47. TROUBLESHOOTING (BY TROUBLE) TABLE OF CONTENTS: 47.4 HYDRAULIC SYSTEM 47.2. ELECTRIC SYSTEMS 47.2.1 WIRING CHECKING PROCEDURE 47.2.2 TROUBLE. 47.3. ENGINE RELATED TROUBLESHOOTING 47-4 73 A727 AT-2T 47-30 47-33 Book Code No. S8LC4711E0247. TROUBLESHOOTING (BY TROUBLE) Issue First edition Revision Date of issue July, 2008 February, 2007 Applicable Machines [SK330-8 = LC10-07001~ ISK350LC-8 : YC10-03501~ + Remarks [sstoa7r1E01 ASIA, OCE) ‘S8LC4711E02 (ASIA, OCE) 47-247. TROUBLESHOOTING (BY TROUBLE) 47.1 HYDRAULIC SYSTEM Preface, The troubleshooting for the failures shown below is explained here. Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number. (1) All controls do not function/slow 2) Engine downistalled (3) Move at lever neutral position (4) Poor fine operability (6) Slow boom up, insufficient power (6) Slow boom down, insufficient power for iting up body (7) Slow arm in, insufficient power (8) Slow independent arm out (in the air) (@) Slow bucket digging (10}Slow bucket dumping (11)$wing operation not functioned/stow (12)Noise during swing operation (13)Swing on a slope drifts when control lever is in neutral position (14)Swing drifts when swing operation is stopped (15}Slow travel speediweak (16)Travel deviation (17)Travel 1s/2nd speed not changed (18)Travel parking on a slope is not held (19)Travel does not run straightly when both crawlers and attachment operated simultaneously. (20}Slow breaker (crusher) operation, weak power (21}0ption selector valve malfunction: not switched to breaker circuit (22}Option selector valve maifunction: not switched to nibbler circuit 47-347. TROUBLESHOOTING (BY TROUBLE) (1) All controls do not function/slow No] Sections ontentsinormal value Corrective action, others Fuse (Check fuse Noa Ifthe fuses blown out, check on (108) tne shor-circuited section 2 |Sately lever lock [Carry outsewice [No K-4 switch [Check action of switch by tester, switen siagnosis Push down the ever and turns on, push Jar check thatthe power voltage up and it tun of. lowered by pushing the lever | down, 3 [Safely lever lock |Checkthat the Measure both terminals of solenoié | Check solenoid uni for possible switching solenoid is switched. [connector 24V by pushing the ever down, [ale correctly Jov by pushing it up ICheck hamess for possible tire 4 | Safety lover lock relay [Cary out service |No-4 K-4 lock lever [Check acton of relay by tester aiagnosis, Push down the lever and it tus off push up and it tums on. 5 Pilot pressure sensor |-Stop engine stop and key is on positon. [Check SV power for controller ‘Altplotiow pressure sensors are OMPa to 0.1MPa, @ [Solenoid valve for | Measure pressure of [About OMPa by pushing the lever up, and | Replace solenoid valve safetylocklever {solenoid At port __|4MPa or more by push it down. 7 [Pilot line fier Disassemble and [Check fiter for clogging [Clean fiter | check it visually @ [Pilot gear pump | Measure pilot primary [Check that tis MPa or mare in high iding| Check gear pump and the rele pressure at gear valve for possible fiure | pump ‘9 [Mutt contrat valve (in [Change postion | Since allare blocked due to poor switching case that rave is performance, check thatthe lever select |eperabie) pattem is set tothe proper positon. 70 [Actual measuring [Carry outservice [No.6 D-1 P1 unload valve (cut valve) [In case where the reading is current value of P1/P2 diagnosis Det P2 unload valve (cut valve) —_|iargely fered trom the actualy Unload proportional see Service Diagnosis Data List Imeasured value, check valve Operation No.3 Boom up ful ever & rlie}p"°pational vale and controler for possible failure, 1 Secondary pressure of| Measure the [Check that P1/P2 unload secondary [Replace proportonal valve Pt, P2 unload proportional valve pressures are within the range of Proportional valve [secondary pressure_[0.5~1,2MPa in boom up fulllever and high iectly atthe ports A7 [ding operation land AS of 8 sections solenoid block 12 Actual measuring [Carry outservice _|-NoSE-1 Pi pump In case where the reading is current value of P1/P2 diagnosis, £-2P2 pump largely difered fom the actually pump proportional See Service Diagnosis Data List measured value, check vave Operation No.18 Travel right fl lever & [proportional valve and controller iding or possile failure. Operation No.18 Travel lf fl lever & | iding 13 | Secondary pressure [Measure the pump [Check that pump proportional valve [Replace proportional valve pump proportional {proportional valve secondary pressure i 2.7MPa or more in valve secondary pressure_|rght (ef) travel fullever and high ing rect in idling operation operation (Ports @3, [Right trave: P1 pump proportional valve 24) Lef travel: P2 pump proportional valve 47-447. TROUBLESHOOTING (BY TROUBLE) No ‘Sections Contents/normal value Corrective action, others 14 |Mainrelet pressure [Carry out service (“See Service Diagnosis Data List [Measure the relief pressure ldiagnoss ‘Operation No.3 Boor up fulllever& relief actually 6 [Check set pressure [Check that Pt and P2 pump pressures are [Reset or replace ‘32MPa in boom up fl ever, high idling land H mode operation 16 [Pump regulator |Visual check When removing, free from abromal [Replace resistance against siding Free from abnormal damage, etc on outside surface ‘Spring free rom breakage, damage, ete 17 [Pump Visual check When removing, inside parts (oyinder [Replace black, piston, valve plate, shat, etc.) are ‘tee from abnormal resistance against sliding, abnormal damage, ete @) Engine downistalled Na Sections ‘Contents/normal value Corrective action, others 1 [Actualmeasuring [Carryoutsewice —|*No.9 E-1 Pt pump in case where the reading is lcurent value of P1IP2 |¢iagnosis E22 pump largely differed from the actualy pump proportional vave| ‘Service Diagnosis Data List |measured value, check Operation No. 1 Operation is nil _{ropertionalvalve and controler for possible failure 2 | Secondary pressure of [Measure the pump [Check that P1/P2 pump proportional. [Replace proportional valve P1, P2 pump proportional valve _|valve pressures are within the range of| proportional valve [secondary pressure [0.5 ta 1.0MPa in control lever neutral directly (Ports a3, a4) _|and high idling operation. 3 [Pressure sensor of Pi, [Check pressure "See Service Diagnosis Dala List | Check preseure sensor and P2 pump Operation No. 1 Operation is nil replace iif necessary (Operation No.3 Boom up full lever & | retet 4 [Pump regulator \Visual check {When removing, free fom abnormal [Replace resistance against siding Free from abnormal damage, ete on outside surface ‘Spring fee from breakage, damage, ete 3 [Pump [Visual check \When removing, inside pars (eyinder [Replace block, piston, vake plate, shaft, etc.) are free from abnormal resistance agains siding, abnormal damage, ete (3) Move at lever neutral position Ne Sections ‘Contentsinormal value Corrective action, others 1 [Pilot pressure sensor [Cary outservice | Check that targeted pilot pressure of [Check remote control valve eiagnosis sensor is OMPa in high idling 2 [Remote control valve _|Check targeted remote |Check that spool's tree from abnormal [Replace control valve [damage and spring is fee from breakage 3 [Main spool [Check targeted spool _|Check that spoolis tree from abnormal Replace Visually [damage and spring is fee from breakage 4 [Overload relief valve |Check targeted spool _|Free from dust entered in port relief [Replace visually |valve, Seat free from abnormality 47-547. TROUBLESHOOTING (BY TROUBLE) No] Sections Contentsinenmal value Corrective action, others 5 [Lock valve poppet [Check targated poppet |Seatis fee from abnormality Replace (incase ofboom and visually am) @ |Lock valve selector [Exchange lock valve [Check thatthe trouble is reversed [Replace (in case of boom and selector of boom/arm {arm land boomvarm 7 [Holding valve spool for [Check that smooth [Free from abnormal resistance against| Replace boom siding of spool in sleeve| siding Do not pull spool out of sleeve |(in case of boom) forcibly. ' [Holding vane rele? [Check targeted spool [Fier fee from abnormal Replace valve for boom visually contamination |(in case of boom) 9 [oyinger [Check targeted cylinder |Make sure of no problem of seals by |Replace cylinder or seals visually disassembling and investigation (4) Poor fine operability No] Sections Contenisinonmal value Corrective action. others 1 [Pressure sensor [Cary outservice [+See Service Diagnosis Data List| Replace pressure sensor diagnosis (Operation No. 1 Operation is nil ‘Allow pressure sensors are OMPa to o.imPa 2 [Actual measuring [Cary aut service _|+No.8 D-1 P1 unload valve (eut valve) fin case where the reading is current value of P1P2 [diagnosis 1D-1 P2 unload valve (cut vale) [largely ditfered trom the actually tunlosd proportional -See Service Diagnosis Data List |measured value, check valve ‘Operation No. 1 Operation is ni {proportional valve and controle for possible failure, 3 | Secondary pressure of |Measure the [Check that P1/P2 unloads secondary |Replace proportional valve Unload proportional [proportional valve [pressures is within the range of valve lsecondary pressure _|2.7MPa ormore in contol lever neutral ldirecay atthe ports A7_|and high ialing operation land AB of 8 sections L solenois block @ [Actual measuring [Cary out service |-No.9E-1 Pt pump in case where the reading is current value of P1P2 diagnosis E2P2 pump largely ctfered from the actualy pump proportional valve| -See Service Diagnosis Data List |measured value, check Operation No. 1 Operation is nit |propertional valve and controle for possible failure 55 [Secondary pressure of [Measure the pump |Check that P1/P2 pump proportional [Replace proportional valve 1, P2 pump lproportional valve _|valve pressures are within the range of Check regulator Proportional valve secondary pressure _[0.5~1.0MPa in control lever neutral | directly. (Ports 3, 24) _|and high iling operation 6 | Siow return check valve [Visual check [Check that slow return check valve [Clean and replace of plat line Iitalled on pilot ne is free from dust (in case of boom up or lenterea arm out) 47-647. TROUBLESHOOTING (BY TROUBLE) (6) Slow boom up, insufficient power Na Sections ‘Contenisinormal value Corrective action, others 1 [Boom up pressure [Carry outsewice [See Service Diagnosis Data List| Check and replace pressure sensor liagnosis Operation No.3 boom upfullever and sensor | retet [Check remote control valve 2 [Remote contol valve [Measure drectly emote [Check thatpressure is 8.0MPa or mare [Check remote control valve control pressure of in boom up full lever and high idling |When equipped with mutt boom up operation [control valve, check it while |cranging lever pattern 3 |Pump pressure sensor |Gany out service _|-See Service Diagnosis Data List [When there is cifference Jdiagnosis fort, P2 | Operation No.4 boom up flllever and |between Pt and P2 pump lpump pressures in| in operation pressures, check high pressure operation sensor. 