Hitachi EX1200-5 Hydraulic Excavator Technical Troubleshooting Manual

TTLA-435-EX

PERFORMANCE CHECK TROUBLESHOOTING

Technical Training Center

SECTION 4

OPERATIONAL PERFORMANCE TEST

CONTENTSÄĄ Group 1 Introduction

Group 4 Component Test

Operational Performance Tests ................T4-1-1

Primary Pilot Pressure ..............................T4-4-1

Preparation for Performance Tests ...........T4-1-2

Secondary Pilot Pressure .........................T4-4-3

Solenoid Valve Set Pressure ....................T4-4-4

Group 2 Engine Test

Main Pump Delivery Pressure...................T4-4-7

Engine Speed ...........................................T4-2-1

Main Relief Valve Set Pressure.................T4-4-8

Overload Relief Valve Set Pressure ........T4-4-12

Group 3 Excavator Test

Main Pump Flow Rate Measurement ......T4-4-16

Travel Speed ............................................T4-3-1

Oil Cooler Fan Motor Drive Pump

Track Revolution Speed ...........................T4-3-2

Flow Rate Measurement .......................T4-4-22

Mistrack ...................................................T4-3-3

Swing Motor Drainage ............................T4-4-28

Travel Parking Function............................T4-3-4

Travel Motor Drainage ............................T4-4-30

Swing Speed ............................................T4-3-5

Swing Function Drift .................................T4-3-6

Group 5 Standard

Swing Motor Leakage ...............................T4-3-8

Operational Performance Standard...........T4-5-1

Maximum Swingable Slant Angle ..............T4-3-9

Main Pump P-Q Diagram..........................T4-5-4

Swing Bearing Play ................................T4-3-10

Oil Cooler Fan Motor Drive Pump

Hydraulic Cylinder Cycle Time ................T4-3-12

P-Q Diagram ..........................................T4-5-4

Cylinder Drift ..........................................T4-3-14

Injection Pump .........................................T4-5-5

Control Lever Operating Force ...............T4-3-15

Control Lever Stroke...............................T4-3-16 Boom Raise/Swing Combined Operation Check ..................................T4-3-17

183T-4-1

(Blank)

183T-4-2

OPERATIONAL PERFORMANCE TEST / Introduction PERATIONAL PERFORMANCE TESTS Use operational performance test procedure to quantitatively check all system and functions on the machine.

Purpose of Performance Tests 1. To comprehensively evaluate each operational function by comparing the performance test data with the standard values.

2. According to the evaluation results, repair, adjust, or replace parts or components as necessary to restore the machine’s performance to the desired standard.

3. To economically operate the machine under optimal conditions.

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.

The machine performance does not always deteriorate as the working hours increase. However, the machine performance is normally considered to reduce in proportion to the increase of the operation hours. Accordingly, restoring the machine performance by repair, adjustment, or replacement shall consider the number of the machine’s working hours.

Definition of “Performance Standard” 1. Operation speed values and dimensions of the new machine.

2. Operational performance of new components adjusted to specifications. Allowable errors will be indicated as necessary.

T4-1-1

OPERATIONAL PERFORMANCE TEST / Introduction PREPARATION TESTS

FOR

PERFORMANCE

Observe the following rules in order to carry out performance tests accurately and safely.

THE MACHINE 1. Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test.

TEST AREA 1. Select a hard and flat surface.

2. Secure enough space to allow the machine to run straight more than 20 m (65 ft 7 in), and to make a full swing with the front attachment extended.

3. If required, rope off the test area and provide signboards to keep unauthorized personnel away.

PRECAUTIONS 1. Before starting to test, agree upon the signals to be employed for communication among coworkers. Once the test is started, be sure to communicate with each other using these signals, and to follow them without fail.

2. Operate the machine carefully and always give first priority to safety.

3. While testing, always take care to avoid accidents due to landslides or contact with high-voltage power lines. Always confirm that there is sufficient space for full swings.

4. Avoid polluting the machine and the ground with leaking oil. Use oil pans to catch escaping oil. Pay special attention to this when removing hydraulic pipings.

MAKE PRECISE MEASUREMENT 1. Accurately calibrate test instruments in advance to obtain correct data.

2. Carry out tests under the exact test conditions prescribed for each test item.

3. Repeat the same test and confirm that the test data obtained can be produced repeatedly. Use mean values of measurements if necessary.

T4-1-2

T105-06-01-003

T105-06-01-004

OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE SPEED

Summary: 1. Measure engine speed using the on-board diagnostic system (Refer to the TROUBLESHOOTING / General group) or an engine speed meter.

2. Measure the engine speeds in each mode.

NOTE: Unless engine speed is correctly adjusted, all performance test results will be inaccurate. Therefore, check engine speed setting before performing any tests.

Speed Pickup

Fuel Injection Pipe

Test Condition: Hydraulic Oil Temperature: 50r5 qC (122r9 qF) Ground Conditions: Solid and level surface Measurement: 1. Stop the engine. Turn the key switch OFF. 2. Connect a speed pickup to the fuel injection pipe.

3. Start the engine. Measure the maximum and minimum engine speeds.

Evaluation: Refer to T4-5 Operational Performance Standard.

T146-04-02-001

T4-2-1

OPERATIONAL PERFORMANCE TEST / Engine Test (Blank)

T4-2-2

OPERATIONAL PERFORMANCE TEST / Excavator Test TRAVEL SPEED Summary: 1. Check the overall operational performance of the travel power system (between the hydraulic pumps and travel motors) by measuring time required for the machine to travel the specified distance.

Preparation: 1. Equally adjust the track sag on both right and left undercarriages.

2. Prepare a flat and firm travel test yard 20 m (65.5 ft) long with fringes 3 to 5 m (9.8 to 16 ft) on both ends for machine acceleration and deceleration.

3. Empty the bucket and roll in the arm.

4. Maintain the hydraulic oil temperature at 50r5 qC (122r9 qF).

Deceleration Zone 3 to 5 m

Finish

Track Sag 490 to 550 mm (19 to 22 in)

T145-05-03-001

Travel Test Distance 20 m

Start

Acceleration Zone 3 to 5 m

T142-05-03-001

Measurement: 1. Measure travel time at both fast and slow travel speeds.

2. Engine Control Dial : Maximum Position 3. Start machine to travel from the rear end of the acceleration zone by moving the travel levers full stroke.

4. Measure the time required to travel the travel test distance 20 m (65.5 ft).

5. After measuring the forward travel time, rotate the machine upperstructure 180q. Then, measure the reverse travel time on the way back to the starting position in the same method.

6. Repeat steps (4) and (5) three times and calculate the average values.

T145-05-03-005

Evaluation: Refer to T4-5 Operational Performance Standard.

Remedy: Refer to the T5-4 Troubleshooting B.

T4-3-1

OPERATIONAL PERFORMANCE TEST / Excavator Test TRACK REVOLUTION SPEED Summary: 1. Check the overall operational performance of the travel power system (between the hydraulic pumps and travel motors) by measuring the track revolution cycle time.

Preparation: 1. Equally adjust the track sag on both right and left undercarriages to 490 to 550 mm (19 to 22 in).

2. Mark one shoe with chalk or a piece of cloth on the track to be measured.

3. Rotate the upperstructure 90q to the track and lower the bucket to raise the track to be measured off the ground. Keep the boom and arm angle between 90 to 110q as illustrated.

4. Maintain the hydraulic oil temperature at 50r5 qC (122r9 qF).

90 to 110q

T142-05-03-011

CAUTION: Never work under a machine raised and solely supported by the boom.

Place blocks under the machine frame to support the machine.

90 to 110q

Measurement: 1. Measure the track rotation time at both fast and slow travel speeds.

2. Engine Control Dial : Maximum Position 3. Operate the travel control lever of the raised track in full forward and reverse.

4. After the track revolution attains to constant speed, measure the time required for the marked shoe to rotate three times in both directions.

5. Raise the other side of the track and repeat the procedure.

6. Repeat steps (3) and (4) three times and calculate the average values.

T142-05-03-012

Forward Reverse

Evaluation: Refer to T4-5 Operational Performance Standard.

T145-05-03-001

Remedy: Refer to the T5-4 Troubleshooting B.

T4-3-2

OPERATIONAL PERFORMANCE TEST / Excavator Test MISTRACK Summary: 1. Check the equilibrium in operational performance between the right and left travel power systems (between the hydraulic pumps and travel motors) by measuring the amount of mistrack found while the machine travels for the specified distance.

NOTE: When tested on a concrete surface road, the amount of mistrack may be reduced.

Preparation: 1. Equally adjust the track sag on both right and left undercarriages to 490 to 550 mm (19 to 22 in).

2. Prepare a flat and firm travel test yard 20 m (65.5 ft) long with fringes 3 to 5 m (9.8 to 16 ft) on both ends for machine acceleration and deceleration.

3. Set the front attachment in the driving position.

4. Maintain the hydraulic oil temperature at 50r5 qC (122r9 qF).

Measurement: 1. Measure the amount of mistracking in both fast and slow travel speeds.

2. Engine Control Dial : Maximum Position 3. Start machine to travel from the rear end of the acceleration zone by moving both travel levers full stroke.

4. Draw a 20 m (65.5 ft) straight line along the rut from the travel start point to the travel end point as illustrated. Measure the maximum distance between the rut and the straight line.

5. Conduct the measurement in both forward and reverse travel operation in the same method.

6. Repeat steps (4) and (5) three times and calculate the average values.

T145-05-03-005

T145-05-03-006

Deceleration Zone 3 to 5 m

Maximum Distance (A) 20 m

Acceleration Zone 3 to 5 m

Evaluation: Refer to T4-5 Operational Performance Standard.

T115-07-03-005

Remedy: Refer to the T5-4 Troubleshooting B.

T4-3-3

OPERATIONAL PERFORMANCE TEST / Excavator Test TRAVEL PARKING FUNCTION

Summary: To measure the parking brake function on a specified slope.

0.5 to 1.0 m

Preparation: 1. The surface of the test slope shall be even with a gradient of 20 % (11.31).

2. Hold the bucket 0.5 to 1.0 m (20 to 39 in) above the ground with the arm and bucket fully rolled in.

3. Maintain the hydraulic oil temperature at 50r5 qC (122r9 qF).

T142-05-03-002

Measurement: 1. Climb the slope and place the travel levers in neutral.

2. Stop the engine.

3. After the machine stops, put alignment marks on a track link or shoe, and the track side frame.

4. After 5 minutes, measure the distance between the marks on the track link or shoe and the track side frame.

0.5 to 1.0 m

T118-04-03-001

Evaluation: Refer to T4-5 Operational Performance Standard.

Position where the machine comes to a stop.

Alignment marks on the track side frame and shoe when the machine comes to a stop.

Displacement measured after 5 minutes.

T105-06-03-006

T4-3-4

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING SPEED Summary: Check the overall operational performance of the swing power system (between the hydraulic pumps and swing motors) by measuring time required for the machine upperstructure to make three complete turns.

Preparation: 1. Confirm that the swing gears and bearing are sufficiently greased.

2. Secure a space wide enough for the machine upperstructure to swing on a flat and firm surface.

Never attempt to perform this test on a slope.

3. Empty the bucket and position the front attachment as described in the following.

Backhoe: With the arm cylinders fully retracted and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height.

Loading shobel: With the arm cylinder fully extended and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height.

4.

NOTE: In case it is difficult to secure the space wide enough, test the machine with the boom raised and the arm retracted.

4. Maintain the hydraulic oil temperature at 50r5 qC (122r9 qF).

T145-05-03-007

T145-05-03-008

CAUTION: Prevent personal injury. Always make sure that the area is clear and that coworkers are out of the swing area before starting the measurement.

Measurement: 1. Engine Control Dial : Maximum Position 2. Auto-Idle Switch : OFF 3. Operate the swing control lever at full stroke.

4. After the swing attains to constant speed, measure the time required for the upperstructure to rotate three times.

5. Measure in both directions (clockwise and counterclockwise).

6. Repeat steps (3) and (5) three times and calculate the average values.

3 Revolutions

Evaluation: Refer to T4-5 Operational Performance Standard.

T145-05-03-009

Remedy: Refer to the T5-4 Troubleshooting B.

T4-3-5

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING FUNCTION DRIFT Summary: 1. Measure the swing drift on the swing bearing outer race circumference when stopping after a 180q full-speed swing.

NOTE: The swing motor is equipped with a swing parking brake mechanical brake.

Preparation: 1. Confirm that the swing gears and bearing are sufficiently greased.

2. Secure a space wide enough for the machine upperstructure to swing on a flat and firm surface.

Never attempt to perform this test on a slope.

3. Empty the bucket and position the front attachment as described in the following.

Backhoe: With the arm cylinders fully retracted and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height.

Loading shovel: With the arm cylinder fully extended and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height.

4. Put aligning marks on the outer circumference of the swing bearing and the track frame.

5. Swing the upperstructure 180q.

6. Maintain the hydraulic oil temperature at 50r5 qC (122r9q F).

T4-3-6

T145-05-03-007

T145-05-03-008

OPERATIONAL PERFORMANCE TEST / Excavator Test CAUTION: Prevent personal injury. Always make sure that the area is clear and that coworkers are out of the swing area before starting the measurement.

Measurement: 1. Engine Control Dial : Maximum Position Auto Idle Switch : OFF 2. Operate the swing lever full stroke. When the upperstructure rotates 180q back to the original position (when the marks on the swing bearing and track frame aligns with each other), return the swing lever to neutral.

3. After the upperstructure stops, measure the distance between the two marks along the outer circumference of the swing bearing.

4. Align the marks again. Then, measure in the opposite direction.

5. Repeat steps (2) to (4) three times and calculate the average values.

Return the swing control lever to the neutral position.

Drift Amount

Rotate 180q

Evaluation: Refer to T4-5 Operational Performance Standard.

Start Rotation

Remedy: Refer to the T5-4 Troubleshooting B.

T142-05-03-003

T4-3-7

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING MOTOR LEAKAGE Summary: Check for upperstructure drift while suspending a load on a slope.

Preparation: 1. Check the lubrication of the swing gear and swing bearing.

2. Park the machine on a smooth slope with a gradient of 26.8 % (15q).

3. Load bucket fully. In lieu of loading the bucket, weight (W: tons) of the following specification can be used.

Backhoe: W=6000 kg (13200 lb) (Up to serial No. 2122) W=6600 kg (14500 lb) (Serial No. 2123 and later) Loading Shovel:W=9450 kg (20800 lb) 4. Backhoe: With the arm rolled out, and bucket rolled in, position the arm top pin height to be level with the boom foot pin. Apply a rated load to the bucket.

Loading Shovel: With the arm cylinder and bucket cylinders fully extended, position the arm top pin flush with the boom foot pin height.

5. Swing the upperstructure to position it 90q to the slope. Make aligning marks on the swing bearing periphery and track frame using tape, as illustrated.

6. Maintain the hydraulic oil temperature at 50r5 qC (122r9 qF).

Measurement: 1. Stop the engine. After five minutes, measure the difference between the marks along the swing bearing periphery and the track frame.

2. Perform the measurement in both right and left swing directions.

3. Perform the measurement three times in each direction and calculate the average values.

Evaluation: Refer to T4-5 Operational Performance Standard.

Remedy: Refer to the T5-4 Troubleshooting B.

T4-3-8

T142-05-03-004

Measure Difference Between Marks

Marking on the Track Frame Marking on the Swing Bearing

T105-06-03-010

OPERATIONAL PERFORMANCE TEST / Excavator Test MAXIMUM SWINGABLE SLANT ANGLE Summary: With the upperstructure swung 90q to the slope, check the maximum slant angle on which the upperstructure can swing to the uphill side.

Preparation: 1. Check that the swing gear and bearing are well lubricated.

2. Load bucket fully. In lieu of loading the bucket, weight (W: tons) of the following specification can be used.

Backhoe: W=6000 kg (13200 lb) (Up to serial No. 2122) W=6600 kg (14500 lb) (Serial No. 2123 and later) Loading Shovel:W=9450 kg (20800 lb) 3. Backhoe: With the arm rolled out, and bucket rolled in, position the arm top pin height to be level with the boom foot pin. Apply a rated load to the bucket.

Loading Shovel: With the arm cylinder and bucket cylinders fully extended, position the arm top pin flush with the boom foot pin height.

4. Climb a slope and swing the upperstructure 90q to the slope.

5. Maintain the hydraulic oil temperature at 50r5 qC (122r9 qF).

Measurement: 1. Engine Control Dial : Maximum Position Auto Idle Switch : OFF 2. Operate the swing lever to full stroke to swing the upperstructure to the uphill side.

3. If the machine can swing, measure the cab floor slant angle.

4. When the machine can swing, increase the slope angle and repeat steps (2 and 3). Check in both clockwise and counterclockwise directions.

5. Perform the measurement three times in each direction and calculate the average values.

Evaluation: Refer to T4-5 Operational Performance Standard.

Remedy: Refer to the T5-4 Troubleshooting B.

T4-3-9

T142-05-03-004

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING BEARING PLAY

Summary: Wear on the swing bearing races and rollers is checked by measuring the play between the outer and inner races of the swing bearing.

Dial㊡ Gauge

Preparation: 1. Confirm that the swing bearing mounting bolts are securely tightened.

2. Confirm that the swing bearing is well lubricated and rotates smoothly with no noise.

3. Attach a dial gauge on the track frame using a magnet base.

4. Position the upperstructure so that the bucket faces toward the front idlers.

5. Position the dial gauge so that its needle point comes in contact with the bottom face of the swing bearing outer race.

6. Empty the bucket

Round Trunk

Magnet㊡ Base

T105-06-03-015

NOTE The measured value will vary depending on the location where the magnet base is secured. Secure the magnet base onto the round trunk or a location as close to the round trunk as possible.

T4-3-10

OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Take measurements of the play at positions A, B, C, and D. 2. Position the front attachment as described in the following.

Backhoe: With the arm cylinders fully retracted and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height.

Loading shovel: With the arm cylinder fully extended and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height.

3. Record the dial gauge reading (h1). Lower the bucket to the ground and use it to raise the front idler 0.5 m (20 in). Record the dial gauge reading (h2).

4. Calculate bearing play (H) from this data (h1 and h2) as follows: H=h2 㧙 h1

A B

D C

Measure the plays at positions A, B, C and D.

T145-05-03-023

Evaluation: Refer to the Performance Standard Table in Group T4-5.

Backhoe

Measurement : (h1)

Measurement : (h2 )

T142-05-03-006

Loading Shovel Measurement : (h1 )

Measurement : (h2 )

T142-05-03-005

T4-3-11

OPERATIONAL PERFORMANCE TEST / Excavator Test HYDRAULIC CYLINDER CYCLE TIME Summary: 1. Check the overall operational performance of the front attachment hydraulic system (between the hydraulic pumps and each cylinder) by measuring the cycle time of the boom, arm, bucket, and bucket dump (open/close) cylinders with the bucket emptied.

Preparation: 1. Maintain the hydraulic oil temperature at 50r5 qC (122r9 qF).

2. Position the front attachment as described in the following. • Backhoe Boom Cylinder: With the bucket cylinder fully extended and the arm cylinder fully retracted, lower the bucket to the ground.

Arm Cylinder: With the bucket cylinder fully extended while positioning the center line between the arm and bucket connection pin centers vertical with the arm cylinder extended half stroke.

Bucket Cylinder: Adjust the boom and arm cylinder so that the center of full stroke movement of the bucket is positioned vertically. • 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 Dump (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.

Backhoe

Boom Cylinder

T145-05-03-012

Arm Cylinder

T118-04-03-003

Bucket Cylinder

T145-05-03-014

Loading Shovel

Boom Cylinder

T145-05-03-015

Arm Cylinder

T145-05-03-016

Bucket Cylinder

T145-05-03-017

Dump Cylinder

T145-05-03-018

T4-3-12

OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Select the following lever and switch positions: Engine Control Lever: Maximum Position Auto-Idle Switch: OFF 2. To measure cylinder cycle times: (Cylinder full stroke includes cylinder cushioning zone.)

(1) Boom cylinders: Measure the time it takes to raise the boom, and the time it takes to lower the boom. To do so, position the boom at one stroke end, then move the control lever to the other stroke end as quickly as possible.

(2) Arm cylinder: Measure the time it takes to roll in the arm, and the time it takes to roll out the arm. To do so, position the arm at one stroke end, then move the control lever to the other stroke end as quickly as possible.

(3) Bucket cylinder: Measure the time it takes to roll in the bucket, and the time it takes to roll out the bucket. To do so, position the bucket at one stroke end, then move the control lever to the other stroke end as quickly as possible.

(4) Bucket dump (Open-Close) cylinder: Mesure the time it takes to open the bucket, and the time it takes to close the bucket. To do so, position the bucket dump at one stroke end, then move the bucket open-close pedal to the other stroke end as quickly as possible.

3. Repeat the measurement three times and calculate the average values.

Evaluation: Refer to T4-5 Operational Performance Standard.

NOTE: Backhoe front : 9.1 m (29 ft) Boom 3.4 m (11 ft) Arm 4.6 m3 (6.0 yd3) Bucket * 5.0 m3 (6.5 yd3) Bucket (PCSA heaped) Loading shovel front: 6.3 m3 (8.2 yd3) Bucket When the bucket weight is increased by welding wear-resist plates, cylinder cycle times may become slower.

Remedy: Refer to the T5-4 Troubleshooting B.

T4-3-13

OPERATIONAL PERFORMANCE TEST / Excavator Test CYLINDER DRIFT

Summary: 1. While holding the soil weight of or a specified weight in the bucket, the dig function drift is measured to check for internal oil leaks in the control valve, boom, arm, and bucket cylinders.

2. After replacing the hydraulic cylinders, slowly operate each cylinder for approx. 10 minutes to bleed air from the hydraulic circuit before starting the test.

Preparation: 1. Load bucket fully. In lieu of loading the bucket, weight (W) of the following specification can be used.

Backhoe: W=6000 kg (13200 lb)(Up to Serial No. 2122) W=6600 kg (14500 lb)(Serial No. 2123 and later) Loading Shovel: W=9450 kg (20800 lb) 2. Position the front attachment as described in the following.

Backhoe: With the arm cylinder with rod approx.50 mm (2 in) extended from the fully retracted position, and bucket cylinder with the rod approx. 50 mm (2 in) retracted from the fully extended, position the arm top pin height flush with the boom foot pin height.

Loading shovel: With the arm cylinder with the rod approx. 50 mm (2 in) retracted from the fully extended position, and bucket cylinder with the approx. 50 mm (2 in) retracted from the fully extended, position the arm top pin height flush with the boom foot pin height.

3. Maintain the hydraulic oil temperature at 50r5 qC (122r9 qF).

T145-05-03-020

T145-05-03-021

BH: Boom and Bucket Cylinders Retraction LD: Boom, Arm and Bucket Cylinders Retraction Mark

Mark

T110-06-03-002

BH: Arm Cylinder Extension

Measurement: 1. Stop the engine.

2. After five minutes have passed, measure the retractions of the boom, arm, and bucket cylinders as illustrated 3. Repeat step (2) three times and calculate the average values.

Mark

Evaluation: Refer to T4-5 Operational Performance Standard.

T110-06-03-001

NOTE: BH: Backhoe LD: Loading Shovel

Solution: Refer to T5-4 Troubleshooting B.

T4-3-14

OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER OPERATING FORCE Summary: 1. Use a spring scale to measure the maximum resistance of each control lever as illustrated.

2. Measure the maximum operating force of the front attachment control lever.

3. Measure the operating force at the grip center of each control lever.

Preparation: Maintain the hydraulic oil temperature at 50r5 qC (122r9 qF).

Measurement: 1. Measure all control levers.

2. Engine Control Dial : Maximum Position.

T107-06-03-003

CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement.

3. Operate each boom, arm, bucket and swing lever to at full stroke and measure the maximum operating force for each.

4. Lower the bucket to the ground to raise one track off the ground. Operate the travel lever to full stroke and measure the maximum operating force required. When finished, lower the track and then jack-up the other track.

5. Repeat steps 3. to 4. three times and calculate the average values.

Evalution: Refer to the Performance Standard Table in Group T4-5.

T4-3-15

T107-06-03-004

OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER STROKE

Summary: 1. Measure each control lever stroke and stroke play, and check if it can be moved smoothly.

2. Measure each lever stroke at the lever grip center.

3. If a stroke play is present in the neutral position, add half the value of the play to the one side stroke.

Preparation: 1. Maintain the hydraulic oil temperature at 50 r 5 qC (122 r 9 qF).

Measurement: 1. Stop the engine.

2. Measure the boom, arm, bucket, swing, and travel levers full stroke from the neutral position at the lever grip top center.

3. Measure the stroke straight from the neutral position to the stroke end.

4. Repeat each measurement three times and calculate the average values.

T107-06-03-005

Evaluation: Refer to T4-5 Operational Performance Standard.

T4-3-16

OPERATIONAL PERFORMANCE TEST / Excavator Test BOOM RAISE/SWING ERATION CHECK

COMBINED

OP-

Summary: 1. Check the combined operation performance while operating the boom raise and swing simultaneously.

2. Run the engine at full speed and check if the boom cylinders move without hesitating.

Preparation: 1. Empty the bucket and position the machine with front attachment positioned as illustrated.

2. Maintain the hydraulic oil temperature at 50 r 5 qC (122 r 9 qF).

CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement.

T142-05-03-007

T142-05-03-008

Measurement: 1. Run the engine at the maximum speed with the auto idle switch OFF. 2. Operate the boom raise and swing levers full stroke. Measure the time required for the machine to swing 90 q and bucket tooth tip height H raised while swinging.

3. Repeat the measurement in both directions three times and calculate the average values.

T142-05-03-009

Evaluation: Refer to T4-5 Operational Performance Standard.

Solution: Refer to T5-4 Troubleshooting B.

H

T142-05-03-010

T4-3-17

OPERATIONAL PERFORMANCE TEST / Excavator Test (Blank)

T4-3-18

OPERATIONAL PERFORMANCE TEST / Component Test PRIMARY PILOT PRESSURE Preparation: 1. Stop the engine.

Tee

Pressure Gauge

CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it.

2. Slowly loosen the cap to release air from the hydraulic oil tank.

3. Disconnect the line end from the pilot filter.

Connect tee (ST 6477) and pressure gauge (ST 6942) between the pilot filer and the line end.

4. Start the engine. Check the connection for oil leaks.

5. Maintain the hydraulic oil temperature at 50r5 qC (122r9 qF).

Measurement: 1. Engine Control Dial: Maximum Speed (Fast Idle Position) 2. Read the primary pilot pressure on the gauge.

Turn the engine control dial to the slow idle, then back to the fast idle.

Read the pressure gauge again.

3. Read the pressure gauge three times in total.

Calculate the average value.

Evaluation: Refer to the Operational Performance Standard group (T4-5).

T4-4-1

T142-05-04-001

OPERATIONAL PERFORMANCE TEST / Component Test Primary Pilot Pressure Adjustment Procedure Adjustment: Adjust the pilot relief valve setting if required.

Pilot Relief Valve

T183-04-04-001

1. Remove the plug.

Plug

: 22 mm

Shim

2. Adjust the set pressure using the shims. Adding shim(s) increases the pressure setting, and vice versa. Add or subtract shims to adjust the setting.

3. Retighten the plug. : 24.5 N m (2.5 kgf m, 18 lbf ft)

T111-06-04-004

4. Recheck the relief pressure setting.

NOTE: Standard Change in Relief Pressure Setting(Reference) 2 Shim Thickness kPa (kgf/cm ) (psi) (mm) 0.25 78 (0.8) (11) 0.5 147 (1.5) (21) 1.0 294 (3.0) (43)

T4-4-2

OPERATIONAL PERFORMANCE TEST / Component Test SECONDARY PILOT PRESSURE

Main Control Valve

The secondary pilot pressure can also be measured Left Travel with the built-in diagnosing system.

NOTE: BH: Backhoe LD: Loading Shovel Preparation: 1. Stop the engine.

Right Travel (Forward) Bucket 1 (BH: Roll-Out, LD: Tilt-Out) Boom 1 (Lower)

(Forward)

Bucket 2 (BH: Roll-Out LD: Tilt-Out) Boom 2 (Lower) BH: Arm 1 (Roll-Out) LD: Arm 1 (Roll-In)

CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap BH: Auxiliary slowly to release any remaining pressure LD: Bucket (Open) before removing it.

2. Slowly loosen the cap to release air from the hydraulic oil tank.

3. Connect tee (ST 6450) and pressure gauge (ST 6942) on the pilot port to be measured. : 17 mm, 22 mm 4. Start the engine. Check the pressure gauge connection for oil leaks.

Bucket 1 (BH: Roll-In, LD: Tilt-In)

BH: Arm 2 (Roll-Out) LD: Arm 2 (Retract) Right Travel (Reverse)

T183-03-03-028

Boom 2 (Raise) Left Travel (Reverse)

Boom 1 (Raise) BH: Arm 2 (Roll-in) LD: Arm 2 (Extend)

5. Maintain the hydraulic oil temperature at 50r5 qC BH: Auxiliary LD: Bucket (122r9 qF).

(Close)

Measurement:

Bucket 2 (BH: Roll-in, LD: Tilt-in)

BH: Arm 1 (Roll-In) T183-03-03-027 LD: Arm 1 (Extend)

Swing Control Valve

CAUTION: Before starting measurement, check that there are no bystanders and/or obstructions within the swing radius.

When measuring the boom lower secondary pilot pressure operate the machine carefully as the base machine front will be raised off the ground. This will cause the base machine to become imbalanced and possibly allow the rear of the machine to come in contact with the ground.

BH: Arm 3 (Roll-Out) LD: Arm 3 (Retract)

1. Engine Control Dial :Maximum Speed

Boom 3 (Lower) Swing (Left) BH: Bucket 3 (Roll-Out) LD: Bucket 3 (Tilt-Out) T183-03-03-030

2. Fully operate the control lever for the function to be measured. Read the secondary pilot pressure on the gauge.

3. Repeat the measurement three times. Calculate Boom 3 (Raise) the average value.

Evaluation: Refer to the Operational Performance Standard group (T4-5).

Swing (Right) BH: Bucket 3 (Roll-In) LD: Bucket 3 (Tilt-In) BH: Arm 3 (Roll-In) LD: Arm 3 (Extend)

T4-4-3

T183-03-03-031

OPERATIONAL PERFORMANCE TEST / Component Test SOLENOID VALVE SET PRESSURE (Travel mode control solenoid valve, flow rate decrease solenoid valve, power decrease solenoid valve, boom mode selection solenoid valve, heavy lift solenoid valve, power increase solenoid valve, oil cooler fan control solenoid valve)

Travel Mode Control Solenoid Valve

Preparation: 1. Stop the engine.

T183-05-04-019

CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it.

Output Port

Flow Rate Decrease Solenoid Valve

2. Slowly loosen the cap to release air from the hydraulic oil tank.

3. Connect tee (ST 6450. For the power decrease solenoid valve, power increase solenoid valve and oil cooler fan control solenoid valve, use ST 6451) and pressure gauge (ST 6942) on the solenoid valve output port. : 17 mm, 22 mm 4. Start the engine. Check the pressure gauge connection for oil leaks.

Output Port

T183-05-04-018

Power Decrease Solenoid Valve Output Port

5. Maintain the hydraulic oil temperature at 50r5q C (122r9 qF).

Measurement: 1. Measure the pressure setting for each solenoid valve as follows: • Travel Mode Control Solenoid Valve Measure the shifting pressure at fast and slow speeds by the travel mode switch.

• Flow Rate Decrease Solenoid Valve Turn the engine control dial to the slow idle position. Read the pressure while applying a load to the front attachment.

• Power Decrease Solenoid Valve Turn the engine control dial to the slow idle position. Read the pressure.

• Boom Mode Selection Solenoid Valve Turn on the boom mode selection switch. Read the pressure.

T183-04-04-001

Boom Mode Selection Solenoid Valve

T4-4-4

Output Port

T183-04-04-001

OPERATIONAL PERFORMANCE TEST / Component Test • Heavy Lift Solenoid Valve Turn on the heavy lift switch. Read the pressure.

• Power Increase Solenoid Valve Observe the pressure change while turning the engine control dial from the slow idle position to the fast idle position.

• Oil Cooler Fan Control Solenoid Valve Heat the hydraulic oil temperature sensor, and read the pressure at 69 qC (156 qF), 70 to 79 qC (158 to 174 qF) and 80 qC (176 qF).

Heavy Lift Solenoid Valve Output Port

2. Repeat the measurements three times and calculate the average values.

Evaluation: Refer to the Operational Performance Standard group (T4-5).

T183-05-04-017

Power Increase Solenoid Valve

Output Port

T183-05-04-016

Oil Cooler Fan Control Solenoid Valve

Output Port

T4-4-5

T183-05-04-016

OPERATIONAL PERFORMANCE TEST / Component Test (Blank)

T4-4-6

OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP DELIVERY PRESSURE The main pump delivery pressure can also be measured with the built-in diagnosing system.

Preparation: 1. Stop the engine.

CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it.

2. Slowly loosen the cap to release air from the hydraulic oil tank.

3. Remove the plug from the test port on the main pump delivery port. Connect adapter (ST 6069), hose (ST 6943), and pressure gauge (ST 6941) on the test port.

Test Port

4. Start the engine. Check the pressure gauge connection for oil leaks.

5. Maintain the hydraulic oil temperature at 50r5 qC (122r9 qF).

Test Port

Pressure Gauge

T183-04-04-002

Measurement: 1. Engine Control Dial : Maximum Speed 2. Measure the pressure with the control levers in neutral.

3. Read the pressure gauge three times in total.

Calculate the average value.

Evaluation: Refer to the Operational Performance Standard group (T4-5).

T183-04-04-003

Remedy: Refer to the Troubleshooting B group (T5-4).

T4-4-7

OPERATIONAL PERFORMANCE TEST / Component Test MAIN RELIEF VALVE SET PRESSURE

The main pump delivery pressure can also be measured with the built-in diagnosing system.

Summary: Measure the main relief valve set pressure at the main pump delivery port.

Preparation: 1. Stop the engine.

CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may pop off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it.

2. Slowly loosen the cap to release air from the hydraulic oil tank.

3. Remove the plug from the test port on the main pump delivery port. Connect adapter (ST 6069), hose (ST 6943), and pressure gauge (ST 6941) on the test port.

4. Start the engine. Check the pressure gauge connection for oil leaks.

Test Port

Test Port

Pressure Gauge

T183-04-04-002

5. Maintain the hydraulic oil temperature at 50r5 qC (122r9 qF).

Measurement: 1. Engine Control Dial : Maximum Speed 2. Operate the bucket, arm and boom control levers to the stroke ends (fully extended and retracted) to relieve the each function. (Operate the control lever one function at a time.)

3. For the swing function, place one side of the bucket against an immovable object and slowly operate the swing lever to the stroke end to relieve the swing function.

T183-04-04-003

Evaluation: Refer to the Operational Performance Standard group (T4-5).

4. For the travel function, place the track to be measured against a pile of soil to make it immovable. Slowly operate the travel lever to the stroke end to relieve the travel function.

