Ex1003 OPERATIONAL PERFORMANCE TES SECTION 06 CONTENTS Group 01- Introduction Group 04- Hydraulic Component Test Purpose 06-01-01 4-1 Pilot Primary Pressure T06-04-01 Terminology 06-01-01 4-2,Pilot Secondary Pressure 06-04-03 Preparation For Performance 4-,Proportional Solenoid Valve Tests 06-01-02 Pressure ( PC Pressure) 06-04-04 4-4,Swing Parking Brake Group 02- Engine Test Releasing Pressure 06-04-07 2-1.Engine Speed 06-02-01 4-5.Reducing Valve Pressure Setting 2-2.Engine Compression Pressure T06-02-03 (PI Pressure) T06-04-08 2.8.Valve Clearance Adjustment. T06-02.04 4-6 Main Pump Delivere Pressure 2-4.Nozzle Check T06-02-06 (Control Levers in Neutral) T06-04-10 2.6.Injection Timing 06-02-08 4-7 Main Relief Pressure RoliefSeting 06-04-11 Group 03- Excavator Test 4-8.Overload Relief Valve 3-1 Travel Speed T06-03-01 Pressure Setting 06-04-15 3-2.Track Revolution Speed 06-03-02 4-9.Main Pump Flow Test 06-04-17 3-3.Mistrack Check 06-03-08, 410.Swing Motor Drainage 06-04-19 3-4.Travel Parking Function Check 06-03-04 4-11.Travel Motor Drainage T06-04-21 3-5.Swing Speed - 06-03-05 3-6.Swing Function Drift Check . 06-03-06 Group 05- Basic Performance Check 3-7.Swing Motor Leakage 06-03-07 Basic Operational Performance Check 3-8.Swing Bearing Play 706-03-08 with the Dr. EX T06-05-01 3.9:Hydraulic Cylinder Gycle Time 706-03-09 5-1.Pressure (P) switch Check .. T06-05-02 3-10.Dig Function Drift Check 06-03-10 5-2 Performance Check with Control Lever 3-11.Control Lever Operating Force 76-08-11 3-12,Control Lever Stroke 06-03-12 3-13.Combined Boom Raise/Arm Roll-In Functions Check 06-03-13 3:14.Combined Boor Raise/Swing Functions Check 06-03-14 in the Neutral Position, and at Relief Pressure o To6-05-03, 5-3.A sensor ( Pump Displacement ‘Angle Sensor ) Check T06-05-05, 5-4.Single Operation Check T06-05-05 134T-06-01Ex1003 Combined Operation 5-5.Combined Boom Raise and Arm Roll-In Operation 5-6.Combined Bucket Roll-In Relief and Boom Raise Check 5-7.Combined Bucket Roll-In ‘and Boom Raise Check 5-8.Combined Travel and Arm Roll-In Relief Check 5-9.Swing Check with Precision Mode (M4) Group 06- Standard Operational Performance Standard 06-05-07 06-05-09 76-05-11 7706-06-12 7106-05-14 06-06-01 1347-06-02OPERATIONAL PERFORMANCE TEST / Introduction PURPOSE Performance tests are used to check: 1. OPERATIONAL PERFORMANCE OF A NEW MACHINE When ever a new machine is delivered in parts and reassembled at a customer's site, it must be tested to confirm that the operational perfor- mance (Excavator Test) of the machine meets HITACHI STANDARDS. 2. OPERATIONAL PERFORMANCE OF A WORK- ING MACHINE With the passage of time, the machine's oper- ational performance deteriorates, so that the machine needs to be serviced periodically to re- store it to its original performance level Before servicing the machine, conduct perfor- mance tests to check the extent of deteriora tion, and to decide what kind of service needs to be done (by referring to the “Allowable Lim. its” in this manual). conditions 3. OPERATIONAL PERFORMANCE OF A REPAIRED MACHINE After the machine is repaired or serviced, it must be tested to confirm that its operational performance was restored by the repair andjor service work done. TERMINOLOGY 1, ‘STANDARD" Specifications applied to the brand-new ma- chine, components and parts. 2. “ALLOWABLE LIMIT” ‘The lowest acceptable performance level. When the performance level of the machine falls be- low this level, the machine must be removed from work and repaired. Necessary parts and components must be replaced, T06-01-01OPERATIONAL PERFORMANCE TEST / Introduction PREPARATION FOR PERFORMANCE TESTS Observe the following rules in order to carry out performance tests accurately and safely. 1. THE MACHINE Repair any defects and damage found, such as cil or water leaks, loose bolts, cracks and so on, before starting to test. 2. TEST AREA (1) Select a hard, flat surtace. (2) Secure enough space to allow the machine to run straight more than 20 m (65 ft 7 inch), and to make a full swing with the front at- tachment extended, (3) If required, rope off the test area and provide signboards to keep unauthorized personnel away. 3, PRECAUTIONS (1) Before starting to test, agree upon the sig- nals to be employed for communication among coworkers. Once the test is started, be sure to communicate with each other us: ing these signals, and to follow them without fail (2) Operate the machine carefully and always give first priority to safety. (8) While testing, always take care to avoid acci- dents 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 eer escaping oll. Pay special attention to this when removing hydraulic pipings. 4, MAKE PRECISE MEASUREMENTS (1) Accurately calibrate test instruments in ad- vanee to obtain correct data, (2) Carry out tests under the exact test condi- tions prescribed for each test item. (8) Repeat the same test and confirm that the test data obtained can be procured repeatedly. Use mean values of ‘measurements if necessary. T06-01-02OPERATIONAL PERFORMANCE TEST / Engine Test 2.1 ENGINE SPEED Measure the engine speed at each power mode (recommended testing equipment: Dr. EX) NOTE: The engine speed at each power mode must meet standard engine speed; if not, all other operational performance data wil be unreliable. Itis essential to perform this test frst Preparation: (1) Warm up the machine, until the engine coolant temperature reaches 50°C (122°F) of more, and the hydraulic ol is 50°-£5°C (122°F +9°F) Ore (2) Push the Pemode switch and confirm that the fuel injection pump governor lever (2) comes into con- tact with the fast-idle stopper (1). NOTE: Never adjust stopper (1). (3) Connect Dr. EX to the diagnosing connector of the PVC, located behind the operator's seat, to obtain realtime engine speed data (4) If Or, EX is not available, connect engine tachome- ter (1) to fuel injection pipe (2) T06-02-01OPERATIONAL PERFORMANCE TEST / Engine Test Measurement: (1) Start the engine, The engine will run at start idle speed. Measure engine speed with Dr. EX (or a tachometer), (2) Press work mode selector switch (2) to the gener- al purpose mode, and tur off auto-idle switch (3) (8) Measure and record the engine speed at each power mode (1) (P, E, L,I. (4) Next, push auto-idle switch (3) ON, and select the P.mode. (8) Lightly operate the bucket control lever a few times, then return the control lever to neutral; the engine will automatically enter the auto-idle speed alter 4 seconds, (6) Measure and record the auto-idle speed. Evaluation: Refer to Group -06 in this section. Remedy: Refer to 07-03 TROUBLESHOOTING B. T06-02-02OPERATIONAL PERFORMANCE TEST / Engine Test 2.2 ENGINE COMPRESSION PRESSURE, 1. Measure compression pressure in the cylinders to check for a decline in engine power. 2. Check exhaust gas color and the amount of blow-by gas from the crankcase. Keep track of engine oil consumption. 3. Check for abnormalities in the intake system, includ ing the air fiter. Preparation: 1. Confirm that valve clearances are correct. 2. Confirm that the batteries are charged properly. 3. Fun the engine until the coolant temperature gauge reaches the operating range. 4. Stop the engine. Remove glow plugs from each cy! inder. 5, Install an adaptor and compression gauge in place of the glow plug in one cylinder. ( Be sure to sulfi- ciently tighten the adaptor and compression gauge to prevent air leakage.) Measurement: 1. Turn the starter to crank the engine. Record the compression pressure of each cylinder. 2. Repeat measurement three times for each cylinder and caleulate the mean values. Evaluation Refer to Group -06 in this section. Remedy: Refer to engine shop manual T06-02-03OPERATIONAL PERFORMANCE TEST / Engine Test 2.3. VALVE CLEARANCE ADJUSTMENT NOTE: 1. Perform the measurement when the engine is cold, 2, Before starting work, olean the head cover ‘mounting area to avoid contamination in the engine. Preparation : 1 Locate the top dead center (TDC) in the compres- sion stroke. Align the TOC mark on the crank pulley with the pointer located on the timing gear case as illustrat- ‘ed. Piston No.1(0F piston No.4) is now positioned at the TOC in its compression stroke. 2. Remove the head cover. 3, Move push rods for the intake and exhaust valves on the No.1 cylinder up and down by hand. If any clearances on the both ends of the push rods are found, piston No.1. is positioned at TOC in the ‘compression stroke. (If the exhaust valve of cylin- der No.1 is pushed down, piston No.4 is positioned at TOC in the compression stroke. Start measurement from the cylinder (No.1 or No.4) positioned at TOC in the compression stroke, ‘Measurement: 1. Insert a thickness gauge into the clearance be- tween the rocker arm and the valve stem end to measure the valve clearance. NOTE: The cylinders are aligned from No. 1 to No. 4 in that order, as viewed from the fan side “TDC Mark T06-02-04OPERATIONAL PERFORMANCE TEST / Engine Test 2. When the measurement is started from No.1 cylin- der, perform the same measurement to all valves indicated with the mark * O' in the table below. (When the measurement is started from No.6 cylin- der, perform the measurement in the valves shown with mark *%",) Cylinder No, Not | No2 | Nod | Nod Valve locations 5 |S | a) Se (EE Se When the ese ment ig"started from No.1 cylinder Ca healie 2 When the measure: ment ig started rom ale ale No.6 cylinder 8. Rotate the crankshaft 360°, Align the TDC mark with the pointer. Then, contin ue measurement of other valves in the same way. Evaluatior Standard Valve Clearance: Intake valve : 0.40 mm (0.0187 inch) Exhaust valve: 0.40 mm (0.0157 inch) Adjustment: if the measurement results are outside the standard specification, adjust the valves clearances in the same order of measurement. 1. Loosen the adjusting screw lock nuts for the rocker arms, Insert the thickness gauge set at 0.4 mm, ad- just the adjusting screws. 2. After adjusting, retighten the lock nuts to the speci- fication, Recheck the valve clearance after the lock nuts are tightened. =t :25.544.9 Nem ( 2,640.5 kgtm, 18.8 Ibi) ) T06-02-05OPERATIONAL PERFORMANCE TEST / Engine Test 2.4.NOZZLE CHECK NOTE: 1. Check the injection pressure and the spray pattern with a nozzle tester. 2. Before starting work, clean the nozzle holder ‘mounting area to avoid contamination in the engine. Preparation: 1, Remove the nozzle holders. Remove all nozzle holders and fuel injection pipings from the engine. 2. Attach a nozzle holder to the nozzle tester. Measurement: By cauTion: never touch epray erty, The fue spray from the nozzle may pene- trate the skin, resulting in serious injury. If fuel penetrates into the blood stream, it may cause blood toxication. 1. Injection pressure After attaching the nozzle holder to the nozzle test- er, strongly make several strokes of the tester to in- ject fuel. Then, while operating the tester at approx, 60 time strokes a minute, measure the fuel injection pressure. If adjustment is required, loosen the lock nuts and adjust the adjusting screws. Tum clockwise to in- crease the pressure, and counterclockwise to de- crease the pressure. 2. Spray pattern For this test, turn the pressure tester knob to by- pass the pressure gauge. Attach the nozzle holder to the nozzle tester. Strongly make several strokes of the tester and check the fuel spray pattern. NOTE: Use clean diesel oil. T06-02-06OPERATIONAL PERFORMANCE TEST / Engine Test Evaluation: 1. Standard Injection Pressure: 18.1 MPa (185 kglfom?, 2 631 psi) Normal 2. Spray Pattern ‘ Large-size spray should not be visible to the na- ked eye No stray sideways sprays should be seen. ‘¢ During initial injection stage, spray size should be fine and injected intermittently ‘¢ There should be no drips found. oy «Injection spray angle must be normal ‘Abnormal Adjustment: ‘@ To adjust the injection pressure, loosen the lock nuts. Adjust the adjusting screw. Tur clockwise to increase the pressure, and counterclockwise to decrease the pressure. 7 @ After adjusting, retighten the lock nuts. T06-02-07OPERATIONAL PERFORMANCE TEST / Engine Test 2.5. INJECTION TIMING Inspection: 1. Position No.1 piston to the top dead center. Turn the crank pulley in the direction of rotation (clock- wise as seen from the front of the engine) to set a “TDC" mark on the crank pulley under the “point- er’, located on the timing gear case. 2. Remove the timing check hole cover on the front section of the fuel injection pump. When the mark on the injection pump is set under the projection of the gear case, No.1 piston is posi- tioned at the top dead center. If the mark is not set under the projection, keep turning to adjust. 3. Tum the crank pulley at approx.30 degrees coun- terclockwise, 4, Flemove the injection piping from No.1 cylinder. 5. Remove the delivery valve holder for No.1 cylinder from the injection pump to pull the delivery valve and the spring out. Reinstall the delivery valve hold- er. F=N 89 to 43. Nim (4 to 4.4 kgfm, 28.9 to 31.8 Ibtt) 6. While supplying fuel with the feed pump, turn the, crank pulley slowly clockwise just until fuel cannot be seen from the top of the delivery valve hole. This is the position where the injection starts. 7. Check the timing mark, located on the crank pulley for what degrees the pointer indicates. Adjustment: 41. Turn the crank pulley so that the pointer comes just above the correct timing position (16 degrees be- fore the TDC) on the crank pulley. 2. Loosen the mounting nuts of the injection pump. 3. When advancing timing, tit the injection pump out- ward against the cylinder block. When delaying timing, tlt the injection pump inward against the cylinder block. 1 Gear case Projection Injeetion pump Alignment mark Gear case Projection Injection pump Alignment mark T06-02-08OPERATIONAL PERFORMANCE TEST / Excavator Test 3.1 TRAVEL SPEED Measure the time required for the excavator to travel a 10 m (92.8 ft) test track. Preparation: 1. Adjust the track sag of both tracks to be equal 2. Prepare a flat and solid test track 10 m (92.8 ft) in length, with extra length of 3 to 5 m (9.8 to 16 ft) on both ends for machine acceleration and decel eration. 3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above the ground with the arm and bucket rolled in 4, Maintain the hydraulic oil temperature at 5025 °C (12289°F) Measurement 1, Measure both the medium and fast speeds of the machine. 2. Before starting either the medium or fast speed tests, adjust the travel mode switch to the speed to be tested, then select the following switch posi- tions: Power mode selector: P mode Work mode selector: General purpose Auto-idle switch: OFF 3. Start traveling the machine in the acceleration zone with the travel levers at full stroke. 4. Measure the time required to travel 10 m (32.8 ft). 5. After measuring the forward travel speed, turn the upperstructure 180° and measure the reverse travel speed 6 Repeat steps (4) and (5) three times in each direo- tion and calculate the average values. Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLE SHOOTING B. st05m Deceteraton 305m ‘eoeleration zone T06-03-01A 9503OPERATIONAL PERFORMANCE TEST / Excavator Test 3.2 TRACK REVOLUTION SPEED Measure the track revolution cycle time with the track raised off ground, Preparation: 1. Adjust the track sag of both side tracks to be equal, 2. On the track to be measured, mark one shoe with chalk. 3. Swing the upperstructure 90° and lower the buck- et to raise the track off ground. Keep the boom- arm angle between 90 to 110° as shown. Place blocks under machine frame. 4, Maintain the hydraulic oil temperature at 5025 °C (12239°F) Measurement: 1. Select the following switch positions: Travel mode switch: Fast Power mode selector: P mode Work mode selector: General purpose Auto-idle switeh: OFF 2, Operate the travel control lever of the raised track in full forward and reverse, 3, Measure the time required for 3 revolutions in both directions. 