Hitachi EX2600-7B Hydraulic Excavator Tier 4 Final Cummins Engine Troubleshooting Technical Manual

PART NO.

TTKEB90-EN-00

EX2600-7B HYDRAULIC EXCAVATOR TECHNICAL MANUAL TROUBLESHOOTING TTKEB90-EN-00

PRINTED IN JAPAN (K) 2019, 04

Technical Manual Troubleshooting

EX2600-7B

Hydraulic Excavator Tier 4 Final Cummins Engine

Service Manual consists of the following separate Part No. Technical Manual (Operational Principle) : Vol. No.TOKEB90-EN Technical Manual (Troubleshooting) : Vol. No.TTKEB90-EN Workshop Manual : Vol. No.WKEB90-EN

INTRODUCTION To The Reader This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.

The machine specification and description according to destination may be explained on this manual.

 If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.):  Service Material Development Center Hitachi Construction Machinery Co., Ltd.  TEL: 81-29-832-7233  FAX: 81-29-831-1162  E-mail: HCM-TIC-GES@hitachi-kenki.com

 Be sure to thoroughly read this manual for correct product information and service procedures.

Additional References Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.

Manual Composition This manual consists the Technical Manual and the Workshop Manual.

 Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures.

 Information included in the Technical Manual: Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.

Page Number Each page has a number, located on the center lower part of the page, and each number contains the following information: Example:  Technical Manual: T 1-3-5 T 1 3 5

 Workshop Manual: W 1-3-2-5 W 1 3 2 5

Technical Manual Section Number Group Number Consecutive Page Number for Each Group

Trademark AdBlue® is a registered trademark of the Verband der Automobilindustrie e.V. (VDA).

IN-1

Workshop Manual Section Number Group Number Sub Group Number Consecutive Page Number for Each Group

INTRODUCTION Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage.

dCAUTION: Indicates potentially hazardous situation which could, if not avoided, result in personal injury or death.

d This is the safety alert symbol. When you see this

IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

symbol, be alert to the potential for personal injury.

Never fail to follow the safety instructions prescribed along with the safety alert symbol.

The safety alert symbol is also used to draw attention to component/part weights.

To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

fNOTE: Indicates supplementary technical information or knowhow.

Units Used SI Units (International System of Units) are used in this manual.

A table for conversion from SI units to other system units is shown below for reference purposes.

Quantity

To Convert From

Into

Multiply By

Length

mm

in

0.03937

mm

ft

0.003281

L

US gal

0.2642

L

US qt

1.057

m3

yd3

1.308

Weight

kg

lb

2.205

Force

N

kgf

0.10197

N

lbf

0.2248

Torque

N·m

kgf·m

Pressure

MPa

kgf/cm

10.197

MPa

psi

145.0

kW

PS

1.360

kW

HP

1.341

Temperature

°C

°F

°C×1.8+32

Velocity

km/h

mph

0.6214

min

rpm

1.0

L/min

US gpm

0.2642

mL/rev

cc/rev

1.0

Volume

Power

-1

Flow rate

0.10197 2

Trademark AdBlue® is a registered trademark of the Verband der Automobilindustrie e.V. (VDA).

IN-2

SYMBOL AND ABBREVIATION Symbol / Abbreviation TO TT T/M W, W/M T4F

IDU DLU ELUF

ELUT

MCU

HMU

CSU ECM EHU

HTC LTC PFU

PMU ODR

Name

Explanation

Technical manual (Operational principle) Technical manual (Operational Principle).

Technical manual (Troubleshooting) Technical manual (Troubleshooting).

Technical manual Technical manual.

Workshop manual Workshop manual (Removal and Installation, Disassembly and Assembly).

EPA Tier 4 Final EPA (The United States Environmental Protection Agency) Tier 4 Final emissions regulations for Non-road mobile machines take effect on Jan,2015.

The engine which powers the machine in this manual complies with this regulations.

Information Display Unit Information display controller. IDU displays the information from each controller on the monitor.

Data Logging Unit Data logging unit. DLU records the information from each controller.

Electric Lever Control Unit for Front Electric control lever controller for controlling the front attachment operation. ELUF controls the pilot pressure which supplies to the control valve according to the control lever stroke.

Electric Lever Control Unit for Travel Electric control lever controller for controlling the travel operation. ELUT controls the pilot pressure which supplies to the control valve according to the control lever stroke.

Monitor Control Unit Controller for the alarm monitor and sub control. MCU judges the alarms, controls the oil cooler fan, and controls autolubrication control.

Hydraulic System Monitoring Unit Hydraulic system monitoring unit. HMU monitors the condition of the hydraulic components such as swing motor and others and the oil cooler.

Contamination Sensing Unit Contamination sensing unit. CSU senses contaminants in the drain circuits of the main pump, swing motor, and travel motor.

Engine Control Module Engine controller. ECM controls fuel injection amount according to the machine operating condition.

Engine Heat Balance Monitoring Unit Engine cooling system monitoring unit. EHU monitors the engine cooling system condition such as HTC radiator, LTC radiator, and others.

High Temperature Cooling Circuit HTC indicates the engine cooling circuit.

Low Temperature Cooling Circuit LTC indicates the supercharger cooling circuit.

Pump Flow Control Unit Pump flow rate control controller. PFU calculates the target pump displacement of each main pump and controls each pump flow rate.

Pump Monitoring Unit Pump monitoring unit. PMU monitors the drain pressure of main pump.

Operation Data Recorder Operation data recorder. ODR automatically records the data related to the detected information which has been set.

SY-1

SYMBOL AND ABBREVIATION Symbol / Abbreviation ACU

Name

Explanation

Aerial Angle Control Unit

BPU

Basic Performance Monitoring Unit

FMU

Fatigue Monitoring Unit

GSM

Global System for Mobile Communications Controller

WIU GPS CAN

Wireless Interface Unit Global Positioning System Controller Area Network

EDQR Valve

Electric Dual Quick Response Valve

SCR

Selective Catalytic Reduction

ECU

Electronic Control Unit

NOx DEF

Nitrogen Oxide Diesel Exhaust Fluid

Aerial angle control unit. ACU controls the circumference check of the machine by using the monitor.

Basic performance monitoring unit. BPU semiautomatically measures the basic performance.

Mechanical fatigue monitoring unit. FMU monitors mechanical fatigue of the structures.

Communication controller. GSM is a type of wireless communication system, is used in more than on 100 countries around Europe and Asia, and becomes the factual global standards of the mobile telephone.

WIU outputs the machine operation data to PC via wireless LAN. Global positioning system.

CAN communication. CAN is a serial communications protocol internationally-standardized by ISO (International Organization for Standardization).

EDQR valve receives command current according to the electric control lever stroke, flows pilot pressure oil according to this command current to the control valve, and moves the spool of the control valve.

The urea SCR system injects diesel exhaust fluid to nitrogen oxide (NOx) exhausted from the engine and purifies NOx. Urea SCR system controller. ECU sends the signals from the sensors of urea SCR system to ECM. Nitrogen oxide.

Diesel exhaust fluid. The diesel exhaust fluid concentration is 32.5 %, which is specified in ISO22241.

SY-2

SAFETY Recognize Safety Information  These are the SAFETY ALERT SYMBOLS.  When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.  Follow recommended precautions and safe operating practices.

SA-2644

Understand Signal Words  On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.  DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.  WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.  CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.  DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.  Some safety signs are occasionally used on this machine that do not use any of the designated signal words mentioned above after the safety alert symbol.

 To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine. 

fNOTE: Indicates an additional explanation for a piece of information.

SA-1

SA-1223

SAFETY Follow Safety Instructions  Carefully read and follow all safety signs on the machine and all safety messages in this manual.  Safety signs should be installed, maintained and replaced when necessary.  If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).  Learn how to operate the machine and its controls correctly and safely.  Allow only trained, qualified, authorized personnel to operate the machine.  Keep your machine in proper working condition.  Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.  Do not modify any machine parts without authorization.

Failure to do so may deteriorate the safety, function, and/ or service life of the part. In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void Hitachi Warranty Policy.  Never attempt to modify or disassemble the inlet/exhaust parts and the aftertreatment device. Avoid shocks to the element of the aftertreatment device, such as striking or dropping objects onto the element. Failure to do so may affect the exhaust gas purifying device, possibly damaging it or lowering its performance.  Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void Hitachi Warranty Policy.  The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/ or your authorized dealer before operating or performing maintenance work on the machine.

SA-2

SA-003

SAFETY Prepare for Emergencies  Be prepared for a fire or an accident.  Keep a first aid kit and fire extinguisher on hand.  Thoroughly read and understand the label attached on the fire extinguisher to use it properly.  To ensure that a fire extinguisher can be always used when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fire extinguisher manual.  Establish emergency procedure guidelines to cope with fires and accidents.  Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.

SA-437

Wear Protective Clothing  Wear close fitting clothing and safety equipment appropriate to the job.

You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask Be sure to wear the correct equipment and clothing for the job. Do not take any chances.  Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.  Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.

SA-3

SA-438

SAFETY Protect Against Noise  Prolonged exposure to loud noise can cause impairment or loss of hearing.  Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

SA-434

Inspect Machine  Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.  In the walk-around inspection be sure to cover all points described in the "Inspect Machine Daily Before Starting" section in the operator’s manual.

SA-435

SA-4

SAFETY General Precautions for the Cab  Before entering the cab, thoroughly remove all dirt and/or oil such as mud, grease, soil or stones from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots, the operator’s foot may slip off the pedal, possibly resulting in a personal accident.  Do not mess up around the operator’s seat with parts, tools, soil, stones, obstacles that may fold up or turn over, cans or lunch box. The levers or pedals become inoperable if obstacle jams in operation stroke of the travel levers/pedals, pilot control shut-off lever or control levers, which may result in serious injury or death.  Avoid storing transparent bottles in the cab. Do not attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire.  Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine.  Keep all flammable materials and/or explosives away from the machine.  Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.  Correctly lay the floor mat specific to the machine. If another floor mat is used, it may be displaced and contact with the travel pedals during operation, resulting in serious injury or death.

SA-5

SAFETY Use Handholds and Steps  Falling is one of the major causes of personal injury.  When you get on and off the machine, always maintain a three-point contact with the steps and handrails.  Do not use any controls as hand-holds.  Never jump on or off the machine. Never mount or dismount a moving machine.  Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.  Never get on and off the machine with tools in your hands.

SA-439

Adjust the Operator's Seat  A seat which is poorly adjusted for the individual operator, or the work to be undertaken, may quickly fatigue the operator leading to misoperation.  The seat should be adjusted whenever the operator of the machine changes.  The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back.  If not, move the seat forward or backward, and check again.  Adjust the rear view mirror position so that the best rear visibility is obtained from the operator’s seat. If the mirror is broken, immediately replace it with a new one.

SA-6

SA-378

SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat  Before rising from the operator’s seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever and/or pedal, possibly resulting in serious personal injury or death.  Before leaving the machine, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Push the engine stop switch to stop the engine.  Before leaving the machine, close all windows, doors, and access covers and lock them.

Fasten Your Seat Belt  If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.  Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine.  Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident.  We recommend that the seat belt is replaced every three years regardless of its apparent condition.  Seat belt is also provided on the trainer’s seat. Be sure the rider on the trainer’s seat properly fastens seat belt before operating the machine.

SA-7

SA-237

SAFETY Move and Operate Machine Safely  Bystanders can be run over.  Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine.  Always keep the travel alarm and horn in working condition. It warns people when the machine starts to move.  Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine.  Use appropriate illumination. Check that all lights are operable before operating the machine. If any faulty illumination is present, immediately repair it.  Ensure the cab door, windows, doors and covers are securely locked.  Check the mirrors and the monitor in the cab for problems.

If there is, replace the problem part (s) or clean the mirror, camera lens and the monitor display.

Refer to operator's manual for information on cleaning the camera lens and the monitor display.

SA-8

SA-426

SAFETY Operate Only from Operator's Seat  Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.  Start the engine only when seated in the operator's seat.  Do not start engine by shorting across starter terminals.  Before starting the engine, confirm that all control levers are in neutral.  Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders.

SA-444

Handle Starting Aids Safely Starting fluid:  Starting fluid is highly flammable.  Keep all sparks and flame away when using it.  Keep starting fluid well away from batteries and cables.  Remove container from machine if engine does not need starting fluid.  To prevent accidental discharge when storing a pressurized container, keep the cap on the container, and store it in a cool, well-protected location.  Do not incinerate or puncture a starting fluid container.

SA-293

Jump Starting  Battery gas can explode, resulting in serious injury.  If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual.  The operator must be in the operator’s seat so that the machine will be under control when the engine starts.

Jump starting is a two-person operation.  Never use a frozen battery.  Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine.

SA-032

SA-9

SAFETY Keep Riders off Machine  Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine.  Only the operator should be on the machine. Keep riders off.  Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.  If the machine is equipped with a second seat and someone other than the operator is on board, the person must always stay in the second seat with the seat belt fastened.

SA-379

Precautions for Operations  Investigate the work site before starting operations.  Be sure to wear close fitting clothing and safety equipment appropriate for the job, such as a hard hat, etc. when operating the machine.  Keep bystanders and obstacles clear of the area of machine operation.

Keep persons other than the operator away from areas where there is danger, such as from flying objects.  Always be aware of the surroundings while operating.

When working in a small area surrounded by obstacles, take care not to hit the upperstructure against obstacles.  When loading onto trucks, bring the bucket over the truck beds from the rear side. Take care not to swing the bucket over the cab or over any person.

M178-05-007

SA-10

SAFETY Investigate Job Site Beforehand  When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.  Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles or banks from collapsing.  Make a work plan. Use machines appropriate to the work and job site.  Reinforce ground, edges and road shoulders as necessary. Keep the machine well back from the edges of excavations and road shoulders.  When working on an incline or on a road shoulder, employ a signal person as required.  Do not allow anyone within the range of work, swing or movement of the machine.  When the ground footing is weak, reinforce the ground before starting work.  When working on frozen ground, be extremely alert. As ambient temperatures rise, footing becomes loose and slippery.  Beware the possibility of fire when operating the machine near flammable materials such as dry grass.

SA-11

SA-380

SAFETY  Make sure the worksite has sufficient strength to firmly support the machine.

When working close to an excavation or at road shoulders, operate the machine with the tracks positioned perpendicular to the cliff face with travel motors at the rear, so that the machine can more easily evacuate if the cliff face collapses.  If working on the bottom of a cliff or a high bank is required, be sure to investigate the area first and confirm that no danger of the cliff or bank collapsing exists. If any possibility of cliff or bank collapsing exists, do not work on the area.  Soft ground may collapse when the machine is operated on it, possibly causing the machine to tip over. When working on soft ground is required, be sure to reinforce the ground first using steel plates strong and firm enough to easily support the machine.  Note that there is always a possibility of machine tipping over when working on rough terrain or on slopes. Prevent machine tipping over from occurring. When operating on rough terrain or on slopes:  Reduce the engine speed.  Select slow travel speed mode.  Operate the machine slowly and be cautious with machine movements.

Restriction of Attachment Installation Do not install an attachment which exceeds the specified weight for the machine structure.

SA-12

M104-05-016

SAFETY Provide Signals for Jobs Involving Multiple Machines  For jobs involving multiple machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

SA-481

Confirm Direction of Machine to Be Driven  Incorrect travel pedal/lever operation may result in serious injury or death.  Before driving the machine, confirm the position of the undercarriage in relation to the operator’s position. If the travel motors are located in front of the cab, the machine will move in reverse when travel pedals/levers are operated facing forwards.

SA-491

SA-13

SAFETY Drive Machine Safely  Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the direction you wish to drive.  Be sure to detour around any obstructions.  Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Do not allow personnel to stay around the machine while traveling.

A

SA-657

 Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.  Never attempt to ascend or descend 30 degrees or steeper slopes.  Be sure to fasten the seat belt.  When driving up or down a slope, keep the bucket facing the direction of travel, approximately 0.5 to 1.0 m (see A on the right) above the ground.  If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.  Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.  Avoid swinging the upperstructure on slopes. Never attempt to swing the upperstructure downhill. The machine may tip over. If swinging uphill is unavoidable, carefully operate the upperstructure and boom at slow speed.  If the engine stalls on a slope, immediately lower the bucket to the ground. Return the control levers to neutral.

Then, restart the engine.  Be sure to thoroughly warm up the machine before ascending steep slopes. If hydraulic oil has not warmed up sufficiently, sufficient performance may not be obtained.

A

SA-658

SA-441

WRONG

SA-590

SA-14

SAFETY  Be sure to fully pull up the stairway before traveling.  Before descending a slope, turn the travel mode switch to the SLOW position on level ground. Do not operate the travel mode switch while descending a slope. The machine may slip, possibly causing safety accident.  When descending a steep slope, avoid quick start or stop traveling in the FAST mode. Failure to do so may result in damage to the travel motors.  Use a signal person when moving, swinging or operating the machine in congested areas. Coordinate hand signals before starting the machine.  Before moving machine, determine which way to move travel pedals/levers for the direction you want to go.

When the travel motors are in the rear, pushing down on the front of the travel pedals or pushing the levers forward moves the machine forward, towards the idlers.  Select a travel route that is as flat as possible. Steer the machine as straight as possible, making small gradual changes in direction.  When traveling on a level surface, position the front with boom (1) fully raised, and arm (2) fully retracted, as illustrated, in order to apply the load as evenly as possible to all of the lower rollers.  Before traveling on them, check the strengths of bridges and road shoulders, and reinforce if necessary.  Use wood plates in order not to damage the road surface.

Be careful of steering when operating on asphalt roads in summer.  When crossing train tracks, use wood plates in order not to damage them.  Do not make contact with electric wires or bridges.  When crossing a river, measure the depth of the river using the bucket, and cross slowly. Do not cross the river when the depth of the river is deeper than the upper edge of the upper roller.  When traveling on rough terrain, reduce engine speed.

Select slow travel speed. Slower speed will reduce possible damage to the machine.  Avoid operations that may damage the track and undercarriage components.  During freezing weather, always clean snow and ice from track shoes before loading and unloading the machine, to prevent the machine from slipping.

Travel Motor M145-05-003

M145-05-004

1

2

M145-05-027

1

2

M145-05-022

SA-15

SAFETY Avoid Injury from Rollaway Accidents  Death or serious injury may result if you attempt to mount or stop a moving machine.

To avoid rollaways:  Select level ground when possible to park the machine.  Do not park the machine on a gradient.  Lower the bucket and/or other work tools to the ground.  Turn the auto-idle switch OFF.  Run the engine at slow idle speed without load for 5 minutes to cool down the engine.  Stop the engine and remove the key from the key switch.  Pull the pilot control shut-off lever to LOCK position.  Block both tracks and lower the bucket to the ground.

Thrust the bucket teeth into the ground if you must park on a gradient.  Position the machine to prevent rolling.  Park at a reasonable distance from other machines.

SA-391

SA-2273

SA-16

SAFETY Avoid Injury from Back-Over and Swing Accidents  If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death.

To avoid back-over and swing accidents:  Always look around before you back up and swing the machine. Be sure that all bystanders are clear.  Keep the travel alarm in working condition (if equipped).

Always be alert for bystanders moving into the work area.

Use the horn or other signal to warn bystanders before moving machine.  Use a signal person when backing up if your view is obstructed. Always keep the signal person in view.

Use hand signals, which conform to your local regulations, when work conditions require a signal person.  No machine motions shall be made unless signals are clearly understood by both signal person and operator.  Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling.  Keep windows, mirrors, and lights clean and in good condition.  Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.  Read and understand all operating instructions in the operator’s manual.

SA-383

SA-384

SA-17

SAFETY Keep People Clear from Working Area  People around the operating machine may be hit severely by the swinging front attachment or counterweight, be caught in other objects, and/or be struck by flying objects, resulting in serious injury or death.  Set up barriers and/or put a “NO ADMISSION” sign at the machine operating site and areas exposed by flying objects to prevent anyone from entering the work area.  Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area.

SA-386

Never Position the Bucket Over Anyone  Never lift, move, or swing the bucket above anyone or above the truck cab.

Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket.

SA-487

SA-18

SAFETY Avoid Undercutting  In order to retreat from the edge of an excavation if the footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with the travel motors at the rear.  If the footing starts to collapse and if retreat is not possible, do not panic. Often, the machine can be secured by lowering the front attachment, in such cases.

SA-488

Avoid Tipping DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE --- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT  The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death.

To avoid tipping:  Be extra careful before operating on a gradient.  Prepare machine operating area flat.  Keep the bucket low to the ground and close to the machine.  Reduce operating speeds to avoid tipping or slipping.  Avoid changing direction when traveling on grades.  NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable.  Reduce swing speed as necessary when swinging loads.

SA-012

 Be careful when working on frozen ground.  Temperature increases will cause the ground to become soft and make ground travel unstable.

SA-440

SA-19

SAFETY Never Undercut a High Bank  The edges could collapse or a land slide could occur causing serious injury or death.

SA-489

Dig with Caution  Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.  Before digging check the location of cables, gas lines, and water lines.  Keep the minimum distance required, by law, from cables, gas lines, and water lines.  If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.  Contact your local “diggers hot line” if available in your area , and/or the utility companies directly.

Have them mark all underground utilities.

SA-382

Operate with Caution  If the front attachment or any other part of the machine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may result as well.  Take care to avoid hitting overhead obstacles with the boom or arm.

SA-389

SA-20

SAFETY Avoid Power Lines  Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines.  When operating near an electric line, never move any part of the machine or load to within 3 m plus twice the line insulator length of overhead wires.  Check and comply with any local regulations that may apply.  Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site.

SA-381

Precautions for Lightning  Lightning may strike the machine.

If lightning comes close, immediately stop the operation, and take the following action.  When you are around the machine or operating cabless machine, evacuate to a safe place far away from the machine.  When you are in the cab, stay in the cab until lightning has passed and safety is assured. Close the cab doors and windows. Lower the bucket to the ground, and stop the engine. Put your hands on your lap to avoid contact with any metal surfaces. Never go out of the cab.

If lightning strikes the machine or near the machine, check all of the machine safety devices for any failure after lightning has passed and safety is assured. If any trouble is found, operate the machine only after repairing it.

SA-21

SA-1088

SAFETY Object Handling  If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death.  When using the machine for craning operations, be sure to comply with all local regulations.  Do not use damaged chains or frayed cables, slings, or ropes.  Before craning, position the upperstructure with the travel motors at the rear.  Move the load slowly and carefully. Never move it suddenly.  Keep all persons well away from the load.  Never move a load over a person’s head.  Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground.  Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall.

SA-014

Protect Against Flying Debris  If flying debris hit eyes or any other part of the body, serious injury may result.  Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.  Keep bystanders away from the working area before striking any object.  Always close the windows and doors, when operating the machine.

SA-432

SA-22

SAFETY Park Machine Safely To avoid accidents:  Park machine on a firm, level surface.  Lower bucket to the ground.  Turn auto-idle switch OFF.  Run engine at slow idle speed without load for 5 minutes.  Press and hold the engine stop switch until stopping the engine completely.  Remove the key from the key switch.  Pull the pilot control shut-off lever to the LOCK position.  Close windows, roof vent, and cab door.  Lock all access doors and compartments.

SA-390

Handle Fluids Safely−Avoid Fires  Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.  Do not refuel the machine while smoking or when near open flame or sparks.  Always stop the engine before refueling the machine.  Fill the fuel tank outdoors.  All fuels, most lubricants, and some coolants are flammable.  Store flammable fluids well away from fire hazards.  Do not incinerate or puncture pressurized containers.  Keep the machine clean and free from dirt and debris such as grease.  Do not store oily rags; they can ignite and burn spontaneously.  Securely tighten the fuel and oil filler caps.

SA-018

SA-019

SA-23

SAFETY Practice Safe Maintenance To avoid accidents:  Understand service procedures before starting work.  Keep the work area clean and dry.  Do not spray water or steam inside cab.  Never lubricate or service the machine while it is moving.  Keep hands, feet and clothing away from power-driven parts.

Before servicing the machine: 1. Park the machine on a level surface.

2. Lower the bucket to the ground.

3. Turn the auto-idle switch off.

4. Run the engine at slow idle speed without load for 5 minutes.

5. Press and hold the engine stop switch to stop the engine.

6. Relieve the pressure in the hydraulic system by moving the control levers several times.

SA-028

7. Remove the key from the key switch.

8. Attach a “Do Not Operate” tag on the control lever.

9. Pull the pilot control shut-off lever to the LOCK position.

10. Allow the engine to cool.  If a maintenance procedure must be performed with the engine running, do not leave the machine unattended.  If the machine must be raised, maintain a 90 to 110˚ angle between the boom and arm. Securely support any machine elements that must be raised for service work.  Never work under a machine raised by the boom.  Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter of this manual.  Keep all parts in good condition and properly installed.  Fix damage immediately. Replace worn or broken parts.

Remove any buildup of grease, oil, or debris.  When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces.  Turn the battery disconnect switch to OFF before adjusting the electrical systems or performing welding on the machine.

SA-24

SA-527

SAFETY  Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.  Always use a work light protected with a guard. If the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

SA-037

Warn Others of Service Work  Unexpected machine movement can cause serious injury.  Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever.

This tag is available from your authorized dealer.

SS3076175

Support Machine Properly  Never attempt to work on the machine without securing the machine first.  Always lower the attachment to the ground before you work on the machine.  If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.

SA-527

SA-25

SAFETY Stay Clear of Moving Parts  Entanglement in moving parts can cause serious injury.  To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

SA-026

SA-2294

Prevent Parts from Flying  Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death.  Do not attempt to remove Grease fitting or valve assembly.  As pieces may fly off, be sure to keep body and face away from valve.  Travel reduction gears are under pressure.  As pieces may fly off, be sure to keep body and face away from air release plug to avoid injury.  Gear oil is hot. Wait for gear oil to cool, then gradually loosen air release plug to release pressure.

SA-26

SA-344

SAFETY Avoid Injury from Attachment Falling Accident  Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death.  To avoid possible personal injury from attachment falling accident, use a platform when replacing an attachment.  Securely store attachments such as a bucket, blade, breaker and other parts to prevent falling.  Keep children and bystanders away from attachment storage areas.

SA-034

Prevent Burns Hot spraying fluids:  After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, water tank and heater lines.

Skin contact with escaping hot water or steam can cause severe burns.  Avoid possible injury from hot spraying water. Do not remove the water tank cap until the engine is cool.

When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap.  The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.

SA-039

Hot fluids and surfaces:  Engine oil, gear oil and hydraulic oil also become hot during operation.

The engine, hoses, lines and other parts become hot as well.  Wait for the oil and components to cool before starting any maintenance or inspection work.

SA-225

SA-27

SAFETY Replace Rubber Hoses Periodically  Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.  Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual.)  Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.

SA-019

Avoid High-Pressure Fluids  Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death.  Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.  Tighten all connections before applying pressure.  Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.  If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

SA-031

SA-292

SA-044

SA-28

SAFETY Prevent Fires Check for Oil Leaks:  Fuel, hydraulic oil and lubricant leaks can lead to fires.  Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil cooler, and loose oil cooler flange bolts.  Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil cooler and oil cooler flange bolts.  Do not bend or strike high-pressure lines.  Never install bent or damaged lines, pipes, or hoses.  Replace fuel hoses and hydraulic hoses periodically even if there is no abnormality in their external appearance.

Check for Shorts:  Short circuits can cause fires.  Clean and tighten all electrical connections.  Check before each shift or after eight (8) to ten (10) hours operation for loose, kinked, hardened or frayed electrical cables and wires.  Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal caps.  Do not operate machine if cable or wires are loose, kinked, etc.  Never attempt to modify electric wirings.

SA-29

SA-019

SAFETY Clean up Flammable Materials:  Spilled fuel and oil, trash, grease, debris, accumulated coal dust, and other flammable materials may cause fires.  Prevent fires by inspecting and cleaning the machine daily, and by removing adhered oil or accumulated flammable materials immediately. Check and clean high temperature parts such as the exhaust outlet and muffler earlier than the normal interval.  Do not wrap high temperature parts such as a muffler or exhaust pipe with oil absorbents.  Do not store oily cloths as they are vulnerable to catching fire.  Keep flammable materials away from open flames.  Do not ignite or crush a pressurized or sealed container.  Check and clean the machine every day and immediately remove accumulated flammable materials.

Check Engine Stop Switch:  If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting.

Always check engine stop switch function before operating the machine every day: 1. Start the engine and run it at slow idle.

2. Press and hold the engine stop switch to confirm that the engine stops.  If any abnormalities are found, be sure to repair them before operating the machine.

Check Heat Shields:  Damaged or missing heat shields may lead to fires.  Damaged or missing heat shields must be repaired or replaced before operating the machine.  If hydraulic hoses are broken while the engine cover is open, splattered oil on the high temperature parts such as muffler may cause fire. Always close the engine cover while operating the machine.

SA-30

SAFETY Check Emergency Engine Stop Switch:  If a fire breaks out, failure to release pressurized air inside the hydraulic oil tank will escalate fire, hampering fire fighting.  Check the emergency engine stop switch function every 250 hours: 1) Start the engine and run it at slow Idle.

2) Press the emergency engine stop switch.

3) Confirm that engine stops and that pressurized air inside the hydraulic oil tank is released (a hissing sound should be heard).  If any abnormalities are found, be sure to repair them before operating the machine.

SA-31

SAFETY Evacuating in Case of Fire  A fire on the machine may result in serious injury or death.  Inspect the following things and prepare in case of fire.

1) Check if the window can be opened and closed smoothly before operating the machine so that escape through the window is possible. If any abnormalities are found, repair them.

2) Before each shift, check that the emergency escape chute is not worn and its mounting hardware is not damaged; if any abnormalities are found, replace with new genuine Hitachi parts before operating the machine.

SA-393

 Before operating the machine for the first time, all new operaters must practice evacuating with the emergency escape device at least once.  If a fire breaks out during operation, evacuate from the machine in the followig way.  Stop the engine by pushing the emergency engine stop switch if there is time.  Use a fire extinguisher if there is time.  Evacuate from the machine using the emergency escape device. (See the chapter "Emergency Escape Device for operator's manual.")  In case of emergency, if the door or window cannot be opened, break the front windowpane or rear windowpane using the emergency evacuation hammer and evacuate the machine. (Refer to the section "Emergency Exit for operator's manual".)

SA-32

SS-1510

SAFETY Beware of Exhaust Fumes  Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.  If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.  White smoke may be generated during the aftertreatment device regeneration. Do not attempt to do aftertreatment device manual regeneration in a badly ventilated indoors.

SA-016

Precautions for Welding and Grinding  Welding may generate gas and/or small fires.  Be sure to perform welding in a well ventilated and prepared area. Store flammable materials in a safe place before starting welding.  Only qualified personnel should perform welding. Never allow an unqualified person to perform welding.  Turn the battery isolation switch to the OFF position before performing welding on the machine.  Grinding on the machine may create fire hazards. Store flammable materials in a safe place before starting grinding.  After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.

SA-33

SA-818

SAFETY Avoid Heating Near Pressurized Fluid Lines  Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders.  Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.  Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.

SA-030

Avoid Applying Heat to Lines Containing Flammable Fluids  Do not weld or flame cut pipes or tubes that contain flammable fluids.  Clean pipes and tubes thoroughly with non-flammable solvent before welding or flame cutting.

Precautions for Handling Accumulator and Gas Damper High-pressure nitrogen gas is sealed in the accumulator and the gas damper. Inappropriate handling may cause explosion, possibly resulting in serious injury or death.

Strictly comply with the following items:  Do not disassemble the unit.  Keep the units away from open flames and fire.  Do not bore a hole, do not cut by torch.  Avoid giving shocks by hitting or rolling the unit.  Before disposing of the unit, sealed gas must be released.

Consult your authorized dealer.

SA-34

SAFETY Remove Paint Before Welding or Heating  Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.  Avoid potentially toxic fumes and dust.  Do all such work outside or in a well-ventilated area.

Dispose of paint and solvent properly.  Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust.

Wear an approved respirator.

2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable materials from area. Allow fumes to disperse at least 15 minutes before welding or heating.

SA-029

Beware of Asbestos and Silica Dust and Other Contamination  Take care not to inhale dust produced in the work site.

Inhalation of asbestos fibers may be the cause of lung cancer. Inhalation of silica dust or other contaminations may cause sickness.  Depending on the work site conditions, the risk of inhaling asbestos fiber, silica dust or other contaminations may exist. Spray water to prevent asbestos fibers, silica dust or other contaminations from becoming airborne. Do not use compressed air.  When operating the machine in a work site where asbestos fibers, silica dust or other contaminations might be present, be sure to operate the machine upwind, and wear a mask rated to prevent the inhalation of asbestos, silica dust or other contaminations.  Keep bystanders out of the work site during operation.  Asbestos fibers might be present in imitation parts. Use only genuine Hitachi Parts.

SA-35

SA-029

SAFETY Prevent Battery Explosions  Battery gas can explode.  Keep sparks, lighted matches, and flame away from the top of battery.  Do not keep tools, metals or flammable materials around the battery or inside the battery room. If a metal tool is placed across the battery terminal, sparks may be created, possibly resulting in fire and/or explosion.  Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.  Do not charge a frozen battery; it may explode. Warm the battery to 16 ˚C ( 60 ˚F ) first.  Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result.  Loose terminals may produce sparks. Securely tighten all terminals.  Connect terminals to the correct electrical poles. Failure to do so may cause damage to the electrical parts or fire.

SA-032

 Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness.  Be sure to wear eye protection when checking electrolyte specific gravity.

Service Air Conditioning System Safely  If spilled onto skin, refrigerant may cause a cold contact burn.  Refer to the instructions described on the container for proper use when handling the refrigerant.  Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere.  Never touch the refrigerant.

SA-405

SA-36

SAFETY Handle Chemical Products Safely  Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, DEF/AdBlue®, battery electrolyte, coolants, paints, and adhesives.  Safety Data Sheet (SDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.  Check the SDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment.  See your authorized dealer for SDS’s (available only in English) on chemical products used with your machine.

SA-2579

Dispose of Waste Properly  Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with Hitachi equipment includes such items as oil, fuel, coolant, DEF/AdBlue®, brake fluid, filters, and batteries.  Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.  Do not pour waste onto the ground, down a drain, or into any water source.  Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.  Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.

SA-37

SA-226

SAFETY Never Ride Attachment Never allow anyone to ride on attachments or the load. This is an extremely dangerous practice.

Notes on Aftertreatment Device About Aftertreatment Device The aftertreatment device removes particulate matter (PM) and NOx (Nitrogen Oxide) from the exhaust gas. Follow the instructions below to prevent the aftertreatment device from being damaged.

Exhaust gas from the aftertreatment device, muffler, exhaust piping and tail piping becomes hot during and right after engine running and regeneration of aftertreatment device. Keep away from the exhaust system or hot gas from the exhaust piping during regeneration. Be careful to avoid skin contact with exhaust gas. It may cause severe burns.  White smoke may be generated during aftertreatment device regeneration. Do not attempt to perform aftertreatment device manual regeneration in a badly ventilated area.  Do not touch water coming directly out of the aftertreatment device. The water is mildly-acidic by oxidation catalyst mounted in the aftertreatment device.

If filter water spills on your skin, immediately flush it out with clean water.

Precautions for Communication Terminal Electrical wave transmitted from the communication terminal may cause malfunction of other electronic devices.

Inquire to the device manufacturer for information on electrical wave disturbance when using an electronic device near the communication terminal.

SA-38

SAFETY Precautions for Communication Terminal Equipment This machine has a communication terminal equipment emitting electrical waves installed in a cover which is in the right side of cab. There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, could be affected and malfunction due the electrical waves emitted from the communication terminal equipment.

Any person fitted with a medical device such as the above should not use this machine, unless the medical device and the rear tray are at least 22 centimeters apart at all times. If this condition cannot be met, please contact your authorized dealer and have the person in charge stop the communication terminal equipment from functioning completely, and confirm that it is not emitting electrical waves.

Specific Absorption Rate ("SAR") (measured by 10 g per unit) of communication terminal equipments: E-GSM900 DCS-1800 WCDMA Band I WCDMA Band VIII

0.12 W/kg (897.6 MHz) 0.06 W/kg (1748.0 MHz) 0.05 W/kg (1950.0 MHz) 0.10 W/kg (892.6 MHz)

 This data was measured by having each type of communication terminal equipment, such as the communication terminal equipment used with this machine, and a human body set apart by 3 cm.  SAR is a measure of the amount of radio frequency energy absorbed by the body when using a wireless application such as a mobile phone.

In Japan: Under the Japanese Radio Act and other relevant Japanese regulations, the maximum SAR value is 2 W/kg (as of March 2010).

In EU member nation: Under the "Council Recommendation 1999/519/EC 12 July 1999", the maximum SAR value is 2 W/kg.

In US: Under the "Federal Communications Commission (FCC) Guidelines (FCC 1997)", the maximum SAR value is 1.5 W/kg.

In Canada: Under the "Canada's Radio Standards Specification (RSS) -102", the maximum SAR value is 1.5 W/kg.

SA-39

SA-2654

SAFETY  Do not attempt to disassemble, repair, modification and displacement of the communication terminal, antenna and cables. Failure to do so may cause damage or fire on the machine and the communication terminal. (Before removing or installing the communication terminal, consult your authorized dealer.)  Do not pinch or forcibly pull cables, cords and connectors.

Failure to do so may cause damage or fire on the machine and the communication terminal due to short/broken circuit.

SA-40

SAFETY Precaution for WIU (Wireless Interface Unit) Communication Equipment (Optional)

2

This machine has a WIU communication equipment emitting electrical waves installed inside the cab.

1- Controller 2- Antenna There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, would be affected and would malfunction by the electrical waves emitted from the WIU communication equipment.

Any person affixed with a medical device such as the above should use this machine with caution.  Never attempt to disassemble, repair, modify or displace the WIU communication equipment, antennas or cables.

Failure to do so may result in damage and/or fire to the base machine or to the WIU communication equipment. (When required to remove or install the WIU communication equipment, consult your nearest Hitachi dealer.)  Do not pinch or forcibly pull cables, cords or connectors.

Failure to do so may cause short circuit or broken circuit that may result in damage and/or fire to the base machine or to the WIU communication equipment.

SA-41

1

MKEB-00-001

SAFETY Machine Fire Suppression What you should do: This machine, like other large mobile machines that operate virtually nonstop, 24 hours per day, 7 days per week, generates considerable heat in close proximity to flammable fluids and is susceptible to fire.

Fires can result in expensive repair or replacement and more importantly serious injury to the equipment operator.

It is strongly recommended that you install a Fire Suppression System (FSS) on this machine and maintain it in good working condition. This machine is equipped with a communication link to ensure seamless operation of FSS with the operation of the machine. It is essential that whichever FSS you choose is compatible with the machine communication system. Before installation of FSS, contact your authorized dealer with installation details. We will provide any required documentation to the FSS supplier for optimum configuration.

What can the local supplier of FSS should provide:  Commissioning expertise  Operator and service training  Service and performance contracts  Support for preventative maintenance  Strong spare parts availability

SA-42

SAFETY Before Returning the Machine to the Customer  After maintenance or repair work is complete, confirm that:  The machine is functioning properly, especially the safety systems.  Worn or damaged parts have been repaired or replaced.

SA-435

SA-43

SAFETY (Blank)

SA-44

SECTION AND GROUP SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction CONTENTS Group 2 Standard Group 3 Engine Test Group 4 Machine Performance Test Group 5 Component Test

TECHNICAL MANUAL (Troubleshooting)

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

COPYRIGHT(C)2019 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Monitor Group 3 Cross Reference Table Group 4 Component Layout Group 5 Troubleshooting for Each Code Group 7 Air Conditioner Group 8 e-Service Group 9 Aftertreatment Device

TECHNICAL MANUAL (Operational Principle)) SECTION 1 GENERAL Group 1 Specifications Group 2 Component Layout Group 3 Component Specifications SECTION 2 SYSTEM Group 1 Controller Group 2 Control System Group 3 ELU System Group 4 Hydraulic System Group 5 Electrical System Group 6 Air Conditioning System

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Swing Device Group 3 Control Valve Group 4 Control Equipment Group 5 Travel Device Group 6 Others (Upperstructure) Group 7 Others (Undercarriage) Group 8 Others (Front Attachment)

WORKSHOP MANUAL SECTION 1 GENERAL INFORMATION Group 1 Precautions for Disassembling and Assembling Group 2 Tightening Group 3 Painting Group 4 Bleeding Air Group 5 Releasing Pressure Group 6 Preparation SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Group 2 Undercarriage Group 3 Loader Front Attachment Group 4 Backhoe Front Attachment SECTION 3 UPPERSTRUCTURE Group 1 Cab Group 2 Cab Bed Group 3 Counterweight Group 4 Upperstructure Group 5 Engine Unit Group 6 Pump Device Group 7 Control Valve Group 8 Other Valves Group 9 Swing Device Group 10 Aftertreatment Device Group 11 Hydraulic Oil Tank Group 12 Fuel Tank Group 13 Lift Cylinder (Fast-Filling System) Group 14 Lift Cylinder (Folding Stairway)

SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Group 2 Travel Device Group 3 Travel Brake Valve Group 4 Drive Tumbler Group 5 Center Joint Group 6 Adjuster Cylinder Group 7 Front Idler Group 8 Upper and Lower Roller Group 9 Track Group 10 Accumulator Group 11 Welding Repair Procedure SECTION 5 LOADER FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder Group 3 Bushing Group 4 Angle Sensor Group 5 Other Valves SECTION 6 BACKHOE FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder Group 3 Bushing Group 4 Angle Sensor Group 5 Other Valves

SECTION 4

OPERATIONAL PERFORMANCE TEST CONTENTS Group 1 Introduction

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

Group 2 Standard

Operational Performance Standard Table.................. T4-2-1 Main Pump P-Q Diagram (P1 to P6).............................. T4-2-5 Oil Cooler Fan Motor Pump P-Q Diagram................... T4-2-6 Oil Cooler Fan Motor Pump I-Q Diagram.................... T4-2-7 Electric Control Lever......................................................... T4-2-8

Group 3 Engine Test

Engine Speed........................................................................ T4-3-1

Group 4 Machine Performance Test

Travel Speed.......................................................................... T4-4-1 Track Revolution Speed..................................................... T4-4-2 Mistrack Check...................................................................... T4-4-3 Travel Parking Leakage...................................................... T4-4-4 Swing Speed.......................................................................... T4-4-5 Swing Function Drift Check............................................. T4-4-6 Swing Motor Leakage........................................................ T4-4-8 Maximum Swingable Slant Angle................................T4-4-10 Swing Bearing Play............................................................T4-4-12 Hydraulic Cylinder Cycle Time.......................................T4-4-14 Cylinder Drift Check..........................................................T4-4-17 Control Lever Operating Force......................................T4-4-19 Control Lever Stroke.........................................................T4-4-20 Combined Operation of Boom Raise and Swing Function Check................................................T4-4-21

Group 5 Component Test

Primary Pilot Pressure......................................................... T4-5-1 Secondary Pilot Pressure (Solenoid Valve of EDQR Valve)................................. T4-5-2 Secondary Pilot Pressure (EDQR Valve)........................ T4-5-4 Main Relief Set Pressure.................................................... T4-5-6 Overload Relief Pressure.................................................T4-5-10 Main Pump Flow Rate Measurement.........................T4-5-12 Oil Cooler Fan Motor Pump Flow Rate.......................T4-5-16 Swing Motor Drainage.....................................................T4-5-21 Travel Motor Drainage.....................................................T4-5-23

KEB90T-4-1

(Blank)

KEB90T-4-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Operational Performance Tests Use operational performance test procedure to quantitatively check all system and functions on the machine.

