Professional Documents
Culture Documents
TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX: 81-29-831-1162
E-mail: dc@hitachi-kenki.com
ADDITIONAL REFERENCES
MANUAL COMPOSITION
• This manual consists the Technical Manual and the • Information included in the Workshop Manual:
Workshop Manual. technical information needed for maintenance
and repair of the machine, tools and devices
• Information included in the Technical Manual: needed for maintenance and repair, maintenance
technical information needed for redelivery and standards, and removal/installation and assem-
delivery, operation and activation of all devices ble/disassemble procedures.
and systems, operational performance tests, and
troubleshooting procedures.
PAGE NUMBER
Example : T 1-3-5
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
UNITS USED
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
• These are the SAFETY ALERT SYMBOLS.
001-E01A-0001
SA-688
002-E01A-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the
machine and all safety messages in this manual.
• Safety signs should be installed, maintained and
replaced when necessary.
003-E01B-0003
SA-2
SAFETY
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or if an accident occurs.
004-E01A-0437
005-E01A-0438
SA-3
SAFETY
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause im-
pairment or loss of hearing.
006-E01A-0434
SA-434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by
walking around it before you start it to avoid per-
sonal injury.
007-E01A-0435
SA-435
SA-4
SAFETY
GENERAL PRECAUTIONS FOR CAB
• Before entering the cab, thoroughly remove all dirt
and/or oil from the soles of your work boots. If any
controls such as a pedal is operated while with
dirt and/or oil on the soles of the operator's work
boots the operator's foot may slip off the pedal,
possibly resulting in a personal accident.
• Do not leave parts and/or tools lying around the
operator's seat. Store them in their specified loca-
tions.
• Avoid storing transparent bottles in the cab. Do
not attach any transparent type window decora-
tions on the windowpanes as they may focus
sunlight, possibly starting a fire.
• Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab
while operating the machine.
• Keep all flammable objects and/or explosives
away from the machine.
• After using the ashtray, always cover it to extin-
guish the match and/or tobacco.
• Do not leave cigarette lighters in the cab. When
the temperature in the cab increases, the lighter
may explode.
524-E01A-0000
SA-5
SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.
008-E01A-0439
SA-439
009-E01A-0462
SA-6
SAFETY
ENSURE SAFETY BEFORE RISING FROM
OR LEAVING OPERATOR'S SEAT
• Before rising from the operator's seat to open/close
either side window or to adjust the seat position, be
sure to first lower the front attachment to the ground
and then move the pilot control shut-off lever to the
LOCK position. Failure to do so may allow the ma-
chine to unexpectedly move when a body part un-
intentionally comes in contact with a control lever,
possibly resulting in serious personal injury or death.
010-E01A-0237
SA-7
SAFETY
MOVE AND OPERATE MACHINE SAFELY
• Bystanders can be run over.
011-E01A-0398
036-E01A-0293-3
SA-8
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may cause
the machine to runaway, possibly resulting in seri-
ous injury or death.
012-E01B-0431
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
S013-E01A-0032
SA-9
SAFETY
KEEP RIDERS OFF MACHINE
• Riders on machine are subject to injury such as be-
ing struck by foreign objects and being thrown off
the machine.
014-E01B-0427
SA-379
M104-05-015
SA-10
SAFETY
INVESTIGATE JOB SITE BEFOREHAND
• When working at the edge of an excavation or on a
road shoulder, the machine could tip over, possibly
resulting in serious injury or death.
• Investigate the configuration and ground condi-
tions of the job site beforehand to prevent the
machine from falling and to prevent the ground,
stockpiles, or banks from collapsing.
• Make a work plan. Use machines appropriate to
the work and job site.
• Reinforce ground, edges, and road shoulders as
necessary. Keep the machine well back from the
edges of excavations and road shoulders.
• When working on an incline or on a road shoulder, SA-380
employ a signal person as required.
• Confirm that your machine is equipped a FOPS
cab before working in areas where the possibility
of falling stones or debris exist.
• When the footing is weak, reinforce the ground
before starting work.
• When working on frozen ground, be extremely
alert. As ambient temperatures rise, footing be-
comes loose and slippery.
• Beware the possibility of fire when operating the
machine near flammable objects such as dry
grass.
• Make sure the worksite has sufficient strength to
firmly support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks po-
sitioned perpendicular to the cliff face with travel
motors at the rear, so that the machine can more
easily evacuate if the cliff face collapses.
• If working on the bottom of a cliff or a high bank is
required, be sure to investigate the area first and
confirm that no danger of the cliff or bank collapsing
exists. If any possibility of cliff or bank collapsing
exists, do not work on the area.
• Soft ground may collapse when operating the ma-
chine on it, possibly causing the machine to tip over.
When working on a soft ground is required, be sure
to reinforce the ground first using large pieces of
steel plates strong and firm enough to easily support
the machine.
• Note that there is always a possibility of machine
tipping over when working on rough terrain or on
slopes. Prevent machine tipping over from occurring.
When operating on rough terrain or on slopes:
• Reduce the engine speed.
• Select slow travel speed mode.
• Operate the machine slowly and be cautious with
machine movements.
SA-11
SAFETY
EQUIPMENT OF HEAD GUARD, ROPS,
FOPS
In case the machine is operated in areas where the
possibility of falling stones or debris exist, equip a
head guard, ROPS, or FOPS according to the poten-
tial hazardous conditions. (The standard cab for this
machine corresponds to ROPS and FOPS.)
SA-490
018-E01A-0481
SA-481
017-E01A-0491
SA-491
SA-12
SAFETY
DRIVE MACHINE SAFELY
• Before driving the machine, always confirm that the
travel levers/pedals direction corresponds to the di-
rection you wish to drive.
SA-658
SA-441
SA-442
SA-13
SAFETY
DRIVE MACHINE SAFELY
• Driving across the face of a slope or steering on a
slope may cause the machine to skid or turnover.
If the direction must be changed, move the ma-
chine to level ground, then, change the direction
to ensure safe operation.
• Avoid swinging the upperstructure on slopes.
Never attempt to swing the upperstructure down-
hill. The machine may tip over. If swinging uphill is
unavoidable, carefully operate the upperstructure
and boom at slow speed. Travel Motor
• If the engine stalls on a slope, immediately lower
the bucket to the ground. Return the control lev-
M104-05-008
ers to neutral. Then, restart the engine.
• Be sure to thoroughly warm up the machine be-
fore ascending steep slopes. If hydraulic oil has
not warmed up sufficiently, sufficient performance
may not be obtained.
• Use a signal person when moving, swinging or
operating the machine in congested areas. Coor-
dinate hand signals before starting the machine.
• Before moving machine, determine which way to
move travel pedals/levers for the direction you
Arrow-Mark
want to go. When the travel motors are in the rear,
pushing down on the front of the travel pedals or M178-03-001
SA-14
SAFETY
• Use wood plates in order not to damage the road
surface. Be careful of steering when operating on
asphalt roads in summer.
• When crossing train tracks, use wood plates in
order not to damage them.
• Do not make contact with electric wires or
bridges.
• When crossing a river, measure the depth of the
river using the bucket, and cross slowly. Do not
cross the river when the depth of the river is
deeper than the upper edge of the upper roller.
• When traveling on rough terrain, reduce engine
speed. Select slow travel speed. Slower speed
will reduce possible damage to the machine.
• Avoid operations that may damage the track and SA-011
undercarriage components.
• During freezing weather, always clean snow and
ice from track shoes before loading and unloading
machine, to prevent the machine from slipping.
SA-15
SAFETY
AVOID INJURY FROM ROLLAWAY ACCI-
DENTS
• Death or serious injury may result if you attempt to
mount or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park ma-
chine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle switch and the H/P mode
switch off.
• Run the engine at slow idle speed without load for
5 minutes to cool down the engine. SA-391
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK posi-
tion.
• Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
SA-392
020-E02A-0493
SA-16
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure, the machine
may hit or run over that person, resulting in serious
injury or death.
021-E01A-0494
SA-17
SAFETY
KEEP PERSON CLEAR FROM WORKING
AREA
• A person may be hit severely by the swinging front
attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.
022-E01A-0386
SA-386
023-E01A-0487
SA-487
AVOID UNDERCUTTING
• In order to retreat from the edge of an excavation if
the footing should collapse, always position the un-
dercarriage perpendicular to the edge of the exca-
vation with the travel motors at the rear.
024-E01A-0488 SA-488
SA-18
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE---SERIOUS OR FATAL CRUSHING IN-
JURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU
CAN JUMP FREE
FASTEN YOUR SEAT BELT
• The danger of tipping is always present when oper-
ating on a grade, possibly resulting in serious injury
or death.
To avoid tipping:
• Be extra careful before operating on a grade.
SA-012
025-E03B-0463
026-E01A-0519
SA-489
SA-19
SAFETY
DIG WITH CAUTION
• Accidental severing of underground cables or gas
lines may cause an explosion and/or fire, possibly
resulting in serious injury or death.
027-E01A-0382
SA-389
028-E01A-0389
SA-20
SAFETY
AVOID POWER LINES
• Serious injury or death can result if the machine or
front attachments are not kept a safe distance from
electric lines.
OBJECT HANDLING
• If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed under-
neath it, resulting in serious injury or death.
SA-21
SAFETY
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the body,
serious injury may result.
031-E01A-0432
SA-432
ards.
• Do not incinerate or puncture pressurized con-
tainers.
• Do not store oily rags; they can ignite and burn
spontaneously.
• Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
SA-22
SAFETY
TRANSPORT SAFELY
• Take care the machine may turn over when loading
or unloading the machine onto or off of a truck or
trailer.
035-E07A-0454
SA-23
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
• Understand service procedures before starting
work.
• Keep the work area clean and dry.
• Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is
moving.
• Keep hands, feet and clothing away from
power-driven parts.
500-E02C-0520
SA-527
SA-24
SAFETY
• If a maintenance procedure must be performed
with the engine running, do not leave machine
unattended.
• If the machine must be raised, maintain a 90 to
100° angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
• Inspect certain parts periodically and repair or re-
place as necessary. Refer to the section discuss-
ing that part in the "MAINTENANCE" chapter of
this manual.
•
SA-037
Keep all parts in good condition and properly in-
stalled.
• Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or de-
bris.
• When cleaning parts, always use nonflammable
detergent oil. Never use highly flammable oil such
as fuel oil and gasoline to clean parts or surfaces.
• Disconnect battery ground cable (-) before mak-
ing adjustments to electrical systems or before
performing welding on the machine.
• Sufficiently illuminate the work site. Use a main-
tenance work light when working under or inside
the machine.
• Always use a work light protected with a guard. In
case the light bulb is broken, spilled fuel, oil, anti-
freeze fluid, or window washer fluid may catch
fire.
501-E01A-0287
T1J1-01-01-001
SA-25
SAFETY
SUPPORT MACHINE PROPERLY
• Never attempt to work on the machine without se-
curing the machine first.
SA-527
519-E01A-0527
502-E01A-0026
SA-026
SA-26
SAFETY
PREVENT PARTS FROM FLYING
• Grease in the track adjuster is under high pressure.
Failure to follow the precautions below may result in
serious injury, blindness, or death.
503-E01B-0344
504-E01A-0034
SA-034
SA-27
SAFETY
PREVENT BURNS
Hot spraying fluids:
505-E01B-0498
S506-E01A-0019
SA-28
SAFETY
AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under
pressure can penetrate the skin or eyes causing se-
rious injury, blindness or death.
507-E03A-0499
SA-292
SA-044
SA-29
SAFETY
PREVENT FIRES
Check for Oil Leaks:
• Fuel, hydraulic oil and lubricant leaks can lead to
fires.
• Check for oil leaks due to missing or loose clamps,
kinked hoses, lines or hoses that rub against each
other, damage to the oil-cooler, and loose
oil-cooler flange bolts.
• Tighten, repair or replace any missing, loose or
damaged clamps, lines, hoses, oil-cooler and
oil-cooler flange bolts.
• Do not bend or strike high-pressure lines.
• Never install bent or damaged lines, pipes, or
hoses.
SA-019
Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris, ac-
cumulated coal dust, and other flammables may
cause fires.
• Prevent fires by inspecting and cleaning the ma-
chine daily and by removing spilled or accumu-
lated flammables immediately.
Check Key Switch:
• If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
Always check key switch function before operating
the machine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to con-
firm that the engine stops.
• If any abnormalities are found, be sure to repair
them before operating the machine.
508-E02B-0019
SA-30
SAFETY
EVACUATING IN CASE OF FIRE
• If a fire breaks out, evacuate the machine in the fol-
lowing way:
18-E02B-0393
SS-1510
509-E01A-0016
SA-016
523-E01A-0818
SA-31
SAFETY
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
• Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
510-E01B-0030
511-E01A-0029
SA-32
SAFETY
BEWARE OF ASBESTOS DUST
• Take care not to inhale dust produced in the work
site. Inhalation of asbestos fibers may be the cause
of lung cancer.
512-E01B-0032
SA-33
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
• If spilled onto skin, refrigerant may cause a cold
contact burn.
513-E01A-0405
SA-405
mended equipment.
• See your authorized dealer for MSDS's (available
only in English) on chemical products used with
your machine.
515-E01A-0309
SA-34
SAFETY
DISPOSE OF WASTE PROPERLY
• Improperly disposing of waste can threaten the en-
vironment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
516-E01A-0226
S517-E01A-0435
SA-435
SA-35
SAFETY
(Blank)
SA-36
SECTION AND GROUP SECTION 4 OPERATIONAL PER-
CONTENTS FORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
TECHNICAL MANUAL
Group 6 Adjustment
(Troubleshooting) SECTION 5 TROUBLESHOOTING
Group 1 General
Group 2 Component Layout
Group 3 Troubleshooting A
Group 4 Troubleshooting B
Group 5 Troubleshooting C
Group 6 Electrical System Inspection
Group 7 ICX
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Control System Group 5 Travel Device
Group 2 Hydraulic System Group 6 Others (Upperstructure)
Group 3 Electrical System Group 7 Others (Undercarriage)
All information, illustrations and speci-
fications in this manual are based on WORKSHOP MANUAL
the latest product information available
at the time of publication. The right is SECTION 1 GENERAL INFORMA- SECTION 3 UNDERCARRIAGE
TION Group 1 Swing Bearing
reserved to make changes at any time
Group 1 Precautions for Disassem- Group 2 Travel Device
without notice.
bling and Assembling Group 3 Center Joint
Group 2 Tightening Torque Group 4 Track Adjuster
Group 3 Painting Group 5 Front Idler
SECTION 2 UPPERSTRUCTURE Group 6 Upper and Lower Roller
Group 1 Cab Group 7 Track
Group 2 Counterweight SECTION 4 FRONT ATTACHMENT
Group 3 Main Frame Group 1 Front Attachment
COPYRIGHT(C)2005
Group 4 Pump Device Group 2 Cylinder
Hitachi Construction Machinery Co., Ltd.
Group 5 Control Valve SECTION 5 ENGINE
Tokyo, Japan
Group 6 Swing Device
All rights reserved
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 9 Shockless Valve
Group 10 Solenoid Valve Unit
SECTION 4
OPERATIONAL PERFORMANCE TEST
CONTENTS
Group 1 Introduction Group 3 Engine Test
Operational Performance Tests ................ T4-1-1 Engine Speed ........................................... T4-3-1
Preparation for Performance Tests ........... T4-1-2 Engine Compression Pressure ................. T4-3-4
Valve Clearance Adjustment ..................... T4-3-5
Group 2 Standard
Nozzle Check............................................ T4-3-8
OperationalPerformance
Injection Timing....................................... T4-3-13
Standard Table........................................ T4-2-1
Lubricant Consumption ........................... T4-3-14
Main Pump P-Q Curve.............................. T4-2-6
Injection Pump.......................................... T4-2-8
Group 4 Excavator Test
DR. ZX Monitor Indicating Values ............. T4-2-9
Travel Speed............................................. T4-4-1
Sensor Activating Range ........................ T4-2-13
Track Revolution Speed ............................ T4-4-2
Mistrack Check ......................................... T4-4-3
Travel Parking Leakage ............................ T4-4-4
Swing Speed............................................. T4-4-5
Swing Function Drift Check....................... T4-4-6
Swing Motor Leakage ............................... T4-4-8
Maximum Swingable Slant Angle .............. T4-4-9
Swing Bearing Play................................. T4-4-10
Hydraulic Cylinder Cycle Time ................ T4-4-12
Dig Function Drift Check ......................... T4-4-14
Control Lever Operating Force................ T4-4-16
Control Lever Stroke ............................... T4-4-18
Combined Operation of
Boom Raise / Swing Function Check .... T4-4-19
Combined Operation of Boom Raise
/ Arm Roll-In Function Check ................ T4-4-20
BWAT-4-1
Group 5 Component Test
Primary Pilot Pressure.............................. T4-5-1
Secondary Pilot Pressure ......................... T4-5-3
Solenoid Valve Set Pressure .................... T4-5-4
Main Pump Delivery Pressure .................. T4-5-7
Main Relief Set Pressure .......................... T4-5-8
Relief Pressure
(When relieving Swing) ......................T4-5-11
Overload Relief Valve Set Pressure........ T4-5-12
Main Pump Flow Rate Measurement ...... T4-5-16
Swing Motor Drainage ............................ T4-5-23
Travel Motor Drainage ............................ T4-5-26
Group 6 Adjustment
Engine Speed Adjustment and
EngineLearning ................................. T4-6-1
Governor Lever and Fuel Cut
Lever Position ................................... T4-6-4
BWAT-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedure to quan- The machine performance does not always deterio-
titatively check all system and functions on the ma- rate as the working hours increase. However, the
chine. machine performance is normally considered to re-
duce in proportion to the increase of the operation
Purpose of Performance Tests hours. Accordingly, restoring the machine perform-
1. To comprehensively evaluate each operational ance by repair, adjustment, or replacement shall con-
function by comparing the performance test data sider the number of the machine’s working hours.
with the standard values.
2. According to the evaluation results, repair, adjust, Definition of “Performance Standard”
or replace parts or components as necessary to 1. Operation speed values and dimensions of the
restore the machine’s performance to the desired new machine.
standard. 2. Operational performance of new components
3. To economically operate the machine under op- adjusted to specifications. Allowable errors will be
timal conditions. indicated as necessary.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the op-
erational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to evalu-
ate the performance test data.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to
run straight more than 20 m (65 ft 7 in), and to
make a full swing with the front attachment ex-
tended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork-
ers. Once the test is started, be sure to commu-
nicate with each other using these signals, and to
follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid acci-
dents due to landslides or contact with
high-voltage power lines. Always confirm that
there is sufficient space for full swings.
4. Avoid polluting the machine and the ground with T105-06-01-003
T105-06-01-004
T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE STAN-
DARD TABLE
The standard performance values are listed in the ta- Engine Control Dial : Fast Idle
ble below. Refer to the Group T4-3 to T4-5 for per- Power Mode Switch : P Mode
formance test procedures. Values in parentheses are Auto-Idle / Acceleration Selector: OFF
reference values. Work Mode Switch : Digging Mode
The following switch positions shall be selected and Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
the hydraulic oil temperature shall be maintained as
indicated below when measuring performance unless
otherwise specified.
Performance Reference
PERFORMANCE TEST DESIGNATION Remarks
Standard page
ENGINE SPEED min
-1
T4-3-1
Slow Idle Speed 1050+100-100 Value indicated on Dr. ZX.
Fast Idle (Normal) 2015+75-75 ↑
Fast Idle (With ECO deactivated) 2115+100-100 ↑
Fast Idle (Relief operation) Boom Raise relief opera-
1850 to 2015 tion
Value indicated on Dr. ZX.
Fast Idle (E mode) 1920+100-100 Value indicated on Dr. ZX.
Fast Idle (HP mode) Boom Raise / Arm Roll-In
1950 to 2200 relief operations.
Value indicated on Dr. ZX.
Auto-idle Speed 1335+100-100 Value indicated on Dr. ZX.
Auto-Acceleration Speed 1675+100-100 ↑
Warming Up Speed 1190+100-100 ↑
ENGINE COMPRESSION PRESSURE 3.5 (36, 509) After engine warm up. T4-3-4
2
MPa (kgf/cm , psi)
VALVE CLEARANCE (IN, EX) mm 0.4 With engine cold. T4-3-5
NOZZULE INJECTION PRESSURE T4-3-8
2
MPa (kgf/cm , psi)
First stage: 18.1
(185, 2630)
Second stage:
22.1
(225, 3200)
INJECTION TIMING (Degrees before TDC) deg. 9° T4-3-13
LUBRICANT CONSUMPTION mL/h Hour meter: 2000 hours or T4-3-14
70 or less
less
TRVEL SPPED sec/10 m T4-4-1
Fast Speed 7.2±0.6
T4-2-1
OPERATIONAL PERFORMANCE TEST / Standard
Performance Reference
PERFORMANCE TEST DESIGNATION Remarks
Standard page
TRACK REVOLUTION SPEED sec/3 rev T4-4-2
Fast Speed 32.6±2.0
MISTRACK mm/20 m
200 or less T4-4-3
(Both fast and slow travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0 T4-4-4
SWING SPEED sec/3 rev 16.0±1.0 Bucket empty T4-4-5
SWING FUNCTION DRIFT CHECK mm/180
o
1706 or less 3.2 Arm T4-4-6
1.4 m3 (PCSA heaped)
Bucket, Bucket empty
SWING MOTOR LEAKAGE mm/5 min 3.2 Arm T4-4-8
0 1.4 m3 (PCSA heaped)
Bucket, Bucket loaded
MAXIMUM SWINGABLE SLANT ANGLE deg. 21.2 or possibly Bucket loaded T4-4-9
more
SWING BEARING PLAY mm 0.2 to 1.25 Allowable Limit: 2.0 to T4-4-10
3.05
HYDRAULIC CYLINDER CYCLE TIME sec 3.2 m Arm T4-4-12
1.4 m3 (PCSA heaped)
Bucket, Bucket empty
Boom Raise ZX330-3G: 3.4±0.3
ZX350H-3G, 350K-3G, 360H-3G: 3.6±0.3
Boom Lower ZX330-3G: 2.4±0.3
ZX350H-3G, 350K-3G, 360H-3G: 2.2±0.3
Arm Roll-In 4.6±0.3
T4-2-2
OPERATIONAL PERFORMANCE TEST / Standard
Performance Reference
PERFORMANCE TEST DESIGNATION Remarks
Standard page
CONTROL LEVER OPERATING FORCE HITACHI Lever Pattern
T4-4-16
N (kgf, lbf)
Boom Lever 18 (1.8, 13.0)
or less
Arm Lever (ISO Lever Pattern: Swing Lever) 15 (1.5, 10.8)
or less
Bucket Lever 15 (1.5, 10.8)
or less
Swing Lever (ISO Lever Pattern: Arm Lever) 18 (1.8, 13.0)
or less
Travel Lever 28 (2.8, 20.3)
or less
CONTROL LEVER STROKE mm HITACHI Lever Pattern T4-4-18
Boom Lever 105±10
Arm Lever (ISO Lever Pattern: Swing Lever) 84±10
Bucket Lever 84±10
Swing Lever (ISO Lever Pattern: Arm Lever) 105±10
Travel Lever 120±10
COMBINED BOOM RAISE/SWING FUNCTION 3.2 m Arm
Time to Swing 90° 4.3±0.3 1.4 m3 (PCSA heaped)
T4-4-19
With bucket empty sec Bucket
T4-2-3
OPERATIONAL PERFORMANCE TEST / Standard
Performance Reference
PERFORMANCE TEST DESIGNATION Remarks
Standard page
SOLENOID VALVE SET PRESSURE Value indicated On T4-5-4
2
MPa (kgf/cm , psi) Dr.ZX±0.2 (2, 28)
MAIN PUMP DELIVERY PRESSURE 2.0±1.0 Value indicated on T4-5-7
2
MPa (kgf/cm , psi) (20±10, 284±142) Dr.ZX.
