Course program

EC380D-EC480D Step 1

Time 1st Day 2nd Day 3rd Day 4th Day 5th Day
08:00 - Sensor & - Auto idle, auto Power Hydraulics
components engine shut-off... transmission (EC480D)
- Cooling system - Swing system - Main pump
- X3 control - Travel system
- X1 control
- EMS 2 check IECU Frame & track Hydraulic circuit
unit - Boom up &
down
- Arm in
- Bucket
- Straight travel
Elec. circuit Aircon system MCV
Electric system - Wiper, radio... Hydraulics - MCV
- Start circuit & - Wiring diagram (EC380D) disassembly
EDB - Main pump
- Related
components
12:00–13:00 Lunch
Opening - Control system Elec. system Hydraulic circuit Pressure
- Overview circuit practice - Boom up & measuring
- Look-around - Related - Start circuit down Option
components - EDB - Arm in hydraulics
- VECU - Bucket - X1, X3 & others
- IECU - Straight travel
IECU operation VECU control & - VCADS Pro Evaluation &
Engine function MCV closing
- D13F engine - Engine speed & - MCV
work mode disassembly
17:00 control

1
 Course program (Update)

EC380D-EC480D Update

Time 1st Day 2nd Day 3rd Day

08:00 - Sensor value check by Power transmission
VCADS Pro
- EMS 2 check Aircon system
Elec. system Hydraulic system
- Start circuit & EDB (EC380D)
- Control system circuit
12:00–13:00 Lunch Lunch Lunch
Opening VECU control & function Hydraulic system
- Overview - Auto idle, auto engine (EC480D)
- Look-around shut-off... - MCV check
- X3 control - Pressure measuring
- X1 control
IECU circuit
Engine Elec. system practice Evaluation & closing
- D13F engine - Start circuit & EDB check
17:00 - Sensor & components - VECU check

1
 Tools and requirements

EC380D-EC480D

Machine
1 Computer with PROSIS per 4 participants
Computer with installed and updated Techtool

Designation Used when Part number

Break out box EMS 2 9998699

Extension cable EMS 2 9990062
Adapter cable EMS 2 9990014
Break out box VECU 14515484
Adapter cable VECU 9993893
Interface VCDS Pro 88890020
Adapter Power shift valve 8920-01805
Pressure gauge Hydraulic pressure measuring 11666051

Components that are good to have

MCV
Main pump
Track drive unit
Swing drive unit

1
 Hydraulic circuit full option (EC380D)
SCISSORS 61 05 SPROCKET U-Q/FIT
HAMMER & CRUSHER dr 14 13
Pi PCD:732.47
06 P3 T

12 87 B
A 59
P2
T B
83 B
B A A
A
60 Pi
A B
TILTING T1 FOR C AG F B D FOR
P1 T2 PS MA9109
65 PWM9129 PWM9130 66
P2 R1 P1 15
P1 R1
T / M LH T / M RH
P3 T

P3 R2 P2 87 B

B
A
A

PS MA9109
S-Q/FIT

PWM9124 PWM9123 40
P T
57 P1 T1
63 A
P2 T2
54
P3 T3

T 64 P4 T4
A1 P T A2 (P3) (P4)
P SE9112 P6 T6
03
MA9116 P7 T7
1 T P 2 N2
P8 T8
Pca1 N1
P9 T9

P5 T5
Pca
Dr3

3 5 4
52 55 56 P2c2 Pcb

6 A1 A2
2 1 Ba

MA9122

P MA9121 PAa2
Aa

T PAa 27
PBa2

PBa PAa2 SE9401

53 S
B
PAc1 84
P
T Pd
DrAc 04
P A B T
Bo Ac
SOL b SOL a
LH RH LH RH
Ao Bc P2 P3 P3 P2
P T
07 PAcs
PAo RIGHT
A Mu B 24
MA9118 MA9117 PAc HAND
Pi Pi
PBc 1 2 3 4
PBo T1 P1 P1 T1
Dr3'

P2c1
82 81
08 41
Pi Bb

Dr
P PBb2 Ab SE9140 SE9140
A
T
PBb 99
89
PAb T B
86 Psp B T T
64 64
P Dra Pi
P1 P3 Pi P
PG Bs Dr Dr
P2 P4 Ar A
A
2P1 2P2 As Br
XL1 XL2 SH
PAs PAr
XR1 XR2
PBs
2PT1 2PT2 09 PBr
T2 T4 Px
T1 T3 P Drb 90
BL Ø0.7 A B
T 11
AL