4 [Actual measuring [Cary out service |-No.8 D-1 P1 unload valve (cut valve) [In case where the reading fs lcurent value of P1/P2 diagnosis 1-1 P2 unload valve (cut valve) [largely iffered from the actually unload proportional +See Service Diagnosis Data List |measured value, check valve ‘Operation No.2 Boom up fulllever & {Proportional valve and controler rete! for possible failure, 5 | Secondary pressure of [Measure the (Check that P1/P2 unload secondary [Replace proportional valve Pt, P2 unloas proportional valve [pressures are within the range of proportional valve [secondary pressure _[0,5~1,2MPa in boom up fll ever and ldcectly atthe ports A7_|high aling operation land AS of 8 sections solenoid block 6 |Acwalmeasuing [Cary out service __|-No.9E-1 Pt pump in case where the reading Jeurent value of P1/P2_|diagnosis £22 pump largely fered from the actualy pump proportional valve| +See Service Diagnosis Data List |measured value, check (Operation No.4 boom up full lever & in Proportional valve and controler operation for possible failure, 7 [Secondary pressure of [Measure the pump [Check that P1/P2 pump proportional [Replace proportional valve P1, P2 pump proportional valve _|valve pressures are within the range of| proportional valve [secondary pressure _|2.1 lo3.0MPain boom up full lever and ect (Ports a3. a4) _|high iaing operation 6 |P2by-pass cut valve |Visual check No problem for sliding abiliy of main [Clean and replace Trouble> poppet and na contamination on arife| Jonly P2 pressure is iow, No problem for siding abit of intemal [piston (Check it trough PBp2 port) 9 [Remote conve valve [Check targeted remote [Check that spools ree from abnormal [Replace control valve \damage and spring i free from breakage 10 |Lock valve poppet [Visual check \When removing, free from abnormal [Replace resistance against siding Check on the casing side for Both Pt and P2 Free from abnormal damage, etc on damage) pressures are iow outside surface 11 |Confux check valve |Visual check {When removing, free from abnormal |Replace eTrouble> resistance against siding (Check on the casing side for lonly P2 pressure is Free from abnormal damage, etc on |damage) high. outside surface 12 |Holding valve for boom |Visual check [When removing, free from abnormal [Replace (poppet) resistance against siding [Check on the casing side for Free from abnormal damage, etc on |damage) Bot Pt and P2 outside surface pressures are high. 47-747. TROUBLESHOOTING (BY TROUBLE) No. 3 [___ Seaions Boom spool Only Pt pressure is high. Contentsinermal valve Visual check When removing, free fram abnormal resistance against siding Spring is free from breakage. Corrective action, others Replace (Check on the casing side for ldarage) 14 |Check boom spool and [Disassembly and |Free from abnormal resistance against| Replace spool assembly recirculation investigation sliding - Spring is free fom breakage. Only P1 pressure is low 15 |Confux spool Visual check [When removing ree rom abnormal [Replace resistance against sliding (check on the easing side for 16 | 7 Only P2 pressure is high Main relief valve [Relief pressure is low. Over load relief valve Relief pressure is low. Spring is free from breakage, Free from abnarmal damage, etc on outside surface [Check set pressure _|-See Service Diagnosis Data List ‘Operation No.3 boom up full lever and rele |Visual check (Head [Pressures 32MPa ormore in boom up| siae) ull lever and high ialing. Free trom |dust entered in over load rolie valve, [Seat is tre from abnormality ldarage) Reset or replace |Wnen only relief pressure of lboom up is law. replace valve (6) Slow boom downvinsufficient power for liting up body No. ‘Secions Contentsinommal value Corrective action. others 1 Boom down pressure [Cary aut service [+See Service Diagnosis Data List ldagnos's ‘Operation No.5 boom down full ever & in operation [Check and replace pressure |Check remote control valve, Remote contol valve Measure remote contl [Check that pressure is &. MPa or more| lpressure of boom down |in boom down fll lever and high idling [Check remote eantrol valve |Wnen equipped with mut directly loperation Jcontrol valve, check it while L changing lever patter. 3 [Actual measuring [Cary out service [Pt unload valve (cut valve) Incase where the reading is curent value of P1 diagnosis, -See Service Diagnosis Data List [largely differed from the actualy unload proportional Operation No.5 boom down fulever &|measured value, check valve in operation proportional valve and controler for possible failure. 4 | Secondary pressure of [Measure the [Check that P1 unload secondary Replace proportional valve unload proportional [proportional valve [pressures are within the range of Jsecondary pressure _|0,8~1.2MPa in boom down fll lever direc atthe ports 7 ofan high ialing operation a sections solenoid block, 5 [Actual measuring [Camry outservice __[-NoSE-1 Pt pump Incase where the reading is curent value of P1 diagnosis -See Service Diagnosis Data List _|a"Gely differed from the actually | pump proportional valve| ‘Operation No.5 boom down full ever {measured value, check in operation proportional valve and controle | Secondary pressure of 1 pump proportonal valve [Measure the pump _|CheckthatP1 pump proportional valve| Jproportonal vatve _|pressures are within the range of 1.80 Jsecondary pressure _|2.5MPa in boom down full ever and direct (Ports 23, a4)_|high icing operation for possible failure Replace proportional valve 47-847. TROUBLESHOOTING (BY TROUBLE) No Sections ‘Contenisinormal value Corrective action, others 7 [Actual measuring [Cary outservice [Check thatthe value is not change _|-Check pressure sensor of lcurent value of travel diagnosis regardless of operation travel straight proportional +See Service Diagnosis Data List _|sIn case where the reading is valve Operation No. 1 Operation is nil | largely ciffered from the Operation No.18 Travel rightful lever| actually measured value, check idling proportional valve and Operation No.19 Travellefflllever& | controller for possible failure ialing 8 [Travel straight [Measure directly the [High ding pressure is 0.8MPa or less [Replace proportional valve proportional vive [travel straight regardless neutra/operation |secondary pressure [proportional valve [secondary pressure, [Remote control valve |Check targeted remote [Check that spoolis free from abnormal [Replace control valve Idamage and spring is free from [breakage 10 |Lock valve poppet _|Visual check \When removing, free from abnormal [Replace resistance against siding Check on the casing side for [Boom down is low. Free from abnormal damage, etc on |damage) outside surface 11 [Holding valve (poppet) | Visual check {When removing, free from abnormal |Replace }Trouble> resistance against slding Free from (Check on the casing side for Boom down is slow. abnormal damage, etc on outside |damage) surface 72 |Boom spool \Visual check |When removing, free from abnormal [Replace eTrouble> resistance against siding [Check on the casing side for [Boom downs slow, Free from abnormal damage, etc on |damage) outside surface Spring i ree from breakage 18 [Check boom spool and [Disassembly and [Free from abnormal resistance against [Replace spool assembly recirculation investigation sliding eTrouble> Spring is ree rom breakage Machine can not be ited by supporting with 14 [Main relief valve [Check set pressure _|-See Service Diagnosis Data List [Reset or replace Operation No.3 boom upfullever and Relief pressure is low. relief 15 [Overload relief valve _|Visual check Free from dust entered in port relief [Replace Trouble> valve. Machine can not be Seat is fee from abnormality ited by supporting with 7) Slow arm in, insufficient power Na Sections ‘Contenisinarmal value Corrective action, others 1 [Asm in pressure sensor [Cary outservice [See Service Diagnosis Data List| Check and replace pressure liagnosis Operation No.6 arm in fulllever and {sensor | retet [Check remote control valve 2 [Remote contol valve _ [Measure directly emote |Check thatpressure is 3 0MPa or mare [Check remote control valve pressure [control pressure of arm lin amin full lever and high iding | When equipped with mut in operation control valve, check it while |cranging lever pattern 47-947. TROUBLESHOOTING (BY TROUBLE) No] Sections 3 Pump pressure sensor Contentsinormal valve ICany out service ldiagnosis for P1, P2 lbump pressures in loperation -See Service Diagnosis Data List ‘Operation No.7 arm in full lever anlin operation Corrective action. others |Wnen there is difference lbetween Pt and P2 pump loressures, check high pressure "Actual measuring current value of P1P2 unload proportional valve | Secondary pressure of Pi, P2 unload proportional valve [Actual measuring current value of P1/P2 pump proportional valve| | Secondary pressure of [Cary out service ldiagnos's Measure the loroportional valve lsecondary pressure lirecty atthe ports A? land AS of 8 sections solenois block, [Cary out service ldagnosis -No.8 0-1 PT unload valve (cut valve) D-1 P2 unload valve (cut valve) -See Service Diagnosis Data List ‘Operation No.6 Arm in flllever & relief Check that P1/P2 unload secondary pressures are within the range of [0.5~1.2MPa in arm in full lever and high icing operation. No.9 E-1 Pt pump E-2P2 pump -See Service Diagnosis Data List (Operation No.7 Arm in fllever & in operation Incase where the reading is largely cffeed from the actualy measured value, check proportional valve and controle for possible failure, Replace proportional valve In case where the reading is largely citfered from the actualy Imeasured value, check proportional valve and controler | for possible failure. 