitor.
NO

Monitor Connector C (20P)
Faulty engine oil pressure 10 9 8 7 6 5 4 3 2 1

switch or engine oil pressure 20 19 18 17 16 15 14 13 12 11
system, or clogged oil filter.
Short-circuited harness be-

tween monitor and engine oil
pressure switch.
Faulty monitor.
T5-5-15
MALFUNCTION OF OVERHEAT INDICA-
TOR
YES
Remove connector
(red and blue cable)
from overheat switch.
YES
Check if indicator lights
when harness end
Key Switch:
·terminal ON
is grounded to
vehicle frame.
· Key switch: ON NO
Indicator doesn’t light Check if indicator

even if engine over- lights when key
heats. switch is turned ON.
· Key switch: ON
NO
YES
Check if indicator
Indicator lights even
goes OFF when
if coolant tempera-
overheat switch is
ture is low.
disconnected.
Disconnect overheat YES
· Key switch: ON
switch. Remove con-
· Engine: Stopped
nector B (20P) from
monitor. Check for con-
NO
tinuity between connec-
tor terminal #6 and ve-
hicle frame.
NO
T5-5-16
Overheat Switch
Faulty overheat switch. Coolant Temperature Operation
Lower than 105 °C OFF
(221 °F)
105 °C (221 °F) or ON
higher
Reconnect overheat YES Broken harness between
monitor and overheat
switch. Check if indica-
switch.
tor lights when monitor
connector B (20P)
terminal #6 is
grounded to vehicle Faulty monitor.
frame. NO
· Key switch: ON
· Without disconnect-
ing connector, Connector (Harness end connector terminals seen
ground connector to
vehicle frame using
such jumper wire as
clip from reverse side 10 9 8 7 6 5 4 3 2 1
of connector. 20 19 18 17 16 15 14 13 12 11
Faulty overheat switch.
Short-circuited harness
between monitor and
overheat switch.
Faulty monitor.
T5-5-17
MALFUNCTION OF AIR FILTER RESTRIC-
TION INDICATOR
YES
Disconnect air filter re-
striction switch at plug
receptacle with green
YES and blue cable. Check if
indicator lights when Reconnect air filter restric-
harness end plug con- tion switch. Remove con-
nector is grounded to nector B (20P) from moni-
vehicle frame. tor. Check for continuity
Even if air filter is Check if indicator NO between monitor harness
clogged, indicator lights when key · Key switch: ON
end connector terminal #7
doesn’t light. switch is turned ON. and vehicle frame.
· Key switch: ON
NO
YES
Although air filter is Check if indicator

Disconnect air filter re-
not clogged, indica- goes OFF when air YES
striction switch at plug
tor lights. filter restriction switch
receptacle with green
is disconnected.
and blue cable and re-
· Disassemble and
· Key switch: ON move connector B (20P)
visually inspect.
from monitor. Check for
· Verify that air filter NO continuity between con-
is not moist.
nector terminal #7 and
vehicle frame.
NO
T5-5-18
Faulty air filter restriction

switch. Air Filter Restriction Switch
Pressure Operation
YES Faulty monitor. 5.1 kPa (520 mmH2O) OFF
6.2 kPa (630 mmH2O) ON

monitor and air filter re-
NO striction switch.
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
Faulty air filter restriction

switch.
between monitor and air
filter restriction switch.
Faulty monitor.
T5-5-19
MALFUNCTION OF BUZZER
NOTE: Regulator terminals L are water-resistant

ure voltage at starter relay 1 terminal R in-
relay 1 terminal R and regulator terminal L
beforehand.
13 V or more Faulty regulator.

Buzzer continues to
sound when key Measure voltage at
switch is turned ON monitor connector A
without starting (16P) terminal #2.
engine. · Key switch: ON Faulty monitor.
(without starting Less than 13 V
YES Faulty engine oil pres-

sure system.
Buzzer continues to Check if engine oil
sound when engine pressure indicator YES Overheat of engine.
is started. lights.
Check if overheat indi-
NO cator lights.
Faulty monitor.
NO
NO Normal.
Buzzer doesn’t
sound even if en- Check if engine
gine oil pressure speed is 900 min
-1
NO Perform troubleshooting
indicator or over- (rpm) or faster. of indicator staying ON.
heat indicator lights
with engine running. Check if alternator
YES indicator lights.
Measure voltage at regu-
YES lator terminal L.
-1
· Engine speed: 900 min
(rpm) or faster
T5-5-20

Monitor Connector A (16P) Starter Relay
8 7 6 5 4 3 2 1 E
16 15 14 13 12 11 10 9 S R
Lower than 13 V or
more than 33.5 V Faulty regulator and alterna-
tor.
Lower than 13 V or
higher than 33.5 V Broken harness between
regulator terminal L and moni-
tor.
Measure voltage at monitor
connector A (16P) terminal #2.
Between 13 V Faulty monitor.
and 33.5 V · Engine speed: 900 min
-1
Between 13 V
(rpm) or faster and 33.5 V
T5-5-21
MALFUNCTION OF LCD
• The following items are described:

1 to 3: To be displayed in the standard mode.
4 to 8: To be displayed in the user’s mode.
9 to 24: To be displayed with built-in diagnosing
system
• In case only LCD is abnormal, the machine will
normally operate.
Display
Description Cause of Trouble
Order
1 Hour Meter Refer to the next page.
2 Trip 1 Faulty Monitor
3 Trip 2
4 Actual Engine Speed In case Dr. EX can display data, monitor is abnormal or communication
5 Hydraulic Oil Tempera- between monitor and MC is interrupted. In case Dr. EX doesn’t display
ture data, corresponding signal sensor is faulty. (The machine must have
any abnormality in the control system. Refer to Troubleshooting B.)
6 Faulty monitor or interrupted communication between ML controller and
7 Load Alarm monitor
8 Hydraulic Oil Filter Faulty monitor or interrupted communication between ICX controller and
monitor
9 Fault Code In case Dr. EX can display data, monitor is abnormal or communication
10 ML Switch between monitor and MC is interrupted. In case Dr. EX doesn’t display
11 Pump 1 Delivery Pres- data, corresponding signal sensor is faulty. (The machine must have
sure any abnormality in the control system. Refer to Troubleshooting B.)
12 Pump 2 Delivery Pres-
sure
13 Pump 1 Control Pres-
sure
14 Pump 2 Control Pres-
sure
15 Target Engine Speed
16 EC Angle
17 Dial Angle
18 Boom Raise Lever
Stroke
19 Arm Roll-In Lever Stroke
20 Swing Lever Stroke
21 Travel Lever Stroke
22 Front Attachment Lever
Stroke
23 Attachment Lever Stroke
24 Work Mode
T5-5-22
MALFUNCTION OF HOUR METER
∗
NOTE: Regulator terminals L are water-resistant
ure voltage at starter relay 1 terminal R in-
relay 1 terminal R and regulator terminal L
beforehand.
Lower than 13 V or
higher than 33. V Faulty regulator or
alternator.
Hour meter
doesn’t count Between 13V
Measure voltage at
operating hours ∗ and 33.5 V Faulty monitor.
regulator terminal L.
with engine run-
-1
ning. · Engine speed: 900 min Measure voltage
· Engine: Running (rpm) or faster at monitor connec-
Between 13V tor A (16P) termi-
and 33.5 V nal #2. Broken harness be-
tween regulator ter-
Lower than 13 V or minal L and monitor.
higher than 33. V