P T
PAL PTa (PTb)
Px Py
Ø5.3
PBL MA9120
38 PL1

Py LEFT
Ø1.0 Ø0.7 HAND 23
SE9111 SE4216 R3
1 2 3 4
Pa T1 pr11 P2 P1

26

BO1 BO

75 AO1
73 AO2 AO
A B
BU1
BU2 T
PWM9145 PWM9146
BU3 BU
AI1 P
74 AI2
AI3
57 SH
SW1 AI

SOLb
SOLa
Pi2 Pi1
SR1 SR
A1 P T A2 SL1 SL
G BD1
P T P T
BD2 BD
MA9111 MA9110 BI1 BI

25

70 LH RH

29 28
Dr6 Dr5 Dr4 Dr3 Dr2
39 P1 Psv a4 P2
1 T P 2
Dr7 Dr1
3.0k 1.5k 2 T 1 4 P 3
01 21 a1 a2

PWM9141

36 91
Pi1 Pi2
F4 F3 F2
34 37 F5 F1

B5 B1
A
Pout Dr T B4 B3 B2
58 20
30
T P E/G
SAFETY
BOOST
TR. 2

Td9 31
Td10
PWM9143 PWM9109 A1 A2 A3
32 19 22
33 T AC
Td11 18
Pin P Dr
Td1 Td2 Td3 Td4 Td5 Td6 Td7 Td8
35 02
PS PS1 P1 P2
16 17
71 72 S1 S5
T
S2 S3 S4

MA9126 MA9125 MA4212

T1 T2 T3
 59
Hydraulic circuit full option (EC480D)
61 dr
Pi 14 13 13 14 P3
87 T
5 83 Pi X X 6 X
B(B/W) A(B/W)
B
A P1
T B B
P2 T2
60 T1 A
A

P2 65 R1 P1 66 MA9109
X PS
R1 A(F/W) B(F/W)
P1 X B DG F AC P3 T
T T
PWM9129 PWM9130 B
R2 P2
15
P3
B
A
A

MA9109
PS
87

P T
PWM9124 PWM9123
P1 T1
A X
57 P2 T2
63 P3 T3
P4 T4
67 X
P6 T6
P7 T7
T 64 P8X T8
A1 P T A2 P9X XT9
P
MA9116 40
P5 T5
SE9112
1 T P 2

5pp 5pc1
3 5 4 98
52 A1 A2 dr3
55 56 Rs2 3
5pc2 5pf 5pc4 dr4 Rs1 dr7 Pz dr1 C2 dr5 4pc4 4pf
6
2 1
P
4pc2
T SE9401
S MA9122 MA9121 27 4 4
53 B 5B5
P 4pa4 B 84
5pb5
T 5A5
A B 5pa5 4pb4 P2 P3 P3 P2
SOL b SOL a 51
Pi
4A3
P T 4pa3
MA9118 MA9117 4B3 T2 P1 P1 T2
5B4 82 81
5pb4 4pb3
5A4
5pa4
4A2
Pd
5B3 dr2
5pb3
5A3 4pp
A B A B 5pa3 4pc1
24 1 2 3 4
7 4pa2
P 86 5pc3 SE9141
4B2
P1 P3
8 SE9141 64
P2 P4 5pb2 64 89 99
4pb2 B T T B
2P1 2P2
dr6
XL1 XL2
XR1 XR2 5B2 4A1 Dr Dr Pia
2PT1 2PT2
× × × × 4pa1 Pi
5A2
T2 T4 M M 4B1 Pib
A A
T1 T3 5pa2
4pb1
T
T Dr Dr
5B1
PG PG
5pb1
5A1
A B P
SH SH 5pa1
90
11 10 9 P T
MA9120

23 1 2 3 4
26
Px R2 pc BO1 BO
P1 pp Py C1 R1 P2 Pg
AO1

4pc5
AO2 AO
BU1
A B 75 BU2
73 BU3 BU
38 SE4216 SE9111
AI1
76 AI2
AI3
PWM9145 PWM9146 74 SH T
SOL b SOL a SW1 AI
Pi2 Pi1 SR1 SR
SL1 SL
BD1 P
BD2 BD

x
X
BI1 BI
G
A1 P T A2 P T P T 39 2 3 4 5 6
1 7
MA9111 MA9110
LH RH
85 25

29 28 1 T P 2
2 T 1 4 P 3
3.0K 1.5K

T1 T2 T3 21
F4 F3 F2
Psv2
F5 F1
a4 Psv1 a1 a2 a5 B1
36 B5

1 PWM9141
91 B4 B3 B2
34 37 20
PWM9143
350cc
Pout Dr T
SAFETY
BOOST
TR. 2

15k
Td9 30 22 A1 A4 A5
58 Pi1 Pi2 19
Td10 31 T AC
T
Td11
32 18
A P1 P4
33 35 P PS PS1
X X 16 Pin P PWM9109 E/G
Td1 Td2 Td3 Td4Td5 Td6 Td7 Td8
17 S1 S5 T
MA9126 MA9125 MA4212
S2 S3 S4
2 Dr1 Dr3
7172
 Overview

A. IECU
1. Vehicle information (Main menu).
- Model: ____________, Serial no.: ____________

2. Time remaining for water separator/fuel filter replacement (Main menu): ____________hours.

3. Auto-idle time set up (Main menu).

- Change the setting to 5 seconds.

