Zx450 3 Troubleshoot
Zx450 3 Troubleshoot
Zx450 3 Troubleshoot
URL:http://www.hitachi-c-m.com
TM_E(TT)
Page 1
TT1J1-E-00
Technical Manual
Troubleshooting
450-3
450LC-3
470H-3
470LCH-3
500LC-3
520LCH-3
Hydraulic Excavator
Service Manual consists of the following separate Part No;
Technical Manual (Operational Principle)
: Vol. No.TO1J1-E
Technical Manual (Troubleshooting)
: Vol. No.TT1J1-E
Workshop Manual
: Vol. No.W1J1-E
2006.1.6, 15:08
INTRODUCTION
TO THE READER
This manual is written for an experienced technician
to provide technical information needed to maintain
and repair this machine.
Be sure to thoroughly read this manual for correct
product information and service procedures.
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition
to this manual.
MANUAL COMPOSITION
This manual consists of three portions: the Technical Manual (Operational Principle), the Technical
Manual (Troubleshooting) and the Workshop Manual.
Information included in the Technical Manual
(Operational Principle):
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems.
PAGE NUMBER
Each page has a number, located on the center
lower part of the page, and each number contains
the following information:
Example : T 1-3-5
W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the
potential for personal injury of machine damage.
IMPORTANT:
CAUTION:
Indicated potentially hazardous situation which could,
if not avoided, result in personal injury or death.
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
NOTE:
Indicates supplementary technical information or
know-how.
UNITS USED
SI Units (International System of Units) are used in
this manual.
MKSA system units and English units are also
indicated in parenthheses just behind SI units.
Quantity
Length
Volume
Weight
Force
Torque
To Convert
From
mm
mm
L
L
3
m
kg
N
N
Nm
Nm
Into
in
ft
US gal
US qt
3
yd
lb
kgf
lbf
kgfm
lbfft
Quantity
Multiply By
0.03937
0.003281
0.2642
1.057
1.308
2.205
0.10197
0.2248
1.0197
0.7375
Pressure
Power
Temperature
Velocity
Flow rate
IN-02
To Convert
From
MPa
MPa
kW
kW
C
km/h
-1
min
L/min
mL/rev
Into
Multiply By
2
kgf/cm
psi
PS
HP
F
mph
rpm
US gpm
cc/rev
10.197
145.0
1.360
1.341
C1.8+32
0.6214
1.0
0.2642
1.0
SAFETY
RECOGNIZE SAFETY INFORMATION
These are the SAFETY ALERT SYMBOLS.
001-E01A-0001
SA-688
SA-1
SA-1223
SAFETY
FOLLOW SAFETY INSTRUCTIONS
003-E01B-0003
SA-2
SA-003
SAFETY
PREPARE FOR EMERGENCIES
SA-437
004-E01A-0437
SA-3
SA-428
SAFETY
PROTECT AGAINST NOISE
006-E01A-0434
SA-434
INSPECT MACHINE
007-E01A-0435
SA-435
SA-4
SAFETY
GENERAL PRECAUTIONS FOR CAB
524-E01A-0000
SA-5
SAFETY
USE HANDHOLDS AND STEPS
008-E01A-0439
SA-439
SA-6
SA-462
SAFETY
ENSURE SAFETY BEFORE RISING FROM
OR LEAVING OPERATOR'S SEAT
Before rising from the operator's seat to open/close
Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If
any item is damaged or worn, replace the seat
belt or component before operating the machine.
Be sure to remain seated with the seat belt securely fastened at all times when the machine is
in operation to minimize the chance of injury from
an accident.
We recommend that the seat belt be replaced
every three years regardless of its apparent condition.
010-E01A-0237
SA-7
SA-237
SAFETY
MOVE AND OPERATE MACHINE SAFELY
Bystanders can be run over.
Take extra care not to run over bystanders. Confirm the location of bystanders before moving,
swinging, or operating the machine.
Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
Use a signal person when moving, swinging, or
operating the machine in congested areas. Coordinate hand signals before starting the machine.
Use appropriate illumination. Check that all lights
are operable before operating the machine. If any
faulty illumination is present, immediately repair it.
SA-426
011-E01A-0398
036-E01A-0293-3
SA-8
SA-293
SAFETY
OPERATE
SEAT
ONLY
FROM
OPERATOR'S
SA-444
JUMP STARTING
SA-9
SAFETY
KEEP RIDERS OFF MACHINE
Riders on machine are subject to injury such as being struck by foreign objects and being thrown off
the machine.
SA-379
M104-05-015
SA-10
SAFETY
INVESTIGATE JOB SITE BEFOREHAND
SA-11
SA-380
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 potential hazardous conditions. (The standard cab for this
machine corresponds to ROPS and FOPS.)
ROPS: Roll-Over Protective Structure
FOPS: Falling Object Protective Structure
SA-490
018-E01A-0481
SA-481
017-E01A-0491
SA-491
SA-12
SAFETY
DRIVE MACHINE SAFELY
SA-657
SA-658
SA-441
SA-442
SA-13
SAFETY
DRIVE MACHINE SAFELY
Travel Motor
M104-05-008
Arrow-Mark
SA-14
M178-03-001
SAFETY
Use wood plates in order not to damage the road
SA-15
SA-011
SAFETY
AVOID INJURY FROM ROLLAWAY ACCIDENTS
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 machine.
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.
Stop the engine and remove the key from the key
switch.
Pull the pilot control shut-off lever to LOCK position.
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-391
SA-392
020-E02A-0493
SA-16
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
SA-17
SA-383
SA-384
SAFETY
KEEP PERSON CLEAR FROM WORKING
AREA
A person may be hit severely by the swinging front
022-E01A-0386
SA-386
023-E01A-0487
SA-487
AVOID UNDERCUTTING
024-E01A-0488
SA-18
SA-488
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE---SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU
CAN JUMP FREE
FASTEN YOUR SEAT BELT
The danger of tipping is always present when operating on a grade, possibly resulting in serious injury
or death.
To avoid tipping:
025-E03B-0463
026-E01A-0519
SA-489
SA-19
SAFETY
DIG WITH CAUTION
If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.
Contact your local "diggers hot line" if available in
your area, and/or the utility companies directly.
Have them mark all underground utilities.
SA-382
027-E01A-0382
If the front attachment or any other part of the machine hits against an overhead obstacle, such as a
bridge, both the machine and the overhead obstacle
will be damaged, and personal injury may result as
well.
SA-389
028-E01A-0389
SA-20
SAFETY
AVOID POWER LINES
SA-381
OBJECT HANDLING
SA-21
SA-014
SAFETY
PROTECT AGAINST FLYING DEBRIS
031-E01A-0432
SA-432
SA-390
SA-018
ards.
SA-22
SA-019
SAFETY
TRANSPORT SAFELY
035-E07A-0454
SA-23
SA-395
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.
Before servicing the machine:
1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load
for 5 minutes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by
moving the control levers several times.
7. Remove the key from the switch.
8. Attach a "Do Not Operate" tag on the control
lever.
9. Pull the pilot control shut-off lever to the LOCK
position.
10. Allow the engine to cool.
SA-028
500-E02C-0520
SA-527
SA-24
SAFETY
If a maintenance procedure must be performed
SA-037
Before performing any work on the machine, attach a "Do Not Operate" tag on the control lever.
This tag is available from your authorized dealer.
501-E01A-0287
T1J1-01-01-001
SA-25
SAFETY
SUPPORT MACHINE PROPERLY
Never attempt to work on the machine without securing the machine first.
If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder
blocks, hollow tires, or props that may crumble
under continuous load. Do not work under a machine that is supported solely by a jack.
519-E01A-0527
SA-527
502-E01A-0026
SA-026
SA-26
SAFETY
PREVENT PARTS FROM FLYING
503-E01B-0344
504-E01A-0034
SA-034
SA-27
SAFETY
PREVENT BURNS
Hot spraying fluids:
SA-039
SA-225
505-E01B-0498
REPLACE
CALLY
RUBBER
HOSES
PERIODI-
SA-28
SA-019
SAFETY
AVOID HIGH-PRESSURE FLUIDS
SA-031
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
SA-30
SAFETY
EVACUATING IN CASE OF FIRE
SA-393
18-E02B-0393
SS-1510
PRECAUTIONS
GRINDING
FOR
WELDING
AND
SA-31
SA-818
SAFETY
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
Flammable spray can be generated by heating near
SA-32
SA-029
SAFETY
BEWARE OF ASBESTOS DUST
SA-029
SA-33
SA-032
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
If spilled onto skin, refrigerant may cause a cold
contact burn.
Refer to the instructions described on the container for proper use when handling the refrigerant.
Use a recovery and recycling system to avoid
leaking refrigerant into the atmosphere.
Never touch the refrigerant.
513-E01A-0405
SA-405
515-E01A-0309
SA-34
SA-309
SAFETY
DISPOSE OF WASTE PROPERLY
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste
used with HITACHI equipment includes such items
as oil, fuel, coolant, brake fluid, filters, and batteries.
SA-226
516-E01A-0226
S517-E01A-0435
SA-435
SA-35
SAFETY
(Blank)
SA-36
TECHNICAL MANUAL
(Troubleshooting)
1 Introduction
2 Standard
3 Engine Test
4 Excavator Test
5 Component Test
6 Adjustment
SECTION 5 TROUBLESHOOTING
Group
Group
Group
Group
Group
Group
Group
Group
1 Diagnosing Procedure
2 Monitor Unit
3 Dr. ZX
4 ICF
5 Component Layout
6 Troubleshooting A
7 Troubleshooting B
8 Electrical System Inspection
COPYRIGHT(C)2006
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
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 Controller
Group 5 Travel Device
Group 6 Signal Control Valve
Group 2 Control System
Group 3 ECM System
Group 7 Others (Upperstructure)
Group 4 Hydraulic System
Group 8 Others (Undercarriage)
Group 5 Electrical System
WORKSHOP MANUAL
SECTION 1 GENERAL INFORMATION SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 1 Precautions for DisassemGroup 2 Travel Device
bling and Assembling
Group 3 Center Joint
Group 2 Tightening Torque
Group 4 Track Adjuster
Group 3 Painting
Group 5 Front Idler
Group 4 Bleeding Air from HydrauGroup 6 Upper and Lower Roller
lic Oil Tank
SECTION 2 UPPERSTRUCTURE
Group 7 Track
SECTION 4 FRONT ATTACHMENT
Group 1 Cab
Group 1 Front Attachment
Group 2 Counterweight
Group 2 Cylinder
Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Solenoid Valve
Group 9 Solenoid Valve
Group 10 Signal Control Valve
Group 11 Shockless Valve
Group 12 Fan Valve
Group 13 Fan Motor
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction
Group 2 Standard
1J1T-4-1
Operation Check...................................T4-4-17
Group 6 Adjustment
Pump Learning .........................................T4-6-1
Torque Adjustment ...................................T4-6-7
1J1T-4-2
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 operational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
Performance Standard is shown in tables to evaluate the performance test data.
Precautions for Evaluation of Test Data
1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
T4-1-1
FOR
PERFORMANCE
T105-06-01-003
T105-06-01-004
T4-1-2
PERFORMANCE
STAN-
Performance
Standard
Performance Test
ENGINE SPEED
Slow Idle
Fast Idle (P mode)
Fast Idle (E mode)
Auto-Idle
Fast Idle
(P mode)
Fast Idle
(HP mode)
ENGINE COMPRESSION PRESSURE
VALVE CLEARANCE (IN, EX)
LUBRICANT CONSUMPTION
(At rated operation)
TRAVEL SPEED
Fast Speed
Slow Speed
TRACK REVOLUTION SPEED
Test procedure:
Engine Control Dial: Fast Idle
Power Mode Switch: HP Mode
Auto-Idle Switch: OFF
Work Mode: Digging Mode
Hydraulic Oil Temperature: 505 C (1229 F)
min-1
90050
165050
163050
118050
175050
185050
mm
2.94 (30)
or less
0.4
mL/h
100 or less
MPa (kgf/cm2)
Reference
Page
T4-3-1
T4-3-3
T4-3-4
T4-3-7
T4-4-1
sec/20 m
13.02.0
20.02.0
500LC-3/520LCH-3: 18.02.0
500LC-3/520LCH-3: 25.02.0
T4-4-2
sec/3 rev
Fast Speed
20.52.0
Slow Speed
31.52.0
MISTRACK CHECK
(With fast and travel speed modes)
TRAVEL MOTOR LEAKAGE
SWING SPEED
SWING FUNCTION DRIFT CHECK
SWING MOTOR LEAKAGE
MAXIMUM SWINGABLE SLANT ANGLE
SWING BEARING PLAY
Remarks
450LC-3/470LCH-3: 22.02.0
500LC-3/520LCH-3: 29.52.0
450LC-3/470LCH-3: 34.02.0
500LC-3/520LCH-3: 41.52.0
mm/20 m
200 or less
T4-4-3
mm/5 min
sec/3 rev
20.01.5
1267 or less
0
17 or more
0.6 to 1.85
T4-4-4
T4-4-5
T4-4-6
T4-4-7
T4-4-8
T4-4-9
mm/180
mm/5 min
deg.
mm
T4-2-1
Bucket empty
Bucket empty
Bucket loaded
Bucket loaded
Allowable limit: 3.1 to 4.35
Performance Test
HYDRAULIC CYLINDER CYCLE TIME
sec
Boom Raise
Boom Lower
Arm Roll-In
Arm Roll-Out
Bucket Roll-In
Bucket Roll-Out
3.60.3
2.50.3
4.50.3
3.10.3
3.50.3
2.90.3
T4-4-13
mm/5 min
3.4 m Arm
3
1.9 m (PCSA heaped)
Bucket, Bucket loaded
Backhoe
Boom Cylinder
Arm Cylinder
Bucket Cylinder
Bucket Bottom
15 or less
20 or less
20 or less
100 or less
Hitachi lever pattern
Reference
Page
T4-4-11
3.4 m Arm
3
1.9 m
(PCSA heaped)
Bucket, Bucket empty
Backhoe
Remarks
16.0 (1.6)
or less
13.0 (1.3)
or less
13.0 (1.3)
or less
16.0 (1.6)
or less
28.0 (2.9)
or less
60.0 (6.1)
or less
60.0 (6.1)
or less
T4-2-2
T4-4-14
Performance Test
CONTROL LEVER STROKE
Boom Lever
Arm Lever (ISO Lever Pattern: Swing Lever)
Bucket Lever
Swing Lever (ISO Lever Pattern: Arm Lever)
Travel Lever
BOOM RAISE/SWING
OPERATION CHECK
COMBINED
sec
5.0 or less
mm
7000 or more
T4-4-16
T4-5-1
+0.7
3.9 0.2
+7.0
(40 2.0)
MPa (kgf/cm2)
3.90.2
(392)
3.4 to 4.0
(34 to 40)
0.2 (2)
+1.0
31.9 1.5
+10
(325 15)
+1.0
34.3 1.5
+10
(350 15)
MPa (kgf/cm2)
+2.0
MPa (kgf/cm2)
MPa (kgf/cm2)
SOLENOID VALVE SET PRESSURE
MAIN RELIEF VALVE SET PRESSURE MPa (kgf/cm2)
Backhoe
When each Boom Lower, Arm, Bucket
Relief Operation
Reference
Page
T4-4-15
9710
8210
8210
9710
12010
RELIEF PRESSURE
Backhoe
mm
Remarks
28.4
+20
(290 )
+1.0
34.3 1.5
+10
(350 15)
T4-2-3
T4-5-3
T4-5-4
T4-5-8
Performance Test
OVERLOAD RELIEF VALVE SET PRESSURE
Backhoe
Remarks
MPa (kgf/cm2)
Reference
Page
T4-5-12
+1.0
L/min
35.3 0
+10
(360 0)
+1.0
27.9 0
+10
(280 0)
+1.0
12.0 0
+10
(120 0)
L/min
0.2 to 0.3
L/min
5 or less
L/min
T4-2-4
T4-5-14
T4-5-16
T4-5-22
Allowable limit: 10
T4-5-24
Flow Rate
L/min (US gpm)
20 (205, 2908)
25 (255, 3635)
30 (305, 4361)
L/min
400
350
300
Flow
Rate
250
200
C
150
100
50
0
0
5.0
(51)
10.0
(102)
15.0
(153)
20.0
(204)
Delivery Pressure
T4-2-5
25.0
(255)
30.0
(306)
35.0
(357)
MPa
(kgf/cm2)
T1J1-04-02-001
Flow Rate
L/min (US gpm)
Approx. 63 (17)
Approx. 59 (16)
Approx. 52 (14)
50
Flow
Rate
25
0
0
5.0
(51)
10.0
(102)
15.0
(153)
Delivery Pressure
T4-2-6
20.0
(204)
25.0
(255)
MPa
(kgf/cm2)
T1J1-04-02-002
Flow Rate
L/min (US gpm)
38130
59740
L/min
75
A
50
Flow
Rate
25
B
0
300
400
500
600
700
T4-2-7
mA
T1J1-04-02-003
Reference
Value
First
Measured Value
Second
Third
Average
Remarks
1600
1700
1800
When boom
raise relieving
1580
1030
750
1650
1750
1850
When boom
raise relieving
1630
1180
900
50
50
50
50
150
150
0.56
4.42
T4-2-8
Reference
Value
First
Measured Value
Second
Third
Average
Remarks
0.7
34.3
31.9
31.9
31.9
31.9
When relieving
When relieving
When relieving
When relieving
31.9
When relieving
When relieving
0.7
34.3
31.9
31.9
0.7
0.7
When relieving
When relieving
When relieving
When relieving
When relieving
31.9
When relieving
T4-2-9
Reference
Value
First
Measured Value
Second
Third
Average
Remarks
0.5
0.5
0.5
0.5
0.5
0.5
When relieving
When relieving
When relieving
When relieving
0.5
When relieving
When relieving
0.45
0.45
0.45
0.45
0.45
0.45
When relieving
When relieving
When relieving
When relieving
0.45
When relieving
When relieving
T4-2-10
Reference
Value
First
Measured Value
Second
Third
Average
Remarks
0.04
4.0
4.0
4.0
4.0
4.0
When relieving
When relieving
When relieving
When relieving
4.0
When relieving
When relieving
0.04
4.0
4.0
4.0
0.04
0.04
When relieving
When relieving
When relieving
When relieving
4.0
When relieving
When relieving
When relieving
boom or arm
When relieving
boom or arm
25
25
T4-2-11
Item
FRONT PILOT PRESSURE *
(MPa)
TRAVEL PILOT
PRESSURE *
(MPa)
BOOM RAISE PILOT
PRESSURE *
(MPa)
BOOM LOWERING
PILOT PRESSURE
(MPa)
ARM ROLL-IN (BH)
PILOT PRESSURE *
(MPa)
ARM ROLL-OUT (BH)
PILOT PRESSURE
(MPa)
BUCKET ROLL-OUT (BH)
PILOT PRESSURE
(MPa)
BUCKET ROLL-IN (BH) PILOT PRESSURE
(MPa)
SWING PILOT
PRESSURE *
(MPa)
LEFT TRAVEL PILOT
PRESSURE
(MPa)
RIGHT TRAVEL
PRESSURE
(MPa)
ATT. CONTROL PILOT
PRESSURE *
(MPa)
C/W REMOVAL PILOT
PRESSURE
(MPa)
BOOM BOTTOM
PRESSURE
(MPa)
POWER BOOST CONTROL
PRESSURE *
(MPa)
Power Digging Switch: ON,
Lever in Neutral
When Boom Raise Relieving
TRAVEL MOTOR CONTROL
PRESSURE *
(MPa)
BOOM MODE CONTROL
PRESSURE
(MPa)
Lever in Neutral
Boom Raise
BOOM FLOW CONTROL
PRESSURE
(MPa)
Lever in Neutral
Combined Operation with
Boom Lower and Arm Roll-In
First
Measured Value
Second
Third
Average
Remarks
When relieving
4.0
When relieving
4.0
When relieving
4.0
When relieving
4.0
When relieving
4.0
When relieving
4.0
When relieving
4.0
4.0
When relieving
4.0
When relieving
4.0
When relieving
4.0
When relieving
When relieving
4.0
When relieving
4.0
34.3
2.15
2.15
When fast speed
traveling
Boom mode selector switch: ON
4.0
0
3.23
When relieving
0
4.0
T4-2-12
Item
PUMP 1 REGULATOR
VALVE CURRENT
(mA)
PUMP 2 REGULATOR
VALVE CURRENT
(mA)
FAN PUMP VALVE
CURRENT
(mA)
BOOM FLOW CONTROL
VALVE CURRENT
(mA)
FAN REVERSE
VALVE 1 CURRENT
FAN REVERSE
VALVE 2 CURRENT
AUXILIARY VALVE 1
CURRENT
AUXILIARY VALVE 2
CURRENT
First
Measured Value
Second
Third
270
Remarks
When boom raise
relieving
When boom raise
relieving
270
381 to 555
650
(mA)
(mA)
(mA)
(mA)
Average
T4-2-13
Item
ENGINE TORQUE *
ACTUAL ENGINE
SPEED *
TARGET ENGINE
SPEED *
ENGINE OIL
PRESSURE *
FUEL FLOW
(MPa)
-1
First
Measured Value
Second
Third
47
1750
1700
(min )
444
(kPa)
(L/h)
BOOST PRESSURE *
(kPa)
128
BATTERY VOLTAGE
(V)
28.2
Remarks
When boom raise
relieving
When boom raise
relieving
When boom raise
relieving
When boom raise
relieving,
When
Neutral: 428 kPa
When boom raise
relieving
When boom raise
relieving
When boom raise
relieving
(min )
-1
Average
T4-2-14
Power
Mode Switch
Work Mode
Auto-Idle
Switch
P Mode
Digging
Mode
OFF
Operation
Slow Idle Speed
Engine Control Dial
Fast Idle Speed
Control Lever: Neutral
Pilot Control Shut-Off Lever: LOCK
Pilot Operation
Pressure Sensor Control Lever: Full Stroke
Pilot Control Shut-Off Lever: UNLOCK
Pump Regulator
Control Lever: Neutral
Pressure Sensor
Jack-up, Travel Lever: Full Stroke (Jack-up
Side)
Pump Delivery
Control Lever: Neutral
Pressure Sensor When Boom Raise Relieving
(Boom Bottom
Pressure Sensor)
Specification
0.3 to 1.0 V
4.0 to 4.7 V
2
0 to 0.049 MPa (0 to 0.5 kgf/cm )
2
T4-2-15
T4-2-16
T4-3-1
Measurement:
1. Measure the items as shown in the table below.
2. When measuring, set the switch and test condition as shown in the table below in response to
the engine speed to be measured.
Remedy:
Refer to Troubleshooting B in Group T5-7.
NOTE: ECO stands for the auto engine speed re-1
duction system by 1600 min .
Item
Slow Idle
Fast Idle
(With ECO deactivated)
Fast Idle
(Relief operation)
Fast Idle
(E mode)
Fast Idle
(HP mode)
Auto-Idle
Engine
Control
Dial
Min. Speed
Power
Mode
Switch
P
Auto-Idle
Switch
Work Mode
OFF
Digging Mode
Check in the Dr. ZX special
functions with ECO deactiDigging Mode
vated. Measure engine speed
with the lever in neutral.
Measure engine speed while
Digging Mode
relieving the boom raise circuit.
Max. Speed
OFF
Max. Speed
OFF
Max. Speed
E Mode
OFF
Digging Mode
Max. Speed
HP Mode
OFF
Digging Mode
Max. Speed
ON
Switch Panel:
Test Conditions
Monitor Unit:
Digging Mode
Engine Control Dial
Auto-Idle Switch
T1V1-04-03-001
T4-3-2
M1J1-01-002
Injector
Connector
Pressure
Gauge
T1J1-04-03-001
Measurement:
1. Turn the starter and measure compression pressure of each cylinder.
2. Repeat the measurement three times and calculate the mean values.
Evaluation:
Refer to Operational Performance Standard in Group
T4-2.
Remedy:
Refer to the engine workshop manual.
T1J1-04-03-002
T4-3-3
Terminal Nut
Harness
T1J1-04-03-006
Injector
Bolt
Harness
Assembly
T1J1-04-03-007
6. Check if piston No.1 (or piston No.6) is now positioned at the T/C in the compression stroke.
NOTE: Move push rods for the intake and exhaust
valves on the No.1 cylinder up and down
by hand. If any clearances on the both
ends of the push rods are found, piston
No.1 is positioned at T/C in the compression stroke. (If the exhaust valve of cylinder
No.1 is pushed down, piston No.6 is positioned at T/C in the compression stroke.
7. Start measurement from the cylinder (No.1 or
No.6) positioned at T/C in the compression
stroke.
T1J1-04-03-008
T/C Mark
Flywheel
Pointer
Gear Case
T1J1-04-03-003
T4-3-4
Rocker Arm
Thickness Gauge
Cylinder No.
Valve locations
When the measurement is
started from No.1 cylinder
When the measurement is
started from No.6 cylinder
No.1
E
I
{
No.2
E
I
Cam
No.3
E
I
No.4
E
I
T4-3-5
No.5
E
I
No.6
E
I
T1J1-04-03-004
Lock Nut
Adjusting
Screw
Bridge
Rocker Arm
Rocker Arm
Thickness Gauge
Cam
T4-3-6
T1J1-04-03-005
T1J1-04-03-004
T4-3-7
T4-3-8
T4-4-1
End
20 m
Deceleration
Zone
3 to 5 m
Acceleration
Zone
3 to 5 m
T105-06-03-001
90 to 110
M104-07-067
T4-4-2
90 to 110
T1J1-04-04-001
Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-7.
Preparation:
1. Adjust the track sag of both tracks to be equal.
2. Provide a flat, solid test yard 20 m (65.6 ft) in
length, with extra length of 3 to 5 m (9.8 to 16 ft)
on both ends for machine acceleration and deceleration.
IMPORTANT: The bucket teeth will hit the boom if
the bucket is rolled-in with the arm
fully rolled-in.
As for this condition: arm fully
rolled-in + Bucket fully rolled-in, set
the bucket at fully rolled-in and a
perform arm roll-in operation.
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above
the ground with the arm and bucket rolled in.
4. Maintain the hydraulic oil temperature at 505 C
(12241 F).
Measurement:
1. Measure the amount of mistracking in both fast,
and slow travel speeds.
2. Measurement conditions are as below.
Travel
Engine
Power
Work
Auto-Idle
Mode
Control
Mode
Mode
Switch
Switch
Dial
Switch
Slow
Digging
Fast Idle HP Mode
OFF
Mode
Mode
Fast
Digging
Fast Idle HP Mode
OFF
Mode
Mode
3. Start traveling the machine in the acceleration
zone with the travel levers at full stroke.
4. Measure the maximum distance between a
straight 20 m (65.6 ft) tread chord line and the
tread made by the machine.
5. After measuring the tracking in forward travel,
turn the upperstructure 180 and measure in reverse travel.
6. Perform the measurement three times and calculate the average values.
T4-4-3
Maximum Distance
Acceleration
Zone:
3 to 5 m
20 m
T105-06-03-022
T4-4-4
0.2 to 0.3 m
T105-06-03-004
T4-4-5
T105-06-03-009
T4-4-6
Digging Mode
T105-06-03-011
OFF
T105-06-03-010
2. Maintain the engine at slow idle. After five minutes, measure the difference between the marks
along the swing bearing periphery and the track
frame.
3. Perform the measurement in both right and left
swing directions.
4. Perform the measurement three times and calculate the average values.
Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-7.
T4-4-7
HP Mode
Digging Mode
OFF
T4-4-8
T105-06-03-011
T4-4-9
Magnetic Base
Dial Gauge
T105-06-03-014
Round Trunk
T105-06-03-015
T4-4-10
Backhoe Front
Measurement: (h1)
Measurement: (h2)
T105-06-03-013
Measurement: (h2)
T4-4-11
TBAR-04-04-002
HP Mode
Digging Mode
T105-06-03-018
OFF
0.5 m
T1V1-04-05-005
T105-06-03-018
T4-4-12
Loading Shovel
Boom Cylinder:
With the bucket cylinder and the arm cylinder fully
extended, lower the bucket to the ground.
Arm Cylinder:
With the arm fully retracted, position the bucket
so that the rear bucket does not come in contact
with the arm stopper. Then, adjust the boom cylinder stroke to position the bucket bottom 1 m (39
in) above the ground.
Bucket Cylinder:
With the bucket closed and held in a load dump
position, adjust the boom cylinder stroke so that
bucket bottom height is approx. 1 m (39 in) above
the ground.
Bucket Open-Close Cylinder:
With the bucket cylinder and arm cylinder fully
extended, adjust the boom cylinder stroke so that
the bucket bottom height approx. 1 m (39 in)
above the ground.
3. Perform the measurement three times and calculate the average values.
Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.
Boom Cylinder
TBAR-04-04-003
Arm Cylinder
TBAR-04-04-004
Remedy:
Refer to the Troubleshooting B in Group T5-7.
Bucket
Cylinder
TBAR-04-04-005
Bucket
Open-Close
Cylinder
TBAR-04-04-006
T4-4-13
Retracted
Distance
Extended
Distance
Retracted
Distance
Same Height
Bucket Bottom
T105-06-03-021
Backhoe:
Boom and Bucket Cylinder Retraction
Loading Shovel:
Boom, Arm and Bucket Cylinder Retraction
Mark Mark
T110-06-03-002
Backhoe:
Arm Cylinder Extension
Mark
Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-7.
T110-06-03-001
T4-4-14
T107-06-03-003
Measurement:
1. Measure each control lever.
2. Measurement conditions are as below.
Engine
Power Mode
Auto-Idle
Control
Work Mode
Switch
Switch
Dial
Fast Idle
HP Mode
Digging Mode
OFF
T4-4-15
T107-06-03-004
T4-4-16
T107-06-03-005
COMBINED
OP-
Summary:
Check boom raise and swing movement 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 sticking.
2. Position the machine with front attachment positioned as illustrated and with the bucket empty.
3. Maintain the hydraulic oil temperature at 505 C
(12241 F).
M104-07-021
HP Mode
Digging Mode
T107-06-03-010
OFF
T107-06-03-011
Remedy:
Refer to the Troubleshooting B in Group T5-7.
T4-4-17
T4-4-18
Plug
T178-03-07-001
Measurement:
1. Measurement conditions are as below.
Engine
Power Mode Auto-Idle
Work Mode
Control Dial
Switch
Switch
Digging
Fast Idle
HP Mode
OFF
Mode
Digging
Slow Idle
HP Mode
OFF
Mode
2. Measure pilot pressure in each specified setting
above without load.
3. Repeat the measurement three times and calculate the average values.
Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.
T4-5-1
Relief Valve
T178-03-07-001
1
2
(mm)
kPa
(kgf/cm 2, psi)
0.25
78
(0.8, 11.3)
0.5
157
(1.6, 22.8)
1.0
304
(3.1, 44.2)
T111-06-04-004
T4-5-2
Pilot Valve
Hose
Nipple
Pressure
Gauge
Tee
T4-5-3
Adapter
T1F3-04-05-008
Solenoid Valve
Pressure Gauge
Hose
Tee
Adapter
T157-05-04-002
T4-5-4
SC
SF
SI
SG
T1V1-03-07-007
O-Ring
IMPORTANT: As O-ring is damaged and oil leakage may cause, do not loosen adjusting screw (8) excessively.
Do not loosen adjusting screw (8)
more than 2 turns.
1. Loosen lock nut (7). Turn adjusting screw (8) and
adjust the set pressure.
2. After adjustment, tighten lock nut (7).
: 10 mm
: 3 mm
: 3 Nm (0.3 kgfm, 2.2 lbfft)
T1V1-04-05-004
T1V1-04-05-003
Pressure
Increase
Pressure
Decrease
W107-02-05-129
T4-5-5
T1J1-04-05-001
Measurement:
1. Measurement Conditions are below.
Engine
Power Mode Auto-Idle
Work Mode
Control Dial
Switch
Switch
Digging
Fast Idle
HP Mode
OFF
Mode
Plug
Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-7.
T1J1-04-05-002
T4-5-6
Plug
Measurement:
1. Measurement Conditions are below.
Engine
Power Mode Auto-Idle
Work Mode
Control Dial
Switch
Switch
Digging
Fast Idle
HP Mode
OFF
Mode
T1J1-04-05-003
T4-5-7
Fan Pump
T1J1-04-05-001
T4-5-8
Plug
T1J1-04-05-002
Main Relief
Valve
T1J1-03-03-008
1
2
3
4
A
T16J-04-04-003
1, 3
Pressure
Increase
Pressure
Decrease
W107-02-05-127
T4-5-9
T178-03-02-001
2
1
T16J-04-05-001
Pressure
Increase
Pressure
Decrease
T157-05-04-023
T4-5-10
Pressure
Setting
Adjustment
Adjustment:
Adjust the set pressure of the travel relief valve using
the adjusting screw after loosening the lock nut.
1. Loosen the lock nut.
: 19 mm
2. Turn the adjusting screw to adjust the pressure
setting, referring to the table below.
: 6 mm
Travel Relief
Valve
T183-01-02-012
Lock Nut
Adjusting Screw
T142-05-04-007
1/4
1/2
3/4
MPa
Change in
2
Pressure (kgf/cm )
(psi)
1.96
3.92
5.88
7.85
(20)
(40)
(60)
(80)
(280)
(570)
(850)
(1140)
Lock Nut
Adjusting Screw
Pressure Increase
Pressure Decrease
W107-02-05-129
T4-5-11
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and release any remaining pressure.
3. Connect Dr. ZX and select the monitoring function.
When Dr. ZX is not available, use the pressure
gauge. Remove the plug from pressure check
port of main pump delivery port. Install adapter
(ST 6069), hose (ST 6943) and pressure gauge
(ST 6941).
Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection
: 6 mm
T1J1-04-05-001
T1J1-04-05-002
T4-5-12
Pressure
Increase
T4-5-13
Pressure
Decrease
W107-02-05-129
T4-5-14
Qc = (Np Q) (Ne i)
Qc : Converted Flow Rate
Q : Measured Flow Rate
Np : Specified Pump Speed:
-1
1803 min (Main Pump 1)
-1
1750 min (Main Pump 2)
Ne : Measured Engine Speed:
Values indicated on Dr. ZX
i:
Pump Speed Ratio:
Main Pump 2 Side = 1.0
Main Pump 1 Side = 1.03 (32/31)
1, 2
10
11
Delivery Hose
(To Control Valve)
T173-04-04-002
12
13
Main Pump 2
Main Pump 1
14
12-
34-
T1J1-04-05-003
12 - Port Psv
13 - Plug
T4-5-15
5. Disconnect the pipe from the port Pr (12). Connect hose (ST 6339) (14) to the disconnected
pipe hole on regulator to be measured. Install
plug (ST 6212) to the disconnected pipe hole on
regulator not to be measured.