4, Raise the other side of machine and repeat the procedure. 5. Repeat steps (4) and (5) three times and calculate the average values, Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING 8. T06-03-02OPERATIONAL PERFORMANCE TEST / Excavator Test 3.3 MISTRACK CHECK Measure the deviation by the tracks from a 20 m (65.5 ‘t) straight line. Preparation: 1. Adjust the track sag of both tracks to be equal. 2. Provide a fiat, solid test yard 20 m (65.5 ft) in length, with extra length of 3 to 5 m (9.8 to 16 ft) ‘on both ends for machine acceleration and decel- eration. 3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above the ground with the arm and bucket rolled in 4, Maintain the hydraulic oil temperature at 5035 °C (12229°F) Measureme! 1, Measure the amount of mistracking at fast, medi- um and slow travel speeds. 2. Before beginning each test, select the following switch positions: Power mode selector: P mode Work mode selector: General purpose Auto-idle switch: OFF 3. Start traveling the machine in the acceleration zone with the travel levers at full stroke. 4, Measure the maximum distance between a straight 20 m (65.5 ft) line and the track made by the ma- chine, 5. After measuring the tracking in forward travel, turn the upperstructure 180° and measure that in re- verse travel 6. Repeat steps (4) and (6) three times and calculate the average values. Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. Maximum distance St05m (8 1020in) extra length ‘deceleration T06-03-03OPERATIONAL PERFORMANCE TEST / Excavator Test 3.4 TRAVEL PARKING FUNCTION CHECK Measure the travel motor slip on a specified slope. Preparation: 1, The face of the test slope shall be even, with a gradient of 20%, 2, Raise the bucket 0.3 to 0.5 m (12 to 20 in) above the ground with the arm and bucket cylinders fully extended, 3. Maintain the hydraulic oll temperature at 505 °C. (12289 °F) Measurement: 1. Climb the slope and place the travel levers in neu- tral 2. Stop the engine. 3. After parking the machine, make aligning marks on the side frame and a track link or shoe. 4, After five minutes, measure between the marks. Evaluation: Refer to Group -06 in this section. Aging marks Distance Remedy: Refer to T07-03 TROUBLESHOOTING 8. T06-03-04OPERATIONAL PERFORMANCE TEST / Excavator Test 3.5 SWING SPEED Measure the time required to swing three complete turns. Preparation: 1. Check the lubrication of the swing gear and swing bearing, 2. Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on slopes. 3. With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin is the same as the boom foot pin. The bucket must bbe empty, 4. Maintain the hydraulic oil temperature at 505 °C (12288° F) Measurement: 1. Select the following switch positions: Power mode selector: P mode Work mode selector: General purpose Auto-idle switch: OFF 2. Operate swing contro! lever fully 3, Measure the time required to swing 3 tums in one direction, 4. Operate swing control lever fully in the opposite di- rection and measure the time required for 3 turns. 5. Repeat steps (3) and (4) three times and calculate the average values. Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-03-05OPERATIONAL PERFORMANCE TEST / Excavator Test 3.6 SWING FUNCTION DRIFT CHECK Measure the swing drift on the bearing outer circumfer- ence when stopping after a 180° full-speed swing. Preparation: 1. Check the lubrication of the swing gear and swing bearing 2. Place the machine on flat, solid ground with ample ‘space for swinging. Do not conduct this test on slopes. ‘Two chalk marks 3. Position the arm cylinder with the rod 50 mm (2 inch) extended from the fully retracted position. 105-06-09.008 4, Position the bucket cylinder with the rod 50 mm (2 inch) retraced from the fully extended position. 5, With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin is the same as the boom foot pin 6. The bucket must be empty. 7. Make two chalk marks: one on the swing bearing and one directly below it on the track frame. & Swing the upperstructure 180°. 9. Maintain the hydraulic oil temperature at 505 °C (12229 °F) Measurement: 1. Conduct this test in the P mode, 2. Select the following switch positions: — Power mode selector: _P mode Measure aiference between marks Work mode selector: General purpose Auto-idle switch: OFF 3. Operate the swing control lever fully and return it 7 to the neutral position when the mark on the up- perstructure aligns with that on track frame after swinging 180°. Marking on the tack frame 4, Measure the distance between the two marks. 5, Align the marks again, swing 180°, then test the ‘opposite direction. eee 6. Repeat steps (4) and (5) three times each and cal- culate the average values. Marking on the swing bearing Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-03-06OPERATIONAL PERFORMANCE TEST / Excavator Test 3.7 SWING MOTOR LEAKAGE Check for upperstructure drift when suspending a load ona slop, Preparation: 1. Check the lubrication of the swing gear and swing bearing 2. Park the machine on a smooth slope with a gradient of 26.8%, 8, Load bucket fully. In lieu of loading the bucket, weight (W) of the following specification can be used. pcm W=M3x1.5 where: luoket heaped capacity (m3) Soil specific gravity 4. With the arm rolled out, and bucket rolled in, position the arm top pin height to be level with the boom foot pin, Apply a rated load to the bucket (bucket capacity x15). 5. Swing the upperstructure to position it 90° to the slope. Make aligning marks on the swing bearing pe- riphery and tracks frame using tape, as illustrated 6. Maintain the hydraulic oil temperature at 505 °C (12289 ° F), Measurement: 1. Maintain the engine at slow idle. After five minutes, measure the difference between the marks along the swing bearing periphery and the track frame. 2, Perform the measurement on both right and left — ‘swing directions. 3, Perform the measurement three times in each direc- tion and calculate the average values. Measure aiference between marks Evaluation: Marking onthe tack frame Refer to Group -06 in this section. Marking onthe swing bearing Remedy: 0 Refer to T07-03 TROUBLESHOOTING B. T06-03-07OPERATIONAL PERFORMANCE TEST / Excavator Test 3.8 SWING BEARING PLAY Measure the swing bearing play using a dial gauge to check the wear of bearing races and balls Preparation: 4, Check swing bearing mounting bolts for loosening. 2. Check the lubrication of the swing bearing. Confirm that bearing rotation is smooth and without noise. 3, Install a dial gauge on the track frame as shown, using a magnetic base. 4, Position the upperstructure so that the boom aligns with the tracks facing towards the front idlers. 5. Position the dial gauge so that its needle point comes into contact with the bottom face of the bear- ing outer race. 6. Bucket should be empty. Measurement: 1. With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin. is the same as the boom foot pin. Record the dial gauge reading (hy). 2. Lower the bucket to the ground and use it to raise the front idler 0.5 m (20 inch), Record the dial gauge reading (ha). 3. Calculate bearing play (H) from this data (hs and he) as follows: Hehe — hy Measucement:(h) ‘The same height as the boom foot Evaluation: Refer to Group -06 in this section. Measurement: th) T06-03-08OPERATIONAL PERFORMANCE TEST / Excavator Test 3.9 HYDRAULIC CYLINDER CYCLE TIME Measure the cycle time of the boom, (standard) arm, and (standard) bucket cylinders. Preparation: 1. To measure the cycle time of the boom cylinders: With the arm rolled out and the empty bucket rolled in, lower the bucket to the ground, as shown. 2. To measure the cycle time of the arm cylinder: With the empty bucket rolled in, position the arm so that itis vertical to the ground. Lower the boom un- til the bucket is 0.5 m (20 in) above the ground, 3. To measure the cycle time of the bucket cylinder: The empty bucket should be positioned at mid- stroke between roll-in and roll-out, so that the side- plate edges are vertical to the ground. 4. Maintain the hydraulic oil temperature at 50°5 °C (12289 °F), Measurement: 1. Select the following switch positions: Power mode selector: P mode Work mode selector: General purpose Auto-idle switch: OFF 2. To measure cylinder cycle times: (1) Boom cylinders: Measure the time it takes to raise the boom, and the time it takes to lower the boom, To do so, position the boom at one stroke end, then move the control lever to the other stroke end as quickly as possible. (2) Armoylinder: Measure the time it takes to roll in the arm, and the time it takes to roll out the arm. To do so, position the arm at one stroke end, then move the control le- ver to the other stroke end as quickly as possible. (3) Bucket cylinders: Measure the time it takes to roll in the bucket, and the time it takes to roll out the bucket. To do so, position the bucket at one stroke end, then move the control lever to the other stroke end as quickly as possible. 3, Repeat each measurement three times and calcu- late the average values. Evaluation: Refer to Group -06 in this section, Remedy: Refer to T07-03 TROUBLESHOOTING B. 06-03-09OPERATIONAL PERFORMANCE TEST / Excavator Test 3.10 DIG FUNCTION DRIFT CHECK Measure dig function drift, which can be caused by oil leakage in the control valve and boom, (standard) arm, and (standard) bucket cylinders, with the loaded bucket, NOTE: When testing the aig function drift just after oy!- inder replacement, slowly operate each cylin der to its. stroke end to purge air. Preparation: 1. Load bucket fully. In liew of loading the bucket, weight (W) of the following specification can be used. Wem 5 where: MS=Bucket heaped capacity (m9) 1.8Soll specific gravity 2. Position the arm cylinder with the rod 50 mm ( 2 inch) extended from the fully retracted position. 3. Position the bucket cylinder with the rod 50 mm (.2 inch) retracted from the fully extended position. 4, With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin is the ‘same as the boom foot pin 5. Maintain the hydraulic oil temperature at 50°&5 °C (12289 °F) Measurement: 1. Stop the engine. 2. Five minutes after the engine has been stopped, measure the changes in the positions of the bottom of the bucket, as well as the boom, arm and bucket cylinders. 3, Repeat step (2) three times. and calculate the aver- age values Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. Extended distance Retracted stance Revacted ‘Arm cylinder extention Boom and bucket cylinders retraction T06-03-10OPERATIONAL PERFORMANCE TEST / Excavator Test 3.11 CONTROL LEVER OPERATING FORCE Use a spring scale to measure the maximum resistance of each control lever at the middle of the grip, Preparation: Maintain the hydraulic oil temperature at 505 °C (12229 °F). Measurement: 1. Start the engine. a 2. Select the following switch positions: Power mode selector. P mode Work mode selector: General purpose Auto-idle switch: OFF 3. Operate each boom, arm, bucket and swing lever at full stroke and measure the maximum operating force for each 4. Lower the bucket to the ground to raise one track off the ground. Operate the travel lever at full stroke and measure the maximum operating force required. When finished, lower the track and then rere. jack-up the other track, 5. Repeat steps (3) and (4) three times and calculate the average values. Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-03-11OPERATIONAL PERFORMANCE TEST / Excavator Test 3.12 CONTROL LEVER STROKE Measure each lever stroke at the lever top using a ruler. NOTE: When the lever has play, take a half of this val- tue and add it to the measured stroke. Prepar Maintain the hydraulic oil temperature at 50°5 °C (12289 °F) Measurement: 1. Stop the engine, 2. Measure each lever stroke at the lever top from neutral to the stroke end using a ruler. 3. Repeat step (2) three times and caloulate the average values. Evaluation: Refer to Group -08 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-03-12OPERATIONAL PERFORMANCE TEST / Excavator Test 3.13 COMBINED BOOM RAISE/ARM ROLL-IN FUNCTIONS CHECK Check boom raise and arm roll-in movement and speeds while operating both functions simultaneously. Preparation: 1. Start the engine and run it at fast idle. Operate the boom and arm cylinders and check to be sure that cylinder movement is smooth, with no sticking, 2. Roll out the empty (standard hoe) bucket with the (standard) arm fully rolled out so that the bucket teeth, bucket pin and arm mounting pin are on a straight line, and hold the bucket teeth distance A above ground. Distance A: 0.5 m (20 in) 3. Maintain the hydraulic oil temperature at 50°45°C (12229 °F), Measuremer 1. Select the following switch positions: Power mode selector : P-mode Work mode selector : General purpose Auto-Idle Switch OFF 2. Raise the boom and roll in the arm simultaneously, both at full stroke. 3. When either of the two functions reaches the stroke end, release the control levers to stop both functions, then measure the height (H) of the buck- et teeth. Measure the time required to move the boom or arm to its stroke end, if required for refer- fence purposes. 4, Repeat steps (2 and 3) three times and calculate the average values. Evaluation: Refer to Group -06 in this section, Remedy: Refer to T07-03 TROUBLESHOOTING B, T06-03-13OPERATIONAL PERFORMANCE TEST / Excavator Test 3.14 COMBINED BOOM RAISE/SWING FUNCTIONS CHECK Check boom raise and swing movement and speeds while operating both functions simultaneously. Preparation: 1. Start the engine and run it at fast idle. Operate the 0r06-08.000 boom raise function and check to be sure that cyl- inder movement is smooth, with no sticking. 2. With the (standard) arm fully rolled out and (stan- dard hoe) bucket fully rolled in, lower the bucket to the ground, The bucket must be empty. 3. Maintain the hydraulic oil temperature at 50°5°C (12289 °F), Measurement: 1. Select the following switch positions: Power mode selector : P mode Work mode selector : General purpose 1979593. Auto-idle switch =: OFF 2. Raise the boom and swing simultaneously, both at {ull stroke, 3. When the upperstructure rotates 90°, release the control levers to stop both functions. Measure the time required to swing 90° and the height (H) of the bucket teeth. 4, Repeat steps (2) and (3) three times and calculate the average values. Evaluation: Refer to Group -08 in this section. orescaos Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-03-14OPERATIONAL PERFORMANCE TEST / Component Test 4.1 PILOT PRIMARY PRESSURE Preparation: 4. Stop the engine. 2, Remove the top cover of the hydraulic oil tank with a.17 mm wrench, 3, Push the pressure release button to bleed air. 4, Loosen and remove plug on the pilot pump delivery, port and connect pressure gauge, (ST 6942) using a 6 mm hexagonal head wrench. 5, Start the engine and check for oil leakage from the port. 6. Maintain the hydraulic oil temperature at 50:5 °C (12229 °F). rose6a4cor Measurement: 1. Select the following switch positions: Power mode selector: P mode and | mode Work mode selector: General purpose Auto-idle switch: OFF 2, Measure the primary pilot pressure in both the P mode (fast idle) and the | mode (slow idle). 3. Repeat step (2) three times and calculate the aver- age values Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-04-01OPERATIONAL PERFORMANCE TEST / Component Test Pilot Primary Pressure Adjustment Adjust pilot relief valve (1) using the following proce- dure: me 22 mm aE 41. Remove plug (2) 2. Install the estimated necessary numbers of shims co) 7 3. Tighten plug (2) to the specified torque. p= at: 24.5 Nim (25 kgfm, 18 IbF tt) 4, Check the relief pressure of relief valve (1). passroo 5, Repeat steps (1) to (4) when readjustment is re- quired Shimsthickn | Change in relief pressure ess (mm) kPa ( katfom®psi) 0.25 78 (0.8, 11.4) 05 147 (1.5, 21.3) 1.0) 294 (3.0, 42.7) T06-04-02OPERATIONAL PERFORMANCE TEST / Component Test 4.2 PILOT SECONDARY PRESSURE Preparation: 1, Stop the engine. 