TROUBLESHOOTING / Troubleshooting A: Fault Code List MC

TROUBLESHOOTING / Troubleshooting A
FAULT CODE LIST

MC
Controller Hardware Failure

Fault Trouble Cause Influenced Control
Code
11000-2 Abnormal EEPROM Faulty MC All Control
11001-2 Abnormal RAM Faulty MC All Control

11002-2 Abnormal A/D Conversion Faulty MC All Control
11003-3 Abnormal Sensor Voltage Faulty MC All Control
11004-2 Abnormal CAN Communication Faulty MC • Heater Control

• Speed Sensing Control
• Attachment Operation Speed
Increase Control
Limit Control
• Attachment Pump Torque
Decrease Control
• Pump 1 Flow Rate Limit Con-
trol
trol
• Attachment Flow Rate Con-
trol (Optional)
• Attachment Valve Selection
(Optional)
• ML Crane
• CAN Cycle Data Communica-
tion
T5-6-2
Symptoms in Machine Opera- Remedy for Dr. ZX Remark

tion When Trouble Occurs.
- Retrial B All Control

Although the engine control dial Retrial B All Control
is operated, engine speed does
not change.
• Machine movement is slow. Retrial B • Check CAN Harness
• The work mode alarm is dis- • Replace MC
played on the monitor unit.
T5-6-3
Engine Failure
Code
11100-2 Abnormal Engine Speed Engine Speed: Less than 4000 Speed Sensing Control
min-1
11101-3 Abnormal Engine Control Dial Voltage: 4.78 V or higher Engine Control Dial Control
Sensor High Voltage
11101-4 Abnormal Engine Control Dial Voltage: Less than 0.22 V Engine Control Dial Control
Sensor Low Voltage
T5-6-4

Machine movement is slow. Retrial B Check Harness
(During speed sensing, torque
is reduced.)
• Trouble condition with the Retrial B • Check Harness
key ON: Engine speed is kept • Replace Engine Control Dial
at idle speed.
• Trouble condition with the
key ON: engine speed is kept
at speed immediately before
trouble.
• Trouble condition with the Retrial B • Check Harness
key ON: Engine speed is kept • Replace Engine Control Dial
at idle speed.
• Trouble condition with the
key ON: engine speed is kept
at speed immediately before
trouble.
T5-6-5
Pump Failure
Code
11200-3 Abnormal Pump 1 Delivery Voltage: 4.5 V or higher • HP Mode Control
Pressure Sensor High Volt- • Travel HP Mode Control
age • E Mode Control
• Travel Torque-Up Control
• Arm Regenerative Control
• Digging Regenerative Control
• Auto-Power Lift Control
• Travel Motor Swash Angle Control
11200-4 Abnormal Pump 1 Delivery Voltage: Less than 0.25 V • HP Mode Control
Pressure Sensor Low Voltage • Travel HP Mode Control
• E Mode Control
11202-3 Abnormal Pump 2 Delivery Voltage: 4.5 V or higher • HP Mode Control
Pressure Sensor High Volt- • Travel HP Mode Control
age • E Mode Control
11202-4 Abnormal Pump 2 Delivery Voltage: Less than 0.25 V • HP Mode Control
Pressure Sensor Low Voltage • Travel HP Mode Control
• E Mode Control
11206-3 Abnormal Pump 1 Pump Voltage: 4.75 V or higher • E Mode Control
Control Pressure Sensor High • Heater Control
Voltage • Travel Motor Swash Angle Control
11206-4 Abnormal Pump 1 Pump Voltage: Less than 0.25 V • E Mode Control
Control Pressure Sensor Low • Heater Control
11208-3 Abnormal Pump 2 Pump Voltage: 4.75 V or higher • E Mode Control

Control Pressure Sensor High • Heater Control
11208-4 Abnormal Pump 2 Pump Voltage: Less than 0.25 V • E Mode Control
Control Pressure Sensor Low • Heater Control
T5-6-6
Symptoms in Machine Operation When Remedy for Dr. ZX Remark

Trouble Occurs.
• Combined operation of arm roll-in and Retrial B • Check Harness
boom raise or combined operation of • Replace Pump 1 Delivery Pressure
arm-roll-in and swing: Arm speed is Sensor
slow.
• Single operation of boom raise: Lifting
force is weak.
• Travel: Slow speed

slow.
• Single operation of boom raise: Lifting
force is weak.

slow.

slow.
• Although speed operating in E mode Retrial B • Check Harness

returns to P speed, returning speed • Replace Pump 1 Control Pressure
becomes low due to this failure. Sensor
T5-6-7
Pilot Failure
Code
11301-3 Abnormal Swing Pilot Pressure Voltage: 4.75 V or higher • Arm Regenerative Control
Sensor High Voltage • Attachment Flow Rate Control
• Swing Alarm Control
11301-4 Abnormal Swing Pilot Pressure Voltage: Less than 0.25 V • Arm Regenerative Control
Sensor Low Voltage • Attachment Flow Rate Control
• Swing Alarm Control
11302-3 Abnormal Boom Raise Pilot Voltage: 4.75 V or higher • HP Mode Control
Pressure Sensor High Voltage • Arm Regenerative Control
• Attachment Flow Rate Control
11302-4 Abnormal Boom Raise Pilot Voltage: Less than 0.25 V • HP Mode Control
Pressure Sensor Low Voltage • Arm Regenerative Control
11303-3 Abnormal Arm Roll-In Pilot Voltage: 4.75 V or higher • HP Mode Control
Pressure Sensor High Voltage • Arm Regenerative Control
11303-4 Abnormal Arm Roll-In Pilot Voltage: Less than 0.25 V • HP Mode Control
Pressure Sensor Low Voltage • Arm Regenerative Control
T5-6-8

