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TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form at the end of this man-
• Be sure to thoroughly read this manual for correct ual.
product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redeliver and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
Example : T 1-3-5
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
UNITS USED
2
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKS system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
L US gal 0.2642 Power kW PS 1.360
Volume L US qt 1.057 kW HP 1.341
3 3
m yd 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
001-E01A-0688 SA-688
002-E01C-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
004-E01A-0437
SA-2
SAFETY
WEAR PROTECTIVE CLOTHING
005-E01A-0438
006-E01A-0434 SA-434
INSPECT MACHINE
S007-E01A-0435
SA-435
SA-3
SAFETY
GENERAL PRECAUTIONS FOR CAB
524-E01A-0000
SA-4
SAFETY
USE HANDHOLDS AND STEPS
008-E01B-0439
009-E01A-0378
SA-5
SAFETY
FASTEN YOUR SEAT BELT
010-E01A-0237
011-E01A-0426
SA-6
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
012-E01B-0444
JUMP STARTING
S013-E01A-0032
SA-7
SAFETY
KEEP RIDERS OFF MACHINE
SA-379
014-E01B-0379
018-E01A-0481
SA-481
SA-8
SAFETY
DRIVE MACHINE SAFELY
SA-387
SA-441
019-E01D-0492
SA-589
SA-9
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle / acceleration seleclter and the SA-391
H/P mode switch off.
• Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK
position.
• Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
SA-392
020-E08A-0493
SA-10
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
S021-E01A-0494
SA-11
SAFETY
AVOID TIPPING
To avoid tipping:
• Be extra careful before operating on a grade.
S025-E01B-0495
SA-12
SAFETY
AVOID POWER LINES
029-E01A-0381
OBJECT HANDLING
032-E01A-0014
SA-13
SAFETY
PROTECT AGAINST FLYING DEBRIS
SA-432
031-E01A-0432
To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle / acceleration selector and H/P
mode switch off.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK
position. SA-390
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.
033-E09B-0390
SA-14
SAFETY
HANDLE FLUIDS SAFELYҥ
ҥAVOID FIRES
034-E01A-0496
SA-019
SA-15
SAFETY
SAFETY TRANSPORTING
S035-E08A-0395
SA-16
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
S500-E02B-0497
SA-17
SAFETY
• Use a portable safety light for working inside or
under the machine.
• Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• Sufficiently illuminate the work site. Use a
maintence work light when working under or
inside the machine.
• Always use a work light protected with a guard. In SA-037
S501-E01A-0287
SA-287
502-E01A-0026
SA-026
SA-18
SAFETY
PREVENT PARTS FROM FLYING
503-E01B-0344
SA-034
504-E01A-0034
SA-040
S522-E01A-0040
SA-19
SAFETY
PREVENT BURNS
• Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot
as well.
SA-225
505-E01B-0498
S506-E01A-0019
SA-20
SAFETY
AVOID HIGH-PRESSURE FLUIDS
SA-292
507-E03A-0499
SA-044
SA-21
SAFETY
PREVENT FIRES
Clean up Flammables:
SA-22
SAFETY
Check Emergency Engine Stop Switch:
• If a fire breaks out, failure to release pressurized air
inside the hydraulic tank will escalate fire, hampering
fire fighting.
• Check the emergency engine stop switch function
every 250 hours:
1) Start the engine and run it at slow Idle.
2) Turn the emergency engine stop switch to the
EMERG. STOP position.
3) Confirm that both engines stop and that pres-
surized air inside the hydraulic oil tank is re-
leased (a hissing sound should be heard).
• If any abnormalities are found, be sure to repair
them before operating the machine.
S508-E02B-0019
SA-393
• In an emergency, if the cab door and/or the front
window cannot be opened, break the front or rear
window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on “EMERGENCY
EXIT” in Operator’s Manual.
518-E02B-0393
SS-1510
SA-23
SAFETY
BEWARE OF EXHAUST FUMES
509-E01A-0016
SA-016
SA-24
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
511-E01A-0029
512-E01C-0032
SA-25
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
513-E01A-0405
• Check the MSDS before you start any job using a SA-309
hazardous chemical. That way you will know
exactly what the risks are and how to do the job
safely. Then follow procedures and use
recommended equipment.
S515-E01A-0309
SA-26
SAFETY
DISPOSE OF WASTE PROPERLY
S516-E01A-0226
S517-E01A-0435 SA-435
SA-27
SAFETY
(Blank)
SA-28
SECTION AND GROUP SECTION 4 OPERATIONAL PER-
CONTENTS FORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
TECHNICAL MANUAL
Group 6 Adjustment
(Troubleshooting) SECTION 5 TROUBLESHOOTING
Group 1 General
Group 2 Component Layout
Group 3 Troubleshooting A
Group 4 Troubleshooting B
Group 5 Troubleshooting C
Group 6 Electrical System Inspection
Group 7 ICX
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Control System Group 5 Travel Device
Group 2 Hydraulic System Group 6 Signal Control Valve
Group 3 Electrical System Group 7 Others (Upperstructure)
All information, illustrations and speci- Group 8 Others (Undercarriage)
fications in this manual are based on
the latest product information available WORKSHOP MANUAL
at the time of publication. The right is SECTION 1 GENERAL INFORMA- SECTION 3 UNDERCARRIAGE
reserved to make changes at any time TION Group 1 Swing Bearing
without notice. Group 1 Precautions for Disassem- Group 2 Travel Device
bling and Assembling Group 3 Center Joint
Group 2 Tightening Torque Group 4 Track Adjuster
SECTION 2 UPPERSTRUCTURE Group 5 Front Idler
Group 1 Cab Group 6 Upper and Lower Roller
Group 2 Counterweight Group 7 Track
Group 3 Main Frame SECTION 4 FRONT ATTACHMENT
COPYRIGHT(C)2001
Group 4 Pump Device Group 1 Front Attachment
Hitachi Construction Machinery Co., Ltd.
Group 5 Control Valve Group 2 Cylinder
Tokyo, Japan
Group 6 Swing Device
All rights reserved
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 9 Solenoid Valve Unit
Group 10 Signal Control Valve
SECTION 4
OPERATIONAL
PERFORMANCE TEST
—CONTENTS—
Group 1 Introduction Hydraulic Cylinder Cycle Time ............... T4-4-12
Operational Performance Tests ............. T4-1-1 Dig Function Drift Check........................ T4-4-14
Preparation for Performance Control Lever Operating Force .............. T4-4-15
Test ..................................................... T4-1-2 Control Lever Stroke ............................. T4-4-16
Boom Raise/Swing Combined
Group 2 Standard Operation Check.................................. T4-4-17
Operational Performance
Standard Table .................................... T4-2-1 Group 5 Component Test
Main Pump P-Q Diagram....................... T4-2-4 Primary Pilot Pressure ........................... T4-5-1
Injection Pump ...................................... T4-2-5 Secondary Pilot Pressure ...................... T4-5-3
Dr.EX Monitor Indicating Values ............ T4-2-6 Main Relief Pressure Shift Control
Sensor Activating Range ....................... T4-2-11 Pressure(SA Pressure) ........................ T4-5-4
Travel Mode Shift Control
Group 3 Engine Test Pressure(SB Pressure) ........................ T4-5-5
Engine Speed........................................ T4-3-1 Boom Mode Selector Control
Engine Compression Pressure .............. T4-3-3 Pressure(SC Pressure)........................ T4-5-6
Valve Clearance .................................... T4-3-4 Main Pump Device Pressure ................. T4-5-7
Nozzle Check ........................................ T4-3-6 Main Relief Pressure ............................. T4-5-8
Injection Timing ..................................... T4-3-8 Overload Relief Valve Set Pressure ....... T4-5-12
Main Pump Flow Rate Measurement ..... T4-5-14
Group 4 Excavator Test Swing Motor Drainage ........................... T4-5-18
Travel Speed ......................................... T4-4-1 Travel Motor Drainage ........................... T4-5-20
Track Revolution Speed ........................ T4-4-2
Mistrack Check ..................................... T4-4-3 Group 6 Adjustment
Travel Parking Function Check .............. T4-4-4 Installation and Adjustment
Swing Speed ......................................... T4-4-5 of Pump Displacement Sensort............ T4-6-1
Swing Function Drift Check ................... T4-4-6 Enging Speed Adjustment and
Swing Motor Leakage ............................ T4-4-7 Engine Learning .................................. T4-6-2
Maximum Swingable Check of Governor Lenver and
Slant Angle .......................................... T4-4-8 Fuel Cut Lever Position........................ T4-6-4
Swing Bearing Play ............................... T4-4-10
17VT-4-1
(Blank)
17VT-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
1. THE MACHINE
Repair any defects and damage found, such as oil
or water leaks, loose bolts, cracks and so on, be-
fore starting to test.
2. TEST AREA
(1) Select a hard, flat surface.
(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. T105-06-01-003
3. PRECAUTIONS
(1) Before starting to test, agree upon the signals
to be employed for communication among
coworkers. Once the test is started, be sure
to communicate with each other using these
signals, and to follow them without fail.
(2) Operate the machine carefully and always
give first priority to safety.
(3) While testing, always take care to avoid 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 escap-
ing oil. Pay special attention to this when re-
moving hydraulic pipings.
T105-06-01-004
T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE STAN-
DARD TABLE
The standard performance values are listed in the ta- test procedure:
ble below. Engine Control Dial : Fast Idle
Refer to the Group T4-3 to T4-5 for performance test Power Mode Switch : HP Mode
procedures. Auto-Idle/Acceleration Selector : OFF
Values indicated in parentheses are reference values. Work Mode Switch : Digging Mode
Hydraulic Oil Temperature : 50±5°C(122±9°F)
Performance Reference
Performance Test Remarks
Standard page
ENGINE SPEED min-1 T4-3-1
Slow Idle 900±100
Fast Idle(HP mode) 1850±100
Fast Idle(E mode) 1820±100
Auto-Idle 1250±100
Fast Idle (1920±100:
−
(HP mode-Boom Relief Operation) Reference Value)
MPa(kgf/cm2)
2.94 (30)
ENGINE COMPRESSION PRESSURE After the engine warm-up T4-3-3
or more
VALVE CLEARANCE (IN, EX) mm 0.4 With the engine cold T4-3-4
NOZZLE INJECTION PRESSURE MPa(kgf/cm2) 17.7 (180) T4-3-6
INJECTION TIMING (Degrees before TDC) deg. 9.7° T4-3-8
TRAVEL SPEED sec/20m T4-4-1
Fast Speed 17.0±2.0
Slow Speed 24.6±2.0
TRACK REVOLUTION SPEED sec/3rev T4-4-2
Fast Speed 32.2±2.0
Slow Speed 46.5±2.0
MISTRACK mm/20m 200 or less T4-4-3
(With fast and travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0 T4-4-4
SWING SPEED sec/3rev 22.0±1.5 T4-4-5
SWING FUNCTION DRIFT CHECK mm/180° 1198 or less T4-4-6
SWING MOTOR LEAKAGE mm/5 min 0 Bucket Loaded T4-4-7
15 or possibly
MAXIMUM SWINGABLE SLANT ANGLE deg. Bucket Loaded T4-4-8
more
SWING BEARING PLAY mm 2.0 or less Allowable Limit : 5.0 T4-4-10
T4-2-1
OPERATIONAL PERFORMANCE TEST / Standard
Performance Reference
Performance Test Remarks
Standard page
HYDRAULIC CYLINDER CYCLE
sec T4-4-12
TIME
3.6 Arm,
3
Backhoe 3.4 m (PCSA heaped)
Bucket
4.0±0.3
Boom Raise
(ZX850H: 4.4±0.4)
3.1±0.3
Boom Lower
(ZX850H: 2.9±0.4)
4.3±0.3
Arm Roll-In
(ZX850H: 4.6±0.4)
3.2±0.3
Arm Roll-Out
(ZX850H: 3.7±0.4)
2.7±0.3
Bucket Roll-In
(ZX850H: 2.7±0.4)
2.7±0.3
Bucket Roll-Out
(ZX850H: 2.8±0.4)
3
Loading Shovel(Tentative) 4.0 m Bucket
Boom Raise (5.2±0.4) Tentative value
Boom Lower (4.5±0.4) ↑
Arm Extend (3.1±0.4) ↑
Arm Retract (2.3±0.4) ↑
Bucket Roll-In (3.8±0.4) ↑
Bucket Roll-Out (3.4±0.4) ↑
Bucket Open (1.2±0.3) ↑
Bucket Close (1.2±0.3) ↑
DIG FUNCTION DRIFT CHECK mm/5min T4-4-14
3.6 Arm
3
Backhoe 3.4 m (PCSA heaped)
Bucket, Bucket loaded
Boom Cylinder 21 or less
Arm Cylinder 16 or less
Bucket Cylinder 15 or less
3
Loading Shovel (Tentative) 4.0 m Bucket
Boom Cylinder (30 or less)
Arm Cylinder (20 or less)
Bucket Cylinder (20 or less)
CONTROL LEVER OPERATING
N(kgf) Hitachi Lever Pattern T4-4-15
FORCE
Boom Lever 18 (1.8) or less
Arm Lever (ISO Lever Pattern: Swing Lever) 15 (1.5) or less
Bucket Lever 15 (1.5) or less
Swing Lever (ISO Lever Pattern: Arm Lever) 18 (1.8) or less
Travel Lever 28 (2.8) or less
T4-2-2
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-3
OPERATIONAL PERFORMANCE TEST / Standard
MAIN PUMP P-Q DIAGRAM
L/min
A
• •
B
•
Flow
Rate
T4-2-4
OPERATIONAL PERFORMANCE TEST / Standard
INJECTION PUMP
Test Conditions:
1. Nozzle assembly: 105780-8140
2. Nozzle: 105780-0000
3. Nozzle holder: 105780-2080
2
4. Nozzle opening pressure: 17.2 MPa (175 kgf/cm )
5. Test fuel: ISO 4113 or SAE J967d
2
6. Transfer pump pressure: 255 kPa (2.6 kgf/cm )
7. Injection pipe:
Inner Dia. 3 ×Outer Dia. 8 - Length 600 mm
(0.118×0.315×23.6 in)
8. Fuel temperature: 40 ±1 °C (104 ± 2 °F)
Governor adjustment
T16J-04-08-009
T4-2-5
OPERATIONAL PERFORMANCE TEST / Standard
DR. EX MONITOR INDICATING VALUES
T4-2-6
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-7
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-8
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-9
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-10
OPERATIONAL PERFORMANCE TEST / Standard
SENSOR ACTIVATING RANGE
1. Checking Method
T4-2-11
OPERATIONAL PERFORMANCE TEST / Standard
(Blank)
T4-2-12
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary:
1. Measure engine speed using the built-in diagnos-
ing system or Dr.EX. If the built-in diagnosing sys-
tem or Dr.EX is not available, use the pulse
counter.
2. Measure the engine speeds in each mode.
Preparation:
1. Select the monitor function of built-in diagnosing
system or Dr. EX. When using the pulse counter,
disconnect the N sensor connector, connect the
pulse counter to the N sensor.
2. Warm up the engine until the engine coolant tem-
perature reaches 50 °C (122 °F) or more, and hy-
draulic oil temperature reaches 50±5 °C (122±9
°F).
T4-3-1
OPERATIONAL PERFORMANCE TEST / Engine Test
Measurement: Evaluation:
1. Check engine speeds for auto-warm up (when Refer to T4-2 Operational Performance Standard.
starting the engine), auto-idle, slow idle, fast idle
(when normal), fast idle (in the E mode), and fast Remedy:
idle (in the HP mode). Refer to T5-4 Troubleshooting B.
2. Select the switch positions and the test conditions
corresponding to the engine speed to be meas-
ured as shown in the table below.
3. When using the pulse counter, read the pulse
counter, calculate the engine speed using the fol-
lowing formula:
-1
Engine Speed (min ) = Pulse Numbers (Hz) × 60
/ 139
Engine Power Ӹ Auto-Idle/ Auto- Work
Control Ӹ Mode Ӹ Acceleration Mode Test Conditions
Dial Switch Selector Switch
Digging
Slow Idle Min. Speed HP OFF
Mode
Fast Idle Digging
Max. Speed HP OFF
(Normal) Mode
Fast Idle (Relief Digging Check the engine speed while
Max. Speed HP OFF
operation) Mode relieving the boom raise circuit.
Fast Idle Digging
Max. Speed E Mode OFF
(E mode) Mode
Check engine speed 4 seconds
Digging
Auto-Idle Max. Speed HP Auto-Idle after returning all control levers
Mode
to neutral.
Engine Con-
trol Dial
Auto-Idle/
Acceleration Selector
Power Mode
Switch
Work Mode
Switch
T178-01-01-004
M16J-01-010
T4-3-2
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders to
check for a decline in engine power.
Preparation:
1. Confirm that valve clearances are correct.
Measurement:
1. Turn the starter to crank the engine. Record the
compression pressure of each cylinder.
Evaluation:
Refer to Group-2 in this section.
RemedyȚ Ț
Refer to engine shop manual.
T4-3-3
OPERATIONAL PERFORMANCE TEST / Engine Test
VALVE CLEARANCE ADJUSTMENT
Summary:
1. Perform the measurement when the engine is
cold.
2. Clean the head cover mounting area to avoid any
foreign matter from getting into the engine sys-
tem.
Pointer
Preparation:
1. Locate the top dead center (TC) in the compres-
sion stroke.
Remove the cover on the left bottom of the fly-
wheel housing.
Align the TC mark on the flywheel periphery with
the pointer located on the flywheel housing by ro-
tating the ring gear using a bar.
Piston No. 1 (or piston No. 6) is now at TC in its
compression stroke.
2. Remove the head cover.
T16J-04-02-003
3. Joggle the intake and exhaust side push rods of
cylinder No. 1 by hand. If they move a little, piston
No.1 is at TC in its compression stroke. (If the ex-
haust valve of cylinder No. 1 is pushed down, pis-
ton No. 6 is at TC in its compression stroke.)
Measurement:
1. Insert a feeler gauge between the rocker arm and
the valve stem to measure the valve clearance.
T4-3-4
OPERATIONAL PERFORMANCE TEST / Engine Test
Evaluation:
Standard Valve Clearance (Cold Engine):
• Intake valve: 0.40 mm (0.016 in)
• Exhaust valve: 0.40 mm (0.016 in)
Adjustment:
If the measured valve clearances do not conform to
the standard value, adjust the valve clearance in the
same order of the measurement.
T111-06-02-009
T4-3-5
OPERATIONAL PERFORMANCE TEST / Engine Test
NOZZLE CHECK
Summary
1. Check the injection pressure and the spray pat-
tern with a nozzle tester.
2. Before starting work, clean the nozzle holder
mounting area to avoid contaminating the engine
system.
Preparation
1. Remove the nozzle holders.
Remove all nozzle holders and fuel injection pip-
ings from the engine.
2. Attach a nozzle holder to the nozzle tester.
Measurement
1. Injection pressure
After attaching the nozzle holder to the nozzle
tester, strongly make several strokes of the tester
to inject 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. Turn 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 pat-
tern.
3. Leak condition
Be sure to keep the pressure as that just before
the injection. Then check any oil leaks around the
nozzle.
T4-3-6
OPERATIONAL PERFORMANCE TEST / Engine Test
Evaluation Normal
1. Standard Injection Pressure:
Refer to T4-2 Operational Performance Standard
Table.
2. Spray Pattern
• Large-size spray should not be visible to the
naked eye.
T102-02-11-006
Adjustment
• To adjust the injection pressure, loosen the lock
nuts. Adjust the adjusting screw.
Turn clockwise to increase the pressure, and
counterclockwise to decrease the pressure.
T107-06-02-007
T4-3-7
OPERATIONAL PERFORMANCE TEST / Engine Test
INJECTION TIMING
Inspection
1. Remove the flywheel timing mark cover. Align the
9.7° BTDC mark (before piston No.1 TDC) on the
flywheel or the crankshaft damper pulley to the
pointer, by turning the ring gear counterclockwise
(as seen from the flywheel side) using a metal bar.
Pointer
Piston No.1 is now positioned in its compression
stroke.
T16J-04-02-004
Adjustment
1. Loosen the two coupling bolts on the injection Injection Pump Flywheel
pump flywheel (or the timing advanser). Injection Pump Pointer
Align the injection pump flywheel (or the timing
advanser) notched line and injection pump body
notched line.
Bolt
T16J-04-02-006
T4-3-8
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
Measure the time required for the excavator to travel
a 20 m (65.6 ft) test track.
Preparation:
1. Adjust the track sag on both side tracks equally.
2. Prepare a flat and solid test track 20 m (65.6 ft) in
length with extra length of 3 to 5 m (9.8 to 16 ft) on
Arm Rolled-In, Bucket Rolled-In
both ends for machine acceleration and decelera- End
tion. Bucket Height: 0.3 to 0.5 m
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above
the ground with the arm and bucket rolled in. Start
20 m Deceleration
4. Maintain hydraulic oil temperature at 50±5 °C Zone
(122±9 °F). 3 to 5 m
Acceleration
Measurement: Zone
3 to 5 m
1. Measure both the slow and fast speeds of the
machine. T105-06-03-001
2. Select the following switch positions:
Travel Engine Power Work Auto-Idle/
Mode Control Mode Mode Acceleration
Switch Dial Switch Switch Selector
Slow Digging
Fast Idle HP Mode OFF
Mode Mode
Fast Digging
Fast Idle HP Mode OFF
Mode Mode
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-1
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRACK REVOLUTION SPEED
Summary:
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
bucket to raise the track off ground. Keep the
boom-arm angle between 90 to 110° as shown.
Place blocks under the machine frame.
T142-05-03-011
Measurement:
1. Select the following switch positions:
Travel Engine Power Work Auto-Idle/
Mode Control Mode Mode Acceleration
Switch Dial Switch Switch Selector
Slow Digging
Fast Idle HP Mode OFF
Mode Mode
Fast Digging
Fast Idle HP Mode OFF
Mode Mode
2. Operate the travel control lever of the raised track
to full stroke.
3. Measure the time required for 3 revolutions in
both directions after a constant track revolution
speed is obtained.
4. Raise the other side and repeat the above proce-
dures.
5. Repeat steps 2. to 4. three times and calculate the
average values.
T142-05-03-012
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-2
OPERATIONAL PERFORMANCE TEST / Excavator Test
MISTRACK CHECK
Summary:
1. Allow the machine to travel 20 m (65.6 ft). Meas-
ure the maximum tread deviation from the tread
chord line drawn between the travel start and end Maximum Distance
points to check the performance equilibrium be-
tween both sides of the travel device systems
(from the main pump to the travel motor). Acceleration
2. If measured on a concrete surface, the tread de- Zone:
viation has a trend to decrease. 3 to 5 m
20 m
Preparation:
1. Adjust the track sag of both tracks to be equal.
2. Provide a flat, solid test yard 20 m (65.6 ft) in
length, with extra length of 3 to 5 m (9.8 to 16 ft)
on both ends for machine acceleration and decel- T105-06-03-022
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 50±5 °C
(122±9 °F).
Measurement:
1. Measure the amount of mistracking in both fast,
and slow travel speeds.