NOTE: If all measured values are lower than the specified main relief pressure, the setting of the main relief valve is suspected to be the cause.

If the relief pressure for a particular function is lower than the specified main relief pressure, something other than the main relief valve is the cause.

5. Read the pressure gauge while relieving each function.

T4-4-8

OPERATIONAL PERFORMANCE TEST / Component Test Main Relief Procedure

Pressure

Setting

Adjustment

Main Control Valve

Adjustment: Adjust the main relief valve pressure settings using plug (for the low-side main relief pressure) and sleeve (for high-side main relief pressure) after loosening lock nut (4).

x High-Side

Main Relief Adjustment Procedure

Pressure

Main Relief Valve

Setting

1. Loosen lock nut 2. Tighten plug until the bottom of piston comes into contact with sleeve. Retighten lock nut 2.

T183-03-03-029

Swing Control Valve Main Relief Valve

: 22 mm, 30 mm : Lock nut 2 (4): 59 Nxm (6 kgfxm, 13 lbfxft) 2. Loosen lock nut 1. Turn sleeve to adjust the relief pressure setting, referring to the table below. : 22 mm, 41 mm : Lock nut 1: 98 Nxm (10 kgfxm, 22 lbfxft)

x Low-Side

Main Relief Adjustment Procedure

Pressure

Setting

Plug

T183-03-03-030

Lock Nut 2 Sleeve

3. Loosen lock nut 2. Turn plug counterclockwise until the specified value is obtained. Retighten lock nut 2.

Lock Nut 1 Piston

: 22 mm, 30 mm : Lock nut 2: 59 Nxm (6 kgfxm, 13 lbfxft) 4. Recheck the set pressures.

NOTE: : Standard Change in Pressure Setting Sleeve and 1/4 1/2 3/4 1 plug turns MPa 4.4 8.8 13.2 17.7 2 (kgf/cm ) (45) (90) (135) (180) (psi) (640) (1280) (1920) (2560)

T162-04-04-010

Sleeve, Plug

Pressure Increase

Pressure Decrease

W107-02-05-127

T4-4-9

OPERATIONAL PERFORMANCE TEST / Component Test Swing Relief Valve

Swing Relief Valve Set Pressure Adjustment Procedure

Adjustment: Loosen the lock nut. : 17 mm 1. Turn the adjusting screw to adjust the pressure setting.

T142-01-02-011

Adjusting Screw

3. Retighten the lock nut.

Lock Nut

: 17 mm : 19.5 to 29.5 N m (2 to 3 kgf m, 15 to 22 lbf ft) 4. Recheck the relief pressure setting.

T142-02-02-006

NOTE: Standard Change in Relief Pressure Setting Screw Turns 1/4 1/2 3/4 1 MPa 2.75 5.49 8.24 11.0 2 (kgf/cm ) (28) (56) (84) (112) (psi) (340) (796) (1195) (1593)

Lock Nut

Pressure Increase

Adjusting Screw

Pressure Decrease

T105-06-05-002

T4-4-10

OPERATIONAL PERFORMANCE TEST / Component Test Swing Relief Valve Set Pressure Adjustment Procedure

Adjustment: 1. Loosen the lock nut. : 19 mm Travel Relief

1. Turn the adjusting screw to adjust the pressure Valve setting.

T183-01-02-012

: 6 mm 3. Retighten the lock nut.

Lock Nut

: 19 mm : 34.3 to 44.1 N m (3.5 to 4.5 kgf m, 25.3 to 32.5 lbf ft) 4. Recheck the relief pressure setting.

Adjusting Screw T142-05-04-007

NOTE: Standard Change in Relief Pressure Setting Screw Turns 1/4 1/2 3/4 1 MPa 1.96 3.92 5.88 7.85 2 (kgf/cm ) (20) (40) (60) (80) (psi) (280) (570) (850) (1140)

Lock Nut

Pressure Increase

Adjusting Screw

Pressure Decrease

W107-02-05-129

T4-4-11

OPERATIONAL PERFORMANCE TEST / Component Test OVERLOAD PRESSURE

RELIEF

VALVE

SET

Summary: 1. The circuit pressure must be increased by applying an external force while blocking the return circuit from the control valve. This measuring method is hazardous and the results obtained with this method are unreliable.

2. The oil flow rate used to set the overload relief pressure is far less than that used to set the main relief pressure. Therefore, measuring the overload pressure in the main circuit by increasing the main relief set-pressure more than the overload valve set-pressure is not a proper method. In addition, in case a main relief valve designed to leak a small quantity of oil before reliving is used, its pre-leaking start pressure must be increased more than the overload relief valve set-pressure.

However, the pre-leaking start pressure is not always increased more than the overload relief valve set-pressure as the adjustable upper limit of the main relief valve set-pressure is provided.

Accordingly, the overload relief valve assembly should be removed from the machine and checked on a specified test stand at a correct oil flow rate. Some overload relief valves come in contact with the control valve body to block the oil passage. When this type of overload relief valve is checked, the control valve body must be precisely finished as the test unit. Provide one control valve other than that on the machine as a test kit.

3. If the overload relief valve performance must be checked on the machine, however, measure the main relief pressure while releasing each front function respective to the measuring overload relief valve. And, assume that the overload relief valve is functioning correctly if the obtained main relief pressure is within the specified value range.

Measure the main pressure of the front functions as follows:

T4-4-12

OPERATIONAL PERFORMANCE TEST / Component Test Overload Relief Valve Set Pressure Adjusting Procedure

x Boom, Arm, Bucket 1, Bucket 2,

Auxiliary: BH/Bucket Open, Close :LD, Swing

NOTE: BH: Backhoe LD: Loading Shovel

NOTE: In principle, adjust the overload relief valve set pressure on a test stand.

Adjusting Screw

Lock Nut

Adjustment: Adjust the pressure setting of the overload relief valve using adjusting screw after loosening lock nut.

1. Loosen lock nut. : 19 mm

2. Turn adjusting screw to adjust the pressure setting referring to the table below.

T162-04-04-004

Adjusting Screw

: 6 mm 3. Retighten lock nut. : 19 mm : 98 Nxm (10 kgfxm, 72 lbfxft) Pressure Increase

Pressure Decrease

4. Recheck the set pressures.

W107-02-05-129

NOTE: Standard Change in Pressure Setting Screw Turns

1/4

1/2

3/4

1

MPa

3.9

7.8

11.7

15.6

(kgf/cm )

(40)

(78)

(120)

(160)

(psi)

(566)

(1131)

(1697)

(2262)

2

T4-4-13

OPERATIONAL PERFORMANCE TEST / Component Test x Boom Mode Selection NOTE: In principle, adjust the overload relief valve set pressure on a test stand.

Adjustment: Adjust the pressure setting of the overload relief valve using sleeve after loosening lock nut (1).

1. Loosen lock nut (1). : 36 mm 2. Turn sleeve to adjust the pressure setting referring to the table below.

Boom Mode Selection

: 30 mm

T183-03-03-028

3. Retighten lock nut.

Sleeve

: 36 mm : 98 Nxm (10 kgfxm, 72 lbfxft)

Lock Nut

4. Recheck the set pressures.

NOTE: Standard Change in Pressure Setting Screw Turns

1/4

1/2

3/4

1

MPa

8.9

17.8

26.7

35.6

(kgf/cm )

(90)

(180)

(270)

(360)

(psi)

(1290)

(2581)

(3872)

(5162)

2

T183-04-04-007

Sleeve

Pressure Increase

Pressure Decrease

W107-02-05-127

T4-4-14

OPERATIONAL PERFORMANCE TEST / Component Test (Blank)

T4-4-15

OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP FLOW RATE MEASUREMENT

NOTE: MC/V: Main Control Valve SC/V: Swing Control Valve

x P-Q Control (Torque Control) Summary: Main pump performance is checked by measuring the pump flow rate with a hydraulic tester installed at the main pump delivery line. Measure the flow rate by using the built-in diagnosing system and a pressure gauge.

Preparation: IMPORTANT: The method described here is a simplified method, so that the flow rate is reduced by approx. 5% compared to the actual measurement (ex. bench test). If the actual measurement is required, connect the return circuit to the hydraulic oil tank instead of the control valve.

to Main Pump 1, 2 and MC/V 㸢 to Main Pump 3 and SC/V 㸢

Delivery Hose Split Flange (ST 6133)

CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it.

T183-04-04-013

Delivery Hose Flange (ST 6123)

Bolt (ST 6458)

1. Stop the engine. Slowly loosen the cap to release air from the hydraulic oil tank. Connect the vacuum pump to the oil filler port.

NOTE: Keep operating the vacuum pump while connecting the measurement piping.

Test Hose (ST 6145)

Adapter (ST 6146) Hydraulic Tester (ST 6299) Adapter (ST 6146)

Main Pump

Test Hose (ST 6145)

2. Remove the delivery hose from the main pump to be measured, then install flange (ST 6123) on the removed hose using split flange (ST 6133) and bolt (ST 6458).

Split Flange (ST 6133) Bolt (ST 6458)

3. Install test hose (ST 6145), adapter (ST 6146) and hydraulic tester (ST 6299) on flange (ST 6123).

Pipe (ST 6132)

T183-04-04-014

4. Install pipe (ST 6132) on the delivery port of the main pump using split flange (ST 6133) and bolt (ST 6458), then install test hose (ST 6145), adapter (ST 6146) and hydraulic tester (ST 6299) on the pipe.

Remove a plug from the pressure check port on the main pump, then install adapter (ST 6069), hose (ST 6943) and pressure gauge (ST 6941).

Pressure Gauge (ST 6941)

Hose (ST 6943)

Adapter (ST 6069)

T4-4-16

T183-04-04-003

OPERATIONAL PERFORMANCE TEST / Component Test 5. Disconnect pipes from pump regulator ports Psv and Pi. Install tee (ST 6640) to port Psv. Connect tee (ST 6640) between port Psv and circuit Psv. Connect hose (ST 6961) and elbow (ST 6635, Code No. 0095) to tee (ST 6640). Connect the other end of hose (ST 6961) to port Pi using elbow (ST 6635, Code No. 0095). Install a plug to the pipe end disconnected from port Pi. (By connecting the pump servo assist pressure (Psv pressure) circuit to port Pi, the condition similar to the maximum pump flow rate (maximum Pi pressure at full stroke operation of the control lever) can be obtained.

Port Psv Port Pi

6. Disconnect the power increase solenoid valve connector and power decrease solenoid valve connector.

7. Fully open the loading valve of the hydraulic tester.

8. Start the engine. Check the line connections for any oil leaks. Select the monitor function on the built-in diagnosing system.

T183-01-02-006

Psv Pressure Hose (ST 6961) Tee (ST 6640) Elbow (ST 6635) Elbow (ST 6635)

Measurement: 1. Hydraulic oil temperature: 50r5 qC (122r9 qF)

T183-04-04-004

2. Engine Control Dial: Maximum speed 3. Slowly close the loading valve of the hydraulic tester to obtain the specified pressure on P-Q curve, and measure the pump flow rate and engine speed at each pressure. (Refer to T4-5-4) 4. Repeat the measurement three times and calculate the average values.

Evaluation: Convert the measured flow rates to the values at the specified pump speed using the following formulas: QC = (NPuQ) / (iuNe) QC: Converted Flow Rate Q: Measured Flow Rate i: Pump Drive Gear Ratio (1.083) -1 NP: Specified Pump Speed (1787 min ) Ne: Measured Engine Speed

T4-4-17

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment: Adjustment of Minimum and Maximum Flow Rate Pump flow rate can be adjusted by changing the maximum stroke of the servo piston.

To adjust the maximum flow rate, loosen nut (1) and turn adjusting screw (2) on the large chamber side end of the servo piston. To adjust the minimum flow rate, loosen nut (3) and turn adjusting screw (4) on the small chamber side end of the servo piston.

NOTE: Turn adjusting screw (2) clockwise to decrease the maximum flow rate and counterclockwise to increase. Turning adjusting screw (2) one forth turns changes -1 approximately 9.2 L/min of flow rate.

Turn adjusting screw (4) clockwise to increase the minimum flow rate and counterclockwise to decrease. Turning adjusting screw (4) one forth turns changes -1 approximately 9.2 L/min of flow rate.

: 30 mm for nut (1), (3) : 13 mm for adjusting screw (2) : 10 mm for adjusting screw (4)

4

3

1

2

T183-04-04-006

(Pump Flow Rate) Q

Maximum Flow Rate Adjustment

(Pump Flow Rate) Q

Minimum Flow Rate Adjustment

Pi

T4-4-18

Pi (Flow Rate Control Pressure)

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment of Torque Control The torque control is performed by pump delivery pressure P. Therefore, the torque constant control is adjusted by changing the set-force of inner spring (2) and outer spring (1).

(Before adjust the screws (4) and (6), mark the end of the adjusting screw with a white marker for the record of the original position.)

When resetting inner spring (2), loosen nut (5) and adjust screw (6).

When resetting outer spring (1), loosen nut (3) and adjust screw (4).

NOTE: When adjusting screw (4) is turned, inner spring (2) set-force varies. Therefore, when adjusting screw (4) is turned, turn adjusting screw (6) 2.17 times the turns of adjusting screw (4) in the opposite direction to keep inner spring (2) set-force unchanged. : 36 mm : Nut (3) : 24 mm : Adjusting Screw (4) : 13 mm : Nut (5) : 4 mm : Adjusting Screw (6) 1

2 3

4

5

6

T117-05-04-005

Outer Spring Adjustment Data Adjusting Screw Turn 1/4 Flow Rate Change 40.9 L/min (10.8 US gal/min) 2 Pressure Change 1.74 MPa (17.8 kgf/cm ) (252 psi) Engine Torque 67.6 N m (6.9 kgf m) Change (50 lbf ft) (Pump Flow Rate)

Inner Spring Adjustment Data Adjusting Screw Turn 1/4 Flow Rate Change 18.9 L/min (5 US gal/min) 2 Pressure Change 1.80 MPa (18.4 kgf/cm ) (261 psi) Engine Torque 45.1 N m (4.6 kgf m) Change (33 lbf ft) (Pump Flow Rate)

Q

Q

P

(Pump Delivery Pressure)

T4-4-19

P

(Pump Delivery Pressure)

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment of Flow Rate Control The flow rate control is performed by pump flow rate control pressure Pi. Therefore, the flow rate control is adjusted by resetting the set-force of spring (1).

Loosen nut (2) and turn adjusting screw (3) to reset the set-force of spring (1).

NOTE: When the flow rate control is adjusted, the relief oil minimizing control is also changed at the same time. : 13 mm : Nut (2) : 4 mm : Adjusting Screw (3)

1

2

3

T117-05-04-006

Spring Adjustment Data Adjusting Screw Turn 1/4 2 Pressure Change (Pi) 0.15 MPa (1.5 kgf/cm ) (21.8 psi) Flow Rate Change 42.7 L/min (11.2 US gal/min)

(Pump Flow Rate) Q

Flow Rate Control

(Pump Flow

Relief Oil Minimizing Control

Rate)

Pi (Flow Rate Control Pressure)

T4-4-20

Q

P (Pump Delivery Pressure)

OPERATIONAL PERFORMANCE TEST / Component Test (Blank)

T4-4-21

OPERATIONAL PERFORMANCE TEST / Component Test OIL COOLER FAN MOTOR DRIVE PUMP FLOW RATE MEASUREMENT

Delivery Hose

x P-Q Control (Torque Control) Summary: Oil cooler fan motor drive pump performance is checked by measuring the pump flow rate with a hydraulic tester installed at the oil cooler fan motor drive pump delivery line.

Preparation: CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it.

1. Stop the engine. Slowly loosen the cap to release air from the hydraulic oil tank. Connect the vacuum pump to the oil filler port.

T183-04-04-015

Split Flange (4506459) Delivery Hose

Bolt (ST 6408) Adapter (ST 6146)

NOTE: Keep operating the vacuum pump while connecting the measurement piping.

Test Hose (ST 6145)

2. Remove the delivery hose, then install flange (ST 6574) on the removed hose using split flange (4506459) and bolt (ST 6408).

Test Hose (ST 6145) Flange(ST 6574) Adapter(ST 6146) Hydraulic Tester (ST 6299) Bolt (ST 6408) Split Flange Pipe (4506459) (ST 6575) Oil Cooler Fan Motor Drive Pump

3. Install test hose (ST 6145), adapter (ST 6146) and hydraulic tester (ST 6299) on flange (ST 6574).

4. Install pipe (ST 6575) on the delivery port of the main pump using split flange (4506459) and bolt (ST 6408), then install test hose (ST 6145), adapter (ST 6146) and hydraulic tester (ST 6299) on the pipe.

Remove a plug from the pressure check port, then install adapter (ST 6069), hose (ST 6943) and pressure gauge (ST 6941).

T183-04-04-018

Hose (ST 6943)

Pressure Gauge (ST 6941)

Adapter (ST 6069)

T4-4-22

T183-04-04-019

OPERATIONAL PERFORMANCE TEST / Component Test 5. Disconnect the pipe from regulator ports Pi. Leave the port Pi open to the atmosphere. Plug the disconnected pipe end.

6. Disconnect the connector of the oil cooler fan control solenoid valve SF. 7. Fully open the loading valve of the hydraulic tester.

8. Start the engine. Check the line connections for any oil leaks.

Pi

Measurement: 1. Engine Control Dial: Maximum speed

T183-04-04-016

2. Slowly close the loading valve of the hydraulic tester to obtain the specified pressure on P-Q curve, and measure the pump flow rate and engine speed at each pressure. (Refer to T4-5-4)

3. Repeat the measurement three times and calculate the average values.

Evaluation: Convert the measured flow rates to the values at the specified pump speed using the following formulas: QC = (NPuQ) / (iuNe) QC: Converted Flow Rate Q: Measured Flow Rate i: Pump Drive Gear Ratio (1.106) -1 NP: Specified Pump Speed (1825 min ) Ne: Measured Engine Speed

T4-4-23

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment: Adjustment of Maximum and Minimum Flow Rate The pump flow rate can be adjusted by changing the maximum servo piston stroke. When adjusting the maximum flow rate, loosen nut (1) and adjusting screw (2) on the servo piston large chamber side.

When adjusting the minimum flow rate, loosen nut (3) and adjusting screw (4) on the servo piston small chamber side.

NOTE: Turning adjusting screw (2) clockwise decreases the maximum flow rate, and turning counterclockwise increases. 1/4 turn of adjusting screw (2) changes the flow rate approx. 3 L/min (0.8 US gal/min).

Turning adjusting screw (4) clockwise increases the minimum flow rate, and turning counterclockwise decreases. 1/4 turn of adjusting screw (4) changes the flow rate approx. 3 L/min (0.8 US gal/min).

: 24 mm : Nut (1), Nut (3) : 8 mm : Adjusting Screw (2) : 8 mm : Adjusting Screw (4)

2

1

3

4

T183-03-01-003

(Pump Flow Rate) Q

Maximum Flow Rate Adjustment

(Pump Flow Rate) Q

Minimum Flow Rate Adjustment

Pi

Pi (Flow Rate Control Pressure)

T4-4-24

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment: Adjustment of Torque Control The torque control is performed by pump delivery pressure P. Therefore, the torque constant control is adjusted by changing the set-force of inner spring (2) and outer spring (1).

(Before adjusting screws (4) and (6), mark the end of the adjusting screw with a white marker for the record of the original position.)

When resetting inner spring (2), loosen nut (5) and adjusting screw (6).

When resetting outer spring (1), loosen nut (3) and adjusting screw (4).

NOTE: When adjusting screw (4) is turned, inner spring (2) set-force varies. Therefore, when adjusting screw (4) is turned, turn adjusting screw (6) 2.24 times the turns of adjusting screw (4) in the opposite direction to keep inner spring (2) set-force unchanged. : 36 mm : Nut (3) : 24 mm : Adjusting Screw (4) : 13 mm : Nut (5) : 4 mm : Adjusting Screw (6)

1

2

3

4

5

6

W117-02-02-017

Outer Spring Adjustment Data Adjusting Screw Turn 1/4 Flow Rate Change 9.3 L/min (2.5 US gal/min) 2 Pressure Change 1.88 MPa (19.2 kgf/cm ) (273 psi) Engine Torque 16.7 N m (1.7 kgf m) Change (12.3 lbf ft)

(Pump Flow

Rate)

Q

P

(Pump Delivery Pressure)

T4-4-25

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment: Adjustment of Flow Rate Control The flow rate control is performed by pump flow rate control pressure Pi. Therefore, the flow rate control is adjusted by resetting the set-force of spring (1).

Loosen nut (2) and turn adjusting screw (3) to reset the set-force of spring (1).

NOTE: When the flow rate control is adjusted, the relief oil minimizing control is also changed at the same time. : 13 mm : Nut (2) : 4 mm : Adjusting Screw (3)

1

2

3

T117-05-04-006

Spring Adjustment Data Adjusting Screw Turn 1/4 2 Pressure Change (Pi) 0.13 MPa (1.3 kgf/cm ) (18.9 psi) Flow Rate Change 6.8 L/min (1.8 US gal/min)

(Pump Flow Rate) Q

Flow Rate Control

(Pump Flow

Relief Oil Minimizing Control

Rate)

Pi (Flow Rate Control Pressure)

T4-4-26

Q

P (Pump Delivery Pressure)

OPERATIONAL PERFORMANCE TEST / Component Test (Blank)

T4-4-27

OPERATIONAL PERFORMANCE TEST / Component Test SWING MOTOR DRAINAGE

Cap

Summary: To check swing motor performance, measure the amount of oil draining from the swing motor while swinging the upperstructure.

Swing motor while swinging the upperstructure.

NOTE: The amount of drain oil from the swing motor will change depending on hydraulic oil temperature.

Maintain hydraulic oil temperature within 50r5 qC (122r9 qF).

Preparation: 1. Maintain hydraulic oil temperature at 50r5 qC (122r9 qF). Rotate the swing motor to warm the inside of the motor.

Drain Hose

M183-07-052

Front Side

CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it.

2. Properly shut down the engine. Slowly loosen cap to release air from the hydraulic oil tank.

T183-04-04-008

3. Disconnect the swing motor drain hose at the hydraulic oil tank end. Install plug (ST 6491) to the disconnected end on the hydraulic oil tank.

Drain Hose

: 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) Preconditions for Measurement: 1. Engine Control Dial : Maximum Speed CAUTION: Prevent personal injury. Always make sure that the area is clear and that coworkers are out of the swing area before starting machine operation. Also, take care not fall off the machine during the measurement.

T183-04-04-009

ST 6491

T183-04-04-010

T4-4-28

OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Amount of Oil Drained While Swinging the Upperstructure (1)Fully retract the arm cylinder. Fully extend the bucket cylinder. Raise the boom so that the arm tip pin height is the same as the boom foot pin height. Be sure that the bucket is empty.

(2)Start the engine. Operate and hold the swing lever full stroke.

Start draining oil measurement after the swing speed reaches a constant maximum speed. The measuring time should be more than 20 seconds.

(3)Repeat the measurement at least three times in both clockwise and counterclockwise directions, and calculate the average values.

2. Amount of Oil Drained While Relieving Swing Motor Circuit (1)Thrust the bucket teeth into the ground as illustrated so that the upperstructure does not rotate when the swing lever is operated full stroke.

(2)Start the engine. Operate and hold the swing lever full stroke. Start drain oil measurement when drain oil starts coming out of the drain hose end. The measuring time should be more than 20 seconds.

(3)Repeat the measurement at least three times in both clockwise and counterclockwise directions, and calculate the average values.

T145-05-03-007

T145-05-03-008

Evaluation: Refer to the Performance Standard Table in Group T4-5.

Conversion of the amount of drain oil measured into the per-minute value First measure the amount of drain oil using a calibrated container. Then, convert the measured drain oil into the per-minute value using the formula below:

T183-04-04-009

'Q = 60 u q / t

Where : 'Q : Amount of drain oil per minute (L/min) t : Time measured (seconds) q : Total amount of drain oil (L)

T4-4-29

OPERATIONAL PERFORMANCE TEST / Component Test TRAVEL MOTOR DRAINAGE

Cap

Summary: To check travel motor performance, measure the amount of oil draining from the travel motor, while rotating the travel motor with the measuring side track jacked up.

NOTE: The amount of drain oil from the travel motor and the drain oil pressure will change depending on hydraulic oil temperature.

Maintain hydraulic oil temperature within 50r5 qC (122r9 qF).

Preparation: 1. Main main hydraulic oil temperature at 50r5 qC (122r9 qF). Rotate the travel motor to warm the inside of the motor.

Drain Hose

M183-07-052

CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may pop off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it.

2. Properly shut down the engine. Slowly loosen cap to release air from the hydraulic oil tank.

M183-01-001

3. Disconnect the travel motor drain hose at the travel motor end. Install plug (ST 6637) to the disconnected end. Connect the drain hose (3/4-16UN) to the travel motor.

Drain Hose

: 27 mm : 93 N m (9.5 kgf m, 69 lbf ft) Preconditions for Measurement: Engine Control Dial: Maximum Position

T157-05-04-019

Drain Hose

ST 6637

T183-04-04-011

T4-4-30

OPERATIONAL PERFORMANCE TEST / Component Test Preconditions for Measurement: 1. Engine Control Dial : Maximum Speed Measurement: (1) Start the engine. Jack up the measuring side track using the front attachment, as illustrated.

90䌞110q

CAUTION: Securely support the raised track using wooden blocks.

T142-05-03-011

(2) Rotate the raised track with the travel lever operated full stroke. Start drain oil measurement after the track rotation speed reaches a constant maximum speed. The measuring time should be more than 20 seconds.

(3) Repeat the measurement at least three times in both forward and reverse directions and calculate the average values.

T142-05-03-012

Evaluation: Refer to the Performance Standard Table in Group T4-5.

Conversion of the amount of drain oil measured into the paramount value First measure the amount of drain oil using a calibrated container. Then, convert the measured drain oil into the paramount value using the formula below: 'Q = 60 u q / t Where : 'Q : Amount of drain oil per minute (L/min) t : Time measured (seconds) q : Total amount of drain oil (L)

T157-05-04-019

T4-4-31

OPERATIONAL PERFORMANCE TEST / Component Test (Blank)

T4-4-32

OPERATIONAL PERFORMANCE TEST / Standard OPERATIONAL DARD

PERFORMANCE

STAN

The standard performance values are listen in the table below. Refer to the Groups 2 to 4 for performance test procedures. Values indicated in parentheses are reference values. The fuel lever shall be placed in the fast idle position and the hydraulic oil temperature is to be maintained at 50 r 5 qC (122 r 9 qF) unless otherwise specified.

EX1200-5 (Standard Performance)

Performance Test ENGINE SPEED Fast Idle Speed Slow Idle Speed Auto-Idle Speed Quick Idle Speed TRAVEL SPEED Fast Speed Mode Slow Speed Mode TRACK REVOLUTION SPEED Fast Speed Mode Slow Speed mode MISTRACK (in both fast and slow mode) TRAVEL MOTOR DRIFT SWING SPEED SWING FUNCTION DRIFT (Backhoe) (Loading Shovel) SWING MOTOR DRIFT MAXIMUM SWINGABLE SLANT ANGLE

min-1

1850r30 850r30 1400r100 850r30 sec /20 m

20.4r1.6 29.2r2.0 sec /3 rev

40.0r3.0 58.0r4.0 mm /20 m mm /5 min sec /3 rev

200 or less 0 30.0r2.0

mm /180q

mm /5 min

1100 or less

0

deg

(Backhoe) (Loading Shovel) SWING BEARING PLAY

Remarks

mm

12 or possibly more 10 or possibly more 2.0 or less

Allowable Limit: 6.3

3

NOTE: BH: Backhoe: With 5.0 m (PCSA heaped) Bucket, 3.4 m Arm, 9.1 Boom 3 LD: Loading Shovel: With 6.5 m Bucket

T4-5-1

OPERATIONAL PERFORMANCE TEST / Standard EX1200-5 (Standard Performance)

Performance Test CYLINDER CYCLE TIME (Backhoe) Boom Raise Boom Lower Arm Roll-In Arm Roll-Out Bucket Roll-In Bucket Roll-Out (Loading Shovel) Boom Raise Boom Lower Arm Extend Arm Retract Bucket Tilt-In Bucket Tilt-Out Bucket Open Bucket Close DIG FUNCTION DRIFT (Backhoe) Boom Cylinder Arm Cylinder Bucket Cylinder Bucket Bottom (Loading Shovel)

4.3r0.5 3.1r0.5 4.5r0.5 3.5r0.5 3.0r0.5 2.3r0.5

Remarks

BE: 4.5r0.5 BE: 3.3r0.5 BE: 4.5r0.5 BE: 4.0r0.5 BE: 3.3r0.5 BE: 2.7r0.5

5.5r0.5 4.0r0.5 2.9r0.5 2.5r0.5 3.3r0.5 2.2r0.5 1.1r0.5 1.6r0.5

30 or less 30 or less 30 or less 400 or less

Boom Cylinder Arm Cylinder Bucket Cylinder Bucket Bottom CONTROL LEVER OPERATING FORCE (HITACHI Control Pattern) kN (kgf) Boom Lever

BE: 50 or less, Allowable limit: 40 BE: 60 or less, Allowable limit: 35 BE: 30 or less, Allowable limit: 35 BE: 600 or less

30 or less 30 or less 30 or less 400 or less

19.7 (2.0) or less

Arm Lever (LD: Extend/Retract)

16.7 (1.7) or less

Arm Lever (BH: Roll-in/Roll-out)

16.7 (1.7) or less

Bucket Lever (*Roll-In/**Roll-Out) Swing Lever (Right/Left)

16.7 (1.7) or less 19.7 (2.0) or less

Travel Lever Bucket Open/Close Pedal

ISO Control Pattern: Swing Lever (Right/Left) ISO Control Pattern: Swing Lever (Right/Left) ISO Control Pattern: Arm Lever (LD: Extend/Retract, BH: Roll-out, Roll-in)

24.5 (2.5) or less

NOTE: * In the case of loading shovel specification, the operation is bucket tilt-in **In the case of loading shovel specification, the operation is bucket tilt-out

3

BH: Backhoe: with 5.0 m (PCSA heaped) Bucket, 3.4 m Arm, 9.1 m Boom 3 LD: Loading Shovel: with 6.5 m Bucket

T4-5-2

OPERATIONAL PERFORMANCE TEST / Standard EX1200-5 (Standard Performance)

Performance Test LEVER STROKE (HITACHI Control Pattern) Boom Lever Arm Lever

mm

105r10 83r10

Bucket Lever Swing Lever

ISO Control Pattern: Swing Lever

83r10 105r10

Travel Lever Bucket Open/Close Pedal BOOM RAISE/SWING COMBINED OPERATION (with Empty Bucket) Time sec/90q Bucket Tooth Tip Height (H) from Ground mm HYDRAULIC COMPONENT MPa (kgf/cm2) PRIMARY PILOT PRESSURE: Fast Idle Slow Idle SECONDARY PILOT PRESSURE SOLENOID VALVE SET PRESSURE MPa (kgf/cm2) Travel Mode Solenoid Valve Flow Rate Reducing Solenoid Valve Power Decrease Solenoid Valve Power Increase Solenoid Valve Oil Cooler Fan Control Solenoid Valve MAIN PUMP DELIVERY PRESSURE MPa (kgf/cm2) MAIN RELIEF PRESSURE MPa (kgf/cm2) Boom, Arm, Bucket, and Bucket Open (LD)

ISO Control Pattern: Arm Lever

115r10 5.5r0.6

BH

7300 or more

BH

5.2r0.5 (53r5) 4.3r0.5 (44r5) 3.6 (37) or less 3.6 (37) or less 3.6 (37) or less 3.6 (37) or less 0 to 2.7 (0 to 27) 0 to 1.36 (0 to 13.9)

Power Boost Travel Swing OVERLOAD RELIEF PRESSURE Arm Roll-out (BH), Arm Retract (LD)

Remarks

31.4r1.0 (320r10) 33.3r1.0 (340r10) 31.4r1.0 (320r10) 10 300㧗 -0 㧗1.0 (29.4 -0)

MPa (kgf/cm2) 1.0

Boom, Arm Roll-In (BH), Arm Extend (LD), Bucket, Bucket Open (LD) Bucket Close (LD) MAIN PUMP FLOW RATE L/min OIL COOLER FAN DRIVE PUMP FLOW RATE SWING MOTOR DRAINAGE L/min (at max. constant speed) TRAVEL MOTOR DRAINAGE L/min (at slow speed with track raised off the ground) NOTE: LD: Loading Shovel BH: Backhoe

T4-5-3

34.3㧗 -0 10 (350㧗 -0) 1.0 33.3㧗 -0 㧗10 (340 -0) 1.0 17.7㧗 -0 㧗10 (180 -0)

Refer to T4-5-4.

Refer to T4-5-4.

2 or less

Allowable Limit: 4

5 or less

Allowable Limit: 10

OPERATIONAL PERFORMANCE TEST / Standard MAIN PUMP P-Q DIAGRAM

OIL COOLER FAN MOTOR DRIVE PUMP P-Q DIAGRAM

x Hydraulic P-Q Control x Hydraulic P-Q Control

• Rated Pump Speed: 1787 min (rpm) • Pump Gear Reduction Ratio: 1.083 • Hydraulic Oil Temperature: 50r5 qC (122r9 qF) -1

• Rated Pump Speed: 1825 min (rpm) • Pump Gear Reduction Ratio: 1.106 • Hydraulic Oil Temperature: 50r5 qC (122r9 qF) -1

NOTE: Refer to T4-4-17.

NOTE: Refer to T4-4-23.

Main Pump P-Q Diagram Q L/min (US gal/min) A 490 (129) B 312 (82) C 107 (28) D 485 (128) E 307 (81) F 151 (40) G 477 (126) H 299 (79) I 220 (58)

P 2 MPa (kgf/cm , psi) 8.4 (86, 1218) 15.7 (160, 2276) 33.3 (340, 4828) 12.6 (128, 1827) 19.9 (203,2885) 33.3 (340, 4828) 19.2 (196, 2784) 26.5 (270, 3842) 33.3 (340, 4828)

Oil Cooler Fan Motor Drive Pump P-Q Diagram Q P 2 L/min (US gal/min) MPa (kgf/cm , psi) A 100 (26) 4.9 (50, 710) B 97 (25) 18.8r0.5 (192r5, 2726r72.5) C 82 (21) 21.6 (220, 3132)

Q (Flow Rate) L/min

Q (Flow Rate) L/min

600 A

D

500

600

G SP Mode Control (Pz) = 3.30 MPa

500

400 400 300

B

200

E Mode Control (PG) = 2.08 MPa

E

H 300 I F C

100

200 A

B

100 0

5

10

15

20

25

30

P (Pressure) MPa

T183-04-04-005

0

C

5

10

15

20

25

30

P (Pressure) MPa

T183-04-04-017

T4-5-4

OPERATIONAL PERFORMANCE TEST / Standard INJECTION PUMP Adjustment condition: 1. Nozzle Assembly: 37561-04000 2. Nozzle Tip: 10-Dia.0.31 3. Injection Pipe: 37561-12700(Dia.2.8-817 mm) 4. Fuel: JIS No.2 Light Oil 5. Fuel Temp.: 40r10 qC (104r18 qF) at inlet of PS pump 6. Pump Room Pressure: 0.3r0.05 MPa (3r0.5 2 kgf/cm ) at inlet of PS pump Adjustment of Injection Quantity: 1. Put together barrel mark and case mark.