MAIN RELIEF VALVE SET PRESSURE T4-5-8
2
MPa (kgf/cm , psi)
With Boom / Arm / Bucket Circuit relieved 31.4+2.0-0.5 Value indicated on
(320+20-5, Dr.ZX.
4550+284-71)
With Bucket Circuit relieved 32.4+2.0-0.5 Value indicated on
(330+20-5, Dr.ZX.
4690+284-71)
RELIEF PRESSURE 32.4+2.0-0.5 Value indicated on T4-5-11
(When relieving Swing) (330+20-5, Dr.ZX.
4690+284-71)
2
MPa (kgf/cm , psi)
OVERLOAD RELIEF VALVE SET PRESSURE (Reference Values T4-5-12
2,
MPa (kgf/cm , psi) at
50L / min)
Boom (Raise/Lower), Arm (Roll-In), 33.4+1.0-0
Bucket (Roll-In) (340+10-0,
4830+142-0)
Arm (Roll-Out), Bucket (Roll-Out) 35.3+1.0-0
(360 -0, 5120+142-0)
+10
MAIN PUMP FLOW RATE TEST L/min - Refer to T4-2-6 and T4-5-16
T4-2-7 Group.
SWING MOTOR DRAINAGE L/min T4-5-23
With constant maximum speed 0.2 to 0.3
With the motor relieved (2 to 5)
TRAVEL MOTOR DRAINAGE L/min T4-5-26
With the track jacked up 10 or less Allowable Limit: 10
With the motor relieved 15 or less Allowable Limit: 15
T4-2-4
OPERATIONAL PERFORMANCE TEST / Standard
(Blank)
T4-2-5
OPERATIONAL PERFORMANCE TEST / Standard
MAIN PUMP P-Q CURVE
(L/min)
300
A B
250
C
D
200
E
Flow Rate
150
100
50
0
4.9 (50) 9.8 (100) 14.7 (150) 19.6 (200) 24.5 (250) 29.4 (300) 34.3 (350)
T173-04-05-001
2
Delivery Pressure MPa (kgf/cm )
T4-2-6
OPERATIONAL PERFORMANCE TEST / Standard
• P-Q Control by Pump Control Pilot Pressure Signal
(Pilot Pressure Characteristics) Points on P-Q Line
(Reference: Measured at Test Stand) Pump Control Pressure Flow Rate
MPa (kgf/cm2) L/min
• Rated Pump Speed: 1900 min-1 (rpm) A − 73±3
• Hydraulic Oil Temperature: 50±5 °C B 0.78±0.05 (8.0±0.5) 93±3
C 2.94+0.05-0.29 (30+0.5-3) 272±3
NOTE: Refer to page T4-5-20.
(L/min)
200
Flow Rate B
100 A
2
MPa (kgf/cm )
0 0.98(10) 1.96(20) 2.94(30)
T4-2-7
OPERATIONAL PERFORMANCE TEST / Standard
INJECTION PUMP
Test Conditions:
1. Injection pump: PE6P120/721LS3000
2. Governor: EP/RSV 200-1350
3. Nozzle and nozzle holder assembly:
105780-8140 (Bosch No. EF8511/9A)
4. Nozzle: 105780-0000 (Bosch No. DN12SD12T)
5. Nozzle holder: 105780-2080 (Bosch No.
EF8511/9)
6. Nozzle opening pressure:
2
17.2 MPa (175 kgf/cm , 2490 psi)
7. Test fuel: ISO 4113 or SAE J967d
8. Transfer pump pressure:
255 kPa (2.6 kgf/cm2, 37 psi)
9. Injection pipe: Inner Dia. 3 mm×Outer Dia. 8
mm-Length 600 mm (0.118×0.315-23.6 in)
10. Fuel temperature: 39 to 41 °C (109.2 to 114.8 °F)
11. Overflow valve opening pressure: 255 kPa (2.6
kgf/cm2, 37.0 psi)
Governor adjustment
Rack limit
Idle-sub spring setting
Above
Boost Compensator Stroke; 0.7±0.1 mm
Governor spring setting
Pack Position
(mm)
Above
-1
Pump Speed min (rpm) T1HH-04-05-001
T4-2-8
OPERATIONAL PERFORMANCE TEST / Standard
DR. ZX MONITOR INDICATING VALUES
T4-2-9
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-10
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-11
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-12
OPERATIONAL PERFORMANCE TEST / Standard
SENSOR ACTIVATING RANGE
1. Checking Method
T4-2-13
OPERATIONAL PERFORMANCE TEST / Standard
(Blank)
T4-2-14
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary:
1. Measure the engine speed using the built-in di- 1
agnosing system (refer to TROUBLESHOOT-
ING/General group.) or Dr. ZX. If the built-in di- 2
agnosing system or Dr. ZX is not available, use
an engine speed meter.
2. Measure the engine speeds in each mode.
NOTE: Measure the engine speed before per-
forming all other tests to check that the
engine speed meets specification. Be-
cause, if the engine speed is not adjusted
correctly, all other performance data will be
unreliable.
3 T107-06-02-002
Preparation:
1. Select the monitor function of the built-in diag-
nosing system (or Dr.ZX). When using an engine
speed meter, install speed pickup (1) to injection
pipe (2).
2. Warm up the machine until the engine coolant
temperature reaches 50 °C (122 °F) or more, and
hydraulic oil is 50±5 °C (122±9 °F).
T1HH-04-02-002
T4-3-1
OPERATIONAL PERFORMANCE TEST / Engine Test
Measurement: Evaluation:
1. Check engine speeds for auto-warm up (when Refer to T4-2 Operational Performance Standard.
starting the engine), auto-idle, slow idle, fast idle
(when normal), fast idle (when the ECO is deac- Remedy:
tivated), fast idle (in the E mode), and fast idle (in Refer to T5-4 Troubleshooting B.
the HP mode).
2. Select the switch positions and the test condi-
tions corresponding to the engine speed to be NOTE: ECO stands for the auto engine speed re-
measured as shown in the table below. duction system by 100 min-1.
Engine Power Auto-Idle/ Auto- Work
Control Mode Acceleration Mode Test Conditions
Dial Switch Selector Switch
Digging
Slow Idle Min. Speed P OFF
Mode
Fast Idle (Normal) Digging
Max. Speed P OFF
Mode
Fast Idle Check in the Dr. ZX special
Digging
(With ECO deac- Max. Speed P OFF functions with ECO deacti-
Mode
tivated) vated.
Fast Idle (Relief Digging Check the engine speed while
Max. Speed P OFF
operation) Mode relieving the boom raise circuit.
Fast Idle Digging
Max. Speed E Mode OFF
(E mode) Mode
Fast Idle Digging Check the engine speed while
Max. Speed HP Mode OFF
(HP mode) Mode relieving the boom raise circuit.
Check engine speed 4 seconds
Digging
Auto-Idle Max. Speed P Auto-Idle after returning all control levers
Mode
to neutral.
Check reduced engine speed
Digging
Auto-Acceleration Max. Speed P Auto-Acceleration within 3 seconds after returning
Mode
all control levers to neutral.
Digging Check only when oil tempera-
Warming Up Max. Speed P OFF
Mode ture is lower than 0 °C (32 °F).
T4-3-2
OPERATIONAL PERFORMANCE TEST / Engine Test
Engine Con-
trol Dial
Auto-Idle/ Accelera-
tion Selector
Power Mode
Switch
Work Mode
Switch
T178-01-01-003 T178-01-01-004
T4-3-3
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders
to check for a decline in engine power.
2. Check exhaust gas color and the amount of
blow-by gas from the crankcase. Keep track of
engine oil consumption.
3. Check for abnormalities in the intake system, in-
cluding the air filter.
Preparation:
1. Confirm that valve clearances are correct.
2. Confirm that the batteries are charged properly.
3. Run the engine until the coolant temperature
gauge reaches the operating range.
4. Stop the engine. Remove glow plugs from each
cylinder.
NOTE: Unless the fuel delivery pipes are discon-
nected, fuel will ignite in the cylinders so
that pressure in the cylinders will increase. T1HH-04-02-003
Measurement:
1. Turn the starter to crank the engine. Record the
compression pressure of each cylinder.
2. Repeat measurement three times for each cylin-
der and calculate the mean values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to engine shop manual.
T4-3-4
OPERATIONAL PERFORMANCE TEST / Engine Test
VALVE CLEARANCE ADJUSTMENT
Summary:
Perform the measurement when the engine is cool.
Pointer
Before starting work, clean the head cover mounting
area to avoid contaminating the engine.
Preparation:
1. Locate top dead center (TDC) in the compression
stroke.
While turning the crank shaft clockwise, align the
matching mark on the crank pulley with the
pointer located on the flywheel housing as illus-
trated.
When the S mark on the driving side flange of the
injection pump coupling aligns with the pointer,
piston No.1 (or piston No.6) is positioned at TDC
in the compression stroke.
Measurement:
1. Insert a feeler gauge into the clearance between
the rocker arm and the valve stem end to meas-
ure the valve clearance.
T173-04-02-007
NOTE: Cylinder Nos. are designated from No.1 to
No.6 as viewed from the fan side.
T4-3-5
OPERATIONAL PERFORMANCE TEST / Engine Test
2. When the measurement is started from cylinder
No.1, perform the same measurement to all
valves indicated with the mark “{” in the table
below. (When the measurement is started from
cylinder No.6, perform the measurement on the
valves shown with the mark “×”.)
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-3-6
OPERATIONAL PERFORMANCE TEST / Engine Test
Adjustment:
• If the measurement results are out of specification,
adjust the valve clearance in the same order of
measurement.
T4-3-7
OPERATIONAL PERFORMANCE TEST / Engine Test
NOZZLE CHECK
Summary:
1. Check the injection pressures and the spray pat-
terns at the first and second stages with a nozzle
tester.
Nozzle Nozzle
Holder
2. Before starting work, clean the nozzle holder
Retaining
mounting area to avoid contaminating the engine Nut
system.
Preparation:
1. Injection Pressure at First Stage:
1-1. Remove the nozzle holder, the fuel injection Injection Pressures T1HH-04-02-007
at First and Second
pipings and so on. Stages:
Retaining
1-2. Remove the retaining nut from the nozzle Nut (Tool) Nozzle
holder. Install the gasket (tool) and retaining
nut (tool) on the nozzle.
Gasket
Gasket (Tool): 157892-1500 (Bosch Automo- (Tool)
tive)
Retaining Nut (Tool): 157892-4000 (Bosch
Automotive)
: 34 N⋅m (3.5 kgf⋅m, 25.5 lbf⋅ft)
2-2. Install the gasket (tool) and the plug (tools) to Retaining Nut
the retaining nut (tool). (Tool) Gasket (Tool)
Gasket (Tool) :026508-1140 (Bosch Automo-
tive)
Plug (Tool): 157892-1600 (Bosch Automotive)
Nozzle Holder
T1HH-04-02-010
T4-3-8
OPERATIONAL PERFORMANCE TEST / Engine Test
2-4. Install the nut (tool) to the holder (tool).
Nut (Tool): 157892-1000 (Bosch Automotive) Nut (Tool)
Holder (Tool)
2-5. Install the pin (tool) to the dial gauge (tool).
Dial Gauge (Tool): 157892-3800 (Bosch
Automotive)
Pin (Tool) (Length: 60 mm): 157892-5300
(Bosch Automotive)
T1HH-04-02-012
Retaining Nozzle
Nut Tester
Plug
T1HH-04-02-013
T4-3-9
OPERATIONAL PERFORMANCE TEST / Engine Test
Measurement
CAUTION: Never allow skin to contact the Injection Pressure at First Stage:
spray directly. The fuel spray from the nozzle
may penetrate the skin,
resulting in serious injury. If the fuel pene-
trates into the blood stream, it may cause
blood toxication. Nozzle Tester
IMPORTANT: Be sure to use clean diesel oil for
the test.
Pressure
T4-3-10
OPERATIONAL PERFORMANCE TEST / Engine Test
2-4. Operate the nozzle tester again in order to in-
crease the pressure inside the nozzle holder
to 34.3 to 44.1 MPa (350 to 450 kgf/cm2, 4980
to 6400 psi). Release the nozzle tester handle.
Holder will decrease (and the needle valve
stroke as indicated on the dial will fall.
T4-3-11
OPERATIONAL PERFORMANCE TEST / Engine Test
3. Spray Pattern
Attach the nozzle holder to the nozzle tester.
Make several strong strokes of the tester and
check the fuel spray pattern. Be sure not to oper-
ate the pressure gauge.
4. Leak Condition
Be sure to keep the pressure as that just before Normal
the injection. Then, check for any oil leakage
around the nozzle.
Evaluation
1. Standard Injection Pressure:
Refer to T4-2 Operational Performance Standard
Table.
2. Spray Pattern
• Large-size spray should not be visible to the na- T1HH-04-02-014
Adjustment
1. Injection pressure at the first stage can be
changed in response to the first nozzle opening
pressure shim thickness.
T1HH-04-02-015
2. Injection pressure at the second stage can be
changed in response to the second nozzle open-
ing pressure shim thickness.
First Nozzle
Opening
Pressure
Shim
T1HH-04-02-007
T4-3-12
OPERATIONAL PERFORMANCE TEST / Engine Test
INJECTION TIMING
Pointer
Inspection/Adjustment:
1. Position piston No.1 at TDC. Turn the crank shaft
clockwise to align the matching mark on the
crank pulley with the pointer on the housing.
NOTE: When the matching mark on the crank pul- Injection Coupling Pointer
ley aligns with the pointer on the housing Pump
and the matching mark on the coupling
aligns with the pointer on the housing, the
injection timing is equal to the position at 9
° before TDC.
T1HH-04-02-017
Coupling
Adjusting
Bolt
T1HH-04-02-018
T4-3-13
OPERATIONAL PERFORMANCE TEST / Engine Test
LUBRICANT CONSUMPTION
Measuring Method
1. Place the machine on level firm ground, and
leave it for at least one hour to let the lubricant
lower to the oil pan.
At this time, confirm that the machine is level,
using a leveler.
2. Record the read-out A (unit: hour) of the hour
meter.
3. Replenish the lubricant up to the high-level
gauge.
4. Operate the machine for at least 100 hours or un-
til the oil level lowers to the low-level gauge.
Evaluation:
Refer to T4-2 Operational Performance Standard.
T4-3-14
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary: Measurement:
Measure the time required for the excavator to travel 1. Measure both the slow and fast speeds of the
a 20 m (65.6 ft) test track. machine.
2. Select the following switch positions:
Preparation: Travel Engine Power Work Auto-Idle/
1. Adjust the track sag on both sidetracks equally. Mode Control Mode Mode Acceleration
2. Prepare a flat and solid test track 20 m (65.6 ft) in Switch Dial Switch Switch Selector
length with extra length of 3 to 5 m (9.8 to 16 ft) Slow Digging
on both ends for machine acceleration and de- Fast Idle P Mode OFF
Mode Mode
celeration. Fast Digging
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above Fast Idle P Mode OFF
Mode Mode
the ground with the arm and bucket rolled in.
4. Maintain hydraulic oil temperature at 50±5 °C 3. Start traveling the machine in the acceleration
(122±9 °F). zone with the travel levers to full stroke.
4. Measure the time required to travel 20 m (65.6
ft).
5. After measuring the forward travel speed, turn
the upperstructure 180° and measure the reverse
Arm Rolled-In, Bucket Rolled-In travel speed.
End 6. Repeat steps 4. to 5. three times in each direc-
Bucket Height: 0.3 to 0.5 m tion and calculate the average values.
Start
20 m Deceleration
Evaluation:
Zone Refer to the Operational Performance Standard in
3 to 5 m Group T4-2.
Acceleration
Zone
3 to 5 m Remedy:
Refer to the Troubleshooting B in Group T5-4.
T105-06-03-001
T4-4-1
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRACK REVOLUTION SPEED
Summary: Measurement:
Measure the track revolution cycle time with the NOTE: When jacking up one side track and rotat-
track raised off ground. ing it, the track doesn’t rotate at fast speed
though the travel made switch is turned to
Preparation: Fast Mode.
1. Adjust the track sag of both side tracks to be (Refer to the “Travel Motor Swash Angle
equal. Control” of the SYSTEM / Control System
2. On the track to be measured, mark one shoe with group in the T/M (Operational Principle).)
chalk.
3. Swing the upperstructure 90° and lower the 1. Select the following switch positions:
bucket to raise the track off ground. Keep the Travel Engine Power Work Auto-Idle/
boom-arm angle between 90 to 110° as shown. Mode Control Mode Mode Acceleration
Place blocks under the machine frame. Switch Dial Switch Switch Selector
Slow Digging
Fast Idle P Mode OFF
Mode Mode
Fast Digging
Fast Idle P Mode OFF
Mode Mode
2. Operate the travel control lever of the raised
90 to 110° track to full stroke.
3. Measure the time required for 3 revolutions in
both directions after a constant track revolution
speed is obtained.
4. Raise the other side and repeat the above
Mark
M104-07-067
procedures.
5. Repeat steps 3. to 5. three times and calculate
CAUTION: Securely support the raised track the average values.
using wooden blocks.
Evaluation:
4. Maintain the hydraulic oil temperature at 50±5 °C Refer to the Operational Performance Standard
(122±9 °F). Table in Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-2
OPERATIONAL PERFORMANCE TEST / Excavator Test
MISTRACK CHECK
Summary: Measurement:
1. Allow the machine to travel 20 m (65.6 ft). 1. Measure the amount of mistracking in both fast,
Measure the maximum tread deviation from the and slow travel speeds.
tread chord line drawn between the travel start 2. Select the following switch positions:
and end points to check the performance Travel Engine Power Work Auto-Idle/
equilibrium between both sides of the travel Mode Control Mode Mode Acceleration
device systems (from the main pump to the travel Switch Dial Switch Switch Selector
motor). Slow Digging
2. If measured on a concrete surface, the tread Fast Idle P Mode OFF
Mode Mode
deviation has a trend to decrease. Fast Digging
Fast Idle P Mode OFF
Mode Mode
Preparation:
1. Adjust the track sag of both tracks to be equal. 3. Start traveling the machine in the acceleration
2. Provide a flat, solid test yard 20 m (65.6 ft) in zone with the travel levers at full stroke.
length, with extra length of 3 to 5 m (9.8 to 16 ft) 4. Measure the maximum distance between a
on both ends for machine acceleration and straight 20 m (65.6 ft) tread chord line and the
deceleration. tread made by the machine.
5. After measuring the tracking in forward travel,
turn the upperstructure 180° and measure in
Maximum Distance reverse travel.
6. Repeat steps 3. to 5. three times and calculate
the average values.
Acceleration
Zone: Evaluation:
3 to 5 m
20 m Refer to the Operational Performance Standard
Table in Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T105-06-03-022
T4-4-3
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL PARKING LEAKAGE
Summary:
To measure the parking brake function on a speci-
fied slope.
Preparation:
1. The surface of the test slope shall be even with a
gradient of 20 % (11.31°).
0.2 to 0.3 m
2. Mark a white line on the travel device cover.
3. Hold the bucket 0.2 to 0.3 m (8 to 12 in) above
the ground with the arm and bucket fully rolled in.
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T105-06-03-004
Measurement:
1. Measure the travel parking brake slip amount
while parked.
2. Climb the slope and place the travel levers in
neutral.
3. Stop the engine.
4. After the machine stops, put alignment marks on
a track link or shoe, and the track side frame.
5. After 5 minutes, measure the distance between
the marks on the track link or shoe and the track
side frame.
Evaluation:
Refer to the Operational Performance Standard
Table in Group T4-2.
Alignment marks on the trackside
frame and shoe when the machine
comes to a stop.
Displacement measured
after 5 minutes.
T105-06-03-006
T4-4-4
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING SPEED
Summary:
Measure the time required to swing three complete CAUTION: Prevent personal injury. Always
turns. make sure that the area is clear and that
co-workers are out of the swing area before
Preparation: starting the measurement.
1. Check the lubrication of the swing gear and
swing bearing. Measurement:
1. Select the following switch positions:
2. Place the machine on flat, solid ground with
ample space for swinging. Do not conduct this Auto-Idle/
Engine Con- Power Mode Work Mode
test on slopes. Acceleration
trol Dial Switch Switch
3. With the arm rolled out and bucket rolled in, hold Selector
the bucket so that the height of the bucket pin is Digging
Fast Idle P Mode OFF
the same as the boom foot pin. The bucket must Mode
be empty.
2. Operate swing control lever fully.
3. Measure the time required to swing 3 turns in
one direction.
4. Operate swing control lever fully in the opposite
direction and measure the time required for 3
turns.
The same height as the
5. Repeat steps 2. to 4. three times and calculate
boom foot pin height the average values.
T105-06-03-013 Evaluation:
Refer to the Operational Performance Standard in
NOTE: In case a sufficient space for the meas- Group T4-2.
urement is difficult to find, carry out the
measurement with the boom fully raised Remedy:
and the arm fully rolled-in. Refer to the Troubleshooting B in Group T5-4.
T178-04-03-001
T4-4-5
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING FUNCTION DRIFT CHECK
Summary:
Measure the swing drift on the bearing outer
circumference when stopping after a 180° full-speed
swing.
Preparation:
1. Check the lubrication of the swing gear and
swing bearing.
2. Place the machine on flat, solid ground with
ample space for swinging. Do not conduct this Two Check Marks
test on a slope.
T105-06-03-008
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. The bucket must
be empty.
4. Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
5. Swing the upperstructure 180°.
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T4-4-6
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Select the following switch positions:
Auto-Idle/
Engine Con- Power Mode Work Mode
Acceleration
trol Dial Switch Switch
Selector
Measure Difference Between Marks
Digging
Fast Idle P Mode OFF
Mode
Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-7
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING MOTOR LEAKAGE
Summary:
Check for upperstructure drift while suspending a
load on a slope.
Preparation:
1. Check the lubrication of the swing gear and
swing bearing.
2. Park the machine on a smooth slope with a
gradient of 26.8 % (15°).
3. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
W=1800 kg (3970 lb)
4. With the arm rolled out, and bucket rolled in,
position the arm top pin height to be level with the
boom foot pin.
5. Swing the upperstructure to position it 90° to the
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as T105-06-03-011
illustrated.
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Select the following switch position:
Auto-Idle/
Power Mode Work Mode
Acceleration Measure Difference Between Marks
Switch Switch
Selector
P Mode Digging Mode OFF
Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-8
OPERATIONAL PERFORMANCE TEST / Excavator Test
MAXIMUM SWINGABLE SLANT ANGLE
Summary: Measurement:
With the upperstructure swung 90° to the slope, 1. Select the following switch positions:
check the maximum slant angle on which the upper- Engine Auto-Idle/
Power Mode Work Mode
structure can swing to the uphill side. Control Acceleration
Switch Switch
Dial Selector
Preparation: Fast Idle P Mode Digging Mode OFF
1. Check that the swing gear and bearing are well
lubricated.
2. Load bucket fully. In lieu of loading the bucket, 2. Operate the swing lever to full stroke to swing the
weight (W) of the following specification can be upperstructure to the uphill side.
used. 3. If the machine can swing, measure the cab floor
W=1800 kg (3970 lb) slant angle.
3. With the arm cylinder fully retracted and the 4. Increase the slope angle and repeat steps 2. and
bucket cylinder fully extended, hold the arm top 3. Check both clockwise and counterclockwise.
pin to the position flush with the boom foot pin 5. Perform the measurement three times.
height.
4. Climb a slope and swing the upperstructure 90° Evaluation:
to the slope. Refer to the Operational Performance Standard in
5. Maintain the hydraulic oil temperature at 50±5 °C Group T4-2.
(122±9 °F).