7 [Measure the pump [Check that P1/P2 pump proportional |Replace proportional valve 1, P2 pump Jproportonal valve _|valve pressures are 2.8MPa or more in Proportional valve secondary pressure [arm n full lever and high iding directly. (Ports a, a4) operation. (Secondary pressure is affected by ol temperature and attachment weight) @ [Actual measuring [Cary out service [+See Service Diagnosis Data List in case where the reading le current value of arm in spool 2 proportional valve ldiagnos's Operation No. 1 Operation is ri ‘Operation No.6 Arm in fllever & relief ‘Operation No.7 Arm in fllever & in operation largely sitfered trom the actualy lmeasured value, check proportional valve and controler tor possibie failure ‘Secondary pressure of arm in spool 2 proportional valve Measure directly the lproportonal valve |secondary pressure at tne ports AB (arm 2 spool) of 8 sections sotenoia block, [Check that secondary pressure of Proportional valve secondary pressures are within the range of allowing Lever neutral: OMPa [Motion in the air 1.7 to 22MPa |Acm in lier. 2.5MPa or more Replace proportional valve 70 "Actual measuring current value of travel straight proportional valve [Cary out service diagnosis [Check thatthe value is not change regardless of operation -See Service Diagnosis Data List ‘Operation No. 1 Operation is nil ‘Operation No, 18 Travel right full lever| Aiding (Operation No.19 Travel ft flllever&| idling |;Check pressure sensor af travel sn case where the reading is largely difered from the actually measured value, check proportional valve and controller for possible failure. ‘Secondary pressure of {travel straight proportional valve Measure deel the proportional valve lsecondary pressure at tne ports AB (travel straight) of 8 sections solenois block [0.8MPa orless in high idling operaton| regardless of neuraloperation Replace proportional valve 47-1047. TROUBLESHOOTING (BY TROUBLE) No Sections ‘Contenisinormal value Corrective action, others 12 |Remote control valve [Check targeted remote [Check that spools free from abnormal [Replace control valve Idamage and spring is free from breakage 73 [Main relief valve [Check set pressure [+See Service Diagnosis Data List [Reset orreplace J Operation No.3 boom upflllever and Relief pressure is low. | reter 14 [Overload relief valve |Visual check (Head [Pressure is 32MPa or mare in arm in. [When only ele pressure ofa side) and relet, nis low, replace valve P1, P2 pressure is low. Free from dust entered in overload relief valve. Seat is free from abnormality 15 [Overload relief valve _|Visual check (Red sde) [Pressure is 32MPa or more in arm out [When only relief pressure ofan eTrouble> and elet, lout is low, replace valve P1, P2 pressure is lov. Free from dust entered in overload relief valve. | Seat i ree for abnormal 16 [Arm 1 spool \Visual check |When removing, free from abnormal |Replace Trouble> resistance against siding (Check on the casing side for P1, P2 pressure is high Free from abnormal damage, etc on |damage) outside surface Spring is free from breakage 7 [Arm 2 spool \Visual check {When removing, free from abnormal [Replace resistance against siding Check on the casing sie for P1, P2 pressure is high Free from abnormal damage, etc on |damage) or tow. outside surface Spring is ree from breakage 18 [Check arm 2 spool and [Disassembly and [Free from abnormal resistance against [Replace spool assembly recirculation investigation sliding eTrouble> ‘Spring is free from breakage |Arm in power is poor. 18 |Check lock valve poppet| Visual check Free from abnormal resistance against [Replace eTrouble> sliding (Check on the casing side for Both P1, P2 pressures, Free from abnormal damage, etc on |damage) are high. |outside surface (8) Slow independent arm out (in the ait) Na. Sections ‘Contenisinarmal value Corrective action, others 1 [Arm outpressure [Cary outservice [See Service Diagnosis Data List| Check and replace pressure lsensor liagnosis (Operation No.8 arm out full lever and |sensor relief [Check remote control valve 2 [Remote contol valve _ [Measure directly emote | Check thatpressure is 3 0MPa or mare [Check remote control valve [control pressure of arm |in arm out fullever and high idling | When equipped with mult lout operation control valve, check i while |cranging lever pattern 3 [Pump pressure sensor [Cary out service __|-See Service Diagnosis Daia List [When there is eifference Jdiagnosis for P’,P2 | Operation No.9 arm out fll lever and [between Pt and P2 pump lpump pressures in | in operation pressures, check high pressure operation | sensor 4 [Actual measuring [Cary out service |-No.8 D-1 P1 unload valve (cut vale) [in case where the reading fs lcurrent value of P1IP2 diagnosis 1-1 P2 unload valve (cut valve) largely cffeed from the actully unload proportional +See Service Diagnosis Data List |measured value, check. valve Operation No. Arm ott fll lever & [proportional valve and controller retet for possible failure 47-1147. TROUBLESHOOTING (BY TROUBLE) [___ Seaions Secondary pressure of 1, P2 unload Proportional valve Contentsinormal valve Measure the lproportonal valve lsecondary pressure livecy atthe ports A? land AS of 8 sections Check that P1/P2 unload secondary pressures are within the range of |0.5~1.2MPa in arm out full ever and high iating operation Corrective action. athers Replace proportional valve solenoia block @ [Actual measuring [Cary out service |-No.9E-1 Pt pump) incase where the reading fs current value of PYP2 diagnosis E2P2 pump largely ditfered from the actually pump proportional vave| -Soe Service Diagnosis Data List ‘Operation No.9 Arm out fll lever & in operation measured value, check proportional valve and controle for possible failure ‘Secondary pressure of 1, P2 pump Proportional valve Measure the pump lproportional valve lsecondary pressure direct (Ports 23, a4) [Check that P1/P2 pump proportional \valve pressures are within the range of 1.7 to .9MPa in arm out fulllever anc high iating operation (Secondary pressure is affected by oll temperature and attachment weight) Replace proportional valve "Actual measuring current value of travel straight proportional ‘valve [Cary out service ldiagnos's [Check thatthe value is not change regardless of eration -See Service Diagnosis Data List ‘Operation No. 1 Operation is nil ‘Operation No, 18 Travel right fll lever Siding ‘Operation No.19 Travel left fulllever&| idling |-Check pressure sensor of travel -1n case where the reading is largely difere from the actually measured value, check proportional valve and controller fr possible fallure. ‘Secondary pressure of travel straight proportional valve Measure directly the proportional valve lsecondary pressure at ine ports AS (travel straight) of 8 sections (0.8MPa orless in high idling operation regardless of neuraloperation Replace proportional valve solenoia block 410 Remote control valve [Check targeted remote |Check hat spools fre from abnormal |Replace lcontrol valve \damage and spring is free from breakage Main relief valve Relief pressure is low. [Check set pressure /-See Service Diagnosis Data List ‘Operation No.3 boam up ful lever and rele Reset or replace 7 73) (ver load relief valve 1, P2 pressure is low. Visual check (Rod side) Pressure is 32MPa or more in arm out lan reliet Free from dust entered in overload Ielet valve, Seat s tree from labnormalty |Wnen only ree pressure of arm Joutis low, replace valve "Arm 1 spook Visual check \When removing, free fram abnormal Replace resistance against sliding (check on the casing sie for 2 pressure is high Free from abnormal damage, etc on |damage) outside surface Spring is free from breakage. 14 [Arm 2 spool Visual check [When removing free from abnormal [Replace resistance against sliding (check on the casing side for pressure is high Free from abnarmal damage, etc on loutside surface Spring is free from breakage. 