2. Measure the infection quantity.

3. Adjust each cylinder to meet the specification of mean quantity.

Infection Pump Part No. Part Name H48273-00000 PS6 Adjust Point No.1 No.2 No.3

Rack Rc (mm) 72.5 83 75

Plunger Assembly Part No. Dia. (mm) H48230-01000 17

Engine Model S6R

Pump Rev. (rpm) 900 900 300

3

Mean q (mm /st)

Allowance (%)

20.2 74.1 22.3

r10 r5 r75

Barrel Mark

Case Mark

RC

T146-04-05-001

T4-5-5

Delivery Valve Part No. H48270-10010

OPERATIONAL PERFORMANCE TEST / Standard (Blank)

T4-5-6

SECTION 5

TROUBLESHOOTING CONTENTS Group 1 General

Group 3 Troubleshooting A

Introduction ..............................................T5-1-1

Troubleshooting A Procedure ...................T5-3-1

Diagnosing Procedure ..............................T5-1-2

Main Controller Fault Code List ................T5-3-2

Built-In Diagnosing System Operation ......T5-1-4

Main Controller A

Built-In Diagnosing Function Display List ..T5-1-6

Fault Code 01, 02, 03 .............................T5-3-4

Binary Number Bit List............................ T5-1-11

Fault Code 04 .........................................T5-3-4

Main Controller Fault Code List ..............T5-1-14

Fault Code 05 .........................................T5-3-5 Fault Code 06 .........................................T5-3-6

Group 2 Component Layout

Fault Code 07 .........................................T5-3-7

Main Components ....................................T5-2-1

Fault Code 08, 09 ...................................T5-3-8

Electrical System Components (1)............T5-2-2

Fault Code 10 .......................................T5-3-10

Electrical System Components (2)............T5-2-3

Fault Code 11, 12, 13 ...........................T5-3-12

Electrical System Components (3)............T5-2-4

Fault Code 14 .......................................T5-3-13

Electrical System Components .................T5-2-5

Fault Code 25 .......................................T5-3-14

On and Around Pumps .............................T5-2-6

Main Controller B

Main Control Valve ...................................T5-2-8

Fault Code 31, 32, 33 ...........................T5-3-15

Swing Control Valve ...............................T5-2-12

Fault Code 34 .......................................T5-3-15

Signal Control Valve ...............................T5-2-17

Fault Code 37 .......................................T5-3-16

Others ....................................................T5-2-26

Sensor Activating Range ........................T5-3-17

Group 4 Troubleshooting B Troubleshooting B Procedure ...................T5-4-1 Correlation between Trouble Symptoms and Part Failures ...................T5-4-2 Engine System Troubleshooting .............T5-4-14 All Actuator System Troubleshooting ......T5-4-40 Front Attachment System Troubleshooting ....................................T5-4-48 Swing System Troubleshooting...............T5-4-62 Travel System Troubleshooting...............T5-4-65 Other System Troubleshooting ...............T5-4-72

183T-5-1

Group 5 Troubleshooting C

Group 6 Troubleshooting D

Troubleshooting C Procedure ...................T5-5-1

Troubleshooting D Procedures .................T5-6-1

Malfunction of Coolant

How to Read Fault Codes on ECM

Temperature Gauge................................T5-5-2

Engine Diagnosis System .......................T5-6-2

Malfunction of Fuel Gauge .......................T5-5-4

Group 7 Electrical System Inspection

Malfunction of Indicator Light Check System ........................................T5-5-6

Precautions for Inspection and

Malfunction of Overheat Indicator .............T5-5-8 Malfunction of Air Cleaner Restriction

Maintenance ...........................................T5-7-1 Instructions for Disconnecting

Indicator ...............................................T5-5-10

Connectors .............................................T5-7-3

Malfunction of Fuel Level Indicator .........T5-5-12

Fuse Inspection ........................................T5-7-4

Malfunction of Preheat Indicator .............T5-5-14

Fusible Link Inspection .............................T5-7-5

Malfunction of Download Indicator ..........T5-5-15

Battery Voltage Check ..............................T5-7-6

Malfunction of Alternator Indicator ..........T5-5-16

Alternator Check ......................................T5-7-8

Malfunction of Engine Oil Pressure

Voltage Check ........................................T5-7-10

Indicator ...............................................T5-5-18

Continuity Check ....................................T5-7-17

Malfunction of Pump Transmission Oil Indicator ..........................................T5-5-20 Malfunction of Engine Exhaust Gas Temperature Indicator...........................T5-5-22 Malfunction of Engine Oil Level Indicator ...............................................T5-5-24 Malfunction of Coolant Level Indicator ....T5-5-26 Malfunction of Hydraulic Oil Level Indicator ...............................................T5-5-28 Malfunction of Auto-Lubrication Indicator ...............................................T5-5-32 Malfunction of Engine Stop Indicator ......T5-5-34 Malfunction of Engine Warning Indicator ...............................................T5-5-36 Malfunction of Quick-Idle Indicator .........T5-5-38 Malfunction of Auto-Idle Indicator ...........T5-5-40 Malfunction of Hour Meter ......................T5-5-42 Malfunction of Buzzer .............................T5-5-44 Malfunction of LCD.................................T5-5-46 Malfunction of Engine Troubleshooting Operation .............................................T5-5-48

183T-5-2

TROUBLESHOOTING / General INTRODUCTION Refer to the inspection and troubleshooting procedures after any machine trouble has occurred. The inspection and troubleshooting procedures are presented in an orderly fashion in this section to help you quickly find the cause and solution of the machine trouble.

The troubleshooting section in this manual consists of 7 groups; General, Component Layout, Troubleshooting A (base machine diagnosis using the built-in diagnosing system’s fault codes), Troubleshooting B (base machine diagnosis starting with inspection of abnormal operational status), Troubleshooting C (monitor diagnosis), Troubleshooting D (engine diagnosis indicated by the flashing pattern of indicator lights), and Electrical System Inspection.

• General • Component Layout • Troubleshooting A (base machine diagnosis using the built-in diagnosing system’s fault codes) • Troubleshooting B (base machine diagnosis starting with inspection of abnormal operational status) Refer to these procedures when troubleshooting by inspecting abnormal machine operational status.

Example: Even if the fuel lever is operated, engine speed doesn’t change.

• Troubleshooting C (monitor diagnosis) Refer to these procedures when gauges and/or indicators are malfunctioning.

Example: The fuel gauge doesn’t operate.

• Troubleshooting D (engine diagnosis relies on the flashing pattern of indicator lights) The engine is diagnosed by referring to the flashing pattern of the engine stop indicator and the engine warning indicator.

• Electrical System Inspection Refer to this group when required to obtain precautions and/or information for the electrical system inspection.

Example: Fuse Inspection

T5-1-1

TROUBLESHOOTING / General DIAGNOSING PROCEDURE These six basic steps are essential for efficient troubleshooting:

1. Study the system • Study the machine’s technical manuals. Know the system and how it works, and what the construction, functions and specifications of the system components are.

T107-07-01-001

2. Ask the operator Before inspecting, get the full story of malfunctions from your star witness --- the operator.

• How is the machine being used? (Find out if the machine is being operated correctly) • When was the trouble noticed, and what types of work the machine doing at that time?

• What are the details of the trouble? Is the trouble getting worse, or did it appear suddenly for the first time?

• Did the machine have any other troubles previously? If so, which parts were repaired before?

T107-07-01-002

3. Inspect the machine Before starting the troubleshooting procedure, check the machine’s daily maintenance points, as shown in the operator's manual.

Also, check the electrical system, including the batteries, as troubles in the electrical system such as low battery voltage, loose connections and blown fuses will result in malfunction of the controllers, causing total operational failure of the machine.

If troubleshooting is started without checking for blown fuses, a wrong diagnosis may result, wasting time. Be sure to check for blown fuses before troubleshooting. Even if a fuse looks normal by visual inspection, a fine crack is difficult to find.

Always use a tester when checking the fuses.

T107-07-01-003

T5-1-2

TROUBLESHOOTING / General 4. Operate the machine yourself Try to identify the trouble by operating the machine yourself.

If the trouble cannot be confirmed, stop the engine and obtain further details of the malfunction from the operator.

Also, check for any incomplete connections of the wire harnesses.

T107-07-01-004

5. Perform troubleshooting

CAUTION: If a harness or pipe is disconnected with the engine running, the machine may operate incorrectly, or high pressure oil may spray, causing personal injury. Be sure to disconnect harnesses or pipes after stopping the engine.

Perform self-diagnosis by operating the built-in self-diagnosing system. In case any fault code has been displayed by diagnosis using the built-in self-diagnosing system, check the cause of the trouble by referring to Troubleshooting A in this section. After the machine trouble has been corrected, the fault code will be deleted. If the engine stop indicator and the engine warning indicator in the cab start flashing by the ECM diagnosis system, check the cause of the trouble by referring to Troubleshooting D in this section.

Therefore, in case problems which are not easily repredicable are encountered, use the built-in self-diagnosing system and ECM diagnosis system to display the fault code. In case no fault codes are displayed, check all related parts/component operating condition using the monitor function of the built-in self-diagnosing system while referring to troubleshooting B in this section.

T107-07-01-006

6. Trace possible causes Before reaching a conclusion, check the most likely causes again. Try to identify the actual cause of the trouble.

Based on your conclusion, make a plan for appropriate repairs to avoid consequent malfunctions.

T5-1-3

T107-07-01-007

TROUBLESHOOTING / General BUILT-IN DIAGNOSING SYSTEM OPERATION

IMPORTANT: This system is to be operated by the HITACHI Dealer Only. Don't explain this system function to the customer.

In the service mode, the monitor LDC displays the diagnosing items, fault codes and monitored results (not all of them).

Built-In Diagnosing System Activation 1. While pressing the monitor SET switch, turn the key switch ON.

Display Selection Switch

Built-In Diagnosing System Operation 1. Each time the display selection switch is pressed, the displayed item will be changed as shown in the table on T5-1-6 or T5-1-7.

NOTE: The fault code is indicated in the display order 8. Fifteen fault codes for the main controller A and five fault codes for the main controller B are indicated. In case more than one fault code is indicated, they will be displayed with an interval of 1 second in order. x The LCD in the service mode displays only the item No. on the left and the monitored result on the right.

The item description is not displayed.

SET Switch

Liquid Crystal Display (LCD)

T183-01-02-013

Display Selection between Main Controller A and B 1. Remove the side cover on the left console.

2. Switch the MC display selection switch.

ON: Displays the main controller A value OFF: Displays the main controller B value NOTE: The main controller A value is displayed when the MC display selection switch is in neutral position.

Side Cover

M183-01-008

MC Display Selection Switch

Machine Front

ON

Neutral

OFF

T5-1-4

T183-05-01-001

TROUBLESHOOTING / General (Blank)

T5-1-5

TROUBLESHOOTING / General BUILT-IN DIAGNOSING FUNCTION DISPLAY LIST

Main Controller A Display Description Order 1.

Hour Meter 2.

Trip1 3.

Trip2 4.

Engine Actual Speed 5.

Hydraulic Oil Temperature 6.

7.

8.

Fault Code * 9.

Main Pump 1 Pressure 10.

Main Pump 2 Pressure 11.

Main Pump 3 Pressure 12.

Front Operation Pressure 13.

Travel Operation Pressure Engine Exhaust Gas 14.

Temperature 15.

EC Angle Digital Input 0 16.

Monitored Result {{{{{ h {{{{{ h {{{{{ h n {{{{ {{{ L1 {{ L2 {{{ 0 {{ 1 {{{{ 2 {{{{ 3 {{{{ 4 {{{{ 5 {{{{ 6 {{{{ 7 8

{{{{ {{

Digital Input 1

9

{{

Digital Input 2

A

{{

Digital Input 3

b

{{

Digital Output

c

{{

Proportional Valve ON/OFF Output

d

{{

Hydraulic Oil Cooling Output Current Power Increase Output Current

E F

Unit

-1

min qC 㧙 % 㧙 MPa MPa MPa MPa MPa qC

Possible to display Possible to display

{{{{ {{{{

mA

Possible to display

18.

19.

20.

22.

23.

Standard Mode Standard Mode (Subtraction) Standard Mode (Subtraction) Possible to display Possible to display Display Purpose Only Display Purpose Only Possible to display Possible to display Possible to display Possible to display Possible to display Possible to display Possible to display

V 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** mA

17.

21.

Remarks

NOTE: * Refer to T5-1-14 for the Fault Codes. ** Refer to T5-1-8 and T5-1-11 for 2 Digits displayed in Hexadecimal Number.

T5-1-6

Possible to display

Possible to display

Possible to display

Possible to display

Possible to display

Possible to display

TROUBLESHOOTING / General

Main Controller B Display Description Order 1.

Hour Meter 2.

Trip1 3.

Trip2 4.

Engine Actual Speed 5.

Hydraulic Oil Temperature 6.

7.

8.

Fault Code * 9.

Digital Input 0

Monitored Result {{{{{ h {{{{{ h {{{{{ h n {{{{ {{{ L1 {{ L2 {{{ 0 {{ 1 {{

10.

Digital Input 1

2

{{

11.

Digital Input 2

3

{{

12.

Digital Input 3

4

{{

13.

Digital Output 1

5

{{

14.

Proportional Valve ON/OFF Output

6

{{

15.

Auto-Lubrication Status 1

7

{{

16.

Auto-Lubrication Status 2 (upper 4 bits) Auto-Lubrication Status 2 (lower 4 bits) Auto-Lubrication Interval Selection

8

{{{{

9

{{{{

A

{{

Digital Output 2 (upper 4 bits) Digital Output 2 (lower 4 bits) 㧙 㧙 㧙

b

{{{{

c

{{{{

17.

18.

19.

20.

21.

22.

23.

NOTE:

Unit

-1

min qC 㧙 % 㧙 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 4 Digits displayed in Binary Number *** 4 Digits displayed in Binary Number *** 2 Digits displayed in Hexadecimal Number ** 4 Digits displayed in Binary Number *** 4 Digits displayed in Binary Number *** 㧙 㧙 㧙

d E F

* Refer to T5-1-15 for the Fault Codes. ** Refer to T5-1-8 and T5-1-11 for 2 Digits displayed in Hexadecimal Number. *** Refer to T5-1-13 for 4 Digits displayed in Binary Number.

T5-1-7

Remarks Standard Mode Standard Mode (Subtraction) Standard Mode (Subtraction) Possible to display Possible to display Display Purpose Only Display Purpose Only Possible to display Possible to display

Possible to display

Possible to display

Possible to display

Possible to display

Possible to display

Possible to display

Possible to display Possible to display Possible to display

Possible to display Possible to display 㧙 㧙 㧙

TROUBLESHOOTING / General Hexadecimal Number and 2 Digits Display Correspondence Chart between Hexadecimal Number and Binary Number Hexadecimal Number Binary Number

0

1

2

3

4

5

6

7

8

9

A

b

C

d

E

F

0000

0001

0010

0011

0100

0101

0110

0111

1000

1001

1010

1011

1100

1101

1110

1111

In Case of Digital Input 0 of Main Controller A (Ex.) Monitor Display

60

8

Hexadecimal Number 2 Digits Display Section

Upper

Lower

1. Convert the upper and lower number in the hexadecimal number 2 digits display section. (Refer to Correspondence Chart between Hexadecimal Number and Binary Number).

Upper 6 0110 Lower 0 0000 Therefore, binary number 01100000 can be obtained.

2. This value corresponds the bit on the Binary Number Bit List (refer to T5-1-11), as follows: bit bit bit bit bit bit bit bit

7 6 5 4 3 2 1 0

0 1 1 0 0 0 0 0

Main Controller Selection Switch = 0 Engine Oil Level Indicator Heavy Lift Switch Display Selection = 0 Checker Connection Blank = 0 Blank = 0 Blank = 0

Main Controller A bit Status of Main Controller (0) Contact Terminal is GND Opened

Current (1) Contact Terminal is Closed

3. If the value is "1", the terminal point corresponding the bit is closed. The contact terminal is connected to ground, so that power flows.

If the value is "0", the terminal point is opened, so that current does not flow. (Refer to Diagram 1) From the above information, it becomes apparent that the engine oil level indicator on the monitor is switched on, the heavy lift switch is turned on, and the checker is disconnected.

4. Convert the value for digital input 1, digital input 2, digital input 3 of the main controller A, and digital input 0, digital input 1, digital input 2 and digital input 3 of the main controller B. Then, calculate the corresponding bit values.

T5-1-8

Diagram 1. In Case of Digital Input

GND

TROUBLESHOOTING / General In Case of Digital Output of Main Controller A (Ex.) Monitor Display

51

c

Hexadecimal Number 2 Digits Display Section

Upper

Lower

1. Convert the upper and lower number on the hexadecimal number 2 digits display section.

(Refer to Correspondence Chart between Hexadecimal Number and Binary Number).

Upper 5 0101 lower 1 0001 Therefore, binary number 01010001 can be obtained.

2. This value corresponds the bit on the Binary Number Bit List (refer to T5-1-11), as follows: bit 7 bit bit bit bit bit bit bit

6 5 4 3 2 1 0

0 1 0 1 0 0 0 1

Engine Exhaust Gas Temperature Alarm Output Engine Oil Pressure Alarm Output Pump Cut-Off Output Travel Alarm Output Engine Protection Output Blank = 0 Engine Stop Request Auto-Idle Output

Main Controller A bit Status of Main Controller (1) GND

Vcc Load

Vcc Load

Cur-

(0) GND

3. If the value is "1", the controller internal voltage at the terminal corresponding the bit is connected to ground, so that power flows.

If the value is "0", the controller internal voltage at the terminal corresponding the bit does not connected to ground, so that power does not flow.

(Refer to Diagram 2) From the above information, it becomes apparent that the engine oil pressure indicator is turned on, and motion alarm and auto-idle control are activated.

4. Convert the value for digital output 1 of the main controller B. Then, calculate the corresponding bit values.

T5-1-9

Diagram 2. In Case of Digital Output

TROUBLESHOOTING / General Correspondence Chart between Hexadecimal Number and Binary Number Hexadecimal Number Binary Number

0

1

2

3

4

5

6

7

8

9

A

b

C

d

E

F

0000

0001

0010

0011

0100

0101

0110

0111

1000

1001

1010

1011

1100

1101

1110

1111

In Case of Proportional Valve ON/OFF Output of Main Controller A (Ex.) Monitor Display

60

d

Upper

Hexadecimal Number 2 Digits Display Section

Lower

1. Convert the upper and lower number on the hexadecimal number 2 digits display section.

(Refer to Correspondence Chart between Hexadecimal Number and Binary Number).

Upper 6 0110 lower 0 0000 Therefore, binary number 01100000 can be obtained.

Main Controller A bit Status of Main Controller

Solenoid Valve

Current

(1) Energized

Solenoid Valve

(0) De-energized

2. This value corresponds the bit on the Binary Number Bit List (refer to T5-1-11), as follows: bit 7 bit 6

0 1

bit 5

1

bit bit bit bit bit

0 0 0 0 0

4 3 2 1 0

Heavy Lift Solenoid Valve Output #1,#2 Pump Power Decrease Solenoid Valve Output #3 Pump Power Decrease Solenoid Valve Output Blank = 0 Blank = 0 Blank = 0 Blank = 0 Blank = 0

Diagram 3. Proportional Valve ON/OFF Output

3. If the value is "1", power flows at the terminal corresponding the bit.

If the value is "0", current does not flow at the terminal. (Refer to Diagram 3) From the above information, it becomes apparent that power flows on the #1, #2 power decrease solenoid valve and #3 pump power decrease solenoid valve.

4. Convert the value for the proportional valve On/Off output of the main controller B. Then, calculate the corresponding bit values.

T5-1-10

TROUBLESHOOTING / General BINARY NUMBER BIT LIST

Upper

Lower

Hexadecimal Number

Binary Number

bit 7

Main Controller A Display Description Order 16

Digital Input 0

17

Digital Input 1

18

Digital Input 2

bit

Digital Input 3

Digital Output

21

Proportional Valve ON/OFF Output

bit 4

bit 3

bit 2

bit 1

Upper

bit 0

bit

Lower

Main Controller Selection Switch Engine Oil Level Indicator Heavy Lift Switch Display Selection Switch Blank = 0 Auto-Idle Switch Overheat Switch S/P Mode Switch Blank = 0

3 2 1 0 3 2 1 0 3

6

Air Filter Restriction Indication Switch Coolant Level Switch Engine Oil Pressure Switch (Low Pressure) Blank = 1 Fuel Level Indicator Alternator Indicator Engine Oil Pressure Switch (High Pressure) Engine Exhaust Gas Temperature Alarm Output Engine Oil Pressure Alarm Output Pump Cut-Off Output Travel Alarm Output Heavy Lift Solenoid Valve Output #1, #2 Pump Power Decrease Solenoid Valve Output #3 Pump Power Decrease Solenoid Valve Output Blank = 0

2

Checker Connection Switch Blank = 0 Blank = 0 Blank = 0 E Mode Switch Blank = 0 Blank = 0 Blank = 0 Pump Contamination Sensor Input (Optional) Blank = 0

0 1

Blank = 0 Blank = 0

3 2 1 0

Blank = 0 Blank = 0 Blank = 0 Blank = 0

3

Engine Protection Output

2 1 0 3 2

Blank = 0 Engine Stop Output Auto-Idle Output Blank = 0 Blank = 0

1

Blank = 0

0

Blank = 0

7 6 5 4 7

20

bit 5

7 6 5 4 7 6 5 4 7

5 4

19

bit 6

6 5 4 7 6 5 4

T5-1-11

TROUBLESHOOTING / General

Upper

Lower

Hexadecimal Number

Binary Number

bit 7

Main Controller B Display Description Order

bit 6

bit

bit 5

bit 4

bit 3

bit 2

bit 1

Upper

bit 0

bit

Lower

9

Digital Input 0

10

Digital Input 1

6 5 4 7

Hydraulic Oil Level Switch (2) Boom Mode Selection Switch Auto-Lubrication Interval Set (A) Blank = 0

2 1 0 3

11

Digital Input 2

6 5 4 7

Blank = 0 Travel Mode Switch Auto-Lubrication Timer Switch (B) Blank = 1

2 1 0 3

12

Digital Input 3

13

Digital 1

6 5 4 7 6 5 4 7

2 1 0 3 2 1 0 3

14

Proportional Valve ON/OFF Output

Blank = 0 Auto-Lubrication Interval Set (B) Auto-Lubrication Cycle Switch (B) Hydraulic Oil Level Alarm Output Load Dump Prevention Output Step Light Output Auto-Lubrication Relay Output Boom Mode Selection Solenoid Valve Output Travel Mode Control Solenoid Valve Output Blank = 0 Blank = 0 Auto-Lubrication Activating Auto-Lubrication Indication Auto-Lubrication Error Occurrence Blank = 0

Checker Connection Switch Blank = 0 Blank = 0 Blank = 0 Auto-Lubrication Main Switch (A) Blank = 0 Blank = 0 Blank = 0 Auto-Lubrication Main Switch (B) Blank = 0 Blank = 0 Blank = 0 Auto-Lubrication Timer Switch (A) Blank = 0 Blank = 0 Blank = 0 Blank = 0 Blank = 0 Blank = 0 Auto-Lubrication Alarm Output Blank = 0

2

Blank = 0

1 0 3 2 1 0

Blank = 0 Blank = 0 Blank = 0 Blank = 0 Lubrication Selection Lubrication Selection

15

Output

Auto-Lubricatio n Status 1

7 6 5 4 7

Main Controller Selection Switch Hydraulic Oil Level Switch (1) Step Light Switch Display Selection Switch Blank = 0

3 2 1 0 3

6 5 4 7 6 5 4

NOTE: Lubrication status of Status 1 are as follows: Stopping: bit1=0 / bit0=0 Manual: bit1=0 / bit0=1 Auto: bit1=1 / bit0=0

Auto-Lubrication

T5-1-12

TROUBLESHOOTING / General NOTE: No need to convert to binary number.

Display Description Upper Data Set Value Order (Long, Middle, Short) = 0 (80, 70, 60) min Selection of (Long, Middle, Short) = 18 Auto-Lubrication 1 (50, 40, 30) min Interval (Long, Middle, Short) = 2 (25, 20, 15) min Selection Pattern of Auto-Lubrication Interval Auto-Lubrication Upper Lower Interval (min.)

0 0 80 0 1 70 0 2 60 1 0 50 1 1 40 1 2 30 2 0 25 2 1 20 2 2 15

4 Digits Displayed in Binary Number

Main Controller B Display Description Order 16

Auto-Lubrication Status 2 (upper 4 bits)

17

Auto-Lubrication Status 2 (lower 4 bits)

19

Digital Output 2 (upper 4 bits)

20

Digital Output 2 (lower 4 bits)

bit 3

bit 2

bit 1

bit 0

bit 3 2 1 0 3 2 1 0 3 2 1 0 3 2 1 0

Auto-Lubrication Activating Auto-Lubrication Indicator Auto-Lubrication Error Occurrence Blank = 0 Blank = 0 Blank = 0 Lubrication Selection Lubrication Selection Hydraulic Oil Level Indicator Load Dump Prevention Output Step Light Output Auto-Lubrication Relay Output Auto-Lubrication Indicator Output Blank = 0 Blank = 0 Blank = 0

NOTE: Lubrication status of Auto-Lubrication Status 2 (lower 4 bits) are as follows: Stopping: bit1=0 / bit0=0 Manual: bit1=0 / bit0=1 Auto: bit1=1 / bit0=0

T5-1-13

Lower

Interval Value

0

Long

1

Middle

2

Short

TROUBLESHOOTING / General MAIN CONTROLLER FAULT CODE LIST Main Controller A Fault Code Trouble 01 Abnormal EEPROM 02 Abnormal RAM 03 Abnormal A/D Conversion 04 Abnormal Sensor Voltage 05 Abnormal Engine Speed

06

07

08 09 10

11 12 13 14

25

Cause • Faulty Main Controller A •

• • • • Abnormal Main Controller A Reception • (Between Main Controller A and Main • Controller B) Abnormal Main Controller A Reception • (Between Main Controller A and DLU, or • between Main Controller A and Built-In Diagnosing System) Abnormal Front Pilot Pressure • Abnormal Travel Pilot Pressure • • Abnormal Engine Control Dial Angle • • • • Abnormal Pump 1 Delivery Pressure • Abnormal Pump 2 Delivery Pressure • Abnormal Pump 3 Delivery Pressure • Abnormal Engine Exhaust Gas Tempera- • ture • • Abnormal Oil Temperature Sensor • • •

T5-1-14

Faulty Main Controller A Faulty Main Controller A Faulty Harness Faulty Engine Speed Sensor 1 Faulty Main Controller A Faulty Harness Faulty Main Controller A Faulty Harness

Faulty Main Controller A Faulty Harness Faulty Pilot Pressure Sensor Faulty Main Controller A Faulty ECM Faulty Harness Faulty Engine Control Dial Faulty Main Controller A Faulty Harness Faulty Pump Delivery Pressure Sensor Faulty Main Controller A Faulty Harness Faulty Exhaust Gas Temperature Sensor Faulty Main Controller A Faulty Harness Faulty Oil Temperature Sensor

TROUBLESHOOTING / General

Main Controller B Fault code Trouble 31 Abnormal EEPROM 32 Abnormal RAM 33 Abnormal A/D Conversion 34 Abnormal Sensor Voltage 37 Abnormal Main Controller B Reception (Between Main Controller B and Built-In Diagnosing System)

Cause • Faulty Main Controller B • Faulty Main Controller B • Faulty Main Controller B • Faulty Harness

T5-1-15

TROUBLESHOOTING / General (Blank)

T5-1-16

TROUBLESHOOTING / Component Layout MAIN COMPONENTS 3

2 1

4 5 6 7 8 9 10 11 12 13 14 15

30 29

28

27 26 25

16

24 23

17 22

18 21

19 20

12345678-

Bucket Cylinder Arm Arm Cylinder Boom Boom Cylinder Front / Swing Pilot Valve Hydraulic Oil Tank Battery

910 11 12 13 14 15 16 -

Fuel Tank Auto-Lubrication Device Swing Device Main Control Valve Oil Cooler Intercooler Radiator Engine

17 18 19 20 21 22 23 -

T5-2-1

Pump Device Signal Control Valve Swing Bearing Travel Device Upper Roller Lower Roller Swing Control Valve

T183-01-02-001

24 25 26 27 28 29 30 -

Center Joint Track Adjuster Pilot Shut-Off Valve Front Idler Accumulator Travel Pilot Valve Bucket

TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM COMPONENTS (1) 2

Overall Layout

3 4

5 6 7

1

8 9 10

11 12 13 14

36 35 15

34

16

33

20

32

19

18

17

21 (Refer to T5-2-6) 22 (Refer to T5-2-6)

31 30

23 29 28

27

24

26 1 - Work Light (on Cab Roof) 2 - Monitor 3 - Quick Idle Switch 4 - Work Light ŅŅŅŅŅŅŅŅŅ (at the right side of Frame) 5 - Starter Relay 1 6 - Battery 7 - Battery Relay 8 - Horn 9 - Fuel Sensor

25

10 - Ambient Air Temperature Sensor 11 - Engine Oil Pressure Sensor 12 - Coolant Level Sensor 13 - Overheat Switch 14 - Coolant Temperature Sensor 15 - Air Cleaner Restriction Switch 16 - Alternator 17 - Exhaust Gas Temperature Sensor 18 - Engine Oil Level Sensor

19 - Boost Pressure Sensor 20 - Starter 21 - Solenoid Valve Unit 22 - Flow Rate Decrease Solenoid Valve 23 - 2-Spool EHC Valve 24 - Engine Speed Sensor 25 - Pump Transmission Oil Pressure Switch 26 - Oil Pressure Sensor 27 - All Operation Pressure Sensor

T5-2-2

T183-01-02-002

28 - Travel Mode Control Solenoid Valve 29 - Heavy Lift Solenoid Valve 30 - Hydraulic Oil Temperature Sensor 31 - Travel Pressure Sensor 32 - Hydraulic Oil Level Switch 33 - AC/DC Converter 34 - Work Light ŅŅŅŅŅŅŅ (Under Cab Floor) 35 - Sunlight Sensor 36 - Work Light (Entrance)

TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM COMPONENTS (2) Relays and Related Components 25

1

2

3

4

5

6

7

26

8

24 9

23 22 21 20 19

31

30

29

28

27 T183-01-02-011

18 10

17 16

15 14 13 12

11 T183-01-02-005

Around Batteries

47 45

48

32

33

46

34 35

44 43

36 37 38 39

42

41

40

T183-01-02-004

12345678910 11 12 -

ECM Relay Power Transistor 1 Power Transistor 2 Power Transistor 3 Flow Rate Decrease Solenoid Valve Relay Auto-Lubrication Relay Auto-Idle Relay Engine Protection Relay Fuse Box (Left) Main Controller B Main Controller A Washer Relay

13 14 15 16 17 18 19 20 21 22 23 24 -

Upper Wiper Relay 1 Upper Wiper Relay 2 Lower Wiper Relay Fuse Box (Right) 12V Power Source Terminal ECM Work Light Relay 2 Horn Relay Step Light Relay Load Dump Relay Engine Stop Relay DC-DC Converter

25 26 27 28 29 -

Work Light Relay 1 Engine Stop Indicator Relay Engine Warning Indicator Relay Preheat Relay 1 Preheat Indicator Relay

37 38 39 40 41 -

Fusible Link 3 Fusible Link 2 Fusible Link 1 Preheat Relay 3 Starter Relay 1

30 31 32 33 34 35 36 -

Alternator Relay Quick Idle Relay Junction Box Engine Stop Solenoid Relay Starter Relay 2 Start Repeating Relay Fusible Link 4

42 43 44 45 46 47 48 -

Fusible Link 5 Battery Relay 1 Preheat Relay 2 Battery Relay 2 Fusible Link 7 Fusible Link 6 Fusible Link 8

T5-2-3

TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM COMPONENTS (3) On and Around Engine 1

T183-01-02-014

3

4

5

6

2 7

8 11

9

10

1 - Air Heater 2 2 - Engine Oil Pressure Switch (High Pressure) 3 - Coolant Temperature Sensor

T183-01-02-003

4 - Overheat Switch 5 - Air Heater 1 (6 Used)

7 - Boost Pressure Sensor 8 - Governor Actuator

6 - Exhaust Gas Temperature Sensor

9 - Engine Stop Solenoid

T5-2-4

10 - Oil Level Switch 11 - Engine Oil Pressure Switch (Low Pressure)

TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM COMPONENTS (4) Monitor and Switch Panels

Monitor Panel 14

15

1

35 34

2

16

33 32 31

3 4

30 29

5 6

28

7

27 26

8

17 18 19 20

25 9 T183-01-02-013

24 23

13

22 21 36

10

12 11

T183-01-02-010

37 M183-01-035

1 - Monitor Panel

5 - Power Mode Switch

11 - Auto-Lubrication (ALU) Timer Switch 12 - Heavy Lift Switch 13 - Boom Mode Selection Switch 14 - Coolant Temperature Gauge 15 - Fuel Gauge Switch Panel

6 - Travel Mode Switch 7 - Work Light Switch

16 - Switch Panel 1 17 - Fuel Level Indicator

8 - Wiper/Washer Switch

18 - Alternator Indicator

9 - Key Switch

19 - Exhaust Gas Temperature Indicator

2 - Quick Idle Switch 3 - Engine Control Dial 4 - Auto-Idle Switch

20 - hydraulic Oil Level Indicator 21 - Engine Warning Indicator 22 - Coolant Level Indicator 23 - Engine Stop Indicator 24 - Auto-Lubrication Indicator 25 - Engine Oil Level Indicator 26 - Pump Transmission Oil Pressure Indicator 27 - Engine Oil Pressure Indicator 28 - Preheat Indicator

10 - Air Conditioner Control Panel

T5-2-5

29 - Download Indicator 30 - Overheat Indicator 31 - Air Filter Restriction Indicator 32 - Lubrication Mode Indicator 33 - Liquid Crystal Display (LCD) 34 - Auto-Idle Indicator 35 - Quick-Idle Indicator 36 - Preheat Switch 37 - Step Light Switch

TROUBLESHOOTING / Component Layout 1

ON AND AROUND PUMPS Front

Pump Device

2

10

3

9 8 7 4

6

Solenoid Valves and Related Components

18 Solenoid Valve Unit

T183-01-02-006

5

11 17

2-Spool EHC Valve

16

12 15 Front

13

14

T183-01-02-007

1 - Main Pump 3 Regulator 2 - Main Pump 1 Regulator

6 - Transmission Lubrication Oil Pump 7 - Pilot Pump

3 - Main Pump 1

8 - Main Pump 2

4 - Oil Cooler Fan Motor Drive Pump 5 - Pump Transmission Oil Pressure Switch

9 - Main Pump 2 regulator

11 - Power Increase Solenoid Valve (ST) 12 - Oil Cooler Fan Control Solenoid Valve (SF) 13 - Pilot Filter 14 - Flow Rate Decrease Solenoid Valve