Monitor Connector (16P) Starter Relay
E
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9 S R
T5-5-23
MALFUNCTION OF HYDRAULIC OIL FIL-
TER INDICATOR (Optional)
Disconnect hydraulic
oil filter restriction YES
switch at plug recepta-
YES cle with white and blue
cable. Check if indica-
tor lights when harness
end plug connector is
grounded to vehicle
Even if hydraulic oil Check if indicator frame.
filter is clogged, indi- lights when key · Key switch: ON NO
cator doesn’t light. switch is turned ON.
· Key switch: ON
NO
YES
Although hydraulic Check if indicator

oil filter is not goes OFF when
clogged, indicator hydraulic oil filter
restriction switch is Disconnect hydraulic oil
lights. filter restriction switch at
disconnected. YES
plug receptacle with
· Key switch: ON white and blue cable
· Engine: Stopped and remove connector
NO C (16P) from monitor.
Check for continuity be-
tween connector termi-
nal #13 and vehicle
frame.
NO
T5-5-24
Faulty hydraulic oil filter

restriction switch.
Reconnect hydraulic Broken harness between Connector (Harness end connector terminals seen
YES
oil filter restriction monitor and hydraulic oil from the open end side)
switch. Check if indica- filter restriction switch.
tor lights when monitor Monitor Connector C (20P)
connector C (20P)
terminal #14 is Faulty monitor. 10 9 8 7 6 5 4 3 2 1
grounded to vehicle
NO 20 19 18 17 16 15 14 13 12 11
frame.
· Key switch: ON
· Without disconnect-
ing connector,
ground connector to
vehicle frame using
jumper wire such as
clip from reverse side
of connector. Burned indicator light.
Faulty hydraulic oil filter

restriction switch.
between monitor and hy-
draulic oil filter restriction
switch.
Faulty monitor.
T5-5-25
(Blank)
T5-5-26
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.

Be sure to remove the negative terminals from the
batteries first when taking wire harnesses and
connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses, and fusible links and, in some
cases, cause fire due to short circuiting.
2. Color coding of wire harnesses. Code Color Code Color
The color codes of the wire harnesses in the R Red W White
electrical system are shown inn the table onn the L Blue G Green
right. Or Orange Lg Light green
In cases on the design sheet where two colors are Y Yellow B Black
indicated for one wire, the left initial stands for the Br Brown P Pink
base color, while the right initial stands for the
Gr Gray V Violet
marking color.
NOTE: 1) Code BW indicates a black base wire

with white fine-line marking.
Right Wrong
2) Initials “O” and “Or” both stand for the
color orange.
3) Wires with longitudinal stripes printed on
them are not color coded. Be sure not to
confuse them with color coded wires.
T107-07-06-001
3. Precautions for connecting and disconnecting

terminal connectors.
1) When disconnecting harnesses, grasp them
by their connectors. Do not pull on the wire
itself. Be sure to release the lock first before
attempting to separate connectors, if a lock Right
is provided. (Refer to “Instructions for Rust
Disconnecting Connector” on page T5-6-3.)
Wrong
2) Water-resistant connectors keep water out (Deformation)
so that if water enters them, water will not
easily drain from them. When checking Wrong
(Separation)
water-resistant connectors, take extra care
not to allow water to enter the connectors. In T107-07-06-002
case water should enter the connectors,

reconnect only after the connectors are
thoroughly dried.
3) Before connecting terminal connectors,
check that no terminals are bent or coming
off. In addition, as most connectors are made
of brass, check that no terminals are rusting.
4) When connecting terminal connectors
provided with a lock, be sure to insert them
together until the lock “clicks.”
5) Pull the harness near the connector, and
check if the connection is correctly
connected.
T5-6-1
4. Precaution for using a circuit tester.
1) Before using a circuit tester, refer to the
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object Wind a Piece of Wire Tester Probe
to be measured, voltage range and current
polarity.
2) Before starting the connector test, always
check the connector terminal numbers,
Sharpen the end of the Wire
referring to the circuit diagram. T107-07-06-003
When the connector size is very small, and the
standard probe size is too large to be used for
testing, wind a fine piece of sharpened wire or
a pin around the probe to make the test easier.
3) When performing the connector test with the
circuit tester, be sure to insert the tester probe
from the connector harness side in order not to
damage the terminals in the connector.
T5-6-2
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
• Push to Unlock and Separate Type
NOTE: Connectors will not be easily separated

even if the lock is pushed while being pulled.
Push the lock first before pulling the con-
nectors.
The lock is located on female side connec-
tor (harness end side). T107-04-05-002
Locations of This Type Connector

Fuel Gauge N Sensor Engine Oil Level Switch Radio
Hydraulic Oil Level Switch EC Motor Coolant Level Switch Speaker
Horn EC Sensor Diode Learning Switch
Cab Harness Pump Delivery Pressure Sensor Key Switch Wiper
Pressure Sensor General Relay Engine Control Dial Monitor
Washer Solenoid Valve
• Pull Up to Unlock and Separate Type

Starter Relay
• Pull to Separate Type T107-04-05-003
IMPORTANT: Generally, the solenoid valve con-

nector has a lock. Always pull to
separate the connector only after un-
locking using a tool such as a pair of
needle nose pliers.

Hydraulic Oil Temperature Sensor
Dr.EX T107-04-05-004
T5-6-3
FUSE INSPECTION
Cracks in a fuse are so fine that it is very difficult or NOTE: All terminals located along the lengthwise
impossible to find by visual inspection. Use a tester to centerline of the fuse box are connected to
correctly inspect fuse continuity by following the in- the power source, while terminals located
structions described below. away from the center of the fuse box are
connected to loads (accessories). There-
1. Turn Key Switch ON fore, test all fuses in the same method ex-
When the key switch is turned ON, current from cept for the glow plug relay circuit fuse.
key switch terminal M activates the battery relay Check the glow plug relay circuit fuse with
so that electric power is supplied to all circuits ex- the key switch turned to the ON position
cept the glow plug relay circuit. (Refer to the cir- then follow the procedure in step 3.
cuit diagram.)
2. Remove the fuse box cover. Set the tester voltage
to meet the circuit specification to be measured.
(Measurement Range: 0 to 30 V) 10 20
3. Ground the negative probe of the tester to the ve- 9 19
hicle frame. Touch the terminals located away
from the center of the fuse box with the positive 8 18
probe of the tester one at a time. When normal 7 17
continuity of a fuse is intact, the tester will indicate
20 to 25 volts (battery voltage). 6 16
5 15
4 14
3 13
2 12
1 11
M178-07-034
Fuse Fuse
Capacity Connected to Capacity Connected to
No. No.
1 5A Radio, Monitor (Backup Power), 11 20 A Work Light Relays 1 and 2
ICX (Main Power)
2 5A MC (Main Power) 12 10 A Wiper Relays A, B, and C,
Wiper Motor, Washer Relay
3 10 A MC (EC Motor Power) 13 20 A Heater (Air Conditioner Unit)
4 10 A MC (Solenoid Valve Power) 14 10 A Horn Relay
5 5A Monitor 15 5A Radio
6 5A MC, ICX (Power ON Signal) 16 10 A Cigarette Lighter
7 5A Air Conditioner Unit 17 5A Room Light
8 5A Optional 1 18 10 A Auxiliary
9 10 A Optional 2 19 5A QOS Controller, Glow Relay
10 5A Optional 3 20 10 A Lubricator (Optional)
T5-6-4
FUSIBLE LINK INSPECTION Battery Relay
Inspection
1. Remove the negative cable from the battery.