6. Remove the vacuum pump. Loosen plug (13) on
top of the pump casing. Bleed air from the casing
until oil only comes out.
7. Fully open the loading valve of hydraulic tester
(5).
8. Start the engine. Check the pressure gauge and
hydraulic tester (5) connection for any oil leaks.
Measurement:
1. Maintain the hydraulic oil temperature at 505 C
(12241 F).
2. Measure the maximum flow rate.
3. Measurement conditions are below.
Engine
Power Mode Auto-Idle
Work Mode
Control Dial
Switch
Switch
Digging
Fast Idle
P Mode
OFF
Mode
4. Adjust the set pressure of relief valve in fan valve
to each pressure point specified along the fan
pump P-Q curve. (Refer to T4-2-6) Slowly restrict
the loading valve of hydraulic tester. Measure the
flow rates and engine speeds at each pressure
point specified in the P-Q curve.
5. Repeat the measurement three times and calculate the average values.
T4-5-16
Qc = (Np Q) (Ne i)
Qc :
Q:
Np :
Ne :
i:
1, 2
10
11
Delivery Hose
(To Control Valve)
T173-04-04-002
Fan Pump
12
13
14
T1J1-04-05-004
T1J1-04-05-003
Fan Pump
12-
34-
56-
12 - Port Pr
13 - Plug
T4-5-17
T1J1-04-05-007
1/4
6.9 L/min
6.7 L/min
2.8 L/min
1
Q
Flow Rate
Decrease
Flow Rate
Increase
W107-02-05-129
Flow Rate
Decrease
W107-02-05-129
T4-5-18
T16J-04-04-006
3
I
Flow Rate
Decrease
Flow Rate
Increase
W107-02-05-129
T4-5-19
2
3
T1J1-04-05-005
I
Flow Rate
Increase
Flow Rate
Decrease
T4-5-20
5
6
T1J1-04-05-006
4, 6
Increase
Decrease
T157-05-04-023
T4-5-21
1
A
B
Machine
Front Side
Auto-Idle
Switch
OFF
T4-5-22
T16J-04-04-007
T4-5-23
T107-06-05-008
Q = 60 q / t
Where:
Q : Amount of drain oil per minute (L/min)
t : Measured time (seconds)
q : Total amount of drain oil (L)
Drain Hose
M183-01-001
Drain Hose
ST 6637
T183-04-04-011
T4-5-24
90 to 110
M104-07-067
90 to 110
T1J1-04-04-001
T157-05-04-019
T4-5-25
T4-5-26
T4-6-1
Self-Diagnostic Result
Select Controller
Dr. ZX
Connector
T1J1-04-06-001
Palm
Dr. ZX
Hot Sync
Cable
Onnecting
Harness
T1V1-05-07-002
T4-6-2
Push OK.
Select failure-diagnosis
controller
Self-Diagnostic Result
Select Controller
Main Controller
Engine Controller
Monitor Controller
ICF Controller
ESC
Function Selection Screen
Push Start.
Is it correct?
ESC
OK
ESC
Select Function
Password
To the
lower
Monitor Display
Special Function
Setup
Model:
|..........................
Ex. Product No. (HCM1J1123456)
Model (01J1)
To the
lower
+
Disp. Record
Start
Back
Title Screen
Push
Select item
+
+
+
+
+
+
Actual Engine
Speed
Engine Speed
Deviation
Clear
+
+
ESC
Blower Motor
Relay Signal
Pump Regulator
Learning SW
Auto Lubrication
Counting SW
Picture Change Signal
Start
ESC
OK
Select item
Requested Engine
Speed
Engine Torque
Start
ESC
Clear
ESC
T4-6-3
Travel Alarm
Swing Alarm
Load Alarm
Pump 1 Regulator
Leaning Condition
Start
Clear
To the next
page
ESC
P Reg. Learn. SW
Select item
+
+
+
+
Pump 2 Regulator
Learning Condition
Pump 1&2 Regulator
Learning Status
Pump 1 Regulator
Valve Current
Pump 2Regulator
Valve Current
OFF
ON
Start
Clear
ESC
HOLD
ESC
Monitor Screen
T4-6-4
Learning
Switch
OFF
E
Side
Upper
Surface
OFF
HOLD
ESC
EX) Failure
P Reg. Learn. SW
OFF
ON
HOLD
ESC
T4-6-5
Display Item
(Learning Status)
Low Eng Speed
Cause
Save Failed
Learnable
EX) Failure
P Reg. Learn. SW
ON
Display Item
(Learning Status)
HOLD
OFF
E
Upper
Surface
Side
Remedy
OFF
ON
Learning
Switch
ESC
T4-6-6
Procedure
1. Connect Palm (Dr. ZX) to the diagnosing
connector in the cab by using the Hot Sync cable
and connecting harness.
2. Turn the key switch ON or start the engine.
3. When turning Palm ON, the following screen is
displayed on the display of Palm.
Initial Screen
Select Dr. ZX icon.
Password Setup Screen (When the password
has unset) Set the password.
Service Software Selection Screen
+ Select Large Class ZX-3.
Function Selection Screen
+ Self-Diagnostic Result
+ Select Controller
5. Select Select (Controller) and operate according
to the instruction under display screen.
Dr. ZX
Connector
T1J1-04-06-001
Palm
Dr. ZX
Hot Sync
Cable
Onnecting
Harness
T1V1-05-07-002
T4-6-7
Push OK.
Select failure-diagnosis
controller
Self-Diagnostic Result
Select Controller
Main Controller
Engine Controller
Monitor Controller
ICF Controller
ESC
Function Selection Screen
Push Start.
Model: XXXXXXX
Controller Ver. XXYY
To the
lower
Is it correct?
ESC
OK
ESC
Push Setup.
SelectFunction
Password
Monitor Display
Special Function
Setup
Input password.
To the next
page
Password __________
+
Op. Manual
Disp. Record
Start
Back
Main Menu Screen
Title Screen
+
+
Push
Parameter Change
ATT Parameter
Change
All Parameter
initialize
+
+
+
ESC
Setup Item Selection Screen
OK
Cancel
Select item
Select item
+
ESC
Li Speed
Adjustment
WU Speed
Adjustment
AI Speed
Adjustment
E Speed
Adjustment
+
+
ESC
Parameter Change Selection
Screen
T4-6-8
P Speed
Adjustment
HP Speed
Adjustment
To the
lower
PQ Torque Control
Pump 1 Torque
Adjustment
ESC
Parameter Change Selection
Screen
PQ Torque Control
Adjustable range:
-1000 120 Nm
Initial:
Current:
Adjustment:
XXX Nm
Execution
ESC
Current:
0 Nm
XXX Nm
Adjustment:
Execute
ESC
Initial
Current
T4-6-9
ESC
T4-6-10
MEMO
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SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 Diagnosing Procedure
Group 3 Dr. ZX
Introduction ..............................................T5-1-1
Outline .....................................................T5-3-1
1J1T-5-1
Group 6 Troubleshooting A
Troubleshooting A Procedure....................T5-6-1
Operational Condition
Enable / Disable Selection ....................T5-3-82
(Optional) .............................................T5-6-35
Notification Function
Enable / Disable Selection ....................T5-3-88
Group 4 ICF
Outline .....................................................T5-4-1
How to
Engine......................................................T5-5-9
Pump Device..........................................T5-5-10
1J1T-5-2
How to Troubleshooting
Group 7 Troubleshooting B
Troubleshooting B Procedure ...................T5-7-1
Relationship between Machine Trouble
Symptoms and Related Parts .................T5-7-2
Correlation between Trouble
Symptoms and Part Failures.................T5-7-20
Engine System Troubleshooting .............T5-7-36
All Actuator System Troubleshooting ......T5-7-54
Front Attachment System
Troubleshooting....................................T5-7-64
Swing System Troubleshooting...............T5-7-74
Travel System Troubleshooting ..............T5-7-77
Other System Troubleshooting ...............T5-7-82
Work After Replacing Components ....... T5-7-108
Charge Air Conditioner
with Refrigerant .................................. T5-7-109
Exchange Inspection ............................ T5-7-118
1J1T-5-3
(Blank)
1J1T-5-4
Diagnosing Procedure
Monitor Unit
Refer to this group as for the display screen and
operating procedures of monitor unit.
Dr. ZX
This group contains the operating procedures for
Dr. ZX.
ICF
This group contains as follows.
Download data from ICF and Upload
Procedures when starting satellite communication,
when installing the satellite communication controller and when replacing ICF
Explanation for the satellite communication system
Component Layout
T5-1-1
story
of
T107-07-01-001
T107-07-01-002
T107-07-01-003
T5-1-2
the
the
the
the
T5-1-3
T5-1-4
T107-07-01-005
T107-07-01-006
T107-07-01-007
T5-1-5
T5-1-6
9
22
10
11
12
13
14
15
21
20
19
18
17
16
T1J1-02-01-003
10 - Fuel Gauge
16 - Menu
17 - Auxiliary Selection
22 - Coolant Temperature
Gauge
T5-2-1
Work Mode
The attachments being used are displayed according to the signals received from MC by using CAN.
Digging Mode
T1V1-05-01-108
Attachment Mode
Breaker
M1J1-01-003
M1J1-01-004
T5-2-2
1 - Coolant Temperature
2 - Hour Meter
3 - Fuel Gauge
4 - Clock
T5-2-3
M1J1-01-003
Coolant Temperature
Sensor Error Display
M1J1-01-010
Alarm Display
T5-2-4
M1J1-01-008
T1V5-05-01-013
T1V5-05-01-097
T1V5-05-01-122
Monitoring Screen
T1V5-05-01-087
T1V5-05-01-025
Controller Version
This screen displays the version of controller.
Monitoring
This screen displays temperature and pressure data
received from each controller by using CAN.
By key operation, the displayed data is hold.
Operating Conditions
This screen displays machine hour, fuel usage and
fuel consumption rate registered by the monitor unit.
T5-2-5
Key 1
Key 2
Attachment Selection
M1J5-01-014
T5-2-6
M1J5-05-003
T1V5-05-01-134
T1V1-05-01-126
T5-2-7
T1V1-05-01-127
Language Settings
T1V5-05-01-049
T1V5-05-01-052
T5-2-8
T1V1-05-01-137
T1V5-05-01-037
Alarm
Primary Screen
T1V1-05-01-128
M1J1-03-001
T5-2-9
Key Switch: ON
Primary Screen
T1V1-05-01-115
T1V1-05-03-001
IMPORTANT: After the engine starts and the alternator starts generating power, alternator alarm is displayed on the
primary screen.
Alternator Alarm
T5-2-10
M1J1-03-005
Starting Screen
T1V1-05-01-115
T1V5-05-01-093
Confirm Key
Erase Key
Primary Screen
T5-2-11
T1V5-05-01-002
T1V1-05-03-001
Confirm Key
Erase Key
T1V5-05-01-093
T1V5-05-01-002
Back Key
T1V5-05-01-004
T1V5-05-01-093
T5-2-12
T1V5-05-01-005
Starting Screen
T1V1-05-01-115
T1V5-05-01-093
T5-2-13
Key 1
Key 2
Key 3
Key 4
Key 5
T1V1-05-01-012
2. While the password duration screen is still displayed, push a relevant key, and password duration time is set. Duration time assigned to each
key is as follows:
key 1: 0 minute
key 2: 30 minutes
key 3: 60 minutes
key 4: 90 minutes
key 5: 120 minutes
NOTE: If password duration time is not set explicitly, 0 minute on duration time is assumed.
Key Switch: ON
T1V1-05-01-115
Primary Screen
T1V1-05-03-001
T5-2-14
Menu Key
Primary Screen
T1V1-05-03-001
2. Select password change from main menu by using keys1 and 2. Push the confirm key. Then, the
password change screen appears.
Key 1
Key 2
T1V5-05-01-129
Confirm Key
T1V5-05-01-041
Registered Password
Confirm Key
T5-2-15
Erase Key
T1V5-05-01-042
Back Key
T1V5-05-01-044
T1V5-05-01-130
A New Password
Confirm Key
T5-2-16
Erase Key
T1V5-05-01-131
T1V5-05-01-132
Confirm Key
Erase Key
T1V5-05-01-133
9. The message "New password has been registered." appears. This completes the password
change process.
T1V5-05-01-043
Key 6
Primary Screen
T5-2-17
T1V1-05-03-001
M1J1-01-007
M1J1-01-008
T5-2-18
M1J1-01-007
T1V5-05-01-013
M1J1-01-009
T5-2-19
Contents of Alarms
Overheat Alarm
Remedy
Temperature of engine coolant is going up abnormally higher.
Stop the work and turn the engine into low idle in order to lower
the coolant temperature.
Alternator Alarm
Auto-Lubrication Alarm
M178-01-036
M183-01-080
M178-01-037
M183-01-071
M178-01-034
T1J1-05-01-005
M183-01-067
T1V1-05-01-102
T1V1-05-01-103
T5-2-20
T5-2-21
T1V1-05-01-115
Menu Key
Primary Screen
T1V1-05-03-001
Key 1
Key 2
Confirm Key
Back Key
Back Key
T5-2-22
T1V5-05-01-114
T1V5-05-01-083
Key 1
Key 2
Confirm Key
Back Key
T1V5-05-01-083
Key 1
Key 2
Confirm Key
Back Key
T1V5-05-01-085
Key 1
Key 6
Key 2
Back Key
Primary Screen
T5-2-23
T1V5-05-01-097
T1V1-05-03-001
T1V1-05-01-115
Menu Key
Primary Screen
T1V1-05-03-001
Key 1
Key 2
Confirm Key
Back Key
Back Key
T5-2-24
T1V5-05-01-114
T1V5-05-01-083
Key 1
Key 2
Key 6
Confirm Key
Back Key
Back Key
T1V5-05-01-083
T1V5-05-01-122
Primary Screen
T5-2-25
T1V1-05-03-001
T1V1-05-01-115
Menu Key
Primary Screen
T1V1-05-03-001
Key 1
Key 2
Confirm Key
Back Key
Back Key
T5-2-26
T1V5-05-01-114
T1V5-05-01-083
Key 1
Key 2
T1V5-05-01-083
Confirm Key
Back Key
Key 1
Key 2
Key 3
Key 4
Confirm Key
T1V5-05-01-087
Back Key
Key 6
Confirm Key
Primary Screen
T5-2-27
T1V5-05-01-088
T1V1-05-03-001
Units
%
C
C
kPa
kPa
C
kPa
C
C
-1
min
-1
min
MPa
MPa
L/min
MPa
MPa
L/min
MPa
MPa
MPa
MPa
MPa
MPa
V
C
MPa
MPa
MPa
MPa
MPa
-
Remarks
T5-2-28
Menu Key
Primary Screen
T1V1-05-03-001
Key 1
Key 2
T1V5-05-01-019
Confirm Key
3. Push the reset key, and a screen appears to confirm if it's OK to reset data.
If its OK to reset data, push the confirm key.
NOTE: When pushing the back key, return to the
previous screen.
IMPORTANT: Total fuel consumption and fuel
consumption rate depend on the
operating environment and the operation method of machine.
The values shown on the screen are
just for reference.
There could arise 20% of differences between actual fuel consumption and fuel consumption which is
displayed by the monitor unit.
Reset Key
Back Key
T1V5-05-01-025
Back Key
Key 6
T5-2-29
Confirm Key
T1V5-05-01-026
Menu Key
Primary Screen
T1V1-05-03-001
Key 1
Key 2
Key 1
Key 2
Confirm Key
T1V5-05-01-019
T5-2-30
Back Key
M1J5-01-014
T5-2-31
Key F1
Primary Screen
M1J1-01-002
Digging
Back Key
Breaker 1
M1J5-05-003
Confirm
Key
T5-2-32
M1J5-01-011
Menu Key
Primary Screen
M1J1-01-002
Back Key
Key 1
Key 2
Confirm Key
T1V5-05-01-019
Digging
Back Key
Breaker 1
M1J5-05-003
Confirm
Key
T5-2-33
M1J5-01-011
T5-2-34
Menu Key
Primary Screen
T1V1-05-03-001
Back Key
Key 1
Key 2
T1V5-05-01-019
Confirm Key
Back Key
Key 2
Key 3
Key 4
Confirm Key
T1V5-05-01-021
Back Key
Key 6
T5-2-35
T1V5-05-01-022
Menu Key
Primary Screen
T1V1-05-03-001
Key 1
Key 2
Confirm Key
Back Key
T1V5-05-01-118
Back Key
Confirm Key
T1V5-05-01-164
Back Key
T1V5-05-01-119
T5-2-36
Key 6
T1V5-05-01-119
T1V1-05-03-001
Fuel Gauge
T5-2-37
Fuel Gauge
Menu Key
Primary Screen
T1V1-05-03-001
Key 1
Key 2
Confirm Key
Back Key
T1V5-05-01-118
Back Key
Confirm Key
T1V5-05-01-119
Back Key
T1V5-05-01-164
T5-2-38
Key 6
T1V5-05-01-164
Primary Screen
T5-2-39
M1J1-01-002
Menu Key
Primary Screen
T1V1-05-03-001
Back Key
Key 1
Key 2
Confirm Key
T1V5-05-01-114
Key 2
Confirm Key
T1V5-05-01-134
Back Key
Key 6
T1V5-05-01-120
T5-2-40
Menu Key
Primary Screen
T1V1-05-03-001
Key 1
Key 2
Confirm Key
Back Key
T1V5-05-01-118
Key 1
Key 2
Confirm Key
Back Key
T1V5-05-01-120
Back Key
Key 6
T5-2-41
T1V5-05-01-134
Menu Key
Primary Screen
T1V1-05-03-001
Back Key
Key 1
Key 2
Confirm Key
T1V5-05-01-114
Back Key
Key 1
Key 2
Confirm Key
T1V5-05-01-120
Back Key
T1V5-05-01-120
T5-2-42
Normal Image
T5-2-43
T1V5-05-01-120
T1V1-05-01-126
Menu Key
Primary Screen
T1V1-05-03-001
Key 1
Key 2
Key 1
Key 2
Confirm Key
T1V5-05-01-114
Confirm Key
T1V5-05-01-120
T1V5-05-01-135
T5-2-44
Mirror Image
T5-2-45
T1V5-05-01-135
T1V1-05-01-127
Menu Key
Primary Screen
T1V1-05-03-001
Key 2
Key 1
Key 2
Confirm Key
Confirm Key
T1V5-05-01-114
T1V5-05-01-120
Back Key
Key 6
T1V5-05-01-136
T5-2-46
Menu Key
Primary Screen
T1V1-05-03-001
Key 1
Key 2
Confirm Key
T1V5-05-01-019
Key 1
Key 2
Confirm Key
T1V5-05-01-049
Key 1
Confirm
Key
Key 2
Key 6
T5-2-47
T1V5-05-01-052
Key 2
T1V5-05-01-052
Key 1
Key 2
Key 3
Key 4
Confirm Key
T1V5-05-01-138
Key 6
Confirm Key
T1V5-05-01-139
Menu Key
Primary Screen
T5-2-48
T1V1-05-03-001
Key 5
T1V5-05-01-052
Confirm Key
T5-2-49
T1V5-05-01-140
Starting Screen
T1V1-05-01-115
Back Key
Reset Key
T1V5-05-01-170
Confirm Key
Reset Screen
T1V5-05-01-171
Menu Key
Primary Screen
T5-2-50
T1V1-05-03-001
Starting Screen
T1V1-05-01-115
Key 1
Back Key
Key 2
Confirm
Key
3. Push the reset key while the maintenance information display screen is displayed.
The message "Reset Data. OK?" appears. Then,
push the confirm key.
The value of remaining hours is reset to that of
change interval. previous change date/hour is
updated with current date and time.
T1V5-05-01-169
Back Key
Reset Key
T1V5-05-01-170
Back Key
Reset Screen
T5-2-51
T1V5-05-01-171
Primary Screen
T1V1-05-03-001
Key 1
Key 2
Confirm Key
Back Key
T1V5-05-01-114
Back Key
Key 1
T5-2-52
Key 6
Key 2
Confirm Key
T1V1-05-01-137
Screen Display
Japanese
T1V1-05-01-141
English
T1V1-05-01-142
Chinese (Simplified)
T1V1-05-01-143
Chinese (Traditional)
T1V1-05-01-144
Korean
T1V1-05-01-145
Indonesian
T1V1-05-01-146
Thai
T1V1-05-01-147
Vietnamese
T1V1-05-01-148
Myanmarese
T1V1-05-01-149
Arabic
T1V1-05-01-150
Persian
T1V1-05-01-151
Turkish
T1V1-05-01-152
Display Languages 2
Language
Screen Display
English
T1V1-05-01-142
Spanish
T1V1-05-01-153
Italian
T1V1-05-01-154
French
T1V1-05-01-155
German
T1V1-05-01-156
Dutch
T1V1-05-01-157
Russian
T1V1-05-01-158
Portuguese
T1V1-05-01-159
Finnish
T1V1-05-01-160
Swedish
T1V1-05-01-161
Norwegian
T1V1-05-01-162
Danish
T1V1-05-01-163
T5-2-53
Key F3
Primary Screen
Mail Screen
T1V1-05-03-001
T1V5-05-01-037
T1V5-05-01-038
Back Key
T1V5-05-01-039
T5-2-54
T1V5-05-01-040
T5-2-55
T5-2-56
TROUBLESHOOTING / Dr. ZX
OUTLINE
Dr. ZX is used for diagnosis of electrical system including MC, ECM, ICF and monitor unit.
Dr. ZX is connected to ICF and failure of each controller and each sensor is displayed as a fault code.
(Self-Diagnostic Result)
Dr. ZX displays the input status of sensors and
switches connected to each controller and the output
status to actuator including solenoid valve from controller with the machine operated in real time. (Controller Diagnosis)
T5-3-1
TROUBLESHOOTING / Dr. ZX
Operation
1. Connect Palm (Dr. ZX) to the diagnosing connector in the cab by using the Hot Sync cable and
connecting harness.
2. Turn the key switch ON or start the engine.
3. When turning Palm ON, the following screen is
displayed on the display of Palm.
Initial Screen:
Select Dr. ZX icon.
Password Setup Screen (When the password has
unset): Set the password.
Service Software Selection Screen:
+ Select ZX-3 Large.
Function Selection Screen:
+ Self-Diagnostic Results
+ Select Controller
4. Select Self-Diagnostic Result and operate according to the instruction under display screen.
Dr. ZX
Connector
T1V1-05-07-001
Palm
Dr. ZX
Connecting
Harness
T1V1-05-07-002
T5-3-2
TROUBLESHOOTING / Dr. ZX
Start
Initial Screen
Input Password
Communication
Error
Service Software
Selection Screen
Select ZX-3 Large
Self-Diagnostic
Result Function
Self-Diagnostic
Result of Each
Controller
Select Controller
Select
Function
Record
T1V7-05-03-165
Select Controller
Engine C/U
Main C/U
Main Menu
Monitor Display
Special Function
Setup
Disp. Record
Password Change
Op. Manual.
Main Menu
Monitor Display
Disp. Record
Password Change
Retry B
Self-Diagnostic
Result
T5-3-3
Information
C/U
Main Menu
Information C/U
Various Setup
Data Download
Save Data Check
Password Change
Monitor Unit
Main Menu
Monitoring
Various Setup
Password Change
TROUBLESHOOTING / Dr. ZX
SELF-DIAGNOSTIC RESULTS
The self-diagnostic result of each controller is displayed.
After starting Dr. ZX, push Self-Diagnostic Result.
T1V7-05-03-001
T1V7-05-03-008
T1V7-05-03-002
MC
ECM
Monitor Unit
ICF
T5-3-4
TROUBLESHOOTING / Dr. ZX
Self-Diagnosis
After starting Dr. ZX,
Self-Diagnostic Result.
push
To the
lower
T1V7-05-03-001
T1V7-05-03-002
T1V7-05-03-008
Trouble
Retry B
ESC
ESC
T1V7-05-03-003
T1V7-05-03-007
T1V7-05-03-005
Retry B Screen
If the message of Details is
long, push the arrow and
change the screen.
Retry B
ESC
T1V7-05-03-002
T5-3-5
TROUBLESHOOTING / Dr. ZX
SELECT CONTROLLER
Select failure-diagnosis controller.
After starting Dr. ZX, push Select Controller.
T1V7-05-03-001
T1V7-05-03-009
MC
ECM
Monitor Unit
ICF
T5-3-6
TROUBLESHOOTING / Dr. ZX
MAIN CONTROLLER
Password:
Title Screen
Operation Manual:
Refer to the procedure of pump learning setup.
Recorded Data:
Displays data recorded in MC by one day by using
Dr. ZX.
T1J1-05-03-034
Password
Change
Return to Controller
Selection Screen.
Op. Manual
Disp. Record
T1V7-05-03-012
Monitor Display
Special Function
Setup
T5-3-7
TROUBLESHOOTING / Dr. ZX
MAIN MENU MONITOR DISPLAY (MC)
Dr. ZX displays the input signals from switches and
sensors and the control signals from MC.
List of Monitor Item
Item
Selecting
Monitoring
Requested Engine Speed
Req. Eng
Engine Torque
Engine Torque
Actual Engine Speed
Actual Speed
Engine Speed Deviation
Eng Speed Deviat
min
%
-1
min
-1
min
P1 Delivery Pres
MPa
PC1 Pressure
MPa
P1 Reg. Pres.
MPa
P1 Disired Disp.
cm
Unit
-1
P2 Delivery Pres
MPa
PC2 Pressure
MPa
MPa
L
%
%
V
Fr Pilot Press
MPa
TR Pilot Press
MPa
Boom Raise
MPa
Boom Lower
MPa
MPa
MPa
MPa
MPa
P2 Disired Disp.
cm
T5-3-8
Data
Input signal from engine control dial
Input signal from ECM
Input signal from ECM
Input signal from ECM
Input signal from pump 1 delivery pressure
sensor
Input signal from pump 1 control pressure
sensor
Max. pressure when operating pump 1
(for 4-spool control valve)
Pump 1 flow control taget rate
Pump 1 flow control taget rate
Input signal from pump 2 delivery
pressure sensor
Input signal from pump 2 control pressure
sensor
Input signal from pump 2 regulator
pressure sensor
Pump 2 flow control target rate
Pump 2 flow control target rate
Load rate of pump 1
Load rate of pump 2
Input signal from engine control sensor
Input signal from hydraulic temperature
sensor
Max. pressure when operating boom, arm,
bucket, swing, counterweight, aux.1 and/or
aux.2
Input signal from pressure sensors
(travel left and right)
Input signal from pressure sensor
(boom raise)
Input signal from pressure sensor
(boom lower)
Input signal from pressure sensor
(arm roll-in)
Input signal from pressure sensor
(arm roll-out)
Input signal from pressure sensor
(bucket roll-in)
Input signal from pressure sensor
(bucket roll-out)
TROUBLESHOOTING / Dr. ZX
Item
Selecting
Swing Pilot Pressure
Monitoring
SW Pilot Press
Left TR Press.
Right TR Press.
Unit
MPa
Bm Bottom Press
E/P SW
HP Mode SW
Auto-Idle SW
Power Boost SW
Key SW
Fan Reverse SW
Test Mode SW
Load Alarm On/Off SW
Coolant Level SW
Engine Oil Level SW
Level Check SW
Gate Lock SW
E/P SW
HP Mode SW
AI SW
Travel 2-Speed Chg Ovr
SW
Power Boost SW
Key SW
Fan Dir. SW
Fan Test Mode SW
Load Alarm On/Off SW
Coolant L SW
Eng Oil L SW
Level Check SW
Gate Lock SW
OFF, ON
OFF, ON
OFF, ON
OFF, ON
OFF, ON
OFF, ON
OFF, ON
OFF, ON
OFF, ON
Boom Mode SW
Bm Mode SW
OFF, ON
OFF, ON
P Reg. Lean. SW
OFF, ON
Lub. Count. SW
OFF, ON
Travel Mode SW
Data
Lo, Hi
T5-3-9
TROUBLESHOOTING / Dr. ZX
Item
Selecting
Picture Change Signal
Loader Bucket (O/C) Flow
Change SW
Auxiliary Digital Input 1
Auxiliary Digital Input 2
Auto Lub. Count Time-Out
Sel. SW
Power Boost Control Pressure
Travel Motor Control Pressure
Boom Mode Control Pressure
Boom Flow Control Pressure
Picture Change
AUX. Di 1
AUX. Di 2
OFF, ON
OFF, ON
A, B
MPa
Tr M Ctrl Pressure
MPa
MPa
MPa
Swing Alarm
Swing Alarm
Load Alarm
Load Alarm
BK Surveil,
Trav. Operat
OFF, ON
Travel Alarm
Data
Loader SW
Travel Alarm
Unit
Monitoring
Action,
No Action
Action,
No Action
Action,
No Action
Learnable
Low Eng Speed
Gate Lock
Awaked
Signal Over Range
Save Failed
Learnable
Low Eng Speed
Gate Lock
Awaked
Signal Over Range
Save Failed
1 In, 1 Su, 1 Fa, 1
Le,
2 In, 2 Su, 2 Fa, 2
Le
Pump 1 CUR
mA
Pump 2 CUR
mA
mA
T5-3-10
TROUBLESHOOTING / Dr. ZX
Item
Unit
Selecting
Boom Flow Control Valve
Current
Fan Reverse Valve 1 Current
Fan Reverse Valve 2 Current
Auxiliary Valve 1 Current
Auxiliary Valve 2 Current
Monitoring
Lubricating Mode
Lub. Mode
ATT 1 Type
ATT 1 Type
ATT 1 No.
ATT 1 No.
ATT 2 Type
ATT 2 Type
ATT 2 No.
ATT 2 No.
ATT 3 Type
ATT 3 Type
ATT 3 No.
ATT 3 No.
ATT 4 Type
ATT 4 Type
ATT 4 No.
ATT 4 No.
ATT 5 Type
ATT 5 Type
ATT 5 No.
ATT 5 No.
mA
mA
mA
mA
mA
OFF, Auto,
Manual
Normal,
Abnormal
SUS., Comp.
BR, PU, CR,
VI, Un, Non
1, 2, 3, 4, 5
BR, PU, CR,
VI, Un, Non
1, 2, 3, 4, 5
BR, PU, CR,
VI, Un, Non
1, 2, 3, 4, 5
BR, PU, CR,
VI, Un, Non
1, 2, 3, 4, 5
BR, PU, CR,
VI, Un, Non
1, 2, 3, 4, 5
BR, PU, CR,
VI, Un, Non
1, 2, 3, 4, 5
T5-3-11
Data
Control signal to solenoid valve unit
(SF)
Control signal to fan reversal solenoid Valve 1
Control signal to fan reversal solenoid Valve 2
Control signal to aux. solenoid valve
Control signal to aux. solenoid valve
Auto-lubrication selection status,
manual (optional)
Auto-lubrication status
Grease pump status
Communication from monitor unit
Communication from monitor unit
Communication from monitor unit
Communication from monitor unit
Communication from monitor unit
Communication from monitor unit
Communication from monitor unit
Communication from monitor unit
Communication from monitor unit
Communication from monitor unit
Communication from monitor unit
Communication from monitor unit
TROUBLESHOOTING / Dr. ZX
Monitor Display
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
Push Start.
T1J1-05-03-010
To the
lower
T1J1-05-03-034
Title Screen
T1V7-05-03-012
T1J1-05-03-012
T1J1-05-03-011
T1J1-05-03-013
Monitor Screen
To the next page
T5-3-12
T1J1-05-03-014
TROUBLESHOOTING / Dr. ZX
Push Record.
To the
lower
T1J1-05-03-014
T1V7-05-03-096
Monitor Screen
If Rec. No. has already been recorded and push Over Write, data
is overwritten. Push ESC and return to Main Menu Screen.
T1V7-05-03-097
Push Comment .
Sush ESC and return to Main
Menu Screen.
To the
lower
T1J1-05-03-015
Recording Screen
T1V7-05-03-100
T1J1-05-03-016
Recording Screen
T1J1-05-03-017
T1J1-05-03-018
T5-3-13
T1J1-05-03-019
TROUBLESHOOTING / Dr. ZX
SPECIAL FUNCTIONS
Deactivation special functions
Special Function Item Table
Item
Content
WU Deactivation
Deactivate WU control
ECO Deactivation
Fan Deactivation
HP Deactivation
Deactivate HP mode
Cut-off Deactivation
T5-3-14
TROUBLESHOOTING / Dr. ZX
Example: ECO Deactivation
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-010
Push Start.
To the
lower
T1J1-05-03-034
T1V7-05-03-012
Title Screen
Push Execute.
Push ESC and return to Deactivation Selection Screen.
T1J1-05-03-020
T1V7-05-03-020
T5-3-15
T1V7-05-03-016
T1V7-05-03-021
TROUBLESHOOTING / Dr. ZX
SETUP
Engine speed, pump delivery flow rate, solenoid valve
output pressure and so on can be adjusted.