10 - Main Pump 3

T5-2-6

15 - Pilot Relief Valve 16 - Power Decrease Solenoid Valve (SA) 17 - Power Decrease Solenoid Valve (SB) 18 - Boom Mode Selection Solenoid Valve (SC)

TROUBLESHOOTING / Component Layout (Blank)

T5-2-7

TROUBLESHOOTING / Component Layout MAIN CONTROL VALVE

2

3

4

5

6

7

8

1

Auxiliary: BH Bucket Open/Close: LD

9 33 Arm 1 Arm 2

10

32 Boom 2

11

Boom 1

31

12 13

30 Bucket 2

29

14

Bucket 1

15 16 28

17

Left Travel

27 18

Right Travel

26 T183-03-03-001

25

24

23

22

21

20

19

NOTE: BH: Backhoe LD: Loading Shovel 1 - Holding Valve Switch Valve (Boom) 2 - Load Check Valve (Arm 2 Tandem Circuit) 3 - Load Check Valve (Arm 2 Parallel Circuit) 4 - Arm Regenerative Valve 5 - Load Check Valve (Arm 1 Parallel Circuit) 6 - Load Check Valve (Auxiliary Tandem Circuit) 7 - Load Check Valve (Arm 1 Tandem Circuit) 8 - Holding Valve Switch Valve (Arm) 9 - Overload Relief Valve ŅŅŅŅ (Aux.: BH, ŅŅŅŅŅŅŅ Bucket Open/Close: LD)

10 - Overload Relief Valve (Arm) 11 - Holding Valve Check Valve (Arm) 12 - Load Check Valve (Boom 2 Tandem Circuit) 13 - Load Check Valve (Boom 2 Parallel Circuit) 14 - Overload Relief Valve (Boom Mode Selection) 15 - Boom Overload Relief Pressure Switch Valve 16 - Load Check Valve (Bucket 2 Tandem Circuit) 17 - Overload Relief Valve (Bucket 2)

18 - Load Check Valve (Left Travel Tandem Circuit) 19 - Load Check Valve (Left Travel Parallel Circuit) 20 - Load Check Valve (Bucket 2 Parallel Circuit) 21 - Check Valve (Main Relief Pressure Combining Circuit) 22 - Flow Combiner Valve 23 - Check Valve (Travel Flow Combine Circuit) 24 - Check Valve (Main Relief Pressure Combining Circuit) 25 - Shuttle Valve

T5-2-8

26 - Main Relief Valve 27 - Load Check Valve (Bucket 1 Tandem Circuit) 28 - Overload Relief Valve (Bucket 1) 29 - Load Check Valve (Boom1 Parallel Circuit) 30 - Overload Relief Valve (Boom) 31 - Holding Valve Check Valve (Boom) 32 - Slow Return Valve 33 - Make-Up Valve (Arm 2)

TROUBLESHOOTING / Component Layout 10

8

G

F

14,15 E

D

C

17 B

Section A A

25

26

24 9 Front

26 4 25

10

28 23

32 Section B

T183-03-03-003

22

T183-03-03-002

1

Section C

35

34

Right Travel

38

Bucket 1

Left Travel

39 Bucket 2

17

28

16 18 27

20 19 17

28 T183-03-03-004

36

T183-03-03-005

37

40

41

NOTE: BH: Backhoe LD: Loading Shovel 34 - Right Travel (Forward) Port

36 - Left Travel (Reverse) Port

35 - Left Travel (Forward) Port

37 - Right Travel (Reverse) Port

38 - Bucket 1 (Roll-Out : BH, Tilt-Out : LD) Port 39 - Bucket 2 (Roll-Out : BH, Tilt-Out : LD) Port

T5-2-9

40 - Bucket 1 (Roll-In : BH, Tilt-In : LD) Port 41 - Bucket 2 (Roll-In : BH, Tilt-In : LD) Port

TROUBLESHOOTING / Component Layout 2

3

4

5

6

7

8

1

Auxiliary: BH Bucket Open/Close: LD

9 33 Arm 1 Arm 2

10

32 Boom 2

11

Boom 1

31

12 13

30 Bucket 2

29

14

Bucket 1

15 16 28

17

Left Travel

27 18

Right Travel

26 T183-03-03-001

25

24

23

22

21

20

19

NOTE: BH: Backhoe LD: Loading Shovel 1 - Holding Valve Switch Valve (Boom) 2 - Load Check Valve (Arm 2 Tandem Circuit) 3 - Load Check Valve (Arm 2 Parallel Circuit) 4 - Arm Regenerative Valve 5 - Load Check Valve (Arm 1 Parallel Circuit) 6 - Load Check Valve (Auxiliary Tandem Circuit) 7 - Load Check Valve (Arm 1 Tandem Circuit) 8 - Holding Valve Switch Valve (Arm) 9 - Overload Relief Valve (Aux.: BH, Bucket Open/Close: LD)

10 - Overload Relief Valve (Arm) 11 - Holding Valve Check Valve (Arm) 12 - Load Check Valve (Boom 2 Tandem Circuit) 13 - Load Check Valve (Boom 2 Parallel Circuit) 14 - Overload Relief Valve (Boom Mode Selection) 15 - Boom Overload Relief Pressure Switch Valve 16 - Load Check Valve (Bucket 2 Tandem Circuit) 17 - Overload Relief Valve (Bucket 2)

18 - Load Check Valve (Left Travel Tandem Circuit) 19 - Load Check Valve (Left Travel Parallel Circuit) 20 - Load Check Valve (Bucket 2 Parallel Circuit) 21 - Check Valve (Main Relief Pressure Combining Circuit) 22 - Flow Combiner Valve 23 - Check Valve (Travel Flow Combine Circuit) 24 - Check Valve (Main Relief Pressure Combining Circuit) 25 - Shuttle Valve

T5-2-10

26 - Main Relief Valve 27 - Load Check Valve (Bucket 1 Tandem Circuit) 28 - Overload Relief Valve (Bucket 1) 29 - Load Check Valve (Boom1 Parallel Circuit) 30 - Overload Relief Valve (Boom) 31 - Holding Valve Check Valve (Boom) 32 - Slow Return Valve 33 - Make-up Valve (Arm 2)

TROUBLESHOOTING / Component Layout 42

Section D

43

Boom 1

Section E

46

4

47

Boom 2 Arm 2

14 30

32

Arm 1

11

33

8

15

12

29

5 3

7

13 2 10

30

T183-03-03-007

1

31

48

45 44

50

49

T183-03-03-006

9 Auxiliary (BH) Bucket Open/Close (LD)

Section F

Section G

10

6

T183-03-03-009

9 33

51 T183-03-03-008

42 - Boom 1 (Lower) Port

45 - Boom 2 (Raise) Port

43 - Boom 2 (Lower) Port

46 - BH: Arm 2 (Roll-Out) Port LD: Arm 2 (Retract) Port 47 - BH: Arm 1 (Roll-Out) Port LD: Arm 1 (Roll-In) Port

44 - Boom 1 (Raise) Port

48 - BH: Arm 2 (Roll-In) Port LD: Arm 2 (Extend) Port 49 - BH: Arm 1 (Retract) Port LD: Arm 1 (Extend) Port

T5-2-11

50 - BH: Auxiliary Port LD: Bucket (Open) Port 51 - BH: Auxiliary Port LD: Bucket (Close) Port

TROUBLESHOOTING / Component Layout SWING CONTROL VALVE 1

2

11

Boom 3

3

10

Swing

4

Bucket 3

5

9

Arm 3

6

T183-03-03-010

8 1 - Main Relief Valve 2 - Load Check Valve (Boom 3) 3 - Load Check Valve (Swing)

7

4 - Load Check Valve (Bucket 3) 5 - Load Check Valve (Arm 3)

7 - Check Valve (Arm 3)

10 - Holding Valve Switch Valve

8 - Make-Up Valve (Arm 3)

11 - Holding Valve Check Valve (Boom 3)

6 - Load Check Valve (Arm 3 Parallel Circuit)

9 - Overload Relief Valve (Swing)

T5-2-12

TROUBLESHOOTING / Component Layout 12

14

16

18

Section A 1 B

C

D

E

F

A

1

10

9

T183-03-03-011

13

Section B

15

T183-03-03-012

19

14

Section C

11

17

Swing

Boom 3

9

3 2 10

9 T183-03-03-014

11 15

T183-03-03-013

13

12 - Boom 3 (Lower) Port

13 - Boom 3 (Raise) Port

14 - Swing (Left) Port

T5-2-13

15 - Swing (Right) Port

TROUBLESHOOTING / Component Layout 1

2

11

Boom 3

3

10

Swing

4

Bucket 3

5

9

Arm 3

6

T183-03-03-010

8 1 - Main Relief Valve 2 - Load Check Valve (Boom 3) 3 - Load Check Valve (Swing)

7

4 - Load Check Valve (Bucket 3) 5 - Load Check Valve (Arm 3)

7 - Check Valve (Arm 3)

10 - Holding Valve Switch Valve

8 - Make-Up Valve (Arm 3)

11 - Holding Valve Check Valve (Boom 3)

6 - Load Check Valve (Arm 3 Parallel Circuit)

9 - Overload Relief Valve (Swing)

T5-2-14

TROUBLESHOOTING / Component Layout 16

18

Section D

Section E

Bucket 3

Arm 3

5 4

6

T183-03-03-015

17

19

7

T183-03-03-016

Section F

7

NOTE: BH: Backhoe

T183-03-03-017

LD: Loading Shovel 16 - Bucket 3 (Roll-Out) Port

17 - BH: Bucket 3 (Roll-In) Port LD: Bucket 3 (Tilt-In) Port

18 - BH: Arm 3 (Roll-Out) Port LD: Arm 3 (Retract) Port

T5-2-15

19 - BH: Arm 3 (Roll-In) Port LD: Arm 3 (Extend) Port

TROUBLESHOOTING / Component Layout (Blank)

T5-2-16

TROUBLESHOOTING / Component Layout SIGNAL CONTROL VALVE

A

A

Pilot Valve Side

T178-03-06-016

Cross Section A-A

Shockless Valve

Arm Flow Rate Control

Auxiliary

Pump 1 and 2 Flow Rate Control Valve

Auxiliary

Flow Combiner Valve Control Spool

Priority Valve

T178-03-06-002

T5-2-17

TROUBLESHOOTING / Component Layout Pilot Port NOTE: BH: Backhoe LD: Loading Shovel Pilot Valve Side Port Name Connecting to Port A Right Pilot Valve Port B Right Pilot Valve Port C Left Pilot Valve Port D Port E Port F

Right Pilot Valve Hydraulic Oil Tank Left Pilot Valve

Port G

Left Pilot Valve

Port H Port I Port J Port K Port L Port M

Right Pilot Valve Travel Pilot Valve Travel Pilot Valve Travel Pilot Valve Travel Pilot Valve Auxiliary Pilot Valve (BH) Bucket Open Pilot Valve (LD) Auxiliary Pilot Valve (BH) Bucket Open Pilot Valve (LD)

Port N Port SA Port SB Port PI Port PH Port SH Port DF

Pump 1 and 2 Regulator

Pilot Shut-Off Valve Pilot Shut-Off Valve

Hydraulic Oil Tank

T5-2-18

Note Boom Raise Pilot Pressure Boom Lower, Bucket Roll-Out Pilot Pressure Arm Roll-Out Pilot Pressure (BH) Arm Roll-In Pilot Pressure (LD) Boom Raise Pilot Pressure Returning to Hydraulic Oil Tank Arm Roll-Out Pilot Pressure (BH) Arm Roll-In Pilot Pressure (LD) Arm Roll-In Pilot Pressure (BH) Arm Roll-Out Pilot Pressure (LD) Bucket Roll-In Pilot Pressure Left Travel Forward Pilot Pressure Left Travel Forward Pilot Pressure Right Travel Forward Pilot Pressure Right Travel Forward Pilot Pressure Auxiliary Pilot Valve (BH) Bucket Open Pilot Valve (LD) Auxiliary Pilot Valve (BH) Bucket Open Pilot Valve (LD) Pump 1 and 2 Control Pressure Plug Primary Pilot Pressure Primary Pilot Pressure (Heat Circuit) Plug Returning to Hydraulic Oil Tank

TROUBLESHOOTING / Component Layout

Pilot Valve Connecting Side C

PH A

E M D H B F

SB G

PI

Pilot Valve Side

N

K

I SH J DF SA

L T178-03-06-016

T5-2-19

TROUBLESHOOTING / Component Layout

NOTE: BH: Backhoe LD: Loading Shovel Control Valve Side Port Name Connecting to Port 1 Control Valve Port 2

Port 3

Port 4

Port 5

Port 6 Control Valve Port 7

Control Valve

Port 8 Port 9 Port 10 Port 11 Port 12 Port 13

Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve

Port 14

Control Valve

Port SE Port SM Port SN Port SP Port SL Port SK

Shuttle Valve Shuttle Valve Shuttle Valve Shuttle Valve Control Valve

T5-2-20

Note Boom Raise Pilot Pressure Plug Plug Plug Plug Arm Roll-Out Pilot Pressure (BH) Arm Roll-In Pilot Pressure (LD) Arm Roll-In Pilot Pressure (BH) Arm Roll-Out Pilot Pressure (LD) Bucket Roll-In Pilot Pressure Left Travel Forward Pilot Pressure Left Travel Reverse Pilot Pressure Right Travel Forward Pilot Pressure Right Travel Reverse Pilot Pressure Auxiliary Close Pilot Pressure (BH) Bucket Close Pilot Pressure (LD) Auxiliary Open Pilot Pressure (BH) Bucket Open Pilot Pressure (LD) Boom Raise Priority Pilot Pressure Auxiliary Swing Brake Release Swing Brake Release Combiner Valve Shifting Pressure Plug

TROUBLESHOOTING / Component Layout

Control Valve Connecting Side SM

3 5

1 13 2

4

SK

SE 8

S3

14 Control Valve Side

7 9 6

10

SN

SL

11

Pressure Sensor (Travel)

12

T5-2-21

SP

T178-03-06-015

TROUBLESHOOTING / Component Layout Shuttle Valve NOTE: BH: Backhoe LD: Loading Shovel

Pump 1 and 2 Flow Control Valve

Arm Flow Rate Control Valve

Flow Combiner Valve Control Spool

Priority Valve

{ {

{

{ {

Arm Roll-Out (BH) Arm Roll-In (LD)

{

{

Arm Roll-In (BH) Arm Roll-Out (LD)

{

{

{ { {

{

{ {

Auxiliary (Close) (BH) Bucket Close (LD)

{

Auxiliary (Open) (BH) Bucket Open (LD)

{

Boom Raise Boom Lower

Bucket Roll-In Bucket Roll-Out Right Travel Left Travel

T5-2-22

TROUBLESHOOTING / Component Layout Swing Arm

1

2

3

4

Boom

Bucket

Left Travel

Right Travel

5

Shockless Valve

6 Arm Flow Rate Control Valve P1 and P2 Pump Flow Rate Control Valve Flow Combiner Valve Control Spool Priority Valve

T183-03-06-001

17 16 15 14 13 12

11 10 9

1 - Auxiliary (BH), Bucket Open/Close (LD)

6 - Right Travel

2 - Arm Roll-Out (BH), Arm Roll-In (LD), Auxiliary (BH), Bucket Open/Close (LD) 3 - Arm Roll-Out (BH), Arm Roll-In (LD)

7 - Left Travel, Right Travel

4 - Boom, Bucket Roll-Out

8 - Boom, Arm, Bucket, Right Travel 9 - Left Travel

8

7

10 - Boom Raise, Arm Roll-Out (BH), Arm Roll-In (LD), Auxiliary (BH), Bucket Open/Close (LD), Left Travel 11 - Boom, Arm, Bucket, Right Travel

15 - Boom Raise, Arm Roll-Out (BH), Arm Roll-In (LD)

12 - Arm Roll-In (BH), Arm RollOut (LD), Bucket Roll-In

16 - Boom Raise, Arm. Roll-Out (BH), Arm Roll-In (LD)

13 - Room Raise, Arm, Bucket

17 - Boom Raise, Arm. Roll-Out (BH), Arm Roll-In (LD), Auxiliary (BH), Bucket Open/Close (LD)

5 - Boom, Arm Roll-Out (BH), Arm Roll-In (LD), Bucket Roll-Out

NOTE: BH: Backhoe LD: Loading Shovel

T5-2-23

14 - Boom, Arm, Bucket

TROUBLESHOOTING / Component Layout

Swing Arm

1

2

3

4

Boom

Bucket Left Travel

Right Travel

5

Shockless Valve

6 Arm Flow Rate Control Valve P1 and P2 Pump Flow Rate Control Valve Flow Combiner Valve Control Spool Priority Valve

T183-03-06-001

17 16 15 14 13 12

11 10 9

NOTE: BH: Backhoe LD: Loading Shovel

T5-2-24

8

7

TROUBLESHOOTING / Component Layout

B

B

Pilot Valve Side

T178-03-06-016

Cross Section B-B 9 5

8

7 16 17 15

13

11

14 10

6

12

3

1

4 2

T178-03-06-009

1 - Auxiliary (BH), Bucket Open/Close (LD)

6 - Right Travel

2 - Arm Roll-Out (BH), Arm Roll-In (LD), Auxiliary (BH), Bucket Open/Close (LD) 3 - Arm Roll-Out (BH), Arm Roll-In (LD)

7 - Left Travel, Right Travel

4 - Boom, Bucket Roll-Out

8 - Boom, Arm, Bucket, Right Travel 9 - Left Travel

10 - Boom Raise, Arm Roll-Out (BH), Arm Roll-In (LD), Auxiliary (BH), Bucket Open/Close (LD), Left Travel 11 - Boom, Arm, Bucket, Right Travel

15 - Boom Raise, Arm Roll-Out (BH), Arm Roll-In (LD)

12 - Arm Roll-In (BH), Arm RollOut (LD), Bucket Roll-In

16 - Boom Raise, Arm Roll-Out (BH), Arm Roll-In (LD)

13 - Room Raise, Arm, Bucket

17 - Boom Raise, Arm Roll-Out (BH), Arm Roll-In (LD), Auxiliary (BH), Bucket Open/Close (LD)

5 - Boom, Arm Roll-Out (BH), Arm Roll-In (LD), Bucket Roll-Out

T5-2-25

14 - Boom, Arm, Bucket

TROUBLESHOOTING / Component Layout OTHERS Valves (1)

1

Swing Device

2

18

17

7 3

Front

4

6

5

T142-01-02-011

T183-01-02-008

Travel Device

Valves (2)

19

8 16 20

15

9

14

10

13 Valves (1)

12

11 T183-01-02-009 T183-01-02-012

1 - Shuttle Valve (Auxiliary Circuit) 2 - Reducing Valve 3 - Heavy Lift Solenoid Valve

6 - Shuttle Valve (Swing Brake Release) 7 - Shuttle Valve (Boom Raise Priority) 8 - Arm Preference Valve

4 - Travel Mode Control Solenoid Valve

9 - Signal Control Valve

5 - Brake Release Pressure Switch Valve

10 - Pump 3 Control Valve

11 - Shock Reducing Valve

16 - Shock Reducing Valve

12 - Shuttle Valve (Swing Make-Up) 13 - Shuttle Valve (For Switching Pump 3 Control Pressure) 14 - Shuttle Valve (BH: Bucket Roll-In) (LD: Bucket Tilt-In) 15 - Shuttle Valve (Pilot Pressure Control)

17 - Swing Parking Brake Release Valve 18 - Swing Relief Valve

NOTE: BH: Backhoe LD: Loading Shovel

T5-2-26

19 - Counterbalance Valve

20 - Travel Relief Valve

TROUBLESHOOTING / Troubleshooting A TROUBLESHOOTING A PROCEDURE Refer to troubleshooting A procedure in case any fault codes are displayed after diagnosing the main controller A and/or B using the built-in diagnosing system.

x How to Read Troubleshooting Flow Charts

YES(OK)

О

(2)

After completing the checking and/or measuring procedures in box (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).

(1) NO(NOT OK)

О ·Key switch: ON

(3)

Instructions, reference, and/or inspection methods and/or measurements are occasionally described under the box. If incorrectly checked or measured, not only will troubleshooting be unsuccessful but also damage to the components may result.

О

Refer to "Electrical System Inspection" group (Group 7) for descriptions in the dotted-line box.

О

Use the built-in diagnosing system for descriptions in the double-line box.

О

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.

NOTE: All harness end connectors are seen from the open end side.

Harness Open End Side

Harness End Connector T158-05-03-001

T5-3-1

TROUBLESHOOTING / Troubleshooting A MAIN CONTROLLER FAULT CODE LIST Main Controller A Fault Code Trouble 01 Abnormal EEPROM 02 Abnormal RAM 03 Abnormal A/D Conversion 04 Abnormal Sensor Voltage 05 Abnormal Engine Speed

06

Cause • Faulty Main Controller A

08 09

Abnormal Main Controller A Reception (Between Main Controller A and Main Controller B) Abnormal Main Controller A Reception (Between Main Controller A and DLU, or between Main Controller A and Built-In Diagnosing System) Abnormal Front Pilot Pressure Abnormal Travel Pilot Pressure

10

Abnormal Engine Control Dial Angle

11 12 13 14

Abnormal Pump 1 Delivery Pressure Abnormal Pump 2 Delivery Pressure Abnormal Pump 3 Delivery Pressure Abnormal Engine Exhaust Gas Temperature

25

Abnormal Oil Temperature Sensor

07

• • • • • •

Faulty Main Controller A Faulty Main Controller A Faulty Harness Faulty Engine Speed Sensor 1 Faulty Main Controller A Faulty Harness

• Faulty Main Controller A • Faulty Harness • • • • • • • • • • • • • • • •

T5-3-2

Faulty Main Controller A Faulty Harness Faulty Pilot Pressure Sensor Faulty Main Controller A Faulty ECM Faulty Harness Faulty Engine Control Dial Faulty Main Controller A Faulty Harness Faulty Pump Delivery Pressure Sensor Faulty Main Controller A Faulty Harness Faulty Exhaust Gas Temperature Sensor Faulty Main Controller A Faulty Harness Faulty Oil Temperature Sensor

TROUBLESHOOTING / Troubleshooting A Main Controller B Fault Code Trouble 31 Abnormal EEPROM 32 Abnormal RAM 33 Abnormal A/D Conversion 34 Abnormal Sensor Voltage 37 Abnormal Main Controller B Reception (Between Main Controller B and Built-In Diagnosing System)

Cause • Faulty Main Controller B • Faulty Main Controller B • Faulty Main Controller B • Faulty Harness

T5-3-3

TROUBLESHOOTING / Troubleshooting A MAIN CONTROLLER A FAULT CODE 01 ABNORMAL EEPROM FAULT CODE 02 ABNORMAL RAM FAULT CODE 03 ABNORMAL A/D CONVERSION YES

Faulty main controller A

Check if engine and machine actuators operate normally.

NO

NO

Faulty main controller A

YES

Look for the cause from other fault phenomenon

Exchange main controller A and main controller B. Check if the fault code is displayed.

* Even if any fault codes are still displayed after retrying, the machine can be used unless there are malfunctioning on the engine or machine.

FAULT CODE 04 ABNORMAL SENSOR VOLTAGE YES

Faulty main controller A

Check if voltage at alternator terminal L is normal. ·24V: With engine stopped ·28V: With engine running

Faulty alternator NO

T5-3-4

TROUBLESHOOTING / Troubleshooting A FAULT CODE 05 ABNORMAL ENGINE SPEED

Disconnect connector from engine speed sensor 1. Check if resistance between sensor end connector terminals #1 and #2 matches specification.

Connect engine speed sensor 1 harness end connector terminals #1 and #2.

YES Disconnect connector D from main controller A. Check for continuity between connector D harness end terminals #D13 and #D14.

NO

¡Specification: 1.3 to 1.6 k:

Connector (Harness End Connector Viewed from the Open End Side) Main Controller A Connector D

D14

Check for continuity between connector D harness end terminal #D13 and engine speed sensor 1 harness end connector terminal #2.

Broken harness between main YES controller A and engine speed sensor 1 (terminal #1)

NO

Broken harness between main controller A and engine speed sensor 1 (terminal #2) Faulty engine speed sensor 1

NO

D13

Faulty main controller A

YES

T183-05-04-009

Engine Speed Sensor 1

T146-05-03-005

T5-3-5

TROUBLESHOOTING / Troubleshooting A FAULT CODE 06 ABNORMAL MAIN CONTROLLER A RECEPTION (BETWEEN MAIN CONTROLLER A AND MAIN CONTROLLER B)

Exchange main controller A and main controller B. Turn off MC display selection switch to change the monitor display to main controller B. Display the faulty code.

Check if Code 37 is displayed.

YES

Faulty main controller A

NO

Broken harness between main controller A and main controller B

Connector (Harness End Connector Viewed from the Open End Side) Main Controller A Connector D

D9

T183-05-04-009

Main Controller B Connector D

D10

T183-05-04-009

T5-3-6

TROUBLESHOOTING / Troubleshooting A FAULT CODE 07 ABNORMAL MAIN CONTROLLER A RECEPTION (BETWEEN MAIN CONTROLLER A AND DLU, OR BETWEEN MAIN CONTROLLER A AND BUILT-IN DIAGNOSING SYSTEM) Between Main Controller A and DLU

YES

Disconnect connector from DLU. Check if voltage between harness end connector terminals #6 and #13 is 5Âą0.5 V.

Disconnect joining connector between DLU and main controller A. Check for continuity between DLU harness end connector terminal #5 and joining connector DLU end terminal #2.

YES

Faulty DLU

NO

Faulty ground wire on DLU

YES

¡Key Switch: ON NO

Reconnect connector D to main controller A. Connect DLU harness end connector terminals #6 and #13 with a clip.

Check for continuity between connector D harness end terminals #D11 and #D12.

Between Main Controller Diagnosing System

A

and

NO

Faulty main controller A

Check harness between DLU harness end connector terminal #6 and connector D harness end terminal #D11 for breakage or short circuit.

Broken harness between DLU YES terminal #6 and connector D terminal #D11

NO

Built-In

Broken harness between main controller A and monitor controller

YES Check harness between main controller A connector harness end terminal #D10 and monitor controller connector B harness end terminal #B1 for breakage or short circuit.

Broken harness between DLU terminal #13 and connector D terminal #D12

Faulty main controller A

NO

Connector DLU

Main Controller Connector D D10

D11

Monitor Controller Connector B D12

B1

Joining Connector (Between DLU and Main Controller A)

T183-05-03-001 T183-05-04-013 T183-05-03-002 T183-05-04-009

T5-3-7

TROUBLESHOOTING / Troubleshooting A FAULT CODE 08 ABNORMAL FRONT PILOT PRESSURE FAULT CODE 09 ABNORMAL TRAVEL PILOT PRESSURE

Disconnect connectors from all operation pressure sensor and NO travel pressure sensor.

Check if voltage between harness end connector terminals #1 and #3 is 5r0.5 V. ·Key switch: ON Check if fault codes are switched after switching all operation pressure sensor with travel pressure sensor and retrying.

Check harness between connector C terminal #C1 (all operation pressure) (or #C2 (travel YES operation pressure)) and all operation pressure sensor (or travel pressure sensor) terminal #2 for breakage or short circuit.

Check if voltage between all operation pressure sensor (or travel pressure sensor) harness end connector NO terminal #1 and vehicle frame matches specification. ·Key switch: ON ·Specification: 5r0.5 V

Connector (Harness End Connector Viewed from the Open End Side) Main Controller A Connector C C2 C10

C1

C23

C31

All Operation Pressure Sensor, Travel Pressure Sensor

1

2

NO

Faulty main controller A

Broken harness between main YES controller A and all operation pressure sensor or travel pressure sensor (terminal #3)

NO

Broken harness between main controller A and all operation pressure sensor or travel pressure sensor (terminal #1) Faulty pressure sensor

YES

C1

YES

Broken harness between main controller A and all operation pressure sensor or travel pressure sensor

3

T5-3-8

TROUBLESHOOTING / Troubleshooting A (Blank)

T5-3-9

TROUBLESHOOTING / Troubleshooting A FAULT CODE 10 ABNORMAL ENGINE ANGLE

Disconnect switch box connector. Check if resistance between switch panel end connector terminals #2 and #4 is 5r0.5 k:.

Reconnect switch box connector. Insert tester probe into connector terminal #3 from the reverse side.

Check if voltage varies as specified when engine control dial is turned.

CONTROL

DIAL

Disconnect switch box connector. Check if YES voltage between harness end connector terminals #2 and #4 is 5r0.5 V.

YES

Disconnect ECM connector J2.

Check harness YES between connector J2 harness end terminal #3 and switch box terminal #3 for breakage or short circuit.

NO

Disconnect main controller A connector C. Check harness between connector J2 harness end terminal #19 and connector C harness end terminal #C3 for breakage or short circuit.

路Key switch: ON Check if voltage between switch panel harness end connector terminal #2 and vehicle frame matches specification.

NO

路Specification: See table below.

YES

NO

路Key switch: ON 路Specification: 5r0.5 V

Engine Control Dial Specification Minimum Speed 0.3 to 1.0 V Maximum Speed 4.0 to 4.7 V Connector (Harness End Connector Viewed from the Open End Side) Main Controller A Connector C

ECM Connector J2

C3 C1

C23 T146-05-03-003

Switch Box

#3

Broken harness between ECM and engine control dial (terminal #4) Broken harness between ECM and engine control dial (terminal #2)

Faulty engine control dial

NO

#4

Broken harness between ECM and engine control dial

#2

T5-3-10

C10

C31

TROUBLESHOOTING / Troubleshooting A

Broken harness between ECM and main controller A

YES

YES

NO

Faulty main controller A

Connect connector J2.

Check if voltage on connector C harness end terminal #C3 is 5r0.5 V.

Faulty ECM NO

T5-3-11

TROUBLESHOOTING / Troubleshooting A FAULT CODE 11 ABNORMAL PUMP 1 DELIVERY PRESSURE FAULT CODE 12 ABNORMAL PUMP 2 DELIVERY PRESSURE FAULT CODE 13 ABNORMAL PUMP 3 DELIVERY PRESSURE

NO

Check if fault codes are switched after switching pump delivery pressure sensor (pump 1) with pump delivery pressure sensor (pump 2) or (pump 3) and retrying.

Disconnect pump delivery pressure sensor. Check if voltage between harness end connector terminals #1 and #3 is 5r0.5 V. ·Key switch: ON

Check harness between main controller A connector C (connector 31P) harness end terminals YES #C4 (pump 1), #C5 (pump 2) or #C6 (pump 3) and pump delivery pressure sensor terminal #2 for breakage or short circuit.

NO

Check if voltage between pump delivery pressure sensor harness end connector terminal #1 and vehicle frame matches specification. ·Key switch: ON ·Specification: 5r0.5 V

Connector (Harness End Connector Viewed from the Open End Side) Main Controller A Connector C C4

C23

C5

NO

Faulty main controller A

Broken harness between main YES controller A and pump delivery pressure sensor (terminal #3)

NO

Broken harness between main controller A and pump delivery pressure sensor (terminal #1) Faulty pump delivery pressure sensor

YES

C1

Broken harness YES between main controller A and pump delivery pressure sensor

C6 C10

C31

Pump Delivery Pressure Sensor

T146-05-03-006

T5-3-12

TROUBLESHOOTING / Troubleshooting A FAULT CODE 14 ABNORMAL ENGINE TEMPERATURE

Disconnect exhaust gas temperature sensor.

Check if sensor end connector resistance matches specification.

EXHAUST

GAS

Disconnect exhaust gas temperature sensor.

Connect exhaust gas temperature sensor harness end connector terminals #1 and #2 with YES a clip.

Remove connector B and connector C from main controller A. Check for continuity between connector B harness end terminal #B22 and connector C terminal #C7.

Faulty main controller A

YES

NO

Connect main controller A connector B harness end terminal #B22 to vehicle frame.

Check for continuity between exhaust gas temperature sensor harness end connector terminal #2 and vehicle frame.

Broken harness between main YES controller A and exhaust gas temperature sensor (terminal #1)

NO

¡Specification: See table below.

Broken harness between main controller A and exhaust gas temperature sensor (terminal #2) Faulty exhaust gas temperature sensor

NO

Exhaust Gas Temperature Sensor Specification Exhaust Gas Temperature Resistance (k:) (qC) (qF) 400 752 77.6 450 842 38.6 500 932 21.0 550 1022 11.2 600 1112 6.45 650 1202 3.62 700 1292 2.16 750 1382 1.28 800 1472 0.769 850 1562 0.467 900 1652 0.293 950 1742 0.189 Connector (Harness End Connector Viewed from the Open End Side) Main Controller A Connector B B1

B8

B19

B25

Connector C C1

C23

C7

Exhaust Gas Temperature Sensor C10

C31

B22

T146-05-03-005

T5-3-13

TROUBLESHOOTING / Troubleshooting A FAULT CODE 25 ABNORMAL OIL TEMPERATURE SENSOR

Connect oil temperature sensor harness end connector terminals #1 and #2 YES with a clip.

Remove connector B and connector C from main controller A. Check for continuity between connector B harness end terminal #B22 and connector C terminal #C24.

Disconnect oil temperature sensor.

Check if sensor end connector resistance matches specification.

NO

¡Specification: See table below.

Oil Temperature Sensor Specification Oil Temperature Resistance(k:) (qC) (qF) -20 -4 16.2r1.6 0 32 (5.88) 20 68 2.45r0.24 40 104 (1.14) 60 140 (0.534) 80 176 0.322 Connector (Harness End Connector Viewed from the Open End Side) Main Controller A Connector B B8

B19

B25 B22

Connector C C10

C1

C23

C31 C24

Oil Temperature Sensor

1

Connect main controller A connector B harness end terminal #B22 to vehicle frame.

Check for continuity between oil temperature sensor harness end connector terminal #2 and vehicle frame.

Broken harness between main YES controller A and oil temperature sensor (terminal #1)

NO

Broken harness between main controller A and oil temperature sensor (terminal #2) Faulty oil temperature sensor

NO

B1

Faulty main controller A

YES

2

T5-3-14

TROUBLESHOOTING / Troubleshooting A MAIN CONTROLLER B IMPORTANT: The fault code is displays on the monitor by the fault signal from main controller B which comes via main controller A. Check that main controller A operates normally before performing troubleshooting of main controller B.

FAULT CODE 31 ABNORMAL EEPROM FAULT CODE 32 ABNORMAL RAM FAULT CODE 33 ABNORMAL A/D CONVERSION YES

Check if machine operates normally.

* Faulty main controller B

Switch main controller B with main controller A. Turn on MC display selection switch, then NO switch the monitor display to main controller A. Check if code 01, 02 or 03 is displayed when fault code is displayed.