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.

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.

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.

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.

T4-1-1

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Preparation for Performance Tests 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.

T105-06-01-003

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.

T105-06-01-004

T4-1-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard The standard measurement conditions are as followings unless instructed in each performance test procedure:  Engine Control Dial: Fast Idle  Auto-Idle Switch: OFF  Hydraulic Oil Temperature : 50±5 °C (122±9 °F).

Operational Performance Standard Table The standard Performance values are listed in the table below.

The detailed measurement procedures are explained in T4-3, T4-4, and T4-5. Refer to the reference page.

Values indicated in parentheses [ ] are reference values.

Performance Test Designation ENGINE SPEED Fast Idle Speed Slow Idle Speed Auto-Idle Speed TRAVEL SPEED Fast Speed Mode Slow Speed Mode TRACK REVOLUTION SPEED Fast Speed Mode Slow Speed Mode MISTRACK (Fast/Slow Speed Mode) TRAVEL PARKING LEAKAGE SWING SPEED SWING FUNCTION DRIFT CHECK SWING MOTOR LEAKAGE MAXIMUM SWINGABLE SLANT ANGLE SWING BEARING PLAY

Unit

Performance Standard

Remark

min-1

Reference Page T4-3-1

1950±50 780±50 1400±50 sec/20 m

T4-4-1 31 45

sec/3 rev

T4-4-2

77±4 109±5 mm/20 m Less than 100 (3.9) (in/65.7 ft) mm (in)/min 0 sec/3 rev 44±5 mm (in)/180 Less than 1331 (52.4) degrees mm (in)/5 min 0 degrees Over 20 mm (in) Less than 0.5 (0.02)

T4-2-1

T4-4-3

Bucket: empty Bucket: empty Bucket: loaded Weight: 22500 kg (49604 lb) Bucket: loaded Weight: 22500 kg (49604 lb)

T4-4-4 T4-4-5 T4-4-6 T4-4-8 T4-4-10 T4-4-12

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Loading Shovel Performance Test Designation HYDRAULIC CYLINDER CYCLE TIME Boom Raise Boom Lower Arm Extend Arm Retract Bucket Tilt-In Bucket Tilt-Out Bucket Open Bucket Close CYLINDER DRIFT CHECK

Unit

Performance Standard sec

HYDRAULIC CYLINDER CYCLE TIME Boom Raise Boom Lower Arm Roll-Out Arm Roll-In Bucket Roll-Out Bucket Roll-In CYLINDER DRIFT CHECK Boom Cylinder Arm Cylinder Bucket Cylinder Bucket Bottom

Bucket: empty

Reference Page T4-4-14

8.2±0.7 5.0±0.5 3.4±0.5 4.2±0.5 4.0±0.5 2.9±0.5 2.1±0.4 2.5±0.4 mm (in)/5 min

Boom Cylinder Arm Cylinder Bucket Cylinder Bucket Bottom Backhoe Performance Test Designation

Remark

Bucket: loaded Weight: 22500 kg (50000 lb)

T4-4-17

Remark

Reference Page T4-4-14

Less than 25 (0.98) Less than 25 (0.98) Less than 20 (0.79) Less than 300 (11.8)

Unit

Performance Standard sec

Bucket: empty 7.7±0.7 4.6±0.5 6.5±0.5 7.1±0.5 4.4±0.5 3.5±0.5

mm (in)/5 min

Bucket: loaded Weight: 25500 kg (56000 lb) Less than 30 (1.18) Less than 45 (1.77) Less than 15 (0.59) Less than 341 (13.4)

T4-2-2

T4-4-17

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation CONTROL LEVER OPERATING FORCE Front/Rear at Right Side

Unit

Performance Standard N (lbf )

Front/Rear at Left Side

Left/Right at Left Side

Travel Control Lever

Bucket Height: H

Reference Page T4-4-19

5.1 to 6.4 (1.15 to 1.44)/6.1 to 7.6 (1.37 to 1.71) 5.2 to 6.5 (1.17 to 1.46)/5.9 to 7.4 (1.33 to 1.66) 5.1 to 6.4 (1.15 to 1.44)/6.1 to 7.6 (1.37 to 1.71) 5.9 to 7.4 (1.33 to 1.67)/5.2 to 6.5 (1.17 to 1.46) 21.6 to 26.3 (4.86 to 5.92) 82 to 100 (18.5 to 22.5) LD only

Left/Right at Right Side

Bucket Open/Close Pedal CONTROL LEVER STROKE Front and Rear at Right Side Right and Left at Right Side Front and Rear at Left Side Right and Left at Left Side Travel Control Lever Bucket Open/Close Pedal COMBINED OPERATION OF BOOM RAISE AND SWING FUNCTION CHECK Time

Remark

T4-4-20

mm (in)

55±7 (2.17±0.28) 55±7 (2.17±0.28) 55±7 (2.17±0.28) 55±7 (2.17±0.28) 138±10 (5.43±0.39) 50±3 (1.97±0.12)

sec/90 5.6±0.5 degrees 5.4±0.5 mm (in) Over 4600 (181.1) Over 5000 (196.9)

fNOTE: LD: Loading Shovel BH : Backhoe

T4-2-3

LD only Bucket: empty

LD BH LD BH

T4-4-21

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Performance Test Designation HYDRAULIC SYSTEM PRIMARY PILOT PRESSURE Engine: Fast Idle

Unit

Performance Remark Standard

MPa (psi)

MPa (psi)

Engine: Slow Idle MAIN PUMP DELIVERY PRESSURE MAIN RELIEF SET PRESSURE Each relief operation of boom raise/lower, arm extend/retract, bucket tilt-in/tilt-out, and bucket open Relief operation of bucket close RELIEF PRESSURE (Relief operation of travel) RELIEF PRESSURE (Relief operation of swing) OVERLOAD RELIEF PRESSURE Boom, Arm, Bucket, and Bucket Open Bucket Close MAIN PUMP FLOW RATE OIL COOLER FAN MOTOR PUMP FLOW RATE SWING MOTOR DRAINAGE TRAVEL MOTOR DRAINAGE Slow speed: With the track raised off the ground

T4-5-2 4.4±0.5 (638±73) Over 3.5 (508)

Engine: Slow Idle SECONDARY PILOT PRESSURE (EDQR Valve) Engine: Fast Idle

T4-5-1 4.4±0.5 (638±73) Over 3.5 (508)

Engine: Slow Idle SECONDARY PILOT PRESSURE (Solenoid Valve of EDQR Valve) Engine: Fast Idle

Reference Page

Control Lever:

Full Stroke

Control Lever:

Full Stroke

MPa (psi) 4.3±0.5 (624±73) Over 3.3 (479) MPa (psi) 29.4+2.0-0 (4264+290-0) MPa (psi) 29.4+2.5-0 (4264+363-0)

T4-5-4 Control Lever:

Full Stroke

Control Lever:

Full Stroke

17.4+2.3-0 (2524+334-0) MPa (psi) 29.4+2.5-0 (4264+363-0) MPa (psi) 29.4+1.5-0.5 (4264+218-73) MPa (psi) 31.4+2.3-0 (4554+334-0) 17.4+2.3-0 (2524+334-0) L/min L/min L/min Less than 29 With constant speed L/min Less than 28

T4-2-4

T4-5-6

T4-5-10

T4-5-12 T4-5-16 T4-5-21 T4-5-23

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Main Pump P-Q Diagram (P1 to P6)  P-Q Control (Torque Control)  Rated Pump Speed: 1835 min-1  Pump Speed Ratio: 1.019  Hydraulic Oil Temperature: 50±5 °C (122±9 °F) NOTE: Refer to T4-5-12.

f

Points on P-Q Line (Main Pumps 1 to 4) Delivery Pressure (P) Flow Rate (Q) MPa (psi) L/min (gpm) A 20.3 (2944) Approx. 356 (94) B 25.0 (3626) Approx. 290 (77) C 29.4 (4264) Approx. 246 (65) Points on P-Q Line (Main Pumps 5 to 6) Delivery Pressure (P) Flow Rate (Q) MPa (psi) L/min (gpm) A 17.7 (2567) Approx. 409 (108) B 25.0 (3626) Approx. 290 (77) C 29.4 (4264) Approx. 246 (65)

Points on P-Q Line (Main Pumps 1 to 4)

Flow Rate (Q) L/min

A B C

Delivery Pressure (P) MPa

TKBD-04-02-001

Points on P-Q Line (Main Pumps 5 to 6)

Flow Rate (Q) L/min

A

B C

Delivery Pressure (P) MPa

T4-2-5

TKBD-04-02-002

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Oil Cooler Fan Motor Pump P-Q Diagram  P-Q Control (Torque Control)  Rated Pump Speed: 2109 min-1  Pump Speed Ratio: 1.082  Hydraulic Oil Temperature: 50±5 °C (122±9 °F) NOTE: Refer to T4-5-16.

f

Points on P-Q Line Delivery Pressure (P) MPa (psi) A 2.9 (421) B 17.9 (2596) C 22.6 (3278)

A

Flow Rate (Q) L/min (gpm) 223 (59) 218 (58) 170 (45)

Flow Rate (Q) L/min

B

C

Delivery Pressure (P) MPa

T4-2-6

TKBF-04-02-001

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Oil Cooler Fan Motor Pump I-Q Diagram Points on I-Q Line Command Current Signal (I) of Pump Control Solenoid Valve mA A 381±30 B 610±40

 I-Q Control  Rated Pump Speed: 2109 min-1  Pump Speed Ratio: 1.082  Hydraulic Oil Temperature: 50±5 °C (122±9 °F).

Flow Rate (Q) L/min (gpm) 223±3 (59±0.8) 26±3 (7±0.8)

Flow Rate (Q) L/min

A

B

Command Current Signal (I) mA

T4-2-7

TKBF-04-02-002

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Electric Control Lever When moving the electric control lever, command current is sent from the controller to ELUF and ELUT according to the control lever stroke.

Front Attachment, Swing 15°

15°

(-)

(-)

Controller

Y

To ELUF

(+)

X (+)

Travel,

12.4°±1°

Bucket Open/Close (Loading Shovel only)

12.4°±1°

Controller

To ELUT

T4-2-8

T18G-03-04-002

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Front Attachment, Swing

90±2% 88+4%-2%

Output Voltage Ratio

Short Zone Approx. 3%

50±1.5%

12+2%-4% 10±2% 15°

15°

Mechanical Control Angle

2, 11 1, 12 Short Zone Resistor for Calibration

4, 9 30±5° Electrical Turning Angle

3, 10 Short Zone Resistor for Calibration

Total Resistance 2 kΩ±15 %

TKEB-04-02-001

(+) Direction on XY Axis

TKEB-04-02-002

T4-2-9

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 2 Standard Travel (Control Curve: 25±5 °C) Control Torque

Output Voltage Ratio V

100

N·m 16.0 15.3±2.3

80±7.5

Output Voltage Ratio

12.0

50±5 20±7.5

8.0 6.5±1.0

0

12.4±1

4.0

0

12.4±1

F

R T18M-03-04-004

0

12.4±1 F

12.4±1 Control Angle (° )

Neutral Switch

R T18M-03-04-003

F-

Front Side

R-

Rear Side 0

Bucket Open/Close (Loading Shovel only) F

(Control Curve: 25±5 °C)

R T18G-03-04-006

Control Torque

Output Voltage Ratio

N·m 16.0

V

100

80±7.5 Output Voltage Ratio

12.0 9.3±1.4 8.0

50±5 20±7.5

0 4.0

12.4±1

3.9±0.6

0

12.4±1

F 0

12.4±1

0

F

Control Angle (° )

R T18M-03-04-004

12.4±1

Neutral Switch

R T18L-03-04-001

F-

Front Side

R-

Rear Side

0 F

R T18G-03-04-006

T4-2-10

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 3 Engine Test Engine Speed Summary: 1. Measure the engine speed by using the monitor unit or a pulse meter.

2. Measure the engine speeds in each condition.

fNOTE: Measure the engine speed before performing all other tests. If the engine speed is not adjusted correctly, all other performance data will be unreliable.

1

Test Conditions  Hydraulic Oil Temperature: 50±5 °C (122±9 °F)  Ground Conditions: Flat and solid ground Preparation: 1. Press and hold the engine stop switch until the engine completely stops rotating. Turn the key switch to the OFF position. Remove the key from the key switch.

2. Disconnect the connector of engine speed sensor (1). Install a pulse meter.

T141-04-02-001

3. Start the engine. Warm up the machine until the coolant temperature reaches 50 °C (122 °F) or more and the hydraulic oil temperature is 50±5 °C (122±9 °F).

1-

Engine Speed Sensor

2

TKEB-04-03-001 2-

T4-3-1

Engine Speed Sensor Connector (Main Harness End)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 3 Engine Test Measurement:

Evaluation:

1. Measure the items as shown in the table below.

Refer to Operational Performance Standard.

2. When measuring, set the switch and test condition as shown in the table below in response to the engine speed to be measured.

Calculate the engine speed by using the following formula.

Engine Speed (min-1) = Pulse Number×60/142 (min-1) Item

Engine Control Dial

Auto-Idle Switch

Slow Idle Speed Fast Idle Speed

Slow Idle Fast Idle

OFF OFF

Auto-Idle Speed

Fast Idle

ON

T4-3-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Travel Speed Summary: 1. Measure the time required for the machine to travel a test track and check the performance of the travel systems (from main pump to travel motor).

Preparation: 1. Adjust track sag of both tracks to dimension (a).

2. Provide a flat, solid test yard 20 m (65.5 ft) in length, with extra length of 2 to 3 m (7 to 10 ft) on both ends for machine acceleration and deceleration.

3. Empty the bucket and fully retract the arm.

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). a

Measurement: 1. Measure in both fast and slow travel modes.

T145-05-03-001

2. Select the following conditions.

Travel Mode Switch

Engine Control Auto-Idle Dial Switch

Slow Mode

Fast Idle

OFF

Fast Mode

Fast Idle

OFF

a-

465 to 535 mm (18.3 to 21.0 in)

3. Start traveling the machine in the acceleration zone with the travel levers to full stroke.

4. Measure the time required to travel between the start and end.

5. After measuring the forward travel speed, turn the upperstructure 180 degrees and measure the reverse travel speed in the same way.

6. Repeat the measurement three times and calculate the mean values.

b

c

d

e

b TKEB-04-04-001

Evaluation: Refer to Operational Performance Standard.

Remedy:

b

c

Refer to Troubleshooting B. bcde-

T4-4-1

Acceleration/Deceleration Zone: 2 to 3 m (7 to 10 ft) End 20 m (66 ft) Start

d

e

b

TKAB-04-04-001

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Track Revolution Speed Summary: 1. Measure the track revolution cycle time with the track raised off ground and check the performance of the travel systems (from main pump to travel motor).

Preparation: 1. Adjust track sag of both tracks to dimension (a). a

2. On the track to be measured, put a mark on one shoe by using a piece of chalk or cloth.

3. Raise the track to be measured off the ground as illustrated.

Securely support the raised machine dCAUTION: off the ground by using blocks.

T145-05-03-001 a-

465 to 535 mm (18.3 to 21.0 in)

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Measurement: 1. Measure on both tracks at slow and fast travel modes with forward and reverse travel.

b

2. Select the following conditions.

Travel Mode Switch Slow Mode

Engine Control Auto-Idle Dial Switch Fast Idle OFF

Fast Mode

Fast Idle

T142-05-03-012

OFF

3. Operate the travel control lever of the track to be measured to full stroke.

b

4. Measure the time required for three revolutions after a constant track revolution speed is obtained.

5. Repeat the measurement three times and calculate the mean values.

TKAB-04-04-002 b-

Evaluation: Refer to Operational Performance Standard.

Remedy: Refer to Troubleshooting B.

T4-4-2

90 to 110 degrees

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Mistrack Check Summary: 1. Allow the machine to travel 20 m (66 ft). Measure the maximum tread deviation from the tread chord drawn between the travel start and end points and check the performance of the travel system (from main pump to travel motor).

2. If measured on a pavement surface, the tread deviation has a trend to decrease.

Preparation: 1. Adjust track sag of both tracks to the nominal dimension.

2. Provide a flat, solid test yard 20 m (66 ft) in length, with extra length of 2 to 3 m (7 to 10 ft) on both ends for machine acceleration and deceleration.

3. Empty the bucket and fully retract the arm.

T145-05-03-006

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Measurement: 1. Measure in both fast and slow travel modes.

2. Select the following conditions.

Travel Mode Switch Slow Mode

Engine Control Auto-Idle Dial Switch Fast Idle OFF

Fast Mode

Fast Idle

OFF

3. Start traveling the machine in the acceleration zone with the travel control levers to full stroke.

TKAB-04-04-003

4. Measure maximum distance (a) between a straight 20 m tread chord and the tread made by the machine.

5. After measuring maximum distance (a) in forward travel, turn the upperstructure 180 degrees and measure maximum distance (a) in reverse travel.

b a c

6. Repeat the measurement three times and calculate the mean values.

Evaluation:

b

Refer to Operational Performance Standard.

Remedy: Refer to Troubleshooting B.

T115-07-03-005 ab-

T4-4-3

Maximum Distance Acceleration/Deceleration Zone: 2 to 3 m (7 to 10 ft)

c-

20 m (66 ft)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Travel Parking Leakage Summary: Measure the parking brake function on a specified slope.

Preparation: a

1. Measure on a flat slope with a gradient of 20 % (11.31 degrees).

2. With the arm and bucket cylinders fully extended, hold the bucket 0.5 to 1.0 m (1.6 to 3.3 ft) above the ground. (Empty the bucket.)

T118-04-03-001

3. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

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

a

2. Stop the engine.

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

4. When five minutes passed, measure the distance between marks on the track link or the shoe, and the track frame.

TKAB-04-04-004 a-

0.5 to 1.0 m (1.6 to 3.3 ft)

Evaluation: Refer to Operational Performance Standard.

b TDAA-04-04-001 b-

T4-4-4

Distance measured when five minutes passed

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Swing Speed Summary: 1. Measure the time required to swing three complete turns and check the performance of the swing system (from main pump to swing motor).

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

2. Place the machine on a flat and solid ground with ample space for swinging. Do not conduct this test on a slope.

a

3. Fully extend the arm and bucket cylinders. Adjust and hold the boom so that the arm end pin height is the same as the boom foot pin height. (Empty the bucket.)

TKEB-04-04-002

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

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

a TKAB-04-04-005

Measurement: 1. Select the following conditions.

Engine Control Dial Fast Idle

a-

Auto-Idle Switch OFF

2. Operate the swing control lever to full stroke and swing the upperstructure.

3. Measure the time required to swing three turns when the swing speed is a constant speed.

4. Check the time in both clockwise and counterclockwise directions.

5. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard.

Remedy: Refer to Troubleshooting B.

T4-4-5

The same height as boom foot pin

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Swing Function Drift Check Summary: 1. Measure the swing drift on the swing bearing outer circumference when stopping after a 180 degrees full-speed swing and check the performance of the swing brake valve.

2. The mechanical brake for the swing parking brake is equipped for the swing motor. a

Preparation: TKEB-04-04-002

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

2. Place the machine on a flat and solid ground with ample space for swinging. Do not conduct this test on a slope.

3. Fully extend the arm and bucket cylinders. Adjust and hold the boom so that the arm end pin height is the same as the boom foot pin height. (Empty the bucket.)

4. Put marks on the swing bearing outer circumference (upperstructure side) and the track frame.

a

a-

The same height as boom foot pin

TKAB-04-04-005

5. Swing the upperstructure 180 degrees.

6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

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

b T105-06-03-008 b-

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

c T105-06-03-009 c-

T4-4-6

Before start the measurement, swing the upperstructure 180 degrees.

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Select the following conditions.

Engine Control Dial

Auto-Idle Switch

Fast Idle

OFF

a

2. Operate the swing control lever to full stroke and swing the upperstructure 180 degrees. When the mark on upperstructure aligns with that on track frame, return the swing control lever to the neutral position.

3. After stopping the upperstructure, measure the arc length (swing bearing circumference) between the two marks on the swing bearing and track frame.

4. Check the arc length in both clockwise and counterclockwise directions.

b c T105-06-03-010 ab-

5. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard.

Remedy: Refer to Troubleshooting B.

T4-4-7

Measure arc length (swing bearing circumference).

Mark on Track Frame

c-

Mark on Swing Bearing

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Swing Motor Leakage Summary: 1. Set the machine on a specified slope and swing the upperstructure 90 degrees to the slope. Measure the upperstructure drift while suspending a load on a specified slope and check the performance of the swing parking brake.

(The mechanical brake for the swing parking brake is equipped for the swing device.)

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

2. Load the bucket. (Refer to the Operational performance Standard about the loading weight.)

T105-06-03-011

3. Fully extend the arm and bucket cylinders. Adjust and hold the boom so that the arm end pin height is the same as the boom foot pin height.

4. Park the machine on a smooth slope with a gradient of 15±1 degrees.

5. Climb a slope and swing the upperstructure to position it 90 degrees to the slope. Put the marks on the swing bearing outer circumference (upperstructure side) and the track frame.

6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T4-4-8

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Stop the engine. When five minutes passed, measure the arc length (swing bearing circumference) between the two marks on the swing bearing and track frame.

a

2. Check the arc length in both clockwise and counterclockwise directions.

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

b

Evaluation:

c

Refer to Operational Performance Standard.

T105-06-03-010

Remedy: Refer to Troubleshooting B.

ab-

T4-4-9

Measure arc length (swing bearing circumference).

Mark on Track Frame

c-

Mark on Swing Bearing

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Maximum Swingable Slant Angle Summary: 1. With the upperstructure swung 90 degrees to the slope, check the maximum slant angle on which the upperstructure can swing to the uphill side.

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

2. Load the bucket. (Refer to the Operational performance Standard about the loading weight.)

3. Fully extend the arm and bucket cylinders. Adjust and hold the boom so that the arm end pin height is the same as the boom foot pin height.

T105-06-03-011

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

5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T4-4-10

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Select the following conditions.

Engine Control Dial

Auto-Idle Switch

Fast Idle

OFF

2. Operate the swing control lever to full stroke to swing the upperstructure to a uphill side.

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

4. When the machine can swing, increase the slant angle. Check the slant angle in both clockwise and counterclockwise directions.

Evaluation: Refer to Operational Performance Standard.

Remedy: Refer to Troubleshooting B.

T4-4-11

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Swing Bearing Play

A

B

Summary: 1. Measure the swing bearing play and check the wear of the swing bearing races and the rollers.

Preparation: 1. Check the swing bearing mounting bolts for looseness.

2. Check lubrication of the swing bearing. Confirm that bearing rotation is smooth without noise.

WKEB-04-01-015

3. Remove bolts (1) (4 used) and washers (2) (4 used).

Remove scraper assemblies (3) (2used).

Details A, B

1, 2

j : 36 mm m : 950 N·m (700 lbf·ft) 4. Secure dial gauge (5) on the upper surface of the track frame by using magnetic base (4).

5. Position the upperstructure so that the boom aligns with the tracks facing towards the front idlers.

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

7. Empty the bucket.

fNOTE: The measured value will vary depending on

3

where magnetic base (1) is secured. Secure magnet base (1) as close to the round trunk as possible.

WKEB-04-01-002

4 4-

Magnetic Base

5 5-

4 4-

T4-4-12

Magnetic Base

5 5-

T105-06-03-014

Dial Gauge

T18P-04-04-002 Dial Gauge

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Measure at positions A, B, C, and D (4 places).

2. Fully extend the arm and bucket cylinders. Hold the boom so that the bucket bottom height is the same as the boom foot pin height. Record dial gauge reading (h1) of the dial gauge.

A D

B C

3. Lower the bucket onto the ground and raise the front idler 0.5 m off the ground by using the front attachment. Record reading (h2) of the dial gauge.

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

T145-05-03-023

Evaluation: Refer to Operational Performance Standard.

Measurement (h1)

Measurement (h2)

a b TKEB-04-04-003

Measurement (h1)

Measurement (h2)

a b TKAB-04-04-006 a-

The same height as boom foot pin

b-

T4-4-13

0.5 m (1.6 ft)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Hydraulic Cylinder Cycle Time In the Case of Loading Shovel Summary: 1. Measure the cycle time of boom, arm, and bucket cylinders, and check the performance of the front attachment system (from main pump to each cylinder).

2. Empty the bucket.

Preparation: 1. Measurement is made for the following positions.  Measurement of the cycle time of the boom cylinder: With the arm and bucket cylinders fully extended, lower the bucket onto the ground.

 Measurement of the cycle time of the arm cylinder: Operate the bucket to the position where the rear bucket does not come in contact with the arm stopper with the arm fully retracted. Raise the boom so that the bucket bottom height is 1.0 m (3.3 ft) above the ground.

T145-05-03-015

T145-05-03-016

 Measurement of the cycle time of the bucket cylinder: Raise the boom so that the bucket tooth tip height is 1.0 m (3.3 ft) above the ground during bucket tilt-out operation.  Measurement of the cycle time of the dump cylinder: Fully extend the arm and bucket cylinders. Raise the boom so that the bucket bottom height is 1.0 m (3.3 ft) above the ground.

T145-05-03-017

2. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T145-05-03-018

T4-4-14

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test In the Case of Backhoe Summary: 1. Measure the cycle time of boom, arm, and bucket cylinders, and check the performance of the front attachment system (from main pump to each cylinder).

2. Empty the bucket.

Preparation: 1. Measurement is made for the following positions.  Measurement of the cycle time of the boom cylinder: With the bucket cylinder fully extended and the arm cylinder fully retracted, lower the bucket onto the ground.

 Measurement of the cycle time of the arm cylinder: With the bucket cylinder fully extended, raise the boom so that the bucket bottom height is 0.5 m (1.6 ft) above the ground when the arm oscillation center faces vertically to the ground. Set the arm so that the center of arm operation is vertical.

 Measurement of the cycle time of the bucket cylinder: Adjust the boom and arm cylinders so that the bucket oscillation center faces vertically to the ground.

TKAB-04-04-007

TKAB-04-04-008

2. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T105-06-03-020

T4-4-15

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: (Common to Loading Shovel and Backhoe) 1. Select the following conditions.

Engine Control Dial Fast Idle

Auto-Idle Switch OFF

2. Measure the cylinder cycle times as follows: (Cylinder full stroke includes cylinder cushioning zone.)  Measurement of the cycle time of the boom cylinder: Operate the boom control lever to full stroke.

Measure the time to raise and lower the boom.  Measurement of the cycle time of the arm cylinder: Operate the arm control lever to full stroke. Measure the time to retract and extend the arm.  Measurement of the cycle time of the bucket cylinder: Operate the bucket control lever to full stroke.

Measure the time to tilt in and tilt out the bucket.  Measurement of the cycle time of the dump cylinder: (Loading Shovel only) Operate the bucket open/close pedal to full stroke.

Measure the time to open and close the bucket.

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

Evaluation: Refer to Operational Performance Standard.

Remedy: Refer to Troubleshooting B.

T4-4-16

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Cylinder Drift Check Summary: 1. Measure the drifted amount of cylinders, which can be caused by oil leakage in the control valve and boom, arm and bucket cylinders, with the bucket loaded. a

2. When measuring the drifted amount just after cylinder replacement, slowly operate the cylinder for 10 minutes and bleed air from the cylinder.

TKEB-04-04-004

Preparation: 1. Load the bucket. (Refer to the Operational Performance Standard about the loading weight.)

2. Fully extend the arm and bucket cylinders. Adjust and hold the boom so that the arm end pin height is the same as the boom foot pin height.

3. Position the arm cylinder and the bucket cylinder with the rod 50 mm away from the full stroke end position.

a TKAB-04-04-010 a-

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T4-4-17

The same height as boom foot pin

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Measurement: 1. Stop the engine.

a

b

2. When 5 minutes passed, measure the change in position of bottom of the bucket, as well as the boom, arm, and bucket cylinders.

b

Boom and Bucket Cylinders: Retracted Distance: a a=A-B Arm Cylinder: Extended Distance: c c=B-A

T110-06-03-002

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

fNOTE: The drift amount is increased according to

the bucket weight when the wear resistant material is installed.

a-

Boom and Bucket Cylinders: Retraction

b-

Mark

c d

d

Evaluation: Refer to Operational Performance Standard.

Remedy: Refer to Troubleshooting B. TDCY-04-04-001

c-

T4-4-18

Arm Cylinder: Extended Distance

d-

Mark

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Control Lever Operating Force Summary: 1. Check a play and operating condition and measure the operating force.

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

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

Measurement:

TKEB-04-04-005

1. Stop the engine.

2. Measure the operating force of each control lever.

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

Evaluation: Refer to Operational Performance Standard.

TKEB-04-04-006

T4-4-19

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Control Lever Stroke Summary: 1. Check a play and operating condition and measure each control lever stroke.

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

3. In case the lever stroke play is present in the neutral position, add half (1/2) the play present to both side lever strokes.

Measurement: 1. Stop the engine.

T107-06-03-005

2. Measure each control lever stroke from neutral to the stroke end of each control lever of boom, arm, bucket, swing, and travel at the grip center.

3. Measure the chord length from neutral to the stroke end.

4. Repeat the measurement three times and calculate the mean values.

Evaluation: Refer to Operational Performance Standard.

T4-4-20

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test Combined Operation of Boom Raise and Swing Function Check Summary: 1. Check the boom raise and swing movement and speed while operating both functions simultaneously.

2. Check if the cylinders do not hesitate while operating the cylinder with the engine running at fast idle.

T142-05-03-008

Preparation: 1. With the arm and bucket cylinders fully extended, lower the bucket onto the ground. (Empty the bucket.)

2. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers

T142-05-03-007

are out of the swing area before starting the measurement.

Measurement: 1. Select the following conditions.

Engine Control Dial

Auto-Idle Switch

Fast Idle

OFF

2. Raise the boom and swing the upperstructure in full stroke at the same time. Measure the time required to swing the upperstructure 90 degrees and height (H) of the bucket teeth. (The bucket should be empty.)

T142-05-03-009

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

Evaluation: Refer to Operational Performance Standard.

Remedy: Refer to Troubleshooting B. T142-05-03-010

T4-4-21

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 4 Machine Performance Test (Blank)

T4-4-22

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Primary Pilot Pressure Preparation: 1. Stop the engine.

Do not turn cap (1) quickly. Cap may dCAUTION: fly off by internal pressure. Slowly loosen cap (1) and release any remaining pressure. Remove cap (1).

2. Loosen cap (1) and release any pressure from the hydraulic oil tank.

1

l : 4 mm 3. Remove plug (3) from manifold (2). Install adapter (ST 6069) and pressure gauge (ST 6942) to the pressure check port. j : 19 mm 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

TKEB-04-05-001

Measurement: 1. Select the following conditions.

Engine Control Dial

Auto-Idle Switch

Fast Idle

OFF

Slow Idle

OFF

2

3

2. Measure the pilot pressure without load by using the pressure gauge under each condition above.

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

Evaluation: Refer to Operational Performance Standard.

TKEB-04-05-002

T4-5-1

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Secondary Pilot Pressure (Solenoid Valve of EDQR Valve) Measurement:

Preparation:

Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers

1. Stop the engine.

are out of the work area before starting the measurement.

Do not turn the cap quickly. The cap dCAUTION: may fly off by internal pressure. Slowly loosen the cap and release any remaining pressure. Remove the cap.

2. Loosen the cap and release any pressure from the hydraulic oil tank.

When measuring the boom lower secondary pilot pressure, set the machine position with the tracks raised off the ground. Take care not to allow the rear of the machine to come in contact with the ground. Take care not to allow the machine overturn as the machine becomes unbalanced.

l : 4 mm 3. Disconnect wire harnesses (1 to 16) according to the circuits to be measured. Remove pressure sensor (17).

Install adapter (ST 6069) and pressure gauge (ST 6942). j : 19 mm

1. Select the following conditions.

Engine Control Dial

Auto-Idle Switch

Fast Idle

OFF

Slow Idle

OFF

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

2. Operate the control lever to be measured. Measure the pilot pressure by using the pressure gauge with the control lever set to the full stroke.

5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

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

Evaluation: Refer to Operational Performance Standard.

fNOTE: When the measured data is abnormal, measure

the primary pilot pressure. When the primary pilot pressure is normal, the EDQR valve can be determined as faulty.

T4-5-2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test

1 2 3 4 5 6 7 15

8 9 10 11 12 13 14 16

TKEB-04-05-003

17

17

TKEB-04-05-004

12345-

Bucket Tilt-In Boom Raise Bucket Tilt-Out Boom Lower Arm Retract

678910-

Arm Extend Travel Left Forward Travel Left Reverse Travel Right Forward Bucket Open

1112131415-

T4-5-3

Travel Right Reverse Bucket Close Swing (Left) Swing (Right) Valve Warmer Solenoid Valve

16- Valve Warmer Solenoid Valve 17- Pressure Sensor

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Secondary Pilot Pressure (EDQR Valve) Preparation:

Measurement:

1. Stop the engine.

d

CAUTION: Do not turn the cap quickly. The cap may fly off by internal pressure. Slowly loosen the cap and release any remaining pressure. Remove the cap.

2. Loosen cap (1) and release any pressure from the hydraulic oil tank.

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

When measuring the boom lower secondary pilot pressure, set the machine position with the tracks raised off the ground. Take care not to allow the rear of the machine to come in contact with the ground. Take care not to allow the machine overturn as the machine becomes unbalanced.

l : 4 mm 3. Disconnect hoses (1 to 14) according to the circuits to be measured.

Install tee (ST 6450) between the disconnected hose and adapter. Install adapter (ST 6069) and pressure gauge (ST 6942) to the tee. j : 19 mm, 22 mm 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

1. Select the following conditions.

Engine Control Dial

Auto-Idle Switch

Fast Idle

OFF

Slow Idle

OFF

2. Operate the control lever to be measured. Measure the pilot pressure by using the pressure gauge with the control lever set to the full stroke.

5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

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

Evaluation: Refer to Operational Performance Standard.

fNOTE: When the measured data is abnormal, measure

the secondary pilot pressure of the solenoid valve of the EDQR valve. When the secondary pilot pressure of the solenoid valve of the EDQR valve is normal, EDQR valve 1 (15) or EDQR valve 2 (16) can be determined as faulty.

T4-5-4

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test

15

16

1 2 3 4 5 6 7 TKEB-04-05-003

8 9 10 11 12 13 14

1234-

Bucket Tilt-In Boom Raise Bucket Tilt-Out Boom Lower

5678-

Arm Retract Arm Extend Travel Left Forward Travel Left Reverse

9101112-

T4-5-5

Travel Right Forward Bucket Open Travel Right Reverse Bucket Close

13141516-

Swing (Left) Swing (Right) EDQR Valve 1 EDQR Valve 2

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Main Relief Set Pressure

fNOTE: The bucket close overload relief set pressure is

lower than the main relief set pressure. Therefore, even when the bucket close circuit is relieved, the main relief set pressure cannot be measured.

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

fNOTE: If all circuit pressure in the circuits to be

measured are lower than the specified range, the probable cause is the set pressure decrease of the main relief valve. If only relief pressure of a particular circuit is lower, the probable cause is a decrease of relief valve pressure corresponding to the circuit or overload relief valve pressure.

Preparation: 1. Stop the engine.

Do not turn the cap quickly. The cap dCAUTION: may fly off by internal pressure. Slowly loosen the cap and release any remaining pressure. Remove the cap.

2. Loosen the cap and release any pressure from the hydraulic oil tank.

Evaluation: Refer to Operational Performance Standard.

l : 4 mm

4

3. Remove plug (4) of the upper part of high-pressure strainers (1 to 3) according to the circuits to be measured. Install adapter (ST 6069) and pressure gauge (ST 6941).

1

l : 6 mm 2

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection.

5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

3

Measurement: 1. Measure the main relief pressure at the fast idle engine speed.

2. Slowly operate each control lever of bucket, arm, and boom. Operate each cylinder to the stroke end and relieve the pressure.  When measuring the pressure of travel, secure the tracks against an immovable object. Slowly operate the travel control lever and relieve the pressure.  When measuring the pressure of swing, secure the upperstructure so that it does not swing. Slowly operate the swing control lever and relieve the pressure.

3. Measure each relief pressure.

4. Repeat the measurement three times and calculate the mean values.

TKBA-04-05-002

Connection of High-Pressure Strainer Main Pump High-Pressure Connected to Strainer P1 1 Control Valve (Left) P2 P3 2 Control Valve (Center) P4 P5 3 Control Valve (Right) P6

T4-5-6

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Main Relief Valve Pressure Adjustment Procedure IMPORTANT: Do not customize the machine illegally.

For example; the machine performance is set over the specification.

The machine life including the components and so on may become short or be broken. Future in addition, a serious trouble may occur.

1

Adjustment: 1. Loosen lock nut (2). j : 17 mm 2. Turn adjusting screw (3) and adjust the set pressure. l : 6 mm 3. After the adjustment, tighten lock nut (2). j : 17 mm TKEB-04-05-009

m : 27.5 to 31.4 N·m (20.5 to 23.0 lbf·ft) 4. After the adjustment, check the set pressure.

1-

Main Relief Valve

fNOTE: Standard Change in Pressure (Reference) Adjusting Screw (3) 1/4 Turns Change in MPa 4.5 Pressure (psi) (653)

1/2

3/4

1

8.9 (1291)

13.4 (1944)

17.8 (2582)

1

2

3 TKEB-04-05-010 12-

Main Relief Valve Lock Nut

3-

Adjusting Screw

3

2

a

b W107-02-05-129

a-

Pressure Increase

b-

Pressure Decrease

2-

Lock Nut

3-

Adjusting Screw

T4-5-7

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Swing Relief Valve Pressure Adjustment Procedure IMPORTANT: Do not customize the machine illegally.

For example; the machine performance is set over the specification.

The machine life including the components and so on may become short or be broken. Future in addition, a serious trouble may occur.

Adjustment: 1. Loosen lock nut (2). j : 41 mm 2. Turn adjusting screw (3) and adjust the set pressure. j : 27 mm

1-

3. After the adjustment, tighten lock nut (2).

M144-07-012

1 Swing Relief Valve

j : 41 mm

1

2

3

m : 19.5 to 29.5 N·m (14.5 to 22.0 lbf·ft) 4. After the adjustment, check the set pressure.

fNOTE: Standard Change in Pressure (Reference) Adjusting Screw (3) 1/4 Turns Change in MPa 2.5 Pressure (psi) (363)

1/2

3/4

1

5.0 (725)

7.5 (1088)

10.0 (1450)

TKEB-04-05-011 12-

Swing Relief Valve Lock Nut

3-

Adjusting Screw

2 3

a

b TKEB-04-05-015

a-

Pressure Increase

b-

Pressure Decrease

2-

Lock Nut

3-

Adjusting Screw

T4-5-8

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Travel Relief Valve Pressure Adjustment Procedure 1

IMPORTANT: Do not customize the machine illegally.

For example; the machine performance is set over the specification.

The machine life including the components and so on may become short or be broken. Future in addition, a serious trouble may occur.

Adjustment: 1. Loosen lock nut (3).

2

j : 17 mm

2 TKEB-04-05-012

2. Turn adjusting screw (4) and adjust the set pressure.

1-

Travel Brake Valve

2-

Travel Relief Valve

l : 6 mm

3

3. After the adjustment, tighten lock nut (3). j : 17 mm m : 34 to 44 N·m (25.0 to 32.5 lbf·ft)

4

4. After the adjustment, check the set pressure.

2

fNOTE: Standard Change in Pressure (Reference) Adjusting Screw (4) 1/4 Turns Change in MPa 1.96 Pressure (psi) (284)

1/2

3/4

1

3.92 (569)

5.88 (853)

7.85 (1139)

T145-05-04-004 23-

Travel Relief Valve Lock Nut

4-

Adjusting Screw

4

3

a

b W107-02-05-129

a3-

T4-5-9

Pressure Increase Lock Nut

b4-

Pressure Decrease Adjusting Screw

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Overload Relief Pressure Summary: 1. The circuit pressure must be increased by applying an external force while blocking the return circuit of the control valve. However, this measuring method is hazardous and the results obtained with this method are unreliable.

2. 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.

3. Measurement on the machine is not recommended because of above mentioned reasons. If the measurement on the machine is required, please substitute the measurement of the main relief set pressure.

T4-5-10

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Overload Relief Valve Pressure Adjustment Procedure (Reference) IMPORTANT: Adjust the overload relief valve pressure on a test stand.

Adjustment: 1. Loosen lock nut (2).

1

1

j : 17 mm 2. Turn adjusting screw (3) and adjust the set pressure. l : 6 mm 3. After the adjustment, tighten lock nut (2). j : 17 mm m : 27.5 to 31.4 N·m (20.5 to 23.0 lbf·ft) 4. After the adjustment, check the set pressure.

TKEB-04-05-009

fNOTE: Standard Change in Pressure (Reference) Adjusting Screw (3) 1/4 Turns Change in MPa 5.3 Pressure (psi) (769)

1/2

3/4

1

10.6 (1537)

15.9 (2306)

21.2 (3075)

1-

Overload Relief Valve

1

2

3 TKEB-04-05-010 12-

Overload Relief Valve Lock Nut

3-

Adjusting Screw

3 2

a

b W107-02-05-129

a-

Pressure Increase

b-

Pressure Decrease

2-

Lock Nut

3-

Adjusting Screw

T4-5-11

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Main Pump Flow Rate Measurement  P-Q Control (Torque Control)

7. Bleed air from the main pump.

8. Connect a pulse meter to the engine speed sensor.

Summary: Install a hydraulic tester to the delivery port of the main pump to be measured. Main pump performance is checked by measuring the pump flow rate.

9. Fully open the loading valve of hydraulic tester (12).

10. Start the engine. Confirm that no oil leakage is observed at the hydraulic tester (12) and pressure gauge connections.

Preparation: Measurement:

1. Stop the engine.

1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Do not turn the cap quickly. The cap dCAUTION: may fly off by internal pressure. Slowly loosen the cap and release any remaining pressure. Remove the cap.

2. Loosen the cap and release any pressure from the hydraulic oil tank.

2. Measure the maximum flow rate.

3. Select the following conditions.

3. Disconnect the delivery hose from the main pump to be measured. Connect pipe (9) to the delivery port of the main pump with split flanges (7) (2 used) and bolts, washers (8) (4 used) of the disconnected hose.