Parameter Change
Item
Li Speed Adjustment
WU Speed Adjustment
AI Speed Adjustment
Unit
Data
-1
-1
-1
-1
-1
-1
min
min
min
E Speed Adjustment
min
P Speed Adjustment
min
HP Speed Adjustment
min
PQ Torque Control
Nm
Nm
Nm
ms
ON, OFF
ON, OFF
HP Mode On/Off
ON, OFF
ON/OFF of HP Control
ON, OFF
ON, OFF
MPa
min
cm
cm
MPa
MPa
MPa
mA
ON, OFF
T5-3-16
TROUBLESHOOTING / Dr. ZX
Attachment Parameter Change
Item
ATT1
ATT1 ATT Type
ATT1 ATT Number
ATT1 P1 Swash Angle Adjustment
ATT1 P2 Swash Angle Adjustment
ATT1 Engine Speed Adjustment
ATT1 Relief Change (OPT)
ATT1 2nd Relief Change (OPT)
ATT1 Accumulator Change (OPT)
ATT1 2-Speed Change (OPT)
ATT2
ATT2 ATT Type
ATT2 ATT Number
ATT2 P1 Swash Angle Adjustment
Unit
Data
BR PU CR VI Attachment selection
Un Non
12345
Attachment setting number selection
L/min
Adjustment of lower limit of maximum pump 1 flow rate
when using attachment
L/min
Adjustment of lower limit of maximum pump 2 flow rate
when using attachment
-1
min
Adjustment of engine speed when using attachment
ON, OFF
Secondary pilot relief valve ON/OFF selection
ON, OFF
Selector valve ON/OFF selection
ON, OFF
Accumulator ON/OFF selection
ON, OFF
2-speed selection ON/OFF selection
BR PU CR VI Attachment selection
Un Non
12345
Attachment setting number selection
L/min
L/min
-1
min
ON, OFF
ON, OFF
ON, OFF
ON, OFF
T5-3-17
TROUBLESHOOTING / Dr. ZX
Item
ATT3
ATT3 ATT Type
Unit
Data
BR PU CR VI
Un Non
12345
L/min
L/min
min
ON, OFF
ON, OFF
ON, OFF
ON, OFF
-1
BR PU CR VI
Un Non
12345
L/min
L/min
min
ON, OFF
ON, OFF
ON, OFF
ON, OFF
-1
Attachment selection
Attachment setting number selection
Adjustment of lower limit of maximum pump 1 flow rate
when using attachment
Adjustment of lower limit of maximum pump 2 flow rate
when using attachment
Adjustment of engine speed when using attachment
Secondary pilot relief valve ON/OFF selection
Selector valve ON/OFF selection
Accumulator ON/OFF selection
2-speed selection ON/OFF selection
Attachment selection
Attachment setting number selection
Adjustment of lower limit of maximum pump 1 flow
rate when using attachment
Adjustment of lower limit of maximum pump 2 flow
rate when using attachment
Adjustment of engine speed when using attachment
Secondary pilot relief valve ON/OFF selection
Selector valve ON/OFF selection
Accumulator ON/OFF selection
2-speed selection ON/OFF selection
T5-3-18
TROUBLESHOOTING / Dr. ZX
Item
ATT5
ATT5 ATT Type
ATT5 ATT Number
ATT5 P1 Swash Angle Adjustment
ATT5 P2 Swash Angle Adjustment
ATT5 Engine Speed Adjustment
ATT5 Relief Change (OPT)
ATT5 2nd Relief Change (OPT)
ATT5 Accumulator Change (OPT)
ATT5 2-Speed Change (OPT)
Unit
Data
BR PU CR VI Attachment selection
Un Non
12345
Attachment setting number selection
L/min
Adjustment of lower limit of maximum pump 1 flow rate
when using attachment
L/min
Adjustment of lower limit of maximum pump 2 flow rate
when using attachment
-1
min
Adjustment of engine speed when using attachment
ON, OFF
Secondary pilot relief valve ON/OFF selection
ON, OFF
Selector valve ON/OFF selection
ON, OFF
Accumulator ON/OFF selection
ON, OFF
2-speed selection ON/OFF selection
T5-3-19
TROUBLESHOOTING / Dr. ZX
ADJUSTMENT DATA LIST
Min. Adjustment
Value
Adjustment Data
Adjustable Range
-1
0 to 150 min
-1
0 to 150 min
Li Speed Adjustment
10 min
WU Speed Adjustment
10 min
-1
Standard
Adjustment
-1
0 min
-1
-1
0 min
-1
-1
0 min
-1
-1
-1
-1
-1
0 min-
-1
0 min
-1
AI Speed Adjustment
10 min
E Speed Adjustment
10 min
P Speed Adjustment
10 min
HP Speed Adjustment
10 min
-200 to 0 min
0 min
PQ Torque Control
10 Nm
-1000 to 120 Nm
0 Nm
10 Nm
-1000 to 0 Nm
0 Nm
10 Nm
-1000 to 0 Nm
0 Nm
40 ms
0 to 3000 ms
3000 ms
OFF
ON
ON
OFF
OFF
0.1 MPa
0.0 MPa
1 min
6 to 253 min
50 min
-1
-1
-1
2.5 cm
2.5 cm
0.1 MPa
0.0 MPa
0.006 MPa
0.000 MPa
0.006 MPa
0.000 MPa
5 mA
-640 to 0 mA
0 mA
OFF
T5-3-20
0.0 to 140.0 cm
0.0 cm
0.0 to 140.0 cm
0.0 cm
Remarks
TROUBLESHOOTING / Dr. ZX
ATTACHMENT ADJUSTMENT DATA LIST
Adjustment Data
Min. Adjustment
Value
Adjustable Range
Standard
Adjustment
BR PU CR VI Un Non
1 to 5
BR
1
0.5 L/min
367 L/min
0.5 L/min
200 L/min
ATT 1
ATT1 ATT Type
ATT1 ATT Number
ATT1 P1 Swash Angle Adjustment
ATT1 P2 Swash Angle Adjustment
ATT1 Engine Speed Adjustment
-1
-1
-1
10 min
0 min
ON/OFF
Unregistration
C/V or O/T
Unregistration
ON/OFF
Unregistration
ON/OFF
OFF
BR PU CR VI Un Non
1 to 5
BR
2
0.5 L/min
367 L/min
0.5 L/min
250 L/min
ATT2
ATT2 ATT Type
ATT2 ATT Number
ATT2 P1 Swash Angle Adjustment
ATT2 P2 Swash Angle Adjustment
ATT2 Engine Speed Adjustment
-1
-1
-1
10 min
0 min
ON/OFF
Unregistration
C/V or O/T
Unregistration
ON/OFF
Unregistration
ON/OFF
OFF
T5-3-21
Remarks
TROUBLESHOOTING / Dr. ZX
Adjustment Data
ATT3
ATT3 ATT Type
ATT3 ATT Number
ATT3 P1 Swash Angle Adjustment
ATT3 P2 Swash Angle Adjustment
ATT3 Engine Speed Adjustment
Min. Adjustment
Value
Adjustable Range
Standard
Adjustment
BR PU CR VI Un Non
1 to 5
BR
3
0.5 L/min
367 L/min
0.5 L/min
280 L/min
-1
-1
-1
10 min
0 min
ON/OFF
Unregistration
C/V or O/T
Unregistration
ON/OFF
Unregistration
ON/OFF
OFF
BR PU CR VI Un Non
1 to 5
Unregistration
Unregistration
0.5 L/min
367 L/min
0.5 L/min
367 L/min
10 min
-500 to 100
0 min
ON/OFF
Unregistration
C/V or O/T
Unregistration
ON/OFF
Unregistration
ON/OFF
OFF
ATT4
Accumulator
Change
(OPT)
ATT4 2-Speed Change (OPT)
-1
T5-3-22
-1
Remarks
TROUBLESHOOTING / Dr. ZX
Adjustment Data
Min. Adjustment
Value
Adjustable Range
Standard
Adjustment
BR PU CR VI Un Non
1 to 5
Unregistration
Unregistration
0.5 L/min
367 L/min
0.5 L/min
367 L/min
ATT5
ATT5 ATT Type
ATT5 ATT Number
ATT5 P1 Swash Angle Adjustment
ATT5 P2 Swash Angle Adjustment
ATT5 Engine Speed Adjustment
-1
-1
-1
10 min
0 min
ON/OFF
Unregistration
C/V or O/T
Unregistration
ON/OFF
Unregistration
ON/OFF
OFF
T5-3-23
Remarks
TROUBLESHOOTING / Dr. ZX
Setup
Parameter Change
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
Push Start.
Push Setup.
T1J1-05-03-010
To the
lower
T1J1-05-03-034
T1V7-05-03-012
Title Screen
T1V7-05-03-022
T1J1-05-03-021
T5-3-24
T1V7-05-03-016
T1V7-05-03-105
TROUBLESHOOTING / Dr. ZX
Parameter Input
Example: Li Speed Adjustment
Input Value = Normal Value
Input the value and push Exec.
Push ESC and return to Parameter
Change Selection Screen.
To the
lower
T1J1-05-03-022
T1J1-05-03-023
T1V7-05-03-107
T5-3-25
T1J1-05-03-024
TROUBLESHOOTING / Dr. ZX
Input Value = Current Value
Input the value and push Exec.
Push ESC and return to Parameter
Change Selection Screen
To the
lower
T1J1-05-03-022
T1J1-05-03-023
T1V7-05-03-107
T5-3-26
T1V7-05-03-108
TROUBLESHOOTING / Dr. ZX
Input Value > Maximum Value
(Input Value < Minimum Value)
Input the value and push Exec.
Push ESC and return to Parameter
Change Selection Screen.
To the
lower
T1J1-05-03-022
T1V7-05-03-107
T5-3-27
T1J1-05-03-023
T1J1-05-03-025
TROUBLESHOOTING / Dr. ZX
When the input value cannot be divided
To the
lower
T1J1-05-03-022
T1V7-05-03-107
T5-3-28
T1J1-05-03-023
T1J1-05-03-026
TROUBLESHOOTING / Dr. ZX
Status Selection
Example: ATT Torque Reducing On/Off: Off
To the
lower
T1J1-05-03-027
T1V7-05-03-111
T1V7-05-03-107
T5-3-29
T1V7-05-03-112
TROUBLESHOOTING / Dr. ZX
Attachment Parameter Change
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
Push Start.
Push Setup.
T1J1-05-03-010
To the
lower
Title Screen
T1J1-05-03-034
T1V7-05-03-022
T1V7-05-03-012
T1J1-05-03-021
T5-3-30
T1V7-05-03-016
T1V7-05-03-114
TROUBLESHOOTING / Dr. ZX
Attachment Parameter Input
Input Value = Normal Value
Push ATT1.
To the
lower
T1V7-05-03-114
T1V7-05-03-115
T1J1-05-03-029
T1V7-05-03-107
T5-3-31
T1J1-05-03-028
TROUBLESHOOTING / Dr. ZX
Input Value = Current Value
Push ATT1.
To the
lower
T1V7-05-03-114
T1V7-05-03-115
T1J1-05-03-030
T1V7-05-03-107
T5-3-32
T1J1-05-03-028
TROUBLESHOOTING / Dr. ZX
Input Value > Maximum Value
Push ATT1.
To the
lower
T1V7-05-03-114
T1V7-05-03-115
T1J1-05-03-031
T1V7-05-03-107
T5-3-33
T1J1-05-03-028
TROUBLESHOOTING / Dr. ZX
When the input value cannot be divided
Push ATT1.
To the
lower
T1V7-05-03-114
T1V7-05-03-115
T1J1-05-03-032
T1V7-05-03-107
T5-3-34
T1J1-05-03-028
TROUBLESHOOTING / Dr. ZX
Status Selection
Example: ATT1, ATT Number
Push ATT1.
To the
lower
T1V7-05-03-114
T1V7-05-03-115
T1J1-05-03-033
T1V7-05-03-107
T5-3-35
T1V7-05-03-123
TROUBLESHOOTING / Dr. ZX
Attachment Setting
Example: Set Crusher 5 to Attachment 1
Push ATT1.
To the
lower
T1V7-05-03-114
T1V7-05-03-115
T1V7-05-03-121
To the
lower
T1V7-05-03-107
T1V7-05-03-115
T1V7-05-03-123
Attachment 1
Key 2
T1V7-05-03-107
T5-3-36
TROUBLESHOOTING / Dr. ZX
Attachment Non-Setting
IMPORTANT: When the attachment is non-setting, the attachment cannot be selected on the monitor unit.
Example: Set Attachment to Non-Setting
Push Non and Push Exec. Push
ESC and return to Parameter
Change Selection Screen.
Push ATT1.
To the
lower
T1V7-05-03-114
T1V7-05-03-115
T1V7-05-03-121
Attachment 4
Attachment 3
Push ESC.
Attachment 5
Attachment 2
Attachment 1
T1V7-05-03-107
T5-3-37
TROUBLESHOOTING / Dr. ZX
All Parameter Initialize
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
Push Start.
Push Setup.
T1J1-05-03-010
To the
next page
T1J1-05-03-034
Title Screen
T1V7-05-03-012
T5-3-38
T1V7-05-03-016
TROUBLESHOOTING / Dr. ZX
Input the password and push OK.
Push Cancel and return to Main
Menu Screen.
Push OK.
Push ESC and return to Main
Menu Screen.
To the
lower
T1V7-05-03-022
T1J1-05-03-021
Explanation Screen
T1J1-05-03-005
OK
abort
Execution Screen
T1J1-05-03-006
T1J1-05-03-007
IMPORTANT: After all parameter initialize operation is completed, turn the key
switch OFF over 3 seconds.
IMPORTANT: If All Parameter Initialize is executed,
pump learning value is erased.
After All Parameter Initialize is executed, perform the pump learning.
(Refer to the Adjustment group /
OPERATIONAL
PERFORMANCE
TEST.)
T5-3-39
T1J1-05-03-008
TROUBLESHOOTING / Dr. ZX
Recorded Data Display
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-010
Push and select No. Push Regeneration and the recorded data is
regenerated.Push DEL and data of
selected No. is deleted.
To the
lower
T1J1-05-03-034
T1V7-05-03-124
Title Screen
T1V7-05-03-012
T5-3-40
T1J1-05-03-014
TROUBLESHOOTING / Dr. ZX
Password Change
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
Push Password.
T1J1-05-03-010
To the
lower
T1J1-05-03-034
T1V7-05-03-126
Title Screen
Input the new password again and
push OK.
Push OK
Screen.
and
return
to
T1V7-05-03-169
Title
T1V7-05-03-128
T5-3-41
T1V7-05-03-127
TROUBLESHOOTING / Dr. ZX
ENGINE CONTROLLER
Password
Title Screen
Recorded Data
Displays data recorded in ECM by one day by using
Dr. ZX.
Password
Change
Return to Controller
Selection Screen.
Op. Manual
Disp. Record
T1J1-05-03-035
Monitor
Display
T5-3-42
TROUBLESHOOTING / Dr. ZX
MAIN MENU MONITOR DISPLAY (ECM)
List of Monitor Item
Item
Selecting
Actual Accelerator Position
Engine Torque
Actual Engine Speed
Target Engine Speed
Glow Signal
Coolant Temperature
Fuel Temperature
Engine Oil Pressure
Fuel Flow
Barometric Pressure
Intake Air Temperature
Boost Pressure
Boost Temperature
Battery Voltage
Total Fuel Used
Unit
Monitoring
Act. Accelera%
tor POS
Engine Torque
%
Act. Eng
-1
min
Speed
-1
Tar. Eng Speed
min
Glow Signal
OFF, ON
Coolant Temp.
C
Fuel Temp.
C
Eng Oil PreskPa
sure
Fuel Flow
L/h
Barome.
kPa
Press.
Intake Air
C
Temp.
Boost Pressure
kPa
Boost Temp.
C
Battery Volt
V
Total
Used
L
Fuel
Data
Input signal from ECM
Input signal from ECM
Input signal from crank speed sensor and cam angle
sensor
Input signal from engine control dial
Glow relay ON/OFF status
Input signal from coolant temperature sensor
Input signal from fuel sensor
Input signal from engine oil pressure sensor
Input signal from ECM
Input signal from atmospheric pressure sensor
Input signal from intake-air temperature sensor
Input signal from boost pressure sensor
Input signal from boost temperature sensor
Input signal from ECM
Input signal from ECM
T5-3-43
TROUBLESHOOTING / Dr. ZX
Monitor Display
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
Push Start.
T1J1-05-03-036
To the
lower
Title Screen
T1J1-05-03-034
T1V7-05-03-130
T1J1-05-03-011
Start recoding.
To the
next page
T1J1-05-03-012
T1J1-05-03-037
T5-3-44
T1J1-05-03-038
Monitor Screen
TROUBLESHOOTING / Dr. ZX
Push Record.
To the
lower
Monitor Screen
T1J1-05-03-038
If Rec. No. has already been recorded and push Over Write, data
is overwritten.
Push ESC and return to Main
Menu Screen.
T1V7-05-03-134
T1V7-05-03-135
Push Comment.
Push ESC and return to Main
Menu Screen.
To the
lower
T1J1-05-03-039
T1V7-05-03-136
T1J1-05-03-040
Recording Screen
Recording Screen
T1J1-05-03-041
T1J1-05-03-042
T5-3-45
T1J1-05-03-043
TROUBLESHOOTING / Dr. ZX
RECORD DATA DISPLAY
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-036
T1J1-05-03-034
T1V7-05-03-124
Title Screen
T1J1-05-03-044
T5-3-46
TROUBLESHOOTING / Dr. ZX
PASSWORD CHANGE
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
Push Password.
T1J1-05-03-036
To the
lower
T1J1-05-03-034
T1V7-05-03-126
Title Screen
Input the newpassword again and
push OK.
Push OK
Screen.
and
return
to
T1V7-05-03-169
Title
T1V7-05-03-128
T5-3-47
T1V7-05-03-127
TROUBLESHOOTING / Dr. ZX
ICF CONTROLLER
Password Change
The password can be changed.
Main Menu
Information C/U Various Setup
Initialization of information C/U, setting of model,
serial No. and time, and initialization of control
data can be done.
Data Download
Daily report data, frequency distribution data, total
operating hours, alarm and failure which are recorded in ICF can be downloaded to Dr. ZX.
Save Data Check
Daily report data, frequency distribution data, total
operating hours, alarm and failure which are
saved in ICF can be checked by using Dr. ZX.
T1V7-05-03-166
T5-3-48
TROUBLESHOOTING / Dr. ZX
MAIN MENU
INFORMATION C/U VARIOUS SETUP
List of Controller Data Setting Item
Item
Information C/U: Initialize
Enter Model and Serial No.
Range of Data
Model
Serial No.
YY
MM
DD
HH
MM
Date
Time
Control Data: Initialize
Satellite Terminal: Initialize
Satellite Terminal No. Confirmation
Communicating State Check
Connect
Comm.
Power
Comm.
Rod Aerial
GPS Aerial
Wave State
Un-Transmit Data Number
Last Transmitting Time
Enter Satellite Comm.
Start/Stop
T5-3-49
Initialize/ESC
ASCII (4 characters) 0 to 9, A to Z
000000 to 999999
2000 to 2100
1 to 12
1 to 31
0 to 23
0 to 59
Initialize/ESC
DEL/ESC
12 digits: 0 to 9, A to Z
Conn/UnConn
OK/NG
ON/OFF
Enable/Stop
OK/NG
OK/NG
ON/OFF
099
YYYY/MM/DD hh: mm: ss
Start/Stop
TROUBLESHOOTING / Dr. ZX
INFORMATION C/U: INITIALIZE
Push OK.
To the
lower
T1V7-05-03-001
Push Information
Setup.
Push Start.
C/U:
T1V7-05-03-009
Various
T1J1-05-03-045
To the
lower
Title Screen
T1V7-05-03-025
T1V7-05-03-026
T1V7-05-03-027
Init
ESC
T1V7-05-03-028
T1V7-05-03-029
T1V7-05-03-027
T5-3-50
TROUBLESHOOTING / Dr. ZX
ENTER MODEL AND SERIAL No.
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-045
Push Start.
Push Information
Setup.
C/U:
Various
To the
lower
T1V7-05-03-025
T1V7-05-03-026
Title Screen
T1V7-05-03-027
ESC
Exes
ESC
OK
T1J1-05-03-012
T1J1-05-03-011
T1V7-05-03-027
T5-3-51
TROUBLESHOOTING / Dr. ZX
ENTER DATE AND TIME
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
Push Information
Setup.
Push Start.
C/U:
Various
T1J1-05-03-045
To the
lower
T1V7-05-03-025
Title Screen
T1V7-05-03-026
T1V7-05-03-027
T5-3-52
TROUBLESHOOTING / Dr. ZX
CONTROL DATA: INITIALIZE
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
Push Start.
C/U:
T1V7-05-03-009
Various
T1J1-05-03-045
To the
lower
Title Screen
T1V7-05-03-025
T1V7-05-03-026
T1V7-05-03-027
Init
ESC
T1V7-05-03-033
T1V7-05-03-034
T1V7-05-03-027
T5-3-53
TROUBLESHOOTING / Dr. ZX
SATELLITE TERMINAL: INITIALIZE
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
Push Start.
T1V7-05-03-009
T1J1-05-03-045
Push Information
Setup.
C/U:
Various
To the
lower
Title Screen
T1V7-05-03-025
Push Exec.
Push
ESC
and
return
to
Information C/U: Various Setup
Screen.
T1V7-05-03-026
T1V7-05-03-035
Init
ESC
T1V7-05-03-036
T1V7-05-03-145
T5-3-54
T1V7-05-03-035
TROUBLESHOOTING / Dr. ZX
SATELLITE TERMINAL No. CONFIRMATION
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
Push Start.
T1V7-05-03-009
T1J1-05-03-045
Push Information
Setup.
C/U:
Various
To the
lower
T1V7-05-03-025
T1V7-05-03-026
Title Screen
T1V7-05-03-037
T1V7-05-03-035
T5-3-55
T1V7-05-03-035
TROUBLESHOOTING / Dr. ZX
COMMUNICATING STATE CHECK
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
Push Information
Setup.
Push Start.
C/U:
T1V7-05-03-009
Various
T1J1-05-03-045
To the
lower
T1V7-05-03-025
T1V7-05-03-026
Title Screen
T1V7-05-03-035
ESC
T1V7-05-03-142
T1V7-05-03-143
T1V7-05-03-035
T5-3-56
TROUBLESHOOTING / Dr. ZX
ENTER SATELLITE COMM. START / STOP
SET
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
Push Information
Setup.
Push Start.
C/U:
Various
T1J1-05-03-045
To the
lower
Title Screen
T1V7-05-03-025
T1V7-05-03-026
T1V7-05-03-035
Exec
ESC
T1V7-05-03-146
T1V7-05-03-147
T5-3-57
T1V7-05-03-035
TROUBLESHOOTING / Dr. ZX
(Blank)
T5-3-58
TROUBLESHOOTING / Dr. ZX
DATA DOWNLOAD
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
Push Start.
T1V7-05-03-009
T1J1-05-03-045
To the
lower
Title Screen
T1V7-05-03-025
T1V7-05-03-039
T1V7-05-03-026
T1V7-05-03-026
T1V7-05-03-148
Alarm Screen
T5-3-59
T1V7-05-03-038
TROUBLESHOOTING / Dr. ZX
SAVE DATA CHECK
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
Push Start.
T1V7-05-03-009
T1J1-05-03-045
To the
lower
T1V7-05-03-025
Title Screen
T1V7-05-03-026
T5-3-60
T1V7-05-03-040
TROUBLESHOOTING / Dr. ZX
PASSWORD CHANGE
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
Push Password.
T1J1-05-03-045
To the
lower
T1V7-05-03-025
T1V7-05-03-126
Title Screen
Input the new password again and
push OK.
Push OK
Screen.
and
return
to
T1V7-05-03-169
Title
T1V7-05-03-128
T5-3-61
T1V7-05-03-127
TROUBLESHOOTING / Dr. ZX
MONITOR CONTROLLER
Password Change
The password can be changed.
Main Menu
Monitoring
Dr. ZX displays the control signals of each controller and the input signals from each sensor.
Various Settings
Dr. ZX can set optional function setting, back
monitor setting, operating condition enable/ disable, time set function enable / disable, maintenance setting, inner hour meter synchronization
and fuel consumption gauge display ON/OFF
selection.
T1J1-05-03-057
T5-3-62
TROUBLESHOOTING / Dr. ZX
MONITORING
List of Monitoring Item
Item
Selecting
Monitoring
Monitor SW Status
Check
Coolant Temperature Coolant Temp.
Fuel Level
Fuel Level
Security Signal
Security Signal
Mail SW
Mail SW
Unit
Data
Switch state of monitor unit
C
%
OFF, ON
OFF,
Fuel,
Forward,
Repair,
General
T1V7-05-03-044
Unit
Switch 1
Switch 8
Switch 7
Switch 14
T5-3-63
TROUBLESHOOTING / Dr. ZX
Monitor Switch Status Check
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
Push Monitoring.
Push Start.
T1J1-05-03-046
To the
lower
T1V7-05-03-025
Title Screen
T1V7-05-03-042
Switch 1
Switch 7
Switch 8
Switch 14
T1V7-05-03-044
T5-3-64
T1V7-05-03-043
TROUBLESHOOTING / Dr. ZX
Other Monitoring
Push OK.
To the
lower
T1V7-05-03-001
Push Start.
T1V7-05-03-009
T1J1-05-03-046
Push Monitoring.
To the
lower
T1V7-05-03-025
Title Screen
T1V7-05-03-045
Monitoring Screen
T5-3-65
T1V7-05-03-042
T1V7-05-03-043
TROUBLESHOOTING / Dr. ZX
VARIOUS SETTINGS
List of Various Setup Item
Item
M1 (Optional Function 1 Allocate)
M2 (Optional Function 2 Allocate)
M3 (Optional Function 3 Allocate)
M4 (Optional Function 4 Allocate)
M5 (Optional Function 5 Allocate)
M6 (Optional Function 6 Allocate)
M7 (Optional Function 7 Allocate)
M8 (Optional Function 8 Allocate)
M9 (Optional Function 9 Allocate)
Overload Alarm Enable / Disable
Back Monitor Setup Back Monitor Function Enable/Disable
Back Monitor Display Normal/Flip Vertical
Operating Condition Enable / Disable
Time Set Function Enable / Disable
Maintenance Setup Maintenance Function Enable / Disable
Notification Function Enable / Disable
Maintenance Display Item ON/OFF
Engine Oil
Engine Oil Filter
Hydraulic Oil
Hydraulic Oil Pilot Filter
Hydraulic Oil Full-Flow Filter
Pump Transmission
Swing Bearing Grease
Travel Device Oil
Swing Device Oil
Air Cleaner Filter
Engine/Air Conditioner V-belt
Air Conditioner Filter
Fuel Filter
Inner Hour Meter Sync.
Fuel Consumption Gauge Display ON/OFF Selection
Unit
Optional Function
T5-3-66
Unset
Work Mode Function
Mail Function
Auto Lubrication Function
Disable/Enable
Disable/Enable
Flip Vertical/Normal
Disable/Enable
Disable/Enable
Disable/Enable
Disable/Enable
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
OFF/ON
Disable/Enable
TROUBLESHOOTING / Dr. ZX
(Blank)
T5-3-67
TROUBLESHOOTING / Dr. ZX
OPTION FUNCTION ALLOCATE
Example: Allocate ML Crane for Menu 7
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
Push Start.
T1J1-05-03-046
To the
lower
T1V7-05-03-025
Title Screen
Push Next.
Push ESC and return to Main
Menu Screen.
T1V7-05-03-042
T1V7-05-03-046
Push Next.
Push Back and return to the former
screen.
T1V7-05-03-047
T1V7-05-03-048
T5-3-68
T1V7-05-03-153
TROUBLESHOOTING / Dr. ZX
To the
lower
T1V7-05-03-153
Push ML Crane.
T1V7-05-03-050
T1V7-05-03-051
Push Exec.
T1J1-05-03-047
T1J1-05-03-048
T5-3-69
T1J1-05-03-049
TROUBLESHOOTING / Dr. ZX
Allocate Mail for Menu 3
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
Push Start.
T1J1-05-03-046
To the
lower
T1V7-05-03-025
T1V7-05-03-042
Title Screen
Push Next.
Push ESC and return to Main
Menu Screen.
Push Next.
Push ESC and return to the former
screen.
T1V7-05-03-046
To the
next page
T1V7-05-03-047
T1V7-05-03-048
T5-3-70
T1V7-05-03-155
TROUBLESHOOTING / Dr. ZX
Push Menu 3.
Push Exec.
Push Mail.
To the
lower
T1V7-05-03-155
T1J1-05-03-050
T1V7-05-03-153
T1V7-05-03-154
T1V7-05-03-046
Key F3
Mail Screen
T1V1-05-03-002
T5-3-71
T1V5-05-01-037
TROUBLESHOOTING / Dr. ZX
Allocate Auto Lubricate for Menu 4
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-046
Push Start.
To the
lower
Title Screen
T1V7-05-03-025
Push Next.
Push ESC and return to Main
Menu Screen.
T1V7-05-03-042
T1V7-05-03-046
Push Next.
Push Back and return to the former
screen.
To the
next page
T1V7-05-03-047
T1V7-05-03-048
T1V7-05-03-155
T5-3-72
TROUBLESHOOTING / Dr. ZX
Push Menu 4.
Push Exec.
To the
lower
T1V7-05-03-050
T1J1-05-03-051
T1J1-05-03-052
T1J1-05-03-053
T1V7-05-03-046
Key F4
M1J1-01-016
T5-3-73
T1J1-05-03-004
TROUBLESHOOTING / Dr. ZX
Make Mail for Menu 3 Disable
Push OK.
To the
lower
T1V7-05-03-001
Push Start.
T1V7-05-03-009
T1J1-05-03-046
To the
lower
Title Screen
T1V7-05-03-025
Push Next.
Push ESC and return to Main
Menu Screen.
T1V7-05-03-042
T1V7-05-03-046
Push Next.
Push Back and return to the former
screen.
To the
next page
T1V7-05-03-047
T1V7-05-03-048
T1V7-05-03-153
T5-3-74
TROUBLESHOOTING / Dr. ZX
Push Unset.
Push Menu 3.
Push Exec.
To the
lower
T1V7-05-03-153
T1J1-05-03-054
T1V7-05-03-155
T1V7-05-03-160
T1V7-05-03-046
T1V1-05-03-002
T5-3-75
T1V1-05-03-001
TROUBLESHOOTING / Dr. ZX
OVERLOAD WARNING ENABLE / DISABLE SELECTION
Overload Warning: Enable
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-046
Push Start.
To the
lower
T1V7-05-03-025
T1V7-05-03-042
T1V7-05-03-161
NOTE:
T1V7-05-03-162
T5-3-76
T1V7-05-03-046
Title Screen
TROUBLESHOOTING / Dr. ZX
Overload Warning: Disable
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-046
Push Start.
To the
lower
T1V7-05-03-025
T1V7-05-03-042
Title Screen
T1V7-05-03-163
NOTE:
T1V7-05-03-164
T5-3-77
T1V7-05-03-046
TROUBLESHOOTING / Dr. ZX
BACK MONITOR SETUP
Back Monitor Function: Enable
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-046
Push Start.
To the
lower
T1V7-05-03-025
T1V7-05-03-042
T1V7-05-03-046
Title Screen
T1V7-05-03-052
T1V7-05-03-053
NOTE:
T5-3-78
T1V7-05-03-054
TROUBLESHOOTING / Dr. ZX
Back Monitor Function: Disable
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-046
Push Start.
To the
lower
T1V7-05-03-025
T1V7-05-03-042
T1V7-05-03-046
Title Screen
T1V7-05-03-052
T1J1-05-03-055
NOTE:
T5-3-79
T1V7-05-03-057
TROUBLESHOOTING / Dr. ZX
Back Monitor Display: Normal
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-046
Push Start.
To the
lower
T1V7-05-03-025
T1V7-05-03-042
T1V7-05-03-046
Title Screen
T1V7-05-03-052
T1J1-05-03-056
NOTE:
T5-3-80
T1V7-05-03-058
TROUBLESHOOTING / Dr. ZX
Back Monitor Display: Flip Vertical
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-046
Push Start.
To the
lower
T1V7-05-03-025
T1V7-05-03-042
T1V7-05-03-046
Title Screen
Push
Back
Monitor
Display
Normal/Filip Vartical. Push ESC
and return to the former screen.
T1V7-05-03-052
T1V7-05-03-055
NOTE:
T5-3-81
T1V7-05-03-056
TROUBLESHOOTING / Dr. ZX
OPERATIONAL CONDITION ENABLE /
DISABLE SELECTION
Operational Condition: Enable
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-046
Push Start.
Push
Operational
Enable/ Disable.
condition
To the
lower
T1V7-05-03-025
T1V7-05-03-042
T1V7-05-03-059
NOTE:
T1V7-05-03-060
T5-3-82
T1V7-05-03-046
Title Screen
TROUBLESHOOTING / Dr. ZX
Operational Condition: Disable
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-046
Push Start.
Push
Operational
Enable/Disable.
condition
To the
lower
T1V7-05-03-025
T1V7-05-03-042
T1V7-05-03-061
NOTE:
T1V7-05-03-062
T5-3-83
T1V7-05-03-046
Title Screen
TROUBLESHOOTING / Dr. ZX
TIME SET FUNCTION ENABLE / DISABLE
SELECTION
Time Set Function: Enable
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
Push Start.
T1V7-05-03-009
T1J1-05-03-046
To the
lower
T1V7-05-03-025
T1V7-05-03-064
NOTE:
T1V7-05-03-063
T1V7-05-03-042
Title Screen
T1V7-05-03-066
T5-3-84
TROUBLESHOOTING / Dr. ZX
Time Set Function: Disable
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
Push Start.
T1V7-05-03-009
T1J1-05-03-046
To the
lower
T1V7-05-03-025
T1V7-05-03-067
NOTE:
T1V7-05-03-063
T1V7-05-03-042
Title Screen
T1V7-05-03-068
T5-3-85
TROUBLESHOOTING / Dr. ZX
MAINTENANCE SETUP
MAINTENANCE OPERATION ALLOW /
NOT ALLOW SELECTION
Maintenance Operation: Allow
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-046
Push Start.
To the
lower
T1V7-05-03-025
Title Screen
Push
Maintenance
Allow/Not Allow.
operation
T1V7-05-03-069
T1V7-05-03-063
T1V7-05-03-042
T1V7-05-03-070
NOTE:
T5-3-86
T1V7-05-03-071
TROUBLESHOOTING / Dr. ZX
Maintenance Operation: Not Allow
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-046
Push Start.
To the
lower
T1V7-05-03-025
Title Screen
Push
Maintenance
Allow/Not Allow.
operation
T1V7-05-03-069
T1V7-05-03-063
T1V7-05-03-042
T1V7-05-03-072
NOTE:
T5-3-87
T1V7-05-03-073
TROUBLESHOOTING / Dr. ZX
NOTIFICATION FUNCTION
DISABLE SELECTION
ENABLE
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-046
Push Start.