2. Select the following switch positions:
Travel Engine Power Work Auto-Idle/
Mode Control Mode Mode Acceleration
Switch Dial Switch Switch Selector
Slow Digging
Fast Idle HP Mode OFF
Mode Mode
Fast Digging
Fast Idle HP Mode OFF
Mode Mode
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-3
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL MOTOR LEAKAGE
Summary:
To measure the parking brake function on a specified
slope.
Preparation:
1. The surface of the test slope shall be even with a 0.2 to 0.3 m
gradient of 20 % (11.31°).
2. Hold the bucket 0.2 to 0.3 m (8 to 12 in) above the
ground with the arm and bucket fully rolled in.
3. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F). T105-06-03-004
Measurement:
T4-4-4
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING SPEED
Summary:
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 T145-05-03-007
space for swinging. Do not conduct this test on
slopes.
3. With the bucket empty, position the front attach-
ment as follows:
Backhoe:
With the arm cylinder fully retracted, and the
bucket cylinder fully extended, raise the boom so
that the arm tip pin height is flush with the boom
foot pin height.
Loading Shovel:
With the arm cylinder and the bucket cylinder fully T145-05-03-008
Measurement:
1. Select the following switch positions:
2. Operate swing control lever fully. Refer to the Performance Standard Table in Group
3. Measure the time required to swing 3 turns in one T4-2.
direction.
Remedy:
4. Operate swing control lever fully in the opposite
Refer to the Troubleshooting B in Group T5-4.
direction and measure the time required for 3
turns.
5. Repeat steps (2 to 4) three times and calculate
the average values.
Evaluation:
T4-4-5
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING FUNCTION DRIFT CHECK
Summary:
Measure the swing drift on the bearing outer circum-
ference 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 a
slope.
3. With the bucket empty, position the front attach- Two Check Marks
ment as follows:
T105-06-03-008
Backhoe:
With the arm cylinder fully retracted, and the
bucket cylinder fully extended, raise the boom so
that the arm tip pin height is fluch with the boom
foot pin height.
Loading shovel:
With the arm cylinder and the bucket cylinder fully
extended, raise the boom so that the arm tip pin
height is flush with the boom foot pin height.
4. Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
5. Swing the upperstructure 180°.
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F). T105-06-03-009
Measurement:
1. Select the following switch positions:
Auto-Idle/ Marking on the Track Frame
Engine Con- Power Mode Work Mode
Acceleration
trol Dial Switch Switch
Selector Marking on the Swing Bearing
Digging
Fast Idle HP Mode OFF
Mode T105-06-03-010
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-6
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING MOTOR LEAKAGE
Summary:
Check for upperstructure drift while suspending a
load on a slope.
Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
Backhoe: W=4500 kg (9920 lb)
Loading shovel: W=6000 kg (13230 lb)
3. Position the front attachment as follows:
Backhoe: T105-06-03-011
With the arm cylinder fully retracted, and the
bucket cylinder fully extended, raise the boom so
that the arm tip pin height is flush with the boom
foot pin height.
Loading shovel:
With the arm cylinder and the bucket cylinder fully
extended, raise the boom so that the arm tip pin
height is flush with the boom foot pin height.
4. Park the machine on a smooth slope with a gradi-
ent of 26.8% (15°).
5. Swing the upperstructure to position it 90° to the
slope. Make aligning marks on the swing bearing Measure Difference Between Marks
periphery and track frame using tape, as illus-
trated.
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-7
OPERATIONAL PERFORMANCE TEST / Excavator Test
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
With the upperstructure swung 90° to the slope,
check the maximum slant angle on which the upper-
structure can swing to the uphill side.
Preparation:
1. Check that the swing gear and bearing are well
lubricated.
2. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
Backhoe: W=4500 kg (9920 lb)
Loading shovel: W=6000 kg (13230 lb)
3. Position the front attachment as follows:
Backhoe: T105-06-03-011
With the arm cylinder fully retracted and the
bucket cylinders fully extended .
Loading shovel:
With the arm cylinder fully extended and the
bucket cylinders fully extended. Hold the arm tip
pin to the position flush with the boom foot pin
height.
4. Climb a slope and swing the upperstructure 90° to
the slope.
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Select the following switch positions:
Engine Auto-Idle/
Power Mode Work Mode
Control Acceleration
Switch Switch
Dial Selector
Fast Idle HP Mode Digging Mode OFF
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-8
OPERATIONAL PERFORMANCE TEST / Excavator Test
(Blank)
T4-4-9
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING BEARING PLAY
Summary:
Measure the swing bearing play using a dial gauge to
check the wear of bearing races and balls.
Preparation:
1. Check swing bearing mounting bolts for loose-
ness.
2. Check the lubrication of the swing bearing. Con-
firm that bearing rotation is smooth and without
noise.
3. Install a dial gauge on the track frame as shown,
Magnetic Base Dial Gauge
using a magnetic base.
T105-06-03-014
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
bearing outer race.
6. Bucket should be empty.
Round trunk
NOTE: The measured value will vary depending on
where the magnet base is secured. Se-
cure the magnet base onto the round trunk
or in a position as close to the round trunk
as possible.
T105-06-03-015
T4-4-10
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Position the front attachment as follows:
Backhoe:
With the arm cylinders fully retracted and the
bucket cylinders fully extended, position the arm
tip pin height is flush with the boom foot pin
height.
Loading shovel:
With the arm cylinder fully extended and the
bucket cylinders fully extended, position the arm
top pin height is flush with the boom foot pin
height.
Record the dial gauge reading (h 1)
2. Lower the bucket to the ground and use it to raise
the front idler 0.5 m (20 in). Record the dial gauge
reading (h2).
3. Calculate bearing play (H) from this data (h1 and
h2) as follows:
H=h2−h1
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Backhoe Front
Measurement : (h1) Measurement : (h2)
Figure 1 Figure 2
T142-05-03-006
Figure 1 Figure 2
T142-05-03-005
T4-4-11
OPERATIONAL PERFORMANCE TEST / Excavator Test
HYDRAULIC CYLINDER CYCLE TIME
Summary:
Check the overall operational performance of the
front attachment hydraulic system (between the hy-
draulic pumps and each cylinder) by measuring the
cycle time of the boom, arm, bucket, and bucket
dump (open/close) cylinders with the empty bucket.
Preparation:
1. Maintain the hydraulic oil temperature at 50±5 °C
(122±9°F).
Measurement:
1. Select the following switch positions:
Engine Auto-Idle/
Power Mode Work Mode
Control Acceleration
Switch Switch Backhoe
Dial Selector
Fast Idle HP Mode Digging Mode OFF
Bucket Cylinder
T145-05-03-014
T4-4-12
OPERATIONAL PERFORMANCE TEST / Excavator Test
• Loading Shovel
Loading Shovel
Boom Cylinder:
With the bucket cylinder and the arm cylinder fully
extended, lower the bucket to the ground.
Arm Cylinder: Boom Cylinder
With the arm fully retracted, position the bucket so
that the rear bucket does not come in contact with
the arm stopper. Then, adjust the boom cylinder
stroke to position the bucket bottom 1 m (39 in)
above the ground. T145-05-03-015
Bucket Cylinder:
With the bucket closed and held in a load dump
position, adjust the boom cylinder stroke so that
bucket bottom height is approx. 1 m (39 in) above
the ground.
Bucket Open-Close Cylinder:
With the bucket cylinder and arm cylinder fully ex- Arm Cylinder
tended, adjust the boom cylinder stroke so that T145-05-03-016
the bucket bottom height approx. 1 m (39 in)
above the ground.
3. Repeat the measurement three times and calcu-
late the average values.
Evaluation:
Refer to T4-2 Operational Performance Standard. Bucket Cylinder
T145-05-03-017
Remedy:
Refer to the T-5-4 Troubleshooting B.
Dump Cylinder
T145-05-03-018
T4-4-13
OPERATIONAL PERFORMANCE TEST / Excavator Test
DIG FUNCTION DRIFT CHECK
Summary:
Measure dig function drift, which can be caused by oil
leakage in the control valve and boom, arm, and
bucket cylinders, with the loaded bucket.
Preparation:
1. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
Backhoe: W=4500 kg (9920 lb)
Loading Shovel: W=6000 kg (13230 lb)
2. Position the front attachment as follows:
Backhoe:
With the arm cylinder fully retracted and the
T145-05-03-021
bucket cylinder fully extended.
Loading shovel: BH: Boom and Bucket Cylinders Retraction
With the arm cylinder and the bucket cylinder fully LD: Boom, Arm and Bucket Cylinders Retraction
extended.
Raise the boom so that the arm tip pin height is Mark Mark
flush with the boom foot pin height concerning
backhoe and loading shovel.
3. With the arm rolled out and the bucket rolled in,
hold the bucket so that the height of the bucket
pin is the same as the boom foot pin.
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F). T110-06-03-002
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T110-06-03-001
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-14
OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER OPERATING FORCE
Summary:
Use a spring scale to measure the maximum resis-
tance of each control lever at the middle of the grip.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
1. Start the engine.
2. Select the following switch positions:
Engine Auto-Idle/
Power Mode Work Mode
Control Acceleration
Switch Switch T107-06-03-003
Dial Selector
Fast Idle HP Mode Digging Mode OFF
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-15
OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER STROKE
Summary:
1. Measure each lever stroke at the lever top using a
ruler.
2. Measure the lever stroke at the grip center of
each control lever.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both
side lever strokes.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C T107-06-03-005
(122±9 °F).
Measurement:
1. Stop the engine.
2. Measure the boom, arm bucket, swing and travel
levers full stroke from the neutral position at the
lever grip top center.
3. Measure the stroke straight from the neutral posi-
tion to the stroke end.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-4-16
OPERATIONAL PERFORMANCE TEST / Excavator Test
BOOM RAISE/SWING COMBINED OP-
ERATION
Summary:
Check boom raise and swing movement speeds
while operating both functions simultaneously.
Preparation:
1. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be T142-05-03-007
used.
Backhoe: W = 4500 kg (9920 lb)
Loading Shovel: W = 6000 kg (13230 lb)
2. Start the engine and run it at fast idle. Operate the
boom raise function and check to be sure that the
cylinder movement is smooth, with out sticking.
3. Position the machine with front attachment posi-
tioned as illustrated. T142-05-03-008
4. Maintain the hydraulic oil temperature at 50 ± 5 °C
(122±9 °F).
Measurement:
1. Select the following switch positions:
Engine Auto-Idle/
Power Mode Work Mode
Control Acceleration
Switch Switch
Dial Selector T107-06-03-010
Evaluation:
Refer to the performance Standard Table in Group
T4-2. T107-06-03-011
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-17
OPERATIONAL PERFORMANCE TEST / Excavator Test
(Blank)
T4-4-18
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Hose Pilot Filter
Preparation:
1. Shut down the engine properly.
Measurement:
1. Select the following switch positions:
T111-06-04-001
Auto-Idle/
Engine Control Power Mode Work Mode
Acceleration
Dial Switch Switch
Selector
Fast Idle HP Mode Digging Mode OFF
Slow Idle HP Mode Digging Mode OFF
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-5-1
OPERATIONAL PERFORMANCE TEST / Component Test
Primary Pilot Pressure Adjustment Procedure
Pilot Relief Valve
Adjustment:
Adjust the setting pressure of the pilot relief valve (the
primary pilot pressure).
: 22 mm
T111-06-04-004
T4-5-2
OPERATIONAL PERFORMANCE TEST / Component Test
SECONDARY PILOT PRESSURE
Evaluation:
The travel, swing, arm roll-in and boom raise pilot Refer to the Performance Standard Table in Group
pressure can also be measured with the built-in diag- T4-2.
nosing system or Dr.EX. The bucket roll-in pilot pres-
sure can be measured with Dr.EX. Remedy:
Preparation: Refer to the Troubleshooting B in Groupe T5-4.
1. Shut down the engine properly.
Measurement:
1. Select the following switch positions:
2. Measure the pilot pressure in each specified set- Auto-Idle/
ting above with the corresponding control lever Engine Power Mode Work Mode
Acceleration
operated full stroke. Control Dial Switch Switch
Selector
3. Repeat the measurement three times and calcu-
Digging
late the average values. Fast Idle HP Mode OFF
Mode
Digging
Slow Idle HP Mode OFF
Mode
T4-5-3
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN RELIEF PRESSURE SHIFT CON-
TROL PRESSURE (SA Pressure)
The control pressure can also be measured with Dr.
EX.
Preparation:
1. Shut down the engine properly.
Measurement:
1. Select the following switch and lever positions:
Auto-Idle /
Engine Con- Control Lev- Power Mode Auto- Work Mode
trol Dial ers Switch Acceleration Switch
Selector
Travel lever
Fast Idle HP Mode OFF Digging Mode
operation
Fast Idle All in neutral HP Mode OFF Precision
Fast Idle All in neutral HP Mode OFF Digging Mode
Evaluation:
Refer to the performance standard table in group T4-
2.
Remedy:
Refer to the troubleshooting B in group T5-4.
T4-5-4
OPERATIONAL PERFORMANCE TEST / Component Test
TRAVEL MODE SHIFT CONTROL PRES-
SURE (SB Pressure)
The control pressure can also be measured with Dr.
EX.
Preparation:
1. Shut down the engine properly.
SB
3. Disconnect the hose end from the solenoid valve
SB output port. Install adapter (ST 6451), fitting (ST
6069), pressure gauge (ST 6315) and coupling (ST
6332).
: 14 mm, 17 mm
Measurement:
1. Select the following switch positions:
Auto-Idle /
Engine Travel Mode Power Mode Work Mode
Acceleration
Control Dial Switch Switch Switch
Selector
Digging
Fast Idle Fast Speed HP Mode OFF
Mode
Digging
Slow Idle Slow Speed HP Mode OFF
Mode
Evaluation:
Refer to the performance standard table in group T4-
2.
Remedy:
Refer to the troubleshooting B in group T5-4.
T4-5-5
OPERATIONAL PERFORMANCE TEST / Component Test
BOOM MODE SELECTOR CONTROL
PRESSURE (SC Pressure)
The control pressure can also be measured with the
built-in diagnosing system or Dr. EX.
Preparation:
1. Shut down the engine properly.
Measurement:
1. Select the following switch and lever positions:
Auto-Idle /
Engine Power Mode Work Mode Boom Mode
Acceleration
Control Dial Switch Switch Selector Switch
Selector
Digging
Fast Idle HP Mode OFF ON
Mode
Digging
Slow Idle HP Mode OFF OFF
Mode
Evaluation:
Refer to the performance standard table in group T4-
2.
Remedy:
Refer to the troubleshooting B in group T5-4.
T4-5-6
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN PUMP DELIVERY PRESSURE
Preparation:
1. Shut down the engine properly.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-5-7
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN RELIEF PRESSURE
Summary:
Measure the main relief valve setting pressure at the
main pump delivery port.
Preparation:
1. Shut down the engine properly.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-5-8
OPERATIONAL PERFORMANCE TEST / Component Test
: 30 mm 3
Lock Nut (2) :Less then 59 N⋅m (6 kgf⋅m, 4
43 lbf⋅ft)
5 A
2. Loosen lock nut (4).
Turn Plug (3) clockwise to adjust the relief pres-
sure setting referring to the table below.
: 41 mm
Lock Nut (4) :Less then 98 N⋅m (10 kgf⋅m,
72 lbf⋅ft)
T4-5-9
OPERATIONAL PERFORMANCE TEST / Component Test
Swing Relief Valve Set-Pressure Adjustment Pro-
cedure
T4-5-10
OPERATIONAL PERFORMANCE TEST / Component Test
Travel Relief Pressure Setting Adjustment
Procedure
Adjustment:
Adjust the pressure setting of the travel relief valve
using the adjusting screw after loosening the lock nut.
T183-01-02-012
3. Retighten the lock nut.
: 19 mm
: 34.3 to 44.1 Nxm (3.5 to 4.5 kgfxm, 25.5 to Lock Nut
32.5 lbf⋅ft)
Adjusting Screw
Reference : Change in Pressure Setting
T142-05-04-007
Screw Turns 1/4 1/2 3/4 1
W107-02-05-129
T4-5-11
OPERATIONAL PERFORMANCE TEST / Component Test
OVERLOAD RELIEF VALVE SET
PRESSURE
Summary:
1. The circuit pressure must be increased by 5. Start the engine. Confirm that no oil leakage is
applying an external force while blocking the observed at the pressure gauge connection.
return circuit from the control valve. This 6. Maintain the hydraulic oil temperature at 50±5 °C
measuring method is hazardous and the results (122±9 °F).
obtained with this method are unreliable.
2. The oil flow rate used to set the overload relief Measurement:
pressure is far less than that used to set the main 1. Select the following switch positions:
relief pressure. Therefore, measuring the over- Auto-Idle /
Engine Power Mode Work Mode
load pressure in the main circuit by increasing the Acceleration
Control Dial Switch Switch
main relief set-pressure more than the overload Selector
valve set-pressure is not a proper method. In Digging
Fast Idle HP Mode OFF
addition, in case a main relief valve designed to Mode
leak a small quantity of oil before reliving is used,
2. Slowly operate bucket, arm, and boom control
its pre-leaking start pressure must be increased
levers to the stroke ends to relieve each function
more than the overload relief valve set-pressure.
one at a time.
However, the pre-leaking start pressure is not al-
3. Read the pressures on the pressure gauge while
ways increased more than the overload relief
releasing the front functions.
valve set-pressure as the adjustable upper limit of
4. Perform the measurement for the bucket, arm,
the main relief valve set-pressure is provided. Ac-
and boom, in that order.
cordingly, the overload relief valve assembly
5. Repeat the measurement three times and
should be removed from the machine and
calculate the average value for each front
checked on a specified test stand at a correct oil
function.
flow rate. Some overload relief valves come in
contact with the control valve body to block the oil Evaluation:
passage. When this type of overload relief valve is 1. Performance of the overload relief valves are
checked, the control valve body must be precisely normal if the measured main relief pressures are
finished as the test unit. Provide one control valve within the specified value range.
other than that on the machine as a test kit.
3. If the overload relief valve performance must be Refer to the Performance Standard Table in
checked on the machine, however, measure the Group T4-2.
main relief pressure while releasing each front
function respective to the measuring overload
relief valve. And, assume that the overload relief
valve is functioning correctly if the obtained main
relief pressure is within the specified value range.
Measure the main pressure of the front functions
as follows:
Preparation:
1. Shut down the engine properly.
Main
CAUTION: The hydraulic oil tank cap may fly Pump 1
off if turned quickly. Slowly turn it to release
internal pressure before removing it.
2. Press the air relief valve on top of the hydraulic oil
tank to release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install adapter (ST 6069) and pressure
Main Pump Delivery Port T17V-04-05-004
gauge (ST 6934) on the port. (4-Spool Side)
: 19 mm
NOTE: The detection port (5-spool side) at main
pump 2 is provided in position similar to
4. Select the monitoring function of the built-in
main pump 1.
diagnosing system (or Dr.EX).
T4-5-12
OPERATIONAL PERFORMANCE TEST / Component Test
Overload Relief Valve Set Pressure Adjusting
Procedure
Adjustment:
Adjust the pressure setting of the overload relief valve
using adjusting screw (2) after loosening lock nut (1).
Adjusting Screw
1. Loosen the lock nut. Lock Nut
: 19 mm
W107-02-05-129
T4-5-13
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN PUMP FLOW RATE MEASUREMENT
• P-Q Control (Torque Control)
Summary:
Main pump performance is checked by measuring 10. Fully open the loading valve located on the port-
the pump flow rate with a hydraulic tester installed at able tester.
the main pump delivery port (one side) to be meas- 11. Start the engine. Check the line connections for
ured. Use Dr. EX and a pressure gauge at the same any oil leaks.
time.
T4-5-14
OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified pump speed using the following formu- Refer to T4-2 Operational Performance Standard.
las:
NOTE: When actually measuring, install pipe (1 or
Qc = (Np × Q) ⁄ (Ne × i) 2) only to the pump to be measured.
1, 2 3 4 5 6 7 8 9 10 11
Delivery Hose
(To Control
Valve)
T173-04-04-002
T17V-04-05-003
1- Pipe E (ST 6144) 4- Adapter PF1 × UNF1-7/8 (ST 6146) 7- Joint (ST 6330) 10- Split Flange (ST 6130)
2- Pipe B (ST 6143) 5- Hydraulic Tester (ST 6299) 8- Test Hose (ST 6320) 11- Bolt (ST 6409) (4 used)
3- Test Hose (ST 6145) 6- Adapter PF1 × UNF1-7/8 (ST 6146) 9- Flange (ST 6118) 12- Plug
T4-5-15
OPERATIONAL PERFORMANCE TEST / Component Test
Adjustment:
Adjustment of Minimum and Maximum Flow Rate NOTE: Turn screw (3) clockwise to decrease the
maximum flow rate and counterclockwise to
Pump flow rate can be adjusted by changing the increase. Turning screw (3) one forth a turn
maximum stroke of the servo piston. changes flow rate approximately 9.2 L/min
To adjust the maximum flow rate, loosen nut (4) and (2.4 US gal.).
turn screw (3) on the large chamber side end of the Turn screw (2) clockwise to increase the
servo piston. minimum flow rate and counterclockwise to
To adjust the minimum flow rate, loosen nut (1) and decrease. Turning screw (2) one forth a
turn screw (2) on the small chamber side end of the turn changes flow rate approximately 9.2
servo piston. L/min (2.4 US gal.).
1 2 3 4
T17V-03-01-003
Q Q
I I
T4-5-16
OPERATIONAL PERFORMANCE TEST / Component Test
Flow Rate Control Setting Adjustment
T162-03-01-002
T4-5-17
OPERATIONAL PERFORMANCE TEST / Component Test
SWING MOTOR DRAINAGE
Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while
swinging the upperstructure.
Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C A
(122±9 °F). Rotate the swing motor to warm the
inside of the motor.
T4-5-18
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Amount of Oil Drained While Swinging the
Upperstructure
(1) With the bucket empty, position the front
attachment as follows:
Backhoe:
With the arm cylinder fully retracted, and the
bucket cylinder fully extended, raise the
boom so that the arm tip pin heigh is flush
with the boom foot pin height.
T145-05-03-007
Loading Shovel:
With the arm cylinder and the bucket cylinder
fully extended, raise the boom so that the
arm tip pin height is flush with the boom foot
pin height.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start draining oil
measurement after the swing speed eaches
a constant maximum speed. The measuring
time should be more than 20 seconds.
(3) Repeat the measurement three times in both
clockwise and counterclockwise directions, T145-05-03-008
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T107-06-05-008
∆Q = 60 × q / t
Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-19
OPERATIONAL PERFORMANCE TEST / Component Test
TRAVEL MOTOR DRAINAGE
Summary:
1. To check travel motor performance, measure the
amount of oil draining from the travel motor, while
rotating the travel motor with the measuring side
track jacked up.
2. During measuring, be sure to prevent personal
injury.
3. Evaluate the travel motor performance from Drain Hose
totaling the data.
4. The amount of drain oil from the travel motor and
the drain oil pressure will change depending on
hydraulic oil temperature.
Preparation:
1. Main hydraulic oil temperature at 50±5 °C (122±9
°F). Rotate the travel motor to warm the inside of
the motor.
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector ST 6637
Digging
Fast Idle HP Mode OFF
Mode
T183-04-04-011
T4-5-20
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
Evaluation:
Refer to the Performance Standard Table in
Group T4-2.