4. System voltage check (Service mode).

- IECU:____________, VECU:____________, EECU:____________, ALT-L:____________

5. Engine sensor value (Service mode).

- Coolant temperature: ____________°C
- Fuel feed pressure: ____________bar

6. Aircon system (Service mode).

- Cabin temperature: ____________°C
- Evaporator temperature: ____________°C

B. Machine Control
1. Engine speed control.
- P mode in Normal, Unloaded: ____________rpm, Loaded: ____________rpm.
- P mode in ECO, Unloaded: ____________rpm, Loaded: ____________rpm.

2. Engine speed control with Control lock-out lever (SW9118).

Check out the work mode for following condition.
a. SW9118=OFF (Down) at G3 mode: ____________mode.
b. SW9118=ON (Up) at the above condition: ____________mode.
c. SW9118=OFF (Down), turn the rpm control switch to G3 or P mode: ____________mode.
d. SW9118=OFF (Down), turn the rpm control switch to G3 mode and turn the auto-idle button on:
____________mode.

3. Audio remote control.

C. Components location
a. FC01 (150A): ______1______
b. FC02 (80A): ____________
c. Electric Distribution Box (EDB): ____________
d. RE2501 (Preheater relay): ____________
e. SO3902 (DC-DC converter): ____________
f. CU3601 (Wiper controller): ____________
g. Ambient filter for Aircon system: ____________

1
 Overview
1

2
3 4

7
6

Fig.1 V1112436

2
 Main menu (IECU)

X3 response mode
Active

Fig.2 V1112438

3
4
Service mode (IECU)

Pressure sensor

Fig.3 V1112440
 Sensor location (D13F)
Sensor Name: Boost press. & Temp. sensor Sensor Name:
Sensor No.: FX1007 Sensor No.:

1 2

5 4 3

Sensor Name: Sensor Name: Sensor Name:

Sensor No.: Sensor No.: Sensor No.:

Sensor Name: Sensor Name:

Sensor No.: Sensor No.:
6 7

Sensor Name:
Sensor No.:
8

11

10 9
Sensor Name:
Sensor No.:

Sensor Name: Sensor Name:

Sensor No.: Sensor No.:
Fig.1 V1112367

1
 EMS2

A. Check sensor values by IECU service mode.

1. Boost pressure at P mode.
- Unloaded: ____________bar, Loaded: ____________bar

2. Max. fuel pressure:____________bar

3. Max. engine oil pressure:____________bar

B. Check the EECU (EB) with break out box for EMS 2.
1. Ground connection of EB at key on.
- Pin no: ____________

2. EECU power
- Pin no: ____________, ____________V

3. Starter lock control

- Pin no: ____________
- Key on: ____________V, Cranking: ____________V

4. Preheating relay control

- Pin no: ____________
- Preheating On: ____________V, Preheating Off: ____________V

5. Preheating status
- Pin no: ____________
- Preheating On: ____________V, Preheating Off: ____________V

6. Coolant level sensor

- Pin no: ____________
- Resistance at normal condition (Key off & disconnect “EB” from the EECU): ____________Ω
- Normal condition: ____________V

7. Water in fuel sensor

- Pin no: ____________
- Normal condition: ____________V

8. Oil level sensor

- Pin no: ____________
- Normal condition: ____________V at EB3, ____________V at EB4

9. Oil pressure sensor

- Pin no: ____________
- Low idle: ____________V at ____________kpa
- High idle: ____________V at ____________kpa

10. Crank case pressure sensor

- Pin no: ____________
- Low idle: ____________V at ____________kpa
- High idle: ____________V at ____________kpa

1
11. Fuel pressure sensor
- Pin no: ____________
- Low idle: ____________V at ____________kpa
- High idle: ____________V at ____________kpa

12. Coolant temp. sensor

- Pin no: ____________
- ____________V at ____________°C

13. Ambient temp. sensor

- Pin no: ____________
- ____________V at ____________°C

C. Check the EECU (EA) with break out box for EMS 2.
1. Check the NCV of injector
- Pin no: ____________
- Low idle: ____________AC V
- High idle: ____________AC V
- Loaded: ____________AC V