• Combined operation of Retrial B • Check Harness
arm-roll-in and swing: Arm • Replace Swing Pilot Pressure
speed is slow. Sensor
• In case of the machine
equipped with the swing
alarm (optional) and when
swing alarm is effective,
swing alarm continues to
ring.
• Combined operation of Retrial B • Check Harness
arm-roll-in and swing: Arm • Replace Swing Pilot Pressure
speed is slow. Sensor
• In case of the machine
equipped with the swing
alarm (optional) and when
swing alarm is effective,
swing alarm continues to
ring.
• During HP control, boom Retrial B • Check Harness
raise speed does not in- • Replace Boom Raise Pilot
crease. Pressure Sensor
• Combined operation of arm
roll-in and boom raise: Arm
speed is slow.
• During HP control, boom Retrial B • Check Harness
raise speed does not in- • Replace Boom Raise Pilot
crease. Pressure Sensor
• Combined operation of arm
roll-in and boom raise: Arm
speed is slow.
• During HP control, arm roll-in Retrial B • Check Harness
speed does not increase. • Replace Arm Roll-In Pilot
• Combined operation of arm Pressure Sensor
roll-in and swing: Arm speed
is slow.
• During HP control, arm roll-in Retrial B • Check Harness
speed does not increase. • Replace Arm Roll-In Pilot
• Combined operation of arm Pressure Sensor
roll-in and swing: Arm speed
is slow.
T5-6-9

Code
11304-3 Abnormal Travel Pilot Pressure Voltage: 4.75 V or higher • Auto-Idle Control
Sensor High Voltage • Idle Speed-Up Control
• ECO Control
• Travel HP Mode Control
• Heater Control
• Pump 1 Flow Rate Limit Control
• Travel Motor Swash Angle Con-
trol
• Travel Alarm Control
11304-4 Abnormal Travel Pilot Pressure Voltage: Less than 0.25 V • Auto-Idle Control
Sensor Low Voltage • Idle Speed-Up Control
• ECO Control
• Heater Control
trol
• Travel Alarm Control
11307-3 Abnormal Front Attachment Pi- Voltage: 4.75 V or higher • Auto-Idle Control
lot Pressure Sensor High • Idle Speed-Up Control
Voltage • ECO Control
• Heater Control
trol
11307-4 Abnormal Front Attachment Pi- Voltage: Less than 0.25 V • Auto-Idle Control
lot Pressure Sensor Low • Idle Speed-Up Control
Voltage • ECO Control
• Heater Control
trol
T5-6-10
Symptoms in Machine Operation When Remedy for Dr. ZX Remark

Trouble Occurs.
• When traveling at idle speed, engine Retrial B • Check Harness
speed does not increase to the specifi- • Replace Travel Pilot Pressure
cation. Sensor
• When traveling, speed does not return
from auto idle speed.
from ECO speed.
• When operating ATT, the machine mis-
tracks.
• In case of the machine equipped with
the travel alarm (optional), travel alarm
continues to ring.
• When traveling at idle speed, engine Retrial B • Check Harness

speed does not increase to the specifi- • Replace Travel Pilot Pressure
cation. Sensor
from auto idle speed.
from ECO speed.
• When operating ATT, the machine mis-
tracks.
• In case of the machine equipped with
the travel alarm (optional), travel alarm
continues to ring.
• When operating the front attachment at Retrial B • Check Harness
idle speed, engine speed does not in- • Replace Front Pilot Pressure
crease to the specification. Sensor
• When operating the front attachment,
speed does not return from auto idle
speed.
speed does not return from ECO speed.
• Although the front attachment is oper-
ated, travel becomes fast.
• When operating the front attachment at Retrial B • Check Harness
idle speed, engine speed does not in- • Replace Front Pilot Pressure
crease to the specification. Sensor
speed does not return from auto idle
speed.
speed does not return from ECO speed.
• Although the front attachment is oper-
ated, travel becomes fast.
T5-6-11
Proportional Solenoid Valve Failure
Code
11400-2 Abnormal Current Feedback of Current: Both of Higher Pump 2 Flow Rate Limit Control
Maximum Pump 2 Flow Rate Limit than 920mA or Less
Control Solenoid Valve than 60 mA
11400-3 Abnormal Feedback High Current of Current: Higher than Pump 2 Flow Rate Limit Control
Maximum Pump 2 Flow Rate Limit 920mA
Control Solenoid Valve
11400-4 Abnormal Feedback Low Current of Current: Less than 56 Pump 2 Flow Rate Limit Control
Maximum Pump 2 Flow Rate Limit mA
Control Solenoid Valve
11401-2 Abnormal Current Feedback of Current: Both of Higher • Speed Sensing Control
Torque Control Solenoid Valve than 920mA or Less • Travel Torque-Up Control
than 60 mA • Attachment Pump Torque De-
crease Control
11401-3 Abnormal Feedback High Current of Current: Higher than • Speed Sensing Control
Torque Control Solenoid Valve 920 mA • Travel Torque-Up Control
• Attachment Pump Torque De-
crease Control
11401-4 Abnormal Feedback Low Current of Current: Less than 56 • Speed Sensing Control
Torque Control Solenoid Valve mA • Travel Torque-Up Control
• Attachment Pump Torque De-
crease Control
11402-2 Abnormal Current Feedback of So- Current: Both of Higher Digging Regenerative Control
lenoid Valve Unit (SF) (Digging than 920mA or Less
Regeneration) than 60 mA
11402-3 Abnormal Feedback High Current of Current: Higher than Digging Regenerative Control
Solenoid Valve Unit (SF) (Digging 920mA
Regeneration)
11402-4 Abnormal Feedback Low Current of Current: Less than 56 Digging Regenerative Control
Solenoid Valve Unit (SF) (Digging mA
Regeneration)
11403-2 Abnormal Current Feedback of So- Current: Both of Higher Arm Regenerative Control
lenoid Valve Unit (SC) (Arm than 920mA or Less
Regeneration) than 60 mA
11403-3 Abnormal Feedback High Current of Current: Higher than Arm Regenerative Control
Solenoid Valve Unit (SC) (Arm Re- 920mA
generation)
11403-4 Abnormal Feedback Low Current of Current: Less than 56 Arm Regenerative Control
Solenoid Valve Unit (SC) (Arm Re- mA
generation)
11404-2 Abnormal Current Feedback of So- Current: Both of Higher • Power Digging Control
lenoid Valve Unit (SG) (Relief than 920mA or Less • Auto-Power Lift Control
Pressure Control) than 60 mA
11404-3 Abnormal Feedback High Current of Current: Higher than • Power Digging Control
Solenoid Valve Unit (SG) (Relief 920mA • Auto-Power Lift Control
Pressure Control)
11404-4 Abnormal Feedback Low Current of Current: Less than 56 • Power Digging Control
Solenoid Valve Unit (SG) (Relief mA • Auto-Power Lift Control
Pressure Control)
T5-6-12
Symptoms in Machine Operation When Trouble Occurs. Remedy for Remark