YES

Look for the cause from other fault phenomenon

Faulty main controller B NO

* Even if any fault codes are still displayed after retrying, the machine can be used unless there are malfunctioning on the engine or machine.

FAULT CODE 34 ABNORMAL SENSOR VOLTAGE

YES

Check if voltage at alternator terminal L is normal.

Switch main controller B with main controller A. Turn on MC display selection switch, then switch the monitor display to main controller A. Check if code 04 is displayed when fault code is displayed.

¡24 V: With engine stopped ¡28 V: With engine running

YES

Faulty main controller B

NO

Broken harness between main controller A and main controller B (Refer to fault code 06)

Faulty alternator NO

T5-3-15

TROUBLESHOOTING / Troubleshooting A FAULT CODE 37 ABNORMAL MAIN CONTROLLER B RECEPTION (BETWEEN MAIN CONTROLLER B AND BUILT-IN DIAGNOSING SYSTEM)

Switch main controller B with main controller A. Turn on MC display selection switch, then switch the monitor display to main controller A. Check if code 07 is displayed when fault code is displayed.

YES

Faulty main controller B

Broken harness between main controller A and main controller B (Refer to fault code 06)

NO

T5-3-16

TROUBLESHOOTING / Troubleshooting A SENSOR ACTIVATING RANGE 1. Checking Method • Hydraulic Oil Temperature: 50r5 qC • Unless specified: Power Engine Auto-Idle Mode Control Dial Switch Switch Maximum OFF OFF Speed • Monitor each sensor using the built-in diagnosing system.

2. Sensor Activating Range Sensor Engine Control Dial

Pressure Sensor

Operation Minimum Speed Maximum Speed Control Lever: Neutral Pilot Control Shut-Off Lever: LOCK Control Lever: Full Stroke Pilot Control Shut-Off Lever: UNLOCK

T5-3-17

Specification 0.3 to 1.0 V 4.0 to 4.7 V 0 to 0.10 MPa 2 (0 to 1.0 kgf/cm ) 3.3 to 3.9 MPa 2 (34 to 40 kgf/cm )

TROUBLESHOOTING / Troubleshooting A (Blank)

T5-3-18

TROUBLESHOOTING / Troubleshooting B TROUBLESHOOTING B PROCEDURE Apply troubleshooting B procedure when diagnosing from the fault phenomenon.

On the front section pages of this group T5-4, there are 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.

• How to Read Troubleshooting Flow Charts YES(OK)

•

(2)

After checking or measuring item (1), select YES (OK) or NO (NOT OK) and proceed to item (2) or (3), as appropriate.

(1)

NO(NOT OK)

• ·Key switch: ON

(3)

Special instructions, or reference item are indicated in the spaces under the box. Incorrect measuring or checking methods will render troubleshooting impossible, and may damage components as well.

•

Use the built-in diagnosing system for descriptions in the double-line box.

•

Causes are stated in the thick-line box. Scanning through the thick-line boxes, possible causes can be seen without going through the flow chart.

NOTE: All harness end connectors are seen from the open end side.

Harness

Harness End Connector Open End Side T158-05-03-001

T5-4-1

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.

Engine System Troubleshooting Trouble Symptom

E-1

E-2

E-3

Starter does not rotate even if key switch is turned to START position.

Although starter rotates, engine does not start.

Even if engine control dial is rotated, engine speed remains unchanged.

E-4 Even if key switch is turned OFF, engine does not stop.

Parts Main Controller A ECM Monitor Controller Switch Box Pilot Pressure Sensor Quick-Idle Switch Auto-Idle Switch Battery Relay Starter Relay 1 Starter Relay 2 Start Repeating Relay ECM Relay Engine Stop Solenoid Relay Quick-Idle Relay Auto-Idle Relay Flow Rate Decrease Solenoid Valve Relay Engine Stop Relay Preheat Relay 1 Preheat Relay 2 Preheat Relay 3 Power Transistor 1 Power Transistor 2 Engine Stop Solenoid Preheat Switch Flow Rate Decrease Solenoid Valve Power Decrease Solenoid Valve Engine Speed Sensor 1 Pump 1 and 2 Control Valve (Signal Control Valve) Shuttle Valve (Swing Make-Up) Shockless Valve (Pump 2 Regulator Pressure Pi Circuit Side) Starter Motor Engine Unit Main Pump / Regulator Shuttle Valve

z z

z z

z z z z z z

z

z z

z z

z

T5-4-2

z

TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently.

E-5 Engine speed is slow, or does not increase.

z

E-6 Quick-idle system is inoperable.

z z

z

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-7 Auto-idle system is inoperable.

z z

E-8

E-9

Even if control lever is operated, speed does not increase (with autoidle ON).

Engine speed does not increase when a particular function is operated (with auto-idle ON).

z

z z z z

z z

z

T5-4-3

TROUBLESHOOTING / Troubleshooting B

Trouble Symptom

E-10 Engine stalls.

E-11

E-12

Even if preheat switch is pressed, air heater 1 does not operate (Engine is difficult to start).

Even if preheat switch is pressed, air heater 2 does not operate.

z

z

Parts Main Controller A ECM Monitor Controller Switch Box Pilot Pressure Sensor Quick-Idle Switch Auto-Idle Switch Battery Relay Starter Relay 1 Starter Relay 2 Start Repeating Relay ECM Relay Engine Stop Solenoid Relay Quick-Idle Relay Auto-Idle Relay Flow Rate Decrease Solenoid Valve Relay Engine Stop Relay Preheat Relay 1 Preheat Relay 2 Preheat Relay 3 Power Transistor 1 Power Transistor 2 Engine Stop Solenoid Preheat Switch Flow Rate Decrease Solenoid Valve Power Decrease Solenoid Valve Engine Speed Sensor 1 Pump 1 and 2 Control Valve (Signal Control Valve) Shuttle Valve (Swing Make-Up) Shockless Valve (Pump 2 Regulator Pressure Pi Circuit Side) Starter Motor Engine Unit Main Pump / Regulator Shuttle Valve

z

z

z z z z

z z z z z z z

T5-4-4

z

TROUBLESHOOTING / Troubleshooting B (Blank)

T5-4-5

TROUBLESHOOTING / Troubleshooting B

All Actuator System Troubleshooting A-1 Trouble Symptom

All actuator speeds are slow.

A-2 All actuators are inoperable.

A-3

A-4

Actuator does not stop even if lever is returned to neutral.

SP mode is inoperable.

Parts Main Controller A Switch Box Flow Rate Decrease Solenoid Valve Power Decrease Solenoid Valve Power Increase Solenoid Valve Engine Speed Sensor 1 Spool Main Relief Valve Main Pump / Regulator Pilot Pump Pilot Valve Pilot Relief Valve Shuttle Valve (Swing Make-Up) Shockless Valve (Pump 2 Regulator Pressure Pi Circuit Side)

z

z z

z z z z

z z

z z

z z z z

z z

T5-4-6

TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently.

A-5 E mode is inoperable.

z z

z

T5-4-7

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.

TROUBLESHOOTING / Troubleshooting B

Front Attachment System Troubleshooting Trouble Symptom

F-1

F-2

F-3

F-4

Some front attachment movement is slow, or is inoperable.

Front attachment drifts remarkably.

Front attachment moves slightly to the opposite direction against the lever operation (boom raise, arm roll-out (BH), arm retract (LD) or bucket close (LD)).

Boom raise is slow at combined arm roll-out (BH)/arm retract (LD) and boom raise operation.

z z

z z

Parts Main Controller A Main Controller B Heavy Lift Switch Boom Mode Selection Switch Flow Rate Decrease Solenoid Valve Relay Power Transistor 1 Heavy Lift Solenoid Valve Boom Mode Selection Solenoid Valve Flow Rate Decrease Solenoid Valve Spool Overload Relief Valve Load Check Valve Shuttle Valve Main Relief Valve Boom Overload Relief Change Valve Main Pump / Regulator Pilot Valve Cylinder Slow-Return Valve Shockless Valve (Signal Control Valve) Arm Flow Rate Control Valve (Signal Control Valve) Shuttle Valve (Boom Raising Priority) Arm Preference Valve Shuttle Valve (Pilot Selection) Pump 3 Control Valve Shuttle Valve (Pump 3 Control Valve Selection) Shuttle Valve (Swing Make-Up) Shockless Valve (Pump 2 Regulator Pressure Pi Circuit Side)

z z

z z

z z

z

z z z z z z

T5-4-8

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.

F-5

F-6

F-7

F-8

Arm cylinder move unevenly at combined arm roll-out (BH)/arm retract (LD) and bucket roll-in (BH)/bucket tilt-in (LD), boom raise or swing operation.

Single arm roll-in (BH)/arm extend (LD), bucket roll-in (BH)/ bucket tilt-in (LD) or boom raise operation is slow.

Heavy lift function does not operate.

Boom mode selection function does not operate.

z z z z z z z z z z

z

z z

z z

z z

z z

z z z z z

T5-4-9

TROUBLESHOOTING / Troubleshooting B

Swing/Travel System Troubleshooting Trouble Symptom

Parts Main Controller B Switch Box Travel Mode Control Solenoid Valve Main Pump / Regulator Spool Overload Relief Valve Load Check Valve Flow Combiner Valve Shuttle Valve (Swing Brake Release) Pump 3 Control Valve Reducing Valve Priority Valve (Signal Control Valve) Flow Combiner Valve Selection Spool (Signal Control Valve) Counterbalance Valve Pilot Valve Shuttle Valve (Pilot Selection) Shuttle Valve (Swing Make-Up) Shockless Valve (Pump 2 Regulator Pressure Pi Circuit Side) Swing Motor Swing Parking Brake Release Valve Swing Reduction Gear Swing Relief Valve Travel Parking Brake Travel Motor Travel Reduction Gear Travel Relief Valve Center Joint

S-1 Swing is unmoving, slow or weak in power.

S-2 Swing drift is large when stopping.

T-1 Both right and left tracks do not rotate or rotate slowly.

T-2 Fast travel is inoperable.

z z z z z

z z

z

z

z z

z

z

z

z

z z z z z z z z

T5-4-10

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.

T-3 Slow travel is inoperable.

T-4

T-5

T-6

One side track does not move, moves slowly or mistracks.

Travel motor runs excessively fast when combined left travel and front attachment operation is performed with left track off the ground.

Machine mistracks during combined travel and front attachment operation.

z z z z

z

z

z

z

z z

z

z z z

z z z z

T5-4-11

TROUBLESHOOTING / Troubleshooting B

Other System Troubleshooting Trouble Symptom

O-1

O-2

O-3

O-4

Auto-lubrication indicator comes ON. (Grease pump does not operate.) (Empty grease in pump)

Grease pump operates excessively slow.

Grease pump does not stop operating.

Oil cooler fan motor does not rotate at speed corresponding to hydraulic oil temperature or does not rotate at all.

Parts Main Controller A Main Controller B Auto-Lubrication Selection Switch Proximity Switch Step Light Switch Auto-Lubrication Relay Step Light Relay Power Transistor 3 Oil Cooler Fan Control Solenoid Valve Grease Pump Oil Cooler Fan Motor Drive Pump Oil Cooler Fan Motor Step Light Follow Plate

z z

z

z z z

z

z

z z z z z

z

z

T5-4-12

TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently.

O-5 Step light does not come ON.

O-6 Even if step light switch is turned OFF, step light does not come OFF after 60 seconds.

z

z

z

z

z

z

O-7 Air conditioner.

z

T5-4-13

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.

TROUBLESHOOTING / Troubleshooting B ENGINE SYSTEM TROUBLESHOOTING E-1 Starter does not rotate even if key switch is turned to START position.

This problem is contributed to by many different causes. Diagnose the power system and the relay system separately to locate the cause of the problem.

• The electrical system is diagnosed in this group.

In case the starter doesn’t rotate due to failure in the engine unit, refer to the engine service manual.

• The same problem will be presented in case either the valve switch or the engine stop switch is activated. Check each switch condition first.

• Check for loose harness connections beforehand.

All indicate 0 V.

(2)

To Relay System Troubleshooting

(T5-4-16) Disconnect start repeating relay end connector.

Connect harness end connector terminals #1 and #2.

Disconnect starter motor ·Key switch: START terminal M. Check for continuity between har0 V - 24 V are ness end terminal and vehicle frame. repeated. ·Starter motor 1: Between terminal M and terminal #1 ·Starter motor 2: Between terminal M and terminal #2

YES Check for voltage at starter motor terminal C.

Check if voltage at starter motor terminal B is 24 V or over. ·Key switch: ON

YES Faulty starter unit, or faulty engine unit.

NO

(1)

NO

Starter Motor 1 Starter Motor 2

Broken harness between starter repeating relay terminal M and starter terminal M. To Power System Troubleshooting

(T5-4-15)

Connector Terminal M Terminal B

Starter Repeating Relay Connector 1 (Harness End)

Terminal C

T146-05-04-004

T5-4-14

T146-05-04-005

TROUBLESHOOTING / Troubleshooting B (1) Power System Troubleshooting

Faulty battery reYES lay, or faulty ground wire from battery relay terminal E. Check if voltage at YES battery relay terminal S is 24 V or over.

NO Check if voltage at Certain starter battery relay termiindicates 0 V nal B connected to corresponding starter is 24 V or over. ¡Key switch: ON

(1)

¡Key switch: ON

Check if voltage at battery relay terminal A is 24 V or over.

NO

NO

Broken harness between battery relay terminal S and fuse #10.

Broken harness between battery relay terminal A and battery.

Broken harness between battery relay terminal B and starter terminal B.

YES

Blown fuse #10, or broken harness between key switch terminal M and battery relay terminal S.

All starters indicate 0 V

Connector Battery Relay

T146-05-04-018

T5-4-15

TROUBLESHOOTING / Troubleshooting B (2)Relay System Troubleshooting Before troubleshooting, check the start repeating relay unit separately.

Cab Side

Test Procedures 1. Disconnect connectors 1 and 2 connected to the starter repeating relay.

2. Supply voltage of 24V to all of relay end connector terminals #3, #10 and #11 from the battery.

(Connect directly from the battery using harnesses.)

3. Measure the voltage at relay end connector 2 terminal #1. Check if it indicates 24 V. * When 0 V is indicated, the starter repeating relay is faulty.

4. Remove one of the harnesses connected to relay end connector terminals #10 or #11, then connect it to the vehicle frame.

5. Measure voltage at connector 2. Check if the voltage indicates 24 V - 0 V alternately. * When either 24 V or 0 V is indicated, the starter repeating relay is faulty.

To Starter Relay 2

To Starter 2 To Starter 1 Engine Side T183-05-04-001

Check if voltage at starter relay 2 connector 1 terminal #1 is 24 V or over.

YES

·Key switch: START ·Measure voltage at the terminals from the rear of connector using a piece of clip with connector connected.

Check if voltage at starter repeating relay connector 1 terminal #3 is 24 V or over. ·Key switch: START ·Measure voltage at the terminals from the rear of connector using a piece of clip with connector connected.

To #19 Fuse

NO

Check if voltage at YES starter relay 2 terminal B is 24 V or over. ·Key switch: START

NO

Broken harness between starter relay connector terminal #1 and starter repeating relay terminal #3.

Blown fuse box 2 fuse #19, or open wires between key switch terminal #G2 and starter repeating relay connector 1 terminal #3.

Connector Starter Repeating Relay Connector 1 (Relay Side)

Starter Relay 2 Connector 2

Starter Relay 2 Connector 1

Starter Relay 2 Terminal B Connector

Starter Relay 2 Terminal C Connector

1 T146-05-04-006

T146-05-04-006 T183-05-04-101

T183-05-04-002

T5-4-16

T146-05-04-008

TROUBLESHOOTING / Troubleshooting B

Disconnect starter relay 2 terminals B YES and C. Check for continuity between safety relay end terminals B and C. ¡Key switch: START

YES Check if voltage at starter relay 1 terminal #1 is 24 V. ¡Key switch: START

Disconnect starter relay 1. Check for YES continuity between harness end connector terminal #2 and vehicle frame.

NO

YES

NO

Faulty starter relay 1.

Faulty ground wire at starter relay 1 terminal #2.

Broken harness between starter relay 1 terminal #1 and safety relay terminal C. Faulty starter relay 2.

NO

Broken wire between starter relay 2 terminal S and starter repeating relay terminal #3.

NO

Connector Starter Relay 1

T146-05-04-009

T5-4-17

TROUBLESHOOTING / Troubleshooting B E-2 Although starter rotates, engine does not start.

Faulty engine (Refer to Engine Manual).

YES Check if governor moves fuel injecYES tion pump rack to ENGINE START position. ·Visual inspection ·Key switch: ON

Perform ECM troubleshooting. Check NO if faulty code on governor is indicated. ·Refer to Troubleshooting D

Check if engine stop solenoid is changed between OFF or ON when turning key switch to ON position.

Repair components according to the fault code.

YES

Disconnect ECM YES Faulty ECM. connector J1.

Check if voltage at ECM connector Check if voltage at NO J1 harness end ECM relay conterminal #23 is 24 NO nector 1 terminal V. #5 is 24 V. YES

Faulty engine stop solenoid.

Check for continuity YES between engine stop solenoid minus end terminal (black) and vehicle frame.

·Visual inspection ·Key switch: ON

Faulty engine stop solenoid ground.

NO Check if voltage at engine stop solenoid plus end NO terminal (white) is 24 V or over.

Broken harness between engine stop solenoid relay and stop solenoid.

YES

·Key switch: ON Check if voltage at engine stop solenoid relay connecNO tor 1 terminal #5 is 24 V. YES Check if voltage at engine stop soleNO noid relay connector 1 terminal #3 is 24 V.

NO

Blown fusible link #4, or broken harness between battery and engine stop solenoid relay.

Connector ECM Connector J1 (Black)

Engine Stop Solenoid Relay Connector 1 ECM Relay Connector 1

Engine Stop Solenoid Relay Connector 2 ECM Relay Connector 2

Engine Stop Relay

T146-05-04-006

T146-05-03-004 T146-05-04-010

T5-4-18

T183-05-04-003

TROUBLESHOOTING / Troubleshooting B

Broken harness between ECM connector J1 terminal #23 and ECM relay terminal #5.

YES

YES Check if voltage at ECM relay connector 2 terminal #2 is 24 V.

NO

Check if voltage at ECM relay connector 1 terminal #3 is 24 V.

Check for continuYES ity between ECM relay connector 2 terminal #1 and vehicle frame.

YES

Faulty ECM relay.

NO

Faulty ground at ECM relay connector 2 terminal #1.

Blown ECM fuse box fuse #4, or broken harness between key switch and ECM relay connector 1 terminal #3.

NO

Blown ECM fuse box fuse #1, or broken harness between battery and ECM rely connector 1 terminal #3.

NO

Faulty engine stop solenoid relay.

YES

¡Starter does not operate if there is a problem in the ground circuit.

Check if voltage at engine stop solenoid relay terminal #1 is 24 V.

Broken harness between engine stop relay terminal #4 and engine stop solenoid relay terminal #1.

YES

Check if voltage at engine stop relay NO terminal #4 is 24 V.

YES YES

Check if voltage at engine stop relay NO terminal #3 is 24 V.

NO

NO

T5-4-19

Check if voltage at engine stop relay terminal #1 is 24 V.

Check if voltage at engine stop relay terminal #2 is 24 V.

(1)

Broken harness between key switch terminal M and engine stop relay terminal #1.

Broken harness between key switch terminal M and engine stop relay terminal #3.

TROUBLESHOOTING / Troubleshooting B

Faulty power transistor 1.

YES

NO

Check if engine stop solenoid is switched after switching power transistor 1 with power transistor 2 or power transistor 3.

NO

NO

(1)

Broken harness between engine stop relay and power transistor 1.

Disconnect engines stop relay and power transistor 1 from connector.

Check for continuity between engine stop relay harness end connector terminal #2 and power transistor 1 harness end connector terminal #4.

NO Disconnect main controller A connector A. Check for continuity between power transisYES tor 1 harness end terminal #1 and connector A harness end terminal #A30.

YES

Broken harness between power transistor 1 and main controller A.

Faulty main controller.

Faulty engine stop relay.

YES

Connector Power Transistor 1

Main Controller A Connector A

T183-05-04-011

T183-05-04-008

A30

T5-4-20

TROUBLESHOOTING /Troubleshooting B (Blank)

T5-4-21

TROUBLESHOOTING /Troubleshooting B E-3 Even if engine control dial is rotated, engine speed remains unchanged. • The engine control dial, ECM and/or harness may have trouble. In those cases, fault code 10 is displayed on the built-in diagnosing system.

Refer to Troubleshooting A.

T5-4-22

TROUBLESHOOTING /Troubleshooting B E-4 Even if key switch is turned OFF, engine does not stop. • The link section between the governor and fuel injection pump may have trouble, or engine stop solenoid may be bound. Check the link section and engine stop solenoid beforehand. • If the above are not the cause, the engine unit may have trouble.

T5-4-23

TROUBLESHOOTING /Troubleshooting B E-5 Engine speed is slow, or does not increase.

• The engine control dial system of the switch box and/or ECM system may have trouble.

• Check for loose harness connections beforehand.

YES

YES

Disconnect switch box.

Check if voltage between harness end connector terminal #2 and terminal #4 matches specification. ·Key switch: ON ·Specification: 5r0.5 V

Check if resistance between switch box terminals #2 and #4 is normal.

Insert probe in switch box connector rear terminals #2 and #3. Check if voltage at those terminals matches specification.

NO

Check if voltage between switch box harness end connector terminal #2 and vehicle frame matches specification. ·Key switch: ON ·Specification: 5r0.5 V

·Resistance specification: 5r0.5 k: ·Voltage specification: 4.0 to 4.7 V

(at maximum speed)

Connect switch box harness end connector terminal #3 and vehicle frame.

Disconnect EMC connector J2.

Check for continuity between ECM harness end connector terminal #17 and vehicle frame.

Faulty engine control dial.

NO

T5-4-24

TROUBLESHOOTING /Troubleshooting B

YES

Faulty ECM system.

NO

Broken harness between switch box and ECM (sensor system).

YES

Faulty ECM system.

NO

Broken harness between switch box and ECM (ground system).

Disconnect ECM connector YES J2.

Check for continuity between EMC connector J2 terminal #16 and switch box harness end connector terminal #4.

Broken harness between switch box and ECM (power system).

NO

Connector (Harness End Connector Viewed from the Open End Side) Switch Box

ECM Connector J2

T183-05-04-004

T146-05-03-004

T5-4-25

TROUBLESHOOTING /Troubleshooting B E-6 Quick-idle system is inoperable.

• Check for loose harness connections beforehand.

NOTE: When the auto-idle switch is turned ON, the quick-idle system operates after 3 seconds.

YES

Faulty quick-idle switch.

Disconnect quickidle switch.

Connect harness end connector terminals with a clip.

Check if quick-idle system is operated. ·Engine: Running ·Control lever: Neutral

NO

Disconnect monitor controller connector C. YES Check for continuity between monitor controller terminal #B11 and terminal #C3.

Disconnect monitor controller connector B. Check for continuity between monitor controller harness end connector terminal #B11 and quick-idle switch end terminal.

Disconnect quick-idle relay.

YES Check for continuity between connector C harness end terminal #C3 and quick-idle relay connector harness end terminal #2.

NO

Faulty monitor controller.

Broken harness between monitor controller and quick-idle switch.

NO

Connector Monitor Controller Connector B

Connector C

C3

Quick-Idle Relay

T183-05-04-014

B11 T183-05-04-003

T183-05-04-013

T5-4-26

TROUBLESHOOTING /Troubleshooting B

Broken harness between monitor controller and quick-idle relay.

NO

Blown fuse #14, or broken harness between fuse box and quick-idle relay.

NO

Check if voltage between quick-idle YES relay connector terminals #1 and #3 is 24 V.

NO

Check if voltage at quick-idle relay YES connector terminal #5 is 24 V.

Faulty quick-idle relay.

YES

Disconnect ECM connector J2.

Check if voltage at YES harness end connector terminal #6 is 24 V. NO

ECM Connector J2

T146-05-03-004

T5-4-27

Faulty ECM.

Broken harness between quick-idle relay and ECM.

TROUBLESHOOTING /Troubleshooting B E-7 Auto-idle system is inoperable.

• The auto-idle system will stop if one of pressure switches is turned ON. • Check for loose harness connections beforehand.

YES

Faulty auto-idle relay.

YES

Check if auto-idle system operates after switching autoidle relay with other general-purpose relay. ·Key switch: ON ·Auto-idle switch: ON ·Control lever: Neutral NO

Disconnect auto-idle relay.

Check if voltage between harness end connector terminals #1 and #3 is 24 V.

Connect connector.

Check if auto-idle sysYES tem operates after switching power transistor 2 with power transistor 1 or power transistor 3. ·Key switch: ON ·Auto-idle switch: ON ·Control lever: Neutral

NO

Faulty power transistor 2.

Disconnect auto-idle relay and power transistor 2.

Check for continuity between auto-idle relay harness end connector terminal #2 and power transistor 2 harness end connector terminal #7.

Blown fuse #14, or broken harness between fuse box and auto-idle relay.

NO

Connector Main Controller A Connector A

B16 Connector B

Switch Box

Power Transistor 2

T183-05-04-004 T183-05-04-005

A29

T5-4-28

2

T183-05-04-011

TROUBLESHOOTING /Troubleshooting B

Check if voltage at YES switch box connector terminal #8 is 5 V. ·Key switch: ON ·Auto-idle switch: ON ·Control lever: Neutral

Disconnect main controller A connector B. YES Check if voltage at harness end connector terminal #B16 is 5 V.

Connect connector.

Disconnect main YES controller A connector A. Check if voltage at connector A terminal #A29 is 5 V.

Connect connector.

Disconnect power YES transistor 2. Check if voltage at harness end connector terminal #2 is 5 V.

NO

(1)

Faulty main controller A.

Broken harness between main controller A and switch box.

NO

Faulty switch box.

NO Broken harness between auto-idle relay and power transistor 2.

NO

YES

Faulty ECM.

Connect connector.

Disconnect ECM conYES nector J2.

Check if voltage at harness end connector terminal #13 is 24 V.

(1)

Broken harness between auto-idle relay and ECM.

NO

Broken harness between main controller A and power transistor 2.

NO

Auto-Idle Relay

ECM Connector J2

T183-05-04-003 T146-05-03-004

T5-4-29

TROUBLESHOOTING /Troubleshooting B E-8 Even if control lever is operated, speed does not increase. (with auto-idle ON) • The pilot sensor (front attachment), main controller A and/or harness may have trouble. In either cases, fault code 08 is displayed on the built-in diagnosing system.

Refer to Troubleshooting A.

T5-4-30

TROUBLESHOOTING /Troubleshooting B E-9 Engine speed does not increase when a particular function is operated (with auto-idle ON)

Speed does not increase only at certain operation.

Faulty shuttle valve.

T5-4-31

TROUBLESHOOTING /Troubleshooting B E-10 Engine stalls.

• The cause differs according to the engine speed.

• If power decrease solenoid valve (SA) has a trouble, the swing speed does not change at E mode.

• The engine speed sensor 1 and/or main controller A may have trouble. In either cases, fault code 05 is displayed on the built-in diagnosing system.

Refer to Troubleshooting A. • Check for loose harness connections beforehand.

Disconnect lines from flow rate decrease solenoid valve. Check if engine stalls when disconnected lines are connected each other directly.

YES Check if output to flow rate decrease solenoid valve is normal.

Around -1 850 min

Check engine speed.

NO

·Built-in diagnosing system: Main controller A Monitor item: Digital output: bit 5: Pump flow rate NO cut-off output Disconnect lines from power decrease solenoid valve (SA, SB). Check if YES engine stalls when disconCheck if outnected lines are connected put to flow each other directly. rate decrease solenoid valve is normal.

Below -1 1400 min

Over -1 1400 min

Install pressure gauge on hose entering flow YES rate decrease solenoid valve input port.

Measure the pressure.

·Built-in diagnosing system: Main controller A Monitor item: Proportional NO valve ON/OFF output: bit 6: #1, 2 pump power decrease solenoid valve output

NOTE: All regulators are unlikely to become inoperable at the same time.

Disconnect and check lines from one solenoid valve, then check the other.

Disconnect flow rate decrease solenoid valve.

Connect harness end connector terminals with a clip.

Check for continuity between harness end connector terminals.

Faulty main controller.

YES Disconnect power decrease solenoid valve (SA, SB).

Connect harness end connector terminals with a clip.

Disconnect main controller A connector A. NO Check for continuity between harness end connector terminals #A19 and #A20 (SB), and terminals #A11 and #A14 (SA).

Faulty main controller A.

Faulty engine and fuel system.

Connector Main Controller A Connector A

A19

A20

Connector D

Flow Rate Decrease Solenoid Valve

Power Transistor 1

T183-05-04-011

A14

T183-05-04-010

T183-05-04-008 T183-05-04-009

D14

T5-4-32

TROUBLESHOOTING /Troubleshooting B

Faulty pump 1 and/or 2 flow rate control valve in signal control valve.

2

Less than 3.9 MPa (40r1 kgf/cm )

Faulty shuttle valve (swing make-up), shockless valve or regulator.

2

3.9 MPa (40r1 kgf/cm ) or over NO Check if voltage at flow YES rate decrease solenoid valve relay connector terminal #5 is 24 V.

Faulty flow rate decrease solenoid valve.

NO

Blown fuse #14.

Check if voltage at flow rate decrease solenoid valve relay connector terYES minals #1 and #3 are 24 V.

NO

Check if voltage at flow rate decrease solenoid valve relay YES connector terminal #2 is 24 V.

Faulty flow rate decrease solenoid valve relay, or broken harness between flow rate decrease solenoid valve relay and power transistor 1.

(1)

YES

Broken harness between flow rate decrease solenoid valve and flow rate decrease solenoid valve relay.

NO

Faulty regulator.

Broken harness between power decrease solenoid valve (SA, SB) and main controller A.

NO

Faulty power decrease solenoid valve.

YES

Flow Rate Decrease Solenoid Valve

Input Port

Flow Rate Decrease Solenoid Valve Relay

Power Decrease Solenoid Valve

T183-05-04-010

T183-05-04-003 T183-05-04-012

T5-4-33

Engine Speed Sensor 1

T146-05-03-006

TROUBLESHOOTING /Troubleshooting B

(1)

YES

Faulty power transistor 1.

NO

Broken harness between power transistor 1 and main controller A.

Check if engine stalls after switching power transistor 1 with power transistor 2 or power transistor 3.

T5-4-34

TROUBLESHOOTING /Troubleshooting B (Blank)

T5-4-35

TROUBLESHOOTING /Troubleshooting B E-11 Even if preheat switch is pressed, air heater 1 does not operate.

(Engine is difficult to start) • This troubleshooting should be applied only when the air heater 1 in the engine doesn’t operate. In case the preheat indicator only doesn’t light, refer to Troubleshooting C. • When the preheat switch is pressed, the air heater 1 is heated by electricity for 60 seconds.

When measuring voltages in the circuit, check the voltage within 60 seconds after pressing the preheat switch, or turn the preheat switch OFF and wait for more than 60 seconds. Then, press the preheat switch again.

Blown fusible link #7, or broken wire between preheat relay 2 terminal M and air heater 1.

YES

YES Check for continuity between preheat relay 2 terminal #2 and vehicle frame.

YES Check if voltage at preheat relay 2 terminal M is 24 V.

NO

Check if voltage YES at preheat relay 2 terminal #1 is 24 V.

·Key switch: ACC ·Preheat switch: ON

·Key switch: ACC ·Preheat switch: ON Check if voltage at preheat relay 2 terminal B is 24 NO V.

NO

Check if voltage at preheat relay 1 terminal #5 is 24 V.

·Key switch: ACC ·Preheat switch: ON

·Key switch: ACC ·Preheat switch: ON

YES

Faulty preheat relay 2.

Faulty ground from preheat relay 2 terminal #2.

Broken harness between preheat relay 1 terminal #5 and preheat relay 2 terminal #1.

Check if voltage at preheat relay 1 NO terminal #3 is 24 V. Broken harness between preheat relay 2 and battery.

NO

Connector ECM Connector J2 (white)

Preheat Relay 1

T183-05-04-003

T146-05-03-004

T5-4-36

TROUBLESHOOTING /Troubleshooting B

Connector ECM Relay

Preheat Relay 2

T183-05-04-102 T146-05-04-010

B

M 1. To Preheat Relay 2. To Ground

YES

Faulty preheat relay 1.

Check for continuity YES between preheat relay 1 terminal #2 and vehicle frame.

Faulty ground from preheat relay 1 terminal #1.

NO YES

Check if voltage at preheat relay 1 terminal #1 is 24 V.

·Key switch: ACC ·Preheat switch: ON

Disconnect ECM J2 and preheat relay 1.

Connect preheat 1 harness end connector terminal #1 and NO vehicle frame. Check for continuity between ECM connector J2 harness end terminal #9 and vehicle frame. ·Key switch: ACC ·Preheat switch: ON

Broken harness between ECM connector J2 terminal #9 and preheat relay 1 terminal #1.

NO

Disconnect ECM relay.

Connect ECM relay harness end connector terminal #5 YES and vehicle frame.

Check for continuity between ECM connector J2 harness end terminal #5 and vehicle frame. ·Key switch: ACC ·Preheat switch: ON

YES Faulty ECM.

NO

Faulty preheat switch.

Blown ECM fuse box fuse #2, or broken harness between ECM connector J2 terminal #5 and ECM relay.

Blown ECM fuse box fuse #3, or broken harness between preheat relay 1 terminal #3 and ECM relay.

NO

T5-4-37

TROUBLESHOOTING /Troubleshooting B E-12 Even if preheat switch is pressed, air heater 2 does not operate.

• The air heater 2 is heated by power for 15 seconds after the preheat switch is pressed. When checking the voltage at each parts, perform the measurement within 15 seconds after the preheat switch is pressed, or turn "OFF" the preheat switch, then turn "ON" the preheat switch again after 15 seconds.

NO

Refer to E-11.

NO NO

Check if air heater 1 is activated. ·Key switch: ACC ·Preheat switch: ON

Check if voltage at preheat relay 3 terminal M is 24 V.

NO

Check if air heater 2 is activated after switching preheat YES relay 3 with preheat relay 2. ·Key switch: ACC ·Preheat switch: ON

Check if voltage at preheat relay 3 terminal B is 24 V. ·Key switch: ACC ·Preheat switch: ON

·Key switch: ACC ·Preheat switch: ON YES

Blown fusible link #8, or broken harness between preheat relay 3 and battery.

Check for continuity between YES preheat relay 3 terminal #2 and vehicle frame.

Broken wire between preheat relay 3 terminal M and air heater 2.

Faulty preheat relay 3.

YES

Connector ECM Connector J2 (white)

T146-05-03-004

T5-4-38

TROUBLESHOOTING /Troubleshooting B

Connector ECM Relay

Preheat Relay 3

T183-05-04-102 T146-05-04-010

B

M 1. To ECM 2. To Ground

Faulty ground from preheat relay 3 terminal #2.