2. Check the spill valve of injector

- Pin no: ____________
- Low idle: ____________AC V
- High idle: ____________AC V
- Loaded: ____________AC V

3. Crank speed sensor

- Pin no: ____________
- Coil resistance (Key off & disconnect “EA” from the EECU): ____________Ω
- Low idle: ____________AC V
- High idle: ____________AC V

4. Cam speed sensor

- Pin no: ____________
- Coil resistance (Key off & disconnect “EA” from the EECU): ____________Ω
- Low idle: ____________AC V
- High idle: ____________AC V

5. Boost temp. sensor

- Pin no: ____________
- ____________V at ____________°C

6. Boost pressure sensor

- Pin no: ____________
- Low idle: ____________V at ____________kpa
- P mode (Loaded): ____________V at ____________kpa

7. Engine oil temp. sensor

- Pin no: ____________
- ____________V at ____________°C

8. Air filter clogging sensor

- Pin no: ____________

2
- Resistance at normal condition (Key off & disconnect “EA” from the EECU): ____________Ω
- Resistance at clogging: ____________Ω
- ____________V between EA29 and EA15 at normal condition.

3
 Start circuit

A. Find out the pin no. on the EDB for each numbering in start circuit using electric circuit animation.
B. Check voltage in each condition.

1. EDB Pin no.: CON2–10

- SW3101=On: 24 V, SW3101=Off: 24 V

2. EDB Pin no.:____________

- SW3101=On: ____________V, SW3101=Off: ____________V

3. EDB Pin no.:____________

- SW3101=On: ____________V, SW3101=Off: ____________V

4. EDB Pin no.:____________

- SW3101=On: ____________V, SW3101=Off: ____________V

5. EDB Pin no.:____________

- SW3101=On: ____________V, SW3101=Off: ____________V

6. EDB Pin no.:____________

- Key On: ____________V, Key Off: ____________V

7. EDB Pin no.:____________

- Key On: ____________V
- Engine running: ____________V
- Key Off: ____________V, for ____________seconds.

8. EDB Pin no.:____________

- Key On: ____________V

9. EDB Pin no.:____________

- ____________V

10. EDB Pin no.:____________

- Key On: ____________V, Cranking: ____________V

11. EDB Pin no.:____________

- Auto mode: ____________V, Manual mode: ____________V

12. EDB Pin no.:____________

- Cranking at SW9118=On: ____________V, Cranking at SW9118=Off: ____________V

13. EDB Pin no.:____________

- Key On: ____________V, Cranking: ____________V

14. EDB Pin no.:____________

- Key On: ____________V, Cranking: ____________V

1
2
FC03 (20A)
AUX. HEATER
DC-DC CONV.
1 RE3101 15A
C
SW3101 A FC02 (80A)
30 87
15B
D B 15A FU24 2 FU29 FU28 FU17 86 85

Fig.1 V1112384
FU22 15A 15A 10A 10A
CNGPS “1”
15A
IECU “IA9”

WECU
SW3301

F-PUMP

R-LAMP
B+
14 RE3301 RE3302
87A 87A
86 87 30 87 30 RE3102
3 4 5 30 87
85 R1
85 86 85 86

200AH
6

BA3101
OFF BR DI10 86 85

31 ON ACC
START C

200AH

BA3102
R

DI13
MO3301

DI12
DI11

VECU “VB2”
13

EECU “EB29”
FC01 (150A)
PRE-HEATER 10 R3201

B+
VECU “VB9”

AUTO/MANUAL
Start circuit

VECU “VA58”
ECC “19” 7
VECU “VA61”

DFM 8
BS 12 11 CNGPS “5”
15 CNGPS “2”
L
IECU “IA10”
W

h IM3812
B- AL3201
9
 Power shift valve

Power shift valve (PWM9401)

Normal mode
Loaded
Idle
Working (AM-IN stroke end)
Mode Control current 2nd pressure Control current 2nd pressure
(mA) (bar/kPa) (mA) (bar/kPa)
P
H
G1
G2
G3
G4
F1
F2
I1
I2

Power shift valve (PWM9401)

ECO mode
Loaded
Idle
Working (AM-IN stroke end)
Mode Control current 2nd pressure Control current 2nd pressure
(mA) (bar/kPa) (mA) (bar/kPa)
P
H
G1
G2
G3
G4
F1
F2
I1
I2
Fig.1 V1112381

1
 VECU check

A. Power supply & communication

1. Power supply & ground
- Main power supply to VECU (Pin. no.: ____________, ____________V)
- Main ground of VECU (Pin. no.: ____________, ____________V)
- Power supply to PWM (Pin. no.: ____________, ____________V)
- Power supply to Solenoid valve (Pin. no.: ____________, ____________V)
- Power supply to PV. (Pin. no.: ____________, ____________V)

2. Control link (J1939)

- H (Pin. no.: ____________, Voltage between “H” & VECU ground: ____________V)
- L (Pin. no.: ____________, Voltage between “L” & VECU ground: ____________V)
- Voltage between “H” & “L”: ____________V
- What does the “H” & “L” stand for?