Dr. ZX
In case ATT flow rate is limited, it cannot be limited. Retrial B • Check Harness
Actual Operation of Proportional Valve during High Current: Retrial B • Check Harness
• Travel mistacks.
• Boom raise operation is slow.
• Arm operation is slow.
• Swing operation is slow.
Actual Operation of Proportional Valve during Low Current: Retrial B • Check Harness
• In case ATT flow rate is limited, it cannot be limited.
Machine overall operation is slow. Retrial B • Check Harness
• The engine is stalled at Li speed.
• Engine Speed: Middle to Fast: Engine Stall or Large Lug Down
• Machine overall operation is slow.
During digging, arm speed is slow. (As deceleration rate is low, Retrial B • Check Harness
this state is not easy to find.)
• Combined operation of boom rasie and arm roll-in during lift-
ing/precision: The boom raise operation is not smooth.
• During digging, arm speed is slow. (As deceleration rate is low,
this state is not easy to find.)
Combined operation of boom raise and arm roll-in with the front Retrial B • Check Harness
attachment over ground, the boom is not raised smoothly and the
arm roll-in full-speed is slow.
• Digging force (arm) becomes weak.
• Combined operation of boom raise and arm roll-in with the front
attachment over ground, the boom is not raised smoothly and
the arm roll-in full-speed is slow.
Pressure increasing is impossible. Retrial B • Check Harness
• Pressure always increases.
• Pressure increasing is impossible.
T5-6-13

Code
11405-2 Abnormal Current Feedback of Current: Both of Higher than Travel Motor Swash Angle
Solenoid Valve Unit (SI) (Travel 920mA or Less than 60 mA Selection Control
Motor Fast Speed Selection)
11405-3 Abnormal Feedback High Cur- Current: Higher than 920mA Travel Motor Swash Angle
rent of Solenoid Valve Unit (SI) Selection Control
(Travel Motor Fast Speed Se-
lection)
11405-4 Abnormal Feedback Low Cur- Current: Less than 56 mA Travel Motor Swash Angle
rent of Solenoid Valve Unit (SI) Selection Control
(Travel Motor Fast Speed Se-
lection)
11410-2 Abnormal Current Feedback of Current: Both of Higher than • Pump 1 Flow Rate Limit
Maximum Pump 1 Flow Rate 920mA or Less than 60 mA Control
Limit Control Solenoid Valve • Travel Pump Flow Rate
(Optional)
11410-3 Abnormal Feedback High Cur- Current: Higher than 920mA • Pump 1 Flow Rate Limit
rent of Maximum Pump 1 Flow Control
Rate Limit Control Solenoid • Travel Pump Flow Rate
Valve (Optional)
11410-4 Abnormal Feedback Low Cur- Current: Less than 56 mA • Pump 1 Flow Rate Limit
rent of Maximum Pump 1 Flow Control
Rate Limit Control Solenoid • Travel Pump Flow Rate
Valve (Optional)
T5-6-14

Dr. ZX
Travel motor is always slow. Retrial B • Check Harness
Operation of Proportional Valve during High Current: Retrial B • Check Harness

• Travel motor is always slow.
Operation of Proportional Valve during Low Current: Retrial B • Check Harness

• Travel motor is always slow.
In case ATT flow rate is limited, it cannot be limited. Retrial B • Check Harness
• Travel mistacks.
• Boom raise operation is slow.
• Arm operations (roll-in, roll-out) are slow.
• Bucket roll-in and Dump operations are slow.
Operation of Proportional Valve during Low Current: Retrial B • Check Harness
• In case ATT flow rate is limited, it cannot be limited.
T5-6-15
CAN Data Reception Failure
Code
11910-2 Actual Engine Speed Faulty Harness • Speed Sensing Control
Received from ECM • Send to ICF
11918-2 Work Mode Faulty Harness • Attachment Operation Speed