∆Q = 60 × q / t
Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T157-05-04-019
T4-5-21
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)
T4-5-22
OPERATIONAL PERFORMANCE TEST / Adjustment
INSTALLATION AND ADJUSTMENT OF
PUMP DISPLACEMENT SENSOR 1, 2
Removal
1. Put matching mark on the pump displacement
sensor and pump housing. Remove the pump
displacement sensor connector from its harness.
T17V-04-06-001
T4-6-1
OPERATIONAL PERFORMANCE TEST / Adjustment
ENGINE SPEED ADJUSTMENT AND EN-
GINE LEARNING
T16J-05-04-002
Holding Bolt
T4-6-2
OPERATIONAL PERFORMANCE TEST / Adjustment
Engine Learning:
Rear Console
1. Turn the key switch OFF Fuse Box
NOTE: In case the engine doesn’t stop when the
key switch is turned OFF, pull the handle Engine
located under the seat to stop the engine. Learning
2. Disconnect Dr. EX. Wait for 5 seconds. Switch
3. Turn the engine learning switch ON.
4. Turn the key switch ON. Wait for 5 seconds.
5. Turn the key switch OFF. Wait for 5 seconds.
6. Turn the engine learning switch OFF.
7. Check the engine speed.
T178-01-02-006
T4-6-3
OPERATIONAL PERFORMANCE TEST / Adjustment
CHECK OF GOVERNOR LEVER AND
FUEL CUT LEVER POSITION
T16J-04-02-008
1 - Fuel Cut Lever
2 - Fuel Cut-Off Cable
(Fuel Cut-Off Handle)
3 - Governor Lever
4 - Governor Cable
(From EC Motor)
T4-6-4
OPERATIONAL PERFORMANCE TEST / Adjustment
• Governor Lever Position
B A
FULL STOP
STOP FULL
T16J-04-02-008
T16J-04-02-008
T4-6-5
OPERATIONAL PERFORMANCE TEST / Adjustment
(Blank)
T4-6-6
MEMO
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SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 General Counterweight Removal / Device
Introduction ..............................................T5-1-1 (Option) ................................................T5-2-10
Diagnosing Procedure ..............................T5-1-2 Components in Control Valve .................T5-2-12
Built-In Diagnosing System Operation ......T5-1-4 Signal Control Valve
Built-In Diagnosing Function Display List ..T5-1-5 Port Location ........................................T5-2-16
Dr. EX Operation ......................................T5-1-6
Dr. EX Fault Code List ..............................T5-1-7 Group 3 Troubleshooting A
Dr. EX Monitoring Item List.......................T5-1-8 Troubleshooting A Procedure ...................T5-3-1
Dr. EX Special Function..........................T5-1-10 Fault Code List .........................................T5-3-2
Dr. EX Service Mode ..............................T5-1-13 Fault Code 01, 02, 03 ...............................T5-3-3
Adjustment Data List ..............................T5-1-24 Fault Code 04...........................................T5-3-3
Binary Number List .................................T5-1-27 Fault Code 05...........................................T5-3-3
Fault Code 06...........................................T5-3-4
Group 2 Component Layout Fault Code 07...........................................T5-3-5
Main Component Layout...........................T5-2-1 Fault Code 08, 09 .....................................T5-3-6
Electrical Component Layout (Overview) ..T5-2-2 Fault Code 10, 11 .....................................T5-3-7
Electrical System Fault Code 12, 13 .....................................T5-3-8
(Rear Deck) ............................................T5-2-3 Fault Code 14, 15, 16, 18 .........................T5-3-9
Electrical System Fault Code 19.........................................T5-3-10
(Around Battery) .....................................T5-2-4 Fault Code 20, 21 ................................... T5-3-11
Electrical System
(Pressure Sensor) ..................................T5-2-4 Group 4 Troubleshooting B
Electrical System Troubleshooting B Procedure ...................T5-4-1
(Monitors and Switches) .........................T5-2-5 Relationship between Machine Trouble
Engine......................................................T5-2-6 Symptoms and Related Parts..................T5-4-2
Pump Device............................................T5-2-7 Correlation between Trouble
Swing Device ...........................................T5-2-7 Symptoms and Part Failures .................T5-4-16
Control Valve............................................T5-2-8 Engine System Troubleshooting .............T5-4-27
Solenoid Valve All Actuator System Troubleshooting ......T5-4-44
(Swing Preference Circuit) ......................T5-2-9 Front Attachment System
Solenoid Valve Unit ..................................T5-2-9 Troubleshooting ....................................T5-4-50
Travel Device .........................................T5-2-10 Swing System Troubleshooting...............T5-4-60
Travel System Troubleshooting...............T5-4-63
17VT-5-1
Other System Troubleshooting ...............T5-4-70 Check by False Signal ............................ T5-6-11
Work After Replacing Components.........T5-4-88 Test Harness ..........................................T5-6-12
Add Compressor Oil ...............................T5-4-88
Charge Air Conditioner with Group 7 ICX
Refrigerant ...........................................T5-4-89 Outline .....................................................T5-7-1
Exchange Inspection ..............................T5-4-97 ICX Fault Code List ..................................T5-7-6
Satellite Terminal Fault Code List .............T5-7-6
Group 5 Troubleshooting C Fault Code 1 to 6......................................T5-7-7
Troubleshooting C Procedure ...................T5-5-1 Fault Code 7 to 10 ....................................T5-7-7
Malfunction of Coolant Some Parts of Data in Daily Report,
Temperature Gauge................................T5-5-2 Frequency Distribution, Cumulative
Malfunction of Fuel Gauge .......................T5-5-4 Operation Hours are not Recorded .........T5-7-8
Malfunction of Indicator Light Troubleshooting and Setting of ICX and
Check System ........................................T5-5-6 Satellite Terminal Using Dr. EX .............T5-7-10
Malfunction of Preheat Indicator ...............T5-5-7 Satellite Communication System ............ T5-7-11
Malfunction of Engine Oil Level
Indicator .................................................T5-5-8
Malfunction of Coolant Level
Indicator ...............................................T5-5-10
Malfunction of Alternator Indicator ..........T5-5-12
Malfunction of Engine Oil Pressure
Indicator ...............................................T5-5-14
Malfunction of Overheat Indicator ...........T5-5-16
Malfunction of Air Filter Restriction
Indicator ...............................................T5-5-18
Malfunction of Buzzer .............................T5-5-20
Malfunction of LCD.................................T5-5-22
Malfunction of Hour Meter ......................T5-5-23
17VT-5-2
TROUBLESHOOTING / General
INTRODUCTION
T5-1-1
TROUBLESHOOTING / General
DIAGNOSING PROCEDURE
T107-07-01-002
T5-1-2
TROUBLESHOOTING / General
4. Operate the machine yourself
Try to identify the trouble by operating the ma-
chine yourself.
If the trouble cannot be confirmed, stop the engine
and obtain further details of the malfunction from
the operator.
Also, check for any incomplete connections of the
wire harnesses.
5. Perform troubleshooting
CAUTION: Never attempt to disconnect har- T107-07-01-004
T5-1-3
TROUBLESHOOTING / General
BUILT-IN DIAGNOSING SYSTEM OPERA-
TION
IMPORTANT: This system is to be operated by the
HITACHI Dealer Only. Don’t explain
this system function to the customer.
T5-1-4
TROUBLESHOOTING / General
BUILT-IN DIAGNOSING FUNCTION DISPLAY LIST
Display
Description Monitored Result Unit Remarks
Order
1 Hour Meter {{{{{ h Standard Mode
2 Trip 1 {{{{{ h Standard Mode (Subtraction)
3 Trip 2 {{{{{ h Standard Mode (Subtraction)
-1
4 Engine Actual Speed n {{{{ min User Mode (Required to set in
the Dr. EX service mode)
5 Hydraulic Oil Tempera- {{{ °C User Mode (Required to set in
ture the Dr. EX service mode)
6 L1 {{{ ҥ Display Purpose Only
7 L2 {{{ ҥ Display Purpose Only
8 Fault Code* 0 {{ ҥ Possible to display
9 1 {{ 0: Switch OFF Display Purpose Only
1: Switch ON
10 Pump 1 Delivery Pres- 2 {{ MPa Possible to display
sure
11 Pump 2 Delivery Pres- 3 {{ MPa Possible to display
sure
12 Pump 1 Pump (Flow) 4 {{ MPa Possible to display
Control Pressure
13 Pump 2 Pump (Flow) 5 {{ MPa Possible to display
Control Pressure
-1
14 Engine Target Speed 6 {{ min Possible to display
15 EC Angle 7 {{ V Possible to display
16 Dial Angle 8 {{ V Possible to display
17 Boom Raise Pilot Pres- 9 {{ MPa Possible to display
sure
18 Arm Roll-In Pilot Pres- A {{ MPa Possible to display
sure
19 Swing Control Pilot b {{ MPa Possible to display
Pressure
20 Travel Control Pilot C {{ MPa Possible to display
Pressure
21 Bucket Control Pilot d {{ MPa Possible to display
Pressure
22 Att. Control Pressure E {{ MPa Possible to display
23 Work Mode F {{ 0: Digging, Trench Display Purpose Only
Digging
1: Breaker
2: Secondary
Crusher
(Demolisher)
3: Crusher
4: Vibro-Hammer
T5-1-5
TROUBLESHOOTING / General
Dr. EX OPERATION
Rear Console
Dr. EX is a troubleshooting tool to diagnose the elec- Fuse Box
tronic control system including the MC (main Control-
ler) and ICX (Information Controller). When Dr. EX is
Dr. EX Connector
connected to either the MC or the ICX, it displays (MC)
whether the controllers and sensors operate normally
in the form of fault codes (Self-Diagnosing Result Dis-
play Function).
In addition, Dr. EX can display the inputs from sensors
and switches to the MC and/or the outputs to actuators
such as solenoid valves from the MC in real time while
operating the machine (Monitor Display Function).
Monitored data
Retry B is displayed.
Self-diagnosing
result is displayed.
T5-1-6
TROUBLESHOOTING / General
Dr. EX FAULT CODE LIST
T5-1-7
TROUBLESHOOTING / General
Dr. EX MONITORING ITEM LIST
T5-1-8
TROUBLESHOOTING / General
T5-1-9
TROUBLESHOOTING / General
Dr. EX SPECIAL FUNCTION
HITACHI
Special function related to Dr.EX screen panels,
Dr.EX
beginning with the start screen, are shown along
VER
**** with the corresponding Dr.EX key operations.
However, Dr.EX screen panels which are not
related to the Dr.EX key operation are excluded.
(C)Hitachi Construction
Machinery Co.,Ltd. 1996
F1: Start F10: Model Menu
F1 Press
Model : ZX800
Ver : 0101
Is model correct?
F1: Correct F10: ESC
F1 Press
Select Functions
F5: ESC
Ȧȓ Press
T5-1-10
TROUBLESHOOTING / General
1 2
F5 Press
F6: WU Deactivation
F6 Press
F7: ECO Deactivation Push Key F1 or F5
F8: Pump Adjustment
F8 Press
F7 Press F1 Press
3
Push Key F1 or F5
F1 Press
ECO Deuctivation
Succeaded
F5: ESC
T5-1-11
TROUBLESHOOTING / General
Select Functions
F5: ESC
F6 Press
F5: ESC
T5-1-12
TROUBLESHOOTING / General
Dr. EX SERVICE MODE
Parameter Change
Engine speed, pump delivery flow rate, and solenoid
valve output pressure can be adjusted.
Rear Console
Activation/Deactivation of parameter change Fuse Box
All items except engine changed in parameter change
Engine
are turned into either activation or deactivation Learning
(standard). Switch
In case activation is selected, the value changed in
parameter change isn’t cleared.
T178-01-02-006
T5-1-13
TROUBLESHOOTING / General
Item Data
Learning Data Display
EC Motor Stop Position Display of the engine stop value in engine learning
EC Motor Maximum Speed Position Display of max. engine speed valve in engine learning
Parameter Change
Li Speed Adjustment Adjustment of minimum engine speed
WU Speed Adjustment Adjustment of warming up engine speed
AI Speed Adjustment Adjustment of auto-idle engine speed
E Speed Adjustment Adjustment of E-mode engine speed
P Speed Adjustment Adjustment of P-mode engine speed
Qi Speed Adjustment Adjustment of Qi engine speed
ATT Speed lncrease Down Wating Time Setting of time required for engine speed increase
Breaker 1 Engine Speed Adjustment Adjustment of breaker 1 operation engine speed
Breaker 2 Engine Speed Adjustment Adjustment of breaker 2 operation engine speed
Breaker 3 Engine Speed Adjustment Adjustment of breaker 3 operation engine speed
Breaker 4 Engine Speed Adjustment Adjustment of breaker 4 operation engine speed
Lubricator Max. Compressing Time The maximum valve of the auto-lubricator compressing time at one cycle
Lubrication Interval (INCREASE) The interval valve of the auto-lubrication (INCREASE) operated time
Lubrication Interval (STANDARD) The interval valve of the auto-lubrication (STANDARD) operated time
Lubrication Interval (COLD WEATHER) The interval valve of the auto-lubrication (COLD WEATHER) operated time
Pump 1 Cut-off Pressure Adjustment Adjustment of pump1 cut-off pressure
Pump 1 Cut-off Operating Lever Operation The lever stroke corresponding to the cut-off pressure of pump 1 as above
Pump 2 Cut-off Pressure Adjustment Adjustment of pump2 cut-off pressure
Pump 2 Cut-off Operating Lever Operation The lever stroke corresponding to the cut-off pressure of pump 2 as above
Standard Mode Pump 1 Max. Displacement The valve to control the maximum displacement of pump 1 at work mode,
“Digging”
Trenching Mode Pump 1 Max. Displacement The valve to control the maximum displacement of pump 1 at work mode,
“Trenching”
Breaker 1 Pump 1 Max. Displacement The valve to control the maximum displacement of pump 1 at ATT mode, “BRK1”
Breaker 2 Pump 1 Max. Displacement The valve to control the maximum displacement of pump 1 at ATT mode, “BRK2”
Breaker 3 Pump 1 Max. Displacement The valve to control the maximum displacement of pump 1 at ATT mode, “BRK3”
Breaker 4 Pump 1 Max. Displacement The valve to control the maximum displacement of pump 1 at ATT mode, “BRK4”
Standard Mode Pump 2 Max. Displacement The valve to control the maximum displacement of pump 2 at work mode,
“Digging”
Trenching Mode Pump 2 Max. Displacement The valve to control the maximum displacement of pump 2 at work mode,
“Trenching”
Breaker 1 Pump 2 Max. Displacement The valve to control the maximum displacement of pump 2 at ATT mode, “BRK1”
Breaker 2 Pump 2 Max. Displacement The valve to control the maximum displacement of pump 2 at ATT mode, “BRK2”
Breaker 3 Pump 2 Max. Displacement The valve to control the maximum displacement of pump 2 at ATT mode, “BRK3”
Breaker 4 Pump 2 Max. Displacement The valve to control the maximum displacement of pump 2 at ATT mode, “BRK4”
All Mode Pump 1 and 2 Max. Reference Torque Total The valve to control the maximum standard torque total of pumps 1 and 2 at all
work mode
Breaker 1 Pump 1 and 2 Max. Reference Torque To- The valve to control the maximum standard torque total of pumps 1 and 2 at ATT
tal mode, “BRK1”
Breaker 2 Pump 1 and 2 Max. Reference Torque To- The valve to control the maximum standard torque total of pumps 1 and 2 at ATT
tal mode, “BRK2”
Breaker 3 Pump 1 and 2 Max. Reference Torque To- The valve to control the maximum standard torque total of pumps 1 and 2 at ATT
tal mode, “BRK3”
Breaker 4 Pump 1 and 2 Max. Reference Torque To- The valve to control the maximum standard torque total of pumps 1 and 2 at ATT
tal mode, “BRK4”
All Mode Pump 2 Max. Desired Torque The valve to control the maximum desired torque of pump 2 at all work mode
Breaker 1 Pump 2 Max. Desired Torque The valve to control the maximum desired torque of pump 2 at ATT mode, “BRK1”
Breaker 2 Pump 2 Max. Desired Torque The valve to control the maximum desired torque of pump 2 at ATT mode, “BRK2”
Breaker 3 Pump 2 Max. Desired Torque The valve to control the maximum desired torque of pump 2 at ATT mode, “BRK3”
Breaker 4 Pump 2 Max. Desired Torque The valve to control the maximum desired torque of pump 2 at ATT mode, “BRK4”
Monitor Display Change
Engine Actual Speed Display/Non-display Monitor setting of display/no-display of actual engine speed
Hydraulic Oil Temperature Display/No-display Monitor setting of display/no-display of hydraulic oil temperature
T5-1-14
TROUBLESHOOTING / General
HITACHI
Service mode related to Dr.EX screen panels,
Dr.EX VER
****
beginning with the start screen, are shown along
with the corresponding Dr.EX key operations.
However, Dr.EX screen panels which are not
(C)Hitachi Construction related to the Dr.EX key operation are excluded.
Machinery Co.,Ltd. 1996
F1: Start F10: Model Menu
F1 Press
Model : ZX800
Ver : 0101
Is model correct?
F1: Correct F10: ESC
F1 Press
F1 Press
T5-1-15
TROUBLESHOOTING / General
Select Function
F5: ESC
F3 Press
Select Item
F2 Press
F1 Press
2 3
T5-1-16
TROUBLESHOOTING / General
2 3
∗∗ Confirmation ∗∗ ∗∗ Confirmation ∗∗
F1 Press F1 Press
5 5
F5: ESC F5: ESC
F5 Press F5 Press
T5-1-17
TROUBLESHOOTING / General
10
F3: NEXT F5: ESC
F3 Press
Select Functions
F6: Lubrication Interval
Select Functions (INCREASE)
F7: Lubrication Interval
F6: E Speed Adjustment (STANDARD)
F7: P Speed Adjustment F8: Lubricaiton Interval
F8: Qi Speed Adjustment (COLD WEATHER)
F3: Next F4: Prev. F5: ESC
F3: Next F4: Prev. F5: ESC
F3 Press
F3 Press
Select Functions
F6: Pump 1 Cut-Off Pressure
Select Fuctions Adjustment
F6: ATT Speed Increase Down F7: Pump 1 Cut-Off Working
Waiting Time Operation
F7: BRK 1 Engine Speed F8: Pump 2 Cut-Off Pressure
Adjustment Adjustment
F8: BRK 2 Engine Speed F3: Next F4: Prev. F5: ESC
Adjustment
F3: Next F4: Prev. F5: ESC F3 Press
12
F3 Press Next Page
T5-1-18
TROUBLESHOOTING / General
12
Select Functions
F6: BRK 1 Max. Pump 1
Displacement
F7: BRK 2 Max. Pump 1 Select Functions
Displacement F6: BRK 2 Max. Pump Ref.
F8: BRK 3 Max. Pump 1 Torque Total
Displacement F7: BRK 3 Max. Pump Ref.
F3: Next F4: Prev. F5: ESC Torque Total
F8: BRK 4 Max. Pump Ref.
Torque Total
F3 Press F3: Next F4: Prev. F5: ESC
Select Fuctions
F6: BRK 4 Max. Pump 2
Displacement
F7: All Mode Max. Pump Ref.
Torque Total
F8: BRK 1 Max. Pump Ref.
Torque Total
F3: Next F4: Prev. F5: ESC
F3 Press
T5-1-19
TROUBLESHOOTING / General
Li Speed Adjustment
F3 Press
Li Speed Adjustment
-1
Current: 0 min
-1
Adjustment: min
SFT
SFT Press
+
Press
2
SFT
Press
SFT
+
Press
2
°
Press
0
*Adjusting Deviation*
*Data Confirmation*
F3 Press
13
Next Page
T5-1-20
TROUBLESHOOTING / General
13
-1
ӸCurrent : 0 min
-1
ӸAdjustment : +20 min
F1 Press
F3: Next
F3 Press
-1
Current: 0 min
-1
Adjustment: +20min
10
F4: Prev. F5: ESC
F5 Press
T5-1-21
TROUBLESHOOTING / General
Select Functions
F6 Press
Select Functions F1 or F2
F5: ESC
F2 Press
F1 Press
11 11
F5: ESC
F5 Press F5 Press
T5-1-22
TROUBLESHOOTING / General
• Operational Performance Check After Adjustment
(Check that pump flow rate and engine speed
have been changed.)
T5-1-23
TROUBLESHOOTING / General
ADJUSTMENT DATA LIST
Adjustable Standard
Adjustment Data Data
Range Adjustment
-1
Li Speed Adjustment Adjustment of minimum engine speed 0 to 120 0 min
-1
WU Speed Adjustment Adjustment of warming up engine speed -80 to 120 0 min
-1
AI Speed Adjustment Adjustment of auto-idle engine speed -120 to 120 0 min
-1
E Speed Adjustment Adjustment of E-mode engine speed -120 to 120 0 min
-1
P Speed Adjustment Adjustment of P-mode engine speed -120 to 100 0 min
-1
Qi Speed Adjustment Adjustment of Qi engine speed 0 to 120 0 min
ATT Speed lncrease Down Setting of time required for engine speed in- 0 to 3000 0 msec
Wating Time crease
-1
BRK 1 Engine Speed Ad- Adjustment of breaker 1 operation engine -500 to 200 0 min
justment speed
-1
BRK 2 Engine Speed Ad- Adjustment of breaker 2 operation engine -500 to 200 0 min
justment speed
-1
BRK 3 Engine Speed Ad- Adjustment of breaker 3 operation engine -500 to 200 0 min
justment speed
-1
BRK 4 Engine Speed Ad- Adjustment of breaker 4 operation engine -500 to 200 0 min
justment speed
Lubricator Max. Compress- The maximum valve of the auto-lubricator 5 to 7 5 min
ing Time compressing time at one cycle
Lubrication Interval The interval valve of the auto-lubrication 10 to 90 30 min
(INCREASE) (INCREASE) operated time
Lubrication Interval The interval valve of the auto-lubrication 10 to 90 45 min
(STANDARD) (STANDARD) operated time
Lubrication Interval (COLD The interval valve of the auto-lubrication 10 to 90 60 min
WEATHER) (COLD WEATHER) operated time
Pump 1 Cut-off Pressure Adjustment of pump1 cut-off pressure -18.81 to 0 0 MPa
Adjustment
Pump 1 Cut-off Working The lever stroke corresponding to the cut-off *1
Operation pressure of pump 1 as above
Pump 2 Cut-off Pressure Adjustment of pump2 cut-off pressure -18.81 to 0 0 MPa
Adjustment
Pump 2 Cut-off Working The lever stroke corresponding to the cut-off *1
Operation pressure of pump 2 as above
3
GENERAL Max. Pump 1 The valve to control the maximum displace- 66 to 278 278 cm
Displacement ment of pump 1 at work mode, “Digging”
3
TRENCH Max. Pump 1 The valve to control the maximum displace- 66 to 278 278 cm
Displacement ment of pump 1 at work mode, “Trenching”
3
BRK 1 Max. Pump 1 The valve to control the maximum displace- 66 to 278 278 cm
Displacement ment of pump 1 at ATT mode, “BRK1”
3
BRK 2 Max. Pump 1 The valve to control the maximum displace- 66 to 278 278 cm
Displacement ment of pump 1 at ATT mode, “BRK2”
3
BRK 3 Max. Pump 1 The valve to control the maximum displace- 66 to 278 278 cm
Displacement ment of pump 1 at ATT mode, “BRK3”
3
BRK 4 Max. Pump 1 The valve to control the maximum displace- 66 to 278 278 cm
Displacement ment of pump 1 at ATT mode, “BRK4”
3
GENERAL Max. Pump 2 The valve to control the maximum displace- 66 to 278 278 cm
Displacement ment of pump 2 at work mode, “Digging”
3
TRENCH Max. Pump 2 The valve to control the maximum displace- 66 to 278 278 cm
Displacement ment of pump 2 at work mode, “Trenching”
NOTE: 1 MPa = 98.07 kPa
1 kgf⋅m = 9807 N⋅m
*1: Refer to T5-1-26.