NO

Broken harness between preheat relay 3 terminal #1 and ECM connector J2 terminal #10.

YES

YES

Disconnect ECM connector J2.

Check if voltage at ECM J2 terminal #10 is 24 V. 路Key switch: ACC 路Preheat switch: ON

NO

Disconnect ECM relay.

Connect ECM relay harness end connector terminal #5 and vehicle frame.

Check for continuity between ECM connector J2 harness end terminal #5 and vehicle frame. 路Key switch: ACC 路Preheat switch: ON

T5-4-39

YES

NO

Faulty ECM.

Faulty preheat switch, or blown ECM fuse box fuse #2.

Broken harness between ECM connector J2 terminal #5 and ECM relay.

TROUBLESHOOTING / Troubleshooting B ALL ACTUATOR SHOOTING

SYSTEM

TROUBLE-

A-1 All actuator speeds are slow.

• Although speed is satisfactory, in case power is weak, the faulty main relief valve is suspected.

• If the flow rate decrease solenoid valve is bound in OFF position, the main pump 1, 2 control pressure Pi decreases, so that the main pump 1, 2 delivery volume decreases.

• If the power decrease solenoid valve is bound in ON position, pilot pressure PG is supplied to the regulator, so that the pump delivery volume decreases.

• If the engine speed is slow (refer to E-5) or SP mode is inoperable (refer to A-4), faulty pilot system (refer to A-2) is suspected.

• Faulty engine is suspected when engine speed decreases remarkably after applying a load.

• Check for loose harness connections beforehand.

YES

YES Check if output to flow rate decrease solenoid valve is normal.

Check if power is sufficient.

Disconnect flow rate deYES crease solenoid valve and reconnect line directly.

Check if delivery volume from main pump 1, 2 decreases.

·Built-in diagnosing system: Main controller A Monitor item: Digital output: bit 5: Pump cut-off output NO

Check if output to YES flow rate decrease solenoid valve is normal. ·Built-in diagnosing system: Main controller A Monitor item: Proportional valve ON/OFF output: bit 6: #1, 2 pump NO power decrease solenoid valve output Faulty main controller A. NO

Faulty main controller A.

Faulty main relief valve.

NO

T5-4-40

TROUBLESHOOTING / Troubleshooting B Output Port To Main Pump 2 Regulator Port Pi Shuttle Valve (Swing Make-Up) Power Decrease Solenoid Valve SB Power Decrease Solenoid Valve SA

Machine Front Side

Flow Rate Decrease Solenoid Valve

T183-05-04-026

Shockless Valve

T183-05-04-015

Faulty engine speed sensor 1 system (refer to Troubleshooting A).

YES Disconnect power decrease solenoid valve (SA, SB) output port. Place a plug on port. Disconnected line is left open to atmosphere.

Check if symptom appears.

YES Check if fault code 05 is displayed.

Faulty main pump or regulator.

NO

·Mistracks to right: Pump 1 ·Mistracks to left: Pump 2 ·Swing is slow: Pump 3 Bound power decrease solenoid valve (SA or SB).

NO YES Only main pump 2 output volume decreases.

NO

T5-4-41

Faulty shuttle valve (swing make-up) and/or shockless valve.

Bound flow rate decrease solenoid valve.

TROUBLESHOOTING / Troubleshooting B A-2 All actuators are inoperable.

• It is unrealistic that all pumps break down at the same time. Faulty pilot system is suspected.

• Check for loose harness connections beforehand.

Find out cause of trouble by tracing other trouble symptoms.

YES

YES Check if primary pilot pressure is normal.

YES Faulty pilot pump, or clogged pilot filter.

·Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section.

Check if pilot control shut-off lever is released.

Check if symptom appears after adjusting, disassembling and NO cleaning pilot relief valve.

End NO

Release pilot control shut-off lever.

NO

T5-4-42

TROUBLESHOOTING / Troubleshooting B A-3 Actuator does not stop even if lever is returned to neutral.

• Bound spool in the pilot valve or bound spool in the control valve is suspected.

YES

Faulty pilot valve. ·When control lever is returned to neutral, pilot pressure is routed to spool end in control valve.

Check if actuator stops when pilot control shut-off lever is raised.

Faulty control valve.

NO

·Although pilot pressure is not routed to spool end in control valve, spool is kept opened due to binding of spool.

T5-4-43

TROUBLESHOOTING / Troubleshooting B A-4 SP mode is inoperable.

• Faulty power increase solenoid valve ST and engine speed sensor 1 are suspected.

• Check for loose harness connections beforehand.

Find out cause of trouble by tracing other trouble symptoms.

YES Check if swing, travel right YES and travel left single operation speed changes when SP mode switch is turned ON and OFF.

Faulty regulator or main pump.

NO

·Swing ]]]] Main pump 3 ·Travel Right]] Main pump 2 ·Travel Left ]]] Main pump 1

Disconnect line from power increase solenoid valve ST output port, then install pressure gauge.

Check if output pressure changes in range of 0 to 3.7 MPa (0 to 38 2 kgf/cm ).

Check if current at power increase solenoid valve ST changes in range of 255 to 416 mA.

NO

·SP mode switch: ON ·Turn engine control dial to change engine speed, then observe pilot pressure change.

·Built-in diagnosing system: Main controller A: Monitor item: Power increase output current ·Turn engine control dial to change engine speed.

Check if faulty code 05 is displayed on built-in NO diagnosing system.

Faulty engine speed sensor 1 system (refer to Troubleshooting A).

YES

Output Port

Power Increase Solenoid Valve ST

Connector Main Controller A Connector A A3

A4

T183-05-04-016 T183-05-04-008

T5-4-44

TROUBLESHOOTING / Troubleshooting B

Faulty power increase solenoid valve ST.

YES

NO

Connect line to engine speed sensor 1.

Disconnect plug receptacle from power increase solenoid valve ST. Connect both disconnected harness end plug receptacles.

Check for continuity between main controller A connector A harness end terminals #A4 and #A3.

Broken harness between power increase solenoid valve and main controller A.

NO

YES Disconnect switch box.

Check for continuity between switch box end conYES nector terminals #6 and #15. ¡SP mode switch: ON NO

Connector Switch Box

T183-05-04-004

T5-4-45

Faulty main controller A, or broken harness between switch box and main controller A.

Faulty switch box, or broken harness between monitor controller and switch box.

TROUBLESHOOTING / Troubleshooting B A-5 E mode is inoperable.

• In case main controller, power decrease solenoid valve or regulator of main pump 3 is inoperable, -1 engine may stall below 1400 min even if E mode switch is turned OFF. • Check for loose harness connections beforehand.

NO

YES

Check if E mode switch is normal. ·E mode switch: ON ·Built-in diagnosing system: Main controller A: Monitor item: Digital input: bit 3: E mode SW

Check if output to power decrease solenoid valve is normal. ·E mode switch: ON ·Built-in diagnosing system: Main controller A monitor item: Proportional valve ON/OFF output: bit 6: #1, 2 Pump power decrease solenoid valve output

Faulty main controller A.

Disconnect power decrease solenoid valve (SA).

Connect harness end connector terminals #1 and #2 with a clip.

YES Disconnect main controller connector A. Check for continuity between terminals #A11 and #A14.

Broken harness beNO tween power decrease solenoid valve SA and main controller A.

YES Disconnect main controller A connector B. Check for continuity between harness end conNO nector terminal #B2 and switch box harness end connector terminal #7.

YES

Broken harness between switch box and NO main controller A.

Connector Main Controller A Connector A

A14

Connector B

Faulty switch box dial.

Power Decrease Solenoid Valve

B2 T183-05-04-005

T5-4-46

T183-05-04-010

TROUBLESHOOTING / Troubleshooting B

YES Disconnect power decrease solenoid valve (SA) from line, then connect disconnected line directly.

Check if each operation speed increases.

T5-4-47

NO

Faulty power decrease solenoid valve (SA).

Faulty main pump 3, or regulator of main pump 3.

TROUBLESHOOTING / Troubleshooting B FRONT ATTACHMENT SYSTEM TROUBLESHOOTING F-1 Some front attachment movement is slow, or is inoperable.

• If the other operations (travel/swing) are normal, the pilot pump (primary pilot pressure) is considered to be normal.

YES Faulty corresponding cylinder.

YES Check for internal oil leakage in corresponding cylinder.

Bound corresponding NO control valve spool.

YES Check if corresponding secondary pilot pressure is normal.

Check if corresponding secondary pilot pressure is normal. ·Built-in diagnosing system: Main controller A Monitor item: Front operation pressure

·Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section. ·Built-in diagnosing system: Main controller A Monitor item: Main pump 1

NO

YES

Faulty corresponding overload relief valve.

Bound shockless valve spool in signal control valve (at boom raise only).

Check if secondary NO pressure at signal control valve inlet is normal.

Faulty pilot valve.

NO

T5-4-48

TROUBLESHOOTING / Troubleshooting B F-2 Front attachment drifts remarkably.

YES

Faulty pilot valve.

YES Faulty corresponding cylinder.

Check if cylinder drift is reduced when pilot shut-off valve is closed.

YES Check if oil leaks in corresponding cylinder.

Faulty corresponding control valve (broken spring, loose spool NO end).

Check if corresponding overload relief valve is NO normal. ¡Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section.

NO

Faulty corresponding overload relief valve.

x Boom Cylinder Internal Leakage Check 1. With the bucket cylinder fully retracted and the arm cylinder slightly extended from the fully retracted position, lower the bucket tooth tips onto the ground.

2. Disconnect hoses from the boom cylinder rod side.

Drain oil from the hoses and cylinders. (Plug the disconnected hose ends.)

T105-07-04-009

3. Retract the arm cylinder to 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.

T5-4-49

TROUBLESHOOTING / Troubleshooting B F-3 Front attachment moves slightly to the opposite direction against the lever operation (boom raise, arm roll-out (BH), arm retract (LD) or bucket close (LD).

NOTE: BH: Backhoe LD: Loading Shovel

YES

YES

Oil leaks in cylinder.

Check if corresponding load check valve in control valve is normal. ¡Disassemble / Visual Inspection

Check if slow-return valve of corresponding cylinder is normal.

Faulty load check valve.

NO

¡Disassemble / Visual Inspection

Faulty corresponding slowreturn valve.

NO

NOTE: 1. During the initial stage of operation, oil pressure and flow rate from the pump is low. Therefore, if the load check valve or slow-return valve is malfunctioning, the oil in the bottom side of the cylinder flows back into the circuit, causing the cylinder rod to temporarily moves to the other direction from the lever operation direction.

2. Since oil pressure and flow rate from the pump is low, if oil leaks from between bottom side (B) and rod side (A) due to faulty cylinder piston ring or cylinder barrel, the cylinder rod is temporary lowered during the initial stage of operation by the load.

In addition, cylinder force is reduced, increasing the front attachment drift in this case.

T5-4-50

When the load check valve is faulty:

When the slow return valve is faulty: T141-05-04-001

TROUBLESHOOTING / Troubleshooting B (Blank)

T5-4-51

TROUBLESHOOTING / Troubleshooting B F-4 Boom raise is slow at combined arm roll-out (BH)/arm retract (LD) and boom raise operation.

NOTE: BH: BH: Backhoe LD: Loading Shovel • The arm flow rate control valve in the signal control valve is switched at combined boom raise and arm roll-out (BH)/arm retract (LD) operation, so that pilot pressure is applied on both sides of the arm 2 spool. Therefore, the arm 2 spool becomes neutral.

Check if shuttle valve YES (preferential boom raising) is bound or scored.

Check if arm 2 spool YES neutral pressure at signal control valve outlet port SE is normal.

YES Check if boom 1 spool selection pressure at signal control valve outlet port #1 is normal.

Check if secondary pressures at signal control valve inlet ports D, A and F are normal.

NO

Bound arm flow rate control valve spool in signal control valve, or faulty shuttle valve.

Bound shockless valve spool in signal control valve.

NO

Faulty pilot valve.

NO Pilot Valve Connecting Side

Signal Control Valve

Control Valve Connecting Side

Port A Port #1

Port D

Port SE

Port F

Control Valve Side

Pilot Valve Side

T178-03-06-015 T178-03-06-016

T5-4-52

TROUBLESHOOTING / Troubleshooting B

Clean or replace shuttle valve (preferential boom raising).

YES

Bound arm 2 spool.

NO

T5-4-53

TROUBLESHOOTING / Troubleshooting B F-5 Arm cylinder moves unevenly at combined arm roll-out (BH)/arm retract (LD) and bucket roll-in (BH)/bucket tilt-in (LD), boom raise or swing operation.

NOTE: BH: Backhoe LD: Loading Shovel • The arm preference valve is switched at combined arm roll-out (BH)/arm retract (LD) and bucket roll-in (BH)/bucket tilt-in (LD), boom raise or swing operation, so that the pilot pressure to the arm 3 is blocked. Therefore, the arm 3 spool does not move.

Clean or replace arm preference valve.

YES

Check if arm preference valve spool is bound or scored.

YES

NO

Clean or replace shuttle valve (pilot selection).

Check if shuttle valve (pilot selection) is bound or scored.

NO

T5-4-54

Bound swing control valve arm 3 spool.

TROUBLESHOOTING / Troubleshooting B (Blank)

T5-4-55

TROUBLESHOOTING / Troubleshooting B F-6 Single arm roll-in (BH)/arm extend (LD), bucket roll-in (BH)/bucket tilt-in (LD) or boom raise operation is slow.

NOTE: BH: Backhoe LD: Loading Shovel • The pump 3 control valve is switched at single arm roll-in/arm extend (LD), bucket roll-in (BH)/bucket tilt-in or boom raise operation, so that pressure oil from the pilot circuit is applied directly to the main pump 3 regulator as flow rate decrease pressure Pi. Therefore, the delivery volume of the main pump 3 increases.

(Refer to the pages for the Pilot Circuit and Main Pump 3 Flow Rate Control Circuit in the Hydraulic System group in the SYSTEM section in the Technical Manual (Operational Principle))

NO

Faulty main pump 3 or regulator (main pump 3).

Check if single bucket NO roll-in (BH)/bucket tiltin (LD) or boom raise operation is slow.

Check if shuttle valve (pilot selection) is bound YES or scored.

NO Check if shuttle valve (pump 3 control valve selection) is bound or scored.

YES Check if pump 3 control valve is bound or scored.

Clean or replace shuttle valve (pump 3 control valve selection).

Clean or replace pump 3 control valve.

YES

T5-4-56

TROUBLESHOOTING / Troubleshooting B

YES

Clean or replace shuttle valve (pilot selection).

Faulty pilot valve.

NO

T5-4-57

TROUBLESHOOTING / Troubleshooting B F-7 Heavy lift function does not operate.

• If the flow rate does not decrease at heavy lift operation, faulty flow rate decrease solenoid valve system is suspected. Refer to Troubleshooting -1 "E-10 Engine stalls" - "around 850 min ."

• Check for loose harness connections beforehand.

NO

NO

Check if front operation speed is slow after switching heavy lift switch with boom mode selection switch. ·Heavy lift switch: ON

Check if front attachment operation speed is slower than normal.

Faulty heavy lift switch.

Disconnect heavy lift switch and main controller A connector B. Check for continuity between heavy lift YES switch harness end connector terminal #3 and connector B terminal #B11.

NO

Broken harness between heavy lift switch and main controller A.

Faulty main controller YES A.

·Heavy lift switch: ON Broken harness between heavy lift switch and main controller A.

NO

YES

Disconnect heavy lift switch and main controller A connector B. Check for continuity between heavy lift switch harness end connector terminal #3 and connector B harness end connector terminal #B11.

Heavy Lift Solenoid Valve (Upper Side) Output Port

Disconnect main controller A connector A and heavy lift solenoid valve.

Connect heavy lift solenoid valve harness YES end connector terminal with a clip.

Check for continuity between connector A harness end connector terminals #6 and #7.

YES

T183-05-04-017

Connector Heavy Lift Switch

Main Controller A Connector A

A6

A7 Connector B

B11 T183-05-04-101

T5-4-58

T183-05-04-005

Broken harness between main controller A and heavy lift solenoid valve.

Disconnect line from heavy lift solenoid valve output port, then install pressure gauge NO on the port.

Check if main control valve main relief selection pressure is 3.9 2 MPa (40 kgf/cm ).

TROUBLESHOOTING / Troubleshooting B

YES

Faulty shuttle valve in main control valve, or faulty main relief valve.

NO

Faulty heavy lift solenoid valve, or faulty main controller A.

T5-4-59

TROUBLSHOOTING / Troubleshooting B F-8 Boom mode selection function does not operate.

• Check for loose harness connections beforehand.

Connect main controller B connector B. Disconnect connector A and boom mode selection solenoid valve SC. Connect boom mode selection solenoid valve SC harness end connector terminals #1 and #2 with a clip.

Check for continuity between harness end connector A terminals #A4 and #A3.

YES

Check if output to boom mode selection solenoid valve is normal. ·Boom mode selection switch: ON ·Built-in diagnosing system: Main controller B Monitor item: Proportional valve ON/OFF output: bit 7: Boom mode selection solenoid valve output

NO

Interchange boom mode selection switch with heavy lift switch and check if system operates properly. ·Boom mode selection switch: ON

Disconnect boom mode selection switch and main controller B connector B. Check for continuity NO between boom mode selection switch harness end connector terminal #3 and connector B harness end connector terminal #B12.

YES

NO

YES

Connector Boom Mode Selection Switch

Main Controller B Connector A A3

A4

Connector B

Boom Mode Selection Solenoid Valve SC

B12

T183-05-04-010 T183-05-04-005 T183-05-04-101

T5-4-60

TROUBLSHOOTING / Troubleshooting B

Broken harness between main controller B and boom mode selection solenoid valve SC.

NO

Faulty boom mode selection solenoid valve SC.

NO Connect main controller B connector A and boom mode selection YES solenoid valve SC. Install tee and pressure gauge at boom mode selection solenoid valve SC output port.

Check if pressure is 3.9 2 MPa (40 kgf/cm ).

Faulty overload relief change valve in main control valve, or faulty overload relief valve.

YES

¡Boom mode selection switch: ON Faulty main controller B.

Broken harness between boom mode selection switch and main controller B. Faulty boom mode selection switch.

Output Port

Boom Mode Selection Solenoid Valve SC

Front

T183-05-04-015

T5-4-61

TROUBLSHOOTING / Troubleshooting B SWING SYSTEM TROUBLESHOOTING S-1 Swing is unmoving, slow or weak in power.

• Check whether the pilot system is faulty or the main circuit is faulty.

• In case other functions (front attachment and travel) operate normally, the pilot pump is considered to be normal. If the pilot system is displaying a problem, the cause of the trouble may exist in the circuit after the pilot valve.

• The brake chatter is heard if a problem exists in the swing parking brake system.

NO

Check if swing YES motor relief pressure is normal.

Check if secondary pilot pressure is normal. ·Built-in diagnosing system: Main controller A Monitor item: Front attachment operation pressure

·Built-in diagnosing system: Main controller A Monitor item: Main pump pressure ·Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section.

Faulty swing control valve spool.

Check if shuttle valve NO (swing brake release) is bound or scored.

Check if single YES boom, bucket, arm and swing operations are slower than specification.

Install tee and pressure gauge at main pump 3 port Pi. Check if swing YES pump control pressure varies smoothly, and pump control pressure becomes 0 MPa (0 2 kgf/cm ) with swing lever in full stroke.

·Specification: Refer to the OPERATIONAL PERFORMANCE TEST section.

YES

Check if shuttle valve (pilot selection) or shuttle valve (pump 3 control valve selection) is bound or scored.

NO Clean or replace shuttle valve (pilot selection).

NO

Check if shuttle valve (pilot selection) is bound or scored.

Faulty swing control YES valve.

Faulty pilot valve.

NO

Port Pi

T183-01-02-006

T5-4-62

TROUBLSHOOTING / Troubleshooting B

YES

Faulty shuttle valve (swing brake release).

Faulty swing parking brake release valve.

YES Check if swing parking brake release valve is NO bound or scored.

Faulty swing motor.

NO

¡When brake shows a trouble after disassembling, also check brake release pressure selection valve.

Clean or replace shuttle valve (pilot valve selection) or shuttle valve (pump 3 control valve selection).

YES

Clean or replace shuttle valve (swing make-up).

YES NO Check if shuttle valve (swing make-up) is bound or scored.

Check if main NO pump 2 delivery pressure is normal.

YES

Faulty shockless valve.

NO

Faulty main pump 2 or regulator (main pump 2).

Check if shockless valve plunger is NO bound.

¡Built-in diagnosing system: Main controller A Monitor item: Main Check if pump 3 conpump 2 pressure YES trol valve is bound.

YES

NO

T5-4-63

Faulty pump 3 control valve.

Faulty main pump 3 or regulator (main pump 3).

TROUBLSHOOTING / Troubleshooting B S-2 Swing drift is large when stopping • In case the upperstructure drifts and shakes, valve related parts may be faulty. In case the upperstructure drifts smoothly, spool related parts may be faulty.

Check if secondary pilot pressure is 0 2 YES MPa (0 kgf/cm ) when swing lever is in neutral.

Check if swing relief pressure is normal. ·Built-in diagnosing system: Main controller A Monitor item: Main pump 3 pressure ·Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section.

·Built-in diagnosing system: Main controller A Monitor item: Front attachment operation pressure ·Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section.

YES Check if swing control valve swing spool operates normally. ·Disassemble / Visual inspection

Check if shuttle valve (pilot selection) is NO bound or scored.

Faulty swing motor or NO reduction gear box.

YES Clean or replace shuttle valve (pilot selection).

Faulty pilot valve.

NO

YES Check if symptom appears after switching swing overload relief valve in swing control NO valve with other overload relief valve except boom mode selection in main control valve.

YES Faulty swing spool (replace spool or swing control valve).

NO

T5-4-64

Faulty swing relief valve.

Faulty swing overload relief valve.

TROUBLSHOOTING / Troubleshooting B TRAVEL SYSTEM TROUBLESHOOTING T-1 Both right and left tracks do not rotate or rotate slowly.

• Both right and left pilot valves, travel motors, and/or control valve spools are unlikely to be faulty at the same time.

• In case both travel systems do not operate, the pilot system, which is applied to both side travel motors, may be faulty. If the primary pilot pressure is lower than specification, not only travel but also all operations are affected. As this section describes the troubleshooting of faulty both left and right tracks, refer to T-4 for the trouble on only one track.

Faulty travel parking brake.

YES Install tee to line of travel parking brake release pressure port, then install pressure gauge.

Check if travel parking brake release pressure is normal. ·Specification: 1.8 MPa (18 2 kgf/cm ) or over. ·Measure pressure in jacking up either side of track.

YES

Faulty shuttle valve (swing brake release).

Check if shuttle valve (swing brake release) is NO faulty.

Faulty reducing valve.

NO

Brake Release Pressure Port

T183-05-04-100

T5-4-65

TROUBLSHOOTING / Troubleshooting B T-2 Fast travel is inoperable.

• If the other solenoid valves are also not activating, check the fuse.

• Check for loose harness connections beforehand.

Disconnect line from reducing 3.9 MPa valve output port, 2 (40 kgf/cm ) then install pressure gauge on the port.

Disconnect line from travel mode control solenoid valve output port, YES then install pressure gauge on the port.

Measure reducing valve selection pressure.

Check if output to travel mode control solenoid valve is normal.

·Travel mode switch: ON

Faulty reducing valve.

2

1.8 MPa (18 kgf/cm )

Measure pressure.

Faulty travel motor switch selection mechanism.

2

3.9 MPa (40 kgf/cm )

·Travel mode switch: ON

Faulty travel mode control solenoid valve, or broken harness between travel mode control solenoid valve and main controller B.

0 MPa 2 (0 kgf/cm )

Disconnect switch box and main controller B connector B. Check for continuity between switch box harness end connector terminal #5 and connector B harness end connector terminal #B13.

·Travel mode switch: ON ·Built-in diagnosing system: Main controller B Monitor item: ProporNO tional valve ON/OFF output: bit 6: Travel mode control solenoid valve output

YES Faulty main controller B.

NO

Faulty switch box, or broken harness between switch box and main controller B.

Connector (Harness End Connector Viewed from the Open End Side) Travel Mode Control Solenoid Valve (Lower Side)

Reducing Valve

Main Controller B Connector B B13

Output Port

Travel Mode Control Solenoid Valve

T183-05-04-022

T183-05-04-021 T183-05-04-020

Switch Box

Output Port T183-05-04-019

T183-05-04-004

T5-4-66

TROUBLSHOOTING / Troubleshooting B T-3 Slow travel is inoperable.

• Check for loose harness connections beforehand.

YES

NO

Check if output to travel mode control solenoid valve is normal.

Disconnect main controller B connector B. Check for continuity between connector B harness end connector terminal #B13 and vehicle frame.

Faulty switch box, or short-circuited harness between switch box and main controller B.

Faulty main controller B. NO

3.9 MPa 2 (40 kgf/cm )

Faulty travel mode control solenoid valve.

Disconnect line from ·Travel mode travel mode control switch: ON solenoid valve output ·Built-in diagnosing port, then install system: Main con- YES pressure gauge on troller B the port.

Monitor item: ProMeasure reducing portional valve valve selection pres0 MPa ON/OFF output: sure.

2 (0 kgf/cm ) bit 6: Travel mode ·Travel mode control solenoid switch: OFF valve output

1.8 MPa 2 (18 kgf/cm ) Disconnect line from reducing valve output port, then install pressure gauge on the port.

Measure pressure. ·Travel mode switch: OFF

Faulty travel motor switch selection mechanism.

Faulty reducing valve.

3.9 MPa 2 (40 kgf/cm )

Connector (Harness End Connector Viewed from the Open End Side) Travel Mode Control Solenoid Valve (Lower Side)

Reducing Valve (Travel Parking Brake)

Main Controller B Connector B

Output Port

T183-05-04-021

Output Port

T183-05-04-020

T183-05-04-019

T5-4-67

TROUBLSHOOTING / Troubleshooting B T-4 One side track does not move, moves slowly or mistracks.

• If only one side of the track does not move, the pilot valve, main control valve, travel motor or center joint may be faulty.

• If travel left and bucket open/close (LD) are also slow, the main pump 1 or main pump 1 regulator may be faulty.

• If travel right is slow and boom, arm and bucket are slightly slow, the main pump 2 or main pump 2 regulator may be faulty.

NOTE: LD: Loading Shovel

Check if secondary travel pressure is normal. ·Built-in diagnosing system: Main controller A Monitor item: Travel operation pressure ·Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section.

YES Check if travel motor drain oil amount is normal.

Check if travel relief NO pressure of slow speed side is normal. ·Built-in diagnosing system: Main controller A Monitor item: Main pump 1 pressure, main pump 2 pressure ·Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section.

Check if symptom is YES reversed when right and left travel line hoses are switched each other at the top of center joint.

YES

Faulty pilot valve.

NO

External Oil Leak

NO

Check if symptom is reversed after switching forward travel relief valve with reverse travel one, or right travel relief valve with left one.

Bound main control valve spool, or oil leak in main control valve.

Relationship between Faulty Seal Location and Mistrack Direction Seal When traveling When pivot turn is No. straight performed 1

·Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section.

Seal Location

m

1

2 2

3

3

4

Left Travel (Forward)

4 Right Travel (Reverse)

5 Left Travel (Reverse)

5

6 7

Right Travel (Forward)

6

External Oil Leak

m

7

T5-4-68

W183-03-08-001

TROUBLSHOOTING / Troubleshooting B

NO

Faulty travel motor. ¡When travel parking brake shows a trouble after disassembling, also check brake release pressure selection valve.

YES Disassemble travel NO motor servo piston.

Check for faulty parts.

Disassemble travel motor counterbalance valve.

YES Check for faulty parts.

NO

Faulty travel motor servo piston.

Faulty travel reduction gear.

Faulty counterbalance valve.

YES

YES

Faulty travel relief valve.

Faulty center joint.

NO

Arrangement of Pipe Line 1

2

3 6

4

1 - Right Travel Reverse 2 - Left Travel Reverse 3 - Left Travel Forward

5

W142-03-03-002

Machine Front Side

T5-4-69

4 - Right Travel Forward 5 - Drain Hose 6 - Pilot Hose (Travel Mode Selection)

TROUBLSHOOTING / Troubleshooting B T-5 Travel motor runs excessively fast when combined left travel and front attachment operation is performed with left track off the ground. • If the priority valve (travel motor overrun protection) in the signal control valve is stuck, the flow combiner valve switches without right travel operating. • Same phenomenon can be observed when the flow combiner valve is bound.

T5-4-70

TROUBLSHOOTING / Troubleshooting B T-6 Machine mistracks during combined travel and front attachment operation.

Faulty flow combiner valve.

YES

Check if flow combiner valve in main control valve is abnormal.

Faulty flow combiner valve selection spool in signal control valve.

YES

NO

Disconnect hose (G) from signal control valve connecting to flow combiner valve, then install pressure gauge.

Measure and check if selection pressure is approx. 3.9 MPa (40 2 kgf/cm ).

NO

YES

Faulty load check valve in main control valve.

NO

Find out cause of trouble by tracing other trouble symptoms.

Check if load check valve in main control valve is abnormal.

Signal Control Valve Control Valve Connecting Side

Control Valve Side

Hose (G) T183-05-04-025

T5-4-71

TROUBLSHOOTING / Troubleshooting B OTHER SYSTEM TROUBLESHOOTING 0-1 Auto-lubrication indicator comes ON. (Grease pump does not operate.)

(Empty grease in pump) • If the Auto-lubrication indicator light comes ON, damaged lubrication hose or clogged distribution valve is suspected.

• If the auto-lubrication selection switch is faulty, the auto-lubrication indicator does not come ON. • Check for loose harness connections beforehand.

• In case of manual lubrication, the auto-lubrication indicator always comes ON.

YES

Grease pump does not operate (both auto and manual).

Disconnect grease pump.

Check if voltage at harness end connector terminal #1 is 24 V. ·Key switch: ON ·During grease pump operation

YES Faulty auto-lubrication relay.

Connect disconnected connector.

Check if grease pump operates after switching NO auto-lubrication relay and other generalpurpose relay.

YES

Empty grease in pump.

Faulty grease pump.

Disconnect autolubrication relay.

Check if voltage between NO harness end connector terminals #1 and #3 is 24 V. Reposition follow plate. ·Disconnect grease pump air lubrication hose at quick coupler. ·Screw in and position follow plate.

Check if grease still exists.

NO

T5-4-72

Replace with new grease tin.

TROUBLSHOOTING / Troubleshooting B

NO Connect connector.

Check if grease pump operates after YES switching power transistor 3 with power transistor 1 or power transistor 2.

Disconnect power transistor 3.

Check if voltage at harness end connector terminal #5 is 24 V.

Disconnect main controller B connector A. Check for continuity YES between power transistor 3 harness end connector terminal #2 and connector A harness end terminal #A26.

YES

NO

Faulty main controller B. Broken harness between main controller B and power transistor 3.

Blown fuse #14, or broken harness between power transistor 3 and fuse #14.

NO

Faulty power transistor 3.

YES

Blown fuse #14, or broken harness between auto-lubrication relay and fuse #14.

NO

Connector Auto-Lubrication Relay

Power Transistor 3

Main Controller B Connector A

T183-05-04-011

5

2

T183-05-04-003

A26

T5-4-73

T183-05-04-008

TROUBLSHOOTING / Troubleshooting B O-2 Grease pump operates excessively slow.

Reinstall or replace exhaust hose.

YES

Grease pump operates excessively slow.

Check if grease pump exhaust hose is kinked or destroyed.

Check if coefficient of grease viscosity becomes high due to winter or cold environment.

NO

O-3 Grease pump does not stop operating.

• If the proximity switch is not correctly adjusted, the grease pump does not stop operating.

• Check for loose harness connections beforehand.

Change to AUTO position.

YES

YES

Check if manual/auto selection valve near grease pump is in MANUAL position.

End

Adjust proximity switch.

Check if grease pump NO stops.

Disconnect proximity switch.

Check if voltage at proxNO imity switch harness end connector terminal #1 is 24 V. ·Key switch: ON

T5-4-74

Push both ends of main controller B connector B YES to securely connect the connector.

Check if grease pump stops.

Broken harness beNO tween proximity switch and fuse.

TROUBLSHOOTING / Troubleshooting B Connector (Harness End Connector Viewed from the Open End Side) Proximity Switch

2

1

Auto-Lubrication Solenoid Valve Relay

Power Transistor 3

#2

3

T183-05-04-011

T183-05-04-003

Main Controller B Connector A

A26

Connector B

T183-05-04-005

B10

YES

Overhaul grease pump.

NOTE: This trouble is caused by the follow plate packing pinched with the grease pump when changing the grease.

When exchanging grease, remove quick coupler from air delivery hose.

NO Check if follow plate packing is damaged.

Find out cause of trouble by tracing other trouble symptoms.

NO

Change grease to EP1.

YES YES Faulty auto-lubrication relay.

Connect proximity switch harness end connector terminal #2 and vehicle frame with a clip.

NO Disconnect main controller B connector B. Check for continuity between main controller B harness connector terminal #B10 and vehicle frame.

Disconnect power transistor 3 and main controller B connector YES A. Check for continuity between connector A harness end terminal #A26 and power transistor 3 harness end connector terminal #2.

Connect disconnected YES connector.

Disconnect autolubrication relay.

Check for continuity between autolubrication relay terminals #3 and #5.

NO

Check if grease pump stops after switching power transistor 3 with NO power transistor 1 or power transistor 2.

(1)

Broken harness between power transistor 3 and main controller B. Broken harness between proximity switch and main controller B.

NO

End (Faulty connector connection)

YES

T5-4-75

TROUBLSHOOTING / Troubleshooting B Proximity Switch Adjustment Procedure 1. Loosen the nut. : 17 mm 2. Slowly tighten the proximity switch by hand until the end of the proximity switch touches the protrusion.

3. Loosen the proximity switch 1/2 to 1 turn. Be sure that the indicator faces in the direction of as the figure on the right.

Indictor Proximity Switch Nut

IMPORTANT: The proximity switch may break.

Do not excessively tighten the nuts.

4. Tighten the nut to secure the proximity switch. : 17 mm : 0.78 N m (0.08 kgf m, 0.57lbf ft)

T142-06-04-024

Proximity Switch Nut Adapter

Protrusion

T142-06-04-025

Pin

Faulty power transistor 3.

YES

(1) Faulty main controller B. NO

T5-4-76

TROUBLSHOOTING / Troubleshooting B (Blank)

T5-4-77

TROUBLSHOOTING / Troubleshooting B O-4 Oil cooler fan motor does not rotate at speed corresponding to hydraulic oil temperature or does not rotate at all. • If the oil cooler fan motor speed control operates normally, the oil cooler fan motor rotates at the corresponding speed to the hydraulic oil temperature. • Check for loose harness connections beforehand.

Install pressure gauge on oil cooler fan control solenoid valve delivery YES port. Check if pilot pressure is normal by each hydraulic oil temperature (refer to Table 2).

Measure hydraulic oil temperature.

Disconnect hydraulic oil temperature sensor, then measure sensor resistance.