Received from Monitor Unit Increase Control
Limit Control
• Attachment Pump Torque
Decrease Control
trol
trol
• Attachment Flow Rate Con-
trol
• Attachment Valve Selection
(Optional)
11919-2 ML Crane Faulty Farness ML Crane
Received from Monitor Unit
11911-2 Security Signal Faulty Harness Theft Prevention Engine Speed,
Received from ECM Engine Torque
11920-2 Fuel Flow Rate Faulty Harness Fuel Flow Rate
Received from ECM
11914-2 Radiator Coolant Temperature Faulty Harness Heater Control
Received from ECM
T5-6-16

Dr. ZX
Machine operation speed is slow. (During speed sensing, Retrial B • Check Harness
torque is decreased.)
During e-service, the engine is stalled.
• Digging Mode: Lock Retrial B • Check Harness
In case flow rate is decreased and speed decreases during
ATT, stop this control, or Digging is not changed into ATT
mode.
• Work Mode Alarm is displayed on the monitor unit.
T1V1-05-01-102C
Until this failure is recovered, although the ML switch is Retrial B • Check Harness
pushed down, engine speed does not decrease to ML speed.
In case theft prevention is turned ON by Dr. ZX, engine Retrial B • Check Harness
speed is kept at Minimum speed and pump torque is kept
Minimum.
When the monitor setting is displayed fuel consumption at Retrial B • Check Harness
moment, engine display at moment is “----“.
Heater Control: Ineffective Retrial B • Check Harness
T5-6-17
Other Failures
Code
11901-3 Hydraulic Oil Temperature Voltage: 4.52 V or higher • Auto-Warming Up Control
Sensor High Voltage • Arm Regenerative Control
11901-4 Hydraulic Oil Temperature Voltage: Less than 0.23 V • Auto-Warming Up Control
Sensor Low Voltage • Arm Regenerative Control
T5-6-18

Dr. ZX
When temperature is low (hydraulic oil temperature is less Retrial B • Check Harness
than 0 °C), the auto-warming up control is inoperable.
When temperature is low (hydraulic oil temperature is less Retrial B • Check Harness
than 0 °C), the auto-warming up control is inoperable.
T5-6-19
ECM
Sensor System
Fault Trouble Cause
Code
636-2 Abnormal Cam Angle Sensor (No Signal) Although the crank signal is present, the cam signal is
not present.
636-2 Abnormal Cam Angle Sensor (Abnormal The pulse of cam signal is not matched.
Signal)
723-2 Abnormal Crank Speed Sensor (No Sig- Although the cam signal is present, the crank signal is
nal) not present.
723-2 Abnormal Crank Speed Sensor (Abnor- The pulse of crank signal is not matched.
mal Signal)
636-7 Phase Mismatch of Cam Angle Sensor The right cam pulse is not present at the gap in the
crank.
172-3 Abnormal Intake-Air Temperature Sensor Voltage at the intake-air temperature sensor is be-
(Abnormal High Voltage) yond 4.95 V in 3 minutes after the engine starts.
172-4 Abnormal Intake-Air Temperature Sensor Voltage at the intake-air temperature sensor is below
(Abnormal Low Voltage) 0.1 V.
110-3 Abnormal Coolant Temperature Sensor Voltage at the coolant temperature sensor is beyond
(Abnormal High Voltage) 4.85 V.
110-4 Abnormal Coolant Temperature Sensor Voltage at the coolant temperature sensor is below
(Abnormal Low Voltage) 0.1 V
102-4 Abnormal Boost Pressure Sensor (Ab- Voltage at the boost pressure sensor is beyond 4.9 V.
normal High Voltage)
102-3 Abnormal Boost Pressure Sensor (Ab- Voltage at the boost pressure sensor is below 0.1 V
normal Low Voltage)
10001-3 Abnormal EGR Position (Brushless The condition which the output signal of EGR position
spec.) cannot be present in.
108-4 Abnormal Atmospheric Pressure Sensor Voltage at the atmospheric pressure sensor is beyond
108-3 Abnormal Atmospheric Pressure Sensor Voltage at the atmospheric pressure sensor is below
174-3 Abnormal Fuel Temperature Sensor (Ab- Voltage at the fuel temperature sensor is beyond 4.85
normal High Voltage) V in 3 minutes after the engine starts.
174-4 Abnormal Fuel Temperature Sensor (Ab- Voltage at the fuel temperature sensor is below 0.1 V.
normal Low Voltage)
T5-6-20
Presumptive Symptoms in Real Machine Opera- Assumptive Conditions at Backup Fault Code
tion (Tech 2)
• While the engine runs, there is nothing abnor- While the engine runs, operate according to P0340
mal with machine operation. standard of the crank sensor. When the en-
• After the engine is stalled, the re-start is im- gine stops, the start is impossible (in order to P0341
possible. prevent the engine from damaging).
• The output power may decrease, white smoke Operate according to standard of the cam sen- P0335
may occur and vibration may occur. sor.
• The engine may be stalled. (If the cam senor is P0336
normal, the engine can re-start.)
• While the engine runs, there is nothing abnor- The timing chain and the belt does not turn P1345
mal with machine operation. smoothly but turn in reverse.
• After the engine is stalled, the re-start is im-
possible.
Nothing special When starting: -10 °C (14 °F) (Start the engine P0113
although what state.)
When operating: 25 °C (77 °F) (Operate nor- P0112
mally.)
Normal temperature: When starting, dark smoke When starting: -20 °C (-4 °F) (Start the engine P0118
may occur and engine combustion sound may be although what state.)
become loud. When operating: 80 °C (176 °F) (Operate
While warming up with fresh air in low tempera- normally.) P0117
ture: Rough idle, engine stall or while smoke may
be occur.
Dark smoke occurs. Boost pressure cannot be corrected. P0238
P0237
There is influence to exhaust gas. As the sensor input is not certain, it cannot be P0487
controlled. Exhaust gas becomes bad.
Operate the engine with EGR valve fully open.
Dark smoke occurs at high altitude. Atmospheric pressure 80 kPa (0.8 kgf/cm2, 12 P0108
psi) (2000 m above the sea)
O0107
Nothing special When starting: -20 °C (-4 °F) (Start the engine P0183
although what state.)
When operating: 70 °C (158 °F) (Operate nor- P0182
mally.)
T5-6-21
Fault Trouble Cause