T5-1-24
TROUBLESHOOTING / General
Adjustable Standard
Adjustment Data Data
Range Adjustment
3
BRK 1 Max. Pump 2 Dis- The valve to control the maximum displace- 66 to 278 278 cm
placement ment of pump 2 at ATT mode, “BRK1”
3
BRK 2 Max. Pump 2 Dis- The valve to control the maximum displace- 66 to 278 278 cm
placement ment of pump 2 at ATT mode, “BRK2”
3
BRK 3 Max. Pump 2 Dis- The valve to control the maximum displace- 66 to 278 278 cm
placement ment of pump 2 at ATT mode, “BRK3”
3
BRK 4 Max. Pump 2 Dis- The valve to control the maximum displace- 66 to 278 278 cm
placement ment of pump 2 at ATT mode, “BRK4”
All Mode Max. Pump Ref. The valve to control the maximum standard 833 to 1570 1570 N⋅m
Torque Total torque total of pumps 1 and 2 at all work mode
BRK 1 Max. Pump Ref. The valve to control the maximum standard 833 to 1570 1570 N⋅m
Torque Total torque total of pumps 1 and 2 at ATT mode,
“BRK1”
BRK 2 Max. Pump Ref. The valve to control the maximum standard 833 to 1570 1570 N⋅m
Torque Total torque total of pumps 1 and 2 at ATT mode,
“BRK2”
BRK 3 Max. Pump Ref. The valve to control the maximum standard 833 to 1570 1570 N⋅m
Torque Total torque total of pumps 1 and 2 at ATT mode,
“BRK3”
BRK 4 Max. Pump Ref. The valve to control the maximum standard 833 to 1570 1570 N⋅m
Torque Total torque total of pumps 1 and 2 at ATT mode,
“BRK4”
All Mode Max. Pump 2 The valve to control the maximum desired 420 to 1116 1116 N⋅m
Desired Torque torque of pump 2 at all work mode
BRK 1 Max. Pump 2 De- The valve to control the maximum desired 420 to 1116 1116 N⋅m
sired Torque torque of pump 2 at ATT mode, “BRK1”
BRK 2 Max. Pump 2 De- The valve to control the maximum desired 420 to 1116 1116 N⋅m
sired Torque torque of pump 2 at ATT mode, “BRK2”
BRK 3 Max. Pump 2 De- The valve to control the maximum desired 420 to 1116 1116 N⋅m
sired Torque torque of pump 2 at ATT mode, “BRK3”
BRK 4 Max. Pump 2 De- The valve to control the maximum desired 420 to 1116 1116 N⋅m
sired Torque torque of pump 2 at ATT mode, “BRK4”
T5-1-25
TROUBLESHOOTING / General
Correspondence Chart between Hexadecimal Number
and Binary Number
Hexadecimal
Number
0 1 2 3 4 5 6 7 8 9 A b C d E F
Binary Number 0000 0001 0010 0011 0100 0101 0110 0111 1000 1001 1010 1011 1100 1101 1110 1111
Upper Lower
T5-1-26
TROUBLESHOOTING / General
BINARY NUMBER BIT LIST
Upper Lower
Hexadecimal
Number
Binary
Number
bit: Explanation
bit7: Boom Raise Operation
bit6: Arm Roll-In Operation
bit5: Bucket Roll-In Operation
bit4: Swing Operation
bit3: Travel Operation
bit2: Attachment Operation (Bucket Open-Close Operation of the Loading Shovel)
bit1: Swing ⋅ Front Attachment
bit0: Auxiliary 2
T5-1-27
TROUBLESHOOTING / General
(Blank)
T5-1-28
TROUBLESHOOTING / Component Layout
MAIN COMPONENT LAYOUT
2 4
1 6 7
8
9
10
11
12
23
22
13
21 14
20
19 15
18
17 T17V-01-02-023
16
1- Bucket 7- Swing Bearing 13 - Engine 19 - Pump Dram Filter
2- Bucket Cylinder 8- Center Joint 14 - Pump Device 20 - Solenoid Valve Unit
3- Arm 9- Swing Device 15 - Pilot Filter 21 - Hydraulic Tank
4- Arm Cylinder 10 - Fuel Tank 16 - Travel Device 22 - Travel Pilot Valve
5- Boom 11 - Control Valve 17 - Oil Filter 23 - Front Attachment Swing
Pilot Valve
6 - Boom Cylinder 12 - Radiator / Oil Cooler / Inter 18 - Signal Control Valve
Cooler / Air Condenser
T5-2-1
TROUBLESHOOTING / Component Layout
ELECTRICAL COMPONENT LAYOUT
(Overview)
Monitor
Horn
· Rear Deck
Battery
Refer to electrical system
(Rear Deck) group
· Fusible Link
· Safety Relay
· Battery Relay
Washer Motor · Glow Plug
Refer to electrical system
(Around Battery) group
· 4-Spool Pressure
Sensor
· 5-Spool Pressure
Sensor
Refer to electrical system
(Pressure Sensor) group Fuel Sensor
Hydraulic
Temperature Sensor
Solenoid Valve
(Swing Preference
Circuit)
Outside Temperature
Sensor
· Solenoid Valve Unit
Refer to solenoid valve
unit group · Pressure Sensor
(Swing + Front)
· Pressure Sensor
(Arm Roll-In)
EC Motor, EC Sensor · Pressure Sensor
(Bucket Roll-In)
· Pressure Sensor
(Boom Raise)
Refer to electrical system
(Pressure Sensor) group
T17V-01-02-001
T5-2-2
TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM
(Rear Deck) 7 8
6
5 9
4
10
11
2
12
1
13
14
(Located at
back side of
sheet)
T17V-01-02-024
24 19
23
18
26
22
17
25
16
21
15
20
T16J-01-01-010
1 - GPS ON/OFF Switch 8 - GPS Controller (Optional) 15 - Load Damp Relay (R1) 21 - Wiper Relay A (R7)
(Satellite Navigation
System Equipped
Machines Only)
2 - Boom Mode Switch 9- Fuse Box 16 - Washer Relay (R2) 22 - Wiper Relay B1 (R8)
3 - Auto-Lubrication Switch 10 - Learning Switch 17 - Work Light Relay 3 (R3) 23 - Wiper Relay B2 (R9)
4 - QOS Controller 11 - Precision Mode Switch 18 - Work Light Relay 2 (R4) 24 - Wiper Relay B3 (R10)
5 - ICX (Information Controller) 12 - Dr.EX Connector to MC 19 - Work Light Relay 1 (R5) 25 - Auto-Lubrication Normal
Rotation Relay (R11)
6 - Power Transistor 13 - Download Connector (Not 20 - Horn Relay (R6) 26 - Auto-Lubrication Reverse
(Auto-Lubrication) Provided on GPS Equipped Rotation (R12)
Machines)
7 - MC (Main Controller) 14 - Dr.EX Connector to ICX
T5-2-3
TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM (Around Battery)
1 2 3 4 5
T17V-01-01-012
ELECTRICAL SYSTEM
(Pressure Sensor)
Control
Valve
7
8
Forward
9
10
View A T17V-01-01-013
Signal Control
A T17V-01-02-030 Valve
Forward
13
11 12
View B
T17V-01-02-031
Signal Control
Valve
14
T16J-03-06-001
1 - Safety Relay 5 - Battery Relay 9 - Pressure Sensor (Boom Raise) 12 - 4-Spool Pressure Sensor (SA)
2 - Glow Relay 6 - Battery 10 - Pressure Sensor (Bucket Roll-In) 13 - Pressure Sensor (Swing)
3 - Fusible Link (45 A) 7 - Pressure Sensor 11 - 5-Spool Pressure Sensor (SB) 14 - Pressure Sensor (Travel)
(Swing + Front)
4 - Fusible Link (75 A) 8 - Pressure Sensor
(Arm Roll-In)
T5-2-4
TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM
(Monitors and Switches)
1 2
23
22
21
24
3
20
19 4 25
18
5
26
17
16
6
15 7 27
14 8
13
12 28
9
11 10 T17V-02-01-025
M178-01-091
T5-2-5
TROUBLESHOOTING / Component Layout
ENGINE
A 1
View A T17V-01-01-011 4
3
2
T17V-01-02-026
10 9
T17V-01-02-027
T5-2-6
TROUBLESHOOTING / Component Layout
PUMP DEVICE
Transmission
2 1
Pump 1
Pump 2
5
Pilot Pump
3
T17V-03-01-001
4
6
View A T17V-01-02-028
SWING DEVICE
7 T17V-01-01-005
1 - Pump 1 Displacement 3 - Pump 2 Control Proportional 5 - Pump 2 Delivery Pressure 7 - Swing Relief Valve
Angle Sensor Solenoid Valve Sensor
2 - Pump 2 Displacement 4 - Pump 1 Control Proportional 6 - Pump 1 Delivery Pressure
Angle Sensor Solenoid Valve Sensor
T5-2-7
TROUBLESHOOTING / Component Layout
CONTROL VALVE
Forward
1
Right Block
(4-Spool)
11
10
9 Left Block 6
(5-Spool)
5
8 Forward 3
Right Block
(4-Spool) 4
7
T16J-03-03-002 T17V-03-03-001
Left Block
(5-Spool)
1 - Arm Flow Rate Control 4 - Overload Relief Valve 7 - Main Relief Valve 10 - Overload Relief Valve
Valve (Arm) (Boom)
2 - Boom Overload Relief 5 - Holding Valve Shift Valve 8 - Holding Valve Shift Valve 11 - Make-Up Valve (Arm)
Selector Valve (Arm) (Boom)
3 - Overload Relief Valve 6 - Overload Relief Valve 9 - Overload Relief Valve
(Swing) (Boom Mode) (Bucket)
T5-2-8
TROUBLESHOOTING / Component Layout
SOLENOID VALVE SOLENOID VALVE UNIT
(Swing Preference Circuit)
1 2 3
T17V-01-01-008
4 5 6 7 T17V-01-01-016
1 - Check Valve 3 - Solenoid Valve (Swing 5 - Solenoid Valve Unit (SA) 7 - Solenoid Valve Unit (SC)
Preference Circuit)
2 - Signal Control Valve 4 - Pilot Relief Valve 6 - Solenoid Valve Unit (SB)
T5-2-9
TROUBLESHOOTING / Component Layout
TRAVEL DEVICE
2
T183-01-02-012
7
5
T17V-01-01-015
T17V-01-01-014
T5-2-10
TROUBLESHOOTING / Component Layout
(Blank)
T5-2-11
TROUBLESHOOTING / Component Layout
COMPONENTS IN CONTROL VALVE
2 3 4 5 6 7 8 9 10 11
1 12
39
Swing
38
Arm 1 13
37 Arm 2
Boom 2
36 14
Boom 1
15
35
16
Bucket 17
Aux.
18
19
20
Travel (R)
34 21
22
33 Travel
(L)
T17V-03-03-010
32 31 30 29 28 27 25 26 24 23
1 - Holding Valve Shift Valve 11 - Load Check Valve 21 - Overload Relief Valve 31 - Shuttle Valve
(Boom) (Arm 1 Tandem Circuit) (Aux.)
2 - Bypass Shut-Out Valve 12 - Holding Valve Shift 22 - Load Check Valve 32 - Main Relief Valve
Valve (Arm) (Travel Tandem Circuit)
3 - Load Check Valve 13 - Overload Relief Valve 23 - Bypass Shut-Out Valve 33 - Load Check Valve
(Arm 2 Tandem Circuit) (Arm) (Bucket Tandem Circuit)
4 - Load Check Valve 14 - Holding Valve Check 24 - Load Check Valve 34 - Overload Relief Valve
(Arm 2 Parallel Circuit) Valve (Arm) (Travel Parallel Circuit) (Bucket)
5 - Check Valve 15 - Load Check Valve 25 - Check Valve 35 - Load Check Valve
(Arm Flow Combining (Boom 2 Tandem (Bucket Flow Combining (Boom 1 Parallel
Circuit) Circuit) Circuit) Circuit)
6 - Check Valve 16 - Load Check Valve 26 - Check Valve 36 - Overload Relief Valve
(Aux. Flow Combining (Boom 2 Parallel Circuit) (Main Relief Pressure (Boom)
Circuit) Combining Circuit)
7 - Arm Regenerative Valve 17 - Overload Relief Valve 27 - Check Valve 37 - Holding Valve Check
(Boom Mode) (Bucket Flow Combining Valve (Boom)
Circuit)
8 - Check Valve 18 - Boom Overload Relief 28 - Flow Combiner Valve 38 - Make-Up Valve (Arm 2)
(Arm 1 (Roll-Out) Parallel Selector Valve
Circuit)
9 - Load Check Valve 19 - Load Check Valve 29 - Check Valve 39 - Overload Relief Valve
(Arm 1 (Roll-In) Parallel Circuit) (Aux. Tandem Circuit) (Flow Combiner Valve Circuit) (Swing)
10 - Load Check Valve 20 - Load Check Valve 30 - Check Valve
(Swing Tandem Circuit) (Aux. Parallel Circuit) (Main Relief Pressure
Combining Circuit)
T5-2-12
TROUBLESHOOTING / Component Layout
30
Front Side
23
32
31
36 34
29 28 T16J-03-03-006
T17V-03-03-003
37
Cross Section B 43 45
Cross Section C
40 41
21
34 25 27
19
22
33
20
24
34
44 6 46 21
T16J-03-03-008 T17P-03-03-006
42 43
40 - Right Travel Forward Port 43 - Right Travel Reverse Port 45 - Bucket (Roll-In) Port 47 - Aux. Port
41 - Left Travel Forward Port 44 - Bucket (Roll-Out) Port 46 - Aux. Port
42 - Left Travel Reverse Port
T5-2-13
TROUBLESHOOTING / Component Layout
2 3 4 5 6 7 8 9 10 11
1 12
39
Swing
38
Arm 1 13
37 Arm 2
Boom 2
36 14
Boom 1
15
35
16
Bucket 17
Aux.
18
19
20
Travel (R)
34 21
22
33 Travel
(L)
T17V-03-03-010
32 31 30 29 28 27 25 26 24 23
1 - Holding Valve Shift Valve 11 - Load Check Valve 21 - Overload Relief Valve 31 - Shuttle Valve
(Boom) (Arm 1 Tandem Circuit) (Aux.)
2 - Bypass Shut-Out Valve 12 - Holding Valve Shift 22 - Load Check Valve 32 - Main Relief Valve
Valve (Arm) (Travel Tandem Circuit)
3 - Load Check Valve 13 - Overload Relief Valve 23 - Bypass Shut-Out Valve 33 - Load Check Valve
(Arm 2 Tandem Circuit) (Arm) (Bucket Tandem Circuit)
4 - Load Check Valve 14 - Holding Valve Check 24 - Load Check Valve 34 - Overload Relief Valve
(Arm 2 Parallel Circuit) Valve (Arm) (Travel Parallel Circuit) (Bucket)
5 - Check Valve 15 - Load Check Valve 25 - Check Valve 35 - Load Check Valve
(Arm Flow Combining (Boom 2 Tandem (Bucket Flow Combining (Boom 1 Parallel
Circuit) Circuit) Circuit) Circuit)
6 - Check Valve 16 - Load Check Valve 26 - Check Valve 36 - Overload Relief Valve
(Aux. Flow Combining (Boom 2 Parallel Circuit) (Main Relief Pressure (Boom)
Circuit) Combining Circuit)
7 - Arm Regenerative Valve 17 - Overload Relief Valve 27 - Check Valve 37 - Holding Valve Check
(Boom Mode) (Bucket Flow Combining Valve (Boom)
Circuit)
8 - Check Valve 18 - Boom Overload Relief 28 - Flow Combiner Valve 38 - Make-Up Valve (Arm 2)
(Arm 1 (Roll-Out) Parallel Selector Valve
Circuit)
9 - Load Check Valve 19 - Load Check Valve 29 - Check Valve 39 - Overload Relief Valve
(Arm 1 (Roll-In) Parallel Circuit) (Aux. Tandem Circuit) (Flow Combiner Valve Circuit) (Swing)
10 - Load Check Valve 20 - Load Check Valve 30 - Check Valve
(Swing Tandem Circuit) (Aux. Parallel Circuit) (Main Relief Pressure
Combining Circuit)
T5-2-14
TROUBLESHOOTING / Component Layout
17
36
18
15
35
16
9
4
11
3
36 13
1 37
T17V-03-03-009
T17P-03-03-005
40 51 53 54
Cross Section F
56
Swing
13
2
A A
10
26
39
38 56
T17V-03-03-004
22 24 T16J-03-03-019
A-A
48 - Boom 1 (Lower) Port 51 - Boom 2 (Raise) Port 54 - Arm 2 (Roll-In) Port 56 - Swing (Left) Port
49 - Boom 2 (Lower) Port 52 - Arm 2 (Roll-Out) Port 55 - Arm 1 (Roll-In) Port 57 - Swing (Right) Port
50 - Boom 1 (Raise) Port 53 - Arm 1 (Roll-Out) Port
T5-2-15
TROUBLESHOOTING / Component Layout
SIGNAL CONTROL VALVE PORT
LOCATION
Pilot Valve Side(ISO PATTERN)
Port Name Connecting to Note
Port A Right Pilot Valve Boom Raise Pilot Pressure
Port B Right Pilot Valve Boom Lower Pilot Pressure
Port C Left Pilot Valve Right Swing Pilot Pressure(Label F)
Port D Left Pilot Valve Left Swing Pilot Pressure(Label E)
Port E Left Pilot Valve Arm Roll-Out Pilot Pressure(Label C)
Port F Left Pilot Valve Arm Roll-In Pilot Pressure(Label D)
Port G Right Pilot Valve Bucket Roll-In Pilot Pressure
Port H Right Pilot Valve Bucket Roll-Out Pilot Pressure
Port I Travel Pilot Valve Left Travel Forward Pilot Pressure
Port J Travel Pilot Valve Left Travel Reverse Pilot Pressure
Port K Travel Pilot Valve Right Travel Forward Pilot Pressure
Port L Travel Pilot Valve Right Travel Reverse Pilot Pressure
Port M Auxiliary Pilot Valve Auxiliary Open Pilot Pressure
Port N Auxiliary Pilot Valve Auxiliary Close Pilot Pressure
Port SA Pump Control Pressure Sensor (4-spool) Pump 1 Flow Rate Control
Port SB Pump Control Pressure Sensor (5-spool) Pump 2 Flow Rate Control
Port PI Pilot Shut-Off Valve Primary Pilot Pressure
Port PH Pilot Shut-Off Valve Primary Pilot Pressure (Heating Circuit)
Port SH Swing Parking Brake Brake Release Pressure
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank
T5-2-16
TROUBLESHOOTING / Component Layout
E
M
D
H
B
F
SB
PI G
Pilot Valve
Side
K N
I
SH
J
DF
SA L
T178-03-06-016
T5-2-17
TROUBLESHOOTING / Component Layout
T5-2-18
TROUBLESHOOTING / Component Layout
1 5
13
2 4
SK
SE
Pressure Sensor 8
(S3: Swing)
14
Control Valve 7
Side 9
6
10
SN
SL
11
T5-2-19
TROUBLESHOOTING / Component Layout
(Blank)
T5-2-20
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
YES(OK)
(2)
After completing the checking and/or measuring procedures in box (1),
Ȁ
ȀО (1) select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
(3)
NO(NOT OK)
Refer to “Electrical System Inspection” Group (Group 6) for descriptions in the dotted-line
ȀȀ
О
box.
ȀȀ
О Use Dr. EX (or the built-in diagnosing system) for descriptions in the double-line box.
ȀȀ
О Causes of machine problems are stated in the thick-line box. Scanning quickly through the
thick-line boxes allows you to estimate the possible causes before actually following the flow
chart.
Harness
Open End
Side
Harness End Connector
T158-05-03-001
T5-3-1
TROUBLESHOOTING / Troubleshooting A
FAULT CODE LIST
Ȁ
Fault Code Trouble Cause
01 Abnormal EEPROM • Faulty MC
02 Abnormal RAM
03 Abnormal A/D Conversion
04 Abnormal Sensor Voltage • Faulty MC
• Faulty Harness
• Faulty Sensor
05 Abnormal N Sensor • Faulty N Sensor
06 Abnormal EC Sensor • Faulty MC
• Faulty Harness
• Faulty EC Sensor
07 Abnormal Engine Control Dial Angle • Faulty MC
• Faulty Harness
• Faulty Engine Control Dial
08 Abnormal Pump 1 Displacement Angle • Faulty MC
09 Abnormal Pump 2 Displacement Angle • Faulty Harness
• Faulty Pump Displacement Angle Sensor
10 Abnormal Pump 1 Delivery Pressure • Faulty MC
11 Abnormal Pump 2 Delivery Pressure • Faulty Harness
• Faulty Pump Delivery Pressure Sensor
12 Abnormal Pump1 Pump Control Pressure • Faulty MC
13 Abnormal Pump2 Pump Control Pressure • Faulty Harness
• Faulty Pump Control Pressure Sensor
14 Abnormal Swing Pilot Pressure • Faulty MC
15 Abnormal Boom Raise Pilot Pressure • Faulty Harness
16 Abnormal Arm Roll-In Pilot Pressure • Faulty Pilot Pressure Sensor
17 Abnormal Bucket Roll-In Pilot Pressure
18 Abnormal Travel Pilot Pressure
19 Abnormal Hydraulic Oil Temperature • Faulty MC
• Faulty Harness
• Faulty Hydraulic Oil Temperature Sensor
20 Pump1 Control Malfunction • Faulty MC
21 Pump2 Control Malfunction • Faulty Harness
• Faulty Pump Control Solenoid Valve
• Faulty Pump Displacement Angle Sensor
Ȁ
T5-3-2
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 01 (ABNORMAL EEPROM)
FAULT CODE 02 (ABNORMAL RAM)
FAULT CODE 03
(ABNORMAL A/D CONVERSION)
FAULT CODE 04
(ABNORMAL SENSOR VOLTAGE)
FAULT CODE 05
(ABNORMAL N SENSOR)
T5-3-3
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 06
(ABNORMAL EC SENSOR) YES Faulty harness be-
Check harness be-
tween MC and EC
tween MC connector
• Check for loose harness connections beforehand. sensor
YES C (31P) terminal #18
and EC sensor termi-
nal #2 for breakage or Faulty MC
short circuit. NO
Disconnect EC sen- · Refer to Adjustment
sor. Check if voltage group in Performance
Disconnect EC sensor. YES between harness end Test section.