Engine Control Dial

Auto-Idle Switch

Fast Idle

OFF

j : 19 mm m : 90 N·m (66 lbf·ft) 4. Connect pipe (9) and hydraulic tester (12) with test hose (10) and adapter (11). Install adapter (11), test hose (10), and flange (13) to hydraulic tester (12).

Test Hose (10) j : 41 mm m : 210 N·m (155 lbf·ft) Adapter (11) j : 55 mm m : 420 N·m (310 lbf·ft) 5. Install the disconnected delivery hose from the main pump with split flanges (14) (2 used) and bolts (15) (4 used). j : 19 mm m : 90 N·m (66 lbf·ft) 6. Install a pressure gauge to the main pump to be measured.

(Refer to Main Relief Set Pressure.)

T4-5-12

4. Adjust the relief set pressure of main relief valve in control valve to each pressure point specified along the main pump P-Q curve. (Refer to T4-2-4.)

Slowly restrict the loading valve of hydraulic tester (12) while relieving pressure in the boom raise circuit. Measure the flow rates and engine speed at each pressure point specified in the P-Q curve.

5. Repeat the measurement three times and calculate the mean values.

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Evaluation: 1. Convert the measured flow rates to those at the specified engine speed by using the following formula.

2. Standard Flow Rate Refer to Operational Performance Standard.

Qc = Ns×Q/Ne Qc : Converted Flow Rate Q : Measured Flow Rate Ns : Specified Engine Speed: 1800 min-1 Ne : Measured Engine Speed

3

4

1 2 7, 8 5

6

TKEB-04-05-006

9

10

11

12

11

10

13 14 15

TKEB-04-05-005

1234-

Delivery Piping (Main Pump 1) Delivery Piping (Main Pump 2) Delivery Piping (Main Pump 3) Delivery Piping (Main Pump 4)

5678-

Delivery Piping (Main Pump 5) Delivery Piping (Main Pump 6) Split Flange Bolt, Washer

9101112-

T4-5-13

Pipe (ST 6132) Test Hose (ST 6145) Adapter (ST 6603) Hydraulic Tester (ST 6299)

13- Flange (ST 6140) 14- Split Flange (4075853) 15- Bolt (J 901250)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Adjustment of Maximum Flow Rate and Minimum Flow Rate (Main Pump) The main pump flow rate can be adjusted by changing the servo piston maximum stroke. Loosen lock nut (1) of the large chamber side of the servo piston, turn adjusting screw (2), and adjust the maximum pump flow rate. Loosen lock nut (3) of the small chamber side of the servo piston, turn adjusting screw (4), and adjust the minimum pump flow rate.

Lock Nut (1)

3

1

2

2

1

3 4

4

j : 30 mm

TKEB-04-05-013

m : 240 N·m (177 lbf·ft)

1-

Lock Nut (3)

2-

j : 30 mm

Lock Nut (Large Chamber Side) Adjusting Screw (Large Chamber Side)

34-

Lock Nut (Small Chamber Side) Adjusting Screw (Small Chamber Side)

m : 240 N·m (177 lbf·ft) Adjustment of Maximum Flow Rate

fNOTE: Standard Change in Flow Rate (Reference) Q

Engine Speed: 1800 min-1 Adjusting Screw Turns

1/4

Change in Flow Rate (Large 9.4 L/min Chamber Side) Change in Flow Rate (Small 9.4 L/min Chamber Side) 1

I

2 Adjustment of Minimum Flow Rate Q

a

b W107-02-05-129

a-

Flow Rate Decrease

b-

Flow Rate Increase

1-

Lock Nut (Large Chamber Side)

2-

Adjusting Screw (Large Chamber Side) I

3

b

4

I: Command Current Signal of Pump Control Solenoid Valve

a W107-02-05-129

a-

Flow Rate Decrease

b-

Flow Rate Increase

3-

Lock Nut (Small Chamber Side)

4-

Adjusting Screw (Small Chamber Side)

T4-5-14

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Adjustment of Main Pump Flow Rate Control The main pump flow rate control is performed by command current signal (I) of the pump control solenoid valve.

Loosen lock nut (2), turn adjusting screw (3), and adjust the flow rate.

Lock Nut (2) j : 17 mm m : 29 N·m (21.5 lbf·ft)

1

2

3

T16J-04-04-006 1-

Spring

2-

Lock Nut

3-

Adjusting Screw

fNOTE: Standard Change in Flow Rate (Reference)

Flow Rate Control

Engine Speed: 1800 min-1 Q

Adjusting Screw Turns

1/4

Change in Flow Rate

49.9 L/min

2

3 I I: Command Current Signal of Pump Control Solenoid Valve

a

b

W107-02-05-129 a-

Flow Rate Decrease

b-

Flow Rate Increase

2-

Lock Nut

3-

Adjusting Screw

T4-5-15

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Oil Cooler Fan Motor Pump Flow Rate

8. Remove plug (9) from the delivery pressure check port of the oil cooler fan motor pump. Install pressure gauge assembly (ST 6934).

 P-Q Control (Torque Control) Summary:

j : 19 mm

Install the hydraulic tester to the delivery port of the oil cooler fan motor pump to be measured. The oil cooler fan motor pump performance is checked by measuring the pump flow rate.

m : 36 N·m (26.5 lbf·ft) 9. Bleed air from the oil cooler fan motor pump.

10. Connect a pulse meter to the engine speed sensor.

11. Fully open the loading valve of hydraulic tester (8).

Preparation: 1. Stop the engine.

Do not turn the cap quickly. The cap dCAUTION: may fly off by internal pressure. Slowly loosen the

12. Start the engine. Confirm that no oil leakage is observed at the hydraulic tester (8) and pressure gauge connections.

cap and release any remaining pressure. Remove the cap.

2. Loosen the cap and release any pressure from the hydraulic oil tank.

Measurement: 1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

2. Measure the maximum flow rate.

3. Disconnect delivery piping (1) from elbow (2) of the oil cooler fan motor pump. j : 36 mm 4. Install coupler (3), adapter (4), and nipple (5) to elbow (2).

3. Select the following conditions.

Engine Control Dial

Auto-Idle Switch

Fast Idle

OFF

4. Adjust the relief set pressure of oil cooler fan motor relief valve to each pressure point specified along the oil cooler fan motor pump P-Q curve. (Refer to T4-2-4.)

j : 36 mm m : 180 N·m (133 lbf·ft)

Slowly restrict the loading valve of hydraulic tester (8). Measure the flow rates and engine speed at each pressure point specified in the P-Q curve.

5. Install adapter (4) and nipple (5) to disconnected delivery piping (1). j : 36 mm

5. Repeat the measurement three times and calculate the mean values.

m : 180 N·m (133 lbf·ft) 6. Install adapters (7) (2 used) to hydraulic tester (8). j : 55 mm m : 420 N·m (310 lbf·ft) 7. Connect test hoses (6) (2 used) to the oil cooler fan motor pump and hydraulic tester (8), and hydraulic tester (8) and delivery piping (1) respectively. j : 41 mm m : 210 N·m (155 lbf·ft)

T4-5-16

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Evaluation: 1. Convert the measured flow rates to those at the specified engine speed by using the following formula.

2. Standard Flow Rate Refer to Operational Performance Standard.

Qc = Ns×Q/Ne Qc : Converted Flow Rate Q : Measured Flow Rate Ns : Specified Engine Speed: 1800 min-1 Ne : Measured Engine Speed 2

9

1

TKEB-04-05-007

4 3

8 5

2

6

7

6

5

4

1

7 TKEB-04-05-008

12-

Delivery Piping (Oil Cooler Fan Motor Pump) Elbow

345-

Coupler (ST 6470) Adapter (ST 6468) Nipple (ST 6147)

678-

T4-5-17

Test Hose (ST 6145) Adapter (ST 6603) Hydraulic Tester (ST 6299)

9-

Plug

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Adjustment of Maximum Flow Rate and Minimum Flow Rate (Oil Cooler Fan Motor Pump) The oil cooler fan motor pump flow rate is adjusted by changing the servo piston maximum stroke.

Loosen lock nut (1) of the large chamber side of the servo piston, turn adjusting screw (2), and adjust the maximum pump flow rate. Loosen lock nut (3) of the small chamber side of the servo piston, turn adjusting screw (4), and adjust the minimum pump flow rate.

Lock Nut (1)

3

1 2

4

j : 30 mm m : 240 N·m (177 lbf·ft) Lock Nut (3) j : 24 mm m : 130 N·m (96 lbf·ft)

TKEB-04-05-014

fNOTE: Standard Change in Flow Rate (Reference)

1-

Engine Speed: 1800 min-1 Adjusting Screw Turns

2-

1/4

Lock Nut (Large Chamber Side) Adjusting Screw (Large Chamber Side)

Change in Flow Rate (Large 5.6 L/min Chamber Side) Change in Flow Rate (Small 4.5 L/min Chamber Side)

34-

Lock Nut (Small Chamber Side) Adjusting Screw (Small Chamber Side)

Adjustment of Maximum Flow Rate Q

1

a

2

b

a-

Flow Rate Decrease

b-

1-

Lock Nut (Large Chamber Side)

2-

3

I

W107-02-05-129 Flow Rate Increase Adjusting Screw (Large Chamber Side)

Adjustment of Minimum Flow Rate Q

4

b

a I

a-

Flow Rate Decrease

b-

3-

Lock Nut (Small Chamber Side)

4-

W107-02-05-129 Flow Rate Increase Adjusting Screw (Small Chamber Side)

T4-5-18

I: Command Current Signal of Pump Control Solenoid Valve

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Adjustment of Oil Cooler Fan Motor Pump Flow Rate Control The oil cooler fan motor pump flow rate control is performed by command current signal (I) of the pump control solenoid valve.

Loosen lock nut (2), turn adjusting screw (3), and adjust the flow rate.

Lock Nut (2) j : 13 mm m : 16 N·m (12 lbf·ft)

1

2 3

T1J1-04-05-005 1-

Spring

2-

Lock Nut

3-

Adjusting Screw

fNOTE: Standard Change in Flow Rate (Reference)

Flow Rate Control

Engine Speed: 1800 min-1 Q

Adjusting Screw Turns

1/4

Change in Flow Rate

13.1 L/min

2

3 I I: Command Current Signal of Pump Control Solenoid Valve

b

a

W107-02-05-129 a-

Flow Rate Decrease

b-

Flow Rate Increase

2-

Lock Nut

3-

Adjusting Screw

T4-5-19

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Adjustment of Torque Constant Control (Oil Cooler Fan Motor Pump) The torque control (oil cooler fan motor pump ) is performed by own pump delivery pressure P. CAUTION: Do not turn adjusting screws (4, 6) over one turn. After the adjustment, securely tighten lock nuts (3, 5).

1

2

3

4 5

d

6

Adjust the set force of springs (1, dCAUTION: 2) while watching the engine performance in

order not to increase the pump driving torque excessively.

1. Loosen lock nut (3), turn adjusting screw (4), and adjust the set force of outer spring (1).

TKEB-04-05-016 1234-

Lock Nut (3) j : 36 mm m : 160 N·m (118 lbf·ft)

5-

Outer Spring Inner Spring Lock Nut (Outer Spring) Adjusting Screw (Outer Spring) Lock Nut (Inner Spring)

6-

Adjusting Screw (Inner Spring)

fNOTE: When turning adjusting screw (4) of outer spring (1), adjusting screw (6) of inner spring (2) turns at the same time. When adjusting only outer spring (1), adjust outer spring (1) and turn adjusting screw (6) of inner spring (2) by the amount [adjusting screw (4) turns × 2.24] reversely.

2. Loosen lock nut (5), turn adjusting screw (6), and adjust the set force of inner spring (2).

3

4 5 6

b

a

Lock Nut (5)

TKEB-04-05-017

j : 17 mm a-

m : 19 N·m (14 lbf·ft)

fNOTE: Standard change (reference) when adjusting the spring

Flow Rate Decrease

b-

Flow Rate Increase

P-Q Control (Torque Adjustment: Outer Spring) Q

Engine Speed: 1950 min-1

Adjusting Screw Turns Flow Rate Pressure Engine Torque

Outer Spring (Adjusting Screw (4)) 1/4

Inner Spring (Adjusting Screw (6)) 1/4

18.7 L/min

10.0 L/min

1.88 MPa (273 psi) 28.1 N·m (20.5 lbf·ft)

2.17 MPa (315 psi) 22.3 N·m (16.5 lbf·ft)

P TDAA-04-05-006 P-Q Control (Torque Adjustment: Inner Spring) Q

P TDAA-04-05-007

T4-5-20

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Swing Motor Drainage Summary: 1. Measure the amount of oil draining from the swing motor while swinging the upperstructure and check the swing motor performance.

2. Secure absolute safety for the measuring persons as well as for the surrounding while measuring.

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

4. Measure the swing motor drainage one by one.

Preparation: 1. Maintain hydraulic oil temperature at 50±5 °C (122±9 °F). Rotate the swing motor and warm the inside of the motor.

Do not turn the cap quickly. The cap dCAUTION: may fly off by internal pressure. Slowly loosen the cap and release any remaining pressure. Remove the cap.

2. Stop the engine. Loosen the cap and release any pressure from the hydraulic oil tank.

3. Disconnect drain hose (1) of the swing motor at the hydraulic oil tank side. Install the plug (1-1/16-12 UN) to the hydraulic oil tank. j : 30 mm, 36 mm m : 176 N·m (130 lbf·ft) Test Conditions

1 1-

1. Select the following conditions.

Engine Control Dial Fast Idle

Auto-Idle Switch OFF

T4-5-21

Drain Hose

M117-07-082

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: Prevent personal injury. Always make dCAUTION: sure that the area is clear and that coworkers are out of the swing area before starting the measurement. Also, take care not to fall off from the machine while measuring.

a

 Amount of Oil Drained While Swinging the Upperstructure 1. Fully retract the arm cylinder. Fully extend the bucket cylinder. Hold the boom so that the arm tip pin height is the same as the boom foot pin height.

Empty the bucket.

TKEB-04-04-002

2. Start the engine. Operate and hold the swing control lever in the full stroke. After the swing speed reaches a constant speed, start the draining oil measurement when the drain oil starts coming out of the drain hose end, and measure the time.

a TKAB-04-04-005

3. Repeat the measurement three times or more in both clockwise and counterclockwise directions, and calculate the mean values.

a-

The same height as boom foot pin

4. The measuring time should be more than 20 seconds.  Amount of Oil Drained While Relieving Swing Motor Circuit 1. Thrust the bucket teeth into the ground so that the upperstructure does not swing.

2. Start the engine. Operate and hold the swing control lever in the full stroke. Start the draining oil measurement when the drain oil starts coming out of the drain hose end, and measure the time.

T107-06-06-005

3. Repeat the measurement three times or more in both clockwise and counterclockwise directions, and calculate the mean values.

4. The measuring time should be more than 20 seconds.

Evaluation: Refer to Operational Performance Standard. * Conversion of amount of measured drain oil into the per-minute value First measure the amount of drain oil by using a calibrated container. Then, convert the measured drain oil into the per-minute value by using the following formula. Q =60×q/t Q : Amount of drain oil per minute (L/min) t : Measured time (seconds) q : Total amount of drain oil (L)

T107-06-05-008

T4-5-22

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Travel Motor Drainage Summary: 1. While rotating the travel motor with the track to be measured raised off the ground, measure the amount of oil draining from the travel motor and check the travel motor performance.

2. Secure absolute safety for the measuring persons as well as for the surrounding while measuring.

3. Judge the travel motor performance from the results including the travel speed, mistrack, and so on overall.

4. The amount of drain oil from the travel motor will change depending on the hydraulic oil temperature. Keep the hydraulic oil temperature.

Preparation: 1. Adjust track sag.

Track sag specification: 465 to 535 mm 2. Maintain hydraulic oil temperature at 50±5 °C (122±9 °F). Rotate the travel motor and warm the inside of the motor.

Do not turn the cap quickly. The cap dCAUTION: may fly off by internal pressure. Slowly loosen the cap and release any remaining pressure. Remove the cap.

3. Stop the engine. Loosen the cap and release any pressure from the hydraulic oil tank.

1

4. Disconnect drain hose (1) of the travel motor at the hydraulic oil tank side. Install the plug (1-1/16-12 UN) to the hydraulic oil tank. j : 30 mm, 36 mm m : 17.5 N·m (13.0 lbf·ft) Test Conditions 1. Select the following conditions.

Engine Control Dial Fast Idle

Auto-Idle Switch OFF

M117-07-087 1-

T4-5-23

Drain Hose

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 5 Component Test Measurement: When the working around moving dCAUTION: parts is unavoidable, pay special attention to

ensure that hands, feet, and clothing do not become entangled. Securely support the raised track off the ground by using the blocks. a

1. Start the engine. Raise the track to be measured off the ground.

2. Rotate the track to be measured. Start drain oil measurement when drain oil starts coming out of the connected drain hose end, and measure the time.

T142-05-03-012 a-

90 ~ 110 degrees

3. Repeat the measurement three times or more in both clockwise and counterclockwise directions, and calculate the mean values.

4. The measuring time should be more than 20 seconds.

a

Evaluation: Refer to Operational Performance Standard.

TKAB-04-04-002

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

a-

Q =60×q/t Q : Amount of drain oil per minute (L/min) t : Measured time (seconds) q : Total amount of drain oil (L)

T4-5-24

90 ~ 110 degrees

MEMO

MEMO

SECTION 5

TROUBLESHOOTING CONTENTS Group 1 Diagnosing Procedure

Introduction........................................................................... T5-1-1 Diagnosis Procedure........................................................... T5-1-2 Electrical System Inspection............................................ T5-1-5 Precautions for Inspection and Maintenance .......... T5-1-6 Instrouctions for Disconnecting Connectors............. T5-1-8 Fuse Inspection...................................................................T5-1-10 Slow Blow Fuse Inspection.............................................T5-1-20 Battery Voltage Check......................................................T5-1-21 Alternator Check................................................................T5-1-22 Continuity Check...............................................................T5-1-23 Voltage and Current Measurement.............................T5-1-24 Check by False Signal.......................................................T5-1-34 Test Wire Harness...............................................................T5-1-35

Group 2 Monitor

Outline..................................................................................... T5-2-1 Warning Indicator (Engine related)............................... T5-2-8 Warning Indicator (Except Engine related)...............T5-2-10 Operating Procedures of Service Menu.....................T5-2-12 Current Alarms Faults List...............................................T5-2-14 System Check......................................................................T5-2-15 Automatic Snapshot.........................................................T5-2-16 Monitor and manual snapshot.....................................T5-2-18 Life...........................................................................................T5-2-38 Controller Information.....................................................T5-2-39 Log Data History.................................................................T5-2-40 Maintenance History........................................................T5-2-41 Various Setup......................................................................T5-2-42 Language Setup.................................................................T5-2-45 How To Display Setting Menu 2....................................T5-2-46 Setting Menu 2...................................................................T5-2-48 Autolube Check..................................................................T5-2-49 IO Monitor............................................................................T5-2-50 Initialization of Automatic snapshot Data................T5-2-51 Electric Lever Adjustment Menu .................................T5-2-52 Pump Adjustment Menu.................................................T5-2-61 Communication Terminal Information......................T5-2-67 Incline Angle Adjustment...............................................T5-2-68 Various Setup......................................................................T5-2-69

Group 3 Cross Reference Table Group 4 Component Layout

Electrical System (Overview)........................................... T5-4-4 Electrical System (Around Cab Bed).............................. T5-4-5 Electrical System (In Cab).................................................. T5-4-6 Electrical System (Around Battery)................................ T5-4-9 Electrical System (Relay Box).........................................T5-4-10 Electrical System (Electrical Equipment Box)...........T5-4-11 Electrical System (Relay Layout of Electrical Equipment Box).........................................T5-4-12 Electrical System (LED Layout of Contamination Sensor Amplifier)...........................T5-4-13 Electrical System (Layout of Contamination Sensor).........................T5-4-14 Electrical System (Monitoring Controller Box)........T5-4-15 Electrical System (Pump Compartment Controller Box)...................T5-4-16 Electrical System (Angle Sensor) (Loading Shovel)...........................................................T5-4-17 Electrical System (Angle Sensor) (Backhoe).............T5-4-18 Engine....................................................................................T5-4-19 Air Cleaner............................................................................T5-4-20 Around Radiator.................................................................T5-4-21 Around Oil Cooler..............................................................T5-4-22 Around Pump......................................................................T5-4-23 4-UNIT PUMP.......................................................................T5-4-25 Control Valve.......................................................................T5-4-26 Pilot Panel.............................................................................T5-4-29 EDQR Valve...........................................................................T5-4-30 Swing Device.......................................................................T5-4-31 Undercarriage.....................................................................T5-4-32 Travel Device.......................................................................T5-4-33 Center Joint..........................................................................T5-4-33 Fast-Filling System.............................................................T5-4-34 Fast-Filling Panel................................................................T5-4-35 Folding Stairway.................................................................T5-4-36 Auto-Lubrication Device.................................................T5-4-39 Hydraulic Oil Tank..............................................................T5-4-40 Fuel Tank...............................................................................T5-4-41 Urea SCR System................................................................T5-4-42 Fuse Layout..........................................................................T5-4-45

Group 5 Troubleshooting for Each Code

Troubleshooting Procedure for Each Code................ T5-5-1 How To Read Fault Code List (Appendix).................... T5-5-5

Main Component (Overview).......................................... T5-4-1 Main Component (Loading Shovel).............................. T5-4-2 Main Component (Backhoe)............................................ T5-4-3

Group 7 Air Conditioner

Troubleshooting................................................................... T5-7-1 Diagnosis Procedure (Air Conditioner Controller)... T5-7-8

KEB90T-5-1

Air Conditioner Controller Fault Code List.................. T5-7-9 Faulty cooling......................................................................T5-7-10 Faulty Heating.....................................................................T5-7-19 Check Refrigerant Quantity Through Sight Glass.......................................................................T5-7-25

Group 8 e-Service

Outline..................................................................................... T5-8-1 List of Operation Data........................................................ T5-8-2 Communication System.................................................... T5-8-3

Group 9 Aftertreatment Device

Remedy at Abnormal DEF Pressure............................... T5-9-1 Remedy at Abnormal DEF Quality................................. T5-9-3 Clean DEF Tank..................................................................... T5-9-4 Remedy when Mixing Oil in DEF Tank.......................... T5-9-5

KEB90T-5-2

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 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 quickly find the cause of the machine trouble and solution.

The troubleshooting section in this manual consists of eight groups as follows.  Diagnosing Procedure This group explains procedures of troubleshooting and precautions, inspection procedure, and information of test harness and/or information for the electrical system inspection.

Example: Fuse Inspection  Monitor This group contains the display screen of monitor and the operating procedures of service menu.  Checklist of Circuit Diagram and Component Layout  Component Layout

 Air Conditioner This group explains air conditioner system, troubleshooting, and procedures of recovering and charging refrigerant to the air conditioner.  e-Service This group contains as follows. Procedures of downloading and uploading data from DLU. Explanation for the communication system.  Aftertreatment Device This group explains procedures of troubleshooting for abnormal DEF pressure and abnormal DEF quality, and DEF tank cleaning.

 Troubleshooting Procedure for Each Code Refer to these procedures if any fault codes are displayed on the monitor.

Example: Fault Code 000006-00: Coolant Temperature Very High

T5-1-1

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Diagnosis 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.

(Construction and functions) 2. Ask the operator Before inspecting, get the full story of malfunctions from the operator below.  Operating condition: How is the machine being used? Find out if the machine is being operated correctly.  Trouble identification: When was the trouble noticed, and what type of work was the machine doing at that time?  Trouble symptom: What are the details of the trouble? Did the trouble slowly get worse, or did it appear suddenly?  Trouble history: Did the machine have any other troubles previously? If so, which parts were repaired before?

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

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

If troubleshooting is started without checking for blown fuses, a wrong diagnosis may result in wasting time. Check for blown fuses before troubleshooting.

Even if a fuse looks normal by visual inspection, a fine crack may exist and it is difficult to find. Always use a circuit tester when checking the fuses.

T107-07-01-001

T107-07-01-002

4. Operate the machine yourself Reproduce the trouble on the machine and make sure the actual phenomenon.

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 corresponding to the trouble.

T107-07-01-003

T5-1-2

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 5. Perform troubleshooting Do not disconnect wire harnesses dCAUTION: or hydraulic lines while the engine is running.

The machine may malfunction or pressurized oil may spout out, possibly resulting in personal injury. Stop the engine before disconnecting wire harnesses or hydraulic lines.

In case any fault code has been displayed by diagnosis by using the service menu of monitor, perform diagnosis by referring to Troubleshooting Procedure for Each Code in this section.

TDCD-05-01-002

T5-1-3

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 6. Trace possible causes Before reaching a conclusion, check the most suspect causes again.

Try to identify the actual cause of the trouble.

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

7. Maintenance mode Before checking the electrical system such as disconnecting the connector, select the maintenance mode on the monitor. (Refer to Monitor.)

T107-07-01-007

T5-1-4

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Electrical System Inspection The precautions and information for the electrical system inspection are explained here. The electrical system inspection contains as follows.  Precautions for Inspection and Maintenance  Instructions for Disconnecting Connectors  Fuse Inspection  Slow Blow Fuse Inspection  Battery Voltage Check  Alternator Check  Continuity Check  Voltage and Current Measurement  Check by False Signal  Test Wire Harness

T5-1-5

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Precautions for Inspection and Maintenance IMPORTANT: Do not turn OFF isolation switches (1, 2) while the engine is running and the key switch is in the position other than OFF. And do not turn OFF isolation switches (1, 2) until the engine has been stopped and indicator (3) is turned off.

Failure to do so may damage the electrical system.

1. Disconnect the power source Turn OFF isolation switches (1, 2) first when taking off wire harnesses and connectors for repair or replacement work. Failure to do so can result in damage to the harnesses, fuses and slow blow fuses and, in some cases, cause fire due to short circuiting.

In addition, even when the key switch is set to the OFF position, the controller may be operated for a specified time. Therefore, turn OFF isolation switches (1, 2) after setting the key switch to the OFF position and waiting until the engine has been stopped and indicator (3) is turned off.

1 3

2

fNOTE: It takes 3 minutes until indicator (3) is turned off.

2. Color coding of wire harnesses As for the color codes of wire harnesses in the electrical system, refer to the table. If one wire harness consists of two colors, two or more codes are indicated. The left code stands for base color and the right code stands for marking color.

Code Color Code Color

R W Red White Or Lg Orange Light green

L Blue Br Brown

G Green P Pink

Y Yellow Gr Gray

TKEB-01-02-015

13-

B Black V Violet

fNOTE:  Code BW indicates a black base wire harness with white fine-line marking.  Initials "O" and "Or" both stand for the color orange.

T5-1-6

Isolation Switch (Battery Circuit) Indicator

2-

Isolation Switch (Starter Circuit)

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 3. Precautions for connecting and disconnecting terminal connectors  Disconnect the connectors by grasping the connector body. Do not pull on the wire harness itself. Release the lock first before attempting to separate the connectors, if a lock is provided. (Refer to Instructions for Disconnecting Connector on T5-18.)  The water-resistant connectors keep water out.

If water enters them, water will not easily drain from them. When checking the water-resistant connectors, take extra care not to allow water to enter the connectors. In case water should enter the connectors, reconnect only after the connectors are thoroughly dried.  Before connecting the connectors, check that no terminals are bent (3) or coming off (4). In addition, as most terminals are made of brass, check that no terminals are rusting (2).  When connecting connectors provided with a lock, insert them together until the lock "clicks".  Pull lightly the wire harness near the connector in order to check if it is correctly connected.

TDAA-05-08-002

1 2 3

4 TDAA-05-08-003 12-

Correct Rusting

34-

Bent Coming Off

4. Precautions for using a circuit tester  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.  Before starting the connector test, always check the connector terminal numbers by 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.  When checking the connector by using a circuit tester, do not damage the terminal inside the connector. Insert a tester probe from the wire harness end of the connector.  Special Tool for Test  Special tool (ST 1479) for removing terminal  Wire harness (ST 6706) of general measuring  Wire harness (ST 6707) for male-male end jumper  Wire harness (ST 6708) for female-male end jumper

fNOTE: Refer to T5-1-33.

T5-1-7

TDAA-05-08-004

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Instrouctions for Disconnecting Connectors  Push, Unlock, and Separate Type (Most connectors are this type.)  The connectors will not be easily separated even if the lock is pushed while being pulled. First push the lock, and then pull the connectors.  The lock is located on female side connector (wire harness end side).

T107-04-05-002

 Raise Lock, Pull, and Separate Type

T107-04-05-003

 Pull and Separate Type NOTE: Before pulling and separating, release the lock of the connector by using a pair of pincers.

f

T107-04-05-004

 Pull and Separate Type After Removing Bolt (1) NOTE: Use a 10 mm wrench.

f

2

Tighten the screw until torque mark (2) appears.

1

T107-04-05-005 1-

T5-1-8

Bolt

2-

Torque Mark

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure  Separate Type After Turning by Hand  Turn knob (5) counterclockwise by hand, pull, and remove it when disconnecting female end connector (3) from male end connector (4) which has been secured in the plate.  Remove panel nut (8) by using a tool, separate male end connector (4) and lock washer (9) when disconnecting male end connector (4) from the plate.

3

5

4

7

4

TKEE91-05-01-007 7-

Matching Mark (Male End)

4 8

9

6

TKEE91-05-01-008 TKEE91-05-01-006 34-

Female End Connector Male End Connector

56-

8-

Knob Matching Mark (Female End)

T5-1-9

Panel Nut

9-

Lock Washer

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure [When connecting connectors]

10

When connecting the connector, pins (10) may be damaged. Take care of the followings.

1. Check that both connecting surfaces are parallel when connecting the connectors. Refer to the picture in lower right. Fit large concave part (A) to large convex part (A’).

A

4

A'

3

fNOTE: Large concave part (A) and small concave parts (B) (2 places) are on the connecting surface of male end connector (4). Large convex part (A’) and small convex parts (B’) (2 places) are on the connecting surface of female end connector (3).

IMPORTANT: When connecting the connector to the incorrect positions and forcibly turn knob (5), pins (10) may be damaged.

2. Turn knob (5) of female end connector (3) clockwise until it "clicks". Then, connect the connector.

B AB-

Male End Connector

B'

Female End Connector TKEE91-05-01-009

Large Concave Part Small Concave Part

A’B’-

Large Convex Part Small Convex Part

10- Pin

4

5

3

TKEE91-05-01-010

(Align the center such as

Fuse Inspection

b

a

.) b

Cracks in a fuse are so fine that it is very difficult or impossible to find by visual inspection. Use a circuit tester in order to correctly inspect fuse continuity by following the instructions described below.

1. Set the key switch to the ON position. When the key switch is in the ON position, current from key switch terminal M turns ON the battery relay and electric power is supplied to the circuits. (Refer to the circuit diagram.)

2. Remove the fuse box cover. Set the circuit tester to the voltage measurement range. (Measurement Range: 0 to 30 V) 3. Ground the negative probe of the circuit tester to the body. Touch the terminals located outside (b) away from center of the fuse box with the positive probe of the circuit tester one at a time. When the circuit tester indicates 20 to 25 V (battery voltage), the fuse is normal.

M178-07-034 a-

T5-1-10

Inner terminals connected to the power source

b-

Outer terminals connected to loads (accessories)

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Rely Box

14 13

9 10

1

11

3 4 5

12

6 7 8

TKEB-01-02-060

2

Fuse Box Fuse Capacity Connected to No. 1 400A Prelube Relay 2 200A Alternator 3 75A Fuse Box 1 4 75A Fuse Box 2 5 75A Fuse Box 2 6 75A Fuse Box 2 7 75A Fuse Box 4 8 75A Fuse Box 3 9 45A Option 10 75A Starter Relay 11 45A ECM Power 12 75A Folding Stairway Relay 13 250A Folding Stairway Pump 1 14 250A Folding Stairway Pump 2

T5-1-11

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

1 2 3 4 5 6 7 8 9 10

TKEB-05-01-001

TKEB-01-02-060

Fuse Box (DEF) Fuse Capacity Connected to No. 1 10A Dosing Module Relay 1 2 10A Dosing Module Relay 2 3 10A ECM NOx Sensor Power 4 20A DEF Line Heater Relay 1 5 20A DEF Line Heater Relay 2 6 20A DEF Piping In-Line Filter Heater 7 20A DEF Fill Hose Heater 8 20A DEF Fill Pipe Heater 9 5A DEF Receiver Heater 10 5A DEF Shut-Off Valve Heater

T5-1-12

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Left Console (Rear Side)

TKEB-01-02-073

1

2

3

4

5

6

7

8

9

10

TKEB-05-01-002

11 12 13 14 15

Fuse No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

16 17 18 19 20

Capacity Connected to 20A 5A 5A 5A 5A 5A 5A 5A 5A 5A 10A 15A 5A 5A 10A 10A 15A 5A 10A 5A

Main Power Key Switch ELUF, ELUT Power IDU Power DLU Power Option Power Radio (Backup) ELUF, ELUT Key ON Signal IDU Key ON Signal DLU Key ON Signal Buzzer Key ON Signal (Control Unit) Key ON Signal (Monitoring Unit) ECM Key ON Signal Horn Air Compressor ACC Signal Cigar Lighter Power Source Terminal (ACC) Power Source Terminal (12 V) Radio (ACC) Power Source Socket (12 V) Pilot Control Shut-Off Lever Switch

T5-1-13

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

TKEB-01-02-073

21 22 23 24 25

Fuse No. 21 22 23 24 25 26 27 28 29 30

26 27 28 29 30

Capacity Connected to 5A 5A 5A 10A 15A 15A 5A -

WIU Power WIU Key ON Signal Key ON Signal (External Connection) Alternator Power (External Connection) Power Source Terminal (24 V) Aerial Angle Power Key ON Signal (Aerial Angle) -

T5-1-14

TKEB-05-01-003

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Electrical Equipment Box

1

2

3

4

5

6

7

8

9 10

11 12 13 14 15 16 17 18 19 20 T18G-05-07-001

TKEB-05-01-004

Fuse Box 1 Fuse Capacity Connected to No. 1 5A MCU, HMU Power 2 5A Delayed Power OFF Power 3 10A Battery Power (External Connection) 4 5A PFU, PMU, EHU Power 5 6 30A Horn Air Compressor (Left) 7 30A Horn Air Compressor (Right) 8 10A Folding Stairway Solenoid Valve (1) 9 5A Electrical Equipment Box Light 10 30A Cab Battery Power 11 10A C/U (J1939) Power (Option) 12 15A Monitoring Unit Power 13 5A Key ON Signal (C/U (J1939)) (Option) 14 10A Key ON Signal (Monitoring Unit) 15 5A ECM Lamp Power 16 5A ELU, PWM Power Relay 17 5A PFU Key Switch ON Signal 18 19 5A PMU, EHU Key Switch ON Signal 20 -

T5-1-15

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

21 22 23 24 25 26 27 28 29 30

31 32 33 34 35 36 37 38 39 40 T18G-05-07-001

TKEB-05-01-004

Fuse Box 2 Fuse Capacity Connected to No. 21 5A Washer Motor Relay 22 5A Travel Mode Relay 23 5A Air Conditioner Main Relay (Right) 24 5A Air Conditioner Main Relay (Left) 25 5A Air Conditioner Main Relay (Rear) 26 5A Battery Relay 27 15A DC/DC Converter 2 28 5A Grease Tank Level Switch 29 20A Cab Bed Pressurization Blower Motor 1 30 20A Cab Bed Pressurization Blower Motor 2 31 20A Air Conditioner Main Power (Right) 32 20A Air Conditioner Main Power (Left) 33 20A Air Conditioner Main Power (Rear) 34 15A Air Conditioner Condenser Fan Motor (Right) 35 15A Air Conditioner Condenser Fan Motor (Left) 36 15A Air Conditioner Condenser Fan Motor (Rear) 37 5A DLU Service Tool 38 5A Communication Terminal Power (Satellite/Potable) 39 5A Folding Stairway Alarm/Flash Light (1) Power 40 5A Alternator Signal Relay

T5-1-16

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

41 42 43 44 45 46 47 48 49 50

51 52 53 54 55 56 57 58 59 60 T18G-05-07-001

TKEB-05-01-004

Fuse Box 3 Fuse Capacity Connected to No. 41 5A Motion Alarm 42 10A Engine Oil Reserve Tank Filling System Main Switch (1) 43 44 5A Travel Mode Selector Solenoid Valve 45 5A Folding Stairway Solenoid Valve (2) 46 5A Air Breather Solenoid Valve 47 15A Seat Suspension Air Compressor Cab Light 48 20A Alternator Power (External Connection) Power Source Terminal (24 V) 49 15A DC/DC Converter 1 50 5A Rear View Camera Monitor 51 10A PWM Power (MCU) 52 5A IDU Power 53 15A PWM Power (ELUF, ELUT) 54 55 15A ECM Data Link 56 10A PWM Power (PFU) 57 58 15A Engine Oil Reserve Tank Pump Unit 59 60 20A Oil Pump

T5-1-17

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

61 62 63 64 65 66 67 68 69 70

71 72 73 74 75 76 77 78 79 80 T18G-05-07-001

TKEB-05-01-004

Fuse Box 4 Fuse Capacity Connected to No. 61 10A Work Light 1 62 10A Work Light 2 63 10A Work Light 3 64 10A Work Light 4 65 10A Work Light 5 66 10A Work Light 6 67 10A Maintenance Light 1 68 10A Maintenance Light 2 69 10A Maintenance Light 3 70 10A Maintenance Light 4 71 72 73 10A Entrance Light 1 74 75 30A Wiper Motor (Slow Speed) 76 30A Wiper Motor (Fast Speed) 77 10A Washer Motor 78 5A Fast Filling Solenoid Valve 79 5A CSU Power 80 -

T5-1-18

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Controller Box (Monitoring Unit)

1 2 3 4 5 6 7 8 9 10

TKEB-01-02-062 TKEB-05-01-001

Fuse No. 1 2 3 4 5 6 7 8 9 10

Capacity Connected to 5A 5A 10A 5A 5A 5A 5A -

ODR Power BPU Power Option Power Key ON Signal (ODR) Key ON Signal (BPU) Key ON Signal (Option) Alternator (Signal Light) -

T5-1-19

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Slow Blow Fuse Inspection

1

1-

Slow Blow Fuse T111-04-05-015

a

1 2

3 a-

Rely Box TKEB-01-02-060

Inspection b

1. Visually inspect slow blow fuse (1).

Replacement 1. Turn OFF isolation switches (2, 3).

2. Pull out slow blow fuse (1). Replace slow blow fuse (1).

3. Turn ON isolation switches (2, 3).

b-

Isolation Switch Box

2-

Isolation Switch

3-

Isolation Switch TKEB-01-02-015

T5-1-20

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Battery Voltage Check 1. Turn OFF the key switch. Check the voltage between the battery positive terminal and the body (ground).

Specification: 24 V

fNOTE: If the voltage is not within the specification,

recharge or replace the battery.

2. Start the engine. Check the voltage between the battery positive terminal and the body (ground).

Specification: 26 to 28 V

fNOTE: If the voltage is not within the specification, check the charging system.

T162-05-06-005

T5-1-21

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Alternator Check Generally, if the alternator has generated electricity, alternator alarm (1) will disappear. If alternator alarm (1) is displayed while the engine is running, the alternator might be defective.

How to Check Alternator 1. Set the key switch to the ON position. Confirm that alternator alarm (1) is displayed.

2. Measure voltage between terminal B (2) and B negative terminal (3) of the alternator. If the measured voltage is around 24 V, the alternator circuit can be considered normal. If the measured voltage is low, a shortage in battery capacity or looseness of the wire connectors between battery and alternator might be the cause of the malfunction. When voltage is 0 V, the ground line of the alternator might be disconnected.

3. Next, start the engine and measure voltage generated while the alternator rotates. As described above, measure voltage between terminal B (2) and B negative terminal (3) of the alternator. If voltage is around 28 V, the alternator is operating normally.

If the measured voltage is same as the battery voltage (around 24 V), there is some trouble with the alternator or the regulator.

1 1-

TKEB-05-01-010 Alternator Alarm

3

2

T18M-05-06-001 2-

T5-1-22

Terminal B

3-

B Negative Terminal

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Continuity Check IMPORTANT: Before continuity check, set the key switch to the OFF position.  Single line continuity check Disconnect both end connectors of the wire harness and check continuity (measure the resistance) between both end terminals:  ∞ Ω = Open circuit  0 Ω = Normal

A

A

 When the one end connector is far apart from the other Connect one end of connector (A) to the body by using a clip. Then, check continuity of the wire harness between terminal (a) and the body.  ∞ Ω = Open circuit  0 Ω = Normal

 Multi line continuity check Disconnect both end connectors of the wire harness, and short circuit two terminals, (A) and (B), at one end connector. Then, check continuity between terminals (a) and (b) at the other connector.

If the ohm meter reading is ∞ Ω, either line (A) - (a), or (B) - (b) is in discontinuity, or both lines (A) - (a) and (B) - (b) are in discontinuity. Discontinuity is not limited at only one place. Check discontinuity of the single line for all uncertain wire harnesses.  Multi line short circuit check Disconnect both end connectors of the wire harness, and check continuity between terminals (A) and (B) or (C).  0 Ω = Short circuit exists between the lines.  ∞ Ω = Normal

a

A

 Single line short circuit check Disconnect both end connectors of the wire harness and check continuity between one end connector terminal of the wire harness and the body:  0 Ω = Short circuit  ∞ Ω = Normal

a

a

T107-07-05-003

A B C

a b c

T107-07-05-004

A B C

a b c

T107-07-05-005

T5-1-23

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Voltage and Current Measurement Turn on the switches so that the specified voltage (current) is supplied to the location to be measured. Judge if the circuit is normal by evaluating whether the measured voltage (current) matches the specification.

24-Volt Circuit Start checking the circuit in order up to the location to be measured from either power source or actuator side.