Code
157-3 Abnormal Common Rail Pressure
Sensor Voltage at the common rail pressure sensor is beyond
Sensor Voltage at the common rail pressure sensor is below
100-4 Abnormal Engine Oil Pressure
Sensor Voltage at the engine oil pressure sensor is beyond
Sensor Voltage at the engine oil pressure sensor is below 0.1
(Abnormal Low Voltage) V.
105-3 Abnormal Boost Temperature Sensor Voltage at the boost temperature sensor is beyond
(Abnormal High Voltage) 4.95 V over 5 minutes after the engine starts or when
coolant temperature is beyond 50 °C (122 °F).
105-4 Abnormal Boost Temperature Sensor Voltage at the boost temperature sensor is below 0.1
(Abnormal Low Voltage) V.
T5-6-22
Presumptive Symptoms in Real Machine Opera- Assumptive Conditions at Backup Fault Code
tion (Tech 2)
The engine may be stalled. The output power The supply pump can not be controlled. P0193
decreases.
P0192
There is no influence when operating the ma- Nothing special P0523

chine.
P0522
There is no influence when operating the ma- Nothing special P1113

chine.
P1112
T5-6-23
TROUBLESHOOTING/ Troubleshooting A
Influence to Engine Operating Rank

Fault Code Trouble Performance (Current State) Remark
(Presumption) A B C D
636-2 Abnormal Cam Angle Sensor (No No influence during
○ ○
Signal) operationg
636-2 Abnormal Cam Angle Sensor After stopping, the
○ ○
(Abnormal Signal) re-start is impossible.
723-2 Abnormal Crank Speed Sensor (No No output power
○
Signal) decrease
723-2 Abnormal Crank Speed Sensor
○
(Abnormal Signal)
636-7 Phase Mismatch of Cam Angle No influence during
Sensor operationg
○ ○
After stopping, the
re-start is impossible.
172-3 Abnormal Intake-Air Temperature No output power
○
Sensor (Abnormal High Voltage) decrease
172-4 Abnormal Intake-Air Temperature
○
Sensor (Abnormal Low Voltage)
110-3 Abnormal Coolant Temperature No output power
○
110-4 Abnormal Coolant Temperature
○
102-4 Abnormal Boost Pressure Sensor No output power
○
(Abnormal High Voltage) decrease
102-3 Abnormal Boost Pressure Sensor
○
(Abnormal Low Voltage)
10001-3 Abnormal EGR Position (Brushless No output power
○
spec.) change
108-4 Abnormal Atmospheric Pressure No output power
○
108-3 Abnormal Atmospheric Pressure
○
174-3 Abnormal Fuel Temperature Sensor No output power
○
(Abnormal High Voltage) decrease
174-4 Abnormal Fuel Temperature Sensor
○
157-3 Abnormal Common Rail Pressure Output power
○
Sensor (Abnormal High Voltage) decrease: 70%
○
100-4 Abnormal Engine Oil Pressure No output power
○
Sensor (Abnormal High Voltage) change
○
T5-6-24
Influence to Engine
Fault Operating Rank
Trouble Performance Remark
Code (Current State)
(Presumption)
105-3 Abnormal Boost Temperature Sensor No output power
○
(Abnormal High Voltage) change
105-4 Abnormal Boost Temperature Sensor
○
Operating Rank
A： Diggingis operabel.
B： Machine can travel with boom raised. (Steering is impossible.)
C： The engine only runs. (Travel, digging and operation with light load are impossible.)
D： The engine cannot stop/ start.
T5-6-25
External Device System
Fault Code Trouble Cause
10002-2 Abnormal EGR valve control Difference between the target valve lift and actual position
isbeyond 20%.
1347-0 Open circuit in suction control valve The suctioncontrol valve drive current is beyond 2400 mA or
drive system, Shorted circuit in + B or below 50 mA. Or, difference between the tartget current and
GND actual current is 1000 mA or more.
651-3 Open circuit in injection nozzle ＃1 No input signal of injector 1 monitor.

drive system
drive system
drive system
654-3 Open circuit in injection nozzle #4 No input signal of injector 4 monitor.
drive system
drive system
drive system
T5-6-26
Presumptive Symptoms in Real Machine Fault Code