- Resistance between “H” & “L”: ____________Ω (Key off)

3. Information (J1587)
- A (Pin. no.: ____________, Voltage between “A” & VECU ground: ____________V)
- B (Pin. no.: ____________, Voltage between “B” & VECU ground: ____________V)
- Voltage between “A” & “B”: ____________V
- Resistance between “A” & “B”: ____________Ω (Key off)

4. VECU status line to IECU

- Pin. no.: ____________
- Voltage between the status line & VECU ground: ____________V
- What is the function of the signal?

B. VECU Function check

1. RPM control switch
- Power supply (Pin no.: ____________, ____________V)
- Switch ground (Pin no.: ____________ )
- Switch signal (Pin no.: ____________ )
- PWM duty% (IECU service mode)
- I2: ____________%, I1: ____________%, F2: ____________%, F1: ____________%, G4: ____________%, G3:
____________%, G2: ____________%, G1: ____________%, H: ____________%, P: ____________%

2. Power max switch (Pin no.: ____________ )

- Off: ____________V, On: ____________V

3. Key on signal (Pin no.: ____________, ____________V)

4. Cranking signal (Pin no.: ____________, ____________V)

5. Starter lock (Pin no.: ____________)

- Control lock-out lever down: ____________V
- Control lock-out lever up: ____________V
- During engine running: ____________V

6. Power supply to main relay (Pin no.: ____________)

- Key on: ____________V

1
- Engine running: ____________V
- After key off: ____________V, for ____________seconds
What is the function of the time delay after key off?

7. Control lock out lever signal (Pin no.: ____________)

- Up: ____________V, Down: ____________V
Engine rpm control with control lock out lever (SW9118) operation
- SW9118=Off at G3: ____________mode
- SW9118=On at the above condition: ____________mode
- SW9118=Off and turn the rpm control switch to G3 or P: ____________mode
- SW9118=Off and turn the rpm control switch to G3 and turn the auto idle on: ____________mode

8. Power shift valve

- Current supply in Auto mode (Pin no.: ____________ )
- Ground connection in Auto mode (Pin no.: ____________ )
- Power supply in manual mode (Pin no.on SW9103: ____________ )
- Ground connection in manual mode (Pin no.on SW9103: ____________ )

9. Limp home signal (Pin no.: ____________)

- High position: ____________V, Neutral position: ____________V)

10. Travel pilot pressure switch signal (Pin no.: ____________)

- Neutral: ____________V, Travel: ____________V)

11. Travel speed control (Pin no.: ____________)

- Travel stop: ____________V
- Travel only at G mode: ____________V
- Travel at F mode: ____________V
- Travel speed signal (Pin no.: ____________, ____________V)

12. Travel speed control (Manual mode)

- Travel stop: ____________V
- Travel: ____________V

13. Travel alarm control (Pin no. : ____________ )

- Travel & travel alarm=On: ____________V
- Travel & travel alarm=Off: ____________V

14. Attachment pilot pressure switch signal (Pin no.: ____________ )

- Neutral: ____________V, Attachment operation: ____________V

15. Power boost button (Pin no.: ____________, ____________V)

16. Power boost solenoid valve control (Pin no.: ____________ )

- G4 mode & power boost button=On: ____________V
- G4 mode & travel only: ____________V
- G4 mode & travel & bucket-in: ____________V
- F1 mode: ____________V

17. Hydraulic temp. sensor (Pin no.: ____________ )

- ____________ V at ____________°C (IECU service mode)

2
18. PWM valve for Hydraulic oil cooling (Pin no.: ____________ )
- I2 mode & Aircon=Off: ____________ mA
- I2 mode & Aircon=On: ____________ mA

19. Quick fit operation

- Quick fit signal (Pin no.: ____________, ____________ V)
- Quick fit confirm (Pin no.: ____________, ____________ V)
- Buzzer stop (Pin no.: ____________, ____________ V)

20. Overload warning pressure sensor

- Power supply (Pin no.: ____________, ____________ V)
- Sensor ground (Pin no.: ____________ )
- Sensor signal (Pin no.: ____________ )

21. X3 proportional control switch

- Power supply (Pin no.: ____________, ____________ V)
- Switch ground (Pin no.: ____________ )
- Switch signal (Pin no.: ____________ )