2. Loosen bolt M8 holding the cable routed in front of
the fusible link box to move the cable out of the
way of the front cover.
3. Open the fusible link box front cover and visually
inspect the fusible link.
Fusible Link M178-07-049
Fusible Link Cover
Replacement
1. Check that the negative cable is removed from

the battery.
2. Remove bolt M8 to take the fusible link off the bat- T178-05-06-002
tery relay.
3. Open the upper and bottom side covers of the
fusible link box. Remove screws M6 (2 used).
4. Take out the fusible link to replace it. Battery
Relay
5. Retighten two screws M6. Bolt M8
6. Install the fusible link box and the cable to the bat-
tery relay.
7. Reconnect the negative cable to the battery.
Cable Screw M6
T107-04-05-008
T5-6-5
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

the battery.
2. Start the engine. Check voltage between the

battery positive terminal and the vehicle frame.
Normal Voltage: 26 to 28 V
NOTE: If voltage is abnormal, check the charging V

system.
T157-07-06-007
T5-6-6
HOW TO TROUBLESHOOT ALTERNATOR
MALFUNCTIONS
In general, the alternator indicator remains off when

the alternator is generating power.
If the alternator indicator comes on while the engine is
running, the alternator might be defective.
How to check the circuit
1. Stop the engine. Turn the key switch to the ON

position. Confirm that the alternator indicator
comes on.
2. Measure the voltage between the B and E

terminals of the alternator. If the measured
voltage is around 24 V, the alternator circuit can
A
be considered normal. If the measured voltage
is low, a shortage in battery capacity or looseness
of the wire connectors of the alternator circuit
A
might be the cause of the malfunction. When the
voltage is 0 V, the wiring between the fuse box
and alternator might be loose or disconnected.
Also, the alternator cannot generate electricity if
the ground line is disconnected.
3. Next, start the engine and measure the voltage

generated while as the alternator rotates. M1HH-07-001
As described above, measure the voltage

between terminals B and E on the side of the Alternator seen from A-A
alternator. If the voltage is around 28 V, the
Terminal B
alternator is operating normally.
If the rated voltage is not being generated, there is
some trouble with the alternator or the regulator.
Terminal E
T1HH-05-06-001
T5-6-7
CONTINUITY CHECK
Harness
Single-line continuity check A a
Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity
Ω
NOTE: When the one connector end is far apart

from the other, connect one end of Connect to A a
connector (A) to the machine chassis using the vehicle
a clip. Then, check continuity of the frame.
harness through the vehicle frame as
illustrated.
Connect to
Ω
the vehicle
If the ohm-meter reading is: 0 Ω = Continuity frame.
∞ Ω = Discontinuity
A a
Single-line short-circuit check
Disconnect both end connectors of the harness and × Short-circuit
check continuity between one end connector of the between the
harness and
harness and the vehicle frame: the vehicle
Ω frame
If the ohm-meter reading is:
0 Ω = Short circuit is present.
∞ Ω = No short circuit is present.
T107-07-05-003
Multi-line continuity check
Disconnect both end connectors of the harness, and First short-circuit
short-circuit two terminals, (A) and (B), at one end
connector, as illustrated. Then, check continuity
between terminals (a) and (b) at the other connector. A a
If the ohm-meter reading is ∞ Ω, either line (A) - (a), B b
C c
or (B) - (b) is in discontinuity. To find out which line is
discontinued, conduct the single line continuity
Second short-circuit
check on both lines individually, or, after changing
the short-circuit terminals from (A) - (B) to (A) - (C),
check continuity once more between terminals (a)
and (c). Ω
NOTE: By conducting the multi-line continuity

T107-07-05-004
check twice, it is possible to find out which
line is discontinued. With terminals (A) and Short-circuit between harnesses.
(C) short-circuited, check continuity
between terminals (a) and (c). A a
×
If the ohm-meter reading is: B b
0 Ω = Line (B) - (b) has discontinuity. C c
∞ Ω = Line (A) - (a) has discontinuity.
Multi-line short-circuit check

Disconnect both end connectors of the harness, and
check continuity between terminals (A) and (B) or Ω
(C).
If the ohm-meter reading is:
0 Ω = Short-circuit exists between the lines.
T107-07-05-005
∞ Ω = No short-circuit exists between the lines.
T5-6-8
(Blank)
T5-6-9
VOLTAGE AND CURRENT MEASURE-
MENT
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 loca-
tion to be measured from either power source or
actuator side. Thereby, the faulty location in the
circuit will be found.
Black Probe (Minus) of Tester:To ground to the vehicle
frame
Red Probe (Plus) of Tester: To touch the location to
be measured
Engine Key Switch Location to be Measured Specification
Power Source
Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (2): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Battery Power 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (1) and Ground: Backup Current* 6 mA
Preheat Circuit
Stopped ON or START Between (6) and Ground: Key Switch 20 to 25 V
Stopped ON or START Between (7) and Ground: Glow Plug 20 to 25 V
Starting Circuit
Started START Between (8) and Ground: Key Switch 20 to 25 V
Started START Between (9) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (10) and Ground: Battery Relay (Switch) 20 to 25 V
Started START Between (11) and Ground: Starter (B) 20 to 25 V
Started START Between (12) and Ground: Starter (C) 20 to 25 V
Started START Between (13) and Ground: Starter Relay (S) 20 to 25 V
Charging Circuit
Fast Speed ON Between (14) and Ground: Alternator (B) / Generating Voltage 26 to 30 V
Fast Speed ON Between (10) and Ground: Battery Relay / Generating Voltage 26 to 30 V
Fast Speed ON Between (15) and Ground: Fuse Box 26 to 30 V
Fast Speed ON Between (16) and Ground: Starter Relay (R) / Generating Volt- 13 to 30 V
Fast Speed ON age
Between (17) and Ground: Monitor 13 to 30 V
Surge Voltage
Prevention Circuit
Slow Idling ON Between (14) and Ground: Alternator (B) 26 to 30 V
Slow Idling ON Between (16) and Ground: Starter Relay (R) 13 to 30 V
Slow Idling ON Between (18) and Ground: Load Damp Relay 26 to 30 V
Slow Idling ON Between (10) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (19) and Ground: Auxiliary 20 to 25 V
Stopped ON Between (20) and Ground: Room light 20 to 25 V
Stopped ON Between (21) and Ground: Cigar Lighter 20 to 25 V
Stopped ON Between (22) and Ground: Radio 20 to 25 V
Stopped ON Between (23) and Ground: Horn 20 to 25 V
Stopped ON Between (9) and Ground: Battery Relay 20 to 25 V
*Measure after disconnecting the negative cable from the battery.
T5-6-10
Key Switch
Battery
6 8
1 2 3 5 4 9
15
Battery Relay
Fuse
10 Box
Starter
18
Load
Dump
Relay
11
12 23 22 21 20 19 17
13
Monitor
Starter Relay
16
Alternator
Glow
Plug
Relay
14
Glow Plug
T178-05-06-001
T5-6-11
5 Voltage Circuit
Signal or
• Voltage between terminal No.1 and the vehicle Two polarities Power source ground
frame (ground) 1 2
With the key switch turned OFF, disconnect the
sensor connector.
Measure the voltage between terminal No.1 on the
machine harness side connector and the vehicle
(ground) under the following conditions.
V
• Key switch position: ON
• Tester black terminal (negative):
Connected to the vehicle (ground)
• Tester red terminal (positive):
T107-07-05-006
Connected to terminal No.1
Three polarities Power source Signal Ground
Evaluation: 1 2 3
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal No.1 is normal.
• Voltage between terminal No.1 and the ground T107-07-05-007
terminal
With the key switch turned OFF, disconnect the Two polarities
1 2
sensor connector.
Measure the voltage between terminal No.1 on the
machine harness side connector and the ground
terminal (terminal No.2 for two polarities, or terminal
No.3 for three polarities) under the following V
conditions.
• Key switch position: ON