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T105-06-03-011
T4-4-9
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING BEARING PLAY
Summary:
Measure the swing bearing play using a dial gauge
to check the wear of bearing races and balls.
Preparation:
1. Check swing bearing mounting bolts for loose-
ness.
2. Check the lubrication of the swing bearing. Con-
firm that bearing rotation is smooth and without
noise.
3. Install a dial gauge on the track frame as shown, Magnetic Dial
using a magnetic base. Base Gauge
T105-06-03-014
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the front
idlers.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race.
6. Bucket should be empty.
T4-4-10
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. With the arm rolled out and bucket rolled in, hold
Measurement: (h1)
the bucket so that the height of the bucket pin is
the same as the boom foot pin. Record the dial
gauge reading (h1).
2. Lower the bucket to the ground and use it to
raise the front idler 0.5 m (20 in). Record the dial
gauge reading (h2).
3. Calculate bearing play (H) from this data (h1 and The same height
as the boom foot
h2) as follows: pin height
H=h2-h1
Evaluation: T105-06-03-007
T105-06-03-017
T4-4-11
OPERATIONAL PERFORMANCE TEST / Excavator Test
HYDRAULIC CYLINDER CYCLE TIME
Preparation:
1. Be sure to measure at the position as follows.
• To measure the cycle time of the boom cylinders:
With the arm rolled out and the empty bucket
rolled in, lower the bucket to the ground, as
shown. T105-06-03-018
T105-06-03-020
T4-4-12
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Select the following switch positions:
Engine Auto-Idle/
Power Mode Work Mode
Control Acceleration
Switch Switch
Dial Selector
Fast Idle P Mode Digging Mode OFF
Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-13
OPERATIONAL PERFORMANCE TEST / Excavator Test
DIG FUNCTION DRIFT CHECK
Summary:
Measure dig function drift, which can be caused by
oil leakage in the control valve and boom, arm, and
bucket cylinders, with the loaded bucket.
(2 in) retracted from the fully extended position. Arm Cylinder Extension
4. With the arm rolled out and the bucket rolled in,
hold the bucket so that the height of the bucket
pin is the same as the boom foot pin.
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Mark
Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the bucket, as well as the boom, arm and
bucket cylinders.
3. Repeat step 2. three times and calculate the T110-06-03-001
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T110-06-03-002
T4-4-14
OPERATIONAL PERFORMANCE TEST / Excavator Test
• Arm Roll-In Position
Summary:
Measure dig function drift, which can be caused by
oil leakage in the control valve and boom, arm, and
bucket cylinders.
Preparation:
1. The bucket must be empty.
2. Position the arm cylinder with the rod 50 mm (2
in) retracted from the fully extended position.
3. Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position.
4. With the arm rolled in and the bucket rolled in.
1m
Lower the boom until the arm tip is 1 m (40 in)
above the ground.
5. Maintain the hydraulic oil temperature at 50±5 °C
T173-04-03-001
(122±9 °F).
Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the arm tip, as well as the boom, arm and
bucket cylinders. Cylinder Retraction
3. Repeat step 2. three times and calculate the
average values. Mark Mark
Evalution:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T110-06-03-002
T4-4-15
OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER OPERATING FORCE
Summary:
1. Use a spring scale to measure the maximum
resistance of each control lever as illustrated.
2. Measure the maximum operating force of the
front attachment control lever.
3. Measure the operating force at the grip center of
each control lever.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T107-06-03-004
T4-4-16
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Measure each control lever.
2. Select the following switch positions:
Engine Auto-Idle/
Power Mode Work Mode
Control Acceleration
Switch Switch
Dial Selector
Fast Idle P Mode Digging Mode OFF
Evalution:
Refer to the Orerational Performance Standard in
Group T4-2.
T4-4-17
OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER STROKE
Summary:
1. Measure each lever stroke at the lever top using
a ruler.
2. Measure the lever stroke at the grip center of
each control lever.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both
side lever strokes.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement: T107-06-03-005
Evalution:
Refer to the Orerational Performance Standard in
Group T4-2.
T4-4-18
OPERATIONAL PERFORMANCE TEST / Excavator Test
COMBINED BOOM RAISE/SWING FUNC-
TION CHECK
Summary:
Check boom raise and swing movement and speeds
while operating both functions simultaneously.
Preparation:
1. Start the engine and run it at fast idle. Operate
the boom raise function and check to be sure that
the cylinder movement is smooth, with out stick-
T107-06-03-009
ing.
2. With the arm fully rolled out and bucket fully
rolled in, lower the bucket to the ground. The
bucket must be empty.
3. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Select the following switch positions: T107-06-03-010
Engine Auto-Idle/
Power Mode Work Mode
Control Acceleration
Switch Switch
Dial Selector
Fast Idle P Mode Digging Mode OFF
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-19
OPERATIONAL PERFORMANCE TEST / Excavator Test
COMBINED BOOM RAISE/ARM ROLL-IN
OPERATION
Summary:
1. Performance of boom raise and arm roll-in com-
bined operation is checked.
2. Make sure that the cylinders don’t hesitate while Arm Mounting Pin
operating the cylinder with the engine running at
fast idle.
Preparation:
1. Retract the arm cylinder fully and extend the
bucket cylinder. so that the bucket teeth and arm
mounting pin are on a straight line Adjust the
boom cylinder so that the bucket tooth tip height
is 0.5 m (1 ft 8 in) above the ground. (Empty the
bucket.) 0.5 m
2. Maintain the hydraulic oil temperature at 50 ± 5
°C (122±9 °F). T107-06-03-006
Measurement:
1. Select the switch positions as follows.
Engine Auto-Idle/
Power Mode Work Mode
Control Acceleration
Switch Switch
Dial Selector
Fast Idle P Mode Digging Mode OFF
Evaluation:
Refer to T4-2 Operational Performance Standard.
T107-06-03-008
Remedy:
Refer to T5-4 Troubleshooting B.
T4-4-20
OPERATIONL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove the plug from the pilot pump delivery
port. Install adapter (ST 6069) and pressure
gauge (ST 6942) on the port.
: 6 mm
Measurement:
1. Select the following switch positions:
Power Auto-Idle/
Engine Con- Work Mode
Mode Acceleration
trol Dial Switch
Switch Selector
General
Fast Idle P Mode Purpose OFF
Mode
General
Slow Idle P Mode Purpose OFF
Mode
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-5-1
OPERATIONL PERFORMANCE TEST / Component Test
Primary Pilot Pressure Adjustment
1
Adjustment:
Adjust the set pressure of relief valve (1) as neces-
sary.
: 22 mm
T1HH-04-04-002
T4-5-2
OPERATIONL PERFORMANCE TEST / Component Test
SECONDARY PILOT PRESSURE
1
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Install pressure gauge (ST 6942) and tee (ST
6450) to the end of pilot line (1) at the respective
control valve spool end, as illustrated.
: 14 mm, 17 mm
Measurement:
1. Select the following switch positions:
Power Auto-Idle/
Engine Work Mode T1HH-04-04-003
Mode Acceleration
Control Dial Switch
Switch Selector
Digging
Fast Idle P Mode OFF
Mode
Digging
Slow Idle P Mode OFF
Mode
Evaluation:
Refer to Performance Standard Table in Group T4-2.
Remedy: T157-05-04-011
T4-5-3
OPERATIONL PERFORMANCE TEST / Component Test
SOLENOID VALVE SET PRESSURE
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Disconnect line (1) from the solenoid valve to be
measured. Install hose (Parts Number: 4216453),
tee (ST 6451), adapter (ST 6461), and pressure
gauge (ST 6942) to the disconnected end at the
solenoid valve side, as illustrated.
: 17 mm, 19 mm, 22 mm
SC
Connect Dr. ZX. Select the monitor function.
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection. SI
SG
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F). T1HH-01-02-008
Pressure Gauge
Hose Piping
Tee Adapter
T173-04-04-006
T4-5-4
OPERATIONL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions:
Power Auto-Idle/
Engine Work Mode
Mode Acceleration
Control Dial Switch
Switch Selector
Digging
Fast Idle P Mode OFF
Mode
Evaluation:
The average value read on the pressure gauge shall
be within ±0.2 MPa (±2 kgf/cm2, ±28 psi) of the value
indicated on Dr. ZX.
T4-5-5
OPERATIONL PERFORMANCE TEST / Component Test
Solenoid Valve Set Pressure Adjustment Proce-
dure
7
IMPORTANT: Do not loosen the adjusting screw
excessively. 8
The O-ring on the threads may come
off the sealing surface, causing oil
leakage.
Be sure to turn the adjusting screw
less than 2 turns to loosen. T107-06-04-020
The distance between the
lock nut end and screw end
should be 2.0 mm (0.079 in)
1. Mark the end of the adjusting screw with a white or less.
marker for the record of the original position.
(Take care not to touch any part of the screw
threads with the white marker.)
2. Loosen lock nut (7). Turn adjusting screw (8) to
adjust the set pressure of the solenoid valve. 8
3. Retighten lock nut (7).
: 10 mm
: 3 mm
: 5 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft) 7
W107-02-05-129
T4-5-6
OPERATIONL PERFORMANCE TEST / Component Test
MAIN PUMP DELIVERY PRESSURE
Measurement:
1. Select the following switch positions: T1HH-04-04-005
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Digging
Fast Idle P Mode OFF
Mode
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-5-7
OPERATIONL PERFORMANCE TEST / Component Test
MAIN RELIEF VALVE SET PRESSURE
Summary:
Measure the main relief valve setting pressure at the
main pump delivery part. Pressure Check Ports
The main relief pressure can also be measured with
the built-in diagnosing system or Dr.ZX.
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install adapter (ST 6069), hose (ST 6943)
and pressure gauge (ST 6941) on the port.
: 6 mm
T4-5-8
OPERATIONL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions:
Power Work Auto-Idle/
Engine
Mode Mode Acceleration
Control Dial
Switch Switch Selector
Dipping
Fast Idle P Mode Mode OFF
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-5-9
OPERATIONL PERFORMANCE TEST / Component Test
Main Relief Set Pressure Adjustment
W107-02-05-129
T4-5-10
OPERATIONL PERFORMANCE TEST / Component Test
RELIEF PRESSURE (When relieving
Swing)
T1HH-01-02-004
T107-02-04-020
Adjusting Plug
Pressure Pressure
Increase Decrease
T157-05-04-023
T4-5-11
OPERATIONL PERFORMANCE TEST / Component Test
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary: Preparation:
1. The circuit pressure must be increased by apply- 1. Shut down the engine properly.
ing an external force while blocking the return cir- 2. Press the air relief valve on top of the hydraulic
cuit from the control valve. This measuring oil tank to release any remaining pressure.
method is hazardous and the results obtained 3. Remove the plug from the main pump delivery
with this method are unreliable. port. Install adapter (ST 6069) and pressure
2. The oil flow rate used to set the overload relief gauge (ST 6934) on the port.
pressure is far less than that used to set the main : 6 mm
relief pressure. Therefore, measuring the over- 4. Select the monitoring function of the built-in di-
load pressure in the main circuit by increasing agnosing system (or Dr.ZX). Start the engine.
the main relief set-pressure more than the over- Confirm that no oil leakage is observed at the
load valve set-pressure is not a proper method. pressure gauge connection.
In addition, in case a main relief valve designed 5. Maintain the hydraulic oil temperature at 50±5 °C
to leak a small quantity of oil before reliving is (122±9 °F).
used, its pre-leaking start pressure must be in-
creased more than the overload relief valve
set-pressure. However, the pre-leaking start
pressure is not always increased more than the
overload relief valve set-pressure as the adjust-
able upper limit of the main relief valve
set-pressure is provided. Accordingly, the over-
load relief valve assembly should be removed
from the machine and checked on a specified
test stand at a correct oil flow rate. Some over-
load relief valves come in contact with the control
valve body to block the oil passage. When this
type of overload relief valve is checked, the con-
trol valve body must be precisely finished as the
test unit. Provide one control valve other than
that on the machine as a test kit.
3. If the overload relief valve performance must be
checked on the machine, however, measure the
main relief pressure while releasing each front
function respective to the measuring overload re-
lief valve. And, assume that the overload relief
valve is functioning correctly if the obtained main
relief pressure is within the specified value range.
Measure the main pressure of the front functions
with the built-in diagnosing system or Dr.ZX as
follows:
T4-5-12
OPERATIONL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions:
Auto-Idle/
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch Pressure
Selector
Check Ports
Digging
Fast Idle P Mode OFF
Mode
Evaluation:
1. Performance of the overload relief valves are
normal if the measured main relief pressures are
T1HH-04-04-005
within the specified value range.
T4-5-13
OPERATIONL PERFORMANCE TEST / Component Test
Overload Relief Valve Set Pressure Adjusting
Procedure
Adjustment:
Adjust the pressure setting of the overload relief
valve using adjusting screw (2) after loosening lock
nut (1).
1 2
1. Loosen lock nut (1).
: 22 mm
W107-02-05-129
T4-5-14
OPERATIONL PERFORMANCE TEST / Component Test
(Blank)
T4-5-15
OPERATIONL PERFORMANCE TEST / Component Test
MAIN PUMP FLOW RATE MEASUREMENT
T4-5-16
OPERATIONL PERFORMANCE TEST / Component Test
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified pump speed using the following formu- Refer to T4-2 Operational Performance Standard.
las:
Qc = (Ns × Q) / Ne
1, 2 3 4 5 6 7 8 9 10 11
T173-04-04-002
14
N sensor
T1HH-01-02-003
T1HH-04-04-010
1- Pipe E (ST 6144) 5- Hydraulic Tester (ST 6299) 9- Flange (ST 6118) 12 - Plug
2- Pipe B (ST 6143) 6- Adapter PF1×UNF1-7/8 10- Split Flange (ST 6130) 13 - Hose (ST 6339)
(ST 6146)
3- Test Hose (ST 6145) 7- Joint (ST 6330) 11- Bolt (ST 6409) (4 Used) 14- Pipe (2 Used)
4- Adapter PF1×UNF1-7/8 8- Test Hose (ST 6320)
(ST 6146)
T4-5-17
OPERATIONL PERFORMANCE TEST / Component Test
• P-Q Control by Pump Control Pilot Pressure Signal
(Pilot Pressure Characteristics)
Summary:
To check the main pump performance, measure the 5. Connect hose (19) and adapter (20) to port T on
pump flow rate by connecting a portable tester at the reducing valve (16). Connect hose (19) after re-
delivery port of the main pump of which the flow rate moving plug L from the return pipe.
is to be measured. Dr.ZX or a pressure gauge is : 19 mm, 22 mm
used for pressure reading purpose in the measure-
ment. 6. Disconnect the N sensor connector.
Connect the pulse counter to the N sensor.
IMPORTANT: This measurement procedure is a
simple method. The measured data 7. Disconnect the vacuum pump. Loosen plug M
will be lower by approx. 5 % than (12) on the pump casing to bleed air from the
the accurately measured value. To casing until oil comes out.
measure accurately, disconnect the
return circuit from the control valve 8. Fully open the loading valve on the portable
and connect it to the hydraulic oil tester.
tank.
9. Disconnect the torque control solenoid valve
Preparation: connector.
1. Refer to steps 1 to 4 on page T4-5-18, connect a
portable tester to the main pump to be measured. 10. Start the engine. Check the pressure gauge con-
nections for any oil leakage.
2. Disconnect the hoses of port Pi at the regulator
on the main pump to be measured.
Attach plug (ST 6213) in the disconnected hose.
: 6 mm, 19 mm
T4-5-18
OPERATIONAL PERFORMANCE TEST / Component Test
1, 2 3 4 5 6 7 8 9 10 11
Port Pi
M T173-04-04-002
12
N sensor
T1HH-04-04-002
T1HH-04-04-009
15 17
To Port Pi on Regulator
14 17 15 16 15 14 13 To Port PC on
Pilot Filter
T1HH-04-04-008
1 - Pipe E (ST 6144) 6 - Adapter PF1×UNF1-7/ 8 11 - Bolt (ST 6409) (4 used) 16 - Reducing Valve (4325439)
(ST 6146)
2 - Pipe B (ST 6143) 7 - Joint (ST 6330) 12 - Plug M 17 - Tee UNF7/16×UNF 7/16
3 - Test Hose (ST 6145) 8 - Test Hose (ST 6320) 13 - Adapter UNF 7/16× 18 - Pressure Gauge (ST 6931)
PF 1/4 (ST 6069)
4 - Adapter PF1×UNF1-7 / 8 9 - Flange (ST 6118) 14 - Hose UNF7/16× 19 - Hose UNF 7/16×
(ST 6146) UNF7/16 (4334309) UNF 7/16 (4334309)
5 - Potable Tester (ST 6299) 10 - Split Flange (ST 6130) 15 - Adapter PF3/8× 20 - Adapter PF3/8×
UNF 7/16 (4200465) UNF 7/16 (4200465)
T4-5-19
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement: Evaluation:
1. Measure the main pump flow rate controlled by 1. Convert the measured pump flow rate into the
the pump control pilot pressure signal. one for the rated pump speed using the following
formula.
2. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
4. Adjust the reducing valve set pressure to the 2. Specified Pump Flow Rate
specified pressure shown on the P-Q diagram of Refer to the Performance Standard Table in
the main pump (Pilot Pressure Characteristics) Group T4-2.
on page T4-2-5.
Measure the flow rate and engine speed at each
specified pressure shown on the P-Q diagram.
T4-5-20
OPERATIONAL PERFORMANCE TEST / Component Test
Regulator Adjustment
6 5
1
3
2
4
10
T1HH-03-01-002
7 8
1 - Lock Nut (For Minimum 4 - Adjusting Screw (For 7 - Lock Nut 9 - Lock Nut
Flow Adjustment) Maximum Flow Adjust- (For P-Q Line Adjustment) For P-Q Line Adjustment)
ment)
2 - Adjusting Screw (For 5 - Lock Nut 8 - Adjusting Screw 10 - Adjusting Screw
Minimum Flow Adjustment) (For Pilot Pressure Char- (For P-Q Line Adjustment) (For P-Q Line Adjustment)
acteristic Adjustment)
3 - Lock Nut (For Maximum 6 - Adjusting Screw
Flow Adjustment) (For Pilot Pressure Char-
acteristic Adjustment)
Pi
2. Maximum Flow Rate After loosening lock nut (3), turn 1) Do not tighten adjusting screw
Q adjusting screw (4). Tightening ad- (2) more than two turns.
justing screw (4) 1/4 a turn de- 2) Do not attempt to increase the
creases the maximum pump flow maximum flow rate. (Do not turn
rate by 10.00 cm3/rev. adjusting screw (4)
counter-clockwise.)
3) Securely retighten lock nut (3)
after adjustment.
Pd
T4-5-21
OPERATIONAL PERFORMANCE TEST / Component Test
4. Pump Output Torque A. After loosening lock nut (7), turn 1) Do not tighten adjusting screw
(P-Q Line) adjusting screw (8). Tightening (8) more than one turn.
Q adjusting screw (8) 1/4 a turn 2) Increase or decrease the flow
increases the pump flow rate by rate. So that the engine is not
A 19.85 cm3/rev. overloaded.
B. After loosening lock nut (9), turn 3) Securely retighten lock nut (3 or
Pd adjusting screw (10). Tightening 9) after adjustment.
Q adjusting screw (10) 1/4 a turn
increases the pump flow rate by
3.73 cm3/rev.
B
Pd
T4-5-22
OPERATIONAL PERFORMANCE TEST / Component Test
SWING MOTOR DRAINAGE
Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while
swinging the upperstructure.
Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F). Rotate the swing motor to warm the T157-05-04-014
T4-5-23
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Amount of Oil Drained While Swinging the Up-
perstructure
(1) Fully retract the arm cylinder. Fully extend the
bucket cylinder. Raise the boom so that the
arm tip pin height is the same as the boom
foot pin height. Check that the bucket is
empty.
(2) Start the engine. Operate and hold the swing The same height as
boom foot pin height
lever full stroke. Start draining oil measure-
ment after the swing speed reaches a con-
T105-06-03-013
stant maximum speed. The measuring time
should be more than 45 seconds.
(3) Repeat the measurement at least three times
in both clockwise and counterclockwise direc-
tions, and calculate the average values.
T4-5-24
OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation:
Refer to the Performance Standard Table in group
T4-2.
ΔQ = 60 × q / t
Where:
ΔQ : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
T107-06-05-008
q : Total amount of drain oil (L)
T4-5-25
OPERATIONAL PERFORMANCE TEST / Component Test
TRAVEL MOTOR DRAINAGE
Summary:
1. While rotating the travel motor with the track
to be measured jacked up, measure amount
of oil draining from the travel motor and
check travel motor performance.
2. Judge travel motor performance from the re-
sults including travel speed, mistrack and so
on overall.
3. The amount of drain oil from the travel motor
will change depending on hydraulic oil tem-
perature.
Preparation:
1. Main hydraulic oil temperature at 50±5 °C (122±9
°F). Rotate the travel motor to warm the inside of
the motor.
2. Stop the engine. Push air bleed valve (1) on top
of the hydraulic oil tank and release any remain-
ing pressure.
3. Disconnect drain hose (2) in the travel motor at
the travel motor end. Install plug (ST 6637) to the
disconnected end. Connect the drain hose
T157-05-04-014
(3/4-16UN) to the travel motor.
: 27 mm 2
: 78 N⋅m (8.0 kgf⋅m, 58 lbf⋅ft)
M178-07-047
T4-5-26
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
Evaluation:
Refer to Operational Performance Standard in T4-2.
ΔQ = 60 × q / t
Where:
ΔQ : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-27
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)
T4-5-28
OPERATIONAL PERFORMANCE TEST / Adjustment
ENGINE SPEED ADJUSTMENT AND
ENGINE LEARNING
5. Loosen the bolt holding the control lever to the EC Holding Bolt
motor output shaft.
Control Lever T157-07-04-015
6. While monitoring the actual engine speed with Dr.
ZX or the engine speed meter, adjust the control
lever so that the minimum speed (slow idle)
matches the specification.
Specification: Refer to T4-2 OPERATIONAL PER
FORMANCE TEST.
T4-6-1
OPERATIONAL PERFORMANCE TEST / Adjustment
Engine Learning:
1. Turn the key switch OFF
Learning
NOTE: In case the engine doesn’t stop when the Switch
key switch is turned OFF, pull the handle
located under the seat to stop the engine.
