EX1200 5D Troubleshooting

INTRODUCTION TO THE READER • This manual is written for an experienced technician

to provide technical information needed to maintain and repair this machine. • Be sure to thoroughly read this manual for correct product information and service procedures.

• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.): Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-29-832-7173 FAX: 81-29-831-1162

ADDITIONAL REFERENCES • Please refer to the materials listed below in addition to this manual.

• The Operator’s Manual • The Parts Catalog

• Operation Manual of the Engine • Parts Catalog of the Engine • Hitachi Training Material

MANUAL COMPOSITION • This manual consists of three portions: the Techni-

• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.

• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.

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

cal Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.

IN-01

INTRODUCTION PAGE NUMBER • Each page has a number, located on the center

lower part of the page, and each number contains the following information: Example : T 1-3-5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual

W: Workshop Manual

SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

•

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

• IMPORTANT:

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

•

IN-02

NOTE: Indicates supplementary technical information or know-how.

INTRODUCTION UNITS USED Example : 24.5 MPa (250 kgf/cm2, 3560 psi)

• SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units.

Quantity Length Volume

Weight Force Torque

To Convert From mm mm L L m3 kg N N N⋅m N⋅m

Into in ft US gal US qt yd3 lb kgf lbf kgf⋅m lbf⋅ft

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

Quantity

Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375

Pressure Power Temperature Velocity Flow rate

IN-03

To Convert From MPa MPa kW kW °C km/h min-1 L/min mL/rev

Into kgf/cm2 psi PS HP °F mph rpm US gpm cc/rev

Multiply By 10.197 145.0 1.360 1.341 °C×1.8+32 0.6214 1.0 0.2642 1.0

INTRODUCTION (Blank)

IN-04

SAFETY RECOGNIZE SAFETY INFORMATION • These are the SAFETY ALERT SYMBOLS. • When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.

• Follow recommended precautions and safe operating practices.

SA-688 001-E01A-0001

UNDERSTAND SIGNAL WORDS • On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.

• DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

• WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

• CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

• DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.

• Some safety signs don’t use any of the designated signal words above after the safety alert symbol are occasionally used on this machine.

• CAUTION also calls attention to safety messages in this manual.

• To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.

•

NOTE indicates an additional explanation for an element of information. 002-E01A-1223

SA-1

SA-1223

SAFETY FOLLOW SAFETY INSTRUCTIONS • Carefully read and follow all safety signs on the machine and all safety messages in this manual.

• Safety signs should be installed, maintained and replaced when necessary.

• If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).

SA-003

• Learn how to operate the machine and its controls correctly and safely.

• Allow only trained, qualified, authorized personnel to operate the machine.

• Keep your machine in proper working condition. • Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.

• The safety messages in this SAFETY chapter are in-

tended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine. 003-E01B-0003

PREPARE FOR EMERGENCIES • Be prepared if a fire starts or if an accident occurs. • Keep a first aid kit and fire extinguisher on hand. • Thoroughly read and understand the label attached on the fire extinguisher to use it properly.

• To ensure that a fire-extinguisher can be always used when necessary, check and service the fire-extinguisher at the recommended intervals as specified in the fire-extinguisher manual.

• Establish emergency procedure guidelines to cope with fires and accidents.

• Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.

004-E01A-0437

SA-2

SA-437

SAFETY WEAR PROTECTIVE CLOTHING • Wear close fitting clothing and safety equipment appropriate to the job.

You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances.

SA-438

• Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.

• Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.

005-E01A-0438

PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing.

• Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

SA-434 006-E01A-0434

INSPECT MACHINE • Inspect your machine carefully each day or shift by

walking around it before you start it to avoid personal injury.

• In the walk-around inspection, be sure to cover all points described in the “PRE-START INSPECTION” chapter in the operator’s manual.

007-E01A-0435

SA-3

SA-435

SAFETY GENERAL PRECAUTIONS FOR CAB • Before entering the cab, thoroughly remove all dirt and/or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident.

• Don’t leave parts and/or tools lying around the operator’s seat. Store them in their specified locations.

• Avoid storing transparent bottles in the cab. Don’t attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire.

• Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine.

• Keep all flammable objects and/or explosives away from the machine.

• After using the ashtray, always cover it to extinguish the match and/or tobacco.

• Don’t leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.

524-E01A-0000

SA-4

SAFETY USE HANDHOLDS AND STEPS • Falling is one of the major causes of personal injury. • When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.

• Do not use any controls as handholds. • Never jump on or off the machine. Never mount or dismount a moving machine.

• Be careful of slippery conditions on platforms, steps, SA-439

and handrails when leaving the machine.

008-E01A-0439

ADJUST THE OPERATOR’S SEAT • A poorly adjusted seat for either the operator or for the

work at hand may quickly fatigue the operator leading to misoperations.

• The seat should be adjusted whenever changing the operator for the machine.

• The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back.

• If not, move the seat forward or backward, and check again.

009-E01A-0378

SA-5

SA-378

SAFETY FASTEN YOUR SEAT BELT • If the machine should overturn, the operator may be-

come injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.

• Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine.

• Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident.

SA-237

• We recommend that the seat belt be replaced every three years regardless of its apparent condition. 010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY • Bystanders can be run over. • Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine.

• Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move.

• Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine. 011-E01A-0426

SA-6

SA-426

SAFETY OPERATE ONLY FROM OPERATOR’S SEAT • Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.

• Start the engine only from the operator’s seat. • NEVER start the engine while standing on the track or on ground.

• Do not start engine by shorting across starter terminals.

• Before starting the engine, confirm that all control lev-

SA-444

ers are in neutral. 012-E01B-0444

JUMP STARTING • Battery gas can explode, resulting in serious injury. • If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator's manual.

• The operator must be in the operator’s seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation.

• Never use a frozen battery.

SA-032

• Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine.

S013-E01A-0032

KEEP RIDERS OFF MACHINE • Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off the machine.

• Only allow the operator on the machine. Keep riders off.

• Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.

SA-379 014-E01B-0379

SA-7

SAFETY INVESTIGATE JOB SITE BEFOREHAND • When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.

• Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.

• Make a work plan. Use machines appropriate to the work and job site.

• Reinforce ground, edges, and road shoulders as nec-

SA-380

essary. Keep the machine well back from the edges of excavations and road shoulders.

• When working on an incline or on a road shoulder, employ a signal person as required.

• Confirm that your machine is equipped a FOPS cab before working in areas where the possibility of falling stones or debris exist.

• When the footing is weak, reinforce the ground before starting work.

• When working on frozen ground, be extremely alert. As ambient temperatures rise, footing becomes loose and slippery.

• Beware the possibility of fire when operating the machine near flammable objects such as dry grass. 015-E01A-0380

PROTECT AGAINST FALLING STONES AND DEBRIS • Confirm that your machine is FOPS cab equipped before working in areas where the possibility of falling stones or debris exist.

SA-490 015-E01A-0380

SA-8

SAFETY PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES • For jobs involving multiple numbers of machines, pro-

vide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

018-E01A-0481 SA-481

CONFIRM DIRECTION OF MACHINE TO BE DRIVEN • Incorrect travel pedal/lever operation may result in serious injury death.

• Before driving the machine, confirm the position of the undercarriage in relation to the operator’s position. If the travel motors are located in front of the cab, the machine will move in reverse when travel pedals/levers are operated to the front. SA-491 017-E01A-0491

SA-9

SAFETY DRIVE MACHINE SAFELY • Before driving the machine, always confirm that the

travel levers/pedals direction corresponds to the direction you wish to drive.

• Be sure to detour around any obstructions. • Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Don’t allow personnel to stay around the machine while traveling. SA-387

• Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.

• When driving up or down a slope, keep the bucket facing the direction of travel, approximately 0.5 to 1.0 m (A) above the ground.

• If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.

SA-388

SA-441

• Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

SA-589

019-E01C-0492

SA-10

SAFETY AVOID INJURY FROM ROLLAWAY ACCI-DENTS • Death or serious injury may result if you attempt to mount or stop a moving machine.

To avoid rollaways: • Select level ground when possible to park machine.

• Do not park the machine on a grade. • Lower the bucket and/or other work tools to the ground.

• Turn the auto-idle switch and the H/P mode switch off.

SA-391

• 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-E02A-0493

SA-11

SAFETY AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS • If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death.

To avoid back-over and swing accidents: • Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR.

• Keep the travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE.

SA-383

• USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. Use hand signals, which conform to your local regulations, when work conditions require a signal person.

• No machine motions shall be made unless signals are clearly understood by both signalman and operator.

• Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling.

• Keep windows, mirrors, and lights clean and in good condition.

• Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.

• Read and understand all operating instructions in the operator’s manual. 021-E01A-0494

SA-12

SA-384

SAFETY KEEP PERSON CLEAR FROM WORKING AREA • A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death.

• Keep all persons clear from the area of operation and machine movement.

• Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area.

SA-386 022-E01A-0386

NEVER POSITION BUCKET OVER ANYONE • Never lift, move, or swing bucket above anyone or a

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

023-E01A-0487

SA-487

AVOID UNDERCUTTING • In order to retreat from the edge of an excavation if the footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with the travel motors at the rear.

• If the footing starts to collapse and if retreat is not possible, do not panic. Often, the machine can be secured by lowering the front attachment, in such cases.

SA-488 024-E01A-0488

SA-13

SAFETY AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE --- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT

• The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death.

To avoid tipping:

SA-012

• Be extra careful before operating on a grade. • Prepare machine operating area flat. • Keep the bucket low to the ground and close to the machine.

• Reduce operating speeds to avoid tipping or slipping. • Avoid changing direction when traveling on grades. • NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable.

• Reduce swing speed as necessary when swinging loads.

SA-440

• Be careful when working on frozen ground. • Temperature increases will cause the ground to become soft and make ground travel unstable. 025-E01B-0495

NEVER UNDERCUT A HIGH BANK • The edges could collapse or a land slide could occur causing serious injury or death.

SA-489 026-E01A-0489

SA-14

SAFETY DIG WITH CAUTION • Accidental severing of underground cables or gas lines

may cause an explosion and/or fire, possibly resulting in serious injury or death.

• Before digging check the location of cables, gas lines, and water lines.

• Keep the minimum distance required, by law, from cables, gas lines, and water lines.

• If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.

SA-382

• Contact your local “diggers hot line” if available in your area , and/or the utility companies directly. Have them mark all underground utilities. 027-E01A-0382

OPERATE WITH CAUTION • If the front attachment or any other part of the machine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may result as well.

• Take care to avoid hitting overhead obstacles with the boom or arm.

028-E01A-0389

SA-389

AVOID POWER LINES • Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines.

• When operating near an electric line, NEVER move any part of the machine or load closer than 3 m plus twice the line insulator length.

• Check and comply with any local regulations that may apply.

• Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site. SA-381

029-E01A-0381

SA-15

SAFETY OBJECT HANDLING • If a lifted load should fall, any person nearby may be

struck by the falling load or may be crushed underneath it, resulting in serious injury or death.

• When using the machine for craning operations, be sure to comply with all local regulations.

• Do not use damaged chains or frayed cables, sables, slings, or ropes.

• Before craning, position the upperstructure with the travel motors at the rear.

SA-014

• Move the load slowly and carefully. Never move it suddenly.

• Keep all persons will away from the load. • Never move a load over a person’s head. • Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground.

• Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall.

030-E01A-0014

PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result.

• Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

• Keep bystanders away from the working area before striking any object.

031-E01A-0432

SA-16

SA-432

SAFETY PARK MACHINE SAFELY To avoid accidents: • Park machine on a level surface.

• Lower bucket to the ground. • Turn auto-idle switch 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 posi-

SA-390

tion.

• Close windows, roof vent, and cab door. • Lock all access doors and compartments.

033-E08B-0390

HANDLE FLUIDS SAFELY－AVOID FIRES • Handle fuel with care; it is highly flammable. If fuel ig-

nites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.

• Do not refuel the machine while smoking or when near open flame or sparks.

• Always stop the engine before refueling the machine. • Fill the fuel tank outdoors. • All fuels, most lubricants, and some coolants are flammable.

SA-018

• Store flammable fluids well away from fire hazards. • Do not incinerate or puncture pressurized containers. • Do not store oily rags; they can ignite and burn spontaneously.

• Securely tighten the fuel and oil filler cap.

SA-019 034-E01A-0496

SA-17

SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: • Understand service procedures before doing work.

• Keep the work area clean and dry. • Do not spray water or steam inside cab. • Never lubricate or service the machine while it is moving.

• Keep hands, feet and clothing away from power-driven parts. Before servicing the machine: 1. Park the machine on a level surface. SA-028

2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. 4. Run the engine at slow idle speed without load for 5 minutes. 5. Turn the key switch to OFF to stop engine. 6. Relieve the pressure in the hydraulic system by moving the control levers several times. 7. Remove the key from the switch. 8. Attach a “Do Not Operate” tag on the control lever. 9. Pull the pilot control shut-off lever to the LOCK position. 10. Allow the engine to cool.

• If a maintenance procedure must be performed with the engine running, do not leave machine unattended.

• If the machine must be raised, maintain a 90 to 110° angle between the boom and arm. Securely support any machine elements that must be raised for service work.

• Never work under a machine raised by the boom. • Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter of this manual.

• Keep all parts in good condition and properly installed.

• Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

• When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces.

• Disconnect battery ground cable(–) before making adjustments to electrical systems or before performing welding on the machine. 500-E02B-0497

SA-18

SA-527

SAFETY • Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.

• Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

SA-037

WARN OTHERS OF SERVICE WORK • Unexpected machine movement can cause serious injury.

• Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever. This tag is available from your authorized dealer.

501-E01A-0287 SS2045102

SUPPORT MACHINE PROPERLY • Never attempt to work on the machine without securing the machine first.

• Always lower the attachment to the ground before you work on the machine.

• If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.

SA-527

519-E01A-0527

STAY CLEAR OF MOVING PARTS • Entanglement in moving parts can cause serious injury. • To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

502-E01A-0026 SA-026

SA-19

SAFETY PREVENT PARTS FROM FLYING • Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in serious injury, blindness, or death.

• Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY.

• As pieces may fly off, be sure to keep body and face away from valve.

• Travel reduction gears are under pressure.

SA-344

• As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury. GEAR OIL is hot.

• Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure. 503-E01B-0344

STORE ATTACHMENTS SAFELY • Stored attachments such as buckets, hydraulic ham-

mers, and blades can fall and cause serious injury or death.

• Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.

SA-034 504-E01A-0034

SA-20

SAFETY PREVENT BURNS Hot spraying fluids:

• After operation, engine coolant is hot and under pres-

sure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns.

• To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap.

SA-039

• The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap. Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become hot

during operation. The engine, hoses, lines and other parts become hot as well.

• Wait for the oil and components to cool before starting

SA-225

any maintenance or inspection work. 505-E01B-0498

REPLACE RUBBER HOSES PERIODICALLY • Rubber hoses that contain flammable fluids under pres-

sure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.

• Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual).

• Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.

S506-E01A-0019

SA-21

SA-019

SAFETY AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death.

• Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.

• Tighten all connections before applying pressure. • Search for leaks with a piece of cardboard; take care

SA-031

to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.

• If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

SA-292

507-E03A-0499

SA-22

SA-044

SAFETY PREVENT FIRES Check for Oil Leaks: • Fuel, hydraulic oil and lubricant leaks can lead to fires.

• Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.

• Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.

• Do not bend or strike high-pressure lines.

SA-019

• Never install bent or damaged lines, pipes or hoses. Check for Shorts: • Short circuits can cause fires.

• Clean and tighten all electrical connections. • Check before each shift or after eight (8) to ten (10) hours operation for loose, kinked, hardened or frayed electrical cables and wires.

• Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal caps.

• DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.. Clean up Flammables: • Spilled fuel, oil, antifreeze fluid and window washer fluid, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires.

• Prevent fires by inspecting and cleaning the machine daily, and by removing spilled or accumulated flammables immediately. Check Key Switch: • If fire breaks out, failure to stop the engine will escalate fire, hampering fire fighting. Always check key switch function before operating the machine every day: 1. Start the engine and run it at slow idle. 2. Turn the key switch to the OFF position to confirm that the engine stops.

• If any abnormalities are found, be sure to repair them before operating the machine.

508-E02B-0019

SA-23

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 pressurized air inside the hydraulic oil tank is released (a hissing sound should be heard).

• If any abnormalities are found, be sure to repair them before operating the machine. Check Heat Shields: • Damaged or missing heat shield may lead to fires. • Damaged or missing heat shields must be repaired or replaced before operating the machine. 508-E02A-0393

EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the following way:

• Stop the engine by turning the key switch to the OFF position if there is time.

• Use a fire extinguisher if there is time. • Exit the machine. • In an emergency, if the cab door or front window can not be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer the explanation pages on the Emergency Evacuation Method.

SA-393

518-E02B-0393

SS-1510

SA-24

SAFETY PRECAUTIONS FOR WELDING AND GRINDING • Welding may generate gas and/or small fires. • Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding.

• Only qualified personnel should perform welding. Never allow an unqualified person to perform welding.

• Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding. • After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.

SA-818

523-E01A-0818

BEWARE OF EXHAUST FUMES •

Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. • If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area. 509-E01A-0016

SA-25

SA-016

SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to yourself and bystanders.

• Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

• Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc..

SA-030

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS • Do not weld or flame cut pipes or tubes that contain flammable fluids.

• Clean them thoroughly with nonflammable solvent before welding or flame cutting them. 510-E01B-0030

REMOVE PAINT BEFORE WELDING OR HEATING • Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.

• Avoid potentially toxic fumes and dust. • Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly. SA-029

• Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. 2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. 511-E01A-0029

SA-26

SAFETY PREVENT BATTERY EXPLOSIONS • Battery gas can explode. • Keep sparks, lighted matches, and flame away from the top of battery.

• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

• Do not charge a frozen battery; it may explode. Warm the battery to 16 °C (60 °F) first.

• Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result.

SA-032

• Loose terminals may produce sparks. Securely tighten all terminals.

• Battery electrolyte is poisonous. If the battery should

explode battery electrolyte may be splashed into eyes, possibly resulting in blindness.

• Be sure to wear eye protection when checking electrolyte specific gravity.

512-E01B-0032

SERVICE AIR CONDITIONING SYSTEM SAFELY • If spilled onto skin, refrigerant may cause a cold contact burn.

• Refer to the freon container for proper use when servicing the air conditioning system.

• Use a recovery and recycling system to avoid venting freon into the atmosphere.

• Never let the freon stream make contact with the skin. SA-405 513-E01A-0405

SA-27

SAFETY HANDLE CHEMICAL PRODUCTS SAFELY • Direct exposure to hazardous chemicals can cause se-

rious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

• Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment.

SA-309

• See your authorized dealer for MSDS’s (available only in English) on chemical products used with your machine. 515-E01A-0309

DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the envi-

ronment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.

• Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

• Do not pour waste onto the ground, down a drain, or into any water source.

• Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

• Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.

516-E01A-0226

SA-28

SA-226

SECTION AND GROUP CONTENTS

TECHNICAL MANUAL (Troubleshooting)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group Group Group Group Group

1 2 3 4 5

Introduction Standard Engine Test Excavator Test Component Test

SECTION 5 TROUBLESHOOTING Group Group Group Group Group Group Group Group

1 General 2 Cross Reference Table 3 Component Layout 4 Troubleshooting A 5 Troubleshooting B 6 Troubleshooting C 7 Troubleshooting D 8 Electrical System Inspection

TECHNICAL MANUAL (Operational Principle) SECTION 1 GENERAL Group 1 Specification Group 2 Component Layout SECTION 2 SYSTEM Group 1 Control System Group 2 Hydraulic System Group 3 Electrical System All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

COPYRIGHT(C)2006 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved

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

WORKSHOP MANUAL SECTION 1 GENERAL INFORMATION Group 1 Precautions for Disassembling and Assembling Group 2 Tightening Torque SECTION 2 UPPERSTRUCTURE Group 1 Cab Group 2 Counterweight Group 3 Pump Device Group 4 Control Valve Group 5 Swing Device Group 6 Pilot Valve Group 7 Pilot Shut-Off Valve Group 8 Shockless Valve Group 9 Solenoid Valve Group 10 Signal Control Valve Group 11 Oil Cooler Fan Motor

SECTION 3 UNDERCARRIAGE Group 1 Swing Bearing Group 2 Travel Device Group 3 Center Joint Group 4 Track Adjuster Group 5 Front Idler Group 6 Upper and Lower Roller Group 7 Track SECTION 4 FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder Group 3 Bushing and Point

SECTION 4

OPERATIONAL PERFORMANCE TEST CONTENTS Group 1 Introduction

Group 5 Component Test

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

Primary Pilot Pressure .............................. T4-5-1

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

Secondary Pilot Pressure ......................... T4-5-3 Solenoid Valve Set Pressure..................... T4-5-4

Group 2 Standard

Main Pump Delivery Pressure................... T4-5-7

Operational Performance Standard .......... T4-2-1

Main Relief Valve Set Pressure................. T4-5-8

Main Pump P-Q Diagram.......................... T4-2-4

Overload Relief Valve Set Pressure ........ T4-5-12

Oil Cooler Fan Motor Drive Pump

Main Pump Flow Rate Measurement ...... T4-5-16

P-Q Diagram........................................... T4-2-4

Oil Cooler Fan Motor Drive Pump Flow Rate Measurement ....................... T4-5-22

Group 3 Engine Test

Swing Motor Drainage ............................ T4-5-28

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

Travel Motor Drainage ............................ T4-5-30

Group 4 Excavator Test Travel Speed ............................................ T4-4-1 Track Revolution Speed............................ T4-4-2 Mistrack .................................................... T4-4-3 Travel Parking Function............................ T4-4-4 Swing Speed ............................................ T4-4-5 Swing Function Drift ................................. T4-4-6 Swing Motor Leakage ............................... T4-4-8 Maximum Swingable Slant Angle.............. T4-4-9 Swing Bearing Play ................................ T4-4-10 Hydraulic Cylinder Cycle Time................ T4-4-12 Cylinder Drift........................................... T4-4-14 Control Lever Operating Force ............... T4-4-15 Control Lever Stroke............................... T4-4-16 Boom Raise/Swing Combined Operation Check................................... T4-4-17

18ET-4-1

(Blank)

18ET-4-2

OPERATIONAL PERFORMANCE TEST / Introduction OPERATIONAL PERFORMANCE TESTS Use operational performance test procedure to quantitatively check all system and functions on the machine. Purpose of Performance Tests 1. To comprehensively evaluate each operational function by comparing the performance test data with the standard values. 2. According to the evaluation results, repair, adjust, or replace parts or components as necessary to restore the machine’s performance to the desired standard. 3. To economically operate the machine under optimal conditions. Kinds of Tests 1. Base machine performance test is to check the operational performance of each system such as engine, travel, swing, and hydraulic cylinders. 2. Hydraulic component unit test is to check the operational performance of each component such as hydraulic pump, motor, and various kinds of valves. Performance Standards “Performance Standard” is shown in tables to evaluate the performance test data. Precautions for Evaluation of Test Data 1. To evaluate not only that the test data are correct, but also in what range the test data are. 2. Be sure to evaluate the test data based on the machine operation hours, kinds and state of work loads, and machine maintenance conditions. The machine performance does not always deteriorate as the working hours increase. However, the machine performance is normally considered to reduce in proportion to the increase of the operation hours. Accordingly, restoring the machine performance by repair, adjustment, or replacement shall consider the number of the machine’s working hours. Definition of “Performance Standard” 1. Operation speed values and dimensions of the new machine. 2. Operational performance of new components adjusted to specifications. Allowable errors will be indicated as necessary.

T4-1-1

OPERATIONAL PERFORMANCE TEST / Introduction PREPARATION TESTS

FOR

PERFORMANCE

Observe the following rules in order to carry out performance tests accurately and safely. THE MACHINE 1. Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test. TEST AREA 1. Select a hard and flat surface. 2. Secure enough space to allow the machine to run straight more than 20 m (65 ft 7 in), and to make a full swing with the front attachment extended. 3. If required, rope off the test area and provide signboards to keep unauthorized personnel away. PRECAUTIONS 1. Before starting to test, agree upon the signals to be employed for communication among coworkers. Once the test is started, be sure to communicate with each other using these signals, and to follow them without fail. 2. Operate the machine carefully and always give first priority to safety. 3. While testing, always take care to avoid accidents due to landslides or contact with high-voltage power lines. Always confirm that there is sufficient space for full swings. 4. Avoid polluting the machine and the ground with leaking oil. Use oil pans to catch escaping oil. Pay special attention to this when removing hydraulic pipings. MAKE PRECISE MEASUREMENT 1. Accurately calibrate test instruments in advance to obtain correct data. 2. Carry out tests under the exact test conditions prescribed for each test item. 3. Repeat the same test and confirm that the test data obtained can be produced repeatedly. Use mean values of measurements if necessary.

T4-1-2

T105-06-01-003

T105-06-01-004

OPERATIONAL PERFORMANCE TEST / Standard OPERATIONAL DARD

PERFORMANCE

STAN-

The standard performance values are listen in the table below. Refer to the Groups 3 to 5 for performance test procedures. Values indicated in parentheses are reference values. The fuel lever shall be placed in the fast idle position and the hydraulic oil temperature is to be maintained at 50 ± 5 °C (122 ± 9 °F) unless otherwise specified. EX1200-5C (Standard Performance)

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

min

Refer to T4-3-1

-1

1850±50 850±50 1400±100 850±50 Refer to T4-4-1

sec /20 m

21.3±1.6 30.5±2.0 Refer to T4-4-2

sec /3 rev

42.0±4.0 61.0±4.0 mm /20 m mm /5 min sec /3 rev

200 or less 0 30.0±2.0

mm /180°

mm /5 min

1100 or less  0

deg

(Backhoe)

Refer to T4-4-3 Refer to T4-4-4 Refer to T4-4-5 Refer to T4-4-6

Refer to T4-4-8 Refer to T4-4-9

12 or possibly more 10 or possibly more

(Loading Shovel) SWING BEARING PLAY

Remarks

mm

2.0 or less

Allowable Limit: 6.3, Refer to T4-4-10

NOTE: BH: Backhoe: With 5.0 m3 (PCSA heaped) Bucket, 3.4 m Arm, 9.1 Boom LD: Loading Shovel: With 6.5 m3 Bucket

T4-2-1

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

Performance Test CYLINDER CYCLE TIME (Backhoe) Boom Raise Boom Lower Arm Roll-In Arm Roll-Out Bucket Roll-In Bucket Roll-Out (Loading Shovel) Boom Raise Boom Lower Arm Extend Arm Retract Bucket Tilt-In Bucket Tilt-Out Bucket Open Bucket Close DIG FUNCTION DRIFT (Backhoe) Boom Cylinder Arm Cylinder Bucket Cylinder Bucket Bottom (Loading Shovel) Boom Cylinder Arm Cylinder Bucket Cylinder Bucket Bottom CONTROL LEVER OPERATING FORCE (HITACHI Control Pattern) Boom Lever

Remarks Refer to T4-4-12

sec

4.3±0.5 3.1±0.5 4.5±0.5 3.5±0.5 3.0±0.5 2.3±0.5

BE: 4.5±0.5 BE: 3.3±0.5 BE: 4.5±0.5 BE: 4.0±0.5 BE: 3.3±0.5 BE: 2.7±0.5

5.5±0.5 4.0±0.5 2.9±0.5 2.5±0.5 3.3±0.5 2.2±0.5 1.1±0.5 1.6±0.5 Refer to T4-4-14

mm/5 min

20 or less 20 or less 30 or less 300 or less

BE: 30 or less BE: 30 or less BE: 30 or less BE: 400 or less

20 or less 20 or less 30 or less 300 or less Refer to T4-4-15 N (kgf)

Arm Lever (LD: Extend/Retract) Arm Lever (BH: Roll-in/Roll-out) Bucket Lever (*Roll-In/**Roll-Out) Swing Lever (Right/Left)

Travel Lever

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

ISO Control Pattern: Swing Lever (Right/Left) ISO Control Pattern: Swing Lever (Right/Left)

19.7 (2.0) or less

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

24.5 (2.5) or less

Bucket Open/Close Pedal NOTE: * In the case of loading shovel specification, the operation is bucket tilt-in **In the case of loading shovel specification, the operation is bucket tilt-out

BH: Backhoe: with 5.0 m3 (PCSA heaped) Bucket, 3.4 m Arm, 9.1 m Boom LD: Loading Shovel: with 6.5 m3 Bucket

T4-2-2

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

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

Refer to T4-4-16

mm

105±10 83±10

Bucket Lever Swing Lever

ISO Control Pattern: Swing Lever

83±10 105±10

Travel Lever Bucket Open/Close Pedal BOOM RAISE/SWING COMBINED OPERATION (with Empty Bucket) Time sec/90° Bucket Tooth Tip Height (H) from Ground mm 2 HYDRAULIC COMPONENT MPa (kgf/cm ) PRIMARY PILOT PRESSURE: Fast Idle Slow Idle SECONDARY PILOT PRESSURE 2 SOLENOID VALVE SET PRESSURE MPa (kgf/cm ) Travel Mode Solenoid Valve Flow Rate Reducing Solenoid Valve Power Decrease Solenoid Valve Power Increase Solenoid Valve Oil Cooler Fan Control Solenoid Valve 2 MAIN PUMP DELIVERY PRESSURE MPa (kgf/cm ) 2 MAIN RELIEF PRESSURE MPa (kgf/cm ) Boom, Arm, Bucket, and Bucket Open (LD)

ISO Control Pattern: Arm Lever

115±10 5.5±0.6 7300 or more 4.9±0.5 (50±5) 3.9±0.5 (40±5) 3.6 (37) or less

BH (5.5±0.6: LD), Refer to T4-4-17 BH (7500 or more: LD) Refer to T4-5-1 Refer to T4-5-2 Refer to T4-5-3

3.6 (37) or less 3.6 (37) or less 3.6 (37) or less 0 to 2.7 (0 to 27) 0 to 1.36 (0 to 13.9)

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

Remarks

Refer to T4-5-8 31.5±1.0 (320±10) 33.3±1.0 (340±10) 29.4±1.0 (300±10) 29.4±1 (300±10)

2

MPa (kgf/cm )

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

T4-2-3

34.3＋1.0-0 (350＋10-0) 33.3＋1.0-0 (340＋10-0) 17.7＋1.0-0 (180＋10-0) − − 2 or less 5 or less

Refer to T4-5-12

Refer to T4-2-4, T4-5-16 Refer to T4-2-4, T4-5-22 Allowable Limit: 4, Refer to T4-5-28 Allowable Limit: 10, Refer to T4-5-30

OPERATIONAL PERFORMANCE TEST / Standard MAIN PUMP P-Q DIAGRAM

OIL COOLER FAN MOTOR DRIVE PUMP P-Q DIAGRAM

• Hydraulic P-Q Control • Rated Pump Speed: 1787 min-1 (rpm) • Pump Gear Reduction Ratio: 1.083 • Hydraulic Oil Temperature: 50±5 °C (122±9 °F)

• Hydraulic P-Q Control • Rated Pump Speed: 1825 min-1 (rpm) • Pump Gear Reduction Ratio: 1.106 • Hydraulic Oil Temperature: 50±5 °C (122±9 °F)

NOTE: Refer to T4-5-17. NOTE: Refer to T4-5-23. Main Pump P-Q Diagram Q L/min (US gal/min) A 490 (129) B 312 (82) C 107 (28) D 485 (128) E 307 (81) F 151 (40) G 477 (126) H 299 (79) I 220 (58)

P MPa (kgf/cm2, psi) 8.4 (86, 1218) 15.7 (160, 2276) 33.3 (340, 4828) 12.6 (128, 1827) 19.9 (203,2885) 33.3 (340, 4828) 19.2 (196, 2784) 26.5 (270, 3842) 33.3 (340, 4828)

Q (Flow Rate) L/min

Oil Cooler Fan Motor Drive Pump P-Q Diagram Q P L/min (US gal/min) MPa (kgf/cm2, psi) A 100 (26) 4.9 (50, 710) B 97 (25) 18.8±0.5 (192±5, 2726±72.5) C 82 (21) 21.6 (220, 3132)

Q (Flow Rate) L/min

600 A

500

D

600

G SP Mode Control (Pz) = 3.30 MPa

500

400 400 300 200

B

E

H 300

E Mode Control (PG) = 2.08 MPa

I F C

100

200 100

0

5

10

15

20

25

30

P (Pressure) MPa T183-04-04-005

0

A

B C

5

10

15

20

25

30

P (Pressure) MPa T183-04-04-017

T4-2-4

OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE SPEED Summary: 1. Measure engine speed by using the on-board diagnostic system (Refer to the TROUBLESHOOTING / General group) or a pulse meter. 2. Measure the engine speeds in each mode. NOTE: Unless engine speed is correctly adjusted, all performance test results will be inaccurate. Therefore, check engine speed setting before performing any tests. Test Condition: Hydraulic Oil Temperature: 50±5 °C (122±9 °F) Ground Conditions: Solid and level surface Measurement: 1. Stop the engine. Turn the key switch OFF. 2. As for the pulse meter, remove the connector from the engine speed sensor. Install the pulse meter. 3. Start the engine. Measure the maximum and minimum engine speeds. As for the pulse meter, read the pulse of engine speed sensor and calculate the engine speed by using the following formula. Engine speed=Pulse value×60/138 (min-1) Evaluation: Refer to T4-2 Operational Performance Standard.

T4-3-1

OPERATIONAL PERFORMANCE TEST / Engine Test (Blank)

T4-3-2

OPERATIONAL PERFORMANCE TEST / Excavator Test TRAVEL SPEED Summary: 1. Check the overall operational performance of the travel power system (between the hydraulic pumps and travel motors) by measuring time required for the machine to travel the specified distance. Preparation: 1. Equally adjust the track sag on both right and left undercarriages. 2. Prepare a flat and firm travel test yard 20 m (65.5 ft) long with fringes 3 to 5 m (9.8 to 16 ft) on both ends for machine acceleration and deceleration. 3. Empty the bucket and roll in the arm. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Deceleration Zone 3 to 5 m

Finish

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

Travel Test Distance 20 m

Measurement: 1. Measure travel time at both fast and slow travel speeds. 2. Engine Control Dial : Maximum Position 3. Start machine to travel from the rear end of the acceleration zone by moving the travel levers full stroke. 4. Measure the time required to travel the travel test distance 20 m (65.5 ft). 5. After measuring the forward travel time, rotate the machine upperstructure 180°. Then, measure the reverse travel time on the way back to the starting position in the same method. 6. Repeat steps (4) and (5) three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard. Remedy: Refer to the T5-5 Troubleshooting B.

T4-4-1

T145-05-03-001

Start

Acceleration Zone 3 to 5 m

T142-05-03-001

T145-05-03-005

OPERATIONAL PERFORMANCE TEST / Excavator Test TRACK REVOLUTION SPEED Summary: 1. Check the overall operational performance of the travel power system (between the hydraulic pumps and travel motors) by measuring the track revolution cycle time. Preparation: 1. Equally adjust the track sag on both right and left undercarriages to 490 to 550 mm (19 to 22 in). 2. Mark one shoe with chalk or a piece of cloth on the track to be measured. 3. Rotate the upperstructure 90° to the track and lower the bucket to raise the track to be measured off the ground. Keep the boom and arm angle between 90 to 110° as illustrated. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

90 to 110°

T142-05-03-011

CAUTION: Never work under a machine raised and solely supported by the boom. Place blocks under the machine frame to support the machine. 90 to 110°

Measurement: 1. Measure the track rotation time at both fast and slow travel speeds. 2. Engine Control Dial : Maximum Position 3. Operate the travel control lever of the raised track in full forward and reverse. 4. After the track revolution attains to constant speed, measure the time required for the marked shoe to rotate three times in both directions. 5. Raise the other side of the track and repeat the procedure. 6. Repeat steps (3) and (4) three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard.

T142-05-03-012

Forward Reverse

T145-05-03-001

Remedy: Refer to the T5-5 Troubleshooting B.

T4-4-2

OPERATIONAL PERFORMANCE TEST / Excavator Test MISTRACK Summary: 1. Check the equilibrium in operational performance between the right and left travel power systems (between the hydraulic pumps and travel motors) by measuring the amount of mistrack found while the machine travels for the specified distance. NOTE: When tested on a concrete surface road, the amount of mistrack may be reduced. Preparation: 1. Equally adjust the track sag on both right and left undercarriages to 490 to 550 mm (19 to 22 in). 2. Prepare a flat and firm travel test yard 20 m (65.5 ft) long with fringes 3 to 5 m (9.8 to 16 ft) on both ends for machine acceleration and deceleration. 3. Set the front attachment in the driving position. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Measurement: 1. Measure the amount of mistracking in both fast and slow travel speeds. 2. Engine Control Dial : Maximum Position 3. Start machine to travel from the rear end of the acceleration zone by moving both travel levers full stroke. 4. Draw a 20 m (65.5 ft) straight line along the rut from the travel start point to the travel end point as illustrated. Measure the maximum distance between the rut and the straight line. 5. Conduct the measurement in both forward and reverse travel operation in the same method. 6. Repeat steps (4) and (5) three times and calculate the average values.

T145-05-03-005

T145-05-03-006

Deceleration Zone 3 to 5 m

Maximum Distance (A) 20 m

Acceleration Zone 3 to 5 m

Evaluation: Refer to T4-2 Operational Performance Standard.

T115-07-03-005

Remedy: Refer to the T5-5 Troubleshooting B.

T4-4-3

OPERATIONAL PERFORMANCE TEST / Excavator Test TRAVEL PARKING FUNCTION Summary: To measure the parking brake function on a specified slope. 0.5 to 1.0 m

Preparation: 1. The surface of the test slope shall be even with a gradient of 20 % (11.31). 2. Hold the bucket 0.5 to 1.0 m (20 to 39 in) above the ground with the arm and bucket fully rolled in. 3. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T142-05-03-002

Measurement: 1. Climb the slope and place the travel levers in neutral. 2. Stop the engine. 3. After the machine stops, put alignment marks on a track link or shoe, and the track side frame. 4. After 5 minutes, measure the distance between the marks on the track link or shoe and the track side frame. Evaluation: Refer to T4-2 Operational Performance Standard.

0.5 to 1.0 m

T118-04-03-001

Position where the machine comes to a stop.

Alignment marks on the track side frame and shoe when the machine comes to a stop. Displacement measured after 5 minutes. T105-06-03-006

T4-4-4

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING SPEED Summary: Check the overall operational performance of the swing power system (between the hydraulic pumps and swing motors) by measuring time required for the machine upperstructure to make three complete turns. Preparation: 1. Confirm that the swing gears and bearing are sufficiently greased. 2. Secure a space wide enough for the machine upperstructure to swing on a flat and firm surface. Never attempt to perform this test on a slope. 3. Empty the bucket and position the front attachment as described in the following. Backhoe: With the arm cylinders fully retracted and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. Loading shobel: With the arm cylinder fully extended and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. NOTE: In case it is difficult to secure the space wide enough, test the machine with the boom raised and the arm retracted. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T145-05-03-007

T145-05-03-008

CAUTION: Prevent personal injury. Always make sure that the area is clear and that coworkers are out of the swing area before starting the measurement. Measurement: 1. Engine Control Dial : Maximum Position 2. Auto-Idle Switch : OFF 3. Operate the swing control lever at full stroke. 4. After the swing attains to constant speed, measure the time required for the upperstructure to rotate three times. 5. Measure in both directions (clockwise and counterclockwise). 6. Repeat steps (3) and (5) three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard.

3 Revolutions

T145-05-03-009

Remedy: Refer to the T5-5 Troubleshooting B.

