TROUBLESHOOTING [ID The followings explain how to troubleshoot when message does not go away even though an appropriate procedure was performed according to the check point on the message, Problem Message Display ‘Symptom of problem Ne FUEL REFILL Message remains even after reflling fuel 1 REFILLCOOLANT —_ | Message remains even atterrefiling coolant, 2 LOW OIL PRESSURE Message remains even after refiling the engine oll| Message remains even the hydraulic oll temperature OVER HEAT is 84(] or loss, and engine coolant tomperature is| 4 92] or less. BATTERY CHARGE | Message does not go away. 5 ELECTRICAL SYSTEM | Message does not go away. 6 PROBLEM (2D) The followings explain how to troubleshoot when the machine does not funetion nor- mally without message being displayed on the screen, 1. Engine control related ‘SYMPTOM OF PROBLEMS PROBLEM NO. ves ENGINE DOESNOT START ELECTRICAL SYSTEM PROBLEMIS | REFER TO INDICATED ON THE MONTTOR, PEPER TO o > REFERTO PROBLEM NO.7 62TROUBLESHOOTING Inspections Prior to Troubleshooting Item Criterion Procedure ‘CHECK ITEMS FOR OPERATION LUBRICANTS / COOLANT 1. Check the fuel level (Check the contaminant in the fuel Check the oil level Check the oil strainer Check the engine oil level (Oil evel in pan) 2 3. 4 5. Check lubrication on each reduction gear 6. 7. Check the coolant level a Check for clogging on the dust indicator Refill with ol Clean and drain Refill lean and drain ‘Add oi ‘Add oi ‘Add coolant Clean or replace ELECTRICAL DEVICES 98, Check ifthe wires on the battery terminals are loos- enor corroded, 10,Check if the wiring on the alternator terminals are loosen or corroded. 11. Check if the wiring on the starter terminals are loos- enor corroded, Tightening or replacement Tightening or replacement Tightening or replacement 21,Check alternator voltage (with running engine 1/2 trl fms) ce EY Tame S| ay SC pac (When turning ON / OFF starter SW.) 63TROUBLESHOOTING Procedure of Troubleshooting Gi When a user contacts for repairs or troubles, the {following information are essential to ask. a. User name . Machine model Serial No, ¢. Working site, etc. | T Faulty smooth operation? Faulty monitor display? LiMessage related 1 Engine related Bar graph About smooth related ‘operation GlUnderstand the trouble summary during the ‘communication withthe user. a, Situations of problems . Specific description of working condition when problem occurred ©. Working environment d. Repair history, maintenance description. Gi Prepare required tools. Crimp pliers (for plug terminal, for round shape terminal) Nipper Plug terminal (For connection)* * AJ wires containing pins for connectors i Goo straight to the working site, check the prob- lem reproduction and self—test display. ‘a, Operate each working function to examine the problems, bb. Check the self-test display. i After reviewing the results of inspections prior to troubleshooting, identify the problems and con- duct temporary repairs. 1. Check items for starting operation b. Other check items 64 preTROUBLESHOOTING How to Use the Flow Chart (10 Problem No. and problem symptoms Above each flow chart, problem No. and problem symptoms are described. Problem No, Problem symptom Message remains even after refling fuel 2 Message remains even after adding coolant (120) About check items prior to operation Check the "Inspections Prior to Troubleshooting List” hefore trying to find the cause. (30 Procedure [After checking or measuring items described in a box, according to the results, choose YES or NO and go to the next box. ithe branch description for YES or NO is directly related to the cause of the problem as a result of checking or measuring, refer to the cause description and perform the troubleshooting procedures shown in the right. [inspection / measurement / judgment criteria are described in a box. Select YES should be chosen if the criteria or questions