Dr.ZX
2. Disconnect Dr. ZX. Wait for 5 seconds. Connector
to MC
3. Turn the learning switch ON.
Learning Switch is
Turned to Stamp E
Learning Switch
Stamp
T4-6-2
OPERATIONAL PERFORMANCE TEST / Adjustment
(Blank)
T4-6-3
OPERATIONAL PERFORMANCE TEST / Adjustment
GOVERNOR LEVER AND FUEL CUT
LEVER POSITION
1 2
T1HH-04-02-002
4 3
T4-6-4
OPERATIONAL PERFORMANCE TEST / Adjustment
• Governor Lever Position
B
FULL
A: STOP
FULL
STOP
T1HH-04-02-002
B A
T1HH-04-02-002
T4-6-5
OPERATIONAL PERFORMANCE TEST / Adjustment
(Blank)
T4-6-6
MEMO
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SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 Introduction Group 3 Troubleshooting A
Introduction .............................................. T5-1-1 Troubleshooting A Procedure .................... T5-3-1
Diagnosing Procedure .............................. T5-1-2 Fault Code List.......................................... T5-3-2
Built-in Diagnosing System Operation ...... T5-1-6 Fault Code 01 (Abnormal Eeprom) .......... T5-3-3
Built-in Diagnosing FunctionDisplay List... T5-1-7 Fault Code 02 (Abnormal Ram) .............. T5-3-3
Dr.ZX Operation ....................................... T5-1-8 Fault Code 03
Dr.ZX Fault Code List ............................. T5-1-10 (Abnormal A/D Conversion) ............... T5-3-3
Dr.ZX Monitoring Item List ...................... T5-1-12 Fault Code 04
Dr.ZX Special Function ........................... T5-1-14 (Abnormal Sensor Voltage) ................ T5-3-3
Dr.ZX Service Mode ............................... T5-1-15 Fault Code 06 (Abnormal EC Sensor)....... T5-3-4
Adjustment Data List .............................. T5-1-25 Fault Code 07
(Abnormal Engine Control Dial Angle)....... T5-3-5
Group 2 Component Layout
Fault Code 10
Main Component Layout........................... T5-2-1
(Abnormal Pump 1 Delivery Pressure) ...... T5-3-6
Electrical Component Layout (Overview).. T5-2-2
Fault Code 11
Electrical System (Relays)........................ T5-2-3
(Abnormal Pump 2 Delivery Pressure) ...... T5-3-6
Electrical System
Fault Code 12
(Monitors and Switches) .................... T5-2-4
(Abnormal Pump 1 Control Pressure) ....... T5-3-7
Engine ...................................................... T5-2-5
Fault Code 13
Pump Device ............................................ T5-2-5
(Abnormal Pump 2 Control Pressure) ....... T5-3-7
Swing Device............................................ T5-2-5
Fault Code 14
Control Valve ............................................ T5-2-6
(Abnormal Swing Pilot Pressure) .............. T5-3-8
Travel Device............................................ T5-2-6
Fault Code 15
Shockless Valve ....................................... T5-2-6
(Abnormal Boom Raise Pilot Pressure)..... T5-3-8
Solenoid Valve Unit .................................. T5-2-6
Fault Code 16
Positioning Control Valve.......................... T5-2-6
(Abnormal Arm Roll-in Pilot Pressure) ...... T5-3-8
Components in Control Valve ................... T5-2-8
Fault Code 18
(Abnormal Travel Pilot Pressure) .............. T5-3-8
Fault Code 19
(Abnormal Oil Temperature)...................... T5-3-9
BWAT-5-1
Group 4 Troubleshooting B Group 6 Electrical System Inspection
Troubleshooting B Procedure ................... T5-4-1 Precautions for Inspection and
Relationship Between Machine Maintenance ...................................... T5-6-1
Trouble Symptoms and Related Instructions for Disconnecting
Parts.................................................. T5-4-2 Connectors ........................................ T5-6-3
Correlation Between Trouble Fuse Inspection ........................................ T5-6-4
Symptoms and Part Failures ........... T5-4-20 Fusible Link Inspection ............................. T5-6-5
Engine System Troubleshooting ............. T5-4-31 Battery Voltage Check .............................. T5-6-6
All Actuator System Troubleshooting ...... T5-4-52 How to Troubleshoot Alternator
Front Attachment System Malfunctions ...................................... T5-6-7
Troubleshooting............................... T5-4-59 Continuity Check....................................... T5-6-8
Swing System Troubleshooting............... T5-4-72 Voltage and Current Measurement ......... T5-6-11
Travel System Troubleshooting .............. T5-4-75 Check by False Signal ............................ T5-6-15
Other System Troubleshooting ............... T5-4-82 Test Harness........................................... T5-6-16
Exchange Inspection .............................T5-4-102
Emergency Boom Lowering Group 7 ICX
Procedure.......................................T5-4-104 Outline ...................................................... T5-7-1
ICX Fault Code List................................... T5-7-8
Group 5 Troubleshooting C Satellite Terminal Fault Code List.............. T5-7-8
Troubleshooting C (Troubleshooting for Fault Code 1 to 4 and 6 ............................ T5-7-9
Monitor) Procedure............................ T5-5-1 Fault Code 7 to 10 .................................... T5-7-9
Malfunction of Coolant Some Parts of Data in DailyReport,
Temperature Gauge........................... T5-5-2 Frequency Distribution, Cumulative
Malfunction of Fuel Gauge........................ T5-5-4 Operation Hours are not Recorded .. T5-7-10
Malfunction of Indicator Light
Check System ................................... T5-5-6
Malfunction of Preheat Indicator ............... T5-5-7
Malfunction of Alternator Indicator ............ T5-5-8
Malfunction of Engine Oil
Pressure Indicator ........................... T5-5-10
Malfunction of Overheat Indicator ........... T5-5-12
Malfunction of Air Filter Restriction
Indicator .......................................... T5-5-14
Malfunction of Buzzer ............................. T5-5-16
Malfunction of LCD ................................. T5-5-18
Malfunction of Hour Meter ...................... T5-5-19
Malfunction of Hydraulic Oil
Filter Indicator(Optional) ......................... T5-5-20
BWAT-5-2
TROUBLESHOOTING / General
INTRODUCTION
Refer to the inspection and troubleshooting proce- • Troubleshooting B (base machine diagnosis start-
dures after any machine trouble has occurred. The ing with inspection of abnormal operational
inspection and troubleshooting procedures are pre- status)
sented in an orderly fashion in this section to quickly Refer to these procedures when no fault codes
find the cause of the machine trouble and solution. are displayed after diagnosing the machine with
Dr. ZX (or the built-in diagnosing system). Trace
The troubleshooting section in this manual consists of the cause of trouble based on the inspected re-
7 groups; General, Component Layout, Troubleshoot- sult of the abnormal symptom.
ing A (base machine diagnosis using fault codes),
Troubleshooting B (base machine diagnosis starting Example: Even if the engine control dial is oper-
with inspection of abnormal operational status), Trou- ated, engine speed remains unchanged.
bleshooting C (monitor diagnosis), Electrical System
Inspection, and ICX. • Troubleshooting C (monitor diagnosis)
Refer to these procedures when gauges and/or
• General indicators are malfunctioning.
T5-1-1
TROUBLESHOOTING / General
DIAGNOSING PROCEDURE
T107-07-01-002
T5-1-2
TROUBLESHOOTING / General
3. Inspect the machine
Before starting the troubleshooting procedure,
check the machine’s daily maintenance points, as
shown in the operator's manual.
T5-1-3
TROUBLESHOOTING / General
5. Perform troubleshooting
CAUTION: Never attempt to disconnect
harnesses or hydraulic lines while the engine
is running. The machine may malfunction or
pressurized oil may spout, possibly resulting
in personal injury. Be sure to stop the engine
before disconnecting harnesses or hydraulic
lines.
T5-1-4
TROUBLESHOOTING / General
(Blank)
T5-1-5
TROUBLESHOOTING / General
BUILT-IN DIAGNOSING SYSTEM OPERA-
TION
T5-1-6
TROUBLESHOOTING / General
BUILT-IN DIAGNOSING FUNCTION DISPLAY LIST
Display
Description Monitored Result Unit Remarks
Order
1 Hour Meter {{{{{ h Standard Mode
2 Trip 1 {{{{{ h Standard Mode (Subtraction)
3 Trip 2 {{{{{ h Standard Mode (Subtraction)
-1
4 Engine Actual Speed n {{{{ min User Mode (Required to set
in the Dr. ZX service mode)
5 Hydraulic Oil Tempera- {{{ °C User Mode (Required to set
ture in the Dr. ZX service mode)
6 L1 {{{ - Display Purpose Only
7 Overload Alarm L2 {{{ % European Spec. Only
8 Fault Code* 0 {{ -
9 ML Switch** 1 {{ 0: Switch OFF
1: Switch ON
10 Pump 1 Delivery Pres- 2 {{ MPa
sure
11 Pump 2 Delivery Pres- 3 {{ MPa
sure
12 Pump 1 Pump (Flow) 4 {{ MPa
Control Pressure
13 Pump 2 Pump (Flow) 5 {{ MPa
Control Pressure
-1
14 Engine Target Speed 6 {{ min
15 EC Angle 7 {{ V
16 Dial Angle 8 {{ V
17 Boom Raise Pilot Pres- 9 {{ MPa
sure
18 Arm Roll-In Pilot Pres- A {{ MPa
sure
19 Swing Control Pilot b {{ MPa
Pressure
20 Travel Control Pilot c {{ MPa
Pressure
21 Front Att. Operation d {{ 0: Not Operating
1: Operating
22 Att. Control Pressure E {{ MPa
23 Work Mode F {{ 0: Digging
1: Breaker
2: Secondary
Crusher
(Demolisher)
3: Crusher
4: Vibro-Hammer
T5-1-7
TROUBLESHOOTING / General
Dr. ZX OPERATION
Rear Console
Dr. ZX is a troubleshooting tool to diagnose the elec- Fuse Box
tronic control system including the MC (main Control-
ler) and ICX (Information Controller). When Dr. ZX is Dr. ZX
connected to either the MC or the ICX, it displays Connector
whether the controllers and sensors operate normally (MC)
in the form of fault codes (Self-Diagnosing Result Dis-
play Function).
In addition, Dr. ZX can display the inputs from sensors
and switches to the MC and/or the outputs to actua-
tors such as solenoid valves from the MC in real time
while operating the machine (Monitor Display Func-
tion).
Palm
(Dr. ZX)
Battery Box
Cable
T178-05-01-167
T5-1-8
TROUBLESHOOTING / General
Operation
1. Connect palm (Dr. ZX) to the diagnosis connec-
tors (MC and ICX) located in the cab, using Hot Start
Sync cable and battery box cable.
Self-diagnostic
Result by control- Enter model
ler is displayed Record
code and serial
No.
Retry B
Select data to
be monitored
Self-diagnostic
Result is displayed Monitored data
is displayed
T5-1-9
TROUBLESHOOTING / General
DR. ZX FAULT CODE LIST
T5-1-10
TROUBLESHOOTING / General
(Blank)
T5-1-11
TROUBLESHOOTING / General
Dr. ZX MONITORING ITEM LIST
T5-1-12
TROUBLESHOOTING / General
Optional
Item Data Unit
Optional Pump 3 Delivery Pressure Input signal from pump 3 delivery pressure sen- MPa
sor
Boom Cylinder Bottom Pressure MPa
Boom Cylinder Rod Pressure MPa
ATT. Control Pressure Input signal from pressure sensor (auxiliary) MPa
Boom Angle V
Arm Angle V
Pump 1 Max. Displacement cm3
Pump 1 Proportional Solenoid Valve Control signal to pump 1 flow rate control sole- MPa
Output noid valve
Travel/Swing/Overload Alarm Tr, Sw, Load
Initial ML Setting Unf, Done, Abrt,
Und
Initial Boom-Angle Setting Unf, Done, Abrt,
Und
T5-1-13
TROUBLESHOOTING / General
Dr. ZX SPECIAL FUNCTION
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS330.
Special function
Execute Execute
T5-1-14
TROUBLESHOOTING / General
Dr. ZX SERVICE MODE
Stamped
Mark E
T1CC-05-01-001
T5-1-15
TROUBLESHOOTING / General
Item Data
Learning Data Display
EC Motor Stop Position Display of the engine stop value in engine learning
EC Motor Maximum Speed Position Display of max. engine speed valve in engine learning
Boom Angle Sensor Correction Value Display of boom angle sensor correction value
Arm Angle Sensor Correction Value Display of arm angle sensor correction value
Parameter Change
Li Speed Adjustment Adjustment of minimum engine speed
WU Speed Adjustment Adjustment of warming up engine speed
AI Speed Adjustment Adjustment of auto-idle engine speed
E Speed Adjustment Adjustment of E-mode engine speed
P Speed Adjustment Adjustment of P-mode engine speed
Breaker Engine Speed Adjustment Adjustment of breaker operation engine speed
Secondary Crusher (Demolisher) Engine Adjustment of secondary crusher (demolisher) operation
Speed Adjustment engine speed
Crusher Engine Speed Adjustment Adjustment of crusher operation engine speed
Vibro-Hammer Speed Adjustment Adjustment of vibratory hammer operation engine speed
Hyd. Breaker P1 Max Swash Angle Adjustment of lowest pump 1 max. flow rate in breaker
Adjustment operation
Secondary Crusher (Demolisher) P1 Max Adjustment of lowest pump 1 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P1 Max Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in crusher
operation
Vibro P1 Max Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in vibratory
hammer operation
Hyd. Breaker P2 Max Swash Angle Adjustment of lowest pump 2 max. flow rate in breaker
Adjustment operation
Secondary Crusher (Demolisher) P2 Max Adjustment of lowest pump 2 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P2 Max Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in crusher
operation
Vibro P2 Max Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in vibratory
hammer operation
Pump PQ Base Torque Correction Adjustment of pump P-Q curve
ATT Speed Increase Down Waiting Time Setting of time required for engine speed increase
Min, Boom CYL. Bottom Pressure Over
Balance
Monitor Display Change
Engine Actual Speed Display/Non-display Monitor setting of display/no-display of actual engine speed
Hydraulic Oil Temperature Display/No-display Monitor setting of display/no-display of hydraulic oil
temperature
Hydraulic Oil Filter LED Display/No-display Monitor setting of ON/OFF of hydraulic oil filter LED.
NOTE: ML specification is only available in Japanese domestic market.
T5-1-16
TROUBLESHOOTING / General
(Blank)
T5-1-17
TROUBLESHOOTING / General
Displaying Engine Learning Data and Angle Sensor Correction Valve
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS330.
T5-1-18
TROUBLESHOOTING / General
EC Motor stop position EC Motor Maximum Boom angle sensor Arm angle sensor correction
engine speed position correction value value
T5-1-19
TROUBLESHOOTING / General
Changing Parameters In The Controller
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS330.
Start the service mode on the condition that the engine learning switch is turned on.
To change the parameter, it is necessary to enter the password. To change the password, refer to the “Changing the password”
section.
The menu will be displayed. Enter the password to change Select the item you want to change. The
Select Parameter Change from the parameter. up- and down-arrow buttons can be
the menu. used to scroll through the item list.
Fig. F
Fig. E T178-05-01-042
T178-05-01-043
Fig. G
Select ESC to return T178-05-01-044
Select ESC to return to Fig. E. Select ESC to return
to Fig. D. to Fig. E.
T5-1-20
TROUBLESHOOTING / General
Enter the new value Confirm the new value Parameter adjustment
result
Enter the new value in the The new value will be displayed
The adjusted value will be
Adjustment space, and press in the Adjustment space. Select
displayed.
Execution. Execute to change to this value.
T5-1-21
TROUBLESHOOTING / General
Changing The User Mode Display on The Monitor Panel
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS330.
Start the service mode on the condition that the engine learning switch is turned on.
T5-1-22
TROUBLESHOOTING / General
T5-1-23
TROUBLESHOOTING / General
T5-1-24
TROUBLESHOOTING / General
ADJUSTMENT DATA LIST
T5-1-25
TROUBLESHOOTING / General
(Blank)
T5-1-26
TROUBLESHOOTING / Component Layout
MAIN COMPONENT LAYOUT
1
3
4
5
6
7
8 9
21
10
11
12
13
20 14
15
19 16
18 17 T1HH-01-02-001
1- Bucket Cylinder 7- Fuel Tank 13- Intercooler 19- Pilot Shut-Off Valve
2- Arm Cylinder 8- Hydraulic Oil Tank 14- Radiator 20- Travel Pilot Valve
3- Boom Cylinder 9- Control Valve 15- Oil Cooler 21- Front Attachment/Swing
Pilot Valve
4- Center Joint 10- Pilot Filter and Pilot Relief Valve 16- Battery
5- Swing Bearing 11- Pump Device 17- Travel Device
6- Swing Device 12- Engine 18- Shockless Valve
T5-2-1
TROUBLESHOOTING / Component Layout
ELECTRICAL COMPONENT LAYOUT
(Overview)
1 2
• Pressure Sensor
(Front Attachment)
• Pressure Sensor
(Travel)
Refer to the Control Valve
group.
6, 7
14
13
12
• Pump 1 Delivery Pressure Sensor
• Pump 2 Delivery Pressure Sensor
• N Sensor
11 Refer to the Pump Device group.
8
• Coolant Temperature Switch
(Engine Preheat Circuit)
• Engine Oil Pressure Switch
• *Engine Oil Level Switch
• Coolant Temperature Sensor
• Overheat Switch
10 Refer to the Engine group
9
T1HH-01-02-002
1 - Wiper Motor 5 - Pump 1 Control Pressure 9 - Battery Relay 13 - Air Cleaner Restriction Switch
sensor (4-Spool Side)
2 - Horn 6 - EC Motor 10 - Ambient Temperature Sensor
3 - Work Light 7 - EC Sensor 11 - Battery 14 - Pressure Sensor (Boom Raise)
4 - Fuel Sensor 8 - Pump 2 Control Pressure 12 - Starter Relay Pressure Sensor (Arm Roll-In)
sensor (5-Spool Side) Pressure Sensor (Swing)
Torque Control Solenoid Valve
Pump 2 Flow Rate Control
Solenoid Valve
T5-2-2
TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM (Relays)
Rear Deck
5
4
3 6
2
8
9
10
T178-01-02-006
15
14
19
18 13
17 12
16 11
T178-01-02-007
1 - GPS ON/OFF Switch 6 - Fuse Box 11 - Load Damp Relay (R1) 16 - Wiper Relay A (R6)
(Satellite Navigation System
Equipped Machines only)
2 - QOS Controller 7 - Learning Switch 12 - Washer Relay (R2) 17 - Wiper Relay B1 (R7)
3 - ICX (Information Controller) 8 - Dr. ZX Connector to MC 13 - Work Light Relay 2 (R3) 18 - Wiper Relay B2 (R8)
4 - MC (Main Controller) 9 - Download Connector 14 - Work Light Relay 1 (R4) 19 - Wiper Relay B3 (R9)
(Not connected in Satellite
Terminal equipped machines)
5 - Satellite Terminal (Optional) 10 - Dr. ZX Connector to ICX 15 - Horn Relay (R5)
T5-2-3
TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM
(Monitors and Switches)
1 2
20
19
21
18
3
17
22
16 4
15
23
5
14 24
6
13 7
12 8
25
11
9
10
T178-01-01-003
T178-01-01-004
1 - Coolant Temperature 8 - Alternator Indicator 14 - Attachment Mode Indicator 20 - Power Mode Switch
Gauge
2 - Fuel Gauge 9 - Hydraulic Oil Filter 15 - Liquid Crystal Display 21 - Travel Mode Switch
Indicator (Optional)
3 - Display Selection Switch 10 - Engine Oil Pressure 16 - Auto-Idle Indicator 22 - Work Light Switch
Indicator
4 - SET Switch 11 - Preheat Indicator 17 - Auto-Acceleration Indicator 23 - Wiper/Washer Switch
5 - Work Mode Switch 12 - Overheat Indicator 18 - Engine Control Dial
6 - Fuel Level Indicator 13 - Digging Mode Indicator 19 - Auto-Idle/Acceleration
Selector
7 - Air Filter Restriction
Indicator
T5-2-4
TROUBLESHOOTING / Component Layout
ENGINE
1 2
3 4
M1HH-07-001
5
M1HH-07-012
SWING DEVICE
PUMP DEVICE
7 8 9
6
14
10
11
13
12 T1HH-01-02-003
T1HH-01-02-004
1 - Coolant Temperature Switch 5 - Engine Oil Level Switch 9 - N Sensor 12 - Pump 1 Delivery Pressure
(Engine Preheat Circuit) Sensor
2 - Engine Oil Pressure Switch 6 - Regulator (Pump 2) 10 - Regulator (Pump 1) 13 - Pump 2 Delivery Pressure
Sensor
3 - Overheat Switch 7 - Pump 2 11 - Pump 1 14 - Swing Relief Valve
4 - Coolant Temperature Sensor 8 - Pilot Pump
T5-2-5
TROUBLESHOOTING / Component Layout
CONTROL VALVE TRAVEL DEVICE
3 3
1 2
T1HH-01-02-005
4
T1V7-01-02-004
6
7
T1HH-01-02-008
T173-03-06-001
1 - Pressure Sensor (Front) 4 - Travel Relief Valve 7 - Solenoid Valve Unit (SG) 9 - Pressure Sensor (Boom Raise)
2 - Pressure Sensor (Travel) 5 - Solenoid Valve Unit (SC) 8 - Pressure Sensor 10 - Pressure Sensor (Swing)
3 - Counterbalance Valve 6 - Solenoid Valve Unit (SI) (Arm Roll-In) 11 - Overload Relief Valve
(Positioning)
T5-2-6
TROUBLESHOOTING / Component Layout
(Blank)
T5-2-7
TROUBLESHOOTING / Component Layout
COMPONENTS IN CONTROL VALVE 1 2 3 4 5 6 7
Travel Motor (Left)
8
9
39
38 10
11
Bucket
Cylinder
37 12
36 13
35 14
Arm
Cylinder
34
Boom
Cylinder
15
16
17
33 32 31 30 18
19
20
29 28 27 26 25 24 23 22 21
Swing Motor
Pump 2 Pump 1
T1HH-03-03-001
34 22 Machine Front
23
11 Machine Front
20 15
3 30
9
35
7 29
27
5
32
33
14 36
24, 25 21 12 T173-03-03-050 1 39 38 T173-03-03-051
T5-2-8
TROUBLESHOOTING / Component Layout
Machine Front
A
B
C
T1HH-03-03-002
5
6 1
4
2
38
39
3 7
T1HH-03-03-003
T1HH-03-03-004
1 - Pump Control Valve 11 - Overload Relief Valve 21 - Load Check Valve 31 - Arm Anti-Drift Valve:
(In 5-Spool Section) (Bucket) (Arm 2 Tandem Passage) Bottom Side (Switch Valve)
2 - Check Valve 12 - Load Check Valve 22 - Needle Valve 32 - Arm Anti-Drift Valve:
(Main Relief Circuit) (Boom 1 Parallel Passage) Bottom Side (Check Valve)
3 - Main Relief Valve 13 - Boom Regenerative Valve 23 - Boom Anti-Drift Valve 33 - Arm Anti-Drift Valve:
(Switch Valve) Bottom Side (Relief Valve)
4 - Check Valve 14 - Boom Anti-Drift Valve 24 - Orifice 34 - Overload Relief Valve
(Main Relief Circuit) (Check Valve) (Arm)
5 - Flow Combiner Valve 15 - Overload Relief Valve 25 - Load Check Valve 35 - Arm Anti-Drift Valve:
(Boom) (Arm 2 Parallel Passage) Rod Side (Check Valve)
6 - Check Valve (Flow 16 - Arm Regenerative Valve 26 - Load Check Valve 36 - Load Check Valve
Combiner Valve Circuit) (Arm 1 Parallel Passage) (Boom 2 Parallel Passage)
7 - Check Valve With Orifice 17 - Check Valve (Arm 27 - Orifice 37 - Load Check Valve
(Bucket Combination) Regenerative Valve Circuit) (Aux. Parallel Passage)
8 - Bucket Flow Rate Control 18 - Bucket Flow Rate Control 28 - Load Check Valve 38 - Travel Flow Rate Control
Valve (Poppet Valve) Valve (Switch Valve A) (Arm 1 Tandem Passage) Valve
9 - Bucket Flow Rate Control 19 - Bypass Shut-Out Valve 29 - Load Check Valve (Swing) 39 - Load Check Valve
Valve (Switch Valve B) (Travel Tandem Passage)
10 - Bucket Regenerative Valve 20 - Pump Control Valve 30 - Arm Anti-Drift Valve:
(In 4-Spool Section) Rod Side (Switch Valve)
T5-2-9
TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7
Travel Motor (Left)
8
9
39
10
38
11
Bucket
Cylinder
37 12
36 13
35 14
Arm
Cylinder
34
Boom
Cylinder
15
16
17
33 32 31 30 18
19
20
29 28 27 26 25 24 23 22 21
Swing Motor
Pump 2 Pump 1
Boom 2 Boom 1
Auxiliary Bucket 22
11 23
15
8
37
9 14
36 12
9
13
10
15
11
T1HH-03-03-006
T1HH-03-03-005
T5-2-10
TROUBLESHOOTING / Component Layout
Section F Section G
20
35 16
26 17
32 31
27 24, 25
29
21
34
T1HH-03-03-008
33 28 18
T1HH-03-03-007
1 - Pump Control Valve 11 - Overload Relief Valve 21 - Load Check Valve 31 - Arm Anti-Drift Valve:
(In 5-Spool Section) (Bucket) (Arm 2 Tandem Passage) Bottom Side (Switch Valve)
2 - Check Valve 12 - Load Check Valve 22 - Needle Valve 32 - Arm Anti-Drift Valve:
(Main Relief Circuit) (Boom 1 Parallel Passage) Bottom Side (Check Valve)
3 - Main Relief Valve 13 - Boom Regenerative Valve 23 - Boom Anti-Drift Valve 33 - Arm Anti-Drift Valve:
(Switch Valve) Bottom Side (Relief Valve)
4 - Check Valve 14 - Boom Anti-Drift Valve 24 - Orifice 34 - Overload Relief Valve
(Main Relief Circuit) (Check Valve) (Arm)
5 - Flow Combiner Valve 15 - Overload Relief Valve 25 - Load Check Valve 35 - Arm Anti-Drift Valve:
(Boom) (Arm 2 Parallel Passage) Rod Side (Check Valve)
6 - Check Valve (Flow 16 - Arm Regenerative Valve 26 - Load Check Valve 36 - Load Check Valve
Combiner Valve Circuit) (Arm 1 Parallel Passage) (Boom 2 Parallel Passage)
7 - Check Valve With Orifice 17 - Check Valve (Arm 27 - Orifice 37 - Load Check Valve
(Bucket Combination) Regenerative Valve Circuit) (Aux. Parallel Passage)
8 - Bucket Flow Rate Control 18 - Bucket Flow Rate Control 28 - Load Check Valve 38 - Travel Flow Rate Control
Valve (Poppet Valve) Valve (Switch Valve A) (Arm 1 Tandem Passage) Valve
9 - Bucket Flow Rate Control 19 - Bypass Shut-Out Valve 29 - Load Check Valve (Swing) 39 - Load Check Valve
Valve (Switch Valve B) (Travel Tandem Passage)
10 - Bucket Regenerative Valve 20 - Pump Control Valve 30 - Arm Anti-Drift Valve:
(In 4-Spool Section) Rod Side (Switch Valve)
T5-2-11
TROUBLESHOOTING / Component Layout
(Blank)
T5-2-12
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
YES(OK)
(2)
After completing the checking and/or measuring procedures in box (1),
・ (1) select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
(3)
NO(NOT OK)
・ Refer to “Electrical System Inspection” Group (Group 6) for descriptions in the dotted-line
box.