T4-4-5

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING FUNCTION DRIFT Summary: 1. Measure the swing drift on the swing bearing outer race circumference when stopping after a 180° full-speed swing. NOTE: The swing motor is equipped with a swing parking brake mechanical brake. Preparation: 1. Confirm that the swing gears and bearing are sufficiently greased. 2. Secure a space wide enough for the machine upperstructure to swing on a flat and firm surface. Never attempt to perform this test on a slope. 3. Empty the bucket and position the front attachment as described in the following. Backhoe: With the arm cylinders fully retracted and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. Loading shovel: With the arm cylinder fully extended and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. 4. Put aligning marks on the outer circumference of the swing bearing and the track frame. 5. Swing the upperstructure 180°. 6. Maintain the hydraulic oil temperature at 50±5 °C (122±9° F).

T4-4-6

T145-05-03-007

T145-05-03-008

OPERATIONAL PERFORMANCE TEST / Excavator Test CAUTION: Prevent personal injury. Always make sure that the area is clear and that coworkers are out of the swing area before starting the measurement. Measurement: 1. Engine Control Dial : Maximum Position Auto Idle Switch : OFF 2. Operate the swing lever full stroke. When the upperstructure rotates 180° back to the original position (when the marks on the swing bearing and track frame aligns with each other), return the swing lever to neutral. 3. After the upperstructure stops, measure the distance between the two marks along the outer circumference of the swing bearing. 4. Align the marks again. Then, measure in the opposite direction. 5. Repeat steps (2) to (4) three times and calculate the average values.

Return the swing control lever to the neutral position.

Drift Amount

Rotate 180°

Evaluation: Refer to T4-2 Operational Performance Standard. Start Rotation

Remedy: Refer to the T5-5 Troubleshooting B.

T142-05-03-003

T4-4-7

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING MOTOR LEAKAGE Summary: Check for upperstructure drift while suspending a load on a slope. Preparation: 1. Check the lubrication of the swing gear and swing bearing. 2. Park the machine on a smooth slope with a gradient of 26.8 % (15°). 3. Load bucket fully. In lieu of loading the bucket, weight (W: tons) of the following specification can be used. Backhoe: W=6000 kg (13200 lb) (Up to serial No. 2122) W=6600 kg (14500 lb) (Serial No. 2123 and later) Loading Shovel:W=9450 kg (20800 lb) 4. Backhoe: With the arm rolled out, and bucket rolled in, position the arm top pin height to be level with the boom foot pin. Apply a rated load to the bucket. Loading Shovel: With the arm cylinder and bucket cylinders fully extended, position the arm top pin flush with the boom foot pin height. 5. Swing the upperstructure to position it 90° to the slope. Make aligning marks on the swing bearing periphery and track frame using tape, as illustrated. 6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Stop the engine. After five minutes, measure the difference between the marks along the swing bearing periphery and the track frame. 2. Perform the measurement in both right and left swing directions. 3. Perform the measurement three times in each direction and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard. Remedy: Refer to the T5-5 Troubleshooting B.

T4-4-8

T142-05-03-004

Measure Difference Between Marks

Marking on the Track Frame Marking on the Swing Bearing T105-06-03-010

OPERATIONAL PERFORMANCE TEST / Excavator Test MAXIMUM SWINGABLE SLANT ANGLE Summary: With the upperstructure swung 90° to the slope, check the maximum slant angle on which the upperstructure can swing to the uphill side. Preparation: 1. Check that the swing gear and bearing are well lubricated. 2. Load bucket fully. In lieu of loading the bucket, weight (W: tons) of the following specification can be used. Backhoe: W=6000 kg (13200 lb) (Up to serial No. 2122) W=6600 kg (14500 lb) (Serial No. 2123 and later) Loading Shovel:W=9450 kg (20800 lb) 3. Backhoe: With the arm rolled out, and bucket rolled in, position the arm top pin height to be level with the boom foot pin. Apply a rated load to the bucket. Loading Shovel: With the arm cylinder and bucket cylinders fully extended, position the arm top pin flush with the boom foot pin height. 4. Climb a slope and swing the upperstructure 90° to the slope. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Engine Control Dial : Maximum Position Auto Idle Switch : OFF 2. Operate the swing lever to full stroke to swing the upperstructure to the uphill side. 3. If the machine can swing, measure the cab floor slant angle. 4. When the machine can swing, increase the slope angle and repeat steps (2 and 3). Check in both clockwise and counterclockwise directions. 5. Perform the measurement three times in each direction and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard. Remedy: Refer to the T5-5 Troubleshooting B.

T4-4-9

T142-05-03-004

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING BEARING PLAY Summary: Wear on the swing bearing races and rollers is checked by measuring the play between the outer and inner races of the swing bearing. Preparation: 1. Confirm that the swing bearing mounting bolts are securely tightened. 2. Confirm that the swing bearing is well lubricated and rotates smoothly with no noise. 3. Attach a dial gauge on the track frame using a magnet base. 4. Position the upperstructure so that the bucket faces toward the front idlers. 5. Position the dial gauge so that its needle point comes in contact with the bottom face of the swing bearing outer race. 6. Empty the bucket NOTE The measured value will vary depending on the location where the magnet base is secured. Secure the magnet base onto the round trunk or a location as close to the round trunk as possible.

T4-4-10

Dial Gauge

Round Trunk

Magnet Base T105-06-03-015

OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Take measurements of the play at positions A, B, C, and D. 2. Position the front attachment as described in the following. Backhoe: With the arm cylinders fully retracted and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. Loading shovel: With the arm cylinder fully extended and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. 3. Record the dial gauge reading (h1). Lower the bucket to the ground and use it to raise the front idler 0.5 m (20 in). Record the dial gauge reading (h2). 4. Calculate bearing play (H) from this data (h1 and h2) as follows: H=h2 － h1

A B

D C

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

T145-05-03-023

Evaluation: Refer to the Performance Standard Table in Group T4-2. Backhoe Measurement : (h1)

Measurement : (h2)

T142-05-03-006

Loading Shovel Measurement : (h1)

Measurement : (h2)

T142-05-03-005

T4-4-11

OPERATIONAL PERFORMANCE TEST / Excavator Test HYDRAULIC CYLINDER CYCLE TIME Summary: 1. Check the overall operational performance of the front attachment hydraulic system (between the hydraulic pumps and each cylinder) by measuring the cycle time of the boom, arm, bucket, and bucket dump (open/close) cylinders with the bucket emptied. Preparation: 1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). 2. Position the front attachment as described in the following. • Backhoe Boom Cylinder: With the bucket cylinder fully extended and the arm cylinder fully retracted, lower the bucket to the ground. Arm Cylinder: With the bucket cylinder fully extended while positioning the center line between the arm and bucket connection pin centers vertical with the arm cylinder extended half stroke. Bucket Cylinder: Adjust the boom and arm cylinder so that the center of full stroke movement of the bucket is positioned vertically. • Loading Shovel Boom Cylinder: With the bucket cylinder and the arm cylinder fully extended, lower the bucket to the ground. Arm Cylinder: With the arm fully retracted, position the bucket so that the rear bucket does not come in contact with the arm stopper. Then, adjust the boom cylinder stroke to position the bucket bottom 1 m (39 in) above the ground. Bucket Cylinder: With the bucket closed and held in a load dump position, adjust the boom cylinder stroke so that bucket bottom height is approx. 1 m (39 in) above the ground. Bucket Dump (Open-Close) Cylinder: With the bucket cylinder and arm cylinder fully extended, adjust the boom cylinder stroke so that the bucket bottom height approx. 1 m (39 in) above the ground.

Backhoe

Boom Cylinder

T145-05-03-012

Arm Cylinder T118-04-03-003

Bucket Cylinder T145-05-03-014

Loading Shovel

Boom Cylinder

T145-05-03-015

Arm Cylinder T145-05-03-016

Bucket Cylinder T145-05-03-017

Dump Cylinder

T145-05-03-018

T4-4-12

OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Select the following lever and switch positions: Engine Control Lever: Maximum Position Auto-Idle Switch: OFF 2. To measure cylinder cycle times: (Cylinder full stroke includes cylinder cushioning zone.) 2-1. Boom cylinders: Measure the time it takes to raise the boom, and the time it takes to lower the boom. To do so, position the boom at one stroke end, then move the control lever to the other stroke end as quickly as possible. 2-2. Arm cylinder: Measure the time it takes to roll in the arm, and the time it takes to roll out the arm. To do so, position the arm at one stroke end, then move the control lever to the other stroke end as quickly as possible. 2-3. Bucket cylinder: Measure the time it takes to roll in the bucket, and the time it takes to roll out the bucket. To do so, position the bucket at one stroke end, then move the control lever to the other stroke end as quickly as possible. 2-4. Bucket dump (Open-Close) cylinder: Mesure the time it takes to open the bucket, and the time it takes to close the bucket. To do so, position the bucket dump at one stroke end, then move the bucket open-close pedal to the other stroke end as quickly as possible. 3. Repeat the measurement three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard. NOTE: Backhoe front : 9.1 m (29 ft) Boom 3.4 m (11 ft) Arm 4.6 m3 (6.0 yd3) Bucket * 5.0 m3 (6.5 yd3) Bucket (PCSA heaped) Loading shovel front: 6.3 m3 (8.2 yd3) Bucket When the bucket weight is increased by welding wear-resist plates, cylinder cycle times may become slower. Remedy: Refer to the T5-5 Troubleshooting B.

T4-4-13

OPERATIONAL PERFORMANCE TEST / Excavator Test CYLINDER DRIFT Summary: 1. While holding the soil weight of or a specified weight in the bucket, the dig function drift is measured to check for internal oil leaks in the control valve, boom, arm, and bucket cylinders. 2. After replacing the hydraulic cylinders, slowly operate each cylinder for approx. 10 minutes to bleed air from the hydraulic circuit before starting the test. Preparation: 1. Load bucket fully. In lieu of loading the bucket, weight (W) of the following specification can be used. Backhoe: W=6000 kg (13200 lb)(Up to Serial No. 2122) W=6600 kg (14500 lb)(Serial No. 2123 and later) Loading Shovel: W=9450 kg (20800 lb) 2. Position the front attachment as described in the following. Backhoe: With the arm cylinder with rod approx.50 mm (2 in) extended from the fully retracted position, and bucket cylinder with the rod approx. 50 mm (2 in) retracted from the fully extended, position the arm top pin height flush with the boom foot pin height. Loading shovel: With the arm cylinder with the rod approx. 50 mm (2 in) retracted from the fully extended position, and bucket cylinder with the approx. 50 mm (2 in) retracted from the fully extended, position the arm top pin height flush with the boom foot pin height. 3. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T145-05-03-020

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

Mark

T110-06-03-002

BH: Arm Cylinder Extension

Mark

Measurement: 1. Stop the engine. 2. After five minutes have passed, measure the retractions of the boom, arm, and bucket cylinders as illustrated 3. Repeat step (2) three times and calculate the average values.

T110-06-03-001

NOTE: BH: Backhoe LD: Loading Shovel

Evaluation: Refer to T4-2 Operational Performance Standard. Solution: Refer to T5-5 Troubleshooting B.

T4-4-14

T145-05-03-021

OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER OPERATING FORCE Summary: 1. Use a spring scale to measure the maximum resistance of each control lever as illustrated. 2. Measure the maximum operating force of the front attachment control lever. 3. Measure the operating force at the grip center of each control lever. Preparation: Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Measure all control levers. 2. Engine Control Dial : Maximum Position.

T107-06-03-003

CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement. 3. Operate each boom, arm, bucket and swing lever to at full stroke and measure the maximum operating force for each. 4. Lower the bucket to the ground to raise one track off the ground. Operate the travel lever to full stroke and measure the maximum operating force required. When finished, lower the track and then jack-up the other track. 5. Repeat steps 3. to 4. three times and calculate the average values. Evalution: Refer to the Performance Standard Table in Group T4-2.

T4-4-15

T107-06-03-004

OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER STROKE Summary: 1. Measure each control lever stroke and stroke play, and check if it can be moved smoothly. 2. Measure each lever stroke at the lever grip center. 3. If a stroke play is present in the neutral position, add half the value of the play to the one side stroke. Preparation: 1. Maintain the hydraulic oil temperature at 50 ± 5 °C (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 position to the stroke end. 4. Repeat each measurement three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard.

T4-4-16

T107-06-03-005

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

COMBINED

OP-

Summary: 1. Check the combined operation performance while operating the boom raise and swing simultaneously. 2. Run the engine at full speed and check if the boom cylinders move without hesitating.

T142-05-03-007

Preparation: 1. Empty the bucket and position the machine with front attachment positioned as illustrated. 2. Maintain the hydraulic oil temperature at 50 ± 5 °C (122 ± 9 °F). CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement.

T142-05-03-008

Measurement: 1. Run the engine at the maximum speed with the auto idle switch OFF. 2. Operate the boom raise and swing levers full stroke. Measure the time required for the machine to swing 90 ° and bucket tooth tip height H raised while swinging. 3. Repeat the measurement in both directions three times and calculate the average values. T142-05-03-009

Evaluation: Refer to T4-2 Operational Performance Standard. Solution: Refer to T5-5 Troubleshooting B.

H

T142-05-03-010

T4-4-17

OPERATIONAL PERFORMANCE TEST / Excavator Test (Blank)

T4-4-18

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

Pressure Gauge

CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it. 2. Slowly loosen the cap to release air from the hydraulic oil tank. 3. Disconnect the line end from the pilot filter. Connect tee (ST 6477) and pressure gauge (ST 6942) between the pilot filer and the line end. 4. Start the engine. Check the connection for oil leaks. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±41 °F). Measurement: 1. Engine Control Dial: Maximum Speed (Fast Idle Position) 2. Read the primary pilot pressure on the gauge. Turn the engine control dial to the slow idle, then back to the fast idle. Read the pressure gauge again. 3. Read the pressure gauge three times in total. Calculate the average value. Evaluation: Refer to the Operational Performance Standard group (T4-2).

T4-5-1

T142-05-04-001

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

Pilot Relief Valve

T183-04-04-001

1. Remove the plug. : 22 mm

Plug

Shim

2. Adjust the set pressure using the shims. Adding shim(s) increases the pressure setting, and vice versa. Add or subtract shims to adjust the setting. 3. Retighten the plug. : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

4. Recheck the relief pressure setting.

T111-06-04-004

NOTE: Standard Change in Relief Pressure Setting (Reference) Shim Thickness kPa (kgf/cm2) (psi) (mm) 0.25 78 (0.8) (11) 0.5 147 (1.5) (21) 1.0 294 (3.0) (43)

T4-5-2

OPERATIONAL PERFORMANCE TEST / Component Test SECONDARY PILOT PRESSURE

Main Control Valve

The secondary pilot pressure can also be measured Left Travel with the built-in diagnosing system. (Forward) NOTE: BH: Backhoe Bucket 2 LD: Loading Shovel (BH: Roll-Out

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

LD: Tilt-Out)

Preparation: 1. Stop the engine.

Boom 2 (Lower)

CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it. 2. Slowly loosen the cap to release air from the hydraulic oil tank. 3. Connect tee (ST 6450) and pressure gauge (ST 6942) on the pilot port to be measured. : 17 mm, 22 mm 4. Start the engine. Check the pressure gauge connection for oil leaks. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±41 °F). Measurement:

BH: Arm 1 (Roll-Out) LD: Arm 1 (Roll-In)

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

BH: Arm 2 (Roll-in) LD: Arm 2 (Extend) BH: Auxiliary LD: Bucket (Close)

Boom 2 (Raise)

Bucket 2 (BH: Roll-in, LD: Tilt-in) BH: Arm 1 (Roll-In) T183-03-03-027 LD: Arm 1 (Extend)

Swing Control Valve

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

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

Evaluation: Refer to the Operational Performance Standard group (T4-2).

T183-03-03-028

Left Travel (Reverse)

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

3. Repeat the measurement three times. Calculate the average value.

Right Travel (Reverse)

Boom 1 (Raise)

CAUTION: Before starting measurement, check that there are no bystanders and/or obstructions within the swing radius. When measuring the boom lower secondary pilot pressure operate the machine carefully as the base machine front will be raised off the ground. This will cause the base machine to become imbalanced and possibly allow the rear of the machine to come in contact with the ground. 1. Engine Control Dial :Maximum Speed

BH: Arm 2 (Roll-Out) LD: Arm 2 (Retract)

BH: Auxiliary LD: Bucket (Open)

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

T4-5-3

T183-03-03-031

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

Travel Mode Control Solenoid Valve

Preparation: 1. Stop the engine. Output Port

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

T183-05-04-019

Flow Rate Decrease Solenoid Valve

2. Slowly loosen the cap to release air from the hydraulic oil tank. 3. Connect tee (ST 6450. For the power decrease solenoid valve, power increase solenoid valve and oil cooler fan control solenoid valve, use ST 6451) and pressure gauge (ST 6942) on the solenoid valve output port. : 17 mm, 22 mm

Output Port

T183-05-04-018

Power Decrease Solenoid Valve

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

Output Port

5. Maintain the hydraulic oil temperature at 50±5° C (122±41 °F). Measurement: 1. Measure the pressure setting for each solenoid valve as follows: • Travel Mode Control Solenoid Valve Measure the shifting pressure at fast and slow speeds by the travel mode switch. • Flow Rate Decrease Solenoid Valve Turn the engine control dial to the slow idle position. Read the pressure while applying a load to the front attachment. • Power Decrease Solenoid Valve Turn the engine control dial to the slow idle position. Read the pressure. • Boom Mode Selection Solenoid Valve Turn on the boom mode selection switch. Read the pressure.

T183-04-04-001

Boom Mode Selection Solenoid Valve

T4-5-4

Output Port

T183-04-04-001

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

• Power Increase Solenoid Valve

Heavy Lift Solenoid Valve

Observe the pressure change while turning the engine control dial from the slow idle position to the fast idle position. • Oil Cooler Fan Control Solenoid Valve Heat the hydraulic oil temperature sensor, and read the pressure at 69 °C (156 °F), 70 to 79 °C (158 to 174 °F) and 80 °C (176 °F). 2. Repeat the measurements three times and calculate the average values.

Output Port

T183-05-04-017

Power Increase Solenoid Valve

Evaluation: Refer to the Operational Performance Standard group (T4-2).

Output Port

T183-05-04-016

Oil Cooler Fan Control Solenoid Valve

Output Port

T4-5-5

T183-05-04-016

OPERATIONAL PERFORMANCE TEST / Component Test (Blank)

T4-5-6

OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP DELIVERY PRESSURE The main pump delivery pressure can also be measured with the built-in diagnosing system. Preparation: 1. Stop the engine. CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it. 2. Slowly loosen the cap to release air from the hydraulic oil tank. 3. Remove the plug from the test port on the main pump delivery port. Connect adapter (ST 6069), hose (ST 6943), and pressure gauge (ST 6941) on the test port.

Test Port

4. Start the engine. Check the pressure gauge connection for oil leaks. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±41 °F).

Test Port Pressure Gauge

T183-04-04-002

Measurement: 1. Engine Control Dial : Maximum Speed 2. Measure the pressure with the control levers in neutral. 3. Read the pressure gauge three times in total. Calculate the average value. Evaluation: Refer to the Operational Performance Standard group (T4-2). Remedy: Refer to the Troubleshooting B group (T5-5).

T4-5-7

T183-04-04-003

OPERATIONAL PERFORMANCE TEST / Component Test MAIN RELIEF VALVE SET PRESSURE The main pump delivery pressure can also be measured with the built-in diagnosing system. Summary: Measure the main relief valve set pressure at the main pump delivery port. Preparation: 1. Stop the engine. CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may pop off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it. 2. Slowly loosen the cap to release air from the hydraulic oil tank. 3. Remove the plug from the test port on the main pump delivery port. Connect adapter (ST 6069), hose (ST 6943), and pressure gauge (ST 6941) on the test port.

Test Port

Test Port Pressure Gauge

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

T183-04-04-002

5. Maintain the hydraulic oil temperature at 50±5 °C (122±41 °F). Measurement: 1. Engine Control Dial : Maximum Speed 2. Operate the bucket, arm and boom control levers to the stroke ends (fully extended and retracted) to relieve the each function. (Operate the control lever one function at a time.) 3. For the swing function, place one side of the bucket against an immovable object and slowly operate the swing lever to the stroke end to relieve the swing function.

T183-04-04-003

Evaluation: Refer to the Operational Performance Standard group (T4-2).

4. For the travel function, place the track to be measured against a pile of soil to make it immovable. Slowly operate the travel lever to the stroke end to relieve the travel function. 5. Read the pressure gauge while relieving each function.

T4-5-8

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

OPERATIONAL PERFORMANCE TEST / Component Test Main Relief Procedure

Pressure

Setting

Adjustment Main Control Valve

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

• High-Side

Main Relief Adjustment Procedure

Pressure

Main Relief Valve

Setting

1. Loosen lock nut 2. Tighten plug until the bottom of piston comes into contact with sleeve. Retighten lock nut 2. : 22 mm, 30 mm : Lock nut 2 (4): 59 N⋅m (6 kgf⋅m, 13 lbf⋅ft)

T183-03-03-029

Swing Control Valve

Main Relief Valve

2. Loosen lock nut 1. Turn sleeve to adjust the relief pressure setting, referring to the table below. : 22 mm, 41 mm : Lock nut 1: 98 N⋅m (10 kgf⋅m, 22 lbf⋅ft)

• Low-Side

Main Relief Adjustment Procedure

Pressure

Setting

3. Loosen lock nut 2. Turn plug counterclockwise until the specified value is obtained. Retighten lock nut 2. : 22 mm, 30 mm : Lock nut 2: 59 N⋅m (6 kgf⋅m, 13 lbf⋅ft)

Plug

T183-03-03-030

Lock Nut 2 Sleeve Lock Nut 1 Piston

4. Recheck the set pressures. NOTE: : Standard Change in Pressure Setting Sleeve and 1/4 1/2 3/4 1 plug turns MPa 4.4 8.8 13.2 17.7 (kgf/cm2) (45) (90) (135) (180) (psi) (640) (1280) (1920) (2560)

T162-04-04-010

Sleeve, Plug

Pressure Increase

Pressure Decrease W107-02-05-127

T4-5-9

OPERATIONAL PERFORMANCE TEST / Component Test Swing Relief Valve

Swing Relief Valve Set Pressure Adjustment Procedure

Adjustment: Loosen the lock nut. : 17 mm 1. Turn the adjusting screw to adjust the pressure setting. T142-01-02-011

Adjusting Screw

2. Retighten the lock nut. : 17 mm : 19.5 to 29.5 N⋅m (2 to 3 kgf⋅m, 15 to 22 lbf⋅ft)

Lock Nut

3. Recheck the relief pressure setting.

T142-02-02-006

NOTE: Standard Change in Relief Pressure Setting Screw Turns 1/4 1/2 3/4 1 MPa 2.75 5.49 8.24 11.0 (kgf/cm2) (28) (56) (84) (112) (psi) (340) (796) (1195) (1593)

Lock Nut

Pressure Increase

Adjusting Screw

Pressure Decrease

T105-06-05-002

T4-5-10

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

Adjustment: 1. Loosen the lock nut. : 19 mm 2. Turn the adjusting screw to adjust the pressure setting. : 6 mm

Travel Relief Valve T183-01-02-012

3. Retighten the lock nut. : 19 mm : 34.3 to 44.1 N⋅m (3.5 to 4.5 kgf⋅m, 25.3 to 32.5 lbf⋅ft)

Lock Nut

4. Recheck the relief pressure setting.

Adjusting Screw

NOTE: Standard Change in Relief Pressure Setting Screw Turns 1/4 1/2 3/4 1 MPa 1.96 3.92 5.88 7.85 (kgf/cm2) (20) (40) (60) (80) (psi) (280) (570) (850) (1140)

T142-05-04-007

Lock Nut

Pressure Increase

Adjusting Screw

Pressure Decrease W107-02-05-129

T4-5-11

OPERATIONAL PERFORMANCE TEST / Component Test OVERLOAD PRESSURE

RELIEF

VALVE

SET

Summary: 1. The circuit pressure must be increased by applying an external force while blocking the return circuit from the control valve. This measuring method is hazardous and the results obtained with this method are unreliable. 2. The oil flow rate used to set the overload relief pressure is far less than that used to set the main relief pressure. Therefore, measuring the overload pressure in the main circuit by increasing the main relief set-pressure more than the overload valve set-pressure is not a proper method. In addition, in case a main relief valve designed to leak a small quantity of oil before reliving is used, its pre-leaking start pressure must be increased more than the overload relief valve set-pressure. However, the pre-leaking start pressure is not always increased more than the overload relief valve set-pressure as the adjustable upper limit of the main relief valve set-pressure is provided. Accordingly, the overload relief valve assembly should be removed from the machine and checked on a specified test stand at a correct oil flow rate. Some overload relief valves come in contact with the control valve body to block the oil passage. When this type of overload relief valve is checked, the control valve body must be precisely finished as the test unit. Provide one control valve other than that on the machine as a test kit. 3. If the overload relief valve performance must be checked on the machine, however, measure the main relief pressure while releasing each front function respective to the measuring overload relief valve. And, assume that the overload relief valve is functioning correctly if the obtained main relief pressure is within the specified value range. Measure the main pressure of the front functions as follows:

T4-5-12

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

• Boom, Arm, Bucket 1, Bucket 2,

Auxiliary: BH/Bucket Open, Close :LD, Swing NOTE: BH: Backhoe LD: Loading Shovel Adjusting Screw

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

Lock Nut

Adjustment: Adjust the pressure setting of the overload relief valve using adjusting screw after loosening lock nut. 1. Loosen lock nut. : 19 mm 2. Turn adjusting screw to adjust the pressure setting referring to the table below. : 6 mm

T162-04-04-004

Adjusting Screw

3. Retighten lock nut. : 19 mm : 98 Nxm (10 kgfxm, 72 lbfxft) 4. Recheck the set pressures. Pressure Increase

NOTE: Standard Change in Pressure Setting

W107-02-05-129

Screw Turns

1/4

1/2

3/4

1

MPa

3.9

7.8

11.7

15.6

(kgf/cm )

(40)

(78)

(120)

(160)

(psi)

(566)

(1131)

(1697)

(2262)

2

Pressure Decrease

T4-5-13

OPERATIONAL PERFORMANCE TEST / Component Test • Boom Mode Selection NOTE: In principle, adjust the overload relief valve set pressure on a test stand. Adjustment: Adjust the pressure setting of the overload relief valve using sleeve after loosening lock nut (1). 1. Loosen lock nut (1). : 36 mm 2. Turn sleeve to adjust the pressure setting referring to the table below. : 30 mm

Boom Mode Selection

3. Retighten lock nut. : 36 mm : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)

T183-03-03-028

Sleeve

4. Recheck the set pressures.

Lock Nut

NOTE: Standard Change in Pressure Setting Screw Turns

1/4

1/2

3/4

1

MPa

8.9

17.8

26.7

35.6

(kgf/cm )

(90)

(180)

(270)

(360)

(psi)

(1290)

(2581)

(3872)

(5162)

2

T183-04-04-007

Sleeve

Pressure Increase

Pressure Decrease W107-02-05-127

T4-5-14

OPERATIONAL PERFORMANCE TEST / Component Test (Blank)

T4-5-15

OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP FLOW RATE MEASUREMENT NOTE: MC/V: Main Control Valve SC/V: Swing Control Valve

• P-Q Control (Torque Control) Summary: Main pump performance is checked by measuring the pump flow rate with a hydraulic tester installed at the main pump delivery line. Measure the flow rate by using the built-in diagnosing system and a pressure gauge. Preparation: IMPORTANT: The method described here is a simplified method, so that the flow rate is reduced by approx. 5% compared to the actual measurement (ex. bench test). If the actual measurement is required, connect the return circuit to the hydraulic oil tank instead of the control valve. CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it. 1. Stop the engine. Slowly loosen the cap to release air from the hydraulic oil tank. Connect the vacuum pump to the oil filler port. NOTE: Keep operating the vacuum pump while connecting the measurement piping.

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

Delivery Hose Split Flange (ST 6133)

T183-04-04-013

Delivery Hose Flange (ST 6123)

Bolt (ST 6458)

Test Hose (ST 6145)

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

Main Pump

Test Hose (ST 6145)

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

Split Flange (ST 6133) Bolt (ST 6458)

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

Pipe (ST 6132) T183-04-04-014

Pressure Gauge (ST 6941)

4. Install pipe (ST 6132) on the delivery port of the main pump using split flange (ST 6133) and bolt (ST 6458), then install test hose (ST 6145), adapter (ST 6146) and hydraulic tester (ST 6299) on the pipe. Remove a plug from the pressure check port on the main pump, then install adapter (ST 6069), hose (ST 6943) and pressure gauge (ST 6941). Hose (ST 6943)

Adapter (ST 6069)

T4-5-16

T183-04-04-003

OPERATIONAL PERFORMANCE TEST / Component Test 5. Disconnect pipes from pump regulator ports Psv and Pi. Install tee (ST 6640) to port Psv. Connect tee (ST 6640) between port Psv and circuit Psv. Connect hose (ST 6961) and elbow (ST 6635, Code No. 0095) to tee (ST 6640). Connect the other end of hose (ST 6961) to port Pi using elbow (ST 6635, Code No. 0095). Install a plug to the pipe end disconnected from port Pi. (By connecting the pump servo assist pressure (Psv pressure) circuit to port Pi, the condition similar to the maximum pump flow rate (maximum Pi pressure at full stroke operation of the control lever) can be obtained. 6. Disconnect the power increase solenoid valve connector and power decrease solenoid valve connector. 7. Fully open the loading valve of the hydraulic tester. 8. Start the engine. Check the line connections for any oil leaks. Select the monitor function on the built-in diagnosing system. Measurement: 1. Hydraulic oil temperature: 50±5 °C (122±41 °F)

Port Psv Port Pi

T183-01-02-006

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

T183-04-04-004

2. Engine Control Dial: Maximum speed 3. Slowly close the loading valve of the hydraulic tester to obtain the specified pressure on P-Q curve, and measure the pump flow rate and engine speed at each pressure. (Refer to T4-2-4) 4. Repeat the measurement three times and calculate the average values. Evaluation: Convert the measured flow rates to the values at the specified pump speed using the following formulas: QC = (NP×Q) / (i×Ne) QC: Converted Flow Rate Q: Measured Flow Rate i: Pump Drive Gear Ratio (1.083) NP: Specified Pump Speed (1787 min-1) Ne: Measured Engine Speed

T4-5-17

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment: Adjustment of Minimum and Maximum Flow Rate Pump flow rate can be adjusted by changing the maximum stroke of the servo piston. To adjust the maximum flow rate, loosen nut (1) and turn adjusting screw (2) on the large chamber side end of the servo piston. To adjust the minimum flow rate, loosen nut (3) and turn adjusting screw (4) on the small chamber side end of the servo piston. : 30 mm for nut (1), (3) : 13 mm for adjusting screw (2) : 10 mm for adjusting screw (4)

4

NOTE: Turn adjusting screw (2) clockwise to decrease the maximum flow rate and counterclockwise to increase. Turning adjusting screw (2) one forth turns changes approximately 9.2 L/min-1 of flow rate. Turn adjusting screw (4) clockwise to increase the minimum flow rate and counterclockwise to decrease. Turning adjusting screw (4) one forth turns changes approximately 9.2 L/min-1 of flow rate.

3

1

2

T183-04-04-006

(Pump Flow Rate) Q

Maximum Flow Rate Adjustment

(Pump Flow Rate) Q

Pi

Minimum Flow Rate Adjustment

Pi (Flow Rate Control Pressure)

T4-5-18

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment of Torque Control The torque control is performed by pump delivery pressure P. Therefore, the torque constant control is adjusted by changing the set-force of inner spring (2) and outer spring (1). (Before adjust the screws (4) and (6), mark the end of the adjusting screw with a white marker for the record of the original position.) When resetting inner spring (2), loosen nut (5) and adjust screw (6). When resetting outer spring (1), loosen nut (3) and adjust screw (4).

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

2 3

4 5

6

T117-05-04-005

Outer Spring Adjustment Data Adjusting Screw Turn 1/4 Flow Rate Change 40.9 L/min (10.8 US gal/min) Pressure Change 1.74 MPa (17.8 kgf/cm2) (252 psi) Engine Torque Change 67.6 N⋅m (6.9 kgf⋅m) (50 lbf⋅ft) (Pump Flow Rate) Q

Inner Spring Adjustment Data Adjusting Screw Turn 1/4 Flow Rate Change 18.9 L/min (5 US gal/min) Pressure Change 1.80 MPa (18.4 kgf/cm2) (261 psi) Engine Torque Change 45.1 N⋅m (4.6 kgf⋅m) (33 lbf⋅ft) (Pump Flow Rate) Q

P

(Pump Delivery Pressure)

T4-5-19

P

(Pump Delivery Pressure)

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment of Flow Rate Control The flow rate control is performed by pump flow rate control pressure Pi. Therefore, the flow rate control is adjusted by resetting the set-force of spring (1). Loosen nut (2) and turn adjusting screw (3) to reset the set-force of spring (1).

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

1 2

3

T117-05-04-006

Spring Adjustment Data Adjusting Screw Turn 1/4 Pressure Change (Pi) 0.15 MPa (1.5 kgf/cm2) (21.8 psi) Flow Rate Change 42.7 L/min (11.2 US gal/min) (Pump Flow Rate) Q

Flow Rate Control

(Pump Flow Rate) Q

Pi (Flow Rate Control Pressure)

T4-5-20

Relief Oil Minimizing Control

P (Pump Delivery Pressure)

OPERATIONAL PERFORMANCE TEST / Component Test (Blank)

T4-5-21

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

Delivery Hose

• P-Q Control (Torque Control) Summary: Oil cooler fan motor drive pump performance is checked by measuring the pump flow rate with a hydraulic tester installed at the oil cooler fan motor drive pump delivery line. Preparation: CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it. 1. Stop the engine. Slowly loosen the cap to release air from the hydraulic oil tank. Connect the vacuum pump to the oil filler port. NOTE: Keep operating the vacuum pump while connecting the measurement piping.

T183-04-04-015

Split Flange (4506459) Delivery Hose

Bolt (ST 6408) Adapter (ST 6146) Test Hose (ST 6145)

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

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

3. Install test hose (ST 6145), adapter (ST 6146) and hydraulic tester (ST 6299) on flange (ST 6574). 4. Install pipe (ST 6575) on the delivery port of the main pump using split flange (4506459) and bolt (ST 6408), then install test hose (ST 6145), adapter (ST 6146) and hydraulic tester (ST 6299) on the pipe. Remove a plug from the pressure check port, then install adapter (ST 6069), hose (ST 6943) and pressure gauge (ST 6941).

T183-04-04-018

Hose (ST 6943)

Pressure Gauge (ST 6941)

Adapter (ST 6069)

T4-5-22

T183-04-04-019

OPERATIONAL PERFORMANCE TEST / Component Test 5. Disconnect the pipe from regulator ports Pi. Leave the port Pi open to the atmosphere. Plug the disconnected pipe end. 6. Disconnect the connector of the oil cooler fan control solenoid valve SF. 7. Fully open the loading valve of the hydraulic tester. 8. Start the engine. Check the line connections for any oil leaks. Pi

Measurement: 1. Engine Control Dial: Maximum speed

T183-04-04-016

2. Slowly close the loading valve of the hydraulic tester to obtain the specified pressure on P-Q curve, and measure the pump flow rate and engine speed at each pressure. (Refer to T4-2-4) 3. Repeat the measurement three times and calculate the average values. Evaluation: Convert the measured flow rates to the values at the specified pump speed using the following formulas: QC = (NP×Q) / (i×Ne) QC: Converted Flow Rate Q: Measured Flow Rate i: Pump Drive Gear Ratio (1.106) NP: Specified Pump Speed (1825 min-1) Ne: Measured Engine Speed

T4-5-23

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment: Adjustment of Maximum and Minimum Flow Rate The pump flow rate can be adjusted by changing the maximum servo piston stroke. When adjusting the maximum flow rate, loosen nut (1) and adjusting screw (2) on the servo piston large chamber side. When adjusting the minimum flow rate, loosen nut (3) and adjusting screw (4) on the servo piston small chamber side.

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

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

2

1

3

4

T183-03-01-003

(Pump Flow Rate) Q

Maximum Flow Rate Adjustment

(Pump Flow Rate) Q

Pi

Minimum Flow Rate Adjustment

Pi (Flow Rate Control Pressure)

T4-5-24

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment: Adjustment of Torque Control The torque control is performed by pump delivery pressure P. Therefore, the torque constant control is adjusted by changing the set-force of inner spring (2) and outer spring (1). (Before adjusting screws (4) and (6), mark the end of the adjusting screw with a white marker for the record of the original position.) When resetting inner spring (2), loosen nut (5) and adjusting screw (6). When resetting outer spring (1), loosen nut (3) and adjusting screw (4).

NOTE: When adjusting screw (4) is turned, inner spring (2) set-force varies. Therefore, when adjusting screw (4) is turned, turn adjusting screw (6) 2.24 times the turns of adjusting screw (4) in the opposite direction to keep inner spring (2) set-force unchanged. : 36 mm : Nut (3) : 24 mm : Adjusting Screw (4) : 13 mm : Nut (5) : 4 mm : Adjusting Screw (6) 1

2

3

4

5

6

W117-02-02-017

Outer Spring Adjustment Data Adjusting Screw Turn 1/4 Flow Rate Change 9.3 L/min (2.5 US gal/min) Pressure Change 1.88 MPa (19.2 kgf/cm2) (273 psi) Engine Torque Change 16.7 N⋅m (1.7 kgf⋅m) (12.3 lbf⋅ft) (Pump Flow Rate) Q

P

(Pump Delivery Pressure)

T4-5-25

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment: Adjustment of Flow Rate Control The flow rate control is performed by pump flow rate control pressure Pi. Therefore, the flow rate control is adjusted by resetting the set-force of spring (1). Loosen nut (2) and turn adjusting screw (3) to reset the set-force of spring (1).

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

1 2

3

T117-05-04-006

Spring Adjustment Data Adjusting Screw Turn 1/4 Pressure Change (Pi) 0.13 MPa (1.3 kgf/cm2) (18.9 psi) Flow Rate Change 6.8 L/min (1.8 US gal/min)

(Pump Flow Rate) Q

Flow Rate Control

(Pump Flow Rate) Q

Pi (Flow Rate Control Pressure)

T4-5-26

Relief Oil Minimizing Control

P (Pump Delivery Pressure)

OPERATIONAL PERFORMANCE TEST / Component Test (Blank)

T4-5-27

OPERATIONAL PERFORMANCE TEST / Component Test SWING MOTOR DRAINAGE

Cap

Summary: To check swing motor performance, measure the amount of oil draining from the swing motor while swinging the upperstructure. Swing motor while swinging the upperstructure. NOTE: The amount of drain oil from the swing motor will change depending on hydraulic oil temperature. Maintain hydraulic oil temperature within 50±5 °C (122±41 °F). Preparation: 1. Maintain hydraulic oil temperature at 50±5 °C (122±41 °F). Rotate the swing motor to warm the inside of the motor.

Drain Hose M183-07-052

Front Side

CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it. 2. Properly shut down the engine. Slowly loosen cap to release air from the hydraulic oil tank. 3. Disconnect the swing motor drain hose at the hydraulic oil tank end. Install plug (ST 6491) to the disconnected end on the hydraulic oil tank. : 27 mm : 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)

T183-04-04-008

Drain Hose

Preconditions for Measurement: 1. Engine Control Dial : Maximum Speed CAUTION: Prevent personal injury. Always make sure that the area is clear and that coworkers are out of the swing area before starting machine operation. Also, take care not fall off the machine during the measurement.