2. Remove the top cover of the hydraulic oil tank with a 17 mm wrench. 3, Push the pressure release button to bleed air. 4. Disconnect pilot piping (1) trom the control valve section to be inspected and install pressure gauge (ST 6942) and adapter (ST 6450) assembly, as shown, using 14 and 17 mm wrenches. 5, Start the engine and check for oil leakage from the adapter. 6, Maintain the hydraulic oll temperature at 505 °C (122£9°F). Measurement: 1. Select the following switch positions: Power mode selector: P mode and | mode Work mode selector: General purpose Auto-idle switch: OFF 2, Measure the secondary pilot pressure in both the P. mode (fast idle) and the | mode (slow idl). 3. Repeat step (2) three times and calculate the aver- rous6o400s age values. Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-04-03OPERATIONAL PERFORMANCE TEST / Component Test 4.3. PROPORTIONAL SOLENOID VALVE PRESSURE SETTING (PC PRESSURE) For Pc pressure Preparation: 1. Stop the engine. 2. Remove the top cover of the hydraulic oi tank with 17 mm wrench. 3. Push the pressure release button to bleed air. 4, To measure the Pc pressure: (1) Connect Dr. EX to the diagnosing connector of the PVC, located behind the operator's seat, to obtain realtime Pc pressure data. (2) Disconnect the Pc pressure piping between propor- tional solenoid valve and the control vaive section to be inspected and install a tee (ST 6288), socket (ST 6240) and pressure gauge (ST 6942) assem: bly, as shown, using 17, 19, and 22 mm wrenches. 5, Start the engine and check for oll leakage from the tee. 6. Maintain the hydraulic oll temperature at 505 °C (12249 °F). Measurement: rioess. 08 1. Select the following switch positions: (For the boom, arm, bucket, swing travel and Aux iary circuits.) Power mode selector: P mode Work mode selector: General purpose Auto.ile switch; OFF 2. Measure the Pc pressure, using pressure gauge and Dr. EX. 8. Repeat step (2) three times and calculate the aver- age values Evaluation : Dr. EX indicated data +0.2 MPa Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-04-04OPERATIONAL PERFORMANCE TEST / Adjustment Pe Pressure Adjustment Adjust the proportional solenoid valves for right and left travel (1), swing (2), bucket (3), boom (4) and arm (5) circuits IMPORTANT: Be sure not to loosen adjusting screw (8) over three turns from the original position. Otherwise, O-ring will unseat, resulting in oil leaks, 1, Put a mark on the end face of adjusting screw (8) with white paint or a similar-substance, to record the original position. (Take care not to get paint on the thread surface.) 2. Loosen lock nut (7) and turn adjusting screw (8) 10 adjust Pe pressure eR [— :4 mm =: 8.83 Nm (0.9 kgm, 7 IbFt) 3. Check the adjustment of adjusting screw (8). Turning direction of adjusting | Counterclockwise | Clockwise ‘Change in Pc pressure Decrease Increase Pc pressure oil flow rate Increase Decrease Adjusting screw tums 14 aya | 4 Pa 28 fear facet ‘Adjusting sorew Change in Pe pressure kgtfem® 1 3 | 4 Psi 142 42.7|56.9 ee increase decrease T06-04-05OPERATIONAL PERFORMANCE TEST / Component Test For Travel Speed Selecting Pressure Preparation: 1, Stop the engine. 2. Remove the top cover of the hydraulic oil tank with 17 mm wrench. 3. Push the pressure release button to bleed air. 4. To measure the speed selecting pressure: (1) Connect Or. EX to the diagnosing connector of the PVC, located behind the operator's seat, to obtain real-time speed selecting pressure data (2) If Dr. EX is not available, disconnect travel speed selecting pressure piping (1) between proportional solenoid valve and the center joint and install adapter (ST 6450) and pressure gauge (ST 6942) assembly, as shown, using 17 mm, 19 mm and 22 mm wrenches. 5, Start the engine and check for oil leakage from the adapter. 6, Maintain the hydraulic oll temperature at 50:+5 °C (12249 °F). Measurement: 1. Select the following switch positions: Travel mode switch: Fast and medium or slow Power MODE selector: P mode Auto-idle switch: OFF 2, Measure the travel speed selecting pressure in the medium or slow mode. 3. Lower the bucket to the ground to raise the track off the ground. Operate the travel lever at full stroke and measure the fast speed pressure. 4. Repeat steps (2) and (3) three times and calculate the average values. Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-04-06OPERATIONAL PERFORMANCE TEST / Component Test 4.4 SWING PARKING BRAKE RELEASING PRESSURE Preparation: 1. Stop the engine, 2. Remove the top cover of the hydraulic oil tank with 17 mm wrench. 8, Push the pressure release button to bleed air. 4, Disconnect swing brake control pressure piping (1) between directional solenoid valve and the swing motor and install an adapter (ST 6450) and pres- sure gauge (ST 6942) assembly, as shown, using 17 mm and 19 mm wrenches. 5. Start the engine and check for oil leakage from the adapter. 6. Maintain the hydraulic oil temperature at 50:15 °C (122£9°F). Measurement: 1. Select the following switch positions: Power mode selector: P mode Auto-idle switch: OFF 2. Operate the swing function or arm roll in function and measure the swing brake control pressure with the brake disengaged. Release the control lever to return to neutral and measure the control pressure when the brake is applied. 3. Repeat step (2) three times and calculate the aver age values. Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. 06-04-07OPERATIONAL PERFORMANCE TEST / Component Test 4.5 REDUCING VALVE PRESSURE SET- TING (PI PRESSURE) Preparation: 1. Stop the engine. 2. Remove the top cover of the hydraulic oil tank with a 17 mm wrench. 3. Push the pressure release button to bleed air. 4, To measure the Pi pressure: (1) Connect Dr. EX to the diagnosing connector of the PVG, located behind the operator's seat, to obtain real-time pressure data, (2) If Dr, EX is not available, disconnect swing brake ‘control pressure piping (1) between the reducing valve and the control valve and install an adapter (ST 6450) and pressure gauge (ST 6942) assem- bly, as shown, using 17 mm and 19 mm wrenches, 5, Start the engine and check for oil leakage from the adapter. 6. Maintain the hydraulic oll temperature at 50+5 °C (12249 °F), Measurement: 1. Select the following switch positions: 10506-06008 Power mode selector: P mode Auto-idle switch: OFF 2, Measure the Pi pressure in the P mode. 3, Repeat step (2) three times and calculate the aver- age values. Evaluation: Refer to Group -06 in this section. Remedy: Reter to T07-03 TROUBLESHOOTING B. T06-04-08OPERATIONAL PERFORMANCE TEST / Component Test Pi Pressure Adjustment Adjust reducing valve (1) using the following procedure: at : 22 mm 2 1. Remove plug (2) 2. Install the estimate mumbers of shims (2) 3. Retighten plug (2) tothe spectied torque — FS 24.5 Nem (25 kghm. 18 loft) 4. Check Pi pressure. Replace the reducing valve assembly if the Pi pres- caus sure is outside the standard Pi pressure range. ‘Shimsthicks | Change in ret pressure ess(mm) | kPa kallem® psi) O.1 392 (04, 57) T06-04-09OPERATIONAL PERFORMANCE TEST / Component Test 4.6 MAIN PUMP DELIVERY PRESSURE (CONTROL LEVERS IN NEUTRAL) Preparation: 1, Stop the engine. 2, Remove the top cover of the hydraulic oil tank with 17 mm wrench. 3. Push the pressure release button to bleed air. 4, To measure the main pump pressure: (1) Connect Dr. EX to the diagnosing connector of the PVC, located behind the operator's seat, to obtain realtime main pump pressure data. (2) If Dr. EX is not available, loosen and remove the plug on the main pump delivery port and connect pressure gauge, (ST 6942) using a 6 mm_hexag- onal head wrench, 5. Start the engine and check for oil leakage from the port 6. Maintain the hydraulic oil temperature at 50:5 °C. (12249 °F) Measurement: 1. Select the following switch positions: Power mode selector: P mode Work mode selector: General purpose Auto-idle switch: OFF 2. Measure the main pump delivery pressure in the P. mode (fast idle) 3. Repeat step (2) three times and calculate the aver- age values. Evaluation: Refer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-04-10OPERATIONAL PERFORMANCE TEST / Component Test 4.7 MAIN RELIEF PRESSURE RELIEF SETTING Preparation: 1. Stop the engine. 2. Remove the top cover of the hydraulic oil tank with 17 mm wrench. 3. Push the pressure release button to bleed air. 4. To measure the main relief pressure: (1) Connect Dr. EX to the diagnosing connector of the PVC, located behind the operator's seat, to obtain real-time main pump pressure data. (2) If Dr. EX is not available, loosen and remove plug on the main pump delivery port and con- ect pressure gauge, (ST 6942) using a 6 mm hexagonal head wrench. 5. Start the engine and check for oil leakage from the port. 6. Maintain the hydraulic oil temperature at 5025 °C (12249 °F), Measurement: 1. Select the following switch positions: Power mode selector: P mode Work mode selector: General purpose Auto-idle switch: OFF 2. Slowly operate each control lever of boom, arm and bucket functions at full stroke over relief and mea- ssure the pressure. 3. In the swing function, place bucket against an im- movable object and measure the relief pressure. 4, In the travel function, lock undercarriage with an im- movable object and measure the relief pressure. 5. Repeat steps (2) to (5) three times and calculate the average values. Evaluatio Refer to Group -06 in this section NOTE: If any one of the measured pressures is lower than the others, it indicates that the relief pres- sure setting of the overioad relief valve of that circuit is lower than the main relief valve pres- sure setting. Check the overload relief valve of that circuit. Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-04-11OPERATIONAL PERFORMANCE TEST / Component Test Main Relief Valve Adjustment A~ Main Relief Valve 1. Unscrew lock nut (2) on the main relief valve 2. Rotate screw (3) to adjust the main relief pressure. 3, Retighten lock nut (2) met 17 mm f— 6mm PE 91.5 Nim (3.2 kgtm, 23 tot) Screw turns va | ve | aa | 4 Adjusting screw wpa =| 279 | 5.59 | a96 | 11.2 ‘Change in relief pressure kgiem? | 20.5 | 57 | 85.2 | 114 psi | aos | an [1212] 1621 = T06-04-12OPERATIONAL PERFORMANCE TEST / Component Test ‘Swing Relief Pressure Adjustment ‘A— Swing Reliet Valve 1. Unscrew lock nut (2) on the swing relief valve. 2, Rotate screw (1) to adjust the swing relief pressure. 3, Retighten lock nut (1) amet 17 mm [— :emm S186 Nem (19 kghm, 197 bf) ‘Screw turns 1/4 4/2 3/4 7 pressure kaem? | 17.5 | 35 | 525 | 70 T06-04-13OPERATIONAL PERFORMANCE TEST / Component Test Travel Relief Pressure Adjustment A~ Travel Reliet Valve 1. Remove travel relief valve assembly. 2, Reterring WO3-02, disassembly sleeve (1) and car- ridge. 3 Insert shims between poppet (3) and spring guide(4) to adjust travel relief pressure. 4, Tighten travel relief valve assembly. Amb 30 mm am: 294 Nem (30 kgtm, 217 bf ft) Shim 0.5 mm (0.02 inch) Unit kPa | kgficm | _ psi Change in relief pressure | 785 8 114 T06-04-14OPERATIONAL PERFORMANCE TEST / Component Test | 4.8 OVERLOAD RELIEF VALVE PRES- SURE SETTING | Checking the pressure setting of the overload relief valves on the machine is not recommended for the fol- lowing reasons: (1) Raising circuit oil pressure by blocking the return circuit of the control valve and applying external force to the machine structure may cause machine damage. (2) Checking the overload relief valve pressure setting (on the machine using a high pump flow rate is not reliable because the valves are adjusted to specifi cation with a fixed flow rate of 50 Limin. However, if required the following procedure is recom: mended to check if the overload relief pressure setting 's normal : (Same as the procedure to check the system pressure regulator relief setting.) Preparation: 4. Stop the engine 2. Remove the top cover of the hydraulic oil tank with a 17 mm wrench. 3. Push the pressure release button to bieed air. 4, To measure the system relief pressure: (1) Connect Dr. EX to the diagnosing connector of the PVC, located behind the operator's seat, to obtain realtime main pump pressure data. (2) If Dr. EX is not available, loosen and remove plug on the main pump delivery port and connect pres- sure gauge, (ST 6942) using a 6 mm_ hexagonal head wrench. 5, Start the engine and check for oil leakage trom the port, 6. Maintain the hydraulic cil temperature at 5045 °C. (12229 °F) Measurement: 1, Select the following switch positions: Power mode selector: P mode Work mode selector: General purpose Auto-idle switch OFF 2, Slowly operate each control lever of boom, arm and bucket functions at full stroke over relief and mea: sure the relief pressure 3, Repeat steps (2) three times and calculate the average values. Evaluation: When the measured pressure is the same as the main relief valve relief setting, the over load relief valve is functioning normally. If the measured pres- sures is lower than the main relief valve relief set ting, the overload relief valve pressure setting of that circuit is abnormal Refer to Group -06 in this section. Remedy: Refer to T07-08 TROUBLESHOOTING 8, T06-04-15A 9503OPERATIONAL PERFORMANCE TEST / Component Test Overload Relief Valve Adjustment 1 Bucket 2 Bucket 2— Boom 5~— Boom 3 Arm 6— Arm 1, Unscrew lock nut (7) on the overload relief valve. 2. Rotate screw (8) to adjust the overload relief pres- sure 3, Retighten lock nut (7) a — Pe 31.5 Nim (3.2 kgm, 23 ibftt) Screw turns va | v2 | gia | 4 MPa 28 | 56 | a4 | 112 Change in reliet pressure xgtem? | 285 | 57 | 952 | 114 psi 405 | art | 1212 | 1621 Adjusting screw De Pressure Pressure increase eerease T06-04-16OPERATIONAL PERFORMANCE TEST / Component Test 4.9 MAIN PUMP FLOW TEST Measure the pressure and flow rate of the main pump using Dr. EX. If Dr. EX is not available, install a portable hydraulic tester between the main pump and the control vaive, as illustrated. Preparation: 1. Stop the engine, 2. Remove the top cover of the hydraulic oil tank with a.17 mm wrench, 3. Push the pressure release button to bleed air. Connect a vacuum pump to the oil supply port of the hydraulic oil tank. IMPORTANT: Operate the vacuum pump while connecting the portable hydraulic tester to the main pump. 4. To measure the pressure and flow rate: (1) Connect Or. EX to the diagnosing connector of the PVC, located behind the operator's seat, to obtain real-time main pump pressure data (2) if Dr. EX is not available: Disconnect hose (A) . Connect flange F (5) split flange (C), bolts (D) to hose (A). Remove plug (E) and install adapter (6) Connect pipe (4), spit flange (C), bots (D), test hose (8), (10), adapters and joints (7), (8), (9) and hydraulic tester (2). Remove plug (F) located on the delivery side of the main pump. Connect pressure gauge (1) If Dr. EX is not available, the following steps are required Steps (1) to (7), (10) and (11) are also neces. sary when using Dr, EX. 1 Pressure Gauge 4 Pipe E (ST 6148) (st 6931) 2 Hydraulic Tester 5~ Flange F (ST 6197) (816299), I~ Test Hose 6— Adapter PFI=PFS/¢ (St 6320)-2 (st 6025) 7H Adapter PEI-PTI 9— Adapter PF1=1-7/8UNF (sr6012) (sr 6145) Joint (ST 8330) 8 Adapter 1-7]GUNFAPT! 