Check if resistance be- connectors #1 and #3
tween sensor side is 5±0.5 V. Check if voltage be-
connector terminals #1 tween EC sensor YES Broken harness be-
tween MC and EC
and #3 is less than · Key switch: ON harness end connec- sensor terminal #3.
2.0±0.4 kΩ. Connect test tor terminal #1 and
harness between EC NO vehicle frame
sensor and base ma- Broken harness be-
matches specification.
chine side harness. tween MC and EC
· Key switch: ON NO sensor terminal #1.
Check if voltage changes
in accordance with speci- · Specification: 5±0.5 V
fications when engine
control dial is rotated.
Faulty EC sensor
· Test Harness: ST 7129 NO
· Specification: See table be- · Refer to Adjustment
low. group in Performance
Test section.
EC Sensor Specification
Minimum Speed 2.5 to 2.7 V
Maximum Speed (HP 3.3 to 3.7 V
Mode Switch: OFF)
Maximum Speed (HP Voltage at Maximum Speed
Mode Switch: ON) (HP Mode Switch: OFF) plus
0.2 V or more
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
C1 C10
C23 C31
#18
EC Sensor
1 2 3
T5-3-4
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 07
(ABNORMAL ENGINE CONTROL DIAL
ANGLE) Faulty harness be-
Check harness be- YES
tween MC connector C tween MC and engine
• Check for loose harness connections beforehand. YES (31P) harness end ter- control dial
minal #6 and switch
Faulty MC
panel terminal #3 for
breakage or short cir- NO
· Refer to Adjustment
Disconnect switch cuit.
group in Performance
panel. Check if voltage Test section.
YES between harness end
Disconnect switch panel. connector terminals #2 Broken harness be-
Check if resistance be- and #4 is 5±0.5 V. YES tween MC and engine
Check if voltage be-
tween switch panel side control dial terminal
· Key switch: ON tween switch panel
connector terminals #2 and #4
harness end connec-
#4 is 5±0.5 kΩ. tor terminal #2 and
Reconnect switch panel. NO Broken harness be-
vehicle frame
Insert tester probe into tween MC and engine
matches specification.
connector terminal #3 from NO control dial terminal
the reverse side. Check if · Key switch: ON #2
voltage varies as specified · Specification: 5±0.5 V
when engine control dial is
turned. Faulty engine control
· Specification: See table NO dial
below.
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#6
C1 C10
C23 C31
Switch Panel
#4 #2
T5-3-5
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 08
(ABNORMAL PUMP 1 DISPLACEMENT
ANGLE)
FAULT CODE 09
(ABNORMAL PUMP 2 DISPLACEMENT
ANGLE)
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#2 #5
C1 C10
C23 C31
1 2 3
T5-3-6
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 10
(ABNORMAL PUMP 1 DELIVERY PRES-
SURE)
FAULT CODE 11
(ABNORMAL PUMP 2 DELIVERY PRES-
SURE)
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#1 #4
C1 C10
C23 C31
3 2 1
T5-3-7
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 12
(ABNORMAL PUMP 1 CONTROL PRES-
SURE)
FAULT CODE 13
(ABNORMAL PUMP 2 CONTROL PRES-
SURE)
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#13 #7
C1 C10
C23 C31
1 2 3
T5-3-8
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 14
(ABNORMAL SWING PILOT PRESSURE)
FAULT CODE 15
(ABNORMAL BOOM RAISE PILOT
PRESSURE)
FAULT CODE 16
(ABNORMAL ARM ROLL-IN PILOT
PRESSURE)
FAULT CODE 17
(ABNORMAL BUCKET ROLL-IN PILOT
PRESSURE) Check harness be- Faulty harness be-
FAULT CODE 18 tween MC connector C
YES tween MC and
(ABNORMAL TRAVEL PILOT PRESSURE) (31P) harness end pressure sensor
YES each corresponding
• All pressure sensors seldom fail at the same time. terminal and pressure
sensor terminal #2 for
Accordingly, if fault codes 14, 15, 16, 17, and 18 breakage or short cir-
Faulty MC
are displayed simultaneously, faulty harness may cuit. NO
be the cause of this problem. Connector C Terminal: · Refer to Adjustment
• Check for loose harness connections beforehand. #14: Pressure Sensor (Swing) group in Performance
#17: Pressure Sensor Test section.
Disconnect pressure (Boom Raise)
sensor. Check if voltage #15: Pressure Sensor
NO between harness end
(Arm Roll-In)
connector terminals #1 #17: Pressure Sensor
and #3 is 5±0.5 V. (Bucket Roll-in)
· Key switch: ON #3: Pressure Sensor
Check if fault code dis- (Travel)
appears after switching Broken harness be-
pressure sensor with an- tween MC and
Check if voltage be- YES
other pressure sensor pressure sensor ter-
tween pressure
and retrying. minal #3
sensor harness end
connector terminal #1
Fault Code: NO and vehicle frame Broken harness be-
14: Pressure Sensor (Swing) matches specification. tween MC and
15: Pressure Sensor pressure sensor ter-
(Boom Raise) · Key switch: ON NO
minal #1
16: Pressure Sensor · Specification: 5±0.5 V
(Arm Roll-In)
17: Pressure Sensor Faulty pressure sen-
(Bucket Roll-In) sor
18: Pressure Sensor YES
(Travel)
ʝ Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#3
C1 C10
C23 C31
#11 #14 #15 #17
Ȁ
Pilot Pressure Sensor
1 2 3
T5-3-9
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 19
(ABNORMAL HYDRAULIC OIL TEMPERA-
TURE)
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector B
B1 B8
B19 B25
#22
MC Connector C
C1 C10
C23 C31
#24
1 2
T5-3-10
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 20
(PUMP 1 CONTROL MALFUNCTION)
FAULT CODE 21
(PUMP 2 CONTROL MALFUNCTION)
MC: Connector A
#3 #4
A1 A11
Pump Control
Solenoid Valve
A25 A32
#19 #20
1 2
T5-3-11
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-3-12
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
YES(OK)
(2)
• After checking or measuring item (1), select either YES (OK) or
О (1) NO (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO(NOT OK)
О • Special instructions or reference item are indicated in the spaces under the box.
Incorrect measuring or checking methods will render troubleshooting impossible,
· Key switch: ON and may damage components as well.
• Explanation of how to use test harness kit required. Refer to “Electrical System
О
Inspection” Group (Group 6) in this section.
О • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
T5-4-1
TROUBLESHOOTING / Troubleshooting B
RELATIONSHIP BETWEEN MACHINE
TROUBLE SYMPTOMS AND RELATED
PARTS
This table indicates the relationship between machine
trouble symptoms and the potential problem parts,
which may cause trouble if failed, and the evaluation
methods of these components.
Parts
EC Motor EC Sensor Engine Control Dial
• Moves governor. • Detects minimum governor • Indicates governor lever posi-
speed position (2.5 V) only tion (engine target speed).
when key switch is turned ON.
Function • Detects minimum and maxi-
mum speed position when en-
gine learning is conducted.
• Governor lever doesn’t move. • Engine speed is controlled • Engine speed doesn’t change
based on idle position set even if engine control dial is
Symptoms in control when key switch is turned ON. turned.
system when trouble Therefore, engine speed is • If discontinuity or short circuit
always controlled with error in occurs in engine control dial,
occurs. idle position setting if set in- target speed of 1200 min-1 is
correctly. used as back-up value.
• Even if engine control dial is • Error in setting will seldom • Engine speed is kept un-
turned, engine speed doesn’t occur so that change in ma- changed from 1200 min-1.
increase from slow idle speed. chine operation will not be no- (Auto-idle system functions.
• Engine start may be difficult ticed. Engine can be stopped by key
though starter rotates. • In case error is set on lower switch.)
• Engine will stall if discontinuity side, engine speed changes
occurs in EC motor while en- but runs slower than normal
gine is running at more than a through the full range when
specified speed. engine control dial is turned.
• Engine will become uncontrol- (Note: In case error is set on
lable if discontinuity occurs in upper side, EC motor is driven
Symptoms in machine EC motor while engine is run- so that it runs faster than the
operation when trou- ning at lower than a specified control range. However, mo-
speed. Engine cannot be tor, a worm gear type, holds
ble occurs. stopped with key switch. governor lever at maximum
constant position, preventing
engine stall. When engine
control dial is turned to mini-
mum speed position, governor
lever is returned to idle posi-
tion.)
• When starting engine, engine
speed fluctuates.
• Starting engine is occasionally
difficult.
T5-4-2
TROUBLESHOOTING / Troubleshooting B
• P mode is inoperable. (with • P mode is inoperable. (with • Engine speed doesn’t in- • Engine speed doesn’t in-
power mode switch at P power mode switch at P mode crease even if auto- crease even if any front at-
mode position, engine speed position, engine speed is not idle/auto-acceleration se- tachment actuator and the
is not increased during arm increased during arm roll-in, lector is auto-idle position. swing are operated with
roll-in, boom raise and boom raise and travel.) • Engine speed doesn’t in- auto-idle/auto-acceleration
travel.) • Auto-acceleration control is crease even if auto- selector is auto-idle position.
• Auto-acceleration control is inoperable. idle/auto-acceleration se- • With power mode switch at
inoperable. • Engine easily stalls. lector is auto-acceleration HP mode position, engine
• Engine easily stalls. position. speed is not increased dur-
• Under swing combined op- • With power mode switch at ing swing or front operation.
erations, swing power is P mode position, engine
weak. speed is not increased dur-
ing travel.
• Travel power is weak.
• Judge if pressure sensor is • Judge if pressure sensor is
faulty or port is clogged by faulty or port is clogged by
switching pressure sensor switching pressure sensor
with another pressure sen- with another pressure sen-
sor. sor.
T2-1 T2-1 T2-1 T2-1
T5-4-3
TROUBLESHOOTING / Troubleshooting B
Symptoms in control • No signals arrive to MC. • No signals arrive to MC. • No signals arrive to MC.
system when trouble
occurs.
• Even if the swing is operated, • Even if boom is raised with P • Even if arm is rolled in with P
the auto-acceleration switch mode, engine speed doesn’t mode, engine speed doesn’t
ON engine speed doesn’t in- increase. increase.
crease. • Even if boom is raised with • Even if arm is rolled in with
• The front attachment has less auto-idle/auto-acceleration se- auto-idle/auto-acceleration se-
power under the swing/the lector is auto-acceleration po- lector is auto-acceleration po-
front combined operation. sition, engine speed doesn’t sition, engine speed doesn’t
increase. increase.
Symptoms in machine
operation when trou-
ble occurs.
Monitor Item: Swing Control Pilot Monitor Item: Boom Raise Pilot Monitor Item: Arm Roll-In Pilot
Pressure (displayed built-in diag- Pressure (displayed built-in diag- Pressure (displayed built-in diag-
By Monitor nostic system). nosing system). nosing system).
Function Monitor pressure change while Monitor pressure change while Monitor pressure change while
Eval- swinging upperstructure. raising boom. rolling arm in.
uation
Using Test
Harness
Others
• Judge if pressure sensor is • Judge if pressure sensor is • Judge if pressure sensor is
faulty or port is clogged by faulty or port is clogged by faulty or port is clogged by
switching pressure sensor with switching pressure sensor with switching pressure sensor with
another pressure sensor. another pressure sensor. another pressure sensor.
NOTE
T5-4-4
TROUBLESHOOTING / Troubleshooting B
• No signals arrive to MC. • No signals arrive to MC. • Loss of pump control. • Loss of pump control.
• Bucket roll-in speed is ex- • No pressure rise and no flow • Machine mistracks. (It may • Machine mistracks. (It may
treamly slow. reduction even if moving be noticed when traveling be noticed when traveling
control lever. straight.) straight.)
• Engine overload or decrease • Engine overload or decrease
in speed may result. in speed may result.
Monitor Item: Bucket Roll-In Monitor Item: Counterweight Monitor Item: Pump 1 Actual Monitor Item: Pump 2 Actual
Pilot Pressure (displayed built- removal Displacement. displacement
in diagnosing system).
Monitor pressure change rolling
bucket in.
T5-4-5
TROUBLESHOOTING / Troubleshooting B
Parts Pump Control Pressure Pump Control Pressure Hydraulic Oil Temperature
Sensor (4-Spool) (SA) Sensor (5-Spool) (SB) Sensor
• Pressure Pi flows from pump • Pressure Pi flows from pump • Monitors hydraulic oil tem-
1 flow control valve to pump 2 flow control valve to pump perature to control auto-
control pressure sensor (4- control pressure sensor (5- warming up.
spool), which sends the sig- spool), which sends the sig-
nal of pressure Pi to MC. nal of pressure Pi to MC.
Function
• Pump control pressure sen- • Pump control pressure sen- • If circuit breakage occurs,
Symptoms in control sor (4-spool) doesn’t send sor (5-spool) doesn’t send system operates as if hydrau-
the signal to MC. the signal to MC. lic oil temperature is 40 °C
system when trouble • Due to the backup mode the • Due to the backup mode the (Dr. EX or monitor will not in-
occurs. operations as below are operations as below are dicate 40 °C in diagnosis op-
done. done. eration).
• Pump 1 is kept at the maxi- • Pump 2 is kept at the maxi- • Even if oil temperature is
mum swash angle regardless mum swash angle regard- lower than 0 °C, auto-
of the control lever stroke. less of the control lever warming up control doesn’t
• The engine stalls easily. stroke. operate so that engine runs at
• The engine stalls easily. idle speed when engine is
started.
Symptoms in machine
operation when trou-
ble occurs.
By Monitor Monitor Item: Pump 1 Pump Monitor Item: Pump 2 Pump Monitor Item: Hydraulic Oil Tem-
Control Pressure Control Pressure perature
Eval- Function
uation
Using Test
Harness
Others
NOTE
T5-4-6
TROUBLESHOOTING / Troubleshooting B
N Sensor Solenoid Valve Unit (SA) Solenoid Valve Unit (SB) Solenoid Valve Unit (SC)
• Monitors engine speed to • Temporarily increases main • Shifts travel motor dis- • Controls boom mode selec-
operate engine speed sens- relief valve set-pressure placement angle. tor. Boom overload relief
ing control. when operating machine ei- pressure decrease 9.8 MPa
ther in main pressure shift, (100 kgf/cm2) @110 L/min.
travel operation and preci-
sion mode.
• Speed sensing control is • In case solenoid valve unit • Travel motor displacement • Boom overload relief pres-
inoperable. (SA) is not activated, pres- angle is fixed to the maxi- sure doesn’t decrease.
sure at port SA becomes 0 mum (slow speed).
MPa (0 kgf/cm2).
• Engine stalls under adverse When the valve is kept • Travel speed mode does • Even if the boom mode
operating conditions such close: not shift to the fast speed selector switch is turned
as at high altitude. • Relief pressure stays at mode with the travel mode ON, vibration cannot be
normal 31.9 MPa (325 switch. controlled at the boom
kfg/cm2). Even if power dig- lower.
ging switch is pressed, re-
lief pressure doesn’t in-
crease. Power doesn’t in-
crease.
• Even if signals from N sen-
sor are not delivered due to
broken circuit or poor sen-
sor installation, few
changes in operational per-
formance occur, making
troubleshooting difficult.
Use monitor function.
T5-4-7
TROUBLESHOOTING / Troubleshooting B
Symptoms in control
system when trouble
occurs.
• Pump 1 flow rate becomes • Pump 2 flow rate becomes • When operating the swing,
minimum if the harness or sole- minimum if the harness or so- boom raise, the swing is al-
noid valve is broken. lenoid valve is broken. ways given priority.
• When operating the
swing⋅boom raise on trenching
Symptoms in machine mode, the swing isn’t given
operation when trou- priority.
ble occurs.
Monitor Item: Pump 1 Desired Monitor Item: Pump 2 Desired Monitor Item: Swing Priority Se-
By Monitor Displacement Displacement lection Pressure
Eval-
Function Pump 1 Actual Displacement Pump 2 Actual Displacement
uation
Using Test
Harness
Others
NOTE
T5-4-8
TROUBLESHOOTING / Troubleshooting B
Auto-Idle/Auto-Acceleration Auto-Idle/Auto-
Precision Mode Switch Travel Mode Selector Acceleration Selec-
Selector (Auto-Idle) tor(Auto-Acceleration)
• Increases pressure and re- • Changes travel mode. • Activates auto-idle control. • Activates auto-acceleration
duces pump flow rate. Fast Mode: 0 V ON: 0 V → Auto-idle is oper- control.
Slow Mode: 5 V able. ON: 0 V → Auto-acceleration
OFF: 5 V → Inoperable. is operable.
OFF: 5 V → Inoperable.
• Broken Circuit: Pressure • Broken Circuit in Switch: • Broken Circuit: Auto-idle • Broken Circuit: Auto-
doesn’t increase. Travel speed remains un- system is inoperable. acceleration control is inop-
It’s unable to reduce the up- changed in slow mode (5 V). • Short Circuit: Even if auto- erable.
per limit of pump maximum • Short Circuit in Switch: idle/auto-acceleration selec- • Short Circuit: Even if auto-
flow rate. Travel speed remains un- tor is OFF, auto-idle control idle/auto-acceleration selec-
• Short Circuit: Precision changed in fast mode (0 V). is always performed. tor is OFF, auto-acceleration
mode switch is OFF, preci- control is always performed.
sion mode is always per-
formed.
• Flow rate doesn’t increase.
• Same as described above. • Even if travel mode selector • Same as described above. • Same as described above.
is turned to the FAST posi-
tion, fast travel mode cannot
be selected.
• Even if travel mode selector
is turned to the SLOW posi-
tion, slow travel mode cannot
be selected.
Monitor Item: Precision Mode Monitor Item: Travel Mode Monitor Item: Auto-Idle/Auto- Monitor Item: Auto-Idle/Auto-
Switch. Switch Accel Switch Accel Switch
T5-4-9
TROUBLESHOOTING / Troubleshooting B
Parts Power Mode Switch Power Mode Switch Power Mode Switch
(HP Mode) (E Mode) (P Mode)
• Activates HP mode control. • Selects E mode. • Select P mode.
ON: 0 V → HP mode is oper- ON: 0 V → E mode ON: 0 V
able. OFF: 5 V → Normal OFF: 0 V
OFF: 5 V → Inoperable. (If E mode and HP mode are
Function not selected, MC judges as P
mode is selected. )
Symptoms in machine
operation when trou-
ble occurs.
By Fault Code
By Monitor Monitor Item: E/P/HP Mode Monitor Item: E/P/HP Mode Monitor Item: E/P/HP Mode
Eval- Function Switch Switch Switch
uation Using Test
Harness
Others
NOTE
T5-4-10
TROUBLESHOOTING / Troubleshooting B
Work Mode Switch Work Mode Switch Attachment Select Switch Boom Mode
(Digging Mode) (Attachment Mode) (Optional) Selector Switch
• Allows normal control to be • Functions only when optional • Functions only when optional • Lowers overload relief pres-
performed. attachment kit is equipped. attachment kit is equipped. sure at the boom cylinder rod
• The upper limit of pump 2 • The upper limit of pump 2 side.
maximum flow is set low maximum flow can be
(250 L/min). changed at three stages.
• It’s unable to reduce the • The upper limit of pump 2 • Broken Circuit : Boom mode
upper limit of pump 2 maxi- maximum flow cannot be selector control is not per-
mum flow, which is as much changed at three stages. formed.
as that of digging mode. • The maximum flow is kept in • Short-Circuit: Overload relief
maximum flow at attachment pressure remains low con-
mode. stantly at the boom cylinder
rod side, and jack up is dis-
abled.
;
Monitor Item: Work Mode Monitor Item: Work Mode Monitor Item: ATT Mode Monitor Item: Boom Mode Se-
lector Switch.
T5-4-11
TROUBLESHOOTING / Troubleshooting B
Parts
Quick Idle Switch Engine Learning Switch Flow Combiner Valve
• Lowers engine speed instan- • Starts engine learning • Supplies hydraulic oil to both
taneously. ON: 0 V → Learning right and left travel spools
OFF: 5 V → Normal Control from pump 1 during combined
operation of travel and
Function front/swing.
• Broken Circuit : Quick idle is • Engine learning is not per- • During combined operation of
disabled. formed. travel and front/swing, insuffi-
• Short Circuit: Quick idle speed cient oil is supplied to left
is set even if quick idle is OFF. travel spool.
Symptoms in control
system when trouble
occurs.
• Same as described above. • Machine will operate normally • While traveling, when
problem is caused by broken front/swing lever is operated,
circuit or discontinuity of machine mistracks to the left.
switch. (Only learning cannot
Symptoms in machine be performed.)
operation when trou- • If short circuit occurs, learning
ble occurs. mode operation starts when
key switch is turned ON.
Therefore, engine will stall at
2 second or 20 seconds after
engine starts.
By Fault Code
By Monitor Monitor Item: Quick Idle Switch Monitor Item: Engine Learning
Eval- Function
uation Using Test
Harness
Others
NOTE
T5-4-12
TROUBLESHOOTING / Troubleshooting B
Pump 1 Flow Control Pump 2 Flow Control Bypass Shut-Out Valve Bypass Shut-Out Valve
Valve Valve (4-Spool Side) (5-Spool Side)
• Supplies flow rate control • Supplies flow rate control • Supplies pressure oil from • Supplies pressure oil from
pressure Pi to pump control pressure Pi to pump control pump 1 to auxiliary spool pump 2 to bucket 1 spool
pressure sensor (4-spool) in pressure sensor (5-spool) in when auxiliary spool is oper- when bucket digging is op-
response to lever stroke response to lever stroke ated. erated.
when boom (lower), bucket when boom (raise), arm (roll
(roll-out/in), or right travel, is out/in), swing (right/left), left
operated. travel, or auxiliary is oper-
ated.
• If spool is bound in the fully • If spool is bound in the fully • If spool is bound in the fully • If spool is bound in the fully
opened position, even if con- opened position, even if opened position, single at- opened position, single at-
trol lever is in neutral, pump 1 control lever is in neutral, tachment operation speed be- tachment operation speed
swash angle is maximum. pump 2 swash angle is comes slow. becomes slow.
(When traveling with travel maximum. (When traveling • If spool is bound in the fully • If spool is bound in the fully
levers held in half way stroke, with travel levers held in half closed position, main relief closed position, main relief
machine mistracks to the way stroke, machine mis- valve continues to relieve with valve continues to relieve
left.) tracks to the right.) all control levers positioned in with all control levers posi-
• If spool is bound in the fully • If spool is bound in the fully neutral. tioned in neutral.
closed position, even if con- closed position, even if con- • If spool is bound in opened • If spool is bound in opened
trol lever is operated, pump 1 trol lever is operated, pump position, when all control lev- position, when all control
swash angle is held to mini- 2 swash angle is held to ers are in neutral, pump 1 levers are in neutral, pump 2
mum. (Right travel is inoper- minimum. (Left travel is in- pressure is higher than pump pressure is higher than
able in single travel opera- operable in single travel op- 2 pressure. pump 1 pressure.
tion. Bucket speed is very eration. Swing speed is very
slow.) slow.)
• Same as described above. • Same as described above. • Same as described above. • Same as described above.