・ Use Dr. EX (or the built-in diagnosing system) for descriptions in the double-line box.
・ Causes of machine problems are stated in the thick-line box. Scanning quickly through the
thick-line boxes allows you to estimate the possible causes before actually following the
flow chart.
Harness
Open End
Side
Harness End Connector
T158-05-03-001
T5-3-1
TROUBLESHOOTING / Troubleshooting A
FAULT CODE LIST
Fault code Problem Cause
01 Abnormal EEPROM • Faulty MC
02 Abnormal RAM
03 Abnormal A/D Conversion
04 Abnormal Sensor Voltage • Faulty MC
• Faulty Harness
• Faulty Sensor
06 Abnormal EC Sensor • Faulty MC
• Faulty Harness
• Faulty EC Sensor
07 Abnormal Engine Control Dial Angle • Faulty MC
• Faulty Harness
• Faulty Engine Control Dial
10 Abnormal Pump 1 Delivery Pressure • Faulty MC
11 Abnormal Pump 2 Delivery Pressure • Faulty Harness
• Faulty Pump Deliver Pressure Sensor
12 Abnormal Pump1 Pump Control Pressure • Faulty MC
13 Abnormal Pump2 Pump Control Pressure • Faulty Harness
• Faulty Pump Control Pressure Sensor
14 Abnormal Swing Lever Stroke • Faulty MC
15 Abnormal Boom Raise Lever Stroke • Faulty Harness
16 Abnormal Arm Roll-In Lever Stroke • Faulty Pilot Pressure Sensor
18 Abnormal Travel Lever Stroke
19 Abnormal Oil Temperature • Faulty MC
• Faulty Harness
• Faulty Oil Temperature Sensor
T5-3-2
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 01 (ABNORMAL EEPROM)
FAULT CODE 02 (ABNORMAL RAM)
FAULT CODE 03
(ABNORMAL A/D CONVERSION)
FAULT CODE 04
(ABNORMAL SENSOR VOLTAGE)
T5-3-3
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 06
(ABNORMAL EC SENSOR) YES Faulty harness be-
Check harness be-
tween MC and EC
tween MC connector
sensor.
YES C (31P) terminal #18
and EC sensor ter-
minal #2 for breakage
or short circuit. Faulty MC.
Disconnect EC sen- NO
sor. Check if voltage
Disconnect EC sensor. YES between harness end · Refer to T4-6-1.
Check if resistance be- connectors #1 and #3
tween sensor side is 5±0.5 V. Check if voltage be- YES Broken harness be-
tween MC and EC
connector terminals #1 tween EC sensor
· Key switch: ON sensor terminal #3.
and #3 is less than harness end connec-
2.0±0.4 kΩ. Connect test tor terminal #1 and
harness between EC NO vehicle frame
sensor and base ma- Broken harness be-
matches specification.
chine side harness. tween MC and EC
· Key switch: ON NO sensor terminal #1.
Check if voltage changes
in accordance with speci- · Specification: 5±0.5 V
fications when engine
control dial is rotated. Faulty EC sensor.
· Test Harness: ST 7129 NO
· Specification: See table be- · Refer to T4-6-1.
low.
EC Sensor Specification
Minimum Speed 2.5 to 2.7 V
Maximum Speed (HP 3.3 to 3.7 V
mode Switch: OFF)
Maximum Speed (HP Voltage at Maximum Speed
mode Switch: ON) (HP Mode Switch: OFF) plus
0.2 V or more
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
C1 C10
C23 C31
#18
EC Sensor
1 2 3
T5-3-4
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 07
(ABNORMAL ENGINE CONTROL DIAL
ANGLE) Faulty harness be-
Check harness be- YES
tween MC connector C tween MC and engine
(31P) harness end ter- control dial.
YES
minal #6 and switch
panel terminal #3 for
breakage or short cir- Faulty MC.
Disconnect switch cuit.
NO
panel. Check if voltage · Refer to T4-6-1.
YES between harness end
Disconnect switch panel. connector terminals #2 Broken harness be-
Check if resistance be- and #4 is 5±0.5 V. YES tween MC and engine
Check if voltage be-
tween switch panel side control dial terminal
· Key switch: ON tween switch panel
connector terminals #2 and #4.
harness end connec-
#4 is 5±0.5 kΩ. tor terminal #2 and
Reconnect switch panel. NO Broken harness be-
vehicle frame
Insert tester probe into tween MC and engine
matches specification.
connector terminal #3 from NO control dial terminal
the reverse side. Check if · Key switch: ON #2.
voltage varies as specified · Specification: 5±0.5 V
when engine control dial is
turned. Faulty engine control
· Specification: See table NO dial.
below.
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#6
C1 C10
C23 C31
Switch Panel
#4 #3 #2
T5-3-5
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 10
(ABNORMAL PUMP 1 DELIVERY PRES-
SURE)
FAULT CODE 11
(ABNORMAL PUMP 2 DELIVERY PRES-
SURE)
Checking Instruction
• Both pump 1 and pump 2 delivery pressure sen-
sors seldom fail at the same time. Accordingly, if
both fault codes 10 and 11 are displayed simulta-
neously, faulty harness may be the cause of this
problem. Faulty harness be-
Check harness be-
YES tween MC and pump
tween MC connector C
delivery pressure
(31P) harness end ter-
sensor.
YES minal #1 (pump 1) or
#4 (pump 2) and pump
delivery pressure sen- Faulty MC.
Disconnect pump de- sor terminal #2 for
livery pressure sensor. breakage or short cir- NO
NO Check if voltage be- · Refer to T4-6-1.
tween harness end
connector terminals #1 Broken harness be-
and #3 is 5±0.5 V Check if voltage be- YES tween MC and pump
tween pump delivery delivery pressure
Check if fault codes are pressure sensor har-
· Key switch: ON sensor terminal #3.
switched after switching ness end connector
pump 1 delivery pressure NO terminal #1 and vehi-
sensor with pump 2 de- Broken harness be-
cle frame matches tween MC and pump
livery pressure sensor specification.
and retrying. NO delivery pressure
· Key switch: ON sensor terminal #1.
· Specification: 5±0.5 V
Faulty pump delivery
YES pressure sensor.
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#1 #4
C1 C10
C23 C31
3 2 1
T5-3-6
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 12
(ABNORMAL PUMP 1 CONTROL PRES-
SURE)
FAULT CODE 13
(ABNORMAL PUMP 2 CONTROL PRES-
SURE)
Checking Instruction
• Both pump 1 and pump 2 control pressure sen-
sors seldom fail at the same time. Accordingly, if
both fault codes 12 and 13 are displayed simul-
taneously, faulty harness may be the cause of
this problem.
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#13 #7
C1 C10
C23 C31
1 2 3
T5-3-7
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 14
(ABNORMAL SWING PILOT PRESSURE)
FAULT CODE 15
(ABNORMAL BOOM RAISE PILOT
PRESSURE)
FAULT CODE 16
(ABNORMAL ARM ROLL-IN PILOT
PRESSURE) Check harness be- Faulty harness be-
FAULT CODE 18 tween MC connector C
YES tween MC and
(ABNORMAL TRAVEL PILOT PRESSURE) (31P) harness end pressure sensor.
YES each corresponding
Checking Instruction terminal and pressure
• All pressure sensors seldom fail at the same time. sensor terminal #2 for
Faulty MC.
breakage or short cir-
Accordingly, if fault codes 14, 15, 16, and 18 are cuit. NO
displayed simultaneously, faulty harness may be · Refer to T4-6-1.
Connector C Terminal:
the cause of this problem. #14: Pressure Sensor (Swing)
Disconnect pressure #2: Pressure Sensor
sensor. Check if volt- (Boom Raise)
age between harness #5: Pressure Sensor
NO end connector termi-
(Arm Roll-In)
nals #1 and #3 is 5±0.5 #3: Pressure Sensor
V. (Travel)
· Key switch: ON
Broken harness be-
Check if fault code dis- tween MC and
appears after switching Check if voltage be- YES
pressure sensor ter-
pressure sensor with an- tween pressure minal #3.
other pressure sensor sensor harness end
and retrying. connector terminal #1
NO and vehicle frame Broken harness be-
Fault Code: matches specification. tween MC and
14: Pressure Sensor (Swing) NO pressure sensor ter-
· Key switch: ON minal #1.
15: Pressure Sensor · Specification: 5±0.5 V
(Boom Raise)
16: Pressure Sensor
(Arm Roll-In) Faulty pressure sen-
18: Pressure Sensor YES sor.
(Travel)
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#2 #3 #5
C1 C10
C23 C31
#14
1 2 3
T5-3-8
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 19
(ABNORMAL OIL TEMPERATURE)
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector B
B1 B8
B19 B25
#22
MC Connector C
C1 C10
C23 C31
#24
1 2
T5-3-9
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-3-10
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
YES (OK)
(2)
• After checking or measuring item (1), select either YES (OK) or
・ (1) NO (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO (NOT OK)
・ • Special instructions or reference item are indicated in the spaces under the box.
Incorrect measuring or checking methods will render troubleshooting impossible,
· Key switch: ON and may damage components as well.
• Explanation of how to use test harness kit required. Refer to “Electrical System
・
Inspection” Group (Group 6) in this section.
・ • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
T5-4-1
TROUBLESHOOTING / Troubleshooting B
RELATIONSHIP BETWEEN MACHINE
TROUBLE SYMPTOMS AND RELATED
PARTS
This table indicates the relationship between machine
trouble symptoms and the potential problem parts,
which may cause trouble if failed, and the evaluation
methods of these components.
Parts
EC Motor EC Sensor
• Moves governor. • Detects minimum governor speed position (2.5 V) only when
key switch is turned ON.
• Detects minimum and maximum speed position when engine
learning is conducted.
Function
• Governor lever doesn’t move. • Engine speed is controlled based on idle position set when
key switch is turned ON. Therefore, engine speed is always
Symptoms in control controlled with error in idle position setting if set incorrectly.
system when trouble
occurs.
• Even if engine control dial is • Error in setting will seldom occur so that change in machine
turned, engine speed doesn’t in- operation will not be noticed.
crease from slow idle speed. • In case error is set on lower side, engine speed changes but
• Engine start may be difficult runs slower than normal through the full range when engine
though starter rotates. control dial is turned. (Note: In case error is set on upper
• Engine will stall if discontinuity side, EC motor is driven so that it runs faster than the control
occurs in EC motor while engine range. However, motor, a worm gear type, holds governor
is running at more than a speci- lever at maximum constant position, preventing engine stall.
fied speed. When engine control dial is turned to minimum speed posi-
• Engine will become uncontrolla- tion, governor lever is returned to idle position.)
Symptoms in machine ble if discontinuity occurs in EC • When starting engine, engine speed fluctuates.
operation when trouble motor while engine is running at • Starting engine is occasionally difficult.
lower than a specified speed.
occurs. Engine cannot be stopped with
key switch.
Others ⎯ ⎯
• Engine is stopped by EC motor. • If EC sensor is faulty, engine learning is not performed.
(Engine stop motor is not pro-
vided.)
NOTE Fuel cut-off cable is provided.
T5-4-2
TROUBLESHOOTING / Troubleshooting B
Engine Control Dial Pump Control Pressure Sensor Pump 1 Delivery Pressure Sensor
• Indicates governor lever position (engine • Monitors pump control pressure to con- • Monitors pump delivery pressure to con-
target speed). trol auto-acceleration system and travel trol HP mode, auto-acceleration, slow
motor swash angle controls. speed torque increase, auto power lift
and travel motor swash angle controls.
• Engine speed doesn’t change even if • No signals arrive to MC • If pump delivery pressure sensor output
engine control dial is turned. is 0 or 5 V, following symptoms will be
• If discontinuity or short circuit occurs in presented by back-up mode function.
engine control dial, target speed of 1600
-1
min is used as back-up value.
• Engine speed is kept unchanged from • Auto-acceleration control is inoperable • HP mode is inoperable.
-1
1600 min . (Auto-idle system functions. (but not noticeable). • Auto-acceleration control is inoperable.
Engine can be stopped by key switch.) • Travel speed is kept in slow mode, not • Machine mistakes occasionally when
allowing to automatically change to fast traveling at slow idle speed.
mode. • Boom raise power is weak during digging
operation.
• Travel speed is kept in slow mode, not
allowing to automatically change to fast
mode.
Fault code 07 is displayed. Fault codes 12 and 13 are displayed. Fault codes 10 is displayed.
Monitor Item: Engine Target Speed, Dial An- Monitor Item: Pump 1 and 2 pump control Monitor Item: Pump 1 delivery pressure
gle (Displayed by built-in diagnosing sys- pressure (Displayed by built-in diagnosing (Displayed by built-in diagnosing system)
tem) system)
⎯ ⎯ ⎯
⎯ ⎯ ⎯
• Evaluation by Dr. ZX
• Broken Circuit: 0.25 V or less
Short Circuit: 4.75 V or more ⎯
T5-4-3
TROUBLESHOOTING / Troubleshooting B
Symptoms in control • If pump delivery pressure sensor output is 0 or • Engine stalls if pump torque is increased.
5 V, following symptoms will be presented by
system when trouble back-up mode function.
occurs.
• HP mode is inoperable. • Engine stalls if pump torque is increased.
• Auto-acceleration control is inoperable.
• Machine mistakes occasionally when traveling
at slow idle speed.
• Arm is slow when arm roll-in and swing com-
bined operation is made.
• Travel speed is kept in slow mode, not allowing
to automatically change to fast mode.
Symptoms in machine
operation when trouble
occurs.
Using Test
⎯ ⎯
Harness
Others ⎯ ⎯
NOTE ⎯ ⎯
T5-4-4
TROUBLESHOOTING / Troubleshooting B
Pressure Sensor
Pressure Sensor (Travel) Pressure Sensor (Swing)
(Front Attachment)
• Monitors travel pilot pressure to control • Monitors front attachment pilot pressure • Monitors swing pilot pressure to control
auto-idle, auto-acceleration, idle to control auto-idle, and idle speed-up arm regenerative system.
speed-up, slow speed torque increase, systems.
and travel motor swash angle controls.
• Engine speed doesn’t increase even if • Engine speed doesn’t increase even if • Since arm regenerative function is inop-
auto-idle/auto-acceleration selector is any front attachment actuator is operated erable, when swing/arm roll-in combined
auto-idle position. with auto-idle/auto-acceleration selector operation is made, initial arm moving
• Engine speed doesn’t increase even if is auto-idle position. speed is slow. (Not remarkable)
auto-idle/auto-acceleration selector is • Occasionally, engine speed hunts while • During arm level crowding operation, arm
auto-acceleration position. operating front attachment at slow idle. speed is slightly slow.
• Occasionally, engine speed hunts while
traveling at slow idle.
• If there is a difference in delivery flow rate
between pumps 1 and 2, machine may
mistrack when traveling at minimum
speed. (Not remarkable)
• Fast travel mode cannot be selected
even if travel mode switch is turned to the
FAST position.
⎯ ⎯ ⎯
⎯ ⎯ ⎯
• Judge if pressure sensor is faulty or port • Judge if pressure sensor is faulty or port • Judge if pressure sensor is faulty or port
is clogged by switching pressure sensor is clogged by switching pressure sensor is clogged by switching pressure sensor
with another pressure sensor. with another pressure sensor. with another pressure sensor.
T5-4-5
TROUBLESHOOTING / Troubleshooting B
Function
Using Test
⎯ ⎯
Harness
Others ⎯ ⎯
• Judge if pressure sensor is faulty or port is • Judge if pressure sensor is faulty or port is
clogged by switching pressure sensor with an- clogged by switching pressure sensor with an-
other pressure sensor. other pressure sensor.
NOTE
T5-4-6
TROUBLESHOOTING / Troubleshooting B
• No signals arrive to MC • If torque control solenoid valve is not ac- • In case solenoid valve unit (SG) is not
tivated, output pressure from solenoid activated, pressure at port SG becomes
2 2
valve is 0 MPa (0 kgf/cm ). 0 MPa (0 kgf/cm ).
• Engine speed doesn’t increase when at- • Even if speed sensing system doesn’t In case solenoid valve unit (SG) is closed:
tachment is operated. work, upper limit power is restricted so • Relief pressure stays at normal 31.4 MPa
• When attachment is operated, operation that machine is operable.
2
(320 kfg/cm ). Even if power digging
speed increases. • Machine may occasionally mistrack when switch is pressed, relief pressure doesn’t
traveling at slow idle speed. increase. Power doesn’t increase.
⎯ ⎯ ⎯
Monitor Item: ATT Control Pressure (dis- Monitor Item: Pump Torque Proportional Monitor Item: Power Digging (Boost) Control
played built-in diagnosing system). Solenoid Valve Output Pressure
Monitor pressure change while operating
attachment.
⎯ ⎯ ⎯
• Judge if pressure sensor is faulty or port • Proportional solenoid valve is used as an
is clogged by switching pressure sensor ON/OFF valve. Therefore, even if power
with another pressure sensor. digging switch is pressed or released,
lamp will come ON when normal. In case
⎯ lamp goes OFF, it may be due to broken
harness.
T5-4-7
TROUBLESHOOTING / Troubleshooting B
Parts
Solenoid Valve Unit (SC) Solenoid Valve Unit (SI)
• Routes return oil from arm cylinder rod side to • When pump delivery pressure is low in fast
bottom side when rolling arm in to increase travel mode, travel motor swash angle is re-
arm speed. duced to increase travel speed.
Function
• In case solenoid valve unit (SC) is not acti- • Fast travel mode cannot be selected.
vated, pressure at port SC becomes 0 MPa (0
2
kgf/cm ). Arm regenerative valve will not oper-
Symptoms in control sys- ate at this time.
tem when trouble occurs.
In case solenoid valve unit (SC) is closed: In case solenoid valve unit (SI) is closed:
• Arm speed is slow in arm level crowd opera- • Even if travel mode switch is turned to FAST
tion. position, fast travel mode cannot be selected.
In case solenoid valve unit (SC) is open: In case solenoid valve unit (SI) is open:
• Arm speed is fast because arm regeneration is • Fast travel mode is always selected.
always operated.
Symptoms in machine
operation when trouble
occurs.
By Fault
⎯ ⎯
Code
By Monitor Monitor Item: Arm Regenerative Proportional Sol. Monitor Item: Travel Motor Control Pressure
Valve Output
Function
Evaluation
Using Test • Install lamp harness (ST 7123) to check output • Install lamp harness (ST 7123) to check output
signals from MC and harness condition. signals from MC and harness condition.
Harness
Others ⎯ ⎯
NOTE ⎯ ⎯
T5-4-8
TROUBLESHOOTING / Troubleshooting B
Max. Pump 1 Flow Rate Limit Solenoid Max. Pump 2 Flow Rate
Valve (Optional) Limit Solenoid Valve N Sensor
• When operating attachment, limits maxi- • When operating attachment, limits • Monitors engine speed to operate en-
mum pump 1 flow rate. maximum pump 2 flow rate. gine speed sensing control.
• In case max. pump 1 flow rate limit solenoid • In case max. pump 2 flow rate limit so- • Speed sensing control is inoperable.
valve is not activated, pressure at output lenoid valve is not activated, pressure at
2 2
port becomes 0 MPa (0 kgf/cm ). output port becomes 0 MPa (0 kgf/cm ).
In case max. pump 1 flow rate limit solenoid In case max. pump 2 flow rate limit sole- • Engine stalls under adverse operating
valve is closed: noid valve is closed: conditions such as at high altitude.
• When operating attachment, operating • When operating attachment, operating
speed doesn’t decrease. speed doesn’t decrease.
In case max. pump 1 flow rate limit solenoid In case max. pump 2 flow rate limit sole-
valve is open: noid valve is open:
• Right travel, bucket, arm and boom speeds • Left travel, arm, boom and swing
are slow because maximum flow rate of speeds are slow because maximum
pump 1 decrease. flow rate of pump 2 decreases.
• Machine mistracks to the right when travel- • Machine mistracks to the left when trav-
ing. eling.
⎯ ⎯ ⎯
Monitor Item: Actual engine speed (If N
sensor fails, engine speed is not meas-
ured.)
⎯ ⎯
⎯ ⎯ ⎯
⎯ ⎯ ⎯
• Even if signals from N sensor are not
delivered due to broken circuit or poor
sensor installation, few changes in op-
erational performance occur, making
⎯ ⎯ troubleshooting difficult. Use monitor
function.
T5-4-9
TROUBLESHOOTING / Troubleshooting B
Parts
Hydraulic Oil Temperature Sensor Engine Learning Switch
• Monitors hydraulic oil temperature to control • Starts engine learning.
auto-warming up and arm regenerative control. ON: 0V→Learning
OFF: 5V→Normal Control
Function
• Even if oil temperature is lower than 0 °C, • Machine will operate normally problem is
auto-warming up control doesn’t operate so that caused by broken circuit or discontinuity of
engine runs at idle speed when engine is switch. (Only learning cannot be performed.)
started. • If short circuit occurs, learning mode operation
• When oil temperature is lower than 10 °C, arm starts when key switch is turned ON. Therefore,
regenerative control is inoperable. engine will stall at 2 second or 20 seconds after
engine starts.