Assumptive Conditions at Backup
Operation (Tech 2)
There is influence to exhaust gas. EGR cannot be controlled. P0488
As exhaust gas becomes bad, EGR stops.
The engine may be stalled and the rotation The supply pump cannot be controlled. P0090
speed increases automatically and abnormally → Prevent the engine from increasing the rotation
according to open or shorted circuitc ondition. speedautomatically and abnormally (Protect the
Dark smoke occurs. Output power is too large. engine).
Vibration of the engine is large, Rough idle, #1 injector cannot be controlled. P0201
output power decrease, faulty increasing of → Stop drive pulse output of #1 injector.
rotation speed, output power decrease
#2 injector cannot be controlled. P0202
→ Stop drive pulse output of #2 injector.
T5-6-27
Fuel System
157-0 Abnormal common rail pressure Common rail pressure is beyond 185 Mpa.
(First stage)
157-0 Abnormal commo rail pressure The first stage “Abnormal common rail presure” is
(Second stage) approveand commonrail pressure is beyond 190 Mpa.
157-2 Abnormal commonrail pressure When DUTY to the suction control valve is 40 % or more, or
(Pump over-pressure) target pressure to the suction control valve is 90 mm3/sec or
less, actual rail pressure is 40 MPa (410 kgf/cm2, 5820 psi)
higher than the target rail pressure.
633-7 Pressure limiter open The pressure limiter is open.
1240-1 No pressure to pump (Fuel leakage) When DUTY to the suction control valve is 33 % or less, or
pressure to the suction control valve is 28000 mm3/sec or
more and 1200 min-1, actual rail pressure is 50 MPa (510
kgf/cm2, 7270 psi) lower than the target rail pressure.
1239-1 No pressure to pump (Fuel leakage) When pressure to the suction control valve is 900 min-1,
actual rail pressure is 15Mpa (150 kgf/cm2, 2180 psi) or less.
T5-6-28

Operation (Tech 2)
Vibration of the engine may be large, Rough idle, Prevention the junection system (pump) from P0088
output power decrease may occur, faulty damage
increasing of rotation speed, dark smoke may (Protect the RP sensor by over-pressure)
occur, output power may be too large.
Vibration of the engine may be large, Rough idle, Prevention the junection system from damage P0088
output power decrease may occur, faulty (Pressure is too much as PR is clogged.)
increasing of rotation speed, dark smoke may
Vibration of the engine may be large, Rough idle, Prevention the junection system (pmp) from P0089
output power decrease may occur, faulty damage
increasing of rotation speed, dark smoke may (Protect the RP sensor by over-pressure)
Output power decrease Rial pressure is beyond the allowable pressure. P1095
Vibration of the engine may be large, Rough idle, Fuel leakage is too much. P1093
output power decrease may occur, faulty Difference between target rail pressure and actual
increasing of rotation speed, dark smoke may rail pressure is larger than the specification.
occur, output power may be too large. (Large deflection)
Vibration of the engine may be large, Rough idle, Fuel leakage is too much. P0087
output power decrease may occur, faulty Actual rail pressure does not increase to the
increasing of rotation speed, dark smoke may required pressure.
T5-6-29

Fault (Current)
Code
10002-2 Abnormal EGR valve control No output power
○
change
1347-0 Open circuit in suction control valve Output power
drive system, Shorted circuit in + B or decrease: 50% ○
GND
651-3 Open circuit in injection nozzle ＃ 1 Output power
○
drive system decrease: 15%
652-3 Open circuit in injection nozzle ＃ 2 (Five cylinders drive.)
○
drive system
653-3 Open circuit in injection nozzle ＃ 3
○
drive system
○
drive system
○
drive system
○
drive system
Operating Rank
Influence to Engine (Current)
Fault
Code
157-0 Abnormal common rail pressure (First Output power
○
stage) decrease: 50%
157-0 Abnormal commo rail pressure Output power
○
(Second stage) decrease: 50%
157-2 Abnormal commonrail pressure Output power
○
(Pump over-pressure) decrease: 50%
633-7 Pressure limiter open Output power
○
decrease: 50%
1240-1 No pressure to pump (Fuel leakage) Output power ○
1239-1 No pressure to pump (Fuel leakage) decrease: 50% ○
Operating Rank
D： The engine cannot stop / start.
T5-6-30
(Blank)
T5-6-31
110-0 Overheating Coolant temperature is beyond 120 °C (248 °F) when

operating the engine.
190-0 Overrunning In case the engine speed is beyond 2500 min-1
987-3 Abnormal check engine lamp No monitor signal of the check engine lamp
1485-2 Abnormal main relay system Voltage in the main relay system is 1 V or less with the main
relay coil output ON.
Although the main relay coil output is turned OFF, the main
relay is keot ON.
T5-6-32

Operation (Tech 2)
There is no influence when operating the Nothing special (The history of overheating is P1173
machine. recorded.)
Engine speed of the excavator may not increase Mistake of gear change, etc. P0219
2500 min-1 or more.

Operation (Tech 2)
There is no influence when operating the Nothing special
machine. P0650
The engine cannot start. Nothing
P1625
Electrical power is kept supplying to the Nothing
machine.
T5-6-33
Operating Ranke
Influence to Engine (Current)
Fault
Code
110-0 Overheating No output power

○
change
190-0 Overrunning No output power
○
change
Influence to Engine Operating Ranke

Fault (Current)
Code
987-3 Abnormal check engine lamp No output power
○
change
1485-2 Abnormal main relay system The engine stops. ○
Nothing (The engine
cannot re-start
○ ○
according to battery
voltage.)
Operating Rank
T5-6-34
(Blank)
T5-6-35
Internal Circuit System
10005-1 Abnormal Charge Circuit (Bank 1) In case volate at bank 1 of charge circuit in ECM is low
10006-1 Abnormal Charge Circuit (Bank 2) In case volate at bank 2 of charge circuit in ECM is low
10008-2 Abnormal A/D Conversion A/D conversion cannot be done.