To the
lower
T1V7-05-03-025
T1V7-05-03-063
T1V7-05-03-042
Title Screen
T1V7-05-03-069
T1V7-05-03-074
NOTE:
T5-3-88
T1V7-05-03-075
TROUBLESHOOTING / Dr. ZX
Notification Function: Disable
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-046
Push Start.
To the
lower
T1V7-05-03-025
Title Screen
Push
Notification
Enable/Disable.
function
T1V7-05-03-069
T1V7-05-03-063
T1V7-05-03-042
T1V7-05-03-076
NOTE:
T5-3-89
T1V7-05-03-077
TROUBLESHOOTING / Dr. ZX
MAINTENANCE DISPLAY ITEMS ON/OFF
SELECTION
Maintenance Display Items: ON
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-046
Push Start.
To the
lower
T1V7-05-03-025
T1V7-05-03-063
T1V7-05-03-042
Title Screen
To the
next page
T1V7-05-03-069
T1V7-05-03-174
T5-3-90
TROUBLESHOOTING / Dr. ZX
To the
lower
T1J1-05-03-009
T1V7-05-03-078
T1V7-05-03-081
to
T1V7-05-03-083
T1V7-05-03-082
T5-3-91
T1V7-05-03-084
TROUBLESHOOTING / Dr. ZX
Maintenance Display Items: OFF
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-046
Push Start.
To the
lower
T1V7-05-03-025
T1V7-05-03-063
T1V7-05-03-042
Title Screen
To the
next page
T1V7-05-03-069
T1V7-05-03-174
T5-3-92
TROUBLESHOOTING / Dr. ZX
Push
ESC
and
return
Maintenance Set Item Screen.
T1V7-05-03-173
T1V7-05-03-175
T5-3-93
to
T1V7-05-03-172
TROUBLESHOOTING / Dr. ZX
INTERNAL HOUR METER SYNCHRONIZATION
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-046
Push Start.
To the
lower
T1V7-05-03-025
T1V7-05-03-063
T1V7-05-03-042
Title Screen
T1V7-05-03-085
T1V7-05-03-086
T5-3-94
TROUBLESHOOTING / Dr. ZX
FUEL COST METER DISPLAY ENABLE /
DISABLE SELECTION
Fuel Cost Meter Display: Enable
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
Push Start.
T1V7-05-03-009
T1J1-05-03-046
To the
lower
T1V7-05-03-025
T1V7-05-03-042
Title Screen
T1V7-05-03-088
NOTE:
T1V7-05-03-086
T5-3-95
T1J1-05-03-059
TROUBLESHOOTING / Dr. ZX
Fuel Cost Meter Display: Disable
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
Push Start.
T1V7-05-03-009
T1J1-05-03-046
To the
lower
T1V7-05-03-025
T1V7-05-03-090
NOTE:
T1J1-05-03-059
T1V7-05-03-042
Title Screen
T1V7-05-03-091
T5-3-96
TROUBLESHOOTING / Dr. ZX
PASSWORD CHANGE
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1J1-05-03-046
Push Password.
To the
lower
T1V7-05-03-025
T1V7-05-03-126
Title Screen
Push OK
Screen.
and
return
to
T1V7-05-03-169
Title
T1V7-05-03-128
T5-3-97
T1V7-05-03-127
TROUBLESHOOTING / Dr. ZX
(Blank)
T5-3-98
TROUBLESHOOTING / ICF
OUTLINE
ICF (Information Controller) saves the input signals
from various sensors and switches of the machine as
data.
Various input signals are recorded as list of daily report data, list of frequency distribution data, list of
total operating hours, list of alarm and list of failure
in ICF.
The recorded data is downloaded to the personal
computer and is uploaded to the center server via LAN,
so that the data can be used as e-Service.
The machine equipped with the satellite communication terminal (optional) sends the data to center server
by using satellite communication. (As for the satellite
communication system, refer to T5-4-24.
T5-4-1
TROUBLESHOOTING / ICF
LIST OF DAILY REPORT DATA
Data which can be downloaded by Palm
Item
Details
Date
Date of daily report data
Time when key switch is first turned ON during a day
Start: Time
(Time is recorded by key switch ON signal.)
Time when key switch is last turned OFF during a day
Stop: Time
(Time is recorded by key switch ON signal.)
The value of the final remained fuel during a day
Fuel Level
(Value is recorded by fuel sensor data from monitor unit.)
The value of fuel used during a day
Fuel Usage Amount
(Value is calculated and recorded by accumulated fuel usage amount
from ECM.)
Hour meter cumulative hours
Machine Hour Meter
(Hours are recorded by hour meter from monitor unit.)
Total engine operating hours selecting HP mode during a day
HP Mode Hours
(Hours are recorded by power mode switch information from MC.)
Engine
Operating
Total engine operating hours selecting P mode during a day
P Mode Hours
Hours
(Hours are recorded by power mode switch information from MC.)
Total engine operating hours selecting E mode during a day
E Mode Hours
(Hours are recorded by power mode switch information from MC.)
Hours when auto-idle switch is turned ON during a day
Auto-Idle Switch ON Time
(Hours are recorded by switch from MC.)
Fast Idle (Hi) Trav- Total operating hours of travel mode (Hi) during a day
(Hours are recorded by travel mode switch information from MC.)
Travel
Operating eling Hours
Hours
Slow Idle (Lo) Trav- Total operating hours of travel mode (Lo) during a day
eling Hours
(Hours are recorded by travel mode switch information from MC.)
Total swing operating hours during a day
Swing Operating Hours
(Hours are recorded by swing pressure sensor information from MC.)
Total operating hours selecting front attachment during a day
Digging Operating Hours
(Hours are recorded by front attachment pressure sensor information
from MC.)
Breaker Operating Total operating hours selecting breaker during a day
Hours
(Hours are recorded by attachment information from MC.)
Secondary Crusher Total operating hours selecting secondary crusher during a day
Operating Hours
(Hours are recorded by attachment information from MC.)
Attachment Operat- Hydraulic Crusher Total operating hours selecting hydraulic crusher during a day
ing Hours
Operating Hours
(Hours are recorded by attachment information from MC.)
Vibrating Hammer Total operating hours selecting vibrating hammer during a day
Operating Hours
(Hours are recorded by attachment information from MC.)
Bucket Operating Total operating hours selecting bucket during a day
Hours or Others
(Hours are recorded by attachment information from MC.)
T5-4-2
TROUBLESHOOTING / ICF
Item
Details
Total machines waiting hours during a day
No Load Time
(Hours are recorded by each pressure sensor information from MC.)
The highest radiator coolant temperature during a day
Radiator Coolant Temperature
(Value is recorded from monitor unit.)
The highest hydraulic oil temperature during a day
Hydraulic Oil Temperature
(Value is recorded from MC.)
The highest intake air temperature during a day
Intake Air Temperature
(Value is recorded from ECM.)
Engine operating hour distribution during a day
Engine Operating Hour Distribution Data (Operating hours are recorded only when alternator output signal is
continuously delivered for more than 10 minutes.)
Machine operating hour distribution during a day
Loaded Time Distribution Data
(Operating hours are recorded only when operating pressure is continuously detected for more than 5 minutes while the engine runs.)
NOTE: The daily operation in this table is equivalent to the hours between 0:00 and
23:59:59 counted by the ICX built-in clock.
In case the engine is kept operated beyond
0:00, such data are recorded as those for
the following day.
T5-4-3
TROUBLESHOOTING / ICF
Data which can be sent by Satellite Communication
Item
Details
Date
Date of daily report data
The value of the final remained fuel during a day
Fuel Level
(Value is recorded by fuel sensor data from monitor unit.)
The value of fuel used during a day
Fuel Usage Amount
(Value is calculated and recorded by accumulated fuel usage amount
from ECM.)
Hour meter cumulative hours
Machine Hour Meter
(Hours are recorded by hour meter from monitor unit.)
Total engine operating hours during daily operation
Engine Operating Hours
(Hours are recorded with alternator signal ON.)
Travel Operating Hours
Total travel operating hours during daily operation
Swing Operating Hours
Total swing operating hours during daily operation
Front Attachment Operating Hours
Total front attachment operating hours during daily operation
Attachment Operating Hours
Total attachment operating hours during daily operation
No Load Time
Total machines waiting hours during daily operation
Radiator Coolant Temperature
The highest radiator coolant temperature during a day
Hydraulic Oil Temperature
The highest hydraulic oil temperature during a day
Intake Air Temperature
The highest intake air temperature during a day
Engine Operating Hour Distribution Data Engine operating hour distribution during daily operation
(Operating hours are recorded only when alternator output signal is
continuously delivered for more than 10 minutes.)
Loaded Time Distribution Data
Machine operating hour distribution during daily operation
(Operating hours are recorded only when operating pressure is
continuously detected for more than 5 minutes while the engine runs.)
NOTE: The daily operation in this table is equivalent to the hours between 0:00 and
23:59:59 counted by the ICX built-in clock.
In case the engine is kept operated beyond
0:00, such data are recorded as those for
the following day.
T5-4-4
TROUBLESHOOTING / ICF
LIST OF FREQUENCY DISTRIBUTION DATA
Item
Details
Frequency distribution of fuel temperature
Frequency distribution of average pump delivery pressure of pumps 1
Pump Load
and 2
Average Pump Delivery Pressure in Frequency distribution of average delivery pressure from pumps during
Digging Operation
digging operation
Average Pump Delivery Pressure in Frequency distribution of average delivery pressure from pumps during
Travel Operation
travel operation
Radiator Coolant Temperature
Frequency information of coolant temperature
Hydraulic Oil Temperature
Frequency information of hydraulic oil temperature
Radiator Coolant Temperature Intake Frequency information on temperature in which intake air temperature is
Air Temperature
pulled from coolant temperature
Hydraulic Oil Temperature Intake Air Frequency information on temperature in which intake air temperature is
Temperature
pulled from hydraulic oil temperature
Frequency information of engine speed and average load rate (average
Pump Load Rate
of pump 1 load rate and pump 2 load rate)
Engine Load Rate
Frequency information of engine speed and engine torque
Radiator Coolant Temperature/Intake Air
Frequency information of coolant temperature and intake air temperature
Temperature
Hydraulic Oil Temperature/Intake Air Frequency information of hydraulic oil temperature and intake air temTemperature
perature
Fuel Temperature
T5-4-5
TROUBLESHOOTING / ICF
LIST OF TOTAL OPERATING HOURS
Item
Details
Engine
Hour
Operating
HP Mode Hours
P Mode Hours
E Mode Hours
T5-4-6
TROUBLESHOOTING / ICF
(Blank)
T5-4-7
TROUBLESHOOTING / ICF
HOW TO DOWNLOAD AND UPLOAD DATA
OF ICF
Rear Console
Satellite
Terminal
ICF
Dr. ZX
Connector
T1J1-04-06-001
Palm
(Dr. ZX)
Hot Sync
Cable
Connecting
Harness
T1V1-05-07-002
T5-4-8
TROUBLESHOOTING / ICF
Data Download
After starting Dr. ZX, push Select
Controller.
Select Function
+
Self-Diagnostic Result
Push OK.
Select Controller
Engine Controller
Main Controller
Monitor Controller
ICF Controller
ESC
ICF
controller Ver.: XXYY
Satellite terminal Controller
Ver.: XXYY
Is it correct?
ESC
OK
ESC
Push Start.
While
downloading
data,
Download Screen is displayed.
Select Item
Password
Data Download
Downloading.
Do not turn off the Palm or
disconnect the download cable.
27%
+
Op. Manual
Start
Back
ESC
Cancel
Title Screen
CAUTION
Initialization has been
completed.
The download
has been interrupted.
OK
Normal End Screen
To the
lower
OK
ESC
Alarm Screen
T5-4-9
To the
lower
TROUBLESHOOTING / ICF
How to Upload Data from Palm to Personal
Computer
1. Set Palm to the cradle. Connect the USB cable to
the personal computer.
2. Push the Hot Sync button.
Palm
T178-05-07-033
T5-4-10
TROUBLESHOOTING / ICF
VARIOUS SETUP OF ICF AND SATELLITE
COMMUNICATION TERMINAL BY USING
Dr. ZX
Before starting satellite communication, installing the
satellite communication terminal and replacing ICF,
perform the following procedures by using Dr. ZX.
ICF Setup Procedures
Start Dr. ZX
1.1 Select Information Controller
No Communication
2. Self-Diagnosing
T5-4-11
TROUBLESHOOTING / ICF
1.1 Select Information Controller
1.2 Select Information C/U: Various Setup
Push OK.
Select Function
+
Self-Diagnostic Result
Select Controller
Engine Controller
Main Controller
Monitor Controller
ICF Controller
ESC
Function Selection Screen
ICF
Controller Ver.: XXYY
Satellite Terminal
Controller Ver.: XXYY
To the
lower
Is it correct?
ESC
Controller Selection Screen
OK
ESC
Push Start.
Select Item
Password
+
Dr. ZX SerVice Soft
(C)Hitachi Construction
Machinery Co., ltd
Select Item
+
Op. Manual
Start
Title Screen
Back
ESC
Main Menu Screen
T5-4-12
ESC
Information C/U: Various Setup
Screen
TROUBLESHOOTING / ICF
1.3 Enter Date and Time
Push Enter Date and Time.
Push ESC and return to Main
Menu Screen.
Select Item
+
YY 2004 MM
01
HH
01
01
MM
Set
ESC
Information C/U: Various Setup
Screen
01
DD
ESC
Select Item
ESC
Main Menu Screen
T5-4-13
TROUBLESHOOTING / ICF
1.4 Enter Model and Serial No.
Push Enter Model and Serial No.
Select Item
+
+
+
To the
lower
ESC
Information C/U: Various Setup
Screen
After inputting model and serial
No., push OK and return to Enter
Model and Serial No. Screen.
Push ESC and return to Information C/U: Various Setup Screen.
Model
01J1
Select Item
Model |
Exec
Exec
ESC
ESC
Ex. Mach.No.(HCM1J112
3456) Model(01J1)
Serial No.
Ex. Mach.No.(HCM1J112
3456) Serial No.(123456)
OK
ESC
ESC
OK
+
+
ESC
Information C/U: Various Setup
Screen
T5-4-14
TROUBLESHOOTING / ICF
1.5 Information C/U: Initialize
Push Information C/U: Initialize.
Select Item
+
+
+
To the
lower
ESC
Information C/U: Various Setup
Screen
Push Init and the controller operating data is initialized.
Push ESC and return to Information C/U: Various Setup Screen.
Select Item
ESC
Init
ESC
OK
+
+
ESC
T5-4-15
TROUBLESHOOTING / ICF
1.6 Satellite Terminal: Initialize
Display the next screen of Information
C/U:
Various
Setup
Screen.
Select Item
+
ESC
Push Exec.
Push ESC and return to Information C/U: Various Setup Screen.
ESC
Next Screen of Information C/U:
Various Setup Screen
Exec
ESC
Select Item
+
+
+
+
OK
Select Item
ESC
Information C/U: Various Setup
Screen
T5-4-16
ESC
Main Menu Screen
To the
lower
TROUBLESHOOTING / ICF
1.7 Satellite Terminal Serial No. Check
Push Satellite Terminal No. Confirmation.
Push ESC and return to Main
Menu Screen.
Select Item
+
+
+
+
Select Item
+
+
+
+
ESC
ESC
ESC
Information C/U: Various Setup
Screen
Select Item
ESC
Main Menu Screen
T5-4-17
TROUBLESHOOTING / ICF
1.8 Satellite
Check
Terminal,
Push
Communicating
State
Check.
Push ESC and return to Main
Menu Screen.
Select Item
+
+
+
+
Communicating
State
ESC
Information C/U: Various Setup
Screen
ESC
Communicating State Check
Rod Aerial
OK
NG
GPS Aerial
OK
NG
Wave State
ON
OFF
2004/07/01 135000
ESC
Select Item
Select Item
+
ESC
ESC
T5-4-18
TROUBLESHOOTING / ICF
1.9 Enter Satellite Comm. Start/Stop
Push and move to the next
screen of Information C/U: Various Setup Screen.
Push Enter Satellite Comm.
Start/Stop.
Select Item
+
+
+
+
To the
lower
ESC
Information C/U: Various Setup
Screen
Stop
Exec
ESC
Select Item
+
+
Exec
Start
+
+
OK
ESC
Information C/U: Various Setup
Screen
T5-4-19
TROUBLESHOOTING / ICF
1.10 Control Data: Initialize
Push Control Data: Initialize.
Select Item
+
+
+
ESC
Information C/U: Various Setup
Screen
Select Item
ESC
Init
ESC
OK
+
+
ESC
Information C/U: Various Setup
Screen
T5-4-20
TROUBLESHOOTING / ICF
(Blank)
T5-4-21
TROUBLESHOOTING / ICF
2. Self-Diagnosing
After starting Dr. ZX,
Self-Diagnostic Result.
push
Self-diagnosing of controllers
below hasn completed.
Select Function
+
Self-Diagnostic Result
Select Controller
Self-Diagnosing
Fault
To the
lower
ESC
ESC
ESC
ICF Controller
Problem was detected.
14000
Fault
14001
Details
Details
CAN Communication Error
ESC
Corrective Action
1)Retry B
2)Check Harness
3)
Retry B
Do you want to escape?
ESC
Details
ESC
ESC
Retry B
Retry B Screen
Execute
Retry B
Self-diagnosing of controllers
below hasn completed.
Engine Controller No Problem
Main Controller
ESC
Fault
Fault
ESC
T5-4-22
ESC
TROUBLESHOOTING / ICF
LIST OF FAULT CODE
Fault Code
Details
Remedy
14000-2
14001-2
ICF: Flash Memory: Read / Write Execute retry B in self-diagnosing and execute the following
Error
item.
Execute 1.5 Information C/U: Initialize (T5-4-15).
ICF: External RAM: Read / Write Error
14002-2
14003-2
14006-2
14008-2
14100-2
14101-2
14102-2
14103-2
14104-2
14105-2
14106-2
T5-4-23
TROUBLESHOOTING / ICF
SATELLITE COMMUNICATION SYSTEM
The satellite communication system is used for maintenance of the machine, e-Service by transmitting
various data of the machine regularly via a low earth
orbit satellite.
GPS Aerial
Communication
Aerial
T1V1-05-07-003
The satellite communication system consists of satellite communication terminal, GPS aerial and communication aerial. The mail function of monitor unit becomes effective.
The functions of each equipment are:
Satellite Terminal
1.
2.
3.
4.
T5-4-24
T1V1-05-07-001
ICF
Monitor Unit
Mail Screen
T1V5-05-01-037
TROUBLESHOOTING / ICF
On the machine equipped with the satellite communication system, the data are sent according to the condition as follows:
Kinds of data sent from the machine by using satellite
communication:
Items
Periodical
Transmission
Kinds of Data
Daily Report Data, Latest Location Information, Fuel Level
Condition
The data are sent once a day. In order to
avoid congested traffic in the communication line, the data is sent randomly
between 0:00 and 02:00.
Transmitting Data at Latest Location Information
The data is sent only when the machine
Engine Start
is moved more than 5 km from the place
where it is recorded lastly.
Emergency
Alarm and Error Information
The transmission starts immediately
Transmission
when the alarm and error occurs.
Hour Meter 100 Hours Frequency Distribution Information
The data is sent when the hour meter
Transmission
exceeds every 100 hours.
Transmission by Mail
General Requirement, Fuel Replenishing The transmission starts when the key on
Requirement, Service Maintenance Re- monitor unit corresponding to requirequirement and Forwarding Requirement
ment is pushed.
T5-4-25
TROUBLESHOOTING / ICF
(Blank)
T5-4-26
28
2
27
26
9
10
25
24
23
22
21
11
20
12
19
18
13
17
16
Control Valve
Signal Control Valve
15
14
1 - Arm Cylinder
2 - Washer Tank
89-
15 - Fan Pump
16 - Travel Device
3 - Swing Bearing
4 - Center Joint
10 - Air Cleaner
11 - Fan Motor
5 - Swing Device
12 - Engine
17 - Drain Filter
18 - Pilot Filter/ Pilot Relief
Valve
19 - Solenoid Valve Unit
6 - Fuel Tank
7 - Reserve Tank
20 - Check Valve
21 - Track Adjuster
T5-5-1
T1J1-01-02-002
2
4
3
5
M1J1-07-032
T1J1-01-02-009
1 - Inter Cooler
2 - Fuel Cooler
5 - Oil Cooler
T5-5-2
6 - Accumulator
M1J1-07-034
1
2
4
5
Around Radiator
(Refer to T1-2-7)
Receiver Tank
Fresh Air
Temperature
Sensor
1 - Monitor Unit
2 - Atmosphere Pressure
Sensor
3 - Coolant Level Switch
45-
11
10
Engine
(Refer to T1-2-9)
T1J1-01-02-002
Fuel Sensor
Pressure Sensor (Swing)
(Refer to T1-2-8)
6 - Intake Air Temperature
Sensor
78-
T5-5-3
10 - Washer Motor
11 - ECM (Engine Controller)
Rear Tray
(Refer to T1-2-5)
11
View B
1
2
3
4
5
6
7
8
9
10
Switch Panel
(Refer to T1-2-6)
T1J1-01-02-010
4 - Auto-Lubrication Switch
(Optional)
5 - Level Check Switch
(Engine Oil Level / Coolant
Level)
6 - Boom Mode Selector
Switch
T5-5-4
T1J1-01-02-003
10
11
12
13
14
15
16
T1V1-01-02-009
21
1 - MC (Main Controller)
2 - Overload Alarm Relay
(Optional)
3 - Fuse Box
4 - Dr. ZX Connector (Use as
Download Connector)
5 - Pump Learning Switch
6 - ICF (Information Controller)
20
19
18
17
7 - Satellite Communication
Terminal (Optional)
8 - Security Relay (R5)
12 - Auto-Lubrication Relay
(R11) (Optional)
13 - Lock Relay (R2)
T5-5-5
T1V1-04-02-001
12-
T5-5-6
56-
Key Switch
Work Light Switch
7-
Wiper/Washer Switch
Around Radiator
5
2
4
M1J1-07-032
T1J1-01-02-006
Around Battery
8
10
11
12
13
T1J1-01-02-005
1 - Horn
2 - Distribution Valve
(Optional)
3 - Boom Bottom Pressure
Sensor
4 - Receiver Tank
8-
Starter Relay
11 - Auto-Lubrication Pump
9-
Battery Relay
10 - Fusible Link
T5-5-7
Front Side
Main Frame
T1J1-01-02-008
13
12
11
10
T1J1-01-02-007
8-
T5-5-8
20
4
5
3
6
9
10
19
11
18
17
12
16
13
15
14
T1J1-01-02-011
1 - EGR Valve
2 - Injector Connector
6 - Coolant Temperature
Sensor
7 - Suction Control Valve
8 - Priming Pump
9 - Fuel Main Filter
10 - Common Rail Pressure
Sensor
17 - Supply Pump
T5-5-9
18 - Overheat Switch
19 - Alternator
20 - Fuel Pre Filter
11
5
6
T1J1-01-02-004
10
SWING DEVICE
TRAVEL DEVICE
12
13
14
M1J1-07-048
M1J1-07-053
12
1 - Pump 2 Regulator Pressure
Sensor
2 - Pump 2 Control Solenoid Valve
3 - Pump 1 Regulator Pressure
Sensor
4 - Pump 1 Control Solenoid Valve
5-
Pump 1
6 - Pump 1 Delivery
Pressure Sensor
7 - Pilot Pump
9-
8 - Pump 2
T5-5-10
T1J1-03-03-003
4
8
6
10
1 - Overload Relief Valve
(Boom Lower)
2 - Overload Relief Valve
(Bucket Roll-Out)
3 - Main Relief Valve
9
7 - Overload Relief Valve
(Boom Mode)
8 - Overload Relief Valve
(Arm Roll-Out)
T5-5-11
T1J1-03-03-004
5
6
45
7
8
44
43
42
10
41
11
40
39
38
12
37
13
14
15
16
36
17
35
18
19
34
20
33
32
31
30
29
28
27 26
25
24
23
22
21
T450-03-03-025
T5-5-12
C
C
H
T450-03-03-001
7
14
34
28
31
T450-03-03-010
T450-03-03-011
1-
2-
34567-
8910 11 12 -
T5-5-13
5
6
45
7
8
44
43
42
10
41
11
40
39
38
12
37
13
14
15
16
36
17
35
18
19
34
20
33
32
31
30
29
28
27 26
25
24
23
22
21
T450-03-03-025
T5-5-14
10
Arm 2
Arm 1
8
9
44
6
45
5
T450-03-03-016
40
11
T450-03-03-023
1-
2-
34567-
8910 11 12 -
T5-5-15
5
6
45
7
8
44
43
42
10
41
11
40
39
38
12
37
13
14
15
16
36
17
35
18
19
34
20
33
32
31
30
29
28
27 26
25
24
23
22
21
T450-03-03-025
T5-5-16
Boom 1
39
13
Bucket
15, 16
35
Auxiliary
33
25
19
38
37
17
12
41
32
36
42
T450-03-03-015
1-
2-
34567-
8910 11 12 -
34
18
T450-03-03-014
T5-5-17
5
6
45
7
8
44
43
42
10
41
11
40
39
38
12
37
13
14
15
16
36
17
35
18
19
34
20
33
32
31
30
29
28
27 26
25
24
23
22
21
T450-03-03-025
T5-5-18
31
30
21
22
29
T450-03-03-013
T450-03-03-012
28
1-
2-
34567-
8910 11 12 -
T5-5-19
5
6
45
7
8
44
43
42
10
41
11
40
39
38
12
37
13
14
15
16
36
17
35
18
19
34
20
33
32
31
30
29
28
27 26
25
24
23
22
21
T450-03-03-025
T5-5-20
24
T450-03-03-008
T450-03-03-001
I
I
T450-03-03-006
1-
2-
34567-
8910 11 12 -
T5-5-21
Port A
Port B
Port C
Port D
Port E
Port F
Port G
Port H
Port I
Port J
Port K
Port L
Port M
Port N
Port SA
Port SB
Port PI
Port PH
Port SH
Port DF
Connecting to
Remark
Check Valve
Pilot Shut-Off Solenoid Valve
Swing Parking Brake
Hydraulic Oil Tank
T5-5-22
PH
E
M
D
B
SB
G
Pilot Valve
Side
PI
N
K
I
J
SH
DF
SA
L
T1J1-03-06-002
SM
1
13
SE
SK
8
S3
14
Control Valve
Side
7
9
10
SN
SL
11
TR
12
T5-5-23
SP
T1J1-03-06-003
Connecting to
Remark
Boom Raise Pilot Pressure
Boom Lower Pilot Pressure
Arm Roll-Out Pilot Pressure
Arm Roll-In Pilot Pressure
Left Swing Pilot Pressure
Right Swing Pilot Pressure
Bucket Roll-In Pilot Pressure
Bucket Roll-Out Pilot Pressure
Left Travel Forward Pilot Pressure
Left Travel Reverse Pilot Pressure
Right Travel Forward Pilot Pressure
Right Travel Reverse Pilot Pressure
Auxiliary Open Pilot Pressure
Auxiliary Close Pilot Pressure
Pressure Sensor (Swing)
Plug
Returning to Hydraulic Oil Tank
Plug
Returning to Hydraulic Oil Tank
Flow Combiner Valve Control Pressure
Arm Flow Rate Control Valve Control Pressure
Plug
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Hydraulic Oil Tank
Hydraulic Oil Tank
Control Valve
Control Valve
-
T5-5-24
PH
E
M
D
B
SB
G
Pilot Valve
Side
PI
N
K
I
J
SH
DF
SA
L
T1J1-03-06-002
SM
1
13
SE
SK
8
S3
14
Control Valve
Side
7
9
10
SN
SL
11
TR
12
T5-5-25
SP
T1J1-03-06-003
T5-5-26
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault
codes are displayed after diagnosing by using Dr. ZX
or the service menu of monitor unit.
YES (OK)
(2)
(1)
NO (NOT OK)
Key switch: ON
(3)
Refer to Electrical System Inspection group (group 8) for descriptions in the dotted-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 End
Connector
Harness
T6L4-05-03-001
T5-6-1
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE LIST
Fault
Code
11000-2
Abnormal EEPROM
Faulty MC
All Control
11001-2
Abnormal RAM
Faulty MC
All Control
11002-2
Faulty MC
All Control
11003-3
Faulty MC
All Control
11004-2
Faulty MC
Shorted Circuit in CAN Bus
Line
11101-3
Engine Control
Work Mode Control
Attachment Mode Control
Horsepower (Speed Sensing)
Control
Fan Pump Flow Rate Control
CAN Cycle Data Communication
Overheat Prevention Control
Engine Control Dial Control
11200-4
11202-3
11202-4
HP Mode Control
Horsepower Control
Relief Flow Rate Reducing
Control (Relief Cut Off)
Auto-Power Lift Control
HP Mode Control
Horsepower Control
Relief Flow Rate Reducing
Control (Relief Cut Off)
Auto-Power Lift Control
HP Mode Control
Horsepower Control
Relief Flow Rate Reducing
Control (Relief Cut Off)
HP Mode Control
Horsepower Control
Relief Flow Rate Reducing
Control (Relief Cut Off)
11101-4
11200-3
Trouble
Cause
T5-6-2
Influenced Control
TROUBLESHOOTING / Troubleshooting A
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Engine speed is kept at backup Retry
Diagnostic
-1
speed (1200 min ).
Procedure B
-
Replace MC
Reference
Page
T5-6-37
Replace MC
T5-6-37
Replace MC
T5-6-37
Replace MC
Check Harness (Sensor Power)
Check Sensor to connected to
MC
Replace MC
Check CAN Harness
T5-6-38
Remedy
No Speed sensing
All abnormal signals via CAN
communication
Engine speed is kept at slow idle
speed.
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Check Harness
Replace Engine Control Dial
Check Harness
Replace Engine Control Dial
Check Harness
Replace Pump 1 Delivery
Pressure Sensor
T5-6-60
Retry
Diagnostic
Procedure B
Check Harness
Replace Pump
Pressure Sensor
T5-6-61
1
Delivery
Retry
Diagnostic
Procedure B
Check Harness
Replace Pump
Pressure Sensor
Delivery
Diagnostic
Increasing speed at HP mode is Retry
Procedure B
difficult.
Less flow rate at 19.6 MPa
Check Harness
Replace Pump
Pressure Sensor
Delivery
T5-6-3
T5-6-39
T5-6-60
T5-6-61
T5-6-62
T5-6-62
TROUBLESHOOTING / Troubleshooting A
Fault
Code
11301-3
Trouble
Cause
Influenced Control
Engine Control
Relief Flow Rate Reducing
Control (Relief Cut Off)
Swing Horsepower Reducing
Control
Boom Mode Selector Control
11301-4
Engine Control
Relief Flow Rate Reducing
Control (Relief Cut Off)
Swing Horsepower Reducing
Control
Boom Mode Selector Control
11302-3
Engine Control
HP Mode Control
Auto-Power Lift Control
Boom Mode Selector Control
T5-6-4
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation
Remedy for Dr. ZX
When Trouble Occurs.
Diagnostic
Cut off override is not impossible. Retry
A/I cannot be released by swing Procedure B
operation.
Flow rate of lever regulated pump
control becomes maximum by
swing operation.
Reducing operation of swing
torque is impossible.
Boom mode selector control is
impossible by swing operation.
Engine speed is lower than
speed at E mode.
Remedy
Check Harness
Replace Swing Pilot Pressure
Sensor
Reference
Page
T5-6-63
Diagnostic
Cut off override is not impossible. Retry
A/I cannot be released by swing Procedure B
operation.
Flow rate of lever regulated pump
control becomes maximum by
swing operation.
Reducing operation of swing
torque is impossible.
Boom mode selector control is
impossible by swing operation.
Engine speed is lower than
speed at E mode.
Check Harness
Replace Swing Pilot Pressure
Sensor
T5-6-63
Diagnostic
Speed at HP mode does not in- Retry
Procedure B
crease by boom raise operation.
A/I cannot be released by boom
raise operation.
Flow rate of lever regulated pump
control becomes maximum by
boom raise operation.
Boom mode selector control is
impossible by boom raise operation.
Auto-power lift does not function
by boom raise operation.
Boom flow rate control valve
control is not operated.
Engine speed is lower than
speed at E mode.
Check Harness
Replace Boom Raise Pilot Pressure Sensor
T5-6-64
T5-6-5
TROUBLESHOOTING / Troubleshooting A
Fault
Code
11302-4
Trouble
Cause
Influenced Control
Engine Control
HP Mode Control
Auto-Power Lift Control
Boom Mode Selector Control
11303-3
Engine Control
HP Mode Control
Boom Mode Selector Control
Boom Flow Rate Control
Valve Control
Auto-Power Lift Control
11303-4
Engine Control
HP Mode Control
Boom Mode Selector Control
Boom Flow Rate Control
Valve Control
Auto-Power Lift Control
T5-6-6
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation
Remedy for Dr. ZX
When Trouble Occurs.
Diagnostic
Speed at HP mode does not in- Retry
Procedure B
crease by boom raise operation.
A/I cannot be released by boom
raise operation.
Flow rate of lever regulated pump
control becomes maximum by
boom raise operation.
Boom mode selector control is
impossible by boom raise operation.
Auto-power lift does not function
by boom raise operation.
Boom flow rate control valve
control is not operated.
Engine speed is lower than
speed at E mode.
Remedy
Check Harness
Replace Boom Raise Pilot Pressure Sensor
Reference
Page
T5-6-64
Diagnostic
Speed at HP mode does not in- Retry
Procedure B
crease by arm roll-in operation.
A/I cannot be released by arm
roll-in operation.
Flow rate of lever regulated pump
control becomes maximum by
arm roll-in operation.
Boom mode selector control is
impossible by arm roll-in operation.
Auto-power lift does not function
by arm roll-in operation.
Boom flow rate control valve
control is not operated.
Engine speed is lower than
speed at E mode.
Check Harness
Replace Arm Roll-In Pilot Pressure Sensor
T5-6-65
Diagnostic
Speed at HP mode does not in- Retry
Procedure B
crease by arm roll-in operation.
A/I cannot be released by arm
roll-in operation.
Flow rate of lever regulated pump
control becomes maximum by
arm roll-in operation.
Boom mode selector control is
impossible by arm roll-in operation.
Auto-power lift does not function
by arm roll-in operation.
Boom flow rate control valve
control is not operated.
Engine speed is lower than
speed at E mode.