Thereby, the faulty location in the circuit will be found.  Black (negative) probe terminal of circuit tester: To the body (to ground) (E)  Red (positive) probe terminal of circuit tester: To touch the location to be measured

Engine Electric Power Circuit Stopped Stopped Stopped Stopped Stopped Stopped Stopped Stopped Stopped Stopped Stopped Stopped Stopped Stopped

Key Switch

Location to be Measured

OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF

Between (2) and (1): Between (3) and (2): Between (3) and (1): Between (5) and (4): Between (6) and (5): Between (6) and (4): Between (7) and Ground: Between (8) and Ground: Between (9) and Ground: Between (10) and Ground: Between (11) and Ground: Between (12) and Ground: Between (13) and Ground: Between (14) and Ground:

Specification

One Battery One Battery Two Batteries One Battery One Battery Two Batteries Battery Power (1) Battery Power (2) Battery Power (3) Slow Blow Fuse 9 (45 A) Slow Blow Fuse 10 (75 A) Fuse (250 A) Fuse (250 A) Slow Blow Fuse 1 (75 A)

10 to 12.5V 10 to 12.5V 22.5 to 25.5V 10 to 12.5V 10 to 12.5V 22.5 to 25.5V 22.5 to 25.5V 22.5 to 25.5V 22.5 to 25.5V 22.5 to 25.5V 22.5 to 25.5V 22.5 to 25.5V 22.5 to 25.5V 22.5 to 25.5V

Preheating Circuit Stopped

ON or START Between (15) and Ground: Key Switch

22.5 to 25.5V

Fast Speed Fast Speed Fast Speed Fast Speed Fast Speed Fast Speed

ON ON ON ON ON ON

Between (16) and Ground: Between (17) and Ground: Between (7) and Ground: Between (8) and Ground: Between (9) and Ground: Between (21) and Ground:

26 to 30V 26 to 30V 26 to 30V 26 to 30V 26 to 30V 26 to 30V

Fast Speed

ON

Between (22) and Ground:

Fast Speed Fast Speed Fast Speed Fast Speed

ON ON ON ON

Between (23) and Ground: Between (24) and Ground: Between (25) and Ground: Between (26) and Ground:

Charging Circuit Alternator (B), Generating Voltage Fuse (200 A), Generating Voltage Battery Relay 1, Generating Voltage Battery Relay 2, Generating Voltage Battery Relay 3, Generating Voltage Folding Stairway Relay 2, Generating Voltage Folding Stairway Relay 3, Generating Voltage Fuse Box 1, Generating Voltage Fuse Box 3, Generating Voltage Fuse Box (Cab 1), Generating Voltage Fuse Box (Cab 2), Generating Voltage

T5-1-24

26 to 30V 26 to 30V 26 to 30V 26 to 30V 26 to 30V

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 25

n

23

r

15

p

26

f

14 10

c

q l

11

21

o

b m

22

i

7

j

13 e

8

d

17 h

k

g

12

9 3

6

1 2

5

4

24

16 a

TKEB-05-01-006

abcde-

Battery Slow Blow Fuse 9 (45 A) Slow Blow Fuse 10 (75 A) Fuse (250 A) Fuse (250 A)

fghij-

Slow Blow Fuse 1 (75 A) Alternator Fuse (200 A) Battery Relay 1 Battery Relay 2

klmno-

T5-1-25

Battery Relay 3 Folding Stairway Relay 2 Folding Stairway Relay 3 Fuse Box 1 Fuse Box 3

pqr-

Fuse Box (Cab 1) Fuse Box (Cab 2) Key Switch

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Engine Starting Circuit

Key Switch

Location to be Measured

Specification

Stopped

ON

Between (1) and Ground:

Horn Air Compressor Relay (R2)

22.5 to 25.5V

Stopped Stopped Stopped Stopped Stopped

ON ON ON ON ON

Between (2) and Ground: Between (3) and Ground: Between (4) and Ground: Between (5) and Ground: Between (6) and Ground:

Horn Air Compressor Relay (L2) Horn Relay Cigar Lighter Power Source Terminal Radio

22.5 to 25.5V 22.5 to 25.5V 22.5 to 25.5V 22.5 to 25.5V 22.5 to 25.5V

T5-1-26

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

r b

a

k j

2

g

f

q

c

n

1

d

4

3

o

6

5 s

p

e

l h

i

abcdef-

Key Switch Fuse Box (Cab 1) Cigar Lighter Power Source Terminal Radio Horn Air Compressor Relay (R2)

ghij-

m

TKEB-05-01-007

Horn Air Compressor Relay (R1) Horn Air Compressor (R) (Option) Horn Pressure Switch (R) (Option) Horn Air Compressor Relay (L2)

k-

Horn Air Compressor Relay (L1) lHorn Air Compressor (L) m- Horn Pressure Switch (L) n- Horn Relay o- Horn Switch p- Horn (R) (Option)

T5-1-27

qrs-

Battery Fuse Box 1 Horn (L)

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Engine Starting Circuit

Key Switch

Location to be Measured

Specification

Stopped Stopped Stopped

ON ON ON

Between (1) and Ground: Between (2) and Ground: Between (3) and Ground:

Battery Relay 1 Battery Relay 2 Battery Relay 3

22.5 to 25.5V 22.5 to 25.5V 22.5 to 25.5V

Stopped

ON

Between (4) and Ground:

Starter 1 (B)

22.5 to 25.5V

Stopped

ON

Between (5) and Ground:

Starter 2 (B)

22.5 to 25.5V

Stopped

ON

Between (6) and Ground:

Engine Start Switch

22.5 to 25.5V

Stopped

ON

Between (7) and Ground:

Engine Stop Switch

22.5 to 25.5V

Stopped

ON

Between (8) and Ground:

ECM

22.5 to 25.5V

Stopped

ON

Between (9) and Ground:

Valve Limit Switch (Return 1)

22.5 to 25.5V

Stopped

ON

Between (10) and Ground: Valve Limit Switch (Return 2)

22.5 to 25.5V

Stopped

ON

Between (11) and Ground: Valve Limit Switch (Suction)

22.5 to 25.5V

Stopped

ON

Between (12) and Ground: Emergency Engine Stop Switch 1

22.5 to 25.5V

Stopped

ON

Between (13) and Ground: Emergency Engine Stop Switch 2

22.5 to 25.5V

Stopped

ON

Between (14) and Ground: Emergency Engine Stop Switch 3

22.5 to 25.5V

Stopped

ON

Between (15) and Ground: Emergency Engine Stop Switch 4

22.5 to 25.5V

Stopped

ON

Between (16) and Ground: Emergency Engine Stop Switch 5

22.5 to 25.5V

Stopped

ON

Between (17) and Ground: Fuse Box 2 (#26)

22.5 to 25.5V

Stopped

ON

Between (18) and Ground: Fuse Box (Cab 2) (#11)

22.5 to 25.5V

Stopped

ON

Between (19) and Ground: Fuse Box (Cab 2) (#13)

22.5 to 25.5V

Started

ON

Between (6) and Ground:

22.5 to 25.5V

Started

ON

Between (20) and Ground: Engine Start Cancellation Relay

22.5 to 25.5V

Started

ON

Between (21) and Ground: Prelube Control Relay

22.5 to 25.5V

Started Started

ON ON

Between (22) and Ground: Prelube Relay Between (23) and Ground: Prelube Motor

22.5 to 25.5V 22.5 to 25.5V

Prelube Circuit Engine Start Switch

T5-1-28

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

r

p

o

n

11

10

9

m

7

l

j

i

12 16 w

23

k

22

x

15

14

13

q

v

s

21

6 20 u

8

c

d

4 g

5

1

e

2

f

b

17

3

h

18

19

a

ｔ TKEB-05-01-008

abcdefgh-

Key Switch Fuse Box (Cab 2) Fuse Box 2 Battery Relay 1 Battery Relay 2 Battery Relay 3 Starter 1 Starter 2

ijkl-

Emergency Engine Stop Switch 1 Emergency Engine Stop Switch 2 Emergency Engine Stop Switch 3 Emergency Engine Stop Switch 4

m- Emergency Engine Stop Switch 5 n- Valve Limit Switch (Return 1) o- Valve Limit Switch (Return 2) p- Valve Limit Switch (Suction) q- Engine Start Switch r- Engine Stop Switch s- Air Bleeding Solenoid Valve

T5-1-29

tuvwx-

Battery Engine Start Cancellation Relay Prelube Control Relay Prelube Relay Prelube Motor

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Engine Key Switch Surge Voltage Prevention Circuit Slow Idle Speed ON

Location to be Measured

Between (1) and Ground:

Alternator (B)

26 to 30V

Slow Idle Speed Slow Idle Speed Slow Idle Speed Slow Idle Speed

Between (2) and Ground: Between (3) and Ground: Between (4) and Ground: Between (5) and Ground:

Delayed Power OFF Relay Battery Relay 1 Battery Relay 2 Battery Relay 3

26 to 30V 26 to 30V 26 to 30V 26 to 30V

ON ON ON ON

Specification

T5-1-30

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure

j

h

i

b

2

a

c

3

4

d

e

5

f

1 g

TKEB-05-01-009

abc-

Key Switch Delayed Power OFF Relay Battery Relay 1

def-

Battery Relay 2 Battery Relay 3 Alternator

ghi-

T5-1-31

Battery Fuse Box (Cab 1) Fuse Box 2

j-

Fuse Box 1

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure 5-Volt Circuit  Voltage between terminal #1 and the body (two-polarities connector or three-polarities connector) Disconnect the connector with the key switch OFF. Measure voltage between terminal #1 (5 V power supply) on the body harness end connector and the body (ground).

Two Polarities

 Key Switch: ON  Black (negative) probe terminal of circuit tester: To the body (to ground)  Red (positive) probe terminal of circuit tester: Terminal #1

TDFB-05-01-003

If the measuring voltage is within 5 ± 0.5 volts, the circuit up to terminal #1 is normal.

Three Polarities

TDFB-05-01-004

 Voltage between terminal #3 and the body (three-polarities connector) Disconnect the connector with the key switch OFF. Measure voltage between terminal #3 (5 V power supply) on the body harness end connector and the body (ground).

Three Polarities

 Key Switch: ON  Black (negative) probe terminal of circuit tester: To the body (to ground)  Red (positive) probe terminal of circuit tester: Terminal #3

TDFB-05-01-005

If the measuring voltage is within 5 ± 0.5 volts, the circuit up to terminal #3 is normal.

T5-1-32

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure  Voltage between terminal #1 and the ground terminal (two-polarities connector or three-polarities connector) Turn OFF the key switch, and disconnect the sensor connector. Measure the voltage between terminal #1 (5 V power supply) on the body harness end connector and the ground terminal (terminal #2 for two-polarities or terminal #3 for three-polarities connector) under the following conditions.  Key Switch: ON  Black (negative) probe terminal of circuit tester: To ground terminal (Terminal #2 or #3)  Red (positive) probe terminal of circuit tester: Terminal #1

Two Polarities

TDFB-05-01-006

Three Polarities

If the measuring voltage is within 5 ± 0.5 volts, the circuit up to terminal #1 and the ground terminal (terminal #2 or #3) is normal.

TDFB-05-01-007

 Voltage between terminal #3 and the ground terminal (three-polarities connector) Turn OFF the key switch, and disconnect the sensor connector. Measure the voltage between terminal #3 (5 V power supply) on the body harness end connector and the ground terminal (terminal #1) under the following conditions.

Three Polarities

 Key Switch: ON  Black (negative) probe terminal of circuit tester: To ground terminal (Terminal #1)  Red (positive) probe terminal of circuit tester: Terminal #3

TDFB-05-01-008

If the measuring voltage is within 5 ± 0.5 volts, the circuit up to terminal #1 and the ground terminal (terminal #1) is normal.

T5-1-33

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Check by False Signal  Terminal #1 (power source) Turn OFF the key switch. Disconnect the sensor connector. Turn ON the key switch. Connect terminal #1 (power source) of the body harness end connector to terminal #2 (signal). (Power voltage is used as a false signal.)

Check this state by using the monitor function of MPDr..

When the maximum value is displayed, MC and the circuit up to the body harness end connector are normal. In case of a pressure switch, it displays "ON" status.

Two Polarities

TDFB-05-01-009

IMPORTANT: Do not connect terminal #1 or #2 to terminal #3 or to the body (ground) when checking a three-polarity connector of terminal #1 (power source).

Three Polarities

fNOTE: Some kinds of sensors can be monitored by the service menu of the monitor.

TDFB-05-01-010

 Terminal #3 (power source) Turn OFF the key switch. Disconnect the sensor connector. Turn ON the key switch. Connect terminal #3 (power source) of the body harness end connector to terminal #2 (signal). (Power voltage is used as a false signal.)

Check this state by using the monitor function of MPDr..

When the maximum value is displayed, MC and the circuit up to the body harness end connector are normal. In case of a pressure switch, it displays "ON" status.

Three Polarities

IMPORTANT: Do not connect terminal #3 or #2 to terminal #1 or to the body (ground) when checking a three-polarity connector of terminal #3 (power source).

fNOTE: Some kinds of sensors can be monitored by the service menu of the monitor.

T5-1-34

TDFB-05-01-011

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Test Wire Harness

Parts Number 4283594 (ST 7126)

Install a test wire harness between connectors. Check the circuit condition depending on whether the test wire harness lamp lights or extinguishes during operation.  Parts Number 4283594 (ST 7126) Use in order to check a single-line (open circuit and/or voltage).

T107-07-05-012

 During Operation: Light is ON. Parts Number (ST 7226)

 Parts Number (ST 7226) Use in order to check the solenoid valve unit circuits.

3 1

 When the corresponding control lever or switch is operated: Light is ON.

2

150

4 50 50

50

2

1 T107-07-06-015

Connect a test wire harness to the wire harness end connector of pressure sensor. Check the state of pressure sensor circuit.  ST 6701 for high-pressure sensor  ST 6703 for low-pressure sensor

TDAA-05-06-003

T5-1-35

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure (Blank)

T5-1-36

SECTION 5 TROUBLESHOOTING Group 2 Monitor Outline Basic Screen

1

2

3

4

5

6

7

8

9

10

11 11

12

13

14

22

15 TKEB-05-02-175

21

1234567-

Machine Model Engine Coolant Temperature Gauge Control Lever Pattern Engine Oil Temperature Gauge Ambient Temperature Gauge Engine Oil Pressure Gauge Clock

20

8910111213-

19

18

Engine Speedmeter Hour Meter Status Display Area Alarm Side Bar DEF Gauge Machine Inclination/Travel Indicator

17

16

14- Alarm Display Area (Except Engine related) 15- Message Display Area 16- Grease Gauge 17- Fuel Gauge 18- Hydraulic Oil Temperature Gauge

T5-2-1

19- Alarm Display Area (Engine related) 20- HCM Fault Code Display Area 21- Cummins Fault Code Display Area 22- Buzzer Indicator

SECTION 5 TROUBLESHOOTING Group 2 Monitor Engine Coolant Temperature Gauge Gauge

H G F E D C B A

TKEB-05-02-062

No

Coolant Temperature (°C)

A

20 to 70

B

71 to 75

C

76 to 80

D

81 to 85

E

86 to 90

F

91 to 95

G

96 to 100

H (Red)

more than 101

Engine Oil Temperature Gauge Gauge

H G F E D C B A

TKEB-05-02-063

No

Engine Oil Temperature (°C)

A

1 to 17

B

18 to 34

C

35 to 51

D

52 to 68

E

69 to 85

F

86 to 102

G

103 to 121

H (Red)

more than 122

T5-2-2

SECTION 5 TROUBLESHOOTING Group 2 Monitor Engine Oil Pressure Gauge Gauge

H G F E D C B A

TKEB-05-02-064

No

Engine Oil Pressure (kPa)

A (Red)

less than 140

B

140 to 260

C

260 to 384

D

384 to 508

E

508 to 632

F

632 to 756

G

756 to 880

H

more than 880

No

Engine Speed (min-1)

A

0

B

2150

C

2500

Engine Speedmeter Meter B

C

A TKEB-05-02-065

T5-2-3

SECTION 5 TROUBLESHOOTING Group 2 Monitor DEF Gauge Gauge

D

E

F

G

C

H

B

I

J

A

TKEB-05-02-066

No

DEF Level (%)

A (Red)

less than 2.8

A (Yellow)

2.8 to 5.2

A (Yellow)

5.2 to 10.4

B

10.4 to 20.4

C

20.4 to 30.4

D

30.4 to 40.4

E

40.4 to 50.4

F

50.4 to 60.4

G

60.4 to 70.4

H

70.4 to 80.4

I

80.4 to 90.4

J

more than 90.4

No

Hydraulic Oil Temperature (°C)

Hydraulic Oil Temperature Gauge Gauge G

H

Sensor Output

A

20 to 50

F

B

51 to 57

E

C

58 to 64

D

65 to 71

D

E

72 to 78

C

F

79 to 86

G

87 to 95

H (Red)

more than 96

B

A

TKEB-05-02-067

T5-2-4

NOTE: Sensor Specification Voltage (V)

Temperature Resistance (kΩ) (°C) -20 16.330 to 13.840 4.162 to 4.080 20 2.590 to 2.320 2.609 to 2.481 80 0.326 to 0.310 0.640 to 0.612 110 0.144 to 0.140 0.305 to 0.298

SECTION 5 TROUBLESHOOTING Group 2 Monitor Fuel Gauge

Sensor Output

Gauge F

G

E

D C B A

TKGB-05-02-005

No

Fuel Level (%)

G

Full Indicator

F

over 100

E

36 to 100

D

30 to 36

C

22 to 30

B

14 to 22

A (Red)

less than 14

No

Grease Level (%)

A (Red)

0 to 10

B

10 to 50

C

50 to 90

Level (%) 48 38 28 18 8

NOTE: Sensor Specification Resistance (Ω) Voltage (V) 10 to 6 19 37 to 27 49.3 92 to 78

0.385 to 0.238 0.683 1.178 to 0.918 1.456 2.170 to 1.970

Grease Gauge Gauge

D

Level Switch Status Level (%) High 0 to 10 OFF 10 to 50 OFF 50 to 50 OFF over 90 ON

C

B

Middle OFF OFF ON ON

Low OFF ON ON ON

1 A

TKEA90-05-02-002

2

D

over 90 3

TKEA90-05-02-003 12-

T5-2-5

Grease Tank Level Switch (High) Grease Tank Level Switch (Middle)

3-

Grease Tank Level Switch (Low)

SECTION 5 TROUBLESHOOTING Group 2 Monitor Machine Inclination/Travel Indicator Gauge

No

Blinking (Red)

Inclination (degree) Pitch (Back and Voltage (V) Forward) more than less than -23.5 3.381

A Blinking (Yellow) -23.4 to -16 Lit (Yellow) -15.9 to -8.5

H

A

B

D G

C

E F

E

D TKEB-05-02-070

-5.9 to 5.9

2.279 to 2.500

3.100 to 3.381





2.819 to 3.100





Normal

-8.4 to 0

2.500 to 2.819





Blinking (Red)

less than -23.5

more than 3.381

less than -16

less than 1.904

3.100 to 3.381

-15.9 to -11

1.904 to 2.091

2.819 to 3.100

-10.9 to -6

2.091 to 2.279

B Blinking (Yellow) -23.4 to -16 Lit (Yellow) -15.9 to -8.5

C

Roll (Right and Voltage (V) Left)

Normal

-8.4 to 0

2.500 to 2.819

-5.9 to 0

2.279 to 2.500

Blinking (Red)

-8.4 to 8.4

2.185 to 2.500

more than -16

less than 1.904

Blinking (Yellow) 



-15.9 to -11

1.904 to 2.091

Lit (Yellow)





-10.9 to -6

2.091 to 2.279

Normal





-5.9 to 0

2.279 to 2.500

Blinking (Red)

more than 23.5 less than 1.623 more than -16

less than 1.904

Blinking (Yellow) 16 to 23.4

1.623 to 1.904

-15.9 to -11

1.904 to 2.091

Lit (Yellow)

8.5 to 15.9

1.904 to 2.185

-10.9 to -6

2.091 to 2.279

Normal

0 to 8.4

2.185 to 2.500

-5.9 to 0

2.279 to 2.500

Blinking (Red)

more than 23.5 less than 1.623 -5.9 to 5.9

2.500 to 2.721

Blinking (Yellow) 16 to 23.4

1.623 to 1.904





Lit (Yellow)

8.5 to 15.9

1.904 to 2.185





Normal

0 to 8.4

2.185 to 2.500





Blinking (Red)

more than 23.5 less than 1.623 more than 16

F Blinking (Yellow) 16 to 23.4 Lit (Yellow) 8.5 to 15.9

more than 3.100

1.623 to 1.904

11 to 15.9

2.913 to 3.100

1.904 to 2.185

6 to 10.9

2.725 to 2.913

Normal

0 to 8.4

2.185 to 2.500

0 to 5.9

2.500 to 2.725

Blinking (Red)

-8.4 to 8.4

2.500 to 2.815

more than 16

more than 3.100



11 to 15.9

2.913 to 3.100



6 to 10.9

2.725 to 2.913

G Blinking (Yellow)  Lit (Yellow)  Normal





0 to 5.9

2.500 to 2.725

Blinking (Red)

more than -23.5

more than 3.381

more than 16

more than 3.100

3.100 to 3.381

11 to 15.9

2.913 to 3.100

2.819 to 3.100

6 to 10.9

2.725 to 2.913

2.500 to 2.819

0 to 5.9

2.500 to 2.725

H Blinking (Yellow) -23.4 to -16 Lit (Yellow) -15.9 to -8.5 Normal

-8.4 to 0

*Voltage tolerance of the gauge is ±1%

T5-2-6

SECTION 5 TROUBLESHOOTING Group 2 Monitor Machine Inclination Pitch Angle (positive angle)

Pitch Angle (negative angle) Sensor Output NOTE: Sensor Specification Inclination (degree) Voltage (V) 60 4.750

TKGB-05-02-008

0 Roll Angle (positive angle)

2.500 TKGB-05-02-007

Roll Angle (negative angle)

-60

0.250 TKGB-05-02-009

These are common on Pitch and Roll.

Travel Indicator Gyroscope Output (Swing Speed: 0 to 3.8 (min-1) = Angular Velocity: 0 to 22.8 (°/s) 0~22.8(°/s)

TKEB-05-02-071

Swing Left  90°

 180°

 270°

 360°

TKEB-05-02-072

Swing Right  90°

 180°

 270°

T5-2-7

 360°

SECTION 5 TROUBLESHOOTING Group 2 Monitor Warning Indicator (Engine related) Each warning indicator is displayed in display area (a).

a

TKEB-05-02-176

List of Warning Indicator (Engine related) Display

Contents of Alarms Charge Alarm

Alarm Description Indicates a problem with the electrical system.

Check the alternator and battery.

Coolant Level Alarm

Check the coolant level and refill if necessary.

Pump Transmission Oil Level Alarm

Check the pump transmission oil level and refill if necessary.

Engine Overrun Alarm

Abnormal rotation of the engine.

Contact your authorized Cummins dealer.

Engine Stop Alarm

There is a problem with the engine or engine-related part.

Contact your authorized Cummins dealer.

Fuel Temperature Alarm

Engine Oil Pressure Alarm

Air Cleaner Clogging Alarm

Remedy Check the battery.

Check battery relays 1, 2.

Check the isolation switch.

Check the alternator.

Check alternator signal relays 1, 2.

Check MCU. Check IDU. Check the coolant level sensor.

Check ECM. Check IDU.  Check the pump transmission oil level switch.

Check MCU. Check IDU. Check the engine speed sensor.

Check ECM. Check IDU.

Check the sensor related to description which is displayed in message display area, or perform troubleshooting B. Check ECM. Check IDU. The fuel temperature has increased Check the fuel temperature abnormally. Stop work, and check for sensor. clogging, etc., of the fuel cooler.

Check ECM. Check IDU. The engine oil pressure is low.

Check the engine oil pressure Stop the engine immediately and check sensor. the engine oil pressure system and oil Check ECM. level.

Check IDU. The air cleaner is clogged.

Check air cleaner restriction Clean or replace the air cleaner element. switches 1, 2.

Check MCU. Check IDU.

T5-2-8

SECTION 5 TROUBLESHOOTING Group 2 Monitor Display

Contents of Alarms Exhaust Gas Temperature Alarm

Alarm Description Remedy The exhaust temperature has increased Check the exhaust temperature abnormally. Stop work and contact your sensor. authorized Cummins dealer.

Check ECM. Check IDU.

Coolant Overheat Alarm The coolant temperature has increased abnormally.

Stop work and run the engine in low idle to allow the coolant to cool down.

Engine Warning Alarm There is a problem with the engine or engine-related part.

Contact your authorized Cummins dealer.

DEF Alarm

DEF SCR System Alarm

SCR Exhaust Gas Temperature Alarm

SCR Cleaning Alarm

Lock On Low-idle Fixed Alarm

Check the coolant temperature sensor.

Check ECM. Check IDU. Check the sensor related to description which is displayed in message display area, or perform troubleshooting B. Check ECM. Check IDU. DEF is low, the temperature is abnormal, Check the sensor related to or quality is poor. description which is displayed in If the DEF is low, refill it. If it is a message display area, or perform system-related problem, contact your troubleshooting B. authorized Cummins dealer.

Check ECM. Check IDU. There is a problem with the DEF SCR Check the sensor related to system. description which is displayed in Contact your authorized Cummins message display area, or perform dealer. troubleshooting B. Check ECM. Check IDU. The SCR exhaust gas temperature has Check the sensor related to increased abnormally. description which is displayed in Contact your authorized Cummins message display area, or perform dealer. troubleshooting B. Check ECM. Check IDU. There is a problem with the SCR exhaust Check the sensor related to gas. description which is displayed in Increase the engine rotations and raise message display area, or perform the boom to provide relief to raise the troubleshooting B. exhaust temperature.

Check ECM. If the problem remains unresolved, Check IDU. contact your authorized Cummins dealer.

The coolant temperature, fuel Wait until completing warming up temperature, and intake manifold the machine. temperature are low, limiting the engine Check ECM. rotations to low-idle.

Check IDU. Warm up the machine to raise the temperature of the coolant, fuel and intake manifold.

T5-2-9

SECTION 5 TROUBLESHOOTING Group 2 Monitor Warning Indicator (Except Engine related) Each warning indicator is displayed in display area (b).

b

TKEB-05-02-176

List of Warning Indicator (Except Engine related) Display

Contents of Alarms Hydraulic Oil Level Alarm

Alarm Description Check the hydraulic oil level and check for oil leakage.

Engine Emergency Stop Alarm

The engine emergency stop switch is activated.

Auto-lubrication Warning

Grease is low, or there is a problem with the lubrication system.

If grease is low, refill it.

If it is a problem with the lubrication system, contact your authorized dealer.

Tension Alarm

There is a problem with the tension of the track.

Check around the front idler.

Stop Valve Alarm

The stop valve is closed.

Open the stop valve.

Hydraulic Oil Overheat Alarm

The hydraulic oil temperature has increased abnormally.

Stop work and run the engine in low idle to allow the oil to cool down.

There is a problem with the electrical lever system.

Contact your authorized dealer.

Control Lever Alarm

Pump Contamination Alarm

Remedy Check the hydraulic oil level warning switch.

Check MCU. Check IDU. Check emergency engine stop switches 1 to 5.

Check MCU. Check IDU. Check the key switch.

Check the auto-lubrication mode switch.

Check MCU. Check IDU. Check the auto-lubrication pressure switch.

Check the adjuster cylinder pressure sensor.

Check ELUT. Check IDU. Check the valve limit switch (suction/return).

Check MCU. Check IDU.

Check the hydraulic oil temperature sensor.

Check MCU. Check IDU. Check the electric control lever.

Check the EDQR valve.

Check ELUF. Check ELUT. Check IDU. A contaminant was detected in the drain Check the contamination sensors circuit of the main pump, swivel motor, or (main pumps 1 to 6, swing travel motor. motors, travel motors).

If there is no problem with the sensor, Check CSU. contact your authorized dealer.

Check IDU.

T5-2-10

SECTION 5 TROUBLESHOOTING Group 2 Monitor Display

Contents of Alarms Stairway Position Alarm

Alarm Description The pilot control shut-off lever has been released while the folding stairway position is lowered.

Control Box Open Alarm The electrical equipment box door is open.

Close the door.

Remedy Check the limit switch (for extending/retracting detection).

Check MCU. Check IDU. Check the limit switch (box light switch).

Check MCU. Check IDU.

Fast-filling Indicator Alarm

The pilot control shut-off lever has been released while the fast-filling panel is lowered.

Check the fast filling panel position switch.

Check MCU. Check IDU.

System Alarm

There is a problem with the machine body network system.

Contact your authorized dealer.

Cannot Start Engine Alarm

The pilot control shut-off lever was released while starting the engine.

Lock the pilot control shut-off lever before starting the engine.

Check the CAN wiring.

Check MCU. Check PFU. Check ELUF. Check ELUT. Check IDU. Check the limit switch (pilot control shut-off lever).

Check MCU. Check ELUT. Check IDU. Check the limit switch (pilot control shut-off lever).

Check MCU. Check ELUT. Check IDU. Check the limit switch (cab bed door).

Check HMU. Check IDU. Check the grease tank level sensor.

Check ELUF.

Pilot Control Shut-Off There is a problem with the pilot control Valve Stick Failure Alarm shut-off lever system.

Contact your authorized dealer.

Cab Bed Door Open Alarm

The cab bed entry door is open.

Close the door.

Grease Level Alarm

Check the grease level and refill if necessary.

Alarm Side Bar When the malfunction or alarm occurs, the alarm side bar is lit or blinks.

T5-2-11

SECTION 5 TROUBLESHOOTING Group 2 Monitor Operating Procedures of Service Menu How to display service menu 1. Push MENU/SET switch (4) of key pad (6) on the basic screen and Service Menu is displayed. Turn MENU/SET switch (4) and select the item from Service Menu.  Current Alarms Faults List  System Check  Automatic Snapshot List  Monitor and manual snapshot  Life  Controller Information  Log Data History  Maintenance History  Various Setup  Language Setup

TKEB-05-02-176

2. When pushing previous screen switch (5), the previous screen appears.

3. When pushing basic screen switch (3), the basic screen appears.

1

2

5

3 4

6 TKEB-05-05-003

1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7

TKEB-05-02-080 7-

T5-2-12

Service Menu

SECTION 5 TROUBLESHOOTING Group 2 Monitor Transition Flow of Monitor Screen

TKEB-05-02-081

T5-2-13

SECTION 5 TROUBLESHOOTING Group 2 Monitor Current Alarms Faults List The current alarms faults details are displayed.

1. Turn MENU/SET switch (4) and select Current Alarms Faults List (7). When pushing MENU/SET switch (4), the Current Alarms Faults List screen (8) appears.

1

2

5

3

fNOTE: The information will not be automatically

4

updated on the Current Alarms Faults List screen (8).

When the information is updated, push function key (left) (1).

6 TKEB-05-05-003

1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7

TKEB-05-02-080 7-

Current Alarms Faults List

8

TKEB-05-02-083 8-

T5-2-14

Current Alarms Faults List Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor System Check The communication state between controllers can be checked.

1. Turn MENU/SET switch (4) and select System Check (7). When pushing MENU/SET switch (4), System Check screen (8) appears.

1

2

5

3

6 4

2. When the communication line is abnormal, line (9) including the error location blinks in red.

TKEB-05-05-003

3. When turning MENU/SET switch (4), Controller location screen (10) appears.

1234-

4. Find out the error position by using System Check screen (8) and Controller location screen (10).

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

fNOTE: When error occurs with System Check, the fault code is displayed in Current Alarms Faults List.

7

TKEB-05-02-080 7-

System Check

8

9

10

TKEB-05-02-173

10- Controller Location Screen

TKEB-05-02-172 89-

T5-2-15

System Check Screen Communication Error Position

SECTION 5 TROUBLESHOOTING Group 2 Monitor Automatic Snapshot When IDU receives any alarm information of monitoring items of the recorded automatic snapshot items, IDU automatically records the related monitoring data for 90 seconds before warning and 10 seconds after warning as a snapshot. The snapshot recorded in IDU can be later checked (replayed) by using key pad (6).

1

2

5

3 4

6

1. Turn MENU/SET switch (4) and select Automatic Snapshot List (7). When pushing MENU/SET switch (4), Automatic Snapshot List screen (8) appears.

TKEB-05-05-003 1234-

2. Turn MENU/SET switch (4) and select the recorded data to be replayed. When pushing MENU/SET switch (4), Automatic Snapshot Replay screen (9) appears.

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

fNOTE: When some recorded data exist, turn MENU/SET switch (4) and the page can be changed.

3. Every time pushing MENU/SET switch (4), the recorded data is repeatedly replayed and stopped replaying. When performing fast forwarding, push function key (right) (2). When performing rewinding, push function key (left) (1).

7

TKEB-05-02-080 7-

Automatic Snapshot List

9 8

TKEB-05-02-084

TKEB-05-02-085

9-

Automatic Snapshot Replay Screen

8-

T5-2-16

Automatic Snapshot List Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor List of Recorded Automatic Snapshot Items Engine related Engine Oil Pressure Low Engine Speed Abnormally High Exhaust Temp Cyl 1 High Exhaust Temp Cyl 2 High Exhaust Temp Cyl 3 High Exhaust Temp Cyl 4 High Exhaust Temp Cyl 5 High Exhaust Temp Cyl 6 High Exhaust Temp Cyl 7 High Exhaust Temp Cyl 8 High Exhaust Temp Cyl 9 High Exhaust Temp Cyl 10 High Exhaust Temp Cyl 11 High Exhaust Temp Cyl 12 High Exhaust Temp Cyl 13 High Exhaust Temp Cyl 14 High Exhaust Temp Cyl 15 High Exhaust Temp Cyl 16 High Coolant Temperature Intake Manifold Temp 1 Abnormally Intake Manifold Temp 2 Abnormally Intake Manifold Temp 3 Abnormally Intake Manifold Temp 4 Abnormally Coolant Level Low Coolant Pressure Low High Fuel Temperature Engine Oil Temperature High Crankcase Pressure High Boost Pressure (Left Bank) Low Boost Pressure (Right Bank) Low Metering Rail Press Abnormally Pump Transmission Oil Level Low

Except Engine related Left Lever (Front/Rear) Abnormally Left Lever (Left/Right) Abnormally Right Lever (Front/Rear) Abnormally Right Lever (Left/Right) Abnormally L-Lever (F/R) Center Signal Fault L-Lever (L/R) Center Signal Fault R-Lever (F/R) Center Signal Fault R-Lever (L/R) Center Signal Fault Travel Pedal (Left) Abnormally Travel Pedal (Right) Abnormally L Travel Pedal Center Signal Fault R Travel Pedal Center Signal Fault Bucket Pedal (Open) Abnormally Bucket Pedal (Close) Abnormally Bucket (Open) Center Signal Fault Bucket (Close) Center Signal Fault Tension Indicator Hydraulic Oil Temperature High Emergency Switch ON

T5-2-17

These four items are only for Loading Shovel.

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitor and manual snapshot IDU receives status information of the components which are used for each control from each controller and displays it on the monitor screen.

The data displayed on the monitor screen is recorded in IDU as a snapshot by using key pad (6). The snapshot recorded in IDU can be later checked (replayed) by using key pad (6).

2

5

3

4

6

1. Turn MENU/SET switch (4) and select Monitor and manual snapshot (7). When pushing MENU/SET switch (4), Monitor and manual snapshot screen (8) appears.

2. Turn MENU/SET switch (4), select the item, and push MENU/SET switch (4).

1

TKEB-05-05-003

1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7

TKEB-05-02-080 7-

Monitor and manual snapshot

8

TKEB-05-02-086 8-

T5-2-18

Monitor and manual snapshot Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitor/Record/Replay IDU receives status information of the components from each controller and performs monitoring/recording/ replaying it.  Monitor The monitoring data is displayed.

1. Turn MENU/SET switch (4) and select Monitor/ Record/ Replay (7). When pushing MENU/SET switch (4), Monitoring item list screen (10) appears.

1

2

5

3

4

6

2. Turn MENU/SET switch (4) and select Monitoring major item (8) to be displayed. When pushing MENU/SET switch (4), the item is selected and Monitoring middle item (9) can be selected.

TKEB-05-05-003

1234-

3. Turn MENU/SET switch (4) and select Monitoring middle item (9) to be displayed. When pushing MENU/SET switch (4), Monitoring screen (11) appears.

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

fNOTE: When pushing function key (right) (2), the data history of each monitoring data is reset to the current data value.

7

fNOTE: When turning MENU/SET switch (4) on

Monitoring screen (11), the page can be changed.

TKEB-05-02-086 7-

12 13

14 15 16

Monitor/Record/Replay

8

9 10

11

TKEB-05-02-087 TKEB-05-02-088

11- Monitoring Screen 12- Monitoring Middle Item 13- Monitoring Minor Item

89-

14- Display Mode 15- Data Sampling Interval 16- Monitoring Data Value

T5-2-19

Monitoring Major Item Monitoring Middle Item

10- Monitoring item list Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor  Record The monitoring data displayed on the monitor screen is recorded in IDU as a snapshot.

1. When pushing function key (left) (1), the monitoring data displayed on Monitoring screen (11) is started recording. When pushing function key (left) (1) again, the monitoring data is stopped recording.

1

2

5

3

2. When pushing previous screen switch (5), the recording is completed and the data is saved.

4

6

 Replay The snapshot recorded in IDU is replayed on Monitoring screen (11).

1. When pushing MENU/SET switch (4) immediately after the recording is completed, the the most recently recorded snapshot is replayed. When pushing MENU/SET switch (4) again, the replaying is stopped.

TKEB-05-05-003

1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

fNOTE: Only the the most recently recorded snapshot

can be replayed. When the other screen is displayed after recording the snapshot, the recorded snapshot of Replay of Monitor and manual snapshot menu is replayed.