• Tester black terminal (negative):
Connected to the ground terminal
(terminal No.2 or 3) T107-07-05-008
• Tester red terminal (positive):
Connected to terminal No.1 Three polarities
1 2 3
Evaluation:
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal No.1 or the ground terminal is
normal.
V
T107-07-05-009
T5-6-12
CHECK BY FALSE SIGNAL
Tow-Polarities
Turn the key switch OFF. After disconnecting the sen- (Oil Temperature)
sor connector, turn the key switch ON. Then, connect (N Sensor)
1 2
machine side harness end connector terminal #1
(power) to terminal #2 (signal). (Power voltage is used
as a false signal.) Check the controller using Dr. EX
monitor function under this condition. When the maxi-
mum value is displayed, the MC and the circuit up to
the machine side harness end connector are normal.
When the pressure switch circuits are normal, Dr. EX Connect
displays “ON.”
IMPORTANT: Don’t connect terminal #1 or #2 to

terminal #3 or to the vehicle frame Three Polarities
T107-07-05-010
(ground) when checking a three-

polarity connector. (Pressure Sensor)
(Pump Delivery Pressure Sensor)
(Pump Control Pressure Sensor) 1 2 3
NOTE: Some kinds of sensors can be monitored (EC Sensor)
by the built-in diagnosing system. (Refer to
the TROUBLESHOOTING / General
group.)
Connect
T107-07-05-011
T5-6-13
TEST HARNESS
With a test harness installed between connectors, the

circuit condition is checked depending on whether the
test harness lamp lights or extinguishes during opera-
tion.
Parts Number 4283594 (ST 7126)

Use to check a single-line (discontinuity and/or volt-
age).
To Location to be Measured.
During Operation: Lamp is ON. To Ground
T107-07-05-012
Parts Number (ST 7123)

Use to check the solenoid valve unit circuits.
When the corresponding control lever or switch is op- 4
erated: Lamp is ON. 3 50
(Refer to T5-4-42, 53, 56, and 75.) 150 50 50
1 2 2 1
T107-07-06-015

Use to check the EC motor circuit.
(Refer to T5-4-28 and 32.) 5
6
50
• EC Motor Circuit
When the engine control dial is rotated: 1 2 2 1
150 50
Both lamps ON: Normal 50
Only one lamp ON: Check for continuity of the cir- 4 3 4 3
cuit connected to the lamp OFF. 7 50
Both lamps OFF: Check the harness together with 8
the relay.

T107-07-06-024

Use to measure the EC sensor circuit signal line volt- (Red)
age (between terminals #2 and #3).
(Black)
Parts Number 4284347 (ST 7129) T107-07-03-009
T5-6-14
Use to check the wiper circuit.
(Refer to T5-4-76.)
2
5 1
2 4 7
1
Parts Number (ST 7227) T178-05-06-003
T5-6-15
(Blank)
T5-6-16
TROUBLESHOOTING / ICX
OUTLINE
The ICX (information controller) stores signals from

various kinds of sensors and switches provided on the
machine as data. The various input signals are
grouped into “Daily Report Data List”, “Frequency Dis-
tribution Data List”, “Cumulative Operation Hour List”,
“Alarm List”, and “Trouble List” and are recorded in the
ICX.
The machine equipped with the optional satellite termi-

nal which will send the data to the center server via the
satellite communication system. (Refer to T5-7-27 for
the satellite communication system.)
T5-7-1
Daily Report Data List
Data Details
1 Key Switch ON Time Time when key switch is first turned ON during daily operation
(Time is recorded by key switch ON signal.)
2 Key Switch OFF Time Time when key switch is last turned OFF during daily operation
(Time is recorded by key switch ON signal.)
3 Engine Start Time Time when engine is first started during daily operation
(Time is recorded by alternator output signal.)
4 Engine Stop Time Time when engine is last stopped during daily operation
(Time is recorded by alternator output signal.)
5 Hour Meter Hour meter cumulative hours
(Hours are recorded by hour meter signal from monitor.)
6 Fuel Level The value of the final remained fuel during a day
(Value is recorded by fuel sensor signal from monitor.)
7 Engine Operating Hours Total engine operating hours during daily operation
(Hours are recorded by alternator output signal.)
8 Swing Operating Hours Total swing operating hours during daily operation
(Hours are recorded by signals from swing pressure sensor.)
9 Travel Operating Hours Total travel operating hours during daily operation
(Hours are recorded by signals from travel pressure sensor.)
10 Front Attachment Operating Hours Total front attachment operating hours during daily operation
(Hours are recorded by signals from front attachment pressure
sensor.)
11 Breaker Operating Hours Total breaker operating hours during daily operation
(Hours are recorded by signals from auxiliary pressure sensor
and attachment mode switch.)
12 Auxiliary Attachment Except for Breaker Total auxiliary attachment except for breaker operating hours
Operating Hours during daily operation
13 *ML Operating Hours Total *ML crane operating hours during daily operation
(Hours are recorded by signals from crane mode switch.)
14 Engine Operating Hour Distribution Engine operating hour distribution during daily operation
(Operating hours are recorded only when alternator output signal
is continuously delivered for more than 10 minutes.)
NOTE: The daily operation in this table is equivalent

to the hours between 0:00 and 23:59:59
counted by the ICX built-in clock. In case
the engine is kept operated beyond 0:00,
such data are recorded as those for the fol-
lowing day.
* ML specification is only available in Japa-

T5-7-2
Frequency Distribution Data List
Data Details
1 Engine Speeds Frequency distribution of engine speeds
(Speeds are recorded by signals from N sensor.)
2 Hydraulic Oil Temperature Frequency distribution of hydraulic oil temperature
(Temperatures are recorded by signals from hydraulic oil tem-
perature sensor.)
3 Coolant Temperature in Radiator Frequency distribution of coolant temperature
(Temperatures are recorded by signals from coolant temperature
sensor.)
4 Average Pump Delivery Pressure Frequency distribution of average delivery pressure from pumps
1 and 2
(Average pressures are recorded by signals from delivery pres-
sure sensors of pumps 1 and 2.)
5 Average Pump Delivery Pressure in Frequency distribution of average delivery pressure from pumps
Digging Operation during digging operation
(Average pressures are recorded by signals from arm roll-in
pressure sensor.)
6 Average Pump Delivery Pressure in Frequency distribution of average delivery pressure from pumps
Travel Operation during travel operation
(Average pressures are recorded by signals from travel pressure
sensor.)
Cumulative Operation Hour List
Data Details
1 Engine Operation Hour Cumulative engine operation hours
(Hours are recorded by alternator output signal.)
2 Swing Operation Hour Cumulative swing operation hours
(Hours are recorded by signals from swing pressure sensor.)
3 Travel Operation Hour Cumulative travel operation hours
(Hours are recorded by signals from travel pressure sensor.)
4 Front Attachment Operation Hour Cumulative front attachment operation hours
(Hours are recorded by signals from front attachment pressure
sensor.)
5 Breaker Operation Hour Cumulative breaker operation hours
6 Auxiliary Attachment Except for Cumulative attachment operation hours except for breaker op-
Breaker Operation Hour eration hours (Hours are recorded by signals from auxiliary pres-
sure sensor and auxiliary mode switch.)
7 *ML Operation Hour Cumulative *ML operation hours
(Hours are recorded by signals from crane mode switch.)
NOTE: ∗ML specification is only available in Japa-