Check Harness
Replace Arm Roll-In Pilot Pressure Sensor
T5-6-65
T5-6-7
TROUBLESHOOTING / Troubleshooting A
Fault
Code
11400-3
11400-4
11402-3
11402-4
11404-3
Trouble
Pump 2 Regulator
High Current
Pump 2 Regulator
Low Current
Boom Flow Control
High Current
Boom Flow Control
Low Current
Power Boost P/S
High Current
Cause
Influenced Control
11404-4
11405-3
11405-4
11410-3
11410-4
11412-3
11412-4
11802-3
11802-4
11901-3
Engine Control
Overheat Prevention Control
Fan Pump Flow Rate Control
11901-4
Engine Control
Overheat Prevention Control
Fan Pump Flow Rate Control
T5-6-8
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation
When Trouble Occurs.
Pump 2 control is impossible.
Check Harness
Check Harness
T5-6-66
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Reference
Page
T5-6-66
Check Harness
T5-6-67
Check Harness
T5-6-67
Check Harness
T5-6-68
Retry
Diagnostic
Procedure B
Check Harness
T5-6-68
Check Harness
T5-6-69
Check Harness
T5-6-69
Check Harness
T5-6-70
Check Harness
T5-6-70
Check Harness
T5-6-71
Check Harness
T5-6-71
Check Harness
Replace Boom Bottom Pressure
Sensor
T5-6-72
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Check Harness
Replace Boom Bottom Pressure
Sensor
T5-6-72
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Check Harness
Replace Hydraulic Oil Temperature Sensor
T5-6-73
Retry
Diagnostic
Procedure B
Check Harness
Replace Hydraulic Oil Temperature Sensor
T5-6-73
T5-6-9
Remedy
TROUBLESHOOTING / Troubleshooting A
Fault
Code
11910-2
11911-2
Trouble
Actual Engine Speed Receive
Error
Security Signal receive Error
Cause
Faulty Harness
Influenced Control
-
Faulty Harness
-
11914-2
11918-2
11920-2
Faulty Harness
11976-3
11976-4
11977-3
11977-4
11980-3
11980-4
11981-3
11981-4
11982-3
11982-4
11983-2
11984-2
11989-3
11989-4
Faulty Harness
Faulty Harness
T5-6-10
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation
When Trouble Occurs.
Stop speed sensing.
Pump learning is impossible.
When engine control security and
pump control security are turned
ON, security is activated.
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Check Harness
Reference
Page
T5-6-75
Check Harness
T5-6-75
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Retry
Diagnostic
Procedure B
Attachment relief selection is im- Retry
Diagnostic
possible.
Procedure B
Attachment relief selection is im- Retry
Diagnostic
possible.
Procedure B
Fan reverse is impossible.
Retry
Diagnostic
Procedure B
Fan reverse is impossible.
Retry
Diagnostic
Procedure B
Fan reverse is impossible.
Retry
Diagnostic
Procedure B
Fan reverse is impossible.
Retry
Diagnostic
Procedure B
Maximum fan speed (with blower Retry
Diagnostic
motor relay ON)
Procedure B
Maximum fan speed
Retry
Diagnostic
Procedure B
Boom mode selector control is Retry
Diagnostic
impossible.
Procedure B
Boom mode selector control is Retry
Diagnostic
impossible.
Procedure B
Check Harness
T5-6-75
Check Harness
T5-6-75
Check Harness
T5-6-75
Check Harness
Check Harness
Check Harness
Check Harness
Check Harness
Check Harness
Check Harness
Check Harness
Check Harness
Check Harness
Check Harness
T5-6-75
Check Harness
T5-6-75
Check Harness
T5-6-79
Check Harness
T5-6-79
Remedy
T5-6-11
TROUBLESHOOTING / Troubleshooting A
Fault
Code
Trouble
Cause
Influenced Control
11991-3
11991-4
T5-6-12
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation
Remedy for Dr. ZX
When Trouble Occurs.
Diagnostic
Increasing travel speed is impos- Retry
Procedure B
sible by right travel operation.
A/I cannot be released by right
travel operation.
Cut off override is impossible by
right travel operation.
Boom mode selector control is
impossible by right travel operation.
Pressure increase when traveling
is impossible by right travel operation.
Rear monitoring display selection
is impossible by right travel operation.
Travel alarm outputs.
Engine speed is lower than
speed at E mode.
Diagnostic
Increasing travel speed is impos- Retry
Procedure B
sible by right travel operation.
A/I cannot be released by right
travel operation.
Cut off override is impossible by
right travel operation.
Boom mode selector control is
impossible by right travel operation.
Pressure increase when traveling
is impossible by right travel operation.
Rear monitoring display selection
is impossible by right travel operation.
Travel alarm outputs.
Engine speed is lower than
speed at E mode.
Remedy
Check Harness
Replace Right Travel Pilot Pressure Sensor
Check Harness
Replace Right Travel Pilot Pressure Sensor
T5-6-13
Reference
Page
T5-6-80
T5-6-80
TROUBLESHOOTING / Troubleshooting A
Fault
Code
11992-3
11992-4
Trouble
Cause
Influenced Control
11993-3
11993-4
T5-6-14
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation
When Trouble Occurs.
No secondary pressure feedback
of pump 2 proportional solenoid
valve (bad response)
Pump learning is impossible.
Reference
Page
T5-6-81
Remedy
Retry
Diagnostic
Procedure B
Check Harness
Replace Pump 2 Regulator Pressure Sensor
Retry
Diagnostic
Procedure B
Check Harness
Replace Pump 2 Regulator Pressure Sensor
T5-6-81
Diagnostic
Increasing travel speed is impos- Retry
Procedure B
sible by left travel operation.
A/I cannot be released by left
travel operation.
Cut off override is impossible by
left travel operation.
Boom mode selector control is
impossible by left travel operation.
Pressure increase when traveling
is impossible by left travel operation.
Rear monitoring display selection
is impossible by left travel operation.
Travel alarm outputs.
Engine speed is lower than
speed at E mode.
Check Harness
T5-6-82
Diagnostic
Increasing travel speed is impos- Retry
Procedure B
sible by left travel operation.
A/I cannot be released by left
travel operation.
Cut off override is impossible by
left travel operation.
Boom mode selector control is
impossible by left travel operation.
Pressure increase when traveling
is impossible by left travel operation.
Rear monitoring display selection
is impossible by left travel operation.
Travel alarm outputs.
Engine speed is lower than
speed at E mode.
Check Harness
T5-6-82
T5-6-15
TROUBLESHOOTING / Troubleshooting A
Fault
Code
11994-3
11994-4
Trouble
Cause
Influenced Control
11995-3
11995-4
T5-6-16
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation
When Trouble Occurs.
No secondary pressure feedback
of pump 1 proportional solenoid
valve (bad response)
Pump learning is impossible.
Reference
Page
T5-6-83
Remedy
Retry
Diagnostic
Procedure B
Check Harness
Replace Pump 1 Regulator Pressure Sensor
Retry
Diagnostic
Procedure B
Check Harness
Replace Pump 1 Regulator Pressure Sensor
T5-6-83
Diagnostic
A/I cannot be released by arm Retry
Procedure B
roll-out operation.
Flow rate of lever regulated pump
control becomes maximum by
arm roll-out operation.
Boom mode selector control is
impossible by arm roll-out operation.
Boom flow rate control valve
control is not operated.
Engine speed is lower than
speed at E mode.
Check Harness
Replace Arm Roll-Out
Pressure Sensor
T5-6-84
Pilot
Diagnostic
A/I cannot be released by arm Retry
Procedure B
roll-out operation.
Flow rate of lever regulated pump
control becomes maximum by
arm roll-out operation.
Boom mode selector control is
impossible by arm roll-out operation.
Boom flow rate control valve
control is not operated.
Engine speed is lower than
speed at E mode.
Check Harness
Replace Arm Roll-Out
Pressure Sensor
Pilot
T5-6-17
T5-6-84
TROUBLESHOOTING / Troubleshooting A
Fault
Code
11997-3
Trouble
Cause
Influenced Control
11997-4
11998-3
11998-4
T5-6-18
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation
Remedy for Dr. ZX
When Trouble Occurs.
Diagnostic
A/I cannot be released by bucket Retry
Procedure B
roll-out operation.
Flow rate of lever regulated pump
control becomes maximum by
bucket roll-out operation.
Boom mode selector control is
impossible by bucket roll-out operation.
Boom flow rate control valve
control is not operated.
Engine speed is lower than
speed at E mode.
Remedy
Check Harness
Replace Bucket Roll-Out Pilot
Pressure Sensor
Reference
Page
T5-6-85
Diagnostic
A/I cannot be released by bucket Retry
Procedure B
roll-out operation.
Flow rate of lever regulated pump
control becomes maximum by
bucket roll-out operation.
Boom mode selector control is
impossible by bucket roll-out operation.
Boom flow rate control valve
control is not operated.
Engine speed is lower than
speed at E mode.
Check Harness
Replace Bucket Roll-Out Pilot
Pressure Sensor
T5-6-85
Retry
Diagnostic
Procedure B
Check Harness
Replace Boom
Pressure Sensor
T5-6-86
Lower
Pilot
Retry
Diagnostic
Procedure B
Check Harness
Replace Boom
Pressure Sensor
Lower
Pilot
T5-6-19
T5-6-86
TROUBLESHOOTING / Troubleshooting A
Fault
Code
11999-3
11999-4
Trouble
Cause
Influenced Control
T5-6-20
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation
Remedy for Dr. ZX
When Trouble Occurs.
Diagnostic
A/I cannot be released by bucket Retry
Procedure B
roll-in operation.
Flow rate of lever regulated pump
control becomes maximum by
bucket roll-in operation.
Boom mode selector control is
impossible by bucket roll-in operation.
Boom flow rate control valve
control is not operated.
Engine speed is lower than
speed at E mode.
Diagnostic
A/I cannot be released by bucket Retry
Procedure B
roll-in operation.
Flow rate of lever regulated pump
control becomes maximum by
bucket roll-in operation.
Boom mode selector control is
impossible by bucket roll-in operation.
Boom flow rate control valve
control is not operated.
Engine speed is lower than
speed at E mode.
Reference
Page
T5-6-87
Remedy
Check Harness
Replace Bucket
Pressure Sensor
Roll-In
Pilot
Check Harness
Replace Bucket
Pressure Sensor
Roll-In
Pilot
T5-6-21
T5-6-87
TROUBLESHOOTING / Troubleshooting A
ECM FAULT CODE LIST
Fault
Code
Trouble
Cause
91-2
100-3
Engine Oil Pressure Sensor Fault (Low Voltage: Less than 0.1 V
Voltage Fault)
Engine Oil Pressure Sensor Fault (High Voltage: More than 4.85 V
Voltage Fault)
Boost Pressure Sensor Fault (Low Volt- Voltage: Less than 0.1 V
age Fault)
100-4
102-3
102-4
105-3
105-4
108-3
108-4
T5-6-22
TROUBLESHOOTING / Troubleshooting A
Presumptive Symptoms in
Real Machine Operation
Assumptive
Conditions at Back-up
Fault Code
(Tech 2)
Reference Page on
Engine Troubleshooting Manual
P1271
1E-474
No back-up
P0522
1E-365
No back-up
P0523
1E-371
Operationality is affected
P0237
1E-305
P0238
1E-312
Operationality is affected.
No back-up
P1113
1E-437
Operationality is affected.
No back-up
P1112
1E-429
P0107
1E-204
P0108
1E-211
T5-6-23
TROUBLESHOOTING / Troubleshooting A
Fault
Code
Trouble
Cause
110-3
Sensor
110-4
Sensor
157-0
Common
Stage)
157-0
157-2
157-3
157-3
Rail
Pressure
Fault
(First
T5-6-24
TROUBLESHOOTING / Troubleshooting A
Fault Code
(Tech 2)
Reference Page on
Engine Troubleshooting Manual
At normal temperature: Black smoke Coolant temperature default setting. (at starting:
emission at starting, greater engine com-20 C, at running: 80 C)
bustion noise are possible.
During idling at atmospheric temperature: Rough idling, engine stall, white
smoke emission
P0118
1E-238
Start ability deteriorates at low tempera- Coolant temperature default setting. (at starting:
ture
-20 C, at running: 80 C)
Black smoke emission is possible
Output lowering depending on conditions
P0117
1E-232
P0088
1E-183
P0088
1E-183
P0089
1E-188
Output lowering
Black smoke emission
Engine stall is possible.
P0193
1E-266
Engine blow up
P0192
1E-260
Presumptive Symptoms in
Real Machine Operation
Assumptive
Conditions at Back-up
T5-6-25
TROUBLESHOOTING / Troubleshooting A
Fault
Code
Trouble
Cause
172-3
172-4
Intake Air Temperature Sensor Fault (Low Voltage: Less than 0.1 V.
Voltage Fault)
174-3
174-4
190-0
Overrun
628-2
ROM Fault
633-7
ROM is faulty.
Re-flash failure
Pressure limiter is opened.
636-2
636-2
636-7
-1
T5-6-26
TROUBLESHOOTING / Troubleshooting A
Fault Code
(Tech 2)
Reference Page on
Engine Troubleshooting Manual
White smoke emission is possible when Intake air temperature destarting at low temperature.
fault setting (at starting: -10
C, at running: 25 C)
P0113
1E-224
White smoke emission is possible when Intake air temperature destarting at low temperature.
fault setting (at starting: -10
C, at running: 25 C)
P0112
1E-218
Not in particular
P0183
1E-252
Operationality is affected.
P0182
1E-246
Output lowering
P0219
1E-303
Engine stopped
Engine stopped
P0601
1E-379
Output lowering
Hunting
Symptom does not change during engine running.
After engine stalls, engine will not start.
P1095
1E-420
P0340
1E-331
P0341
1E-337
P1345
1E-500
Presumptive Symptoms in
Real Machine Operation
Assumptive Conditions at
Back-up
T5-6-27
TROUBLESHOOTING / Troubleshooting A
Fault
Code
Trouble
Cause
639-2
Bus-off is detected.
639-3
651-3
Open Circuit in Injection Nozzle #1 Drive No injector 1 monitor input signal exists.
System
652-3
Open Circuit in Injection Nozzle #2 Drive No injector 2 monitor input signal exists.
System
653-3
Open Circuit in Injection Nozzle #3 Drive No injector 3 monitor input signal exists.
System
654-3
Open Circuit in Injection Nozzle #4 Drive No injector 4 monitor input signal exists.
System
655-3
Open Circuit in Injection Nozzle #5 Drive No injector 5 monitor input signal exists.
System
656-3
Open Circuit in Injection Nozzle #6 Drive No injector 6 monitor input signal exists.
System
723-2
723-2
987-3
T5-6-28
TROUBLESHOOTING / Troubleshooting A
Assumptive Conditions at
Back-up
Fault Code
(Tech 2)
Reference Page on
Engine Troubleshooting Manual
U2104
1E-529
U2106
1E-534
P0201
1E-273
P0202
1E-278
P0203
1E-283
P0204
1E-288
P0205
1E-293
P0206
1E-298
P0335
1E-319
P0336
1E-325
P0650
1E-397
Presumptive Symptoms in
Real Machine Operation
No back-up
T5-6-29
TROUBLESHOOTING / Troubleshooting A
Fault
Code
Trouble
Cause
1077-2
CPU Fault
1079-2
1080-2
1239-1
1240-1
1347-0
1347-4
1348-0
1348-4
1485-2
10001-3
10002-2
T5-6-30
TROUBLESHOOTING / Troubleshooting A
Assumptive Conditions at
Back-up
Fault Code
(Tech 2)
Reference Page on
Engine Troubleshooting Manual
P0606
1E-383
P1631
1E-514
P1632
1E-517
Presumptive Symptoms in
Real Machine Operation
Output lowering
P1094
1E-411
P1093
1E-402
P0091
1E-193
PCV1 stop
P0092
1E-199
P1291
1E-193
PCV2 stop
P1292
1E-199
No back-up
P1625
1E-505
P0487
1E-353
P0488
1E-359
T5-6-31
TROUBLESHOOTING / Troubleshooting A
Fault
Code
Trouble
Cause
10003-2
Injection Nozzle Common 1 Drive System No injector 1, 2, 3 monitor input signal exists.
Fault
10004-2
Injection Nozzle Common 2 Drive System No injector 4, 5, 6 monitor input signal exists.
Fault
10005-1
10006-1
10007-2
10008-2
10009-2
10010-2
10011-2
10013-2
EEPROM Fault
EEPROM is faulty.
T5-6-32
TROUBLESHOOTING / Troubleshooting A
Assumptive Conditions at
Back-up
Fault Code
(Tech 2)
Reference Page on
Engine Troubleshooting Manual
P1261
1E-454
P1262
1E-464
P0611
1E-385
P0612
1E-388
Output lowering
P0606
1E-383
Output lowering
Black smoke emission
P1630
1E-512
P1633
1E-520
Operationality is affected.
P1634
1E-523
P1635
1E-526
No back-up
P0603
1E-381
Presumptive Symptoms in
Real Machine Operation
Engine blow up
Output lowering
Black smoke emission
Engine stall is possible.
Operationality is not affected.
T5-6-33
TROUBLESHOOTING / Troubleshooting A
ICF FAULT CODE LIST
Fault Code
Trouble
Cause
Remedy
14000-2
Abnormal CAN Data cannot be received Check for CAN communication bus line.
Communication due to the noise on the
CAN bus line.
14001-2
Flash Memory: In case the internal After initializing the information C/U by
Read / Write memory is
abnormal using Dr. ZX, retry in the troubleshooting.
Error
when the key is turned If the error code is displayed after retry,
ICF may be broken.
ON
Replace ICF.
Reference
Page
T5-6-89
T5-6-89
NOTE: When initializing the information C/U, all stored data is deleted.
14002-2
External RAM: In case the internal After initializing the information C/U by
Read / Write memory is
abnormal using Dr. ZX, retry in the troubleshooting.
Error
when the key is turned If the error code is displayed after retry,
ICF may be broken.
ON
Replace ICF.
T5-6-89
NOTE: When initializing the information C/U, all stored data is deleted.
14003-2
T5-6-89
14006-2
Satellite Communication
Terminal:
Communication
Error
T5-6-93
14008-2
Abnormal
ternal RAM
T5-6-93
T5-6-34
TROUBLESHOOTING / Troubleshooting A
SATELLITE TERMINAL FAULT CODE LIST (OPTIONAL)
Fault Code
Trouble
Remedy
Cause
Reference
Page
T5-6-94
14100-2
Abnormal
EEPROM
14101-2
T5-6-94
14102-2
Abnormal Local In case the data cannot Check the transmitting and receiving
Loup Back
receive from the satellite, antenna of satellite.
T5-6-94
14103-2
The satellite is In case the satellite is not Check the transmitting and receiving
not found.
found.
antenna of satellite.
T5-6-94
14104-2
T5-6-94
14105-2
T5-6-94
14106-2
Sending
receiving
are
matched.
T5-6-94
T5-6-35
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE LIST
Fault Code
Trouble
Reference
Page
Thermistor temperature is Cool the monitor unit and so on until T5-6-95
85 C (185 F) or higher. temperature inside the monitor unit is
less than 85 C (185 F).
Remedy
Cause
13303-2
Abnormal
Thermistor
Temperature
13304-2
13306-2
Abnormal
EEPROM
flow
T5-6-96
T5-6-97
13308-2
Abnormal CAN Bus off occurs beyond Refer to CAN Harness Check on page
Communication five times.
T5-6-40 to 59.
T5-6-97
13310-2
Shorted circuit The state, input 10530 Check coolant temperature sensor and
in
Coolant or less, is kept over 60 harness.
seconds.
Temperature
Sensor
T5-6-98
13311-2
Shorted circuit The state, input 31 or Check fuel level sensor and harness.
in Fuel Level less, is kept over 60
Sensor
seconds.
T5-6-99
13311-4
Open circuit in The state, input 13520 Check fuel level sensor and harness.
Fuel
Level or less, is kept over 60
Sensor
seconds.
T5-6-99
T5-6-36
the
Troubleshooting
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11000 to 11002
Fault Code
11000-2
11001-2
11002-2
Trouble
Abnormal EEPROM
Abnormal RAM
Abnormal A/D Converter
Cause
Faulty MC
Faulty MC
Faulty MC
YES
*Faulty MC.
T5-6-37
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11003
Fault Code
11003-3
Trouble
Abnormal Sensor Voltage
Cause
Faulty MC
Faulty sensor.
Disconnect all
connectors at MC
end. Check for
continuity between
terminals #1 and #3
of harness end
connector of each
sensor.
YES
Short-circuited harness
between MC and sensor in
the harness with continuity.
Faulty MC.
NO
T1J1-05-06-001
T5-6-38
T1J1-05-06-002
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11004
Fault Code
11004-2
Trouble
Abnormal CAN Communication
Cause
Faulty MC
Dr.ZX
Satellite
Terminal
(Optional)
ICF
Monitor Unit
CAN Harness
MC
ECM
T1J1-02-01-004
T5-6-39
TROUBLESHOOTING / Troubleshooting A
CAN HARNESS CHECK
Check the wiring connections first.
NO
Check for continuity in
YES CAN harness between
MC and ECM.
Key switch: OFF
Refer to Continuty
Check in CAN
Harness on T5-6-44.
NO
Normal.
NO
T5-6-40
TROUBLESHOOTING / Troubleshooting A
Disconnect all
connectors in MC,
ICF, ECM and
monitor unit.
YES Check for continuity
between CAN circuit
and ground circuit in
MC, ICF, ECM and
monitor unit.
Short-circuited CAN
harness between ground
circuit and CAN circuit.
YES
Short-circuited CAN
harness between power
circuit and CAN circuit.
YES
NO
Short-circuited CAN
YES harness between key
signal circuit and CAN
circuit.
Check for continuity
between High side and
NO Low side in CAN
harness.
To A
NO
T5-6-41
TROUBLESHOOTING / Troubleshooting A
Short-circuited CAN
harness.
YES
Connect connector
YES in MC.
Check if fault code
11004-2 is
displayed.
Connect all
connectors except
connector MC-C in
MC.
Check if resistance
between terminals
#C4 and #C15 of
NO harness end of
connector MC-C is
within 6010 .
Key switch: ON
NO
Connect connector in
MC. Disconnect
connector ICF-C in
ICF.
Check if resistance
between terminals
#C5 and #C11 of
harness end of
connector is within
6010 .
Faulty MC.
YES
YES
NO
MC
Connector MC-C
(Harness end)
#C4
Connect connector in
ICF.
Disconnect
connector in ECM.
Check if resistance
between terminals
#18 and #37 of
harness end of
connector is within
12010 .
Key switch: OFF
#C15
NO
Check the
connection of ICF
and connector.
Faulty ICF.
YES
YES
Connect connector
in ECM. Check if
fault code 11004-2
is displayed.
Key switch: ON
NO
C10
C1
C23
Connect connector
in ICF.
Check if fault code
11004-2 is
displayed.
Key switch: ON
Connector
Check the
connection of MC
and connector.
NO
C31
Connect connector in
ECM.
Disconnect
connector monitor-B
in monitor unit.
Check if resistance
between terminals
#B6 and #B7 of
harness end of
connector is within
12010 .
Key switch: OFF
ICF
Connector ICF-C
(Harness end)
#C5
T1V1-05-04-002
#C11
ECM
Connector
(Harness end)
#18
Monitor Unit
Connector Monitor-B Connector
(Harness end)
#37
#B7
#B6
T1GR-05-04-002
T183-05-04-013
T5-6-42
TROUBLESHOOTING / Troubleshooting A
NO
Faulty ECM.
YES
YES
Connect connector in
monitor unit.
Check if fault code
11004-2 is displayed.
Key switch: ON
NO
YES
Failure in any controller
of MC, ICF, ECM and
monitor unit.
NO
T5-6-43
TROUBLESHOOTING / Troubleshooting A
Continuity Check in CAN Harness
IMPORTANT: Before continuity check, turn the key
switch OFF.
C23
#C15
C10
C31
ECM
Connector
(Harness end)
#18
#37
T1GR-05-04-002
T5-6-44
TROUBLESHOOTING / Troubleshooting A
Between MC and ICF
CAN Harness (High Side)
Check for continuity between terminal #C4 of
harness end of connector MC-C in MC and
terminal #C5 of harness end of connector ICF-C
in ICF.
CAN Harness (Low Side)
Check for continuity between terminal #C15 of
harness end of connector MC-C in MC and
terminal #C11 of harness end of connector ICF-C
in ICF.
Connector
MC
Connector MC-C
(Harness end)
#C4
#C15
C10
C1
C23
C31
ICF
Connector ICF-C
(Harness end)
#C5
#C11
T1V1-05-04-002
T5-6-45
TROUBLESHOOTING / Troubleshooting A
Between MC and Monitor Unit
CAN Harness (High Side)
Check for continuity between terminal #C4 of
harness end of connector MC-C in MC and
terminal #B7 of harness end of connector
monitor-B in the monitor unit.
CAN Harness (Low Side)
Check for continuity between terminal #C15 of
harness end of connector MC-C in MC and
terminal #B6 of harness end of connector
monitor-B in the monitor unit.
Connector
MC
Connector MC-C
(Harness end)
#C4
#C15
C10
C1
C23
C31
Monitor Unit
Connector Monitor-B
(Harness end)
#B7
#B6
T183-05-04-013
T5-6-46
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Ground Circuit
IMPORTANT: Before continuity check, turn the key
switch OFF.
In case of continuity, the circuit between
CAN circuit and ground circuit is
shorted.
In case of discontinuity, the circuit is
normal.
Connector
Connector MC-C
(Harness end)
#C4
C10
C1
C23
MC
Between CAN Circuit (High Side) and Ground
Circuit
Check for continuity between terminal #C4 of
harness end of connector MC-C and terminal #A2
of harness end of connector in MC-A.
C31
Connector MC-A
(Harness end)
#A2
T183-05-04-008
Connector MC-B
(Harness end)
#B8
#B18
T183-05-04-021
T5-6-47
TROUBLESHOOTING / Troubleshooting A
Between CAN Circuit (Low Side) and Ground
Circuit
Check for continuity between terminal #C15 of
harness end of connector MC-C and terminal #A2
of harness end of connector in MC-A.
Connector
Connector MC-C
(Harness end)
#C15
C10
C1
C23
C31
Connector MC-A
(Harness end)
#A2
#A13
T183-05-04-008
Connector MC-B
(Harness end)
#B8
#B18
T183-05-04-021
T5-6-48
TROUBLESHOOTING / Troubleshooting A
ECM
Between CAN Circuit (High Side) and Ground
Circuit
Check for continuity between terminals #18 and
#1 of harness end of connector.
ECM
Connector
(Harness end)
#18
#43
#4
#3
#1
T1GR-05-04-002
ECM
Connector
(Harness end)
#37
#43
#4
T5-6-49
#3
#62
#1
T1GR-05-04-002
TROUBLESHOOTING / Troubleshooting A
ICF
Between CAN Circuit (High Side) and Ground
Circuit
Check for continuity between terminals #C5 and
#C14 of harness end of connector ICF-C.
ICF
Connector ICF-C
(Harness end)
#C5
#C14
T1V1-05-04-002
#C15
ICF
Connector ICF-C
(Harness end)
Monitor Unit
Between CAN Circuit (High Side) and Ground
Circuit
Check for continuity between terminals #B7 and
#B11 of harness end of connector in the monitor
unit.
#C15
T1V1-05-04-002
#C11
Monitor Unit
Connector Monitor-B
(Harness end)
#B7
#B11
Monitor Unit
Connector Monitor-B
(Harness end)
#B6
#B11
T5-6-50
T183-05-04-013
T183-05-04-013
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Power Circuit
Connector
Connector MC-C
(Harness end)
#C4
C1
MC
C23
C10
C31
Connector MC-A
(Harness end)
#A1
#A12
T183-05-04-008
Connector MC-B
(Harness end)
#B7
#B17
T183-05-04-021
T5-6-51
TROUBLESHOOTING / Troubleshooting A
Between CAN Circuit (Low Side) and Power
Circuit
Check for continuity between terminal #C15 of
harness end of connector MC-C and terminal #A1
of harness end connector MC-A.
Connector
Connector MC-C
(Harness end)
#C15
C1
C23
C10
C31
Connector MC-A
(Harness end)
#A1
#A12
T183-05-04-008
Connector MC-B
(Harness end)
#B7
#B17
T183-05-04-021
T5-6-52
TROUBLESHOOTING / Troubleshooting A
ECM
Between CAN Circuit (High Side) and Power
Circuit
Check for continuity between terminals #18 and
#2 of harness end of connector.
ECM
Connector
(Harness end)
#18
#5
#2
ECM
Connector
(Harness end)
#37
T1GR-05-04-002
#5
ICF
Between CAN Circuit (High Side) and Power
Circuit
Check for continuity between terminals #C5 and
#C1 of harness end of connector ICF-C.
ICF
Connector ICF-C
(Harness end)
#C1
#C2
T1GR-05-04-002
#C5
T1V1-05-04-002
ICF
Connector ICF-C
(Harness end)
#C2
#C1
#C11
T5-6-53
T1V1-05-04-002
TROUBLESHOOTING / Troubleshooting A
Monitor Unit
Between CAN Circuit (High Side) and Power
Circuit
Check for continuity between terminal #B7 of
harness end of connector monitor-B in the monitor
unit and terminal #A16 of harness end of
connector monitor-A in the monitor unit.
Monitor Unit
Connector Monitor-A
(Harness end)
#A16
T183-05-05-001
Monitor Unit
Connector Monitor-B
(Harness end)
#B7
T183-05-04-013
Monitor Unit
Connector Monitor-A
(Harness end)
#A16
T183-05-05-001
Monitor Unit
Connector Monitor-B
(Harness end)
#B6
T183-05-04-013
T5-6-54
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Key Signal Circuit
Connector
Connector MC-C
(Harness end)
#C4
C10
C1
C23
MC
Between CAN Circuit (High Side) and Key Signal
Circuit
Check for continuity between terminal #C4 of
harness end of connector MC-C and terminal
#B16 of harness end of connector MC-B.
C31
Connector MC-B
(Harness end)
#B16
T183-05-04-021
Connector
Connector MC-C
(Harness end)
#C15
C1
C23
C10
C31
Connector MC-B
(Harness end)
#B16
T183-05-04-021
T5-6-55
TROUBLESHOOTING / Troubleshooting A
ECM
Between CAN Circuit (High Side) and Key Signal
Circuit
Check for continuity between terminals #18 and
#24 of harness end of connector.
ECM
Connector
(Harness end)
#18
#24
T1GR-05-04-002
ECM
Connector
(Harness end)
#37
#24
T1GR-05-04-002
ICF
Between CAN Circuit (High Side) and Key Signal
Circuit
Check for continuity between terminals #C5 and
#C7 of harness end of connector ICF-C.
ICF
Connector ICF-C
(Harness end)
#C5
#C7
T1V1-05-04-002
ICF
Connector ICF-C
(Harness end)
#C7
#C11
T5-6-56
T1V1-05-04-002
TROUBLESHOOTING / Troubleshooting A
Monitor Unit
Between CAN Circuit (High Side) and Power
Circuit
Check for continuity between terminal #B7 of
harness end of connector monitor-B in the monitor
unit and terminal #A7 of harness end of connector
monitor-A in the monitor unit.
Monitor Unit
Connector Monitor-A
(Harness end)
#A7
T183-05-05-001
Monitor Unit
Connector Monitor-B
(Harness end)
#B7
T183-05-04-013
Monitor Unit
Connector Monitor-A
(Harness end)
#A7
T183-05-05-001
Monitor Unit
Connector Monitor-B
(Harness end)
#B6
T183-05-04-013
T5-6-57
TROUBLESHOOTING / Troubleshooting A
Discontinuity Check in CAN Harness
IMPORTANT: Before continuity check, turn the key
switch OFF.
In case of continuity, the circuit between
CAN (high side) circuit and CAN (low
side) circuit is shorted.
In case of discontinuity, the circuit is
normal.
Connector MC-C
Check for continuity between terminals #C4 and
#C15 of harness end of connector MC-C in MC.
MC
Connector MC-C
(Harness end)
#C4
C1
C23
#C15
C10
C31
Connector ECM
Check for continuity between terminals #18 and
#37 of harness end of connector in ECM.
ECM
Connector
(Harness end)
#18
#37
T1GR-05-04-002
T5-6-58
TROUBLESHOOTING / Troubleshooting A
Connector ICF-C
Check for continuity between terminals #C5 and
#C11 of harness end of connector ICF-C in ICF.
ICF
Connector ICF-C
(Harness end)
#C5
#C11
T1V1-05-04-002
Monitor Unit
Connector Monitor-B
(Harness end)
#B7
#B6
T183-05-04-013
T5-6-59
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11101
Fault Code
Trouble
11101-3 Abnormal Engine Control Dial Sensor High Voltage
11101-4 Abnormal Engine Control Dial Sensor Low Voltage
Disconnect connector of
switch panel.
Check fi resistance
between terminals #1 and
#3 of switch panel end of
connector is 50.5 k.
Insert a probe of tester
from the back of connector
in terminal #2 with switch
panel connector
connected.
When rotating engine
control dial, chack if
voltage becomes
specification.
Specification: Refer to
the table below.
Disconnect connector
of switch panel.
Check if voltage
between terminals #1
YES
and #3 of harness end
of connector is 50.5
V.
Cause
Voltage: 4.75 V or higher
Voltage: Less than 0.25 V
Check if harnes
between terminal
#D15 of harness end
YES of connector MC-D in
MC and terminal #2 in
switch panel is open
or shorted.
Faulty MC.
NO
Key switch: ON
NO
Check fi voltage
between terminal #1
of harness end of
connector in switch
panel and machine is
specification.
Key switch: ON
Specification: 50.5 V
Open circuit in
harness between MC
YES and engine control
dial (terminal #3).
NO
Open circuit in
harness between MC
and engine control
dial (terminal #1).
Faulty engine control
dial.
NO
T183-05-04-009
#C15
Switch Panel
#3 #2 #1
T5-6-60
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11200
Fault Code
11200-3
11200-4
Trouble
Abnormal Pump 1 Delivery Pressure Sensor High Voltage
Abnormal Pump 1 Delivery Pressure Sensor Low Voltage
Disconnect connector
of pump 1 delivery
pressure sensor.