Check if relationship between hydraulic oil temperature and resistance value are correctly. (Refer to Table 1).

Disconnect oil cooler fan control solenoid valve wire on one side.

Connect tester NO (ammeter) between disconnected wire.

Check if power is normal by each hydraulic oil temperature (refer to Table 2).

YES

Oil Cooler Fan Control Solenoid Valve

T146-05-04-012

C C1

Hydraulic Oil Temperature Sensor T183-05-04-021

C10

T146-05-04-012

C23

YES

Faulty oil cooler fan motor.

NO

Faulty oil cooler fan motor drive pump.

Faulty hydraulic oil sensor (oil cooler fan motor speed control).

Connector

B22

Disconnect oil cooler fan control solenoid valve. Connect harness end connector terminals #1 and #2.

NO Disconnect main controller A connectors B and C. Check for continuity between harness end connector terminals #C24 and #B22.

Measure oil cooler fan motor drive pump flow rate.

Check if flow rate is normal.

NO

Main Controller A B

YES Faulty oil cooler fan control solenoid valve.

C31 C24

T5-4-78

TROUBLSHOOTING / Troubleshooting B

YES

Faulty main controller A.

NO

Broken harness between oil cooler fan control solenoid valve and main controller A.

Oil Cooler Fan Control Solenoid Valve

Tester A

T183-05-04-023

Table 1: Relationship between Hydraulic Oil Temperature and Hydraulic Oil Temperature Sensor 2 (Oil Cooler Fan Motor Speed Control) Resistance Hydraulic Oil Temperature Resistance (k:) (qC) (qF) -30 -22 28.6 -20 -4 16.2r1.6 -10 14 9.56 0 32 5.88 10 50 3.73 20 68 2.45r0.24 30 86 1.65 40 104 1.14 50 122 0.808 60 140 0.534 70 158 0.430 80 176 0.322r0.032 90 194 0.245 100 212 0.189 110 230 0.148 120 248 0.117

Table 2: Relationship between Temperature and Oil Cooler Fan Motor Speed Hydraulic Oil Pilot Pressure from Oil Cooler Temperature Solenoid Valve Fan Motor -1 (qC) [qF] [Current from MC] Speed (min ) (69 or lower) 1.36 MPa 800 2 [156 or lower] (14 kgf/cm ) [309 mA] (70 to 79) 0.99 MPa 1100 2 [158 to 174] (10 kgf/cm ) [285 mA] (80 or higher) 0 [20 mA] 1400r50 [176 or higher]

Delivery Port

NOTE: The above oil cooler fan motor speed shows the motor speed at rated engine -1 speed (1650 min ).

T5-4-79

TROUBLESHOOTING / Troubleshooting B O-5 Step light does not come ON. • Check for loose harness connections beforehand.

YES

Faulty step light relay.

YES Check if step light comes ON after switching step light relay with other general-purpose relay.

NO

Check if step light comes ON when connecting main controller B connector B terminal #B11 and vehicle frame. ¡Measure voltage at the terminals from the rear of connector using a piece of clip with connector connected.

Disconnect step light.

Check if step light comes ON when connecting NO harness end terminal to vehicle frame.

NO

Broken harness between main controller B and step light switch.

Disconnect main controller B connectors A and B. Connect connector A harness end terminal #A27 and connector B harness end terminal #B11 with a clip.

Check if step light comes ON.

Step Light

Faulty step light switch.

YES

M183-01-036

Connector Step Light Relay

Main Controller B Connector A

Connector B

T183-05-04-003

Step Light Switch

A27

B11

T183-05-04-024

T5-4-80

T183-05-04-005

TROUBLESHOOTING / Troubleshooting B

YES

Faulty main controller B.

Check if voltage at NO step light relay harness end connector terminal #3 is 24 V.

NO

Disconnect step light relay.

Connect harness end connector terminal #5 and terminal #3 with a clip.

Check if step light comes ON.

Connect connector.

Disconnect step light YES terminal.

Check if voltage at harness end terminal is 24 V.

YES

NO

NO

Faulty step light.

Broken harness between step light and step light relay.

Broken harness between step light relay and fuse box 1 fuse #8, or blown fuse #8.

Broken harness between step light relay and main controller B.

YES

T5-4-81

TROUBLESHOOTING / Troubleshooting B O-6 Even if step light switch is turned OFF, step light does not come OFF after 60 seconds. • Check for loose harness connections beforehand.

YES

Check if step light comes OFF after switching step light relay with other generalpurpose relay.

Faulty step light relay.

NO

YES

Broken harness between main controller B and step light switch.

NO

Faulty main controller B, or short-circuited harness between step light relay and main controller B.

Disconnect main controller B connector B. Check if step light comes OFF.

Disconnect step light switch.

NO Check if step light comes OFF.

Faulty step light switch.

YES

T5-4-82

TROUBLESHOOTING / Troubleshooting B (Blank)

T5-4-83

TROUBLESHOOTING / Troubleshooting B O-7 Malfunction of Air Conditioner The air conditioner has a self-diagnosis function.

The self-diagnosis functions to: 1) Display Fault Codes 2) Change Displayed Fault Codes 3) Delete Fault Code 4) End Fault Code Display

x Display Fault Code 1. Press the fan OFF switch to turn the fan OFF. 2. Press and hold both the upper and lower sides of the temperature control switch on the air conditioner control panel at the same time for more than 3 seconds with the key switch ON.

Temperature Control Switch

Fan OFF Switch

NOTE: After operation has been performed, the buzzer will sound.

3. If any fault codes are found, the LCD displays the fault codes as ÂŞE{{Âź.

NOTE: If more than one fault code is found, the lower number fault code will be displayed first.

M178-01-017

LCD

Fault Code List Location in Trouble Abnormal circulation air sensor

Fault Code E11 E12

Abnormal fresh air sensor Abnormal solar radiation sensor

E13 E14 E18

Abnormal evaporator sensor

E21 E22

Abnormal damper

E43 E44 E45

Water temperature sensor

E15 E16

Abnormal refrigerant

E51

Cause

Symptom

Broken circuit in air circulation sensor Short-circuited circulation air sensor Broken circuit in fresh air sensor Short-circuited fresh air sensor Short-circuited solar radiation sensor

Y value (air flow-in temperature) cannot be adjusted in response to the settemperature.

Broken circuit in evaporator sensor Short-circuited evaporator sensor Abnormal air vent damper Abnormal air mix damper Abnormal circulation/fresh air damper Broken circuit in water temperature sensor Short-circuited water temperature sensor Abnormal high/low refrigerant pressure

T5-4-84

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 qC (50 qF).

Corresponding damper servo becomes inoperable.

Operation is controlled under such circumstance as the water temperature is set to 60 qC (140 qF). (Warm-up control is not performed.)

The compressor clutch is disengaged.

(The compressor stops.)

TROUBLESHOOTING / Troubleshooting B x Change Displayed Fault Code 1. When displaying more than one fault code, press either the upper or bottom side of the temperature control switch key. The following fault code is displayed.

Temperature Control Switch

NOTE: Each time the displayed fault code is changed, the buzzer sounds. In case only one fault code exists, the displayed fault code remains unchanged.

M178-01-017

LCD

x Delete Fault Code

LCD

1. Press and hold both the circulation air switch and the fresh air switch for more than 3 seconds at the same time to delete the fault code.

NOTE: After the fault code is deleted, the buzzer will sound.

2. After the fault code has been deleted, the LCD displays ÂŞE{{Âź.

M178-01-017

Circulation Air Switch

Fresh Air Switch

Fan OFF Switch

x End Fault Code Display 1. Press the fan OFF switch, or press the upper side of the fan switch key. The self-diagnostic mode is complete.

M178-01-017

Fan Switch

T5-4-85

TROUBLESHOOTING / Troubleshooting B Ұ Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to Hitachi Tsuchiura Works Quality Assurance Dept. after experiencing a problem with your machine’s air conditioning system.

AIR CONDITIONER TROUBLE REPORT !

File No. (1) What Checked by: Model (Serial No. ) Operation Type Manual Semi-Auto Full-Auto Delivery Date Year Month (2) When Date Year Month Day Operating Hour ( h) Time Morning Daytime Evening Night Frequency Every Day Once a Week Once a Month Times per (3) Where Job Site Address State County Town Access Road Condition Paved Not Paved (Gravel Sand Soil) (4) How (Operating Conditions) Weather Fine Cloudy Rain Snow Atmospheric Temperature Very Hot Hot Cold Very Cold Operating Conditions Parking Traveling Working Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when full-auto operation A/C ON OFF Air Induction Re-Circulation Fresh Air Circulation Control AUTO ON OFF Not Available Panel Fill following items when operated in manual mode or when manual control type unit is used.

Vent Position

Front

Front / Rear

Fan

First

Second

(5) How (Problem Symptom) Abnormal Compressor Operation Symptom Not turned ON Not turned OFF Others Uncontrollable air temperature Symptom No cool air No warm air Others Uncontrollable air volume Symptom Air flows in Hi mode only No air flows Small air volume

Foot Third

Uncontrollable vent hole Symptom Vent hole isn’t selected Others Abnormal panel indication Faulty Indica- Vent Hole tor A/C

2

check that the connectors are correctly connected while repeatedly disconnecting and reconnecting connectors.

Fresh Air Circulation Fan OFF xx

Hi)

Temperature Control Symptom

Sixth

Check Result!

(1) Is problem reproducible ?

Reproducible Not reproducible (2) Pressure (To be measured at gauge manifold) Low Pressure High Pressure (3) Which parts have been replaced ?

1

AUTO

x

Fifth

Before replacing the control amplifier, be sure to

Others

Fan (Lo

Front / Rear and Foot Fourth

Stays OFF Stays ON Blinks Others

T5-4-86

TROUBLESHOOTING / Troubleshooting C TROUBLESHOOTING C (TROUBLESHOOTING FOR MONITOR) PROCEDURE Use troubleshooting C when any monitors, such as gauges or indicators, malfunction.

x How to Read Troubleshooting Flow Charts YES(OK)

•

(2)

After completing the checking and/or measuring procedures in box (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).

(1) (3) NO(NOT OK)

• ·Key switch: ON

Instructions, reference, and/or inspection methods and/or measurements are occasionally described under the box. If incorrectly checked or measured, not only will troubleshooting be unsuccessful but also damage to the components may result.

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.

•

NOTE: All harness end connectors are seen from the open end side.

Harness

Harness End Connector Open End Side T158-05-03-001

T5-5-1

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF COOLANT TEMPERATURE GAUGE • This troubleshooting procedures should be performed after checking that the other instruments are performing correctly.

• Check for loose harness connections beforehand.

Gauge Pointer Does Not Move At All YES Disconnect coolant temperature sensor 1 terminal (white).

Ground harness end terminal to vehicle frame. Check if pointer swings to the right side.

Connect disconnected terminal.

Ground monitor controller connector B terminal #B18 to vehicle frame. Check if pointer swings to the right side.

·Key switch: ON NO

·Key switch: ON ·Connect terminal from the rear of connector using a piece of clip with connector connected.

Gauge Pointer Swings Over Scale YES

Disconnect coolant temperature sensor 1 terminal (white).

Check if pointer returns to zero.

YES

·Key switch: ON NO

Connect disconnected terminal. Disconnect monitor controller connector B. Check if pointer returns to zero.

NO

Gauge Pointer Keeps Moving Unstably

YES

Disconnect coolant temperature sensor 1 terminal (white).

Ground harness end terminal to vehicle frame. Check if pointer swings and is stabilized to the right side. ·Key switch: ON

NO

T5-5-2

TROUBLESHOOTING / Troubleshooting C

Coolant Temperature Gauge

Faulty coolant temperature sensor 1.

NO

Faulty coolant temperature gauge.

M183-01-010

YES

Coolant Sensor 1 Resistance

Broken harness between coolant temperature gauge and coolant temperature sensor 1.

Coolant Temperature qC (qF) 25 (77) 40 (104) 50 (122) 80 (176) 95 (203) 105 (221) 120 (248)

Faulty coolant temperate sensor 1.

Short-circuited harness between coolant temperature gauge and sensor 1.

Resistance (k:) 7.6 4.0r0.32 2.7r0.22 0.98 0.6 0.45 0.3r0.02

Connector Monitor Controller Connector B

Faulty coolant temperature gauge.

T183-05-04-013

Faulty coolant temperature sensor 1.

Faulty coolant temperature gauge.

T5-5-3

B18

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF FUEL GAUGE • This troubleshooting procedures should be performed after checking that the other instruments are performing correctly.

• Check for loose harness connections beforehand.

Fuel Gauge Pointer Does Not Move At All YES

Disconnect fuel sensor.

Ground harness end connector to vehicle frame. Check if pointer swings to the right side.

Connect disconnected connector.

Ground monitor controller connector B terminal #B19 to vehicle frame.

Check if pointer swings to the right side.

·Key switch: ON NO

·Key switch: ON ·Connect terminal from the rear of connector using a piece of clip with connector connected.

Fuel Gauge Pointer Swings Over Scale

YES

YES

Disconnect fuel sensor. Check if pointer returns to zero. ·Key switch: ON NO

Connect disconnected connector.

Disconnect monitor controller connector B. Check if pointer returns to zero.

NO

Fuel Gauge Pointer Keeps Moving Unstably

YES

Disconnect fuel sensor.

Ground harness end connector to vehicle frame.

Check if pointer swings and is stabilized to the right side. ·Key switch: ON

NO

T5-5-4

TROUBLESHOOTING / Troubleshooting C Fuel Gauge Upper Limit 1/2

Lower Limit

Faulty fuel sensor.

NO

Faulty fuel gauge.

M183-01-011

Fuel Sensor Float FULL

YES

Broken harness between fuel gauge and sensor.

3/4 257 mm 138.5 mm R370

22 ѯ 33ѯ

70.5 mm

Faulty fuel sensor.

1/2

228 mm

27ѯ 28ѯ

338 mm

Electric Resistance

1/4

Short-circuited harness between fuel gauge and sensor.

EMPTY

T107-04-03-020

Float Position Faulty fuel gauge.

Upper Limit (FULL)

10

+1.0 -0.5

3/4

(19)

1/2

32r3

1/4

(49.5)

Lower Limit (EMPTY)

Faulty fuel sensor.

Resistance (:)

+12 +2

80

Connector Monitor Controller Connector B

Faulty fuel gauge.

T183-05-04-013

B19

T5-5-5

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF INDICATOR LIGHT CHECK SYSTEM • Check for loose harness connections beforehand.

YES

Indicator does not come ON when indicator light check operation is performed.

Check if all indicators do not come ON.

NO

Connector Monitor Controller Connector C C1

T183-05-04-014

T5-5-6

Check power line. ·Fuse ·Disconnect monitor controller connector C. Check for continuity between harness end terminal #C1 and fuse terminal #7.

Go to individual troubleshooting according to malfunctioning indicator.

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-5-7

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF OVERHEAT INDICATOR • Check for loose harness connections beforehand.

NOTE: Overheat Switch Operating Temperature: 101 qC (213.8 qF) or more

YES

Indicator Does Not Come ON Even If Engine Overheats Disconnect engine overheat switch terminal #M4.

YES Ground harness end terminal to vehicle frame.

Check if indicator comes ON.

NO

·Key switch: ON NO

Turn indicator light check switch ON. Check if indicator comes ON.

Connect disconnected terminal. Ground main controller A connector B terminal #B12 to vehicle frame. Check if indicator comes ON. ·Key switch: ON ·Connect terminal from the rear of connector using a piece of clip with connector connected.

·Key switch: ON

NO

YES

Disconnect monitor controller connector B. Check if voltage at harness end connector terminal #B6 is 5 V.

Indicator Comes ON Even If Coolant Temperature Is Low

YES

Faulty overheat switch.

Disconnect overheat switch. Check if indicator goes OFF. ·Key switch: ON

YES Connect disconnected terminal.

Disconnect main controller NO A connector B. Check for continuity between harness end connector terminal #B12 and vehicle frame.

NO

T5-5-8

Short-circuited harness between overheat switch and main controller A.

Faulty main controller A.

TROUBLESHOOTING / Troubleshooting C

Faulty overheat switch.

Faulty main controller A.

Broken harness between main controller A and overheat switch.

Faulty main controller A, or broken harness between monitor controller and main controller A.

NO

Faulty monitor controller, or burned indicator light.

YES

Connector Main Controller A Connector B

B12

T183-05-04-021

Monitor Controller Connector B B6

T183-05-04-013

T5-5-9

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF AIR CLEANER RESTRICTION INDICATOR • Check for loose harness connections beforehand.

YES

YES

Disconnect air cleaner restriction switch. Ground harness end connector to vehicle frame. Check if indicator comes ON. ·Key switch: ON

Even if air cleaner is clogged, indicator does not come ON.

Check if indicator comes ON when key switch is turned ON.

NO

NO

YES

Although air cleaner is not clogged, indicator comes ON. ·Disassemble / Visual Inspection ·Verify that air cleaner is not moist.

Check if indicator goes OFF when air cleaner restriction switch is disconnected.

YES

·Key switch: ON

NO

Disconnect air cleaner restriction switch and monitor controller connector B. Check for continuity between monitor controller harness end connector terminal #B7 and vehicle frame.

NO

T5-5-10

Disconnect monitor controller connector B. Keep air cleaner restriction switch connector connected to vehicle frame.

Check for continuity between monitor controller harness end connector terminal #B7 and vehicle frame.

TROUBLESHOOTING / Troubleshooting C

Faulty air cleaner restriction switch.

YES

Faulty monitor controller.

NO

Broken harness between monitor controller and air cleaner restriction switch.

Air Cleaner Restriction Switch

Pressure 5.0 kPa (508r48 mmH2O) or lower 5.0 kPa (508r48 mmH2O) or more

Operation OFF ON

Burned indicator light, or faulty monitor.

Connector Monitor Controller Connector B B7

T183-05-04-013

Faulty air cleaner restriction switch.

Short-circuited harness between monitor controller and air cleaner restriction switch.

Faulty monitor controller.

T5-5-11

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF FUEL LEVEL INDICATOR • Check for loose harness connections beforehand.

YES

YES

Indicator does not come ON even if fuel gauge pointer reaches "E".

Disconnect fuel sensor.

Ground harness end connector to vehicle frame. Check if indicator comes ON.

Turn key switch to ON position.

Check if indicator comes ON.

NO

NO

YES

Indicator comes ON even if fuel still remains.

Disconnect fuel sensor. Check if indicator goes OFF. ¡Key switch: ON

YES Disconnect fuel level sensor and monitor controller connector B. Check for continuity beNO tween monitor controller harness end connector terminal #B19 and vehicle frame.

NO

T5-5-12

Disconnect monitor controller connector B. Keep connecting fuel sensor harness end connector connected to vehicle frame.

Check for continuity between monitor controller harness end connector terminal #B19 and vehicle frame.

TROUBLESHOOTING / Troubleshooting C

Faulty fuel sensor.

YES

Faulty monitor controller.

NO

Broken harness between monitor controller and fuel sensor.

Burned indicator light, or faulty monitor controller.

Connector

Faulty fuel sensor.

Monitor Controller Connector B

Short-circuited harness between monitor controller and fuel sensor.

T183-05-04-013

B19

Faulty monitor controller.

T5-5-13

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PREHEAT INDICATOR • Check that all other indicators work correctly. • Check for loose harness connections beforehand.

Indicator Does Not Come ON Even If Air Heater Is Operating Faulty preheat indicator relay.

YES

Check if indicator comes ON after switching preheat indicator relay and other generalpurpose relay.

Connect disconnected connector.

YES Disconnect monitor controller connector B. Check if voltage at harness end connector terminal #B20 is 24 V.

Disconnect preheat indicator relay from connector.

NO Check if voltage at harness end connector terminal #1 is 24 V.

YES Faulty monitor controller, or burned indicator light.

Broken harness between monitor controller and NO preheat indicator relay.

Broken harness between preheat indicator relay and preheat relay (2).

NO

Indicator Comes ON Even If Air Heater Is Not Operating YES

Faulty monitor controller.

Disconnect monitor controller connector B. Check if indicator comes ON.

Short-circuited harness between monitor controller and preheat indicator relay.

YES

Check if voltage at harness end connector terNO minal #B20 is 24 V.

Connect connector.

Check if indicator comes ON after switching preNO heat indicator relay and other general-purpose relay.

NO Faulty preheat indicator relay.

Short-circuited harness between preheat indicator relay and preheat YES relay (2), or faulty preheat relay (2).

Connector Monitor Controller Connector B

Preheat Indicator Relay

B20 T183-05-04-003

T5-5-14

T183-05-04-014

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF DOWNLOAD INDICATOR • Check for loose harness connections beforehand.

Indicator Does Not Come ON Even If DLU Data Memory Is Full

YES Burned indicator light, or faulty monitor controller.

YES Check if DLU data memory capacity is full.

Disconnect DLU. Check if voltage at harness end connector terminal #26 is 24 V.

Disconnect monitor controller connector C. YES Check for continuity between DLU harness end connector terminal #105 and connector C harness end terminal #C20.

Faulty DLU. NO

Broken harness between DLU and monitor controller.

NO

Blown fuse #5 (fuse box (ECM)), or broken harness between fuse box (ECM) and DLU.

NO

Indicator Comes ON Even If Download Is Completed Faulty DLU.

YES

Disconnect DLU. Check if indicator goes OFF.

Disconnect monitor controller connector C. Check for continuity between DLU connector end connector terminal NO #105 and connector C harness end terminal #C20.

Short-circuited harness between DLU and monitor controller.

YES

Faulty monitor controller.

NO

Connector Monitor Controller Connector C

DLU Connector #26

T183-05-04-014

#105

T5-5-15

C20

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ALTERNATOR INDICATOR • Check for loose harness connections beforehand.

YES

13 V or more

Alternator indicator stays ON after engine is started. ·Engine: Running

Check for continuity between alternator relay terminals #1 and #2.

Measure voltage at alternator relay terminal #1. ·Engine: Running

NO

Disconnect alternator terminal L, then ground the terminal to vehicle frame.

Disconnect alternator reLess than lay.

Check for continuity be13 V tween alternator relay harness end connector terminal #5 and vehicle frame.

YES

NO

Less than 10 V

YES Measure voltage at alternator terminal L. ·Key switch: ON ·Engine: Stop Although alternator output is low, alternator indicator does not come ON.

Turn key switch ON. Check if indicator comes ON.

10 V or more

NO

T5-5-16

TROUBLESHOOTING / Troubleshooting C

Disconnect alternator relay.

Check for continuity between harness end connector terminal #2 and vehicle frame.

YES

Short-circuited harness between alternator relay and alternator.

Faulty monitor controller.

NO

Connector Alternator Relay

Faulty alternator relay.

Faulty alternator.

Broken harness between alternator terminal L and alternator relay.

0V Measure voltage at alternator relay terminal #1. ¡Engine: Running 24 V

Faulty alternator relay.

Faulty monitor controller, or broken harness between alternator relay and alternator.

Faulty alternator.

Burned alternator indicator light, or faulty monitor controller.

T5-5-17

T183-05-04-003

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR • Check for restricted oil filter.

• Check for loose harness connections beforehand.

NOTE: Engine Oil Pressure Switch Operation Pressure -1 For High Pressure (1500 min or more): 2 OFF at 0.29 MPa (3.0 kgf/cm ) or less -1 For Low Pressure (1500 min or less): OFF 2 at 0.15 MPa (1.5 kgf/cm ) or less

NO

Indicator Does Not Come ON Even If Key Switch Is Turned ON Disconnect main controller A connector B. Check YES for continuity between harness end connector terminals #B9 and #B10 and vehicle frame.

Disconnect harness from engine oil pressure switch which has a continuity between veYES hicle frame.

Check for continuity between oil pressure switch terminal and vehicle frame.

·Key switch: OFF Turn indicator light check switch ON. Check if indicator comes ON.

·Engine oil pressure switch (High pressure): Green ·Engine oil pressure switch (Low pressure): Brown

·Key switch: ON

NO

Disconnect monitor controller connector C. Check if voltage at harness end connector terminal #C18 is 5 V.

YES

NO

Indicator Stays ON After Engine Is Started (Oil Level and Oil Pressure are Normal)

Faulty engine oil pressure switch.

YES

Disconnect engine oil pressure switch.

Check if indicator ·Key switch: ON ·Engine: Stop NO

NO

Faulty main controller A.

YES

Short-circuited harness between engine oil pressure switch and main controller A.

Disconnect main controller A connector B. Check for continuity between harness end connector terminals #B9 and #B10 and vehicle frame. ·#B10: Oil pressure switch for high pressure #B9: Oil pressure switch for low pressure

T5-5-18

TROUBLESHOOTING / Troubleshooting C

Faulty main controller A.

Faulty engine oil pressure switch.

Short-circuited harness between main controller A and engine oil pressure switch.

NO

YES

Faulty main controller A, or broken harness between main controller A and monitor controller.

Faulty monitor controller, or burned indicator light.

Connector Monitor Controller Connector C

Main Controller A Connector B

B9

B10

T183-05-04-014 T183-05-04-021

T5-5-19

C18

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PUMP TRANSMISSION OIL PRESSURE INDICATOR • Check for loose harness connections beforehand.

YES

YES

Indicator does not come ON even if pump transmission oil pressure is insufficient.

Disconnect pump transmission oil pressure switch. Ground harness end terminal #M4 to vehicle frame.

Check if indicator comes ON. ·Key switch: ON

Turn key switch to ON position.

Check if indicator comes ON.

NO

Connect disconnected terminal.

Ground monitor controller connector A terminal #A13 to vehicle frame.

Check if indicator comes ON. ·Key switch: ON ·Connect terminal from the rear of connector using a piece of clip with connector connected.

·Key switch: ON

NO

YES

Indicator stays ON even if engine is started.

Disconnect pump transmission oil pressure switch.

Check if indicator goes OFF. ·Key switch: ON ·Engine: Stop

Disconnect monitor controller connector A. Keep cab connector disconnected.

Check for continuity between monitor harness end connector terminal #A13 and vehicle frame.

NO

T5-5-20

TROUBLESHOOTING / Troubleshooting C

Pump Transmission Oil Pressure Switch Pressure Operation less than 39 to 59 kPa ON 2 (0.4 to 0.6 kgf/cm ) Indication pressure 39 to 59 kPa OFF 2 (0.4 to 0.6 kgf/cm ) or more

Faulty pump transmission oil pressure switch.

YES

Broken harness between monitor controller and pump transmission oil pressure switch.

Faulty monitor controller.

NO

Connector Monitor Controller Connector A

Burned indicator light, or faulty monitor controller.

T183-05-05-001

A13

Faulty pump transmission oil pressure switch, faulty oil pressure system or restricted oil filter.

YES

Short-circuited harness between monitor controller and pump transmission oil pressure switch.

Faulty monitor controller.

NO

T5-5-21

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE EXHAUST GAS TEMPERATURE INDICATOR • Check for loose harness connections beforehand.

NOTE: Sensing Temperature of Exhaust Gas Temperature Sensor: 700 qC (1292 qF) or more Indicator Does Not Come ON even If Engine Exhaust Gas Temperature Rises

Disconnect exhaust gas temperature sensor.

YES Connect harness end connectors #1 and #2 with a clip. Check if indicator comes ON.

YES

Disconnect main controller A connectors B and C. Check for continuity NO between connector B harness end terminal #B22 and connector C harness end terminal #C7.

·Key switch: ON Turn indicator light check switch ON. Check if indicator comes ON.

Connect disconnect connectors.

YES Disconnect monitor controller connector C. Check if voltage at harness end connector terminal #C17 is 5 V.

NO

·Key switch: ON

NO

Disconnect monitor controller connector C. Check if voltage at harness end connector terminal #C17 is 5 V.

Indicator Stays ON Even If Engine Speed Becomes Low-Idle YES

Disconnect exhaust gas temperature sensor.

Check if indicator goes OFF. ·Key switch: ON

Faulty exhaust gas temperature sensor.

Short-circuited harness between exhaust gas temperature sensor and main controller A.

YES Disconnect main controller A connector C. Check for continuity beNO tween connector C harness end terminal #C7 and exhaust gas temperature sensor harness end connector terminal #1.

Connect disconnected connector.

Disconnect monitor controller connector C. NO Check if voltage at harness end connector terminal #C17 is 5 V.

T5-5-22

YES

NO

Faulty main controller A, or short-circuited harness between main controller A and monitor controller.

Faulty monitor controller.

TROUBLESHOOTING / Troubleshooting C

Connector Faulty exhaust gas temperature sensor.

YES

Exhaust Gas Temperature Sensor

Faulty monitor controller.

T146-05-03-005

Main Controller A Connector B

NO

Faulty main controller A, or broken harness between main controller A and monitor controller.

Broken harness between main controller A and exhaust gas temperature sensor.

B22

T183-05-04-021

Main Controller A Connector C

YES

Faulty monitor controller, or burned indicator light.

C7 C10

C1

NO

Faulty main controller A, or broken harness between main controller A and monitor controller.

C23

C31

Monitor Controller Connector C

T183-05-04-014

C17

T5-5-23

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE OIL LEVEL INDICATOR • Check that all other indicators work correctly.

• Check that machine is parked on level surface.

• Check for loose harness connections beforehand.

Indicator Does Not Come ON Even If Oil Level is Above "Lo" Level

YES

YES

Disconnect engine oil level switch. Ground harness end connector terminal #2 to vehicle frame.

Check if indicator comes ON.

Turn key switch to ON position.

Check if indicator comes ON.

Connect engine oil level switch.

Disconnect monitor controller connector B. Check for continuity between harness end connector terminal #B8 and vehicle frame.

NO

NO

Indicator Comes ON Even If Oil Level Is Below "Lo" Level

YES

YES

Disconnect engine oil level switch.

Check if indicator comes ON.

Check oil level with an oil level gauge.

Check if oil level is below "Lo" level.

NO

NO

T5-5-24

Disconnect monitor controller connector B. Keep engine oil level switch disconnected.

Check for continuity between connector B harness end terminal #B8 and vehicle frame.

TROUBLESHOOTING / Troubleshooting C

YES

Faulty monitor controller.

Connector Monitor Controller Connector B B8

NO

Broken harness between monitor controller and engine oil level switch.

T183-05-04-013

Faulty engine oil level switch.

Engine Oil Level Switch

Burned indicator light, or faulty monitor controller.

YES

Short-circuited harness between monitor controller and engine oil level switch.

Faulty monitor controller.

NO

Faulty engine oil level switch.

Normal.

T5-5-25

T146-05-03-005

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF COOLANT LEVEL INDICATOR • Check that all other indicators work correctly.

• Check that machine is parked on level surface.

• Check for loose harness connections beforehand.

Indicator Does Not Come ON Even If Coolant Level Is Lowered Below Lower Limit

YES

Disconnect coolant YES level switch on radiator at the side of machine. Check if indicator comes ON.

YES

·Key switch: ON NO Turn key switch to ON position. Check if indicator comes ON.

NO

Connect disconnected connector.

Disconnect main controller A connector B. Check for continuity between harness end connector terminal #B13 and vehicle frame.

NO

Disconnect monitor controller connector B. Check for continuity between harness end connector terminal #B9 and vehicle frame.

Indicator Comes ON Even If Coolant Level Is Normal Faulty coolant level switch.

YES Disconnect coolant level switch on radiator at the side of machine. Ground harness end connector terminal #2 to vehicle frame.

Check if indicator comes ON. ·Key switch: ON

NO

Connect disconnected connector.

Disconnect monitor controller connector B. Check for continuity between harness end connector terminal #B9 and vehicle frame.

YES

NO

T5-5-26

Faulty monitor controller.

Broken harness between coolant level switch and monitor controller.

TROUBLESHOOTING / Troubleshooting C

Faulty coolant level switch.

Short-circuited harness between coolant level switch and main controller A.

Faulty main controller A.

YES

Burned indicator light, or faulty monitor controller.

NO

Broken harness between monitor controller and coolant level switch.

Connector Monitor Controller Connector B

Coolant Level Switch

B9

T183-05-04-010 T183-05-04-013

Main Controller A Connector B

T183-05-04-021

B13

T5-5-27

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF LEVEL INDICATOR

HYDRAULIC

OIL

• Check that all other indicators work correctly.

• Check that machine is parked on level surface.

• Check for loose harness connections beforehand.

Indicator Does Not Come ON Even If Hydraulic Oil Level Is Lowered Below Lower Limit

YES

Disconnect hydraulic oil level switch 1. Ground YES harness end connector terminal to vehicle frame.

Check if indicator comes ON after 5 seconds.

Faulty hydraulic oil level switch 1.

Connect disconnected connector.

Disconnect hydraulic oil level switch 2.

NO Ground harness end connector terminal to vehicle frame. Check if indicator comes ON after 5 seconds.

·Key switch: ON

·Key switch: ON

Turn indicator light check switch ON. Check if indicator comes ON. ·Key switch: ON NO

NO

Disconnect monitor controller connector C and main controller B connector B. Check for continuity between connector C harness end terminal #C14 and connector B harness end terminal #B23.

YES

T5-5-28

YES Faulty hydraulic oil level switch 2.

NO

Connect disconnected connector.

Disconnect main controller B connector B. Check for continuity between harness end connector terminal #B15 and vehicle frame.

Burned indicator light, faulty monitor controller, or broken harness between monitor controller and main controller B.

Connect monitor controller connector C. Connect main controller B terminal #B15 and harness end connector #B15 with a clip.

Check if indicator comes ON.

TROUBLESHOOTING / Troubleshooting C Connector Monitor Controller Connector C

Main Controller B Connector B

Hydraulic Oil Level Switch 1, 2

T183-05-04-010

T183-05-04-014

C14

B23

B15

T183-05-04-021

Faulty main controller B.

YES Check for continuity YES between harness end connector terminal #B16 and vehicle frame.

Broken harness between hydraulic oil level switch 2 and main controller B.

NO

Broken harness between hydraulic oil level switch 1 and main controller B.

NO

Broken harness between main controller B and hydraulic oil level switch 2.

YES Check if indicator comes ON after YES switching hydraulic oil level switch 1 and hydraulic oil level switch 2.

NO

Disconnect hydraulic oil level switch 1.

Check for continuity between main controller B harness end connector terminal #B15 and hydraulic oil level switch 2 harness end connector terminal #1.

Faulty hydraulic oil level switch 2.

NO

YES

Disconnect hydraulic oil level switch 1.

Ground harness end connector terminal to vehicle frame.

Check if indicator comes ON after 5 seconds.

YES

Faulty hydraulic oil level switch 1.

Faulty main controller B. NO

Broken harness between main controller B and hydraulic oil level switch 1.

NO

T5-5-29

TROUBLESHOOTING / Troubleshooting C Indicator Comes ON Even If Hydraulic Oil Level Is Normal

YES

Faulty hydraulic oil level switch 1.

Disconnect hydraulic oil level switch 1.

Check if indicator goes OFF.

NO

Connect disconnected connectors.

Disconnect main conNO troller B connector B. Check for continuity between harness end connector terminals #B15, B16 and vehicle frame.

Disconnect hydraulic oil level switch 2. Check if indicator goes OFF.