10~ Test Hose (ST 6000) (st 6145) Joint (ST 6330) T06-04-17A, 9503OPERATIONAL PERFORMANCE TEST / Component Test 10, " 12 Disconnect vacuum pump from the oil supply port Loosen plug (G) on the pump housing until cil flows out to bleed air Tighten air breather cap on the hydraulic oil tank. Disconnect connector (I) of differential pressure sensor (H) to increase the pump swash angle to maximum, Connect engine tachometer to the fuel injection pipe. Fully open the loading valve of the portable hy- draulic tester. Start the engine and check for oil leakage from the port. Maintain the hydraulic oll temperature at 505 SC (12229 °F) Measurement: (When using a portable hydraulic tester) 1. Select the following switch positions: Travel mode switch: Fast Power MODE selector: P mode Work mode selector: General purpose Auto-idle switeh: OFF 2. Siowly operate the loading valve of the portable hydraulic tester to increase delivery pressure to 11.8 MPa (120 kgficm2) and 19.6 MPa (200 kgf/em2), and measure flow rate at each pres- sure. 3. Repeat step (2) three times and calculate the average values. Evaluation: 1. Conversion Calculate flow data using pump standard speed data, employing the formula below: Qe: Calculated flow rate Q = Measuring flow rate i: Transmission reduction rate ( =1) Np: Pump standard speed (2300 min-') Ne: Measuring engine speed 2. Reefer to Group -06 in this section. Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-04-18OPERATIONAL PERFORMANCE TEST / Component Test 4.10 SWING MOTOR DRAINAGE Purpose of the measurement: To check for wear and damage in the swing mtr. AA CAUTION: Make sure the area is clear and large enough to safely swing the upperstructure. NOTE: The amount of drain oil from the swing motor will change depending on the oil temperature. Maintain the oil temperature within 505 °C (1229 °F) for correct measurement. Preparation : 1. Before measuring, swing the upperstructure a few times to warm up the inside of the swing motor. 2, Stop the engine. Push the pressure release button T08-06-08-0 cn the hydraulic oll tank to bleed air. 3, Disconnect drain hose (1) of the swing motor trom the oil cooler return pipe. Plug the screw hole on the oll cooler return pipe. Place a container at the end of the drain hose to receive drain ol am: 22 mm an 59 Nim (6 kgm, 43 IDF At) 4, Start the engine, Select each switch position as fol- lows: Power mode selector: P mode Work mode selector: General purpose Auto-idle switch: OFF T06-04-19OPERATIONAL PERFORMANCE TEST / Component Test Measurement (1) : Measure the amount of drain oil while swinging the up- perstructure. 1. Fully retract the arm cylinder and extend the bucket cylinder. Raise the boom so that the bottom of the unloaded bucket is about 1 m (1 yd) above the ‘ground 2, Swing the upperstructure with a full swing control lever stroke ; after the swing speed becomes con- stant, start the measurement. 3, Measure the amount of drain oil and the time. The measuring time must be more than 45 seconds. 4, Repeat the measurement at least three times in both directions, right and left, and calculate the average values. Measurement (2) : Measure the amount of drain oil with the swing motor stalled. 1. Insert the bucket into the ground, as illustrated, to stall the swing motor. 2. Operate the swing control lever for more than 45 seconds. Measure the amount of drain oil and the time. 3. Repeat the measurement at least three times in both directions, right and left, and calculate the average values. Evaluation : Reter to Group -06 in this section. 1. Measure the total amount of drain oil with a cali- brated container. 2. Calculate the amount of drain oll per minute using the following equation: Q= 60g Q: Amount of drain oil per minute ( Limin ) 1: Measuring time ( sec) @: Total amount of drain oil (L.) Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-04-20OPERATIONAL PERFORMANCE TEST / Component Test 4.11 TRAVEL MOTOR DRAINAGE Purpose of the measurement: To check for wear and damage in the travel motor. IMPORTANT: (1) The amount of drain oil from the travel motor will change depending on the oil temperature. Maintain the oil tempera- ture within 50450 °C (12249 °F) for correct measurement. (2) Measure travel speed and mistracking in addition to measuring the amount of drain oil, Use the data obtained from all three tests to check the travel motors. Preparation : 1. Swing the upperstructure to the side to be tested, Lower the bucket to raise the track off the ground, 2. Rotate the raised track back and forth to warm up. the inside of the travel motor before measuring 8. Stop the engine. Push release button on the hy- draulic ol tank to bleed air 4, Disconnect drain hose (1) from the travel motor and, close the drain hose end with a plug. Connect hose (ST 6622) to the travel motor and place a container the end of the hose to receive drain oil ame: 22 mm me 49 Nim (5 kgtm, 96 Ibtt) 5, Start the engine and select each switch position as, follows: Travel mode switch: Fast r9r.08-06.008 Power selector: P mode Auto-idle switch: OFF T06-04-21OPERATIONAL PERFORMANCE TEST / Component Test Measurement 1. Rotate the travel motor for more than 45 seconds. Measure the amount of drain oil and the time. 2 Repeat the measurement at least three times in both directions, back and forth, and calculate the average values. Evaluation Refer to Group -06 in this section. ro 26.08.098 1, Measure the total amount of drain oil with a cali- brated container. 2, Calculate the amount of drain oil per minute using the following equation Q ait x q Q: Amount of drain oil per minute ( L{min ) t: Measuring time ( sec ) 4: Total amount of drain oil (L) Remedy: Refer to T07-03 TROUBLESHOOTING B. T06-04-22OPERATIONAL PERFORMANCE / Basic Performance Check BASIC OPERATIONAL PERFORMANCE CHECK WITH THE DR. EX. 1. Purpose : To check the machine performance using the monitor function of the Dr. EX. Operational performance of the pump displace- ment solenoid valves, pressure switches (P switches) and all sensors can be checked as well NOTE: Refer to the table in section T06-06 for ‘operational performance standards. 2. Preparation : 1. Measurement tools required: Or. EX, Stopwatch 2. Arrange a firm level test area spacious enough to allow the front attachment to move, the upperstructure to swing, and the machine to travel. 3. Connect the Dr. EX to the diagnostic connec- tor in the operator's cab and select the Moni- tor Data function, 4, Select the following switch positions: Powe moderselector: P mode Work mode selector: General purpose mode (M1) Maintain the hydraulic oil temperature at 025°C (12249° F), 5. Select sensing signals and command signals to be measured. If the measurement results are outside standard values, perform troubleshooting and adjustment with the diagnostic tools (pressure gauge, har- ness lamp kits, and testers). Refer to Section TO7 in this manual 3. 1 Measurement When measuring front attachment perfor- mance, position the cylinder piston outside the cushion range (located just before both stroke ends.) Then, push switch F1 on the Dr. EX to stabi- lize the display reading, PC pressure measured with the pressure gauge must be within + 0.2 MPa (2 kgl/m?, 28 psi ) the PC pressure reading by the Dr. EX, If the pressure gauge value exceeds this al- lowance, adjust the pump displacement sole- noid valve, referring to Section TO6 in this manual 3. The data for some items are not always avail- able, depending on the version of the PVC. Refer to the table in section T06-06 for data items available for checking with a given PVC. version. NOTE: Only Dr. EX IC cards with a version No, after 2.05 will display PVC version Nos. on the screen, T06-05-01OPERATIONAL PERFORMANCE / Basic Performance Check 5.1 PRESSURE (P) SWITCH CHECK Check if the P switch is functioning correctly, Operation Indication on Dr.€X Boom raise em Travel Tr Boom lower, Arm roll-out, Bucket rolhinfout ot Swing ‘Sw arm rolkin am When the above checks are made, the Dr. EX should display data in a negative format. If a nega- tive format is not displayed, the following troubles may exist. Investigate the cause using the appropri- ate diagnostic tools. 1, P switch is not connected correctly 2. P switch failure. 3. Loose connection of P switch. 4, Broken wire hamess. 5. Loose connection at the junction box in the cab. 6. Loose connection between PVC and EC, NOTE: If P switches are not correctly connect: ed, the machine performance of such operations as leveling, combined opera- tion of travel and front, and auto-idie, andjor controllability will dectine, If the P switch is at fault, the Dr. EX will not display an error code in the selt- diagnosing operation. T06-05-02OPERATIONAL PERFORMANCE / Basic Performance Check §.2, _PERFORMANCE CHECK WITH CONTROL LEVER IN THE NEUTRAL POSITION, AND AT RELIEF PRESSURE Preparation : Select the following switch positions: Power mode selector : P mode Work mode switch : General purpose mode(M1) Maintain the hydraulic oil temperature at 5025°C (12249°F) Before measuring the engine speed, make sure that the fuel injection pump governor lever comes into contact with the fast- idle stopper. Measurement Measure the following items, Items to be measured with the control lever in the neutral position. (A) Engine speed: N (min~1) (B) Differential pressure of pump delivery oil: AP (kglf cm?) (C) Pump delivery oil pressure: P (kgf! om’) (D) Pump flow rate: Q (Yimin) Items to be measured at relief pressure. Roll in the arm to relief pressure. (F) Engine speed: N (min~") (G) Differential pressure of pump delivery ol: AP (kgf om") (H) Pump delivery oll pressure: P (kgf! om?) (1) Pump flow rate: Q (Limin) (J) Actuallset engine speed difference: AN (nin) NOTE: (1) The displayed values on Dr. EX may vary. Try to read the median values. The engine speed change is displayed with changes of 4 min (pm) or more. (2) Differential pressure of pump deliv- ery oil is liable to change by oil tem- porature. Be sure to maintain the hydraulic oil temperature at 50#5°C (12249°F), (3) To make it easier to read the pump delivery pressure, the display on the Dr. EX is designed to respond slowly to pressure change. Try to read it after it becomes stabilized. (4) When the measurement results do ‘not meet the standard values, refer to the items shown on the following page T06-05-03OPERATIONAL PERFORMANCE / Basic Performance Check If any of the troubles shown below are found during the check described in 5-2, investigate the causes and repair as necessary. tern Problems Causes Check and Repair Methods Engine speed too slow [A)-1_Reduced engine power a) {A)-2 Too much unloaded pump drive | Pump delivery oll pressure will toraue ingrease. Differential pressure | (B)-1_Faully DP sensing signal. Tn case check value does not (8) | too small Unload valve failure. change after DP sensor replaced, check unload valve. (D)_| Flow rate too high (0-1 Faulty A sensor sensing signal. | Adjust or replace A sensor. Check A sensor drive link. relief pressure too small Differential pressure at | (G)-1 Overload relief valve leak or setting pressure is decreased. too small and relief pressure at relief pressure too low (G) [Difterential pressure | (G)-2 Main rele valve falure (eg) stuck with foreign matter). pressure exceeds standards valve. Pump delivery (HP sensor failure: Faulty adjustment of main relief | after replacing P sensor, adjust TFdata stil exceeds standards adjusting screw of main relief valve. too small and relief wali} Differential pressure | (H)-2 Faulty setting of overload relief Check pressure while reliefing other circuit actuator. (| pressure too low (H)S Stuck spool or broken spring in unloading valve, Disassemble and check unloading valve, (H-4 Reduced main pump flow rate. Check flow rate with flow meter. Change main pump it failed breaker. (Hy-5 Oil contamination while using ‘Check for main pump failure. [rate sensor. Reduced pump flow | ()-1_ Faulty sensing signal from A Reduced engine power. ‘Check sensing signal from A sensor. Check causes of power loss such as grade of fuel, etc. much slower than set ‘Actual engine speed is |(Jj-1 Reduced engine power or excessively increased main Check for causes of faulty sensing signal from A sensor or speed. pump drive torque, loss of engine power. w) Check operation of stop motor. ‘Actual engine speedis |(J)-2 Sensing signal from A sensor _| Check sensing signal from A much higher than set, too high, sensor. speed. Reference It pump delivery pressure does not reach relief pres- sure, the source of trouble may exist in the following points. Check one by one, 1. Leaks in load sensing line, (1) Shuttle valve stuck open, due to foreign matter. Pressure oil leaks increase the differential pressure. ‘The pump flow rate is thus reduced and the unload- ing valve opens to the hydraulic oil tank. Therefore, the main pump pressure does not increase, 2. Stuck unloading valve, and faulty main relief valve, overload relief valve, or cross relief valve. Although the pump flow rate increases, the pump delivery pressure cannot reach relief pressure. T06-05-04OPERATIONAL PERFORMANCE / Basic Performance Check 5.3 A SENSOR (PUMP DISPLACE- MENT ANGLE SENSOR ) CHECK Measure the sensing signals from A sensor when the pump displacement angle is at a minimum or maximum position. When measuring at a minimum angle. Position the control lever in neutral (Differential pressure should be over 20 kgffem®,) When measuring at a maximum angle. Move the control levers (for the boom raise, arm rollin, and bucket rollin) full stroke. {f the measurement results do not meet the standard values, the following troubles might exist. Check each iter 1. Faulty signal due to A sensor failure. 2. Faulty signal due to loose connection of A sen- sor. 3. A sensor drive link failure in the pump. 5.4. SINGLE OPERATION CHECK Refer to Section T06-03 for check procedure. Check travel speed at medium speed. Operations to be checked (A) Boom raise (B) Boom lower (C) Armrollin (0) Arm roll-out (E) Bucket rolkin (F) Bucket roll-out (G) Swing (H) Travel Check ites: Operation speed (sec) PC pressure (katfem?) Pump differential pressure AP (katie?) Pump delivery pressure P (kgt/om®) Pump flow rate Q(Umin) ‘Actual/set engine speed difference AN (min-') NOTE: (1) Measure the actuator speed using a stop watch, and use the Dr. EX to measure items other than the actuator speed. (2) When monitoring with the Dr. EX, the displayed valu can be held by pushing the F1 key. Before a cylin- der piston enters the cushion range, push the F1 key to measure its normal operating speed. (3) Do not attempt to measure with a ong arm or heavy bucket attached; incorrect data wil be obtained. T06-05-05OPERATIONAL PERFORMANCE / Basic Performance Check It any measurement results do not meet stan- dard values, perform troubleshooting, referring to the table in the following page to investigate the causes and repair or adjust as necessary. 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Faia Seca oN whan | Faukyovtoaarabt ave | Repace vate Ts cho Couelieericmoaene | cast ovsandraictvare [pelo os ‘it reticed dna 5 | Reuatarapesd soo tt | Rosen nay ecersn | — tow eno vae PE Cepmetonrcewion |smmpopoation presoure, ro (a) Nos ise broken (a) Check tse conti. 1 Soleracverecomecter |B) Greck comer Sosmecies (@) Ronomal BE pressure. |e) Ast PC presse ¢shgpessre gee sober ex T06-05-06OPERATIONAL PERFORMANCE / Basic Performance Check COMBINED OPERATION Performance of combined operation varies depending on each PC pressure. If the proportional solenoid valve outputs a different PC pressure from the command sig- ‘nal sent out by the PVC, the machine cannot function as it was designed to. This section describes the relevant checking proce- dures. 5.5 COMBINED BOOM RAISE AND ARM ROLL-IN OPERATION Summary Mainly check for abnormality in arm PC pressure. Preparation : 1, Select the following switch positions Power mode selector : P mode Work mode selector : General purpose mode (M1) Auto-idle switeh : OFF 2. Install the standard front: Standard arm and hoe bucket. 