22. X3 PWM (or Solenoid) valve

- X3 left PWM (or Solenoid) (Pin no.: ____________ )
- X3 right PWM (or Solenoid) (Pin no.: ____________ )

23. X3 On/Off control switch

- X3 RH-switch (Pin no.: ____________ , ____________ V)
- X3 LH-switch (Pin no.: ____________ , ____________ V)

24. X1 proportional control switch

- Power supply (Pin no.: ____________, ____________ V)
- Switch ground (Pin no.: ____________ )
- Switch signal (Pin no.: ____________ )
- PWM duty, Neutral: ____________%, Half stroke: ____________%, Full stroke: ____________% (IECU service
mode)

25. X1 pilot pressure switch (Pin no.: ____________, ____________ V)

26. X1 flow control valve (Pin no.: ____________ )

Set the following flow condition on IECU and check the control current
-40 lpm (1 pump min. flow): ____________ mA
-300 lpm (1 pump max., flow EC380D): ____________ mA
-350 lpm (1 pump max., flow EC480D): ____________ mA
-340 lpm (2 pump flow EC380D): ____________ mA
-390 lpm (2 pump flow EC480D): ____________ mA

27. Hammer/Shear select solenoid valve

- Hammer select (Pin no.: ____________ , ____________ V)
- Shear select (Pin no.: ____________ , ____________ V)

28. X1 PWM valve

- X1 left (Pin no.: ____________ )
- X1 right (Pin no.: ____________ )
- Half stroke: ____________ mA, Full stroke: ____________mA

3
29. X1 conflux solenoid valve (Pin no.: ____________ )
- 1 pump flow: ____________ V)
- 2 pump flow: ____________ V)

30. X1 pressure preset control

- X1 pressure preset left (Pin no.: ____________ )
- X1 pressure preset right (Pin no.: ____________ )
Set the following condition on IECU and check the output current
- Shear: 360 bar & 1 pump max. flow (X1=On: ____________mA, X1=Off: ____________mA)
- Hammer: 200 bar & 1 pump max. flow (X1=On: ____________mA, X1=Off: ____________mA)

31. X1 2-switch control

- LH switch (Pin no.: ____________ , ____________ V)
- RH switch (Pin no.: ____________ , ____________ V)

32. X1 1-switch control (Pin no.: ____________ , ____________ V)

C. Error check
1. Main power supply to VECU, Fuse no.: ____________
- Pull out the fuse and check the error message.

2. Power supply to PV, Fuse no.: ____________

- Pull out the fuse and check the error message.

3. Power supply to PWM, Fuse no.: ____________

- Pull out the fuse and check the error message.

4. Main power supply to IECU, Fuse no.: ____________

- Pull out the fuse and check the consequence.

5. Main power supply to EECU, Fuse no.: ____________

- Pull out the fuse and check the error message.

6. Main power supply to ECC, Fuse no.: ____________

- Pull out the fuse and check the error message.

7. Main power supply to WECU, Fuse no.: ____________

- Pull out the fuse and check the error message.

8. Make short circuit on the information link (J1587) using lead wire on the break out box.
- Error code: ____________
- Machine operation (Machine control, response, etc.):

9. Make short circuit on the control (J1939) using lead wire on the break out box.
- Error code: ____________

4
- Machine operation (Machine control, response, etc.):

10. Make short circuit both the control link (J1939) and the information link (J1939) using lead wire on the break
out box.
- Error code: ____________
- Machine operation (Machine control, response, etc.):

- Limp home low (Power shift valve control current: ____________mA)

- Limp home high (Power shift valve control current: ____________mA)

5
 Control system circuit

)
FU 20
15 A

(
1 5A
AUX. HEATER & TIMER
30

( )
SW 9118 MA91 26
M ek
C ON TR OL LOC K-O U T L EVER

rpm
87A
87

85

11
)

8
SW 91 03

9
4

12

10
(

3
30

86

D i07
AU X. H EATER FAN SIG .

SW9 40 6

SW9 40 5

VA2 0
OPER ATING
VB1 5
( ) ( ) POW ER +24 V
KEY - “ACC (54)” ( ) VA5 7
ECC

IECU B5

D i13

D i01
VA51

Di0 5
J15 87 (B)
J15 87 (A)

6
C AN (L)
CN 5 - “AC C ”

5
CAN (H )

Pin no.:
Pin no.:
Pump PV +
CN GPS
C omm unicatio n
)

VA67 VA3 2 70

4
C N-GPS Pump PV -
VA45 VA5

2 3
(

C N2 - “ALT-L ” R 91 01
D i11
C N1 - “3 0” ( ) MAIN REL AY
1

J15 87 (B)
( )
J15 87 (A) ( )
VB1 2
C AN(L) 87A
VB6
CAN (H ) 30 87
( ) FU 22

Connector name.:
86 85
KEY-“C ”
MO3 30 1

30
( )