T183-04-04-009

ST 6491

T183-04-04-010

T4-5-28

OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Amount of Oil Drained While Swinging the Upperstructure 1-1. Fully retract the arm cylinder. Fully extend the bucket cylinder. Raise the boom so that the arm tip pin height is the same as the boom foot pin height. Be sure that the bucket is empty. 1-2. Start the engine. Operate and hold the swing lever full stroke. Start draining oil measurement after the swing speed reaches a constant maximum speed. The measuring time should be more than 20 seconds. 1-3. Repeat the measurement at least three times in both clockwise and counterclockwise directions, and calculate the average values. 2. Amount of Oil Drained While Relieving Swing Motor Circuit 2-1. Thrust the bucket teeth into the ground as illustrated so that the upperstructure does not rotate when the swing lever is operated full stroke. 2-2. Start the engine. Operate and hold the swing lever full stroke. Start drain oil measurement when drain oil starts coming out of the drain hose end. The measuring time should be more than 20 seconds. 2-3. Repeat the measurement at least three times in both clockwise and counterclockwise directions, and calculate the average values.

T145-05-03-007

T145-05-03-008

Evaluation: Refer to the Performance Standard Table in Group T4-2. ∗ Conversion of the amount of drain oil measured into the per-minute value First measure the amount of drain oil using a calibrated container. Then, convert the measured drain oil into the per-minute value using the formula below: ∆Q = 60 × q / t

T183-04-04-009

Where : ∆Q : Amount of drain oil per minute (L/min) t : Time measured (seconds) q : Total amount of drain oil (L)

T4-5-29

OPERATIONAL PERFORMANCE TEST / Component Test TRAVEL MOTOR DRAINAGE

Cap

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

NOTE: The amount of drain oil from the travel motor and the drain oil pressure will change depending on hydraulic oil temperature. Maintain hydraulic oil temperature within 50±5 °C (122±41 °F). Preparation: 1. Main main hydraulic oil temperature at 50±5 °C (122±41 °F). Rotate the travel motor to warm the inside of the motor.

Drain Hose

M183-07-052

CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may pop off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it. 2. Properly shut down the engine. Slowly loosen cap to release air from the hydraulic oil tank. 3. Disconnect the travel motor drain hose at the travel motor end. Install plug (ST 6637) to the disconnected end. Connect the drain hose (3/4-16UN) to the travel motor. : 27 mm : 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)

M183-01-001

Drain Hose

Preconditions for Measurement: Engine Control Dial: Maximum Position

Drain Hose

T157-05-04-019

ST 6637

T183-04-04-011

T4-5-30

OPERATIONAL PERFORMANCE TEST / Component Test Preconditions for Measurement: Engine Control Dial : Maximum Speed Measurement: 1. Start the engine. Jack up the measuring side track using the front attachment, as illustrated. 90～110°

CAUTION: Securely support the raised track using wooden blocks. T142-05-03-011

2. Rotate the raised track with the travel lever operated full stroke. Start drain oil measurement after the track rotation speed reaches a constant maximum speed. The measuring time should be more than 20 seconds. 3. Repeat the measurement at least three times in both forward and reverse directions and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2.

T142-05-03-012

∗ Conversion of the amount of drain oil measured into the paramount value First measure the amount of drain oil using a calibrated container. Then, convert the measured drain oil into the paramount value using the formula below: ∆Q = 60 × 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

T4-5-31

OPERATIONAL PERFORMANCE TEST / Component Test (Blank)

T4-5-32

MEMO ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ 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........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................

MEMO ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ 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SECTION 5

TROUBLESHOOTING CONTENTS Group 1 General

Group 4 Troubleshooting A

Introduction .............................................. T5-1-1 Diagnosing Procedure .............................. T5-1-2 Built-In Diagnosing System Operation ...... T5-1-4 Built-In Diagnosing Function Display List.. T5-1-6 Binary Number Bit List.............................T5-1-11 Main Controller Fault Code List .............. T5-1-14

Group 2 Cross Reference Table Electrical Circuit Diagram ......................... T5-2-1 Hydraulic Circuit Diagram (Backhoe)........ T5-2-6 Hydraulic Circuit Diagram (Loading Shovel)................................................... T5-2-8

Group 3 Component Layout Main Components .................................... T5-3-1 Electrical System Components (1)............ T5-3-2 Electrical System Components (2)............ T5-3-3 Electrical System Components (3)............ T5-3-8

Troubleshooting A Procedure .................... T5-4-1 Main Controller Fault Code List ................ T5-4-2 Main Controller A Fault Code 01, 02, 03 ............................. T5-4-4 Fault Code 04 ......................................... T5-4-4 Fault Code 05 ......................................... T5-4-5 Fault Code 06 ......................................... T5-4-6 Fault Code 07 ......................................... T5-4-7 Fault Code 08, 09 ................................... T5-4-8 Fault Code 10 ....................................... T5-4-10 Fault Code 11, 12, 13............................ T5-4-12 Fault Code 25 ....................................... T5-4-13 Main Controller B Fault Code 31, 32, 33 ........................... T5-4-14 Fault Code 34 ....................................... T5-4-14 Fault Code 37 ....................................... T5-4-15 Sensor Activating Range......................... T5-4-16

Group 5 Troubleshooting B

Electrical System Components (4)............ T5-3-9

Troubleshooting B Procedure ................... T5-5-1

On and Around Pumps ........................... T5-3-10

Correlation between Trouble

Main Control Valve ................................. T5-3-12

Symptoms and Part Failures ................... T5-5-2

Swing Control Valve ............................... T5-3-16

Engine System Troubleshooting ............. T5-5-14

Signal Control Valve ............................... T5-3-21

All Actuator System Troubleshooting ...... T5-5-36

Others .................................................... T5-3-30

Front Attachment System Troubleshooting .................................... T5-5-44 Swing System Troubleshooting ............... T5-5-58 Travel System Troubleshooting............... T5-5-61 Other System Troubleshooting................ T5-5-68 Work After Replacing Components ......... T5-5-92 Add Compressor oil ................................ T5-5-92 Charge Air Conditioner With Refrigerant ............................................ T5-5-93

18ET-5-1

Group 6 Troubleshooting C

Group 7 Troubleshooting D

Troubleshooting C (Troubleshooting for Monitor) Procedure .............................................T5-6-1

Troubleshooting D Procedures .................T5-7-1 Fault Code Indication by Indicator Blinking Pattern ......................................T5-7-3

Malfunction of Coolant Temperature Gauge................................T5-6-2

Fault Codes for Quantum Engines ............T5-7-5

Malfunction of Fuel Gauge .......................T5-6-4

Group 8 Electrical System Inspection

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

Precautions for Inspection and

Malfunction of Overheat Indicator .............T5-6-8 Malfunction of Air Cleaner Restriction

Maintenance ...........................................T5-8-1 Inspections for Disconnecting

Indicator ...............................................T5-6-10

Connectors .............................................T5-8-3

Malfunction of Fuel Level Indicator .........T5-6-12

Fuse Inspection ........................................T5-8-4

Malfunction of Preheat Indicator .............T5-6-14

Fusible Link Inspection .............................T5-8-7

Malfunction of Download Indicator ..........T5-6-15

Battery Voltage Check ..............................T5-8-8

Malfunction of Alternator Indicator ..........T5-6-16

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

Malfunction of Engine Oil Pressure

Voltage Check ........................................T5-8-10

Indicator ...............................................T5-6-18

Continuity Check ....................................T5-8-17

Malfunction of Pump Transmission Oil Pressure Indicator ...........................T5-6-20 Malfunction of Engine Oil Level Indicator ...............................................T5-6-22 Malfunction of Coolant Level Indicator ....T5-6-24 Malfunction of Hydraulic Oil Level Indicator ...............................................T5-6-26 Malfunction of Auto-Lubrication Indicator ...............................................T5-6-30 Malfunction of Engine Stop Indicator ......T5-6-32 Malfunction of Engine Warning Indicator ...............................................T5-6-34 Malfunction of Quick-Idle Indicator .........T5-6-36 Malfunction of Auto-Idle Indicator ...........T5-6-38 Malfunction of Hourmeter .......................T5-6-40 Malfunction of Buzzer .............................T5-6-42 Malfunction of Liquid Crystal Display (LCD)...T5-6-44 Malfunction of Engine Troubleshooting Operation .............................................T5-6-46

18ET-5-2

TROUBLESHOOTING / General INTRODUCTION Refer to the inspection and troubleshooting procedures after any machine trouble has occurred. The inspection and troubleshooting procedures are presented in an orderly fashion in this section to help you quickly find the cause and solution of the machine trouble. The troubleshooting section in this manual consists of 8 groups; General, Cross Reference Table, Component Layout, Troubleshooting A (base machine diagnosis using the built-in diagnosing system’s fault codes), Troubleshooting B (base machine diagnosis starting with inspection of abnormal operational status), Troubleshooting C (monitor diagnosis), Troubleshooting D (engine diagnosis indicated by the flashing pattern of indicator lights), and Electrical System Inspection. • General • Cross Reference Table • Component Layout • Troubleshooting A (base machine diagnosis using the built-in diagnosing system’s fault codes) • Troubleshooting B (base machine diagnosis starting with inspection of abnormal operational status) Refer to these procedures when troubleshooting by inspecting abnormal machine operational status. Example: Even if the fuel lever is operated, engine speed doesn’t change. • Troubleshooting C (monitor diagnosis) Refer to these procedures when gauges and/or indicators are malfunctioning. Example: The fuel gauge doesn’t operate. • Troubleshooting D (engine diagnosis relies on the flashing pattern of indicator lights) The engine is diagnosed by referring to the flashing pattern of the engine warning indicator. • Electrical System Inspection Refer to this group when required to obtain precautions and/or information for the electrical system inspection. Example: Fuse Inspection

T5-1-1

TROUBLESHOOTING / General DIAGNOSING PROCEDURE These six basic steps are essential for efficient troubleshooting: 1. Study the system • Study the machine’s technical manuals. Know the system and how it works, and what the construction, functions and specifications of the system components are. T107-07-01-001

2. Ask the operator Before inspecting, get the full story of malfunctions from your star witness --- the operator. • How is the machine being used? (Find out if the machine is being operated correctly) • When was the trouble noticed, and what types of work the machine doing at that time? • What are the details of the trouble? Is the trouble getting worse, or did it appear suddenly for the first time? • Did the machine have any other troubles previously? If so, which parts were repaired before?

T107-07-01-002

3. Inspect the machine Before starting the troubleshooting procedure, check the machine’s daily maintenance points, as shown in the operator's manual. Also, check the electrical system, including the batteries, as troubles in the electrical system such as low battery voltage, loose connections and blown fuses will result in malfunction of the controllers, causing total operational failure of the machine. If troubleshooting is started without checking for blown fuses, a wrong diagnosis may result, wasting time. Be sure to check for blown fuses before troubleshooting. Even if a fuse looks normal by visual inspection, a fine crack is difficult to find. Always use a tester when checking the fuses.

T5-1-2

T107-07-01-003

TROUBLESHOOTING / General 4. Operate the machine yourself Try to identify the trouble by operating the machine yourself. If the trouble cannot be confirmed, stop the engine and obtain further details of the malfunction from the operator. Also, check for any incomplete connections of the wire harnesses.

5. Perform troubleshooting

T107-07-01-004

CAUTION: If a harness or pipe is disconnected with the engine running, the machine may operate incorrectly, or high pressure oil may spray, causing personal injury. Be sure to disconnect harnesses or pipes after stopping the engine. Perform self-diagnosis by operating the built-in self-diagnosing system. In case any fault code has been displayed by diagnosis using the built-in self-diagnosing system, check the cause of the trouble by referring to Troubleshooting A in this section. After the machine trouble has been corrected, the fault code will be deleted. If the engine stop indicator and the engine warning indicator in the cab start flashing by the ECM diagnosis system, check the cause of the trouble by referring to Troubleshooting D in this section. Therefore, in case problems which are not easily repredicable are encountered, use the built-in self-diagnosing system and ECM diagnosis system to display the fault code. In case no fault codes are displayed, check all related parts/component operating condition using the monitor function of the built-in self-diagnosing system while referring to troubleshooting B in this section.

T107-07-01-006

6. Trace possible causes Before reaching a conclusion, check the most likely causes again. Try to identify the actual cause of the trouble. Based on your conclusion, make a plan for appropriate repairs to avoid consequent malfunctions. T107-07-01-007

T5-1-3

TROUBLESHOOTING / General BUILT-IN DIAGNOSING OPERATION

SYSTEM

IMPORTANT: This system is to be operated by the HITACHI Dealer Only. Don't explain this system function to the customer. In the service mode, the monitor LDC displays the diagnosing items, fault codes and monitored results (not all of them). Built-In Diagnosing System Activation 1. While pressing the monitor SET switch, turn the key switch ON.

Display Selection Switch

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

SET Switch

NOTE: The fault code is indicated in the display order 8. Fifteen fault codes for the main controller A and five fault codes for the main controller B are indicated. In case more than one fault code is indicated, they will be displayed with an interval of 1 second in order. • The LCD in the service mode displays only the item No. on the left and the monitored result on the right. The item description is not displayed.

Liquid Crystal Display (LCD)

T183-01-02-013

Display Selection between Main Controller A and B 1. Remove the side cover on the left console. 2. Switch the MC display selection switch. ON: Displays the main controller A value OFF: Displays the main controller B value NOTE: The main controller A value is displayed when the MC display selection switch is in neutral position.

Side Cover M183-01-008

MC Display Selection Switch

Machine Front

ON

Neutral OFF

T5-1-4

T183-05-01-001

TROUBLESHOOTING / General (Blank)

T5-1-5

TROUBLESHOOTING / General BUILT-IN DIAGNOSING DISPLAY LIST Main Controller A Display Description Order 1. Hour Meter 2. Trip1 3. Trip2 4. Engine Actual Speed 5. Hydraulic Oil Temperature 6. 7. 8. Fault Code * 9. Main Pump 1 Pressure 10. Main Pump 2 Pressure 11. Main Pump 3 Pressure 12. Front Operation Pressure 13. Travel Operation Pressure Engine Exhaust Gas 14. Temperature 15.

FUNCTION

Monitored Result

Unit

{{{{{ h {{{{{ h {{{{{ h n {{{{ {{{ L1 {{ L2 {{{ 0 {{ 1 {{{{ 2 {{{{ 3 {{{{ 4 {{{{ 5 {{{{ 6 0

min-1 °C － % － MPa MPa MPa MPa MPa °C

EC Angle Digital Input 0

7 8

{{{{ {{

Digital Input 1

9

{{

Digital Input 2

A

{{

Digital Input 3

b

{{

Digital Output

c

{{

Proportional Valve ON/OFF Output

d

{{

Hydraulic Oil Cooling Output Current Power Increase Output Current

E

{{{{

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

F

{{{{

mA

16.

17.

18.

19.

20.

21. 22. 23.

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

T5-1-6

Remarks Standard Mode Standard Mode (Subtraction) Standard Mode (Subtraction) Possible to display Possible to display Display Purpose Only Display Purpose Only Possible to display Possible to display Possible to display Possible to display Possible to display Possible to display Fixed by 0 °C (32 °F) (Not used for the CUMMINS engine) Possible to display Possible to display

Possible to display

Possible to display

Possible to display

Possible to display

Possible to display

Possible to display Possible to display

TROUBLESHOOTING / General

Main Controller B Display Description Order 1. Hour Meter 2. Trip1 3. Trip2 4. Engine Actual Speed 5. Hydraulic Oil Temperature 6. 7. 8. Fault Code * 9. Digital Input 0

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

10.

Digital Input 1

2

{{

11.

Digital Input 2

3

{{

12.

Digital Input 3

4

{{

13.

Digital Output 1

5

{{

14.

Proportional Valve ON/OFF Output

6

{{

15.

Auto-Lubrication Status 1

7

{{

16.

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

8

{{{{

9

{{{{

A

{{

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

b

{{{{

c

{{{{

17. 18.

19. 20. 21. 22. 23. NOTE:

Unit

min-1 °C － % － 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 4 Digits displayed in Binary Number *** 4 Digits displayed in Binary Number *** 2 Digits displayed in Hexadecimal Number ** 4 Digits displayed in Binary Number *** 4 Digits displayed in Binary Number *** － － －

d E F

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

T5-1-7

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

Possible to display

Possible to display

Possible to display

Possible to display

Possible to display

Possible to display

Possible to display Possible to display Possible to display

Possible to display Possible to display － － －

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

Hexadecimal

0

1

2

3

4

5

6

7

8

9

A

b

C

d

E

F

0000

0001

0010

0011

0100

0101

0110

0111

1000

1001

1010

1011

1100

1101

1110

1111

In Case of Digital Input of Main Controller A (Ex.) Monitor Display 60

8 Upper

Hexadecimal Number 2 Digits Display Section Lower

1. Convert the upper and lower number in the hexadecimal number 2 digits display section. (Refer to Correspondence Chart between Hexadecimal Number and Binary Number). Upper 6 0110 Lower 0 0000 Therefore, binary number 01100000 can be obtained. 2. This value corresponds the bit on the Binary Number Bit List (refer to T5-1-11), as follows: bit bit bit bit bit bit bit bit

7 6 5 4 3 2 1 0

⇔ ⇔ ⇔ ⇔ ⇔ ⇔ ⇔ ⇔

0 1 1 0 0 0 0 0

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

Main Controller A bit Status of Main Controller

(0)

Contact Terminal is GND Opened Current

(1) Contact Terminal is Closed

Diagram 1. In Case of Digital Input

3. If the value is "1", the terminal point corresponding the bit is closed. The contact terminal is connected to ground, so that power flows. If the value is "0", the terminal point is opened, so that current does not flow. (Refer to Diagram 1) From the above information, it becomes apparent that the engine oil level indicator on the monitor is switched on, the heavy lift switch is turned on, and the checker is disconnected. 4. Convert the value for digital input 1, digital input 2, digital input 3 of the main controller A, and digital input 0, digital input 1, digital input 2 and digital input 3 of the main controller B. Then, calculate the corresponding bit values.

T5-1-8

GND

TROUBLESHOOTING / General In Case of Digital Output of Main Controller A (Ex.) Monitor Display 51

c Upper

Hexadecimal Number 2 Digits Display Section Lower

1. Convert the upper and lower number on the hexadecimal number 2 digits display section. (Refer to Correspondence Chart between Hexadecimal Number and Binary Number). Upper 5 0101 lower 1 0001 Therefore, binary number 01010001 can be obtained. 2. This value corresponds the bit on the Binary Number Bit List (refer to T5-1-11), as follows: bit 7

⇔

0

bit bit bit bit bit bit bit

⇔ ⇔ ⇔ ⇔ ⇔ ⇔ ⇔

1 0 1 0 0 0 1

6 5 4 3 2 1 0

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

Main Controller A bit Status of Main Controller

Current Vcc Load

(1) GND

Vcc Load

(0) GND

Diagram 2. In Case of Digital Output

3. If the value is "1", the controller internal voltage at the terminal corresponding the bit is connected to ground, so that power flows. If the value is "0", the controller internal voltage at the terminal corresponding the bit does not connected to ground, so that power does not flow. (Refer to Diagram 2) From the above information, it becomes apparent that the engine oil pressure indicator is turned on, and motion alarm and auto-idle control are activated. 4. Convert the value for digital output 1 of the main controller B. Then, calculate the corresponding bit values.

T5-1-9

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

0

1

2

3

4

5

6

7

8

9

A

b

C

d

E

F

0000

0001

0010

0011

0100

0101

0110

0111

1000

1001

1010

1011

1100

1101

1110

1111

In Case of Proportional Valve ON/OFF Output of Main Controller A (Ex.) Monitor Display 60

d Upper

Hexadecimal Number 2 Digits Display Section Lower

1. Convert the upper and lower number on the hexadecimal number 2 digits display section. (Refer to Correspondence Chart between Hexadecimal Number and Binary Number). Upper 6 0110 lower 0 0000 Therefore, binary number 01100000 can be obtained. 2. This value corresponds the bit on the Binary Number Bit List (refer to T5-1-11), as follows: bit 7 bit 6

⇔ ⇔

0 1

bit 5

⇔

1

bit bit bit bit bit

⇔ ⇔ ⇔ ⇔ ⇔

0 0 0 0 0

4 3 2 1 0

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

3. If the value is "1", power flows at the terminal corresponding the bit. If the value is "0", current does not flow at the terminal. (Refer to Diagram 3) From the above information, it becomes apparent that power flows on the #1, #2 power decrease solenoid valve and #3 pump power decrease solenoid valve. 4. Convert the value for the proportional valve On/Off output of the main controller B. Then, calculate the corresponding bit values.

T5-1-10

Main Controller A bit Status of Main Controller

Current Solenoid Valve

(1) Energized

Solenoid Valve (0) De-energized

Diagram 3. Proportional Valve ON/OFF Output

TROUBLESHOOTING / General BINARY NUMBER BIT LIST Upper

Lower

Hexadecimal Number Binary Number

bit 7

Main Controller A Display Description Order 16

Digital Input 0

17

Digital Input 1

18

Digital Input 2

bit 6

bit

Digital Input 3

Digital Output

21

Proportional Valve ON/OFF Output

bit 3

bit 2

bit 1

Upper

bit 0

bit

Lower

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

3 2 1 0 3 2 1 0 3

6

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

2

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

0 1

Blank = 0 Blank = 0

3 2 1 0

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

3

Engine Protection Output

2 1 0 3 2

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

1

Blank = 0

0

Blank = 0

7 6 5 4 7

20

bit 4

7 6 5 4 7 6 5 4 7

5 4

19

bit 5

6 5 4 7 6 5 4

T5-1-11

TROUBLESHOOTING / General Upper

Lower

Hexadecimal Number Binary Number

bit 7

Main Controller B Display Description Order

bit 6

bit

bit 5

bit 4

bit 3

bit 2

bit 1

Upper

bit 0

bit

Lower

9

Digital Input 0

10

Digital Input 1

6 5 4 7

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

2 1 0 3

11

Digital Input 2

6 5 4 7

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

2 1 0 3

12

Digital Input 3

13

Digital 1

6 5 4 7 6 5 4 7

2 1 0 3 2 1 0 3

14

Proportional Valve ON/OFF Output

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

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

2

Blank = 0

1 0 3 2 1 0

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

15

Output

Auto-Lubricatio n Status 1

7 6 5 4 7

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

3 2 1 0 3

6 5 4 7 6 5 4

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

Auto-Lubrication

T5-1-12

TROUBLESHOOTING / General NOTE: No need to convert to binary number. Display Description Upper Data Set Value Order (Long, Middle, Short) = 0 (80, 70, 60) min Selection of (Long, Middle, Short) = 18 Auto-Lubrication 1 (50, 40, 30) min Interval (Long, Middle, Short) = 2 (30, 20, 10) min

Lower

Interval Value

0

Long

1

Middle

2

Short

Selection Pattern of Auto-Lubrication Interval Auto-Lubrication Upper Lower Interval (min.) 0 0 80 0 1 70 0 2 60 1 0 50 1 1 40 1 2 30 2 0 30 2 1 20 2 2 10 4 Digits Displayed in Binary Number

bit 3

Main Controller B Display Description Order

16

Auto-Lubrication Status 2 (upper 4 bits)

17

Auto-Lubrication Status 2 (lower 4 bits)

19

Digital Output 2 (upper 4 bits)

20

Digital Output 2 (lower 4 bits)

bit 2

bit 1

bit 0

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

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

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

T5-1-13

Manual: bit1=0 / bit0=1 Auto: bit1=1 / bit0=0

TROUBLESHOOTING / General MAIN CONTROLLER FAULT CODE LIST Main Controller A Fault Code Trouble 00 Normal 01 Abnormal EEPROM 02 Abnormal RAM 03 Abnormal A/D Conversion 04 Abnormal Sensor Voltage 05 Abnormal Engine Speed

06

07

08 09 10

11 12 13 14

25

Cause • Faulty Main Controller A •

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

T5-1-14

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

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

TROUBLESHOOTING / General Main Controller B Fault code Trouble 30 Normal 31 Abnormal EEPROM 32 Abnormal RAM 33 Abnormal A/D Conversion 34 Abnormal Sensor Voltage 37 Abnormal Main Controller B Reception (Between Main Controller B and Built-In Diagnosing System)

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

T5-1-15

TROUBLESHOOTING / General (Blank)

T5-1-16

TROUBLESHOOTING / Cross Reference Table IMPORTANT: The No. indicates the component number in the circuit diagram. The position indicates the component’s position in the circuit diagram. The number at left side is horizontal lines of drawing frame, the alphabet at right side is vertical lines of drawing frame. Refer to the page and item number in the following group.

ELECTRICAL CIRCUIT DIAGRAM No.

Position

001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030 031 032 033

1G 1G 2G 1H 2K 2B 4C 4I 5C 5F 6H 6H 6I 5J 8C 7C 7C 7D 7D 7D 7D 7E 7E 7E 8D 8D 8D 8D 8D 8D 8D 8D 8D

Component Name Work Light (on Cab Roof) Work Light (at the right side of Frame) Work Light (Under Cab Floor) Horn Fresh Air Sensor (Air Conditioner) DLU (Cummins) Data Link Connector RADIO DLU (Mitsubishi) Sunlight Sensor Wiper Relay (Low) Wiper Relay (High 1) Wiper Relay (High 2) Air Conditioner Unit Monitor Coolant Temperature Gauge Fuel Gauge Liquid Crystal Display (LCD) Switch Panel 1 Auto-Idle Indicator Quick-Idle Indicator Lubrication Mode Indicator (OFF) Lubrication Mode Indicator (Manual) Lubrication Mode Indicator (Auto) Overheat Indicator (L1) Air Filter Restriction Indicator (L2) Fuel Level Indicator (L3) Preheat Indicator (L4) Download Indicator (L5) Alternator Indicator (L6) Engine Oil Pressure Indicator (L7) Pump Transmission Oil Pressure Indicator (L8) Exhaust Gas Temperature Indicator (L9)

T5-2-1

Page T5-3-2 T5-3-2 T5-3-2 T5-3-2 T5-3-2 T5-3-4 T5-3-3 T5-3-4 T5-3-2 T5-3-4 T5-3-4 T5-3-4 T5-3-2 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9

Item Number 1 4 31 8 10 10 10 32 26 25 24 2 14 15 33 16 34 35 32 32 32 30 31 17 28 29 18 27 26 19

Note

TROUBLESHOOTING / Cross Reference Table

No.

Position

034 035 036 037 038 039 040 041 044 045 046 047 048 049 050 051 052 053 054 055 056 057 058 059 060 061 062 063 064 065

8D 8D 8D 8E 8E 8E 8I 8G 10G 10G 9L 9L 9L 9L 10K 10K 11K 11K 11K 12K 14K 11D 11F 12F 11G 11H 14D 14D 14D 14D

Component Name Engine Oil Level Indicator (L10) Coolant Level Indicator (L11) Hydraulic Oil Level Indicator (L12) Auto-Lubrication Indicator (L13) Engine Stop Indicator (L14) Engine Warning Indicator (L15) Travel Alarm Stop Switch (Option) Washer Relay (R3) Work Light Relay 1 (R5) Quick Idle Relay (R9) Heavy Lift Solenoid Valve (SC) Travel Mode Control Solenoid Valve (ST) Oil Cooler Fan Control Solenoid Valve (SF) Power Increase Solenoid Valve (ST) Oil Pressure Sensor 3 Oil Pressure Sensor 2 Oil Pressure Sensor 1 Hydraulic Oil Temperature Sensor Pilot Pressure Sensor (Travel) Pilot Pressure Sensor (All) Solenoid Valve Unit Quick Idle Switch Horn Switch Horn Relay (R6) Power Transistor Unit 2 Power Transistor Unit 1 Auto-Idle Switch Work Light Switch Wiper/Washer Switch Engine Control Dial

T5-2-2

Page T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-3 T5-3-4 T5-3-4 T5-3-4 T5-3-2 T5-3-2 T5-3-10 T5-3-10 T5-3-2 T5-3-2 T5-3-2 T5-3-2 T5-3-2 T5-3-2 T5-3-2 T5-3-2 T5-3-2 T5-3-4 T5-3-4 T5-3-4 T5-3-9 T5-3-9 T5-3-9 T5-3-9

Item Number 25 22 20 24 23 21 5 23 28 2 25 24 12 11 22 22 22 26 27 23 16 3 30 27 13 14 4 7 8 3

Note

TROUBLESHOOTING / Cross Reference Table

No.

Position

066 067 068 069 070 071 072 073 074 075 076 077 078 079 080 081 082 083 084 085 086 087 088 089 091 092 093 094 095 096 097

14D 14D 13F 14F 13H 16A 16C 16D 16H 15K 16K 17F 17F 17F 17F 18H 18I 17K 18K 18H 19H 20K 17C 18C 18G 19G 19B 20C 22B 21C 21F

Component Name Travel Mode Switch Power Mode Switch Auto-Idle Relay (R6) Engine Protection Relay (R27) Flow Rate Decrease Solenoid Valve Relay (R7) Fuse Box 1 Fuse Box 2 DC/DC Converter MC Display Selection Switch Flow Rate Decrease Solenoid Valve Pump Transmission Oil Pressure Switch Boom Mode Selection Switch Buzzer Cancel Switch Heavy Lift Switch Entrance Light Switch Power Transistor Unit 3 Main Controller B (MCX-B) Hydraulic Oil Level Switch1 Hydraulic Oil Level Switch2 Auto-Lubrication Relay (R11) Auto-Lubrication (ALU) Timer Switch Air Cleaner Restriction Switch Entrance Light Relay Load Dump Relay Preheat Indicator Relay (R13) Coolant Level Sensor Relay (R30) Key Switch Engine Stop Relay Engine Stop Solenoid Relay (R18) Entrance Light Engine Warning Indicator Relay (R15)

T5-2-3

Page T5-3-9 T5-3-9 T5-3-4 T5-3-4 T5-3-4 T5-3-4 T5-3-4 T5-3-2 T5-3-3 T5-3-10 T5-3-10 T5-3-9 T5-3-3 T5-3-9 T5-3-9 T5-3-4 T5-3-4 T5-3-2 T5-3-2 T5-3-4 T5-3-9 T5-3-2 T5-3-4 T5-3-4 T5-3-9 T5-3-4 T5-3-2 T5-3-4

Item Number 6 5 6 7 1 17 18 29 3 14 5 13 4 12 36 12 16 28 28 3 11 14 20 4 9 21 33 9

Note

TROUBLESHOOTING / Cross Reference Table

No.

Position

098 099 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119

21G 21I 21I 22I 22I 23B 22F 25B 25B 25B 25B 25C 25C 25C 25C 26E 25F 26B 28C 28C 29D 29F

Component Name Engine Stop Indicator Relay (R16) Cummins Indicator Panel Protction Indicator (L3) Stop Indicator (L2) Warning Indicator (L1) Starter Relay (R19) ECM Relay (R17) Fusible Link 1 (45A) Fusible Link 2 (75A) Fusible Link 3 (75A) Fusible Link 4 (45A) Fusible Link 5 (250A) Fusible Link 6 (100A) Fusible Link 7 (125A) Fusible Link 8 (125A) Auto-Lubrication Device Fuel Level Sensor 1 Pole Junction Battery Relay 2 Battery Relay 1 Battery (12Vx2) Alternator

T5-2-4

Page T5-3-4 T5-3-6 T5-3-4 T5-3-6 T5-3-6 T5-3-6 T5-3-6 T5-3-6 T5-3-6 T5-3-6 T5-3-6 T5-3-1 T5-3-2 T5-3-6 T5-3-6 T5-3-6 T5-3-1 T5-3-8

Item Number 8 2 11 13 12 11 10 4 9 7 8 10 9 6 5 3 8 2

Note

TROUBLESHOOTING / Cross Reference Table

No.

Position

120 121 122 123 124 125 126 127 128 129 130

29G 29G 29H 31F 30F 30G 31H 29J 9G 9I 27F

Component Name Engine Oil Level Switch Grid Heater Relay 1 Grid Heater Relay 2 Coolant Temperature Sensor Starter 2 Starter 1 Engine Speed Sensor (Pump) ECM (Cummins) Work Light Relay 2 (R4) Main Controller A (MCX-A) Coolant Level Sensor

Page T5-3-8 T5-3-8 T5-3-2 T5-3-2 T5-3-2 T5-3-8 T5-3-4 T5-3-4 T5-3-2

T5-2-5

Item Number 6 5 15 15 19 1 22 15 12

Note

TROUBLESHOOTING / Cross Reference Table HYDRAULIC CIRCUIT DIAGRAM (BACKHOE) No.

Position

001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018

1G, H 1I 1J 3C, E 3D 4H 5K 4I 2K 4B 4B 3D 4G 5J

019 020 021 022 023 024 025 026 027 028 029 030

7D 6D 9F 8G 9H 10B 10F 10F 11F 11F 11G 10K

Component Name Front / Swing Pilot Valve Travel Pilot Valve Accumulator Boom Cylinder Bucket Cylinder Shuttle Valve (Bucket Roll-In) Shock Reducing Valve Shuttle Valve (Pilot Pressure Control) Pilot Shut-Off Valve Oil Cooler Oil Cooler Fan Motor Arm Cylinder Hydraulic Oil Tank Shuttle Valve (For Switching Pump 3 Control Pressure) Swing Device Travel Device Brake Release Pressure Switch Valve Shuttle Valve (Boom Raise Priority) Signal Control Valve Main Control Valve Heavy Lift Solenoid Valve Reducing Valve Shuttle Valve (Swing Brake Release) Travel Mode Control Solenoid Valve Shuttle Valve (Auxiliary Circuit) Arm Preference Valve

T5-2-6

T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-30 T5-3-30 T5-3-30 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-30

Item Number 6 30 29 5 1 18 16 17 27 13 14 3 7 10

T5-3-1 T5-3-1 T5-3-30 T5-3-30 T5-3-1 T5-3-1 T5-3-30 T5-3-30 T5-3-30 T5-3-30 T5-3-30 T5-3-30

11 21 6 9 19 12 4 3 7 5 2 11

Page

Note

TROUBLESHOOTING / Cross Reference Table

No.

Position

031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048

12I 12K 15K 14K 16G 15I 16I 16I 17I 17I 18I 18H 20H 20H 20H 19I 19J 19J

Component Name Swing Control Valve Pump 3 Control Valve Shockless Valve Shuttle Valve (Swing Make-Up) Engine Main Pump 3 Main Pump 2 Oil Cooler Fan Motor Drive Pump Pilot Pump Transmission Lubrication Oil Pump Main Pump 1 Flow Rate Decrease Solenoid Valve Power Decrease Solenoid Valve (SA) Power Decrease Solenoid Valve (SB) Boom Mode Selection Solenoid Valve (SC) Power Increase Solenoid Valve (ST) Oil Cooler Fan Control Solenoid Valve (SF) Pilot Filter

T5-2-7

Page T5-3-1 T5-3-30 T5-3-30 T5-3-30 T5-3-1 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10

Item Number 24 13 14 15 17 10 8 4 7 6 3 14 16 17 18 11 12 13

Note

TROUBLESHOOTING / Cross Reference Table HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL) No.

Position

001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018

1F, G 1H 1H 1I 1J 2C, E 2C, D 2D 3D 4H 5K 4I 2K 4B 4B 4D 4G 5J

019 020 021 022 023 024 025 026 027 028 029 030

7D 6D 9F 8G 9H 10B 10F 10F 11F 11F 11G 10K

Component Name Front / Swing Pilot Valve Pilot Valve (Bucket Open) Travel Pilot Valve Pilot Valve (Bucket Close) Accumulator Boom Cylinder Bucket Cylinder Dump Cylinder Level Cylinder Shuttle Valve (Bucket Roll-In) Shock Reducing Valve Shuttle Valve (Pilot Pressure Control) Pilot Shut-Off Valve Oil Cooler Oil Cooler Fan Motor Arm Cylinder Hydraulic Oil Tank Shuttle Valve (For Switching Pump 3 Control Pressure) Swing Device Travel Device Brake Release Pressure Switch Valve Shuttle Valve (Boom Raise Priority) Signal Control Valve Main Control Valve Heavy Lift Solenoid Valve Reducing Valve Shuttle Valve (Swing Brake Release) Travel Mode Control Solenoid Valve Shuttle Valve (Auxiliary Circuit) Arm Preference Valve

T5-2-8

T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-30 T5-3-30 T5-3-30 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-30

Item Number 6 33 30 34 29 5 1 35 32 18 16 17 27 13 14 3 7 10

T5-3-1 T5-3-1 T5-3-30 T5-3-30 T5-3-1 T5-3-1 T5-3-30 T5-3-30 T5-3-30 T5-3-30 T5-3-30 T5-3-30

11 21 6 9 19 12 4 3 7 5 2 11

Page

Note

TROUBLESHOOTING / Cross Reference Table

No.

Position

031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048

12I 12K 15K 14K 16G 15I 16I 16I 17I 17I 18I 18H 20H 20H 20H 19I 19J 19J

Component Name Swing Control Valve Pump 3 Control Valve Shockless Valve Shuttle Valve (Swing Make-Up) Engine Main Pump 3 Main Pump 2 Oil Cooler Fan Motor Drive Pump Pilot Pump Transmission Lubrication Oil Pump Main Pump 1 Flow Rate Decrease Solenoid Valve Power Decrease Solenoid Valve (SA) Power Decrease Solenoid Valve (SB) Boom Mode Selection Solenoid Valve (SC) Power Increase Solenoid Valve (ST) Oil Cooler Fan Control Solenoid Valve (SF) Pilot Filter

T5-2-9

Page T5-3-1 T5-3-30 T5-3-30 T5-3-30 T5-3-1 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10

Item Number 24 13 14 15 17 10 8 4 7 6 3 14 16 17 18 11 12 13

Note

TROUBLESHOOTING / Cross Reference Table (Blank)

T5-2-10

TROUBLESHOOTING / Component Layout MAIN COMPONENTS Backhoe

3

2 1

4

5 6 7 8 9 10

36 37

11 12

31

13

14

15

16

30 29

28 27 Loading Shovel

26

4

25

5 32

24

3 2 35

31

17 23

18 22 6 21

1

19 20 30 33

34 T183-01-02-016

1 - Bucket Cylinder 2 - Arm

11 - Swing Device 12 - Main Control Valve

21 - Travel Device 22 - Upper Roller

3 - Arm Cylinder

13 - Oil Cooler

23 - Lower Roller

4 - Boom

14 - Oil Cooler Fan Motor

24 - Swing Control Valve

5 - Boom Cylinder

15 - Intercooler

25 - Center Joint

678910 -

16 17 18 19 20 -

26 27 28 29 30 -

Front / Swing Pilot Valve Hydraulic Oil Tank Battery (12Vx2) Fuel Tank Auto-Lubrication Device

Radiator Engine Pump Device Signal Control Valve Swing Bearing

T5-3-1

Track Adjuster Pilot Shut-Off Valve Front Idler Accumulator Travel Pilot Valve

31 - Bucket 32 - Level Cylinder (Loading Shovel Only) 33 - Pilot Valve (Bucket Open) (Loading Shovel Only) 34 - Pilot Valve (Bucket Close) (Loading Shovel Only) 35 - Dump Cylinder (Loading Shovel Only) 36 - Condenser (Air Conditioner) 37 - Fuel Cooler

TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM COMPONENTS (1) Overall Layout 3

2

4

5

6

1

7 8

11

9 10

34

12

(Refer to T5-3-4)

(Refer to T5-3-11)

13 33 32 14

31 30 29

15 16 (Refer to T5-3-10)

(Refer to T5-3-3)

28

17 (Refer to T5-3-10) 18 (Refer to T5-3-10)

(Refer to T5-3-30) 27

26 25

19 (Refer to T5-3-8) 24

(Refer to T5-3-30) 23 1 - Work Light (on Cab Roof)

20 22

21

2 - Monitor

10 - Fresh Air Sensor (Air Conditioner) 11 - Fuel Temperature

3 - Quick Idle Switch

12 - Coolant Level Sensor

4 - Work Light (at the right side of Frame) 5 - Starter Relay 1

13 - Coolant Temperature Sensor

6 - Battery

15 - Starter 1,2

7 - Battery Relay

16 - Solenoid Valve Unit

8 - Horn

17 - Flow Rate Decrease Solenoid Valve 18 - 2-Spool EHC Valve

9 - Fuel Level Sensor

14 - Air Cleaner Restriction Switch

19 - Engine Speed Sensor (Pump) 20 - Engine Speed Sensor 2 (ECM) 21 - Pump Transmission Oil Pressure Switch 22 - Oil Pressure Sensor 1, 2, 3 23 - Pilot Pressure Sensor (All) 24 - Travel Mode Control Solenoid Valve (ST) 25 - Heavy Lift Solenoid Valve (SC) 26 - Hydraulic Oil Temperature Sensor 27 - Pilot Pressure Sensor (Travel)

T5-3-2

T18E-01-02-009

28 - Hydraulic Oil Level Switch 1, 2 29 - DC/DC Converter 30 - Horn Switch 31 - Work Light (Under Cab Floor) 32 - Sunlight Sensor 33 - Entrance Light 34 - Electrical Equipment Box

TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM COMPONENTS (2) In the Cab

2

3

1 6

3

7

8

9

T18E-01-02-010

1

2 4

5

M18E-01-009

T18E-01-02-013

1 - 12 V Power Source Terminal 2 - DC-DC Converter

4 - Buzzer Cancel Switch 5 - Travel Alarm Stop Switch (Optional)

6-

Engine Fault Code Display Panel 7 - Fault Diagnosing Switch A

3 - MC Display Selection Switch

T5-3-3

8-

Fault Diagnosing Switch B

9-

DLU Check Switch

TROUBLESHOOTING / Component Layout Electrical Equipment Box

1

2

3

4

5

6

7

8

9

10

28 27 26 25 11

24 23 22

21

20

19

18

17

16

15

14

13

12 T18E-01-02-003

1 - Flow Rate Decrease Solenoid Valve Relay (R7) 2 - *Quick Idle Relay (R9) 3 - Auto-Lubrication Relay (R11) 4 - Preheat Indicator Relay (R13) 5 - *Coolant Lever Switch Relay 6 - *Auto-Idle Relay (R6) 7 - *Engine Protection Relay (R27)

8 - *Engine Stop Indicator Relay (R16) 9 - *Engine Warning Indicator Relay (R15) 10 - DLU (Cummins, Mitsubishi)

15 - Main Controller A (MCX-A) 16 - Main Controller B (MCX-B) 17 - Fuse Box 1

22 - Work Light Relay 2 (R4)

24 - Wiper Relay (High 2)

11 - *ECM Relay (R17)

18 - Fuse Box 2

25 - Wiper Relay (High 1)

12 - Power Transistor Unit 3

19 - Step Light Relay

26 - Wiper Relay (Low)

13 - Power Transistor Unit 2 14 - Power Transistor Unit 1

20 - Load Dump Relay 21 - *Engine Stop Relay

27 - Horn Relay (R6) 28 - Work Light Relay 1 (R5)

23 - Washer Relay (R3)

NOTE: The items with mark ”*” are not used for the machine equipped with CUMMINS engine.