3. Check that the slow-return valve functions normally with the engine running at fast idle. 4, Maintain the hydraulic oil temperature at 5025°C (12289°F), 5. With the arm cylinder extended full stroke, position the teeth end and the arm pivot pin center in a line, as shown in fig. A. Hold the bucket so that the height (H1) of the teeth end is 0.5 m (20 in) above the surface. (The bucket must be empty.) Measurement 1. Operate the boom control lever to raise and the arm control lever to rollin full stroke, at the same time, from the position shown in fig. A Move the control levers to their stroke ends to ex- tend the boom and arm cylinders full stroke. Mea- sure the moving time of each cylinder. 2. Teeth end height measurement. Operate the boom control lever to raise and the arm control lever to rollin full stroke, at the same time, from the position shown in fig. A. Return both levers to neutral when either the boom or the arm cylinder reaches its stroke end, Measure the teeth end height (H2), as shown in fig. c. 3, Measurement by the Dr. EX. Measure the pump differential pressure, pump de- livery pressure, pump flow rate, boom PC pressure, and arm PC pressure. Push hold key (F1) at the point when the arm is perpendicular to the ground, 4, Repeat each measurement 3 times and calculate the average values. Fig. A Fa. T06-05-07OPERATIONAL PERFORMANCE / Basic Performance Check Evaluation NOTE: (1) Compare the standard values in the ta- ble in section TO6- 06 with the Dr. EX measured values. If any measured val- ue does not meet standards, refer to the table below for corrective action. (2) Check if the arm PC pressure (at the ‘SB port } is normal Problems Causes Check and Repair Front attachment movement is unstable. 1-1 Aerated piping between solenoid valve and control valve. Loosen piping to release air. Bucket contacts ground at point B shown in fig. B, or 2-1 No.8 fuse broken Check using lamp kit or circuit tester. height H 2 is lower than standards. 2-2 Broken harness for solenoid valve, solenoid valve connector disconnected, or misconnected. Check using lamp kit or circuit tester. 2-3 Low arm PC pressure. (at SB port) ‘Measure PC pressure. Replace or readjust solenoid vaive. 2-4 Faulty variable pressure compensated valve for arm. Disassemble to clean or replace variable pressure compensated valve. 2-5 DP sensor sensing signal too high Check that Dr. EX indicates 0.5 kgl/cm’ or less with engine stopped and key switch ON. ‘Arm cycle time is slow or height H 2 is higher than 3-1 Atm PC pressure (at SB port) too high, Measure PC pressure. Replace or readjust solenoid valve. standard, 3-2 Short stroke of arm spool. Measure arm spoo! pilot pressure or disassemble solenoid valve to check. 3-3 Failure in switch panel. Use Dr. EX to check for signal in grading mode (M3) and precision mode (M4) 3-4 Faulty arm variable pressure compensated valve. Disassemble valve to clean or replace it, T06-05-08OPERATIONAL PERFORMANCE / Basic Performance Check 5.6 COMBINED BUCKET ROLL-IN RE- LIEF AND BOOM RAISE CHECK ‘Summary : Mainly check for boom PC-pressure (SA port out- ut) abnormalities, Preparation : 1. Solect the following switch positions : Power mode selector : P mode Work mode selector : General purpose mode (M1) ‘Auto-idle switch : OFF 2. Install the standard front: Standard hoe bucket and arm. 8. Check that the slow-return valves function normally with the engine running at fast idle. 4, Maintain the hydraulic oll temperature at 50:5°C (12229°F). 5, With the arm rolied-out and bucket rolled-in both fully, lower the bucket onto the ground. ‘The bucket must be empty. Measurement : 1, While the bucket lever moved in the rollin position, relieving, move the boom raise lever to the stroke end, 2, Measure the boom cylinder stroke time, from the bucket on the ground to the most boom raised po- 3. Dr.EX measurement, Measure the pump differential pressure, pump de- livery pressure, pump flow rate, boom PC pressure, and actual/set engine speed difference. Be sure to push the hold key (F1) just before the boom reaches the cushion zone. 4, Repeat each measurement 3 times and calculate the average values. Evaluation : Compare the standard values in the table in section 706-06 with the Dr. EX measured values. If any mea- sured value does not meet standards, refer to the table below for corrective action, T06-05-09OPERATIONAL PERFORMANCE / Basic Performance Check Problems Causes Check and repair Front attachment movement is, unstable. 1-1 Aerated pipings between solenoid valve and control valve. Loosen pipings to release ait. ‘Actual/set engine speed difference is large. ‘Adjust engine. Boom raise is slow. ‘3-1 Boom PC pressure(SA port output) too high. ‘Adjust or replace solenoid valve. 3-2 Faulty variable pressure compensated valve, resulting in decreased flow rate. Disassemble to clean or replace variable pressure compensated valve. 3-3 Wrongly installed (connected) solenoid vaive Boom raise is too fast. 4-1 Boom PC pressure (SA port output) too low, or an open exists in wire harnesses, ‘Adjust or replace solenoid valve. Replace open wire harness. 4-2 Faulty variable pressure compensated valve, resulting in increased flow rate. Disassemble to clean or replace variable pressure compensated valve. T06-05-10OPERATIONAL PERFORMANCE / Basic Performance Check 5.7 COMBINED BUCKET ROLL-IN AND BOOM RAISE CHECK ‘Summary : Mainly check for bucket PC-pressure (SC port out put) abnormalities. Preparation : 1, Select the following switch positions Power mode selector : P mode Work mode selector : General purpose mode (M1) ‘Auto-idle switch : OFF 2. Install the standard front: Standard hoe bucket and arm. 3. Check that the slow-return valves function normally with the engine running at fast idle. 4, Maintain the hydraulic oil temperature at 5025°C (12289°F). 5. With the arm and bucket fully rolled-out, lower the bucket onto the ground. The bucket must be empty. Measurement : 1. Simultaneously move the bucket roll-in and boom raise levers to their stroke ends. 2. Measure the bucket cylinder stroke time. 3. Dr. EX measurement. Measure the pump differential pressure, pump delivery pressure, pump flow rate, bucket PC Pressure, and actualjset engine speed ditfer- ence. Be sure to push the hold key (F1) just be- fore the boom reaches the cushion zone. 4, Repeat each measurement 3 times and calcu- late the average values. Evaluation : Compare the standard values in the table in section 706-06 with the Or. EX measured values. if any measured value does not meet standards, refer 10 the table below for corrective action, Problems Causes Check and repair Front attachment movement is unstable. valve and control valve. 1-1 Aerated pipings between solenoid Loosen pipings to release air. Actual/set engine speed difference is large. ‘Adjust engine. Bucket rolkin is slow. 3-1 Bucket PC pressure too high, ‘Adjust or replace solenoid valve. rate, 3-2 Faulty variable pressure compensated valve, resulting in decreased flow Disassemble to clean or replace variable pressure compensated valve. solenoid valve. 3-3 Wrongly installed (connected) Bucket rollin is fast, but boom raise is too slow. hamesses. 4-1 Bucket PC pressure (SC port output) too low, or an open exists in wire ‘Adjust or replace solenoid valve. Replace open wire harness. increased flow rate. 4-2 Faulty bucket variable pressure ‘compensated valve, resulting in assemble to clean or replace VPCV. T06-05-11OPERATIONAL PERFORMANCE / Basic Performance Check 5.8 COMBINED TRAVEL AND ARM ROLL-IN RELIEF CHECK Summary : (1) Mainly check Arm PC pressure (SB port output) for abnormalities, after stabilizing machine. Compare measured Arm PC pressure to (1). Preparation : 1. Select the following switch positions. Power mode selector : P mode Work mode selector : General purpose mode (M1) Travel mode switch : Fast mode Auto-idle switch : OFF 2. Maintain the hydraulic oil temperature at 5025°C (12259°F), 3. Prepare a firm, level area spacious enough for the tasts. 4, With the arm and bucket rolled-in, raise the boom, as shown. The bucket must be empty. Measurement : 1. While traveling in the fast speed mode with the le- vers full stroke, move the arm control lever in the rolkin position, relieving it, 2. Dr. EX measurement. Measure the travel PC pressure, arm PC pressure, pump differential pressure , pump delivery pres- sure, pump flow rate, after stabilizing machine. 8. Repeat each measurement 3 times and calculate the average values. Evaluation : ‘Compare the standard vales in the table in section TO6- 06 with the Dr. EX measured values. T06-05-12OPERATIONAL PERFORMANCE / Basic Performance Check Check points This travel and arm roth ‘combined operation is a simulation of soft ground extrication. The arm cylin- der force while the tracks spin is decided by the pump delivery pressure. However, measured values are liable to be changed by the hydraulic oll tem- perature. If any measured value does not meet standards, re- fer to the table below for corrective action. Problems Causes Check and repair Traveling movement is unstable. 1-1 Aerated pipings between solenoid valve and control valve. Loosen pipings to release air. Althrough travel PC Pressure raises to its standard, pump delivery pressure is too low. 2:1 Travel PC pressure (SE port output) too low. ‘Adjust or replace solenoid valve. 2-2 Travel variable pressure ‘compensated valve is failed so that flow rate for travel cannot be decreased. Disassemble to clean or replace variable pressure compensated valve. Travel PC pressure does raise to its standard ‘3-1 When pump differential pressure is, larger than standard, travel PC pressure cannot be raised. Disassemble and clean travel shuttle valve. Replace DP sensor. Travel motor cannot, changeover to its maximum angle position so that travel ‘speed cannot be decreased. 4-1 Travel changeover pressure setting too high, Disassemble and clean travel shuttle valve. Replace OP sensor. 4-2 Travel changeover pressure setting normal. Measure changeover signal at travel motor. Replace or adjust solenoid valve. T06-05-13OPERATIONAL PERFORMANCE / Basic Performance Check 5.9 SWING CHECK WITH PRECISION MODE (M4) ‘Summary : Mainly check for swing PC pressure(SD port out- ut) abnormaties. Preparation : 1. Select the following switch positions : Power selector : P mode Work mode selector: General purpose mode (M1) and Precision mode (M4) Auto- idle switch : OFF 2, Maintain the hydraulic oll temperature at 505°C (1222977). 3. Prepare a firm, level area wide enough for the swing check. 4, With the arm rolled out and bucket rolled in both fully, move the boom so that the arm top pin height “The same height a is the same as boom foot pin height. The bucket the boom fot pn must be empl. heh Measurement : 1. Operate the swing control lever fully, in both the general purpose and precision modes. 2. Dr. EX measurement. Measure the pump differential pressure, pump flow rate, and swing PC pressure in both the general purpose and precision modes . Be sure to push the hold key (F1) when the swing speed is held con- stant 3. Check the measured value differences in the gen- eral purpose and precision modes. 4. Repeat each measurement 3 times and calculate the average values. Evaluation : Compare the standard values in the table in section 706-06 with the Dr. EX measured values. If any mea- sured value does not meet the standards, refer to the table on the next page for the corrective action. T06-05-14OPERATIONAL PERFORMANCE / Basic Performance Check Check point The pump flow rate changes are similar to those shown below. Measure both maximum and minimum values and use the mean for the evaluation, I any measured value does not meet standards, refer to the table below for corrective action. Problems Causes Check and repair ‘Swing movement is | 1-1 Aerated pipings between solenoid —_| Loosen pipings to release air. unstable. valve and control valve. Pump flow rate in| 2-1 Swing PC pressure(SD port output) | Adjust or replace solenoid vaive. precision mode t00 low, (Ma) too high. . 2-2 Swing variable pressure compensated | Disassemble to clean or replace valve is failed so that flow rate for variable pressure compensated swing cannot be controlled. valve. T06-05-15OPERATIONAL PERFORMANCE / Basic Performance Check 5.10 BOOM RAISE PILOT PRESSURE SENSOR ‘Summary : Mainly check boom raise pilot pressure sensor. Preparation : 1. Select the following switch positions Power mode selector : P mode Work mode selector : General purpose mode (M1) Travel mode switch : Fast mode Auto-idle switch : OFF 2. Maintain the hydraulic oil temperature at 5025°C (12289°F), 3. Prepare a firm, level area spacious enough for the tests. 4, With the arm and bucket rolled in, raise the boom, as shown. ‘The bucket must be empty. Measurement : 1107.98.05-08, 1. Operate boom control lever to raise the boom to relief, then record data displayed on the Dr. EX. 2. Operate boom control lever to raise the boom slow- ly. Then, confirm that the data displayed on the Dr. EX changes from zero to maximum. Evaluation Refer to Group 06 in this section. Reference: When displayed data shows 0 kgl/cm2, this indicates wire harness damage T06-05-16OPERATIONAL PERFORMANCE / Basic Performance Check 5.11 ARM CYLINDER BOTTOM PRES- SURE SENSOR Summary : Mainly check arm cylinder bottom pressure sensor. Preparation : 1. Select the following switch positions : Power selector : P mode Work mode selector : General purpose mode (M1) Travel mode switch : Fast mode Auto-idle switch : OFF 2. Maintain the hydraulic oil temperature at 50%5°C (12289°F), 3. Prepare a firm, level area spacious enough for the tests, 4. With the arm and bucket rolled in, raise the boom, as shown. The bucket must be empty. 