10007-2 Abnormal CPU Within 100 msec after the key switch is turned ON, failure of
main CPU is detected by sub CPU.
(Sub CPU resets CPU.)
1077-2 Abnormal IC for CPU watching No change of RUN-SUB pulse in 20 msec
628-2 Abnormal ROM ROM is broken.
10013-2 Abnormal EEPROM EEPROM is broken.
1079-2 Abnormal 5 V Power Source 1 When battery volate is between 16 V and 32 V, voltage of
Voltage IGKEY power source is 5.5 V or more or 4.5 V or less.
10003-2 Abnormal Injection Nozzle Common No monitor siganals of injectors 1, 3, 5

1 Drive System
10004-2 Abnormal Injection Nozzle Common No monitor siganals of injectors 2, 4, 6
2 Drive System
T5-6-36

Operation (Tech 2)
Vibration of the engine may be large, Rough idle, The injector cannot be controlled. P0611
output power decrease may occur, faulty → Stop output of drive signal at broken common
increasing of rotation speed may occur, the side
engine may be stalled. (Protect the engine from damage) P0612
Output power decrease, dark smoke occur. All analogue sensor cannot be used. P1630
Output power decrease CPU is broken. P0606
The engine cannot start. P0606
Output power decrease Sub CPU is broken. P0601

The engine stops. Data of ROM cannot be read. P1603
There is no influence when operating the Data cannot be written to EEPROM. P1631
machine.
Same as Abnormal accelerator Sensor ← P1632
Same as Abnomal atmospheric and in-take ← P1633

temperaturecsensors
Same as Abnomal coolant temperature, fuel ← P1634

temperature and hydraulic oil pressure sensors
Same as Abnomal boost pressure and boost ← P1635

temperature sensors
Same as Abnomal rail pressure and EGR ← P1261

position sensors
Vibration of the engine may be large, Rough idle, The injector cannot be controlled. P1262
output power decrease may occur, faulty → Stop output of drive signal at broken common
increasing of rotation speed may occur, the side
engine may be stalled. (Protect the engine from damage)
T5-6-37

Fault Code Trouble Performance (Current) Remark
10005-1 Abnormal Charge Circuit (Bank 1) Output power ○ ○
10006-1 Abnormal Charge Circuit (Bank 2) decrease: 60%
○ ○
(Three cylinders drive.)
10008-2 Abnormal A/D Conversion Output power
○
decrease: 50%
10007-2 Abnormal CPU Output power
○
decrease: 50%
The engine cannot
○
start.
1077-2 Abnormal IC for CPU watching Output power
○
decrease: 50%
628-2 Abnormal ROM The engine stops. ○
10013-2 Abnormal EEPROM No output power
○
decrease
1079-2 Abnormal 5 V Power Source 1 Voltage Idle Speed Operation ○
1080-2 Abnormal 5 V Power Source 2 Voltage No output power
○
decrease
○
change
○
decrease
10011-2 Abnormal 5 V Power Source 5 Voltage Output power
○ ○
decrease: 50%
10003-2 Abnormal Injection Nozzle Common 1 Output power
○ ○
Drive System decrease: 60%
10004-2 Abnormal Injection Nozzle Common 2 (Three cylinders drive.)
○ ○
Drive System
Operating Rank
T5-6-38
(Blank)
T5-6-39
Communication System
639-2 Abnormal CAN Bus Line Detect the bus line off.
639-3 Abnormal CAN Time Out In case the CAN data reception is not approved in
prescribedtime
T5-6-40

Operation (Tech 2)
Speed is turnd into idle speed. CAN communication is operable. U2104
U2106
T5-6-41

Fault
Trouble Performance (Current) Remark
Code
639-2 Abnormal CAN Bus Line Idle speed ○
639-3 Abnormal CAN Time Out ○
T5-6-42
(Blank)
T5-6-43
ICF
14000-2 Abnormal CAN Communication Data cannot be received due to the noise on the CAN bus
line.
14001-2 ICF: Flash Memory: Read / Write In case the internal memory is abnormal when the key is
Error turned ON
14002-2 ICF: External RAM: Read / Write In case the internal memory is abnormal when the key is
Error turned ON
14003-2 ICF: EEPROM: Sum Check Error In case the internal memory is abnormal when the key is
turned ON
14006-2 ICF: Satellite Communication In casse communication to the satellite terminal cannot be
Terminal: Communication Error done over 30 seconds.
14008-2 ICF: Abnormal Internal RAM In case the internal memory is abnormal when the key is
turned ON
T5-6-44
Fault Code Remedy
14000-2 Check for CAN communication bus line.
14001-2 After initializng the information C/U by using Dr. ZX, re-try in the troubleshooting.
If the error code is displayed after re-try, ICF may be broken.
Replace ICF.
NOTE: When initialising the information C/U, all stored data is deleted.
14002-2 After initializng the information C/U by using Dr.ZX, re-try in the troubleshooting.
Replace ICF.
NOTE: When initialising the information C/U, all stored data is deleted.
14003-2 As ICF may be broken, replace ICF.
14006-2 Check for the items below.