Check fi voltage
NO
between terminals #1
and #3 of harness end
of connector is 50.5
V.
Key switch: ON
Check if harnes
between terminal #C3
YES of harness end of
connector MC-C in MC
and terminal #2 in
pump 1 delivery
pressure sensor is
open or shorted.
NO
Check fi voltage
between terminal #1
of harness end of
connector in pump 1
delivery pressure
sensor and machine
is specification.
Key switch: ON
Refer to the table
upward.
YES
MC
Connector MC-C
Pump 1 Delivery
Pressure Sensor
#C3
C1
C23
Cause
Voltage: 4.75 V or higher
Voltage: Less than 0.25 V
C10
C31
T1J1-05-06-002
T5-6-61
Faulty MC.
NO
YES Open circuit in harness
between MC and pump 1
delivery pressure sensor
(terminal #3).
NO
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11202
Fault Code
11202-3
11202-4
Trouble
Abnormal Pump 2 Delivery Pressure Sensor High Voltage
Abnormal Pump 2 Delivery Pressure Sensor Low Voltage
Check if harnes
between terminal #C12
YES of harness end of
connector MC-C in MC
and terminal #2 in
pump 2 delivery
pressure sensor is
open or shorted.
Disconnect connector
of pump 2 delivery
pressure sensor.
Check fi voltage
NO
between terminals #1
and #3 of harness end
of connector is 50.5
V.
Key switch: ON
NO
Check fi voltage
between terminal #1
of harness end of
connector in pump 2
delivery pressure
sensor and machine
is specification.
Key switch: ON
Refer to the table
upward.
Pump 2 Delivery
Pressure Sensor
MC
Connector MC-C
#C12
C23
Faulty MC.
NO
YES Open circuit in harness
between MC and pump 2
delivery pressure sensor
(terminal #3).
NO
YES
C1
Cause
Voltage: 4.75 V or higher
Voltage: Less than 0.25 V
C10
C31
T1J1-05-06-002
T5-6-62
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11301
Fault Code
11301-3
11301-4
Trouble
Abnormal Swing Pilot Pressure Sensor High Voltage
Abnormal Swing Pilot Pressure Sensor Low Voltage
Cause
Voltage: 4.75 V or higher
Voltage: Less than 0.25 V
Check if harnes
YES between terminal #D16
of harness end of
connector MC-D in MC
and terminal #2 in
pressure sensor is
open or shorted.
Disconnect connector
of pressure sensor.
Check fi voltage
between terminals #1
NO and #3 of harness end
of connector is 50.5
V.
Check fi voltage
between terminal #1
of harness end of
connector in pressure
NO sensor and machine
is specification.
Key switch: ON
Switch pressure sensor
with other pressure
sensor and retry.
Check if fault code
disappears.
Key switch: ON
Refer to the table
upward.
Faulty MC.
NO
YES
#D16
T1J1-05-06-001
T183-05-04-009
T5-6-63
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11302
Fault Code
11302-3
11302-4
Trouble
Abnormal Boom Raise Pilot Pressure Sensor High Voltage
Abnormal Boom Raise Pilot Pressure Sensor Low Voltage
Check if harnes
between terminal #C13
of harness end of
YES
connector MC-C in MC
and terminal #2 in
pressure sensor is
open or shorted.
Disconnect connector
of pressure sensor.
NO Check fi voltage
between terminals #1
and #3 of harness end
of connector is 50.5
V.
Check fi voltage
between terminal #1 of
harness end of
NO connector in pressure
sensor and machine is
specification.
Key switch: ON
Switch pressure sensor
with other pressure
sensor and retry.
Check if fault code
disappears.
Key switch: ON
Refer to the table
upward.
YES
#C13
C1
C23
C10
C31
Cause
Voltage: 4.75 V or higher
Voltage: Less than 0.25 V
T1J1-05-06-001
T5-6-64
Faulty MC.
NO
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11303
Fault Code
11303-3
11303-4
Trouble
Abnormal Arm Roll-In Pilot Pressure Sensor High Voltage
Abnormal Arm Roll-In Pilot Pressure Sensor Low Voltage
Cause
Voltage: 4.75 V or higher
Voltage: Less than 0.25 V
Check if harnes
between terminal #C23
YES of harness end of
connector MC-C in MC
and terminal #2 in
pressure sensor is
open or shorted.
Disconnect connector
of pressure sensor.
NO Check fi voltage
between terminals #1
and #3 of harness end
of connector is 50.5
V.
Check fi voltage
between terminal #1
of harness end of
NO connector in pressure
sensor and machine
is specification.
Key switch: ON
Switch pressure sensor
with other pressure
sensor and retry.
Check if fault code
disappears.
Key switch: ON
Refer to the table
upward.
Faulty MC.
NO
YES
MC
Connector MC-C
C1
#C23
C23
C31
T1J1-05-06-001
T5-6-65
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11400
Fault Code
11400-3
11400-4
Trouble
Cause
Abnormal Feedback High Current of Pump 2 Control Solenoid Current: Higher than 920 mA
Valve
Abnormal Feedback Low Current of Pump 2 Control Solenoid Current: Less than 56 mA
Valve
YES
Switch connectors of
pump 2 control solenoid
valve and control
solenoid valve.
Check if fault code in
torque control solenoid
valve is displayed.
YES
Faulty MC.
NO
T1J1-05-06-003
#A30
T183-05-04-008
T5-6-66
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11402
Fault Code
11402-3
11402-4
Trouble
Cause
Abnormal Feedback High Current of Solenoid Valve Unit Current: Higher than 920 mA
(SF) (Boom Flow Rate Control Valve Control)
Abnormal Feedback Low Current of Solenoid Valve Unit Current: Less than 56 mA
(SF) (Boom Flow Rate Control Valve Control)
YES
Switch connectors of
solenoid valve unit (SF)
and other solenoid
valve unit (SC, SG or
SI).
Check if fault code in
switched solenoid valve
unit is displayed.
YES
Faulty MC.
NO
After switching
connectors, operate
combined operation of
boom lower and bucket
or arm, and check by
using Dr. ZX.
Open circuit in harness.
NO
#A20
T1V1-05-04-003
T183-05-04-008
T5-6-67
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11404
Fault Code
11404-3
11404-4
Trouble
Abnormal Feedback High Current of Solenoid Valve Unit (SG)
(Main Relief Pressure Control)
Abnormal Feedback Low Current of Solenoid Valve Unit (SG)
(Main Relief Pressure Control)
Cause
Current: Higher than 920 mA
Current: Less than 56 mA
YES
YES
Faulty MC.
NO
After switching
connectors, operate
boom raise relieved,
and check by using Dr.
ZX.
Open circuit in harness.
NO
MC
Connector MC-A
#A7
T1V1-05-04-003
#A23
T183-05-04-008
T5-6-68
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11405
Fault Code
11405-3
11405-4
Trouble
Abnormal Feedback High Current of Solenoid Valve Unit (SI)
(Travel Motor Displacement Angle Control)
Abnormal Feedback Low Current of Solenoid Valve Unit (SI)
(Travel Motor Displacement Angle Control)
Cause
Current: Higher than 920 mA
Current: Less than 56 mA
YES
Switch connectors of
solenoid valve unit (SI)
and other solenoid
valve unit (SF, SC or
SG).
Check if fault code in
switched solenoid valve
unit is displayed.
YES
Faulty MC.
NO
After switching
connectors, turn travel
mode switch to FAST,
and check by using Dr.
ZX.
Open circuit in harness.
NO
#A17
#A11
T1V1-05-04-003
T183-05-04-008
T5-6-69
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11410
Fault Code
11410-3
11410-4
Trouble
Cause
Abnormal Feedback High Current of Pump 1 Control Solenoid Current: Higher than 920 mA
Valve
Abnormal Feedback Low Current of Pump 1 Control Solenoid Current: Less than 56 mA
Valve
YES
YES
Faulty MC.
NO
MC
Connector MC-A
#A16
#A22
T1J1-05-06-003
T183-05-04-008
T5-6-70
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11412
Fault Code
11412-3
11412-4
Trouble
Cause
Abnormal Feedback High Current of Fan Pump Control Solenoid Current: Higher than 920 mA
Valve
Abnormal Feedback Low Current of Fan Pump Control Solenoid Current: Less than 56 mA
Valve
YES
YES
Faulty MC.
NO
MC
Connector MC-A
#A15
#A9
T1J1-05-06-003
T183-05-04-008
T5-6-71
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11802
Fault Code
11802-3
11802-4
Trouble
Abnormal Boom Bottom Pressure Sensor High Voltage
Abnormal Boom Bottom Pressure Sensor Low Voltage
Check if harnes
between terminal #C24
of harness end of
YES connector MC-C in MC
and terminal #2 in
boom bottom pressure
sensor is open or
shorted.
Disconnect connector
of boom bottom
pressure sensor.
NO Check fi voltage
between terminals #1
and #3 of harness end
of connector is 50.5
V.
Check fi voltage
between terminal #1
of harness end of
connector in boom
NO bottom pressure
sensor and machine
is specification.
Key switch: ON
Switch boom bottom
pressure sensor and
pump 2 delivery
pressure sensor.
Check if fault code
(11202) disappears.
Key switch: ON
Refer to the table
upward.
YES
MC
Connector MC-C
C10
C1
C23
Cause
Voltage: 4.5 V or higher
Voltage: Less than 0.25 V
C31
T1J1-05-06-001
#C24
T5-6-72
Faulty MC.
NO
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11901
Fault Code
Trouble
11901-3 Hydraulic Oil Temperature Sensor High Voltage
11901-4
Cause
Intake Air Temp.: 21 C or higher
Voltage: 4.10 V or higher
The above condition holds 30 seconds or more.
Voltage: Less than 0.23 V
The above condition holds 30 seconds or more.
Disconnect connector of
hydraulic oil temperature
sensor.
Check if resistance at
sensor end connector is
specification.
Specification: Refer to
the table below.
Connect terminals #1
and #2 of harness end
of connector in
hydraulic oil
temperature sensor by
YES using a clip.
Disconnect connector
MC-D from MC.
Check for continuity
between terminals #D2
and #D6 of harness
end of connector
MC-D.
Faulty MC.
YES
NO
NO
NO
#D2
#D6
T183-05-04-009
T5-6-73
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-6-74
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODES 11910,11911, 11914, 11918, 11920, 11983, 11984
Fault Code
11910-2
11911-2
11914-2
11918-2
11920-2
11983-2
11984-2
Trouble
Actual Engine Speed Receive Error
Sent from ECM
Security Signal Receive Error
Sent from monitor unit
Radiator Water Temperature Receive Error
Sent from ECM
Work Mode Receive Error
Sent from monitor unit
Fuel Flow Receive Error
Sent from ECM
Intake Air Temperature Receive Error
Sent from ECM
Boost Temperature Receive Error
Sent from ECM
Cause
Faulty CAN Harness
Faulty CAN Harness
Faulty CAN Harness
Faulty CAN Harness
Faulty CAN Harness
Faulty CAN Harness
Faulty CAN Harness
Dr. ZX
Satellite Terminal
(Optional)
ICF
Monitor Unit
CAN Harness
MC
ECM
T1J1-02-01-004
T5-6-75
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODES 11910, 11911, 11914,
11918, 11920, 11983, 11984
(CAN HARNESS CHECK)
Check the wiring connections first.
Disconnect all
connectors of MC, ICF,
ECM and monitor unit.
YES Check for continuity
between ground circuit
(MC, ICF, ECM,
monitor unit) and CAN
circuit.
Check for continuity in
YES CAN harness between
MC and ECM.
NO
NO
Normal.
NO
T5-6-76
TROUBLESHOOTING / Troubleshooting A
YES
YES
Check for continuity
between key signal
circuit (MC, ICF,
NO ECM, monitor unit)
and CAN circuit.
Key switch: OFF
Refer to
Discontinuity
Check between
CAN Circuit and
Key Signal Circuit
on T5-6-55 to 57.
YES
NO
NO
Connector
MC
Connector MC-C
(Harness end)
#C4
YES
NO
To A
Disconnect
connector in ECM.
Connect MC-C
connector in MC.
Check if resistance
between terminals
#18 and #37 of
harness end of
connector in ECM is
within 12010 .
Key switch: OFF
#C15
C10
C1
C23
C31
Monitor Unit
Connector Monitor-B
(Harness end)
#18
#37
T1GR-05-04-002
T5-6-77
To B
TROUBLESHOOTING / Troubleshooting A
NO
Connect connector
in MC. Check if fault
code 11004-2 is
displayed.
Key switch: ON
Connect connector
ECM.
YES Check if fault code
11004-2 is
displayed.
Key switch: ON
B
Connect connector in
ECM.
Disconnect
connector ICF-C in
ICF.
Check if resistance
between terminals
NO #C5 and #C11 of
harness end of
connector is within
12010 .
Faulty MC.
YES
NO
Faulty ECM.
YES
Connect connector
in ICF.
YES Check if fault code
11004-2 is
displayed.
Key switch: ON
Connect connector in
ICF.
Disconnect
connector monitor B
in monitor unit.
Check if resistance
between terminals
#B6 and #B7 of
harness end of
connector is within
12010 .
NO
YES
YES
Connect connector
in monitor unit.
Check if fault code
11004-2 is
displayed.
Key switch: ON
NO
Connector
ECM
Connector
(Harness end)
ICF
Connector ICF-C
(Harness end)
#B7
#B6
#C5
T183-05-04-013
#C11
T1V1-05-04-002
T5-6-78
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11989
Fault Code
11989-3
11989-4
Trouble
Abnormal Feedback High Current of Solenoid Valve Unit (SC)
(Boom Mode Control)
Abnormal Feedback Low Current of Solenoid Valve Unit (SC)
(Boom Mode Control)
Cause
Current: Higher than 920 mA
Current: Less than 56 mA
YES
Switch connectors of
solenoid valve unit (SC)
and other solenoid
valve unit (SF, SG or
SI).
Check if fault code in
switched solenoid valve
unit is displayed.
YES
Faulty MC.
NO
After switching
connectors, operate
combined operation of
boom lower and bucket
or arm, and check by
using Dr. ZX.
Open circuit in harness.
#A10
T1V1-05-04-003
T183-05-04-008
T5-6-79
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11991
Fault Code
11991-3
11991-4
Trouble
Abnormal Travel Right Pilot Pressure Sensor High Voltage
Abnormal Travel Right Pilot Pressure Sensor Low Voltage
Cause
Voltage: 4.75 V or higher
Voltage: Less than 0.25 V
Check if harnes
YES between terminal #D9
of harness end of
connector MC-D in MC
and terminal #2 in
pressure sensor is
open or shorted.
Disconnect connector
of pressure sensor.
Check fi voltage
between terminals #1
NO and #3 of harness end
of connector is 50.5
V.
Check fi voltage
between terminal #1
of harness end of
connector in pressure
NO sensor and machine
is specification.
Key switch: ON
Switch pressure sensor
with other pressure
sensor and retry.
Check if fault code
disappears.
Key switch: ON
Refer to the table
upward.
Faulty MC.
NO
YES
T1J1-05-06-001
T183-05-04-009
T5-6-80
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11992
Fault Code
11992-3
11992-4
Trouble
Abnormal Pump 2 Regulator Pressure Sensor High Voltage
Abnormal Pump 2 Regulator Pressure Sensor Low Voltage
Check if harnes
between terminal #D4
of harness end of
YES connector MC-D in MC
and terminal #2 in
pump 2 regulator
pressure sensor is
open or shorted.
Disconnect connector
of pump 2 regulator
pressure sensor.
NO Check fi voltage
between terminals #1
and #3 of harness end
of connector is 50.5
V.
Key switch: ON
Check fi voltage
between terminal #1
of harness end of
connector in pump 2
NO regulator pressure
sensor and machine
is specification.
Key switch: ON
Refer to the table
upward.
YES
Cause
Voltage: 4.75 V or higher
Voltage: Less than 0.25 V
T1J1-05-06-001
T183-05-04-009
T5-6-81
Faulty MC.
NO
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11993
Fault Code
11993-3
11993-4
Trouble
Abnormal Travel Left Pilot Pressure Sensor High Voltage
Abnormal Travel Left Pilot Pressure Sensor Low Voltage
Cause
Voltage: 4.75 V or higher
Voltage: Less than 0.25 V
Check if harnes
YES between terminal #D14
of harness end of
connector MC-D in MC
and terminal #2 in
pressure sensor is
open or shorted.
Disconnect connector
of pressure sensor.
Check fi voltage
between terminals #1
NO and #3 of harness end
of connector is 50.5
V.
Check fi voltage
between terminal #1
of harness end of
connector in pressure
NO sensor and machine
is specification.
Key switch: ON
Switch pressure sensor
with other pressure
sensor and retry.
Check if fault code
disappears.
Key switch: ON
Refer to the table
upward.
Faulty MC.
NO
YES
T1J1-05-06-001
#D14
T183-05-04-009
T5-6-82
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11994
Fault Code
11994-3
11994-4
Trouble
Abnormal Pump 1 Regulator Pressure Sensor High Voltage
Abnormal Pump 1 Regulator Pressure Sensor Low Voltage
Check if harnes
between terminal #D11
of harness end of
YES connector MC-D in MC
and terminal #2 in
pump 1 regulator
pressure sensor is
open or shorted.
Disconnect connector
of pump 1 regulator
pressure sensor.
NO Check fi voltage
between terminals #1
and #3 of harness end
of connector is 50.5
V.
Key switch: ON
Check fi voltage
between terminal #1
of harness end of
connector in pump 1
NO regulator pressure
sensor and machine
is specification.
Key switch: ON
Refer to the table
upward.
YES
Cause
Voltage: 4.75 V or higher
Voltage: Less than 0.25 V
#D11
T1J1-05-06-001
T183-05-04-009
T5-6-83
Faulty MC.
NO
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11995
Fault Code
11995-3
11995-4
Trouble
Abnormal Arm Roll-Out Pilot Pressure Sensor High Voltage
Abnormal Arm Roll-Out Pilot Pressure Sensor Low Voltage
Cause
Voltage: 4.75 V or higher
Voltage: Less than 0.25 V
Check if harnes
YES between terminal #D5
of harness end of
connector MC-D in MC
and terminal #2 in
pressure sensor is
open or shorted.
Disconnect connector
of pressure sensor.
Check fi voltage
between terminals #1
NO and #3 of harness end
of connector is 50.5
V.
Check fi voltage
between terminal #1
of harness end of
connector in pressure
NO sensor and machine
is specification.
Key switch: ON
Switch pressure sensor
with other pressure
sensor and retry.
Check if fault code
disappears.
Key switch: ON
Refer to the table
upward.
Faulty MC.
NO
YES
T1J1-05-06-001
T183-05-04-009
T5-6-84
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11997
Fault Code
11997-3
11997-4
Trouble
Cause
Abnormal Bucket Roll-Out Pilot Pressure Sensor High Voltage: 4.75 V or higher
Voltage
Abnormal Bucket Roll-Out Pilot Pressure Sensor Low Voltage: Less than 0.25 V
Voltage
Check if harnes
between terminal #C11
of harness end of
YES
connector MC-C in MC
and terminal #2 in
pressure sensor is
open or shorted.
Disconnect connector
of pressure sensor.
NO Check fi voltage
between terminals #1
and #3 of harness end
of connector is 50.5
V.
Check fi voltage
between terminal #1 of
harness end of
NO connector in pressure
sensor and machine is
specification.
Key switch: ON
Switch pressure sensor
with other pressure
sensor and retry.
Check if fault code
disappears.
Key switch: ON
Refer to the table
upward.
YES
#C11
C1
C23
C10
C31
T1J1-05-06-001
T5-6-85
Faulty MC.
NO
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11998
Fault Code
11998-3
11998-4
Trouble
Abnormal Boom Lower Pilot Pressure Sensor High Voltage
Abnormal Boom Lower Pilot Pressure Sensor Low Voltage
Check if harnes
between terminal #C1
of harness end of
YES
connector MC-C in MC
and terminal #2 in
pressure sensor is
open or shorted.
Disconnect connector
of pressure sensor.
NO Check fi voltage
between terminals #1
and #3 of harness end
of connector is 50.5
V.
Check fi voltage
between terminal #1 of
harness end of
NO connector in pressure
sensor and machine is
specification.
Key switch: ON
Switch pressure sensor
with other pressure
sensor and retry.
Check if fault code
disappears.
Key switch: ON
Refer to the table
upward.
YES
#C1
C1
C23
C10
C31
Cause
Voltage: 4.75 V or higher
Voltage: Less than 0.25 V
T1J1-05-06-001
T5-6-86
Faulty MC.
NO
TROUBLESHOOTING / Troubleshooting A
MC FAULT CODE 11999
Fault Code
11999-3
11999-4
Trouble
Cause
Abnormal Bucket Roll-In Pilot Pressure Sensor High Voltage Voltage: 4.75 V or higher
Abnormal Bucket Roll-In Pilot Pressure Sensor Low Voltage Voltage: Less than 0.25 V
Check if harnes
between terminal #C2
of harness end of
YES
connector MC-C in MC
and terminal #2 in
pressure sensor is
open or shorted.
Disconnect connector
of pressure sensor.
NO Check fi voltage
between terminals #1
and #3 of harness end
of connector is 50.5
V.
Check fi voltage
between terminal #1 of
harness end of
NO connector in pressure
sensor and machine is
specification.
Key switch: ON
Switch pressure sensor
with other pressure
sensor and retry.
Check if fault code
disappears.
Key switch: ON
Refer to the table
upward.
YES
#C2
C1
C23
C10
C31
T1J1-05-06-001
T5-6-87
Faulty MC.
NO
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-6-88
TROUBLESHOOTING / Troubleshooting A
ICF FAULT CODES 14000 to 14003
Fault Code
Trouble
14000-2 Abnormal CAN Communication
14001-2
14002-2
14003-2
Remedy
Execute retry B in self-diagnosing.
If this error code is displayed after retry, check the following
item.
Check the CAN communication line (harness).
Execute retry B in self-diagnosing and execute the following
item.
Execute Information C/U: Initialize.
Execute retry B in self-diagnosing.
If this error code is displayed after retry, check the following
item.
Execute Control Data: Initialize.
Execute Enter Model and Serial No..
Then, execute self-diagnosing and execute retry B.
T5-6-89
TROUBLESHOOTING / Troubleshooting A
INFORMATION C/U: INITIALIZE
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
Push Information
Setup.
Push Start.
C/U:
T1V7-05-03-009
Various
T1V7-05-03-024
To the
lower
Title Screen
T1V7-05-03-025
T1V7-05-03-026
T1V7-05-03-027
Init
ESC
T1V7-05-03-028
T1V7-05-03-029
T1V7-05-03-027
T5-6-90
TROUBLESHOOTING / Troubleshooting A
CONTROL DATA: INITIALIZE
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
Push Information
Setup.
Push Start.
C/U:
T1V7-05-03-024
To the
lower
Title Screen
T1V7-05-03-025
T1V7-05-03-026
T1V7-05-03-027
Init
ESC
T1V7-05-03-033
T1V7-05-03-034
T1V7-05-03-027
T5-6-91
TROUBLESHOOTING / Troubleshooting A
ENTER MODEL AND SERIAL No.
After starting Dr. ZX, push Select
Controller.
Push OK.
To the
lower
T1V7-05-03-001
T1V7-05-03-009
T1V7-05-03-024
Push Start.
Push Information
Setup.
C/U:
Various
To the
lower
T1V7-05-03-025
T1V7-05-03-026
Title Screen
T1V7-05-03-027
ESC
Exes
ESC
OK
T1V7-05-03-030
T1V7-05-03-031
T1V7-05-03-027
T5-6-92
TROUBLESHOOTING / Troubleshooting A
ICF FAULT CODES 14006, 14008
Fault Code
Trouble
Remedy
14006-2 ICF:
Satellite
Communication Execute retry B in self-diagnosing.
Terminal: Communication Error
If this error code is displayed after retry, check the following
item.
Check the communication line.
Check the power source line of satellite terminal.
Check the fuse.
14008-2
T5-6-93
ICF
Connector ICF-A
#A8
#A9
#A31
Satellite
Connector A
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
Satellite
Connector B
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
TROUBLESHOOTING / Troubleshooting A
SATELLITE TERMINAL (OPTIONAL) FAULT CODES 14100 to 14106
Fault Code
Trouble
14100-2 Abnormal EEPROM
14101-2
14102-2
14103-2
14104-2
14105-2
14106-2
Remedy
Execute retry B in self-diagnosing.
If this error code is displayed after retry, replace the
controller.
Check the communication aerial of satellite terminal.
Execute retry B in self-diagnosing.
If this error code is displayed after retry, replace the
are controller.
T1J1-01-02-003
Communication Aerial
GPS Aerial
T1V1-05-06-004
T5-6-94
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13303
Fault Code
13303-2
Trouble
Remedy
Cool the monitor unit until temperature inside the monitor unit
becomes less than 85 C.
YES
YES
Normal.
Check if temperature
around monitor unit is
high.
NO
T5-6-95
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13304
Fault Code
Trouble
13304-2 Abnormal REG Input H Level
Check the wiring connections first.
Remedy
Refer to the following.
Measure voltage at
terminal #C7 of
connector monitor-C.
Engine: Running
Measure voltage at
terminal L in
regulator.
33.5 V or higher
Monitor Unit
Connector Monitor-C
6
12
33.5 V or higher
1
7
#C7
T5-6-96
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODES 13306, 13308
Fault Code
Trouble
13306-2
Abnormal EEPROM
13308-2
Remedy
If this error code is displayed after re-try, replace the monitor
unit.
Refer to Check CAN Harness (T5-6-44 to 59).
T5-6-97
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13310
Fault Code
13310-3
Trouble
Shorted
Circuit
Temperature Sensor
Remedy
in
YES
Check if resistance of
coolant temperature
sensor is specification.
YES
NO
Resistance
(C)
(k)
25
7.6
40
4.00.35
50
2.70.216
80
0.98
95
0.60
105
0.45
120
0.30
6
1
#2
1
7
#C8
#3
T5-6-98
T1J1-05-06-004
TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13311
Fault Code
13311-3
13311-4
Trouble
Remedy
Check if resistance of
fuel level sensor is
specification.
YES
NO
Connect terminal #1 of
harness end of
connector in fuel level
sensor to machine.
Check for continuity
between terminal #C2 of
harness end of
connector in monitor unit
and machine.
NO
Float Position
Float
Resistance ()
3/4
93 mm
204 mm
-4
26
1/2
385
1/4
53
Alarm Level
853
90
+10
-0
1/2
Monitor Unit
Connector Moniter-C
338 mm
+0
3/4
10
1/4
Fuel Sensor
#C2
EMPTY
6
1
T178-05-05-001
T5-6-99
1
7
TROUBLESHOOTING / Troubleshooting A
PILOT SHUT-OFF LEVER ALARM
Pilot shut-off lever alarm is displayed on the
monitor unit screen.
YES
Pilot Shut-Off
Lever
Pilot Shut-Off
Switch
T1V1-05-06-005
T5-6-100
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code
is displayed on the service menu in monitor unit
(built-in diagnosing system) and Dr.ZX although the
machine operation is abnormal.
When the fault code is displayed, refer to
Troubleshooting A and start the troubleshooting.
On the front section pages of this group are the tables
indicating the relationship between machine trouble
symptoms and related parts which may cause such
trouble if failed.
Start the troubleshooting with more probable causes
selected by referring to these tables.
(1)
NO (NOT OK)
(3)
Special instructions or reference item are indicated in the spaces under the box.
Key switch: ON
(2)
Explanation of how to use test harness kit required. Refer to Electrical System
Inspection group (group 8) in this section.
Use the service menu in monitor unit (built-in diagnosing system) or Dr.ZX.
Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
T5-7-1
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
Engine Control Dial
Pump 1 Delivery
Pressure Sensor
HP mode is inoperable.
HP mode is inoperable.
speed.
Function
Symptoms in machine
operation when trouble
occurs.
Using Test
Harness
Others
By MC Fault
Code
Evaluation
Pump 2 Delivery
Pressure Sensor
By Monitor
Function
NOTE
Descriptions of Control
(Operational Principle
Section in T/M)
T2-1
T5-7-2
TROUBLESHOOTING / Troubleshooting B
Pressure Sensor
(Boom Raise)
Pressure Sensor
(Boom Lower)
Pressure Sensor
(Arm Roll-Out)
to MC.
Abnormal high voltage: As the sensor is
detected as fully operated, the sensor is
controlled.
to MC.
Abnormal high voltage: As the sensor is
detected as fully operated, the sensor is
controlled.
to MC.
T2-1
T2-1
T2-1
T5-7-3
TROUBLESHOOTING / Troubleshooting B
Parts
Pressure Sensor
(Arm Roll-In)
Symptoms in machine
operation when trouble
occurs.
By MC Fault
Code
Evaluation
By Monitor
Function
NOTE
Descriptions of Control
(Operational Principle
Section in T/M)
Using Test
Harness
Others
Pressure Sensor
(Bucket Roll-In)
Symptoms in control
system when trouble
occurs.
Pressure Sensor
(Bucket Roll-Out)
T2-1
T2-1
T2-1
T5-7-4
TROUBLESHOOTING / Troubleshooting B
Pressure Sensor
(Swing)
Pressure Sensor
(Right Travel)
Pressure Sensor
(Left Travel)
to MC.
Abnormal high voltage: As the sensor is
detected as fully operated, the sensor is
controlled.
to MC.
Abnormal high voltage: As the sensor is
detected as fully operated, the sensor is
controlled.
to MC.
T2-1
T2-1
T2-1
T5-7-5
TROUBLESHOOTING / Troubleshooting B
Parts
Pressure Sensor
(Counterweight Removal)
(Optional)
Pressure Sensor
(Attachment)
(Optional)
Function
Symptoms in machine
operation when trouble
occurs.
By MC Fault
Code
Evaluation
loaded.
By Monitor
Function
Using Test
Harness
Others
Monitor Item:
Pressure
NOTE
T2-1
T5-7-6
Boom
T2-1
Bottom
TROUBLESHOOTING / Troubleshooting B
Pump 1 Regulator
Pressure Sensor
Pump 2 Regulator
Pressure Sensor
Machine mistracks.
Engine is overloaded.
Work speed is lowered.
Machine mistracks.
Engine is overloaded.
Work speed is lowered.
of main pump 1.
is inoperable.)
of main pump 2.
is inoperable.)
T2-1
T2-1
T2-1
T5-7-7
TROUBLESHOOTING / Troubleshooting B
Parts
Function
Symptoms in machine
operation when trouble
occurs.
By MC Fault
Code
Evaluation
By Monitor
Function
Others
Descriptions of Control
(Operational Principle
Section in T/M)
Using Test
Harness
NOTE
tion.
T2-1
T2-1
T2-1
T5-7-8
TROUBLESHOOTING / Troubleshooting B
duced.
T2-1
T2-1
T2-1
T5-7-9
TROUBLESHOOTING / Troubleshooting B
Parts
Pilot Shut-Off
Solenoid Valve
MC
Function
Symptoms in machine
operation when trouble
occurs.
By MC Fault
Code
Evaluation
tions, control system malfunction may differ. (The following symptoms in machine
operation indicates that MC
logic circuit has failed.)
As pump displacement is
Using Test
Harness
Others
By Monitor
Function
NOTE
Descriptions of Control
(Operational Principle
Section in T/M)
T2-1
T2-5
T5-7-10
T2-1
TROUBLESHOOTING / Troubleshooting B
Auto-Idle Switch
crease.
Shorted Circuit: Pressure increases for 8
seconds after turning key switch ON, and
stops increasing.
Fast Mode: 0 V
Slow Mode: 5 V
T2-1
able.
T2-1
T2-1
T5-7-11
TROUBLESHOOTING / Troubleshooting B
Parts
Selects E mode.
Selects P mode.
Function
ON: 0 V E mode
OFF: 5 V Normal
ON: 0 V
OFF: 0 V
(If E mode and HP mode are
not selected, MC judges as P
mode is selected.)
HP mode
Symptoms in machine
operation when trouble
occurs.
By MC Fault
Code
Evaluation
By Monitor
Function
Using Test
Harness
Others
NOTE
Descriptions of Control
(Operational Principle
Section in T/M)
T2-1
T2-1
T5-7-12
T2-1
TROUBLESHOOTING / Troubleshooting B
Boom Mode
Selector Switch
Open circuit:
Pilot shut-off switch is always turned
OFF.
Pilot shut-off solenoid valve is not
shifted.
Even if lever is operated with pilot
shut-off lever in UNLOCK position, all
actuator are not operated.
Shorted circuit:
Pilot shut-off switch is always turned ON.
Engine does not start.
If shorted circuit occurs while starting
engine, operate lever with pilot shut-off
lever in LOCK position so that actuator is
operated.
T2-5
T2-1
T2-1
T5-7-13
TROUBLESHOOTING / Troubleshooting B
Parts
Learning Switch
ON: 0 V Learning
OFF: 5 V Normal control
Function
formed.
lower circuit.
circuit or discontinuity of
switch, machine operates
normally. (Only learning
cannot be performed.)
If shorted circuit occurs,
learning mode operation
starts when key switch is
turned ON. Therefore, engine
will stall at 2 second or 20
seconds after engine starts.
By MC Fault
Code
Evaluation
Symptoms in machine
operation when trouble
occurs.
Using Test
Harness
Others
By Monitor
Function
NOTE
Descriptions of Control
(Operational Principle
Section in T/M)
T2-1
T3-3
T5-7-14
T3-3
TROUBLESHOOTING / Troubleshooting B
T2-1, T3-3
T2-4
T3-3
T5-7-15
TROUBLESHOOTING / Troubleshooting B
Parts
Bucket Regenerative
Valve
Function
Symptoms in machine
operation when trouble
occurs.
Evaluation
By MC Fault
Code
By Monitor
Function
Using Test
Harness
Others
NOTE
Descriptions of Control
(Operational Principle
Section in T/M)
T3-3
T3-3
T5-7-16
T3-3
TROUBLESHOOTING / Troubleshooting B
not open.
not open.
not lower.
If check valve is kept open, front attachment drift increases due to oil leaks in
control valve.
Boom moves jerky or boom speed becomes slow depending on valve bound
conditions.
T 3-3
T3-3
T3-6
T5-7-17
TROUBLESHOOTING / Troubleshooting B
Parts
Function
Symptoms in machine
operation when trouble
occurs.