Symptoms in machine
operation when trouble
occurs.
NOTE ⎯ ⎯
T2-1 T2-1
Descriptions of Control
(Operational Principle
Section in T/M)
T5-4-10
TROUBLESHOOTING / Troubleshooting B
• Broken Circuit: Pressure doesn’t in- • Broken Circuit in Switch: Travel speed • Depending on trouble situations, control
crease. remains unchanged in slow mode (5V). system malfunction may differ. (The fol-
• Short Circuit: Pressure increases for 8 • Short Circuit in Switch: lowing symptoms in machine operation
seconds after turning key switch and Travel speed remains unchanged in fast indicates that MC logic circuit has failed.)
stops increasing. mode (0V).
• Power digging control doesn’t operate if • Even if travel mode selector is turned to • Even if key switch is turned ON, EC mo-
broken circuit or short circuit occurs. the FAST position, fast travel mode can- tor will not move to the START position
not be selected. so that engine cannot start. Even though
• Even if travel mode selector is turned to engine starts, speed stays slow.
the SLOW position, fast travel mode is • Since pump displacement is held at
operated. minimum, all actuator speeds are slow.
Monitor Item: Power Digging (Boost) Switch Monitor Item: Travel Mode
⎯
⎯ ⎯ ⎯
⎯ ⎯ ⎯
• Before suspecting a failure in MC, be
sure to check the fuses in control system.
If any sensor in 5 V system is
short-circuited, all sensor fault codes will
⎯ ⎯ be displayed.
T5-4-11
TROUBLESHOOTING / Troubleshooting B
• Broken Circuit: Auto-idle system is inoperable. • Broken Circuit: Auto-acceleration control is in-
• Short Circuit: Even if auto-idle/auto-acceleration operable.
selector is OFF, auto-idle control is always per- • Short Circuit: Even if auto-idle/auto-acceleration
formed. selector is OFF, auto-acceleration control is al-
Symptoms in control ways performed.
system when trouble
occurs.
Symptoms in machine
operation when trouble
occurs.
By Fault
⎯ ⎯
Code
Monitor Item: Auto-Idle/Auto-Accel Switch Monitor Item: Work Mode Switch
By Monitor
Evaluation Function
Using Test
⎯ ⎯
Harness
Others ⎯ ⎯
NOTE ⎯ ⎯
T5-4-12
TROUBLESHOOTING / Troubleshooting B
• Broken Circuit: Even if HP mode is se- • Broken Circuit: Even if E mode is se-
lected, HP mode is inoperable. lected, engine speed doesn’t decrease.
• Short Circuit: Even if HP mode switch is • Short Circuit: Engine speed doesn’t in-
turned OFF, HP mode system is not de- crease to the maximum. Auto-idle control
activated. Attachment speed increase is inoperable.
control (optional) becomes inoperable. ―
⎯ ⎯ ⎯
Monitor Item: E/P/HP Mode Switch Monitor Item: E/P/HP Mode Switch Monitor Item: Work Mode Switch
⎯ ⎯ ⎯
⎯ ⎯ ⎯
⎯ ⎯ ⎯
T5-4-13
TROUBLESHOOTING / Troubleshooting B
• When operating attachment, engine speed is • When operating attachment, engine speed is
not controlled. not controlled.
Symptoms in control
system when trouble
occurs.
• Even if auxiliary valve is operated, engine • Even if auxiliary valve is operated, engine
speed doesn’t increase. speed doesn’t increase.
• Even if attachment mode is selected, maximum • Even if attachment mode is selected, maximum
engine speed doesn’t decrease. engine speed doesn’t decrease.
Symptoms in machine
operation when trouble
occurs.
By Fault
⎯ ⎯
Code
Monitor Item: Work Mode Switch
By Monitor
⎯
Evaluation Function
Using Test
⎯ ⎯
Harness
Others ⎯ ⎯
NOTE ⎯ ―
T5-4-14
TROUBLESHOOTING / Troubleshooting B
Flow Combiner Valve Travel Flow Control Valve Bucket Flow Control Valve
• Supplies hydraulic oil to both right and • To ensure pressure oil to raise boom • To restrict the bucket circuit to assist
left travel spools from pump 1 during when travel and boom raise functions are boom to raise when a combined opera-
combined operation of travel and operated at the same time. tion of bucket, arm roll-in, and boom raise
front/swing. is made.
• During combined operation of travel and • Oil flow is not restricted properly. • Always restrict the bucket circuit if switch
front/swing, insufficient oil is supplied to valve is seized in operation.
left travel spool.
• While traveling, when front/swing lever is • If fully closed, shock increases when • Bucket speed decreases if poppet valve
operated, machine mistracks to the left. travel combined operation is made. is seized or switch valve is seized so that
• If fully opened, boom is not raised when the poppet valve is closed.
the combined operation of travel down a • Boom does not rise when the combined
slope and boom raise with bucket loaded operation of bucket, arm roll-in, and
is made. (Boom raise single operation boom raise is made with poppet valve
can be achieved.) fully opened, or if switch valve is seized
so that poppet valve is fully opened.
⎯ ⎯ ⎯
⎯ ⎯ ⎯
⎯ ⎯ ⎯
⎯ ⎯ ⎯
― ⎯ ⎯
T5-4-15
TROUBLESHOOTING / Troubleshooting B
• The same as described be- • Arm regenerative function does • The same as described be-
low. not operate. low.
Symptoms in control
system when trouble
occurs.
• If check valve is kept closed, • Arm speed is very slow when • If check valve is kept closed,
boom lower speed decreases. leveling. bucket is not smoothly rolled
• If check valve is kept opened, in.
jacking up the machine using • If check valve is kept opened,
the front attachment is diffi- bucket power is weak.
cult.
Symptoms in machine
operation when trouble
occurs.
By Fault
⎯ ⎯ ⎯
Code
By Monitor
Evalua- ⎯ ⎯ ⎯
Function
tion
Using Test
⎯ ⎯ ⎯
Harness
Others ⎯ ⎯ ⎯
NOTE ⎯ ⎯ ⎯
T5-4-16
TROUBLESHOOTING / Troubleshooting B
• Check valve does not open if switch • Check valve does not open if switch • Check valve does not open if switch
valve is seized. valve is seized. valve is seized.
• If check valve does not open, arm roll-in • If check valve does not open, arm roll-out • If check valve does not open, boom is not
speed decreases. speed decreases. lowered.
• If check valve is kept opened, arm drift • If check valve is kept opened, arm drift • If check valve is kept opened, boom drift
increases due to the control valve inner increases due to the control valve inner increases due to the control valve inner
leakage. leakage. leakage.
• According to the degree of seizure in • According to the degree of seizure in • According to the degree of seizure in
check valve, arm roll-in operation be- check valve, arm roll-out operation be- check valve, boom lower operation be-
comes jerky, or slower. comes jerky, or slower. comes jerky, or slower.
⎯ ⎯ ⎯
⎯ ⎯ ⎯
⎯ ⎯ ⎯
⎯ ⎯ ⎯
⎯ ⎯ ⎯
T5-4-17
TROUBLESHOOTING / Troubleshooting B
Parts
Pump Control Valve
Bypass Shut-Off Valve
(4-Spool Side)
• Supplies pressure oil from pump 1 to auxiliary • Operating boom raise/lower, arm roll-in/out,
spool when auxiliary spool is operated. bucket roll-in/out, right travel and auxiliary, flow
rate control pressure Pi is supplied to pump 1
regulator in response to the operation.
Function
Symptoms in control
system when trouble
occurs.
• If spool is bound in the fully opened position, • Seized in neutral, pump 1 is turned the
single attachment operation speed becomes maximum swash angle though the control lever
slow. is in neutral. (If the travel lever is kept at half
• If spool is bound in the fully closed position, stroke, the machine mistracks to the left.)
main relief valve continues to relieve with all • Seized in neutral, pump 1 control pressure
control levers positioned in neutral. sensor indicates the maximum pressure.
• If pump 1 control pressure is monitored, it indi- • Seized with pump control valve operated, pump
cates the maximum value. 1 is kept at the minimum swash angle, operating
• If spool is bound in opened position, when all the control lever.
control levers are in neutral, pump 1 pressure is (Right travel is in operable in single travel
higher than pump 2 pressure. operation. Bucket speed is very slow.)
Symptoms in machine
operation when trouble
occurs.
By Fault
⎯ ⎯
Code
Monitor Item: Pump 1 Delivery Pressure, Pump 1 Monitor Item: Pump 1 Control Pressure.
By Monitor Control Pressure.
Evaluation Function
Using Test
⎯ ⎯
Harness
Others ⎯ ⎯
NOTE ⎯ ⎯
T3-3 T3-3
Descriptions of Control
(Operational Principle
Section in T/M)
T5-4-18
TROUBLESHOOTING / Troubleshooting B
• Pump control pressure of • If spool is bound in the fully • If spool is bound in the fully • If spool is bound in the fully
pump 2 doesn’t change if opened position, swing park- opened position, bucket opened position, boom
pump control valve (5-spool ing brake is kept released. speed becomes slow when doesn’t raise during
side) spool are seized and (Machine vibrates while trav- boom raise and bucket com- 3-combined operation of
the spring is broken. eling.) bined operation is made. bucket, arm roll-in and boom
• If spool is bound in the fully (Bucket flow rate control is raise.
closed position, swing park- inoperable.) • If spool is bound in the fully
ing brake is kept applied. • If spool is bound in the fully closed position, bucket speed
(Dragging is felt.) closed position, boom doesn’t becomes slow in bucket sin-
raise during 3-combined op- gle operation. (Bucket flow
eration of bucket, arm roll-in, rate control is always effec-
and boom raise. tive.)
• Seized in neutral, pump 2 is • Same as described above. • Same as described above. • Same as described above.
turned the maximum swash
angle though the control lever
is in neutral. (If the travel
lever is kept at half stroke,
the machine mistracks to the
right.)
• Seized in neutral, pump 2
control pressure sensor indi-
cates the maximum pressure.
• Seized with pump control
valve operated, pump 2 is
kept at the minimum swash
angle, operating the control
lever.
(Left travel is inoperable in
single travel operation. Swing
speed is very slow.)
⎯ ⎯ ⎯ ⎯
Monitor Item: Pump 2 Control Monitor Item: Pump 2 Control
Pressure. Pressure. ⎯ ⎯
⎯ ⎯ ⎯ ⎯
⎯ ⎯ ⎯ ⎯
⎯ ⎯ ⎯ ⎯
T3-3 T3-3
T5-4-19
TROUBLESHOOTING / Troubleshooting B
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
Parts
MC (Main Controller) z
QOS Controller
EC Motor z
EC Sensor { z
Pump 1 Delivery Pressure
Sensor
Pump 2 Delivery Pressure
Sensor
Pump 1 Control Pressure
Sensor
Pump 2 Control Pressure
Sensor
Pressure Sensor (Travel)
Pressure Sensor
(Front Attachment)
Pressure Sensor (Swing)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Auxiliary)
N Sensor
Hyd. Oil Temperature Sensor
Coolant Temperature Sensor
Key Switch z
Engine Control Dial
Auto-Idle/Acceleration Selector
Power Mode Switch
Work Mode Switch
Auxiliary Mode Switch
Engine Learning Switch z
Battery Relay z
Glow Relay
Engine Electrical Equipment z
Engine Unit z z
Governor z z
Check batteries. Check fuel system Check fuel cut-off handle and engine control
(filters and piping). cable. Be sure to perform engine learning after
Remarks replacing engine.
T5-4-20
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
z z z { z
z { {
{ {
{
{
z {
z
z
z {
z {
z {
Check engine control
cable.
T5-4-21
TROUBLESHOOTING / Troubleshooting B
Parts
MC (Main Controller) z z z
QOS Controller
EC Motor
EC Sensor
Torque Control Solenoid Valve
Pump 1 Delivery Pressure
{
Sensor
Pump 2 Delivery Pressure
{
Sensor
Pump 1 Control Pressure
{
Sensor
Pump 2 Control Pressure
{
Sensor
Pressure Sensor (Travel) {
Pressure Sensor
(Front Attachment)
Pressure Sensor (Swing) {
Auto-Idle/Acceleration Selector z
Remarks
T5-4-22
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
z z z
z
z
z
z z
z z
z
{
Check fuel system for Check batteries.
clogging.
T5-4-23
TROUBLESHOOTING / Troubleshooting B
Parts
MC (Main Controller) z
Torque Control Solenoid Valve {
N Sensor {
Spool
Main Relief Valve {
Main Pump z z z
Regulator { z z
Pilot Pump z
Pilot Valve
Pilot Relief Valve z
Pump Control Valve
z
(4-Spool Side)
Pump Control Valve
z
(5-Spool Side)
Remarks
T5-4-24
TROUBLESHOOTING / Troubleshooting B
A-4 A-5
Actuator doesn’t stop Actuator speed is faster
even if control lever is than normal. Machine
returned to neutral. mistracks when travel
lever is operated at the
half stroke.
Precise control can not
be performed.
T5-4-25
TROUBLESHOOTING / Troubleshooting B
Parts
MC (Main Controller) z
Solenoid Valve Unit (SG) z
Solenoid Valve Unit (SC) z
Pump 1 Delivery Pressure
Sensor
Pump 2 Delivery Pressure
{
Sensor
Pressure Sensor
{
(Swing)
Pressure Sensor
{
(Boom Raise)
Pressure Sensor
{
(Arm Roll-In)
Oil Temperature Sensor
Power Digging Switch z
Spool z
Main Relief Valve z z
Overload Relief Valve z z
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve z
Bucket Regenerative Valve
Travel Flow Rate Control
z
Valve
Bucket Flow Rate Control
Valve
Boom Anti-Drift Valve
Arm Anti-Drift Valve
Needle Valve
Shockless Valve z
Pilot Valve z
Cylinder z
Remarks
T5-4-26
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
z
z
z
z
z
z z z
z z z
z
z
z z
T5-4-27
TROUBLESHOOTING / Troubleshooting B
Parts
MC (Main Controller)
Torque Control Solenoid
Valve
Solenoid Valve Unit (SI)
Pump 1 Delivery Pressure
Sensor
Pump 2 Delivery Pressure
Sensor
Pump 1 Control Pressure
Sensor
T5-4-28
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
T-5 T-6 T-7 O-1 O-2
Occasionally, machine mis- No steering force and no Fast travel is inoperable. Wiper is inoperable or Air Conditioner mal-
tracks when traveling with gradeability when travel Travel mode does not not retracted. function
engine running at slow mode is fast. change from slow mode
speed. to fast mode.
z z
{ {
{ {
{ {
z
z
T5-4-29
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-30
TROUBLESHOOTING / Troubleshooting B
ENGINE SYSTEM TROUBLESHOOTING
T178-05-04-001
T105-07-04-002
T5-4-31
TROUBLESHOOTING / Troubleshooting B
E-2 Although starter rotates, engine doesn’t
start.
Faulty engine.
YES
· Key switch: ON
Check EC motor drive circuit.
NO
T1HH-04-02-002
4 3
T5-4-32
TROUBLESHOOTING / Troubleshooting B
• Governor Lever Position
B
FULL
A: STOP
FULL
STOP
T1HH-04-02-002
B A
T1HH-04-02-002
T5-4-33
TROUBLESHOOTING / Troubleshooting B
E-3 When engine control dial is fully rotated,
engine stalls.
Occasionally engine stalls during operation
with engine control dial fully rotated and
auto-idle ON.
Engine speed is slower than specification in
all operating ranges.
Idle speed is faster or slower than specifica-
tion.
• In case engine learning has not been performed • Refer to pages for Engine Learning in the SYS-
or engine learning has been incorrectly per- TEM/Control System group in the T/M (Opera-
formed, engine speed becomes slower than tional Principle).
specification across the operating range. • Check for loose harness connections before-
• In case the EC sensor is faulty, engine speed is hand.
controlled based on the governor lever position,
which is judged as the idle position when the key
switch is turned ON. Accordingly, discrepancies
in engine speed from specification will result.
Depending on where the governor lever is posi-
tioned when the key switch is turned ON, dis-
crepancy will differ, causing this trouble to be not
reproducible.
T5-4-34
TROUBLESHOOTING / Troubleshooting B
· Refer to T4-6-1.
T5-4-35
TROUBLESHOOTING / Troubleshooting B
E-4 Even if engine control dial is rotated, engine
speed remains unchanged.
· Refer to T4-6-1.
T5-4-36
TROUBLESHOOTING / Troubleshooting B
E-5 Engine speed doesn’t increase after engine
is started.
More than 0 °C
when starting Normal.
T5-4-37
TROUBLESHOOTING / Troubleshooting B
E-6 Faulty HP mode
• Sensors detect the conditions necessary to oper- • Refer to the pages for HP Mode Control in the
ate the HP mode. Therefore, if any of these sen- SYSTEM / Control System group in the T/M (Op-
sor fails, the HP mode becomes inoperable. erational Principle).
• Pressure sensors (arm roll-in and boom raise) • Check for loose harness connections before-
and pump 1 and 2 delivery pressure sensors are hand.
also engaged in the HP mode control. However, if
these sensors fail, other operating functions will
be also affected. (Refer to the relationship be-
tween machine trouble symptoms and related
parts on page T5-4-2.)
Faulty power mode
switch or broken
harness between
NO power mode switch
and MC.
Monitor power mode
switch. Check if indica-
tion HP is highlighted
when power mode
NO switch is turned to “HP Check if governor
mode”. lever comes in contact YES Faulty engine.
with full-side stopper
while relieving boom
raise circuit pressure.
YES
Check if any fault Faulty MC.
codes are displayed. · Monitor item: E/P/HP
mode switch NO
· Refer to T4-6-1.
Faulty corresponding
sensor or broken
harness between
sensor and MC.
YES
· Fault codes:
Pump 1 delivery pressure sensor: 10
Pump 2 delivery pressure sensor: 11
Pilot pressure sensor (boom raise): 15
Pilot pressure sensor (arm roll-in): 16
T5-4-38
TROUBLESHOOTING / Troubleshooting B
• Although the power mode switch isn’t turned to the
HP mode position, HP mode is operable.
T5-4-39
TROUBLESHOOTING / Troubleshooting B
E-7 Even if key switch is turned OFF, engine
doesn’t stop. (In case the engine doesn’t
stop, stop the engine by pulling the engine
stop handle located under the seat stand.
Then, begin inspection.)
T5-4-40
TROUBLESHOOTING / Troubleshooting B
E-8 Faulty auto-idle system
• In case trouble symptoms E1 to E7 are recog- • Refer to the pages for Auto-Idle Control in the
nized, perform the troubleshooting of these trou- SYSTEM / Control System group in the T/M (Op-
bles beforehand. erational Principle).
• Although the failure in pressure sensors (travel • Check for loose harness connections before-
and front attachment) will have relevance to mal- hand.
function of the auto-idle control. However, if these
sensors fail, other operating functions will also be
affected. (Refer to the relationship between ma- Normal (Turn power
chine trouble symptoms and related parts on mode switch to a posi-
page T5-4-2.) YES tion other than the E
mode.)
Faulty MC.
· Monitor item: Auto-idle / NO
auto-accel switch
· Auto-idle / · Refer to T4-6-1.
auto-acceleration selec-
tor: OFF
T5-4-41
TROUBLESHOOTING / Troubleshooting B
E-9 Faulty E mode
Faulty MC.
YES
· Monitor item: · Refer to T4-6-1.
E/P/HP mode switch
Faulty MC.
· Monitor item: E/P/HP switch NO
· Power mode switch: P mode
· Refer to T4-6-1.
T5-4-42
TROUBLESHOOTING / Troubleshooting B
E-10 Faulty auto-acceleration system
Related Fault Code: 10, 11, 12, 13, 14, 15, 16, and
18
• In case trouble symptoms E-1 to E-9 are recog- • Refer to the pages for Auto-Acceleration Control
nized, perform the troubleshooting of these trou- in the SYSTEM / Control System group in the
bles beforehand. T/M (Operational Principle).
• Although the failure in pressure sensors (travel,
swing, boom raise, and arm roll-in), pump 1 and
2 delivery pressure sensors, and pump 1 and 2
control pressure sensors will have relevance to
malfunction of the auto-acceleration control.
However, if these sensors fail, other operating
functions will also be affected. (Refer to the rela-
tionship between machine trouble symptoms and
related parts on page T5-4-2.) Faulty auto-idle /
auto-acceleration selector or
broken harness between
Monitor auto-idle / auto-acceleration switch and MC.
NO
auto-acceleration selector.
Check if displayed “AA” is
turned OFF or ON in response
to auto-acceleration switch
operation.
Faulty MC.
YES
· Refer to T4-6-1.
· Monitor item:
Auto-idle/auto-accel
switch
Faulty MC.
· Monitor item: Auto-idle / NO
auto-accel switch
· Auto-idle / auto-acceleration se- · Refer to T4-6-1.
lector:
Auto-idle position
T5-4-43
TROUBLESHOOTING / Troubleshooting B
E-11 When traveling or operating front attach-
ment with engine running at slow idle, en-
gine hunts.
Faulty MC.
· Monitor item: NO
Engine target speed
· Possible to display with built-in · Refer to T4-6-1.
diagnosing system
T5-4-44
TROUBLESHOOTING / Troubleshooting B
E-12 Engine speed doesn’t increase even if at-
tachment is operated in attachment mode.
• In case trouble symptoms E-1 to E-11 are recog- • Refer to the pages for Attachment Operation
nized, perform the troubleshooting of these trou- Speed Increase Control in the SYSTEM / Control
bles beforehand. System group in the T/M (Operational Principle).
• Although the failure in pressure sensor (auxiliary) • Check for loose harness connections before-
and power mode switch will have relevance to hand.
the malfunction of the attachment operation
speed increase control. However, if these sensor
and switches fail, other operating functions will
also be affected. (Refer to the relationship be-
tween machine trouble symptoms and related
parts on page T5-4-2.)
Normal (Set to “In-
NO crease (+)”.)
Check if attachment
speed adjustment
has been set to “In-
NO crease (+)” in Dr. ZX Monitor attachment
service mode. pilot pressure. Check YES
if pressure varies in To A
response to lever
Check if P speed ad-
stroke.
justment has been YES
set to “Decrease” in Faulty auxiliary pres-
Dr. ZX service mode. sure sensor.
NO
T5-4-45
TROUBLESHOOTING / Troubleshooting B
E-13 When attachment mode is selected, engine
speed doesn’t decrease.
T5-4-46
TROUBLESHOOTING / Troubleshooting B
E-14 Engine stalls within several seconds after
engine has started.
T5-4-47
TROUBLESHOOTING / Troubleshooting B
E-15 Engine stalls during operation under ad-
verse condition such as at high altitude.
Disassemble to check
regulator.
YES
Monitor actual engine
speed. Check if engine
speed is abnormal. · Monitor item: Pump torque
proportional solenoid valve
output
· Refer to the Operational Per-
· Monitor item: formance Test section.
Engine actual speed Faulty N sensor, or faulty
harness between N
sensor and MC.
YES
A
Broken harness be-
tween torque control so-
lenoid valve and MC.
NO
T5-4-48
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-49
TROUBLESHOOTING / Troubleshooting B
E-16 Engine is difficult to start at low tempera-
ture. (During cold weather or in cold dis-
tricts, the engine is difficult to start or
doesn’t start although pre-heated.)
• Check if electricity is routed to the glow plugs. • Check battery at the same time.
Check the glow plugs for any abnormality. • Check for loose harness connections before-
• The pre-heat system operates only when coolant hand.
temperature is below 10 °C (50 °F). When cool-
ant temperature is higher than 10 °C (50 °F), the
pre-heat system doesn’t operate.
Remove
the
copper
plate.