NO

Disconnect monitor controller connector C. Check for continuity between connector C harness end terminal #C14 and connector B harness end terminal #B23.

Short-circuited harness between hydraulic oil YES level switch 1, 2 and main controller B.

Faulty hydraulic oil level switch 2.

YES

Connector Monitor Controller Connector C

Main Controller B Connector B

Hydraulic Oil Level Switch 1, 2 B16

T183-05-04-010

T183-05-04-014

C14

B23

B15 T183-05-04-021

T5-5-30

TROUBLESHOOTING / Troubleshooting C

YES

NO

Short-circuited harness between monitor controller and main controller B.

Faulty monitor controller or main controller B.

T5-5-31

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF AUTO-LUBRICATION INDICATOR • Check for loose harness connections beforehand.

24 V

Indicator comes ON even if auto-lubrication system operates normally.

Disconnect monitor controller connector C. Check for voltage at harness end connector terminal #C15.

NOTE: Indicator comes ON when lubrication mode switch is turned to "Manual" position.

Disconnect main controller B connector A. Check for continuity between monitor controller connector C harness end terminal #C15 and connector A harness end terminal #A29.

Faulty monitor controller.

0V

YES Indicator does not come ON even if auto-lubrication system is abnormal or lubrication mode switch is turned to "Manual" position.

¡Key switch: ON

Turn key switch to ON position.

Check if indicator comes ON.

NOTE: Indicator does not come ON if lubrication mode switch is faulty.

NO

T5-5-32

Disconnect monitor controller connector C. Check for voltage at harness end connector terminal #C15.

Burned indicator light, or faulty monitor controller.

TROUBLESHOOTING / Troubleshooting C

Connector Monitor Controller Connector C

Main Controller B Connector A

T183-05-04-014

C15

YES

A29

Short-circuited harness between monitor controller and main controller B.

Faulty main controller B. NO

0V

Faulty main controller B, or broken harness between monitor controller and main controller B.

Faulty monitor controller.

24 V

T5-5-33

T183-05-04-008

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE STOP INDICATOR • Check for loose harness connections beforehand.

NO

Indicator comes ON even if engine has no trouble.

Faulty engine stop indicator relay.

Check if indicator comes ON after switching engine stop indicator relay and other general-purpose relay. ·Key switch: ON YES

Disconnect ECM connector J2. Check if indicator goes OFF. ·Key switch: ON

YES

Indicator does not come ON even if engine has troubles.

Turn key switch to ON position.

Check if indicator comes ON.

Disconnect ECM connector J2. Ground harness end connector terminal #1 to vehicle frame.

Check if indicator comes ON. ·Key switch: ON

NO

T5-5-34

Burned indicator light, or faulty monitor controller.

TROUBLESHOOTING / Troubleshooting C

Connector Engine Stop Indicator Relay

ECM

J2

Monitor Controller Connector C

T183-05-04-014

T183-05-04-003

C19 T146-05-03-004

YES

Faulty ECM.

NO

NO

Disconnect engine stop indicator relay. Keep ECM connector J2 disconnected.

Check for continuity between connector J2 terminal #1 and engine stop indicator relay harness end connector terminal #1.

Connect ECM connector J2.

Disconnect monitor controller connector C. Check for continuity between connector C harness end terminal #C19 and engine stop indicator relay harness end connector terminal #3.

YES

Short-circuited harness between monitor controller and engine stop indicator relay.

Faulty monitor controller.

NO Short-circuited harness between engine stop indicator relay and ECM.

YES

YES

Disconnect engine stop indicator relay. Keep ECM connector J2 terminal #1 connected to vehicle frame.

NO Check for continuity between engine stop indicator relay harness end connector terminal #1 and vehicle frame.

Faulty ECM.

Check if indicator comes ON after YES switching engine stop indicator relay and other generalpurpose relay.

Disconnect monitor controller connector YES C. Check for continuity between connector C harness end terminal #C19 and engine stop indicator relay harness end connector terminal #3.

NO

YES

NO

Faulty monitor controller.

Broken harness between monitor controller and engine stop indicator relay.

Faulty engine stop indicator relay.

Broken harness between engine stop indicator relay and ECM.

NO

T5-5-35

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE WARNING INDICATOR • Check for loose harness connections beforehand.

NO

Indicator comes ON even if engine has no trouble.

Check if indicator comes ON after switching engine warning indicator relay and other general-purpose relay. ·Key switch: ON YES

YES

Indicator does not come ON even if engine has troubles.

Faulty engine warning indicator relay.

Turn key switch to ON position.

Check if indicator comes ON.

Disconnect ECM Connector J2.

Check if indicator goes OFF.

Disconnect ECM connector J2.

Ground harness end connector terminal #2 to vehicle frame.

Check if indicator comes ON. ·Key switch: ON

NO

T5-5-36

Burned indicator light, or faulty monitor controller.

TROUBLESHOOTING / Troubleshooting C

Connector Engine Warning Indicator Relay

ECM

J2

Monitor Controller Connector C

T183-05-04-014

T183-05-04-003

C16

T146-05-03-004

YES

Faulty ECM.

NO

NO

Disconnect engine warning indicator relay. Keep ECM connector J2 disconnected.

Check for continuity between connector J2 terminal #2 and engine warning indicator relay harness end connector terminal #1.

Connect ECM connector J2.

Disconnect monitor controller connector C. Check for continuity between connector C harness end terminal #C16 and engine warning indicator relay harness end connector terminal #3.

YES

Short-circuited harness between monitor controller and engine warning indicator relay.

Faulty monitor controller.

NO Short-circuited harness between engine warning indicator relay and ECM.

YES

YES

Faulty ECM.

Faulty engine warning indicator relay.

NO

Check for continuity between engine warning indicator relay harness end connector terminal #2 and vehicle NO frame.

Check if indicator comes ON after YES switching engine warning indicator relay and other general-purpose relay.

Disconnect monitor controller connector C. Check for continuity YES between connector C harness end terminal #C16 and engine warning indicator relay harness end connector terminal #3.

NO

T5-5-37

YES Faulty monitor controller.

NO

Broken harness between monitor controller and engine warning indicator relay.

Broken harness between engine warning indicator relay and ECM.

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF QUICK-IDLE INDICATOR • Check for loose harness connections beforehand.

Connector Monitor Controller Connector B

T183-05-04-013

Connector C

C3

T183-05-04-014

Disconnect monitor conYES troller connector B. Check if indicator comes ON. Indicator comes ON even if quick-idle system is not operating.

Disconnect quick-idle switch.

Check if indicator comes ON.

Disconnect monitor conYES troller connector C. Check if voltage at harness end connector terminal #C3 is 24 V. Short-circuited harness between quick-idle NO switch and monitor controller.

Faulty quick-idle switch.

NO

Indicator does not come ON even if quick-idle system is operating.

Burned indicator light, or faulty monitor controller.

T5-5-38

TROUBLESHOOTING / Troubleshooting C

Faulty quick-idle relay, or short-circuited harness between monitor controller and quick-idle relay.

YES

Faulty monitor controller.

NO

T5-5-39

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF AUTO-IDLE INDICATOR • Check for loose harness connections beforehand.

Connector Switch Box

T183-05-04-004

Monitor Controller Connector C B10

T183-05-04-013

Burned indicator light, or faulty monitor controller.

YES

Indicator does not come ON even if autoidle system is operating.

Disconnect monitor controller connector B. Check if voltage at harness end connector terminal #B10 is 24 V.

Broken harness between switch box and monitor controller.

NO

YES

Indicator comes ON even in auto-idle system is not operating.

YES

Faulty monitor controller.

NO

Short-circuited harness between switch box and monitor controller.

Disconnect monitor controller connector B. Check if indicator comes ON.

Disconnect switch box.

Check if indicator comes ON.

Faulty switch box.

NO

T5-5-40

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-5-41

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF HOURMETER • Check for loose harness connections beforehand.

Hourmeter Does Not Operate When Engine Is Running

YES Check if hourmeter opNO erates after switching alternator indicator relay and other generalpurpose relay.

NOTE: Check that room light comes ON before switching the relay.

Check if alternator indicator comes ON. ·Engine: Running

Faulty alternator relay.

Less than 13 V or 33.5 V or more Faulty alternator.

Measure voltage at NO alternator terminal L. ·Engine speed: -1 900 min (rpm) 13 V or more or more. less than 33.5 V

·Engine: Running

Disconnect alternator relay.

Measure voltage at harness end connector terminal #3.

Refer to "MALFUNCTION OF ALTERNATOR INDICATOR" (Alternator indicator stays ON after engine is started).

YES

Connector Monitor Controller Connector A

Alternator Relay

A2

T183-05-05-001

T5-5-42

T183-05-04-003

TROUBLESHOOTING / Troubleshooting C

Broken harness between alternator and alternator relay.

0V

Connect alternator relay.

Disconnect monitor controller connector A. 13 V or more Measure voltage at harless than 33.5 V ness end connector terminal #A2.

13 V or more less than 33.5 V

Faulty monitor controller.

0V

Broken harness between monitor controller and alternator relay.

T5-5-43

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF BUZZER • Check for loose harness connections beforehand.

10 V or more Buzzer continues to sound when key switch is turned ON without starting engine.

Measure voltage at monitor controller connector A terminal #A2. ·Key switch: ON without starting engine

Faulty alternator.

Less than 10 V Measure voltage at alternator relay Less than terminal #5.

10 V 10 V or more

Check if pump transmission oil pressure indicator comes ON.

YES

NO

Check if engine stop indicator comes ON. NO

NO Buzzer does not sound even if pump transmission oil pressure indicator or engine stop indicator comes ON.

Faulty monitor controller.

Faulty pump transmission oil pressure system.

YES

Buzzer continues to sound when engine is started.

Faulty alternator relay.

Faulty engine system.

Check if buzzer stops by pressing buzzer cancel switch.

Normal (Engine speed is too slow).

Check if alternator indicator comes ON.

YES

Measure voltage at regulator terminal L. ·Engine: Running

T5-5-44

TROUBLESHOOTING / Troubleshooting C

Connector Alternator Relay

Starter Relay 2 (Harness End)

Monitor Controller Connector A (Harness End)

A2

1 2

3

T183-05-05-001

T183-05-04-003

YES

Normal.

Faulty monitor controller.

NO

less than 13 V

13 V or more

Disconnect alternator terminal L, then ground the terminal to vehicle frame.

Disconnect starter relay 2.

Check for continuity between starter relay 2 harness end connector terminal #2 and vehicle frame.

Measure voltage at starter relay 2 terminal #2. ¡Engine: Running

YES

Faulty alternator.

NO

Broken harness between alternator terminal L and starter relay 2.

Faulty starter relay 2.

Less than 0 V

Disconnect starter relay 2.

Disconnect monitor controller connector A. Check for continuity between 24 V or more connector A harness end connector terminal #A2 and vehicle frame.

T5-5-45

YES

Short-circuited harness between monitor controller and starter relay 2.

Faulty monitor controller.

NO

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF LIQUID CRYSTAL DISPLAY (LCD) • This section describes the following items: 1 to 7: Displayed in normal condition.

8 to 23: Displayed when switched to the build-in diagnosing system. • Check that the machine control is not malfunctioning.

Main Controller A Side Display Description Order 1 Hourmeter 2 Trip1 3 Trip2 Engine Actual Speed 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Hydraulic Oil Temperature

Fault Code Main Pump 1 Pressure Main Pump 2 Pressure Main Pump 3 Pressure Front Attachment Operation Pressure Travel Operation Pressure Engine Exhaust Gas Temperature EC Angle Digital Input 0 Digital Input 1 Digital Input 2 Digital Input 3 Digital Output Proportional Valve ON/OFF Output Hydraulic Oil Cooling Output Current Power Increase Output Current

Causes Refer to T5-5-42.

Faulty monitor.

Faulty sensor system detecting corresponding signal. (There should be some abnormality with the machine control. Refer to Troubleshooting B).

Faulty sensor system detecting corresponding signal. (There should be some abnormality with the machine control. Refer to Troubleshooting B).

T5-5-46

TROUBLESHOOTING / Troubleshooting C

• This section describes the following items: 1 to 7: Displayed in normal condition.

8 to 23: Displayed when switched to the build-in diagnosing system. • Check that the machine control is not malfunctioning.

Main Controller B Side Display Description Order 1 Hourmeter 2 Trip1 3 Trip2 Engine Actual Speed 4 5 6 7 8 9 10 11 12 13 14 15 16

17 18 19 20 21 22 23

Hydraulic Oil Temperature

Fault Code Digital Input 0 Digital Input 1 Digital Input 2 Digital Input 3 Digital Output Proportional Valve ON/OFF Output Auto-Lubrication Status 1 Auto-Lubrication Status 2 (upper 4 bits) Auto-Lubrication Status 2 (lower 4 bits) Auto-Lubrication Interval Selection Digital Output 2 (upper 4 bits) Digital Output 2 (lower 4 bits)

Causes Refer to T5-5-42.

Faulty monitor.

Faulty sensor system detecting corresponding signal. (There should be some abnormality with the machine control. Refer to Troubleshooting B).

Faulty monitor, or faulty communication between monitor and MC. Faulty sensor system detecting corresponding signal. (There should be some abnormality with the machine control. Refer to Troubleshooting B).

T5-5-47

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE TROUBLESHOOTING OPERATION • Check for loose harness connections beforehand.

Connector Diagnostic Switch 1 2

YES

Fault code is not displayed when engine has some trouble even if engine diagnostic switch is turned to ON position.

Check if fault code is displayed after switching engine diagnostic switch and heavy lift switch or boom mode selection switch. ·Engine diagnostic switch: ON

Disconnect engine diagnostic switch.

Check for continuity between harness end conNO nector terminal #3 and fuse box (ECM) fuse #2.

Faulty engine diagnostic switch.

Connect engine diagnostic switch.

YES Disconnect ECM relay.

Check for continuity between harness end connector terminal #5 and fuse box (ECM) fuse #2.

NO

T5-5-48

3

Blown fuse box (ECM) fuse #2, or broken harness between engine diagnostic switch and fuse box (ECM).

TROUBLESHOOTING / Troubleshooting C

ECM

J1

ECM

J2

ECM Relay

2 T146-05-04-010

T146-05-03-004

T146-05-03-003

0V

YES

Connect ECM relay.

Disconnect ECM connector J1.

Check if voltage at harness end connector terminal #23 is 24 V.

24 V

Faulty ECM.

Connect ECM connector J1.

Disconnect ECM connector J2.

Check if voltage at harness end connector terminal #21 is 24V.

24 V

Faulty ECM.

0V

Broken harness between engine diagnostic switch and ECM.

Broken harness between fuse box (ECM) and ECM relay.

NO

T5-5-49

T146-05-04-006

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-5-50

TROUBLESHOOTING / Troubleshooting D TROUBLESHOOTING D PROCEDURES Refer to Troubleshooting D if the engine stop indicator and the engine warning indicator in the cab start flashing by the ECM diagnosis system. Refer to the System section in the Technical Manual (Operational Principle).

T5-6-1

TROUBLESHOOTING / Troubleshooting D HOW TO READ FAULT CODES ON ECM ENGINE DIAGNOSIS SYSTEM IMPORTANT: Be sure to record all displayed fault codes and check that the displayed fault codes are correctly read by re- Troubleshooting ferring to the fault code list on page Switch T5-6-3.

1. Turn the key switch to the ACC or ON position with the engine stopped.

2. Turn the troubleshooting switch ON. The engine warning indicator will start displaying the fault codes.

3. The fault codes are displayed in 2-digit figures.

Each digit is comprised of a number between 1 and 5. The figure is presented by the number of flashes, having a short pause between each digit.

In case more than one fault code exists, a long pause will be observed between the displayed fault codes.

4. After all fault codes stored in the ECM have been displayed, the fault codes are re-displayed from the beginning.

5. Turn the key switch OFF to end the fault code display.

M183-01-008

T183-01-02-013

Engine Warning Indicator

Example: Fault Code 2-1 and 4-3

1-flash = 1.

2-flashes = 2.

4-flashes = 4.

3-flashes = 3

ON

Long Pause

OFF Fault Code 2-1

Fault Code 4-3

T5-6-2

T146-05-03-007

TROUBLESHOOTING / Troubleshooting D Trouble Status and Fault Codes by Engine Warning Indicator Trouble Status Abnormal engine speed sensor 2 signal

Abnormal boost pressure sensor signal

Abnormal governor (actuator driver) electric power signal Abnormal governor angle (actuator position) sensor signal Abnormal Sensor (Boost pressure sensor electric power signal

Evaluation Output signal at an engine -1 speed of 100 min or slower, Root-mean square value: 1.5 V or less Less than 0.25 V, or more than 4.75 V

Fault Code *(2-1)

Short-circuited governor power line

*(4-1)

Deactivating the fuel restriction control system by the boost pressure Stopping the engine

Less than 0.05 V, or more than 4.95 V

*(4-5)

Stopping the engine

Sensor Power Voltage: Less than 4.75 V, or more than 5.25 V

*(4-3)

None

NOTE: Fault code “*(2-3)� means that the engine warning indicator flashes twice, makes one pause, and flashes 5 times.

T5-6-3

*(2-3)

Engine Control Stopping the engine

TROUBLESHOOTING / Troubleshooting D Inspection Method Referring to the trouble status shown in the table, check the harness between the ECM and each sensor for discontinuity and short circuit. When the harness is normal, either the corresponding sensor or the ECM may be faulty.

Connector Terminal Layout of ECM and Sensors Switch Box

ECM J1 Connector (Black) (Harness End Connector) Boost Pressure Sensor

Governor

T183-05-04-004

Drive Power

Sensor Ground Output

Ground

Power

Boost Pressure Sensor (Harness End Connector) T146-05-03-004

T146-05-03-006

Sensor Output

Ground

Angle Sensor Ground Sensor Output Power

Engine Speed Sensor Output

Governor

Power

ECM J2 Connector (White) (Harness End Connector) Governor (Harness End Connector) Sensor Output Ground

Angle Sensor Power

T146-05-03-001

Shield Line

Ground

Sensor Output

Governor Drive Power

T146-05-03-003

Ground Switch Box

Engine Speed Sensor 2 (Harness End Connector)

T146-05-03-005

Sensor Output

Shield Line

T5-6-4

Power

TROUBLESHOOTING / Electrical System Inspection PRECAUTIONS FOR INSPECTION AND MAINTENANCE 1. Disconnect Power Source Be sure to remove the negative terminals from the batteries first when taking wire harnesses and connectors off for repair or replacement work.

Failure to do so can result in damage to the wire harnesses, fuses, and fusible links and, in some cases, cause fire due to short circuit.

2. Color Coding of Wire Harnesses The color codes of the wire harnesses in the electrical system are shown in the table on the light. In some cases, where two colors are indicated for one wire, the left initial stands for the base color, while the right initial stands for the marking color.

Code

R

W

L

G

Y

B

Color

Red

White

Blue

Green

Yellow

Black

Code

Or

Lg

Br

p

Gr

V

Color

Orange

Light Green

Brown

Pink

Gray

Violet

NOTE: 1) Code BW indicates a black base wire with white fine-line marking.

2) Initials “O” and “Or” both stand for the color orange.

3) Wires with longitudinal stripes printed on them are not color coded. Be sure not to confuse them with color coded wires.

T5-7-1

TROUBLESHOOTING / Electrical System Inspection 3. Precautions for Connecting and Disconnecting Terminal Connectors 1) When disconnecting harnesses, grasp them by their connectors. Do not pull on the wire itself. Be sure to release the lock first before attempting to separate connectors, if a lock is provided.

2) Water-resistant connectors keep water out so that if water enters the connector, water will not easily drain. When checking water-resistant connectors, take extra care not to allow water to enter these types of connectors. In case water should enter this connector, reconnect only after thoroughly drying the connector.

3) Before connecting terminal connectors, check that no terminals are bent or missing. In addition, as most connectors are made of brass, check that no terminals are corroding.

4) When connecting terminal connectors provided with a lock, be sure to insert them together until the lock “clicks.�

4. Precaution for Using a Circuit Tester 1) Before using a circuit tester, refer to the instructions in the circuit tester manual.

Then, set the circuit tester to meet the object to be measured, voltage range and current polarity .

2) Before starting the connector test, always check the connector terminal numbers, referring to the circuit diagram. When the connector size is very small, and the standard probe size is too large to be used for testing, wind a fine piece of sharpened wire or a pin around the probe to make the test easier.

T5-7-2

Correct

Incorrect

T107-07-06-001

Correct Rust Bending Separation

T107-07-06-002

Wind wire around the probe.

Probe

Sharpen the tip of wire.

T107-07-06-003

TROUBLESHOOTING / Electrical System Inspection INSPECTIONS CONNECTORS

FOR

DISCONNECTING

1. Push the lock to disconnect.

NOTE: 1) Connectors may not be separated if the lock is pushed while the connectors are pulled. Be sure to push the lock first before pulling the connectors.

2) The lock is provided on the female connector (harness side).

T107-04-05-002

Locations of This Type Connector Hydraulic Oil Level Switch Proximity Switch Washer Boom Mode Selection Switch Air Conditioner Clutch Governor Actuator Monitor Controller Work Light Main Pump Delivery Pressure Sensor Oil Level Switch

Diode Front All Pressure Sensor Starter Relay 2 Buzzer Cancel Switch Air Conditioner Pressure Switch Air Conditioner Sensor Air Compressor Speaker Boost Pressure Sensor

Wiper Motor Flow Rate Decrease Solenoid Valve Travel Pressure Sensor Heavy Lift Switch Auto-Lubrication Timer Switch Air Conditioner Controller Air Conditioner Unit Ambient Air Temperature Sensor ECM Relay Exhaust Gas Temperature Sensor

Coolant Level Sensor Data Link Engine Diagnostic Switch Key Switch DC-DC Controller Room Light ECM Engine Speed Sensor

2. Pull to disconnect.

Locations of This Type Connector Oil Pressure Sensor Air Vent Select Servo Motor Switch Box Frash Memory DLU A/M Servo Motor Radio Fusible Link

Circulation Servo Motor Preheat Switch Power Transistor Hydraulic Oil Temperature Sensor Thermo-Guard Switch Step Light Switch Sun Exposure Sensor T107-04-05-004

T5-7-3

TROUBLESHOOTING / Electrical System Inspection FUSE INSPECTION 3. Connect the negative probe to the vehicle ground, and touch the outside terminal of each fuse with the positive probe of the tester.

When normal continuity of a fuse is intact, the tester will indicate 20 to 25 volts.

Fuse failure is often caused by a fine crack in the fuse, and such fine cracks are very hard to detect by visual inspection.

Checking fuse continuity with a tester is far superior to sight inspection.

1. Turn the key switch ON In doing so, the battery relay is activated by the current from terminal M of the key switch, and electric power is supplied to all circuits except the No.19 fuse circuit and the No.20 fuse circuit.

NOTE: (a) All the inside terminals of the fuses in the fuse box are connected to the power source, while the outside terminals are connected to the accessories.

Test all fuses using the same method, except the fuses for the No.19 fuse circuit and the No.20 fuse circuit. (b) To check the fuse for the No.19 fuse circuit and No.20 fuse circuit, turn the key switch to the START position and perform the test as described in (3).

2. Remove the fuse box cover and set the correct voltage measurement range of the tester.

(Measurement range: 0 to 30 V)

No.20 Fuse Circuit

No.19 Fuse Circuit

Accessory (Outside)

ŇĽ

+

Accessory (Outside)

Power Source (Inside)

T142-06-06-004

T5-7-4

TROUBLESHOOTING / Electrical System Inspection Connection in Fuse Box Fuse No. 1 2 3

Description Backup Controller Power ON SIG.

Capacity 5A 5A 5A

Connected to Monitor Controller Main Controller B Main Controller A, Main Controller B

Remarks Backup power source Main power source Power source ON sig.

4 5 6 7 8

DC-DC Converter MCX SOL Travel Alarm Switch Box Step Light

20 A 10 A 5A 5A 5A

DC-DC Converter Main Controller A, Main Controller B Travel Alarm (Optional) Monitor Controller, Main Controller A Step Light Relay

Power source Power source Power source Main power source Power source

9 10 11

Air Conditioner BATT Light

5A 10 A 20 A

Air Conditioner Battery Relay, Battery Relay 2 Work Light Relay 1, Work Light Relay 2

Power source Power source Power source

12

Wiper

20 A

Wiper Relay

Power source

13 14

Air Conditioner Solenoid

20 A 15 A

Air Conditioner (Heater) Flow Rate Decrease Solenoid Valve Relay, Power Transistor 1, Power Transistor 2, Quick Idle Relay

Power source Power source

15 16 17 18

Radio Lighter Room Lamp Horn

5A 10 A 5A 10 A

Radio Lighter Room Lamp Horn Relay

Power source Power source Power source Power source

19

Start Repeating Relay

5A

Starter Relay 2, Start Repeating Relay

Power source

20

ECM. ENG. Start, SIG

5A

ECM

Power source

10 9 8 7 6

20 19 18 17 16 15 14 13 12 11

5 4 3 2 1

T183-05-06-002

T5-7-5

TROUBLESHOOTING / Electrical System Inspection Fuse Box (ECM) Remove side cover from the right console in the cab.

Fuses are located in the position as illustrated to the right.

M183-01-008

Side Cover

M183-01-082

1

2

3

4

5

6

M144-07-111

Connection in Fuse Box (ECM) Fuse No.

Description

1

ECM Main Power Source

2 3

Capacity

Connected to

Remarks

20 A

ECM Relay

Main power source

Preheat Switch

5A

Engine Diagnostic Switch, Preheat Switch

Power source

Preheat Relay

5A

Preheat Relay 1

Power source

4

ECM Relay

5A

ECM Relay

Power Source

5

DLU Main Power Source

5A

DLU

Power source

6

OPT 5

20 A

T5-7-6

TROUBLESHOOTING / Electrical System Inspection FUSIBLE LINK INSPECTION

Fusible Link 7

Fusible Link 6 Fusible Link 8

x Fusible Link 1 to 4 Pull off the fusible links to visually inspect.

x Fusible Link 5 to 8 1. Remove nuts (2 used) and harness. : 12.5 mm 2. Remove and visually inspect each fusible link.

Fusible Link 5

Fusible Link 1 to 4 T183-01-02-004

Fusible Link 5 to 8 Nut

Fusible Link

Harness

T183-05-06-001

BATTERY VOLTAGE CHECK 1. Turn the key switch OFF. Check voltage between the battery positive terminal and the vehicle.

V

Normal Voltage: 24 V NOTE: If voltage is abnormal, recharge or replace the battery.

2. Start the engine. Check voltage between the battery positive terminal and the vehicle.

Normal Voltage: 26 to 28 V NOTE: If voltage is abnormal, check the charging system.

T142-06-06-002

T5-7-7

TROUBLESHOOTING / Electrical System Inspection ALTERNATOR CHECK In general, the alternator indicator remains off when the alternator is generating power.

If the alternator indicator comes on while the engine is running, the alternator might be defective.

Generating Voltage Measurement 1. Measure voltages at terminals R and B after starting the engine.

Specification: Terminal R: More than 14 V Terminal B: Approx. 28 V

T5-7-8

Terminal B

Terminal R

T146-05-06-001

TROUBLESHOOTING / Electrical System Inspection (Blank)

T5-7-9

TROUBLESHOOTING / Electrical System Inspection VOLTAGE CHECK Operate the key switch and the engine control dial as specified to apply voltage to the point to be measured.

Check if the specified (standard) voltage is obtained at each point.

Tester Probes: Black (-) Probe :To vehicle (Grounding) Red (+) Probe:To the point to be measured.

24 Voltage Circuits For each 24 voltage circuit, start checking either from the power source side or the actuator side.

Thereby, the failed part in each circuit can be located, if any.

Engine Power Source Circuit Stopped Stopped Stopped Stopped Stopped Starting Circuit Cranking Cranking Cranking Cranking Cranking Cranking Cranking Cranking Accessory Circuit Stopped Stopped Stopped Stopped Charging Circuit Running Running Running Running Running Surge Voltage Prevention Circuit Running-Stopped Running-Stopped

Key Switch

Check Point

Standard

OFF OFF OFF OFF OFF

Between (2) and (1): One Battery Between (3) and (2): One Battery Between (3) and (1): Two Battery Between (4) and (E): Power Source Between (5) and (E): Fusible Link

10 to 12.5 V 10 to 12.5 V 20 to 25 V 20 to 25 V 20 to 25 V

START START START START START START START START

Between (6) and (E) : Key Switch Between (7) and (E) : Fuse Between (8) and (E) : Start Repeating Relay (SS) Between (9) and (E) : Starter Relay 2 (B) Between (10) and (E): Starter Relay 2 (S) Between (11) and (E): Starter Relay 1 (Coil) Between (12) and (E): Starter Relay 1 (Switch) Between (13) and (E): Starter Motor (C)

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

ACC ACC ACC ACC

Between (14) and (E): Lighter Between (15) and (E): Radio Between (16) and (E): Room Light Between (17) and (E): Horn

20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V

ON ON ON ON ON

Between (18) and (E): Alternator (B) Between (19) and (E): Battery Relay 1 (B) Between (20) and (E): Alternator (L) Between (21) and (E): Charge Relay Between (22) and (E): Monitor Controller

26 to 30 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V

ON-OFF ON-OFF

Between (23) and (E): Load Dump Relay (Coil) Between (24) and (E): Battery Relay (Coil)

20 to 25 V 20 to 25 V

T5-7-10

TROUBLESHOOTING / Electrical System Inspection Power Source Circuit

Key Switch

5 Fuse Box

Fusible Link Preheat Relay 2

Battery Relay 2 Fuse Box (ECM)

4 Battery Relay 1

Load Damp Relay

3

2

1

ECM Relay Battery

Monitor Controller

Main Controller B

ECM

T183-02-03-001

T5-7-11

TROUBLESHOOTING / Electrical System Inspection Starting Circuit

Key Switch

Fuse Box

Fuse Box

6

Engine Stop Solenoid Junction Box Engine Stop Solenoid Relay

7

Engine Stop Relay

10

Battery Relay 2

12 11 Fusible Link (100A)

Starter Relay 1

Battery Relay 1

Starter Relay 2

Battery

9 8 Start Repeating Relay B L

Alternator R Starter Motor

Motor

13

13 Coil

T5-7-12

Main Contactor

T183-02-03-003

TROUBLESHOOTING / Electrical System Inspection Accessory Circuit

15

14 Fuse Box

Radio Cigar Lighter Cab Light

Key Switch Fusible Link #1

Preheat Relay 2

Horn

16 17 Battery Relay 2

Battery Relay 1

Battery T183-02-03-006

T5-7-13

TROUBLESHOOTING / Electrical System Inspection Charging Circuit

Fuse Box (ECM)

Key Switch

Fuse Box

Fusible Link #1

Preheat Relay 2

Fusible Link #7 Fusible Link #2

Battery Relay 2 Fusible Link #3

Fuse Box

Junction Box

Engine Stop Fusible Solenoid Relay Link #4 Fusible Link #5

19

Battery Relay 1 Battery

Starter Relay 1 Fusible Link #6 100 A (Alternator)

21 Charge Relay

18

Monitor Controller

Alternator

22

20

T183-02-03-005

T5-7-14

TROUBLESHOOTING / Electrical System Inspection Surge Voltage Prevention Circuit

Key Switch

Fuse Box

Fusible link

23

Preheat Relay Stop Solenoid Relay Load Damp Relay

Junction Box

Power Transistor 3

Battery Relay

Engine Stop Relay

24 Main Controller B

Battery

ECM

Alternator

Charge Relay

Starter Relay 2

Monitor Controller

T183-02-03-007

T5-7-15

TROUBLESHOOTING / Electrical System Inspection 5-Volt Circuit • Voltage between Terminal #1 and Vehicle Frame Turn the key switch OFF. After disconnecting the sensor connector, measure the voltage between machine side harness end connector terminal #1 (5 V power) and the vehicle frame (ground) under the following conditions.

Power Source 1

Signal or Ground 2

Two Polarities

V

Key Switch: ON Black Probe (Minus) of Tester: Vehicle Frame (Ground) Red Probe (Plus) of Tester: Terminal #1

T107-07-05-006

When the voltage matches 5 r 0.5 V, the circuit up to terminal #1 is normal.

Power Source Signal Ground 2 3 1 Three Polarities

V

• Voltage between Terminal #1 and Ground Terminal Turn the key switch OFF. After disconnecting the sensor connector, measure the voltage between machine side harness end connector terminal #1 (5 V power) and the ground terminal (terminal #2 for two polarities, terminal #3 for three polarities) under the following conditions.

T107-07-05-007

1

2

Two Polarities

V

Key Switch: ON Black Probe (Minus) of Tester: Ground Terminal (Terminal #2 or #3) Red Probe (Plus) of Tester: Terminal #1 T107-07-05-008

When the voltage matches 5 r 0.5 V, the circuit up to terminal #1 or the ground terminal is normal.

1

2

3

Three Polarities

V

T107-07-05-009

T5-7-16

TROUBLESHOOTING / Electrical System Inspection CONTINUITY CHECK Harness

Single-line continuity check Disconnect both end connectors of the harness and check continuity between both ends: If the ohm-meter reading is: 0 : Continuity f : Discontinuity NOTE: When the one end connector is far apart from the other, connect one end of connector (A) to the machine chassis using a clip. Then, check continuity of the harness through the vehicle frame as illustrated.

A

:

Connect to the vehicle frame.

:

a

A

Single-line short-circuit check Disconnect both end connectors of the harness and check continuity between one end connector of the harness and the vehicle frame: If the ohm-meter reading is: 0 : Short circuit is present. f : No short circuit is present.

Multi-line continuity check Disconnect both end connectors of the harness, and short-circuit two terminals, (A) and (B), at one end connector, as illustrated. Then, check continuity between terminals (a) and (b) at the other connector.

If the ohm-meter reading is f :, either line (A) - (a), or (B) - (b) is in discontinuity. To find out which line is discontinued, conduct the single line continuity check on both lines individually, or, after changing the shortcircuit terminals from (A) - (B) to (A) - (C), check continuity once more between terminals (a) and (c).

a

A

Connect to the vehicle frame.

If the ohm-meter reading is: 0 : Continuity f : Discontinuity

a

u

Short-circuit between the harness and the vehicle frame

:

T107-07-05-003

First short-circuit

A B C

a b c

Second short-circuit

:

NOTE: By conducting the multi-line continuity check twice, it is possible to find out which line is discontinued. With terminals (A) and (C) short-circuited, check continuity between terminals (a) and (c).

If the ohm-meter reading is: 0 : Line (B) - (b) has discontinuity. f : Line (A) - (a) has discontinuity.

Multi-line short-circuit check Disconnect both end connectors of the harness, and check continuity between terminals (A) and (B) or (C).

If the ohm-meter reading is: 0 : Short-circuit exists between the lines. f : No short-circuit exists between the lines.

T107-07-05-004

Short-circuit between harnesses.

A B C

u

a b c

:

T107-07-05-005

T5-7-17

TROUBLESHOOTING / Electrical System Inspection (Blank)

T5-7-18