T5-3-4

TROUBLESHOOTING / Component Layout (Blank)

T5-3-5

TROUBLESHOOTING / Component Layout Around Batteries

1

2

12 13 10 11

3 4 5 6

9

1234-

Air Heater Signal Relay Starter Relay (R19) Battery Relay 1 Fusible Link 5 (250A)

567-

8

Battery Relay 2 1 Pole Junction Fusible Link 7 (125A)

7

T183-01-02-015

8 - Fusible Link 8 (125A) 9 - Fusible Link 6 (100A) 10 - Fusible Link 4 (45A)

T5-3-6

11 - Fusible Link 3 (75A) 12 - Fusible Link 2 (75A) 13 - Fusible Link 1 (45A)

TROUBLESHOOTING / Component Layout Used Circuit Fusible Link Part Name Fusible Link 1

Fusible Link 2

Fusible Link 3

Fusible Link 4 Fusible Link 5 Fusible Link 6 Fusible Link 7 Fusible Link 8

Circuit Monitor, Back up Power Circuit Main Controller B, DLU Main Power Circuit ECM Power Circuit Work Light Relays 1, 2 Power Circuit Washer Relay, Wiper Relay (L, H1, H2), Wiper Motor Power Circuit Air Conditioner Power Circuit Auto-Lubrication Solenoid Valve Relay, Flow Rate Decrease Solenoid Valve Relay, Power Transistors 1, 2 and 3 DC-DC Converter Power Circuit Main Controller A, B Solenoid Power Circuit Travel Alarm Power Circuit Monitor, Main Controller A Main Power circuit Step Light Relay Power Circuit Air Conditioner Air Heater Signal Relay Power Circuit Starter Relay Power Circuit Alternator Preheat Relay 1 Power Circuit Preheat Relay 2 Power Circuit

T5-3-7

Connected Fuse Box 1 (#1, #2) Fuse Box 2 (#1) Fuse Box 2 (#11～14)

Fuse Box 2 (#4～9)

Air Heater Signal Relay Starter Relay 1 Alternator Preheat Relay 1 Preheat Relay 2

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

8

5 9

4

3

7

11

2

10

12

6

1

T18E-01-02-011

1 - ECM (Cummins) 2 - Alternator 3 - Engine Speed Sensor 1 (ECM)

4-

Engine Speed Sensor 2 (Pump) 5 - Coolant Temperature Sensor 6 - Engine Oil Level Sensor

7-

Preheat Relay

8-

Starter

9-

Coolant Temperature Sensor (ECM)

T5-3-8

10 - Engine Oil Pressure Sensor 11 - Suction Manifold Temperature Sensor 12 - Fuel Temperature Sensor

TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM COMPONENTS (4) Monitor Panel

Monitor and Switch Panels

14

15

1 35 34 16

33

2

32 31 3

30 29

4

28

5 6

27 26

7 8

25

17 18 19 20

T183-01-02-013

24 23

9

22 21

10

13 12 11

36 M183-01-035

T183-01-02-010

1 - Monitor Panel 2 - Quick Idle Switch 3 - Engine Control Dial 4 - Auto-Idle Switch

10 - Air Conditioner Control Panel 11 - Auto-Lubrication (ALU) Timer Switch 12 - Heavy Lift Switch

6 - Travel Mode Switch

13 - Boom Mode Selection Switch 14 - Coolant Temperature Gauge 15 - Fuel Gauge

7 - Work Light Switch

16 - Switch Panel 1

8 - Wiper/Washer Switch

17 - Fuel Level Indicator (L3)

9 - Key Switch

18 - Alternator Indicator (L6)

5 - Power Mode Switch

19 - *Exhaust Gas Temperature Indicator (L9) 20 - Hydraulic Oil Level Indicator (L12) 21 - Engine Warning Indicator (L15) 22 - Coolant Level Indicator (L11) 23 - Engine Stop Indicator (L14) 24 - Auto-Lubrication Indicator (L13) 25 - Engine Oil Level Indicator (L10) 26 - Pump Transmission Oil Pressure Indicator (L8) 27 - Engine Oil Pressure Indicator (L7)

28 - Preheat Indicator (L4) 29 - Download Indicator (L5) 30 - Overheat Indicator (L1) 31 - Air Filter Restriction Indicator (L2) 32 - Lubrication Mode Indicator (OFF) (Manual) (Auto) 33 - Liquid Crystal Display (LCD) 34 - Auto-Idle Indicator 35 - Quick-Idle Indicator 36 - Entrance Light Switch

NOTE: The Item with mark “*” is not used for the machine equipped with CUMMINS engine.

T5-3-9

TROUBLESHOOTING / Component Layout 1

ON AND AROUND PUMPS Front

Pump Device

2

10

3

9 8 7 4

6

Solenoid Valves and Related Components

18 Solenoid Valve Unit

T183-01-02-006

5

11 17

16

2-Spool EHC Valve

12 15 Front

13

14

T183-01-02-007

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

6 - Transmission Lubrication Oil Pump 7 - Pilot Pump

3 - Main Pump 1

8 - Main Pump 2

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

9 - Main Pump 2 regulator

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

10 - Main Pump 3

T5-3-10

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

TROUBLESHOOTING / Component Layout Coolant Level Switch

T18E-01-02-012

T5-3-11

TROUBLESHOOTING / Component Layout MAIN CONTROL VALVE

2

3

4

5

6

7

8

9

Auxiliary: BH Bucket Open/Close: LD

1

10 34 Arm 1 Arm 2

11

33

Boom 2 Boom 1

12

32

13 14

31

Bucket 2

15

Bucket 1

16

30

17 18

Left Travel

29 28 19

Right Travel

27 26

25

24

23

22 21

20

T18E-03-03-001

NOTE: BH: Backhoe LD: Loading Shovel 1 - Holding Valve Switch Valve (Boom) 2 - Load Check Valve (Arm 2 Tandem Circuit) 3 - Load Check Valve (Arm 2 Parallel Circuit) 4 - Arm Regenerative Valve 5 - Load Check Valve (Arm 1 Parallel Circuit1) 6 - Load Check Valve (Arm 1 Parallel Circuit2) 7 - Load Check Valve (Auxiliary Tandem Circuit) 8 - Load Check Valve (Arm 1 Tandem Circuit) 9 - Holding Valve Switch Valve (Arm)

10 - Overload Relief Valve (Aux.: BH, Bucket Open/Close: LD) 11 - Overload Relief Valve (Arm) 12 - Holding Valve Check Valve (Arm) 13 - Load Check Valve (Boom 2 Tandem Circuit) 14 - Load Check Valve (Boom 2 Parallel Circuit) 15 - Overload Relief Valve (Boom Mode Selection) 16 - Boom Overload Relief Pressure Switch Valve 17 - Load Check Valve (Bucket 2 Tandem Circuit) 18 - Overload Relief Valve (Bucket 2)

19 - Load Check Valve (Left Travel Tandem Circuit)

27 - Main Relief Valve

20 - Load Check Valve (Left Travel Parallel Circuit) 21 - Load Check Valve (Bucket 2 Parallel Circuit) 22 - Check Valve (Main Relief Pressure Combining Circuit) 23 - Flow Combiner Valve

28 - Load Check Valve (Bucket 1 Tandem Circuit) 29 - Overload Relief Valve (Bucket 1) 30 - Load Check Valve (Boom1 Parallel Circuit) 31 - Overload Relief Valve (Boom) 32 - Holding Valve Check Valve (Boom) 33 - Slow Return Valve

24 - Check Valve (Travel Flow Combine Circuit) 25 - Check Valve (Main Relief Pressure Combining Circuit) 26 - Shuttle Valve

T5-3-12

34 - Make-Up Valve (Arm 2)

TROUBLESHOOTING / Component Layout 11

9

G

F

15, 16 18 E

D

C

B

Section A

A

26

27

25 10 Front

27

4

26

31

29 24

33 Section B

T183-03-03-003

23

T183-03-03-002

1

Section C

36

35

Right Travel

39

Bucket 1

Left Travel

40 Bucket 2

18

29

17 19

28

21 20 18

29 T183-03-03-004

37

T183-03-03-005

38

41

42

NOTE: BH: Backhoe LD: Loading Shovel

35 - Right Travel (Forward) Port

37 - Left Travel (Reverse) Port

36 - Left Travel (Forward) Port

38 - Right Travel (Reverse) Port

39 - Bucket 1 (Roll-Out : BH, Tilt-Out : LD) Port 40 - Bucket 2 (Roll-Out : BH, Tilt-Out : LD) Port

T5-3-13

41 - Bucket 1 (Roll-In : BH, Tilt-In : LD) Port 42 - Bucket 2 (Roll-In : BH, Tilt-In : LD) Port

TROUBLESHOOTING / Component Layout 2

3

4

5

6

7

8

9

Auxiliary: BH Bucket Open/Close: LD

1

10 34 Arm 1 Arm 2

11

33

Boom 2 Boom 1

12

32

13 14

31

Bucket 2

15

Bucket 1

16

30

17 Left Travel

18

29 28 19

Right Travel

27 26

25

24

23

22 21

20

T18E-03-03-001

NOTE: BH: Backhoe LD: Loading Shovel 1 - Holding Valve Switch Valve (Boom) 2 - Load Check Valve (Arm 2 Tandem Circuit) 3 - Load Check Valve (Arm 2 Parallel Circuit) 4 - Arm Regenerative Valve 5 - Load Check Valve (Arm 1 Parallel Circuit1) 6 - Load Check Valve (Arm 1 Parallel Circuit2) 7 - Load Check Valve (Auxiliary Tandem Circuit) 8 - Load Check Valve (Arm 1 Tandem Circuit) 9 - Holding Valve Switch Valve (Arm)

10 - Overload Relief Valve (Aux.: BH, Bucket Open/Close: LD) 11 - Overload Relief Valve (Arm) 12 - Holding Valve Check Valve (Arm) 13 - Load Check Valve (Boom 2 Tandem Circuit) 14 - Load Check Valve (Boom 2 Parallel Circuit) 15 - Overload Relief Valve (Boom Mode Selection) 16 - Boom Overload Relief Pressure Switch Valve 17 - Load Check Valve (Bucket 2 Tandem Circuit) 18 - Overload Relief Valve (Bucket 2)

19 - Load Check Valve (Left Travel Tandem Circuit)

27 - Main Relief Valve

20 - Load Check Valve (Left Travel Parallel Circuit) 21 - Load Check Valve (Bucket 2 Parallel Circuit) 22 - Check Valve (Main Relief Pressure Combining Circuit) 23 - Flow Combiner Valve

28 - Load Check Valve (Bucket 1 Tandem Circuit) 29 - Overload Relief Valve (Bucket 1) 30 - Load Check Valve (Boom1 Parallel Circuit) 31 - Overload Relief Valve (Boom) 32 - Holding Valve Check Valve (Boom) 33 - Slow Return Valve

24 - Check Valve (Travel Flow Combine Circuit) 25 - Check Valve (Main Relief Pressure Combining Circuit) 26 - Shuttle Valve

T5-3-14

34 - Make-Up Valve (Arm 2)

TROUBLESHOOTING / Component Layout 43

Section D

44

Boom 1

Section E

47

4

48

Boom 2 Arm 2

16 31

33

Arm 1

12

34

9

15

13

30

6 3 14

8

2 11

31

T183-03-03-007

1

32

49

46

50

T183-03-03-006

45

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

Section F

10 Section G

11

7

T183-03-03-009

9 34

52 T183-03-03-008

43 - Boom 1 (Lower) Port

46 - Boom 2 (Raise) Port

44 - Boom 2 (Lower) Port

47 - BH: Arm 2 (Roll-Out) Port LD: Arm 2 (Retract) Port 48 - BH: Arm 1 (Roll-Out) Port LD: Arm 1 (Roll-In) Port

45 - Boom 1 (Raise) Port

49 - BH: Arm 2 (Roll-In) Port LD: Arm 2 (Extend) Port 50 - BH: Arm 1 (Retract) Port LD: Arm 1 (Extend) Port

T5-3-15

51 - BH: Auxiliary Port LD: Bucket (Open) Port 52 - BH: Auxiliary Port LD: Bucket (Open) Port

TROUBLESHOOTING / Component Layout SWING CONTROL VALVE 1

2

11

Boom 3

3

10

Swing

4

Bucket 3

5

9

Arm 3

6

8

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

4 - Load Check Valve (Bucket 3) 5 - Load Check Valve (Arm 3) 6 - Load Check Valve (Arm 3 Parallel Circuit)

7

7 - Check Valve (Arm 3) 8 - Make-Up Valve (Arm 3) 9 - Overload Relief Valve (Swing)

T5-3-16

T18E-03-03-002

10 - Holding Valve Switch Valve 11 - Holding Valve Check Valve (Boom 3)

TROUBLESHOOTING / Component Layout 12

Section A

14

16

18

1 B

C

D

E

F

A

1

10

9

T183-03-03-011

13

Section B

15

T183-03-03-012

19

14

Section C

11

17

Swing

Boom 3

9

3 2 10

9

11 15

T183-03-03-013

13

12 - Boom 3 (Lower) Port

13 - Boom 3 (Raise) Port

14 - Swing (Left) Port

T5-3-17

15 - Swing (Right) Port

T183-03-03-014

TROUBLESHOOTING / Component Layout

1

2

11

Boom 3

3

10

Swing

4

Bucket 3

5

9

Arm 3

6

8

12-

Main Relief Valve

Load Check Valve (Boom 3) 3 - Load Check Valve (Swing)

4-

Load Check Valve (Bucket 3) 5 - Load Check Valve (Arm 3) 6 - Load Check Valve (Arm 3 Parallel Circuit)

7

7-

Check Valve (Arm 3) 8 - Make-Up Valve (Arm 3) 9 - Overload Relief Valve (Swing)

T5-3-18

T18E-03-03-002

10 - Holding Valve Switch Valve 11 - Holding Valve Check Valve (Boom 3)

TROUBLESHOOTING / Component Layout 16

18

Section D

Section E

Bucket 3

Arm 3

5 4

6

T183-03-03-015

17

19

7

T183-03-03-016

Section F

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

7

T183-03-03-017

17 - Bucket 3 (Roll-In) Port

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

T5-3-19

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

TROUBLESHOOTING / Component Layout (Blank)

T5-3-20

TROUBLESHOOTING / Component Layout SIGNAL CONTROL VALVE

A

A

Pilot Valve Side

T178-03-06-016

Cross Section A-A

Shockless Valve

Arm Flow Rate Control

Auxiliary

Pump 1 and 2 Flow Rate Control Valve

Auxiliary

Flow Combiner Valve Control Spool

Priority Valve

T178-03-06-002

T5-3-21

TROUBLESHOOTING / Component Layout Pilot Port NOTE: BH: Backhoe LD: Loading Shovel Pilot Valve Side Port Name Port A Port B Port C

Connecting to Right Pilot Valve Right Pilot Valve Left Pilot Valve

Port D Port E Port F

Right Pilot Valve Hydraulic Oil Tank Left Pilot Valve

Port G

Left Pilot Valve

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

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

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

Pump 1 and 2 Regulator − Pilot Shut-Off Valve Pilot Shut-Off Valve − Hydraulic Oil Tank

T5-3-22

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

TROUBLESHOOTING / Component Layout

Pilot Valve Connecting Side C

PH A

E M D H B

F

SB G

PI

Pilot Valve Side

N

K

I SH

J DF SA

L T178-03-06-016

T5-3-23

TROUBLESHOOTING / Component Layout NOTE: BH: Backhoe LD: Loading Shovel Control Valve Side Port Name Port 1 Port 2 Port 3 Port 4 Port 5 Port 6

Connecting to Control Valve − − − − Control Valve

Port 7

Control Valve

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

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

Port 14

Control Valve

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

Shuttle Valve Shuttle Valve Shuttle Valve Shuttle Valve Control Valve −

T5-3-24

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

TROUBLESHOOTING / Component Layout

Control Valve Connecting Side SM

3 5

1 13 2 SK

4 SE 8

S3

14 Control Valve Side

7 9 6

10

SN

SL

11

Pressure Sensor (Travel)

12

T5-3-25

SP

T178-03-06-015

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

Pump 1 and 2 Flow Control Valve Boom Raise Boom Lower Arm Roll-Out (BH) Arm Roll-In (LD) Arm Roll-In (BH) Arm Roll-Out (LD) Bucket Roll-In Bucket Roll-Out Right Travel Left Travel Auxiliary (Close) (BH) Bucket Close (LD) Auxiliary (Open) (BH) Bucket Open (LD)

Arm Flow Rate Control Valve

Flow Combiner Valve Control Spool

Priority Valve

{ {

{ −

− −

{ {

{

−

−

{

{

−

−

{

{ { { −

− − − −

− − { −

{ { − −

−

−

−

{

−

−

−

{

T5-3-26

TROUBLESHOOTING / Component Layout Swing Arm

1

2

3

4

Boom

Bucket

Left Travel

Right Travel

5

Shockless Valve

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

T183-03-06-001

17 16 15 14 13 12 1 - Auxiliary (BH), Bucket Open/Close (LD)

6 - Right Travel

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

7 - Left Travel, Right Travel

4 - Boom, Bucket Roll-Out

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

11 10

9

8

7 14 - Boom, Arm, Bucket

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

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

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

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

13 - Room Raise, Arm, Bucket

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

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

NOTE: BH: Backhoe LD: Loading Shovel

T5-3-27

TROUBLESHOOTING / Component Layout

Swing Arm

1

2

3

4

Boom

Left Travel

Bucket

Right Travel

5

Shockless Valve

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

T183-03-06-001

17 16 15 14 13 12

11 10

NOTE: BH: Backhoe LD: Loading Shovel

T5-3-28

9

8

7

TROUBLESHOOTING / Component Layout

B

B

Pilot Valve Side

T178-03-06-016

Cross Section B-B 9 5

8

7 16 17 15

13

11

14 10

6

12

3

1

4 2

T178-03-06-009

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

6 - Right Travel

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

7 - Left Travel, Right Travel

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

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

14 - Boom, Arm, Bucket

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

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

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

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

13 - Room Raise, Arm, Bucket

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

T5-3-29

TROUBLESHOOTING / Component Layout OTHERS Valves (1)

1

2

Swing Device

3

20

19

9 4 Front Side

8 5

7

6

T142-01-02-011

T183-01-02-008

Travel Device

Valves (2) 10

11

21

12

18 22

17 16 13 Valves (1)

15

14 T18E-01-02-002 T183-01-02-012

1 - Pilot Pressure Sensor (Travel) 2 - Shuttle Valve (Auxiliary Circuit) 3 - Reducing Valve 4 - Heavy Lift Solenoid Valve

5 - Travel Mode Control Solenoid Valve 6 - Brake Release Pressure Switch Valve

7 - Shuttle Valve (Swing Brake Release) 8 - Pilot Pressure Sensor (All) (Front Operation) 9 - Shuttle Valve (Boom Raise Priority) 10 - Shuttle Valve (For Switching Pump 3 Control Pressure) 11 - Arm Preference Valve

13 - Pump 3 Control Valve 14 - Shockless Valve 15 - Shuttle Valve (Swing Make-Up) 16 - Shock Reducing Valve

17 - Shuttle Valve (Pilot Pressure Control)

12 - Signal Control Valve

T5-3-30

18 - Shuttle Valve (Bucket Roll-In) 19 - Swing Parking Brake Release Valve 20 - Swing Relief Valve 21 - Counterbalance Valve

22 - Travel Relief Valve

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

• How to Read Troubleshooting Flow Charts

YES (OK)

・

(2)

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

(1) NO (NOT OK)

・ · Key switch: ON

(3)

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

・

Refer to "Electrical System Inspection" group (Group 8) for descriptions in the dotted-line box.

・

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

・

Causes of machine problems are stated in the thick-line box. Scanning quickly through the thick-line boxes allows you to estimate the possible causes before actually following the flow chart.

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

Harness Open End Side

Harness End Connector T158-05-03-001

T5-4-1

TROUBLESHOOTING / Troubleshooting A MAIN CONTROLLER FAULT CODE LIST Main Controller A Fault Code Trouble 00 Normal 01 Abnormal EEPROM 02 Abnormal RAM 03 Abnormal A/D Conversion 04 Abnormal Sensor Voltage 05 Abnormal Engine Speed

06

Cause

• Faulty Main Controller A

08 09

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

10

Abnormal Engine Control Dial Angle

11 12 13 25

Abnormal Pump 1 Delivery Pressure Abnormal Pump 2 Delivery Pressure Abnormal Pump 3 Delivery Pressure Abnormal Oil Temperature Sensor

07

• • • • • •

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

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

T5-4-2

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

TROUBLESHOOTING / Troubleshooting A Main Controller B Fault Code Trouble Cause 30 Normal 31 Abnormal EEPROM • Faulty Main Controller B 32 Abnormal RAM 33 Abnormal A/D Conversion 34 Abnormal Sensor Voltage • Faulty Main Controller B 37 Abnormal Main Controller B Reception • Faulty Main Controller B (Between Main Controller B and Built-In • Faulty Harness Diagnosing System)

T5-4-3

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

∗Faulty main controller A.

Check if engine and machine actuators operate normally.

NO

NO

Faulty main controller A.

YES

Look for the cause from other fault phenomenon.

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

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

FAULT CODE 04 ABNORMAL SENSOR VOLTAGE YES

Faulty main controller A.

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

Faulty alternator.

NO

T5-4-4

TROUBLESHOOTING / Troubleshooting A FAULT CODE 05 ABNORMAL ENGINE SPEED

Disconnect connector from engine speed sensor 1. Check if resistance between sensor end connector terminals #1 and #2 matches specification. · Specification: 200 to 300 Ω

Connect engine speed sensor 1 harness end connector terminals #1 and #2. YES Disconnect connector D from main controller A. Check for continuity between connector D harness end terminals #D13 and #D14.

NO

Main Controller A Connector D

D14

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

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

NO

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

NO

Connector (Harness End Connector Viewed from the Open End Side)

D13

Faulty main controller A.

YES

T183-05-04-009

Engine Speed Sensor 1

T18E-05-04-001

T5-4-5

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

Exchange main controller A and main controller B. Turn off MC display selection switch to change the monitor display to main controller B. Display the faulty code. Check if Code 37 is displayed.

YES

Faulty main controller A.

NO

Broken harness between main controller A and main controller B.

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

D9

T183-05-04-009

Main Controller B Connector D

D10

T183-05-04-009

T5-4-6

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

YES

Disconnect connector 76B from DLU. Check if voltage between harness end connector terminals #41 and #33 is 5±0.5 V.

Disconnect joining connector between DLU and main controller A. Check for continuity between DLU harness end connector 76B terminal #32 and joining connector DLU end terminal #2.

YES

Faulty DLU.

NO

Faulty ground wire on DLU.

YES

· Key Switch: ON NO

Reconnect connector D to main controller A. Connect DLU harness end connector 76B terminals #41 and #33 with a clip.

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

Between Main Controller Diagnosing System

A

and

NO

Faulty main controller A.

Check harness between DLU harness end connector 76B terminal #41 and connector D harness end terminal #D11 for breakage or short circuit.

Broken harness between DLU harness YES end connector 76B terminal #41 and connector D terminal #D11.

NO

Built-In

Broken harness between main controller A and monitor controller.

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

Broken harness between DLU harness end connector 76B terminal #33 and connector D terminal #D12.

Faulty main controller A.

NO

Connector DLU

Main Controller Connector D

Connector 76B

D10

D11

Monitor Controller Connector B D12

B1

Joining Connector (Between DLU and Main Controller A)

T18E-05-04-003 T183-05-04-013 T18E-05-04-002 T183-05-04-009

T5-4-7

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

Disconnect connectors from all operation pressure sensor and NO travel pressure sensor. Check if voltage between harness end connector terminals #1 and #3 is 5±0.5 V. · Key switch: ON Check if fault codes are switched after switching all operation pressure sensor with travel pressure sensor and retrying.

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

Check if voltage between all operation pressure sensor (or travel pressure sensor) harness end connector NO terminal #1 and vehicle frame matches specification. · Key switch: ON · Specification: 5±0.5 V

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

C1

C23

C31

All Operation Pressure Sensor, Travel Pressure Sensor

1

2

NO

Faulty main controller A.

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

NO

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

YES

C1

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

3

T5-4-8

TROUBLESHOOTING / Troubleshooting A (Blank)

T5-4-9

TROUBLESHOOTING / Troubleshooting A FAULT CODE 10 ABNORMAL ENGINE ANGLE

Disconnect switch box connector. Check if resistance between switch box end connector terminals #2 and #4 is 5±0.5 kΩ. Reconnect switch box connector. Insert tester probe into connector terminal #3 from the reverse side. Check if voltage varies as specified when engine control dial is turned.

CONTROL

DIAL

Disconnect switch box connector. YES Check if voltage between harness end connector terminals #2 and #4 is 5±0.5 V.

Disconnect ECM connector 31 poles. Check harness YES between connector 31 poles harness end terminal #5 and switch box terminal #3 for breakage or short circuit.

· Key switch: ON

NO

· Specification: See table below.

Disconnect ECM connector 31 poles. Check for continuity between switch box harness end connector terminal #4 and ECM harness end connector terminal #6.

YES Broken harness between ECM and engine control dial.

NO

NO

Faulty harness between switch box and engine control dial.

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

Check for continuity between switch box YES harness end connector terminal #2 and ECM harness end connector #4.

Faulty engine control dial.

NO

Engine Control Dial Specification Maximum Speed 0.3 to 1.0 V Minimum Speed 4.0 to 4.7 V Connector (Harness End Connector Viewed from the Open End Side) ECM Connector 31 Poles

Switch Box

#4

#3

#2

T18E-05-04-004

T5-4-10

TROUBLESHOOTING / Troubleshooting A

YES

NO

Faulty ECM.

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

T5-4-11

TROUBLESHOOTING / Troubleshooting A FAULT CODE 11 ABNORMAL PUMP 1 DELIVERY PRESSURE FAULT CODE 12 ABNORMAL PUMP 2 DELIVERY PRESSURE FAULT CODE 13 ABNORMAL PUMP 3 DELIVERY PRESSURE Disconnect pump delivery pressure NO sensor. Check if voltage between harness end connector terminals #1 and #3 is 5±0.5 V.

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

· Key switch: ON

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

NO

Check if voltage between pump delivery pressure sensor harness end connector terminal #1 and vehicle frame matches specification. · Key switch: ON · Specification: 5±0.5 V

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

C23

C5

NO

Faulty main controller A.

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

NO

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

YES

C1

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

C6 C10

C31

Pump Delivery Pressure Sensor

T146-05-03-006

T5-4-12

TROUBLESHOOTING / Troubleshooting A FAULT CODE 25 ABNORMAL OIL TEMPERATURE SENSOR

Connect oil temperature sensor harness end connector terminals #1 and #2 YES with a clip. Remove connector B and connector C from main controller A. Check for continuity between connector B harness end terminal #B22 and connector C terminal #C24.

Disconnect oil temperature sensor. Check if sensor end connector resistance matches specification.

NO

· Specification: See table below.

Oil Temperature Sensor Specification Oil Temperature Resistance(kΩ) (°C) (°F) -20 -4 16.2±1.6 0 32 (5.88) 20 68 2.45±0.24 40 104 (1.14) 60 140 (0.534) 80 176 0.322 Connector (Harness End Connector Viewed from the Open End Side) Main Controller A Connector B B8

B19

B25 B22

Connector C C10

C1

C23

C31 C24

Oil Temperature Sensor 1

Connect main controller A connector B harness end terminal #B22 to vehicle frame. Check for continuity between oil temperature sensor harness end connector terminal #2 and vehicle frame.

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

NO

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

NO

B1

Faulty main controller A.

YES

2

T5-4-13

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

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

Check if machine operates normally.

* Faulty main controller B.

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

YES

Look for the cause from other fault phenomenon.

Faulty main controller B. NO

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

FAULT CODE 34 ABNORMAL SENSOR VOLTAGE

Check if voltage at alternator terminal B is normal.

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

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

YES

Faulty main controller B.

NO

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

NO

T5-4-14

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

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

YES

Faulty main controller B.

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

NO

T5-4-15

TROUBLESHOOTING / Troubleshooting A SENSOR ACTIVATING RANGE 1. Checking Method

• Hydraulic Oil Temperature: 50±5 °C • Unless specified: Engine Control Dial

Power Mode Switch

Auto-Idle Switch

S/P

OFF

Maximum Speed

• Monitor each sensor using the built-in diagnosing system. 2. Sensor Activating Range Sensor Engine Control Dial

Pressure Sensor

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

T5-4-16

Specification 0.3 to 1.0 V 4.0 to 4.7 V 0 to 0.10 MPa (0 to 1.0 kgf/cm2) 3.3 to 3.9 MPa (34 to 40 kgf/cm2)

TROUBLESHOOTING / Troubleshooting B TROUBLESHOOTING B PROCEDURE Apply troubleshooting B procedure when diagnosing from the fault phenomenon. On the front section pages of this group T5-5, there are tables indicating the relationship between machine trouble symptoms and related parts which may cause such trouble if failed. Start the troubleshooting with more probable causes selected by referring to these tables.

• How to Read Troubleshooting Flow Charts YES(OK)

•

(2)

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

(1)

NO(NOT OK)

• · Key switch: ON

(3)

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

•

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

•

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

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

Harness

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

T5-5-1

TROUBLESHOOTING / Troubleshooting B CORRELATION BETWEEN TROUBLE SYMPTOMS AND PART FAILURES This table indicates the relationship between machine troubles and parts contributing to the cause of the trouble if failed. Engine System Troubleshooting Trouble Symptom

Main Controller A ECM Monitor Controller Switch Box Pilot Pressure Sensor Quick-Idle Switch Auto-Idle Switch Battery Relay Starter Relay Starter Relay 1 Starter Relay 2 Flow Rate Decrease Solenoid Valve Relay Preheat Relay 1 Preheat Relay 2 Power Transistor 1 Power Transistor 2 Flow Rate Decrease Solenoid Valve Power Decrease Solenoid Valve Engine Speed Sensor 1 Pump 1 and 2 Control Valve (Signal Control Valve)

E-1

E-2

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

Although starter rotates, engine does not start.

z z

z z

z z z z

Shuttle Valve (Swing Make-Up) Shockless Valve (Pump 2 Regulator Pressure Pi Circuit Side) Starter Motor Engine Unit Main Pump / Regulator Shuttle Valve

E-3 Even if engine control dial is rotated, engine speed remains unchanged.

z z

z

T5-5-2

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

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

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

z

E-6 Quick-idle system is inoperable.

z z

z

In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom.

E-7

E-8

E-9

Auto-idle system is inoperable.

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

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

z z

z

z z z z

z

T5-5-3

TROUBLESHOOTING / Troubleshooting B

Trouble Symptom

E-10 Engine stalls.

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

E-11 Even if preheat switch is pressed, air heater does not operate (Engine is difficult to start).

z z

z z z z z z z z z

z z

T5-5-4

TROUBLESHOOTING / Troubleshooting B (Blank)

T5-5-5

TROUBLESHOOTING / Troubleshooting B

All Actuator System Troubleshooting A-1 Trouble Symptom

All actuator speeds are slow.

A-2 All actuators are inoperable.

A-3

A-4

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

SP mode is inoperable.

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

z

z z

z z z z

z z

z z

z z z z

z z

T5-5-6

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

A-5 E mode is inoperable.

z z

z

T5-5-7

In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom.

TROUBLESHOOTING / Troubleshooting B

Front Attachment System Troubleshooting Trouble Symptom

F-1

F-2

F-3

F-4

Some front attachment movement is slow, or is inoperable.

Front attachment drifts remarkably.

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

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

Parts Main Controller A Main Controller B Heavy Lift Switch Boom Mode Selection Switch Flow Rate Decrease Solenoid Valve Relay Power Transistor 1 Heavy Lift Solenoid Valve Boom Mode Selection Solenoid Valve Flow Rate Decrease Solenoid Valve Spool Overload Relief Valve Load Check Valve Shuttle Valve Main Relief Valve Boom Overload Relief Change Valve Main Pump / Regulator Pilot Valve Cylinder Slow-Return Valve Shockless Valve (Signal Control Valve) Arm Flow Rate Control Valve (Signal Control Valve)

z z

z z

z z

z z

z z

z

z z z z z

Shuttle Valve (Boom Raising Priority) Arm Preference Valve Shuttle Valve (Pilot Selection) Pump 3 Control Valve Shuttle Valve (Pump 3 Control Valve Selection) Shuttle Valve (Swing Make-Up) Shockless Valve (Pump 2 Regulator Pressure Pi Circuit Side)

z

T5-5-8

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

In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom.

F-5

F-6

F-7

F-8

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

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

Heavy lift function does not operate.

Boom mode selection function does not operate.

z z z z z z z z z z

z

z z

z z

z z

z z

z z z z z

T5-5-9

TROUBLESHOOTING / Troubleshooting B

Swing/Travel System Troubleshooting Trouble Symptom

S-1 Swing is unmoving, slow or weak in power.

S-2 Swing drift is large when stopping.

T-1 Both right and left tracks do not rotate or rotate slowly.

T-2 Fast travel is inoperable.

Parts Main Controller B Switch Box Travel Mode Control Solenoid Valve Main Pump / Regulator Spool Overload Relief Valve Load Check Valve Flow Combiner Valve Shuttle Valve (Swing Brake Release) Pump 3 Control Valve Reducing Valve Priority Valve (Signal Control Valve) Flow Combiner Valve Selection Spool (Signal Control Valve) Counterbalance Valve Pilot Valve Shuttle Valve (Pilot Selection) Shuttle Valve (Swing Make-Up) Shockless Valve (Pump 2 Regulator Pressure Pi Circuit Side) Swing Motor Swing Parking Brake Release Valve Swing Reduction Gear Swing Relief Valve Travel Parking Brake Travel Motor Travel Reduction Gear Travel Relief Valve Center Joint

z z z z z

z z

z

z

z z

z

z

z

z

z z z z z z z z

T5-5-10

TROUBLESHOOTING / Troubleshooting B In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom.

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

T-3 Slow travel is inoperable.

T-4

T-5

T-6

One side track does not move, moves slowly or mistracks.

Travel motor runs excessively fast when combined left travel and front attachment operation is performed with left track off the ground.

Machine mistracks during combined travel and front attachment operation.

z z z z

z

z

z

z

z z

z

z z z

z z z z

T5-5-11

TROUBLESHOOTING / Troubleshooting B

Other System Troubleshooting Trouble Symptom

O-1

O-2

O-3

O-4

Auto-lubrication indicator comes ON. (Grease pump does not operate.) (Empty grease in pump)

Grease pump operates excessively slow.

Grease pump does not stop operating.

Oil cooler fan motor does not rotate at speed corresponding to hydraulic oil temperature or does not rotate at all.

Parts Main Controller A Main Controller B Auto-Lubrication Selection Switch Proximity Switch Step Light Switch Auto-Lubrication Relay Step Light Relay Power Transistor 3 Oil Cooler Fan Control Solenoid Valve Grease Pump Oil Cooler Fan Motor Drive Pump Oil Cooler Fan Motor Step Light Follow Plate

z z

z

z z z

z

z

z z z z z

z

z

T5-5-12

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

O-5 Step light does not come ON.

O-6 Even if step light switch is turned OFF, step light does not come OFF after 60 seconds.

z

z

z

z

z

z

O-7 Air conditioner.

z

T5-5-13

In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom.

TROUBLESHOOTING / Troubleshooting B ENGINE SYSTEM TROUBLESHOOTING E-1 Starter does not rotate even if key switch is turned to START position. This problem is contributed to by many different causes. Diagnose the power system and the relay system separately to locate the cause of the problem.

• The electrical system is diagnosed in this group. In case the starter does not rotate due to failure in the engine unit, refer to the engine service manual. • The same problem will be presented in case either the valve switch or the engine stop switch is activated. Check each switch condition first. • Check for loose harness connections beforehand. 0 V.

(2)

To Relay System Troubleshooting

(T5-5-16)

YES Check for voltage at starter motor terminal C. · Key switch: START Check if voltage at starter motor terminal B is 24 V or over.

24 V

Faulty starter unit, or faulty engine unit.

· Key switch: ON

(1)

NO

To Power System Troubleshooting

(T5-5-15)

Terminal B

Terminal C

Terminal M

T18E-05-05-010

T5-5-14

TROUBLESHOOTING / Troubleshooting B (1) Power System Troubleshooting

Faulty battery reYES lay, or faulty ground wire from battery relay terminal E. Check if voltage at YES battery relay terminal S is 24 V or over. NO Check if voltage at Certain starter battery relay terindicates 0 V minal B connected to corresponding starter is 24 V or over. · Key switch: ON

(1)

· Key switch: ON

Check if voltage at battery relay terminal A is 24 V or over.

NO

NO

Broken harness between battery relay terminal S and fuse #10. Broken harness between battery relay terminal A and battery. Broken harness between battery relay terminal B and starter terminal B.

YES

Blown fuse #10, or broken harness between key switch terminal M and battery relay terminal S.