T5-7-3
Alarm List
Code Data Details

81 Engine Oil Level Date and time when engine oil level indicator lighted are recorded by
signals from engine oil level switch.
85 Coolant in Radiator Date and time when coolant level indicator lighted are recorded by
signals from coolant level switch.
86 Hydraulic Oil Filter Date and time when hydraulic oil filter indicator lighted are recorded
by signals from hydraulic oil filter restriction switch.
89 Overheat Date and time when overheat indicator lighted are recorded by sig-
nals from overheat switch.
90 Engine Oil Pressure Date and time when engine oil pressure indicator lighted are re-
corded by signals from engine oil pressure switch.
93 Air Filter Restriction Date and time when air filter restriction indicator lighted are recorded
by signals from air filter restriction switch.
94 Alternator Indicator Date and time when alternator indicator lighted are recorded by sig-
nals from monitor controller.
NOTE: In case the above alarms are recorded,

check individual item. If malfunction of the
monitor is found, refer to troubleshooting C.
T5-7-4
Trouble List
Fault
Trouble Details
Code
01 Abnormal EEPROM Occurrence time and date of fault code 01
02 Abnormal RAM Occurrence time and date of fault code 02
03 Abnormal A/D Conversion Occurrence time and date of fault code 03
04 Abnormal Sensor Voltage Occurrence time and date of fault code 04
06 Abnormal EC Sensor Occurrence time and date of fault code 06
07 Abnormal Engine Control Dial Occurrence time and date of fault code 07
10 Abnormal Pump 1 Delivery Pressure Occurrence time and date of fault code 10
11 Abnormal Pump 2 Delivery Pressure Occurrence time and date of fault code 11
12 Abnormal Pump 1 Control Pressure Occurrence time and date of fault code 12
13 Abnormal Pump 2 Control Pressure Occurrence time and date of fault code 13
14 Abnormal Swing Lever Stroke Occurrence time and date of fault code 14
15 Abnormal Boom Raise Lever Stroke Occurrence time and date of fault code 15
16 Abnormal Arm Roll-In Lever Stroke Occurrence time and date of fault code 16
18 Abnormal Travel Lever Stroke Occurrence time and date of fault code 18
19 Abnormal Oil Temperature Sensor Occurrence time and date of fault code 19
64 MC Communication Error Time and date when communication error between MC
and ICX occurred.
65 Monitor Communication Error Time and date when communication error between moni-
tor and ICX occurred.
66 Satellite Terminal Communication Error Time and date when communication error between satel-
lite terminal and ICX occurred.
NOTE: In case the above fault codes are recorded,

refer to troubleshooting A.
T5-7-5
ICX FAULT CODE LIST
Fault
Trouble Remarks
Code
1 Abnormal Internal Ram In case of SAM error
2 Abnormal Flush Memory In case of SAM error
3 Abnormal Exterior In case of SAM error or read-write error
4 Abnormal EEPROM In case of SAM error
6 Abnormal Time In case RTC data was other than figures.
7 MC Communication Timeout (For ZAXIS) In case MC communication didn’t last for more than 7
seconds.
8 Monitor Communication Timeout In case monitor communication didn’t last for more than
24 seconds.
9* MC Communication Timeout (For EX5) In case MC communication didn’t last for more than 20
seconds.
10 Satellite Terminal Communication Timeout In case satellite communication didn’t last for more than
1 minute.
NOTE * Fault code 9 may be displayed on only the

machine (Type: EX5 with minor change), to
which the ICX is installed later.
SATELLITE TERMINAL FAULT CODE LIST
Fault
Trouble Remarks
Code
101 Satellite Terminal: Internal Error Abnormal EEPROM
102 Satellite Terminal: Internal Error Abnormal sent data
103 Satellite Terminal: Internal Error In case reception is difficult.
104 Satellite Terminal: Communication Error In case satellite communication cannot be accomplished.
105 Satellite Terminal: Internal Error In case sending retry over occurred or local loop back
test failed with power ON.
106 Satellite Terminal: Communication Error In case sending retry over occurred.
107 Satellite Terminal: Abnormal Harness In case reception data doesn’t match sending data.
T5-7-6
FAULT CODE 1 TO 4 AND 6
YES *Faulty ICX
Check if all data are normally

cumulated.
Faulty ICX
NO
· Refer to T5-7-10 for replacing
*even if the fault code remains displayed after retrying, ICX.
the machine can be operated as it is when data rec-
ord is normally cumulated.
FAULT CODE 7 TO 10
YES Faulty ICX

Check for continuity between
ICX and corresponding com- · Refer to T5-7-10 for replacing
ponent while referring to the ICX.
following table. Broken harness between ICX
and corresponding compo-
NO nent
Fault code ICX terminal # Corresponding component terminal #

7 Connector C terminal #11 Mc connector D terminal #10
8 Connector B terminal #1 Monitor connector B terminal #3
10 Connector B terminal #5 Satellite terminal DSUb9 pin terminal #2
T5-7-7
SOME PARTS OF DATA IN DAILY REPORT,
FREQUENCY DISTRIBUTION, CUMULA-
TIVE OPERATION HOURS ARE NOT RE-
CORDED
• All necessary data signals may not be input into

the ICX. Individual signals are utilized to record
more than one data. While referring to the table
below, check the corresponding system for any
abnormality.
Related Data Input Signal

Key switch ON and OFF time Key switch
Engine start and stop time, Engine operating hours (Daily report and cumu- Alternator
lative operation hour), Engine operating hour distribution
Hour meter Monitor controller
Coolant temperature distribution in radiator Coolant temperature sensor
Remaining fuel level (detected at regular data sending time) Fuel level sensor
Travel operating hours (Daily report and cumulative operation hour), Aver- Travel pressure sensor
age pump delivery pressure distribution in travel operation
Front attachment operating hours (Daily report and cumulative operation Front attachment pressure sensor
hour)
Swing operating hours (Daily report and cumulative operation hour) Swing pressure sensor
Average pump delivery pressure distribution in digging operation Arm roll-in pressure sensor
Breaker operating hours (Daily report and cumulative operation hour), Auxil- Auxiliary pressure sensor
iary attachment except for breaker operating hours (Daily report and cumu-
lative operation hour)
Distribution of average pump delivery pressure, average pump delivery Pump 1 delivery pressure sensor
pressure in digging operation and travel operation
Distribution of average pump delivery pressure, average pump delivery Pump 2 delivery pressure sensor
pressure in digging operation and travel operation
Engine speed distribution N sensor
Breaker operating hours (Daily report and cumulative operation hour) Attachment mode switch
Auxiliary attachment except for breaker operating hours (Daily report and Auxiliary mode switch
cumulative operation hour)
*ML operating hours (Daily report and cumulative operation hour) Crane mode switch
NOTE: *ML specification is available only in Japa-

T5-7-8
Corrective Action Remarks

Check harness between ICX terminal A5 and key In case engine doesn’t start, refer to troubleshooting B.
switch terminal M.
Check harness between ICX terminal A2 and alternator In case alternator indicator malfunctions, refer to trou-
terminal L. bleshooting C.
Check harness between ICX terminal B1 and monitor In case hour meter malfunctions, refer to troubleshoot-
terminal B3. ing C.
Check harness between ICX terminal B1 and monitor In case coolant temperature gauge malfunctions, refer
terminal B3. to troubleshooting C.
Check harness between ICX terminal B1 and monitor In case fuel gauge malfunctions, refer to troubleshoot-
terminal B3. ing C.
Check harness between ICX terminal C11 and MC ter- In case machine control system malfunctions, refer to
minal D10. troubleshooting B.
T5-7-9
TROUBLESHOOTING AND SETTING OF
ICX AND SATELLITE TERMINAL USING
DR.EX
Troubleshooting of ICX can be performed using Dr. EX.