47-12 ldamage)47. TROUBLESHOOTING (BY TROUBLE) No Sections ‘Contenisinormal value Corrective action, others 18 |Check arm 2 spool and [Disassembly and [Free from abnarmalresistance against [Replace spool assembly recirculation investigation (spring [sliding side) Spring is free from breakage Both Pt, P2 pressures are low 16 [Check lock valve poppet| Visual check Free from abnormal resistance against |Replace eTrouble> sliding Check on the casing side for Both P1, P2 pressures Free from abnormal damage, etc on |damage) are high outside surface (@) Bucket digging is slow Na Sections Contenisinormal value Corrective action, others 1 [Bucketdiggingpressure|Carry outsewice [See Service Diagnosis Data List| Check and replace pressure sensor liagnosis Operation No.12 bucket digging ful. sensor | lever and relet [Check remote control valve 2 |Remote control valve _ [Measure directly emote |Check thatpressure is 3.0MPa or mare |Check remote control valve control pressure of in bucket digging fll lever and high | When equipped with mut bucket aging iaing operation control valve, check it while |cranging lever pattern 3 |Pump pressure sensor |Cany out service __|-See Service Diagnosis Data List [When there is aifference Jdiagnosis or’, P2 | Operation No.13 Bucket digging ful [between Pt and P2 pump lpump pressures in| lever and in operation pressures, check high pressure operation sensor 4 [Actual measuring [Cary out service _|-No.8 D-1 P1 unload valve (cut valve) In case where the reading fs lcurent value of P1IP2_ |diagnosis 10-1 P2 unload valve (cut vate) largely iffered from the actully unload proportional +See Service Diagnosis Data List |measured value, check valve (Operation No.12 Bucket digging ful {proportional valve and controler lever & relist for possible failure, 5 | Secondary pressure of [Measure the (Check that P1/P2 unload secondary [Replace proportional valve Pt, P2 unloaa proportional valve [pressures are within the range of proportional valve [secondary pressure _|0.5~1.2MPain bucket digging fll lever| ldcectly atthe ports A7_|and high idling operation land AS of 8 sectons solenoid block % [Actual measuring [Carry out service __|-No.S E-1 Pi pump Ii case where the reading leurent vaiue of P1P2 diagnosis, £2 P2 pump largely difered from the actualy Purp proporbonal valve See Service Diagnosis Data List |measured value, check (Operation No.13 Bucket digging ful. [Proportional valve and controller lever & in operation fr possible fare. 7 [Secondary pressure of Measure the pump [Check that Pt pump proportional valve [Replace proportional valve P1, P2 pump proportional valve [pressures is 2384Pa or more and P2 proportional vate secondary pressure [pump proportional valve pressure 's directly (Ports a3, a4) |1.9 10 2.5MPa in bucket digging full {lever and high iting operation. ® [Attachment boost [Cary outsenice [No.3 POWER BOOST [Check hamess lsolenoia command —_|giagnosis Bucket cigging COMP OFF MEAS —_|Replace solenoid valve lorF 9 [Attachment boost [Measure switching | Check that pressure is OMPa in bucket [Replace solenoid valve Jsolenoia secondary |valve secondary —_|digging full ever and high ating pressure pressure |operation 47-1347. TROUBLESHOOTING (BY TROUBLE) No. 10 Secions ‘Actual measunng current value of travel straight proportional valve Cont ICany out service diagnosis yenisinormal valve -See Service Diagnosis Data List ‘Operation No, 12 Bucket digging full lever & relief Corrective action. others Incase where the reading is largely ditfered from the actualy Imeasured value, check proportional valve and controler | for possible failure. ‘Secondary pressure of travel straight proportional valve Measure drecly the loroportional valve lsecondary pressure at tne ports AB (travel straight) of 8 sections [Check that travel straight secondary [pressure is 2.7MPa or more in bucket eigging full lever and igh iting loperation Replace proportional valve solenoid block 12 |P2 by-pass cut valve _ | Visual check [No problem for sliding ability of main. [Clean or replace poppet and no contamination on once] Only P2 pressure is low [No problem for sliding bilty of internal piston (Check it through PBp2 port.) 18 | Check stroke liter |Vsual check \When piston is removed from cover, it|Replace - Both P1,P2 pressures are high. Is free from abnormal resistance against sliding Free from abnormal damage, ete on outside surface (check on the easing sie for ldamage.) 14 Remote control valve [Check targeted remote (Check that spools tree rom abnormal Replace lcontrol valve \damage and spring is ree from breakage 15 |Main relief valve [Check set pressure _|-See Service Diagnosis Data List [Reset or replace ‘Operation No.3 Boom up fulllever and| reliet 16 [Travel straight spool |Vsual check [When removing, free from abnormal [Replace resistance against sliding (check on the casing side for 2 pressure is high Free from abnormal damage, ete on |damage) outside surface | Spring is ree from breakage. 17 [Bucket spoo! Visual check \When removing, free fram abnormal Replace resistance against sliding (check on the casing side for Both P1, P2 pressures are high. Free fram abnarmal damage, ete on outside surface Spring is free from breakage, ldamage) 8 ‘Overload relief vale [Check targeted spoo! visually Free from dust entered in overload relief valve, [Seat is tre from abnormality, Replace (10)Bucket dump is slow No. ‘Sections Cont ents normal valve Corrective action. others Bucket dump pressure ‘Remote control valve [Cary out service liagnos's Measure directly remote control pressure of loucket dump -See Service Diagnosis Data List ‘Operation No.14 Bucket dump fll lever and relief [Check that pressure is. OMPa or more in bucket dump full ever and high iting operation [Check and replace pressure |Check remote control valve [Check remote cantrol valve lWnen equipped with mut lcontol valve, check it while changing lever pattern Pump pressure sensor [Cary out service liagnosis for P1, P2 loump pressures in loperation |-See Service Diagnosis Data List ‘Operation No.15 Bucket dump fll lever and in operation |Wnen there is ference lbetween Pt and P2 pump pressures, check high pressure 47-1447. TROUBLESHOOTING (BY TROUBLE) No Sections ‘Contenisinormal value Corrective action, others 4 [Actual measuring [Cary out service —_|+No.8 D-1 P1 unload valve (cut vale) incase where the reading is lcurent value of P1IP2 diagnosis 1D+1 P2 unload valve (cut valve) largely iffered from the actully unload proportional +See Service Diagnosis Data List |measured value, check valve Operation No. 14 Bucket dump ful {proportional valve and contoler lever &ralist for possible failure. 5 | Secondary pressure of [Measure the (Check that P1/P2 unload secondary [Replace proportional valve Pt, P2 unloae proportional valve Proportional valve [secondary pressure ldvectly at the ports A7 land AS of 8 sections solenoid block pressures are within the range of (0.5~1,2MPa in bucket dump full lever ‘and high iding operation. Replace proportional valve [Actual measuring lcurent value of P1/P2 pump proportional valve [Carty out service Jdiagnosss (Cary out service ldiagnosis *No.9 E-1 Pt pump E22 pump +See Service Diagnosis Data List (Operation No. 1§ Bucket dump full lever & in operation In case where the reading ls largely differed from the actually Imeasured value, check proportional valve and controller for possible failure, [Secondary pressure of Pt, P2 pump proportional valve Measure the pump Proportional valve [secondary pressure directly (Ports a3, a4) Checkthat P1 pump proportional valve pressures is 1 6MPa or more and P2 ‘pump proportional valve pressure is “.8MPa of more in bucket dump full lever and high idling operation [Replace proportional valve 3 [Acwalmeasuring [Carryout sewice _|-See Service Diagnosis Data List |In case where the reading Jcurent vale of ravel |aiagnosis Operation No.4 Bucket dump ful largely fered fom the actually straight proportional lover & reli! measured value, check lave ropertional valve and controler orpossible faiure 9 [Secondary pressure of [Measure dvealy the (Check hat wavelsvaight secondary [Replace properbonal valve rave straight Iproporional valve _|pressureis,7MPa or more in bucket proportional valve secondary pressure at | dump fullever and high icing the ports AG (vavel —_|operaton svaight) of sections solenoid block 70 [P2 by-pass cut valve |Vieual check No problem for adng ably ofmain [Clean and replace poppet and no contamination on orf lonlyP2 pressure is ow Noproblem forsiting abil ofirteral [piston (Cheek it through PBP2 port) 71 | Check stroke titer Visual check Free fom abnormal damage and wear Replace on outside of piston inside cover |(Check onthe casing ste for Plot pressure is low. | loamage) 12 [Remote contol valve [Check targeted remote | Check hat spools Fee from abnormal Replace control valve {damage and spring i ree from [breakage 13 |Mainretfvaive [Check set pressure See Service Diagnosis Data List [Reset or replace Operation No.3 Boom up fullever and Rete pressure is low | eter 14 [Travel straint spoot [Visual check 'wnen remaving, fee from abnormal [Replace resistance against sling (check onthe casing side for P2 pressure is high Free from abnormal damage, ete on |damage) outside surface 15 [Bucket spoot Visual check lWhen removing, ee fom abnormal [Replace resistance against siding (check onthe casing ade for Both P1, P2 pressures are high. Free from abnormal damage, ete on outside surface | Soring is tree from breakage. 