5. Confirm that the main relief system pressure and overload relief pressure are set correctly. Measurement : 1. Operate arm control lever to roll in the arm to relief, then record data displayed on the Dr. EX. Evaluation : Refer to Group 06 in this section. Reference: When displayed data shows 0 kgl/cm2, this indicates wire hamess damage. T06-05-17OPERATIONAL PERFORMANCE / Basic Performance Check T06-05-18OPERATIONAL PERFORMANCE TEST / Standard Power selector P mode Work mode switch Hydraulic oil temperature OPERATIONAL PERFORMANCE STANDARD This is a operational performance test table of the PVC version number Refer to Group 02 for testing provedute. General Purpose mode 8085 °C (12249 °F) Upper row : Standard Lower row : Allowable limit PVC Version No} EX100-3 rem ey Remarks 2.1 |ENGINE SPEED (ein) P mode 2460260 E mode 2 100 “i Umode 1850 = mode 950 Auto-idle | + 2002100 Start idle 10802100 2.2 {ENGINE kgticm’) 31.0 COMPRESSION PRESSURE 230 2.3 |VALVE CLEARANCE (men) 0.4 2.4 |NOZZLE INJECTION PRESSURE 14.7 (150) Pa ten? 2.5, [INJECTION TIMING cara) |_16° 3.1. | TRAVEL SPEED (secit0m) | "Fast speed : x1 00:3 65205 | Medium speed : EX100-3 (9.00.8) | Slow speed : EX100-3 (16.5+2.0) | Fast speed : EX100M-3 8.2405 (ear eS 3.2 | TRAVEL REVOLUTION SPEED {sec/3rev), | “Fast speed: €x100-3 iasee0 | Fast speed: Exi0on-3 19.023.0 33. |MISTRACK temizomy | 200= (Siow/ mediumy fast \"aa_ [TRAVEL MOTOR LEAK (raven) ° || 25 [swine speed secre) | 16.4214 || 36 [SWING FUNCTION DRIFT ennireo) | 650 37_ [SWING MOTOR LEAK (rmsminy 0 3.8 [SWING BEARING PLAY om | igs Note = 1 kgtfem2= 98.07 kPa T06-06-01A 9503OPERATIONAL PERFORMANCE TEST / Standard PVC versione | €X100-3 Irem 1400 Remarks 3.9 | HYDRAULIC CYLINDER CYCLE TIME Boom raise (eee) | 3.1203 Boom iower : EX100:3, 32303 Boom lower : EX100M-3 ‘Arm roii-in ‘Arm rol-out Bucket rol-in Bucket roli-out ‘ylinder ful stroke 3.10 | DIG FUNCTION DRIFT CHECK (resin) Boom cylinder ‘Arm cylinder Bucket cylinder Bucket bottom 3.11 [CONTROL LEVER OPERATING FORCE 99 Boom lever ‘Arm lever Bucket lever ‘Swing lever Travel lever ‘3.12 | CONTROL LEVER STROKE. (ram) Boom iever yo5i10 Arm lever 83210 Bucket lever 83210 Swing lever 405210 Travel lever 400s10 Note : 1 kgf= 9.807 N T06-06-02A 9503OPERATIONAL PERFORMANCE TEST / Standard PVC versione] EX100-3 3.13 | BOOM RAISE / ARM ROLL-IN Time (sec) | (4.7+0.5) sl |SOOOMRAISE [SING Tele |151505 COMPONENT TEST 4.1 | PILOT PRIMARY PRESSURE {kai/om®) 52°75 4.2 | PILOT SECONDARY PRESSURE (xgiicm’) 26< (PC pressure) 7 | Sing PRRNING Bran Ret EASING 25 |i pnessuié sen | 3808 4.6 [MAINPUMP DELIVERY PRESSURE — | 4; 4.7 | SYSTEM RELIEF PRESSURE — {kgticm’) Swing 350°", Travel 350°, 4.8 | OVERLOAD RELIEF VALVE PRESSURE | (Reference) Sainte sree | ero%s ‘Bucket (roll-out) (kgticm?) (3857 9) Travel ikgtiem®) (355°) 75 [MAW PURP FLEW rae mm [088 at 200k (L/min) 13446, 79 | SING WOTOR DRANAGE -Sogt™a] 09 Relief(timin) O7= T06-06-03A 9503OPERATIONAL PERFORMANCE TEST / Standard || PVC Verson Ne] EX100-3 oe | Tem 1400 4.11 [TRAVEL MOTOR DRAINAGE umn) | 1.01020 asec ot round ‘50 Ftel 181040 5.0 USING Dr. EX 52 IN THE NEUTRAL POSITION BEngine speed Nm | 2.480850 ®Ditferential pressure: AP (Katiem’) 24 to 26 ©Pump delivery pressure : P (xgtom’) 271033, ‘@Pump fiow rate a (Uminy | 2310.37 ‘AT RELIEF PRESSURE (ARM ROLL-IN) Engine speed N pm | 2250 to 2 400 GDitterential pressure: AP. katlom) 003 Pump delivery pressure :P taglem’) | 95010 370 TPump flow rate Qin) | 5810 70 DActuallset engine speed difference | (—S0t0 120) AN (pm) 5.3 | A SENSOR (Pump displacement angle) Inthe neutral postion: A eq) | 3.01034 ‘Combined boomjarmybucket : A” (dea) | 23.2 10 24.0 | | Ditferential pres AP. diem’ (62) 5.4_| SINGLE OPERATION || ‘®BOOM RAISE (sec) 3.120.3, Boom PC pressure SA tkgtiom’) 7 | Differential pressure AP Aagtion®) (8 to 15) || Pump delivery pressure: P_ agin’) | (100 to 180) | Pump flow rate Q min) | 150t0 190 | ®BOOM LOWER (sec) | 2.2403 | Boom PC pressure = SA gicn’) 8 | Differential pressure AP tkgtiom’) (9 to 20) | Pump delivery pressure: P (glen) . Pump flow rate Qn) | “40 t0 60 Note : 1 kgliome= 98.07 kPa T06-06-04OPERATIONAL PERFORMANCE TEST / Standard PVCversionNe | EX100-3, Pump delivery pressure : P—_agtion’) | (60 to 210) rem Aa Remarks OARM ROLLIN ‘see) | 3.6208 Arm PC pressure SB tkgticm’) 0 Differential pressure: AP. kgliem®) | (12 to 18) Pump delivery pressure ; P txgtiem’) | (80 to 160) Pump tiow rate Qin | 15510 190 ‘ciuallset engine speed diference O10 160 BN~ om (®ARM ROLL-OUT (sec) 2,440.3, ‘Arm PC pressure SB tegtiem’) 18 Differential pressure AP (kgticm*) (8to 17) Pump flow rate Q min | 130t0 160 ‘Actual/set engine speed difference Oto t00 AN tom ©BUCKET ROLL-IN (see) | 9.0203 Bucket PC pressure: SC__gttem') 0 Differential pressure: AP tkgtom®) | (12 to 15) Pump delivery pressure: P —gem*)_| (60 to 120) Pump flow rate Q ___Wminy | 1200 160 @BUCKET ROLL-OUT (sec) | 2.2403 Bucket PC pressure: SC tkgtiem’) | Ot03 Differential pressure: AP ig (8015) Pump delivery pressure: P kliem) | (2002100) Pump fiow rate Q umn) | 105 to 130 ‘Actual/set engine speed difference ‘Oto 100 om) ‘@SWING SPEED (eociaren) | 16.421.4 ‘Swing PC pressure SD fegien’) i0 Differential pressure: AP tkgtiem’) | (12 to 22) Pump delivery pressure : P —_fagtiem’ | (80 to 110) Pump flow rate Q wm | 701095 Note : 1 kgf/cm2> 98.07 kPa T06-06-05OPERATIONAL PERFORMANCE TEST / Standard PVC version Ne] EX100-3 Tem 1400 Remarks @TRAVEL SPEED Travel PC pressure SE (kgtlen’) 7Ttot Differential pressure 1 AP tgtiem?) | (11 + 3.0) Pump delivery pressure: P (kgm | (60 to 110) (Fast) : 195220 Pump flow rate . Q (min) | 2004120 COMBINED OPERATION ” 5.5 | Boom raise / Arm roll-in (sec) | 4.0t05.2 Teeth end point Height : H (mm) 20002 Boom PC pressure :SA”aglem) | 161030 Arm PC pressure SB tkgtiom’?) 21 to 30 Differential pressure: AP aglom’) | 4108 Pump delivery pressure: P_——_tagiiem’) | (90 to 120) “Pump flow rate a miny | (200: 6.6 | Bucket roll-in relief / Boom ‘ee | 351048 Boom PC pressure :SA _tigtiom’) | 24 to 33 Ditferential pressure? AP agiom) | (Ot07) Pump delivery pressure: P —_tkgliem’)_| (190 to 280) Pump tiow rate timmy | (75 to 190) Actualset engine speed diference Oto 100 (rom 57 | Bucket rollin / Boom raise: (sec) | 301052 Boom PC pressure :SA glen) | 191028 Differential pressure: AP glen’) | (4.9t07.0) Pump delivery pressure: P (kglom*) | (110 to 130) Pump flow rate Q tmn | (1703) ‘Actualset engine speed difference Oto 100 (om 5.8 | Travel / Arm roll-in relief Travel PG pressure :SE gem’) | 32t0 36 ‘Arm PG pressure SB diem’) | (271037) Differential pressure: AP (kgtiem’) | (Oto 12) Pump delivery pressure: P _aglem®)_| (220 to 360) Pump tow ate :Q (min) | (60 to 120) Ghangeover pressure of travel motor, | 8°, ‘eaten? Note : 1 kgf/om2= 98.07 kPa ‘T06-06-06OPERATIONAL PERFORMANCE TEST / Standard PVC versionNe| EX100-3. 7 AAD Remarks 5.9 | SWING : PRECISION MODE (M4) Swing PC pressure :SD__egtem 34 Differential pressure: AP (ram | (21 to 28) Pump delivery pressure: P_ gion’) | (80 t0 110) Pump flow rate Q_tuininy | 42t0.50) 5.10 [BOOM RAISE PILOT PRESSURE SEN-| 4,1 SOR : ion 1 5.1 | ARM BOTTOM PRESSURE SENSOR: | 50 9 Note : 1 kgffom2= 98.07 kPa T06-06-07A 9503OPERATIONAL PERFORMANCE TEST / Standard + (REFERNCE) Pa Points Pump P-@ Curve Dogene!2Trveing Soman? PVC Version NO,: EX100-3 1400 Pressure |] Flow Raw | | Pressue | Fon Rate Pump Type allem? Lin kalo? min | Pump Rated Speed: 2 200 min«(rpm) 3 za @ aay 0 ve] 105) DP sensor: Disconect 720 is 70 200 250 30 350 0.09807 MPa os f # 200 | ‘ ) min +s 10 IP. ° woot t 200 a0 360 > keijem? T06-06-08OPERATIONAL PERFORMANCE TEST / Standard Injection Pump Test conditions 4. Nozzle : 2. Nozzle injection pressure :17.2 MPa (175 kgt/em® ) 3, Test fuel : JIS NO. 2 fuel 4, Transfer pump pressure : 0.16 MPa (1.6 kgt/cm* ) 5. Injection pipe : Inner Dia. 1.6% Outer Dia. 6 Length 580 mm ( 0.063 = 0.236 ~ 22.8 inch) 6. Fuel temperature : 40 to 45 °C ( 104 to 113 °F) NOTE ; The nozzle test injection pressure is 14.7 MPa ( 150. kgi/om* ). However, actual machine injection pres- sure is 17.2 MPa (175 kgm’). Injection rate adjustment ‘Adjusting | Pump speed | Control rod posi- | Stokes ‘Average injection | Maximum variance | Foed | Remarks point | (min) tion (mm ) rate(em®) | between oylinders (5) A 1180 (10.0) 67.6211 42 B 475 7.0 * 10.0814 14 > Control rod position; 7.6 Governor adjustment About 13 Icing spring setting Governor spring setting Rt (00, Control rod position (mm) (R1-0.1) O95 1250815 sassso 475; 1150.5 Pump speed min* (rpm) > mee T06-06-09OPERATIONAL PERFORMANCE TEST / Standard T06-06-10Ex100 Group 01- Diagnosing Procedure Introduction Diagnosing Procedure Start-up Procedure of DEX Reterial "8° Sell-Diagnosis Function Group 02- Troubleshooting A List of EC Relating Fault Codes List of PVC Relating Fault Codes Fault Codes 01,02,03,04 and 06 Fault Code 05 Fault Codes 09 and 10 Fault Code 13 5 Fault Codes 17,18,19 and 21 Fault Code 20 Fault Codes 22 Fault Codes 25 and 26 Fault Codes 27 and 28 Fault Codes 29 and 30 Fault Codes 31 and 32 Fault Codes 33 and 34 Fault Codes 35 and 36 SECTION 07 TROUBLESHOOTING CONTENTS 07-01-01 07-01-02 07-01-07 07-01-09, T07-01-10 7107-02-01 ‘T07-02-02 07-02-03 07-02-04 07-02-06 07-02-08 07-02-10 07-02-11 07-02-12 07-02-16 07-02-18 707-02-20 07-02-22 T07-02-24 7107-02-26 Group 03 - Troubleshooting B Outline Effect of Electronic Component Malfunctions on Machine Operations Machine Malfunctions and possible Causes Engine Troubleshooting ‘Actuators Troubleshooting Front Attachments Troubleshooting ‘Swing Troubleshooting Travel Troubleshooting Others Troubleshooting Group 04 - Troubleshooing C Monitor Panel, Switch and Sensor Location . Malfunction of Coolant Temperature Gauge Malfunction of Fuel Gauge Malfunction of Level Check ‘Switch Malfunction of Engine Oil Level indicator Malfunction of Coolant Level Indicator. Malfunction of Hydraulic Oil Level indicator Malfunction of Alternator Indicator Malfunction of Engine Oil Pressure Indicator Malfunction of Overheat Indicator Malfunction of Fuel Level Indicator a 707-03-01 07-03-02 07-03-07 707-03-10 07-03-20 07-03-24 1707-03-30 707-03-34 7107-03-43, T07-04-01 707-04-02 707-04-04 7107-04-06 07-04-08 07-04-10 707-0412 707-04-14 7107-04-16 07-04-18 T07-04-20 1347-07-01&x1003 Malfunction of Air Filter Restriction Indicator 707-04-22 Malfunction of Buzzer 707-04-24 Malfunction of Hour Meter... TO7-04-26 Group 05 - Harness Check Electrical Test Precautions 07-05-01 Continuity Check... ‘07-05-02 Voltage Check ...... 07-05-03, 5 Volt Circuit 707-05-04 Check Using False Signal ..... 07-05-05 Resistance Check - T07-05-07 Lamp Harness Check .... 07-05-08 1347-07-02TROUBLESHOOTING / Diagnosing Procedure INTRODUCTION Flow charts are provided in this section in order to make inspection and troubleshooting procedures easy to follow. Use these charts to guide you in locating the source of any problems that may arise. PoE Self-diagnosing Yos Potential problems are roughly divided into three groups as shown below; namely, those in signal sending (Group A), machine hardware (Group B), and gauges and indicators (Group C). Troubleshooting A function of Dr. EX Oca shows fault code TROUBLESHOOTING A (Signal sending) Use these charts when the self-diagnosing function of Dr.EX shows any fault code. (Controllers auto matically diagnose and memorize malfunctions that have occurred in the signal sending system.) Example: Wire disconnection in the Differential Pressure Sensor (DP sensor) TROUBLESHOOTING B (Hardware} Use these charts when the machine is exhibiting troubie but no fault code is shown on Dr€X's cis- play. Example: Slow travel speed. (Signal sending) Troubleshooting C (Gauges and ind ators) Yes Monitor Ne Malfunction Troubleshooting B (Hardware) No TROUBLESHOOTING C (Gauges and indicators) Use these charts when any gauges or indicators matfunction. Example: The fuel gauge does not operate. T07-01-01TROUBLESHOOTING / Diagnosing Procedure DIAGNOSING PROCEDURE These six basic steps are essential for efficient trouble shooting: 1. Study the system. 2. Ask the operator. 3. Inspect the machine, 4, Operate the machine yourself 5, Perform troubleshooting 6. Trace possible causes. 1. Study the system Study the machine's technical manuals. Know the sys tem and how it works, and what the construction, func- tions and specifications of the system components are. 2. Ask the operator Before inspecting, get the full story of malfunctions from your star witness -~- the operator. (a) How is the machine being used? ( Find out if the machine is being operated correctly) (b) When was the trouble noticed, and what types of ‘work the machine doing at that time? (c) What are the details of the trouble? Is the trouble getting worse, or did it appear suddenly for the first time? (6) Did the machine have any other troubles pre- viously? If so, which parts were repaired before? T07-01-02TROUBLESHOOTING / Diagnosing Procedure 3. Inspect the machine Before starting the troubleshooting procedure, check the machine's daily maintenance points, as shown in the operator's manual. ‘Also, check the electrical system, including the batter- ies, as troubles in the electrical system such as low bat- tery voltage, loose connections and blown fuses will re sult in malfunction of the controllers, causing total oper- ational failure of the machine. 4, Operate the machine yourself Try to identity the trouble by operating the machine yourselt, if the trouble cannot be confirmed, stop the engine and obtain further details of the malfunction from the opera tor. Also, check for any incomplete connections of the wire harnesses. 5. Perform troubleshooting Connect the diagnostic analyzer, Dr.EX, to the PVC to obtain malfunction records. It any fault codes are displayed on the monitor, check sensing signal circuits, referring to Troubleshooting A. If no fault code is displayed on the monitor, despite the fact that the machine has a malfunction, check functions of components other than those in the sensing signal circuits, using real-time data monitored by Dr.€X 07-01-03TROUBLESHOOTING / Diagnosing Procedure 6. Trace possible causes Before reaching a conclusion, check the most likely causes again. Try to identity the actual cause of the trouble. Based on your conclusion, make a plan for appropriate repairs to avoid consequent maifunctions, T07-01-04TROUBLESHOOTING / Diagnosing Procedure Check Battery Voltage 1. Tum the key switeh OFF. 2, Measure the voltage between the positive terminal of the battery and the ground (machine body), using a voltmeter. Correct Voltage Reading : Approximately 24 V 3. Start the engine, 4, Measure the battery voltage again. Correct Voltage Reading: 26 to 28V Check Fuses Fuse discontinuity is often caused by a fine crack in the fuse, and such fine cracks are very hard to detect by vi- sual inspection. Use a circuit tester or a Hitachi Lamp Harness Set for fuse continuity inspection. 1. Tur key switch ON Note: Turn the key switch to the HEAT position when checking the glow relay fuse (Fuse No. 20) 2, Remove fuse box cover and preset the voltage measurement range of the tester. 3, Touch the outside terminal of each fuse with the positive probe of the tester. Connect the negative probe to the machine for grounding, The tester will indicate 20 to 25 volts when normal. Note: All the inside terminals of the fuses in the fuse box are connected to the power source, while the outside terminals are connected 10 the ac: cessories. Accessones T07-01-05TROUBLESHOOTING / Diagnosing Procedure Check FusiblE Link 1, Remove the negative cable from the battery. 2. Loosen bolt M8 connecting the cable from the fus- ible link box to the starter and manually tum the ca- ble to the horizontal position, out of the way of the front cover, as shown in fig. 3. Open the front cover of the fusible link box and in- hrorakenone spect the fusible link inside. 07-01-06TROUBLESHOOTING / Diagnosing Procedure Dr. EX Dr. EX is a handy micro computer used for diagnos- ing matfunctions of the machine control system, in- cluding the pump and valve controller (PVC) and the engine controller (EC). When the Dr. EX is connected to the controller, mal- functions recorded in the controller memory are indi- cated as fault codes on the Dr. EX display. (Self Diagnosing Function) Input signals from the sensors or switches that are connected to the controller, or output signals from the controller to solenoid valves can be monitored ‘on a real-time basis while the machine is being oper- ated.(Read-Time Monitoring Function) Dr. EX START-UP PROCEDURE 4. Connect the harness of the Dr. EX to the diagnosing connector of the PVC, located behind the operator's seat. NOTE : Only this connecting harness can be used to connect the Dr. EX to the controller. Do not use any other harness to connect Dr. EX to the controller. 2. Turn the key switch to the ON position or start the engine. 3. Turn the Dr. EX ON. Alter a few seconds, following patterns will appear on the Dr. EX display 3+1 Initial Pattern 8-2 Model Code Pattern Example Model: EX200 PVC: 0800 — Version No. EC: 0100+ Version No. 3-3 Function Selection Pattern F4: * Self-diagnosing results” F.2: “Monitor data’ 4. Select key F1 (Proceed according to the instructions that appear on the display.) NOTE : For the operation procedure of the Dr. EX, refer to the Dr. EX OPERATOR'S MANUAL. Inia Pattern a! ‘Gan not Model Code ‘communicate nme Confirmation check PvE } see ace See seicaton uae Contrater Sat. Biagnosing = Result of Contoller Sol Diagnoing Display I Pevial Aor Retrial 8 I Result of Contraller Sell Diagnoing Display Monitor }>| Record] |] Data Selecting Pattern Monitor Data Display 07-01-07TROUBLESHOOTING / Diagnosing Procedure CLEARING SELF-DIAGNOSING FUNCTION There are two ways to erase fault codes, depending on problem area. 1, Problems with controllers (PVC and EC) (Retrial “A’) 2. Problems with sensors (Retrial “B") RETRIAL “A” 1, Tum the Dr. EX OFF, with its hamess still connect ed to the diagnosing connector of the PVC. 2. Turn the key switch OFF. 3. After 10 seconds or more have passed, turn the key switch to the ON position or start the engine. 