T5-4-13
TROUBLESHOOTING / Troubleshooting B
• If spool is bound in the fully • If spool is bound in the fully • Arm regenerative function is
opened position, what ever is opened position, swing park- inoperable.
operated, at this time flow ing brake is kept released.
combiner valve is shifted. (Machine vibrates while travel-
• If spool is bound in the fully ing.)
closed position, when travel • If spool is bound in the fully
and front/swing combined op- closed position, swing parking
Symptoms in control eration is made, machine mis- brake is kept applied.
system when trouble tracks to the left. (left travel (Dragging is felt.)
speed is slow.) • If spool is bound in the fully
occurs. closed position, the pressure
sensor (Front) is always
turned OFF. Thus the engine
speed isn’t faster when the
control lever is operated dur-
ing the auto-idle control.
• Same as described above. • Same as described above. • Arm speed is extremely slow if
it is kept close.
• Arm roll-out isn’t operated
smoothly if it is kept open.
Symptoms in machine
operation when trou-
ble occurs.
By Fault Code
By Monitor
Eval-
Function
uation
Using Test
Harness
Others
NOTE
T5-4-14
TROUBLESHOOTING / Troubleshooting B
MC
• Controls engine, pump, and
valve operation.
• Before suspecting a failure in
MC, be sure to check the
fuses in control system. If any
sensor in 5 V system is short-
circuited, fault code 04 will be
displayed.
T2-1
T5-4-15
TROUBLESHOOTING / Troubleshooting B
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine
troubles and parts contributing to the cause of the
trouble if failed.
Engine System Troubleshooting
E-1 E-2 E-3 E-4
Starter doesn’t rotate. Although starter ro- When engine control dial is Even if engine control
Trouble tates, engine doesn’t fully rotated, engine stalls. dial is rotated, engine
Symptom start. Occasionally engine stalls speed remains un-
during operation with engine changed.
control dial fully rotated and
auto-idle ON. Engine speed
is slower than specification
in all operating range. Idle
speed is faster or slower
Parts than specification.
MC (Main Controller) z z z
QOS Controller
EC Motor z z
EC Sensor { z
Pump 1 Delivery Pressure
Sensor
Pump 2 Delivery Pressure
Sensor
Pump 1 Displacement Angle
Sensor
Pump 2 Displacement Angle
Sensor
Pressure Sensor (Travel)
Pressure Sensor (Swing⋅Front
Attachment)
Pressure Sensor (Swing)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Auxiliary)
N Sensor
Hyd. Oil Temperature Sensor
Coolant Temperature Switch
Key Switch z
Engine Control Dial z
Auto-Idle/Acceleration Selector
Power Mode Switch {
Quick Idle Switch { {
Engine Learning Switch z
Battery Relay z
Glow Plug Relay
Engine Electrical Equipment z
Engine Unit z z z
Governor z z z
Check batteries. Check fuel system Check fuel cut-off handle Check engine control
(Filters and piping). and engine control cable. cable.
Remarks Be sure to perform engine
learning after replacing en-
gine.
T5-4-16
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at the
scribed provided that each trouble occurs same time, find out all faulty components
independently. while checking all suspected components
in each trouble symptom.
z z z z {
{
{
{ { {
{ {
{ {
z {
z z
{ { {
{ { {
T5-4-17
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at the
scribed provided that each trouble occurs same time, find out all faulty components
independently. while checking all suspected components
in each trouble symptom.
Parts
MC (Main Controller) z z z
QOS Controller
EC Motor {
EC Sensor
Pump Control Solenoid Valve
Pump 1 Delivery Pressure
{
Sensor
Pump 2 Delivery Pressure
{
Sensor
Pump 1 Displacement Angle
{
Sensor
Pump 2 Displacement Angle
{
Sensor
Pressure Sensor (Travel) { {
Pressure Sensor (Swing⋅Front
z
Attachment)
Pressure Sensor (Swing) {
Pressure Sensor (Boom
{
Raise)
Pressure Sensor (Arm Roll-In) {
Pressure Sensor (Auxiliary)
N Sensor
Hyd. Oil Temperature Sensor
Coolant Temperature Switch
Key Switch
Engine Control Dial
Auto-Idle/Acceleration Selec-
z z
tor
Power Mode Switch z
Work Mode Switch
Quick Idle Switch z
Engine Learning Switch
QOS Controller
Glow Plug Relay
Engine Electrical Equipment
Engine Unit
Governor
Pump Regulator
Remarks
z : Related, required to check that this component will not be the direct cause of
{ : Related. However, in case this component fails, the trouble concerned.
other trouble symptom will be more noticeable so
T5-4-18
TROUBLESHOOTING / Troubleshooting B
z
z
z
z
z
z
{ {
z
{
Check fuel system for Check batteries.
clogging.
T5-4-19
TROUBLESHOOTING / Troubleshooting B
T5-4-20
TROUBLESHOOTING / Troubleshooting B
T5-4-21
TROUBLESHOOTING / Troubleshooting B
Parts
MC (Main Controller) z
Solenoid Valve Unit (SA) z
Solenoid Valve Unit (SC)
Solenoid Valve (Swing Prefer-
ence Circuit)
Pressure Sensor (Swing)
Pressure Sensor (Bucket Roll-
z
In)
Precision Mode Switch z
Work Mode Switch
Spool z z
Main Relief Valve z z
Overload Relief Valve z z
Holding Valve
Load Check Valve
Boom Mode Selector Switch
Boom Overload Relief Selec-
tor Valve
Arm Regenerative Valve z
Shockless Valve (Outside of
z
Signal Control Valve)
Shockless Valve (Inside of
z
Signal Control Valve)
Shuttle Valve (Signal Control
z
Valve)
Pilot Valve z
Cylinder
Also, refer to A-2 and
Remarks A-3
T5-4-22
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at the
scribed provided that each trouble occurs same time, find out all faulty components
independently. while checking all suspected components
in each trouble symptom.
{ { z
z {
z {
z z
z
z
z
z
z z
Also, refer to F-5.
T5-4-23
TROUBLESHOOTING / Troubleshooting B
Parts
MC (Main Controller) { {
Solenoid Valve (Swing Prefer-
ence Circuit)) z z
Solenoid Valve Unit (SA) z
Solenoid Valve Unit (SB)
Pressure Sensor (Travel) {
Pressure Sensor (Swing) z
Travel Mode Switch
Pump Device
Spool
Check Valve
Flow Combiner Valve
Swing Parking Brake Release
z
Spool (Signal Control Valve)
Pump Control Pressure Sen-
sor (4-Spool)
Pump Control Pressure Sen-
sor (5-Spool)
Pump 1 Flow Control Valve
(Signal Control Valve)
Pump 2 Flow Control Valve
(Signal Control Valve)
Flow Combiner Control Spool
(Signal Control Valve)
Shuttle Valve (Signal Control
z
Valve)
Swing Device z
Travel Device
Center Joint
Pilot Valve z {
Pump 1 Displacement Angle
Sensor
Pump 2 Displacement Angle
Sensor
Main Relief Valve z
Work Mode Switch z {
Also, refer to A-1, F-2
and T-4.
Remarks
T5-4-24
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at the
scribed provided that each trouble occurs same time, find out all faulty components
independently. while checking all suspected components
in each trouble symptom.
T-2 T-3 T-4
One side track doesn’t Machine mistracks Fast travel is inoperable.
rotate or rotates during travel and front Travel mode doesn’t
slowly. Machine mis- attachment combined change from slow mode
tracks. operation. to fast mode.
z
{
z
z
z
z
z z
z
T5-4-25
TROUBLESHOOTING / Troubleshooting B
Parts
MC (Main Controller) {
Solenoid Valve Unit (SA) z
Pressure Sensor
z
(Counterweight Removal)
Main Relief valve {
Counterweight Removal Cylin-
z
der
Counterweight Removal Pilot
z
Valve
Refer to T5-4-70. Refer to T5-4-74. Refer to T5-4-76.
Remarks
T5-4-26
TROUBLESHOOTING / Troubleshooting B
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter doesn’t rotate.
Faulty starter or
YES faulty harness
between starter
Check if voltage at and battery relay.
YES battery relay
terminal A is 24 V.
Faulty battery
NO relay.
Check if both voltages
YES at key switch terminal
#5 and #6 are 24 V.
· Key switch: START YES Faulty key switch.
Check for
Check if battery
continuity between
voltage and
battery positive
electrolyte density NO terminal and key
is normal, and Faulty harness
switch terminal #1.
fusible link (45 A) is between battery
not blown. NO and key switch.
· Voltage: More than
24 V
Density: 1.25 to
1.28 Faulty battery or
NO fusible link.
T16J-05-04-001
T105-07-04-002
Terminal A
T5-4-27
TROUBLESHOOTING / Troubleshooting B
E-2 Although starter rotates, engine doesn’t
start.
T16J-04-02-008
1 - Fuel Cut Lever
2 - Fuel Cut-Off Cable
(Fuel Cut-Off Handle)
3 - Governor Lever
4 - Governor Cable
(From EC Motor)
T5-4-28
TROUBLESHOOTING / Troubleshooting B
• Governor Lever Position
B A
FULL STOP
STOP FULL
T16J-04-02-008
T16J-04-02-008
T5-4-29
TROUBLESHOOTING / Troubleshooting B
E-3 When engine control dial is fully rotated,
engine stalls.
Occasionally engine stalls during operation
with engine control dial fully rotated and
auto-idle ON.
Engine speed is slower than specification in
all operating ranges.
Idle speed is faster or slower than
specification.
T5-4-30
TROUBLESHOOTING / Troubleshooting B
T5-4-31
TROUBLESHOOTING / Troubleshooting B
E-4 Even if engine control dial is rotated, engine
speed remains unchanged.
• If the EC fails, the engine will not stop with the key
switch ON.
• Check if the quick idle switch is turned off.
• Check for loose harness connections beforehand.
T5-4-32
TROUBLESHOOTING / Troubleshooting B
E-6 In the P mode, engine speed is not increased
during arm roll-in, boom raise or travel.
T5-4-33
TROUBLESHOOTING / Troubleshooting B
E-8 Malfunction of HP mode.
T5-4-34
TROUBLESHOOTING / Troubleshooting B
E-10 Malfunction of auto-idle
T5-4-35
TROUBLESHOOTING / Troubleshooting B
E-11 Malfunction of E mode
T5-4-36
TROUBLESHOOTING / Troubleshooting B
E-12 Malfunction of auto-acceleration
Related Fault Code: 8, 9, 10, 11, 12, 13, 14, 15, 16,
and 18
T5-4-37
TROUBLESHOOTING / Troubleshooting B
E-13 Malfunction of quick idle.
T5-4-38
TROUBLESHOOTING / Troubleshooting B
E-14 Engine stalls within several seconds after
engine has started.
Check if engine
learning switch is
turned to the learning Faulty learning switch,
position. or short-circuited
harness between
learning switch and MC,
NO
or check fuel system for
clogging.
T5-4-39
TROUBLESHOOTING / Troubleshooting B
E-15 Engine stalls during operation under
adverse condition such as at high altitude.
T5-4-40
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-41
TROUBLESHOOTING / Troubleshooting B
E-16 Engine is difficult to start at low
temperature. (During cold weather or in
cold districts, the engine is difficult to start
or doesn’t start although pre-heated.)
Disconnect coolant
temperature switch. Check if
voltage at glow plug is 20 to 24
YES Faulty QOS controller.
V.
· Key switch: ON
Disconnect QOS controller.
Ground harness end connector
NO terminal #4 to vehicle frame.
Check if problem is corrected.
Remove
the
copper
plate.
T5-4-42
TROUBLESHOOTING / Troubleshooting B
T5-4-43
TROUBLESHOOTING / Troubleshooting B
ALL ACTUATOR SYSTEM TROUBLE-
SHOOTING
A-1 All actuator speeds are slow.
Check if work
mode can be NO Turn precision mode
shifted. switch to OFF, or
Check if precision faulty precision mode
· Monitor item: Work mode is OFF. switch.
mode switch YES
· Monitor item: Precision A
YES
mode switch
YES Faulty pilot pump or
clogged pilot filter.
Check if same
NO symptom still ap-
pears after disas-
sembling, cleaning,
and adjusting pilot End.
relief valve. NO
Check if primary
A pilot pressure is Faulty N sensor or
normal. YES broken harness in N
sensor circuit.
· Fully boom raised or arm
roll-in
· Monitor item: Boom raise
pilot pressure, arm dig- Monitor actual en-
ging pilot pressure gine speed. Check
if abnormal speed NO Main relief valve fail-
YES
is indicated. ure.
T5-4-44
TROUBLESHOOTING / Troubleshooting B
YES
Overheat of coolant.
T5-4-45
TROUBLESHOOTING / Troubleshooting B
A-2 Left travel is inoperable during single travel
operation. Single swing operation speed is
slow. Arm is slightly slow during arm level
crowding. (All problems occur at the same
time.)
Faulty corresponding
sensor or broken har-
YES ness between sensor
and MC.
· Fault code: Pump 2 dis-
placement angle sensor: 09
Pump 2 delivery pressure
sensor: 11
Pump control pressure sen-
sor (5-spool): 13
Pump 2 control solenoid
valve: 21
T5-4-46
TROUBLESHOOTING / Troubleshooting B
A-3 Right travel is inoperable during single travel
operation. Single bucket operation speed is
slow. Boom is not raised properly during
arm level crowding. (All problems occur at
the same time.)
Misalignment of pump
NO 1 displacement angle
sensor or pump 1 fail-
ure.
Check if pump 1 de-
sired displacement is · Refer to Adjustment
minimum value with group in perform-
control levers in neu- ance Test section.
tral.
Also, check if pump 1 YES Faulty pump 1.
desired displacement Monitor pump 1
is maximum when left pump control pres-
travel lever is operated NO sure. Check if
full stroke white left pressure increases
track is jacked up. in proportion to left
Check if any fault travel lever stroke. Bound pump 1 flow
· Monitor item: Pump 1 codes are dis- rate control valve in
YES played. NO signal control valve.
desired displacement. · Monitor item: Pump 1
flow control pressure
· Possible to display with
built-in diagnostic sys-
tem.
Faulty corresponding
sensor or broken har-
YES ness between sensor
and MC.
· Fault code: Pump 1 dis-
placement angle sensor: 08
Pump 1 delivery pressure
sensor: 10
Pump control pressure sen-
sor (4-spool): 12
Pump 1 control solenoid
valve: 20
T5-4-47
TROUBLESHOOTING / Troubleshooting B
A-4 Actuator doesn’t stop even if control lever is
returned to neutral.
T5-4-48
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-49
TROUBLESHOOTING / Troubleshooting B
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
F-1 All front attachment actuator power is weak.
Pressure Increases.
2
Less than 31.9 MPa (325 kgf/cm ) Faulty precision mode
Ҵ NO switch or broken har-
2 Normal.
34.3 MPa (350 kgf/cm ) ness between precision
mode switch and MC.
Monitor pump 1
and 2 delivery
pressures.
· Monitor item: Monitor precision
YES
Pump 1 and 2 deliv- mode switch.
Pressure Check if display is Monitor solenoid valve
ery pressure (SA) pressure.
doesn’t normal.
· Possible to display Check if pressure is
increase.
with built-in diagnos- · Monitor item: YES approx. 3.9 MPa (40
tic system Precision mode switch 2
kgf/cm ).
· Check pump delivery
pressure change · Monitor item:
while travelling. Power Boost Control
· Power mode switch: Valve Out NO
P mode
T5-4-50
TROUBLESHOOTING / Troubleshooting B
Connector (Harness End Connector Viewed from the open End Side)
T183-05-04-010
Faulty MC.
T5-4-51
TROUBLESHOOTING / Troubleshooting B
F-3 Some cylinders are inoperable or speeds are
slow.
T5-4-52
TROUBLESHOOTING / Troubleshooting B
F-4 Arm doesn’t work smoothly in arm roll-in
digging single operation.
T183-05-04-010
T5-4-53
TROUBLESHOOTING / Troubleshooting B
F-6 Jack up is made even if the boom mode se-
lector switch is ON.
T5-4-54
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-55
TROUBLESHOOTING / Troubleshooting B
F-7 When boom raise or arm roll-out is operated,
boom or arm starts to move after moving
slightly downward.
T5-4-56
TROUBLESHOOTING / Troubleshooting B
F-8 Front attachment drifts remarkably.
T5-4-57
TROUBLESHOOTING / Troubleshooting B
F-9 During combined operation of front attach-
ment and swing, front attachment speed is
slow.
NO
ʝ YES
ʝ
ʝ Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#3
C1 C10
C23 C31
Ȁ #14
1 2 3
T5-4-58
TROUBLESHOOTING / Troubleshooting B
Faulty MC.
NO
· Refer to Adjustment group in
Performance Test section.
T5-4-59
TROUBLESHOOTING / Troubleshooting B
SWING SYSTEM TROUBLESHOOTING
S-1 Swing is slow or unmoving.
T5-4-60
TROUBLESHOOTING / Troubleshooting B
T5-4-61
TROUBLESHOOTING / Troubleshooting B
S-2 Swing is too fast
T5-4-62
TROUBLESHOOTING / Troubleshooting B
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Both right and left tracks do not rotate or ro-
tate slowly.
T5-4-63
TROUBLESHOOTING / Troubleshooting B
T-2 One side track doesn’t rotate or rotates
slowly. Machine mistracks.
4 Right Travel
(Reverse)
Left Travel 4
5 (Reverse) 5
Right Travel
(Forward)
6 Left Travel
(Forward) 6
7
7
and External oil leak and External Leak T16J-03-07-001
T5-4-64
TROUBLESHOOTING / Troubleshooting B
Front
2
1
3
4
M162-07-071
1 - Left Travel (Forward) 3 - Right Travel (Reverse) 5 - Pilot (Travel Speed Change) 6 - Drain
2 - Right Travel (Forward) 4 - Left Travel (Reverse)
T5-4-65
TROUBLESHOOTING / Troubleshooting B
T-3 Machine mistracks during travel and front at-
tachment combined operation.
SL Port
T16J-03-06-001
(Control Valve Side)
T5-4-66
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-4-67
TROUBLESHOOTING / Troubleshooting B
T-4 Fast travel is inoperable.
Travel mode doesn’t change from slow mode
to fast mode.
T5-4-68
TROUBLESHOOTING / Troubleshooting B
Faulty MC.
T183-05-04-010
T5-4-69
TROUBLESHOOTING / Troubleshooting B
OTHER SYSTEM TROUBLESHOOTING
O-1 Wiper is inoperable or not retracted.
T5-4-70
TROUBLESHOOTING / Troubleshooting B
Lamp S
M B S
L E
Ground
T178-05-04-004
Retracted Position
Operating Range
T178-05-04-005
Lamp S
T157-07-04-004
T5-4-71
TROUBLESHOOTING / Troubleshooting B
0-2 Malfunction of counterweight removal device.
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
Pressure Sensor (Counterweight removal)
C1 C10
1 2 3
C23 C31
T5-4-72
TROUBLESHOOTING / Troubleshooting B
T5-4-73
TROUBLESHOOTING / Troubleshooting B
O-3 Malfunction of auto-lubrication system.
T5-4-74
TROUBLESHOOTING / Troubleshooting B
• Auto-lubrication system can not stop even after the
lapse of lubrication time.
• Interval: 45 minutes (Adjustable from 10 to 90
minutes), lubrication time-5 minutes.
YES Faulty auto-lubrication
Exchange auto- normal rotation relay.
lubrication normal
rotation relay with YES Faulty MC.
auto-lubrication re-
verse rotation relay. · Refer to Adjustment
Check if auto- group in Performance
lubrication system Test section
stops. Check if voltage at
power transistor ter- YES Short-circuited har-
NO minal #1 is 5 V. Disconnect power ness between auto-
transistor. lubrication normal rota-
· Key switch: ON Check continuity be- tion relay terminal #2
tween auto-lubrication and power transistor
normal rotation relay terminal #4.
NO harness end connector
terminal #2 and frame.
Faulty power transis-
NO tor.
· Refer to Adjustment
Check if auto- group in Performance
lubrication indicator Test section
is turned on.
Faulty lubrication switch,
or short-circuited harness
NO between MC and auto-
lubrication switch.
T5-4-75
TROUBLESHOOTING / Troubleshooting B
Greasing into Piping
• Greasing into piping between the distribution valve • Greasing into supply piping (ranging from grease
and lubricating points pump to the distribution valve on arm) for five min-
utes.
• Piping between the distribution valve on boom 1. Disconnect hose (2) from the grease pump and
and lubricating points: remove the plug from supply port (3) of the distri-
1. Open discharge ports at the top of the distribution bution valve on the frame.
valve on the boom to the atmosphere. (Do not at- 2. Attach a grease nipple to supply port (1) of the dis-
tach plugs.) tribution valve on arm, and grease into it.
2. Grease into nipples at the centralized greasing 3. Plug hose (2) and or supply port (3) whichever
block for boom. grease comes out first, continue to grease until
3. Seal the ports with plugs when grease comes out grease comes out from the unpluged end or port.
from discharge ports of the distribution valve on 4. After confirming that grease comes out from the
the boom. end or port, connect hose (2) to the grease pump,
4. Continue to grease into nipples at the centralized and install the plug on supply port (3).
greasing block until lubricating points are filled
fully with grease.
1
• Piping between the distribution valve on the frame
and boom cylinder bottom side: Arm
1. Grease into discharge ports at the top of the dis-
tribution valve on the frame, and confirm that the
boom cylinder bottom side is filled fully with
grease. Boom
T5-4-76
TROUBLESHOOTING / Troubleshooting B
O-4 Malfunction of Air Conditioner
T5-4-77
TROUBLESHOOTING / Troubleshooting B
• Change Displayed Fault Code
1. When displaying more than one fault code, press Temperature
either the upper or bottom side of the temperature Control Switch
control switch key. The following fault code is dis-
played.
NOTE: Each time the displayed fault code is
changed, the buzzer sounds. In case only
one fault code exists, the displayed fault
code remains unchanged.
M178-01-017
LCD
M178-01-017
Fan Switch
ȀȀ
T5-4-78
TROUBLESHOOTING / Troubleshooting B
Ұ Please fill in all sections and return this AIR CONDITIONER Others
TROUBLE REPORT to Hitachi Tsuchiura Works Quality Assurance
Dept. after experiencing a problem with your machine’s air condi-
tioning system.
< AIR CONDITIONER TROUBLE REPORT >
File NoȎ
(1) What Checked by:
Model (Serial No. )
Operation Type Manual Semi-Auto Full-Auto
Delivery Date Year Month
(2) When
Date Year Month Day Operating Hour ( h)
Time Morning Daytime Evening Night
Frequency Every Day Once a Week Once a Month Times per
(3) Where
Job Site Address State County Town
Access Road Condition Paved Not Paved (Gravel Sand Soil)
(4) How (Operating Conditions)
Weather Fine Cloudy Rain Snow
Atmospheric Temperature Very Hot Hot Cold Very Cold
Operating Conditions Parking Traveling Working
Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when
full-auto operation
A/C ON OFF
Air Induction Re-Circulation Fresh Air Circulation
Control
AUTO ON OFF Not Available
Panel
Fill following items when operated in manual mode or when manual control type unit is used.
Vent Position Front Front / Rear Foot Front / Rear and Foot
Fan First Second Third Fourth Fifth Sixth
(5) How (Problem Symptom)
Abnormal Compressor Operation
Symptom Not turned ON <Check Result>
Not turned OFF (1) Is problem reproducible ?