12 13

14 15 16

11 TKEB-05-02-088 11- Monitoring Screen 12- Monitoring Middle Item 13- Monitoring Minor Item

T5-2-20

14- Display Mode 15- Data Sampling Interval 16- Monitoring Data Value

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitoring Item List Monitoring Major Item: Engine Monitoring Middle Item Engine Power Output

Monitoring Minor Item Turbine State

Protection/Intake air

Protection/Coolant

Protection/Engine Oil

Protection/Fuel Temperature

Fuel Pump Control

T5-2-21

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Monitoring Data Value ECM Engine Speed Operation (Excluding Travel) Engine Load Factor Atmospheric Pressure Boost Pressure 1 Boost Pressure 2 Air Cleaner Restriction Switch HTC RAD Rear Side Temperature 1 HTC RAD Rear Side Temperature 2 Intake Manifold Temperature LBF Intake Manifold Temperature RBF Air Cleaner Restriction Switch LTC RAD Front Side Temperature Intake Manifold Temperature LBR Intake Manifold Temperature RBR ECM Engine Speed HTC RAD Coolant Temperature (ECM) HTC RAD Coolant Inlet Temperature 1 HTC RAD Coolant Inlet Temperature 2 Coolant Pressure Coolant Level HTC RAD Coolant Outlet Temperature ECM Engine Speed Engine Oil Pressure Engine Oil Temperature PreFilter Pressure Crank Case Pressure ECM Engine Speed Fuel Temperature Ambient Temperature Fuel Temp (Fuel Cooler Outlet) ECM Engine Speed Engine Load Factor Throttle Position Engine Speed Fuel Delivery Pressure Injector Rail Pressure -

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitoring Middle Item

Combustion & Intake

Monitoring Minor Item Engine Speed Control

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Initial Status

Left Bank (Front)

Left Bank (Rear)

Right Bank (Front)

Right Bank (Rear)

T5-2-22

Monitoring Data Value Target Engine Speed Actual Engine Speed Throttle Position Auto-Idle ECM Engine Speed Engine Load Factor Operation (Excluding Travel) Operation (Travel) Engine Speed Atmospheric Pressure Engine Load Factor Intake Manifold Temperature Boost Pressure Air Cleaner Restriction Switch Exhaust Temperature #1 Exhaust Temperature #3 Exhaust Temperature #5 Exhaust Temperature #7 Engine Load Factor Intake Manifold Temperature Boost Pressure Air Cleaner Restriction Switch Exhaust Temperature #9 Exhaust Temperature #11 Exhaust Temperature #13 Exhaust Temperature #15 Engine Load Factor Intake Manifold Temperature Boost Pressure Air Cleaner Restriction Switch Exhaust Temperature #2 Exhaust Temperature #4 Exhaust Temperature #6 Exhaust Temperature #8 Engine Load Factor Intake Manifold Temperature Boost Pressure Air Cleaner Restriction Switch Exhaust Temperature #10 Exhaust Temperature #12 Exhaust Temperature #14 Exhaust Temperature #16

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitoring Middle Item

Monitoring Minor Item Left Bank

Right Bank

Deviation-Left Bank (Front)

Deviation-Left Bank (Rear)

Deviation-Right Bank (Front)

Deviation-Right Bank (Rear)

T5-2-23

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Monitoring Data Value Exhaust Temperature #1 Exhaust Temperature #3 Exhaust Temperature #5 Exhaust Temperature #7 Exhaust Temperature #9 Exhaust Temperature #11 Exhaust Temperature #13 Exhaust Temperature #15 Exhaust Temperature #2 Exhaust Temperature #4 Exhaust Temperature #6 Exhaust Temperature #8 Exhaust Temperature #10 Exhaust Temperature #12 Exhaust Temperature #14 Exhaust Temperature #16 Engine Speed Engine Load Factor Intake Manifold Temperature Boost Pressure Delta Exhaust Temperature #1 Delta Exhaust Temperature #3 Delta Exhaust Temperature #5 Delta Exhaust Temperature #7 Engine Speed Engine Load Factor Intake Manifold Temperature Boost Pressure Delta Exhaust Temperature #9 Delta Exhaust Temperature #11 Delta Exhaust Temperature #13 Delta Exhaust Temperature #15 Engine Speed Engine Load Factor Intake Manifold Temperature Boost Pressure Delta Exhaust Temperature #2 Delta Exhaust Temperature #4 Delta Exhaust Temperature #6 Delta Exhaust Temperature #8 Engine Speed Engine Load Factor Intake Manifold Temperature Boost Pressure Delta Exhaust Temperature #10 Delta Exhaust Temperature #12 Delta Exhaust Temperature #14 Delta Exhaust Temperature #16

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitoring Middle Item Main Pump Control

Monitoring Minor Item Initial Status

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Main Pump #1

Main Pump #2

Main Pump #3

Main Pump #4

Main Pump #5

T5-2-24

Monitoring Data Value Engine Speed Pilot Pump Pressure Operation (Excluding Travel) Engine Load Factor Hydraulic Oil Tank Temperature P/M Oil Temperature Target Displacement Regulated Pump Control Displacement Target Drive Torque Actual Displacement Delivery Pressure Swash Angle Control Pressure Swash Angle Control Target Current Swash Angle Control FB Current Target Displacement Regulated Pump Control Displacement Target Drive Torque Actual Displacement Delivery Pressure Swash Angle Control Pressure Swash Angle Control Target Current Swash Angle Control FB Current Target Displacement Regulated Pump Control Displacement Target Drive Torque Actual Displacement Delivery Pressure Swash Angle Control Pressure Swash Angle Control Target Current Swash Angle Control FB Current Target Displacement Regulated Pump Control Displacement Target Drive Torque Actual Displacement Delivery Pressure Swash Angle Control Pressure Swash Angle Control Target Current Swash Angle Control FB Current Target Displacement Regulated Pump Control Displacement Target Drive Torque Actual Displacement Delivery Pressure Swash Angle Control Pressure Swash Angle Control Target Current Swash Angle Control FB Current

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitoring Middle Item

Monitoring Minor Item Main Pump #6

Main Pump/Torque (#1-#2)

Main Pump/Torque (#3-#4)

Main Pump/Torque (#5-#6)

Main Pump/Torque (Total)

Coolant Heat Balance

HTC Radiator 1

T5-2-25

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Monitoring Data Value Target Displacement Regulated Pump Control Displacement Target Drive Torque Actual Displacement Delivery Pressure Swash Angle Control Pressure Swash Angle Control Target Current Swash Angle Control FB Current Cutoff Torque Decrease #1 Swing Torque Decrease #1 Actual Torque #1 Cutoff Torque Decrease #2 Swing Torque Decrease #2 Actual Torque #2 Cutoff Torque Decrease #3 Swing Torque Decrease #3 Actual Torque #3 Cutoff Torque Decrease #4 Swing Torque Decrease #4 Actual Torque #4 Cutoff Torque Decrease #5 Swing Torque Decrease #5 Actual Torque #5 Cutoff Torque Decrease #6 Swing Torque Decrease #6 Actual Torque #6 Engine Speed Engine Load Factor Target Base Torque S.S Torque Engine Speed Ambient Temperature HTC RAD Rear Side Temperature 1 HTC RAD Rear Side Temperature 2 Engine Load Factor Coolant Pressure -

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitoring Middle Item

Monitoring Minor Item HTC Radiator 2

LTC Radiator

Engine Oil

Pump Transmission

Level/Temperature

Oil Cooler Fan Control Mode

T5-2-26

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Monitoring Data Value Engine Speed Ambient Temperature Engine Load Factor HTC RAD Coolant Temperature (ECM) HTC RAD Coolant Inlet Temperature 1 HTC RAD Coolant Inlet Temperature 2 HTC RAD Coolant Outlet Temperature Engine Speed Ambient Temperature Engine Load Factor LTC RAD Front Side Temperature LTC RAD Coolant Inlet Temperature LTC RAD Coolant Outlet Temperature Engine Speed Ambient Temperature HTC RAD Coolant Temperature (ECM) Engine Load Factor Engine Oil Temperature Engine Speed O/C Front Side Temperature 1 O/C Front Side Temperature 2 Ambient Temperature P/M Oil Level Status P/M Oil Temperature Engine Speed Pilot Pump Pressure Ambient Temperature Hydraulic Oil Tank Temperature Target Current Feed Back Current Fan Control Pressure -

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitoring Middle Item SCR System

Monitoring Minor Item SCR System 1

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

SCR System 2

SCR System 3

T5-2-27

Monitoring Data Value Engine Speed DEF Tank Level DEF Tank Temperature Aftertreatment 1 DEF Tank Heater Engine Load Factor DEF Concentration DEF Property Aftertreatment 2 DEF Tank Heater Engine Speed Aftertreatment 1 Temp (Intake) Aftertreatment 1 Temp (Outlet) Ambient Temperature Aftertreatment 2 Temp (Intake) Aftertreatment 2 Temp (Outlet) Engine Speed Aftertreatment 1 NOx (Intake) Aftertreatment 1 NOx (Outlet) Dosing Quantity Engine Load Factor Aftertreatment 2 NOx (Intake) Aftertreatment 2 NOx (Outlet) -

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitoring Major Item: Common Monitoring Middle Item Hydraulic Oil Heat Balance

Monitoring Minor Item Efficiency Oil Cooler 1

Efficiency Oil Cooler 2

Oil Cooler Fan Pump State

Oil Cooler Fan Control

Control Mode

Performance Statistics

OperationPress (Boom, Arm, Bucket)

OperationPress (Swing, Travel)

T5-2-28

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Monitoring Data Value Hydraulic Oil Tank Temperature O/C Front Side Temperature 1 O/C Front Side Temperature 2 Ambient Temperature O/C Rear Side Temperature 1 O/C Rear Side Temperature 2 Hydraulic Oil Tank Temperature O/C Inlet Oil Temperature 1 O/C Inlet Oil Temperature 2 Ambient Temperature O/C Outlet Oil Temperature 1 O/C Outlet Oil Temperature 2 Engine Speed Engine Load Factor Ambient Temperature Hydraulic Oil Tank Pressure Oil Cooler Fan Pump Drain Pressure Oil Cooler Fan Pump Delivery Pressure Engine Speed Pilot Pump Pressure Hydraulic Oil Tank Temperature Ambient Temperature Target Current Feed Back Current Fan Control Pressure Engine Speed Throttle Position Boom Raise Boom Lower Arm Extend/Roll-In Arm Retract/Roll-Out Bucket Tilt-In/Roll-In Bucket Tilt-Out/Roll-Out Engine Speed Throttle Position Swing (Left) Swing (Right) Travel (Left Forward) Travel (Left Backward) Travel (Right Forward) Travel (Right Backward)

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitoring Middle Item

Monitoring Minor Item OperationTime (Boom Raise, Swing)

OperationTime (Travel)

Boom Operation

Boom Raise

Boom Lower

Boom Lower (Make-Up)

Boom Operation

T5-2-29

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Monitoring Data Value Engine Speed Boom Raise Time Swing (Left) Time Swing (Right) Time Engine Speed Travel (Left Forward) Travel (Left Backward) Travel (Right Forward) Travel (Right Backward) Engine Speed Pilot Pump Pressure Target Operation Pressure Actual Operation Pressure Lever Operation Ratio Target Current Feed Back Current Engine Speed Pilot Pump Pressure Target Operation Pressure Actual Operation Pressure Lever Operation Ratio Target Current Feed Back Current Engine Speed Pilot Pump Pressure Target Make-Up Pressure Actual Make-Up Pressure Lever Operation Ratio Target Current (Make-Up) Feed Back Current (Make-Up) Pilot Pump Pressure Lever Operation Ratio (Raise) Actual Operation Pressure (Raise) Feed Back Current (Raise) Lever Operation Ratio (Lower) Actual Operation Pressure (Lower) Feed Back Current (Lower)

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitoring Middle Item Arm Operation

Monitoring Minor Item Arm Extend/Arm Roll-In

Arm Retract/Arm Roll-Out

Arm Operation

Bucket Operation

Bucket Tilt-In/Bucket Roll-In

Bucket Tilt-Out/Roll-Out

Bucket Operation

T5-2-30

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Monitoring Data Value Engine Speed Pilot Pump Pressure Target Operation Pressure Actual Operation Pressure Lever Operation Ratio Target Current Feed Back Current Engine Speed Pilot Pump Pressure Target Operation Pressure Actual Operation Pressure Lever Operation Ratio Target Current Feed Back Current Pilot Pump Pressure Operation Ratio (Extend/Roll-In) Operation Pressure (Extend/Roll-In) Feed Back Current (Extend/Roll-In) Operation Ratio (Retract/Roll-Out) Operation Pressure (Retract/Roll-Out) Feed Back Current (Retract/Roll-Out) Engine Speed Pilot Pump Pressure Target Operation Pressure Actual Operation Pressure Lever Operation Ratio Target Current Feed Back Current Engine Speed Pilot Pump Pressure Target Operation Pressure Actual Operation Pressure Lever Operation Ratio Target Current Feed Back Current Pilot Pump Pressure Operation Ratio (Tilt-In/Roll-In) Operation Pressure (Tilt-In/Roll-In) Feed Back Current (Tilt-In/Roll-In) Operation Ratio (Tilt-Out/Roll-Out) Operation Pressure (Tilt-Out/Roll-Out) Feed Back Current (Tilt-Out/Roll-Out)

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitoring Middle Item

Monitoring Minor Item Bucket Open (LD only)

Bucket Close (LD only)

Bucket Operation (LD only)

Swing Operation

Swing (Left)

Swing (Right)

Swing Operation

fNOTE: LD: Loading Shovel

T5-2-31

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Monitoring Data Value Engine Speed Pilot Pump Pressure Target Operation Pressure Actual Operation Pressure Lever Operation Ratio Target Current Feed Back Current Engine Speed Pilot Pump Pressure Target Operation Pressure Actual Operation Pressure Lever Operation Ratio Target Current Feed Back Current Pilot Pump Pressure Lever Operation Ratio (Open) Actual Operation Pressure (Open) Feed Back Current (Open) Lever Operation Ratio (Close) Actual Operation Pressure (Close) Feed Back Current (Close) Engine Speed Pilot Pump Pressure Target Operation Pressure Actual Operation Pressure Lever Operation Ratio Target Current Feed Back Current Engine Speed Pilot Pump Pressure Target Operation Pressure Actual Operation Pressure Lever Operation Ratio Target Current Feed Back Current Pilot Pump Pressure Lever Operation Ratio (Left) Actual Operation Pressure (Left) Feed Back Current (Left) Lever Operation Ratio (Right) Actual Operation Pressure (Right) Feed Back Current (Right)

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitoring Middle Item Travel Operation

Monitoring Minor Item Travel (Left Forward)

Travel (Left Backward)

Travel (Right Forward)

Travel (Right Backward)

Trvel Operation (Forward)

Trvel Operation (Backward)

T5-2-32

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Monitoring Data Value Engine Speed Pilot Pump Pressure Target Pressure (Left Forward) Actual Pressure (Left Forward) Lever Ratio (Left Forward) Target Current (Left Forward) Feed Back Current (Left Forward) Engine Speed Pilot Pump Pressure Target Pressure (Left Backward) Actual Pressure (Left Backward) Lever Ratio (Left Backward) Target Current (Left Backward) Feed Back Current (Left Backward) Engine Speed Pilot Pump Pressure Target Pressure (Right Forward) Actual Pressure (Right Forward) Lever Ratio (Right Forward) Target Current (Right Forward) Feed Back Current (Right Forward) Engine Speed Pilot Pump Pressure Target Pressure (Right Backward) Actual Pressure (Right Backward) Lever Ratio (Right Backward) Target Current (Right Backward) Feed Back Current (Right Backward) Pilot Pump Pressure Lever Ratio (Left Forward) Actual Pressure (Left Forward) Feed Back Current (Left Forward) Lever Ratio (Right Forward) Actual Pressure (Right Forward) Feed Back Current (Right Forward) Pilot Pump Pressure Lever Ratio (Left Backward) Actual Pressure (Left Backward) Feed Back Current (Left Backward) Lever Ratio (Right Backward) Actual Pressure (Right Backward) Feed Back Current (Right Backward)

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitoring Middle Item

Pilot Circuit Warm-Up Control

Monitoring Minor Item Motion Alarm

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Solenoid Valve 1

Solenoid Valve 2

Solenoid Valve 3

Auto Lubrication Control

Initial Status

Lubrication Status

T5-2-33

Monitoring Data Value Engine Speed Travel Lever Operation Actual Pressure (Left Forward) Actual Pressure (Left Backward) Motion Alarm Output Actual Pressure (Right Forward) Actual Pressure (Right Backward) Hydraulic Oil Tank Temperature Solenoid Valve Hydraulic Temp Target Current Feed Back Current Ambient Temperature Operation Pilot Pump Pressure Solenoid Valve Outlet Pressure Hydraulic Oil Tank Temperature Solenoid Valve Hydraulic Temp Target Current Feed Back Current Ambient Temperature Operation Pilot Pump Pressure Solenoid Valve Outlet Pressure Hydraulic Oil Tank Temperature Solenoid Valve Hydraulic Temp Target Current Feed Back Current Ambient Temperature Operation Pilot Pump Pressure Solenoid Valve Outlet Pressure Engine Speed Pilot Pump Pressure Mode Switch (A) Mode Switch (B) Interval Setting Switch 1 Interval Setting Switch 2 Interval Setting Switch 3 Lubrication Status Relay Output Pressure Switch Alarm Status -

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitoring Middle Item State of centralized oil supply

Monitoring Minor Item Fast Fill

Wiper Control

Wiper Control

State of Pump / Motor

Initial Status

Main Pump (Drain Pressure)

Oil Cooler Fan Pump State

Swing Motor (#1-#2)

T5-2-34

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Monitoring Data Value Engine Speed Pilot Pump Pressure Panel Position Switch Panel Control Relay Output Fast Fill Warning Fuel Full Lamp Interval Washer Switch Wiper Mode Wiper Relay Output (Low) Wiper Relay Output (Blade Stop) Wiper Relay Output (High) Engine Speed Pilot Pump Pressure Operation (Excluding Travel) Engine Load Factor Drain Pressure Main Pump #1 Drain Pressure Main Pump #2 Drain Pressure Main Pump #3 Drain Pressure Main Pump #4 Drain Pressure Main Pump #5 Drain Pressure Main Pump #6 Hydraulic Oil Tank Pressure Oil Cooler Fan Pump Drain Pressure Oil Cooler Fan Pump Delivery Pressure Swing Motor Inlet Pressure 1 Drain Pressure Swing Motor #1 Drain Pressure Swing Motor #2 Swing Motor Inlet Pressure 2 -

SECTION 5 TROUBLESHOOTING Group 2 Monitor Monitoring Middle Item Tension on Track

Monitoring Minor Item Tension Status

Actual Pressure

Lever Ratio

Front Operating Pressure

Each cylinder pressure state

T5-2-35

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

Monitoring Data Value Engine Speed Travel Operation (Left-Forward) Travel Operation (Left-Backward) Adjust Cylinder Pressure Travel Operation (Right-Forward) Travel Operation (Right-Backward) Engine Speed Pilot Pump Pressure Travel Pressure (Left-Forward) Travel Pressure (Left-Backward) Adjust Cylinder Pressure Travel Pressure (Right-Forward) Travel Pressure (Right-Backward) Engine Speed Pilot Pump Pressure Lever Ratio (Left Forward) Lever Ratio (Left Backward) Adjust Cylinder Pressure Lever Ratio (Right Forward) Lever Ratio (Right Backward) Boom Cylinder Bottom Pressure Boom Cylinder Rod Pressure Arm Cylinder Bottom Pressure Arm Cylinder Rod Pressure Bucket Cylinder Bottom Pressure Bucket Cylinder Rod Pressure -

SECTION 5 TROUBLESHOOTING Group 2 Monitor Replay Select the recorded snapshot in IDU and replay it.

1. Turn MENU/SET switch (4) and select Replay (7).

When pushing MENU/SET switch (4), Recorded Snapshot List screen (8) appears.

2. Turn MENU/SET switch (4) and select the recorded snapshot to be replayed. When pushing MENU/ SET switch (4), Manual Snapshot Replay screen (9) appears.

1

2

5

3

4

6

fNOTE: When some recorded data exist, turn MENU/SET switch (4) and the page can be changed.

3. Every time pushing MENU/SET switch (4), the recorded data is repeatedly replayed and stopped replaying. When performing fast forwarding, push function key (right) (2). When performing rewinding, push function key (left) (1).

TKEB-05-05-003

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Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7

TKEB-05-02-086 7-

10 11

Replay

12

13 8

9 TKEB-05-02-090 9-

Manual Snapshot Replay Screen 10- Monitoring Middle Item

11- Monitoring Minor Item 12- Display Mode 13- Monitoring Data Value

TKEB-05-02-089 8-

T5-2-36

Recorded Snapshot List Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor Initialization of Record Data All manual snapshot data recorded in IDU are deleted.

1. Turn MENU/SET switch (4) and select Initialization of Record Data (7). When pushing MENU/SET switch (4), Confirmation screen (8) for Initialization of Record Data appears and all manual snapshot data recorded in IDU are deleted.

fNOTE: The automatic snapshot data cannot be deleted

1

2

5

3

4

6

by this operation.

TKEB-05-05-003

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Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7

TKEB-05-02-086 7-

Initialization of Record Data

8

TKEB-05-02-091 8-

T5-2-37

Confirmation screen for Initialization of Record Data

SECTION 5 TROUBLESHOOTING Group 2 Monitor Life IDU receives and records cumulative information including engine running hours and machine operating hours, which are recorded by DLU by using Ke-CAN. IDU displays them on the monitor screen.

1. Turn MENU/SET switch (4) and select Life (7) from Service Menu. When pushing MENU/SET switch (4), Life data screen (11) appears.

1

2

5

3

4

6

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Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7

TKEB-05-02-080 7-

Life

8

9

10 11 TKEB-05-02-092 89-

T5-2-38

Machine Information Operation Statistics

10- Histogram 11- Life Data Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor Controller Information IDU displays the controller configuration, the drawing No. and software version of each controller on the monitor display.

1. Turn MENU/SET switch (4) and select Controller Information (7) from Service Menu. When pushing MENU/SET switch (4), Controller Information screen (8) appears.

1

2

5

3

4

6

fNOTE: The items of communication terminal and WIU, which have been set on the option setup screen, are displayed.

TKEB-05-05-003

fNOTE: When Controller Information screen (8)

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appears and communication error is displayed, push function key (left) (1) and re-read the data. Even when communication error is displayed after re-reading the data, check connections related to the controller by using System Check. (Refer to T5-2-5.)

2. When turning MENU/SET switch (4), the page can be changed.

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

The information of IDU font, figure, system, text, and language is displayed here.

7

TKEB-05-02-080 7-

Controller Information

8

TKEB-05-02-093

TKEB-05-02-094 8-

T5-2-39

Controller Information Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor Log Data History The log data (fault history) recorded in DLU is displayed.

The items which can be displayed are 38 items on one page and maximum items are 114 items on 3 pages.

1. Turn MENU/SET switch (4) and select Log Data History (7) from Service Menu. When pushing MENU/SET switch (4), Log Data History screen (8) appears.

1

2

5

3

4

6

2. Turn MENU/SET switch (4) and select the log data to be checked. When pushing MENU/SET switch (4), the fault description is displayed.

TKEB-05-05-003

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Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7 TKEB-05-02-080 7-

Log Data History

8

TKEB-05-02-095 8-

T5-2-40

Log Data History Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor Maintenance History IDU displays the maintenance history of the periodic replacement parts (air filter, engine oil, and hydraulic oil, etc.) and remaining time until the next replacement on the monitor display.

The maintenance record is also controlled here.

1

2

5

3

1. Turn MENU/SET switch (4) and select Maintenance History (7) from Service Menu. When pushing MENU/SET switch (4), Maintenance History list screen (8) appears.

6

4

TKEB-05-05-003

 Information updating after maintenance 1. Turn MENU/SET switch (4) and select the item to be updated from Maintenance History list screen (8).

When pushing MENU/SET switch (4), the item name, current Hour Meter, and Date are displayed. When pushing MENU/SET switch (4) again, current Hour Meter and Date are saved as the new maintenance record.

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Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7 TKEB-05-02-080 7-

Maintenance History

8

9

10

TKEB-05-02-096

TKEB-05-02-097 10- Current Hour Meter and Date

8-

T5-2-41

Maintenance History List Screen

9-

Previous Updating Date, Hour Meter

SECTION 5 TROUBLESHOOTING Group 2 Monitor Various Setup The various setting menu is displayed.

1. Turn MENU/SET switch (4) and select Various Setup (7) from Service Menu. When pushing MENU/SET switch (4), Setting Menu screen (8) appears.

1

2

5

3

Maintenance setup

2. Turn MENU/SET switch (4) and select the item to be changed. When pushing MENU/SET switch (4), the selected item blinks and can be changed.

3. Turn MENU/SET switch (4) and select the number.

When pushing MENU/SET switch (4), Setup is completed.

4

6

1. Turn MENU/SET switch (4) and select Maintenance setup (9) from Setting Menu. When pushing MENU/ SET switch (4), Maintenance Setup List screen (10) appears.

TKEB-05-05-003

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Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

fNOTE: When Maintenance setup is reset to default,

push function key (left) (1). Next, push MENU/SET switch (4).

7

TKEB-05-02-098 7-

Various Setup

9 10

8

TKEB-05-02-099

TKEB-05-02-100 10- Maintenance Setup List Screen

8-

T5-2-42

Setting Menu Screen

9-

Maintenance setup

SECTION 5 TROUBLESHOOTING Group 2 Monitor Time Adjustment 1. Turn MENU/SET switch (4) and select Time Adjustment (7) from Setting Menu. When pushing MENU/SET switch (4), Time Adjustment screen (8) appears.

2. When pushing MENU/SET switch (4), Time Difference (11) blinks and can be changed.

3. Turn MENU/SET switch (4) and select Time Difference (11). When pushing MENU/SET switch (4), time that Time Difference (11) is added to Greenwich Mean Time (9) is set.

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TKEB-05-05-003

fNOTE: Time selected from Local Standard Time (10) is

set when Greenwich Mean Time (9) can not be received

by DLU.

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Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7

TKEB-05-02-099 7-

Time Adjustment

9 10 11

8

TKEB-05-02-101 89-

T5-2-43

Time Adjustment Screen Greenwich Mean Time

10- Local Standard Time 11- Time Difference

SECTION 5 TROUBLESHOOTING Group 2 Monitor Setting Put-out Lights Delay Time 1. Turn MENU/SET switch (4) and select Setting Putout Lights Delay Time (7) from Setting Menu. When pushing MENU/SET switch (4), Setting Put-out Lights Delay Time screen (8) appears.

2. When pushing MENU/SET switch (4), list box (9) is displayed.

3. Turn MENU/SET switch (4) and select Delay Time from list box (9). When pushing select/set switch (4), Delay Time is set.

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6

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Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7

TKEB-05-02-099 7-

Setting Put-out Lights Delay

Time

8

9

TKEB-05-02-102 8-

T5-2-44

Setting Put-out Lights Delay Time Screen

9-

List Box

SECTION 5 TROUBLESHOOTING Group 2 Monitor Language Setup The language on the monitor screen can be changed.

1. Turn MENU/SET switch (4) and select Language Setup (7) from Service Menu. When pushing MENU/ SET switch (4), Language Setup screen (8) appears.

2. Turn MENU/SET switch (4) and select the language.

When pushing MENU/SET switch (4), the language can be changed.

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2

5

3

4

6

TKEB-05-05-003

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Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7 TKEB-05-02-098 7-

Language Setup

8

TKEB-05-02-103 8-

T5-2-45

Language Setup Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor How To Display Setting Menu 2 IMPORTANT: Setting Menu 2 is provided only for service activity. Do not explain this function to your customers.

The following items can be set by using Setting Menu 2.  Autolube Check  IO Monitor  Initialization of Automatic snapshot Data  Electric Lever Adjustment Menu  Pump Adjustment Menu  Communication Terminal Information  Incline Angle Adjustment  Various Setup

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6

TKEB-05-05-003

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1. Push MENU/SET switch (4) of key pad (6) on the basic screen and Service Menu is displayed. Turn MENU/SET switch (4) and select Various Setup (7) from Service Menu.

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

2. Keep pushing function key (left) (1) over 3 seconds with Setting Menu screen (8) shown. After "+" is displayed on the screen upper right area (9), release function key (left) (1).

3. Keep pushing function key (right) (2) over 3 seconds After "+" is changed to "++" on the screen upper right area (9), release function key (right) (2).

7

TKEB-05-02-098 7-

Various Setup

9

8

TKEB-05-02-104 8-

T5-2-46

Setting Menu Screen

9-

Screen Upper Right Area

SECTION 5 TROUBLESHOOTING Group 2 Monitor 4. Keep pushing MENU/SET switch (4) over 3 seconds.

After "++" disappears on the screen upper right area (9), Setting Menu 2 (10) appears.

fNOTE: When pushing basic screen switch (3) on the

Setting Menu 2 (10) screen, the basic screen appears.

When pushing basic screen switch (3) on the hierarchy below Setting Menu 2 (10), the Setting Menu 2 (10) appears.

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2

5

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4

6

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Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

9

10

TKEB-05-02-105 9-

T5-2-47

Screen Upper Right Area

10- Setting Menu 2

SECTION 5 TROUBLESHOOTING Group 2 Monitor Setting Menu 2 Transition Flow of Monitor Screen

TKEE91-05-02-008

T5-2-48

SECTION 5 TROUBLESHOOTING Group 2 Monitor Autolube Check The interval of auto-lubrication mode is forcibly set to 3 minutes.

NOTE: This is not activated at manual lubrication mode. Before this is activated, select auto-lubrication mode.

1. Turn MENU/SET switch (4) and select Autolube Check (7) from Setting Menu 2. When pushing MENU/SET switch (4), Autolube Check screen (8) appears.

f

1

2

5

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6

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Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7

TKEB-05-02-105 7-

Autolube Check

8

TKEB-05-02-106 8-

T5-2-49

Autolube Check Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor IO Monitor The following 5 items of input/output state of each controller can be checked.  POWER The voltage values of main power and each sensor power can be checked.  AI (Analog Input) (AI1/AI2/AI3) The input voltage from the analog sensor can be checked.  DI (Digital Input) (DI1/DI2/DI3) The contact state of switch and relay can be checked.  PWMOUT The state of PWM output current value can be checked.  DO (Digital Output) The state of solenoid output, LED output, and relay output can be checked.

1

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6

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Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

TKEB-05-05-003 Previous Screen Switch Key Pad

7

1. Turn MENU/SET switch (4) and select IO Monitor (7). When pushing MENU/SET switch (4), IO Monitor screen (8) appears.

2. Turn MENU/SET switch (4) and select the controller to be checked. When pushing MENU/SET switch (4), controller state screen (9) appears.

fNOTE: The items are not displayed depending on the

7-

controller.

IO Monitor

TKEB-05-02-105

fNOTE: When turning MENU/SET switch (4), the page can be changed.

fNOTE: When the displayed items are not stable,

8

updating is temporarily stopped by pushing function key (left) (1).

8-

IO Monitor Screen

TKEB-05-02-107

9

9-

T5-2-50

Controller State Screen

TKEB-05-02-108

SECTION 5 TROUBLESHOOTING Group 2 Monitor Initialization of Automatic snapshot Data The automatic snapshot data recorded in IDU is deleted.

IMPORTANT: When initializing, all automatic snapshot data are deleted. The data to be deleted can not be selected.

1. Turn MENU/SET switch (4) and select Initialization of Automatic snapshot Data (7).

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2. When pushing MENU/SET switch (4), Initialization of Automatic snapshot Data screen (8) appears.

3. When pushing MENU/SET switch (4), the automatic snapshot data is initialized.

TKEB-05-05-003

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Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7

TKEB-05-02-105 7-

Initialization of Automatic snapshot Data

3

TKEB-05-02-109 8-

T5-2-51

Initialization of Automatic snapshot Data Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor Electric Lever Adjustment Menu The following 3 items of electric control lever operation can be adjusted.  Parameter Setting The response characteristics is adjusted when the electric control lever is operated.  Cylinder Stroke Control Setup The cylinder stroke control is set to enable/disable.  Angle Adjustment Menu The angles of boom, arm, and bucket are adjusted.

1. Turn MENU/SET switch (4) and select Electric Lever Adjustment Menu (7). When pushing MENU/SET switch (4), Electric Lever Adjustment Menu screen (8) appears.

1

2

5

3

4

6

TKEB-05-05-003

1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

2. Turn MENU/SET switch (4), select the item to be adjusted, and push MENU/SET switch (4).

7

TKEB-05-02-105 7-

Electric Lever Adjustment Menu

8

TKEB-05-02-110 8-

T5-2-52

Electric Lever Adjustment Menu Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor Parameter Setting The following 9 items of electric control lever operation characteristics can be adjusted.

Loading Shovel  Boom raise operation  Boom lower operation  Arm extend operation  Arm retract operation  Bucket tilt-in operation  Bucket tilt-out operation  Swing operation  Travel operation  Bucket open/close operation

1

TKEB-05-02-111

Backhoe

1-

 Boom raise operation  Boom lower operation  Arm Roll-Out operation  Arm Roll-In operation  Bucket Roll-In operation  Bucket Roll-Out operation  Swing operation  Travel operation

Parameter Setting Screen (Loading Shovel)

2

The response characteristics of the electric control lever is changed when each parameter value is changed.

When the value is smaller, the response characteristics is faster. When the value is bigger, the response characteristics is slower.

When the response characteristics to push the electric control lever is changed, change the Rising parameter value. When the response characteristics to return the electric control lever is changed, change the Falling parameter value.

NOTE: The adjustable range of Rising and Falling parameter values is 0.0 to 0.8.

TKEA90-05-02-021 2-

f

T5-2-53

Parameter Setting Screen (Backhoe)

SECTION 5 TROUBLESHOOTING Group 2 Monitor  How to Change Parameter 1. Turn MENU/SET switch (4) and select Parameter Setting (7). When pushing MENU/SET switch (4), Parameter Setting screen (8) appears.

2. Turn MENU/SET switch (4) and set the cursor to the value to be changed. When pushing MENU/SET switch (4), related item (9) blinks.

3. Turn MENU/SET switch (4) and change the value.

When turning it clockwise, the value is bigger. When turning it counterclockwise, the value is smaller.

4. When fixing the value, push MENU/SET switch (4).

Item (9) stops blinking and the value is fixed. When the changed value is reset, push previous screen switch (5). Item (9) stops blinking and the value is reset.

5. Other items can be changed in the same way as step 2 to step 4.

1

2

5

3

4

6

TKEB-05-05-003

1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7

TKEB-05-02-110 7-

8

Parameter Setting

10

9

11

TKEA90-05-02-021

TKEB-05-02-111 8-

Parameter Setting Screen (Loading Shovel)

9-

Item

10- Parameter Setting Screen (Bachhoe)

T5-2-54

11- Item

SECTION 5 TROUBLESHOOTING Group 2 Monitor Cylinder Stroke Control Setup The cylinder stroke control is set to enable/disable.

NOTE: The boom, arm, and bucket cylinders are set together. They cannot be individually set.

1. Turn MENU/SET switch (4) and select Cylinder Stroke Control Setup (7). When pushing MENU/SET switch (4), Cylinder Stroke Control Setup screen (8) appears.

f

1

2

5

3

4

6

2. When pushing MENU/SET switch (4), list box (9) is displayed. Turn MENU/SET switch (4) and select ON (enable) or OFF (disable). When pushing MENU/SET switch (4), the selection is completed.

TKEB-05-05-003 1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7

TKEB-05-02-110 7-

Cylinder Stroke Control Setup

9 8

TKEB-05-02-112

TKEB-05-02-113 9-

List Box

8-

T5-2-55

Cylinder Stroke Control Setup Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor Angle Adjustment Menu ELUF stores each cylinder stroke end position for the cylinder stroke end shock prevention control by using the angle sensor.

IMPORTANT: Adjust the angle sensor in case of the following conditions.  When the machine is delivered  When the front attachment is replaced  When the angle sensors (boom, arm, and bucket) are replaced  When ELUF is replaced 1. Turn MENU/SET switch (4) and select Angle Adjustment Menu (7). When pushing MENU/SET switch (4), Angle Adjustment Menu screen (8) appears.

1

2

5

3

4

6

TKEB-05-05-003 1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7

TKEB-05-02-110 7-

Angle Adjustment Menu

8

TKEB-05-02-114 8-

T5-2-56

Angle Adjustment Menu Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor Boom Angle adjustment The boom cylinder stroke end position is set by using the boom angle sensor.

fNOTE: This is only for boom raise operation. This is

unnecessary for boom lower operation.

1. Turn MENU/SET switch (4) and select Boom Angle adjustment (7) from Angle Adjustment Menu.

When pushing MENU/SET switch (4), Boom Angle adjustment screen (8) appears.

1

2

5

3

4

6

2. Operate the boom until the maximum position of boom raise. Volt (10) is changed according to the operation.

TKEB-05-05-003 1234-

fNOTE: When the cylinder rod reaches the cylinder

stroke end position, Volt (10) becomes equal to Current (11).

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

fNOTE: Boom Angle (9) is the angle value converted

from Volt (10).

3. When the boom is set in the maximum position of boom raise and the cylinder rod reaches the cylinder stroke end position, keep the position until the value is stable.

7

4. When pushing MENU/SET switch (4), Volt (10) is updated as Sampling (12).

IMPORTANT: Volt (10) must be within the following adjustable range before Sampling (12) is updated.

When the error message is displayed, check the boom angle sensor or adjust the cylinder rod length.

5. When pushing MENU/SET switch (4) again, Sampling (12) is updated as Current (11).

Adjustable Range of Boom Angle Sensor Set Voltage Loading Shovel 3.36±0.28 V Backhoe 3.77±0.28 V

TKEB-05-02-114 7-

Boom Angle adjustment

8

9 10 11 12

TKEB-05-02-115 8-

Boom Angle adjustment Screen 9- Angle (Calculated Boom Angle Value) 10- Voltage (Measurement Value of Output Voltage from Boom Angle Sensor)

T5-2-57

11- Current (Set Value of Output Voltage from Boom Angle Sensor) 12- Sampling (Updated Value of Output Voltage from Boom Angle Sensor)

SECTION 5 TROUBLESHOOTING Group 2 Monitor Arm Angle adjustment The arm cylinder stroke end position is set by using the arm angle sensor.

1. Turn MENU/SET switch (4) and select Arm Angle adjustment (7) from Angle Adjustment Menu.

When pushing MENU/SET switch (4), Arm Angle adjustment screen (8) appears.

2. Operate the arm until the maximum position of arm extend. Volt (10) is changed according to the operation.

1

2

5

3

4

6

TKEB-05-05-003

fNOTE: When the cylinder rod reaches the cylinder

stroke end position, Volt (10) becomes equal to Current (11).

fNOTE: Arm Angle (9) is the angle value converted from

Volt (10).

3. When the arm is set in the maximum position of arm extend and the cylinder rod reaches the cylinder stroke end position, keep the position until the value is stable.

1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

7

4. When pushing MENU/SET switch (4), Volt (10) is updated as Sampling (12).

IMPORTANT: Volt (10) must be within the following adjustable range before Sampling (12) is updated.

When the error message is displayed, check the arm angle sensor or adjust the cylinder rod length.

5. When pushing MENU/SET switch (4) again, Sampling (12) is set as Current (11). Then, adjust Arm Retract.

TKEB-05-02-114 7-

Adjustable Range of Arm Angle Sensor Set Voltage Loading Shovel Arm Extend 1.61±0.28 V Arm Retract 3.67±0.28 V Backhoe Arm Roll-Out 4.01±0.28 V Arm Roll-In 1.07±0.28 V

Previous Screen Switch Key Pad

Arm Angle adjustment

8

9 10 11 12

6. Before adjusting Arm Retract, operate the arm until the maximum position of arm retract in the same way as step 1 to step 5.

TKEB-05-02-116 8-

Arm Angle adjustment Screen 9- Angle (Calculated Arm Angle Value) 10- Voltage (Measurement Value of Output Voltage from Arm Angle Sensor)

T5-2-58

11- Current (Set Value of Output Voltage from Arm Angle Sensor) 12- Sampling (Updated Value of Output Voltage from Arm Angle Sensor)

SECTION 5 TROUBLESHOOTING Group 2 Monitor Bucket Angle adjustment The bucket cylinder stroke end position is set by using the bucket angle sensor.

1. Turn MENU/SET switch (4) and select Bucket Angle adjustment (7) from Angle Adjustment Menu.

When pushing MENU/SET switch (4), Bucket Angle adjustment screen (8) appears.

2. Operate the bucket until the maximum position of bucket tilt-in. Volt (10) is changed according to the operation.

1

2

5

3

4

6

TKEB-05-05-003

fNOTE: When the cylinder rod reaches the cylinder

stroke end position, Volt (10) becomes equal to Current (11).

fNOTE: Angle (9) is the angle value converted from Volt

(10).

3. When the bucket is set in the maximum position of bucket tilt-in and the cylinder rod reaches the cylinder stroke end position, keep the position until the value is stable.

1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

4. When pushing MENU/SET switch (4), Volt (10) is updated as Sampling (12).

Previous Screen Switch Key Pad

7

IMPORTANT: Volt (10) must be within the following adjustable range before Sampling (12) is updated.

When the error message is displayed, check the bucket angle sensor or adjust the cylinder rod length.

5. When pushing MENU/SET switch (4) again, Sampling (12) is set as Current (11). Then, adjust Bucket Tilt-Out.

TKEB-05-02-114 7-

Adjustable Range of Bucket Angle Sensor Set Voltage Loading Shovel Bucket Tilt-In 4.08±0.28 V Bucket Tilt-Out 0.78±0.28 V Backhoe Bucket Roll-In 4.11±0.28 V Bucket Roll-Out 0.88±0.28 V

Bucket Angle adjustment

8

9 10 11 12

6. Before adjusting Bucket Tilt-Out, operate the bucket until the maximum position of bucket tilt-out in the same way as step 1 to step 5.

TKEB-05-02-117 8-

Bucket Angle adjustment Screen 9- Angle (Calculated Bucket Angle Value) 10- Voltage (Measurement Value of Output Voltage from Bucket Angle Sensor)

T5-2-59

11- Current (Set Value of Output Voltage from Bucket Angle Sensor) 12- Sampling (Updated Value of Output Voltage from Bucket Angle Sensor)

SECTION 5 TROUBLESHOOTING Group 2 Monitor Boom Angle Adjustment Screen (Backhoe)

Bucket Angle Adjustment Screen (Backhoe)

11

1 2 3

12 13

4

14 15

5

TKEA90-05-02-022

123-

Boom Angle adjustment Screen Angle (Calculated Boom Angle Value) Voltage (Measurement Value of Output Voltage from Boom Angle Sensor)

4-

5-

Current (Set Value of Output Voltage from Boom Angle Sensor) Sampling (Updated Value of Output Voltage from Boom Angle Sensor)

TKEA90-05-02-024

11- Bucket Angle adjustment Screen 12- Angle (Calculated Bucket Angle Value) 13- Voltage (Measurement Value of Output Voltage from Bucket Angle Sensor)

Arm Angle Adjustment Screen (Backhoe) 6 7 8 9 10

TKEA90-05-02-023 678-

Arm Angle adjustment Screen Angle (Calculated Arm Angle Value) Voltage (Measurement Value of Output Voltage from Arm Angle Sensor)

9-

Current (Set Value of Output Voltage from Arm Angle Sensor) 10- Sampling (Updated Value of Output Voltage from Arm Angle Sensor)

T5-2-60

14- Current (Set Value of Output Voltage from Bucket Angle Sensor) 15- Sampling (Updated Value of Output Voltage from Bucket Angle Sensor)

SECTION 5 TROUBLESHOOTING Group 2 Monitor Pump Adjustment Menu The following 2 items of main pump operation can be adjusted.

1

2

 Pump Learning  Pump Characteristic Setting

5

3

1. Turn MENU/SET switch (4) and select Pump Adjustment Menu (7). When pushing MENU/SET switch (4), Pump Adjustment Menu screen (8) appears.

6

4

TKEB-05-05-003 1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7

TKEB-05-02-105 7-

Pump Adjustment Menu

8

TKEB-05-02-118 8-

T5-2-61

Pump Adjustment Menu Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor Pump Learning IMPORTANT: There are individual differences for delivery flow rate on each main pump. If the pump learning is not performed, the machine performance may not be enough to output.

When the swash plate angle sensors are installed in the main pumps in order to improve the main pump control.

When the following work has been performed, perform the pump learning.  When the main pumps and the main pump regulators have been replaced  When the solenoid valves for main pump control have been replaced  When the swash plate angle sensors of main pumps have been replaced  When PFU has been replaced

1

2

5

3

4

6

TKEB-05-05-003 1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

IMPORTANT: Set the pilot control shut-off lever to the LOCK position before performing the pump learning.

1. Turn MENU/SET switch (4) and select Pump Learning (7). When pushing MENU/SET switch (4), Pump Learning screen (8) appears.

56-

Previous Screen Switch Key Pad

7

2. When there is the pump which has not performed the pump learning, turn MENU/SET switch (4) and select the corresponding pump. When pushing function key (left) (1), the checkmarks are removed.

TKEB-05-02-118 7-

Pump Learning

8

8-

T5-2-62

Pump Learning Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor 3. When pushing MENU/SET switch (4), Pump Learning Conditions screen (9) appears. Check if pilot control shut-off lever state (10), engine speed (11), hydraulic oil temperature (12) meet the following conditions.

9 10

 Pilot control shut-off lever: LOCK position  Engine speed: Fast idle  Hydraulic oil temperature: 50±5 °C

11 12

IMPORTANT: Do not touch the pilot control shut-off lever and electric control lever while performing the pump learning.

4. After checking that Pump Learning Conditions are met, push MENU/SET switch (4). Then, the pump learning starts.

5. When the pump learning is completed, Result (13) is displayed. When the pump learning has failed, error code (14) is displayed. Refer to Pump Learning Error Code and Remedy on the next page.

TKEB-05-02-120 9-

Pump Learning Conditions Screen 10- Pilot Control Shut-Off Lever State

11- Engine Speed 12- Hydraulic Oil Temperature:

13

14

TKEB-05-02-119 13- Result

T5-2-63

14- Error Code

SECTION 5 TROUBLESHOOTING Group 2 Monitor Pump Learning Error Code and Remedy Code

Failure reason

Instruction

0x01 0x02 0x03

Inspect the wire harness.

Inspect the wire harness.

Inspect the wire harness.

0x04

Communication Error (KeCAN) PFU-ELUF Communication Error (KeCAN) PFU-MCU Communication Error (KeCAN) PFU-IDU (TX) PFU Sensor 5V Output Error

0x05

Regulator Pressure Sensor Error

0x06

Solenoid Valve FB Current Error

0x07

Pump Swash Plate Angle Sensor Error

0x08

Pressure of regulator is out of normal range.

Pressure of regulator cannot be correction.

Pump swash plate angle sensor signal is out of normal range.

Pump swash plate angle sensor signal is not stable.

Pump swash plate angle sensor signal cannot be correction.

0x09 0x0A 0x0B 0x0C

Inspect the wire harness and sensors on the failure pump.

Inspect all pressure sensors, swash plate angle sensors, and wire harness on the failure pump.

Inspect the Solenoid valve and wire harness on the failure pump.

Inspect the swash plate angle sensor and wire harness on the failure pump.

Inspect the Pressure sensor and Solenoid valve on the failure pump.

Inspect the Pressure sensor and Solenoid valve on the failure pump.

Inspection the installation of Pump swash plate angle sensor on the failure pump. See next page.

Inspection the installation of Pump swash plate angle sensor on the failure pump. See next page.

Inspection the Pressure sensor and Solenoid valve on the failure pump.

T5-2-64

SECTION 5 TROUBLESHOOTING Group 2 Monitor Inspection of Pump Swash Plate Angle Sensor When the pump learning has failed and error code (12) for the pump swash plate angle sensor is displayed, check the installation of the pump swash plate angle sensor.

After checking that the pump swash plate angle sensor is correctly installed, check if output voltage is within the specification.  Check installation of the pump swash plate angle sensor 1. Remove socket bolts (2) and washers (3) (2 used for each). Remove the pump swash plate angle sensor (1) from the pump which the pump learning has failed.

1

2, 3

TKEB-05-02-043

l : 5 mm 2. Check that plate spring (5) is installed at the end of feedback shaft (4).