All starters indicate 0 V

Connector Battery Relay

T146-05-04-018

T5-5-15

TROUBLESHOOTING / Troubleshooting B (2) Relay System Troubleshooting

Check if voltage YES at starter relay 1 and 2 terminal S is beyond 24V.

Disconnect starter relay 1 and 2 terYES minal E. Check for continuity between harness end terminal E and vehicle frame.

Broken harness YES between starter relay 1 and starter YES Check for continumotor 1 or starter ity between terrelay 2 and starter minal B and C. motor 2.

NO

Faulty starter relay 1 or 2 ground.

NO

Check if voltage at starter relay connector terminal #1 is beyond 24V. · Key switch: START

Check if voltage at starter relay 1 and 2 NO output side is beyond 24V.

Faulty starter relay 1 or 2.

Broken harness YES Remove starter between starter relay and starter relay 1 and 2 terrelay 1 or 2. minal #2. Check for continuity between terminal #2 YES Faulty starter relay. and vehicle frame. NO Faulty ground of starter relay termiNO nal #2.

Blown fuse of fuse box 2 terminal #19, or broken harness between key switch terminal G2 and starter relay connector terminal #1.

NO

Connector Starter Relay 1

Starter Relay 2

Starter Relay 1

Starter Relay 2

T18E-05-05-002 T146-05-04-009

T18E-05-05-004 T18E-05-05-003

T5-5-16

TROUBLESHOOTING / Troubleshooting B (Blank)

T5-5-17

TROUBLESHOOTING / Troubleshooting B E-2 Although starter rotates, engine does not start.

YES YES

YES

Check if air is bled from fuel pipe of engine.

Remove connector 31 poles. Check if voltage at harness end connector terminal #1 is 24V.

NO

· Key switch: ON

YES Check if voltage at input side of fuse NO box 2 terminal #3 is 24V. · Key switch: ON

Remove ECM connector 21 poles. Check if voltage at harness end connector terminals #G and #D is 24V respectively.

NO

· Key switch: OFF

Bleed air from coupling of engine injection pump. Blown fuse of fuse box terminal #3, or broken harness between fuse box and ECM. Broken harness between fuse box and key switch terminal M.

Blown fuse terminal #1, or broken harness between fuse box 2 terminal #2 and ECM.

YES

NO

Faulty engine. (Refer to the Engine Manual)

Check if voltage at fuse box terminal #2 is 24V.

Broken harness between fuse box and key switch terminal M.

NO

Connector ECM Connector 21 Poles

ECM Connector 31 Poles #G

#D

#1

T18E-05-05-005

T5-5-18

T18E-05-04-004

TROUBLESHOOTING /Troubleshooting B (Blank)

T5-5-19

TROUBLESHOOTING /Troubleshooting B E-3 Even if engine control dial is rotated, engine speed remains unchanged.

• The engine control dial, ECM and/or harness may have trouble. In those cases, fault code 10 is displayed on the built-in diagnosing system. Refer to Troubleshooting A.

T5-5-20

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

• The key switch may be faulty. • If the above are not the cause, the engine unit may have trouble.

T5-5-21

TROUBLESHOOTING /Troubleshooting B E-5 Engine speed is slow, or does not increase.

• The engine control dial system of the switch box and/or ECM system may have trouble.

• Check for loose harness connections beforehand.

YES

YES

Disconnect switch box. Check if voltage between harness end connector terminal #2 and terminal #4 matches specification. · Key switch: ON · Specification: 5±0.5 V

Check if resistance between switch box terminals #2 and #4 is normal. Insert probe in switch box connector rear terminals #2 and #3. Check if voltage at those terminals matches specification.

NO

Check if voltage between switch box harness end connector terminal #4 and vehicle frame matches specification. · Key switch: ON · Specification: 5±0.5 V

· Resistance specification: 5±0.5 kΩ · Voltage specification: 0.3 to 1 V

(at maximum speed)

Connect switch box harness end connector terminal #3 and vehicle frame. Disconnect EMC connector 31 poles. Check for continuity between ECM harness end connector terminal #5 and vehicle frame.

Faulty engine control dial.

NO

T5-5-22

TROUBLESHOOTING /Troubleshooting B

YES

Faulty ECM system.

NO

Broken harness between switch box and ECM (sensor system). YES

Faulty ECM system.

NO

Broken harness between switch box and ECM (ground system).

Disconnect ECM connector 31 poles. YES Check for continuity between EMC connector 31 poles terminal #6 and switch box harness end connector terminal #2.

Broken harness between switch box and ECM (power system).

NO

Connector (Harness End Connector Viewed from the Open End Side) Switch Box

ECM Connector 31 Poles

T183-05-04-004

T18E-05-04-004

T5-5-23

TROUBLESHOOTING /Troubleshooting B E-6 Quick-idle system is inoperable.

• Check for loose harness connections beforehand. NOTE: When the auto-idle switch is turned ON, the quick-idle system operates after 3 seconds.

YES

Faulty quick-idle switch.

Disconnect quick-idle switch. Connect harness end connector terminals with a clip. Check if quick-idle system is operated. · Engine: Running · Control lever: Neutral

NO

Disconnect monitor controller connector YES C. Check for continuity between monitor controller terminal #C3

Disconnect monitor controller connector B. Check for continuity between monitor controller harness end connector terminal #B11 and quick-idle switch end terminal.

NO

NO

Connector C

C3

T183-05-04-014

B11 T183-05-04-013

T5-5-24

Faulty monitor controller. Broken harness between monitor controller and quick-idle switch.

Connector Monitor Controller Connector B

Disconnect ECM connector 31 poles. Check for continuity YES between monitor controller connector terminal #C3 and ECM connector 31 poles harness end terminal #19.

TROUBLESHOOTING /Troubleshooting B

Broken harness between ECM and monitor controller.

NO

Faulty ECM. YES

ECM Connector 31 Poles

19

T18E-05-04-004

T5-5-25

TROUBLESHOOTING /Troubleshooting B E-7 Auto-idle system is inoperable.

• The auto-idle system will stop if one of pressure switches is turned ON.

• Check for loose harness connections beforehand.

Disconnect harness from switch box. Check for continuity between switch box connector terminal #8 and vehicle

Connect connector. Disconnect main controller A conYES nector B. Check for continuity between harness end connector terminal #B16 and vehicle frame.

· Key switch: START · Auto-idle switch: ON · Control lever: Neutral

Connect connector. Disconnect main controller A conYES nector A. Check for continuity between main controller terminal #A29 and vehicle frame.

Disconnect ECM YES Faulty ECM. connector 31 poles. Connect main controller conYES nector A terminal #A29 to vehicle frame. Check for continuity between ECM connector 31 Broken harness poles terminal #20 between main conand vehicle frame. NO troller and ECM.

Faulty main controller A.

NO

Broken harness between main controller A and switch box.

NO

Faulty switch box. NO

Connector Main Controller A Connector A

ECM Connector 31 Poles

B16 Connector B

#20

Switch Box

T183-05-04-004

A29

T183-05-04-005

T18E-05-04-004

T5-5-26

TROUBLESHOOTING /Troubleshooting B (Blank)

T5-5-27

TROUBLESHOOTING /Troubleshooting B E-8 Even if control lever is operated, speed does not increase. (with auto-idle ON)

• The pilot sensor (front attachment), main controller A and/or harness may have trouble. In either cases, fault code 08 is displayed on the built-in diagnosing system. Refer to Troubleshooting A.

T5-5-28

TROUBLESHOOTING /Troubleshooting B E-9 Engine speed does not increase when a particular function is operated (with auto-idle ON)

Faulty shuttle valve.

Speed does not increase only at certain operation.

T5-5-29

TROUBLESHOOTING /Troubleshooting B E-10 Engine stalls. Install pressure gauge on hose entering flow YES rate decrease solenoid valve input port. Measure the pressure.

• The cause differs according to the engine speed. • If power decrease solenoid valve (SA) has a trouble, the swing speed does not change at E mode.

• The engine speed sensor 1 and/or main controller A may have trouble. In either cases, fault code 05 is displayed on the built-in diagnosing system. Refer to Troubleshooting A. • Check for loose harness connections beforehand. Disconnect lines from flow rate decrease solenoid valve. Check if engine stalls when disconnected lines are connected each other directly.

YES Check if output to flow rate decrease solenoid valve is normal.

Around 850 min-1

Check engine speed.

· Built-in diagnosing system: Main controller A Monitor item: Digital output: bit 5: Pump flow rate NO cut-off output Disconnect lines from power decrease solenoid valve (SA, SB). Check if YES engine stalls when disconCheck if outnected lines are connected put to flow each other directly. rate decrease solenoid valve is normal.

Below 1400 min-1

Over 1400 min-1

NO

· Built-in diagnosing system: Main controller A Monitor item: Proportional NO valve ON/OFF output: bit 6: #1, 2 pump power decrease solenoid valve output

NOTE: All regulators are unlikely to become inoperable at the same time. Disconnect and check lines from one solenoid valve, then check the other.

Disconnect flow rate decrease solenoid valve. Connect harness end connector terminals with a clip. Check for continuity between harness end connector terminals.

Faulty main controller. YES Disconnect power decrease solenoid valve (SA, SB). Connect harness end connector terminals with a clip. Disconnect main controller A connector A. NO Check for continuity between harness end connector terminals #A19 and #A20 (SB), and terminals #A11 and #A14 (SA). Faulty main controller A.

Faulty engine and fuel system.

Connector Main Controller A Connector A

A19

A20

Connector D

Flow Rate Decrease Solenoid Valve

Power Transistor 1

T183-05-04-011

A14

T183-05-04-010

T183-05-04-008 T183-05-04-009

D14

T5-5-30

TROUBLESHOOTING /Troubleshooting B Faulty pump 1 and/or 2 flow rate control valve in signal control valve.

Less than 3.9 MPa (40±1 kgf/cm2)

Faulty shuttle valve (swing make-up), shockless valve or regulator.

2

3.9 MPa (40±1 kgf/cm ) or over NO Check if voltage at YES flow rate decrease solenoid valve relay connector terminal #5 i 24 V

Faulty flow rate decrease solenoid valve. NO

Check if voltage at flow rate decrease solenoid valve relay connector terYES minals #1 and #3 are 24 V.

Blown fuse #14.

NO Check if voltage at flow rate decrease solenoid valve relay YES connector terminal #2 is 24 V.

NO

YES

Faulty flow rate decrease solenoid valve relay, or broken harness between flow rate decrease solenoid valve relay and power transistor 1.

(1) Broken harness between flow rate decrease solenoid valve and flow rate decrease solenoid valve relay. Faulty regulator.

Broken harness between power decrease solenoid valve (SA, SB) and main controller A.

NO

Faulty power decrease solenoid valve.

YES

Flow Rate Decrease Solenoid Valve

Input Port

Flow Rate Decrease Solenoid Valve Relay

Power Decrease Solenoid Valve

T183-05-04-010

T183-05-04-003 T183-05-04-012

T5-5-31

Engine Speed Sensor 1

T146-05-03-006

TROUBLESHOOTING /Troubleshooting B

(1)

YES

Faulty power transistor 1.

NO

Broken harness between power transistor 1 and main controller A.

Check if engine stalls after switching power transistor 1 with power transistor 2 or power transistor 3.

T5-5-32

TROUBLESHOOTING /Troubleshooting B (Blank)

T5-5-33

TROUBLESHOOTING /Troubleshooting B E-11 Preheat does not operate. (Engine is difficult to start)

• This troubleshooting should be applied only when

• If preheat operates again after the preheat opera-

the air heater in the engine does not operate. In case the preheat indicator only does not light, refer to Troubleshooting C. • Preheat operates when temperature of engine suction becomes below 0 °C (32 °F).

tion, turn the key switch OFF and after 5 minutes try to operate preheat. (Preheat does not operate within 5 minutes.) • Preheat stops automatically after 30 seconds with preheat operated.

YES

YES

Disconnect preheat signal relay connector. Check if voltage at preheat signal relay terminal #1 is 24V. · Key switch: ON

Disconnect connector from preheat signal relay terminal #2. YES Check for continuity between harness end connector terminal #2 and vehicle frame.

Check voltage at preheat signal relay terminal #5 is 24V.

YES Faulty preheat signal relay. Check if voltage at preheat signal NO relay terminal #3 is 24V. NO

Broken harness between ECM terminal #1 and preheat signal relay terminal #1.

YES Disconnect ECM connector 2 poles. Check voltage at NO ECM end connector terminal #1 is 24V.

Broken harness between battery and preheat signal relay, or broken fusible link 4. Faulty preheat signal relay terminal #2 ground.

NO

Faulty ECM.

NO

Conector Preheat Signal Relay

3

(A)

ECM

5 T146-05-04-009

T18E-05-05-002

B

M T183-05-04-102

1 To ECM 2 To GND T183-05-04-102

T5-5-34

TROUBLESHOOTING /Troubleshooting B YES Check voltage at YES preheat relay terminal M is 24V. Check voltage at YES preheat relay terminal B is 24V. Check for contiYES nuity between preheat relay terminal #2 and vehicle frame. (A)

Check voltage at preheat relay terminal #1 is 24V.

NO

Faulty preheat relay. Broken harness between battery and preheat relay terminal #2, or broken fusible links 7, 8.

Faulty preheat relay terminal #2 ground.

NO

Broken harness between preheat relay terminal #1 and preheat signal relay terminal #5.

NO

YES

(B)

NO

(B)

Faulty air heater.

Check for continuity between preheat relay and air heater.

Broken harness between preheat relay and air heater.

NO

T5-5-35

TROUBLESHOOTING / Troubleshooting B ALL ACTUATOR SHOOTING

SYSTEM

TROUBLE-

A-1 All actuator speeds are slow.

• Although speed is satisfactory, in case power is weak, the faulty main relief valve is suspected.

• If the flow rate decrease solenoid valve is bound

•

• • •

in OFF position, the main pump 1, 2 control pressure Pi decreases, so that the main pump 1, 2 delivery volume decreases. If the power decrease solenoid valve is bound in ON position, pilot pressure PG is supplied to the regulator, so that the pump delivery volume decreases. If the engine speed is slow (refer to E-5) or SP mode is inoperable (refer to A-4), faulty pilot system (refer to A-2) is suspected. Faulty engine is suspected when engine speed decreases remarkably after applying a load. Check for loose harness connections beforehand.

YES

YES Check if output to flow rate decrease solenoid valve is normal. Check if power is sufficient.

Disconnect flow rate deYES crease solenoid valve and reconnect line directly. Check if delivery volume from main pump 1, 2 decreases.

Check if output to YES flow rate decrease solenoid valve is normal. · Built-in diagnosing system: Main controller A Monitor item: Proportional valve ON/OFF output: bit 6: #1, 2 pump NO power decrease solenoid valve output Faulty main controller NO

· Built-in diagnosing system: Main controller A Monitor item: Digital output: bit 5: Pump cut-off output NO

A.

Faulty main controller A.

Faulty main relief valve.

NO

T5-5-36

TROUBLESHOOTING / Troubleshooting B Output Port To Main Pump 2 Regulator Port Pi Shuttle Valve (Swing Make-Up) Power Decrease Solenoid Valve SB Power Decrease Solenoid Valve SA

Machine Front Side

Flow Rate Decrease Solenoid Valve

T183-05-04-026

Shockless Valve

T183-05-04-015

Faulty engine speed sensor 1 system (refer to Troubleshooting A).

YES Disconnect power decrease solenoid valve (SA, SB) output port. Place a plug on port. Disconnected line is left open to atmosphere. Check if symptom appears.

YES Check if fault code 05 is displayed.

Faulty main pump or regulator.

NO

· Mistracks to right: Pump 1 · Mistracks to left: Pump 2 · Swing is slow: Pump 3 Bound power decrease solenoid valve (SA or SB).

NO YES Only main pump 2 output volume decreases. NO

T5-5-37

Faulty shuttle valve (swing make-up) and/or shockless valve. Bound flow rate decrease solenoid valve.

TROUBLESHOOTING / Troubleshooting B A-2 All actuators are inoperable.

• It is unrealistic that all pumps break down at the same time. Faulty pilot system is suspected.

• Check for loose harness connections beforehand.

Find out cause of trouble by tracing other trouble symptoms.

YES

YES Check if primary pilot pressure is normal. · Measurement: Refer to the OPERATIONAL PERFORMANCE TEST ti Check if pilot control shut-off lever is released.

YES Faulty pilot pump, or clogged pilot filter. Check if symptom appears after adjusting, disassembling NO and cleaning pilot relief valve.

NO

End

Release pilot control shut-off lever.

NO

T5-5-38

TROUBLESHOOTING / Troubleshooting B A-3 Actuator does not stop even if lever is returned to neutral.

• Bound spool in the pilot valve or bound spool in the control valve is suspected.

YES

Faulty pilot valve. · When control lever is returned to neutral, pilot pressure is routed to spool end in control valve.

Check if actuator stops when pilot control shut-off lever is raised.

Faulty control valve. NO

· Although pilot pressure is not routed to spool end in control valve, spool is kept opened due to binding of spool.

T5-5-39

TROUBLESHOOTING / Troubleshooting B A-4 SP mode is inoperable.

• Faulty power increase solenoid valve ST and engine speed sensor 1 are suspected.

• Check for loose harness connections beforehand.

Find out cause of trouble by tracing other trouble symptoms.

YES Check if swing, travel right YES and travel left single operation speed changes when SP mode switch is turned ON and OFF.

Faulty regulator or main pump.

NO

· Swing ········Main pump 3 · Travel Right ····Main pump 2 · Travel Left·······Main pump 1

Disconnect line from power increase solenoid valve ST output port, then install pressure gauge. Check if output pressure changes in range of 0 to 3.7 MPa (0 to 38 kgf/cm2).

Check if current at power increase solenoid valve ST changes in range of 255 to 416 mA.

NO

· SP mode switch: ON · Turn engine control dial to change engine speed, then observe pilot pressure change.

· Built-in diagnosing system: Main controller A: Monitor item: Power increase output current · Turn engine control dial to change engine speed.

Check if faulty code 05 is displayed on built-in NO diagnosing system.

Faulty engine speed sensor 1 system (refer to Troubleshooting A).

YES

Output Port

Power Increase Solenoid Valve ST

Connector Main Controller A Connector A A3

A4

T183-05-04-016 T183-05-04-008

T5-5-40

TROUBLESHOOTING / Troubleshooting B

Faulty power increase solenoid valve ST.

YES

NO

Connect line to engine speed sensor 1. Disconnect plug receptacle from power increase solenoid valve ST. Connect both disconnected harness end plug receptacles. Check for continuity between main controller A connector A harness end terminals #A4 and #A3.

Broken harness between power increase solenoid valve and main controller A.

NO

YES Disconnect switch box. Check for continuity between switch box end conYES nector terminals #6 and #15. · SP mode switch: ON NO

Connector Switch Box

T183-05-04-004

T5-5-41

Faulty main controller A, or broken harness between switch box and main controller A.

Faulty switch box, or broken harness between monitor controller and switch box.

TROUBLESHOOTING / Troubleshooting B A-5 E mode is inoperable.

• In case main controller, power decrease solenoid valve or regulator of main pump 3 is inoperable, engine may stall below 1400 min-1 even if E mode switch is turned OFF. • Check for loose harness connections beforehand.

Faulty main controller A.

NO

YES

Check if E mode switch is normal. · E mode switch: ON · Built-in diagnosing system: Main controller A: Monitor item: Digital input: bit 3: E mode SW

Check if output to power decrease solenoid valve is normal. · E mode switch: ON · Built-in diagnosing system: Main controller A monitor item: Proportional valve ON/OFF output: bit 6: #1, 2 Pump power decrease solenoid valve output

Disconnect power decrease solenoid valve (SA). Connect harness end connector terminals #1 and #2 with a clip. Disconnect main controlYES ler connector A. Check for continuity between terminals #A11 and #A14.

Broken harness beNO tween power decrease solenoid valve SA and main controller A.

YES YES

Disconnect main controller A connector B. Check for continuity between harness end conNO nector terminal #B2 and switch box harness end connector terminal #7.

Broken harness between switch box and NO main controller A.

Connector Main Controller A Connector A

A14

Connector B

B2

Faulty switch box dial.

Power Decrease Solenoid Valve

T183-05-04-005

T5-5-42

T183-05-04-010

TROUBLESHOOTING / Troubleshooting B

YES Disconnect power decrease solenoid valve (SA) from line, then connect disconnected line directly. Check if each operation speed increases.

NO

Faulty power decrease solenoid valve (SA).

Faulty main pump 3, or regulator of main pump 3.

Output Port

Power Decrease Solenoid Valve (SA)

Input Port

T18E-05-05-001

T5-5-43

TROUBLESHOOTING / Troubleshooting B FRONT ATTACHMENT SYSTEM TROUBLESHOOTING F-1 Some front attachment movement is slow, or is inoperable.

• If the other operations (travel/swing) are normal, the pilot pump (primary pilot pressure) is considered to be normal.

YES Faulty corresponding cylinder. YES Check for internal oil leakage in corresponding cylinder. Bound corresponding NO control valve spool.

YES Check if corresponding secondary pilot pressure is normal.

Check if corresponding secondary pilot pressure is normal. · Built-in diagnosing system: Main controller A Monitor item: Front operation pressure

· Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section. · Built-in diagnosing system: Main controller A Monitor item: Main pump 1

NO YES

Faulty corresponding overload relief valve. Bound shockless valve spool in signal control valve (at boom raise only).

Check if secondary NO pressure at signal control valve inlet is normal. NO

T5-5-44

Faulty pilot valve.

TROUBLESHOOTING / Troubleshooting B F-2 Front attachment drifts remarkably.

YES

Faulty pilot valve.

YES Faulty corresponding cylinder. Check if cylinder drift is reduced when pilot shut-off valve is closed.

YES Check if oil leaks in corresponding cylinder.

Faulty corresponding control valve (broken spring, loose spool NO end).

Check if corresponding overload relief valve is NO normal. · Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section. NO

Faulty corresponding overload relief valve.

• Boom Cylinder Internal Leakage Check 1. With the bucket cylinder fully retracted and the arm cylinder slightly extended from the fully retracted position, lower the bucket tooth tips onto the ground. 2. Disconnect hoses from the boom cylinder rod side. Drain oil from the hoses and cylinders. (Plug the disconnected hose ends.) T105-07-04-009

3. Retract the arm cylinder to lift the bucket off the ground. If oil flows out of the hose disconnected pipe ends and the boom cylinders are retracted at this time, oil leaks in the boom cylinders. In case no oil flows out of the hose disconnected pipe ends but the boom cylinders are retracted, oil leaks in the control valve.

T5-5-45

TROUBLESHOOTING / Troubleshooting B F-3 Front attachment moves slightly to the opposite direction against the lever operation (boom raise, arm roll-out (BH), arm retract (LD) or bucket close (LD). NOTE: BH: Backhoe LD: Loading Shovel

YES

YES

Check if corresponding load check valve in control valve is normal. · Disassemble / Visual Inspection

Check if slow-return valve of corresponding cylinder is normal.

Oil leaks in cylinder.

NO

· Disassemble / Visual Inspection

Faulty load check valve.

Faulty corresponding slow-return valve.

NO

NOTE: 1. During the initial stage of operation, oil pressure and flow rate from the pump is low. Therefore, if the load check valve or slow-return valve is malfunctioning, the oil in the bottom side of the cylinder flows back into the circuit, causing the cylinder rod to temporarily moves to the other direction from the lever operation direction. 2. Since oil pressure and flow rate from the pump is low, if oil leaks from between bottom side (B) and rod side (A) due to faulty cylinder piston ring or cylinder barrel, the cylinder rod is temporary lowered during the initial stage of operation by the load. In addition, cylinder force is reduced, increasing the front attachment drift in this case.

T5-5-46

When the load check valve is faulty:

When the slow return valve is faulty: T141-05-04-001

TROUBLESHOOTING / Troubleshooting B (Blank)

T5-5-47

TROUBLESHOOTING / Troubleshooting B F-4 Boom raise is slow at combined arm roll-out (BH)/arm retract (LD) and boom raise operation. NOTE: BH: BH: Backhoe LD: Loading Shovel

• The arm flow rate control valve in the signal control valve is switched at combined boom raise and arm roll-out (BH)/arm retract (LD) operation, so that pilot pressure is applied on both sides of the arm 2 spool. Therefore, the arm 2 spool becomes neutral.

Check if shuttle valve YES (preferential boom raising) is bound or scored. Check if arm 2 spool YES neutral pressure at signal control valve outlet port SE is normal.

YES Check if boom 1 spool selection pressure at signal control valve outlet port #1 is normal.

Check if secondary pressures at signal control valve inlet ports D, A and F are normal.

NO

Bound arm flow rate control valve spool in signal control valve, or faulty shuttle valve.

Bound shockless valve spool in signal control valve.

NO

Faulty pilot valve. NO

Signal Control Valve

Pilot Valve Connecting Side

Control Valve Connecting Side

Port A Port #1

Port D

Port SE

Port F

Control Valve Side

Pilot Valve Side

T178-03-06-016

T5-5-48

T178-03-06-015

TROUBLESHOOTING / Troubleshooting B

Clean or replace shuttle valve (preferential boom raising).

YES

Bound arm 2 spool. NO

T5-5-49

TROUBLESHOOTING / Troubleshooting B F-5 Arm cylinder moves unevenly at combined arm roll-out (BH)/arm retract (LD) and bucket roll-in (BH)/bucket tilt-in (LD), boom raise or swing operation. NOTE: BH: Backhoe LD: Loading Shovel

• The arm preference valve is switched at combined arm roll-out (BH)/arm retract (LD) and bucket roll-in (BH)/bucket tilt-in (LD), boom raise or swing operation, so that the pilot pressure to the arm 3 is blocked. Therefore, the arm 3 spool does not move.

Clean or replace arm preference valve.

YES

Check if arm preference valve spool is bound or scored.

YES

NO

Clean or replace shuttle valve (pilot selection).

Check if shuttle valve (pilot selection) is bound or scored.

NO

T5-5-50

Bound swing control valve arm 3 spool.

TROUBLESHOOTING / Troubleshooting B (Blank)

T5-5-51

TROUBLESHOOTING / Troubleshooting B F-6 Single arm roll-in (BH)/arm extend (LD), bucket roll-in (BH)/bucket tilt-in (LD) or boom raise operation is slow. NOTE: BH: Backhoe LD: Loading Shovel

• The pump 3 control valve is switched at single arm roll-in/arm extend (LD), bucket roll-in (BH)/bucket tilt-in or boom raise operation, so that pressure oil from the pilot circuit is applied directly to the main pump 3 regulator as flow rate decrease pressure Pi. Therefore, the delivery volume of the main pump 3 increases. (Refer to the pages for the Pilot Circuit and Main Pump 3 Flow Rate Control Circuit in the Hydraulic System group in the SYSTEM section in the Technical Manual (Operational Principle))

NO

Faulty main pump 3 or regulator (main pump 3).

Check if single bucket NO roll-in (BH)/bucket tilt-in (LD) or boom raise operation is slow. Check if shuttle valve (pilot selection) is bound YES or scored.

NO Check if shuttle valve (pump 3 control valve selection) is bound or scored.

YES Check if pump 3 control valve is bound or scored.

Clean or replace shuttle valve (pump 3 control valve selection).

Clean or replace pump 3 control valve.

YES

T5-5-52

TROUBLESHOOTING / Troubleshooting B

YES

Clean or replace shuttle valve (pilot selection).

Faulty pilot valve. NO

T5-5-53

TROUBLESHOOTING / Troubleshooting B F-7 Heavy lift function does not operate.

• If the flow rate does not decrease at heavy lift operation, faulty flow rate decrease solenoid valve system is suspected. Refer to Troubleshooting "E-10 Engine stalls" - "around 850 min-1." • Check for loose harness connections beforehand.

NO

Check if front operation speed is slow after switching heavy lift switch with boom mode selection switch. · Heavy lift switch: ON

Check if front attachment operation speed is slower than normal.

NO

Faulty heavy lift switch.

Disconnect heavy lift switch and main controller A connector B. Check for continuity between heavy lift YES switch harness end connector terminal #3 and connector B terminal #B11.

NO

Broken harness between heavy lift switch and main controller A.

Faulty main controller YES A.

· Heavy lift switch: ON

YES

Disconnect heavy lift switch and main controller A connector B. Check for continuity between heavy lift switch harness end connector terminal #3 and connector B harness end connector terminal #B11.

Heavy Lift Solenoid Valve (Upper Side) Output Port

Broken harness between heavy lift switch and main controller A.

NO

Disconnect main controller A connector A and heavy lift solenoid valve. Connect heavy lift solenoid valve harness YES end connector terminal with a clip. Check for continuity between connector A harness end connector terminals #6 and #7.

YES

T183-05-04-017

Connector Heavy Lift Switch

Main Controller A Connector A

A6

A7

Connector B

B11 T183-05-04-101

T5-5-54

T183-05-04-005

Broken harness between main controller A and heavy lift solenoid valve.

Disconnect line from heavy lift solenoid valve output port, then install pressure gauge NO on the port. Check if main control valve main relief selection pressure is 3.9 MPa (40 kgf/cm2).

TROUBLESHOOTING / Troubleshooting B

YES

Faulty shuttle valve in main control valve, or faulty main relief valve.

NO

Faulty heavy lift solenoid valve, or faulty main controller A.

T5-5-55

TROUBLSHOOTING / Troubleshooting B F-8 Boom mode selection function does not operate.

• Check for loose harness connections beforehand. Connect main controller B connector B. Disconnect connector A and boom mode selection solenoid valve SC. Connect boom mode selection solenoid valve SC harness end connector terminals #1 and #2 with a clip. Check for continuity between harness end connector A terminals #A4 and #A3.

YES

Check if output to boom mode selection solenoid valve is normal. · Boom mode selection switch: ON · Built-in diagnosing system: Main controller B Monitor item: Proportional valve ON/OFF output: bit 7: Boom mode selection solenoid valve output

NO

Interchange boom mode selection switch with heavy lift switch and check if system operates properly. · Boom mode selection switch: ON

Disconnect boom mode selection switch and main controller B connector B. Check for continuity NO between boom mode selection switch harness end connector terminal #3 and connector B harness end connector terminal #B12.

YES

NO

YES

Connector Boom Mode Selection Switch

Main Controller B Connector A A3

A4

Connector B

B12

Boom Mode Selection Solenoid Valve SC

T183-05-04-010 T183-05-04-005 T183-05-04-101

T5-5-56

TROUBLSHOOTING / Troubleshooting B

Broken harness between main controller B and boom mode selection solenoid valve SC.

NO

Connect main controller B connector A and boom mode selection YES solenoid valve SC. Install tee and pressure gauge at boom mode selection solenoid valve SC output port. Check if pressure is 3.9 MPa (40 kgf/cm2). · Boom mode selection switch: ON

Faulty boom mode selection solenoid valve SC.

NO

Faulty overload relief change valve in main control valve, or faulty overload relief valve.

YES

Faulty main controller B.

Broken harness between boom mode selection switch and main controller B. Faulty boom mode selection switch. Output Port

Boom Mode Selection Solenoid Valve SC Front

T183-05-04-015

T5-5-57

TROUBLSHOOTING / Troubleshooting B SWING SYSTEM TROUBLESHOOTING S-1 Swing is unmoving, slow or weak in power.

• Check whether the pilot system is faulty or the main circuit is faulty.

• In case other functions (front attachment and travel) operate normally, the pilot pump is considered to be normal. If the pilot system is displaying a problem, the cause of the trouble may exist in the circuit after the pilot valve. • The brake chatter is heard if a problem exists in the swing parking brake system.

NO

Check if swing YES motor relief pressure is normal.

Check if secondary pilot pressure is normal. · Built-in diagnosing system: Main controller A Monitor item: Front attachment operation pressure

· Built-in diagnosing system: Main controller A Monitor item: Main pump pressure · Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section.

Faulty swing control valve spool.

Check if shuttle valve NO (swing brake release) is bound or scored.

Check if single YES boom, bucket, arm and swing operations are slower than specification.

Install tee and pressure gauge at main pump 3 port Pi. Check if swing YES pump control pressure varies smoothly, and pump control pressure becomes 0 MPa (0 kgf/cm2) with swing lever in full stroke.

· Specification: Refer to the OPERATIONAL PERFORMANCE TEST section. YES

Check if shuttle valve (pilot selection) or shuttle valve (pump 3 control valve selection) is bound or scored.

NO Clean or replace shuttle valve (pilot selection). NO

Check if shuttle valve (pilot selection) is bound or scored.

Faulty swing control YES valve. Faulty pilot valve.

NO

Port Pi

T183-01-02-006

T5-5-58

TROUBLSHOOTING / Troubleshooting B

YES

Faulty shuttle valve (swing brake release).

Faulty swing parking brake release valve.

YES Check if swing parking brake release valve is NO bound or scored.

Faulty swing motor.

NO

· When brake shows a trouble after disassembling, also check brake release pressure selection valve. Clean or replace shuttle valve (pilot valve selection) or shuttle valve (pump 3 control valve selection).

YES

Clean or replace shuttle valve (swing make-up).

YES NO Check if shuttle valve (swing make-up) is bound or scored. Check if main NO pump 2 delivery pressure is normal. · Built-in diagnosing system: Main controller A Monitor item: Main pump 2 pressure

YES

Faulty shockless valve.

NO

Faulty main pump 2 or regulator (main pump 2).

Check if shockless valve plunger is NO bound.

YES Check if pump 3 conYES trol valve is bound. NO

T5-5-59

Faulty pump 3 control valve. Faulty main pump 3 or regulator (main pump 3).

TROUBLSHOOTING / Troubleshooting B S-2 Swing drift is large when stopping

• In case the upperstructure drifts and shakes, valve related parts may be faulty. In case the upperstructure drifts smoothly, spool related parts may be faulty.

Check if secondary pilot pressure is 0 2 YES MPa (0 kgf/cm ) when swing lever is in neutral.

Check if swing relief pressure is normal. · Built-in diagnosing system: Main controller A Monitor item: Main pump 3 pressure · Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section.

· Built-in diagnosing system: Main controller A Monitor item: Front attachment operation pressure · Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section. Check if symptom appears after switching swing overload relief valve in swing control NO valve with other overload relief valve except boom mode selection in main control valve.

YES Check if swing control valve swing spool operates normally. · Disassemble / Visual inspection

Check if shuttle valve (pilot selection) is NO bound or scored.

YES Faulty swing spool (replace spool or swing control valve).

Faulty swing motor or NO reduction gear box. YES Clean or replace shuttle valve (pilot selection).

NO

YES

NO

T5-5-60

Faulty pilot valve.

Faulty swing relief valve

Faulty swing overload relief valve.

TROUBLSHOOTING / Troubleshooting B TRAVEL SYSTEM TROUBLESHOOTING T-1 Both right and left tracks do not rotate or rotate slowly.

• Both right and left pilot valves, travel motors, and/or control valve spools are unlikely to be faulty at the same time. • In case both travel systems do not operate, the pilot system, which is applied to both side travel motors, may be faulty. If the primary pilot pressure is lower than specification, not only travel but also all operations are affected. As this section describes the troubleshooting of faulty both left and right tracks, refer to T-4 for the trouble on only one track.

Faulty travel parking brake.

YES Install tee to line of travel parking brake release pressure port, then install pressure gauge. Check if travel parking brake release pressure is normal. · Specification: 1.8 MPa (18 kgf/cm2) or over. · Measure pressure in jacking up either side of track.

YES

Faulty shuttle valve (swing brake release).

Check if shuttle valve (swing brake release) is NO faulty. Faulty reducing valve. NO

Brake Release Pressure Port

T183-05-04-100

T5-5-61

TROUBLSHOOTING / Troubleshooting B T-2 Fast travel is inoperable.

• If the other solenoid valves are also not activating, check the fuse.

• Check for loose harness connections beforehand. Disconnect line from reducing 3.9 MPa valve output port, (40 kgf/cm2) then install pressure gauge on the port. Disconnect line from travel mode control solenoid valve output port, YES then install pressure gauge on the port. Measure reducing valve selection pressure. Check if output to travel mode control solenoid valve is normal.

· Travel mode switch: ON

Faulty reducing valve.

1.8 MPa (18 kgf/cm2)

Measure pressure.

Faulty travel motor switch selection mechanism.

2

3.9 MPa (40 kgf/cm )

· Travel mode switch: ON

Faulty travel mode control solenoid valve, or broken harness between travel mode control solenoid valve and main controller B.

0 MPa (0 kgf/cm2)

Disconnect switch box and main controller B connector B. Check for continuity between switch box harness end connector terminal #5 and connector B harness end connector terminal #B13.

· Travel mode switch: ON · Built-in diagnosing system: Main controller B Monitor item: Propor- NO tional valve ON/OFF output: bit 6: Travel mode control solenoid valve output

YES Faulty main controller B.

NO

Faulty switch box, or broken harness between switch box and main controller B

Connector (Harness End Connector Viewed from the Open End Side) Travel Mode Control Solenoid Valve (Lower Side)

Reducing Valve Output Port

Main Controller B Connector B B13

Travel Mode Control Solenoid Valve

T183-05-04-021

T183-05-04-022

T183-05-04-020

Switch Box

Output Port T183-05-04-019

T183-05-04-004

T5-5-62

TROUBLSHOOTING / Troubleshooting B T-3 Slow travel is inoperable.

• Check for loose harness connections beforehand.

YES

NO

Check if output to travel mode control solenoid valve is normal.

Disconnect main controller B connector B. Check for continuity between connector B harness end connector terminal #B13 and vehicle frame.

Faulty switch box, or short-circuited harness between switch box and main controller B.

Faulty main controller B. NO

3.9 MPa (40 kgf/cm2)

Disconnect line from · Travel mode travel mode control switch: ON solenoid valve output · Built-in diagnosing port, then install YES pressure gauge on system: Main controller B the port. Monitor item: ProMeasure reducing portional valve valve selection pres0 MPa ON/OFF output: sure. (0 kgf/cm2) bit 6: Travel mode · Travel mode control solenoid switch: OFF valve output

Faulty travel mode control solenoid valve.

1.8 MPa (18 kgf/cm2) Disconnect line from reducing valve output port, then install pressure gauge on the port. Measure pressure. · Travel mode switch: OFF

Faulty travel motor switch selection mechanism. Faulty reducing valve.

3.9 MPa (40 kgf/cm2)

Connector (Harness End Connector Viewed from the Open End Side) Travel Mode Control Solenoid Valve (Lower Side)

Reducing Valve (Travel Parking Brake)

Main Controller B Connector B

Output Port

T183-05-04-021

Output Port

T183-05-04-020

T183-05-04-019

T5-5-63

TROUBLSHOOTING / Troubleshooting B T-4 One side track does not move, moves slowly or mistracks.

• If only one side of the track does not move, the pilot valve, main control valve, travel motor or center joint may be faulty. • If travel left and bucket open/close (LD) are also slow, the main pump 1 or main pump 1 regulator may be faulty. • If travel right is slow and boom, arm and bucket are slightly slow, the main pump 2 or main pump 2 regulator may be faulty. NOTE: LD: Loading Shovel

Check if secondary travel pressure is normal. · Built-in diagnosing system: Main controller A Monitor item: Travel operation pressure · Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section.

YES Check if travel motor drain oil amount is normal.

Check if travel relief NO pressure of slow speed side is normal. · Built-in diagnosing system: Main controller A Monitor item: Main pump 1 pressure, main pump 2 pressure · Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section.

Check if symptom is YES reversed when right and left travel line hoses are switched each other at the top of center joint.

YES

Faulty pilot valve.

NO

External Oil Leak

NO

Check if symptom is reversed after switching forward travel relief valve with reverse travel one, or right travel relief valve with left one.

Bound main control valve spool, or oil leak in main control valve.

Relationship between Faulty Seal Location and Mistrack Direction Seal When traveling When pivot turn is No. straight performed 1

· Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section.