Specification: 20 to 24 V
Specification: Below 10 Ω
T105-07-04-006
T105-07-04-007
T5-4-50
TROUBLESHOOTING / Troubleshooting B
T5-4-51
TROUBLESHOOTING / Troubleshooting B
ALL ACTUATOR SYSTEM TROUBLE-
SHOOTING
• Reduction in pump 1 and 2 flow rate due to some • Although speed is satisfactory, in case power is
reasons or faulty pilot system may cause this weak, refer to the troubleshooting for faulty relief
trouble. valve (F-1).
• Also, check for fuse of the torque control solenoid • Check for loose harness connections before-
valve. hand.
Check if primary
pilot pressure is Faulty N sensor or
normal. broken harness in N
YES sensor circuit.
· Monitor item:
Pump torque NO
proportional solenoid
valve output
· Refer to the opera-
tional performance
Test section
T5-4-52
TROUBLESHOOTING / Troubleshooting B
Pressure Gauge
Mounting Port Torque Control
Solenoid Valve
Pilot Filter
T1HH-03-06-003
T173-03-01-001
Faulty MC.
· Refer to T4-6-6.
T5-4-53
TROUBLESHOOTING / Troubleshooting B
A-2 Left travel is inoperable during single travel
operation. Single swing operation speed is
slow. Arm is slightly slow during arm level
crowding. (All problems occur at the same
time.)
T5-4-54
TROUBLESHOOTING / Troubleshooting B
A-3 Right travel is inoperable during single
travel operation. Single bucket operation
speed is slow. Boom is not raised properly
during arm level crowding. (All problems
occur at the same time.)
T5-4-55
TROUBLESHOOTING / Troubleshooting B
A-4 Actuator doesn’t stop even if control lever
is returned to neutral.
NO
· Although pilot pressure is not
routed to spool end in control
valve, spool is kept opened
due to binding of spool.
T5-4-56
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-57
TROUBLESHOOTING / Troubleshooting B
A-5 Actuator speed is faster than normal
Machine mistracks when travel lever is op-
erated at half stroke. Precise control cannot
be performed.
T5-4-58
TROUBLESHOOTING / Troubleshooting B
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
T5-4-59
TROUBLESHOOTING / Troubleshooting B
F-2 Even if power digging switch is pressed,
power doesn’t increase. Boom raise power
is weak when digging.
Monitor pump 1
and 2 delivery
pressures. Monitor power
digging switch. Remains unchanged.
Check if indication
Pressure “Pd” is turned ON
· Monitor item: doesn’t or OFF in response Check pressure at
Pump 1 and 2 Deliv- increase. to power digging solenoid valve unit
ery Pressure switch operation. YES (SG) port.
· Possible to display
with built-in diagnos-
tic system
· Check pump delivery · Check pressure
pressure change change while pressing Changes.
· Monitor item: power digging switch.
while pressing power 0.49 MPa (5 kgf/cm2) or less
Power Digging (Boost) · Measurement: Refer to
digging switch. ↓
Switch the Operational Per- 0.98 MPa (10 kgf/cm2) or less
· Proceed to YES if boom formance Test section.
raise power is weak in
digging operation.
T5-4-60
TROUBLESHOOTING / Troubleshooting B
Disconnect solenoid
valve unit (SG). Con-
nect test harness (ST Faulty solenoid valve unit
7123) between sole- YES
(SG).
noid valve unit and
harness. Check if test
harness lamp comes
ON.
Faulty harness between so-
lenoid valve unit (SG) and
NO MC.
· Power Digging Switch:
ON
T5-4-61
TROUBLESHOOTING / Troubleshooting B
F-3 Some cylinders are inoperable or speeds
are slow.
• When other actuators (travel and swing motors) • In case single arm roll-in operation speed is slow,
operate normally, the pilot pump (primary pilot refer to F-7.
pressure) is considered to be normal. • In case single boom lower operation speed is
• In case single bucket operation speed is slow, slow, refer to F-8.
refer to F-6. Faulty cylinder (faulty
YES
Monitor pump con- seal kit).
trol pressure. Check Check if overload
if pump control pres- YES relief pressure is
sure changes normal.
smoothly while Faulty overload relief
Monitor or meas- moving control lever valve.
ure secondary pilot YES slowly. NO
pressure. Check if
secondary pilot
pressure is normal. Bound control valve
· Monitor item: spool.
Pump 1 flow control NO
pressure, pump 2 flow
· Secondary pilot pres- control pressure
sure: · Possible to display with
Refer to Operational built-in diagnosing sys- Faulty pilot valve.
tem. YES
Performance Test Sec-
tion. Check if secondary
· Monitor item: Boom pilot pressure is cor-
raise pilot pressure, NO rect at the inlet port of Bound shockless
arm roll-in pilot pressure the shockless valve. valve spool.
· Possible to display with NO
built-in diagnosing sys-
tem
· In case of boom lower, · Check only when
bucket roll-out/in and arm is not
arm roll-out, connect rolled-out. In case
the pressure gauge to cylinders other than
the pilot port in control arm roll-out are ab-
valve. normal, skip this
step and proceed to
the NO line.
Shockless Valve
2 1
3
4
5
6
7
8
T1HH-03-06-001
T5-4-62
TROUBLESHOOTING / Troubleshooting B
F-4 During the Combined Operation of Travel
and Boom Raise, Boom does not Rise.
T5-4-63
TROUBLESHOOTING / Troubleshooting B
F-5 Arm speed is slow in a combined operation.
Arm speed is slow during arm level crowd-
ing.
YES
· Monitor item:
Arm Regenerative Pro-
Check if any fault portional Solenoid Valve
codes are dis- Output
played. · Perform boom raise and
arm roll-in combined op-
eration.
· Refer to the Operational
Performance Test.
· Fault Codes:
11: Pump 2 Delivery
Pressure Sensor Faulty corresponding
14: Pressure Sen- sensor or faulty MC, or
sor (Swing) broken harness be-
15: Pressure Sen- tween MC and sensor.
sor (Boom Raise) YES
16: Pressure Sen-
sor (Arm Roll-In)
T5-4-64
TROUBLESHOOTING / Troubleshooting B
T5-4-65
TROUBLESHOOTING / Troubleshooting B
F-6 Bucket is slow in bucket roll-in single op-
eration. Bucket doesn’t move smoothly in
bucket roll-in single operation.
• Faulty bucket flow rate control valve or bucket Faulty bucket regen-
regenerative valve may cause this trouble. erative valve (Disas-
• Refer to the COMPONENT OPERATION / Con- semble and clean, or
YES replace.)
trol Valve group in the T/M (Operational Princi-
ple).
Disconnect pipe SL and adapter
connected bucket flow rate control Check if bucket re-
valve (switch valve B) in the con- YES generative valve in
trol valve from bucket flow rate bucket spool is Find out cause of trou-
control valve (switch valve A). bound or scored. ble by tracing other
Connect adapters (PF 1/4) (2 NO trouble symptoms.
used), hoses (2 used), a tee and a
pressure gauge between bucket
NO flow rate control valve (switch
valve A and B).
Check if relief pressure is approx.
Check if bucket flow 3.9 MPa (40 kgf/cm2) while per-
forming 3-function combined op- Bound bucket flow rate
rate control valve
eration of boom raise, arm roll-in, control valve (switch
(switch valve B) in
and bucket roll-in. NO valve A) control spool
control valve is
in signal control valve.
bound or scored.
T1HH-05-04-001
T5-4-66
TROUBLESHOOTING / Troubleshooting B
F-7 When starting to move in combined opera-
tion, arm doesn’t smoothly move. Arm starts
to move slightly slow in arm roll-in single
operation. These troubles often occur when
oil temperature is low.
T5-4-67
TROUBLESHOOTING / Troubleshooting B
F-8 Boom Starting Speed is Slow and/or Jerky
During Combined Operations. During Boom
Lower Single Operation, Boom Speed is
Slightly Slow.
T5-4-68
TROUBLESHOOTING / Troubleshooting B
F-9 When Operating the Control Lever to Raise
Boom or to Roll-out Arm, Boom or Arm
Starts to Move after Slightly Moving in the
Reverse Direction.
T5-4-69
TROUBLESHOOTING / Troubleshooting B
F-10 Front Attachment Cylinder Drift is Large.
YES Normal.
Needle Valve
Lock Nut
M1HH-05-001
T5-4-70
TROUBLESHOOTING / Troubleshooting B
T5-4-71
TROUBLESHOOTING / Troubleshooting B
SWING SYSTEM TROUBLESHOOTING
T5-4-72
TROUBLESHOOTING / Troubleshooting B
NO
T5-4-73
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-74
TROUBLESHOOTING / Troubleshooting B
TRAVEL SYSTEM TROUBLESHOOTING
Checking Instructions
Checking Instructions
T5-4-75
TROUBLESHOOTING / Troubleshooting B
T-3 One Side Track does not Move or Move
Slowly, or the Machine cannot Travel
Straight (Mistracks).
Checking Instructions
• Check if the slack of both track is epual.
• If one side system only does not operate, pilot Check if travel motor oil
valve, control valve, travel motor, or center joint YES drain amount is normal.
might be faulty.
• Mistracks occur due to faulty pump control. In Check if travel relief
this case, a symptom such as bucket or swing pressure in slow speed · Specification: Refer to
function speed is slow in single operation, or arm side system is normal. Operational Perform-
roll-in or boom raise speed is slow is recognized. NO ance Test section.
Refer to A-2 and A-3 if a symptom and mistracks
occur at the same time.
Check if the symptom · Relieve travel system.
is reversed when right · Monitor item: Pump 1 Switch rear and front or
and left travel line and 2 delivery pres- right and left travel relief
YES hoses connected to top sure valves with each other.
of center joint are · Specification: Refer to Check if symptom is
Check if travel pilot switched with each Operational Perform- reversed.
secondary pressure other. NO
ance Test section.
is normal. · Possible to display
with built-in diagnosing
system. Bound control valve
spool.
· Monitor item: Travel YES
control pressure
· Possible to display
with built-in diag- Faulty pilot valve.
nosing system.
NO
6 T105-07-04-015
External Oil ←
7 Leak
T5-4-76
TROUBLESHOOTING / Troubleshooting B
Pipe Layout
1 2 Front
5 4 W157-03-03-003
T5-4-77
TROUBLESHOOTING / Troubleshooting B
T-4 During a Combined Operation of Travel and
Front Function, the Machine Mistracks.
NO
T5-4-78
TROUBLESHOOTING / Troubleshooting B
T-6 No steering force and no grade ability when
travel mode is Fast.
T5-4-79
TROUBLESHOOTING / Troubleshooting B
T-7 Fast travel is inoperable.
Travel mode doesn’t change from slow
mode to fast mode.
· Monitor:
Travel motor control pres-
sure
· Travel mode: Fast
· Measurement: Refer to
OPERATIONAL PER-
FORMANCE TEST section.
· Fault Codes:
10: Pump 1 Delivery Pressure Sensor
11: Pump 2 Delivery Pressure Sensor
12: Pump 1 Control Pressure Sensor
(4-Spool)
13: Pump 2 Control Pressure Sensor
(5-Spool)
T5-4-80
TROUBLESHOOTING / Troubleshooting B
Disconnect solenoid
valve unit (SI). Connect Faulty solenoid valve unit
YES (SI).
test harness (ST 7123)
between solenoid valve
NO unit (SI) and harness.
Check if test harness Broken harness between
lamp comes ON. solenoid valve and MC.
NO
T5-4-81
TROUBLESHOOTING / Troubleshooting B
OTHER SYSTEM TROUBLESHOOTING
Checking Instructions
• The wiper is driven by electric power routed via • If the front window is open, the wiper won’t oper-
the relay circuit controlled by the monitor assem- ate. Check that the front window is securely
bly. In case the wiper is inoperable, first check closed.
the wiper motor and links for any abnormality us-
ing an auxiliary electric power and the test har-
ness. Faulty front window
open/close switch or
short-circuited harness
between front window
YES open/close switch and
monitor.
T5-4-82
TROUBLESHOOTING / Troubleshooting B
Lamp S
M B S
L E
Ground
T178-05-04-004
Retracted Position
Operating Range
T178-05-04-005
Lamp S
T157-07-04-004
T5-4-83
TROUBLESHOOTING / Troubleshooting B
O-2 Air Conditioner Malfunction
Normal Operation
Press lower side fan switch. Press upper side fan switch.
Keep pressing OFF switch STEP 1
for more than 3 seconds. Display Function Con-
firmation
Press lower side fan switch. Press upper side fan switch.
Keep pressing OFF switch STEP 2
for more than 3 seconds. Present Trouble
Diagnosing
Press lower side fan switch. Press upper side fan switch.
Press lower side fan switch. Press upper side fan switch.
Keep pressing OFF switch
for more than 3 seconds. STEP 4
Sensing Temperature
Display
Press lower side fan switch. Press upper side fan switch.
Keep pressing OFF switch
for more than 3 seconds. STEP 5
Component Operation Check
Press AUTO switch and Press AUTO Press A/C Press A/C switch and
lower side fan switch. Switch and switch and upper side fan switch.
upper side lower side
fan switch. fan switch.
Keep pressing OFF switch STEP 6-1 STEP 6-2
for more than 3 seconds. Correction of the Set Selection of Celsius and Fahrenheit
Temperature Temperature Indication
Keep pressing OFF switch
for more than 3 seconds.
Self-Diagnosis
T5-4-84
TROUBLESHOOTING / Troubleshooting B
Self-Diagnostic System Activation
Fan Switch LCD Air Conditioner Switch
Turn the key switch ON while pressing the air condi-
tioner switch and mode switch on air conditioner
control panel.
T5-4-85
TROUBLESHOOTING / Troubleshooting B
STEP 2 Present Trouble Diagnosing
The LCD indicates the fault codes for present ab-
Fan Switch LCD
normalities of the mix door, mode encoder, and/or
sensors.
T5-4-86
TROUBLESHOOTING / Troubleshooting B
STEP 3 Past Trouble Diagnosing
The LCD indicates the fault codes for past abnor-
Fan Switch LCD Air Conditioner Switch
malities of the mix door, mode encoder, and/or sen-
sors.
The past stored fault codes are deleted.
T5-4-87
TROUBLESHOOTING / Troubleshooting B
STEP 4 Sensing Temperature Display
The LCD indicates the sensing temperature detected
Fan Switch Fan Mark LCD Air Conditioner Switch
by each temperature sensor (excluding the insulation
sensor).
NOTE: The coolant temperature sensor indicates Fresh Air Vent Switch OFF Switch
“H” when coolant temperature is more than
21 °C (70 °F) and “L” when coolant tem-
perature is less than 21 °C (70 °F).
• Sensing temperature detected by each sensor is
automatically displayed on the LCD and is cycled at
an interval of 3 seconds with the timer. The timer is
turned ON or OFF by operating the fresh air vent
switch.
• Referring to the fan mark can check which sensing
temperature is displayed.
• Select the next step to be performed by operating
the switches as follows:
• Press the upper side of the fan switch: To pro-
ceed to “STEP 5.”
• Press the lower side of the fan switch: To return
to “STEP 3.”
• Keep pressing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed)
T5-4-88
TROUBLESHOOTING / Troubleshooting B
STEP 5 Component Operation Check Air Conditioner
Fan Switch LCD Switch AUTO Switch
Each component operation is checked by performing
pattern operation.
Table 1
Component Indication Operation Pattern Remarks
on LCD
Air Mix Damper 51 Controls opening extent of air mix 0%, 50%, 100%: “C”, “5”, and “H” are
damper: 0% (fully closed) → indicated next to the decimal point re-
50%*→ 100% (fully opened) spectively.
Fan 52 Controls air flow volume: Lo → Indicators corresponding to air flow vol-
M(Lo) → M(Hi) → Hi ume light.
Air Vent Loca- 53 Selects air vent: Front*→ Indicator corresponding to selected air
tion Front/Rear → Front/Foot → Foot vent lights.
Fresh/Circula-tio 54 Select Ventilation Mode: Circula- Indicator corresponding to selected
n Air Vent Selec- tion* → Fresh mode light.
tion
Air Conditioner 55 Turns air conditioner switch: ON* ON: Indicator lights.
→ OFF OFF: Indicator is extinguished.
T5-4-89
TROUBLESHOOTING / Troubleshooting B
STEP 6-1 Correction of the Set Temperature
Fine correction of the set temperature. Temperature
Fan Switch LCD Control Switch AUTO Switch
25°C (77 °F) and set temperature correction is -1°C OFF Switch
(-34 °F), the actually controlled temperature be-
comes 24°C (75 °F).
• Select the next step to be performed by operating
the switches as follows:
• Press the AUTO switch and lower side of the fan
switch: To return to “STEP 5.”
• Keep pressing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed)
T5-4-90
TROUBLESHOOTING / Troubleshooting B
STEP 6-2 Selection of Celsius and Fahrenheit
Temperature Indication
Fan Switch LCD Air Conditioner Switch
Selection of Celsius and Fahrenheit Temperature In-
dication.
• Each time when the fresh air vent switch is pressed,
Celsius or Fahrenheit temperature may be dis-
played alternately.
• Temperature is displayed at the top of the LCD
window as follows.
(C: Celsius, F: Fahrenheit) T178-05-08-001
T5-4-91
TROUBLESHOOTING / Troubleshooting B
※ Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to Hitachi Tsuchiura Works Quality Assurance Dept. after
experiencing a problem with your machine’s air conditioning system.
< AIR CONDITIONER TROUBLE REPORT > File No.
(1) What Checked by:
Model (Serial No. )
Operation Type Manual Semi-Auto Full-Auto
Delivery Date Year Month
(2) When
Date Year Month Day Operating Hour ( h)
Time Morning Daytime Evening Night
Frequency Every Day Once a Week Once a Month Times per
(3) Where
Job Site Address State County Town
Access Road Condition Paved Not Paved (Gravel Sand Soil)
(4) How (Operating Conditions)
Weather Fine Cloudy Rain Snow
Atmospheric Temperature Very Hot Hot Cold Very Cold
Operating Conditions Parking Traveling Working
Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when
full-auto operation
A/C ON OFF
Control Air Induction Re-Circulation Fresh Air Circulation
Panel AUTO ON OFF Not Available
Fill following items when operated in manual mode or when manual control type unit is used.
Vent Position Front Front / Rear Foot Front / Rear and Foot
Fan First Second Third Fourth Fifth Sixth
(5) How (Problem Symptom)
Abnormal Compressor Operation
Symptom Not turned ON <Check Result>
Not turned OFF (1) Is problem reproducible ?
Others Reproducible
Uncontrollable air temperature Not reproducible
(2) Pressure (To be measured at gauge manifold)
Symptom No cool air
Low Pressure
No warm air
High Pressure
Others
(3) Which parts have been replaced ?
Uncontrollable air volume
1
Symptom Air flows in Hi mode only
No air flows
2
Small air volume
Others
Uncontrollable vent hole
∗ Before replacing the control amplifier, be sure to
check that the connectors are correctly connected
Symptom Vent hole isn’t selected
while repeatedly disconnecting and reconnecting
Others connectors.
Abnormal panel indication
Faulty Indicator Vent Hole
A/C
AUTO
Fresh Air Circulation
Fan OFF
Fan (Lo • •• Hi)
Temperature Control
Symptom Stays OFF
Stays ON
Blinks
Others
T5-4-92
TROUBLESHOOTING / Troubleshooting B
T5-4-93
TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Refrigerant pressure Bubbles can be seen in sight Piping and/or parts are stained with oil,
in both high and glass. respond to gas detector.
low-pressure sides is
low.
No oil stain is found or gas detector
doesn’t respond. Refrigerant has not
been refilled for longer than one sea-
son.
No bubbles are seen in sight
glass.
Refrigerant pressure
in low-pressure side Bubbles can be seen in sight Compressor cylinder is extremely hot,
Insuffi- is high. glass. emitting a smell.
cient
Cooling
Power
Refrigerant pressure in Compressor cylinder is extremely hot,
high-pressure side is low. emitting a smell.
Refrigerant pressure
in high-pressure side Bubbles can be seen in sight Refrigerant pressure in low-pressure
is high. glass. side is low.
Even if condenser is sprayed with water, few bubbles appear. Receiver dryer tem-
perature is low.
Thermistor cools.
T5-4-94
TROUBLESHOOTING / Troubleshooting B
Gas leaks from pipe joints and/or parts. Re-tighten or replace parts.
Frozen expansion valve or water in circuit. After evacuation, refill refrigerant and/or replace re-
ceiver dryer.
Gas leaks from case. Seal gaps using vinyl tape or packing compound.
Poor contact of expansion valve temperature sensing cylinder. Make good contact. Replace temperature sensing
stay.
Clogged high-pressure circuit before receiver dryer. Remove clog, or replace parts.
Clean Condenser.
Gas leaks from case. Seal gaps using vinyl tape or packing compound.
Even if function and performance are normal, when Instruct user on correct air-conditioner operation.
air-conditioner is kept operated for a long time with thermistor (Reset thermistor to either minimum or middle cooling
in max. cooling position and air flow in M or L mode, frost may position or increase air flow.)
form.
T5-4-95
TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Gas blowing sound (roaring). Gas vibration noise (compressor discharge and/or
suction gas noise).
Expansion valve connection, whistle Abnormal noise from expansion valve (Expansion
Noise sound, gas blowing sound. valve is normally functioning.).
Noisy compressor.
Compressor rotating sound.
Vibration and/or loose screws due to excessive drive
belt looseness.
T5-4-96
TROUBLESHOOTING / Troubleshooting B
Repair or replace.
Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.
Replace.
Repair or replace.
Replace.
Clean.
Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in
L mode for more than 10 minutes, flush smell out by condensed water.
T5-4-97
TROUBLESHOOTING / Troubleshooting B
Compressor
Inoperable
cooling Clutch terminal voltage is low.
system.
T5-4-98
TROUBLESHOOTING / Troubleshooting B
Oil and refrigerant leaks from front housing, and/or cylinder block joint. Replace.
No leaks (normal).
Replace.
Blown gasket (See NOTE 3 on page T5-4-101.)
T5-4-99
TROUBLESHOOTING / Troubleshooting B
Compressor
Trouble other than compressor. Refer to the Cooling Circuit Troubleshooting Ta-
ble on page T5-4-94.
Abnormal
noise
T5-4-100
TROUBLESHOOTING / Troubleshooting B
Loose screws.
Broken valve.
Replace.
Blown gasket.
NOTE:
1. Don’t quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A
slight oil seepage will appear due to the seal construction. However, this oil seepage will not
cause malfunction. Be sure to accurately check whether oil is leaking or seeping only.
2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose sur-
face may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
high-pressure side and low-pressure side is 0.49 MPa (5 kgf/cm2) or less. When the clutch is
turned OFF, the pressure difference between high-pressure side and low-pressure side will dis-
appear within about 10 seconds.
T5-4-101
TROUBLESHOOTING / Troubleshooting B
EXCHANGE INSPECTION
Check Method:
1. Switch two delivery pressure sensors located as
Figure A
shown in figure A to figure B.
2. Retry troubleshooting. T157-07-04-006
Result:
In case the pump 2 delivery pressure is abnormal
(fault code 11), the pump 1 delivery pressure sensor
is considered to be faulty.
Pump 2 Pump 1
In case the pump 1 delivery pressure is abnormal (4-Spool
(5-Spool
(fault code 10), the pump 1 delivery pressure sensor Section) Section)
harness is considered to be faulty.
PP1 PP2
Figure B T157-07-04-006
T5-4-102
TROUBLESHOOTING / Troubleshooting B
T5-4-103
TROUBLESHOOTING / Troubleshooting B
EMERGENCY BOOM LOWERING PRO-
CEDURE 2
: 6 mm
2 1
3. After the front attachment is lowered completely,
tighten needle valve (2).