4. Disconnect the harness from the diagnosing con- rector. 5. After one second or more have passed, reconnect the harness to the diagnosing connector. IMPORTANT: If the harness of the Dr. EX is con: nected to the diagnosing connector without interruption of at least one second, fault codes may not erased. 6. Then, check the fault code again according to the normal method 10 seconds or more "2“Gne second 07-01-08TROUBLESHOOTING / Diagnosing Procedure RETRIAL “B’ 1. Leave the key switch in the ON position. (The en- gine may be stopped or may be running.) 2. Disconnect the hatness from the diagnosing con- nector. 3, After one second or more has passed, reconnect the harness to the diagnosing connector. IMPORTANT: If the harness of the Dr. EX is con- nected to the diagnosing connector without an interruption of at least one second, fault codes may not be erased, 4, Then, check the fault code again, following the nor- ‘mal method, If the fault code is displayed again, the problem exists. The fault code wil be displayed with NO actual prob- lems existing in the following cases’ 1, When a sensor connector was previously discon: nected with the key switch ON or the engine run- ring,( This may happen when replacing a part.) 2. When the PVC or EC connector was previously re- placed or disconnected. 3. When the battery was removed, or when fuse No. 2 or No. 7 was previously replaced Be sure to perform Retrial “A” in order to erase the fault codes in the above cases. at 3} "2“One second 07-01-09TROUBLESHOOTING / Diagnosing Procedure SELF-DIAGNOSIS FUNCTION The PVC (Pump and Valve Controller) has a function to record the results of analysis; when trouble with controllers (PVC, EC) occurs, or an electrical abnor- mality (disconnection, short-circuit, internal short- circult, short-circuit of lines, etc.) occurs in the com- munication system between the PVC and EC or each sensing signal (01) to (08), the PVC records this information and notification of the trouble will be displayed as a fault code on the Dr. EX. Problems (A) to (k) are not displayed as a fault code. However, since a checking function for sens- ing and control signals is provided in the PVC, these signal system problems can be investigated using the monitor function provided on the Dr. EX. Prossure Switch “Travel Mode Switch Sch Dr. EX output | J Output Input ot __ [Reraute Tomporaure] [senor (7 Sensor Diterenial Pressure 2 Sensor (OP Sensor Pump Valve Contoler 03 [Pressure Sensor eve) Yer sen 04 _ [Pump Displacement [angle Sensor (A Sensor 05 _[Boomraise Pict [Pressure Sensor ap? Sensor 06 __[ambonom Pressure Sensor a (ABP Senson ee Ln, feroporiona Scenoia awe GND ‘yerauic Warm 7 [Up Swen Engine Controller (0) J, Proportional Solenoi (> \\raive ‘rave! Speed) Engine Speed Sensor i Sensor Engine Gonirol Sensor EC Sensor) oe lengrot K : + eC Motor i T07-01- 10TROUBLESHOOTING / Troubleshooting A LIST OF EC-RELATED FAULT CODES FAULT CODE TROUBLE CORRECTIVE ACTION Failure (lype-1) of EC 1) Retry diagnostic procedure A ( For problems with the controller (PVC and EC)) 2) Replace EC if power selector control and Jor auto-idle is abnormal 02 Failure (type-2) of EC 1) Retry diagnostic procedure A 2) Replace EC if power selector control and Jor auto-idle is abnormal 03 Failure (type-3) of EC 1). Retry diagnostic procedure A 2) Replace EC if power selector control and Jor auto-idle is abnormal 04 Failure (type-4) of EC 1) Retry diagnostic procedure A 2) Replace EC if Power selector control and Jor over 8 fault codes are found 05 Signal from PVC is not transmitted toEC 1) Retry diagnostic procedure B (For problems with the sensors) 2) Check hamess 3) Replace PVC or EC if auto-idle is abnormal 1) Retry diagnostic procedure B 2) Replace EC if power selector control is abnormal 06 Failure (type-6) of EC 03 Short circuit of EC sensor and/or 1) Retry diagnostic procedure 8 harness 2) Check EC sensor hamess 3) Replace EC sensor 10 Disconnected EC sensor and/or | 1) Retry diagnostic procedure B hamess 2) Check EC sensor hamess 3) Replace EC sensor 13 N sensor is abnormal 1). Retry diagnostic procedure B 2) Check N sensor hamess 3) Replace N sensor T07-02-01TROUBLESHOOTING / Troubleshooting A LIST OF PVC RELATING FAULT CODES FAULT CODE TROUBLE CORRECTIVE ACTION 7 Failure (type-17) of PVC |1) Retry diagnostic procedure A 18 Failure (type-18) of PVC |2) Replace PVC if engine stops or working speed ea Failure (type-19) of PVC is abnormal 20, Signal from EC is not 1). Retry diagnostic procedure B transmitted to PVC. 2) Check harness 3) Replace PVC or EC if abnormal speed sensing operation is found a1 Failure (type-21) of PVC | 1) Retry diagnostic procedure B 2) Replace PVC 22. Abnormal pump control | 1) Retry diagnostic procedure B 2) Hames check 3) Check pump displacement solenoid valve 4) Check pump displacement angle sensor 5) Check PVC 25 Short-circult of DP sensor | 1) Retry diagnostic procedure 8 26 andjor hamess 2) Check DP sensor harness Disconnected DP sensor |3) Replace DP sensor and/or hamess 27 Short-circuit of P sensor |1) Retry diagnostic procedure B 28 andjor hamess 2) Check P sensor harness Disconnected P sensor 3) Replace P sensor and/or hamess 29 Short-circuit of A sensor] 1) Retry diagnostic procedure 8 30 and/or hamess 2) Check A sensor hamess Disconnected A sensor | 3) Replace A sensor and/or hamess 3 Disconnected T sensor | 1) Retry diagnostic procedure B 32 andjor harness 2) Check T sensor hamess Short-cicuit of T sensor |3) Replace T sensor andjor hamess 33 Disconnected BpiP sensor | 1) Retry diagnostic procedure 8 34 es 2). Check BpiP sensor hamess Short-circuit of BpiP 3) Replace BpiP sensor sensor and/or harness 35 Disconnected ABP sensor | 1) Retry diagnostic procedure B 36 nines 2) Check ABP sensor harness Short-cireut of ABP 3) Replace ABP sensor sensor andjor harness BpiP: Boom raise pilot pressure sensor ABP: Arm bottom pressure sensor T07-02-02TROUBLESHOOTING / Troubleshooting A EC-RELATED FAULT CODES FAULT CODES 01, 02, 03, 04 and 06 Fault codes 01, 02, 03, 04 and 06 indicate troubles If one of these codes is still displayed atter retrial, inthe EC itself and malfunction of the machine is observed, replace the EC with new one. FAULT CODE TROUBLE CORRECTIVE ACTION or Failure (type-1) of EC 1) Retry diagnostic procedure A 02 Failure (type-2) of EC 2) Replace EC it 03 Failure (type-3) of EC a) Engine speed does not change when any of the power mode selector (P, E, L, 1), the accelerator switch, or the decelerator switch are depressed b) The auto-idle does not function when the auto-idle switch is turned ON. 04 Failure (Iype-4) of EC 1). Retry diagnostic procedure A 2) Replace EC it a) The engine runs at slow speed when the P-mode switch is depressed. b) Dr. EX displays fault codes of eight or ‘more in number. 06 Failure (type-6) of EC 1) Retry diagnostic procedure 8 2) Replace EC if a) The engine runs at slow speed when the P-mode switch is depressed. b) EC motor activation is abnormal. Yes * EC rouble [are the Wunetions of line engine and the machine normal ? a Replace EC NOTE: * The machine can be used when ma- chine and engine functions are normal, even if Dr. EX continues to display fauit codes after retrying diagnostic proce- dure A or B. 07-02-03TROUBLESHOOTING / Troubleshooting A FAULT CODE 05 Fault code 05 indicates a communication error from the PVC to the EC. When this code is displayed, check the hamess for problems between the PVC and the EC. FAULT CODE TROUBLE ‘CORRECTIVE ACTION 05 Signal from PVG is not transmitted |1) Retry diagnostic procedure B toEC 2) Check harness 3) Replace PVC and EC if the auto-idle does not function when the auto-idle switch is turned ON. ra PVC or EO wovbla ee eee OK [Replace PVC and EC. [check harass be no” }tween PVG ane EC rouble in harness NoTOR between PVC ara EC NOTE: * The machine can be used when ma- chine and engine functions are normal, ‘even if Dr. EX continues to display fault codes after retrying diagnostic proce- gure B. T07-02-04TROUBLESHOOTING / Troubleshooting A HARNESS CHECK BETWEEN PVC and EC 1. Tum the key switch OFF. Remove the PVC to EC hamess connectors 2. Check the continuity of each harness between the following terminals: No. 11 of PVC and No. 2 of EC; No. 4 of PVC and No. 9 of EC; No. 5 of PVC and No. 3 of EC: No. 12 of PVC and No. 10 of EC. Connector al EC side ae qo Connecter at PVC side 5 4 A ECO —— 07-02-05TROUBLESHOOTING / Troubleshooting A FAULT CODES 09 and 10 Fault code 09 indicates that the sensing signal (input voltage from the sensor) is higher than 4.75 V; pos- sible causes include a malfunction of EC sensor or & break in the wireharness between terminal No. 35 and EC sensor side connector No. 3 (ground line) Fault code 10 indicates that the sensing signal (input voltage from the sensor) is lower than 0.25 V; possi- ble causes include a break in the wirenamess be- tween the EC sensor and the EC, or a short circuit between the 5 volt line and the ground line. FAULT CODE TROUBLE CORRECTIVE ACTION 09 Short-circuit of EC sensor andjor | 1) Retry diagnostic procedure B harness 2) Check harness 3) Replace EC sensor 10 Disconnected EC sensor and/or ames OK (within the normal valve ange) Harness check be- EO sensor check tween EC ang EC NOT OK (auto he normal value range) Replace EC sensor EC Sensor Check 1. Turn the key switch OFF , and remove the con- nector of EC sensor. 2. Measure the resistance between terminals No. 1 and No, 3 of the EC sensor connector. Normal value : 1.70.4 kQ Uf resistance is with in specification, go next to step 3. T07-02-06TROUBLESHOOTING / Troubleshooting A 3. Remove the connector of the EC sensor and at- tach the test harness (ST 1729) to the EC sensor hamess. Touch the (+) side test probe of the cir- cuit tester to the red terminal and the (—) side test probe to the black terminal 4, Turn ON the key switch and confirm that the volt- age value changes as each mode (P, E, L and !) of the power mode selector change The normal values for each mode are: 7 P:37-4.1 V, E:3.3-35 V,L:3.0.8.4V, 12. 10707-09008 Harness Check Between the EC and EC Sensor 1, Turn the key switch OFF and remove the connec- tor of the sensor. i 2. Tum the key switch ON and measure the voltage between terminal No. 1 (+ side) and terminal No. yo2g 43 3 (— side) of the hamess side connector. Normal value : 5 + 0.5 V If the voltage is within the normal value range, rorerosoie both harnesses between terminal No. 21 of EC and terminal No. 1 of EC sensor: as well as be- ‘tween terminal No. 35 of the EC and terminal No. ry) 3 of the EC sensor are normal 3. When the above-mentioned voltage is not normal, check which hamess is defective. EC sensor 1 ec at ge Be 341. Turn ON the key switch and measure the volt age between terminal No.1 of the hamess side connector and the machine body (ground). Normal value : 5 +0.5 V ifthe voltage is within the normal value range, the harness between terminal No. 21 of the EC and terminal No. 1 of the EC sensor are nor- mal 3-2, I the voltage measured in step 3-1 is normal, check the continuity between terminal No. 3 of the hamess side connector and machine body (ground). If the continuity exists, the harness between terminal No. 35 of the EC and terminal No. 3 of the EC sensor is normal 7 4, Attach Dr. EX to the machine and short-circuit terminals No. 1 and No. 2 of the harness side connector with a clip, or jumper wire. At that time, if the monitor display of the EC sensor indicates Care. snl be taken maximum value, the harness between terminal nak iano sre , ‘achine withthe et No. $4 of the EC and terminal No. 2 of the EC \~ ° sensor is normal rereravers 07-02-07TROUBLESHOOTING / Troubleshooting A FAULT CODE 13 Fault code 13 indicates trouble in the N sensor sys- tem In case the harness between N sensor and EC is disconnected, the EC judge the engine rotation to be 0 min-* (rpm) (the equivalent of the engine being OFF), so no fault code will be displayed. ‘Therefore, confirmation by the monitor function of Dr. EX is required FAULT CODE TROUBLE CORRECTIVE ACTION 13, N sensor is abnormat 1). Retry diagnostic procedure B 2) Check N sensor hamess 3) Replace N sensor Harness between Hd IEC ana N sensor disconnactes is the umber ox erie revere Repace omin" (rpm)? (OK [Check harness between EC and N sensor Froube in harness [Check esis between EC ane Ny tance of N NOTOK [sensor No" [sensor Replace N sensor NoT ok N Sensor Check 1. Turn the key switch OFF. Remove the N sensor connector. 2. Measure the resistance between terminals No. 1 and No. 2 of the N sensor connector. Normal value : 810 + 240 @ at 20°C (68°F, T07-02-08TROUBLESHOOTING / Troubleshooting A Harness Check Between EC and N Sensor 1. Tum the key switch OFF. Remove the sensor connector and EC connector. 2. Short-circuit terminals No. 1 and No. 2 of the hamess side connector of the N sensor with a clip, or jumper wire. 3. Check the continuity between terminal No. 4 and terminal No. 11 of the EC side connector. Hf continuity exists, these are normal, 4, When the above mentioned continuity does not exist, check which hamess is disconnected, 4-1. Ground terminal No. 4 of the EC side connec- tor to the vehicle body with a clip, or jumper wire. Check the continuity between terminal No.1 of harness side connector of the N sen- sor and the machine body (ground), If continuity exists, it is normal. 4-2, Ground terminal No. 11 of the EC side con- rector to the vehicle body with a clip, or jumper wire. Check the continuity between terminal No. 2 of hamess side connector of the N sensor and the machine body (ground). It continuity exists, it is normal 1, 2 port banat oon ray t2_Sf 1 2 fe] na /t T 1 2 fey 10a 4 07-02-09TROUBLESHOOTING / Troubleshooting A PVC-RELATED FAULT CODES FAULT CODES 17, 18, 19 and 21 If one of these codes is stil displayed after retrial, ‘and malfunction of the machine is observed, replace the PVC with a new one. FAULT CODE TROUBLE CORRECTIVE ACTION 7 Failure (type-17) of PVC 1) Retry diagnostic procedure A 18 Failure (Iype-18) of PVC 2) Replace PVC if engine stops or working 19 Failure (Iype-19) of PVC speed is abnormal 2a Failure (type-21) of PVC 1). Retry diagnostic procedure 8 2) Replace PVC Yes * Pvc trouble [Are the functions of line engine and the machine normal? Replace PC No * NOTE: * The machine can be used when machine and engine functions are normal, even if Dr. EX continues to alsplay fault codes after re- trying diagnostic procedure A or B. 07-02-10TROUBLESHOOTING / Troubleshooting A FAULT CODE 20 In case this code is displayed, check the harness for problems between the PVC and EC. FAULT CODE TROUBLE ‘CORRECTIVE ACTION 20 Signal from EC is not transmitted to |1) Retry diagnostic procedure B Pvc 2) Hamess check 3) If abnormalities are found in the functions of the engine and machine, replace the EC and PVC with new one ok * Replace PVC and Ec Harness check be een PVC and EC Hamess trouble be. tween PVC and EC. NOTOK NOTE :* In case of the replacement of the PVC and EC, since itis dificult to judge which controller is defective, replace both controller at the same time. T07-02-11TROUBLESHOOTING / Troubleshooting A FAULT CODE 22 Fault code 22 indicates the trouble that, even if the PVC sends a control signal to set the objective axial angle to the pump, the actual pump axial angle does ‘not conform to the command, Possible causes are: 1. trouble of the pump displacement solenoid valves, 2. trouble of the A sensor. 