Before starting satellite communication, or after replac-
ing the satellite terminal and/or the ICX, initial setting of
the ICX must be conducted as described in the follow-
ing page using Dr. EX.
ICX initial setting

ICX Enter Enter Enter time Internal Satellite Enter
diagnosis model date difference hour terminal gateway
and and time between meter diagnosis control
serial the local time setting center
No. and UTC ID No.
Dr. EX Work No. 2 3-1 3-2 3-3 3-4 4 5-1
ICX setting/confirmation
• • • • • •
after ICX replacement
• • • • • • •
• • • • • •
when battery is installed
Satellite terminal set-

ting/confirmation • • • • • •
Satellite terminal set-
ting/confirmation after
satellite terminal re-
placement
• • • • • •
ICX and satellite termi-
nal/confirmation after
ICX and satellite terminal
replacement
• • • • • • •
NOTE: When required to conduct both Dr. EX
Work No. 5-6 and 5-7, conduct these steps
in the order of Dr. EX work No. 5-6 and 5-7
after completing all other steps described in
the table.
Don’t conduct step Dr. EX work No. 3-4 un-
less the ICX is replaced.
• :Work to be done.
T5-7-10
Satellite terminal initial setting Remarks

Enter Mail Satellite Satellite Satellite Satellite
geodetic switch terminal communication terminal communication
system con- No. con- line inbound-cue start/stop
firmation firmation confirmation initialization setting
5-2 5-3 5-4 5-5 5-6 5-7
• • • • • • Should be done during

delivery to customer
If ICX has been re-
placed, ICX setting and
• • • • • • confirmation are re-

quired even when satel-
lite communication is
not made.
• • • • • •
For details, see the
service bulletin. (No.
Dr. EX-018)
• • • • • • Should be done during

delivery to customer.
• • • • • •
• • • • • •
T5-7-11
1. Basic Operation of Dr. EX for Diagnosing and
Setting The ICX and Satellite Terminal
1-1 Starting Dr. EX

IMPORTANT: Setting the ICX and satellite terminal
should be done while the engine
stopped.
(1) Turn on the key (do not start the engine).
(2) Connect the Dr. EX connector (For ICX) located at
left side of the rear console
(3) Start Dr. EX program. When the Model Menu is
displayed, select "ICX1-E".
<< Model Menu >> (S01)

1.ICX1-E Ver 5.01 Select
2.
3.
4.
5.
Select number
F3: Next↓ V1.00
(4) ICX1-E version display screen

Press F1. The screen will change to the "Function
Selection".
ICX Controller
• C/U Software Revision

Ver 5.01
F1: Next F10: Escape
T178-01-02-006
(5) Function Selection screen Dr. EX Connector
The Function Selection screen consists of 3 (For ICX)
pages. Each screen below appears by pressing
F3 and F4.
Select Function Select Function

F5: F5: Satellite Terminal
No. Confirmation
F6: ICX Initial Setting F3 F6: ICX Diagnosis
F7: Mail Switch F7: Satellite Terminal

Confirmation Diagnosis
F3: Next↓ F10: Escape F3: Next↓ F4: Previous↑ F10: Escape
F3
Select Function
F5: Satellite Comm.
Line Confirmation
F6: Satellite Terminal
Inbound-Cue Init
F7: Satellite Comm.
Start/Stop Set
F4: Previous↑ F10: Escape
T5-7-12
1-2 Stopping Dr. EX
(1) Press F10: Escape several times to change the
screen to the Function Selection.
F10: Escape
Select Function
F5:
F6: ICX Initial Setting
F7: Mail Switch

Confirmation
F3: Next↓ F10: Escape
(2) Turn off the Dr. EX power switch.

(3) Disconnect the Dr. EX cable from Dr. EX connec-
tor (For ICX) located at left side of the rear con-
sole.
(4) Turn off the key.
2. ICX Diagnosis
NOTE: Wait one minute or more after turning the
key switch on.
(1) Select ICX Diagnosis on the Function Selection
screen.
Confirm the message: "No trouble exists".
If any trouble exists, refer to page T5-7-6.
T178-01-02-006
Dr. EX Connector
Select Function Select Function (For ICX)
No. Confirmation
F6: ICX Initial Setting F3 F6: ICX Diagnosis Select

T5-7-13
3. ICX Initial Setting
3-1 Enter Model and Serial Number
(1) Select ICX Initial Setting on the Function Selection

screen.
Select Function
F5:
F6: ICX Initial Setting Select
F7: Mail Switch

Confirmation
(2) Select Enter Model and Serial No. on the Function

Selection screen
Select Function
F5: Enter Model Select
Serial No.
F6: Enter Date and Time
F7: Enter Time

Difference from UTC
(3) Confirm that the model and serial number on the

machine nameplate and those displayed on the Dr.
EX screen are identical.
Example:When the nameplate shows 1S1P060001, Dr.

EX displays: Model: 01S1, Serial No.:
060001
Model and Serial No.
• Model: 01S1
• Serial No.: 060001
F1: Correct F10: Escape
T5-7-14
(4) If the model and serial number displayed on Dr.
EX are incorrect, correct them.
(Use F1, F2, F4 or F5 to move the inverted display
portion. Press ENT to set characters at the in-
verted display portion.)
NOTE: When the model is 1S1, enter 4-digit char-
acters or 01S1 on the screen.
Model and Serial No. Enter Model

• Model: ∗∗∗∗ • Model: ∗∗∗∗
• Serial No.: ∗∗∗∗∗∗ F1 ABCDEFGHIJKLMNOPQRST

UVWXYZ0123456789→←
F1: ↑ F2: ↓ F4: ← F5: →

F1: Correct F10: Escape ENT: Input
Enter the model on the nameplate.
NOTE: When the serial number is

60001, enter 6-digit nu-
merical figure or 060001.
Enter Model Enter Serial No.
• Model: ∗∗∗∗ • Serial No.: ∗∗∗∗∗∗
F1 ENT
F1: OK F2: NG F10: Escape ENT: Confirm

Press F1 if the entered data is correct. Enter the model on the nameplate.
Enter Serial No.

• Serial No.: ∗∗∗∗∗∗
F1 Setting has been F10

completed
F1: OK F2: NG F10: Escape F10: Escape
Press F1 if the entered data is correct.
Model and Serial No.