Evaluation
Proximity Switch
(Auto Lubrication System)
If
By MC Fault
Code
By Monitor
Function
Using Test
Harness
Others
NOTE
Descriptions of Control
(Operational Principle
Section in T/M)
T3-3
T2-4, T3-6
T5-7-18
T2-1
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-19
TROUBLESHOOTING / Troubleshooting B
CORRELATION
BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine
troubles and parts contributing to the cause of the
trouble if failed.
E-1
Starter does not rotate.
E-2
Even if starter rotates, engine
does not start.
E-3
When engine control dial is
fully rotated, engine stalls.
When engine control dial is
fully rotated with P mode or
HP mode, engine speed is
slow.
Parts
MC (Main Controller)
ECM
ICF
Monitor Unit
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pump 1 Regulator Pressure Sensor
Pump 2 Regulator Pressure Sensor
Starter Cut Relay (R4)
ECM Main Relay (R14)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Attachment)
Pilot Shut-Off Switch
Engine Stop Switch
Key Switch
Engine Control Dial
Auto-Idle Switch
Power Mode Switch
Battery Relay
Starter Relay
Engine Electrical Equipment
Engine Unit
z
{
{
z
z
z
{
z
z
z
Check batteries.
Remarks
z
{
{
z
Check fuel system (Filters and
piping).
T5-7-20
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.
In case more than one trouble occurs at
the same time, find out all faulty components while checking all suspected components in each trouble symptom.
E-4
Even if engine control dial is
rotated, engine speed remains
unchanged.
z
z
E-5
Faulty HP mode.
E-6
Faulty E mode.
z
{
z
{
z
z
z
z
z
z
E-7
Faulty auto-idle system.
z
{
z
z
{
z
z
Open circuit in CAN harness
(Connector is disconnected.)
z
z
{
T5-7-21
TROUBLESHOOTING / Troubleshooting B
z : Related, required to check
{ : Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will
not be the direct cause of the trouble concerned.
Trouble
Symptom
E-8
Even if key switch is turned
OFF, engine does not stop.
E-9
Engine speed does not increase
even if attachment is operated
in attachment mode.
Parts
MC (Main Controller)
ECM
ICF
Monitor Unit
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pump 1 Regulator Pressure Sensor
Pump 2 Regulator Pressure Sensor
Starter Cut Relay (R4)
ECM Main Relay (R14)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Attachment)
Pilot Shut-Off Switch
Engine Stop Switch
Key Switch
Engine Control Dial
Auto-Idle Switch
Power Mode Switch
Battery Relay
Starter Relay 2
Engine Electrical Equipment
Engine Unit
z
{
Remarks
T5-7-22
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently
In case more than one trouble occurs at
the same time, find out all faulty components while checking all suspected components in each trouble symptom.
Trouble
Symptom
E-10
When attachment mode is
selected, engine speed does
not decrease.
E-11
Engine stalls during operation
under adverse condition such
as at high altitude.
z
{
z
{
E-12
Engine is difficult to start at
low temperature.
Parts
MC (Main Controller)
ECM
ICF
Monitor Unit
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pump 1 Regulator Pressure Sensor
Pump 2 Regulator Pressure Sensor
Pump 1 Control Solenoid Valve
Pump 2 Control Solenoid Valve
Glow Plug Relay
Engine Electrical Equipment
Engine Unit
Pump Regulator
{
{
{
{
{
{
{
z
z
z
z
Check fuel system for clogging.
Remarks
T5-7-23
TROUBLESHOOTING / Troubleshooting B
A-1
All actuators are not operated.
A-2
All actuator speeds are slow.
A-3
Left travel is inoperable during
single travel operation. Single
swing operation speed becomes
slow. Arm speed is slightly slow
during arm level crowding.
Parts
MC (Main Controller)
ECM
Monitor Unit
Pilot Shut-Off Relay (R2)
Security Relay (R5)
Main Relief Valve
Main Pump
z
{
{
z
{
z
{
Pilot Pump
Pilot Relief Valve
Pilot Shut-Off Switch
Pilot Shut-Off Solenoid Valve
Pump 1 Control Solenoid
Valve
Pump 2 Control Solenoid
Valve
Pump 1 Regulator Pressure
Sensor
Pump 2 Regulator Pressure
Sensor
Pump 1 Delivery Pressure
Sensor
Pump 2 Delivery Pressure
Sensor
z
z
{
z
{
{
{
{
{
{
Refer to F-1.
Remarks
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently. In case more than one trouble occurs at the same time, find out all
faulty components while checking all suspected components in each trouble symptom.
T5-7-24
TROUBLESHOOTING / Troubleshooting B
A-4
Right travel is inoperable during
single travel operation. Single
bucket operation speed becomes slow. Boom is not raised
properly during arm level
crowding.
z
z
T5-7-25
TROUBLESHOOTING / Troubleshooting B
z : Related, required to check
{ : Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will
not be the direct cause of the trouble concerned.
Trouble
Symptom
A-5
Actuator does not stop even if
control lever is turned to neutral.
A-6
Actuator speed is faster than
normal.
Machine mistracks when travel
lever is operated at half stroke.
Precise control cannot be performed.
A-7
Fan rotation speed remains unchanged at maximum.
z
{
Parts
MC (Main Controller)
ECM
Monitor Unit
Main Pump
Main Pump Regulator
Fan Pump
Fan Pump Regulator
Pump 1 Delivery Pressure
Sensor
Pump 2 Delivery Pressure
Sensor
Pump 1 Regulator Pressure
Sensor
Pump 2 Regulator Pressure
Sensor
Pump 1 Control Solenoid
Valve
Pump 2 Control Solenoid
Valve
Fan Pump Control Solenoid
Valve
Pressure Sensor (Attachment)
Engine Control Dial
Air Conditioner Switch (Blower
Motor Relay)
Hydraulic Oil Temperature
Sensor
Intake Air Temperature Sensor
Boost Temperature Sensor
Coolant Temperature Sensor
Spool
Fan Motor
Fan Valve
Pilot Valve
Oil Cooler Bypass Check
Valve
Low-Pressure Relief Valve
Pilot Pump
z
z
z
z
z
z
z
z
z
{
{
{
{
{
z
Refer to A-2.
Remarks
T5-7-26
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently
In case more than one trouble occurs at
the same time, find out all faulty components while checking all suspected components in each trouble symptom.
A-8
Overheating occurs.
Fan rotation speed is slow.
A-9
Flow rate of pump2 is not reduced to specification when operating attachment.
A-10
Attachment operating speed is
too slow.
A-11
Overheating easily occurs when
operating breaker.
z
z
z
z
z
z
z
z
z
z
z
z
z
{
{
Refer to A-2 or A-3.
T5-7-27
TROUBLESHOOTING / Troubleshooting B
z : Related, required to check
{ : Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will
not be the direct cause of the trouble concerned.
F-1
All front attachment actuator
power is weak.
F-2
Even if power digging switch
is pushed, power does not
increase. Boom raise power is
weak when digging.
F-3
Some cylinder is inoperable
or speeds are slow.
Parts
MC
Pressure Sensor (Boom Raise)
Pressure Sensor (Boom Lower)
Pressure Sensor (Arm Roll-Out)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Bucket Roll-Out)
Pressure Sensor (Bucket Roll-In)
Pressure Sensor (Swing)
Pressure Sensor (Attachment)
Solenoid Valve Unit (SG)
Solenoid Valve Unit (SF)
Solenoid Valve Unit (SC)
Power Mode Switch
Boom Mode Selector Switch
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pump 1 Regulator Pressure Sensor
Pump 2 Regulator Pressure Sensor
Pump 1 Control Solenoid Valve
Pump 2 Control Solenoid Valve
Spool
Main Relief Valve
Overload Relief Valve
Boom Overload Relief Control Valve
Load Check Valve
Anti-Drift Valve
Boom Flow Rate Control Valve
Arm Flow Rate Control Valve
Boom Regenerative Valve
Arm Regenerative Valve
Bucket Regenerative Valve
Shockless Valve (Signal Control Valve)
Arm Flow Rate Control Valve Control
Spool
Shuttle Valve
Pilot Valve
Shockless Valve
Cylinder
z
z
z
{
z
z
{
Refer to A-1 or A-2.
Refer to A-3.
Remarks
T5-7-28
TROUBLESHOOTING / Troubleshooting B
In case more than one trouble occurs at
the same time, find out all faulty components while checking all suspected components in each trouble symptom.
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently
F-4
Arm speed or bucket speed is
slow during combined operation
of boom lower and arm or boom
lower and bucket.
F-5
Boom raise speed is slow during arm crowding operation
(during combined operation of
boom raise and arm roll-in)
Arm moves jerky.
F-6
Even if boom mode selector
switch is pushed, machine is
raised off ground.
F-7
When boom raise or arm
roll-out is operated, boom or
arm starts to move after slightly
moving downward.
z
z
{
{
{
{
z
z
z
z
z
z
z
z
z
{
z
{
z
{
{
{
{
z
Refer to A-3.
T5-7-29
TROUBLESHOOTING / Troubleshooting B
z : Related, required to check
{ : Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will
not be the direct cause of the trouble concerned.
Trouble
Symptom
F-8
Front attachment drifts remarkably.
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently
In case more than one trouble occurs at
the same time, find out all faulty components while checking all suspected components in each trouble symptom.
F-9
Front attachment speed is slow
during combined operation of
front attachment and swing.
Parts
MC (Main Controller)
Pressure Sensor (Boom Raise)
Pressure Sensor (Boom Lower)
Pressure Sensor (Arm Roll-Out)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Bucket Roll-Out)
Pressure Sensor (Bucket Roll-In)
Pressure Sensor (Swing)
Pressure Sensor (Auxiliary)
Solenoid Valve Unit (SG)
Solenoid Valve Unit (SF)
Solenoid Valve Unit (SC)
Power Mode Switch
Boom Mode Selector Switch
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pump 1 Regulator Pressure Sensor
Pump 2 Regulator Pressure Sensor
Pump 1 Control Solenoid Valve
Pump 2 Control Solenoid Valve
Spool
Main Relief Valve
Overload Relief Valve
Boom Overload Relief Control Valve
Load Check Valve
Anti-Drift Valve
Boom Flow Rate Control Valve
Arm Flow Rate Control Valve
Boom Regenerative Valve
Arm Regenerative Valve
Bucket Regenerative Valve
Shockless Valve (Signal Control
Valve)
Arm Flow Rate Control Valve Control
Spool
Shuttle Valve
Pilot Valve
Shockless Valve
Cylinder
z
{
{
{
{
{
{
z
{
z
{
z
{
z
{
z
Remarks
T5-7-30
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-31
TROUBLESHOOTING / Troubleshooting B
S-1
Swing is slow or unmoving.
S-2
Swing is fast.
When swing is operated fully,
swing speed is slow.
T-1
Both right and left tracks do
not rotate or rotate slowly.
Parts
MC (Main Controller)
Pressure Sensor (Swing)
Pressure Sensor (Right Travel)
Pressure Sensor (Left Travel)
Solenoid Valve Unit (SI)
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pump 1 Regulator Pressure Sensor
Pump 2 Regulator Pressure Sensor
Pump 1 Control Solenoid Valve
Pump 2 Control Solenoid Valve
Main Pump
Main Pump Regulator
Pilot Pump
Pilot Relief Valve
Spool
Main Relief Valve
Load Check Valve
Flow Combiner Valve
Pilot Valve
Swing Device
Travel Device
Center Joint
Flow Combiner Valve Control Spool
Swing Parking Brake Release Spool
Shuttle Valve
Travel Mode Switch
z
z
{
{
{
{
{
{
{
{
{
{
z
z
{
z
z
z
{
{
z
z
Refer to A-1 or A-2.
Remarks
T5-7-32
TROUBLESHOOTING / Troubleshooting B
T-3
T-4
T-2
One side track does not rotate Machine mistracks during com- Fast travel is inoperable. Travel
or rotates slowly. Machine mis- bined operation of travel and mode does not change from
tracks.
front attachment.
slow mode to fast mode.
{
{
{
z
{
{
{
{
{
{
{
z
{
{
{
{
z
z
z
z
z
z
z
z
{
z
In case either bucket or swing is
also slow, refer to A-3 or A-4.
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently
In case more than one trouble occurs at
the same time, find out all faulty components while checking all suspected components in each trouble symptom.
T5-7-33
TROUBLESHOOTING / Troubleshooting B
O-2
O-1
O-3
Wiper is inoperable or not re- Counterweight removal / in- Counterweight removal / intracted.
stallation device is not oper- stallation speed is fast.
ated or power is weak.
Precise operation cannot be
performed.
Parts
MC
Monitor Unit
Wiper Relay (R6)
Auto Lubrication Relay (R11)
Pressure Sensor (Counterweight)
Solenoid Valve Unit (SG)
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pump 1 Regulator Pressure Sensor
Pump 2 Regulator Pressure Sensor
Pump 1 Control Solenoid Valve
Pump 2 Control Solenoid Valve
Fan Pump Control Solenoid Valve
Auto Lubrication Device
Engine Oil Level Switch
Coolant Level Switch
Wiper/Washer Switch
Level Check Switch
Auto Lubrication Switch
Key Switch
Wiper Motor
Air Conditioner
Main Pump
Main Pump Regulator
Fan Pump
Pilot Pump
Pilot Relief Valve
Main Relief Valve
Pilot Valve
Counterweight Removal Device
Distribution Valve
z
z
z
z
{
{
{
{
{
{
z
{
{
{
{
{
z
Refer to A-1, F-1 or F-2.
Remarks
T5-7-34
{
z
TROUBLESHOOTING / Troubleshooting B
O-4
Auto lubrication is faulty.
z
{
O-5
Level check is faulty.
O-6
Air conditioner malfunction
z
z
z
z
{
{
z
z
z
Refer to T5-7-96.
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently
In case more than one trouble occurs at
the same time, find out all faulty components while checking all suspected components in each trouble symptom.
T5-7-35
TROUBLESHOOTING / Troubleshooting B
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter does not rotate.
IMPORTANT: As electric current from the key
switch is not routed to starter relay
with the pilot shut-off lever in
UNLOCK position, the starter does
not rotate. (Refer to Electrical System.)
YES
Switch starter cut relay
YES with other general relay.
Check if starter rotates.
Key switch: START
NO
Voltage: 24 V or more
Density: 1.26 or more
NO
NO
Battery Relay:
Key Switch:
Terminal A
T105-07-04-002
T5-7-36
T178-05-04-001
TROUBLESHOOTING / Troubleshooting B
NO Check if voltage at
terminal A in battery
relay is 24 V.
Disconnect connector
of starter relay.
Connect terminal S of
harness end of conYES nector to machine.
Check for continuity
between terminal #4 of
harness end of connector in starter cut
relay and machine.
Check if voltage at
YES terminal #2 of harness end of connector in starter cut
relay is 0 V.
Key switch: ON
NO
YES
NO
NO
Starter Relay
E
S
T183-05-04-003
T5-7-37
TROUBLESHOOTING / Troubleshooting B
E-2 Even if starter rotates, engine does not start.
YES
Connect terminal #5 of
harness end of connector in ECM main relay to
machine.
YES Disconnect connector in
ECM.
Check for continuity
between terminals #2
and #5 of harness end
of connector.
Connect terminal #1
of harness end of
connector in ECM
main relay to maYES
chine.
Check for continuity
between terminals
#21 and #40 of harness end of connector in ECM.
Open circuit in harness
between ECM main relay
NO and ECM.
Open circuit in harness
between key switch and
ECM main relay.
NO
Check if fuse #8 is
blown.
Connector ECM
#21
#24
#5
T183-05-04-003
T1GR-05-04-002
#40
T5-7-38
#2
TROUBLESHOOTING / Troubleshooting B
Check if voltage
between terminal
YES #24 of harness
end of connector
in ECM and machine is 24V.
Key switch: ON
Open circuit in harness
between key switch and
ECM.
NO
NO
NO
Connector ICF-C
Connector MC-B
#B16
B1
B8
12
T1GR-05-04-002
B19
B25
#C7
T5-7-39
TROUBLESHOOTING / Troubleshooting B
E-3 When engine control dial is fully rotated, engine stalls.
When engine control dial is fully rotated, engine speed becomes slow.
Trouble
Abnormal Sensor Voltage
CAN Communication Error
YES
Reference Page
T5-6-38
T5-6-39
Refer to Troubleshooting
A.
MC or ECM cannot
be selected on controller diagnosis by
Dr. ZX.
NO
T5-7-40
TROUBLESHOOTING / Troubleshooting B
E-4 Even if engine control dial is rotated, engine
speed remains unchanged.
Trouble
CAN Communication Error
Abnormal Engine Control Dial
Reference Page
T5-6-39
T5-6-60
YES
Check if fault code 11101-3 or
11101-4 is displayed.
Monitor engine control dial
angle (standard voltage) by
using Dr. ZX.
Check if voltage is normal.
Standard voltage
Slow idle position: 0.3 to 1.0 V
Fast idle position: 4.0 to 4.7 V
Monitor item:
EC dial angle
Possible to display by built-in
diagnosing system.
YES
NO
T5-7-41
Faulty MC.
NO
TROUBLESHOOTING / Troubleshooting B
E-5 Faulty HP mode
Trouble
CAN Communication Error
Abnormal Pump 1 Delivery Pressure Sensor
Abnormal Pump 2 Delivery Pressure Sensor
Abnormal Boom Raise Pilot Pressure Sensor
Abnormal Arm Roll-In Pilot Pressure Sensor
Reference Page
T5-6-39
T5-6-61
T5-6-62
T5-6-64
T5-6-65
operate HP mode. Therefore, if any of these sensors fails, HP mode becomes inoperable.
Pressure sensors (arm roll-in and boom raise)
and pump 1 and 2 delivery pressure sensors are
also engaged in the HP mode control. However, if
these sensors fail, other operating functions will
be also affected.
NO
NO
Faulty MC.
YES
Refer to Troubleshooting
A.
YES
T5-7-42
TROUBLESHOOTING / Troubleshooting B
Even if the power mode switch is not turned to HP
mode, HP mode is operable.
Related Fault Code
MC 11004
Trouble
CAN Communication Error
Reference Page
T5-6-39
YES
YES
NO
Faulty ECM.
T5-7-43
TROUBLESHOOTING / Troubleshooting B
E-6 Faulty E mode
Trouble
CAN Communication Error
Abnormal Pump 1 Delivery Pressure Sensor
Abnormal Pump 2 Delivery Pressure Sensor
Abnormal Pump 2 Regulator Pressure Sensor
Abnormal Pump 1 Regulator Pressure Sensor
Reference Page
T5-6-39
T5-6-61
T5-6-62
T5-6-81
T5-6-83
NO
NO
Faulty MC.
YES
Refer to Troubleshooting
A.
YES
T5-7-44
TROUBLESHOOTING / Troubleshooting B
Even if power mode switch is not turned to E mode,
engine speed decreases.
Trouble
CAN Communication Error
Reference Page
T5-6-39
NO
YES
Refer to Troubleshooting A.
T5-7-45
TROUBLESHOOTING / Troubleshooting B
E-7 Faulty auto-idle system
Trouble
CAN Communication Error
Abnormal Swing Pilot Pressure Sensor
Abnormal Boom Raise Pilot Pressure Sensor
Abnormal Arm Roll-In Pilot Pressure Sensor
Abnormal Right Travel Pilot Pressure Sensor
Abnormal Left Travel Pilot Pressure Sensor
Abnormal Arm Roll-Out Pilot Pressure Sensor
Abnormal Bucket Roll-Out Pilot Pressure Sensor
Abnormal Boom Lower Pilot Pressure Sensor
Abnormal Bucket Roll-In Pilot Pressure Sensor
Abnormal CAN
Reference Page
T5-6-39
T5-6-63
T5-6-64
T5-6-65
T5-6-80
T5-6-82
T5-6-84
T5-6-85
T5-6-86
T5-6-87
T5-6-28, 29
YES
Check if Auto-Idle is
displayed on monitor
unit.
Auto-idle switch: ON
NO
YES
Faulty MC.
NO
YES
NO
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
#B18
T5-7-46
TROUBLESHOOTING / Troubleshooting B
Even if auto-idle switch is turned OFF, auto-idle is
operable.
Related Fault Code
MC 11004
Trouble
CAN Communication Error
YES
Shorted circuit in
harness between MC
and auto-idle switch.
Disconnect connector
MC-B in MC and switch
panel connector.
Check for continuity between terminal #B13 of
harness end of connector
MC-B and machine.
Auto-idle switch: OFF
Reference Page
T5-6-39
Faulty MC.
NO
B1
B8
B19
B25
#B13
T5-7-47
TROUBLESHOOTING / Troubleshooting B
E-8 Even if key switch is turned OFF, engine
does not stop. (In case engine does not stop,
stop engine by pulling engine stop handle
located under seat stand. Then, begin inspection.)
YES
Check if voltage at
terminal #5 in key
switch is 24 V.
Key switch: OFF
NO
Disconnect
connector in ECM.
Check if voltage
between terminal #24
NO of harness end of
connector and
machine is o V.
Key switch: OFF
Shorted circuit in
harness between key
switch and ECM.
Faulty ECM.
YES
Key Switch:
ECM Connector
(Harness end)
#24
T1GR-05-04-002
T105-07-04-002
T5-7-48
TROUBLESHOOTING / Troubleshooting B
E-9 Engine speed does not increase even if attachment is operated in attachment mode.
Related Fault Code
MC 11004
Trouble
CAN Communication Error
Reference Page
T5-6-39
NO
Check if engine
speed increase /
decrease of corresponding attachment is set to Increase (+) as for
parameter change
in Dr. ZX.
NO
Monitor attachment
control pilot
pressure.
YES Check if pressure
varies in response
to lever stroke.
Monitor item: Att.
control pilot pressure
Possible to display
by built-in diagnosing
system
YES
T5-7-49
YES
Faulty MC.
NO
TROUBLESHOOTING / Troubleshooting B
E-10 When attachment mode is selected, engine
speed does not decrease.
Related Fault Code
MC 11004
Trouble
CAN Communication Error
Reference Page
T5-6-39
In case trouble symptoms E-1 to E-11 are recognized, perform the troubleshooting of these troubles first.
Refer to the pages for Attachment Operation
Speed Limit Control in the SYSTEM / Control
System group in the T/M (Operational Principle).
Check the wiring connections first.
YES
Faulty MC.
NO
Normal (set to
decrease (-).)
T5-7-50
TROUBLESHOOTING / Troubleshooting B
E-11 Engine stalls during operation under adverse condition such as at high altitude.
Related Fault Code
11004
11200
11202
MC 11400
11410
11992
11994
Trouble
CAN Communication Error
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pump 2 Control Solenoid Valve Circuit
Pump 1 Control Solenoid Valve Circuit
Pump 2 Regulator Pressure Sensor
Pump 1 Regulator Pressure Sensor
Reference Page
T5-6-39
T5-6-61
T5-6-62
T5-6-66
T5-6-70
T5-6-81
T5-6-83
NO
Faulty MC or faulty
adjustment of regulator.
Refer to Operational
Performance Test.
T5-7-51
TROUBLESHOOTING / Troubleshooting B
E-12 Engine is difficult to start at low temperature. (During cold weather or in cold districts, engine is difficult to start or does not
start even if pre-heated.)
Faulty sensor.
YES
Disconnect connector of
coolant temperature sensor.
Check if voltage at glow plug
is 20 to 24 V.
Faulty ECM.
YES
Key switch: ON
NO
Disconnect connector in
ECM. Connect terminal #10
of harness end of connector
to machine. Check if problem is corrected.
Connect to machine from
the back of connector by
using a clip with the connector connected.
NO
Resistance Check
Remove
the
copper
plate.
Specification: Below 10
Specification: 20 to 24 V
T105-07-04-006
T5-7-52
T105-07-04-007
TROUBLESHOOTING / Troubleshooting B
4
3
T1GR-05-04-002
NO
YES
Connect connector in
glow plug relay. Connect
terminal #4 of harness
end of connector to machine. Check if voltage at
glow plug is 20 to 24 V.
Key switch: ON
YES
Below 10
Disconnect connector in
glow plug relay.
Check if voltages at terminals #1 and #3 of harness
end of connector in glow
plug relay are 20 to 24 V.
If terminal #1 is 0 V, open
circuit in harness between glow plug relay
and battery. If terminal #3
is 0 V, open circuit in
harness between glow
plug relay and terminal M
in key switch.
Key switch: ON
NO
T5-7-53
TROUBLESHOOTING / Troubleshooting B
ALL ACTUATOR
SHOOTING
SYSTEM
TROUBLE-
YES
NO
NO
NO
Connector (Harness end of connector viewed from the open
side)
Pilot Shut-Off Solenoid Valve
Disconnect connector
of pilot shut-off solenoid
YES valve.
Check for continuity
between terminals #1
and #2 of solenoid
valve end of connector.
T183-05-04-010
NO
YES
T1J1-05-07-006
T5-7-54
YES
NO
TROUBLESHOOTING / Troubleshooting B
A-2 All actuator speeds are slow.
YES
NO
Check if same
symptom still appears after disassembling, cleaning,
and adjusting pilot
relief valve.
End.
NO
Refer to Engine
Troubleshooting
Manual.
YES
NO
T5-7-55
TROUBLESHOOTING / Troubleshooting B
A-3 Left travel
operation.
slow. Arm
crowding.
time.)
YES
Switch pump 2
Check
any fault
deliveryif pressure
codes are
withdispump
NO sensor
played.
1 delivery pressure sensor.
Check if symptom
is improved.
Faulty pump 2.
NO
NO
Monitor pump 2
regulator pressure.
Check if pressure
with control lever
in neutral is
changed to pressure when operating control lever.
Monitor item:
Pump 2 regulator
pressure
Possible to display by built-in
diagnosing system
Jack up left track
and fully operate
left travel control
lever.
Switch pump 2
regulator pressure
sensor with pump
1 regulator pressure sensor.
Check if symptom
is improved.
Left travel operation
YES
NO
T5-7-56
TROUBLESHOOTING / Troubleshooting B
A-4 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.)
YES
Switch pump 1
Check
any fault
deliveryif pressure
codes are
withdispump
NO sensor
played.
2 delivery pressure sensor.
Check if symptom
is improved.
Faulty pump 1.
NO
NO
Monitor pump 1
regulator pressure.
Check if pressure
with control lever
in neutral is
changed to pressure when operating control lever.
Monitor item:
Pump 1 regulator
pressure
Possible to display by built-in
diagnosing system
Jack up right
track and fully
operate right
travel control
lever.
Switch pump 1
regulator pressure
sensor with pump
2 regulator pressure sensor.
Check if symptom
is improved.
Right travel operation
YES
NO
T5-7-57
TROUBLESHOOTING / Troubleshooting B
A-5 Actuator does not stop even if control lever
is returned to neutral.
YES
T5-7-58
TROUBLESHOOTING / Troubleshooting B
A-7 Fan rotation speed remains unchanged at
maximum.
YES
Install a pressure
gauge to port Pr in
fan pump regulator.
When following conditions exist, check if
pressure is changed.
Air conditioner switch:
ON
Engine control dial:
SlowFast
NO
Port Pr
T1J1-05-07-001
T5-7-59
TROUBLESHOOTING / Troubleshooting B
A-8 Overheating occurs.
Fan rotation speed is slow.
Related Fault Code
11004
MC 11412
11901
ECM 110
Trouble
CAN Communication Error
Abnormal Fan Pump Control Solenoid Valve
Abnormal Hydraulic Oil Temperature Sensor
Abnormal Coolant Temperature Sensor
Reference Page
T5-6-39
T5-6-71
T5-6-73
T5-6-24, 25
YES
Disconnect connector
of fan control solenoid
valve.
Check if fan rotation
speed becomes fast.
YES
NO
Install a pressure
gauge to port Pr in
fan pump regulator.
Check if pressure at
port Pr is 3.9 MPa
2
(40 kgf/cm , 570 psi).
YES
NO
Measure drain
amount of fan motor.
Check if drain
amount is normal.
Faulty fan motor.
NO
Port Pr
T1J1-05-07-001
T5-7-60
TROUBLESHOOTING / Troubleshooting B
A-9 Flow rate of pump 2 is not reduced to specification when operating attachment.
Related Fault Code
11004
11400
MC
11918
11992
Trouble
CAN Communication Error
Abnormal Pump 2 Control Solenoid Valve
Work Mode Receive Error
Abnormal Pump 2 Regulator Pressure Sensor
Reference Page
T5-6-39
T5-6-66
T5-6-75, 76
T5-6-81
YES
Refer to Troubleshooting A.
YES
NO
Faulty MC.
NO
T5-7-61
TROUBLESHOOTING / Troubleshooting B
A-10 Attachment operating speed is too slow.
YES
Check if auxiliary
YES spool in control
valve is stuck or
bound.
Monitor ATT pilot
pressure.
Check if pressure is
within specification.
Monitor item:
Att. Control Pilot
Pressure
Possible to display
by built-in diagnosing
system
Engine control dial:
Fast
Control pedal: Full
stroke
NO
Faulty MC or faulty
monitor unit.
T5-7-62
TROUBLESHOOTING / Troubleshooting B
A-11 Overheating occurs easily when operating
breaker.
Related Fault Code
11410
MC 11918
11994
Trouble
Abnormal Pump 1 Control Solenoid Valve
Work Mode Receive Error
Abnormal Pump 1 Regulator Pressure Sensor
Reference Page
T5-6-70
T5-6-75, 76
T5-6-83
YES
Faulty MC.
NO
T5-7-63
TROUBLESHOOTING / Troubleshooting B
FRONT ATTACHMENT SYSTEM TROUBLESHOOTING
F-1 All front attachment actuator power is weak.
T5-7-64
TROUBLESHOOTING / Troubleshooting B
F-2 Even if power digging switch is pushed,
power does not increase.
Boom raise power is week when digging.
Related Fault Code
11302
MC
11404
Trouble
Abnormal Boom Raise Pilot Pressure Sensor
Abnormal Solenoid Valve Unit (SG)
Reference Page
T5-6-64
T5-6-68
Refer to the pages for the SYSTEM / Power Digging Control group in T/M (Operational Principle).
YES
Refer to Troubleshooting A.
NO
NO
YES
T5-7-65
YES
Faulty MC.
NO
TROUBLESHOOTING / Troubleshooting B
F-3 Some cylinders are inoperable or speeds are
slow.
NO
Monitor item:
Pump 1 flow control
NO
pressure, pump 2 flow
control pressure
Possible to display by
using built-in diagnosing
system
T5-7-66
TROUBLESHOOTING / Troubleshooting B
F-4 Arm speed or bucket speed is slow during
combined operation of boom lower and arm
or boom lower and bucket.
Related Fault Code
11303
11402
11995
MC
11997
11998
11999
Trouble
Abnormal Arm Roll-In Pilot Pressure Sensor
Abnormal Solenoid Valve Unit (SF)
Abnormal Arm Roll-Out Pilot Pressure Sensor
Abnormal Bucket Roll-Out Pilot Pressure Sensor
Abnormal Boom Lower Pilot Pressure Sensor
Abnormal Bucket Roll-In Pilot Pressure Sensor
Reference Page
T5-6-65
T5-6-67
T5-6-84
T5-6-85
T5-6-86
T5-6-87
YES
Refer to Troubleshooting A.
YES
NO
T5-7-67
NO
TROUBLESHOOTING / Troubleshooting B
F-5 Boom raise speed is slow during arm
crowding operation (during combined operation of boom raise and arm roll-in) Arm
moves jerky.
Install a pressure
gauge to port SK in
signal control valve.
YES Check if pressure is
approx. 3.9 MPa (40
2
kgf/cm , 570 psi).
Engine control dial:
Fast
Boom raise and
arm roll-in are relieved.
NO
Port SK
T1J1-05-07-002
T5-7-68
TROUBLESHOOTING / Troubleshooting B
F-6 Even if the boom mode selector switch is
pushed, machine is raised off ground.
Related Fault Code
MC 11989
Trouble
Abnormal Solenoid Valve Unit (SC)
Reference Page
T5-6-79
Refer to the pages for Boom Mode Selector Control in SYSTEM / Control System group in T/M
(Operational Principle).
Check the wiring connections first.
NO
Exchange boom mode
selector switch with level
NO check switch.
Check if system operates
properly.
Monitor boom mode
selector switch.
Check if ON is displayed.
Monitor item: Boom
mode SW
YES
NO
YES
NO
Faulty MC.
YES
#2
B1
#9
Faulty MC.
B8
T1J1-05-07-003
B19
T5-7-69
B25
TROUBLESHOOTING / Troubleshooting B
F-7 When boom raise or arm roll-out is operated,
boom or arm starts to move after moving
slightly downward.
NO
Check if excessive
YES cylinder internal leakage is found.
YES
T5-7-70
(B)
When the load check
valve is faulty:
(A)
T105-07-04-012
TROUBLESHOOTING / Troubleshooting B
F-8 Front attachment drifts remarkably.
YES
YES
Check if cylinder
drift is reduced
when pilot shut-off
valve is closed.
YES
NO
NO
Faulty corresponding
cylinder.
Faulty corresponding
control valve (damaged
spring or loose spool
end).
Faulty corresponding
overload relief valve.
3. Retract the arm cylinder and lift the bucket off the
ground. If oil flows out of the hose disconnected
pipe ends and the boom cylinders are retracted at
this time, oil leaks in the boom cylinders. In case
no oil flows out of the hose disconnected pipe
ends but the boom cylinders are retracted, oil
leaks in the control valve.
T5-7-71
TROUBLESHOOTING / Troubleshooting B
F-9 Front attachment speed is slow during combined operation of front attachment and
swing.
Related Fault Code
11200
11301
MC
11410
11994
Trouble
Abnormal Pump 1 Delivery Pressure Sensor
Abnormal Swing Pilot Pressure Sensor
Abnormal Pump 1 Control Solenoid Valve
Abnormal Pump 1 Regulator Pressure Sensor
Reference Page
T5-6-61
T5-6-63
T5-6-70
T5-6-83
YES
Refer to Troubleshooting A.
T5-7-72
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-73
TROUBLESHOOTING / Troubleshooting B
SWING SYSTEM TROUBLESHOOTING
S-1 Swing is slow or unmoving.
YES
Monitor secondary
pilot pressure.
Check if secondary
pilot pressure is
normal.