Seal Location

←

1

2 2

3

4

3

Left Travel (Forward)

4 Right Travel (Reverse)

5

Left Travel (Reverse)

5

6 7

Right Travel (Forward)

6

External Oil Leak

←

7

T5-5-64

W183-03-08-001

TROUBLSHOOTING / Troubleshooting B NO

Faulty travel motor. · When travel parking brake shows a trouble after disassembling, also check brake release pressure selection valve. YES Disassemble travel NO motor servo piston. Check for faulty parts.

Disassemble travel motor counterbalance valve. YES Check for faulty parts.

NO

Faulty travel motor servo piston.

Faulty travel reduction gear. Faulty counterbalance valve.

YES

YES

Faulty travel relief valve.

Faulty center joint.

NO

Arrangement of Pipe Line 1

2 3

6

4

1 - Right Travel Reverse 2 - Left Travel Reverse 3 - Left Travel Forward

5

W142-03-03-002

Machine Front Side

T5-5-65

4 - Right Travel Forward 5 - Drain Hose 6 - Pilot Hose (Travel Mode Selection)

TROUBLSHOOTING / Troubleshooting B T-5 Travel motor runs excessively fast when combined left travel and front attachment operation is performed with left track off the ground.

• If the priority valve (travel motor overrun protection) in the signal control valve is stuck, the flow combiner valve switches without right travel operating. • Same phenomenon can be observed when the flow combiner valve is bound.

T5-5-66

TROUBLSHOOTING / Troubleshooting B T-6 Machine mistracks during combined travel and front attachment operation.

Faulty flow combiner valve.

YES

Check if flow combiner valve in main control valve is abnormal.

Faulty flow combiner valve selection spool in signal control valve.

YES

NO

Disconnect hose (G) from signal control valve connecting to flow combiner valve, then install pressure gauge. Measure and check if selection pressure is approx. 3.9 MPa (40 kgf/cm2).

NO

YES

Faulty load check valve in main control valve.

NO

Find out cause of trouble by tracing other trouble symptoms.

Check if load check valve in main control valve is abnormal.

Signal Control Valve Control Valve Connecting Side

Control Valve Side

Hose (G) T183-05-04-025

T5-5-67

TROUBLSHOOTING / Troubleshooting B OTHER SYSTEM TROUBLESHOOTING 0-1 Auto-lubrication indicator comes ON. (Grease pump does not operate.) (Empty grease in pump)

• If the Auto-lubrication indicator light comes ON, damaged lubrication hose or clogged distribution valve is suspected. • If the auto-lubrication selection switch is faulty, the auto-lubrication indicator does not come ON. • Check for loose harness connections beforehand. • In case of manual lubrication, the auto-lubrication indicator always comes ON.

YES

Grease pump does not operate (both auto and manual).

Disconnect grease pump. Check if voltage at harness end connector terminal #1 is 24 V. · Key switch: ON · During grease pump operation

YES Faulty auto-lubrication relay. Connect disconnected connector. Check if grease pump operates after switching NO auto-lubrication relay and other general-purpose relay.

YES

Empty grease in pump.

Faulty grease pump.

Disconnect auto-lubrication relay. Check if voltage between NO harness end connector terminals #1 and #3 is 24 V. Reposition follow plate. · Disconnect grease pump air lubrication hose at quick coupler. · Screw in and position follow plate.

Check if grease still exists.

NO

T5-5-68

Replace with new grease tin.

TROUBLSHOOTING / Troubleshooting B

NO Connect connector. Check if grease pump operates afYES ter switching power transistor 3 with power transistor 1 or power transistor 2.

Disconnect power transistor 3. Check if voltage at harness end connector terminal #5 is 24 V.

Disconnect main controller B connector A. Check for continuity YES between power transistor 3 harness end connector terminal #2 and connector A harness end terminal #A26.

YES

NO

Faulty main controller B. Broken harness between main controller B and power transistor 3. Blown fuse #14, or broken harness between power transistor 3 and fuse #14.

NO

Faulty power transistor 3.

YES

Blown fuse #14, or broken harness between auto-lubrication relay and fuse #14.

NO

Connector Auto-Lubrication Relay

Power Transistor 3

Main Controller B Connector A

T183-05-04-011

5

2

T183-05-04-003

A26

T5-5-69

T183-05-04-008

TROUBLSHOOTING / Troubleshooting B O-2 Grease pump operates excessively slow.

Grease pump operates excessively slow.

YES

Reinstall or replace exhaust hose.

NO

Check if coefficient of grease viscosity becomes high due to winter or cold environment.

Check if grease pump exhaust hose is kinked or destroyed.

O-3 Grease pump does not stop operating.

• If the proximity switch is not correctly adjusted, the grease pump does not stop operating.

• Check for loose harness connections beforehand.

Change to AUTO position.

YES YES

Check if manual/auto selection valve near grease pump is in MANUAL position.

End

Adjust proximity switch. Check if grease pump NO stops. Disconnect proximity switch. Check if voltage at proxNO imity switch harness end connector terminal #1 is 24 V. · Key switch: ON

T5-5-70

Push both ends of main controller B connector B YES to securely connect the connector. Check if grease pump stops.

Broken harness beNO tween proximity switch and fuse.

TROUBLSHOOTING / Troubleshooting B Connector (Harness End Connector Viewed from the Open End Side) Proximity Switch

2

1

Auto-Lubrication Solenoid Valve Relay

Power Transistor 3

#2

3

T183-05-04-011

T183-05-04-003

Main Controller B Connector A

A26

Connector B

T183-05-04-005

B10

YES

Overhaul grease pump. NOTE: This trouble is caused by the follow plate packing pinched with the grease pump when changing the grease. When exchanging grease, remove quick coupler from air delivery hose.

NO Check if follow plate packing is damaged.

Find out cause of trouble by tracing other trouble symptoms.

NO

Change grease to EP1. YES YES Faulty auto-lubrication relay.

Disconnect power transistor 3 and main controller B connector Connect proximity YES A. switch harness end Check for continuity connector terminal #2 between connector A and vehicle frame with harness end terminal a clip. #A26 and power tranNO Disconnect main consistor 3 harness end troller B connector B. connector terminal #2. Check for continuity between main controller B harness conNO nector terminal #B10 and vehicle frame.

Connect disconnected YES connector. Disconnect auto-lubrication relay. Check for continuity between auto-lubrication relay terminals #3 and #5.

NO

Check if grease pump stops after switching power transistor 3 with NO power transistor 1 or power transistor 2.

Broken harness between power transistor 3 and main controller B. Broken harness between proximity switch and main controller B. End (Faulty connector connection)

YES

T5-5-71

(1)

TROUBLSHOOTING / Troubleshooting B Proximity Switch Adjustment Procedure 1. Loosen the nut. : 17 mm 2. Slowly tighten the proximity switch by hand until the end of the proximity switch touches the protrusion. 3. Loosen the proximity switch 1/2 to 1 turn. Be sure that the indicator faces in the direction of as the figure on the right.

Indictor Proximity Switch Nut

IMPORTANT: The proximity switch may break. Do not excessively tighten the nuts. 4. Tighten the nut to secure the proximity switch. : 17 mm : 0.78 N⋅m (0.08 kgf⋅m, 0.57lbf⋅ft)

T142-06-04-024

Proximity Switch Nut Adapter

Protrusion

T142-06-04-025

Pin

Faulty power transistor 3.

YES

(1) Faulty main controller B. NO

T5-5-72

TROUBLSHOOTING / Troubleshooting B (Blank)

T5-5-73

TROUBLSHOOTING / Troubleshooting B O-4 Fan motor does not rotate at speed corresponding to hydraulic oil temperature or fuel temperature. Fan motor does not rotate at all.

• If the oil cooler fan motor speed control operates normally, the oil cooler fan motor rotates at the corresponding speed to the hydraulic oil temperature. • Check for loose harness connections beforehand.

Install pressure gauge on fan control solenoid valve delivery port. YES Check if pilot pressure is normal by hydraulic oil temperature and fuel temperature (refer to Table 2). Measure hydraulic oil temperature. Disconnect hydraulic oil temperature sensor, then measure sensor resistance. Check if relationship between hydraulic oil temperature and resistance value are correctly. (Refer to Table 1.)

Disconnect fan control solenoid valve wire on one side. Connect tester (amNO meter) between disconnected wire. Check if power is normal by each hydraulic oil temperature (refer to Table 2).

· (If polot pressure to hydraulic oil temperature is different from that to fuel temperature, lower pilot pressure is selected.) YES

Measure oil cooler fan motor drive pump flow rate. Check if flow rate is normal.

Faulty fan motor drive pump.

Faulty hydraulic oil sensor or fuel temperature sensor (fan motor speed control).

Connector Main Controller A B

Fan Control Solenoid Valve

T146-05-04-012

Hydraulic Oil Temperature Sensor T183-05-04-021

C10

T146-05-04-012

C23

Faulty fan motor.

NO

NO

C C1

Disconnect fan control solenoid valve. Connect harness end connector terminals #1 and #2. NO Disconnect main controller A connector A. Check for continuity between harness end connector terminals A6 and A7. YES

· Check fuel temperature sensor in the same procedures.

B22

YES Faulty fan control solenoid valve.

C31 C24

T5-5-74

TROUBLSHOOTING / Troubleshooting B

YES

Faulty main controller A.

NO

Broken harness between oil cooler fan control solenoid valve and main controller A. Fan Control Solenoid Valve

Table 1: Relationship of Sensor (Fan Motor Speed Control) Resistance (Hydraulic oil temperature sensor and fuel temperature sensor are same.) Temperature Resistance (kΩ) (°C) (°F) -30 -22 28.6 -20 -4 16.2±1.6 -10 14 9.56 0 32 5.88 10 50 3.73 20 68 2.45±0.24 30 86 1.65 40 104 1.14 50 122 0.808 60 140 0.534 70 158 0.430 80 176 0.322±0.032 90 194 0.245 100 212 0.189 110 230 0.148 120 248 0.117

Tester A

Delivery Port

T183-05-04-023

Table 2: Relationship between Temperature and Fan Motor Speed Fuel Fan Motor Speed Hydraulic Oil Pilot Pressure from Fan Control Temperature Temperature Solenoid Valve [Current from MC] 66 °C (151 °F) 800→1100 min-1 70 °C (157 °F) 0.99 Mpa (10 kgf/cm2, 142 psi) [285 mA] 69 °C (156 °F) 1100→1400±50 80 °C (176 °F) 0 MPa (0 kgf/cm2, 0 psi) min-1 [200 mA] 63 °C (145 °F) 1100→800 min-1 65 °C (149 °F) 1.36 Mpa (14 kgf/cm2, 199 psi) [309 mA] 66 °C (151 °F) 1400±50→1100 75 °C (167 °F) 0.99 Mpa (10 kgf/cm2, 142 psi) min-1 [285 mA] NOTE: The above fan motor speed shows the motor speed at rated engine speed (1650 min-1).

T5-5-75

Fan Motor Speed Mode Low→Middle Middle→High Middle→Low High→ Middle

TROUBLESHOOTING / Troubleshooting B O-5 Step light does not come ON. • Check for loose harness connections beforehand.

YES

Faulty step light relay.

YES Check if step light comes ON after switching step light relay with other general-purpose relay.

NO

Check if step light comes ON when connecting main controller B connector B terminal #B11 and vehicle frame. ·Measure voltage at the terminals from the rear of connector using a piece of clip with connector connected.

Disconnect step light. Check if step light comes ON when connecting NO harness end terminal to vehicle frame.

Step Light

NO

Broken harness between main controller B and step light switch.

Disconnect main controller B connectors A and B. Connect connector A harness end terminal #A27 and connector B harness end terminal #B11 with a clip. Check if step light comes ON.

Faulty step light switch. YES

M183-01-036

Connector Step Light Relay

Step Light Switch

Main Controller B Connector A

Connector B

T183-05-04-003

A27

B11

T183-05-04-024

T5-5-76

T183-05-04-005

TROUBLESHOOTING / Troubleshooting B

YES

NO

Faulty main controller B.

Disconnect step light relay. Connect harness end connector terminal #5 and terminal #3 with a clip. Check if step light comes ON.

Check if voltage at NO step light relay harness end connector terminal #3 is 24 V.

Connect connector. Disconnect step light YES terminal. Check if voltage at harness end terminal is 24 V.

NO

YES

NO

Faulty step light.

Broken harness between step light and step light relay.

Broken harness between step light relay and fuse box 1 fuse #8, or blown fuse #8. Broken harness between step light relay and main controller B.

YES

T5-5-77

TROUBLESHOOTING / Troubleshooting B O-6 Even if step light switch is turned OFF, step light does not come OFF after 60 seconds. • Check for loose harness connections beforehand.

YES

Check if step light comes OFF after switching step light relay with other general-purpose relay.

Faulty step light relay.

NO

YES

Broken harness between main controller B and step light switch.

NO

Faulty main controller B, or short-circuited harness between step light relay and main controller B.

Disconnect main controller B connector B. Check if step light comes OFF.

Disconnect step light switch. NO Check if step light comes OFF.

Faulty step light switch. YES

T5-5-78

TROUBLESHOOTING / Troubleshooting B (Blank)

T5-5-79

TROUBLESHOOTING / Troubleshooting B O-7 Malfunction of Air Conditioner The air conditioner has a self-diagnosis function. The self-diagnosis functions to: 1) Display Fault Codes 2) Change Displayed Fault Codes 3) Delete Fault Code 4) End Fault Code Display

• Display Fault Code

1. Press the fan OFF switch to turn the fan OFF. 2. Press and hold both the upper and lower sides of the temperature control switch on the air conditioner control panel at the same time for more than 3 seconds with the key switch ON. NOTE: After operation has been performed, the buzzer will sound.

Temperature Control Switch

Fan OFF Switch

3. If any fault codes are found, the LCD displays the fault codes as E{{. NOTE: If more than one fault code is found, the lower number fault code will be displayed first.

LCD

M178-01-017

Fault Code List Location in Trouble Abnormal circulation air sensor

Fault Code E11 E12

Cause Broken circuit in air circulation sensor Short-circuited circulation air sensor Broken circuit in fresh air sensor Short-circuited fresh air sensor

Abnormal fresh air sensor

E13 E14

Abnormal solar radiation sensor

E18

Short-circuited solar radiation sensor

Abnormal evaporator sensor

E21

Broken circuit in evaporator sensor Short-circuited evaporator sensor Abnormal air vent damper Abnormal air mix damper Abnormal circulation/fresh air damper Broken circuit in water temperature sensor Short-circuited water temperature sensor Abnormal high/low refrigerant pressure

E22 Abnormal damper

E43 E44 E45

Water temperature sensor

E15 E16

Abnormal refrigerant

E51

T5-5-80

Symptom Y value (air flow-in temperature) cannot be adjusted in response to the set-temperature. Operation is controlled under such circumstance as no fresh air sensor is provided. Operation is controlled under such circumstance as no solar radiation sensor is provided. Operation is controlled under such circumstance as the evaporator temperature is set to 10 °C (50 °F). Corresponding damper servo becomes inoperable.

Operation is controlled under such circumstance as the water temperature is set to 60 °C (140 °F). (Warm-up control is not performed.) The compressor clutch is disengaged. (The compressor stops.)

TROUBLESHOOTING / Troubleshooting B • Change Displayed Fault Code

1. When displaying more than one fault code, press either the upper or bottom side of the temperature control switch key. The following fault code is displayed. 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.

Temperature Control Switch

LCD

• Delete Fault Code

LCD

1. Press and hold both the circulation air switch and the fresh air switch for more than 3 seconds at the same time to delete the fault code. NOTE: After the fault code is deleted, the buzzer will sound. 2. After the fault code has been deleted, the LCD displays E{{.

M178-01-017

Circulation Air Switch

Fresh Air Switch

M178-01-017

Fan OFF Switch

• End Fault Code Display

1. Press the fan OFF switch, or press the upper side of the fan switch key. The self-diagnostic mode is complete.

Fan Switch

T5-5-81

M178-01-017

TROUBLESHOOTING / Troubleshooting B ※ Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to Hitachi Tsuchiura Works Quality Assurance Dept. after experiencing a problem with your machine’s air conditioning system. < AIR CONDITIONER TROUBLE REPORT > File No. (1) What Checked by: Model (Serial No. ) Operation Type Manual Semi-Auto Full-Auto Delivery Date Year Month (2) When Date Year Month Day Operating Hour ( h) Time Morning Daytime Evening Night Frequency Every Day Once a Week Once a Month Times per (3) Where Job Site Address State County Town Access Road Condition Paved Not Paved (Gravel Sand Soil) (4) How (Operating Conditions) Weather Fine Cloudy Rain Snow Atmospheric Temperature Very Hot Hot Cold Very Cold Operating Conditions Parking Traveling Working Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when full-auto operation A/C ON OFF Air Induction Re-Circulation Fresh Air Circulation Control Panel AUTO ON OFF Not Available 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 (1) Is problem reproducible ? Not turned OFF Reproducible Others Not reproducible Uncontrollable air temperature (2) Pressure (To be measured at gauge manifold) Symptom No cool air Low Pressure No warm air High 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 Others ∗ Before replacing the control amplifier, be sure to Uncontrollable vent hole check that the connectors are correctly connected Symptom Vent hole isn’t selected while repeatedly disconnecting and reconnecting Others connectors. Abnormal panel indication Faulty Indicator Vent Hole A/C AUTO Fresh Air Circulation Fan OFF Fan (Lo • •• Hi) Temperature Control Symptom Stays OFF Stays ON Blinks Others

T5-5-82

TROUBLESHOOTING / Troubleshooting B (Blank)

T5-5-83

TROUBLESHOOTING / Troubleshooting B Cooling Circuit

Refrigerant pressure in both high and low pressure sides is low.

Bubbles can be seen in sight glass.

No bubbles are seen in sight glass.

Piping and/or parts are stained with oil, respond to gas detector. No oil stain is found or gas detector doesn’t respond. Refrigerant has not been refilled for longer than one season.

After cooling at fast speed continuously, cooling power is reduced. Air flow volume remains unchanged. Air flow volume is reduced. Refrigerant pressure in low pressure side is high. Insufficient Cooling Power

Bubbles can be seen in sight glass.

Refrigerant pressure in high pressure side is low.

Compressor cylinder is extremely hot, emitting a smell.

Compressor cylinder is extremely hot, emitting a smell.

Heater unit emits hot air.

Refrigerant pressure in high pressure side is high.

Bubbles can be seen in sight glass.

Refrigerant pressure in low pressure side is low.

Condenser is stained and clogged. Even if condenser is sprayed with water, few bubbles appear. Receiver dryer temperature is low.

After cooling at fast speed continuously, cooling power is reduced. Air flow volume is reduced.

Frost forms.

Thermistor doesn’t cool. Thermistor cools.

T5-5-84

TROUBLESHOOTING / Troubleshooting B

Gas leaks from pipe joints and/or parts.

Re-tighten or replace parts.

Normal leakage of refrigerant from hoses.

Refill refrigerant.

Improper adjustment (excessive restriction) of expansion valve.

Readjust or replace expansion valve.

Clogged expansion valve.

Remove clog, or replace receiver and/or expansion valve.

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 sensing cylinder.

Make good contact. Replace temperature sensing stay.

Improper adjustment (excessive open) of expansion valve.

Readjust or replace.

Insufficient compressor discharge (faulty gasket and/or valve).

Replace.

Improper water stop valve wire adjustment and/or faulty stop valve.

Check and readjust or replace.

Poor airtight fitting of outside air damper (outside air induction type). Clogged high pressure circuit before receiver dryer.

Repair.

Remove clog, or replace parts. Clean Condenser.

Excessive refrigerant.

Remove excessive refrigerant to proper level.

Air is mixed in system.

After evacuation, refill refrigerant and/or replace receiver dryer.

Incorrect thermistor location.

Correct thermister location.

Gas leaks from case.

Seal gaps using vinyl tape or packing compound.

Faulty thermistor (stays ON).

Disconnected thermister cord.

Even if function and performance are normal, when air-conditioner is kept operated for a long time with thermistor in max. cooling position and air flow in M or L mode, frost may form.

Instruct user on correct air-conditioner operation. (Reset thermistor to either minimum or middle cooling position or increase air flow.)

T5-5-85

TROUBLESHOOTING / Troubleshooting B Cooling Circuit

Case connection.

Louver resonance. Fan contacts case, or foreign matter enters case.

Blower fan connection.

Noise

Brush friction noise, metal and/or thrust washer contact noise.

Gas blowing sound (roaring).

Gas vibration noise (compressor discharge and/or suction gas noise).

Expansion valve connection, whistle sound, gas blowing sound.

Abnormal noise from expansion valve (Expansion valve is normally functioning.).

Faulty clutch bearing, and/or idle pulley bearing. Clutch disengaging sound. Contact of clutch amature due to resonance, or loose belt and/or screws. Noisy compressor. Compressor rotating sound. Vibration and/or loose screws due to excessive drive belt looseness.

Broken heater core and/or hose. Water leak and/or splash. Clogged case drain port and/or drain hose. Others Absorbed cigarette and dust smell on evaporator fins.

Abnormal smell.

T5-5-86

TROUBLESHOOTING / Troubleshooting B

Repair or replace. Remove foreign matter. Readjust fan motor location. Slight noise is unavoidable. Replace if loud.

No functional problem exists. Provide silencer if intolerable.

Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.

Replace. Repair or replace clutch. Re-tighten screws.

Repair or replace. Re-adjust drive belt.

Replace. Clean.

Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in L mode for more than 10 minutes, flush smell out by condensed water.

T5-5-87

TROUBLESHOOTING / Troubleshooting B Compressor Compressor doesn’t rotate.

Clutch terminal voltage is normal 24 V.

Inoperable cooling system.

Clutch terminal voltage is low. Clutch terminal voltage is 0 V. Bubbles exist even after refrigerant is refilled. Both high and low side pressures are low.

Both compressor and blower motor rotate.

Check for oil and refrigerant leaks from parts other than compressor and pipe joints using gas detector.

Check for oil and refrigerant leaks from compressor (no leaks from parts other than compressor) using gas detector.

Refer to NOTE 1 and 2 on page T5-5-95. Refrigerant has not been refilled for longer than one season. Stain on exterior.

Refrigerant is discharged within 1 to 2 months after being recharged. Check for refrigerant leaks using gas detector. Refrigerant is kept charged for longer than 2 years.

High pressure side is slightly low and low pressure side is high.

Compressor cylinder is not hot. (Refrigerant returns to compressor in liquid form.) No refrigerant returns in liquid form. High pressure side is low.

Bubbles can be seen through sight glass.

Others

High pressure side is high. Temperature is not cooled when compressor is operated at fast speed continuously.

Refer to the Cooling Circuit Troubleshooting Table on page T5-5-84.

Air flow from blower is insufficient.

Compressor rotation is abnormally draggy. Overheating is susceptible to occur.

Trouble other than compressor.

Refer to the Cooling Circuit Troubleshooting Table on page T5-5-84.

T5-5-88

TROUBLESHOOTING / Troubleshooting B

Seized clutch.

Replace.

Improper gap between amature and rotor (improper air gap). Replace. Broken or short-circuited core cable. Shaft doesn’t rotate (internally locked).

Replace.

Faulty Electrical System.

Faulty Electrical System.

Faulty mechanical seal, gasket, and/or charge valve. Replace. Oil leaks from oil plug. Oil and refrigerant leaks from front housing, and/or cylinder block joint. Normal leaks from hoses.

Replace. Charge refrigerant.

No leaks (normal).

Refer to the Cooling Circuit Troubleshooting Table on page T5-5-84. Broken valve (See NOTE 3 on page T5-5-95.) Replace. Blown gasket (See NOTE 3 on page T5-5-95.)

Check and adjust oil level.

Excessive oil. Broken clutch bearing due to overly tightened belt.

Replace.

Shaft doesn’t rotate. Replace. Shaft rotates draggy.

T5-5-89

TROUBLESHOOTING / Troubleshooting B Compressor

Noise is heard when clutch is OFF.

Abnormal noise

Noise is heard when clutch is ON.

T5-5-90

TROUBLESHOOTING / Troubleshooting B

Broken clutch bearing. Replace. Contact or slip due to poor air gap. Faulty idle pulley bearing. Refer to the Cooling Circuit Troubleshooting Table on page T5-5-84.

Saggy belt. Loose screws.

Broken valve. Replace. Blown gasket. Abnormal internal noise.

Replace.

Vibration due to saggy belt. Refer to the Cooling Circuit Troubleshooting Table on page T5-5-84.

Loose screws.

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 surface 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 high pressure side and low pressure side is 0.49 MPa (5 kgf/cm2) or less. When the clutch is turned OFF, the pressure difference between high pressure side and low pressure side will disappear within about 10 seconds.

T5-5-91

TROUBLESHOOTING / Troubleshooting B WORK AFTER NENTS

REPLACING

COMPO-

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. 1. Add compressor oil 2. Charge air conditioner with refrigerant • Purging • Charge air conditioner with refrigerant • Warm up operation • Inspection

ADD COMPRESSOR OIL Compressor oil quantity to be added after component replacement: 180 cm3 (0.19 qt)

T5-5-92

TROUBLESHOOTING / Troubleshooting B CHARGE AIR REFRIGERANT

CONDITIONER

WITH

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. 1. Pressure rise in the high pressure side Air

If air remains in the air conditioner circuit, this disturbs the heat exchange between refrigerant and air in the condenser, causing pressure to rise in the high pressure side (compressor side). Usually, refrigerant gas is easily liquefied; however, air cannot be liquefied and remains as a gas in the condenser because the temperature at which air liquefies is extremely low. That is, liquidation of the refrigerant gas in the condenser decreases by the amount of air in the circuit, and the gas pressure in the high pressure side increases accordingly.

Pressure increases if air remains in the air conditioner circuit

W115-02-10-001

2. Metal corrosion If air remains in the air conditioner circuit, a chemical reaction between refrigerant and moisture in the air takes place, and as a result, hydrochloric acid, that corrodes metals such as aluminum, copper and iron, is produced.

Hydrochloric acid corrodes metals if moisture exists

Hydrochloric acid

W115-02-10-002

Metal corrosion

3. Plugging of the expansion valve by moisture When high pressure refrigerant gas passes through the expansion valve, gas pressure decreases and temperature drops. Moisture included in high pressure refrigerant gas in the air conditioner circuit freezes at the expansion valve orifice, plugging refrigerant flow. Operation of the air conditioner becomes unstable and cooling efficiency lowers.

Ice produced at the expansion valve disturbs refrigerant flow, lowering cooling efficiency

Plugged refrigerant flow W115-02-10-003

Low cooling efficiency

T5-5-93

TROUBLESHOOTING / Troubleshooting B Purging Procedure

Gauge Manifold

IMPORTANT: Never mistake the charge hose connections. 1. Close the high and low pressure valves on the gauge manifold (Parts Number 4360564). Connect the high-pressure-side charge hose and the low-pressure-side charge hoses to the high-pressure-side charge valve (“D” marked) and to the low-pressure-side charge valve (“S” marked) located on the compressor, respectively. Connect the charge hose located on the center of the manifold bottom to the vacuum pump (Parts Number 4360565). NOTE: Vacuum Pump Joint Number 4360566).

Adapter

Low Pressure Valve Low Pressure Charge Hose

High Pressure Valve High Pressure Charge Hose

Center Pressure Charge Hose Vacuum Pump

(Parts

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

T5-5-94

TROUBLESHOOTING / Troubleshooting B IMPORTANT: If the pointer returns to 0, retighten the line connections and perform purging again. 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 approximately five minutes and confirm that the pointer does not return to 0.

Close Close

In Operation

W115-02-10-005

4. With the high pressure and low pressure valves of the gauge manifold closed, connect the charge hose to the refrigerant container (Parts Number 4347644).

Refrigerant Container

W115-02-10-007

5. Loosen the charge hose connection to the gauge manifold and open the refrigerant container valve to purge air in the charge hose with the refrigerant pressure.

Loosen

Open

W115-02-10-007

T5-5-95

TROUBLESHOOTING / Troubleshooting B IMPORTANT: Always stop the engine when charging the air conditioner with refrigerant. Never position the refrigerant container upside down during charging operation. When changing the refrigerant container during charging operation, be sure to purge air from the charge hose, as shown in step 10. 6. Fully tighten the charge hose connection to the gauge manifold. Open the high pressure valve and refrigerant container valve to charge with refrigerant (R134a). Close the high pressure valve and refrigerant container valve when the high pressure gauge reading reaches 98 kPa (1 kgf/cm2, 14 psi). NOTE: Use warm water of 40 °C (104 °F) or less to warm the refrigerant container to aid in charging operation.

IMPORTANT: Use the leak tester for R134a. 7. After charging, check the line connections for gas leaks using leak tester (Parts Number 4360567).

T5-5-96

High Pressure Gauge Tighten

Open

Open

W115-02-10-007

W115-02-10-008

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. Operating Conditions of the Air Conditioner: Engine Speed : Slow Idle Cab Window : Fully Open Cooler Switch : ON Airflow Volume : Maximum Thermo Switch : Maximum IMPORTANT: Never open the high pressure valve in the gauge manifold. 9. Open the low pressure valve in the gauge manifold and the refrigerant container valve to charge with refrigerant until the bubbles seen in the receiver/drier sight glass disappear.

Open

NOTE: The required refrigerant quantity is 1250 g±50 g (3±0.01 lb).

Open

10. If the refrigerant container becomes empty during the charging work, replace it with a new refrigerant container as follows: (1) Close the high pressure and low pressure valves on the manifold gauge. (2) Replace the empty container with a new one. (3) Tighten, then slightly loosen the refrigerant container joint. (4) Slightly open the low pressure valve on the manifold gauge. (5) When the refrigerant container joint starts to leak, immediately tighten the refrigerant container joint and close the low pressure valve on the manifold gauge.

W115-02-10-007

Close

Close

11. After charging, close the low pressure valve in the gauge manifold and the refrigerant container valve, and stop the engine.

W115-02-10-007

T5-5-97

TROUBLESHOOTING / Troubleshooting B 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 refrigerant, cooling efficiency will lower and abnormal high pressure will arise in the air conditioner circuit, causing danger. 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 : Slow Idle Cab Window : Fully Open Cooler Switch : ON Airflow Volume : Maximum Thermo Switch : Maximum NOTE: As the bubbles in the sight glass vary depending on the ambient temperature, check refrigerant quantity confirming the changes in pressure .

Sight Glass

Receiver/Drier

W115-02-10-009

Checking procedures: Stop the air conditioner and wait until refrigerant returns to the balanced pressure. Then, start the air conditioner again. Relation between Refrigerant Quantity and Refrigerant Flow in Sight Glass: Refrigerant Flow in Sight Glass Refrigerant (approx. 1 min. after air conditioner Quantity switch is turned ON) (immediately after)

(approx. 1 mm after)

Adequate

Explanation for Refrigerant Flow in Sight Glass Immediately after the air conditioner is turned ON, few bubbles are seen. Then the flow becomes transparent and shows thin milk white color.

W115-02-10-016

No bubbles are seen after the air conditioner is turned ON.

Overcharged W115-02-10-017

Bubbles are seen continuously after the air conditioner is turned ON.

Not Enough W115-02-10-018

CAUTION: Wait until the high-pressure-side pressure drops to less than 980 kPa (10 kgf/cm2, 142 psi) before attempting to disconnect the high-pressure-side charge hose. Otherwise, refrigerant and compressor oil may spout.

W115-02-10-019

Bubbles exist: Bubbles are seen in refrigerant flow as both liquid refrigerant and refrigerant gas exist, being mixed. W115-02-10-020

Transparent: Refrigerant flow is transparent as only liquid refrigerant exists.

115-02-10-021

Milk white: Refrigerant flow shows thin milk white as oil and refrigerant are separated.

10. After checking refrigerant quantity, disconnect the low-pressure-side charge hose first. Wait for the high-pressure-side pressure to drop to less than 980 kPa (10 kgf/cm2, 142 psi). Disconnect the high-pressure-side charge hose.

T5-5-98

TROUBLESHOOTING / Troubleshooting B Warm-up Operation After charting the air conditioner, carry out warm-up operation five minute to lubricate system with compressor oil. Operating Conditions of the Air Conditioner Engine Speed : Slow Idle Cab Window : Fully Open Cooler Switch : ON Airflow Volume : Maximum Thermo Switch : Maximum Inspection After warm-up operation, carry out gas leak check and performance check. CAUTION: Refrigerant will produce poisonous material if exposed to heat of 1000 °C (1800 °F) or more. Never bring refrigerant close to a fire. 1. Check the air conditioner for gas leaks using a leak tester. (1) Perform checking under well-ventilated conditions. (2) Thoroughly wipe off dust from the charge hose connections of the compressor. (3) Pay special attention to check the line connections. (4) If any gas leaks are found, retighten the line connections. 2. Performance Check Carry out performance check of the air conditioner after checking each air conditioner component. (1) Check each component for abnormalities. (2) Carry out ON-OFF check of the compressor clutch. (3) Check compressor fan belt tension. (4) Check the coolant level in the radiator. (5) Operate the air conditioner and check the performance.

T5-5-99

Leak Tester

W115-02-10-013

Retighten Line Connection

W115-02-10-014

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.

T5-5-100

TROUBLESHOOTING / Troubleshooting C TROUBLESHOOTING C (TROUBLESHOOTING FOR MONITOR) PROCEDURE Use troubleshooting C when any monitors, such as gauges or indicators, malfunction.

• How to Read Troubleshooting Flow Charts YES(OK)

•

(2)

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

(1)

NO(NOT OK)

• · Key switch: ON

(3)

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

Causes of machine problems are stated in the thick-line box. Scanning quickly through the thick-line boxes allows you to estimate the possible causes before actually following the flow chart.

•

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

Harness

Harness End Connector Open End Side

T158-05-03-001

T5-6-1

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PERATURE GAUGE

COOLANT

TEM-

• This troubleshooting procedures should be performed after checking that the other instruments are performing correctly. • Check for loose harness connections beforehand. Gauge Pointer Does Not Move At All

YES

Disconnect coolant temperature sensor terminal (white). Ground harness end terminal to vehicle frame. Check if pointer swings to the right side.

Connect disconnected terminal. Ground monitor controller connector B terminal #B18 to vehicle frame. Check if pointer swings to the right side.

· Key switch: ON NO

· Key switch: ON · Connect terminal from the rear of connector using a piece of clip with connector connected.

Gauge Pointer Swings Over Scale YES

Disconnect coolant temperature sensor terminal (white). Check if pointer returns to zero.

YES

· Key switch: ON NO

Connect disconnected terminal. Disconnect monitor controller connector B. Check if pointer returns to zero. NO

Gauge Pointer Keeps Moving Unstably YES Disconnect coolant temperature sensor terminal (white). Ground harness end terminal to vehicle frame. Check if pointer swings and is stabilized to the right side. · Key switch: ON

NO

T5-6-2

TROUBLESHOOTING / Troubleshooting C

Coolant Temperature Gauge

Faulty coolant temperature sensor .

NO

Faulty coolant temperature gauge. M183-01-010

YES

Broken harness between coolant temperature gauge and coolant temperature sensor .

Coolant Sensor Resistance Coolant Temperature °C (°F) 25 (77) 40 (104) 50 (122) 80 (176) 95 (203) 105 (221) 120 (248)

Faulty coolant temperate sensor . Short-circuited harness between coolant temperature gauge and sensor .

Resistance (kΩ) 7.6 4.0±0.32 2.7±0.22 0.98 0.6 0.45 0.3±0.02

Connector Monitor Controller Connector B

Faulty coolant temperature gauge.

T183-05-04-013

B18

Faulty coolant temperature sensor .

Faulty coolant temperature gauge.

T5-6-3

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF FUEL GAUGE

Connector

• This troubleshooting procedures should be per-

Monitor Controller Connector B

Fuel Sensor

formed after checking that the other instruments are performing correctly. • Check for loose harness connections beforehand. T183-05-04-010

Fuel Gauge Pointer Does Not Move At All

T183-05-04-013

B19

YES Disconnect fuel sensor from connector. Ground harness end connector terminal #2 to vehicle frame. Check if pointer swings to the right side.

Connect disconnected connector. Ground monitor controller connector B terminal #B19 to vehicle frame. Check if pointer swings to the right side.

· Key switch: ON NO

· Key switch: ON · Connect terminal from the rear of connector using a piece of clip with connector connected.

Fuel Gauge Pointer Swings Over Scale YES

Disconnect fuel sensor from connector. Check if pointer returns to zero.

YES

· Key switch: ON NO

Connect disconnected connector. Disconnect monitor controller connector B. Check if pointer returns to zero. NO

Fuel Gauge Pointer Keeps Moving Unstably

YES Disconnect fuel sensor from connector. Ground harness end connector terminal #2 to vehicle frame. Check if pointer swings and is stabilized to the right side. · Key switch: ON

NO

T5-6-4

TROUBLESHOOTING / Troubleshooting C Fuel Gauge Upper Limit 1/2

Lower Limit

Faulty fuel sensor.

NO

Faulty fuel gauge.

M183-01-011

Fuel Sensor Float FULL

YES

Broken harness between fuel gauge and sensor.

3/4

257 mm 138.5 mm

R370

22 ° 33°

70.5 mm

Faulty fuel sensor.

228 mm

1/2

27° 28°

338 mm

Electric Resistance

1/4

Short-circuited harness between fuel gauge and sensor.

EMPTY

T107-04-03-020

Faulty fuel gauge.

Faulty fuel sensor.

Faulty fuel gauge.

T5-6-5

Float Position

Resistance (Ω)

Upper Limit (FULL)

10+1.0-0.5

3/4

(19)

1/2

32±3

1/4

(49.5)

Lower Limit (EMPTY)

80+12+2

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF INDICATOR LIGHT CHECK SYSTEM • Check for loose harness connections beforehand. YES Indicator does not come ON when indicator light check operation is performed.

Check power line. · Fuse · Disconnect monitor controller connector C. Check for continuity between harness end terminal #C1 and fuse terminal #7 (fuse box 1).

Check if all indicators do not come ON.

NO

Connector Monitor Controller Connector C C1

T183-05-04-014

T5-6-6

Go to individual troubleshooting according to malfunctioning indicator.

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-6-7

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF OVERHEAT INDICATOR • Check for loose harness connections beforehand. NOTE: Overheat Switch Operating Temperature: 100 °C (212 °F) or more Indicator Does Not Come ON Even If Engine Overheats Faulty monitor controller or burnt indicator light.

NO

Turn indicator light check switch ON. Check if indicator comes ON. · Key switch: ON

Broken harness between DLU and monitor.

NO Disconnect DLU connector D. Disconnect monitor controller connector B. Check for continuity beYES tween DLU connector D terminal #66 and monitor controller terminal #B6.

Disconnect ECM connector 9 poles and DLU connector C. Check for continuity between ECM terminal #C and DLU terminal #52. YES Check for continuity between ECM terminal #D and DLU terminal #51.

YES Faulty DLU or faulty engine.

NO

Broken harness between ECM and DLU.

Connector DLU Connector D

DLU Connector C

ECM Connector 9 Poles #C

#D

T18E-05-06-002

#66

#51

#52

T5-6-8

T18E-05-06-004

T18E-05-06-003

TROUBLESHOOTING / Troubleshooting C Indicator Comes ON Even If Coolant Temperature Is Low

YES

Faulty engine.

Disconnect ECM connector 9 poles. Check if indicator goes OFF. YES

NO

Disconnect the removed terminal. Disconnect DLU connector D. Check if indicator goes OFF.

Disconnect the removed terminal. Disconnect monitor connector B. NO Check for continuity between harness end connector terminal #6 and vehicle frame.

Faulty DLU.

YES Short-circuited harness between DLU and monitor.

Broken monitor. NO

Monitor Connector #6

T183-05-04-013

T5-6-9

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF AIR CLEANER RESTRICTION INDICATOR • Check for loose harness connections beforehand.

YES

YES

Disconnect air cleaner restriction switch. Ground harness end connector (Yellow) side to vehicle frame. Check if indicator comes ON. · Key switch: ON

Even if air cleaner is clogged, indicator does not come ON.