47-15 \damage)47. TROUBLESHOOTING (BY TROUBLE) No] Sections Contentsinormal valve Corrective action. others 16 [Overload relet valve [Check targeted spool [Free from dust entered in overload Replace visually reli valve, [Seat is tree from abnormality. (11)Swing does not move'siow No. Secions Contentsinommal value Corrective acon. others 1 | Swing pressure sensor [Cary outservice __[-See Service Diagnosis Data List| Check and replace pressure diagnosis ‘Operation No.11 Swing fulllever and |sensor in operation [Check remote control valve 2 |Remote control valve _ [Measure drecly remote | Check that pressure is 3,0MPa ormore Check remote contol valve Jcontrl pressure of {in boom up full lever and high iding [When equipped with mult lewing loperation control valve, check it while |changing lever pattern 3 | Swing parking brake [Carry out service [No.3 F-2 SWING-BRAKE [Check swing pressure sensor solencid diagnosis lLeverneutral COMP.ON MEAS Check hamess |ON Swing: COMP OFF MEAS OFF “z [Swing parking brake |Measurement of Lever neutral OMPa Replace solencid vane solencid lsolenois valve A2 port_|In operation: AMPa or mare 5 Shuttle valve Visual check INo contamination on spool cover [Clean or replace: (short side) and orice Pilot pressure is low [No damage on spool cover (long side) land shuttle @ [Pump pressure sensor [Cary aut service _|+See Service Diagnosis Dala List __ [Check high pressure eensor Jdiagnosis for P2 pump | Operation No.11 Swing fll ever and lpressures in operation | in operation 7 Actual measuring [Carry out service __|-No.6 D-2 P2 unload valve (eut valve |in case where the reading ls current value of P2 [diagnosis -See Service Diagnosis Data List _|a"9elydifered trom the actually | unload proportional ‘Operation No. 11 Swing full ever & in {measured value, check valve operation proportional valve and controle for possible failure, 8 | Secondary pressure of |Measure the [Check that P2 unload secondary Replace proportional valve 2 unload proportional [proportional valve pressures are within the range of valve lsecondary pressure {0,5~1.2MPain swing fulllever andhigh direct at ne ports AS of|iding operation 5 sections solenoid block 9 [Actual measuring [Cary outservice —_|+No.9E-2 P2 pump In case where the reading is current value of P2—_|diagnosis, largely citfered from the actualy pump proportional vave| |-See Service Diagnosis Data List |measured value, check ‘Operation No.11 Swing ull lever & in [Proportional valve and controle operation for possible failure, 10 [Secondary pressure of [Measure the pump _|Checkthat P2 pump proportional valve [Replace proportional valve P2 pump proportonal [proportional valve [pressure is 2.7MPa or more in swing valve lsecondary pressure {fll lever and high idling operation direct (Ports 23, a4) TT |Actual measuring [Carry outservice [Check that the value snot change __|-Check pressure sensor of current value of ravel [diagnosis regardless of operation travel straight proportional +See Service Diagnosis Data List __|-In case where the reading is valve (Operation No. 1 Operation snl | largely diferes fram the (Check this trouble by (Operation No. 18 Travel right fll lever| actually measured value, check ‘only swing operation) Siding Proportional vale and ‘Operation No.19 Travel eR flllever & | controller for possible failure. idling 47-1647. TROUBLESHOOTING (BY TROUBLE) No 12 Sections [Secondary pressure of lravel straight proportional valve (Check this trouble by lonly swing operation) ‘Contents/normal value [Measure directly the |0.8MPa orlessin high idling operation| proportional valve regardless of neutraloperation [secondary pressure at the ports AB (travel straight) of 8 sections solenoid block Corrective action, others [Replace proportional valve 13 [Remote contol valve [Check targeted remote [Check that spools fee from abnormal [Replace control valve Idamage and spring is free from breakage 14 [Travel straight spool [Visual check |When removing, free from abnormal [Replace resistance against siding Check on the casing sie for P2 pressure is low, Free from abnormal damage, etc on |damage) outside surface Spring is free from breakage 15 [Swing spool [Visual check {When removing, free from abnormal [Replace Trouble> resistance against siding Check on the casing side for P2 pressure is high Free from abnormal damage, etc on |damage) outside surface | Soring is tree from breakage. 16 |Swing let valve [Check set pressure _|-See Service Diagnosis Data List [Reset or replace: Operation No, 10 Swing full ever and Relief pressure is low. | retet 17 | Swing motor \Visual check Inner pars (eyinder block, piston, [Replace valve brake etc) are to be free from abnormal resistance agains siding Free from abnormal damage, ete on outside surface (brake plate etc) 18 [Swing reduction gear olfTake sample olfrom [Sampling oll does not include a lot of [Disassemble and inspect lswing reduction gear |metal powder. reduction gear rain 18 [Swing reduction \Visual check “Tooth surface is not worn abnormally |Replace and is not chipped. (12)Noise occurred at swing operation Ne Sections ‘Contentsinormal value Corrective action, others 1 [Swing parking brake [Carry outsewice [No.3 F-2 SWING-BRAKE [Check swing pressure sensor sotenoia leiagnosis Lever neutral: COMP. ON MEAS. ON |Check hamess. ‘Swing: COMP OFF MEAS OFF 2 Measurement of Lever neutral: MPa |Replace solenoid valve solenoid valve A2 port_|in operation: AMPa or more 3 [Boast check valve |Visual check {When removing, free from abnormal [Replace (Sound of cavitation at resistance against siding stopping) Spring is free from breakage 4 |By-pass check valve |Vieual check {When removing, free from abnormal [Replace (Sound of cavitation at resistance against siding stopping) Spring is free from breakage 5 [Swing motor [Visual check Disassemble and inspect abnormal [Replace (Brake valvettiction |wear and scufing plate) © | Swing motor piston __|Visual check [When removing, free fom abnormal [Replace resistance against sling Spring is free from breakage 47-747. TROUBLESHOOTING (BY TROUBLE) No. 7 | Swing reauction gear ol ‘Secions Cont [Take sample ol from yenisnormal valve [Sampling ol does nat include a lot of Corrective action. others Disassemble and inspect, lswing reduction gear {metal powder reduction gear drain ' | Swing reduction Visual check Tooth surface has ne abnormally worn [Replace land chipped. (13)Swing drifts on a slope while swing control lever is in neutral position No. 1 Secions ‘Swing pressure sensor ‘Remote control valve | Swing parking brake Cont [Cary out service ldiagnos's [Check targeted remote lcontol valve ICany out service enisnormal value [Engine stop & starter key ON All pilot low pressure sensors are within range of 0 to 0.1MPa. (Check that spools free from abnormal \damage and spring is free from breakage [No F-2 SWING-BRAKE Corrective action. others [Check and replace pressure Replace [Check swing pressure sensor solenoid diagnosis Lever neutral: COMP. ON MEAS. ON |Check hamess [Swing: COMP OFF MEAS OFF Check parking brake release switch 4 [Measurement of |Lever neutral OMPa Replace solenaid vae | Jsolenois valve A2 port_|tn operation: AMPa or more 5 | Swing motor Visual check [Disassemble and inspect abnormal [Replace (Brake valvertiction wear and scuffing (plate) 6 | Parking brake Visual check Piston and fiction plate do not have [Replace (14)Swing drifts at stopping labnormal resistance against sing [Free from spring damage No. Secions Cantentsinonmal value Conectve action. others 1 | Shuttle valve Visual check [No contamination on spool cover [Clean or replace - (shor side) and orifice. No damage on Pilot pressure is low |spo0l cover (long side) and shuttle ‘Swing pressure sensor [Cary out service ldiagnos's [Engine stop & starter key ON All pilot low pressure sensors are within range of Oto 0.1MPa. Replace pressure sensor ‘Swing relief valve Relief pressure is low. [Check set pressure /-See Service Diagnosis Data List ‘Operation Na. 10 Swing fll ever and reliet Reset or replace "Anti-reacton valve Visual check Free from dit entering ‘Sliding part should be free trom foreign Imatterentering, normaldamage an [clean or replace 5 [Remote control valve [Check targeted remote |Check that spools free from abnormal [Replace lcontrot valve \damage and spring is free from breakage | Swing mator Visual check Inner pars (eynder black, piston, [Replace \valve brake etc) are tobe free from labnormal resistance against sling Fre from abnormal damage, ete on outside surface (brake plate etc) 47-1847. TROUBLESHOOTING (BY TROUBLE) (18)Travel speed is slow/poor Na Sections ‘Contenisinormal value Corrective action, others 1 [Travel ight and lef [Carry outservice | "See Service Diagnosis Data List [Check and replace pressure pressure sensor liagnosis Operation No.18 Travel right full lever sensor and idling [Check remote contro valve Operation No. 19 Travel lf fllever a iaing 2 [Remote contol valve _ [Measure drecly emote |Check thatpressure is. 1MPa or mare [Check remote control valve contrat pressure of in travel right (lef), forward (reverse) travel rght and let __|fulllever and high idling operation 3 |Aetwal measuring [Cary out service __|+No.