50 30
VB9 87A

31
86
30 87
C NG PS5
CN 5
86 85

85
( ) VA5 8
VA2 6
( ) EEC U B2 9
SE9 401
C
A

VA48 C ra nking p ositio n RE3 30 1

B Pa

VB2
VA49
( ) MA4 21 2
1
( ) 3
VB1 0 0
SPEED SOL . 2
VA3 8
3

2
SW 91 61

8 7
V

10 9
EA5 7
EB5 8
EB5 9
EB6 1

( )
VB3 H i-Lo w fee db ack
( ) EB29 Pre-He ater R e lay ( )
EECU

GN D
EB25 VA11

)
( )
3

2
SW9 16 2

EB7 RE4 20 6
87A SA4 20 6
V

(
15 A
30 87
J1 587 (B)
H E25 01

EA33 +12 V
1

J1 587 (A) VA27

EA34 86 85
C AN(L)
)

EB55 VA1 2
C AN (H) TR AVEL AL ARM
EB51 H YD . OIL TEMP. VA40
30a
)

Pin no.:
2
EB1 5
EB5 7

31

GN D
RE2 50 1

1
DI25 01

PWM9 14 3
1

VA63
(
(

C OOL ING FAN SPEED +

Connector name.:

VA9
)

2
30

86

C OOL ING FAN SPEED -

( )
(

IVS ( )
VA47
( ) X3 LEF T +
1

VA8
SW 271 3

2 1 Trave l p ilot p s
VA43 VA5 4 X3 LEF T -
)

( ) X3 R IG HT +
SE9111
X3 R IG HT -
2

VA5 3
(
15A

RE3 302
2 1 ( ) MA9111 MA9 11 0
FC0 1
150 A

VA19

X3 RIG HT
30
J15 87 (A)
J15 87 (B)
C AN(L)

SE9112
IM3 81 2

X3 LEFT
h

H amm er p ilot p s
2 1
( )
IA8
ALT - “L ” ( ) ( ) X1 FL OW C ON TR OL +
VA5 6
IB14
( )
C N2
C NG PS2
X1 FL OW C ON TR OL -
VA3 0
AU TO GR EASE IA3 2 1 Flo at p osition p ilot p s
VA1 7 ( )
PWM9 12 3
Pin no.:
Pin no.:
Pin no.:

IL LU MINATION IA2 VA6

( ) IB5 ( )
IA15 VA34 ( )
GN D VA5 5
IA12
SE2 30 3

VA2 9
( ) MA912 2 MA9 12 1
2

IA4
( )
SW2 701
IECU

rpm R PM C O NTR OL SW
GN D VA3 9
IB13
2
1

+6.5 V GN D
( ) VA14
( )
3

C AM4 GN D
IC4
C AM#1 ~CAM# 4

C AM 4 SIG . IC3 MA911 7 MA9 11 8

VECU

C AM3 GN D
IC2
C AM 3 SIG . ( )
IC1
C AM2 GN D Q UIC K FIT OPER ATIO N VA6 4
IB9 VA23
C AM 2 SIG .
IB8 ( )
C AM1 GN D
IB7
C AM 1 SIG . VA6 5
IB1
MA911 6
10
)

ON
X1

J15 87 (B)
IA17
J15 87 (A) X1 C ON FLU X
IA7 ( )
1

7
SW 91 04

1
0
2

C AN(L)
( )
1

QU IC K FIT
(

CAN (H )
1

IA6 BU ZZER STO P

VA1 6
( )
F U2 4

QU IC K FIT C ON FIRM
2

VA4 2
1 5A

IA11
( )
IA9
30

VA5 9 FL OAT PO SIT IO N

C NG PS1 SW 9110
C N1
( ) 1
)

3
0 P-MAX
2 ( )
Kw
+
(
15A

8 7
FU 11

10 9
( )
10 A
15A

VA1 X1 PR ESSU R E PR ESET L EFT+

( ) X1 PR ESSU R E PR ESET L EFT-

J1 587 (B) VA2
B
X1 PR ESSU R E PR ESET R IGH T+
J1 587 (A) A VA2 4
C X1 PR ESSU R E PR ESET R IGH T-
C AN(L) A2 5
C AN(H) MA9 12 5
KEYPAD

SW 916 3
ECO

( ) Pow er boo st
X1 -L H SW. VA3

( )

X1 -R H SW. VA2 8 VB8

8 7 6 5 4 3 2 1

J15 87 (B) SW 910 8

J15 87 (A) ( )
)

Fig.1 V1112369

BO OST/H AM MER SW.