• Model: ∗∗∗∗
• Serial No.: ∗∗∗∗∗∗
Reconfirm that the model and serial

number displayed on the screen agree
with those on the nameplate.
T5-7-15
3-2 Enter Date and Time
(1) Select ICX Initial Setting on the Function Selection (4) If the local year/month/date data are incorrect or, if
screen. the time inaccuracy is more than 5 minutes, key in
the correct year, month, date and time. (Key in by
Select Function selecting the keys from 0 through 9 on Dr. EX.)
F5:
F6: ICX Initial Setting Select Date, Time

• Local Time
F7 Mail Switch YY MM DD : 2000/06/01
Confirmation Time : 09:00:00
F3: Next↓ F10: Escape • UTC
YY MM DD : 2000/06/01
Time : 00:00:00
(2) Select Enter Date and Time on the Function Se-
lection screen below.
F1
Select Function
F5: Enter Model Date, Time
Serial No. • Local Time
F6: Enter Date and Time Select YY MM DD : 2000/06/01
Time : 10:00:00
F7: Enter Time
Difference from UTC
ENT: Verify
Determine the current date

and time by pressing ENT. ENT
(3) Confirm the current date and time.
NOTE: The local time of 13:27:53 is equivalent to
13 hours, 27 minutes and 53 seconds. Date, Time
• Local Time
YY MM DD : 2000/06/01
Time : 10:00:00
Date, Time • UTC
• Local Time YY MM DD : 2000/06/01
YY MM DD : 2000/06/01 Time : 01:00:00
Time : 13:27:53 F1: OK F2: NG F10: Escape
• UTC
YY MM DD : 2000/06/01
Time : 04:27:53 F1
If the local year/month/date data are correct and the

time inaccuracy is between 5 minutes, press F10.
Setting has been

completed
F10: Escape
F10
Date, Time
• Local Time
YY MM DD : 2000/06/01
Time : 10:00:00
• UTC
YY MM DD : 2000/06/01
Time : 01:00:00
Reconfirm that the local day,

month, year and time data are
correct.
T5-7-16
3-3 Enter time difference from UTC
(1) Select ICX Initial Setting on the Function Selection (4) If the time difference between the local time and
screen. UTC is incorrect, enter the correct time difference.
Enter Time Difference

Select Function
F5: Time Difference: +0900
(Japan: +0900)
F7: Mail Switch

Confirmation F1: Correct F10: Escape
F1
(2) Select Enter Time Difference from UTC on the
Function Selection screen.
Select Function Time Difference: +0900
F5: Enter Model (Japan: +0900)
Serial No.
F1: Previous↑ F2: Next↓
F7: Enter Time Select F3: Confirm F10: Escape
Difference from UTC
F3: Next↓ F10: Escape Pressing F1 and F2 changes Ex: Press
the time difference in units of F1 twice
30 minutes.
(3) Confirm the time difference between the local time
of the area in where the machine is operating and Enter Time Difference
UTC. Time Difference: +0800
Example: In case of Japan, time difference is dis- (Japan: +0900)
played as +0900.
Enter Time Difference F3: Confirm F10: Escape
Time Difference: +0900

Ex: Japan +0900 F3
Setting has been completed
F10: Escape
F10
Time Difference: +0900

(Japan: +0900)
Reconfirm the time difference

is correct.
T5-7-17
3-4 Internal hour meter setting
key switch on.
(1) Select ICX Initial Setting on the Function Selection

screen.
Select Function
F5:
F7: Mail Switch

Confirmation
(2) Select Internal Hour Meter Setting.

F5: Enter Model F5: Internal Hour Select
Serial No. Meter Setting
F6: Enter Date and Time F3 F6: Enter Gateway
Control Center ID No.
F7: Enter Time F7: Enter Wake-up Time
Difference from UTC
(3) Press F1 to set hour.
Hour Meter
• ICX Internal Hour Meter To the next step
00000.00
• External Hour Meter F1 Setting has been
00100.00 completed
F1: Set F10: Escape F10: Escape
(4) Confirm that the ICX internal hour displayed and

the external hour displayed are identical.
Hour Meter
• ICX Internal Hour Meter
00100.00
• External Hour Meter
00100.00
F1: Set F10: Escape
T5-7-18
4. Satellite Terminal Diagnosis
key switch on.
(1) Select Satellite Terminal Diagnosis on the Func-

tion Selection screen.
Confirm the message: "No trouble exists".
If any trouble exists, refer to page T5-7-6.

No. Confirmation
F7: Mail Switch F7: Satellite Terminal Select

T5-7-19
5. Satellite Terminal Initial Setting
(4) If the gateway control center ID No. is incorrect,
5-1 Enter gateway control center ID No. enter the correct data.
(The gateway control center ID No. must be checked
since the ORBCOMM satellite base station ID is dif-
ferent depending on region.) Gateway Control Center
GCC ID:
(1) Select ICX Initial Setting on the Function Selection Japan
screen.
Select Function F1: Correct F10: Escape

F5:
F6: ICX Initial Setting Select F1
F7: Mail Switch

Confirmation
F3: Next↓ F10: Escape Gateway Control Center
GCC ID:
Japan
(2) Select Gateway Control Center ID No.
F2: Next↓
Select Function F1: Confirm F10: Escape
F5: Enter Model
Serial No. Press F2 until the correct Ex: Press
F6: Enter Date and Time gateway control center ID is F2 once.
displayed.
F7: Enter Time
Difference from UTC Gateway Control Center
GCC ID:
F3 USA
Select Function
F5: Internal Hour F1: Previous↑ F2: Next↓
Meter Setting F3: Confirm F10: Escape
F6: Enter Gateway Select
F7: Enter Wake-up Time F3
F3: Next↓ F4: Previous↑ F10: Escape
(3) Confirm that the correct gateway control center ID Setting has been
No. is correct. completed
NOTE: Since there is no gateway control center in
some regions, contact Hitachi Construction F10: Escape
Machinery Co. Ltd. International Product
Support department for details. F10
Gateway Control Center

Gateway Control Center
GCC ID:
Japan GCC ID:
USA

Reconfirm that the gateway

control center ID is correct.
T5-7-20
5-2 Enter Geodetic System
(The geodetic system must be checked since the (4) If the geodetic system data is incorrect, enter the
GPS geodetic system is different depending region.) correct data.
(1) Select ICX Initial Setting on the Function Selection GPS Datum Table
screen.
Coordinate System:
Select Function WGS84
F5:
F6: ICX Initial Setting Select F1: Correct F10: Escape

F7: Mail Switch
Confirmation
F3: Next↓ F10: Escape F1
(2) Select GPS Geodetic System. GPS Datum Table
Select Function Coordinate System:

F5: Enter Model WGS84
Serial No.
F2: Next↓
F7: Enter Time F1: Confirm F10: Escape
Difference from UTC
F3: Next↓ F10: Escape Press F2 until the correct Ex: Press
GPS geodetic system is F2 twice.
displayed.
F3
Select Function GPS Datum Table

F5: Internal Hour
Meter Setting Coordinate System:
F6: Enter Gateway ADINDAN
F7: Enter Wake-up Time
F3: Next↓ F4: Previous↑ F10: Escape F3: Confirm F10: Escape
F3 F3
Select Function
F5: Enter Controller
Type
F6: Enter Downloaded
Operator's Name
Setting has been
F7: GPS Datum Table Select completed
F10: Escape
(3) Confirm that the GPS geodetic system data is cor-

F10
rect.
NOTE: Since GPS geodetic system is different de-
pending on region and map software, con- GPS Datum Table
tact Hitachi Construction Machinery Co. Ltd. Coordinate System:
International Product Support department ADINDAN
for details.
GPS Datum Table F1: Correct F10: Escape

Coordinate System:
Reconfirm that the GPS
TOKYO
geodetic system
data is correct.
T5-7-21
5-3 Mail Switch Confirmation
(1) Select Mail Switch Confirmation on the Function
Selection screen.
Select Function
F5:
F6: ICX Initial Setting
F7: Mail Switch Select

Confirmation
(2) Mail switch status confirmation
Mail Switch Status

Display
Mail Switch: ON OFF
F1: HOLD F10: Escape
Turn on and off the mail switch to

confirm that character color
(black/while) changes according to
the switch status.
T5-7-22
5-4 Satellite terminal number
(1) Select Satellite Terminal No. on the Function Se-
lection screen.