3. trouble of the PVC itself Because the fault code 22 is a synthetic judgment of the PVC, if another fault code (e.g. A sensor trouble) is displayed at the same time, check and repair for the other fault code fist. FAULT CODE TROUBLE CORRECTIVE ACTION 22. ‘Abnormal pump control 1) Retry diagnostic procedure 8 2) Harness check 38) Check pump displacement solenoid valve 4) Check A sensor 5) Check PVC. Jeisplayed at the Pump Swing conra ever Operttecneutal [ee coerce tess brake. {Check actuating circuit {Check pressure switch ‘ers and arm {rolen operations. 07-03-31TROUBLESHOOTING / Troubleshooting B $-5 Upperstructure does not Swing. First, check if the problem is in the pilot circuit or main circuit Disassemble and clean shutle valve No problem exis (6), then reassemole Check i problem sil exits il pressure does not increase. Upperstructure does not swing (Check it spring in ‘Same problem exists Abnormal No ‘Check i swing pict pressure at outlet of pilot valve is norma Yes (Check pump delivery pressure by Dr. EX * Power mode selector P mode + Swing contral lever: Ful eroke swing rele! valve is + Disassemble swing rele valve and inspect visually Normal No (0 pressute increases but uppersucture does net swing * Operate swing convo! lever {Chock dvectonal | {solenoid vave creut | L_} andrepar treauites. | Yoo |Checkitsame | | prabi sil exists {ster rep ‘Same problem 07-03-32Felure of shuttle valve (8) Failure of swing pl vane Replace swing relet Disassembve and lean canal valve No problem exists vane Faire of swing spe and raaseomdle, Check againit same problem exists. No problem exists Falure of swing Disassemble and clean swing variable varabie Compensated valve ccnmmreatovave to pion same po) Sc aoe mate, Talus Sapo Seems | sama] err vo secin aekse iGiekhie, | fre Fale oo Bisassemte ane No problem ensis ‘arable pressure tener Scans va vo prtien Gres aa are cua arg Negron eine taniio oscar snorgroet Sane pon esse exists: z eee clean shuttle valve Problem exists No. 2 in Joad sensing Coed Problem | Check it same potion ot cana en sane pom [eowetvne nten T07-03-33TROUBLESHOOTING / Troubleshooting B TRAVEL TROUBLESHOOTING T-1 Travel Speed is Slower Than Specified Ranges Right and left side pilot valves rarely experience prob- lems at the same time. This troubleshooting is for such problems as when travel speed is slower than specified ranges but the travel speed range shift is OK. In case travel speed does not change, refer to *T-2 TRAVEL ‘SPEED DOES NOT CHANGE". Grok Fro ood ve_| nal nen = ‘an operation other than ft aperomes Sure Shear pi Sintra eet {hed aaiaing caval} sm tan | for travel and repair it 4 [ovcaomemaae Dassarbiand ean No | check if same problem sitll exists, No problem exists No problem exists T07-03-34Same problem este Failure of 8 spool ‘control valve section Disassemble and clean shut tie valves No.1 and No.2 in load sensing circuit, and reassemble. Check if same problem stil exists. Failure of shuttle valves No.1 and No.2 No problem exits in load sensing circuit. Failure of main travel ‘spool. Disassemble and clean or replace 3- ‘spool control valve section. Failure of shuttle valve (1). Disassemble and clean or replace shuttle valve (T), Failure of pilot valve End 1707-03-35TROUBLESHOOTING / Troubleshooting B T-2 Travel Speed does not Change It the travel mode indicator does not change to an- other mode after changing the travel mode, switch panel 2 has failed. If the travel mode indicator changes to another mode but travel speed does not change after pushing the travel mode switch, the pump or motor swash plate angle control circuit’ has failed. 1 kgffem®= 0.09807 Mpa Fall of travel motor swash angle contol “Travel speed does not change from fast speed to medium speed and vice versa, \When traveling in fast speed Yer Check it display of travel made switch (Siow, Mi. Fast) changes when vavel mode | |_| ‘viteh postion is changed No However, when the tracks are packed with mud, in- creasing the resistance to travel, travel speed may not attain fast speed acceleration; this is normal. When traveling on fat groune 52-10. kglem (730 6 28 sy Wan operat vavel ‘ater over rele pressure Bio Gkaliem? (28 88s) (Check changeover pres ‘made, travel speed does not shit to medium mode automatically. “Travel speed does not charge as travel made switchs ned Failure of pump swash angle conto! Travel speed does not change trom medium to slow speed, and “Travel speed does not change as ravel mode switchs cnanges. sure a vavel motor +Travel mode : Fast speed + Operate ravel motor over rlet pressure and fat groune Under ether operating conditions Same problem exists neck and repairtravel | | pressure switen cecut, | + Check if same probiem sill — No problem exists T07-03-36F Check and repair travel | proportional sotenod valve + actuating circuit. Check it [Same problem sill exists, | Check and repair travel | pressure switch circuit + Check i same prabler sil F Chock and repair wavel | proportional solenaid valve actuating circuit. Check i { Same problem stil exists, Same probiem exists Failure of travel moter swash angle change contol system No problem exists same Becblom | Check P senso: harness sts | and repair required ‘Same problem exis | Check it sme problem si End F Check a sensor har No problem exists End No problem exists ‘Same problam exists End Exchange travel pressure compensat- 6 valve with another pressure com pensated valve. Check i same prob: ‘om sill exists. If same problem exist, replace 3 spool contol valve section End No problem exists End F Check hamess be: tween switch panel 2 1 and contvoiee 07-03-37TROUBLESHOOTING / Troubleshooting B 1-3 The Excavator Mistracks When the excavator mistracks with the connector (SM) for travel-proportional solenoid valve discon- nected, a stuck travel spool may be the cause, oF omeeed the variable pressure compensated valvefor travel 4, | eanvanave may have a problem, compensa vate foray a reason, Checetsame prbion si ets Check saver roan os track side speed cee _ ves _| charges by sxcarging et and Taft wael hoses on centr Check pot oh press at ute of photvaesis noma ves Disassemble and Check if travet reliet ‘clean shuttle valve pressure of slower S| Mandreessorbe, -—] No) Messuee! sioner No | Check same eee prbion st exits — senino. | Problem wnen | Problem when pot travling sight wing Extemal leakage 2 | speed wit not shit -|bé a [eee : . i =H ee 4 * | Boor | — er Sel | Se a T07-03-38(Check slower track side speed changes Yes by exchanging et and right ravel contol valve spools. Failure of eonvol valve sp001 Replace 3-spoo! contrl valve section Failure of variable pressure compensated valve Failure of vavel No Same _ | Check it drain oil je Beem | vane rom revel taro honor cual pected Sane [Dsssenbie ord cut $iBin | Seen rel er rT servo piston and Disassemble and clean vavel motor counter balance valve and reassemble. Check same problem stl exists, reassemble. Check it same problem stil exists, Feallure of center ont No problem exis Falure of ravel ‘motor servo piston No probiem exis Fealure of counter valance vaive ‘Same problem exis Repair or replace ‘aval rele valve Failure of pt valve No problem exis Faire of ste valve (7) T07-03-39TROUBLESHOOTING / Troubleshooting B T-4Both Right and Left Travel Motors do not Ro- tate. When both right and left travel motors do not rotate, pi- lot oil control system common to both right and left trav- el motors may have a problem. ‘Same problem exists ‘check actuatng | € ckcul of proportional | solenoid valve for 1. kgllem?= 0.09807 Mpa Fe ‘raveland repaieit | ‘check plot ot required, Chek ts! pressure at outet {ame probier eit, | Yes ul ‘Shots over 25 No problem ens Kall 270 ps. ‘Chock plato pressures over No eostving (7330s) = Check pt ol pressure ‘tet port of vavel piotvave Ne Either Right or Left Motor does not Rotate. When either right or left motor does not rotate, control valve, travel device andjor pilot valve may have a prob- lem. ‘Same problem exists Disassombie and clean the problem yes _| side of ave! control valve spo0. yy Check t same eee problem sil exits Yes __| wit side hose on comer joint and No probiem exists check i he problem sie changes. (check i pict ot Re pressure at outet of travel plot valve is ‘Same problem exists over 2 ktm? —— (70 pai. Disassemble and clean shute valve (7) and reassemble No] Checkitsame | FL problem sil exists, No problem oasis T07-03-40Failure of shut valve No.t and No.2 inthe load sensing system End Failure of pict valve (Disassemble anc clean i) Cicgging betwoen Same problem exists pilot shut-of valve and pit vale —— Failure of 3 spool Disassemble and clean variable pressure compensated valve for travel on the problem se ane check it same problem sil exists contral valve section Failure of variable No problem exits pressure Compensated valve foc travel Faire of rave sp00! Falure of rave motor Fallure of pill valve Failure of ste vave (7) 07-03-41TROUBLESHOOTING / Troubleshooting B 1-5 Travel Power is Weak When both travel motors deliver less than normal pow- er, the main pump system pressure relief valves may have a problem. When only one travel motor delivers less power, the travel motor and its circuit may have a problem. 4 kgffem®= 0.09807 Mpa CCheck pump delivery pressure using Or EX mentoring une: * Power mode selector P mode + Operate travel moter over sysiem reich pressure. + Week made selector ‘witen : General purpose Below 960 kaon 977 ps) ‘apt ancjr role travel eet vate More orless han 21 tom? 0 85 ps § = Replace the PVC Check he changeover pressure 4 ol vel motor ving Seageeaane | caareireal ver 280 |] Grex montorng teor stem? | uneson Waitin 2106 kate 977 pall ne + Fare of ravel + Power mode selector P mode + Operate travel motor cover system reli pressure, + Work made selector ‘witeh : Genera purpose {Chock actwating creat | of ravel proportonal | Slonoid'valve and parking brake system. + Faiure of travel motor ‘swash angle contro! 1 real requres 1 Chock same problem | Strerts system, + Travel motor seized, End No problem exists T07-03-42TROUBLESHOOTING / Troubleshooting B OTHER TROUBLESHOOTING (0-1 Work Mode Selector Switch does not Operate When indicator lights do not change when the work mode selector switch is operated, switch panel 2 may have a problem. When indicator lights change but actual operating speeds do not change, the pressure switch andjor pro- portional solenoid valves may have a problem. 7 { Check actuating circuit Ys ot proportional Cheek ifthe display "> vves_|| switch (Bm, Tr, Ot Sw, Amy" changes when | |I-| ‘each control lever is operated. Check ifthe display + Dr. EX monitoring ° 4 “work mode selector funetion L___' Check pressure switch} switch” changes when No it i) ‘work mode selector position is changed, + Change work mode selector switch postion 7 3 + Dr. EX monitoring function { Check harmess i Dr EX monitoring function [__totween switch panel | No {2and PVC 3 Reference Work mode Applications General purpose mode (M1) Applied to general digging and loading work (m2) When swing and boom raise are operated at same time, priority is given to swing speed. Trenching mode ‘Arm speed becomes slower. When arm is operated with boom or Grading mode (m3) bucket, boom or bucket speed also become slower. Other operating speeds except travel/boom lower become slower. Precision mode (m4) Allowing more precise control when lifting/lowering loads. T07-03-43TROUBLESHOOTING / Troubleshooting B 0-2Slow Response to Control Lever Operation Displayed figure changes after more than 1'second Failure of pump servo piston control system Check pump Displayed figure changes _| Failure of pilot oil displacement angle ater moce thant second | circuit (Low pilot pressure, failure of ‘change speed while pilot valve. or other) ‘operating the control lever in question, Check display speed change of P switch signal when the Displayed fgure || control lever in charges thn || queston is operated Failure of control Displayed figure ale changes win ‘second (0-3Excessive Noise andjor Vibration From the Pump ‘¢ Failure of pump Feallure of pump ‘Check if diferential vyex_|| pressure ana Ne if pu pump delivery Pe depoconent |L] pressure ae ea Eger [Falue of OP angi is stable. be sensor andlor P Replace sen- sorin question Check it A L| ‘sensor is in No} ane Specie No | sated cor stil exists rect + Floplace OP Failure of pum Sensor andjorP Saal ean Sensor and peer ome Correct L instalation of A sensor or replace T07-03-44TROUBLESHOOTING / Troubleshooting B (0-4 Wiper does not Function Changing the control from intermittent to continuous op- eration is done in the switch panel 1, and the switch panel and the windshield wiper motor are connected with one wire (1) Wiper does not move, in either the intermittent or continuous mode. ‘When in continuous opera: tion position, windshield wip- ‘er moves But when in inter: mittent operation position, i does not move. ‘When in intermittent opera- tion position, windshield wip- fer moves but when in con- tinuous operation position, it does not move. (2) Windshield wiper does not move in both intermittent or continuous operation positions Failure of switch panel 1 { Referring to HAR: Failure of windshield wiper motor Yes_| NESS CHECK and Failure of harness i check up to where ' voltage is 24 Vols ‘Check indicator ight + Key switch : ON changes when windshiels + Wiper switch wiper switch position inter ‘Continuous operation mitteni/eontinuous) is Position changed. + Key switch : ON Failure of windshield wiper motor relay + Windshield wiper switch Ne Continuous / intermittent positions, Failure of switch panel 1 1707-03-45TROUBLESHOOTING / Troubleshooting B 0-5 Fuse Failure Failure of fuses for work lights is explained here as an example. Check other fuse failures (horn, windshield wiper, cab heater and so on) in the same way When a fuse falls soon after it is replaced, disconnect, all parts from the circuit and check the circuit in the cur- rent flow direction, reconnecting each part one by one, Fase bows out ‘Aer diasonnocting corr rector for ight ray 1 —- tnd 2 and work ihe ows out (three) . Check if fuse fails Soon air use No.1) 8 replaced Keyswitch: ON Connect the comecior ferightrelay and heck fuse fas wen ¥ } ight switch is tuned on acl : ater lay Key switch ON t ox Light relay 2 Al 7, Work ight (boom) = (2 Switch panel Work ight (F) Work tight) Light relay 1 T07-03-46Short circuit of har- ness between fuse No.11 and light relay No.t or terminal No.3 ‘Shor circuit of har ness between termi: nal No.S on light relay (Check if fuse falls when left work Fuse biows out lightis connect- 0, + Key usten ON + Work int switch ON (Check if fuse fails when right work oK light ls connect- ed. + Key swieh ON + Werk ight switch: ON Fuse blows out No.1 and work lights. Failure of left work light. Failure of right work ‘Check if fuse falls when right relay No.2 is connected Fuse blows out light ‘Shor circuit of har- ness between termi ‘nal No.5 on light relay (0K | and work ight switch is tuned ON. + Key switch ON + Boom work light swteh ON No.2 and boom work light Failure of boom Fuse blows out work light 3K] light is connect. ed. (Check iffuse falls ‘when boom work End 0K 07-03-47TROUBLESHOOTING / Troubleshooting B 07-03-48TROUBLESHOOTING / Troubleshooting C MONITOR PANEL, SWITCH AND SENSOR LOCATION 1 Buzer 6 2 Fuel sending uit 7 3~ Low fue! lave siteh a 4— Hydraulic ol lvel switch a 5~ Coolant temperature sensor 10 A~ Coolant temperature gauge BA Fue! gauge (C— Hour meter D~ Alternator indicator E— Engine ol pressure indicator F— Ai fier restition incicator G— Ovethoat indicator HO Fuel level indicator I= Engine preneatincicator JH Engine oil leve indicator K— Coolant evel indlestor = Hydeauie of evel indicator NM Level check swith Engine ol pressure switch Engine ol level switcn Overneat eter Coolant evel switch Arter estction switch T07-04-01