@ D-1 P1 unload valve (cut valve) [in case where the reading fs lcurent value of P1/P2_|diagnosis 1D+1 P2 unload valve (cut vale) [largely iffered from the actully unload proportional +See Service Diagnosis Data List |measured value, check valve (Operation No.1 Travel right ful lever Proportional valve and controler aiding for possible failure, Operation No. 19 Travelleftfulllever & iting 4 | Secondary pressure of [Measure the (Check that P1/P2 unload secondary [Replace proportional valve P1, P2 unloas [Proportional valve _|pressures are within the range of proportional valve [secondary pressure followings in travel right (lo), forward Idectly at the ports A7_|(reverse) fulllever and high fling land AS of 8 sections —_|operation solenoid block ‘Travel right (P1 unload) 0.5 to 1.0MPa| Travel left (P2 unload) 0.5 to 1.0MPa 5 [Actual measuring [Cary outservice __|-No.9 E-1 Pt pump In case where the reading ie leurent value of P1/P2_|diagnosis £22 pump largely differed from the actualy pump proportional valve| +See Service Diagnosis Data List |measured value, check (Operation No. 18 Travel rightful lever Proportional valve and controler idling for possible failure Operation No, 19 Travel ef flllever& iting 6 | Secondary pressure of [Measure the pump [Check that P1/P2 unload secondary [Replace proportional valve Pt, P2 pump proportional valve [pressures are within the range of proportional valve [secondary pressure followings in travel right (le), forward directly (Ports 3, a4) |(reverse) fllever and high iting operation [Travel right (P1 pump): 2.7MPa or {Travellef (P2 pump): 2.7MPa or more 7 |Acual measuring _|Gany out service [Check thatthe value is nat change “Check volage of low pressure lcurent value of travel |diagnosis regardless of operation ‘sensor other than sensor for straight proportional +See Service Diagnosis Data List| tavel valve Operation No. 1 Operation is nil |-in case where the reading is Operation No.1 Travel right ul lever| largely difered from the idling actually measured value, check| Operation No. 19 Travelleftfulllever&| proportional valve and | ating controller for possible failure 3 | Secondary pressure of [Measure directly the |0.8MPa orless in high idling operation [Replace proportional valve travel straight proportional valve regardless of neutraloperation proportional valve __|secondary pressure | 9 |Remote control valve _|Check targeted remate [Check that spoolis free from abnormal Replace control valve \damage and spring i fee from breakage Check seating ability of shuttle valve and entry of dustin orice 47-1947. TROUBLESHOOTING (BY TROUBLE) No] Sections Contentsinomal valve Corrective action. others 10 |Travelstraght spool | Visual check |When removing, free fram abnormal Replace resistance against siding (Check on the casing side for 1 pressure is high Free from abnormal damage, etc on |damage) outside surface Spring is free from breakage. 1 [Travel spool Visual check of targeted [When removing, free from abnormal [Replace lspoot resistance against sliding (check on the casing side for Pump pressure is high Free from abnormal damage, etc on |damage) loutside surface | Spring is free from breakage. 12 | Travel motor relief valve|Check set pressure _|Check P1 and P2 pump pressures are [IP 1 islow, right vavel matorAf [32MPa or more in right and lef travel relief valve is file. levers fll lever (rele operation at If P2 is low, lef travel motorAfs locked crawler bet) and high ling [relief valve I file. 3 [Travel motor Visual check liner pars (piston, cylinder block, [Replace \valve plate, brake valve spool) ara to be tre fram abnormal resistance agains sling Free trom abnormal damage, ete on outside surface (brake plate etc) 14 [Parking brake in travel |Visual check \When removing, free from abnormal Replace motor resistance against sliding [No sticking on friction plate and separator plate 15 [Travel reduction gear cif Take sample ollrom [Sampling oll does nat include a lt of [Disassemble and inspect lvavel reduction gear {metal powder. reduction gear rain 76 | Travel reduction Visual check Tooth surface is not worn abnormally [Replace land is not chipped. (16)Travel deviation No. Sections Contentsinormal value Corectve action, others 1 (Travelrightand le [Cary outservioe [>See Service Diagnosis Data List | Check and replace pressure pressure sensor diagnosis ‘Operation No. 18 Travel right full lever|sensor and iing |Check remote control valve (Operation No.19 Travel left full lever | and idling 2 |Remote control valve _ [Measure drecty remote | Check that pressure is 2. MPa ormore Check remate contol valve Jcontrol pressure of in travel right (let), forward (reverse) lvavel ight and lett {fll lever and high idling operation 3 [Actual measuring [Cary out service |Check thatthe value is not change |-Check voltage of ow pressure current value of travel diagnosis regardless of operation sensor other than sensor for straight proportional |-See Service Diagnosis Data List | tavel walve ‘Operation No. Operation sil _|-in case where the reading is ‘Operation No, 18 Travel right fll lever| largely difere from the Biding actually measured value, check (Operation No. 19 Travel eR flllever &| proportional vale and | iding controle fr possible fallure. 4 | Secondary pressure of [Measure direcity the _ |0.8MPa orless in high idling operation [Replace proportional valve {travel straight lproportonal valve _ regardless of neutraloperation Lproportional vate _|secondary pressure 47-2047. TROUBLESHOOTING (BY TROUBLE) No Sections ‘Contentsinormal value Corrective action, others 5 [Actual measuring [Cary out service —_|+No.8 D-1 Pi unload valve (cut vale) in case where the reading is lcurent value of P1IP2 diagnosis 1D+1 P2 unload valve (cut valve) largely iffered from the actully unload proportional +See Service Diagnosis Data List |measured value, check valve ‘Operation No.18 Travel rightful ever [Proportional valve and controller ‘ding for possible failure, Operation No.19Travelleftflllever & iting 6 | Secondary pressure of [Measure the (Check that P1/P2 unload secondary [Replace proportional valve Pt, P2 unloas proportional valve [pressures are within the range of proportional valve [secondary pressure followings in travel right (le), forward directly at the ports A7_|(reverse) ful lever and high iting land AS of 8 sections —_|operation solenoid block Travel right (P1 unload): 0.5 to 1.0MPal ‘Travel left (2 unload) 0.5 to 1.0MPa 7 |Acwal measuring [Cary out service |+No.9 E-1 Pt pump In case where the reading ie leurent value of P1/P2_|diagnosis E22 pump largely fered from the actually pump proportional valve| +See Service Diagnosis Data List |measured value, check (Operation No.1 Travel right ful lever [Proportional valve and controler aiding for possible failure, Operation No. 19 Travellef fulllever & | ating 3 [Secondary pressure of [Measure the pump [Check that P1/P2 unload secondary [Replace proportional valve P1, P2 pump [Proportional valve {pressures are within the range of proportional valve [secondary pressure followings in travel right (lo), forward ldvectly (Ports 23, a4) |(reverse) flllever and high iting operation {Travel right (Pt pump): 2.7MPa or ‘Travel lef (P2 pump): 2.7MPa or more @ [Exchange PY for P2 _ |Exchange delivery pipe [Check the direction of deviation _|[fthe direcion is changed, lof Pt for P2 inspect a pump. Ifthe direction is not changes, inspect a valve land travel unit 10 |Remote contol valve [Check targeted remote [Check that spoolis fre fom abnormal [Replace control valve \damage and spring is free from breakage Check sealing ability of shutle valve and entry of dustin orifice 11 [Travel straight spool |Visual check {When removing, free from abnormal [Replace resistance against siding (Check on the casing side for P pressure is high. Free from abnormal damage, ete on damage) outside surface |Soring is tree from breakage 12 [Travel spool \Visual check of targeted [When removing, free from abnormal [Replace spool resistance against siding Check on the casing side for Pump pressure is high Free from abnormal damage, etc on |damage) outside surface Spring is free from breakage 73 [Travel motor relief valve|Check sel pressure [Check P1 and P2 pump pressures are [P1 is low, right ravel matorAf 32MPa of more in right and lef travel levers fll lever (relief operation at locked crawler belt) and high idling rele valve is falled IFP2 is low, let travel motorAts relet valve is faled Replace as necessary 47-2147. TROUBLESHOOTING (BY TROUBLE) 4 No. ‘Secions “Travel motor Visual check Contentsinormal valve inner pars (piston, cylinder block, \valve plate, brake valve spool) are to be free from abnormal resistance agains sliding Free from abnormal damage, etc on outside surface (brake plate etc) Corrective action. others Replace 6 “Travel eduction gear ail Take sample ol from lvavel reduction gear rain [Sampling ol does not include a lot of metal powder. Disassemble and inspect reduction gear 6 "Travel eduction Visual check FTaoth surface ie nat womn abnormally land is not chippes. Replace 7 Pump regulator Visual check [When removing, free from abnormal resistance against sliding Free from abnarmal damage, etc on outside surface |Spring fre fom breakage, damage, ete. Replace 8 Pump Visual check [when removing, inside pars (cyinder block, piston, valve plate, shat, etc.) late free from abnormal resistance against sliding, abnormal damage, etc Replace No] Sections (17)Travel 1/2 speed cannot be switched (ln.case of the traveling speed may sometimes speed change.) does not change from Cant ‘st to 2nd because this machine eq tentsinormal value under heavy loading (for example traveling on a slope or traveling on a soft ground), the ips the function of automatic Corrective ation. others "Travel 12 speed switching solenod [Cary out service ldiagnos's [Switch travel 1/2 speed to 2nd speed [No F-3 1/2-TRAVEL Lever neutral COMP OFF MEAS OFF ‘Travel operation COMP ON MEAS ON [Check pressure sensor [check harness [Check travel 1/2 speed switch lon gauge cluster "Travel 12 epeed switching solenoid Measure AS port pressure on solenoid valve Lever neutral OMPa In operation: 4MPa or mare Replace solencid valve motor 3 |1i2 speed switching |Vsual check (Check that sp0a! sree rom abnormal |Replace spool in travel motor \damage and spring is ree from (Check on the casing side for breakage ldamage) 4 |1i2 speed switching |Vsual check Fre from entry of aust, Remove dust ar replace office in travel motor 5 Ting piston in travel [Visual check Free from abnormal wear on piston Replace (check on the casing side for ldamage) (18)Machine does not stay ona slope in traveling No. ‘Sections Cont ents normal valve Corrective action. athers 1 Pilot pressure sensor [Cary out service diagnosis /-Engine stop & starter key switch is ON ‘Targeted plot low pressure sensor is in range of 0 to 0.1MPa [Check pressure sensor and replace as necessary |Check remote control valve 2 Remote control vale [Check targeted remote control valve (Check that spools free from abnormal \damage and spring is free from breakage 47-22 Replace47. TROUBLESHOOTING (BY TROUBLE) No Sections Parking brake in travel ‘Contenisinormal value \Visual check |wnen removing, free from abnormal resistance against siding ‘Spring fee from breakage, damage, ete Corrective action, others [Replace JOnfice of passage for parking brake in travel \Visual check Free from entry of dust |Remave dust or replace (19)Machine does not travel straight in simultaneous operation of traveling and attachment Sections ‘Contentsinormal valve Corrective action, others [Actual measuring Jeurent value of travel stright proportional valve [Cany out service [No.8 D-3 S-TRAVEL is should be liagnosis COMP 580mA and MEAS 550 to '510mA in both travel full ever and in ‘boom up ful lever at high icing /-Check voltage of low pressure ‘sensor other than travel sensor] sn case where the reading is largely differed from the actually measured value, check| proportional valve and controller for possible failure. 