F5: F5: Satellite Terminal Select
No. Confirmation

(2) Confirm that the serial number and the satellite

communication contract number are identical.
Satellite Terminal No.
Serial No.: 8GBDA701086
F10: Escape
T5-7-23
5-5 Satellite communication line confirmation
NOTE: Do not perform this work at places out of
the range of satellite electric wave, such as
inside the house, tunnel, etc.
(1) Select Satellite Communication Line Confirmation

on the Function Selection screen.

No. Confirmation

F3
Select Function
F5: Satellite Comm. Line Select
Confirmation
Inbound-Cue Init
F7: Satellite Comm.
Start/Stop Set
(2) Confirm the satellite communication line status.

NOTE: Identify the cause if both of the GPS and
rod antenna statuses are NG after 5 min-
utes.
However, it may take time to become OK
depending on the place or time zone since
satellite is always moving.
Satellite Communication
Line Display
GPS Antenna: OK NG
Rod Antenna: OK NG
F1: HOLD F10: Escape
Confirm that GPS antenna and rod

antenna become OK.
T5-7-24
5-6 Satellite terminal inbound-cue initialization
(1) Select Satellite Terminal Inbound-Cue Initialization
on the Function Selection screen.

No. Confirmation
F6: INX Initial Setting F3 F6: ICX Diagnosis

F3
Select Function
F5: Satellite Comm. Line
Confirmation
F6: Satellite Terminal Select
Inbound-Cue Init
F7: Satellite Comm.
Start/Stop Set
(2) Initialization processing
Press F1 to initialize F1 Wait. Initializing

all data.
F1: Initialize F10: Escape
Initialization has been completed
F10: Escape
T5-7-25
5-7 Satellite communication start/stop setting
(1) Select Satellite Comm. Start/Stop Set on the
Function Selection screen.
No. Confirmation

F3
Select Function
F5: Satellite Comm. Line
Confirmation
Inbound-Cue Init
F7: Satellite Comm. Select
Start/Stop Set
(2) Satellite communication start/stop setting

When setting Satellite Communication Start:
Satellite Communication Satellite Communication
Start/Stop Start/Stop
Sate. Comm.: Start Stop F1 Sate. Comm.: Start Stop
F4:← F5: →
F1: Correct F10: Escape ENT: Confirm
Press F4 and F5 to move the ENT
cursor to "Start", then press
ENT.
Start/Stop
Setting has been F1 Sate. Comm.: Start Stop

completed
F10: Escape F1: OK F2: NG F10: Escape
When setting Satellite Communication Stop:

Satellite Communication Satellite Communication
Start/Stop Start/Stop
Sate. Comm.: Start Stop F1 Sate. Comm.: Start Stop
F4:← F5: →
F1: Correct F10: Escape ENT: Confirm
Press F4 and F5 to move the ENT
cursor to "Stop", then press
ENT.
Start/Stop
Setting has been F1 Sate. Comm.: Start Stop

completed
F10: Escape F1: OK F2: NG F10: Escape
T5-7-26
SATELLITE COMMUNICATION SYSTEM
GPS Antenna
The satellite communication system is used for the
maintenance of the machine by transmitting various
data of the machine regularly via a low earth orbit sat-
ellite.
NOTE: Since the satellite communication system is Communication

available depending on region, contact Hi- Antenna
tachi Construction Machinery Co. Ltd. In-
ternational Product Support department for
details.
Depending on the circumstances of the
machine (ex. in the constructions, in the
tunnel, affected by the surrounding building
and affected of noise), the data transfer
rate may become slower, or the communi-
cation might not be established. M178-13-002
Also, the satellite communication system

using a low earth orbit satellite transmits
digital data through the radio wave. If there
is excessively noise or use of electrical
equipment which caused noise placed near
the machine, they cause reduces data
transfer rate or communication might not be
established at worst.
The satellite communication system is composed of:

Satellite terminal, GPS antenna, communication an-
tenna and mail switch. The functions of each equip-
ment are:
M178-13-003
Mail Switch
• Satellite Terminal
It receives the data from ICX, GPS antenna and Satellite Terminal
mail switch, and send the data to the communica-
tion antenna.
• GPS Antenna
It receives the location information of the machine
from a low earth orbit satellite.
• Communication Antenna
It communicates the data with a low earth orbit
satellite.
• Mail Switch
It sends date and time information, latest location
of the machine and the fuel level (%) when the
switch is pressed.
T178-01-02-006
T5-7-27
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 satellite com-

munication:
Items Kinds of Data Condition
Periodical Operation Record, Latest Location Infor- The data are transmitted once every day.
Transmission mation, Fuel Level To avoid congested traffic in the commu-
nication line, the data is transmitted ran-
domly between 0:00 and 02:00.
Transmitting Data at Latest Location Information The data is transmitted only when the
Engine Start machine is moved more than 5 km from
the place where it is recorded lastly.
Emergency Alarm and Error Information The transmission starts immediately
Transmission when the alarm and error occurs.
Hour Meter 100 Hours Frequency Distribution Information The data is transmitted when the hour
Transmission meter exceeds every 100 hours.
Transmission by Mail Date and time when the switch is pressed, The transmission starts immediately
Switch Latest location of the machine, Fuel level when the mail switch is pressed.
T5-7-28

t05 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

t05 PDF

Uploaded by

Copyright:

Available Formats

SECTION 5

Group 6 Electrical System Inspection

Refer to the inspection and troubleshooting procedures

The troubleshooting section in this manual consists of

• General • Electrical System Inspection

• Troubleshooting C (monitor diagnosis)

Example: Malfunction of fuel gauge

These six basic steps are essential for efficient trou-

1. Study the System

2. Ask the operator T107-07-01-001

(a) How is the machine being used? (Find out if

(b) When was the trouble noticed, and what

(c) What are the details of the trouble? Is the

(d) Did the machine have any other troubles pre-

3. Inspect the machine

Also, check the electrical system, including the

pressurized oil may spout, possibly resulting

Perform self-diagnosis by connecting Dr. EX to

ҰNote that the fault codes displayed do not nec-

6. Trace possible causes

In the service mode, the monitor LCD displays the

Built-In Diagnosing System Activation

NOTE: * Refer to T5-1-7 for the Fault Codes.

NOTE: This group describes how to operate Dr. EX

NOTE: Special functions allow the ECO and WU OK

4. Select F1. Then, continue to operate Dr. EX by Self-Diagnosing

Fault Code Trouble Cause

Dr. EX displays the input signals from the switches and

Item Data Unit

NOTE: ML specification is only available in Japa-

(Example) Model : ZX200

(Example) Ver : 0400

Special Functions NOTE: Refer to T4-2-2.

F7: ECO Deactivation 2

F1: Execute F5: ESC

Dr. EX has three (3) modes, learning value display,

Learning Value Display

Monitor Display Information Setting

• Accessing Service Mode

(Example) Model : ZX200

(Example) Ver : 0400

Service mode selected.

In service mode, self-diagnostic

F1: Rechecked F5: ESC

F3: Special Functions

Select Functions Select item

F7 Press F6 Press F5 Press

Select item EC Motor Stop Position

F3: Next F5: ESC F5: ESC

Hyd. Breaker P1 Max. Hyd. Breaker P1 Max.

Hyd. Breaker P1 Max.

F1: Execution F2: Corr F5 Press

Adjusting Deviation Data Name:

F3: Next F5: ESC

Adjustment was made as follows:

Adjusting Deviation Data Name:

Hyd. Breaker P1 Max.

F4: Prev. F5: ESC

Turn off Dr.EX

F7: Hydraulic Oil Temp

F8: Hyd. Oil Filter LED

F3: Next F5: ESC

Engine Actual Speed 5