1-

Pump Swash Plate Angle Sensor

23-

Socket Bolt Washer

3. Check that matching mark (6) at the end of the pump swash plate angle sensor (1) faces opposite the sensor harness.

4 5

4. Insert the end of the pump swash plate angle sensor (1) into plate spring (5). Temporarily install the pump swash plate angle sensor (1) with socket bolts (2) and washers (3) (2 used for each).

A 6

5. Fully turn the pump swash plate angle sensor (1) clockwise. Tighten socket bolts (2). l : 5 mm

Section A

m : 10 N·m (7.4 lbf·ft)  Check output voltage from the pump swash plate angle sensor (1) 1. Select Setting Menu 2, IO Monitor, and PFU MONITOR in sequence. Check AI1/AI2 (Analog Input). (Refer to T5-2-50.)

TKEB-05-02-044 45-

Feedback Shaft Plate Spring

2. Check that the following values are within the specification.

Output Voltage from Pump Swash Plate Angle Sensor Monitor Item Voltage Pump 1: AN_IN 2 3.75±0.2 V Pump 2: AN_IN 5 3.75±0.2 V Pump 3: AN_IN 8 3.75±0.2 V Pump 4: AN_IN 11 3.75±0.2 V Pump 5: AN_IN 14 3.75±0.2 V Pump 6: AN_IN 17 3.75±0.2 V

6-

Matching Mark

12 7 8 9 10 11

3. When the values are out of the specification, replace the swash plate angle sensor (1) of the corresponding pump.

7-

4. Perform the pump learning again.

8-

TKEB-05-02-121

9-

T5-2-65

Output Voltage from Pump 1 Swash Plate Angle Sensor Output Voltage from Pump 2 Swash Plate Angle Sensor Output Voltage from Pump 3 Swash Plate Angle Sensor

10- Output Voltage from Pump 4 Swash Plate Angle Sensor 11- Output Voltage from Pump 5 Swash Plate Angle Sensor 12- Output Voltage from Pump 6 Swash Plate Angle Sensor

SECTION 5 TROUBLESHOOTING Group 2 Monitor Pump Characteristic Setting When the pump learning has failed, temporarily reset the value to the default (pump characteristic default in designing).  Change pump characteristic 1. Turn MENU/SET switch (4), select the pump to be changed, and push MENU/SET switch (4).

2. Turn MENU/SET switch (4) in list box (9), select the characteristic value, and push MENU/SET switch (4).

1

2

5

3

4

6

fNOTE: When changing pump characteristic values

TKEB-05-05-003

together, push function key (left) (1) and display Sub Menu (10). Turn MENU/SET switch (4), select the characteristic value, and push MENU/SET switch (4).

Then, all pump characteristic values are changed together.

1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

7

Previous Screen Switch Key Pad

8

TKEB-05-02-122 7-

10- Sub Menu

Success Date

8-

Characteristic (Current)

10

9

TKEB-05-02-124

TKEB-05-02-123 9-

T5-2-66

List Box

SECTION 5 TROUBLESHOOTING Group 2 Monitor Communication Terminal Information The operation state of communication terminal (satellite communication terminal or mobile communication terminal) can be checked.

1. Turn MENU/SET switch (4) and select Communication Terminal Information (7). When pushing MENU/SET switch (4), Communication Terminal Information screen (8) appears.

1

2

5

3

4

6

List of Operation State When connecting the satellite communication terminal Item Displayed Value Condition Signal strength 0 Not available 1 Available Disconnected Handheld Device Unused Antenna Signal Communication Module Condition GPRS Connecting Condition

TKEB-05-05-003 1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

* As the items except for Signal strength are only for the mobile communication terminal, "-" is displayed.

When connecting the mobile communication terminal Item Displayed Condition Value Signal strength 250 Out of service 0 Weak signal 1  2  3 Strong signal 254 Undetectable Disconnected Handheld Device 0 to 1 Out of service Antenna Signal 2 to 8 Weak signal 9 to 12  13 to 17  18 to 31 Strong signal 99 Undetectable Disconnected Communication 0 Normal Module Condition 1 Abnormal Disconnected GPRS Connecting 0 Failure Condition 1 Success Disconnected

7

TKEB-05-02-105 7-

Communication Terminal Information

8

TKEB-05-02-125 8-

T5-2-67

Communication Terminal Information Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor Incline Angle Adjustment The forward and back leveling position and right and left leveling position of the machine are set by the incline angle sensor.

1. Turn MENU/SET switch (4) and select Incline Angle Adjustment (7). When pushing MENU/SET switch (4), Incline Angle Adjustment screen (8) appears.

2. When pushing MENU/SET switch (4), the items of Adjustment 1 (9) blink. Swing the upperstructure to the front idler side. After the values are stable, push MENU/SET switch (4). The items of Adjustment 1 (9) are fixed. Then, adjust Adjustment 2 (10).

3. Swing the upperstructure to the travel motor side.

After the values are stable, push MENU/SET switch (4). The items of Adjustment 2 (10) are fixed.

1

2

5

3

4

6

TKEB-05-05-003 1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7

TKEB-05-02-105 7-

Incline Angle Adjustment

9

10

8

TKEB-05-02-127

TKEB-05-02-126 8-

T5-2-68

Incline Angle Adjustment Screen

9- Adjustment 1 10- Adjustment 2

SECTION 5 TROUBLESHOOTING Group 2 Monitor Various Setup The following 4 items can be set.  Controlled Parameter Setup  Option Setup  Unit Setup  Setting Serviceman mode setup

1

2

5

3

1. Turn MENU/SET switch (4) and select Various Setup (7). When pushing MENU/SET switch (4), Setting Menu screen (8) appears.

6

2. Turn MENU/SET switch (4), select the item to be set, and push MENU/SET switch (4).

4

TKEB-05-05-003 1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7

TKEB-05-02-105 7-

Various Setup

8

8-

T5-2-69

Setting Menu Screen

TKEA90-05-02-025

SECTION 5 TROUBLESHOOTING Group 2 Monitor Controlled Parameter Setup The relief flow rate decrease control and swing high pressure decrease horsepower control are set to enable/ disable.

1. Turn MENU/SET switch (4) and select Controlled Parameter Setup (7). When pushing MENU/SET switch (4), Controlled Parameter Setup screen (8) appears.

2

5

3

4

6

2. Turn MENU/SET switch (4) and select the item to be set. When pushing MENU/SET switch (4), list box (9) is displayed.

3. Select ON (enable) or OFF (disable) from list box (9).

When pushing MENU/SET switch (4), the control state is updated.

1

TKEB-05-05-003 1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7

TKEA90-05-02-025 7-

Controlled Parameter Setup

8

9

TKEB-05-02-129

TKEB-05-02-130 9-

List Box

8-

T5-2-70

Controlled Parameter Setup Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor Precision Mode Precision Mode is set to enable/disable.

1. Turn MENU/SET switch (4) and select Precision Mode Setup (7). When pushing MENU/SET switch (4), Precision Mode Setup screen (8) appears.

1

2

5

3

2. When pushing MENU/SET switch (4), list box (9) is displayed.

4

6

3. Select ON (enable) or OFF (disable) from list box (9).

When pushing MENU/SET switch (4), the control state is updated.

TKEB-05-05-003 1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

7

TKEA90-05-02-025 7-

Controlled Parameter Setup

8

9

TKEA90-05-02-029

TKEA90-05-02-030 9-

List Box

8-

T5-2-71

Precision Mode Setup Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor Option Setup The items of WIU and communication terminal of Option Setup can be set.

IMPORTANT: In case the delivered machine is equipped with WIU and communication terminal, the setting has been set when delivered. In case they are installed after delivered, perform this.

When performing this correctly, the correct judgement is impossible by using System Check.

1

2

5

3

4

6

1. Turn MENU/SET switch (4) and select Option Setup (7). When pushing MENU/SET switch (4), Option Setup screen (8) appears.

TKEB-05-05-003

2. Turn MENU/SET switch (4) and select the item to be set. When pushing MENU/SET switch (4), list box (9) is displayed.

1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

3. Select either of the displayed items from list box (9).  WIU: Off/On  Communication terminal: Off/ Satellite/ Mobile 4. When pushing MENU/SET switch (4), Setup is fixed.

7

TKEA90-05-02-025 7-

Option Setup

9 8

TKEB-05-02-131

TKEB-05-02-132 9-

List Box

8-

T5-2-72

Option Setup Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor Unit Setup The unit of the values which are displayed on the basic screen can be changed.

IMPORTANT: This is enable only for the values on the basic screen. This is not enable for the snapshot screen.

1. Turn MENU/SET switch (4) and select Unit Setup (7). When pushing MENU/SET switch (4), Unit Setup screen (8) appears.

2. Turn MENU/SET switch (4) and select the item to be set. When pushing MENU/SET switch (4), list box (9) is displayed.

3. Select either of the displayed items from list box (9).  Temperature: degree C/degree F  Pressure: Pa/PSI  Clock: 24 hour/12 hour 4. When pushing MENU/SET switch (4), Setup is fixed.

1

2

5

3

4

6

TKEB-05-05-003 1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Key Pad

fNOTE: When Unit Setup is reset to default, push

function key (right) (2). Next, push function key (left) (1).

Default Temperature Pressure Clock

7

Degree C Pa 24 hour

TKEA90-05-02-025 7-

Unit Setup

8

9

TKEB-05-02-133 8TKEB-05-02-134 9-

List Box

T5-2-73

Unit Setup Screen

SECTION 5 TROUBLESHOOTING Group 2 Monitor Setting Serviceman mode setup The following items can be set.  Sampling(s): Sampling Interval The sampling interval of each monitoring item can be changed on the manual snapshot screen.

For the item such as pressure and current, which is rapidly changed, make the sampling interval short.

For the item such as temperature, which is slowly changed, make the sampling interval long.

For the manual snapshot, the sampling numbers at one time have been determined. The shorter the sampling interval is, the shorter total time recorded at the snapshot at one time is.  Message change interval When some fault messages are displayed on the basic screen, the displayed time for one message can be set.  Numerical display setting The digital value can be displayed near each analog meter on the basic screen.  Buzzer forcible stop setting The buzzer can be temporarily set to disable.

IMPORTANT: Set the buzzer forcible stop setting only when the buzzer is temporarily stopped at the maintenance. when setting the key switch to the OFF position, this setting is cleared.

T5-2-74

SECTION 5 TROUBLESHOOTING Group 2 Monitor 1. Turn MENU/SET switch (4) and select Setting Serviceman mode setup (7). When pushing MENU/ SET switch (4), Setting Serviceman mode setup screen (8) appears.

2. Turn MENU/SET switch (4) and select the item to be set. When pushing MENU/SET switch (4), list box (9) is displayed.

3. Turn MENU/SET switch (4), select the item to be set from list box (9), and push MENU/SET switch (4).

When the setting is fixed, push function key (left) (1).  Manual snapshot Sampling: 0.1 to 3.0 seconds  Meter screen Message change interval time(s): 1 ~ 10 Numerical display (ON/OFF): ON/OFF  Buzzer Control Buzzer forcible stop (ON/OFF): ON/OFF

1

2

5

3

4

6

1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

TKEB-05-05-003 Previous Screen Switch Key Pad

4. Set all items in the same way.

7

fNOTE: The buzzer forcible stop setting is not saved.

Therefore, the operation of function key (left) (1) is unnecessary.

Default Sampling (sec) Message change interval time (sec) Numerical display (ON/OFF) Buzzer forcible stop (ON/OFF)

1.0 3 OFF OFF

7-

Setting Serviceman mode setup

TKEA90-05-02-025

8

8-

Setting Serviceman mode setup Screen

TKEB-05-02-135

9

9-

T5-2-75

List Box

TKEB-05-02-136

SECTION 5 TROUBLESHOOTING Group 2 Monitor Time Adjustment 1

2

Input Local Standard Time and Time Difference, then set Greenwich Mean Time in DLU.

5

3

1. Turn MENU/SET switch (4) and select Time Adjustment (7) from Setting Menu. When pushing MENU/SET switch (4), Time Adjustment screen (8) appears.

6

2. Turn MENU/SET switch (4) and select Local Standard Time(10). When pushing MENU/SET switch (4), selected item blinks and can be changed.

3. Turn MENU/SET switch (4) and select the value, then push MENU/SET switch (4). Appear Key Guidance(12) which has not displaied.

1234-

Function Key (Left) Function Key (Right) Basic Screen Switch MENU/SET Switch

4

56-

TKEB-05-05-003 Previous Screen Switch Key Pad

4. Turn MENU/SET switch (4) and select Time Difference(11). When pushing MENU/SET switch (4), Time Difference(11) blinks and can be changed.

5. Turn MENU/SET switch (4) and select the value, then push MENU/SET switch (4).

6. When pushing Function Key (Left)(1), Greenwich Mean Time(9) is set as the value which Local Standard Time(10) minus Time Difference (11). And, Time Difference(11) is also set.

7

fNOTE: When communication error is happening

between IDU and DLU as Time Adjustment Screen(13), Greenwich Mean Time(14) in IDU cannot be set even if input both Local Standard Time(10) and Time Difference(11).

TKEA90-05-02-025 7-

13

Time Adjustment

8

14 9

10

11 12 TKEA90-05-02-032 13- Time Adjustment Screen (When communication error is happening)

14- Greenwich Mean Time (When communication error is happening)

TKEA90-05-02-031 8- Time Adjustment Screen 9- Greenwich Mean Time 10- Local Standard Time

T5-2-76

11- Time Difference 12- Key Guidance

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table IMPORTANT: The No. indicates the component number in the circuit diagram.

The position indicates the component’s position in the circuit diagram.

The number at left side is horizontal lines of drawing frame, the alphabet at right side is vertical lines of drawing frame.

Refer to the page and item number in the following group.

Electrical Circuit Diagram (1/12) (Cab) No.

Position Component Name

Page

001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030

5B 5B 6B 9B 9H 9I 9J 10K 15B 12H 18B 19A 22A 24A 22D 20D 18D 16H 17H 23D 23D 22D 22D 23F 23G 22G 22F 21F 24D 25D

T5-4-4 T5-4-7 T5-4-7 T5-4-7 T5-4-8 T5-4-8 T5-4-8 T5-4-8 T5-4-7 T5-4-8 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-8 T5-4-8 T5-4-8 T5-4-7 T5-4-7 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-6

Entrance Light (For Rear of Cab) Dome Light (Rear) Dome Light (Front) ELUF DC-DC Converter 1 DC-DC Converter 2 Power Source Terminal Data Link Connector (For ECM) ELUT Fuse Box (Cab 1,Cab 2) Radio Air Conditioner Controller (Right) Air Conditioner Controller (Left) Air Conditioner Controller (Rear) Cigar Lighter DLU WIU (Option) Satellite Communication Terminal (Option) Mobile Communication Terminal (Option) Day/Night Mode Switch Fast Filling Switch Maintenance Mode Switch Option Switch 4 Work Light Switch Maintenance Light Switch Buzzer Stop Switch Option Switch 3 Option Switch 1 Warning Light (Red) Caution Light (Yellow)

T5-3-1

Item Note Number 3 3 2 4 9 8 1 7 5 2,3 19 16 17 18 4 13 12 7 7 20 23 22 39 26 24 21 38 36 11 12

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table No.

Position Component Name

Page

031 032 033

25E 25G 25H 25I 25H 27A 30B 30D 26E 26F 27G 28G 26H 27H 27H 28H 26J 27J 27J 28J 30H 30H 32H 32I 29I 29J 29K

T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-8 T5-4-6 T5-4-8 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-7 T5-4-4 T5-4-4 T5-4-4 T5-4-6 T5-4-6

034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 049 050 051 052 053 054 055 056

Key Pad Electric Control Lever (Left) Horn Switch (Left) Horn Switch (Right) Electric Control Lever (Right) IDU Main Monitor Buzzer Wiper/Washer Switch Wiper Interval Switch Electric Control Lever (Bucket Open/Close) Electric Control Lever (Travel) Key Switch Option Switch 2 Travel Mode Switch Engine Stop Switch Entrance Light Switch Dome Light Switch Auto-idle Switch Engine Start Switch Hour Meter Wiper Motor Work Light (Upper Front of Cab)(Left) Work Light (Upper Front of Cab)(Right) Lock Lever Switch Emergency Engine Stop Switch Engine Control Dial

fNOTE: LD: Loading Shovel

T5-3-2

Item Note Number 15 5 5 9 9 10 1 11 13 14 6,8 LD 7 32 37 34 33 25 31 30 29 1 2 1 1 28 27

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table Electrical Circuit Diagram (2/12) (Control Box (1)) No.

Position Component Name

Page

001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030

10A 10D 10G 10I 12C 13D 16B 12E 20B 20B 20C 20C 20D 20D 20E 20E 20F 20F 20G 20G 20H 18H 18H 19I 19I 18J 17K 17L 16L 21I

T5-4-11 T5-4-11 T5-4-11 T5-4-11 T5-4-11 T5-4-11 T5-4-11 T5-4-11 T5-4-12 T5-4-12 T5-4-12 T5-4-12 T5-4-12 T5-4-12 T5-4-12 T5-4-12 T5-4-12 T5-4-12 T5-4-12 T5-4-12 T5-4-12 T5-4-12 T5-4-12 T5-4-12 T5-4-12 T5-4-12 T5-4-12 T5-4-12 T5-4-12 T5-4-12

Fuse Box 1 (#1 to 20) Fuse Box 2 (#21 to 40) Fuse Box 3 (#41 to 60) Fuse Box 4 (#61 to 80) Limit Switch (Electrical Equipment Box Door) Electrical Equipment Box Light MCU Auto-Lubrication Interval Switch Work Light Relay (1) Work Light Relay (2) Work Light Relay (3) Work Light Relay (4) Work Light Relay (5) Work Light Relay (6) Entrance Light Relay Maintenance Light Relay (1) Maintenance Light Relay (2) Maintenance Light Relay (3) Maintenance Light Relay (4) (Unused) Alternator Signal Relay 1 Engine Oil Reserve Tank Pump Unit Relay Engine Oil Reserve Tank Filling System Relay (1) Engine Oil Reserve Tank Filling System Relay (2) Grease Tank Level Signal Relay (1) Grease Tank Level Signal Relay (2) Grease Tank Filling System Relay Cab Bed Pressurization Blower Motor Relay (1) Cab Bed Pressurization Blower Motor Relay (2) Cab Bed Pressurization Relay Folding Stairway Alarm/Flash Light Relay (1)

T5-3-3

Item Note Number 2 1 4 3 13 14 10 5 10 11 12 13 14 15 16 17 18 19 20 21 39 44 45 46 47 48 8 9 49 40

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table No.

Position Component Name

031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 049 050

21I 21J 21J 21K 21L 27B 25B 27B 25C 26C 26C 25D 24D 25E 26F 26F 26G 26G 27G 26H

051 052

26I 26J

053 054 055 056 057

26J 25K 26K 27K 26K

Page

Fast Filling Panel Position Relay T5-4-12 Delayed Power OFF Relay T5-4-12 Travel Mode Relay T5-4-12 Fast Filling Relay T5-4-12 Folding Stairway Alarm/Flash Light Relay (2) T5-4-12 Horn Air Compressor Relay (L1) T5-4-12 Horn Air Compressor Relay (L2) T5-4-12 Horn Air Compressor Relay (R1) T5-4-12 Horn Air Compressor Relay (R2) T5-4-12 Horn Relay T5-4-12 Wiper Relay (1) T5-4-12 Wiper Relay (2) T5-4-12 Prelube Signal Relay T5-4-12 Wiper Relay (3) T5-4-12 Washer Motor Relay T5-4-12 Air Conditioner Main Relay (Right) T5-4-12 Air Conditioner Main Relay (Left) T5-4-12 Air Conditioner Main Relay (Rear) T5-4-12 Engine Start Cancellation Relay T5-4-12 Air Conditioner Condenser Fan Motor Relay T5-4-12 (Right) Air Conditioner Condenser Fan Motor Relay (Left) T5-4-12 Air Conditioner Condenser Fan Motor Relay T5-4-12 (Rear) ELU Pilot Control Shut-Off Solenoid Valve Relay T5-4-12 ELU PWM Power Relay (1) T5-4-12 ELU PWM Power Relay (2) T5-4-12 ELU PWM Power Relay (3) T5-4-12 Folding Stairway Relay 1 T5-4-12

T5-3-4

Item Note Number 22 23 24 25 41 1 26 2 27 28 3 29 42 4 30 5 6 7 43 31 32 33 34 35 36 37 38

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table Electrical Circuit Diagram (3/12) (Control Box (2)) No.

Position Component Name

001 002 003 004 005 006 007 008 009 010

6B 4C 5C 5C 8B 8B 8C 6D 6D 6E

011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027

6E 8E 7F 4H 5H 7K 17B 24D 20I 21I 21I 21I 21K 21K 21J 19K 19K

Page

Maintenance Light (Cab Bed) T5-4-4 Limit Switch (Cab Bed Door) T5-4-9 Cab Bed Pressurization Blower Motor (1) T5-4-1 Cab Bed Pressurization Blower Motor (2) T5-4-1 Ambient Air Temperature Sensor 1 T5-4-5 Entrance Light (For Left Fender) T5-4-4 Horn (Left) T5-4-5 Work Light (Upper Left Side of Left Bed) (Option) Work Light (Front Side of Cab Bed) T5-4-4 Work Light (Upper Right Side of Left Bed) (Option) Work Light (Front Side of Cab Bed) T5-4-4 Condenser (With Receiver-Dryer) T5-4-4 Ambient Air Pressure Sensor (For Air Conditioner) Compressor (For Air Conditioner) T5-4-1 Air Conditioner Pressure Switch Air Conditioner Unit T5-4-4 HMU T5-4-11 CSU T5-4-11 Lamp Check Switch T5-4-11 Engine Maintenance Lamp (Left) T5-4-11 Engine Warning Lamp (Left) T5-4-11 Engine Stop Lamp (Left) T5-4-11 Engine Maintenance Lamp (Right) T5-4-11 Engine Warning Lamp (Right) T5-4-11 Engine Stop Lamp (Right) T5-4-11 Engine Diagnostic Switch T5-4-11 Fault Code INC / DEC Switch T5-4-11

T5-3-5

Item Note Number 6 6 30 30 1 35 3 36 36 33 29 38 11 12 7 6 6 6 6 6 6 8 9

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table Electrical Circuit Diagram (4/12) (Frame (1)) No.

Position Component Name

001 002 003

3E 5E 5E

004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030

5F 6F 6D 6E 6F 7D 7E 9D 9E 9F 8F 10F 11E 10F 11G 11G 15D 15E 15F 17G 19A 20C 20D 20D 20E 22D 22D

Page

Folding Stairway Alarm/Flash Light T5-4-36 Limit Switch 2 (For Extending Stroke End Control) T5-4-36 Limit Switch 3 (For Retracting Stroke End T5-4-36 Control) Limit Switch 5 (Pilot Shut-Off Lever) T5-4-36 Limit Switch 4 (For Retracting Detection) T5-4-36 Folding Stairway Relay 4 T5-4-36 Folding Stairway Solenoid Valve 1 T5-4-38 Folding Stairway Solenoid Valve 3 T5-4-38 Folding Stairway Solenoid Valve 2 T5-4-38 Limit Switch 1 (For Extending Detection) T5-4-36 Folding Stairway Relay 2 T5-4-36 Folding Stairway Relay 3 T5-4-36 Work Light (For Folding Stairway) T5-4-36 Folding Stairway Pump T5-4-36 Emergency Folding Stairway Stop Switch T5-4-37 Retract Switch T5-4-37 Extend Switch T5-4-37 Isolation Switch (For Folding Stairway Pump 1) T5-4-37 Isolation Switch (For Folding Stairway Pump 2) T5-4-37 Motion Alarm (Left) T5-4-4 Isolation Switch (Battery Circuit) T5-4-9 Isolation Switch (Starter Circuit) T5-4-9 Battery T5-4-9 Fuse Box (DEF) T5-4-10 Dosing Module Relay 1 T5-4-10 Dosing Module Relay 2 T5-4-10 DEF Line Heater Relay 1 T5-4-10 DEF Line Heater Relay 2 T5-4-10 Battery Relay 1 T5-4-10 Battery Relay 2 T5-4-10

T5-3-6

Item Note Number 11 5 6 12 7 3 11 6 13 4 1 2 10 8 3 1 2 6 5 31 4 5 2 28 27 26 25 24 1 2

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table No.

Position Component Name

Page

031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048 049 050 051

23E 22E 22F 23F 24D 24D 25C 26C 26E 26E 26F 26G 26G 27G 27G 27G 27H 27H 26H 26H 26H

T5-4-10 T5-4-10 T5-4-10 T5-4-10 T5-4-10 T5-4-10 T5-4-10 T5-4-10 T5-4-10 T5-4-10 T5-4-10 T5-4-10 T5-4-10 T5-4-10 T5-4-10 T5-4-10 T5-4-10 T5-4-10 T5-4-10 T5-4-10 T5-4-10

Battery Relay 3 Fuse (400A) (For Prelube Relay) Prelube Relay Fuse (200A) (For Alternator) Fuse (250A) (For Folding Stairway Pump 1) Fuse (250A) (For Folding Stairway Pump 2) Engine Protection Relay Alternator Signal Relay 2 Prelube Control Relay Starter Relay (Upper) Starter Relay (Lower) Slow Blow Fuse 1 (75A) Slow Blow Fuse 2 (75A) Slow Blow Fuse 3 (75A) Slow Blow Fuse 4 (75A) Slow Blow Fuse 5 (75A) Slow Blow Fuse 6 (75A) Slow Blow Fuse 7 (45A) Slow Blow Fuse 8 (75A) Slow Blow Fuse 9 (45A) Slow Blow Fuse 10 (75A)

T5-3-7

Item Note Number 3 4 5 6 20 21 23 22 7 8 9 10 11 12 13 14 15 16 17 18 19

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table Electrical Circuit Diagram (5/12) (Frame (2)) No.

Position Component Name

Page

001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021

3B 3B 3C 3E 3E 2F 3F 2F 2G 3F 4H 3I 3I 3I 3I 3J 3J 3K 7C 7D 10C

Work Light (Left Side of Right Bed) Work Light (Right Side of Right Bed) Horn (Right) (Option) Boom Angle Sensor Auto-Lubrication Solenoid Valve Grease Tank Level Sensor (Upper) Grease Tank Level Sensor (Middle) Grease Tank Level Sensor (Lower) Pressure Switch (For Auto Lubrication) Auto-Lubrication Mode Switch Pressure Sensor (For Hydraulic Oil Tank) Air Bleeding Solenoid Valve Hydraulic Oil Level Check Switch Hydraulic Oil Level Warning Switch Hydraulic Oil Temperature Sensor Valve Limit Switch (Suction) Work Light (Right Side of Center Frame) (Option) Motion Alarm (Right) Bucket Angle Sensor Arm Angle Sensor Boom Lower Make-Up Solenoid Valve

022 023

10C 10D

Unused Valve Warmer Solenoid Valve (3)

024

9D

025

9D

026

10E

027 028 029 030 031 032

7F 7F 7G 7G 7G 7H

Pilot Pressure Sensor (Boom Lower Make-Up Solenoid Valve) Pilot Pressure Sensor (Valve Warmer Solenoid Valve (3)) Valve Warmer Solenoid Valve Temperature Sensor Drain Pressure Sensor (Front Swing Motor) Contamination Sensor (Front Swing Motor) Swing Motor Inlet Pressure Sensor (Front) Swing Motor Inlet Pressure Sensor (Rear) Pressure Sensor (For Adjuster Cylinder End) Contamination Sensor (Travel Motor)

T5-4-4 T5-4-4 T5-4-17, 18 T5-4-39 T5-4-39 T5-4-39 T5-4-39 T5-4-39 T5-4-39 T5-4-40 T5-4-40 T5-4-40 T5-4-40 T5-4-40 T5-4-40 T5-4-4 T5-4-17, 18 T5-4-17, 18 T5-4-2 T5-4-3 T5-4-2 T5-4-2 T5-4-3 T5-4-2 T5-4-3 T5-4-2 T5-4-3 T5-4-2 T5-4-3 T5-4-31 T5-4-14 T5-4-31 T5-4-31 T5-4-33 T5-4-14

T5-3-8

Item Note Number 7 7 1 8 9 8 7 3 6 4 1 2 3 5 6 20 3 2 10 8 10 10 8 10 8 10 8 10 8 2 8 5 5 5 9

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table No.

Position Component Name

Page

033 034 035 036 037 038 039 040 041 042 043 044 045 046

7H 7I 10H 10I 10I 10I 10J 10J 13I 13J 14I 14J 14J 11K

T5-4-31 T5-4-14 T5-4-28 T5-4-28 T5-4-28 T5-4-28 T5-4-28 T5-4-28 T5-4-33 T5-4-33 T5-4-33 T5-4-33 T5-4-33 T5-4-32

Drain Pressure Sensor (Rear Swing Motor) Contamination Sensor (Rear Swing Motor) Pressure Sensor (Bucket Cylinder Rod Side) Pressure Sensor (Boom Cylinder Bottom Side) Pressure Sensor (Boom Cylinder Rod Side) Pressure Sensor (Arm Cylinder Rod Side) Pressure Sensor (Arm Cylinder Bottom Side) Pressure Sensor (Bucket Cylinder Bottom Side) Swing Angular Position Switch 3 Swing Angular Position Switch 2 Swing Angular Position Switch 4 Swing Angular Position Switch 1 Swing Angular Position Switch 5 Swing Angular Rate Sensor 2 (Undercarriage)

T5-3-9

Item Note Number 2 7 6 4 5 3 2 1 6 6 6 6 6 4

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table Electrical Circuit Diagram (7/12) (Frame (4)) No.

Position Component Name

Page

1 2 3 4

2D 2E 3E 3F

T5-4-41 T5-4-41 T5-4-41 -

Item Note Number 1 2 3 -

5

2F

-

-

6

3G

-

-

7

3G

-

-

8

1H

T5-4-34

5

9 10 11 12 13 14

1I 2I 1J 1J 10D 10D

T5-4-35 T5-4-35 T5-4-29 T5-4-30

1 2 9 1

S7

15 16

10D 10E

T5-4-30 T5-4-30

2 3

S6 S5

17 18

10E 10E

T5-4-30 T5-4-30

4 5

S4 S3

19

10E

T5-4-30

6

S2

20 21

10F 10F

T5-4-30 T5-4-30

7 8

S1 SH

22

10G

T5-4-30

9

23 24

10G 10G

T5-4-30 T5-4-30

10 11

25 26

10H 10H

T5-4-30 T5-4-30

12 13

27

10H

T5-4-30

14

28 29 30

10H 10I 10K

T5-4-30 T5-4-30 T5-4-30

15 16 33

Fuel Level Switch (High) Fuel Level Switch (Low) Fuel Level Sensor Engine Oil Reserve Tank Filling System Control Switch (Option) Engine Oil Reserve Tank Filling System Power Switch (Option) Engine Oil Reserve Tank Fill Warning Light (Option) Engine Oil Reserve Tank Shut-Off Valve Open Indicator Light (Option) Fast-Filling Panel Raise/Lower Solenoid Valve (Fast Filling System) Fuel Full Warning Light Grease Tank Fill Warning Light DEF Fill Hose Heater 1 DEF Receiver Heater EDQR Valve (Left) Pilot Pressure Sensor (LD: Bucket Tilt-In / BH: Bucket Roll-In) Pilot Pressure Sensor (Boom Raise) Pilot Pressure Sensor (LD: Bucket Tilt-Out / BH: Bucket Roll-Out) Pilot Pressure Sensor (Boom Lower) Pilot Pressure Sensor (LD: Arm Retract / BH: Arm Roll-Out) Pilot Pressure Sensor (LD: Arm Extend / BH: Arm Roll-In) Pilot Pressure Sensor (Left Travel Forward) Pilot Pressure Sensor (Valve Warmer Solenoid Valve 1) LD: Bucket Tilt-In Solenoid Valve BH: Bucket Roll-In Solenoid Valve Boom Raise Solenoid Valve LD: Bucket Tilt-Out Solenoid Valve BH: Bucket Roll-Out Solenoid Valve Boom Lower Solenoid Valve LD: Arm Retract Solenoid Valve BH: Arm Roll-Out Solenoid Valve LD: Arm Extend Solenoid Valve BH: Arm Roll-In Solenoid Valve Left Travel Forward Solenoid Valve Valve Warmer Solenoid Valve 1 Valve Warmer Solenoid Valve Temperature Sensor 1

T5-3-10

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table No.

Position Component Name

Page

031 032 033 034

15D 15D 15D 15E

035 036

15E 15E

037 038 039

15E 15F 15F

040 041 042 043 044 045 046 047 048 049 050

15G 15G 15G 15H 15H 15H 15H 15I 15J 15K 15K

051

15K

EDQR Valve (Right) Pilot Pressure Sensor (Left Travel Reverse) Pilot Pressure Sensor (Right Travel Forward) Pilot Pressure Sensor (LD: Bucket Open / BH: Unused) Pilot Pressure Sensor (Right Travel Reverse) Pilot Pressure Sensor (LD: Bucket Close / BH: Unused) Pilot Pressure Sensor (Swing Left) Pilot Pressure Sensor (Swing Right) Pilot Pressure Sensor (Valve Warmer Solenoid Valve 2) Left Travel Reverse Solenoid Valve Right Travel Forward Solenoid Valve LD: Bucket Open Solenoid Valve / BH: Unused Right Travel Reverse Solenoid Valve LD: Bucket Close Solenoid Valve / BH: Unused Swing Left Solenoid Valve Swing Right Solenoid Valve Valve Warmer Solenoid Valve 2 Travel Mode Selector Solenoid Valve Pilot Control Shut-Off Solenoid Valve Pressure Sensor (Pilot Control Shut-Off Solenoid Valve) Valve Warmer Solenoid Valve Temperature Sensor 2

T5-3-11

Note

T5-4-29 T5-4-30 T5-4-30 T5-4-30

Item Number 10 17 18 19

T5-4-30 T5-4-30

20 21

S4 S3

T5-4-30 T5-4-30 T5-4-30

22 23 24

S2 S1 SH

T5-4-30 T5-4-30 T5-4-30 T5-4-30 T5-4-30 T5-4-30 T5-4-30 T5-4-30 T5-4-29 T5-4-29 T5-4-29

25 26 27 28 29 30 31 32 5 6 8

T5-4-30

34

S7 S6 S5

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table Electrical Circuit Diagram (8/12) (Frame (5)) No.

Position Component Name

Page

001 002 003 004 005 006 007 008 009

6E 6E 6F 6F 6G 6G 11B 16B 21B

T5-4-16 T5-4-16 T5-4-16 T5-4-16 T5-4-16 T5-4-16 T5-4-16 T5-4-16 T5-4-16

DEF Fill Hose Heater Relay DEF Fill Line Heater Relay DEF Fill Line Heater Signal Relay DEF Piping In-Line Filter Heater Relay DEF Receiver Heater Relay DEF Shut-Off Valve Heater Relay EHU PMU PFU

T5-3-12

Item Note Number 5 6 4 9 8 7 3 1 2

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table Electrical Circuit Diagram (9/12) (Frame (6)) No.

Position Component Name

Page

001

1I

T5-4-24

Item Note Number 15

002

1J

T5-4-24

14

003

1K

T5-4-24

22

004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030

5D 5D 5D 5E 5F 5F 5F 6I 6I 6I 6J 5K 5K 10D 10D 10D 10E 10F 10F 10I 10I 10I 10J 10K 10K 16D 16E

T5-4-24 T5-4-23 T5-4-14 T5-4-24 T5-4-24 T5-4-23 T5-4-24 T5-4-24 T5-4-24 T5-4-14 T5-4-24 T5-4-23 T5-4-23 T5-4-24 T5-4-23 T5-4-14 T5-4-24 T5-4-23 T5-4-24 T5-4-24 T5-4-24 T5-4-14 T5-4-24 T5-4-23 T5-4-23 T5-4-14 T5-4-24

1 9 1 2 7 11 3 6 5 2 4 10 12 8 9 3 9 11 10 13 12 4 11 10 12 5 17

Regulator Pressure Sensor (Oil Cooler Fan Motor Drive Pump) Delivery Pressure Sensor (Oil Cooler Fan Motor Drive Pump) Control Solenoid Valve (Oil Cooler Fan Motor Drive Pump) Drain Pressure Sensor (Main Pump 1) Swash Plate Angle Sensor (Main Pump 1) Contamination Sensor (Main Pump 1) Delivery Pressure Sensor (Main Pump 1) Pump Transmission Oil Level Switch Control Solenoid Valve (Main Pump 1) Regulator Pressure Sensor (Main Pump 1) Regulator Pressure Sensor (Main Pump 2) Delivery Pressure Sensor (Main Pump 2) Contamination Sensor (Main Pump 2) Drain Pressure Sensor (Main Pump 2) Swash Plate Angle Sensor (Main Pump 2) Control Solenoid Valve (Main Pump 2) Drain Pressure Sensor (Main Pump 3) Swash Plate Angle Sensor (Main Pump 3) Contamination Sensor (Main Pump 3) Delivery Pressure Sensor (Main Pump 3) Control Solenoid Valve (Main Pump 3) Regulator Pressure Sensor (Main Pump 3) Regulator Pressure Sensor (Main Pump 4) Delivery Pressure Sensor (Main Pump 4) Contamination Sensor (Main Pump 4) Drain Pressure Sensor (Main Pump 4) Swash Plate Angle Sensor (Main Pump 4) Control Solenoid Valve (Main Pump 4) Contamination Sensor (Main Pump 5) Delivery Pressure Sensor (Main Pump 5)

T5-3-13

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table No.

Position Component Name

Page

031 032 033 034 035 036 037 038 039 040 041 042 043 044

15E 15E 15F 15F 16I 16J 15J 15J 15K 15K 22B 22C 22C 22C

T5-4-24 T5-4-23 T5-4-23 T5-4-24 T5-4-24 T5-4-24 T5-4-14 T5-4-24 T5-4-23 T5-4-23 T5-4-22 T5-4-4 T5-4-22 T5-4-22

Item Note Number 16 9 11 18 21 20 6 19 10 12 2 18 13 14

045 046 047

22D 22D 22D

T5-4-22 T5-4-22 T5-4-22

8 9 15

048

22E

T5-4-22

10

049

22E

T5-4-22

1

050

22E

T5-4-22

5

051 052 053

25B 25B 26B

T5-4-4 T5-4-4 T5-4-4

19 19 17

054

26B

T5-4-4

14

055 056 057

25C 25C 25C

T5-4-4 T5-4-22 T5-4-22

15 12 11

Drain Pressure Sensor (Main Pump 5) Swash Plate Angle Sensor (Main Pump 5) Control Solenoid Valve (Main Pump 5) Regulator Pressure Sensor (Main Pump 5) Regulator Pressure Sensor (Main Pump 6) Delivery Pressure Sensor (Main Pump 6) Contamination Sensor (Main Pump 6) Drain Pressure Sensor (Main Pump 6) Swash Plate Angle Sensor (Main Pump 6) Control Solenoid Valve (Main Pump 6) Oil Cooler Front Air Temperature Sensor 1 Work light (Rear of Oil Cooler) Pump Transmission Oil Temperature Sensor Pump Transmission Oil Cooler Outlet Oil Temperature Sensor Oil Cooler Rear Air Temperature Sensor 1 Oil Cooler Rear Air Temperature Sensor 2 Oil Cooler Inlet Hydraulic Oil Temperature Sensor 1 Oil Cooler Inlet Hydraulic Oil Temperature Sensor 2 Oil Cooler Outlet Hydraulic Oil Temperature Sensor 1 Oil Cooler Outlet Hydraulic Oil Temperature Sensor 2 Valve Limit Switch (Return 2) Valve Limit Switch (Return 1) Emergency Engine Stop Switch 4 (Engine Room Rear) Emergency Engine Stop Switch 5 (Engine Room Front) Maintenance Light (Pump Compartment) Fuel Cooler Inlet Fuel Temperature Sensor Fuel Cooler Outlet Fuel Temperature Sensor

T5-3-14

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table Electrical Circuit Diagram (10/12) (Frame (7)) No.

Position Component Name

001 002 003 004 005 006 007 008 009 010 011 012 013 014 015

2B 2C 2C 2C 2C 2D 2D 1E 1E 1E 1F 1F 1G 1G 1H

016

1H

017 018 019 020 021 022 023 024 025 026 027 028 029

1I 1I 2I 2I 2J 2K 3K 3K 5D 5J 5K 4K 10B

Page

HTC Radiator Rear Air Temperature Sensor 1 T5-4-21 HTC Radiator Rear Air Temperature Sensor 2 T5-4-21 LTC Radiator Inlet Coolant Temperature Sensor T5-4-21 LTC Radiator Outlet Coolant Temperature Sensor T5-4-21 HTC Radiator Inlet Coolant Temperature Sensor 1 T5-4-21 HTC Radiator Inlet Coolant Temperature Sensor 2 T5-4-21 HTC Radiator Outlet Coolant Temperature Sensor T5-4-21 LTC Radiator Front Air Temperature Sensor T5-4-21 Work Light (Left Side of Radiator) T5-4-4 Work Light (Rear of Radiator) T5-4-4 Coolant Level Sensor T5-4-21 Coolant Level Check Switch 1 T5-4-21 Coolant Level Check Switch 2 T5-4-21 Ether Solenoid Valve Emergency Engine Stop Switch 2 (Engine Room T5-4-4 Front) Emergency Engine Stop Switch 3 (Engine Room T5-4-4 Rear) Maintenance Light 1 (Engine Compartment) T5-4-4 Maintenance Light 2 (Engine Compartment) T5-4-4 Air Cleaner Restriction Switch 1 T5-4-20 Air Cleaner Restriction Switch 2 T5-4-20 Prelube Motor T5-4-19 Alternator T5-4-19 Starter 1 (Upper) T5-4-19 Starter 2 (Lower) T5-4-19 ECM (Cummins) (Left) T5-4-19 Engine Speed Sensor T5-4-19 Engine Oil Level Sensor T5-4-19 Prelube Pressure Switch T5-4-19 Fuel Lift Pump Solenoid Valve -

T5-3-15

Item Note Number 14 13 12 8 10 11 7 6 26 22 5 9 4 27 21 13 16 2 2 6 12 7 7 4 1 10 2 -

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table No.

Position Component Name

Page

030 031 032 033 034 035 036 037

15E 16J 15J 15J 15K 15K 22B 22C

T5-4-4 T5-4-34

Water In Fuel Sensor DEF Fill Hose Heater 2 DEF Fill Hose Heater 3 DEF Fill Pipe Heater 1 DEF Fill Pipe Heater 2 DEF Shut-Off Valve Heater Motion Alarm (Rear) Fast Filling Panel Position Switch

T5-3-16

Item Note Number 24 6

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table Electrical Circuit Diagram (11/12) (Frame (8)) No.