are met to the situation; Select NO if the they are not met. [Under a box, necessary preparation work, operation methods, judgment criteria are described, These must be read carefully before starting inspection and measurement and follow the procedures starting step (1) since negligent preparation work or wrong operation methods may eause damage to the machine. (DAD Wire color Refer to the table below for the wire colors of the measuring points for trouble shooting. (Refer to the following pages for the connector No.) Wire color chart, smb |B Dw pe PP py pe gmat a | yt | s >. | car | rea | vorow | Ute T S| ous | Gray ab indicates the color b stripe on the color a foundation wire. Example) BR: Red stripe on black foundation. (050) Always turn OFF the key switch before connecting or disconnecting the connectors. preTROUBLESHOOTING Fuel Refill Problem symptom (Problem No.1) (Message remains even after refilling fuel Fe sev SHITEH OFF mT Keyswincston xy SWIneH OFF seat reaehecrren xo mans [Bebe Rafer toh ale sow othe et sensor stekeon. yg [ Pasonoe th nner of Na] (Ground fel neo Jeonnector esiance Note: All bar graph lights are off when circuit disconnection occurs. Resistance between GL and BG Monitor [f Refilthe fuel | 2 3 4 5 8 7 8 Pepe) | 800075 | 7561 | 1C47 | 477197 | 377190 | sors24 | 2ari19 | 19C}10 66TROUBLESHOOTING Refill Cooling water Problem symptom (Problem No.2) [Message remains even after refilling coolant. Ge ReplaceTROUBLESHOOTING Low Engine Oil Pressure Problem symptom (Problem No.3) (Message remains even after refilling engine oil correctly. eS 68TROUBLESHOOTING Over Heat Problem symptom (Problem No.4) (Message remains even the hydraulic oil temperature is 98[] or less, and engine cool- ant temperature is 105C] or less. Precautions 1. Cheek if the bar graph of water temperature or oil temperature shows eight, seales. Ea : nag § tere a Eas a ‘Teron ar anh a wer tore [eee (wate) to measure The xo befcivotherno= | Replace seasoe YRS | and CNAD to meneure he resistance nad comnectionot | Cian the s ‘coer |g YS | of CNT and CNAO to mes: cioan the cetera utonmaim | Yes JeNTand CNAO. | GRAD connec Note: All bar graph lights are off when circuit disconnection occurs. 69 EOnECIE]TROUBLESHOOTING TROUBLESHOOTING cause [procepure 2) Oil temp bar graph lights the vight scales. Besnsoreetie | no setcomecinar [oan 10 hurrt the eta Uhethermo= eee [teria on en oa Note: All bar graph lights are off when circuit disconnection occurs. Resistance value of the sensor Note:Resistance value varies with the temperature, Unit : KC Water temperature | Water temperature | Oiltemperature (Oil temperature) sensor sensor 200 6.08 245 300 4.24 1.66 400 3.02, 1.45 500 2.18 081 600 161 081 700 1.19 0.43) 800 0.91 0.92. 70TROUBLESHOOTING Alternator Problem symptom (Problem No.5) Message does not go away. fla Trevor sane = | . = ame ot Sua io = * mdm § | prnses fest! f sth ‘mounasioonna case rmoceoone ournetroesoer |_NO___| ftiun te vatagesetwec fe [NO SoreceutotLe® | a. wie or nutcce fain meas, [St . v0 Seen a preTROUBLESHOOTING Electrical Problems Problem symptom (Problem No.6) "sno eaey pg j cunaccrn _|| ae Maa a xd | es eiectaomaayenc, 77 cw wsTIOWNoD ENGINE [ENGINE CONTROLLER m ATROUBLESHOOTING (Chek the trouble anti by src suport teabeshocting Key Sith Os 03 dilay 4 082 lay pes No ves ToC Menge nay by dsonnetingslenidvalvgconestar, PS ‘Mosengs esa by Aonnetng ONDA enna PE TDC seror sna) (a2 arden Somes ore Replace Replace 73 preTROUBLESHOOTING Problem symptom (Problem No.7) [Engine does not start even though message, "Electrical system problem”, is not displayed. Precautions (check there is no abnormality in the engine and fuel system, (Fuses are not broken, (starter motor runs and engine cranks. | oem | onze oxo sroP Moro EMERGENCY ows re ay fs . 7 # xo Checle ime Sota LJ motenirasrass are | ot Vegeta mmm | nee | down rey rely. I ves Dep 4 pre