ȀReproducible
Others
ȀNot reproducible
Uncontrollable air temperature
(2) Pressure (To be measured at gauge manifold)
Symptom No cool air
ȀLow Pressure
No warm air
ȀHigh Pressure
Others
(3) Which parts have been replaced ?
Uncontrollable air volume
1
Symptom Air flows in Hi mode only
No air flows 2
Small air volume
∗ Before replacing the control amplifier, be sure to
Others check that the connectors are correctly connected
while repeatedly disconnecting and reconnecting
Uncontrollable vent hole connectors.
Symptom Vent hole isn’t selected
Others
Abnormal panel indication
Faulty Indica- Vent Hole
tor A/C
AUTO
Fan OFF
Temperature Control
T5-4-79
TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Insuff-
icient
Cooling Refrigerant pressure in high Compressor cylinder is extremely hot,
Power pressure side is low. emitting a smell.
Refrigerant pres- Bubbles can be seen in sight Refrigerant pressure in low pressure
sure in high pres- glass. side is low.
sure side is high.
Condenser is stained and clogged.
Even if condenser is sprayed with water, few bubbles appear. Receiver dryer tem-
perature is low.
T5-4-80
TROUBLESHOOTING / Troubleshooting B
Gas leaks from pipe joints and/or parts. Re-tighten or replace parts.
Clogged low pressure circuit and/or evaporator. Remove clog, or replace parts.
Frozen expansion valve or water in circuit. After evacuation, refill refrigerant and/or replace
receiver dryer.
Gas leaks from case.
Seal gaps using vinyl tape or packing compound.
Poor contact of expansion valve temperature Make good contact. Replace temperature sensing
sensing cylinder. stay.
Improper adjustment (excessive open) of expan-
Readjust or replace.
sion valve.
Improper water stop valve wire adjustment and/or Check and readjust or replace.
faulty stop valve.
Repair.
Poor airtight fitting of outside air damper (outside
air induction type).
Gas leaks from case. Seal gaps using vinyl tape or packing compound.
Even if function and performance are normal, Instruct user on correct air-conditioner operation.
when air-conditioner is kept operated for a long (Reset thermistor to either minimum or middle
time with thermistor in max. cooling position and cooling position or increase air flow.)
air flow in M or L mode, frost may form.
T5-4-81
TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Gas blowing sound (roaring). Gas vibration noise (compressor discharge and/or
suction gas noise).
Expansion valve connection, whistle Abnormal noise from expansion valve (Expansion
Noise sound, gas blowing sound. valve is normally functioning.).
Noisy compressor.
Compressor rotating sound.
Vibration and/or loose screws due to excessive drive
belt looseness.
T5-4-82
TROUBLESHOOTING / Troubleshooting B
Repair or replace.
Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.
Replace.
Repair or replace.
Replace.
Clean.
-1
Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min in
L mode for more than 10 minutes, flush smell out by condensed water.
T5-4-83
TROUBLESHOOTING / Troubleshooting B
Compressor
Check for oil and refrigerant leaks from parts other than
Both high and low side
compressor and pipe joints using gas detector.
pressures are low.
Both com-
pressor
and blower
motor ro- Check for oil and
tate. refrigerant leaks
from compressor Refer to NOTE 1 and 2 on page T5-4-87.
(no leaks from
Refrigerant has not been refilled for longer
parts other than
than one season.
compressor) using
gas detector.
Stain Refrigerant is discharged within 1 to 2
on months after being recharged. Check for
exterior. refrigerant leaks using gas detector.
Trouble other than compressor. Refer to the Cooling Circuit Troubleshooting Table on page
T5-4-80.
T5-4-84
TROUBLESHOOTING / Troubleshooting B
Oil and refrigerant leaks from front housing, and/or cylinder block joint. Replace.
No leaks (normal).
T5-4-85
TROUBLESHOOTING / Troubleshooting B
Compressor
Abnormal
noise
T5-4-86
TROUBLESHOOTING / Troubleshooting B
Broken valve.
Replace.
Blown gasket.
NOTE:
1. Don’t quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A
slight oil seepage will appear due to the seal construction. However, this oil seepage will not
cause malfunction. Be sure to accurately check whether oil is leaking or seeping only.
2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose sur-
face may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
2
high pressure side and low pressure side is 0.49 MPa (5 kgf/cm ) or less. When the clutch is
turned OFF, the pressure difference between high pressure side and low pressure side will disap-
pear within about 10 seconds.
T5-4-87
TROUBLESHOOTING / Troubleshooting B
WORK AFTER REPLACING COMPO-
NENTS
The following work is required after replacing
compressor, high pressure hose, low pressure hose,
condenser, receiver tank, liquid hose, and air
conditioner unit.
The same work is required when gas leakage is found.
T5-4-88
TROUBLESHOOTING / Troubleshooting B
CHARGE AIR CONDITIONER WITH
REFRIGERANT
Necessity of Purging
Be sure to purge the air conditioner circuit with a
vacuum before charging with refrigerant (R134a)
because the following problems can arise if air or
other gases remain in the A/C circuit.
2. Metal corrosion
Metal corrosion
T5-4-89
TROUBLESHOOTING / Troubleshooting B
Purging Procedure Gauge Manifold
1. Close the high and low pressure valves on the
gauge manifold (Parts Number 4360564). Low Pressure
Connect the high-pressure-side charge hose and Valve
the low-pressure-side charge hoses to the high- Low Pressure
Charge Hose High Pressure
pressure-side charge valve (“D” marked) and to
Valve
the low-pressure-side charge valve (“S” marked)
located on the compressor, respectively. High Pressure
Connect the charge hose located on the center of Charge Hose
the manifold bottom to the vacuum pump (Parts Center Pressure
Number 4360565). Charge Hose
Vacuum Pump
W115-02-10-005
Low Pressure
Side S
Compressor
D
High Pressure
Side
T142-02-05-018
Fully Open
2. Open the high pressure and low pressure valves
in the gauge manifold. Perform purging for 10
minutes or more by operating the vacuum pump. Fully Open
In Operation
W115-02-10-005
T5-4-90
TROUBLESHOOTING / Troubleshooting B
3. When the low pressure gauge reading falls
below-755 mmHg, stop the vacuum pump and
close the high and low pressure valves. Wait for Close
approximately five minutes and confirm that the
pointer does not return to 0. Close
In Operation
W115-02-10-005
Refrigerant
Container
W115-02-10-007
Open
W115-02-10-007
T5-4-91
TROUBLESHOOTING / Troubleshooting B
6. Fully tighten the charge hose connection to the
High
gauge manifold. Open the high pressure valve Pressure
and refrigerant container valve to charge with Gauge
refrigerant (R134a). Tighten
Close the high pressure valve and refrigerant
container valve when the high pressure gauge
2 Open
reading reaches 98 kPa (1 kgf/cm , 14 psi).
T5-4-92
TROUBLESHOOTING / Troubleshooting B
8. Confirm that the high pressure and low pressure
valves in the gauge manifold and the refrigerant
container valve are closed.
Start the engine and operate the air conditioner.
Open
W115-02-10-007
T5-4-93
TROUBLESHOOTING / Troubleshooting B
12. Start the engine and operate the air-conditioner
again.
Observe the sight glass of the receiver/drier to
check refrigerant quantity.
Operating Conditions of the Air Conditioner:
Engine Speed :ȀSlow Idle
Cab Window :ȀFully Open Sight Glass
Cooler Switch :ȀON
Airflow Volume :ȀMaximum
Thermo Switch :ȀMaximum
IMPORTANT: If the air conditioner is operated with
very low refrigerant, a bad load will
be exerted on the compressor. If the
air conditioner is overcharged with
Receiver/Drier
refrigerant, cooling efficiency will
lower and abnormal high pressure
will arise in the air conditioner
circuit, causing danger.
NOTE: As the bubbles in the sight glass vary
W115-02-10-009
depending on the ambient temperature,
check refrigerant quantity confirming the
changes in pressure .
T5-4-94
TROUBLESHOOTING / Troubleshooting B
Warm-up Operation
After charting the air conditioner, carry out warm-up
operation five minute to lubricate system with
compressor oil.
Inspection
After warm-up operation, carry out gas leak check
and performance check.
2. Performance Check
Carry out performance check of the air conditioner
after checking each air conditioner component.
(1) Check each component for abnormalities.
Retighten Line
(2) Carry out ON-OFF check of the compressor Connection
clutch.
(3) Check compressor fan belt tension.
(4) Check the coolant level in the radiator.
(5) Operate the air conditioner and check the
performance.
W115-02-10-014
T5-4-95
TROUBLESHOOTING / Troubleshooting B
3. The checklist before the summer season is as
follows:
(1) Check each air conditioner component for
abnormalities.
(2) Check the line connections for oil leaks.
(3) Check refrigerant quantity.
(4) Check the engine cooling circuit.
(5) Check belts for wear. Replace if necessary.
4. Off-Season Maintenance
(1) During off-season, operate the idler pulley
and compressor at least once a month for a
short time to check for any abnormal sounds.
(2) Do not remove the compressor belts during
off-season. Operate the compressor
occasionally at slow speed for 5 to 10
minutes with the belt slightly loosened in
order to lubricate the machine parts.
T5-4-96
TROUBLESHOOTING / Troubleshooting B
EXCHANGE INSPECTION Front
A View A
Exchange inspection method is a troubleshooting
method to find the trouble location by exchanging the
suspected part / component with another part SB SA
/component having identical characteristics.
code:12)
T5-4-97
TROUBLESHOOTING / Troubleshooting B
T5-4-98
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C
(TROUBLESHOOTING FOR MONITOR)
PROCEDURE
YES(OK)
(2)
After completing the checking and/or measuring procedures in box
О (1) (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
(3)
NO(NOT OK)
О Causes of machine problems are stated in the thick-line box. Scanning quickly through
the thick-line boxes, allows you to estimate the possible causes before actually following
the flow chart.
Open End
Side Harness End Connector
T158-05-03-001
T5-5-1
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF COOLANT TEMPERA-
TURE GAUGE
YES
YES
YES
T5-5-2
TROUBLESHOOTING / Troubleshooting C
105 ńC
(95 ńC)
Faulty coolant temperature
sensor
70 ńC
T157-07-05-001
Faulty monitor
NO
ȑȐ ș Ș ȗ Ȗ ȕ Ȕ ȓ Ȓ ȑ
ȒȐ ȑș ȑȘ ȑȗ ȑȖ ȑȕ ȑȔ ȑȓ ȑȒ ȑȑ
Faulty monitor
T5-5-3
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF FUEL GAUGE
YES
YES
YES
T5-5-4
TROUBLESHOOTING / Troubleshooting C
Fuel Sensor
Float
Faulty fuel sensor
FULL
R370
YES Faulty monitor 257 mm 3/4
93 mm
1/4
338 mm
EMPTY
Faulty fuel sensor T178-05-05-001
NOTE: 1 mm = 0.03937 in
Float Position Resistance (Ω)
YES Short-circuited harness be- Upper Limit (FULL)
+0
10 -4
tween monitor and sensor
3/4 26
1/2 38±5
1/4 53
Faulty monitor
Warning Level 85±3
NO +10
Lower Limit (EMPTY) 90 -0
ȑȐ ș Ș ȗ Ȗ ȕ Ȕ ȓ Ȓ ȑ
ȒȐ ȑș ȑȘ ȑȗ ȑȖ ȑȕ ȑȔ ȑȓ ȑȒ ȑȑ ȑ Ȓ
Faulty monitor
T5-5-5
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF INDICATOR LIGHT
CHECK SYSTEM
Check power line.
• Check for loose harness connections beforehand. ⋅ Fuse
YES ⋅ Remove connector C (20P)
from monitor. Check for con-
tinuity between harness end
terminal #1 and fuse terminal
Indicator doesn’t light when #7.
Check if all indicators don’t
indicator light check operation
light.
is performed.
ȑȐ ș Ș ȗ Ȗ ȕ Ȕ ȓ Ȓ ȑ
ȒȐ ȑș ȑȘ ȑȗ ȑȖ ȑȕ ȑȔ ȑȓ ȑȒ ȑȑ
T5-5-6
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF PREHEAT INDICATOR
ȑȐ ș Ș ȗ Ȗ ȕ Ȕ ȓ Ȓ ȑ ȑ Ȓ ȓ
ȒȐ ȑș ȑȘ ȑȗ ȑȖ ȑȕ ȑȔ ȑȓ ȑȒ ȑȑ Ȕ ȕ Ȗ
T5-5-7
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE OIL LEVEL
INDICATOR
Without connecting
connector to engine oil YES
level switch, remove
connector B (20P)
NO from monitor. Check
for continuity between
Check if indicator monitor harness end
Indicator doesn’t lights by removing connector terminal #8
light even if engine NO
connector (with and vehicle frame.
oil level is lower black and white
than specification. cable) from engine
oil level switch.
YES
Without connecting
connector to engine oil
level switch, remove
connector B (20P)
NO from monitor. Check
Remove connector for continuity between
Lower than 8.4 mm (with black and white
below LOW level mark monitor harness end
cables) from engine oil connector terminal #8
on oil level gauge level switch. Check if and engine oil level
indicator goes OFF by switch connector.
grounding harness
end connector to vehi-
Indicator comes ON
cle frame.
even if engine oil Check oil level with YES
level matches oil level gauge.
specification.
Above 8.4 mm
below LOW level mark
on oil level gauge
T5-5-8
TROUBLESHOOTING / Troubleshooting C
Faulty monitor ON
H A (Indicator ON)
L
(Indicator OFF)
Faulty engine oil level switch
OFF
A: 8.4 mm (0.33 in)
T107-04-03-010
Broken harness between en- Connector (Harness end connector terminals seen
gine oil level switch and moni- from the open end side)
NO tor
Monitor Connector B (20P)
T5-5-9
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF COOLANT LEVEL IN-
DICATOR
Without connecting
connector to coolant YES
level switch, remove
connector B (20P)
NO
from monitor. Check
for continuity between
Check if indicator monitor harness end
Indicator doesn’t
lights by removing connector terminal #9 NO
light even if coolant
connector (with blue and vehicle frame.
level is lower than
cable) from coolant
specification.
level switch.
YES
Without connecting
connector to coolant
level switch, remove
connector B (20P)
NO from monitor. Check
Remove connector for continuity between
(with blue cables) from monitor harness end
coolant level switch. connector terminal #9
No Check if indicator goes and coolant level
OFF by grounding switch connector.
harness end connec-
Indicator comes ON Check if coolant tor terminal #1 to vehi-
even if coolant level level in coolant res- cle frame.
YES
matches specifica- ervoir is lower than
tion. LOW mark.
Yes
T5-5-10
TROUBLESHOOTING / Troubleshooting C
ON
Faulty monitor
FULL
LOW
T5-5-11
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ALTERNATOR INDICA-
TOR
Between 13 V
and 33.5 V
Between 13 V
and 33.5 V Measure voltage at
monitor connector A
(16P) terminal #2.
Alternator indicator Measure voltage at · Engine: Running Less than 13 V or
stays ON after en- regulator terminal L.
∗
higher than 33.5 V
gine is started.
· Engine: Running
Less than 13 V or
higher than 33.5 V
Between 10 V
and 33.5 V
NO
T5-5-12
TROUBLESHOOTING / Troubleshooting C
Starter Relay
Ș ȗ Ȗ ȕ Ȕ ȓ Ȓ ȑ
ȑȖ ȑȕ ȑȔ ȑȓ ȑȒ ȑȑ ȑȐ ș
Faulty monitor
Faulty regulator
T5-5-13
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE OIL PRES-
SURE INDICATOR
NO
YES
Check if indicator
Indicator stays ON goes OFF when
after engine is engine oil pressure YES
Reconnect engine oil
started. switch is discon-
pressure switch and
nected.
· Check oil filter for remove connector C
clogging. · Key switch: ON (20P) from monitor.
· Engine: Stopped NO Check for continuity
between harness end
connector terminal #18
and vehicle frame.
NO
T5-5-14
TROUBLESHOOTING / Troubleshooting C
Faulty monitor
NO
Faulty monitor
T5-5-15
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF OVERHEAT INDICA-
TOR
YES
Remove connector
(red and blue cable)
from overheat switch
YES (105 °C). Check if indi-
cator lights when har-
·ness
Key end terminal
Switch: ON is
grounded to vehicle
frame.
· Key switch: ON NO
NO
YES
Check if indicator
Indicator lights even goes OFF when
if coolant tempera- overheat switch
ture is low. (105 °C) is discon-
nected. Disconnect overheat YES
· Key switch: ON switch (105 °C). Re-
· Engine: Stopped move connector B
(20P) from monitor.
NO
Check for continuity
between connector
terminal #6 and vehicle
frame.
NO
T5-5-16
TROUBLESHOOTING / Troubleshooting C
Overheat Switch
Faulty overheat switch Coolant Temperature Operation
(105 °C) Lower than 105 °C OFF
(221 °F)
105 °C (221 °F) or ON
higher
Reconnect overheat YES Broken harness between
monitor and overheat
switch. Check if indica-
switch (105 °C)
tor lights when monitor
connector B (20P)
terminal #6 is
grounded to vehicle Faulty monitor
frame. NO
· Key switch: ON
· Without disconnect-
ing connector, Connector (Harness end connector terminals seen
ground connector to
Monitor Connector B (20P)
vehicle frame using
such jumper wire as
clip from reverse side ȑȐ ș Ș ȗ Ȗ ȕ Ȕ ȓ Ȓ ȑ
of connector. ȒȐ ȑș ȑȘ ȑȗ ȑȖ ȑȕ ȑȔ ȑȓ ȑȒ ȑȑ
Burned indicator light
Short-circuited harness
between monitor and
overheat switch (105 °C)
Faulty monitor
Overheat Switch
(105ѵ) T17V-01-02-027
T5-5-17
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF AIR FILTER RESTRIC-
TION INDICATOR
YES
Disconnect air filter re-
striction switch at plug
receptacle with green
YES and blue cable. Check if
indicator lights when Reconnect air filter restric-
harness end plug con- tion switch. Remove con-
nector is grounded to nector B (20P) from moni-
vehicle frame. tor. Check for continuity
Even if air filter is Check if indicator NO between monitor harness
clogged, indicator lights when key · Key switch: ON
end connector terminal #7
doesn’t light. switch is turned ON. and vehicle frame.
· Key switch: ON
NO
YES
T5-5-18
TROUBLESHOOTING / Troubleshooting C
ȑȐ ș Ș ȗ Ȗ ȕ Ȕ ȓ Ȓ ȑ
ȒȐ ȑș ȑȘ ȑȗ ȑȖ ȑȕ ȑȔ ȑȓ ȑȒ ȑȑ
Short-circuited harness
between monitor and air
filter restriction switch
Faulty monitor
T5-5-19
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF BUZZER
NO Normal
Buzzer doesn’t
sound even if en- Check if engine
gine oil pressure speed is 900 min
-1
NO Perform troubleshooting
indicator or over- (rpm) or faster. of indicator staying ON.
heat indicator lights
with engine running. Check if alternator
YES indicator lights.
Measure voltage at regu-
YES lator terminal L.
-1
· Engine speed: 900 min
(rpm) or faster
T5-5-20
TROUBLESHOOTING / Troubleshooting C
Ș ȗ Ȗ ȕ Ȕ ȓ Ȓ ȑ ȥ
ȑȖ ȑȕ ȑȔ ȑȓ ȑȒ ȑȑ ȑȐ ș ȳ Ȳ
Lower than 13 V or
more than 33.5 V Faulty regulator and alternator
Lower than 13 V or
higher than 33.5 V Broken harness between
regulator terminal L and moni-
tor
Measure voltage at monitor
connector A (16P) terminal #2.
Between 13 V Faulty monitor
-
and 33.5 V · Engine speed: 900 min
1
(rpm) or faster Between 13 V
and 33.5 V
T5-5-21
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF LCD
Display
Description Cause of Trouble
Order
1 Hour Meter Refer to the next page.
2 Trip 1 Faulty Monitor
3 Trip 2
4 Actual Engine Speed In case Dr. EX can display data, monitor is abnormal or communication
5 Hydraulic Oil Tempera- between monitor and MC is interrupted. In case Dr. EX doesn’t display
ture data, corresponding signal sensor is faulty. (The machine must have
any abnormality in the control system. Refer to Troubleshooting B.)
6 Not Operate
7
8 Fault Code In case Dr. EX can display data, monitor is abnormal or communication
9 between monitor and MC is interrupted. In case Dr. EX doesn’t display
10 Pump 1 Delivery Pres- data, corresponding signal sensor is faulty. (The machine must have
sure any abnormality in the control system. Refer to Troubleshooting B.)
11 Pump 2 Delivery Pres-
sure
12 Pump 1 Control Pres-
sure
13 Pump 2 Control Pres-
sure
14 Target Engine Speed
15 EC Angle
16 Dial Angle
17 Boom Raise Lever
Stroke
18 Arm Roll-In Lever Stroke
19 Swing Lever Stroke
20 Travel Lever Stroke
21 Bucket Lever Stroke
22 Attachment Lever Stroke
23 Work Mode
T5-5-22
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HOUR METER
∗
NOTE: Regulator terminals L are water-resistant
type connectors so that it is not practical to
measure voltage at these terminals. Meas-
ure voltage at starter relay terminal R in-
stead. Check for continuity between starter
relay terminal R and regulator terminal L
beforehand.
Lower than 13 V or
higher than 33. V Faulty regulator or
alternator
Hour meter
doesn’t count Between 13V
Measure voltage at
operating hours ∗ and 33.5 V Faulty monitor
regulator terminal L.
with engine run-
-1
ning. · Engine speed: 900 min Measure voltage
· Engine: Running (rpm) or faster at monitor connec-
Between 13V tor A (16P) termi-
and 33.5 V nal #2. Broken harness be-
tween regulator ter-
Lower than 13 V or minal L and monitor
higher than 33. V
ȥ
Ș ȗ Ȗ ȕ Ȕ ȓ Ȓ ȑ
ȑȖ ȑȕ ȑȔ ȑȓ ȑȒ ȑȑ ȑȐ ș ȳ Ȳ
T5-5-23
TROUBLESHOOTING / Troubleshooting C
(Blank)
T5-5-24
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
T5-6-1
TROUBLESHOOTING / Electrical System Inspection
4. Precaution for using a circuit tester.
1) Before using a circuit tester, refer to the
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object Wind a Piece of Wire Tester Probe
to be measured, voltage range and current
polarity.
2) Before starting the connector test, always
check the connector terminal numbers,
Sharpen the end of the Wire
referring to the circuit diagram. T107-07-06-003
When the connector size is very small, and the
standard probe size is too large to be used for
testing, wind a fine piece of sharpened wire or
a pin around the probe to make the test easier.
T5-6-2
TROUBLESHOOTING / Electrical System Inspection
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
T5-6-3
TROUBLESHOOTING / Electrical System Inspection
FUSE INSPECTION
Cracks in a fuse are so fine that it is very difficult or NOTE: All terminals located along the lengthwise
impossible to find by visual inspection. Use a tester to centerline of the fuse box are connected to
correctly inspect fuse continuity by following the in- the power source, while terminals located
structions described below. away from the center of the fuse box are
connected to loads (accessories). There-
1. Turn Key Switch ON fore, test all fuses in the same method ex-
When the key switch is turned ON, current from cept for the glow plug relay circuit fuse.
key switch terminal M activates the battery relay Check the glow plug relay circuit fuse with
so that electric power is supplied to all circuits ex- the key switch turned to the ON position
cept the glow plug relay circuit. (Refer to the cir- then follow the procedure in step 3.
cuit diagram.)