( )
( )
)

SW 915 8 VA6 9
)
(

VA3 3

VA3 5
(
30

(
J1 587 (A)
6 J1 587 (B)
F U0 2

C AN (L )

FU 26

FU SE FO R SO L.
1 0A

10 A

FU SE FO R PV
)
15 B

1 5A
PO3 90 4

& REL AY
1
2
3
4
5

7
8

FU 18
10 A

(
15A
14
7

11
17

12

WECU

1
 Comp. name Location
1 PWM9141 Power shift valve J-8
2 MA9126
3 MA4212
4 SA4206
5 PWM9143
6 PWM9145
7 PWM9146
8 MA9111
9 MA9110
10 PWM9109
11 PWM9123
12 PWM9124
13 MA9121
14 MA9122
15 MA9117
16 MA9118
17 MA9116
18 MA9120
19 PWM9129
20 PWM9130
21 MA9125
22 MA9109 PWM9141
23 SE9140
24 SE9112
Electric components location

25 SE9111
26 SE4216
27 SE9105
28 SE9401
29 SE2303

Fig.1 V1112376

1
 EC380D
Hyd. Elec. Location
comp. name comp. no.
18 Servo filter K-8
17
22
26
27
28
29
38
38
40
41
51
52
55
56
57
57
58
59
63 X1 2-pump sol. MA9116
64
64
65
66
74 18
86
87
90
Hydraulic components location (EC380D)

91

Fig.1 V1112371

1
 Pressure measuring (EC380D)

1. Boom-up (At full stroke end)

Working mode P1 (bar) P2 (bar)
P
G4
F1

2. Arm-in (At full stroke end)

Working mode P1 (bar) P2 (bar)
P
G4
F1

3. Arm-out (At full stroke end)

Working mode P1 (bar) P2 (bar)
P
G4
F1

4. Bucket-in (At full stroke end)

Working mode P1 (bar) P2 (bar)
P
P (One touch power boost=On)

5. Bucket-out (At full stroke end)

Working mode P1 (bar) P2 (bar)
P

6. Travel
Working mode P1 (bar) P2 (bar)
P (Travel only)
P (Travel & bucket-in)

7. X1 (Hammer)
Working mode P1 (bar) P2 (bar)
P (300 LPM Setting on IECU)
P (400 LPM setting on IECU)

8. X1 (Shear)
Working mode P1 (bar) P2 (bar)
P (300 LPM Setting on IECU)
P (400 LPM setting on IECU)

1
9. Negative control pressure
Bucket-in Pi 2 (bar) Pi 1 (bar)
Neutral
Partial stroke
Full stroke

10. Pilot pressure

Working mode (bar)
P
H
G1
F1
I2

2
 EC480D
Hyd. Elec. Location
comp. name comp. no.
18 Servo filter K-8
17
22
26
28
29
36
40
51
52
56
57
57
58
59
63 X1 2-pump sol. MA9116
64
64
65
66
74
86
87 18
90
91
Hydraulic components location (EC480D)

Fig.1 V1112374

1
 Pressure measuring (EC480D)

1. Boom-up (At full stroke end)

Working mode P1 (bar) P2 (bar)
P
G4
F1

2. Arm-in (At full stroke end)

Working mode P1 (bar) P2 (bar)
P
G4
F1

3. Arm-out (At full stroke end)

Working mode P1 (bar) P2 (bar)
P
G4
F1

4. Bucket-in (At full stroke end)

Working mode P1 (bar) P2 (bar)
P
P (One touch power boost=On)

5. Bucket-out (At full stroke end)

Working mode P1 (bar) P2 (bar)
P

6. Travel
Working mode P1 (bar) P2 (bar)
P (Travel only)
P (Travel & bucket-in)

7. X1 (Hammer)
Working mode P1 (bar) P2 (bar)
P (350 LPM Setting on IECU)
P (510 LPM setting on IECU)

8. X1 (Shear)
Working mode P1 (bar) P2 (bar)
P (350 LPM Setting on IECU)
P (510 LPM setting on IECU)

1
9. Negative control pressure (Boom operation)
G1 mode Pi 2 (Boom-up, bar) Pi 2 (Boom-down, bar) Pi 2 (Boom-down & travel-
LH, bar)
Neutral
Partial stroke
Full stroke

10. Negative control pressure (Bucket operation)

G1 mode Pi 2 (Bucket-in, bar) Pi 1 (Bucket-in, bar) Pi 2(Bucket-out, bar)
Neutral
Partial stroke
Full stroke

11. Pilot pressure

Working mode (bar)
P
H
G1
F1
I2