Check if indicator comes ON when key switch is turned ON.

NO

NO

YES

Although air cleaner is not clogged, indicator comes ON. · Disassemble / Visual Inspection · Verify that air cleaner is not moist.

Check if indicator goes OFF when air cleaner restriction switch is disconnected.

YES

· Key switch: ON NO

Disconnect air cleaner restriction switch and monitor controller connector B. Check for continuity between monitor controller harness end connector terminal #B7 and vehicle frame. NO

T5-6-10

Disconnect monitor controller connector B. Keep air cleaner restriction switch connector connected to vehicle frame. Check for continuity between monitor controller harness end connector terminal #B7 and vehicle frame.

TROUBLESHOOTING / Troubleshooting C

Faulty air cleaner restriction switch.

YES

NO

Air Cleaner Restriction Switch

Pressure 5.0 kPa (508±48 mmH2O) or lower 5.0 kPa (508±48 mmH2O) or more

Faulty monitor controller.

Operation OFF ON

Broken harness between monitor controller and air cleaner restriction switch. Burned indicator light, or faulty monitor.

Connector Monitor Controller Connector B B7

T183-05-04-013

Faulty air cleaner restriction switch.

Short-circuited harness between monitor controller and air cleaner restriction switch.

Faulty monitor controller.

T5-6-11

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF FUEL LEVEL INDICATOR • Check for loose harness connections beforehand.

YES

YES

Indicator does not come ON even if fuel gauge pointer reaches "E".

Disconnect fuel sensor from connector. Ground harness end connector terminal #2 to vehicle frame. Check if indicator comes ON.

Turn key switch to ON position. Check if indicator comes ON.

NO

NO

YES

Indicator comes ON even if fuel still remains.

Disconnect fuel sensor from connector. Check if indicator goes OFF. · Key switch: ON

YES Disconnect fuel level sensor and monitor controller connector B. Check for continuity beNO tween monitor controller harness end connector terminal #B19 and vehicle frame. NO

T5-6-12

Disconnect monitor controller connector B. Keep connecting fuel sensor harness end connector connected to vehicle frame. Check for continuity between monitor controller harness end connector terminal #B19 and vehicle frame.

TROUBLESHOOTING / Troubleshooting C

Faulty fuel sensor.

YES

Faulty monitor controller.

NO

Broken harness between monitor controller and fuel sensor. Burned indicator light, or faulty monitor controller.

Connector Faulty fuel sensor.

Fuel Sensor

Short-circuited harness between monitor controller and fuel sensor.

T183-05-04-010

Monitor Controller Connector B

Faulty monitor controller.

T183-05-04-013

B19

T5-6-13

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PREHEAT INDICATOR • Check that all other indicators work correctly. • Check for loose harness connections beforehand. Indicator Does Not Come ON Even If Air Heater Is Operating Faulty preheat indicator relay.

YES

Check if indicator comes ON after switching preheat indicator relay and other general-purpose relay. Disconnect preheat indicator relay from connector. NO Check if voltage at harness end connector terminal #1 is 24 V.

Connect disconnected connector. Disconnect monitor YES controller connector B. Check for continuity between harness end connector terminal #B20 and vehicle frame.

YES Faulty monitor controller, or burned indicator light.

Broken harness between monitor controller and NO preheat indicator relay.

Broken harness between preheat indicator relay and preheat relay 1 or blown fuse (5A).

NO

Indicator Comes ON Even If Air Heater Is Not Operating YES

Disconnect monitor controller connector B. Check if indicator comes ON.

Faulty monitor controller.

Short-circuited harness between monitor controller and preheat indicator relay.

YES Disconnect preheat indicator relay. Check for continuity beNO tween harness end connector terminal #3 and vehicle frame.

Connect connector. Check if indicator comes ON after switchNO ing preheat indicator relay and other general-purpose relay.

Connector

NO Faulty preheat indicator relay. Short-circuited harness between preheat indicator relay and preheat YES relay 2 or faulty preheat relay 2.

Monitor Controller Connector B

Preheat Indicator Relay

B20 T183-05-04-003

T5-6-14

T183-05-04-014

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF DOWNLOAD INDICATOR • Check for loose harness connections beforehand. Indicator Does Not Come ON Even If DLU Data Memory Is Full YES Disconnect monitor controller connector C. Check for continuity between terminal #C20 and vehicle frame.

Burnt indicator bulb, or faulty monitor controller.

YES

Faulty DLU.

NO

Broken harness between DLU and monitor controller.

Disconnect DLU connector D. Check for continuity beNO tween terminals #56 and #C20.

Indicator Comes ON Even If Download Is Completed Faulty DLU.

YES

Disconnect DLU connector D. Check if indicator goes OFF.

Disconnect monitor controller connector C. Check for continuity between DLU harness end connector terminal #56 NO and connector C harness end terminal #C20.

Short-circuited harness between DLU and monitor controller.

YES

Faulty monitor controller. NO

Connector Monitor Controller Connector C

DLU Connector D #56

T183-05-04-014 T18E-05-06-002

T5-6-15

C20

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ALTERNATOR INDICATOR • Check for loose harness connections before-

Connector

hand. Monitor Controller Connector A

A2

T183-05-05-001

Alternator indicator stays ON after engine is started. · Engine: Running

Disconnect alternator terminal R, then ground the terminal to vehicle frame. Disconnect connector A of monitor controller. Check for continuity between alternator relay harness end connector terminal #A2 and vehicle frame.

YES

Faulty alternator.

Broken harness between alternator terminal R and monitor controller or faulty monitor controller.

NO

Less than 10 V

Faulty monitor controller, or broken harness between monitor controller and alternator.

YES Measure voltage at alternator terminal R. · Key switch: ON · Engine: Stop Although alternator output is low, alternator indicator does not come ON.

Faulty alternator. Turn key switch ON. Check if indicator comes ON.

10 V or more

Burned alternator indicator light, or faulty monitor controller.

NO

T5-6-16

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-6-17

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR • Check for restricted oil filter. • Check for loose harness connections beforehand.

• Even if the key switch is ON with the engine stopped, the engine oil pressure indicator does not come ON. Even If Engine Oil Pressure Becomes Low With Engine Running, Indicator Does Not Come ON • Check if the engine has trouble by using the fault code monitor at engine side beforehand.

Turn indicator light check switch ON. Check if indicator comes ON.

Connect the connector. Disconnect DLU connector 76C and ECM connector 9 poles. YES Check for continuity between terminals #52 and C. Check for continuity between terminals #51 and D.

Disconnect monitor controller connector C and YES DLU connector 76D. Check for continuity between terminals #55 and #C18.

NO

· Key switch: ON

YES Faulty DLU.

Broken CAN harness. NO Broken harness between DLU and monitor. Faulty monitor controller, or burnt indicator bulb.

NO

Indicator Stays ON After Engine Is Started (Oil Level and Oil Pressure are Normal) • Check if the engine has trouble by using the fault code monitor at engine side beforehand. YES

Faulty DLU.

NO

Broken or short-circuited CAN harness.

Check for continuity of YES CAN harness. Check for shorted-circuited CAN harness. Disconnect DLU connector 76D. Check if indicator goes OFF.

YES

NO

Disconnect harness between DLU and monitor. Check for continuity between terminals #55 and vehicle frame.

Short-circuited harness between monitor and DLU.

Broken monitor. NO

T5-6-18

TROUBLESHOOTING / Troubleshooting C

Connector DLU Connector 76D

DLU Connector 76C

ECM Connector 9 Poles #C

#55

T18E-05-06-002

#51

#52

#5

T18E-05-06-004 T18E-05-06-003

T5-6-19

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PUMP TRANSMISSION OIL PRESSURE INDICATOR • Check for loose harness connections beforehand. Indicator does not come ON even if pump transmission oil pressure is insufficient. YES

YES

Disconnect pump transmission oil pressure switch. Ground harness end terminal #M4 to vehicle frame. Check if indicator comes ON. · Key switch: ON

Turn key switch to ON position. Check if indicator comes ON.

NO

Connect disconnected terminal. Ground monitor controller connector A terminal #A13 to vehicle frame. Check if indicator comes ON. · Key switch: ON · Connect terminal from the rear of connector using a piece of clip with connector connected.

· Key switch: ON

NO

Indicator stays ON even if engine is started. YES Disconnect pump transmission oil pressure switch. Check if indicator goes OFF. · Key switch: ON · Engine: Stop

Disconnect monitor controller connector A. Keep cab connector disconnected. Check for continuity between monitor harness end connector terminal #A13 and vehicle frame.

NO

T5-6-20

TROUBLESHOOTING / Troubleshooting C

Pump Transmission Oil Pressure Switch Pressure Operation less than 39 to 59 kPa ON (0.4 to 0.6 kgf/cm2) Indication pressure 39 to 59 kPa OFF (0.4 to 0.6 kgf/cm2) or more

Faulty pump transmission oil pressure switch.

YES

Broken harness between monitor controller and pump transmission oil pressure switch.

Faulty monitor controller. NO

Connector Monitor Controller Connector A

Burned indicator light, or faulty monitor controller.

T183-05-05-001

A13

Faulty pump transmission oil pressure switch, faulty oil pressure system or restricted oil filter.

YES

Short-circuited harness between monitor controller and pump transmission oil pressure switch.

Faulty monitor controller. NO

T5-6-21

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE OIL LEVEL INDICATOR • Check that all other indicators work correctly. • Check that machine is parked on level surface. • Check for loose harness connections beforehand. Indicator Does Not Come ON Even If Oil Level is Normal YES

NO

Disconnect engine oil level switch. Ground harness end connector terminal #1 to vehicle frame. Check if indicator comes ON.

Turn key switch to ON position. Check if indicator comes ON.

Connect engine oil level switch. Disconnect monitor controller connector B. Check for continuity between harness end connector terminal #B8 and vehicle frame.

YES

NO

Indicator Does Not Come ON Even If Oil Level Is Lower Than Low

YES

NO

Disconnect engine oil level switch. Check if indicator comes ON.

Check oil level with an oil level gauge. Check if oil level is higher than low limit.

NO

YES

T5-6-22

Disconnect monitor controller connector B. Keep engine oil level switch disconnected. Check for continuity between connector B harness end terminal #B8 and vehicle frame.

TROUBLESHOOTING / Troubleshooting C

YES

Faulty monitor controller.

Connector Monitor Controller Connector B

NO

B8

Broken harness between monitor controller and engine oil level switch.

T183-05-04-013

Faulty engine oil level switch.

Engine Oil Level Switch

Burned indicator light, or faulty monitor controller.

YES

Short-circuited harness between monitor controller and engine oil level switch.

Faulty monitor controller. NO

Faulty engine oil level switch.

Normal.

T5-6-23

T18E-05-06-006

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF COOLANT LEVEL INDICATOR • Check that all other indicators work correctly. • Check that machine is parked on level surface. • Check for loose harness connections beforehand. Indicator Does Not Come ON Even If Coolant Level Is Lower than Low • Check if fault cod 235 is displayed on the engine fault code monitor beforehand. • If fault code 235 is displayed, the following troubles may occur. Faulty engine (coolant level sensor or ECM) Broken or short -circuited harness between ECM and coolant level sensor. NO

Turn key switch ON. Check if indicator comes ON.

Burnt indicator bulb, or faulty monitor controller.

YES

YES

Disconnect monitor controller connector B. Disconnect DLU connector 76D. Check for continuity between DLU terminals #76 to 57D and vehicle frame.

YES Faulty DLU.

NO

Indicator Comes ON Even If Coolant Level Is YES Normal YES

Disconnect DLU connector 76D. Check for continuity between DLU end terminal 76-57D and vehicle frame.

NO

Disconnect DLU connector 76C and ECM connector 9 poles. Check for continuity between terminals #76 to 52 and C. Check for continuity between terminals #76 to 51 and D.

Disconnect monitor controller connector B. Check for short-circuited harness between DLU terminals #76 to 57 and monitor controller terminal B9.

Broken harness between DLU and monitor controller.

NO

Disconnect DLU connector 76C and ECM connector 9 poles. Check for continuity between terminals #76 to 52 and C. Check for continuity between terminals #76 to 51 and D.

Disconnect coolant level sensor connector and ECM connector 21 poles. Check for broken or short-circuited harness between terminals below.

NO

Faulty harness between ECM and DLU.

Broken or short-circuited harness between DLU and ECM. NO

YES

Broken or short-circuited harness between ECM and coolant level sensor. Faulty engine. (coolant level sensor or ECM)

· Coolant level sensor Terminals #A and ECM #T Terminals #B and ECM #V Terminals #C and ECM #U Terminals #D and ECM #S Faulty monitor controller. YES

NO

T5-6-24

Broken or short-circuited harness between DLU and monitor controller.

TROUBLESHOOTING / Troubleshooting C

DLU Connector 76D

Monitor Controller

DLU Connector 76C

Connector B #57

B9

T18E-05-06-002

T183-05-04-013

Coolant Level Sensor Connector

ECM Connector 9 Poles #D

#C

T18E-05-06-007

T18E-05-06-003

T5-6-25

#51

#52

T18E-05-06-004

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF LEVEL INDICATOR

HYDRAULIC

OIL

• Check that all other indicators work correctly. • Check that machine is parked on level surface. • Check for loose harness connections beforehand. Indicator Does Not Come ON Even If Hydraulic Oil Level Is Lowered Below Lower Limit

YES

Disconnect hydraulic oil level switch 1. Ground YES harness end connector terminal to vehicle frame. Check if indicator comes ON after 5 seconds. · Key switch: ON

Faulty hydraulic oil level switch 1.

Connect disconnected connector. Disconnect hydraulic oil level switch 2. NO Ground harness end connector terminal to vehicle frame. Check if indicator comes ON after 5 seconds. · Key switch: ON

Turn indicator light check switch ON. Check if indicator comes ON. · Key switch: ON

NO

Disconnect monitor controller connector C and main controller B connector B. Check for continuity between connector C harness end terminal #C14 and connector B harness end terminal #B23.

YES Faulty hydraulic oil level switch 2.

NO

Connect disconnected connector. Disconnect main controller B connector B. Check for continuity between harness end connector terminal #B15 and vehicle frame.

NO

Burned indicator light, faulty monitor controller, or broken harness between monitor controller and main controller B.

YES

Connect monitor controller connector C. Connect main controller B terminal #B15 and harness end connector #B15 with a clip. Check if indicator comes ON.

T5-6-26

TROUBLESHOOTING / Troubleshooting C Connector Monitor Controller Connector C

Main Controller B Connector B

Hydraulic Oil Level Switch 1, 2

T183-05-04-010

T183-05-04-014

C14

B23

B15

T183-05-04-021

Faulty main controller B.

YES Check for continuity YES between harness end connector terminal #B16 and vehicle frame.

Broken harness between hydraulic oil level switch 2 and main controller B.

NO

Broken harness between hydraulic oil level switch 1 and main controller B.

NO

Broken harness between main controller B and hydraulic oil level switch 2.

YES Check if indicator comes ON after YES switching hydraulic oil level switch 1 and hydraulic oil level switch 2.

NO

Disconnect hydraulic oil level switch 1. Check for continuity between main controller B harness end connector terminal #B15 and hydraulic oil level switch 2 harness end connector terminal #1.

Faulty hydraulic oil level switch 2.

NO

YES

Disconnect hydraulic oil level switch 1. Ground harness end connector terminal to vehicle frame. Check if indicator comes ON after 5 seconds.

YES

Faulty hydraulic oil level switch 1.

Faulty main controller B. NO

Broken harness between main controller B and hydraulic oil level switch 1.

NO

T5-6-27

TROUBLESHOOTING / Troubleshooting C Indicator Comes ON Even If Hydraulic Oil Level Is Normal

YES

Faulty hydraulic oil level switch 1.

Disconnect hydraulic oil level switch 1. Check if indicator goes OFF.

NO

Connect disconnected connectors. Disconnect main conNO troller B connector B. Check for continuity between harness end connector terminals #B15, B16 and vehicle frame.

Disconnect hydraulic oil level switch 2. Check if indicator goes OFF.

NO

Disconnect monitor controller connector C. Check for continuity between connector C harness end terminal #C14 and connector B harness end terminal #B23.

Short-circuited harness between hydraulic oil YES level switch 1, 2 and main controller B.

Faulty hydraulic oil level switch 2.

YES

Connector Monitor Controller Connector C

Main Controller B Connector B

Hydraulic Oil Level Switch 1, 2 B16

T183-05-04-010

T183-05-04-014

C14

B23

B15 T183-05-04-021

T5-6-28

TROUBLESHOOTING / Troubleshooting C

YES

NO

Short-circuited harness between monitor controller and main controller B.

Faulty monitor controller or main controller B.

T5-6-29

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF AUTO-LUBRICATION INDICATOR • Check for loose harness connections beforehand.

Indicator Comes ON Even If Auto-lubrication System Operates Normally. NOTE: Indicator comes ON when lubrication mode switch is turned to "Manual" position.

24 V

Disconnect monitor controller connector C. Check for voltage at harness end connector terminal #C15.

Disconnect main controller B connector A. Check for continuity between monitor controller connector C harness end terminal #C15 and connector A harness end terminal #A29.

Faulty monitor controller. 0V

Indicator Does Not Come ON Even If Auto-lubrication System is Abnormal or Lubrication Mode Switch is Turned to "Manual" Position. YES

Disconnect monitor controller connector C. Check for voltage at harness end connector terminal #C15. · Key switch: ON

Turn key switch to ON position. Check if indicator comes ON.

Burned indicator light, or faulty monitor controller.

NO

T5-6-30

TROUBLESHOOTING / Troubleshooting C

Connector Monitor Controller Connector C

Main Controller B Connector A

T183-05-04-014

C15

YES

A29

Short-circuited harness between monitor controller and main controller B.

Faulty main controller B. NO

0V

Faulty main controller B, or broken harness between monitor controller and main controller B.

Faulty monitor controller. 24 V

T5-6-31

T183-05-04-008

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE STOP INDICATOR • Check for loose harness connections beforehand. Even If Engine is Normal, Indicator comes ON. • Check if fault code corresponding to ECM is not displayed beforehand.

NO

Faulty engine stop indicator relay.

Switch stop indicator relay and other general-purpose relay. Check if indicator comes ON. · Key switch: ON

YES Disconnect DLU connector 76D. Check if voltage between YES DLU terminals #76 to #64 and vehicle frame is 24V.

Disconnect DLU connector 76D and monitor connector C. Check for NO short-circuited harness between terminals #67 and vehicle frame.

Faulty DLU.

YES Short-circuited harness between DLU and monitor.

Faulty monitor. NO

Indicator does not come ON even if engine has troubles. Burnt indicator bulb, or faulty monitor controller.

NO

Turn key switch ON. Check if indicator comes

YES

Faulty engine stop indicator relay.

Switch stop indicator relay and other general-purpose relay. YES Check if indicator comes ON. Disconnect DLU connector 76D. Check if voltage beNO tween DLU terminals #76 to #64 and vehicle frame is 24V.

NO DLU Disconnect connector 76D. NO Check if voltage between terminals #8 and #9 is 24V.

NO Faulty DLU.

Broken harness between DLU and relay. (termiYES nals #5 to #64) YES

Faulty DLU.

Check for continuity between monitor C19 YES and terminals #67. Broken harness between NO monitor and DLU.

T5-6-32

TROUBLESHOOTING / Troubleshooting C

Connector DLU Connector D

DLU Connector A #64

Monitor Connector C #8

#9

T18E-05-06-008

T18E-05-06-002

#67

T5-6-33

T18E-05-06-009

#19

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE WARNING INDICATOR • Check for loose harness connections beforehand.

Indicator comes ON even if engine has no trouble. Short-circuited harness between ECM and monitor controller.

YES Disconnect monitor controller connector C. Check for continuity for vehicle frame and terminal #16.

Faulty monitor controller. NO

Indicator does not come ON even if engine has troubles.

YES

Turn key switch to ON position. Check if indicator comes ON.

Disconnect monitor controller connector C and ECM connector 31 poles. Check for continuity between terminals #C16 and #17. · Key switch: ON

YES Broken harness between monitor controller and ECM.

Faulty ECM. NO

Burned indicator light, or faulty monitor controller.

NO

T5-6-34

TROUBLESHOOTING / Troubleshooting C

Connector Engine Warning Indicator Relay

ECM Connector 31 Poles

Monitor Controller Connector C #17

T183-05-04-014

T183-05-04-003

C16

T18E-05-04-004

T5-6-35

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF QUICK-IDLE INDICATOR • Check for loose harness connections beforehand.

Connector Monitor Controller Connector B

T183-05-04-013

Connector C

C3

T183-05-04-014

Indicator comes ON even if quick-idle system is not operating.

Disconnect monitor conYES troller connector B. Check if indicator comes ON. Disconnect quick-idle switch. Check if indicator comes ON.

Disconnect monitor conYES troller connector C. Check if voltage at harness end connector terminal #C3 is 24 V.

NO

Short-circuited harness between quick-idle switch and monitor controller.

Faulty quick-idle switch. NO

Indicator does not come ON even if quick-idle system is operating. Burned indicator light, or faulty monitor controller.

T5-6-36

TROUBLESHOOTING / Troubleshooting C

Faulty quick-idle relay, or short-circuited harness between monitor controller and quick-idle relay.

YES

Faulty monitor controller. NO

T5-6-37

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF AUTO-IDLE INDICATOR • Check for loose harness connections beforehand.

Connector Switch Box

T183-05-04-004

Monitor Controller Connector B B10

Indicator does not come ON even if auto-idle system is operating.

T183-05-04-013

Burned indicator light, or faulty monitor controller.

YES Disconnect monitor controller connector B. Check if voltage at harness end connector terminal #B10 is 24 V.

Broken harness between switch box and monitor controller.

NO

Indicator comes ON even if auto-idle system is not operating.

YES

Disconnect switch box. Check if indicator comes ON.

YES

Faulty monitor controller.

NO

Short-circuited harness between switch box and monitor controller.

Disconnect monitor controller connector B. Check if indicator comes ON.

Faulty switch box. NO

T5-6-38

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-6-39

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF HOURMETER • Check for loose harness connections beforehand. Hourmeter Does Not Operate When Engine Is Running Less than 13 V or 33.5 V or more

13 V or more less than 33.5 V

NO Measure voltage at alternator terminal L. · Engine speed: 900 min-1 (rpm) or more.

Connect alternator relay. Disconnect monitor controller connector A. 13 V or more Measure voltage at less than 33.5 V harness end connector terminal #A2.

Check if alternator indicator comes ON. · Engine: Running

Faulty monitor controller.

0V

Broken harness between monitor controller and alternator. Refer to "MALFUNCTION OF ALTERNATOR INDICATOR" (Alternator indicator stays ON after engine is started).

YES

Connector Monitor Controller Connector A

Faulty alternator.

A2

T183-05-05-001

T5-6-40

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-6-41

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF BUZZER • Check for loose harness connections beforehand. Buzzer sounds continuously key switch is turned ON without starting engine. 10 V or more Measure voltage at monitor controller connector A terminal #A2. · Key switch: ON without starting engine

Faulty alternator.

Faulty monitor controller.

Less than 10 V

Buzzer sounds continuously when engine is started. YES

Check if pump transmission oil pressure indicator comes ON.

Faulty pump transmission oil pressure system.

YES

NO

Check if engine stop indicator comes ON. NO

Buzzer does not sound even if pump transmission oil pressure indicator or engine stop indicator comes ON.

Faulty engine system.

Check if buzzer stops by pressing buzzer cancel switch.

Normal (Engine speed is too slow).

NO

Check if alternator indicator comes ON. Measure voltage at regulator terminal R.

YES

· Engine: Running

T5-6-42

TROUBLESHOOTING / Troubleshooting C Connector

Starter Relay 2 (Harness End)

Monitor Controller Connector A (Harness End)

A2

1 2

3

T183-05-05-001

YES

Normal.

Faulty monitor controller. NO

less than 13 V

Disconnect alternator terminal R and monitor controller connector A. Check for continuity between terminals R and #A2.

YES

Faulty alternator.

NO

Broken harness between alternator terminal R and monitor panel.

Faulty monitor controller. 13 V or more

T5-6-43

TROUBLESHOOTING / Troubleshooting C MALFUNCTION DISPLAY (LCD)

OF

LIQUID

CRYSTAL

• This section describes the following items: 1 to 7: Displayed in normal condition. 8 to 23: Displayed when switched to the build-in diagnosing system. • Check that the machine control is not malfunctioning. Main Controller A Side Display Description Order 1 Hourmeter 2 Trip1 3 Trip2 Engine Actual Speed 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Hydraulic Oil Temperature − − Fault Code Main Pump 1 Pressure Main Pump 2 Pressure Main Pump 3 Pressure Front Attachment Operation Pressure Travel Operation Pressure Engine Exhaust Gas Temperature EC Angle Digital Input 0 Digital Input 1 Digital Input 2 Digital Input 3 Digital Output Proportional Valve ON/OFF Output Hydraulic Oil Cooling Output Current Power Increase Output Current

Causes Refer to T5-6-40 Faulty monitor. Faulty sensor system detecting corresponding signal. (There should be some abnormality with the machine control. Refer to Troubleshooting B).

Faulty sensor system detecting corresponding signal. (There should be some abnormality with the machine control. Refer to Troubleshooting B).

T5-6-44

TROUBLESHOOTING / Troubleshooting C

• This section describes the following items: 1 to 7: Displayed in normal condition. 8 to 23: Displayed when switched to the build-in diagnosing system. • Check that the machine control is not malfunctioning. Main Controller B Side Display Description Order 1 Hourmeter 2 Trip1 3 Trip2 Engine Actual Speed 4 5 6 7 8 9 10 11 12 13 14 15 16

17 18 19 20 21 22 23

Hydraulic Oil Temperature − − Fault Code Digital Input 0 Digital Input 1 Digital Input 2 Digital Input 3 Digital Output Proportional Valve ON/OFF Output Auto-Lubrication Status 1 Auto-Lubrication Status 2 (upper 4 bits) Auto-Lubrication Status 2 (lower 4 bits) Auto-Lubrication Interval Selection Digital Output 2 (upper 4 bits) Digital Output 2 (lower 4 bits) − − −

Causes Refer to T5-6-40. Faulty monitor. Faulty sensor system detecting corresponding signal. (There should be some abnormality with the machine control. Refer to Troubleshooting B).

Faulty monitor, or faulty communication between monitor and MC. Faulty sensor system detecting corresponding signal. (There should be some abnormality with the machine control. Refer to Troubleshooting B).

T5-6-45

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE TROUBLESHOOTING OPERATION • Check for loose harness connections beforehand.

Fault code is not displayed when engine has some trouble even if engine diagnostic switch is turned to ON position.

Broken harness between engine fault diagnosing switch A and ground.

NO Check for continuity beYES tween harness end terminal #2 and vehicle frame.

YES Faulty ECM.

Disconnect ECM connector 31 poles. YES Check for continuity between harness end terminals #1 and #18.

Disconnect engine fault diagnosing switch A connector. Check for continuity between terminals.

Broken harness between ECM and engine fault NO diagnosing switch A.

· Engine fault diagnostic switch: ON Faulty engine fault diagnosing switch A.

NO

Connector ECM Connector 31 Poles

Fault Diagnostic Switch B

Fault Diagnostic Switch A

#18

1 2

3 T18E-05-06-010

#12 T18E-05-04-004

#13

T5-6-46

TROUBLESHOOTING / Troubleshooting C Even if some troubles occur in the engine and engine fault diagnosing switch B is switched, the previous or following fault code is not displayed. NOTE: If only one trouble occurs in the engine and engine fault diagnosing switch B is switched, the fault code does not change.

Faulty engine fault diagnosing switch B.

YES

Disconnect engine fault diagnosing switch B connector. Connect harness end terminals #1 to #3 and #2 to #3. Check if fault code switches.

YES

· Key switch: ON · Engine fault diagnosing switch A: ON NO

Disconnect ECM connector 31 poles. Check for continuity between harness end terminals #1 and #13, #2 and #12. NO

T5-6-47

Faulty ECM.

Broken harness between engine fault diagnosing switch B and ECM.

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-6-48

TROUBLESHOOTING / Troubleshooting D TROUBLESHOOTING D PROCEDURES Refer to Troubleshooting D if the engine stop indicator and the engine warning indicator in the cab start flashing by the ECM diagnosis system. Refer to the System section in the Technical Manual (Operational Principle).

T5-7-1

TROUBLESHOOTING / Troubleshooting D Inspection Method When any trouble occurs in the engine control system, one of the following indicators come ON: • • • • •

Monitor Panel

Overheat Indicator Engine Oil Pressure Indicator Coolant Level Indicator Engine Warning Indicator 1 Engine Stop Indicator 1 4

In addition, the following indicators on the engine fault code indicator panel blink or come ON to indicate the fault code or fault level.

5

• Engine Warning Indicator 2 • Engine Stop Indicator 2 • Engine Protection Indicator ECM (Electronic Control Module) memorizes malfunctions of the engine in the form of fault codes. This fault code can be displayed in two forms: 2

• Indicated by the blinking pattern of the engine warning indicator and engine stop indicator. • Displayed by INSITE (diagnostic tool by CUMMINS CO.)

3

1

T183-01-02-013

Engine Fault Code Indicator Panel

When the fault code is displayed, record the fault code (3 digit number), and contact CUMMINS CO. for advise. NOTE: The fault level indicates the seriousness of the trouble which is preset in ECM. The engine warning indicator, engine stop indicator or engine protection indicator comes ON according to the seriousness of the trouble.

T141-05-03-002

6

7

8

M18E-01-009

1 - Engine Warning Indicator 1 2 - Engine Stop Indicator 1 3 - Coolant Level Indicator 4 - Overheat Indicator

T5-7-2

5 - Engine Oil Pressure Indicator 6 - Engine Warning Indicator 2 7 - Engine Stop Indicator 2 8 - Engine Protection Indicator

TROUBLESHOOTING / Troubleshooting D FAULT CODE INDICATION BY INDICATOR BLINKING PATTERN The fault code is indicated by the blinking pattern of the engine warning indicator 2 and engine stop indicator 2 if the engine fault diagnosing switch A and/or B is operated. NOTE: The engine warning indicator 1 and engine stop indicator 1 on the monitor panel may blink when the fault diagnosing switch A and/or B is operated. This does not indicate the fault code. Fault Diagnosing Switch There are two diagnostic switches: A and B. These switches are used to indicate the fault codes. Both diagnostic switches are self-return type, so a fault code is indicated while switches are pressed up or down. Switch A: The fault code is indicated by pressing the switch upward. Switch B: This is used when more than one fault code is memorized. The next fault code is displayed when pressing the switch up once, and previous fault code is displayed when pressing the switch down once. Troubleshooting Procedure 1. Turn key switch to ON position. (Engine: Stop) When Fault Code is Not Memorized: The engine warning indicator 2, engine stop indicator 2 and engine protection indicator come ON in sequence. Then, all three indicators go OFF. When Faulty Code is Memorized: The engine warning indicator 2, engine stop indicator 2 and engine protection indicator come ON in sequence. Then, all three indicators go OFF. After that, the indicator corresponding to the fault level stays ON.

T5-7-3

Fault Diagnosing Switch B

Fault Diagnosing Switch A

M18E-01-009

TROUBLESHOOTING / Troubleshooting D 2. Turn the engine fault diagnosing switch A ON (press upward). The engine warning indicator 2 and engine stop indicator 2 blink in the following sequence. (Three indicators stay ON when no fault code is memorized). • The engine warning indicator 2 blinks once. • After approx. one seconds, the engine stop indicator 2 blinks. The blinking number indicates the hundredth digit. • After approx. one seconds, the engine stop indicator 2 blinks. The blinking number indicates the tenth digit. • After approx. one seconds, the engine stop indicator 2 blinks. The blinking number indicates the first digit. • Finally, the engine warning indicator 2 blinks once. 3. The fault code is indicated repeatedly in the above sequence.

Example: in case of Fault Code 132 (Fault code is indicated in three digit number) hundredth number

tenth number

first number

ON

OFF

NOTE: When wires of the engine control system has been disconnected for service, ECM recognizes it as malfunction and stores it in the history. This record remains even if it is reconnected. The diagnostic tool INSITE is required to erase this record. NOTE: The code indicated on the fault code indicator panel shows the trouble occurring currently. The diagnostic tool INSITE is required to indicate the past history.

T5-7-4

one second

one second

T141-05-03-004

TROUBLESHOOTING / Troubleshooting D FAULT CODES FOR QUANTUM ENGINES

S020 3

114 Yellow

QSK60

113 Yellow

QSK45

635 7

QST30

S020 7

QSK23

112 Red

QSK19

Engine Control Module – Critical internal failure

QSX15

629 12

QSM11

S254 12

DESCRIPTION

QSL9

111 Red

FMI

QSC

SID(S) PID(P) FMI

QSB

SPN

FAULT CODE/ LAMP

X

X

X

X

X

X

X

X

X

X

Engine Timing Actuator is not responding to ECM commands

X

X

635 3

Engine Timing Actuator Circuit shorted high

X

X

S020 4

635 4

Engine Timing Actuator Circuit shorted low

115 Red

P190 2

190 2

116 Red

P156 3

156 3

Engine Speed/Position Sensor Circuit lost both of two signals from the magnetic pickup sensor Fuel Timing Pressure Sensor Circuit shorted high

117 Red

P156 4

156 4

118 Yellow

P135 3

119 Yellow

X

X

X

X

X

X

X

X X

X

X

X

X

X

X

X

X

X

X

X

Fuel Timing Pressure Sensor Circuit shorted low

X

X

X

X

135 3

Fuel Pump Delivery Pressure Sensor Circuit - shorted high

X

X

X

X

P135 4

135 4

Fuel Pump Delivery Pressure Sensor Circuit - shorted low

X

X

X

X

121 Yellow

P190 10

190 10

122 Yellow

P102 3

102 3

Engine Speed/Position Sensor Circuit lost one of two signals from the magnetic pickup sensor Intake Manifold Pressure Sensor #1 Circuit - shorted high

123 Yellow

P102 4

102 4

Intake Manifold Pressure Sensor #1 Circuit - shorted low

124* Yellow

102 16

125* None

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

High Intake Manifold Pressure Left Bank

X

X

X

102 18

Low Intake Manifold Pressure Left Bank

X

X

X

126* Yellow

1129 16

High Intake Manifold Pressure Right Bank

X

X

X

127* None

1129 18

Low Intake Manifold Pressure Right Bank

X

X

X

NOTE: *Denotes Cense Fault codes.

T5-7-5

TROUBLESHOOTING / Troubleshooting D

QSK45

QSK60

X

X

X

129* None

1129 4

Right Bank Intake Manifold Pressure Sensor Circuit Failed Low

X

X

X

QSX15

Right Bank Intake Manifold Pressure Sensor Circuit Failed High

QSL9

1129 3

QSC

128* None

DESCRIPTION

QSB

QST30

FMI

QSK23

SPN QSK19

SID(S) PID(P) FMI

QSM11

FAULT CODE/ LAMP

131 Red

P091 3

091 3

Accelerator Pedal Position Sensor Circuit - shorted high

X

X

X

X

X

X

X

X

X

X

132 Red

P091 4

091 4

Accelerator Pedal Position Sensor Circuit - shorted low

X

X

X

X

X

X

X

X

X

X

133 Red

P029 3

974 3

Remote Accelerator Pedal Position Sensor Circuit - shorted high

X

X

X

X

X

133 Red

P029 3

29 3

Remote Accelerator Pedal Position Sensor Circuit - shorted high

X

X

134 Red

P029 4

974 4

Remote Accelerator Pedal Position Sensor Circuit - shorted low

134 Red

P029 4

29 4

Remote Accelerator Pedal Position Sensor Circuit - shorted low

X

X

135 Yellow

P100 3

100 3

Engine Oil Pressure Sensor Circuit shorted high

X

X

X

136* None

1208 3

Pre Filter Oil Pressure Sensor Circuit Failed High

X

X

X

137* None

1208 4

Pre Filter Oil Pressure Sensor Circuit Failed Low

X

X

X

X

X

X

X

X

X X

X

X

X

X

X

X

X

X

P100 4

100 4

Engine Oil Pressure Sensor Circuit shorted low

X

X

X

X

X

143 Yellow

P100 1

100 18

Engine Oil Pressure Low - Warning

X

X

X

X

X

143 White

P100 1

100 1

Engine Oil Pressure Low - Warning

144 Yellow

P110 3

110 3

Engine Coolant Temperature Sensor Circuit - shorted high

X

X

X

X

145 Yellow

P110 4

110 4

Engine Coolant Temperature Sensor Circuit - shorted low

X

X

X

X

146 Yellow

P110 0

110 16

Engine Coolant Temperature High – Warning

X

X

X

T5-7-6

X

X

141 Yellow

NOTE: *Denotes Cense Fault codes.

X

X X

X

X

X

X

X

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

TROUBLESHOOTING / Troubleshooting D SID(S) PID(P) FMI

QSB

QSC

QSL9

QSM11

QSX15

QSK19

QSK23

QST30

QSK45

QSK60

SPN

FAULT CODE/ LAMP

147 Red

P091 8

091 8

Accelerator Pedal Position Sensor Circuit - low frequency

X

X

X

X

X

X

X

X

X

X

148 Red

P091 8

091 8

Accelerator Pedal Position Sensor Circuit - high frequency

X

X

X

X

X

X

X

X

X

X

151 Red

P110 0

110 0

Engine Coolant Temperature High – Critical

X

X

X

X

X

151 White

P110 0

110 0

Engine Coolant Temperature High – Critical

X

X

153 Yellow

P105 3

105 3

Intake Manifold Temperature Sensor #1 Circuit - shorted high

X

X

X

X

154 Yellow

P105 4

105 4

Intake Manifold Temperature Sensor #1 Circuit - shorted low

X

X

X

155 Red

P105 0

105 0

Intake Manifold Temperature #1 High Critical

X

X

X

155 White

P105 0

105 0

Intake Manifold Temperature #1 High Critical

156* Yellow

1131 3

157* Yellow

FMI

DESCRIPTION

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

1131 4

Left Bank Rear Intake Manifold Temperature Sensor Circuit Failed High Left Bank Rear Intake Manifold Temperature Sensor Circuit Failed Low

X

X

158* White

1131 0

High Intake Manifold Temperature Left Bank Rear

X

X

159* Yellow

1132 3

X

X

161* Yellow

1132 4

Right Bank Front Intake Manifold Temperature Sensor Circuit Failed High Right Bank Front Intake Manifold Temperature Sensor Circuit Failed Low

X

X

162* White

1132 0

High Intake Manifold Temperature Right Bank Front

X

X

163* Yellow

1133 3

X

X

164* Yellow

1133 4

Right Bank Rear Intake Manifold Temperature Sensor Circuit Failed High Right Bank Rear Intake Manifold Temperature Sensor Circuit Failed Low

X

X

165* White

1133 0

High Intake Manifold Temperature Right Bank Rear

X

X

NOTE: *Denotes Cense Fault codes.

T5-7-7

X X

X

TROUBLESHOOTING / Troubleshooting D

Rack Position Sensor #1 Circuit shorted Low

X

172 Red

S023 6

638 6

Rack Actuator Position #1 Circuit grounded circuit

X

173 Yellow

S023 7

638 7

Rack Actuator - mechanically stuck open

X

184 Yellow

S233 2

609 2

Engine Control Module Identification Input State Error

185 Yellow

S231 2

639 2

Engine Control Module Network Communication Error

187 Yellow

S232 4

620 4

Sensor Supply Voltage #2 Circuit shorted low

X

X

211 None

S216 11

1484 31

Additional OEM/Vehicle Diagnostic Codes have been logged. Check other ECM's for DTC's. OEM Component Failure

X

X

175 3

Engine Oil Temperature Sensor Circuit - shorted high

X

175 3

Engine Oil Temperature Sensor Circuit - shorted high

175 4

Engine Oil Temperature Sensor Circuit - shorted low

175 4

Engine Oil Temperature Sensor Circuit - shorted low

175 0

Engine Oil Temperature High - Critical

175 0

Engine Oil Temperature High - Critical

211* None 212 Yellow

613 14 P175 3

212* Yellow 213 Yellow

P175 4

213* Yellow 214 Red

P175 0

214* White 219 Maint

P17 1

1380 17

Low Oil Level in the Centinel makeup oil tank

219 White

P17 1

1380 1

Low Oil Level in the Centinel makeup oil tank

221 Yellow

P108 3

108 3

Ambient Air Pressure Sensor Circuit – shorted high

NOTE: *Denotes Cense Fault codes.