2. Remove the fuse box cover. Set the tester voltage
to meet the circuit specification to be measured.
(Measurement Range: 0 to 30 V) 10 20
3. Ground the negative probe of the tester to the ve- 9 19
hicle frame. Touch the terminals located away
from the center of the fuse box with the positive 8 18
probe of the tester one at a time. When normal 7 17
continuity of a fuse is intact, the tester will indicate
20 to 25 volts (battery voltage). 6 16
5 15
4 14
3 13
2 12
1 11
M178-07-034
Fuse Fuse
Capacity Connected to Capacity Connected to
No. No.
1 5A Radio, Monitor ICX (Backup 11 20 A Work Light Relays 1 and 3
Power)
2 5A MC (Main Power) 12 10 A Wiper Relays (R7, R8, R9,
R10), Wiper Motor, Washer
Relay, Washer
3 10 A MC (EC Motor Power) 13 20 A Heater (Air Conditioner Unit)
4 10 A MC (Solenoid Valve Power) 14 5A Air Conditioner Unit
5 5A Travel Alarm 15 10 A Horn Relay
6 5A MC, ICX (Power ON Signal) 16 5A Radio
7 5A Switch Box 17 10 A Cigarette Lighter
8 10 A Lubricator 18 5A Room Light
9 10 A Optional 1 (Light, etc.) 19 10 A Auxiliary
10 5A Auto-Lubrication 20 5A QOS Controller, Glow Relay
T5-6-4
TROUBLESHOOTING / Electrical System Inspection
FUSIBLE LINK INSPECTION AND RE- Fusible Link
PLACEMENT
Inspection
Replacement
Normal Voltage: 26 to 28 V
T162-05-06-005
T5-6-5
TROUBLESHOOTING / Electrical System Inspection
HOW TO TROUBLESHOOT ALTERNATOR
MALFUNCTIONS
1. Stop the engine. Turn the key switch to the ON B Connector (L, R)
position. Confirm that the alternator indicator
comes on.
T5-6-6
TROUBLESHOOTING / Electrical System Inspection
CONTINUITY CHECK
Harness
Single-line continuity check A a
Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity
Ω
T5-6-7
TROUBLESHOOTING / Electrical System Inspection
VOLTAGE AND CURRENT MEASURE-
MENT
24-Volt Circuit
Start checking the circuit in order up to the loca-
tion to be measured from either power source or
actuator side. Thereby, the faulty location in the
circuit will be found.
Black Probe (Minus) of Tester : To ground to the vehi-
cle frame
Red Probe (Plus) of Tester : To touch the location
to be measured
Engine Key Switch Location to be Measured Specification
Power Source Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (2): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Battery Power 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (1) and Ground: Backup Current* 6 mA
Preheat Circuit
Stopped ON or START Between (6) and Ground: Key Switch 20 to 25 V
Stopped ON or START Between (7) and Ground: Glow Plug 20 to 25 V
Starting Circuit
Started START Between (8) and Ground: Key Switch 20 to 25 V
Started START Between (9) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (10) and Ground: Battery Relay (Switch) 20 to 25 V
Started START Between (11) and Ground: Starter (B) 20 to 25 V
Started START Between (12) and Ground: Starter (C) 20 to 25 V
Started START Between (13) and Ground: Starter Relay (S) 20 to 25 V
Charging Circuit
Fast Speed ON Between (14) and Ground: Alternator Generating Voltage 26 to 30 V
(B)
Fast Speed ON Between (10) and Ground: Battery Relay / Generating 26 to 30 V
Voltage
Fast Speed ON Between (15) and Ground: Fuse Box / Generating Voltage 26 to 30 V
Fast Speed ON Between (16) and Ground: Generating Voltage 13 to 30 V
Fast Speed ON Between (17) and Ground: Monitor 13 to 30 V
Surge Voltage Pre-
vention Circuit
Slow Idling ON Between (14) and Ground: Alternator (B) 26 to 30 V
Slow Idling ON Between (16) and Ground: Starter Relay (R) 13 to 30 V
Slow Idling ON Between (18) and Ground: Load Damp Relay 26 to 30 V
Slow Idling ON Between (10) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (19) and Ground: Auxiliary 20 to 25 V
Stopped ON Between (20) and Ground: Room light 20 to 25 V
Stopped ON Between (21) and Ground: Cigar Lighter 20 to 25 V
Stopped ON Between (22) and Ground: Radio 20 to 25 V
Stopped ON Between (23) and Ground: Horn 20 to 25 V
Stopped ON Between (9) and Ground: Battery Relay 20 to 25 V
*Measure after disconnecting the negative cable from the battery.
T5-6-8
TROUBLESHOOTING / Electrical System Inspection
Key Switch
Battery
1 2 3 5 4 9
6 8
15
Battery Relay
Starter Fuse
B 10 Box
C
18 Load
11 Damp
B Relay
12
S
E
23 22 21 20 19 17
Starter Relay R
13
Alternator 16
Monitor
14 Glow
Plug
Relay
7
Glow Plug
T16J-05-06-002
T5-6-9
TROUBLESHOOTING / Electrical System Inspection
5 Voltage Circuit
Signal or
• Voltage between terminal No.1 and the vehicle Two polarities Power source ground
frame (ground) 1 2
With the key switch turned OFF, disconnect the
sensor connector.
Measure the voltage between terminal No.1 on the
machine harness side connector and the vehicle
(ground) under the following conditions.
V
• Key switch position: ON
• Tester black terminal (negative):
Connected to the vehicle (ground)
• Tester red terminal (positive):
T107-07-05-006
Connected to terminal No.1
Three polarities Power source Signal Ground
Evaluation: 1 2 3
If the measuring voltage is within 5±0.5 volts, the
circuit up to terminal No.1 is normal.
terminal
With the key switch turned OFF, disconnect the Two polarities
1 2
sensor connector.
Measure the voltage between terminal No.1 on the
machine harness side connector and the ground
terminal (terminal No.2 for two polarities, or terminal
No.3 for three polarities) under the following V
conditions.
T107-07-05-009
T5-6-10
TROUBLESHOOTING / Electrical System Inspection
CHECK BY FALSE SIGNAL
Tow-Polarities
Turn the key switch OFF. After disconnecting the sen- (Oil Temperature)
sor connector, turn the key switch ON. Then, connect (N Sensor)
1 2
machine side harness end connector terminal #1
(power) to terminal #2 (signal). (Power voltage is used
as a false signal.) Check the controller using Dr. EX
monitor function under this condition. When the maxi-
mum value is displayed, the MC and the circuit up to
the machine side harness end connector are normal.
When the pressure switch circuits are normal, Dr. EX Connect
displays “ON.”
Connect
T107-07-05-011
T5-6-11
TROUBLESHOOTING / Electrical System Inspection
TEST HARNESS
1 2 2 1
• EC Motor Circuit
When the engine control dial is rotated:
Both lamps ON: Normal 5
Only one lamp ON: Check for continuity of the cir- 6
cuit connected to the lamp OFF. 50
Both lamps OFF: Check the harness together with 1 2 2 1
150 50
the relay. 50
4 3 4 3
7 50
8
Parts Number 4284347 (ST 7129) Parts Number 4274589 (ST 7125)
T107-07-06-024
Use to measure the EC sensor or pump displacement
sensor circuit signal line voltage (between terminals #2
and #3).
(Red)
(Black)
T5-6-12
TROUBLESHOOTING / Electrical System Inspection
Parts Number (ST 7227)
Use to check the wiper circuit.
2
5 1
2 4 7
1
T5-6-13
TROUBLESHOOTING / Electrical System Inspection
(Blank)
T5-6-14
TROUBLESHOOTING / ICX
OUTLINE
T5-7-1
TROUBLESHOOTING / ICX
Daily Report Data List
Data Details
1 Key Switch ON Time Time when key switch is first turned ON during daily opera-
tion
(Time is recorded by key switch ON signal.)
2 Key Switch OFF Time Time when key switch is last turned OFF during daily opera-
tion
(Time is recorded by key switch ON signal.)
3 Engine Start Time Time when engine is first started during daily operation
(Time is recorded by alternator output signal.)
4 Engine Stop Time Time when engine is last stopped during daily operation
(Time is recorded by alternator output signal.)
5 Hour Meter Hour meter cumulative hours
(Hours are recorded by hour meter signal from monitor.)
6 Engine Operating Hours Total engine operating hours during daily operation
(Hours are recorded by alternator output signal.)
7 Swing Operating Hours Total swing operating hours during daily operation
(Hours are recorded by signals from swing pressure sen-
sor.)
8 Travel Operating Hours Total travel operating hours during daily operation
(Hours are recorded by signals from travel pressure sen-
sor.)
9 Front Attachment Operating Hours Total front attachment operating hours during daily opera-
tion
(Hours are recorded by signals from front attachment pres-
sure sensor.)
10 Breaker Operating Hours Total breaker operating hours during daily operation
Breaker Mode 1 : (Hours are recorded by signals from auxiliary pressure sen-
sor and attachment mode switch.)
11 Breaker operating Hours Total breaker operating hours during daily operation
Breaker Mode 2: (Hours are recorded by signals from auxiliary pressure sen-
Breaker Mode 3: sor and attachment mode switch.)
12 Engine Operating Hour Distribution Engine operating hour distribution during daily operation
(Operating hours are recorded only when alternator output
signal is continuously delivered for more than 10 minutes.)
T5-7-2
TROUBLESHOOTING / ICX
Frequency Distribution Data List
Data Details
1 Engine Speeds Frequency distribution of engine speeds
(Speeds are recorded by signals from N sensor.)
2 Hydraulic Oil Temperature Frequency distribution of hydraulic oil temperature
(Temperatures are recorded by signals from oil tempera-
ture sensor.)
3 Coolant Temperature in Radiator Frequency distribution of coolant temperature
(Temperatures are recorded by signals from coolant tem-
perature sensor.)
4 Average Pump Delivery Pressure Frequency distribution of average delivery pressure from
pumps 1 and 2
(Average pressures are recorded by signals from delivery
pressure sensors of pumps 1 and 2.)
5 Average Pump Delivery Pressure in Digging Frequency distribution of average delivery pressure from
Operation pumps during digging operation
(Average pressures are recorded by signals from arm roll-
in pressure sensor.)
6 Average Pump Delivery Pressure in Travel Frequency distribution of average delivery pressure from
Operation pumps during travel operation
(Average pressures are recorded by signals from travel
pressure sensor.)
Data Details
1 Engine Operation Hour Cumulative engine operation hours
(Hours are recorded by alternator output signal.)
2 Swing Operation Hour Cumulative swing operation hours
(Hours are recorded by signals from swing pressure sen-
sor.)
3 Travel Operation Hour Cumulative travel operation hours
(Hours are recorded by signals from travel pressure sen-
sor.)
4 Front Attachment Operation Hour Cumulative front attachment operation hours
(Hours are recorded by signals from front attachment pres-
sure sensor.)
5 Breaker Operating Hours Total breaker operating hours during daily operation
Breaker Mode 1 : (Hours are recorded by signals from auxiliary pressure sen-
sor and attachment mode switch.)
6 Breaker operating Hours Total breaker operating hours during daily operation
Breaker Mode 2: (Hours are recorded by signals from auxiliary pressure sen-
Breaker Mode 3: sor and attachment mode switch.)
T5-7-3
TROUBLESHOOTING / ICX
Alarm List
T5-7-4
TROUBLESHOOTING / ICX
Trouble List
Fault
Trouble Details
Code
01 Abnormal EEPROM Occurrence time and date of fault code 01
02 Abnormal RAM Occurrence time and date of fault code 02
03 Abnormal A/D Conversion Occurrence time and date of fault code 03
04 Abnormal Sensor Voltage Occurrence time and date of fault code 04
05 Abnormal Engine Speed Occurrence time and date of fault code 05
06 Abnormal EC Sensor Occurrence time and date of fault code 06
07 Abnormal Engine Control Dial Occurrence time and date of fault code 07
10 Abnormal Pump 1 Delivery Pressure Occurrence time and date of fault code 10
11 Abnormal Pump 2 Delivery Pressure Occurrence time and date of fault code 11
12 Abnormal Pump 1 Control Pressure Occurrence time and date of fault code 12
13 Abnormal Pump 2 Control Pressure Occurrence time and date of fault code 13
14 Abnormal Swing Lever Stroke Occurrence time and date of fault code 14
15 Abnormal Boom Raise Lever Stroke Occurrence time and date of fault code 15
16 Abnormal Arm Roll-In Lever Stroke Occurrence time and date of fault code 16
17 Abnormal Bucket Roll-In Lever Stroke Occurrence time and date of fault code 17
18 Abnormal Travel Lever Stroke Occurrence time and date of fault code 18
19 Abnormal Oil Temperature Sensor Occurrence time and date of fault code 19
20 Abnormal Pump 1 Control Malfunction Occurrence time and date of fault code 20
21 Abnormal Pump 2 Control Malfunction Occurrence time and date of fault code 21
64 MC Communication Error Time and date when communication error between MC
and ICX occurred.
65 Monitor Communication Error Time and date when communication error between moni-
tor and ICX occurred.
66 Satellite Terminal Communication Error Time and date when communication error between satel-
lite terminal and ICX occurred.
T5-7-5
TROUBLESHOOTING / ICX
ICX FAULT CODE LIST
Fault
Trouble Remarks
Code
1 Abnormal Internal Ram In case of SAM error
2 Abnormal Flush Memory In case of SAM error
3 Abnormal Exterior In case of SAM error or read-write error
4 Abnormal EEPROM In case of SAM error
5 Overwritten Data Save Area In case data save area was overwritten.
6 Abnormal Time In case RTC data was other than figures.
7 MC Communication Timeout In case MC communication lasted for less than 100 ms.
8 Monitor Communication Timeout In case monitor communication didn’t last for more than
12 seconds.
9* MC Communication Timeout In case MC communication didn’t last for more than 20
seconds.
10 Satellite Terminal Communication Timeout In case satellite communication didn’t last for more than
20 seconds.
Fault
Trouble Remarks
Code
101 Satellite Terminal: Internal Error Abnormal EEPROM
102 Satellite Terminal: Internal Error Abnormal sent data
103 Satellite Terminal: Internal Error In case reception is difficult.
104 Satellite Terminal: Communication Error In case satellite communication cannot be accomplished.
105 Satellite Terminal: Internal Error In case sending retry over occurred or local loop back
test failed with power ON.
106 Satellite Terminal: Communication Error In case sending retry over occurred.
107 Satellite Terminal: Abnormal Harness In case reception data doesn’t match sending data.
T5-7-6
TROUBLESHOOTING / ICX
FAULT CODE 1 TO 6
FAULT CODE 7 TO 10
T5-7-7
TROUBLESHOOTING / ICX
SOME PARTS OF DATA IN DAILY REPORT,
FREQUENCY DISTRIBUTION, CUMULA-
TIVE OPERATION HOURS ARE NOT RE-
CORDED
Engine start and stop time, Engine operating hours (Daily report and cumu- Alternator
lative operation hour), Engine operating hour distribution
Hour meter Monitor controller
Remaining fuel level (detected at regular data sending time) Fuel level sensor
Travel operating hours (Daily report and cumulative operation hour), Aver- Travel pressure sensor
age pump delivery pressure distribution in travel operation
Front attachment operating hours (Daily report and cumulative operation Front attachment ⋅ swing pressure
hour) sensor
Swing operating hours (Daily report and cumulative operation hour) Swing pressure sensor
Average pump delivery pressure distribution in digging operation Arm roll-in pressure sensor
Breaker operating hours (Daily report and cumulative operation hour), Auxil- Auxiliary pressure sensor
iary attachment except for breaker operating hours (Daily report and cumu-
lative operation hour)
Distribution of average pump delivery pressure, average pump delivery Pump 1 delivery pressure sensor
pressure in digging operation and travel operation
Distribution of average pump delivery pressure, average pump delivery Pump 2 delivery pressure sensor
pressure in digging operation and travel operation
Engine speed distribution N sensor
Breaker operating hours (Daily report and cumulative operation hour) Attachment mode switch
Breaker operating hours (Daily report and cumulative operation hour) Auxiliary mode switch
T5-7-8
TROUBLESHOOTING / ICX
T5-7-9
TROUBLESHOOTING / ICX
TROUBLESHOOTING AND SETTING OF
ICX AND SATELLITE TERMINAL USING
DR.EX
T5-7-10
TROUBLESHOOTING / ICX
SATELLITE COMMUNICATION SYSTEM
GPS Antenna
The satellite communication system is used for the
maintenance of the machine by transmitting various
data of the machine regularly via a low earth orbit sat-
ellite.
T178-01-02-006
T5-7-11
TROUBLESHOOTING / ICX
On the machine equipped with the satellite communi-
cation system, the data are sent according to the con-
dition as follows:
T5-7-12
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-298-31-1162
PAGE NO.:
DATE: (Located at the bottom center in the page. If two or more
revisions are requested, use the comment column)
FAX:
REPLY:
ZAXIS 800 HYDRAULIC CIRCUIT DIAGRAM Authorized hitachi Dealer Use Only
Parts numbers on the drawing are provided only for reference purpose.
To order parts on the drawing, be sure to consult the Parts Catalog.
PRESSURE SENSOR
(SWING)
PRESSURE SENSOR
(TRAVEL)
PRESSURE SENSOR
(SWING+FRONT)
(ARM ROLL-IN)
(BACKET ROLL-IN)
(BOOM RAISE)
COMBINER
FLOW RATE
P1 PUMP
FLOW
SHOCKLESS
VALVE
FLOW RATE
RELEASE
P-BRAKE
SWING
P2 PUMP
PRESSURE SENSOR
(5-SPOOL)
PRESSURE SENSOR
(4 -SPOOL)
ANGLE SENSOR
PRESSURE SENSOR
(SWING)
PRESSURE SENSOR
(TRAVEL)
PRESSURE SENSOR
(SWING+FRONT)
(ARM ROLL-IN)
(BACKET ROLL-IN)
(BOOM RAISE)
COMBINER
FLOW RATE
P1 PUMP
FLOW
A B
SHOCKLESS
VALVE
PRESSURE SENSOR
B
FLOW RATE
RELEASE
P-BRAKE
C
SWING
P2 PUMP
PRESSURE SENSOR
(5-SPOOL)
PRESSURE SENSOR
(4 -SPOOL)
ANGLE SENSOR
CONTROLLER
CONNECTION SW
INTERIOR
ILLUMINATION INTERIOR ILLUMINATION
POW. ON POWER INPUT
SATELLITE / PC
POWER ON
REG INPUT
EC DIAL SIGNAL INPUT
MAIL SW
BATTERY 12Vx2 B S ACC(LOAD) EC DIAL SIGNAL INPUT(GND)
BATTERY RELAY LIQUID CRYSTAL
ALT(LOAD)
WIPER SIGNAL INPUT
BACK UP
A E WIPER SIGNAL INPUT
FUSIBLE LINK(75A) WIPER SIGNAL INPUT(GND)
LOAD DUMP
RELAY OVERHEAT
AIR FILTER
LIQUID CRYSTAL SWITCH
LIGHT
WIPER
HEATER
A/C OFF RELAY
HORN
RADIO
LIGHTER
ROOM LAMP
AUX.
GLOW RELAY
BACKUP
CONTROLLER
EC MOTOR
SOLENOID
TRAVEL ALARM
POWER ON
SW BOX
LUBRICATOR
AUTO LUB.
JOINT A LOW FILTER
STARTER INDICATOR RESET SW
GLOW SIGNAL
SAFETY RELAY
JOINT B DIGGING MODE SW WORK LIGHT
MONITOR(STD) CHARGE
AUX3
LIGHT 1
FUEL PUMP ENG. OIL LEVEL EXT DIGITAL GND
SPEAKER(R) COOLANT LEVEL EXT
AIR FILTER CLOG ALARM SW INPUT
CHARGE EXT
BREAKER WORK LIGHT SW INPUT
LOW FUEL EXT COOLANT TEMP (#4436537)
SPEAKER(L) DIGGING MODE LED GLOW EXT
WIPER OPTION POWER AUX2 SW INPUT
RADIO AUTO LUB ALARM ENG. OIL LEVEL SW(BUILT IN ENG)
BUILT-IN FUEL PUMP
PRESTISION MODE SW. ENG. OIL PRESS SW(BUILT-IN ENG)
PULL-UP
OVERHEAT SW #4371318
LIGHT RELAY 1 OUTPUT ENG. OIL LEVEL SW INPUT
RELAY CIRCUIT
LIGHT RELAY 2,3 OUTPUT COOLANT LEVEL SW INPUT
WIPER C RELAY OUTPUT AUTO IDLE SW INPUT AUTO IDLE
GLOW PLUG WIPER BM RELAY OUTPUT AUTO ACCEL SW INPUT AUTO ACCEL
WIPER A RELAY OUTPUT WASHER SW INPUT WASHER SW
CAB HARNESS
SLOW
BUZZER
FRONT WINDOW:ON HP/P/E MODE
LIGHT RELAY 2
WORK LIGHT (STD,HD CAB)
AUTO LUB
RELAY 1
BOOM LIGHT(R)
LIGHT RELAY 1
AUTO LUB
BOOM LIGHT(L)
(OPT.)
BOX EARTH
PRECTISION BOOM
MODE SW. MODE SW.
MOTION
SWING SIGNAL
LEARNING SW
HORN (L) QUICK IDLE SW.
ENG
NATURAL
VALVE
HEATER
CONTROLLER
BLOWER
MOTOR (MB) MAIN SOLENOID
BLOWER RESIST. (BLC) GND GND
BLOWER MAIN RELAY
COMP. CLUTCH RELAY
SHIELD
INSIDE TEM. SENSOR (THI)
FROST SENSOR (THI)
SOLAR RADIATION SENSOR MONITOR
PRESSURE SWITCH
WATER TEM.
SENSOR (THW)
A/C UNIT
PRIORITY
SWING
(5-SPOOL)(SB)
PRESSURE 2
CONTROL
LEVEL REGULATED
(4-SPOOL)(SA)
PRESSURE 1
CONTROL
LEVEL REGULATED
REMOVAL
C/W
DELIVERY A DELIVERY A
PRESS SENSOR 2 PRESS SENSOR 1
MODE
TRAVEL
MODE
BOOM
SOLENOID
PUMP 1
N
INSIDE OUTOSIDE SENSOR
EC PUMP 2 PUMP 1
AMBIENT SENSOR (5-SPOOL) (4-SPOOL)
SENSOR SOLENOID FRONT+ ARM BOOM BUCKET TRAVEL SWING
VALVE UNIT HYD. TEMP MOTOR PRESSURE SENSOR (HIGH) PRESSURE SENSOR (HIGH)
SENSOR SWING ROLL-IN RAISE
PRESSURE
SENSOR (LOW)
HEATER UNIT (OPTION) PRESSURE SENSOR (LOW) PRESSURE SENSOR (LOW)