2 | Secondary pressure of [Measure directly the Check secondary pressure i within [Replace proportional valve travel straignt Proportional valve range of 1.8 to 2.2MPa in both travel proportional valve [secondary pressure {ull lever and in boom up fl ever at high iting 3 [Travel straight spool |Visual check {When removing, free from abnormal |Replace resistance against sling Free from abnormal damage, ete on outside surtace Spring is free from breakage Check on the casing side for ldamage) (20)Breaker works slowly and power is poor (In case of conflux, check pt unload/pump and travel straight) Na Sections ‘Contenisinarmal value Corrective action, others 1 [Pressure sensorfor [Carry outsewice | "See Service Diagnosis Data List| Check and replace pressure loptional atachment —_|¢iagnosis Operation No.16 P2 side OPT ful |senso lever and reef [Check remote contr valve 2 |Remote control valve _ [Measure directly remote [Check thatpressureis2.1MPa or more [Check remote contol valveO lcontrol pressure of {in optional attachment fulllever and lravel ight and lett [high idling operation 3 [Actual measuring _|Cany out service _|-See Service Diagnosis Data List [In case where te reading is lourent value of P1IP2 |¢iagnosis Operation No.16 P2 side OPT ful | largely ifered from the unload proportional lever and relief actually measured value, check| valve proportional valve and controller for possible failure. 4 | Secondary pressure of [Measure the (Check that P1/P2 unload secondary [Replace proportional valve Pt, P2 unloae proportional valve [pressures are ithinthe range of0.5t0 proportional valve [secondary pressure |1.2MPa ldvectly atthe ports A7 land AS of 8 sections solenoid block 5 [Acwal measuring [Cary out service “Service Diagnosis Dala List _|+Check vollage of low pressure lcurrent valve of ravel stright proportional valve liagnosis Operation No.16 P2 side OPT ful lever & relief ‘sensor other than sensor for ‘optional attachment sn case where the reading is largely differed from the actually measured value, check| proportional valve and Controller for possible failure 47-2347. TROUBLESHOOTING (BY TROUBLE) Only Pt pressure is low [Relief pressure poppet and no contamination on orifice] [No problem for siding biltyofinternal piston (Check t though PBp2 port.) No] Sections Contentsinormal valve Corrective action, others 6 | Secondary pressure of [Measure directly the Check that travel straight secondary Replace proportional valve travel straight proportional valve pressure is2,7MPa or more in optional Proportional valve secondary pressure at attachment full lever and high iling tre ports AS (travel [operation stright) of 8 sections solenoia block 7 [Pi by-pass cut valve [Visual check [No problem for sliding billy of main [Clean or replace pressure is high ‘Spool for optional attachment Pt, P2 pressures are high resistance against sliding Free from abnormal damage, etc on loutside surface Spring is free from breakage. Visual check \When removing, fre from abnormal resistance against sliding Free from abnormal damage, ete on outside surface Spring is free from breakage. 8 [Check set pressure |+See Service Diagnosis Dala List [Reset or replace (Operation No.16 P2 side OPT full lever and relief (Get value of factory shipment is 245MPa.) [Remote control valve [Check targeted remote [Check sealing abilty of shuttle valve [Replace lcontrot valve and entry of dustin orfice 10 [Travel straight spool |Vsual check |wnen removing, free from abnormal [Replace (check on the casing side for ldamage) Replace (check on the casing side for ldamage) 2 ‘Overload relief vale [Check targeted spool [Free from dust entered in overload) visually lie valve [Seat is tre from abnormality, Replace (21)Selector valve for opti \n malfunctions: Breaker circuit is not obtained. (Indication of failure is displayed. For reference, see "Table47-1 Action of optional | selector solenoid valve") No. ‘Seaions Contentsinonmal valve Coneative action. others 1 |N&B selector spool [Visual check [When removing, free from abnormal [Replace resistance agains sliding (check on the casing side for Free from abnormal damage, etc on |damage) outside surfoce | Spring is free from breakage 2 |N&B selector solenoid [Screw for emergency Check thatthe error indication is [Replace solenoid valve Iisappeared by turning emergency 3 |N&B selector solenoid [Cary out service __|+No.11 F-4 Option selectors B mode [Check solenaid vale diagnosis COMP ON, MEAS ON [check namess ‘Spool positon BRK Selector switch BRK 4 |N&B selector pressure [Cary out service |-No.16 6-11 [Check pressure sensor sensor ldiagnos's Data List Icheck narmess 3.0MPa at B mode and 0.0MPa at A mode 47-2447. TROUBLESHOOTING (BY TROUBLE) (22)Selector valve for option malfunctions: Nibbler circuit is not obtained. Ne (Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valv Sections ‘Contentsinarmal vale Corrective action, others 1 INBB selector spo! INBB selector solenoid [Visual check (Cary out service liagnosis |When removing, free fom abnormal resistance against siding Free from abnormal damage, outside surface | Soring is tree from breakage. *No.11 F-4 Option selector is A mode COMP OFF, MEAS OFF ‘Spool postion NIB Selector switch NIB Replace Check on the casing side for ldamage) (Check solenoid vawve [check hamess 47-2547. TROUBLESHOOTING (BY TROUBLE) Table47-1 Action of optional selector solenoid valve Oxon Seb vane )S#tvte]sateyioa| yg | sobeor | go | sae stuwogroas wo, Era [eer irs everays| "| “Tae” | 5 lacing) Waning apley [iain input ‘output * | comp, | Pes" [pressure ‘splay eas sosor | Roming | OW [OFA OFF er Noma — = Theron ven era SELECTOR VANE Uzi aloes Rt 2 oN OFF a oN Breaker] Nowmal xiLURE" [simultaneously 3 ELECTOR VANE runing on | orf | a | OFF | rater] noma SELECT - Rurmng [OW | “ORF [A [an a Ra Poa [Running | — oN | OFF | 8 [ oN Brese|Naal e 3 SELECTOR VALVE [FOO deed [rsrora] on | ome |e | om | none | noma st rosiasoar 7 SELECTOR VALVE rung] on | ofr |e | on | was | normat SECT - 3 [Raring| on | “OFF | 8 OF a Waa (Foal 3 SELECTOR WAVE [nora] on | om | — | — | — [rate ae ers dee ‘5 Sapprgh = = E t= ore ee = a a a E 47-2647. TROUBLESHOOTING (BY TROUBLE) 47.2. ELECTRIC SYSTEMS 47.24 WIRING CHECKING PROCEDURE Check for continuity between connector terminals, presence or absences of short-circuit with other wires, and presence or absences of short-circuit with machine body grounding (1) Checking for disconnection between connectors, (When both ends measurements easy because of short distance between connectors.) Measure the resistance using tester Pull out opposite connector first. ‘When the resistance is zero (0), its in normal condition. (When both ends measurementis difficult because of long distance between connectors.) Measure the resistance using tester. Pull out opposite connector first ‘Where the resistance is zero (0), ifthe terminal on tone side is connected to frame body grounding with jumper wire, itis in normal condition, The resistance is 1M 0 or more when the terminal ton one side is not connected to frame body grounding with jumper wire, itis in normal condition, @ Checking for presence or absence of short-circuit with machine body Measure the resistance using tester Pull out opposite connector first ‘When the resistance is 1M 0 or more, itisin normal condition, (3) Checking for presence or absence of short-circuit between wirings. Measure the resistance using tester. Pull out opposite connector first. ‘When the resistance is 1M 0 or more, itis in normal condition, CONNECTOR JUMPER, mie of pes Kr ESTER hestex 47-27 —e—h FRANE BODY GROUNDING S ) FRAME BODY GROUNDING H47. TROUBLESHOOTING (BY TROUBLE) (4) Checking connector terminal for contact Insert male terminal ito female terminal unit, and then check that the inserting force is equivalent to other female terminals. If looseness is there, replace the female terminal with new one, Clean the dirt terminal (ACAUTION Do not insert the male terminal the thickness differs. It may cause loose connection. (8) Caution which should be paid in measuring voltage When measuring the power supply to electric equipment at connector position with the grounding terminal contained inside of connector, measure the voltage between grounding inside of connector and power terminal, When measuring the voltage