Position Component Name

Page

001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022

3B 3B 3C 3C 3D 3D 3D 3E 3E 3E 3F 3F 3F 3G 1G 7B 7B 7C 7D 7D 7E 11F

T5-4-42 T5-4-42 T5-4-42 T5-4-42 T5-4-42 T5-4-43 T5-4-43 T5-4-43 T5-4-43 T5-4-43 T5-4-43 T5-4-19

DEF Piping In-Line Filter Heater 1 DEF Piping In-Line Filter Heater 2 DEF Supply Module Coolant Valve DEF Supply Module 1 DEF Tank Coolant Valve DEF Supply Module 2 DEF Line Heater 1-1-1 (Suction 1) DEF Line Heater 1-1-2 (Suction 2) DEF Line Heater 1-2 (Pressure) DEF Line Heater 2-1-1 (Suction 1) DEF Line Heater 2-1-2 (Suction 2) DEF Line Heater 2-2 (Pressure) DEF Line Heater 1-3 (Return) DEF Line Heater 2-3 (Return) DEF Sensor Unit NOx Sensor ECU (Outlet) 1 SCR Inlet/Outlet Temperature Sensor ECU 1 NOx Sensor ECU (Outlet) 2 SCR Inlet/Outlet Temperature Sensor ECU 2 Dosing Module 1 Dosing Module 2 ECM (Cummins) (Right)

T5-3-17

Item Note Number 4 7 3 8 1 1 2 3 4 6 5 4

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table Electrical Circuit Diagram (12/12) (Control Box (3)) No.

Position Component Name

Page

001 002 003 004 005 006 007

4B 3D 3D 3E 8B 13B 18B

T5-4-15 T5-4-15 T5-4-15 T5-4-15 T5-4-15 T5-4-15 T5-4-15

Fuse Box (Monitoring) (#1 to 10) Body Tilt Sensor 1 (Pitch) Body Tilt Sensor 2 (Roll) Swing Angular Rate Sensor 1 (Upper Structure) ODR BPU (Option) FMU (Option)

T5-3-18

Item Note Number 7 5 6 4 1 3 2

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table Hydraulic Circuit Diagram (Loading Shovel) No.

Position Component Name

Page

001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021

3A 3A 4A 4B 4C 3C 3C 3C 3C 4C 4C 5D 3D 2D 2E 2E 2E 2F 2F 2F 2F

T5-4-29 T5-4-29 T5-4-29 T5-4-29 T5-4-29 T5-4-29 T5-4-34 T5-4-34 T5-4-34 T5-4-34 T5-4-29 T5-4-29 T5-4-1 T5-4-1 T5-4-23 T5-4-25 T5-4-25 T5-4-25 T5-4-25 T5-4-25 T5-4-23

Item Note Number 1 9 10 3 6 7 5 2 3 1 5 4 15 32 6 1 2 3 4 5 5

022 023 024 025 026 027 028 029 030

2E 3F 3E 3F 4E 4F 5E 2G 2G

T5-4-23 T5-4-23 T5-4-23 T5-4-23 T5-4-23 T5-4-23 T5-4-1 T5-4-23 T5-4-23

3 3 1 1 2 2 8 8 7

Accumulator (For Pilot Pressure) EDQR Valve (Left) EDQR Valve (Right) Boom Raise Priority Selector Valve Pilot Control Shut-Off Solenoid Valve Check Valve (For Pilot Pressure) Fast-Filling Panel Raise/Lower Solenoid Valve Check Valve Slow Return Valve Lift Cylinder Travel Mode Selector Solenoid Valve Reducing Valve (For Travel Mode Control) Engine Pump Transmission Pump Transmission Oil Filter 4-Unit Pump Oil Cooler Fan Motor Drive Pump Pilot Pump Air Conditioner Compressor Motor Pump Pump Transmission Oil Pump Bypass Check Valve (For Pump Transmission Oil Pump) Main Pump 5 Main Pump 6 Main Pump 1 Main Pump 2 Main Pump 3 Main Pump 4 High-Pressure Strainer Pilot Filter Pilot Relief Valve

T5-3-19

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table No.

Position Component Name

Page

031 032 033 034 035 036 037

4H 4G 4G 4H 6G 5H 5D

T5-4-22 T5-4-1 T5-4-22 T5-4-22 T5-4-1 T5-4-29

Item Note Number 3 12 4,7 6 7 2

038 039 040 041 042 043 044 045 046 047 048 049 050 051 052 053 054 055 056 057 058 059 060

6A 6C 6E 6G 6G 7G 8G 7A 7A 8A 7B 8B 10B 7B 9B 9C 7E 8E 8E 8E 9E 9E 7F

T5-4-26 T5-4-26 T5-4-26 T5-4-1 T5-4-40 T5-4-1 T5-4-36 T5-4-36 T5-4-36 T5-4-1 T5-4-33 T5-4-33 T5-4-32 T5-4-31 T5-4-32 T5-4-32 T5-4-32 T5-4-32 T5-4-31 T5-4-33

5 1 4 8 9 13 28 2 1 1 1 7 3 6 8 1 2

Pump Transmission Oil Cooler Oil Cooler Fan Motor Oil Cooler Fuel Cooler Oil Cooler ByPass Check Valve Bypass Filter Relief Valve (Air Conditioner Compressor Motor Pump) Control Valve (Left) Control Valve (Center) Control Valve (Right) Bypass Check Valve Hydraulic Oil Tank Air Bleeding Solenoid Valve Auto-Lubrication Device Folding Stairway Pump Valve Unit (For Folding Stairway) Folding Stairway Cylinder Check Valve Stop Valve Compressor Motor Travel Motor (Left) Travel Brake Valve (Left) Adjuster Cylinder (Left) Swing Motor (Rear) Center Joint Pilot Pressure Control Valve (For Travel Stop) Relief Valve Accumulator (For Adjuster Cylinder) Swing Motor (Front) Travel Motor (Right)

T5-3-20

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table No.

Position Component Name

Page

061 062 063 064 065 066 067 068 069 070 071 072 073 074

9G Travel Brake Valve (Right) 9F Adjuster Cylinder (Right) 10A ELU 11A Electric Control Lever (Left) 11A Electric Control Lever (Travel) 11B Electric Control Lever (Right) 11B Electric Control Lever (Bucket Open/Close) 12C,12F Boom Cylinder 12C,12E Bucket Cylinder 12D Arm Cylinder 12D,12E Dump Cylinder 12E Level Cylinder 10F Make-Up Valve (For Boom) 11F Solenoid Valve

T5-4-33 T5-4-32 T5-4-7 T5-4-6 T5-4-6 T5-4-6 T5-4-6 T5-4-2 T5-4-2 T5-4-2 T5-4-2 T5-4-2 T5-4-2 T5-4-2

fNOTE: LD: Loading Shovel

T5-3-21

Item Note Number 1 1 4,5 5 7 9 6,8 LD 8 3 1 4 2 9 10

SECTION 5 TROUBLESHOOTING Group 3 Cross Reference Table (Blank)

T5-3-22

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Main Component (Overview) 1

2 3

4

5

6

7

8

9

10 11 31 30 29 28 12 13

14 32 27 26

15 16

25 24

1234-

Swing Device (2 Used) Center Joint Fuel Tank Auto-Lubrication Device (Lubricator) 5- Hydraulic Oil Tank 6- Control Valve (3 Used) 7- Bypass Filter 8- High-Pressure Strainer (6 Used) 9- Fuel Cooler 10- Pump Transmission Oil Cooler

111213141516-

23

22

17 21

Oil Cooler (2 Used) Oil Cooler Fan Motor Pump Device DEF Tank Engine Accumulator (For Pilot) (3 Used) 17- Radiator 18- Accumulator (For Adjuster Cylinder) 19- Travel Brake Valve (2 Used)

20

2021222324252627-

T5-4-1

19

18

Travel Device (2 Used) Pilot Pressure Control Valve Relief Valve (For Accumulator) Accumulator (For Adjuster Cylinder) Reducing Valve (For Accumulator) Air Cleaner (For Cab Bed Pressurization) Swing Bearing Adjuster Cylinder (2 Used)

TKEB-01-02-008

28- Compressor Motor 29- Compressor (For Air Conditioner) (3 Used) 30- Blower Motor (For Cab Bed Pressurization) (2 Used) 31- Washer Tank 32- Pump Transmission

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Main Component (Loading Shovel)

7 6

8

5

A

2 1

4

3 TKEB-01-02-010

View A

9

10 TKEB-01-02-007 123-

Arm Cylinder Level Cylinder Bucket Cylinder (2 Used)

456-

Dump Cylinder (2 Used) Bucket Arm

789-

T5-4-2

Boom Boom Cylinder (2 Used) Make-Up Valve

10- Solenoid Valve

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Main Component (Backhoe) 4

5

3

6

2 1

A

TKBA-01-02-004

12-

Bucket Arm

34-

Bucket Cylinder Arm Cylinder

5-

Boom Cylinder (2 Used)

6-

Boom

View A

7

8 78-

Make-Up Valve Solenoid Valve

T5-4-3

TKEA90-01-02-002

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Electrical System (Overview) 1

2

3

4

5

6

7

8

9

10

11

12

13 14

15 16 17

18

38

37 36

35

19 20 21 22

34 33

23 32

31

24

30

25

29 28

1-

Work Light (Upper Front of Cab) (2 Used) 2- Wiper Motor 3- Entrance Light (For Rear of Cab) 4- Controller Box (Monitoring) 5- Electrical Equipment Box 6- Maintenance Light (Cab Bed) 7- Work Light (Front Side of Right Fender) (2 Used) 8- Air Bleeding Solenoid Valve 9- Hydraulic Oil Level Check Switch 10- Hydraulic Oil Level Warning Switch

27

TKEB-01-02-009

26

11- Valve Limit Switch (Suction) 12- Hydraulic Oil Temperature Sensor 13- Maintenance Light 1 (Engine Compartment) 14- Emergency Engine Stop Switch 5 15- Maintenance Light (Pump Compartment) 16- Maintenance Light 2 (Engine Compartment) 17- Emergency Engine Stop Switch 4 18- Work Light (Rear of Oil Cooler)

19- Valve Limit Switch (Return) (2 Used) 20- Motion Alarm (Right) 21- Emergency Engine Stop Switch 3 22- Work Light (Rear of Radiator) 23- Fast Filling Panel Position Switch 24- Motion Alarm (Rear) 25- Fast-Filling Panel Raise/Lower Solenoid Valve 26- Work Light (Left Side of Radiator) 27- Emergency Engine Stop Switch 2

T5-4-4

2829303132333435363738-

Fuel Level Sensor Fuel Level Switch (2 Used) Battery (4 Used) Motion Alarm (Left) Isolation Switch Box Condenser (With ReceiverDryer) (3 Used) Relay Box Entrance Light (For Left Fender) Work Light (Front Side of Cab Bed) (2 Used) Horn Air Conditioner Unit (3 Used)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Electrical System (Around Cab Bed) Detail A

A

2

3

TKEB-01-02-044

1-

Ambient Air Temperature Sensor 1

2-

Ambient Air Temperature Sensor 2 (For Cummins)

1

3-

T5-4-5

Horn

TKEB-01-02-045

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Electrical System (In Cab) Detail A

4 5 6

3

7

8

9

11

10

12

13 14

26

2

20

1

24 23

15

22 16

21 39

A

17 38 18

40 36 B

19 TKEB-01-02-068

27

Detail B

28

29 30

33

31

34

25 32

37

35 TKEB-01-02-069

TKEB-01-02-067

123456789-

Main Monitor Aerial Angle Monitor (Option) Rear View Monitor (Option) Front View Monitor (Option) Electric Control Lever (Left)/ Horn Switch Electric Control Lever (Bucket Close) (only LD) Electric Control Lever (Travel) Electric Control Lever (Bucket Open) (only LD) Electric Control Lever (Right)/ Horn Switch

10111213141516-

Pilot Shut-Off Lever Warning Light (Red) Caution Light (Yellow) Wiper/Washer Switch Wiper Interval Switch Key Pad Air Conditioner Controller (Right) 17- Air Conditioner Controller (Left) 18- Air Conditioner Controller (Rear) 19- Radio

202122232425262728-

Day/Night Mode Switch Buzzer Stop Switch Maintenance Mode Switch Fast Filling Switch Maintenance Light Switch Entrance Light Switch Work Light Switch Engine Control Dial Emergency Engine Stop Switch 29- Engine Start Switch 30- Auto-Idle Switch 31- Dome Light Switch

fNOTE: LD: Loading Shovel T5-4-6

323334353637383940-

Key Switch Engine Stop Switch Travel Mode Switch Unused Option Switch 1 Option Switch 2 Option Switch 3 Option Switch 4 Unused

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout 2

3

1

TKEB-01-02-070

4

5

7

123-

Hour Meter Dome Light (Front) Dome Light (Rear)

456-

ELUF ELUT ACU

6

7-

T5-4-7

Satellite Communication Terminal (Option)/Mobile Communication Terminal

TKEB-01-02-071

(Option)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

1

T146-01-03-023 TKEB-01-02-072

2

3

4

5 6

7

8

9

13

12

10

11

12-

Power Source Terminal Fuse Box (Cab 1) (Refer to T5-4-46)

345-

Fuse Box (Cab 2) (Refer to T5-4-47) Cigar Lighter 12V Socket

6789-

T5-4-8

Download Connector (for DLU) Data Link Connector (For ECM) DC-DC Converter 2 DC-DC Converter 1

10111213-

IDU Buzzer WIU (Option) DLU

TKEB-01-02-073

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Electrical System (Around Battery) 6

3

4

5

1

TKEB-01-02-015

2 TKEB-01-02-014

123-

Isolation Switch Box Battery DLU Indicator

4-

Isolation Switch (Battery Circuit)

5-

T5-4-9

Isolation Switch (Starter Circuit)

6-

Limit Switch (Cab Bed Door)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Electrical System (Relay Box) 27 26

25 24

23 22

28

21

1 2 3

20 16 10 17 11 18 12 19

4

13 14 5

TKEB-01-02-059

15

6

7

8

9 TKEB-01-02-060

1234-

Battery Relay 1 Battery Relay 2 Battery Relay 3 Fuse (400 A) (For Prelube Relay) 5- Prelube Relay 6- Fuse (200 A) (For Alternator) 7- Prelube Control Relay 8- Starter Relay (Upper) 9- Starter Relay (Lower) 10- Slow Blow Fuse 1 (75 A) (For Fuse Box)

11- Slow Blow Fuse 2 (75 A) (For Fuse Box) 12- Slow Blow Fuse 3 (75 A) (For Fuse Box) 13- Slow Blow Fuse 4 (75 A) (For Fuse Box) 14- Slow Blow Fuse 5 (75 A) (For Fuse Box) 15- Slow Blow Fuse 6 (75 A) (For Fuse Box) 16- Slow Blow Fuse 7 (45 A) (For Option)

17- Slow Blow Fuse 8 (75 A) (For Starter Relay) 18- Slow Blow Fuse 9 (45 A) (For ECM Main Power) 19- Slow Blow Fuse 10 (75 A) (For Folding Stairway Relay) 20- Fuse (250 A) (For Folding Stairway Pump 1) 21- Fuse (250 A) (For Folding Stairway Pump 2) 22- Alternator Signal Relay 2 23- Engine Protection Relay

T5-4-10

2425262728-

DEF Line Heater Relay 2 DEF Line Heater Relay 1 Dosing Module Relay 2 Dosing Module Relay 1 Fuse Box (DEF) (Refer to T54-45)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Electrical System (Electrical Equipment Box)

TKEB-01-02-065

11

12

13

14

10 9 8 7 6 5

A

4 3 2 1

TKEB-01-02-063 A-

Refer to Relay Layout in T5-4-11.

1234-

Fuse Box 2 (Refer to T5-4-49) Fuse Box 1 (Refer to T5-4-48) Fuse Box 4 (Refer to T5-4-51) Fuse Box 3 (Refer to T5-4-50)

567-

Auto-Lubrication Interval Switch Engine Fault Code Indicator Lamp Check Switch

8-

Engine Troubleshooting Switch 9- Engine Fault Code Select Switch 10- MCU

T5-4-11

11- HMU 12- CSU 13- Limit Switch (Electrical Equipment Box Door) 14- Electrical Equipment Box Light

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Electrical System (Relay Layout of Electrical Equipment Box)

A

1

2

3

4

6

7

8

9

5

B

10 11 12 13 14 15 16 17

C

18 19 20 21 22 23 24 25

D

26 27 28 29 30 31 32 33

E

34 35 36 37 38 39 40 41

F

42 43 44 45 46 47 48 49

A

B C D E F

TKEB-01-02-066

1-

Horn Air Compressor Relay (L1) 2- Horn Air Compressor Relay (R1) 3- Wiper Relay (1) (For Slow Speed Control) 4- Wiper Relay (3) (For Fast Speed Control) 5- Air Conditioner Main Relay (Right) 6- Air Conditioner Main Relay (Left) 7- Air Conditioner Main Relay (Rear) 8- Cab Bed Pressurization Blower Motor Relay (1) 9- Cab Bed Pressurization Blower Motor Relay (2) 10- Work Light Relay (1) (Front Left Side of Cab Bed) 11- Work Light Relay (2) (Front Right Side of Cab Bed) 12- Work Light Relay (3) (Upper Front of Cab)

[L1] [L2] [L3] [L4] [L5] [L6] [L7] [L8] [L9] [1] [2] [3]

13- Work Light Relay (4) (Front of Right Fender) 14- Work Light Relay (5) (Rear of Oil Cooler, Rear of Radiator) 15- Work Light Relay (6) (Left Side of Radiator) 16- Entrance Light Relay 17- Maintenance Light Relay (1) (Engine Compartment) 18- Maintenance Light Relay (2) (Pump Compartment) 19- Maintenance Light Relay (3) (Cab Bed) 20- Unused 21- Alternator Signal Relay 1 22- Fast Filling Panel Position Relay 23- Delayed Power OFF Relay 24- Travel Mode Relay 25- Fast Filling Relay 26- Horn Air Compressor Relay (L2)

[4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17]

27- Horn Air Compressor Relay (R2) 28- Horn Relay 29- Wiper Relay (2) (For Wiper Stop Position Control) 30- Washer Motor Relay 31- Air Conditioner Condenser Fan Motor Relay (Right) 32- Air Conditioner Condenser Fan Motor Relay (Left) 33- Air Conditioner Condenser Fan Motor Relay (Rear) 34- ELU Pilot Control ShutOff Solenoid Valve Relay 35- ELU PWM Power Relay (1) (For Key ON Signal Monitoring) 36- ELU PWM Power Relay (2) (For Pilot Control Shut-Off Switch ON Signal Monitoring)

fNOTE: Alphanumeric characters in parentheses are the relay No. in the circuit diagram.

T5-4-12

[18] [19] [20] [21] [22] [23] [24] [25] [26] [27]

37- ELU PWM Power Relay (3) (For Emergency Engine Stop Switch ON Signal Monitoring) 38- Folding Stairway Relay 1 39- Engine Oil Reserve Tank Pump Unit Relay 40- Folding Stairway Alarm/ Flash Light Relay (1) 41- Folding Stairway Alarm/ Flash Light Relay (2) 42- Prelube Signal Relay 43- Engine Start Cancellation Relay 44- Engine Oil Reserve Tank Filling System Relay (1) 45- Engine Oil Reserve Tank Filling System Relay (2) 46- Grease Tank Level Signal Relay (1) 47- Grease Tank Level Signal Relay (2) 48- Grease Tank Filling System Relay 49- Cab Bed Pressurization Relay

[28]

[29] [30] [31] [32] [33] [34] [35] [36] [37] [38] [39] [40]

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Electrical System (LED Layout of Contamination Sensor Amplifier) 1

2

3 4 5 6

10

7

10

8 10 9

TKEB-01-02-064

TKEB-01-02-063

123-

Main Pump 1 Main Pump 2 Main Pump 3

456-

Main Pump 4 Main Pump 5 Main Pump 6

789-

T5-4-13

Swing Motor (Front) Rear Swing Motor Travel Motor

10- Unused

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Electrical System (Layout of Contamination Sensor) 1

2

3

4

5

6

TKEB-01-02-016

8

7

9 123-

Contamination Sensor (Main Pump 1) Contamination Sensor (Main Pump 2) Contamination Sensor (Main Pump 3)

456-

TKEB-01-02-017

Contamination Sensor (Main Pump 4) Contamination Sensor (Main Pump 5) Contamination Sensor (Main Pump 6)

789-

T5-4-14

Contamination Sensor (Rear Swing Motor) Contamination Sensor (Front Swing Motor) Contamination Sensor (Travel Motor)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Electrical System (Monitoring Controller Box)

TKEB-01-02-061

1

2

6

5

4

12-

ODR BPU (Option)

34-

3

TKEB-01-02-088

Swing Angular Rate Sensor (Upperstructure) Body Tilt Sensor 1 (Pitch)

56-

T5-4-15

Body Tilt Sensor 2 (Roll) Fuse Box (Monitoring) (Refer to T5-4-52)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Electrical System (Pump Compartment Controller Box) 4

5

6

2 1 3

TKEB-01-02-018

123-

PMU PFU EHU

456-

DEF Fill Line Heater Signal Relay DEF Fill Hose Heater Relay DEF Fill Line Heater Relay

7

78-

T5-4-16

8

TKEB-01-02-019

9

DEF Shut-Off Valve Heater Relay DEF Receiver Heater Relay

9-

DEF Piping In-Line Filter Heater Relay

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Electrical System (Angle Sensor) (Loading Shovel)

Detail C

3

A C

TKEB-01-02-023

B

TKEB-01-02-020

Detail A

View B

1 2 TKEB-01-02-022

TKEB-01-02-021

1-

Boom Angle Sensor

2-

Arm Angle Sensor

3-

T5-4-17

Bucket Angle Sensor

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Electrical System (Angle Sensor) (Backhoe)

1

A

3

TKBD-01-02-021

View A

2

TKBD-01-02-022 1-

Boom Angle Sensor

2-

Arm Angle Sensor

3-

T5-4-18

Bucket Angle Sensor

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Engine

B

1

2 A

3

TKEB-01-02-051

View A

View B

4

5

6

8

7

9

123-

Engine Speed Sensor (ECM) Prelube Pressure Switch Fuel Filter (Stage 1)

456-

ECM Fuel Filter (Stage 2) Prelube Motor

10

11

12 TKEB-01-02-053

TKEB-01-02-052

789-

T5-4-19

Starter Oil Filter Engine Oil Temperature Sensor

10- Engine Oil Level Sensor 11- Coolant Filter 12- Alternator

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Air Cleaner

1

A

1-

Air Cleaner

2-

TKEB-01-02-024

Air Cleaner Restriction Switch (2 Used)

Detail A

2

TKEB-01-02-025

T5-4-20

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Around Radiator View A

3 D

A

2

4 1

5

6

B TKEB-01-02-038

C

TKEB-01-02-034

Detail C

Detail B

7

14 8

TKEB-01-02-037 Detail D

9

13 12

TKEB-01-02-036

11 12345-

HTC Radiator LTC Radiator Coolant Reserve Tank Coolant Level Check Switch 2 Coolant Level Sensor

678-

LTC Radiator Front Air Temperature Sensor HTC Radiator Outlet Coolant Temperature Sensor LTC Radiator Outlet Coolant Temperature Sensor

10

9- Coolant Level Check Switch 1 10- HTC Radiator Inlet Coolant Temperature Sensor 1 11- HTC Radiator Inlet Coolant Temperature Sensor 2

T5-4-21

TKEB-01-02-035 12- LTC Radiator Inlet Coolant Temperature Sensor 13- HTC Radiator Rear Air Temperature Sensor 2 14- HTC Radiator Rear Air Temperature Sensor 1

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Around Oil Cooler Detail A

8

B A

5

1 2

TKEB-01-02-042

6

Detail B

3 7 9 4 D

C

TKEB-01-02-039

TKEB-01-02-043 View C

14

View D

15

10

11

13

TKEB-01-02-040

12345-

Oil Cooler Outlet Hydraulic Oil Temperature Sensor 1 Oil Cooler Front Air Temperature Sensor Pump Transmission Oil Cooler Oil Cooler (Rear) Oil Cooler Outlet Hydraulic Oil Temperature Sensor 2

678-

Fuel Cooler Oil Cooler (Front) Oil Cooler Rear Air Temperature Sensor 1 9- Oil Cooler Rear Air Temperature Sensor 2 10- Oil Cooler Inlet Hydraulic Oil Temperature Sensor 2

12 11- Fuel Cooler Outlet Fuel Temperature Sensor 12- Fuel Cooler Inlet Fuel Temperature Sensor 13- Pump Transmission Oil Temperature Sensor 14- Pump Transmission Oil Cooler Outlet Oil Temperature Sensor

T5-4-22

TKEB-01-02-041

15- Oil Cooler Inlet Hydraulic Oil Temperature Sensor 1

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Around Pump 1

A

B

2

8

C

7

6

5

4

Views A, B, C

3

TKEB-01-02-011

9 12

11 10 TKEB-01-02-080

1-

2-

Main Pump 1 (Pump Transmission Side)/Main pump 2 (Pump End Side) Main Pump 3 (Pump Transmission Side)/Main pump 4 (Pump End Side)

3-

456-

Main Pump 5 (Pump Transmission Side)/Main pump 6 (Pump End Side) 4-UNIT PUMP Bypass Check Valve (For Pump Transmission Oil Pump) Pump Transmission Oil Filter

789-

Pilot Relief Valve Pilot Filter Swash Plate Angle Sensor (Main Pumps 1, 3, 5) 10- Swash Plate Angle Sensor (Main Pumps 2, 4, 6)

T5-4-23

11- Control Solenoid Valve (Main Pumps 1, 3, 5) 12- Control Solenoid Valve (Main Pumps 2, 4, 6)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

1

2

3

7

8

9

10

13 12 6

11 A

5 4

14

B

TKEB-01-02-030

View A

View B

22 16 17

18

15 19 123456-

Drain Pressure Sensor (MP1) Delivery Pressure Sensor (MP1) Regulator Pressure Sensor (MP1) Drain Pressure Sensor (MP2) Delivery Pressure Sensor (MP2) Regulator Pressure Sensor (MP2)

20 7-

21

TKEB-01-02-081

TKEB-01-02-031

Pump Transmission Oil Level Switch 8- Drain Pressure Sensor (MP3) 9- Delivery Pressure Sensor (MP3) 10- Regulator Pressure Sensor (MP3) 11- Drain Pressure Sensor (MP4) 12- Delivery Pressure Sensor (MP4)

13- Regulator Pressure Sensor (MP4) 14- Delivery Pressure Sensor (Oil Cooler Fan Motor Pump) 15- Regulator Pressure Sensor (Oil Cooler Fan Motor Pump) 16- Drain Pressure Sensor (MP5) 17- Delivery Pressure Sensor (MP5)

fNOTE: MP: Main Pump T5-4-24

18- Regulator Pressure Sensor (MP5) 19- Drain Pressure Sensor (MP6) 20- Delivery Pressure Sensor (MP6) 21- Regulator Pressure Sensor (MP6) 22- Control Solenoid Valve (Oil Cooler Fan Motor Pump)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout 4-UNIT PUMP

1

TKEB-01-02-004

2

3

4

5

TKBD-01-02-003

12-

4-UNIT PUMP Oil Cooler Fan Motor Pump (Plunger Pump)

3-

Pilot Pump (Tandem Gear Pump)

4-

T5-4-25

Air Conditioner Compressor Motor Pump (Tandem Gear Pump)

5-

Pump Transmission Oil Pump (Gear Pump)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Control Valve

fNOTE: The illustration shows the layout viewed from the machine front.

Control Valve (Right)

1

2

8

3

9

4

Control Valve (Center)

5

6

7

10 11 12 13 14 15

16

Control Valve (Left)

17 18 19 20 21 22

23 24

25 26

27 28

29

30 31 32

36 37

33 34

35

38 39 40 41 TKEB-01-02-032

T5-4-26

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Control Valve (Right)

Control Valve (Center)

123456789101112131415-

16171819202122232425262728-

Overload Relief Valve (Boom Lower) Make-Up Valve (Boom Lower) Overload Relief Valve (Bucket Tilt-Out) Make-Up Valve (Bucket Tilt-Out) Overload Relief Valve (Arm Retract) Make-Up Valve (Arm Retract) Overload Relief Valve (Swing Left) Make-Up Valve (Boom Raise) Overload Relief Valve (Boom Raise) Make-Up Valve (Bucket Tilt-In) Overload Relief Valve (Bucket Tilt-In) Make-Up Valve (Arm Extend) Overload Relief Valve (Arm Extend) Overload Relief Valve (Swing Right) Main Relief Valve

Control Valve (Left) 29303132333435363738394041-

Main Relief Valve Overload Relief Valve (Arm Retract) Make-Up Valve (Arm Retract) Overload Relief Valve (Boom Lower) Make-Up Valve (Boom Lower) Overload Relief Valve (Bucket Tilt-Out) Make-Up Valve (Bucket Tilt-Out) Make-Up Valve (Arm Extend) Overload Relief Valve (Arm Extend) Make-Up Valve (Boom Raise) Overload Relief Valve (Boom Raise) Make-Up Valve (Bucket Tilt-In) Overload Relief Valve (Bucket Tilt-In)

T5-4-27

Main Relief Valve Overload Relief Valve (Boom Raise) Make-Up Valve (Boom Raise) Overload Relief Valve (Bucket Open) Make-Up Valve (Bucket Open) Overload Relief Valve (Arm Extend) Make-Up Valve (Arm Extend) Make-Up Valve (Bucket Tilt-In) Overload Relief Valve (Bucket Tilt-In) Overload Relief Valve (Bucket Close) Overload Relief Valve (Bucket Close) Make-Up Valve (Arm Retract) Overload Relief Valve (Arm Retract)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

2

1

12-

Pressure Sensor (Bucket Cylinder Bottom Side) Pressure Sensor (Arm Cylinder Bottom Side)

34-

3

4

Pressure Sensor (Arm Cylinder Rod Side) Pressure Sensor (Boom Cylinder Bottom Side)

56-

T5-4-28

5

Pressure Sensor (Boom Cylinder Rod Side) Pressure Sensor (Bucket Cylinder Rod Side)

6

TKEB-01-02-033

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Pilot Panel

1

A

3

2

TKEB-01-02-012

View A

10

4

5

9

6

8

12-

Accumulator (For Pilot) Relief Valve (For Air Conditioner Compressor Motor Pump Circuit)

34-

Boom Raise Priority Selector Valve Reducing Valve (For Travel Mode Control)

TKEB-01-02-013

7

567-

T5-4-29

Travel Mode Selector Solenoid Valve Pilot Shut-Off Solenoid Valve Check Valve (For Pilot)

8-

Pressure Sensor (Pilot Control Shut-Off Solenoid Valve) 9- EDQR Valve (Left) 10- EDQR Valve (Right)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout EDQR Valve

17 25

18

26

19 1

27

20 9

2

28

10 21 11 22 12 23 13 24 14

3 4 5 6 7

29 30 31 32

15 8

16

34

TKEB-01-02-054

33

123-

45678-

Pilot Pressure Sensor (Bucket Tilt-In) Pilot Pressure Sensor (Boom Raise) Pilot Pressure Sensor (LD: Bucket Tilt-Out/BH: Bucket Roll-Out) Pilot Pressure Sensor (Boom Lower) Pilot Pressure Sensor (LD: Arm Retract/BH: Arm Roll-Out) Pilot Pressure Sensor (LD: Arm Extend/BH: Arm Roll-In) Pilot Pressure Sensor (Left Travel Forward) Pilot Pressure Sensor (Valve Warmer Solenoid Valve 1)

9- Bucket Tilt-In Solenoid Valve 10- Boom Raise Solenoid Valve 11- LD: Bucket Tilt-Out Solenoid Valve/BH: Bucket Roll-Out Solenoid Valve 12- Boom Lower Solenoid Valve 13- LD: Arm Retract Solenoid Valve/BH: Arm Roll-Out Solenoid Valve 14- LD: Arm Extend Solenoid Valve/BH: Arm Roll-In Solenoid Valve 15- Left Travel Forward Solenoid Valve 16- Valve Warmer Solenoid Valve 1 17- Pilot Pressure Sensor (Left Travel Reverse)

18- Pilot Pressure Sensor (Right Travel Forward) 19- Pilot Pressure Sensor (LD: Bucket Open/BH: Unused) 20- Pilot Pressure Sensor (Right Travel Reverse) 21- Pilot Pressure Sensor (LD: Bucket Close/BH: Unused) 22- Pilot Pressure Sensor (Swing Left) 23- Pilot Pressure Sensor (Swing Right) 24- Pilot Pressure Sensor (Valve Warmer Solenoid Valve 2) 25- Left Travel Reverse Solenoid Valve

fNOTE: LD: Loading Shovel BH: Backhoe

T5-4-30

26- Right Travel Forward Solenoid Valve 27- LD: Bucket Open Solenoid Valve/BH: Unused 28- Right Travel Reverse Solenoid Valve 29- LD: Bucket Close Solenoid Valve/BH: Unused 30- Swing Left Solenoid Valve 31- Swing Right Solenoid Valve 32- Valve Warmer Solenoid Valve 2 33- Valve Warmer Solenoid Valve Temperature Sensor 1 34- Valve Warmer Solenoid Valve Temperature Sensor 2

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Swing Device 1

2

3

3

4

1-

Swing Motor

2-

Swing Motor Drain Pressure Sensor

5

34-

T5-4-31

Make-Up Valve Relief Valve

2

1

TKEB-01-02-046

4

5-

Swing Motor Inlet Pressure Sensor

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Undercarriage 6

7

1

8 9 5 4 3

2 TKEB-01-02-006

123-

Adjuster Cylinder Grease Fitting Pilot Pressure Control Valve (For Travel Stop)

456-

Swing Angular Rate Sensor (Undercarriage) Check Valve Relief Valve

789-

T5-4-32

Center Joint Accumulator (For Adjuster Cylinder) Reducing Valve

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Travel Device

TKEB-01-02-047

1

Center Joint

2

3

TKEB-01-02-048

View A

6

4

5

A TKEB-01-02-049

12-

Travel Brake Valve Travel Motor

34-

Travel Reduction Gear Slip Ring

TKEB-01-02-050

5-

T5-4-33

Pressure Sensor (For Adjuster Cylinder End)

6-

Swing Angular Position Switch

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Fast-Filling System

TKEB-01-02-001

2 3 1 5

4

6

TKEB-01-02-002

12-

Lift Cylinder Check Valve

34-

Slow Return Valve Fast-Filling Panel

5-

T5-4-34

Fast-Filling Panel Raise/Lower Solenoid Valve

6-

Fast Filling Panel Position Switch

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Fast-Filling Panel

1

3

9

1234-

Fuel Full Warning Light Grease Tank Full Warning Light Engine Oil Hydraulic Oil

56-

2

4

10

Gear Oil (Front Side Swing Device) Gear Oil (Rear Side Swing Device)

5

6

11

12

78910-

T5-4-35

7

Grease Pump Transmission Oil Coolant (HTC Radiator) Coolant (LTC Radiator)

8

TKEB-01-02-089

11- Fuel 12- DEF

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Folding Stairway Folding Stairway 4 5

1 2 3

6 7

8 Section A-A

Section C-C

View B

A

9 10

B

A

11

12

C

C

13 14

T18L-01-02-039 1234-

Folding Stairway Relay 2 Folding Stairway Relay 3 Folding Stairway Relay 4 Limit Switch (For Extending Detection)

567-

Limit Switch (For Extending Stroke End Control) Limit Switch (For Retracting Stroke End Control) Limit Switch (For Retracting Detection)

8- Folding Stairway Pump 9- Valve Unit (Refer to T5-4-36) 10- Work Light (For Folding Stairway) 11- Folding Stairway Alarm/Flash Light

T5-4-36

12- Limit Switch (Pilot Lock Lever) 13- Folding Stairway Cylinder 14- Folding Stairway Lock Lever

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Switch Box

1

2

3

TKEB-01-02-057

In Switch Box 4

5

6

T18N-01-03-005

TKEB-01-02-091

12-

Retract Switch Extend Switch

34-

Emergency Folding Stairway Stop Switch Switch Box

5-

T5-4-37

Isolation Switch (Folding Stairway Pump 2)

6-

Isolation Switch (For Folding Stairway Pump 1)

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Valve Unit 1

2

3

4

5

6

7 8 14

9

13

12

11

10

T18L-01-02-034

15 3

2

11

6

14

P3

8

P1

B A1 A2

P2

A3

10 5

4 7

M T

1234-

Overload Relief Valve (Folding Stairway Cylinder Bottom Side) Orifice Check Valve Check Valve

12

5678-

1

Check Valve Folding Stairway Solenoid Valve 3 Main Relief Valve Check Valve

PF

9

T18L-01-02-035

9- Check Valve 10- Throttle Valve 11- Folding Stairway Solenoid Valve 1 12- Check Valve

13- Folding Stairway Solenoid Valve 2 14- Slow Return Valve 15- Overload Relief Valve (Folding Stairway Cylinder Rod Side)

15

13

T5-4-38

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Auto-Lubrication Device

11

TKEB-01-02-074

TKEB-01-02-026

View A

1

2

7

8

A

3

9

10

4

TKEB-01-02-028

6

1234-

Grease Pump Air Breather Pressure Switch Grease Filter

5

TKEB-01-02-027

567-

Grease Pressure Gauge Auto-Lubrication Mode Switch Hydraulic Oil Pressure Gauge

8-

Auto-Lubrication Solenoid Valve 9- Grease Tank Level Sensor 10- Vent Valve

T5-4-39

11- Auto-Lubrication Interval Switch

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Hydraulic Oil Tank

4

1

2 3

A TKEB-01-02-055

View A

6

5 TKEB-01-02-056

12-

Air Bleeding Solenoid Valve Hydraulic Oil Level Check Switch

3-

Hydraulic Oil Level Warning Switch

4-

Pressure Sensor (For Hydraulic Oil Tank)

56-

T5-4-40

Hydraulic Oil Temperature Sensor Valve Limit Switch

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Fuel Tank

1

2

3 TKEB-01-02-005

1-

Fuel Level Switch (High)

2-

Fuel Level Switch (Low)

3-

T5-4-41

Fuel Level Sensor

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Urea SCR System DEF Tank

View A

5

6

1

A

7 8

2

123-

DEF Sensor Unit DEF Tank DEF Tank Coolant Valve

3

45-

4

TKEB-01-02-075

DEF Supply Module Coolant Valve DEF Piping In-Line Filter 1

678-

T5-4-42

DEF Piping In-Line Filter 2 DEF Supply Module 1 DEF Supply Module 2

TKEB-01-02-092

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Urea SCR Muffler Unit

A

2 View A

7

3

4

TKEB-01-02-078

5

1-

TKEB-01-02-077

1

ECU (NOx Sensor 1) (Right Bank)

23-

ECU (Temperature Sensor 1) (Right Bank) ECU (NOx Sensor 2) (Left Bank)

45-

T5-4-43

ECU (Temperature Sensor 2) (Left Bank) Dosing Module 2 (Left Bank)

6

TKEB-01-02-079

67-

Dosing Module 1 (Right Bank) SCR Muffler

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout (Blank)

T5-4-44

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Fuse Layout Relay box

1 2 3 4 5 6 7 8 9 10

TKEB-05-01-001

TKEB-01-02-060

Fuse Box (DEF) Fuse Capacity Connected to No. 1 10A Dosing Module Relay 1 2 10A Dosing Module Relay 2 3 10A ECM NOx Sensor Power 4 20A DEF Line Heater Relay 1 5 20A DEF Line Heater Relay 2 6 20A DEF Piping In-Line Filter Heater 7 20A DEF Fill Hose Heater 8 20A DEF Fill Pipe Heater 9 5A DEF Receiver Heater 10 5A DEF Shut-Off Valve Heater

T5-4-45

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Left Console (Rear Side)

TKEB-01-02-073

1

2

3

4

5

6

7

8

9

10

TKEB-05-01-002

11 12 13 14 15

Fuse No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

16 17 18 19 20

Capacity Connected to 20A 5A 5A 5A 5A 5A 5A 5A 5A 5A 10A 15A 5A 5A 10A 10A 15A 5A 10A 5A

Main Power Key Switch ELUF, ELUT Power IDU Power DLU Power Option Power Radio (Backup) ELUF, ELUT Key ON Signal IDU Key ON Signal DLU Key ON Signal Buzzer Key ON Signal (Control Unit) Key ON Signal (Monitoring Unit) ECM Key ON Signal Horn Air Compressor ACC Signal Cigar Lighter Power Source Terminal (ACC) Power Source Terminal (12 V) Radio (ACC) Power Source Socket (12 V) Pilot Control Shut-Off Lever Switch

T5-4-46

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

TKEB-01-02-073

21 22 23 24 25

Fuse No. 21 22 23 24 25 26 27 28 29 30

26 27 28 29 30

Capacity Connected to 5A 5A 5A 10A 15A 15A 5A -

WIU Power WIU Key ON Signal Key ON Signal (External Connection) Alternator Power (External Connection) Power Source Terminal (24 V) Aerial Angle Power Key ON Signal (Aerial Angle) -

T5-4-47

TKEB-05-01-003

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Electrical Equipment Box

1

2

3

4

5

6

7

8

9 10

11 12 13 14 15 16 17 18 19 20 T18G-05-07-001

TKEB-05-01-004

Fuse Box 1 Fuse Capacity Connected to No. 1 5A MCU, HMU Power 2 5A Delayed Power OFF Power 3 10A Battery Power (External Connection) 4 5A PFU, PMU, EHU Power 5 6 30A Horn Air Compressor (Left) 7 30A Horn Air Compressor (Right) 8 10A Folding Stairway Solenoid Valve (1) 9 5A Electrical Equipment Box Light 10 30A Cab Battery Power 11 10A C/U (J1939) Power (Option) 12 15A Monitoring Unit Power 13 5A Key ON Signal (C/U (J1939)) (Option) 14 10A Key ON Signal (Monitoring Unit) 15 5A ECM Lamp Power 16 5A ELU, PWM Power Relay 17 5A PFU Key Switch ON Signal 18 19 5A PMU, EHU Key Switch ON Signal 20 -

T5-4-48

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

21 22 23 24 25 26 27 28 29 30

31 32 33 34 35 36 37 38 39 40 T18G-05-07-001

TKEB-05-01-004

Fuse Box 2 Fuse Capacity Connected to No. 21 5A Washer Motor Relay 22 5A Travel Mode Relay 23 5A Air Conditioner Main Relay (Right) 24 5A Air Conditioner Main Relay (Left) 25 5A Air Conditioner Main Relay (Rear) 26 5A Battery Relay 27 15A DC/DC Converter 2 28 5A Grease Tank Level Switch 29 20A Cab Bed Pressurization Blower Motor 1 30 20A Cab Bed Pressurization Blower Motor 2 31 20A Air Conditioner Main Power (Right) 32 20A Air Conditioner Main Power (Left) 33 20A Air Conditioner Main Power (Rear) 34 15A Air Conditioner Condenser Fan Motor (Right) 35 15A Air Conditioner Condenser Fan Motor (Left) 36 15A Air Conditioner Condenser Fan Motor (Rear) 37 5A DLU Service Tool 38 5A Communication Terminal Power (Satellite/Potable) 39 5A Folding Stairway Alarm/Flash Light (1) Power 40 5A Alternator Signal Relay

T5-4-49

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

41 42 43 44 45 46 47 48 49 50

51 52 53 54 55 56 57 58 59 60 T18G-05-07-001

TKEB-05-01-004

Fuse Box 3 Fuse Capacity Connected to No. 41 5A Motion Alarm 42 10A Engine Oil Reserve Tank Filling System Main Switch (1) 43 44 5A Travel Mode Selector Solenoid Valve 45 5A Folding Stairway Solenoid Valve (2) 46 5A Air Breather Solenoid Valve 47 15A Seat Suspension Air Compressor Cab Light 48 20A Alternator Power (External Connection) Power Source Terminal (24 V) 49 15A DC/DC Converter 1 50 5A Rear View Camera Monitor 51 10A PWM Power (MCU) 52 5A IDU Power 53 15A PWM Power (ELUF, ELUT) 54 55 15A ECM Data Link 56 10A PWM Power (PFU) 57 58 15A Engine Oil Reserve Tank Pump Unit 59 60 20A Oil Pump

T5-4-50

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout

61 62 63 64 65 66 67 68 69 70

71 72 73 74 75 76 77 78 79 80 T18G-05-07-001

TKEB-05-01-004

Fuse Box 4 Fuse Capacity Connected to No. 61 10A Work Light 1 62 10A Work Light 2 63 10A Work Light 3 64 10A Work Light 4 65 10A Work Light 5 66 10A Work Light 6 67 10A Maintenance Light 1 68 10A Maintenance Light 2 69 10A Maintenance Light 3 70 10A Maintenance Light 4 71 72 73 10A Entrance Light 1 74 75 30A Wiper Motor (Slow Speed) 76 30A Wiper Motor (Fast Speed) 77 10A Washer Motor 78 5A Fast Filling Solenoid Valve 79 5A CSU Power 80 -

T5-4-51

SECTION 5 TROUBLE SHOOTING Group 4 Component Layout Controller Box (Monitoring Unit)

1 2 3 4 5 6 7 8 9 10

TKEB-01-02-062 TKEB-05-01-001

Fuse No. 1 2 3 4 5 6 7 8 9 10

Capacity Connected to 5A 5A 10A 5A 5A 5A 5A -

ODR Power BPU Power Option Power Key ON Signal (ODR) Key ON Signal (BPU) Key ON Signal (Option) Alternator (Signal Light) -

T5-4-52

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting for Each Code Troubleshooting Procedure for Each Code Refer to troubleshooting procedure during diagnosis when accessing active alarm and fault codes viewed from the monitor screen.