1. Check if the communication line is abnormal.
2. Check if the electrical power source of communication terminal is abnormal.
• Electrical power source
• Fuses
3. Check if the satellilte terminal is broken.
14008-2 Re-try in the troubleshooting by using Dr.ZX.
T5-6-45
Satellite Terminal
14100-2 Satellite Communication Terminal: Data cannot be received due to the noise on the CAN bus
Abnormal EEPROM line.
14101-2 Satellite Communication Terminal: In case the internal memory is abnormal when the key is
Abnormal IB/OB Queue turned ON
Abnormal Local Loup Back turned ON
The satellite is not found. turned ON
14104-2 Satellite Communication Terminal: In casse communication to the satellite terminal cannot be
Fail 1 of Remote Loup Back done over 30 seconds.
Fail 2 of Remote Loup Back turned ON
14106-2 Satellite Communication Terminal: In case sending and receiving data are unmatched.
Sending and receiving data are
mistached.
T5-6-46
Fault Code Remedy
14100-2 Replace the controller.
T5-6-47
Monitor Unit
13303-2 Abnormal Thermister Temperature Thermister temperature is 85 °C (185 °F) or higher.

13304-2 Abnormal REG Input H Level During REG input H level
13305-2 Abnormal Manual Glow EXT Output In case Glow EXT input is not matched with Glow EXT output
13306-2 Abnormal EEPROM When failure reading EEPROM occurs
13308-2 Abnormal CAN Communication Bus off occurs beyond five times.
13310-2 Shorted circuit in Coolant The state, input 105±30 Ω or less, is kept over 60 seconds.
Temperature Sensor
13311-2 Shorted circuit in Fuel Leverl Sensor The state, input 3±1 Ω or less, is kept over 60 seconds.
13311-4 Open circuit in Fuel Leverl Sensor The state, input 135±20 Ω or less, is kept over 60 seconds.
T5-6-48

TROUBLESHOOTING / Troubleshooting A: Fault Code List MC

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TROUBLESHOOTING / Troubleshooting A: Fault Code List MC

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TROUBLESHOOTING / Troubleshooting A

FAULT CODE LIST

Controller Hardware Failure

11001-2 Abnormal RAM Faulty MC All Control

11004-2 Abnormal CAN Communication Faulty MC • Heater Control

Symptoms in Machine Opera- Remedy for Dr. ZX Remark

- Retrial B All Control

Symptoms in Machine Opera- Remedy for Dr. ZX Remark

11208-3 Abnormal Pump 2 Pump Voltage: 4.75 V or higher • E Mode Control

Symptoms in Machine Operation When Remedy for Dr. ZX Remark

• Combined operation of arm roll-in and Retrial B • Check Harness

• Combined operation of arm roll-in and Retrial B • Check Harness

• Combined operation of arm roll-in and Retrial B • Check Harness

• Although speed operating in E mode Retrial B • Check Harness

Symptoms in Machine Opera- Remedy for Dr. ZX Remark

Fault Trouble Cause Influenced Control

Symptoms in Machine Operation When Remedy for Dr. ZX Remark

• When traveling at idle speed, engine Retrial B • Check Harness

Symptoms in Machine Operation When Trouble Occurs. Remedy for Remark

Machine overall operation is slow. Retrial B • Check Harness

Fault Trouble Cause Influenced Control

Symptoms in Machine Operation When Trouble Occurs. Remedy for Remark

Operation of Proportional Valve during High Current: Retrial B • Check Harness

Operation of Proportional Valve during Low Current: Retrial B • Check Harness

11918-2 Work Mode Faulty Harness • Attachment Operation Speed

Symptoms in Machine Operation When Trouble Occurs. Remedy for Remark

Symptoms in Machine Operation When Trouble Occurs. Remedy for Remark

Fault Trouble Cause

There is no influence when operating the ma- Nothing special P0523

There is no influence when operating the ma- Nothing special P1113

Influence to Engine Operating Rank

External Device System

Fault Code Trouble Cause

651-3 Open circuit in injection nozzle ＃1 No input signal of injector 1 monitor.

Presumptive Symptoms in Real Machine Fault Code

Fault Code Trouble Cause

Presumptive Symptoms in Real Machine Fault Code

Influence to Engine Operating Rank

Fault Code Trouble Cause

110-0 Overheating Coolant temperature is beyond 120 °C (248 °F) when

190-0 Overrunning In case the engine speed is beyond 2500 min-1

Fault Code Trouble Cause

Presumptive Symptoms in Real Machine Fault Code

Presumptive Symptoms in Real Machine Fault Code

The engine cannot start. Nothing

110-0 Overheating No output power

Influence to Engine Operating Ranke

Internal Circuit System

Fault Code Trouble Cause

10008-2 Abnormal A/D Conversion A/D conversion cannot be done.

10003-2 Abnormal Injection Nozzle Common No monitor siganals of injectors 1, 3, 5

Presumptive Symptoms in Real Machine Fault Code

The engine cannot start. P0606

Output power decrease Sub CPU is broken. P0601

Same as Abnormal accelerator Sensor ← P1632

Same as Abnomal atmospheric and in-take ← P1633

Same as Abnomal coolant temperature, fuel ← P1634

Same as Abnomal boost pressure and boost ← P1635

Same as Abnomal rail pressure and EGR ← P1261

Influence to Engine Operating Rank

Fault Code Trouble Cause

Presumptive Symptoms in Real Machine Fault Code