: 6 mm
: 7.9 N⋅m (0.8 kgf⋅m, 5.8 lbf⋅ft)
M1HH-05-001
T5-4-104
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C (TROUBLE-
SHOOTING FOR MONITOR) PROCEDURE
YES (OK)
(2)
After completing the checking and/or measuring procedures in box
・ (1) (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
・ Causes of machine problems are stated in the thick-line box. Scanning quickly through
the thick-line boxes, allows you to estimate the possible causes before actually following
the flow chart.
Open End
Side
Harness End Connector
T158-05-03-001
T5-5-1
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF COOLANT TEM-
PERATURE GAUGE
Disconnect coolant
temperature sensor. Faulty coolant temperature
YES sensor.
Ground harness end
Gauge pointer terminal to vehicle
keeps moving frame, Check if pointer
unstably. swings and is stabi-
lized to (H) side.
Faulty monitor.
NO
· Key switch: ON
T5-5-2
TROUBLESHOOTING / Troubleshooting C
105 ゚ C
(95 ゚
70 ゚ C
T157-07-05-001
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-3
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF FUEL GAUGE
Faulty monitor.
NO
· Key switch: ON
T5-5-4
TROUBLESHOOTING / Troubleshooting C
Fuel Sensor
Float
FULL
R381.9 mm
257 mm 3/4
93 mm
70.5 mm
1/2
204 mm
1/4
338 mm
EMPTY
T178-05-05-001
NOTE: 1 mm = 0.03937 in
10 9 8 7 6 5 4 3 2 1
1 2
20 19 18 17 16 15 14 13 12 11
T5-5-5
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF INDICATOR LIGHT
CHECK SYSTEM
Conduct troubleshooting of
each indicator, which does
NO not light.
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-6
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF PREHEAT INDICATOR
• The preheat system operates only when coolant • In case the preheat system malfunctions, refer to
temperature is below 10 °C (50 °F), lighting the the troubleshooting B for E-16 Engine is difficult to
preheat indicator for 8 seconds. (Refer to the start at low temperature.
SYSTEM /Electrical Circuit group.) • Check for loose harness connections beforehand.
Remove connector
(with black and Faulty coolant tem-
white cables) from YES perature switch.
Preheat indicator
coolant tempera-
lights even though
ture switch. Check
preheat system
if indicator goes Faulty QOS con-
doesn’t operate YES
OFF by grounding troller.
(coolant tempera-
harness end con-
ture is more than
nector to vehicle Without connecting
10 °C (50 °F)).
frame. Disconnect QOS QOS controller, re-
move connector B Short-circuited har-
controller. Check if
(20P) from monitor. ness between QOS
indicator goes YES
Check for continuity controller and moni-
OFF.
NO between monitor tor.
harness end con-
NO nector terminal #20
and vehicle frame.
· Key switch: ON
· Key switch: ON Faulty monitor.
NO
10 9 8 7 6 5 4 3 2 1 1 2 3
20 19 18 17 16 15 14 13 12 11 4 5 6
T5-5-7
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ALTERNATOR INDI-
CATOR
• Check for loose harness connections beforehand. NOTE: *Regulator terminals L are water-resistant
type connectors so that it is not practical to
measure voltage at these terminals.
Measure voltage at starter relay terminal R
instead. Check for continuity between
starter relay terminal R and regulator ter-
minal L beforehand.
Between 13 V
and 33.5 V Faulty monitor.
Measure voltage at
Between 13 V monitor connector A
and 33.5 V (16P) terminal #2.
Broken harness between
Alternator indicator regulator terminal L and
stays ON after en- Measure voltage at monitor.
· Engine: Running
gine is started. regulator terminal L.* Less than 13 V or
higher than 33.5 V
Between 10 V
and 33.5 V Faulty monitor.
Measure voltage at
YES regulator terminal L.*
Although alternator
output is low, alter- Check if indicator Faulty regulator.
nator indicator lights when key · Key switch: ON
· Engine: Stopped Less than 10 V or
doesn’t light. switch is turned ON. higher than 33.5 V
E
8 7 6 5 4 3 2 1
S R 16 15 14 13 12 11 10 9
T5-5-8
TROUBLESHOOTING / Troubleshooting C
(Blank)
T5-5-9
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE OIL PRES-
SURE INDICATOR
• Check for loose harness connections beforehand. NOTE: During one or two minutes after the engine
is stopped, engine oil pressure may still
exist. When the engine is restarted under
this condition, the indicator may not light.
Faulty monitor.
NO
T5-5-10
TROUBLESHOOTING / Troubleshooting C
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-11
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF OVERHEAT INDICA-
TOR
Faulty monitor.
NO
Check if indicator
Indicator lights even
goes OFF when
if coolant tempera-
overheat switch is Disconnect overheat
ture is low.
disconnected. switch. Remove con- Short-circuited harness be-
YES tween monitor and overheat
nector B (20P) from
monitor. Check for con- switch.
· Key switch: ON tinuity between connec-
· Engine: Stopped tor terminal #6 and vehi-
NO cle frame.
Faulty monitor.
NO
T5-5-12
TROUBLESHOOTING / Troubleshooting C
Overheat Switch
Coolant Temperature Operation
Lower than 105 °C OFF
(221 °F)
105 °C (221 °F) or ON
higher
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-13
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF AIR FILTER RESTRIC-
TION INDICATOR
· Key switch: ON
Burned indicator light.
NO
A
Broken harness between
monitor and air filter restriction
switch.
NO
T5-5-14
TROUBLESHOOTING / Troubleshooting C
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-15
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF BUZZER
• Check for loose harness connections beforehand. NOTE: *Regulator terminals L are water-resistant
type connectors so that it is not practical to
measure voltage at these terminals.
Measure voltage at starter relay terminal R
instead. Check for continuity between
starter relay terminal R and regulator ter-
minal L beforehand.
T5-5-16
TROUBLESHOOTING / Troubleshooting C
8 7 6 5 4 3 2 1 E
16 15 14 13 12 11 10 9 S R
Lower than 13 V or
more than 33.5 V Faulty regulator and alterna-
tor.
T5-5-17
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF LCD
Display
Description Cause of Trouble
Order
1 Hour Meter Refer to the next page.
2 Trip 1 Faulty Monitor.
3 Trip 2
4 Actual Engine Speed In case Dr. ZX can display data, monitor is abnormal or communication
5 Hydraulic Oil Tempera- between monitor and MC is interrupted. In case Dr. ZX doesn’t display
ture data, corresponding signal sensor is faulty. (The machine must have
any abnormality in the control system. Refer to Troubleshooting B.)
6 Faulty monitor or interrupted communication between ML controller and
7 Load Alarm monitor.
8 Hydraulic Oil Filter Faulty monitor or interrupted communication between ICX controller
and monitor.
9 Fault Code In case Dr. ZX can display data, monitor is abnormal or communication
10 ML Switch between monitor and MC is interrupted. In case Dr. ZX doesn’t display
11 Pump 1 Delivery Pres- data, corresponding signal sensor is faulty. (The machine must have
sure any abnormality in the control system. Refer to Troubleshooting B.)
12 Pump 2 Delivery Pres-
sure
13 Pump 1 Control Pres-
sure
14 Pump 2 Control Pres-
sure
15 Target Engine Speed
16 EC Angle
17 Dial Angle
18 Boom Raise Lever
Stroke
19 Arm Roll-In Lever Stroke
20 Swing Lever Stroke
21 Travel Lever Stroke
22 Front Attachment Lever
Stroke
23 Attachment Lever Stroke
24 Work Mode
T5-5-18
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HOUR METER
8 7 6 5 4 3 2 1 E
16 15 14 13 12 11 10 9 S R
T5-5-19
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HYDRAULIC OIL FIL-
TER INDICATOR (Optional)
A
Faulty monitor.
NO
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
T5-5-20
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
T5-6-1
TROUBLESHOOTING / Electrical System Inspection
3. Precautions for connecting and disconnecting
terminal connectors.
1) When disconnecting harnesses, grasp them
Right Wrong
by their connectors. Do not pull on the wire
itself. Be sure to release the lock first before
attempting to separate connectors, if a lock
is provided. (Refer to “Instructions for
Disconnecting Connector” on page T5-6-3.)
2) Water-resistant connectors keep water out T107-07-06-001
T5-6-2
TROUBLESHOOTING / Electrical System Inspection
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
T5-6-3
TROUBLESHOOTING / Electrical System Inspection
FUSE INSPECTION
Cracks in a fuse are so fine that it is very difficult or NOTE: All terminals located along the lengthwise
impossible to find by visual inspection. Use a tester to centerline of the fuse box are connected to
correctly inspect fuse continuity by following the in- the power source, while terminals located
structions described below. away from the center of the fuse box are
connected to loads (accessories). There-
1. Turn Key Switch ON fore, test all fuses in the same method ex-
When the key switch is turned ON, current from cept for the glow plug relay circuit fuse.
key switch terminal M activates the battery relay Check the glow plug relay circuit fuse with
so that electric power is supplied to all circuits the key switch turned to the ON position
except the glow plug relay circuit. (Refer to the then follow the procedure in step 3.
circuit diagram.)
2. Remove the fuse box cover. Set the tester volt-
age to meet the circuit specification to be meas-
ured. (Measurement Range: 0 to 30 V) 10 20
3. Ground the negative probe of the tester to the 9 19
vehicle frame. Touch the terminals located away
from the center of the fuse box with the positive 8 18
probe of the tester one at a time. When normal 7 17
continuity of a fuse is intact, the tester will indi-
cate 20 to 25 V (battery voltage). 6 16
5 15
4 14
3 13
2 12
1 11
M178-07-034
Fuse Fuse
Capacity Connected to Capacity Connected to
No. No.
1 5A Radio, Monitor (Backup 11 20 A Work Light Relays 1 and 2
Power), ICX (Main Power)
2 5A MC (Main Power) 12 10 A Wiper Relays A, B, and C,
Wiper Motor, Washer Relay
3 10 A MC (EC Motor Power) 13 20 A Heater (Air Conditioner Unit)
4 10 A MC (Solenoid Valve Power) 14 10 A Horn Relay
5 5A Monitor 15 5A Radio
6 5A MC, ICX (Power ON Signal) 16 10 A Cigarette Lighter
7 5A Air Conditioner Unit 17 5A Room Light
8 5A Optional 1 18 10 A Auxiliary
9 10 A Optional 2 19 5A QOS Controller, Glow Plug
Relay
10 5A Optional 3 20 10 A Lubricator (Optional)
T5-6-4
TROUBLESHOOTING / Electrical System Inspection
FUSIBLE LINK INSPECTION Battery Relay
Inspection
Replacement
battery relay.
3. Open the upper and bottom side covers of the
fusible link box. Remove screws M6 (2 used).
4. Take out the fusible link to replace it. Battery
Relay
5. Retighten screws M6 (2 used). Bolt M8
6. Install the fusible link box and the cable to the
battery relay.
7. Reconnect the negative cable to the battery.
Cable Screw M6
T107-04-05-008
T5-6-5
TROUBLESHOOTING / Electrical System Inspection
BATTERY VOLTAGE CHECK
Normal Voltage: 24 V
Normal Voltage: 26 to 28 V
T157-07-06-007
T5-6-6
TROUBLESHOOTING / Electrical System Inspection
HOW TO TROUBLESHOOT ALTERNATOR
MALFUNCTIONS
Terminal E
T1HH-05-06-001
T5-6-7
TROUBLESHOOTING / Electrical System Inspection
CONTINUITY CHECK
Harness
Single-line continuity check A a
Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity
Ω
T5-6-8
TROUBLESHOOTING / Electrical System Inspection
Multi-line continuity check
Disconnect both end connectors of the harness, First short-circuit
and short-circuit two terminals, (A) and (B), at one
end connector, as illustrated. Then, check continuity
A a
between terminals (a) and (b) at the other connector. B b
If the ohm-meter reading is ∞ Ω, either line (A) - (a), C c
or (B) - (b) is in discontinuity. To find out which line
is discontinued, conduct the single line continuity Second short-circuit
check on both lines individually, or, after changing
the short-circuit terminals from (A) - (B) to (A) - (C),
check continuity once more between terminals (a)
Ω
and (c).
A a
×
B b
C c
T107-07-05-005
T5-6-9
TROUBLESHOOTING / Electrical System Inspection
(Blank)
T5-6-10
TROUBLESHOOTING / Electrical System Inspection
VOLTAGE AND CURRENT MEASURE-
MENT
24-Volt Circuit
Start checking the circuit in order up to the loca-
tion to be measured from either power source or
actuator side. Thereby, the faulty location in the
circuit will be found.
Black Probe (Minus) of Tester : To ground to the vehi-
cle frame
Red Probe (Plus) of Tester : To touch the location
to be measured
T5-6-11
TROUBLESHOOTING / Electrical System Inspection
T5-6-12
TROUBLESHOOTING / Electrical System Inspection
Key Switch
Battery
6 8
1 2 3 5 4 9
15
Battery Relay
Fuse
10 Box
Starter
18 Load
Damp
Relay
11
12 23 22 21 20 19 17
13 Monitor
Starter Relay
16
Alternator
Glow
Plug
Relay
14
Glow Plug
T178-05-06-001
T5-6-13
TROUBLESHOOTING / Electrical System Inspection
5 Voltage Circuit
Power Signal or
• Voltage between terminal #1 and the vehicle Two Polarities Source Ground
frame (ground) 1 2
With the key switch turned OFF, disconnect the
sensor connector.
Measure the voltage between terminal #1 on the
machine harness side connector and the vehicle
(ground) under the following conditions.
V
• Key switch position: ON
• Tester black terminal (negative):
Connected to the vehicle (ground)
• Tester red terminal (positive):
T107-07-05-006
Connected to terminal #1
Power
Three Polarities
Source Signal Ground
Evaluation: 1 2 3
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal #1 is normal.
terminal
With the key switch turned OFF, disconnect the Two Polarities
1 2
sensor connector.
Measure the voltage between terminal #1 on the
machine harness side connector and the ground
terminal (terminal #2 for two polarities, or terminal
#3 for three polarities) under the following V
conditions.
T107-07-05-009
T5-6-14
TROUBLESHOOTING / Electrical System Inspection
CHECK BY FALSE SIGNAL
Two Polarities
Turn the key switch OFF. After disconnecting the sen- (Oil Temperature)
sor connector, turn the key switch ON. Then, connect (N Sensor)
1 2
machine side harness end connector terminal #1
(power) to terminal #2 (signal). (Power voltage is used
as a false signal.) Check the controller using Dr. ZX
monitor function under this condition. When the
maximum value is displayed, the MC and the circuit
up to the machine side harness end connector are
normal. When the pressure switch circuits are normal, Connect
Dr. ZX displays “ON”.
Connect
T107-07-05-011
T5-6-15
TROUBLESHOOTING / Electrical System Inspection
TEST HARNESS
T107-07-06-015
Parts Number (ST 7123)
T5-6-16
TROUBLESHOOTING / Electrical System Inspection
Parts Number 4284347 (ST 7129)
Use to measure the EC sensor circuit signal line
voltage (between terminals #2 and #3).
(Red)
(Refer to T5-3-4.)
(Black)
T5-6-17
TROUBLESHOOTING / Electrical System Inspection
(Blank)
T5-6-18
TROUBLESHOOTING / ICX
OUTLINE
T5-7-1
TROUBLESHOOTING / ICX
Daily Report Data List
Data Details
1 Key Switch ON Time Time when key switch is first turned ON during daily operation
(Time is recorded by key switch ON signal.)
2 Key Switch OFF Time Time when key switch is last turned OFF during daily operation
(Time is recorded by key switch ON signal.)
3 Engine Start Time Time when engine is first started during daily operation
(Time is recorded by alternator output signal.)
4 Engine Stop Time Time when engine is last stopped during daily operation
(Time is recorded by alternator output signal.)
6 Fuel Level The value of the final remained fuel during a day
(Value is recorded by fuel sensor signal from monitor.)
7 Engine Operating Hours Total engine operating hours during daily operation
(Hours are recorded by alternator output signal.)
8 Swing Operating Hours Total swing operating hours during daily operation
(Hours are recorded by signals from swing pressure sensor.)
9 Travel Operating Hours Total travel operating hours during daily operation
(Hours are recorded by signals from travel pressure sensor.)
10 Front Attachment Operat- Total front attachment operating hours during daily operation
ing Hours (Hours are recorded by signals from front attachment pressure sensor.)
11 Breaker Operating Hours Total breaker operating hours during daily operation
(Hours are recorded by signals from auxiliary pressure sensor and attach-
ment mode switch.)
12 Auxiliary Attachment Ex- Total auxiliary attachment except for breaker operating hours during daily
cept for Breaker Operating operation
Hours (Hours are recorded by signals from auxiliary pressure sensor and attach-
ment mode switch.)
T5-7-2
TROUBLESHOOTING / ICX
Data Details
13 *ML Operating Hours Total *ML crane operating hours during daily operation
(Hours are recorded by signals from crane mode switch.)
14 Engine Operating Hour Engine operating hour distribution during daily operation
Distribution (Operating hours are recorded only when alternator output signal is con-
tinuously delivered for more than 10 minutes.)
NOTE: The daily operation in this table is equiva- *ML specification is only available in Japa-
lent to the hours between 0:00 and nese domestic market.
23:59:59 counted by the ICX built-in clock.
In case the engine is kept operated be-
yond 0:00, such data are recorded as
those for the following day.
Data Details
1 Engine Speeds Frequency distribution of engine speeds
(Speeds are recorded by signals from N sensor.)
4 Average Pump Deliv- Frequency distribution of average delivery pressure from pumps 1 and 2
ery Pressure (Average pressures are recorded by signals from delivery pressure sensors of
pumps 1 and 2.)
5 Average Pump Deliv- Frequency distribution of average delivery pressure from pumps during digging
ery Pressure in Dig- operation
ging Operation (Average pressures are recorded by signals from arm roll-in pressure sensor.)
6 Average Pump Deliv- Frequency distribution of average delivery pressure from pumps during travel
ery Pressure in Travel operation
Operation (Average pressures are recorded by signals from travel pressure sensor.)
T5-7-3
TROUBLESHOOTING / ICX
Cumulative Operation Hour List
Data Details
1 Engine Operation Hour Cumulative engine operation hours
(Hours are recorded by alternator output signal.)
6 Auxiliary Attachment Cumulative attachment operation hours except for breaker operation hours
Except for Breaker (Hours are recorded by signals from auxiliary pressure sensor and auxiliary
Operation Hour mode switch.)
T5-7-4
TROUBLESHOOTING / ICX
Alarm List
85 Coolant in Radiator Date and time when coolant level indicator lighted are recorded by
signals from coolant level switch.
86 Hydraulic Oil Filter Date and time when hydraulic oil filter indicator lighted are recorded
by signals from hydraulic oil filter restriction switch.
89 Overheat Date and time when overheat indicator lighted are recorded by sig-
nals from overheat switch.
90 Engine Oil Pressure Date and time when engine oil pressure indicator lighted are re-
corded by signals from engine oil pressure switch.
93 Air Filter Restriction Date and time when air filter restriction indicator lighted are re-
corded by signals from air filter restriction switch.
94 Alternator Indicator Date and time when alternator indicator lighted are recorded by sig-
nals from monitor controller.
T5-7-5
TROUBLESHOOTING / ICX
Trouble List
Fault
Trouble Details
Code
01 Abnormal EEPROM Occurrence time and date of fault code 01
07 Abnormal Engine Control Dial Occurrence time and date of fault code 07
10 Abnormal Pump 1 Delivery Pressure Occurrence time and date of fault code 10
11 Abnormal Pump 2 Delivery Pressure Occurrence time and date of fault code 11
12 Abnormal Pump 1 Control Pressure Occurrence time and date of fault code 12
13 Abnormal Pump 2 Control Pressure Occurrence time and date of fault code 13
14 Abnormal Swing Lever Stroke Occurrence time and date of fault code 14
15 Abnormal Boom Raise Lever Stroke Occurrence time and date of fault code 15
16 Abnormal Arm Roll-In Lever Stroke Occurrence time and date of fault code 16
18 Abnormal Travel Lever Stroke Occurrence time and date of fault code 18
19 Abnormal Oil Temperature Sensor Occurrence time and date of fault code 19
65 Monitor Communication Error Time and date when communication error between
monitor and ICX occurred.
66 Satellite Terminal Communication Error Time and date when communication error between sat-
ellite terminal and ICX occurred.
T5-7-6
TROUBLESHOOTING / ICX
(Blank)
T5-7-7
TROUBLESHOOTING / ICX
ICX FAULT CODE LIST
Fault
Trouble Remarks
Code
1 Abnormal Internal RAM In case of SAM error
7 MC Communication Timeout (For ZAXIS) In case MC communication didn’t last for more than 7
seconds.
8 Monitor Communication Timeout In case monitor communication didn’t last for more than
24 seconds.
9* MC Communication Timeout (For EX5) In case MC communication didn’t last for more than 20
seconds.
10 Satellite Terminal Communication Timeout In case satellite communication didn’t last for more than
1 minute.
Fault
Trouble Remarks
Code
101 Satellite Terminal: Internal Error Abnormal EEPROM
104 Satellite Terminal: Communication Error In case satellite communication cannot be accom-
plished.
105 Satellite Terminal: Internal Error In case sending retry over occurred or local loop back
test failed with power ON.
106 Satellite Terminal: Communication Error In case sending retry over occurred.
107 Satellite Terminal: Abnormal Harness In case reception data doesn’t match sending data.
T5-7-8
TROUBLESHOOTING / ICX
FAULT CODE 1 TO 4 AND 6
Faulty ICX.
NO
FAULT CODE 7 TO 10
T5-7-9
TROUBLESHOOTING / ICX
SOME PARTS OF DATA IN DAILY REPORT,
FREQUENCY DISTRIBUTION, CUMULA-
TIVE OPERATION HOURS ARE NOT RE-
CORDED
Engine start and stop time, Engine operating hours (Daily report and cumulative Alternator
operation hour), Engine operating hour distribution
Travel operating hours (Daily report and cumulative operation hour), Average Travel pressure sensor
pump delivery pressure distribution in travel operation
Front attachment operating hours (Daily report and cumulative operation hour) Front attachment pressure
sensor
Swing operating hours (Daily report and cumulative operation hour) Swing pressure sensor
Average pump delivery pressure distribution in digging operation Arm roll-in pressure sen-
sor
Breaker operating hours (Daily report and cumulative operation hour), Auxiliary Auxiliary pressure sensor
attachment except for breaker operating hours (Daily report and cumulative op-
eration hour)
Distribution of average pump delivery pressure, average pump delivery pressure Pump 1 delivery pressure
in digging operation and travel operation sensor
Distribution of average pump delivery pressure, average pump delivery pressure Pump 2 delivery pressure
in digging operation and travel operation sensor
Breaker operating hours (Daily report and cumulative operation hour) Attachment mode switch
Auxiliary attachment except for breaker operating hours (Daily report and cumula- Auxiliary mode switch
tive operation hour)
*ML operating hours (Daily report and cumulative operation hour) Crane mode switch
T5-7-10
TROUBLESHOOTING / ICX
Check harness between ICX terminal B1 and monitor In case hour meter malfunctions, refer to trouble-
terminal B3. shooting C.
Check harness between ICX terminal B1 and monitor In case coolant temperature gauge malfunctions, refer
terminal B3. to troubleshooting C.
Check harness between ICX terminal B1 and monitor In case fuel gauge malfunctions, refer to troubleshoot-
terminal B3. ing C.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
T5-7-11
TROUBLESHOOTING / ICX
(Blank)
T5-7-12
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Tel: 81-29-982-7084
Fax: 81-29-831-1162
E-mail: dc@hitachi-kenki.com
REPLY:
ZX330-3G CONNECTORS