between frame body grounding and power source, the disconnection of wiring to grounding inside of connector cannot be identified ‘Since the voltage may vary between with connector connected and with connector nat connected, Measure the voltage with each connector connected whenever possible. (6) Checking the general view of connector ‘a, Check the terminal crimped condition Pull one electric cable with the about 3kg force, ‘and make sure that the cable does not come out of the terminal When came out, replace the terminal and crimp itagain. '. Check connector for imperfect insertion ‘Check that all top ends form a line on the same position as seen from the connector engaged side. When moved along, push itn further through wire inserting hole. . Check connector for intruding of water. Pullout the connector and check that the inside is free from intruding of water, When water intruding is found, check rubber plug for damage and also that the sealing is fitted properly. INSERT NALE TERMINAL PEMALE TERMINAL 1 wwcomer 47-2847. TROUBLESHOOTING (BY TROUBLE) (7) When abnormality occurs at intervals When the abnormality situation can not be reoccurred during checking operation, try the following operations. a. Check that variable of display exists or not on the. service diagnosis screen while shaking the hhamess or giving shock by operating the machine, b, Check that variables of resistance and voltage exist or not using tester while shaking the hamess. . Tum starter switch on and apply electricity continuously, and check it again after the temperature of wiring and equipment was raised. (8) Checking on body grounding Check attaching bolts of grounding terminal for loosening. ‘And also check that there is no loose connection due to corrosion, There are multiple groundings like centralized grounding box shown in the figure and battery grounding, engine grounding, hom grounding fixed together with horn, body grounding placed on attaching section of boom working light Block of ground I located tinder ior plate of Cab 47-2947. TROUBLESHOOTING (BY TROUBLE) 472.2 TROUBLE (1) Engine does not stop. (2) "CPU DATA COMMUNICATION ERROR" is displayed on mult display. (3) Auto accel does not actuate, (The engine speed does not automatically slow down.) (4) Auto accel does not actuate. (The engine speed does not automatically speed up.) (8) Wiper does nat function. 47-3047. TROUBLESHOOTING (BY TROUBLE) (1) Engine does not stop. Na Sections ‘Contenisinormal value Corrective action, others 1 |Starterkey ewiten [Check signal of starter |No.« K-3 Key switch [Check continuity between key switch ON by OFF at starter key switch OFF position terminals of starter switch using lcarying out service ON at starter key switch ON postion tester eiagnosis. 2 [Engine forcible stop _|When ON is displayed [No.4 K-3 Key switch [Check on engine forcible stop relay ith the starter switch |OFF at starter key switch OFF position|elay [OFF then pull out R-25 |ON at starter key switch ON postion lengine forcible stop relay and carry out the service diagnosis. 3 [Wiring \Vottage between ine OV when starter switch is OFF [Check hamess [No.62 among starter check siode D-9 between 'smtch, engine forcible starter switch and auto idling stop relay, mechatro stop relay 1 controller and the body grounding (2) "CPU DATA COMMUNICATION ERROR’ is displayed on multi display, Ne Sections ‘Contentsinarmal value Corrective action, others 1 [Fuse INo.t fuse (5A) Not blown fuse [Check hamess | [Replace fuse 2 |Mechatro controller |Accel control Engine speed varies according to [Check mechatro contraller and ‘accel potentiometer operation, replace as necessary (Use remote control because the auto accel function is working) 3 |Wwiing Transmission ecuit tne [See "WIRING CHECKING [Repair wiring [No.770 from mechatro_|PROCEDUR’ controler to gauge lcuster 4 [Gauge cluster [Gauge cluster [Replace gauge duster (3) Auto accel does not actuate, (The engine speed does not automatically slow down) Ne Sections ‘Contentsinormal value Corrective action, others 1 [Engine coolant [Check engine coolant [No.2 G-5 WATER TEMP [Replace engine coolant sensor temperature temperature by carrying |Auto accel does not work in the lout service diagnosis. |temperature -15°C or less. |Warm up and raise the coolant temperature to ~ 15°C or more 2 [Gauge custer Incication of auto accel [Mark Displayinat clsplay"for auto [Replace gauge cluster accel switches by auto accel switch | operation on gauge cluster 3 |Low pressure sensor [Service diagnosis [Each control pressure of No.5 and |Check low pressure sensor No. inthe range of 0-0. MPa at control lever neutral peition (4) Auto accel does not actuate, (The engine speed does not automatically speed up.) Ne Sections ‘Contentsinarmal value Corrective action, others 1 Low pressure sensor [Service diagnosis Each control pressure of No.5 and |Check low pressure sensor No. ie raised with control lever operated 47-3147. TROUBLESHOOTING (BY TROUBLE) (8) Wiper does not function ing range of ford an reverse movements} Wiper motor (D Rise up (storing) position DCD” Riso up limit switch’s ON range @ Upper reversing position @~@’ Reverse lit swich's ON range @ Lower reversing position No. ‘Sections Contents/normal value Corrective action. others 1 Fuse (Check fuse No20 Replace fuse 2 [swig ‘Service diagnosis No.19 D125 [Check wiper interlock switch ‘Wier intrtock switch Wiper switch cisplay (0125) is OFF with front window closed, |and repair iif necessary [check according to (WIRING |CHECKINGPROCEDURE" and repair tif necessary Rise up limit switch bul In wiper motor Reverse mit switch ‘Service diagnosis No.25 Wiper system [Check according to ‘WIRING |CHECKING PROCEDURE” ‘Switch action in operation Normal ion @ cao Rie up eee OW OFF OFF, Rt ‘Arc prevention relay R29: Forward rotation relay R30: Reverse rotation relay ‘Service diagnosis No.2 Wiper system 47-3247. TROUBLESHOOTING (BY TROUBLE) 47.3. ENGINE RELATED TROUBLESHOOTING Gheskng Filters Liquid [Leak dogaina Factors =| [5 3| |e IB 2) le] |g 28] | | felele| |e Flelel tls] |S! fe s/s /Slelelele|_ (SIS |8 [Sle isle Trouble lz le. [|S [6 [6 |e [8 fi fz |S Poor start ability (Take a long time) elo 9} 2 Faulty engine starting/engine does not rotate. ° | Fauty engi yengine rota Eamrenceecree™” fo] fol | | fel | | | le i | Faulty engine starting/exhaust gas is emitted butongine dows not stat ih fl inectn) | [O[° ° ojo Engine poor run-up (Low follow-up ability) o|o ° Rotation in bad condition (hunting) °o °o fe) "| Engine stalled during operation o| fo ° 3 | Output s towered ole @ of fo & [Overheating ef [fo Exhaust smoke is in black ° ° lo Exhaust smoke is white OMG Larger oil consumption (or blue exhaust gas) ° o [Eat contamination of of of _fefeL_f fo o = [Larger fuel consumption ° ef _fofo 5 | intruding of olin cootant, backflow, reduction B | of coolant quantity Hydraulic pressure down (Monitor lights up) ° ° ‘Oi quantity inereased. intruding of water and fue © Vibration 47-3347. TROUBLESHOOTING (BY TROUBLE) Factors Trouble ‘Checking Electric equipment ‘Shovel side Shovel side Engine side 8/3 gle « Alek & 5 é 3 3 é € lure of hydraul Fe ‘Startup circuit wiring ‘Starter Key switch Loose connection of battery cable terminal Battery rely [Alternator Safely relay Hydraulic switch Poor start abilty (Take a long time) © [Glow plug [0 [Glow relay Faulty engine starting/engine does not rotate. ° ° ° ° © [0 [Starter motor ° Faully engine starting/engine rotates but no exhaust gas (No fuel injection) Fauly starting Faully engine starting/exhaust gas is emitted but engine does not start (With fuel injection) Engine poor run-up (Low follow-up ability) Foe Rotation in bad condition (hunting) Engine stalled during operation. ‘Output is towered Poor output ‘Overheating Exhaust smoke isin black Exhaust smoke is white Larger oil consumption (or blue exhaust gas) Early contamination of oll Larger fuel consumption Intruding of oll in coolant, back flow, reduction of coolant quantity Other falures Hydraulic pressure down (Monitor lights up) (Ol quantity increased, (Intruding of water and fuel) Vibration 47-3447. TROUBLESHOOTING (BY TROUBLE) Factors Trouble Fuel system Intake ana exhaust system Lubrication system Joooin| fsystem 2 E 3 Seizing and interference of turbocharger Damage of EGR cooler Failure of ol pump ‘Seal of turbocharger worn, damaged Failure of relief valve Leak and crush of hydrauli piping Damage of water pump Failure of thermostat (Not open) Failure of regulator valve Turbocharger Poor start ability (Take a long time) z ° lo Faulty engine starting/engine does not rotate. Faulty engine starting/engine rotates but no exhaust gas (No fuel injection) Fauly starting Faulty engine starting/exhaust gas is emitted but engine does not start (With fuel injection) Engine poor run-up (Low follow-up ability) ea Rotation in bad condition (hunting) Engine stalled during operation. Output is lowered, Poor ouput] ‘Overheating Exhaust smoke is in black Exhaust smoke is white Larger oll consumption (or blue exhaust gas) ° Early contamination of ol] Larger fuel consumption Other falures Intruding of oilin coolant, back flow, reduction of coolant quantity Hydraulic pressure down (Monitor lights up) il quantity increased, (Iniruding of water and fuel Vibration 47-3547. TROUBLESHOOTING (BY TROUBLE) Factors Engine body a] ie e/alg isle els) _[8) |e 5/slS ele lel8/Sis/ sie Trouble allele Sls is|2 2/8 |8 | Faulty engine starting/engine does not rotate. ° IE -| Engine poor run-up (Low follow-up ability) ° oO | Engine stalled during operation, ° 2 | Outoutis towered ol fe 2 | overheating Cte EET] Elicia fonction wasn fo} Ja 47-36