Specification: Refer to
Operational Performance Test.
Disassemble and clean
Monitor item: Swing
pilot valve.
NO Check if trouble occurs.
pilot pressure
Possible to display by
using built-in diagnosing
system
NO
YES
NO
Port SH
T1J1-05-07-005
T5-7-74
TROUBLESHOOTING / Troubleshooting B
YES
NO
YES
T5-7-75
TROUBLESHOOTING / Troubleshooting B
S-2 Swing is fast.
When swing is operated fully, swing speed is
slow.
Related Fault Code
MC 11301
Trouble
Abnormal Swing Pilot Pressure Sensor
Reference Page
T5-6-63
YES
Refer to Trouble
shooting A.
T5-7-76
TROUBLESHOOTING / Troubleshooting B
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Both right and left tracks do not rotate or
rotate slowly.
T5-7-77
TROUBLESHOOTING / Troubleshooting B
T-2 One side track does not rotate or rotates
slowly. Machine mistracks.
YES
Check if secondary
travel pilot pressure is
normal.
Monitor item: Travel
pilot pressure
Possible to display
by using built-in diagnosing system
NO
Check if symptom is
reversed when right
YES and left travel line
hoses are switched
each other at the top of
center joint.
Measurement: Refer to
Operational Performance Test section.
NO
Seal Location
2
3
3
Right Travel
(Reverse)
4
Left Travel
(Reverse)
4
5
Right Travel
(Forward)
Left Travel
(Forward)
6
7
7
and External oil leak
T5-7-78
T16J-03-07-001
TROUBLESHOOTING / Troubleshooting B
NO
YES
YES
Disassemble and
clean travel motor
counterbalance valve.
Check if same symptom occurs.
NO
YES
NO
NO
6
5
T1J1-05-07-004
1 - Drain
2 - Right Travel (Forward)
T5-7-79
TROUBLESHOOTING / Troubleshooting B
T-3 Machine mistracks during combined operation of travel and front attachment.
YES
NO
YES
NO
YES
Signal Control Valve
(Control Valve Side)
Port SL
T1J1-05-07-002
T5-7-80
TROUBLESHOOTING / Troubleshooting B
T-4 Fast travel is inoperable.
Travel mode does not change from slow
mode to fast mode.
Related Fault Code
11405
MC 11991
11993
Trouble
Abnormal Solenoid Valve Unit (SI)
Abnormal Right Travel Pilot Pressure Sensor
Abnormal Left Travel Pilot Pressure Sensor
Reference Page
T5-6-69
T5-6-80
T5-6-82
NO
YES
YES
NO
T5-7-81
TROUBLESHOOTING / Troubleshooting B
OTHER SYSTEM TROUBLESHOOTING
O-1 Wiper is inoperable or not retracted.
Checking Instructions
The wiper is driven by electric power routed via
the relay circuit controlled by the monitor assembly. In case the wiper is inoperable, first check the
wiper motor and links for any abnormality by using
an auxiliary electric power and the test harness.
If the front window is open, the wiper does not
operate. Check that the front window is securely
closed.
YES
Disconnect monitor A
connector in monitor unit.
Connect terminal #A2 of
YES
harness end of connector
to machine.
Disconnect wiper relay.
NO Check for continuity between terminal #2 of harness end of connector and
NO
machine.
Set Time
8 second
6 second
3 second
NO
Connector
Wiper Motor (Harness end)
T1V1-05-07-005
#A2
T183-05-05-001
T5-7-82
Monitor Unit
Monitor A Connector (Harness end)
NO
INT. Position
Slow
Middle
Fast
TROUBLESHOOTING / Troubleshooting B
Wiper Drive Circuit
Wiper Motor
Wiper Relay
Main
Window
Contact
Point
T5-7-83
T1V1-05-07-004
TROUBLESHOOTING / Troubleshooting B
O-2 Counterweight removal/installation device is
not operated or power is weak.
Related Fault Code
MC 11404
Trouble
Abnormal Solenoid Valve unit (SG)
Reference Page
T5-6-68
Refer to the page for Pump Control for Counterweight Removal and Installation in Control System
group/ SYSTEM in T/M (Operational Principle).
If other actuator is not operated or slow, the pilot
system may be faulty. Refer to A-1.
If power is weak, refer to F-1 and F-2.
Check the wiring connections first.
YES
NO
Monitor secondary
pilot pressure.
Check if secondary
pilot pressure is normal.
Monitor item: C/W
removal pilot pressure
Counterweight removal/installation operation
NO
Disconnect connector of
pressure sensor (counterweight).
NO Check if voltage at terminal #1 of harness end
of connector is 50.5 V.
Key switch: ON
Disconnect connector
D in MC.
Connect terminal #3 of
connector D to machine.
Check for continuity
YES between terminal #2 of
harness end of connector of pressure
sensor (counterweight)
and machine.
Refer to F-1 and F-2.
YES
MC
Connector MC-D
#D3
T1J1-05-06-001
T183-05-04-009
T5-7-84
TROUBLESHOOTING / Troubleshooting B
YES
YES
NO
NO
T5-7-85
TROUBLESHOOTING / Troubleshooting B
O-3 Counterweight removal/installation speed is
fast. Precise operation cannot be performed.
Related Fault Code
11200
11202
11400
MC
11410
11992
11994
Trouble
Abnormal Pump 1 Delivery Pressure Sensor
Abnormal Pump 2 Delivery Pressure Sensor
Abnormal Pump 2 Control Solenoid Valve
Abnormal Pump 1 Control Solenoid Valve
Abnormal Pump 2 Regulator Pressure Sensor
Abnormal Pump 1 Regulator Pressure Sensor
Reference Page
T5-6-61
T5-6-62
T5-6-66
T5-6-70
T5-6-81
T5-6-83
Refer to the page for Pump Control for Counterweight Removal and Installation in Control System group / SYSTEM in T/M (Operational Principle).
When operating counterweight removal / installation, flow rates of pumps 1 and 2 are minimum.
Therefore, if other actuator speed is fast, the
pump control may be faulty. Refer to A-6.
Check the wiring connections first.
NO
YES
Monitor secondary
pilot pressure.
Check if secondary
pilot pressure is normal.
NO
Faulty MC.
T1J1-05-06-001
T5-7-86
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-87
TROUBLESHOOTING / Troubleshooting B
O-4 Auto lubrication is faulty.
YES
YES
NO
Damaged lubrication
pipings on front attachment.
Check if grease pump
is operated.
Monitor lubrication
pump status.
Check if Comp. is
displayed.
Monitor item: Lubrication control output
Auto lubrication switch:
ON
NO
NO
YES
NO
YES
NO
#B3
B1
B8
T1J1-05-07-003
#9
B19
T5-7-88
B25
TROUBLESHOOTING / Troubleshooting B
Damaged lubrication
pipings between grease
pump and distribution
valve on upperstructure
(attached proximity
switch), or faulty distribution valve on upperstructure, or no grease.
YES
YES
NO
Disconnect connector in
grease pump.
Check if voltage at terminal
#2 of harness end of connector is 24 V.
Disconnect proximity
switch.
Check if voltage at terminal
#3 of harness end of connector is 24 V.
Key switch: ON
Auto lubrication switch: ON
NO
YES
NO
NO
Key switch: ON
Auto lubrication switch: ON
YES
T183-05-04-003
T5-7-89
TROUBLESHOOTING / Troubleshooting B
Even if auto lubrication time is over, auto lubrication
does not stop.
YES
Switch auto lubrication
relay (R11) with other
general relay. Check if
auto lubrication stops.
NO
YES
Faulty MC.
NO
Disconnect connector
MC-B in MC.
Check if auto lubrication
stops.
T5-7-90
TROUBLESHOOTING / Troubleshooting B
Procedure to fill up grease to lubrication pipe (air
bleed procedure)
2
5
4
T1J1-05-07-007
T5-7-91
TROUBLESHOOTING / Troubleshooting B
Filling up grease to boom lubrication pipe
1. Remove elbows (2, 3).
2. Install the nipple (J75482) to the port where elbows (2, 3) were removed.
3. Apply grease through the nipple by using a
grease gun.
4. When filling up grease to the port (2) side:
Check if grease comes out of adapter (1) in the
boom end and check for any leakage of grease
from the lubrication pipe.
5. When filling up grease to the port (3) side:
Check if grease is supplied to each pin and check
for any leakage of grease from distribution valve
(4) and the lubrication pipe.
6. Remove the nipple. Install elbows (2, 3).
Boom
1
A
T1J1-05-07-008
View A
4
T1J1-05-07-009
T5-7-92
TROUBLESHOOTING / Troubleshooting B
Filling up grease to arm lubrication pipe
B
5
T1J1-05-07-011
Arm
T1J1-05-07-010
T5-7-93
TROUBLESHOOTING / Troubleshooting B
O-5 Level check is faulty.
Trouble
Can Communication Error
Can Communication Error
Reference Page
T5-6-39
T5-6-97
YES
YES
NO
MC
MC-C Connector C
#C9
C1
C23
T183-05-04-010
T5-7-94
C10
C31
#C21
TROUBLESHOOTING / Troubleshooting B
Even if the level check switch is turned OFF, the
alarm (green or red) is displayed on the monitor
unit.
Related Fault Code
MC
11004
Monitor Unit 13308
Trouble
Can Communication Error
Can Communication Error
Reference Page
T5-6-39
T5-6-97
YES
YES
Connect disconnect
connector.
Disconnect connectors of
coolant level switch and
engine oil level switch.
Check if alarm disappears.
YES
NO
Disconnect connector
B in monitor unit.
Check if alarm disappears.
Disconnect connector
C in MC.
Check if alarm disappears.
NO
T5-7-95
TROUBLESHOOTING / Troubleshooting B
O-6 Malfunction of Air Conditioner
The air conditioner has a self-diagnosis function.
The self-diagnosis functions to:
Display Fault Codes
Change Displayed Fault Codes
Delete Fault Code
End Fault Code Display
Temperature
Control Switch
T5-7-96
LCD
M178-01-017
TROUBLESHOOTING / Troubleshooting B
Fault Code List
Location in Trouble
Abnormal circulation
air sensor
Fault
Code
E11
E12
Cause
Broken circuit in air circulation
sensor
Short-circuited circulation air
sensor
Broken circuit in fresh air sensor
Short-circuited fresh air sensor
E13
E14
Abnormal solar
radiation sensor
E18
E21
E22
Abnormal damper
E43
E44
E45
Water temperature
sensor
E15
E16
Abnormal refrigerant
E51
T5-7-97
Symptom
Y value (air flow-in temperature) cannot
be adjusted in response to the
set-temperature.
Operation is controlled under such circumstance as no fresh air sensor is provided.
Operation is controlled under such circumstance as no solar radiation sensor is
provided.
Operation is controlled under such circumstance as the evaporator temperature
is set to 10 C (50 F).
Corresponding damper servo becomes
inoperable.
TROUBLESHOOTING / Troubleshooting B
Change Displayed Fault Code
Temperature
Control Switch
LCD
M178-01-017
LCD
Circulation
Air Switch
Fresh Air
Switch
M178-01-017
T5-7-98
M178-01-017
TROUBLESHOOTING / Troubleshooting B
Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to the related post / after experiencing a problem with
your machines 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
Air Induction
Re-Circulation
Fresh Air Circulation
Control
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
<Check Result>
Symptom
Not turned ON
(1) Is problem reproducible ?
Not turned OFF
Reproducible
Others
Not
reproducible
Uncontrollable air temperature
(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
Before replacing the control amplifier, be sure to
Uncontrollable vent hole
check that the connectors are correctly connected
Symptom
Vent hole isnt 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
T5-7-99
TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Refrigerant pressure
in both high and
low-pressure sides is
low.
Insufficient
Cooling
Power
Refrigerant pressure
in low-pressure side
is high.
Refrigerant pressure in
high-pressure side is low.
Refrigerant pressure
in high-pressure side
is high.
Frost forms.
T5-7-100
TROUBLESHOOTING / Troubleshooting B
Gas leaks from pipe joints and/or parts.
Refill refrigerant.
Readjust or replace.
Replace.
Repair.
Excessive refrigerant.
T5-7-101
TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Case connection.
Louver resonance.
Fan contacts case, or foreign matter enters case.
Noise
Abnormal smell.
T5-7-102
TROUBLESHOOTING / Troubleshooting B
Repair or replace.
Remove foreign matter. Readjust fan motor location.
Slight noise is unavoidable.
Replace if loud.
Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.
Replace.
Repair or replace clutch. Re-tighten screws.
Repair or replace.
Re-adjust drive belt.
Replace.
Clean.
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.
T5-7-103
TROUBLESHOOTING / Troubleshooting B
Compressor
Compressor does not rotate.
Inoperable
cooling
system.
Check for oil and refrigerant leaks from parts other than
compressor and pipe joints by using gas detector.
Check for oil and refrigerant leaks from compressor (no
leaks from parts other than compressor) by using gas
detector.
(Refer to NOTE 1,
2 on page
Stain on exterior.
High-pressure side is
slightly low and
low-pressure side is high.
T5-7-104
TROUBLESHOOTING / Troubleshooting B
Seized clutch.
Replace.
Replace.
Oil and refrigerant leaks from front housing, and/or cylinder block joint.
Normal leaks from hoses.
Replace.
Charge
refrigerant.
No leaks (normal).
Excessive oil.
T5-7-105
TROUBLESHOOTING / Troubleshooting B
Compressor
Compressor rotation is abnormally draggy.
Overheating
is susceptible
to occur.
Trouble other than compressor.
Abnormal
noise
T5-7-106
TROUBLESHOOTING / Troubleshooting B
Replace.
Saggy belt.
Loose screws.
Broken valve.
Replace.
Blown gasket.
Abnormal internal noise.
Replace.
Loose screws.
NOTE:
1. Do not 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. 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 surface 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 0.5 MPa (5 kgf/cm2) or less. When the clutch is
turned OFF, the pressure difference between high-pressure side and low-pressure side will disappear within about 10 seconds.
T5-7-107
TROUBLESHOOTING / Troubleshooting B
WORK
NENTS
AFTER
REPLACING
COMPO-
T5-7-108
TROUBLESHOOTING / Troubleshooting B
CHARGE
AIR
REFRIGERANT
CONDITIONER
WITH
Necessity of Purging
Make sure to purge the air conditioner circuit with a
vacuum before charging with refrigerant (R134a)
because the following problems can arise if air or
other gases remain in the A/C circuit.
Air
W115-02-10-001
2. Metal corrosion:
If air remains in the air conditioner circuit, a
chemical reaction between refrigerant and
moisture in the air takes place, and as a result,
hydrochloric acid, that corrodes metals such as
aluminum, copper and iron, is produced.
Hydrochloric acid
corrodes metals if
moisture exists.
Hydrochloric Acid
W115-02-10-002
Metal Corrosion
Plugged Refrigerant
Flow
W115-02-10-003
Low Cooling
Efficiency
T5-7-109
TROUBLESHOOTING / Troubleshooting B
Purging Procedure
Gauge Manifold
Adapter
Low Pressure
Valve
Low Pressure
Charge Hose
High Pressure
Valve
High Pressure
Charge Hose
Center Pressure
Charge Hose
Vacuum Pump
(Parts
W115-02-10-005
Low Pressure
Side
S
Compressor
D
High Pressure
Side
T142-02-05-018
Fully Open
Fully Open
W115-02-10-005
T5-7-110
TROUBLESHOOTING / Troubleshooting B
IMPORTANT: If the pointer returns to 0, retighten
the line connections and perform
purging again.
Close
Close
In Operation
W115-02-10-005
Refrigerant
Container
W115-02-10-007
Loosen
Open
W115-02-10-007
T5-7-111
TROUBLESHOOTING / Troubleshooting B
IMPORTANT: Always stop the engine when
charging the air conditioner with
refrigerant. Do not position the
refrigerant container upside down
during charging operation. When
changing the refrigerant container
during charging operation, purge air
from the charge hose, as shown in
step 10. Charge the low pressure
side hose first.
6. Fully tighten the charge hose connection to the
gauge manifold. Open the high pressure valve
and refrigerant container valve to charge with
refrigerant (R134a).
Close the high pressure valve and refrigerant
container valve when the high pressure gauge
2
reading reaches 98 kPa (1 kgf/cm , 14 psi).
NOTE: Use warm water of 40 C (104 F) or less to
warm the refrigerant container to aid in
charging operation.
High
Pressure
Gauge
Tighten
Open
Open
W115-02-10-007
W115-02-10-008
T5-7-112
TROUBLESHOOTING / Troubleshooting B
8. Confirm that the high pressure and low pressure
valves in the gauge manifold and the refrigerant
container valve are closed.
Start the engine and operate the air conditioner.
Operating Conditions of the Air Conditioner:
Engine Speed : Slow Idle
Cab Window : Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum
Open
Open
W115-02-10-007
Close
T5-7-113
Close
W115-02-10-007
TROUBLESHOOTING / Troubleshooting B
IMPORTANT: If the air conditioner is operated with
very low refrigerant, a bad load will
be exerted on the compressor. If the
air conditioner is overcharged with
refrigerant, cooling efficiency will
lower and abnormal high pressure
will arise in the air conditioner circuit,
causing danger.
12. Start the engine and operate the air-conditioner
again.
Observe the sight glass of the receiver tank and
check refrigerant quantity.
Operating Conditions of the Air Conditioner:
Engine Speed : Slow Idle
Cab Window : Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum
Sight Glass
Receiver Tank
W115-02-10-009
T5-7-114
TROUBLESHOOTING / Troubleshooting B
Relation between Refrigerant Quantity and Refrigerant
Flow in Sight Glass:
Refrigerant
Quantity
(approx. 1 mm after)
Adequate
W115-02-10-016
Overcharged
W115-02-10-017
Bubbles are seen continuously after the air conditioner is turned ON.
Not Enough
W115-02-10-018
W115-02-10-019
115-02-10-021
Milk white:
Refrigerant flow shows thin milk white
as oil and refrigerant are separated.
CAUTION: Wait until the high-pressure-side
pressure drops to less than 980 kPa (10
2
kgf/cm , 142 psi) before attempting to disconnect the high-pressure-side charge hose.
Otherwise, refrigerant and compressor oil
may spout.
13. After checking refrigerant quantity, disconnect the
low-pressure-side charge hose first. Wait for the
high-pressure-side pressure to drop to less than
2
980 kPa (10 kgf/cm , 142 psi). Disconnect the
high-pressure-side charge hose.
NOTE: Do not discharge refrigerant in the charge
hose in order not to discharge refrigerant
into the atmosphere for the environmental
protection.
T5-7-115
TROUBLESHOOTING / Troubleshooting B
Warm-up Operation
After charting the air conditioner, carry out warm-up
operation five minute to lubricate system with
compressor oil.
Operating Conditions of the Air Conditioner:
Engine Speed : Slow Idle
Cab Window : Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum
Inspection
After warm-up operation, carry out gas leak check
and performance check.
CAUTION: Refrigerant
will
produce
poisonous material if exposed to heat of 1000
C (1800 F) or more. Never bring refrigerant
close to a fire.
1. Check the air conditioner for gas leaks by using a
leak tester.
Perform
checking
under
well-ventilated
conditions.
Thoroughly wipe off dust from the charge hose
connections of the compressor.
Pay special attention to check the line
connections.
If any gas leaks are found, retighten the line
connections.
2. Performance Check
Carry out performance check of the air
conditioner after checking each air conditioner
component.
Check each component for abnormalities.
Carry out ON-OFF check of the compressor
clutch.
Check compressor fan belt tension.
Check coolant level in the radiator.
Operate the air conditioner and check the
performance.
Leak Tester
W115-02-10-013
Retighten Line
Connection
W115-02-10-014
T5-7-116
TROUBLESHOOTING / Troubleshooting B
3. The checklist before the summer season is as
follows:
Check each air conditioner component for
abnormalities.
Check the line connections for oil leaks.
Check refrigerant quantity.
Check the engine cooling circuit.
Check belts for wear. Replace if necessary.
4. Off-Season Maintenance
During off-season, operate the idler pulley and
compressor at least once a month for a short time
in order to check for any abnormal sounds.
Do not remove the compressor belts during
off-season. Operate the compressor occasionally
at slow speed for 5 to 10 minutes with the belt
slightly loosened in order to lubricate the machine
parts.
T5-7-117
TROUBLESHOOTING / Troubleshooting B
EXCHANGE INSPECTION
Exchange inspection method is a troubleshooting
method to find the trouble location by exchanging the
suspected part / component with another part / component having identical characteristics.
Many sensors and solenoid valves used on this machine are identical. Therefore, using this switch-check
method, faulty part / component, and/or harness can
be easily found.
Example: Abnormal pump 1 delivery pressure sensor
(Fault code: 11200)
Check Method:
1. Switch connector of two delivery pressure sensors.
2. Retry troubleshooting.
Result:
In case the pump 2 delivery pressure sensor is abnormal (fault code 11202), the pump 1 delivery pressure sensor is considered to be faulty.
In case the pump 1 delivery pressure sensor is abnormal (fault code 11200), the pump 1 delivery pressure sensor harness is considered to be faulty.
Pump 1 Delivery
Pressure Sensor
Pump 2 Delivery
Pressure Sensor
T1J1-05-07-012
T5-7-118
TROUBLESHOOTING / Troubleshooting B
Applicability of Switch-Check Method
Fault Code
11000-2
11001-2
11002-2
11003-3
11004-2
11101-3
11101-4
11200-3
11200-4
11202-3
11202-4
11301-3
11301-4
11302-3
11302-4
11303-3
11303-4
11400-3
11400-4
11402-3
11402-4
11404-3
11404-4
11405-3
11405-4
Trouble
Abnormal EEPROM
Abnormal RAM
Abnormal A/D Converter
Abnormal Sensor Voltage
CAN Communication Error
EC Dial sensor Circuit High Input
EC Dial sensor Circuit Low Input
Pump 1Delivery Pressure Sensor Circuit High Input
Pump 1 Delivery Pressure Sensor Circuit Low Input
Pump 2 Delivery Pressure Sensor Circuit High Input
Pump 2 Delivery Pressure Sensor Circuit Low Input
Swing Pilot Pressure Sensor Circuit High Input
Swing Pilot Pressure Sensor Circuit Low Input
Boom Raise Pilot Pressure Sensor Circuit High Input
Boom Raise Pilot Pressure Sensor Circuit Low Input
Arm Roll-in Pilot Pressure Sensor Circuit High Input
Arm Roll-in Pilot Pressure Sensor Circuit Low Input
Pump 2 Regulator Valve FB High Current
Pump 2 Regulator Valve FB Low Current
Boom Flow Control Valve FB High Current
Boom Flow Control Valve FB Low Current
Power Boost P/S Valve FB High Current
Power Boost P/S Valve FB Low Current
Travel Swash Angle P/S Valve FB High Current
Travel Swash Angle P/S Valve FB Low Current
T5-7-119
Applicability
Not Applicable
Not Applicable
Not Applicable
Applicable (Harness / Sensor)
TROUBLESHOOTING / Troubleshooting B
Fault Code
11410-3
11410-4
11412-3
11412-4
11802-3
11802-4
11901-3
11901-4
11910-2
11911-2
11914-2
11918-2
11920-2
11976-3
11976-4
11977-3
11977-4
11980-3
11980-4
11981-3
11981-4
11982-3
11982-4
11983-2
11984-2
11989-3
11989-4
Trouble
Pump 1 Regulator Valve FB High Current
Pump 1 Regulator Valve FB Low Current
Hyd. Fan P/S Valve FB High Current
Hyd. Fan P/S Valve FB Low Current
Boom Bottom Pressure Sensor Circuit High Input
Boom Bottom Pressure Sensor Circuit Low Input
Hyd. Oil Temp Sensor Circuit High Input
Hyd. Oil Temp Sensor Circuit Low Input
Actual Engine Speed Receive Error
Security Signal Receive Error
Radiator Water Temp Receive Error
Work Mode Receive Error
Fuel Flaw Receive Error
Auxiliary Valve 2 FB High Current
Auxiliary Valve 2 FB Low Current
Auxiliary Valve 1 FB High Current
Auxiliary Valve 1 FB Low Current
ATT Relief Change Valve FB High Current
ATT Relief Change Valve FB Low Current
Fan Reverse Valve 2 FB High Current
Fan Reverse Valve 2 FB Low Current
Fan Reverse Valve 1 FB High Current
Fan Reverse Valve 1 FB Low Current
Intake Air Temperature Receive Error
Boost Temperature Receive Error
Boom Mode Control Valve FB High Current
Boom Mode Control Valve FB Low Current
T5-7-120
Applicability
Applicable (Harness / Solenoid Valve)
Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable
Not Applicable
Applicable (Harness / Solenoid Valve)
TROUBLESHOOTING / Troubleshooting B
Fault Code
11991-3
11991-4
11992-3
11992-4
11993-3
11993-4
11994-3
11994-4
11995-3
11995-4
11997-3
11997-4
11998-3
11998-4
11999-3
11999-4
Trouble
Right Travel Pilot Pressure Sensor Circuit High Input
Right Travel Pilot Pressure Sensor Circuit Low Input
Pump 2 Regulator Pressure Sensor Circuit High Input
Pump 2 Regulator Pressure Sensor Circuit Low Input
Left Travel Pilot Pressure Sensor Circuit High Input
Left Travel Pilot Pressure Sensor Circuit Low Input
Pump 1 Regulator Pressure Sensor Circuit High Input
Pump 1 Regulator Pressure Sensor Circuit Low Input
Arm Roll-Out Pilot Pressure Sensor Circuit High Input
Arm Roll-Out Pilot Pressure Sensor Circuit Low Input
Bucket Roll-Out Pilot Pressure Sensor Circuit High Input
Bucket Roll-Out Pilot Pressure Sensor Circuit Low Input
Boom Lowering Pilot Pressure Sensor Circuit High Input
Boom Lowering Pilot Pressure Sensor Circuit Low Input
Bucket Roll-In Pilot Pressure Sensor Circuit High Input
Bucket Roll-In Pilot Pressure Sensor Circuit Low Input
T5-7-121
Applicability
Applicable (Harness / Sensor)
Applicable (Harness / Sensor)
Applicable (Harness / Sensor)
Applicable (Harness / Sensor)
Applicable (Harness / Sensor)
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-7-122
Code
R
L
Or
Y
Br
Gr
Color
Red
Blue
Orange
Yellow
Brown
Gray
Code
W
G
Lg
B
P
V
Color
White
Green
Light green
Black
Pink
Violet
T5-8-1
T5-8-2
Right
Wrong
T107-07-06-001
Right
Rust
Wrong
(Deformation)
Wrong
(Separation)
T107-07-06-002
Tester Probe
FOR
DISCONNECTING
T107-04-05-003
T1J1-05-08-003
T5-8-3
T5-8-4
20
30
40
19
29
39
18
17
16
15
14
13
12
11
38
28
27
26
37
36
25
35
24
23
34
33
22
32
21
31
M178-07-034
Fuse
No.
1
2
Capacity
Connected to
20 A
10 A
Light Relay 2
Wiper Relay, Washer Relay,
Wiper Motor
Heater (Air Conditioner Unit)
Pilot Shut-Off Relay, Pilot
Shut-Off Solenoid Valve, MC
Solenoid Valve Power
Optional 1, Attachment Power,
Travel Alarm (Optional)
Optional 2
Electronic Grease Gun
ECM Main Relay
Radio (Backup Power), Security Horn, Security Horn Relay
3
4
20 A
10 A
5A
6
7
8
9
10 A
10 A
30 A
5A
10
11
12
13
14
15
16
17
18
5A
10 A
5A
10 A
15 A
10 A
5A
5A
5A
19
20
5A
10 A
M178-07-034
Fuse
No.
21
22
Capacity
Connected to
10 A
10 A
23
24
10 A
10 A
25
5A
Immobilizer (Optional)
26
27
28
29
5A
5A
20 A
30
31
32
33
34
35
36
37
38
10 A
10 A
10 A
10 A
10 A
-
39
40
T5-8-5
Fusible Link
Inspection
1. Visually check if fusible links have blown.
Replacement
1. Remove the negative cable from the battery.
2. Push (to unlock) and pull to disconnect fusible
link connector. Replace the fusible link.
3. Reconnect the negative cable to the battery.
M1J1-07-015
Battery Relay
Fusible Link
T111-04-05-015
To Battery Relay
T162-05-06-005
T5-8-6
Monitor Unit
Alternator Alarm
T5-8-7
T1J1-05-01-007
Connector (L, R)
T16J-05-06-001
Connect to
the vehicle
frame.
Connect to
the vehicle
frame.
Short-circuit
between the
harness and
the vehicle
frame.
T107-07-05-003
T5-8-8
A
B
C
a
b
c
Second short-circuit
T107-07-05-004
a
b
c
T107-07-05-005
T5-8-9
AND
CURRENT
MEASURE-
Turn key switch ON so that the specified voltage (current) is supplied to the location to be measured. Judge
if the circuit is normal by evaluating whether the
measured voltage (current) matches the specification.
24-Volt Circuit
Start checking the circuit in order up to the location to be measured from either power source or
actuator side. Thereby, the faulty location in the
circuit will be found.
Black Probe (Negative) of Tester:
To ground to the vehicle frame
Red Probe (Positive) of Tester:
To touch the location to be measured
Engine
Power Source
Circuit
Stopped
Stopped
Stopped
Stopped
Stopped
Stopped
Preheat Circuit
Stopped
Stopped
Charging Circuit
Fast Speed
Key Switch
Location to be Measured
Specification
OFF
OFF
OFF
OFF
OFF
OFF
10 to 12.5 V
10 to 12.5 V
20 to 25 V
20 to 25 V
20 to 25 V
6 mA
ON or START
ON or START
20 to 25 V
20 to 25 V
ON
26 to 30 V
Fast Speed
ON
Fast Speed
ON
Fast Speed
Fast Speed
ON
ON
ON
ON
ON
ON
26 to 30 V
13 to 30 V
26 to 30 V
26 to 30 V
ON
ON
ON
ON
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
Surge Voltage
Prevention Circuit
Idle Speed
Idle Speed
Idle Speed
Idle Speed
Accessory Circuit
Stopped
Stopped
Stopped
Stopped
NOTE: *: Before measurement, disconnect the negative cable from the battery.
T5-8-10
26 to 30 V
26 to 30 V
13 to 30 V
13 to 30 V
7
Glow
Plug
Key Switch
Glow Plug
Relay
Fuse
Box
Battery Relay
10
Battery
17
Starter
Relay
13
Load Damp
Relay
16 15
14
11
Alternator
C7
Monitor
Unit
T1J1-05-08-002
12
T5-8-11
Key Switch
START
START
START
START
START
START
START
START
START
START
START
START
START
START
START
Location to be Measured
Between (18) and Ground: Key Switch
Between (19) and Ground: Battery Relay (Coil)
Between (20) and Ground: Battery Relay (Switch)
Between (21) and Ground: Starter (B)
Between (22) and Ground: Starter (C)
Between (23) and Ground: Starter Relay (S)
Between (24) and Ground: Starter Cut Relay
Between (25) and Ground: Fuse Box
Between (26) and Ground: Fuse Box
Between (27) and Ground: ICF (C7)
Between (28) and Ground: Monitor Unit (A7)
Between (29) and Ground: MC (B16)
Between (30) and Ground: ECM (1-24)
Between (31) and Ground: ECM Main Relay
Between (32) and Ground: ECM Main Relay
T5-8-12
Specification
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
5V
20 to 25 V
Battery
Relay
Starter Cut
Relay
20
25
19
26
Battery
23
ECM Main
Relay
24
Starter
Relay
32
31
21
Starter
22
MC
ICF
Monitor Unit
C7
A7
B16
ECM
V24
T1J1-05-08-002
29
28
T5-8-13
27
30
Key Switch
ON
ON
ON
ON
ON
Location to be Measured
Between (33) and Ground: Fuse Box
Between (34) and Ground: Pilot Shut-Off Relay
Between (35) and Ground: Pilot Shut-Off Solenoid Valve
Between (36) and Ground: Pilot Shut-Off Relay
Between (37) and Ground: Security Relay
T5-8-14
Specification
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
Key Switch
37
Battery
Relay
33
Fuse
Box
Battery
Security
Relay
Pilot Shut-Off
Solenoid Valve
35
Pilot Shut-Off
Switch
Pilot
Shut-Off
Relay
36
34
T1J1-05-08-002
T5-8-15
Signal or
Ground
Power
Source
1
Two Polarities
frame
Disconnect the connector with the key switch OFF.
Measure voltage between terminal #1 on the
machine harness end connector and the vehicle
frame (ground).
Key switch: ON
Tester black terminal (negative):
T107-07-05-006
Evaluation:
If the measuring voltage is within 50.5 volts, the
circuit up to terminal #1 is normal.
Power
Source Signal Ground
1
2
3
Three Polarities
T107-07-05-007
Two Polarities
1
Key switch: ON
Tester black terminal (negative):
Connected to the ground terminal
(terminal #2 or #3)
Tester red terminal (positive):
Connected to terminal #1
T107-07-05-008
Evaluation:
If the measured voltage is within 50.5 volt, the
circuit up to terminal #1 or the ground terminal
(terminal #2 or #3) is normal.
Three Polarities
1
T107-07-05-009
T5-8-16
Two Polarities
Turn the key switch OFF. Disconnect the sensor connector. Turn the key switch ON. Connect terminal #1
(power source) of machine harness end connector to
terminal #2 (signal). (Power voltage is used as a false
signal.) Check this state by using the monitor function
of Dr. ZX. When the maximum value is displayed, MC
and the circuit up to the machine harness end connector are normal. If ON is displayed, the pressure
switch circuits are normal.
IMPORTANT: Do not connect terminal #1 or #2 to
terminal #3 or to the vehicle frame
(ground)
when
checking
a
three-polarity connector.
NOTE: Some kinds of sensors can be monitored
by the service menu of monitor (the built-in
diagnosing system).
Connect
T107-07-05-010
Three Polarities
(Pressure Sensor)
(Pump Delivery Pressure Sensor)
(Pump Regulator Pressure Sensor)
(Boom Bottom Pressure Sensor)
Connect
T107-07-05-011
T5-8-17
To Location to be Measured.
T5-8-18
To Ground
T107-07-05-012
MEMO
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MODEL:
PUBLICATION NO.:
YOUR NAME:
DATE:
FAX:
PAGE NO.:
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