5

1 12-

2

3

TKEB-05-05-009

4

Fault Code of Cummins/MTU Fault Code of HCM

34-

fNOTE: Current Alarm Fault List (5) shows active fault (s) and or alarm (s).

fNOTE: The contents of the screen are an example.

T5-5-1

Alarm Display Trouble Contents

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting for Each Code How to Check Fault Diagnosis Results IDU displays the troubleshooting results from each controller on gauge screen (Fig. A) of the monitor.

Use the key pad (1) to navigate through the monitor menu's.

1

Alarm side bars (2) will constantly illuminate or blink according to the machine condition.

Machine Condition Normal Abnormal

Alarm Side Bar (2) TKEB-05-05-003

Not display Illuminate (Yellow) Blinking (Red)

When a malfunction occurs, the alarm icon is illuminated in the Alarm Display Area (engine related) (4) and Alarm Display Area (Except Engine related) (5).

At the same time, fault or alarm codes are displayed in the Cummins/MTU Fault Code Display area (6) and HCM Fault Code Display Area (7), and comments information that relate to the codes in Fault Comments display area (8).

fNOTE: When multiple malfunctions occur at the same time, the codes will scroll through at preset (some seconds) intervals.

Single Engine Specification

2

2

4 5

3

6

7

TKEB-05-02-176

8

Twin Engine Specification

2

2

4 5

3

6

12345-

T5-5-2

7

Key Pad Alarm Side Bar Buzzer Indicator Alarm Display Area (Engine related) Alarm Display Area (Except Engine related)

8

678-

TKGB91-05-05-002E

Cummins/MTU Fault Code Display Area HCM Fault Code Display Area Fault Comments Display Area

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting for Each Code Current Alarms Faults List

1

1. Push MENU/SET switch (4) of the key pad (1) to move from the Gauge screen to the Service Menu screen. (Fig. A)

6

2

5

3

2. Turn MENU/SET switch (4) to highlight Current Alarms Faults List (7), then push the MENU/SET switch (4) to display the Current Alarms and Faults.

(Fig. B)

4

fNOTE: The Current Alarms Faults List screen (Fig. B) will

not be automatically updated, if any of fault/alarm is newly activated or inactivated. To refresh display and show current alarms, push left function key (6) of key pad (1).

TKEB-05-05-003 1234-

Key Pad Function Key (Right) Basic Screen Switch MENU/SET Switch

56-

Previous Screen Switch Function Key (Left)

Fig. A

fNOTE: When pushing previous screen switch (5), the previous screen is displayed. When pushing gauge screen switch (3), the gauge screen is displayed.

7

TKEB-05-05-010 Fig. B

TKEB-05-05-011

T5-5-3

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting for Each Code System Check

1

The communication state between controllers can be checked.

1. Push MENU/SET switch (4) of the key pad (1) to move from the gauge screen to the Service Menu screen. (Fig. A)

2

2. Turn MENU/SET switch (2) to highlight System Check (3). Push the MENU/SET switch (2) to display the System Check information. (Fig. B)

TKEB-05-05-003 1-

3. When abnormal situation happens in the communication line, error locations (4) blink in red.

Key Pad

2-

MENU/SET Switch

Fig. A

4. Find out the error position by using the System Check screens (Fig. B) and controller location screen (Fig. C).

fNOTE: When error occurs with System Check, the fault

3

code is displayed in Current Alarms Faults List screen.

TKEB-05-05-010

Fig. B

Fig. C

4

TKEB-05-02-172

T5-5-4

TKFB91-05-02-016

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting for Each Code How To Read Fault Code List (Appendix) The details described in "Fault Code List" are explained here.

Download and use "Fault Code List" from the e-Cabinet menu of the Global e-Service.

The fault code list describes the following information.

1

2

3

4

5 TKEB-05-02-174E

1. Monitor Display The items displayed on the monitor are listed.

– Cummins/MTU Fault Code (6) Fault codes for the Cummins/MTU engine – HCM Fault Code (7) Fault codes for HCM – Fault Comment (8) Overview of fault codes 2. Trouble The fault code generation conditions and remedies are listed.

– Generation Condition The fault code generation conditions are listed.

a a-

– Symptom Sample symptoms that occur when faults are detected are listed.

b Cummins/MTU Fault Code

c

TKEB-05-02-176

bc-

HCM Fault Code Fault Comment

e-

Warning Lamp (Red)

d

– Remedy Sample remedies to be conducted when faults are detected are listed.

e

3. Buzzer/Lamp Display – Warning Buzzer List referencing whether or not the buzzer sounds while faults or alarms are detected.

– Warning/Caution Lamp Displayed List referencing whether or not the (yellow) caution lamp (d) or the (red) warning lamp (e) are illuminated on the left console while faults or alarms are detected.

fNOTE: The screen is for reference only.

TKFB91-05-05-003 d-

T5-5-5

Caution Lamp (Yellow)

SECTION 5 TROUBLESHOOTING Group 5 Troubleshooting for Each Code

1

2

3

4

5 TKEB-05-02-174E

4. IO Monitor (Refer to T5-2-50.)

List referencing the controller issuing the detected faults or alarms.

f

f. Controller Name List referencing the controller issuing the detected faults or alarms. g. Signal Name List referencing the controller input or output circuit causing the detected faults or alarms.

5. Connectors Chart (Refer to the attached electrical circuit diagram.)

The connector types and connector terminal numbers described in "Connectors Chart" are listed. h. Type The connector types described in "Connectors Chart" are listed.

f-

Controller Name

g-

Signal Name

TKEB-05-02-107

g

i. Ter. No. Related connector terminal numbers when faults are detected are listed.

TKEB-05-02-108

h

i

TKFB91-05-05-004E h-

T5-5-6

Connector Type

i-

Terminal No.

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Troubleshooting IMPORTANT:  When replacing the air conditioner compressor due to the breakage of air conditioner compressor from internal lock, sufficiently clean the air conditioner circuit or replace all the parts.  When cleaning is insufficient or all the parts are not replaced, the air conditioner may be broken due to contaminants remaining in the circuit.  Using deteriorated LLC (coolant) or lowconcentration LLC, the heater core will receive a bad influence and it may lead water leaks and shorten the service life of machine.

Replace coolant and manage LLC concentration according to the Operator's Manual.

T5-7-1

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Component Layout

Detail A C

A

B

23

22

TKEB-05-07-036

21

TKEB-05-07-018 Detail B

12

16

13 15

11

18 1

17

4 2

8

5

10

3

7

9

6

19

20 TKEB-05-07-002

123456-

Air Conditioner Condenser (Right) Air Conditioner Condenser (Left) Air Conditioner Condenser (Rear) Receiver Tank (Right) Receiver Tank (Left) Receiver Tank (Rear)

7-

Air Conditioner Compressor (Right) 8- Air Conditioner Compressor (Left) 9- Air Conditioner Compressor (Rear) 10- Air Conditioner Compressor Motor 11- Air Conditioner Unit (Right)

121315161718-

Air Conditioner Unit (Left) Air Conditioner Unit (Rear) Fresh Air Filter (Right) Fresh Air Filter (Left) Fresh Air Filter (Rear) Ambient Air Temperature Sensor (Right) 19- Ambient Air Temperature Sensor (Left)

T5-7-2

20- Ambient Air Temperature Sensor (Rear) 21- Re-Circulated Air Filter (Right) 22- Re-Circulated Air Filter (Left) 23- Re-Circulated Air Filter (Rear)

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner View C

View D E

26 24

29

25

28

31 32

27

33 D

30

TKEB-05-07-019

34

TKEB-05-07-020

Air Conditioner Unit

View E

35

11, 12, 13

G F

H

36 TKEB-05-07-022 FGH-

37

To 27, 28, 32, 33, 36 To 29, 31, 35 To 30, 34, 37

24- Air Conditioner Controller (Right) 25- Air Conditioner Controller (Left) 26- Air Conditioner Controller (Rear)

TKEB-05-07-021

27282930-

Defroster Vent (Right) Front Vent (Right) Side Vent (Right) Foot Vent (Right)

31323334-

T5-7-3

Side Vent (Left) Front Vent (Left) Defroster Vent (Left) Foot Vent (Left)

35- Rear Vent (Rear) 36- Side Vent (Rear) 37- Foot Vent (Rear)

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner

J

I TKEB-05-07-023

View I

View J

38 TKEB-05-07-024

40

39

TKEB-05-07-025 38- Air Conditioner Compressor Motor Pump

39- Hot Water Return Hose

40- Hot Water Outlet Hose

T5-7-4

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner

44

43 42 41

46

50

49

48

45

52

47

53 54

51

TKEB-05-07-005

41- Compressor Relay 42- Re-Circulated Air Temperature Sensor 43- Fresh/Re-Circulated Air Damper Servo Motor

4445464748-

Frost Sensor Evaporator Heater Core Air Mix Damper Servo Motor Air Vent Damper Servo Motor

4950515253-

T5-7-5

Blower Motor Relay Power Transistor Blower Motor Expansion Valve Sight Glass

54- High/Low Pressure Switch

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner (Blank)

T5-7-6

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Electrical Circuit Diagram The illustration shows the circuit of air conditioner (rear). The circuits of air conditioner (right, left) are the same as the circuit of air conditioner (rear).

17 A

18

E F G H

B D 16

1 19

G H

20

C 4

2

15

5

3 11

10

6

8 12 7

14

9

13

ABCD1234-

Slow Blow Fuse 3 Slow Blow Fuse 2 Battery Key Switch ON Signal Air Conditioner Condenser (Rear) Air Conditioner Compressor (Rear) Air Conditioner Unit (Rear) Ambient Air Temperature Sensor (Rear)

EF56789-

Air Conditioner Condenser Fan Motor Relay (Left) Air Conditioner Condenser Fan Motor Relay (Right) Air Conditioner Controller (Rear) Compressor Relay Re-Circulated Air Temperature Sensor Fresh/Re-Circulated Air Damper Servo Motor Frost Sensor

GH10111213141516-

T5-7-7

Air Conditioner Main Relay (Right) Air Conditioner Main Relay (Left) Air Mix Damper Servo Motor Air Vent Damper Servo Motor Blower Motor Relay Power Transistor Blower Motor High/Low Pressure Switch (Rear) Fuse Box (Cab 1)

TKEB-02-06-001

17- Fuse Box 2 18- Air Conditioner Condenser Fan Motor Relay (Rear) 19- Air Conditioner Main Relay (Rear) 20- Air Conditioner Condenser Fan Motor (Rear)

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Diagnosis Procedure (Air Conditioner Controller) Air conditioner controller (1) has the self-diagnosis function in order to check the operation of the major parts. The operation of each actuator and sensor system can be checked by using this function. When the failed location is traced, inspection of the respective part is required.

1. Push OFF switch (2).

2. Push the upper and lower parts of temperature control switch (3) over 3 seconds at the same time.

fNOTE: When the procedure is normally operated, the

buzzer sounds.

3. The fault codes are displayed on liquid crystal panel (4).

fNOTE: The smallest number of fault codes is displayed. fNOTE: Even if fault code E18 is always displayed, this is not abnormal.

fNOTE: When some fault codes exist and the upper or

lower part of temperature control switch (3) is pushed, the next fault code is displayed. When the fault code is changed, the buzzer sounds.

fNOTE: When the fresh/re-circulated air switch (5)

and the lower part of fan switch (6) are pushed over 3 seconds at the same time, the fault codes are deleted.

When the fault codes are deleted, the buzzer sounds.

4. When pushing OFF switch (2), the self-diagnosis function is finished.

1

3

2

6

TDCR-05-08-011

4 12-

Air Conditioner Controller OFF Switch

34-

5

Temperature Control Switch Liquid Crystal Panel

56-

T5-7-8

Fresh/Re-Circulated Air Switch Fan Switch

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Air Conditioner Controller Fault Code List Fault Code

Trouble

Cause

Symptoms in Machine Operation When Trouble Occurs.

Operation is controlled under such circumstances as no recirculated air temperature sensor is provided.

E11

Open circuit in re-circulated air temperature sensor

Voltage: more than 4.95 V

E12

Short circuit in re-circulated air temperature sensor

Voltage: less than 0.3 V Operation is controlled under such circumstances as no recirculated air temperature sensor is provided.

E13

Open circuit in Voltage: more than ambient temperature 4.88 V sensor

E14

Short circuit in Voltage: less than ambient temperature 0.096 V sensor

E18 E21

No abnormality Open circuit in frost sensor

Voltage: more than 4.79 V

E22

Short circuit in frost sensor

Voltage: less than 0.096 V

The compressor clutch is disengaged. (The compressor stops.)

E43

Abnormal air vent damper servo motor

Air vent damper servo motor becomes inoperable.

44

Abnormal air mix damper servo motor

E51

Abnormal high/low refrigerant pressure

Short circuit: Voltage: 0V Open circuit: Voltage: more than 5 V Short circuit: Voltage: less than 0.2 V Open circuit: Voltage: more than 4.8 V Voltage: 0 V

Operation is controlled under such circumstance as no ambient temperature sensor is provided.

Operation is controlled under such circumstance as no ambient temperature sensor is provided.

The compressor clutch is disengaged. (The compressor stops.)

Air mix damper servo motor becomes inoperable.

The compressor clutch is disengaged. (The compressor stops.)

T5-7-9

Remedy Check the wire harness.

Replace the recirculated air temperature sensor.

Check the wire harness.

Replace the recirculated air temperature sensor.

Check the wire harness.

Replace the ambient temperature sensor.

Check the wire harness.

Replace the ambient temperature sensor.

Check the wire harness.

Replace the frost sensor.

Check the wire harness.

Replace the frost sensor.

Check the wire harness.

Replace the air vent damper servo motor.

Check the wire harness.

Replace the air mix damper servo motor.

Check the wire harness.

Replace the high/low pressure switch.

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling Faulty cooling (1) Condition:  Fault code: Un-displayed  Airflow volume: faulty Blower motor Normal speed rotates

Slow speed

Blower motor does not rotate

Clogged re-circulated air filter Clogged fresh air filter Obstacles are found in inlet area Deformation or breakage of blower Frosted evaporator Adhered dirt on evaporator surface Power source decreases

Poor battery terminal contact Faulty blower motor Faulty power transistor Faulty blower motor relay Faulty blower motor Faulty power transistor Blower interferes with case Faulty controller Faulty ground Faulty wire harness, disconnection of connector Blowout of power transistor thermal fuse due to locked blower motor Blowout of fuse Replace with the Blower motor is locked same capacity fuse Faulty wire harness Short circuit

T5-7-10

Filter cleaning Filter cleaning Remove obstacles Replace the blower Go to A Evaporator surface cleaning Check the battery charging system Repair Replace Replace Replace Replace Replace Repair Replace the controller Make sure to ground Check the wire harness Replace the blower motor Replace the blower motor Refer to wire harness diagram and check Check the wire harness

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner A: Frosted evaporator Frosted evaporator Stop air conditioner and melt ice With voltage applied to Faulty magnet clutch magnet clutch circuit Faulty wire harness of frost sensor Faulty frost sensor characteristics Frost sensor is out from evaporator (faulty sensitivity) No voltage applied to magnet clutch

T5-7-11

Check of clutch circuit

Replace the clutch relay

Short circuit check

Repair

Characteristic check

Replace the frost sensor.

Reinsert (floating distance from evaporator is 3 mm or less) Faulty magnet clutch

Replace the magnet clutch

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (2) Condition:  Fault Code: Un-displayed  Airflow volume: Normal  Compressor: Compressor rotates normally  Compressor pressure: Normal Fresh air enters Close the window and door.

Readjust the fresh/re-circulated air selection damper.

Disconnection of A/M Set the link again. link

T5-7-12

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner (Blank)

T5-7-13

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (3) Condition:  Fault Code: Un-displayed  Airflow volume: Normal  Compressor: Compressor rotates normally  Compressor pressure: Abnormal Pressure on lowOvercharge of air Discharge refrigerant thoroughly and recharge refrigerant to proper pressure side is too conditioner with refrigerant level after purging high (approx. 0.29 Faulty compressor Breakage of head gasket Replace the compressor.

MPa or more) Breakage of inlet valve Replace the compressor.

Foreign matter is caught in inlet Replace the compressor. valve Excessive open of Faulty valve Replace the valve. expansion valve Pressure on highAbnormally low ambient temperature pressure side is too Lack of refrigerant To B low (pressure is not Faulty compressor Swash plate shoe is locked Replace the compressor. approx. 0.98 MPa or Piston is locked Replace the compressor. more) Faulty suction discharge valve Replace the compressor.

Faulty expansion valve Clogged valve (foreign matter) Replace the valve Temporary clogged due to freezing Thoroughly perform purging valve (water intrusion) after replacing valve and receiver.

Pressure on lowAbnormally low ambient temperature pressure side is too Lack of refrigerant Go to B low (pressure is Clogged in refrigeration cycle Go to C approx. 0.05 MPa or Faulty expansion valve Go to D less) Frosted evaporator Go to A Pressure is high on Lack of condenser cooling Clogged fin with dirt or mud Cleaning of fin (washing) both sides of highOvercharge of air Discharge refrigerant thoroughly and recharge refrigerant to proper pressure and lowconditioner with refrigerant level after purging. pressure Pressure is low on Lack of refrigerant both sides of highpressure and lowpressure

T5-7-14

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner A: Frosted evaporator Frosted evaporator Stop air conditioner and melt ice.

With voltage applied to Faulty magnet clutch magnet clutch circuit Faulty wiring of frost sensor Faulty frost sensor characteristics Frost sensor is out from evaporator (faulty sensitivity) No voltage applied to magnet clutch

B: Lack of refrigerant Lack of refrigerant

C: Clogged in refrigeration cycle Clogged in refrigeration cycle

D: Faulty expansion valve Faulty expansion valve

Check of clutch circuit

Replace the clutch relay

Short circuit check

Repair

Characteristic check

Replace the frost sensor

Reinsert (floating distance from evaporator is 3 mm or less) Faulty magnet clutch

Replace the magnet clutch.

Lack of refrigerant quantity Gas leak

Charge refrigerant to proper level.

Check leak and charge with refrigerant after repairing faulty.

Clogged receiver tank Clogged foreign matter in piping

Replace Replace

Clogged valve (foreign matter) Replace the valve.

Temporary clogged due to freezing valve Thoroughly perform purging after (water intrusion) replacing valve and receiver.

T5-7-15

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (4) Condition:  Fault Code: Un-displayed  Airflow volume: Normal  Compressor: Compressor does not rotate normally Broken V belt or slipping Faulty compressor (locked) Faulty magnet Repair or clutch replace

Clutch does not operate due to faulty electrical system

Check wiring

Re-ajust V belt or Replace V belt.

Replace Open circuit in stator coil Replace Air gap between rotor and stator is too large Repair or Replacement Clutch slipping Slip caused by key breakage or inserting no key Replace the key.

Greasy clutch surface Remove oil.

Layer short of coil Replace Battery voltage drop Charge Caught foreign matter between rotor and stator Overhaul Faulty controller Replace the controller.

Faulty compressor clutch relay Replace Faulty frost sensor Replace Faulty high/low pressure switch Replace Abnormal high Too high Abnormally high ambient temperature pressure (2.54 MPa or Lack of Clogged fin with Cleaning of fin more) condenser dirt or mud (washing) cooling Overcharge air Discharge refrigerant thoroughly and conditioner with recharge refrigerant to proper level refrigerant after purging.

Air incorporation Discharge refrigerant thoroughly and in refrigeration recharge refrigerant to proper level cycle after purging.

Too low Abnormally low ambient temperature (0.98 MPa or Lack of refrigerant Go to B less) Clogged during refrigeration cycle Go to C Faulty expansion valve Go to D Frosted evaporator Go to A

T5-7-16

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner A: Frosted evaporator Frosted evaporator Stop air conditioner and melt ice.

With voltage applied to Faulty magnet clutch magnet clutch circuit Faulty wiring of frost sensor Faulty frost sensor characteristics Frost sensor is out from evaporator (faulty sensitivity) No voltage applied to magnet clutch

B: Lack of refrigerant Lack of refrigerant

C: Clogged in refrigeration cycle Clogged in refrigeration cycle

D: Faulty expansion valve Faulty expansion valve

Check of clutch circuit

Replace the clutch relay

Short circuit check

Repair

Characteristic check

Replace the frost sensor

Reinsert (floating distance from evaporator is 3 mm or less).

Faulty magnet clutch

Replace the magnet clutch.

Lack of refrigerant quantity Gas leak

Charge refrigerant to proper level.

Check leak and charge with refrigerant after repairing faulty.

Clogged receiver tank Clogged foreign matter in piping

Replace Replace

Clogged valve (foreign matter) Replace the valve.

Temporary clogged due to freezing valve Thoroughly perform purging after (water intrusion) replacing valve and receiver.

T5-7-17

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty cooling (5) Condition:  Fault Code: E44 (Abnormal air mix damper servo motor) Faulty wiring, open Wirings inspection circuit, disconnection of connector Faulty servo motor Replace Caught foreign matter Remove foreign matter.

Condition:  Fault Code: E51 (Abnormal high/low refrigerant pressure) High pressure switch is Abnormally high ambient temperature operated Lack of condenser Clogged fin with dirt or mud Cleaning of fin (washing) cooling Overcharge air Discharge refrigerant thoroughly and recharge refrigerant to conditioner with proper level after purging refrigerant Air incorporation in Discharge refrigerant thoroughly and recharge refrigerant to refrigeration cycle proper level after purging Low pressure switch is Abnormally low ambient temperature operated Lack of refrigerant Lack of refrigerant quantity Charge refrigerant to proper level.

Gas leak Check leak and charge with refrigerant after repairing faulty.

Faulty compressor Swash plate shoe is locked Replace the compressor.

Piston is locked Replace the compressor.

Faulty suction discharge valve Replace the compressor.

Faulty expansion valve Clogged valve (foreign matter) Replace the valve.

Temporary clogged due to Thoroughly perform purging freezing valve (water intrusion) after replacing valve and receiver.

T5-7-18

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty Heating Faulty heating (1) Condition:  Fault code: Un-displayed Faulty air flow Blower motor volume rotates.

Normal speed

Clogged re-circulated air filter Clogged fresh air filter Obstacles are found in inlet area Deformation or breakage of blower Adhered dirt on evaporator surface

Slow speed

Power source decreases.

Poor battery terminal contact Faulty blower motor Faulty power transistor Blower motor Blowout of fuse Replace with the Blower motor is does not rotate. same capacity fuse, locked, Faulty wiring Short circuit Faulty blower motor relay Faulty blower motor Faulty power transistor Blower interferes with case Faulty controller Faulty ground in body Faulty wire harness, disconnection of connector Blowout of power transistor thermal fuse due to locked blower motor Air flow volume Coolant temperature is low. is normal Coolant Disconnection of air mix damper link temperature is Air incorporation in hot-water circuit normal.

Clogging, breakage, and bending of piping Extremely low ambient temperature Lack of engine coolant level Broken heater core

T5-7-19

Filter cleaning Filter cleaning Remove obstacles.

Replacement of blower Evaporator surface cleaning Check battery charging system.

Repair Replace Replace Replace the blower motor.

Refer to wiring diagram and check.

Check the wire harness.

Replace Replace Replace Repair Replace the controller.

Make sure to ground.

Check the wire harness.

Replace the blower motor.

Set the link again.

Bleed air from the circuit.

Repair or replace Refill engine coolant to proper level.

Replace the heater core.

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Faulty heating (2) Condition:  Fault Code: E44 (Abnormal air mix damper servo motor) Caught foreign matter Remove foreign matter.

Faulty wire harness, open circuit, Check the wire disconnection of connector harness.

Faulty servo motor Replace

T5-7-20

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Others  Faulty air vent switch Fault code is un-displayed.

Fault code E43 (Abnormal air vent damper servo motor)

Disconnection of link Faulty wire harness, open circuit, disconnection of connector Faulty servo motor Caught foreign matter

 Faulty fresh / re-circulated air selection Fault code is un-displayed.

Disconnection of link Faulty wire harness, open circuit, disconnection of connector Faulty servo motor Caught foreign matter  Ambient temperature is higher or lower than settemperature Fault code E11 (Open circuit in reOpen circuit in wire harness, circulated air temperature sensor) disconnection of connector Open circuit in re-circulated air temperature sensor Fault code E12 (Short circuit in reShort circuit in wire harness circulated air temperature sensor) Short circuit in re-circulated air temperature sensor Fault code is un-displayed. (Normal reFaulty cooling, faulty heating circulated air temperature sensor)

T5-7-21

Set the link again.

Check the wire harness.

Replace Remove foreign matter.

Set the link again.

Check the wire harness.

Replace Remove foreign matter.

Check the wire harness.

Replace Check the wire harness.

Replace Check by referring to the items of faulty cooling and faulty heating.

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner  Noise Case connection Blower fan motor connection

Gas blowing sound (roaring) Expansion valve connection, Whistle sound, Gas blowing sound.

Clutch disengaging sound

Compressor rotating sound

 Others Water leak, Water splash

Abnormal smell

Louver resonance Fan contacts case, Foreign matter enters case Brush friction noise, metal and/or thrust washer contact Gas vibration noise (compressor discharge and/or suction gas noise) Abnormal noise from expansion valve, Expansion valve is normally functioning Faulty clutch bearing, and/or idle pulley bearing Contact of clutch amature due to resonance. Loose belt, Loose screws Noisy compressor Vibration due to V belt looseness, Loose screws

Repair or replace.

Remove foreign matter. Readjust fan motor location.

Slight noise is unavoidable. Replace if loud.

No functional problem exists.

Broken heater core, Broken hose Clogged case drain port and/or drain hose Absorbed cigarette and dust smell on evaporator fins

Replace Clean

T5-7-22

Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.

Replace Repair or replace the clutch. Re-tighten screws.

Repair or replace Re-adjust the belt. Re-tighten screws.

Clean the evaporator.

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Cooling circuit check by using manifold gauge Condition:  Engine Speed: Fast idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool  Fresh/re-circulated air selection: Re-circulated Air 1. In normal  Low-pressure side pressure: 0.15 to 0.25 MPa  High-pressure side pressure: 1.37 to 1.57 MPa NOTE: The reading of manifold gauge may depend on conditions.

f

TDAA-05-07-018

2. Lack of refrigerant quantity Trouble

Pressure is low on both sides of high-pressure and low-pressure. Cooling performance is low.

Cause Refrigerant quantity is low. Gas leak.

Remedy Check and repair of gas leak. Charge air conditioner with refrigerant.

TDAA-05-07-019

3. Excessive refrigerant, lack of condenser cooling Trouble

Pressure is high on both sides of highpressure and low-pressure. Cooling performance is low.

Cause Overcharge air conditioner with refrigerant.

Faulty condenser cooling.

Remedy Adjust refrigerant quantity. Clean condenser.

Check for machine cooling system.

TDAA-05-07-020

4. Water incorporation in circuit.

Trouble

After using a certain period of time, lowpressure side gradually indicates negative pressure.

Cause Water is mixed in circuit.

Remedy Replace receiver tank. Thoroughly perform purging before charging refrigerant to remove water.

TDAA-05-07-021

T5-7-23

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner 5. Faulty compression of compressor Trouble

Low-pressure side is high and high-pressure side is low. High-pressure becomes equal to low-pressure immediately after stopping the air conditioner.

Cause Faulty compressor.

Remedy Check and repair of compressor.

TDAA-05-07-022

6. Refrigerant does not circulate (clogged circuit) Trouble

When absolutely clogging, low-pressure side indicates negative pressure quickly. When slightly clogging, low-pressure side gradually indicates negative pressure.

Cause Dirt or water adheres or freezes to expansion valves, refrigerant does not flow.

Remedy Replace receiver tank. Perform purging.

TDAA-05-07-023

7. Air incorporation in circuit Trouble

Pressure is high on both sides of highpressure and low-pressure. When touching low-pressure piping, it is not cold.

Cause Air is mixed in system.

Remedy Replace refrigerant. Perform purging.

TDAA-05-07-024

8. Excessive open of expansion valve Trouble

Pressure is high on both sides of highpressure and low-pressure. Frost (dew) adheres to low-pressure piping.

Cause Faulty expansion valve.

Remedy Replace expansion valve.

TDAA-05-07-025

T5-7-24

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner Check Refrigerant Quantity Through Sight Glass Condition:  Engine Speed: Fast idle  Cab Window: Fully Open  Air Conditioner: ON  Airflow volume: Maximum  Temperature Control Switch: Maximum cool  Fresh/re-circulated air selection: Re-circulated Air Refrigerant Quantity Sight Glass Appropriate

Almost clear. Gas bubbles may be seen but will disappear by changing engine speed.

TKEB-05-07-026

Insufficient

A steady stream of gas bubbles is seen in the liquid flowing from the receiver tank.

TKEB-05-07-027

Scarce

No bubbles but misty.

TKEB-05-07-028

T5-7-25

SECTION 5 TROUBLESHOOTING Group 7 Air Conditioner (Blank)

T5-7-26

SECTION 5 TROUBLESHOOTING Group 8 e-Service Outline The input signals from various sensors and switches of the machine as data are recorded as Operation Data in DLU. The recorded data can be downloaded to the personal computer. The downloaded data can be uploaded to the center server via LAN, and can be used as “e-Service”. The machine equipped with the communication terminal (optional) sends the data to the center server by using the communication terminal. (As for the communication system, refer to T5-8-3.)

T5-8-1

SECTION 5 TROUBLESHOOTING Group 8 e-Service List of Operation Data List of Daily Report Data Item Date Machine Hour Meter Travel Operating Time Swing Operating Time Machine Operation Time Engine Load Information

Engine Blow-By Information Engine Speed Histogram

780 to 1200 min-1 1201 to 1600 min-1 over 1601 min-1 Engine Coolant less than 83 °C Temperature 84 to 96 °C Histogram over 97 °C Hydraulic Oil less than 80 °C Temperature 81 to 90 °C Histogram over 91 °C Controller Information Latitude Longitude

Details Date of daily report data.

Hour meter cumulative hours. (Hours are recorded by hour meter from DLU.) Total travel operating hours during a day. (Hours are recorded by travel operation pressure information from ELUT.) Total swing operating hours during a day. (Hours are recorded by swing operation pressure information from ELUF.) Total operating hours which adding travel operating hours and swing operating hours, during a day.

The mean Engine Load Information every hour. (The value that the fuel consumption (L/hr) from ECM is divided by the rated fuel consumption (L/hr) is recorded.)

The Engine Blow-By Information every hour. (The value is recorded by engine blow-by information from ECM.) The distribution of each Engine Speed every hour. (The distribution is recorded by engine speed information from PFU.) The distribution of each Engine Coolant Temperature every hour. (The distribution is recorded by engine coolant temperature information from ECM.) The distribution of each Hydraulic Oil Temperature every hour. (The distribution is recorded by hydraulic oil temperature information from MCU.) The software version of each controller.

Final position during a day. (Signal from GPS antenna.)

Final position during a day. (Signal from GPS antenna.)

fNOTE: The daily operation in this table is equivalent to the hours between 0:00 and 23:59:59 counted by GMT (world standard time) which is received by using a GPS antenna. In case the engine is kept operated beyond 0:00, such data are recorded as those for the following day.

T5-8-2

SECTION 5 TROUBLESHOOTING Group 8 e-Service Communication System The communication system is used for maintenance of the machine: “e-Service” by transmitting various data of the machine regularly via the communication terminal.

fNOTE: The communication system transmits digital

data through the radio wave. Depending on the circumstances of the machine (ex. in a building, in a tunnel, affected by surrounding buildings, and affected of noise), the data transfer rate may become slower, or the communication might not be established. If there is excessively noise or use of electrical equipment which causes noise near the machine, they cause reduces data transfer rate or communication might not be established at worst.

The communication terminal, GPS antenna, and communication antenna are installed to the machine equipped with the communication system.

The functions of each equipment are:  Communication Terminal: Receives the data from DLU, and sends the data to the communication antenna.  GPS Antenna: Receives location information of the machine.  Communication Antenna: Communicates the data.

T5-8-3

SECTION 5 TROUBLESHOOTING Group 8 e-Service (Blank)

T5-8-4

SECTION 5 TROUBLESHOOTING Group 9 Aftertreatment Device Remedy at Abnormal DEF Pressure If the following fault codes are displayed, perform the remedy according to the procedure.

Fault Code HCM Code 000531-02 000531-16 000531-18 031521-02 031521-16 031521-18

Cummins Code 03596 03575 03574 04468 04467 04466

Description AT1 DEF Pressure Data Erratic AT1 DEF Pressure High AT1 DEF Pressure Low AT2 DEF Pressure Data Erratic AT2 DEF Pressure High AT2 DEF Pressure Low

Procedure Procedure Detail 1 Check appearance of the machine and confirm that DEF leakage is observed.

Condition Key Switch: OFF

2

Check if DEF piping in-line filter (a), supply module strainer (b), supply module filter (c), and dosing module strainer (d) are clogged.

Key Switch: OFF

3

Check the wire harness.

Key Switch: OFF

Check if the wire harness is abnormal.

4

Sample DEF. Check if DEF is dirty.

Key Switch: OFF

Check if dirt is observed.

5

Clean the DEF tank. Replace DEF. (Refer to T5-9-4.)

Run the engine for 5 minutes after the engine starts. Check if the fault codes described above are displayed.

Key Switch: OFF

-

6

7

Evaluation Remedy Check if leakage is YES: Replace the parts observed. in which leakage is observed.

NO: Go to Procedure No. 2.

Check if clogging YES: Replace the clogged is observed. filter. Clean the strainer.

Go to Procedure No. 4.

NO: Go to Procedure No. 3.

Start the engine.

Check if the fault Key Switch: OFF after codes described evaluation above are displayed.

Contact your nearest Cummins Key Switch: OFF dealers for the current Cummins fault code and the details.

T5-9-1

-

YES: Correctly connect the wire harness. Go to Procedure No. 6.

NO: Go to Procedure No. 7.

YES: Go to Procedure No. 5.

NO: Go to Procedure No. 6.

Go to Procedure No. 6.

YES: Go to Procedure No. 7.

NO: End of confirmation End of confirmation

SECTION 5 TROUBLESHOOTING Group 9 Aftertreatment Device

a

b

TKEB-05-09-001 abc-

c

DEF Piping In-Line Filter Supply Module Strainer Supply Module Filter

Detail e

d

e TKEB-01-02-079

TKEB-05-09-002 d-

T5-9-2

Dosing Module Strainer

SECTION 5 TROUBLESHOOTING Group 9 Aftertreatment Device Remedy at Abnormal DEF Quality If the following fault codes are displayed, perform the remedy according to the procedure.

Fault Code HCM Code 031501-02 031501-03 031501-04 031501-09 031501-10 031501-11 031501-13 031501-15 031501-18

Cummins Code 03878 01686 01685 03868 04277 01715 01714 04842 03867

Description AT DEF Quality Sensor Data Erratic AT DEF Quality Sensor Circuit Failed High AT DEF Quality Sensor Circuit Failed Low AT DEF Quality Sensor Abnormal Update Rate AT DEF Quality Abnormal Rate of Change AT DEF Quality Sensor Root Cause Not Known AT DEF Quality Sensor Out of Calibration AT DEF Quality Above Normal Operating Range AT DEF Quality Below Normal Operating Range

Procedure Procedure Detail 1 Measure DEF concentration in the DEF tank by using a DEF concentration gauge. (*1)

Condition Key Switch: OFF

Evaluation Specification (32±3%)

2

Check the wire harness.

Key Switch: OFF

Check if the wire harness is abnormal.

3

Clean the DEF tank. Replace DEF. (Refer to T5-9-4.)

Check DEF Concentration by monitoring.

Key Switch: OFF

-

Key Switch: ON

Specification (32±3%)

4

5

Start the engine. Check if the fault Start the engine.

Check if the fault codes described above are displayed. Key Switch: OFF after codes described evaluation above are displayed.

6

Contact your nearest Cummins Key Switch: OFF dealers for the current Cummins fault code and the details.

-

Remedy YES: Go to Procedure No. 2.

NO: Go to Procedure No. 3.

YES: Correctly connect the wire harness. Go to Procedure No. 4.

NO: Go to Procedure No. 3.

Go to Procedure No. 4.

YES: Go to Procedure No. 5.

NO: Go to Procedure No. 6.

YES: Go to Procedure No. 6.

NO: End of confirmation End of confirmation

*1 Use commercially available DEF concentration gauge. Follow the instructions of the gauge for the information about how to use it.

T5-9-3

SECTION 5 TROUBLESHOOTING Group 9 Aftertreatment Device Clean DEF Tank When the DEF tank must be cleaned, clean the DEF tank as follows.

Procedure Procedure Detail 1 Loosen valve (a). Drain DEF from the DEF tank.

2 Remove bolts, washers (b) (18 used). Remove covers (c) (3 used).

3 Clean the DEF tank by high-pressure washing through the cover mounting port. Or insert a hose through the cover mounting port and clean the DEF tank. (*1) 4 Tighten valve (a).

5 Install covers (c) (3 used) with bolts, washers (b) (18 used). j : 17 mm

Condition Key Switch: OFF Key Switch: OFF Key Switch: OFF

Key Switch: OFF Key Switch: OFF

m : 50 N·m(37 lbf·ft) 6 7

After cleaning the DEF tank, fill new DEF. Ensure that the DEF level is scale mark "2" or more on the monitor. If the DEF level is below the scale mark "2", add DEF.

Key Switch: OFF Key Switch: ON

*1 Do not use a fabric towel when cleaning the inside of the DEF tank. Accumulation of thread may cause clogging.

b

c TKEB-05-09-003

a abc-

Valve Bolt, Washer Cover

T5-9-4

SECTION 5 TROUBLESHOOTING Group 9 Aftertreatment Device Remedy when Mixing Oil in DEF Tank When liquid other than DEF (such as oil) is mixed in the DEF tank, liquid in the DEF tank must be changed with new DEF. When oil is mixed in the DEF tank, the parts must be replaced. Perform the remedy as follows.

Procedure Procedure Detail Condition 1 Identify the mixed liquid. If no oil is mixed, clean the DEF tank.

Key Switch: OFF 2 If oil is mixed, the parts must be replaced. Check that the Key Switch: OFF machine is operated or not after mixing the liquid.

If the machine was not operated after mixing oil, clean the DEF tank and replace the DEF sensor unit.

If the machine was operated after mixing oil, oil may enter the DEF piping or aftertreatment device and it may cause fire at worst. In this case, clean the DEF tank and replace the DEF sensor unit, DEF supply module, DEF dosing module, aftertreatment device, and DEF piping.

T5-9-5

SECTION 5 TROUBLESHOOTING Group 9 Aftertreatment Device (Blank)

T5-9-6

MEMO

MEMO

THE ATTACHED DOCUMENT LIST  Attached Document The following diagrams are attached to this manual.

1. ELECTRICAL CIRCUIT DIAGRAM (1/12) 2. ELECTRICAL CIRCUIT DIAGRAM (2/12) 3. ELECTRICAL CIRCUIT DIAGRAM (3/12) 4. ELECTRICAL CIRCUIT DIAGRAM (4/12) 5. ELECTRICAL CIRCUIT DIAGRAM (5/12) 6. ELECTRICAL CIRCUIT DIAGRAM (6/12) 7. ELECTRICAL CIRCUIT DIAGRAM (7/12) 8. ELECTRICAL CIRCUIT DIAGRAM (8/12) 9. ELECTRICAL CIRCUIT DIAGRAM (9/12) 10. ELECTRICAL CIRCUIT DIAGRAM (10/12) 11. ELECTRICAL CIRCUIT DIAGRAM (11/12) 12. ELECTRICAL CIRCUIT DIAGRAM (12/12) 13. ELECTRICAL CIRCUIT DIAGRAM (AERIALANGLE) 14. ELECTRICAL CIRCUIT DIAGRAM (CAMERA) 15. CONNECTORS 16. HYDRAULIC CIRCUIT DIAGRAM (BACKHOE)  Fault Code List Download and use “fault code list” form the e-cabinet menu of the Global e-Service.