T5-7-8

X

X

X

QSK60

733 4

QST30

S024 4

QSK23

167 Yellow

QSK19

X

QSX15

Rack Position Sensor #1 Circuit shorted high

QSM11

733 3

QSL9

S024 3

DESCRIPTION

QSC

166 Yellow

FMI

QSB

SID(S) PID(P) FMI

QSK45

SPN

FAULT CODE/ LAMP

X

X

X

X

X

X

X

X

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

TROUBLESHOOTING / Troubleshooting D SPN

Engine Oil Burn Valve Solenoid Circuit – shorted low

225 Yellow

S086 4

1266 4

Engine Oil Replacement Valve Solenoid Circuit - shorted low

227 Yellow

S232 3

620 3

Sensor Supply Voltage #2 Circuit shorted high

231 Yellow

P109 3

109 3

Engine Coolant Pressure Sensor Circuit - shorted high

X

232 Yellow

P109 4

109 4

Engine Coolant Pressure Sensor Circuit - shorted low

X

233 Yellow

P109 1

109 18

Engine Coolant Pressure Low Warning

233 White

P109 1

109 1

Engine Coolant Pressure Low Warning

234 Red

P190 0

190 0

Engine Speed High - Cricital

X

X

X

X

X

235 Red

P111 1

111 1

Engine Coolant Level Low - Critical

X

X

X

X

X

235 White

P111 1

111 1

Engine Coolant Level Low - Critical

237 Yellow

S030 2

644 2

External Speed Input (Multiple Unit Sychronization) - data incorrect

241 Yellow

P084 2

084 2

Vehicle Speed Sensor Circuit - data incorrect

X

X

X

X

X

242 Yellow

P084 10

084 10

Vehicle Speed Sensor Circuit tampering has been detected

X

X

X

X

X

243 Yellow

P121 4

513 4

Engine Brake Driver #1 Circuit shorted low

X

X

X

245 Yellow

S033 4

647 4

Fan Clutch Circuit - shorted low

X

X

X

X

X

252 Yellow

P098 2

098 2

Engine Oil Level #1 Sensor Circuit data incorrect

NOTE: *Denotes Cense Fault codes.

T5-7-9

QSK60

1265 4

QSK45

S085 4

QST30

223 Yellow

QSK19

Ambient Air Pressure Sensor Circuit – shorted low

QSX15

108 4

QSM11

P108 4

DESCRIPTION

QSL9

222 Yellow

FMI

QSC

SID(S) PID(P) FMI

QSB

FAULT CODE/ LAMP

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

X

X X

X

X

X X

TROUBLESHOOTING / Troubleshooting D

Fuel Shutoff Valve Circuit - shorted low

254 None

S017 4

632 4

Fuel Shutoff Valve Circuit - shorted low

255 Yellow

S017 3

632 3

Fuel Shutoff Valve Circuit - shorted high

259 Red

S017 7

632 7

Fuel Shutoff Valve - stuck open

261 Yellow

P174 0

174 16

Fuel Temperature High - Warning

261 White

P174 0

174 0

Fuel Temperature High - Warning

263 Yellow

P174 3

174 3

Fuel Temperature Sensor Circuit shorted high

264 Yellow

P174 11

174 11

Fuel Temperature Sensor Circuit - data out-of-range

265 Yellow

P174 4

174 4

268 Yellow

P094 2

271 Yellow

X

X

X

X

X

X

X

X

X

X

X X

X

QSK60

632 4

QSK45

S017 4

QST30

254 Red

QSK19

Engine Oil Level #1 Low - Critical

QSX15

098 1

QSM11

P098 1

DESCRIPTION

QSL9

253 White

FMI

QSC

SID(S) PID(P) FMI

QSB

SPN

FAULT CODE/ LAMP

X X

X

X

X X

X X

X

X

X

X

X

Fuel Temperature Sensor Circuit shorted low

X

X

X

X

X

X

94 2

Fuel Pressure Sensor Circuit - data incorrect

X

X

S126 4

1347 4

High Fuel Pressure Solenoid Valve #1 Circuit - shorted low

X

X

272 Yellow

S126 3

1347 3

High Fuel Pressure Solenoid Valve #1 Circuit - shorted high

X

X

273 Yellow

S127 4

1348 4

High Fuel Pressure Solenoid Valve #2 Circuit - shorted low

X

X

274 Yellow

S127 3

1348 3

High Fuel Pressure Solenoid Valve #2 Circuit - shorted high

X

X

275 Yellow

S126 7

1347 7

Fuel Pumping Element #1 (Front) mechanically stuck

X

X

276 Yellow

S018 3

633 3

Fuel Injection Control Valve Circuit shorted high

X

X

NOTE: *Denotes Cense Fault codes.

T5-7-10

X

TROUBLESHOOTING / Troubleshooting D

278 Yellow

P073 11

1075 11

Fuel Priming Pump Control Circuit shorted high/low

279 Yellow

S018 4

633 4

281 Yellow

S126 7

282 Yellow

QSC

QSL9 X

X

X

Fuel Injection Control Valve Circuit shorted low

X

X

1347 7

High Fuel Pressure Solenoid Valve #1 - mechanically stuck

X

X

S127 7

1348 7

High Fuel Pressure Solenoid Valve #2 - mechanically stuck

X

X

283 Yellow

S221 3

1043 3

X

X

X

284 Yellow

S221 4

1043 4

X

X

X

285 Yellow

S231 9

639 9

Engine Speed/Position Sensor #1 (Crankshaft) Supply Voltage Circuit shorted high Engine Speed/Position Sensor #1 (Crankshaft) Supply Voltage Circuit shorted low SAE J1939 Multiplexing PGN Timeout Error

X

X

X

X

X

286 Yellow

S231 13

639 13

SAE J1939 Multiplexing Configuration Error

X

X

X

X

X

287 Red

P091 2

91 19

SAE J1939 Multiplexing Accelerator Pedal Sensor System Error

X

X

X

X

X

288 Red

P029 2

974 19

SAE J1939 Multiplexing Remote Throttle Data Error

X

X

X

X

X

292 White

P223 14

1083 14

Auxiliary Temperature Sensor Input # 1 Engine Protection - Critical

293 Yellow

S441 3

441 3

Auxiliary Temperature Sensor Input # 1 Circuit – shorted high

293 Yellow

P223 3

1083 3

Auxiliary Temperature Sensor Input # 1 Circuit – shorted high

293 Yellow

S154 3

1083 3

Auxiliary Temperature Sensor Input # 1 Circuit – shorted high

294 Yellow

S441 4

441 4

Auxiliary Temperature Sensor Input # 1 Circuit – shorted low

294 Yellow

P223 4

1083 4

Auxiliary Temperature Sensor Input # 1 Circuit – shorted low

NOTE: *Denotes Cense Fault codes.

T5-7-11

QSB

X X

QSK60

Fuel Injection Control Valve mechanically stuck

QSK45

633 7

X

X

X

X

X

X

X

X

X

QST30

S018 7

DESCRIPTION

QSK19

277 Yellow

FMI

QSX15

SID(S) PID(P) FMI

QSM11

SPN

FAULT CODE/ LAMP

X

X

X

TROUBLESHOOTING / Troubleshooting D

295 Yellow

P108 2

108 2

Ambient Air Pressure Sensor Circuit data incorrect

X

X

296 Red

P223 14

1387 14

Auxiliary Pressure Sensor Input # 2 Engine Protection - Critical

296 White

P223 14

1084 14

Auxiliary Pressure Sensor Input # 2 Engine Protection - Critical

297 Yellow

P223 3

1387 3

Auxiliary Pressure Sensor Input # 2 Circuit – shorted high

297 Yellow

P223 3

1084 3

Auxiliary Pressure Sensor Input # 2 Circuit – shorted high

298 Yellow

P223 4

1387 4

Auxiliary Pressure Sensor Input # 2 Circuit – shorted low

298 Yellow

P223 4

1084 4

Auxiliary Pressure Sensor Input # 2 Circuit – shorted low

299 None

S117 14

1384 31

Engine Shutdown Commanded by J1939

299 Yellow

S117 11

1384 31

Engine Shutdown Commanded by J1939

X

X

311 Yellow

S001 6

651 6

Injector Solenoid Valve Cylinder #1 Circuit – grounded circuit

X

X

312 Yellow

S005 6

655 6

Injector Solenoid Valve Cylinder #5 Circuit – grounded circuit

X

X

313 Yellow

S003 6

653 6

Injector Solenoid Valve Cylinder #3 Circuit – grounded circuit

X

X

314 Yellow

S006 6

656 6

Injector Solenoid Valve Cylinder #6 Circuit - grounded circuit

X

X

315 Yellow

S002 6

652 6

Injector Solenoid Valve Cylinder #2 Circuit – grounded circuit

X

X

316 Yellow

S078 3

931 3

318 Yellow

S078 7

931 7

X

X

X

X

QSK60

X

QSK45

X

X

X

X

QST30

Auxiliary Temperature Sensor Input # 1 Circuit – shorted low

QSK19

QSX15

1083 4

QSL9

S154 4

DESCRIPTION

QSC

294 Yellow

FMI

QSB

SID(S) PID(P) FMI

QSM11

SPN

FAULT CODE/ LAMP

X

X X

X

X

X

X

X

X

X

X

X

X

X

X

Fuel Supply Pump Actuator Circuit shorted high

X

X

X

Fuel Supply Pump Actuator – mechanically stuck

X

X

X

NOTE: *Denotes Cense Fault codes.

T5-7-12

X

X

X

TROUBLESHOOTING / Troubleshooting D

Injector Solenoid Valve Cylinder #4 Circuit - grounded circuit

X

322 Yellow

S001 5

651 5

Injector Solenoid Valve Cylinder #1 Circuit - open circuit

X

323 Yellow

S005 5

655 5

Injector Solenoid Valve Cylinder #5 Circuit – open circuit

X

324 Yellow

S003 5

653 5

Injector Solenoid Valve Cylinder #3 Circuit – open circuit

X

325 Yellow

S006 5

656 5

Injector Solenoid Valve Cylinder #6 Circuit – open circuit

X

328 Yellow

S152 7

1348 7

Fuel Pumping Element #2 (Rear) mechanically stuck

X

X

329 Yellow

S233 14

1077 14

Fuel System Leakage error

X

X

331 Yellow

S002 5

652 5

Injector Solenoid Valve Cylinder #2 Circuit – open circuit

X

332 Yellow

S004 5

654 5

Injector Solenoid Valve Cylinder #4 Circuit – open circuit

X

341 Yellow

S253 2

630 2

Engine Control Module – data lost

X

342 Red

S253 13

630 13

Engine Control Module – out of calibration

343 Yellow

S254 12

629 12

Engine Control Module - Warning internal hardware failure

346 Yellow

S253 12

630 12

Engine Control Module - Warning Software error

349 Yellow

P191 0

191 16

Transmission Output Shaft (Tailshaft) Speed High – Warning

349 Yellow

P191 0

191 0

Transmission Output Shaft (Tailshaft) Speed High – Warning

352 Yellow

S232 4

1079 4

Sensor Supply Voltage #1 Circuit shorted low

NOTE: *Denotes Cense Fault codes.

T5-7-13

X

X

X

QSK60

654 6

X

QSK45

S004 6

X

X

X

X

X

X

X

X

X

X

X

QST30

321 Yellow

QSX15

Real Time Clock - Power Interrupt

QSM11

251 2

QSL9

P251 2

DESCRIPTION

QSC

319 Maint

FMI

QSB

SID(S) PID(P) FMI

QSK19

SPN

FAULT CODE/ LAMP

X X

X

X

X

X

X

X

X X

X

X

X

X

X

TROUBLESHOOTING / Troubleshooting D

1076 4

Fuel Pump Control Module, Fuel Control Valve Circuit - shorted low

X

363 Yellow

S251 7

1076 7

Fuel Pump Control Module, Fuel Control Valve - mechanically stuck

X

364 Yellow

S233 9

1077 9

X

365 Yellow

S233 4

1077 4

Fuel Pump Control Module, CAN Communication Error - abnormal update rate Fuel Pump Control Module, Supply Voltage Circuit - shorted low

366 Yellow

S233 2

1077 2

Fuel Pump Control Module, Supply Voltage Circuit - data incorrect

X

367 Yellow

P190 11

1078 11

Fuel Pump Control Module, Increment Angle Time Sensor Error

X

368 Yellow

S254 8

1078 8

Fuel Pump Control Module, Timing Error

X

369 Yellow

P190 2

1078 2

Fuel Pump Control Module, Engine Synchronization Error

X

372 Yellow

S233 11

1077 11

Fuel Pump Control Module, Idle Validation Error

X

373 Red

S233 3

1077 3

Fuel Pump Control Module, Fuel Shutoff Error

X

374 Yellow

S233 12

1077 12

Fuel Pump Control Module, Self-Test Error

X

375 Yellow

S254 2

629 2

Fuel Pump Control Module, Electronic Calibration Code Error

X

376 Yellow

S233 13

1077 13

Fuel Pump Control Module, Fueling or Engine Speed Mismatch

X

377 Yellow

S233 7

1077 7

Fuel Pump Control Module, Stuck Relay Error

X

378 Yellow

S018 5

633 5

Fueling Actuator #1 Circuit - open circuit

X

379 Yellow

S018 6

633 6

Fueling Actuator #1 Circuit - grounded circuit

X

NOTE: *Denotes Cense Fault codes.

T5-7-14

X

QSK60

S251 4

QSK45

362 Yellow

QST30

X

QSX15

Fuel Pump Control Module, Fuel Control Valve Circuit - shorted high

QSM11

1076 3

QSL9

S251 3

DESCRIPTION

QSC

361 Red

FMI

QSB

SID(S) PID(P) FMI

QSK19

SPN

FAULT CODE/ LAMP

TROUBLESHOOTING / Troubleshooting D

X

X

X

382 Yellow

S237 11

626 11

Intake Air Heater (Relay Enable) #2 Circuit - data incorrect

X

X

X

X

384 Yellow

S237 11

626 11

Start Assist Device Control Circuit Error (Ether Injection)

385 Yellow

S232 3

620 3

OEM Sensor Supply Voltage Circuit shorted high

X

X

X

386 Yellow

S232 3

1079 3

Sensor Supply Voltage #1 Circuit shorted high

X

X

X

X

X

387 Yellow

S221 3

1043 3

Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted high

X

X

X

X

X

389 Yellow

S033 11

647 11

Fan Clutch Circuit Error

X

X

X

391 Yellow

S017 11

632 11

Fuel Shutoff Valve Supply Voltage error

X

394 Yellow

S020 5

635 5

Timing Actuator #1 Circuit - open circuit

X

395 Yellow

S020 6

635 6

Timing Actuator #1 Circuit - grounded circuit

X

396 Yellow

S083 5

1244 5

Fueling Actuator #2 Circuit - open circuit

X

397 Yellow

S083 6

1244 6

Fueling Actuator #2 Circuit - grounded circuit

X

398 Yellow

S084 5

1245 5

Timing Actuator #2 Circuit - open circuit

X

399 Yellow

S084 6

1245 6

Timing Actuator #2 Circuit - grounded circuit

X

414* Yellow

S250 9

608 9

Data Communication error over the J1587 data link Circuit

415 Red

P100 1

100 1

Engine Oil Pressure Low – Critical

415 White

P100 1

100 1

Engine Oil Pressure Low – Critical

NOTE: *Denotes Cense Fault codes.

T5-7-15

X

QSK60

X

QSK45

Intake Air Heater (Relay Enable) #1 Circuit - data incorrect

QST30

626 11

QSK19

QSL9

S237 11

DESCRIPTION

QSX15

QSC

381 Yellow

FMI

QSM11

SID(S) PID(P) FMI

QSB

SPN

FAULT CODE/ LAMP

X

X

X

X

X X

X

X

X

X

X X

TROUBLESHOOTING / Troubleshooting D

1319 2

Intake Manifold Boost Pressure Imbalance

P111 2

111 2

Engine Coolant Level Sensor Circuit data incorrect

423 Yellow

P156 2

156 2

Fuel Timing Pressure or Timing Actuator Stuck

426 None

S231 2

639 2

SAE J1939 datalink - cannot transmit

426 Yellow

S231 2

639 2

SAE J1939 datalink - cannot transmit

639 2

SAE J1939 datalink - cannot transmit

426* None

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X X

S231

639 9

SAE J1939 not fast enough

428 Yellow

P097 3

97 3

Water in Fuel Sensor Circuit - shorted high

429 Yellow

P097 4

097 4

Water in Fuel Sensor Circuit - shorted low

X

X

431 Yellow

S230 2

558 2

Accelerator Pedal Idle Validation Circuit - data incorrect

X

X

431 Yellow

P091 2

91 2

Accelerator Pedal Idle Validation Circuit - data incorrect

432 Red

S230 13

558 13

Accelerator Pedal Idle Validation Circuit - out of calibration

432 Red

P091 13

91 13

Accelerator Pedal Idle Validation Circuit - out of calibration

433 Yellow

P102 2

102 2

Intake Manifold Pressure Sensor Circuit - data incorrect

X

X

X

X

X

434 Yellow

S251 2

627 2

Power Lost without Ignition Off

X

X

X

X

X

435 Yellow

P100 2

100 2

Engine Oil Pressure Sensor Circuit data incorrect

X

X

T5-7-16

X

X

X

427 None

NOTE: *Denotes Cense Fault codes.

X

QST30

X

QSK19

X

QSK60

Water in Fuel Indicator High – Maintenance

QSK45

097 15

QSX15

422 Yellow

DESCRIPTION

QSM11

P097 0

FMI

QSL9

418 WIF / Maint. 419 Yellow

SPN QSC

SID(S) PID(P) FMI

QSB

FAULT CODE/ LAMP

X X

X

X

X

X

X

X

X

X

X

X X

X

X

X

X

X

X X

TROUBLESHOOTING / Troubleshooting D

441 None

P168 1

168 1

Battery #1 Voltage Low - Warning

442 Yellow

P168 0

168 16

Battery #1 Voltage High - Warning

442 Yellow

P168 0

168 0

Battery #1 Voltage High - Warning

443 Yellow

S221 4

1043 4

Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted low

X

X

X

444 Yellow

S232 1

620 18

OEM Sensor Supply Voltage Low Warning

X

X

X

446* None

N/A

GSP Communication Failure

447* None

N/A

448* None

X

X

X

X

X

X

X

X

X

X

X

RPC Number Not Supported

X

X

X

N/A

RPC Argument Mismatch

X

X

X

X

X

X

DESCRIPTION

QST30

QSK60

X

QSK45

QSX15

Battery #1 Voltage Low - Warning

QSM11

168 18

QSL9

P168 1

QSC

441 Yellow

FMI

QSB

SID(S) PID(P) FMI

QSK19

SPN

FAULT CODE/ LAMP

X X

X

X

X

X

X

X X

X

X

449 Yellow

P094 0

094 16

Fuel Pressure High - Warning

X

X

X

451 Yellow

P157 3

157 3

Injector Metering Rail #1 Pressure Sensor Circuit - shorted high

X

X

X

451 Red

P157 3

157 3

Injector Metering Rail #1 Pressure Sensor Circuit - shorted high

452 Yellow

P157 4

157 4

Injector Metering Rail #1 Pressure Sensor Circuit - shorted low

452 Red

P157 4

157 4

Injector Metering Rail #1 Pressure Sensor Circuit - shorted low

X

X

X

455 Red

S018 3

633 3

Fuel Control Valve Circuit - shorted high

X

X

X

466 Yellow

S032 4

1188 4

Turbocharger #1 Wastegate Control Circuit - shorted low

467 Yellow

S020 2

635 2

Timing Rail Actuator Circuit - data incorrect

X

X

X

NOTE: *Denotes Cense Fault codes.

T5-7-17

X

X

X

X

TROUBLESHOOTING / Troubleshooting D

Engine Oil Level Low - Maintenance

471 Maint.

P098 1

98 1

Engine Oil Level Low - Maintenance

472 Maint.

P017 2

1380 2

Engine Oil Level #2 Low – Maintenance

473 Yellow

P017 2

1380 2

Engine Oil Level #2 Low – Warning

1318 9

Exhaust Port Temperature Bank Imbalance

479* None

094 18

Fuel Pressure Low - Warning

X

483 Yellow

P129 3

1349 3

Injector Metering Rail #2 Pressure Sensor Circuit - shorted high

X

484 Yellow

P129 4

1349 4

Injector Metering Rail #2 Pressure Sensor Circuit - shorted low

X

485 Yellow

P129 0

1349 16

Injector Metering Rail #2 Pressure High - Warning

X

486 Yellow

P129 1

1349 18

Injector Metering Rail #2 Pressure Low - Warning

X

487 None

S237 1

626 1

Start Assist Device - Canister Empty (Ether Injection)

488 Yellow

P105 0

105 16

Intake Manifold Temperature High – Warningl

X

X

X

489 Yellow

P191 1

191 18

Transmission Output Shaft (Tailshaft) Speed Low – Warning

X

X

X

489 Yellow

P191 1

191 1

Transmission Output Shaft (Tailshaft) Speed Low – Warning

493

S018

1076

Fuel Pump Calibration Trim Circuit

13

13

Error

S221 11

1043 11

Engine Speed/Position Sensor #2 (Camshaft) Supply Voltage

T5-7-18

X

X

X

X

X

X

X

X

X

X

X

P094 1

NOTE: *Denotes Cense Fault codes.

X

X

482 Yellow

496 Yellow

QSK60

98 17

QSK45

P098 1

X

QST30

471 Maint.

QSK19

Fuel Rail Actuator Circuit - data incorrect

QSX15

633 2

QSM11

S018 2

DESCRIPTION

QSL9

468 Yellow

FMI

QSC

SID(S) PID(P) FMI

QSB

SPN

FAULT CODE/ LAMP

X

X

X

X X

TROUBLESHOOTING / Troubleshooting D

497 Yellow

S114 2

1377 2

Multiple Unit Synchronization Switch Circuit - data incorrect

498 Yellow

P098 3

098 3

499 Yellow

P098 4

514 Red

QSK60 X

098 4

Engine Oil Level Sensor – circuit shorted low

X

X

S018 7

633 7

Fuel Control Valve - mechanically stuck

X

X

515 Yellow

P091 3

091 3

Accelerator Pedal Frequency Position Sensor Supply Circuit - shorted high

X

X

X

516 Yellow

P091 4

091 4

Accelerator Pedal Frequency Position Sensor Supply Circuit - shorted low

X

X

X

517 Yellow

S251 12

1076 12

Fuel Metering Solenoid - bad device

X

524 Yellow

P113 2

113 2

OEM Alternate Droop Switch Validation - data incorrect

X

X

X

527 Yellow

P154 3

702 3

Auxiliary Input/Output #2 Circuit shorted high

X

X

X

527 Yellow

S040 3

702 3

Auxiliary Input/Output #2 Circuit shorted high

X

X

528 Yellow

P093 2

093 2

OEM Alternate torque validation switch - data incorrect

X

X

X

X

X

529 Yellow

S051 3

703 3

Auxiliary Input/Output #3 Circuit shorted high

X

X

X

X

X

X

X

539 Yellow

S018 11

633 11

Injector Control Valve Electronic Filter (Transorb) Error

X

X

546 Yellow

P094 3

94 3

Fuel Delivery Pressure Sensor Circuit shorted high

X

547 Yellow

P094 4

94 4

Fuel Delivery Pressure Sensor Circuitshorted low

X

551 Yellow

S230 4

558 4

Accelerator Pedal Idle Validation Circuit - shorted low

551 Red

P091 4

091 4

Accelerator Pedal Idle Validation Circuit - shorted low

X

X

553 Yellow

P157 0

157 16

Injector Metering Rail #1 Pressure High - warning level

NOTE: *Denotes Cense Fault codes.

T5-7-19

X

X

QST30

X

X

QSX15

Engine Oil Level Sensor – circuit shorted high

QSL9

X

QSC

X

DESCRIPTION

QSB

QSK45

FMI

QSK19

SID(S) PID(P) FMI

QSM11

SPN

FAULT CODE/ LAMP

X

X

X X

X

X X

X

X

X

X

X X

X

X X

X

X

TROUBLESHOOTING / Troubleshooting D

QSK60 X

554 Yellow

P157 2

157 2

Fuel Pressure Sensor Error

X

X

X

555 Yellow

P022 0

1264 16

Engine Blowby - Warning Level

555 White

P022 0

1264 0

Engine Blowby - Warning Level

X

X

581 Yellow

P015 3

1381 3

Fuel Supply Pump Inlet Pressure Sensor Circuit - shorted high

X

X

X

582 Yellow

P015 4

1381 4

Fuel Supply Pump Inlet Pressure Sensor Circuit – shorted low

X

X

X

583 Yellow

P015 1

1381 18

Fuel Supply Pump Inlet Pressure Low warning level

X

X

X

595 Yellow

P103 0

103 16

Turbocharger #1 Speed High - warning level

596 Yellow

P167 0

167 16

Electrical Charging System Voltage High - warning level

X

X

597 Yellow

P167 1

167 18

Electrical Charging System Voltage Low - Warning Level

X

X

598 Red

P167 1

167 1

Electrical Charging System Voltage Low - Critical Level

X

X

599 Red

S025 14

640 14

OEM Commanded Dual Output Shutdown

X

X

X

611 None

S151 11

1383 31

Engine Hot Shutdown

X

X

X

X

X

611 None

S151 14

1383 31

Engine Hot Shutdown

612* Red

99 1

High Lubricating Oil Filter Restriction

616* None

1173 16

High Turbo Compressor Inlet Temp RB

617* None

1172 0

High Turbo Compressor Inlet Temp LB

X

621* Yellow

1137 18

Low #1 LB Cylinder Power

X

X X

X

X

NOTE: *Denotes Cense Fault codes.

T5-7-20

QST30

X

QSK19 X

QSX15

Injector Metering Rail #1 Pressure High - warning level

QSM11

157 0

QSL9

P157 0

DESCRIPTION

QSC

553 Red

FMI

QSB

SID(S) PID(P) FMI

QSK45

SPN

FAULT CODE/ LAMP

X

X

X

X

X

X

X

X

X

X

TROUBLESHOOTING / Troubleshooting D SPN QSK45

QSK60

X

X

X

623* Yellow

1139 18

Low #3 LB Cylinder Power

X

X

X

624* Yellow

1140 18

Low #4 LB Cylinder Power

X

X

X

625* Yellow

1141 18

Low #5 LB Cylinder Power

X

X

X

626* Yellow

1142 18

Low #6 LB Cylinder Power

X

X

X

627* Yellow

1143 18

Low #7 LB Cylinder Power

X

628* Yellow

1144 18

Low #8 LB Cylinder Power

X

631* Yellow

1143 (45) 1145 (60) 18 1329 1

Low #1 RB Cylinder Power

1144 (45) 1146 (60) 18 1329 1

Low #2 RB Cylinder Power

1145 (45) 1147 (60) 18 1329 1

Low #3 RB Cylinder Power

1146 (45) 1148 (60) 18 1329 1

Low #4 RB Cylinder Power

631* Yellow 632* Yellow 632* Yellow 633* Yellow 633* Yellow 634* Yellow 634* Yellow

Low #1 RB Cylinder Power

Low #2 RB Cylinder Power

Low #3 RB Cylinder Power

Low #4 RB Cylinder Power

NOTE: *Denotes Cense Fault codes.

T5-7-21

QSX15

Low #2 LB Cylinder Power

QSL9

1138 18

QSC

622* Yellow

DESCRIPTION

QSB

QST30

FMI

QSK19

SID(S) PID(P) FMI

QSM11

FAULT CODE/ LAMP

X

X

X

X

X

X

X

X

X

X

X

X

TROUBLESHOOTING / Troubleshooting D

QSK60

QST30

QSK19

QSX15

QSM11

DESCRIPTION

QSL9

FMI

QSK45

635* Yellow

SPN QSC

SID(S) PID(P) FMI

QSB

FAULT CODE/ LAMP

X

X

X

X

1147 (45) 1149 (60) 18 1329 1

Low #5 RB Cylinder Power

Low #6 RB Cylinder Power

636* Yellow

1148 (45) 1150 (60) 18 1329 1

637* Yellow

1151 18

Low #7 RB Cylinder Power

X

638* Yellow

1152 18

Low #8 RB Cylinder Power

X

641* Red

1137 0

High #1 LB Cylinder Exhaust Temperature

X

X

X

642* Red

1138 0

High #2 LB Cylinder Exhaust Temperature

X

X

X

643* Red

1139 0

High #3 LB Cylinder Exhaust Temperature

X

X

X

644* Red

1140 0

High #4 LB Cylinder Exhaust Temperature

X

X

X

645* Red

1141 0

High #5 LB Cylinder Exhaust Temperature

X

X

X

646* Red

1142 0

High #6 LB Cylinder Exhaust Temperature

X

X

X

647* Red

1143 0

High #7 LB Cylinder Exhaust Temperature

X

648* Red

1144 0

High #8 LB Cylinder Exhaust Temperature

X

635* Yellow 636* Yellow

Low #5 RB Cylinder Power

X

Low #6 RB Cylinder Power

649 None

S153 0

1378 0

Change Lubricating Oil and Filter

649 White

S153 11

1378 31

Change Lubricating Oil and Filter

NOTE: *Denotes Cense Fault codes.

T5-7-22

X

X

X X

X

TROUBLESHOOTING / Troubleshooting D

QST30

QSK45

QSK60 X

651* Red

657* Red

1143 1145 0 1144 1146 0 1145 1147 0 1146 1148 0 1147 1149 0 1148 1149 0 1150 0

(30,45) (60)

High #1 RB Cylinder Exhaust Temperature

X

X

X

658* Red

1151 0

652* Red

(30,45) (60)

High #2 RB Cylinder Exhaust Temperature

X

X

X

653* Red

(30,45) (60)

High #3 RB Cylinder Exhaust Temperature

X

X

X

654* Red

(30,45) (60)

High #4 RB Cylinder Exhaust Temperature

X

X

655* Red

(30,45) (60)

High #5 RB Cylinder Exhaust Temperature

X

X

X

656* Red

(30,45) (60)

High #6 RB Cylinder Exhaust Temperature

X

X

X

659* None

QSX15

X

QSL9

X

QSC

Change Lubricating Oil and Filter

649* None

DESCRIPTION

QSK19

FMI

QSM11

SPN

SID(S) PID(P) FMI

QSB

FAULT CODE/ LAMP

High #7 RB Cylinder Exhaust Temperature

X

High #8 RB Cylinder Exhaust Temperature

X

Change fuel filter

661* Yellow

1137 16

High #1 LB Cylinder Power

661* Yellow

1323 0

High #1 LB Cylinder Power

662* Yellow

1138 16

High #2 LB Cylinder Power

662* Yellow

1324 0

High #2 LB Cylinder Power

663* Yellow

1139 16

High #3 LB Cylinder Power

NOTE: *Denotes Cense Fault codes.

T5-7-23

X

X

X

X

X

X

X

X

X

X

X

TROUBLESHOOTING / Troubleshooting D

QSK45

QSK60

QST30

QSK19

QSX15

DESCRIPTION

QSM11

FMI

QSL9

SPN QSC

SID(S) PID(P) FMI

QSB

FAULT CODE/ LAMP

X

X

X

X

X

X

663* Yellow

1325 0

High #3 LB Cylinder Power

664* Yellow

1140 16

High #4 LB Cylinder Power

664* Yellow

1326 0

High #4 LB Cylinder Power

665* Yellow

1141 16

High #5 LB Cylinder Power

665* Yellow

1327 0

High #5 LB Cylinder Power

666* Yellow

1142 16

High #6 LB Cylinder Power

666* Yellow

1328 0

High #6 LB Cylinder Power

667* Yellow

1143 16

High #7 LB Cylinder Power

X

668* Yellow

1144 16

High #8 LB Cylinder Power

X

669* None

X

X

X

X

Change coolant filter

X

X

X

671* None

1137 4

Cyl #1 LB Exhaust Temp Sens Failed Low

X

X

X

672* None

1138 4

Cyl #2 LB Exhaust Temp Sens Failed Low

X

X

X

673* None

1139 4

Cyl #3 LB Exhaust Temp Sens Failed Low

X

X

X

674* None

1140 4

Cyl #4 LB Exhaust Temp Sens Failed Low

X

X

X

675* None

1141 4

Cyl #5 LB Exhaust Temp Sens Failed Low

X

X

X

676* None

1142 4

Cyl #6 LB Exhaust Temp Sens Failed Low

X

X

X

677* None

1143 4

Cyl #7 LB Exhaust Temp Sens Failed Low

X

678* None

1144 4

Cyl #8 LB Exhaust Temp Sens Failed Low

X

NOTE: *Denotes Cense Fault codes.

T5-7-24

TROUBLESHOOTING / Troubleshooting D

QSK60

QSK19

QSX15

QSK45

Change Coolant

QST30

679* None

DESCRIPTION

QSM11

FMI

QSL9

SPN QSC

SID(S) PID(P) FMI

QSB

FAULT CODE/ LAMP

X

X

X

691* None

1172 3

LBF Turbo Comp Inlet Temp Sens Failed High

X

692* None

1172 4

LBR Turbo Comp Inlet Temp Sens Failed Low

X

694* None

1173 3

RBF Turbo Comp Inlet Temp Sens Failed High

X

X

695* None

1174 4

RBR Turbo Comp Inlet Temp Sens Failed Low

X

X

711* Yellow

1143 (45) 1145 (60) 16 1329 0

High #1 RB Cylinder Power

X

X

1144 (45) 1146 (60) 16 1330 0

High #2 RB Cylinder Power

X

X

1145 (45) 1147 (60) 16 1331 0

High #3 RB Cylinder Power

X

X

1146 (45) 1148 (60) 16 1332 0

High #4 RB Cylinder Power

X

X

1147 (45) 1148 (60) 16 1333 0

High #5 RB Cylinder Power

X

X

1148 (45) 1149 (60) 16

High #6 RB Cylinder Power

X

X

711* Yellow 712* Yellow 712* Yellow 713* Yellow 713* Yellow 714* Yellow 714* Yellow 715* Yellow 715* Yellow 716* Yellow

High #1 RB Cylinder Power

High #2 RB Cylinder Power

High #3 RB Cylinder Power

High #4 RB Cylinder Power

High #5 RB Cylinder Power

NOTE: *Denotes Cense Fault codes.

T5-7-25

X

X

X

X

X

TROUBLESHOOTING / Troubleshooting D

QSK60

QSK45

QST30

QSK19

QSX15

DESCRIPTION

QSM11

FMI

QSL9

SPN QSC

SID(S) PID(P) FMI

QSB

FAULT CODE/ LAMP

716* Yellow

1334 0

High #6 RB Cylinder Power

717* Yellow

1150 0

High #7 RB Cylinder Power

X

718* Yellow

1151 0

High #8 RB Cylinder Power

X

1264 3

Crankcase Blowby Pressure Sensor Circuit - shorted high

719 Yellow

P022 3

721* None

727* None

1143 1145 4 1144 1146 4 1145 1147 4 1146 1148 4 1147 1149 4 1148 1150 4 1151 4

728* None

722* None 723* None 724* None 725* None 726* None

729 Yellow

P022 4

X

X

X

X

X

(30,45) (60)

Cyl #1 RB Exhaust Temp Sens Failed Low

X

X

X

(30,45) (60)

Cyl #2 RB Exhaust Temp Sens Failed Low

X

X

X

(30,45) (60)

Cyl #3 RB Exhaust Temp Sens Failed Low

X

X

X

(30,45) (60)

Cyl #4 RB Exhaust Temp Sens Failed Low

X

X

X

(30,45) (60)

Cyl #5 RB Exhaust Temp Sens Failed Low

X

X

X

(30,45) (60)

Cyl #6 RB Exhaust Temp Sens Failed Low

X

X

X

Cyl #7 RB Exhaust Temp Sens Failed Low

X

1152 4

Cyl #8 RB Exhaust Temp Sens Failed Low

X

1264 4

Crankcase Blowby Pressure Sensor Circuit - shorted low

X

X

X

X

747* None

Trend Data Memory Nearly Full

X

X

X

748* None

Trend Data Memory Full

X

X

X

749* None

Fault Log Snapshot Data Nearly Full

X

X

X

NOTE: *Denotes Cense Fault codes.

T5-7-26

TROUBLESHOOTING / Troubleshooting D

755 Yellow

Fault Log Snapshot Data Full P157 7

157 7

Injector Metering Rail #1 Pressure Malfunction

QSK60

X

X

X

X

X

X

QST30

QSK19

X

QSK45

754* None

Engine Speed/Position #2 - Cam sync error

QSX15

723 2

DESCRIPTION

QSM11

S064 2

FMI

QSL9

753 None

SPN QSC

SID(S) PID(P) FMI

QSB

FAULT CODE/ LAMP

X

756* None

Change Lubricating Oil Filters

X

X

X

757* None

Catastrophic Power Loss - ECM Data Lost

X

X

X

758 Yellow

P129 7

1349 7

Injector Metering Rail #2 Pressure Malfunction

772 Yellow

S118 11

1657 11

Needle Movement Sensor Left Bank

X

773 Yellow

S119 11

1658 11

Needle Movement Sensor Right Bank

X

768 Yellow

S009 11

923 11

Output Device Driver (VGT or Transmission shift PWM signal)

777 Yellow

P173 0

1180 0

Turbocharger #1 Turbine Inlet Temperature High - warning level

779 Yellow

S051 11

703 11

Auxiliary Equipment Sensor Input # 3 (OEM Switch)

951 None

P166 2

166 2

Cylinder Power Imbalance between cylinders

1000* None

X

X

X

X

X

X

X X

X

Vehicle Controller initiated fault log

X

2154* None

611 3

Post-Filter Oil Pressure Sensor CircuitShorted high

X

X

X

2155* None

611 4

Post-Filter Oil Pressure Sensor CircuitShorted Low

X

X

X

Auxiliary Equipment Sensor Input # 2 (OEM Pressure Sensor) Engine Protection – Warning Auxiliary Equipment Sensor Input # 3 (OEM Switch) Engine Protection Critical

2194 Yellow

P223 11

1387 11

2195 Red

S051 14

703 14

NOTE: *Denotes Cense Fault codes.

T5-7-27

X

X

X

X

X

X

TROUBLESHOOTING / Troubleshooting D (Blank)

T5-7-28

TROUBLESHOOTING / Electrical System Inspection PRECAUTIONS FOR INSPECTION AND MAINTENANCE 1. Disconnect Power Source Be sure to remove the negative terminals from the batteries first when taking wire harnesses and connectors off for repair or replacement work. Failure to do so can result in damage to the wire harnesses, fuses, and fusible links and, in some cases, cause fire due to short circuit. 2. Color Coding of Wire Harnesses The color codes of the wire harnesses in the electrical system are shown in the table on the light. In some cases, where two colors are indicated for one wire, the left initial stands for the base color, while the right initial stands for the marking color. Code

R

W

L

G

Y

B

Color

Red

White

Blue

Green

Yellow

Black

Code

Or

Lg

Br

p

Gr

V

Color

Orange

Brown

Pink

Gray

Violet

Light Green

NOTE: 1) Code BW indicates a black base wire with white fine-line marking. 2) Initials “O” and “Or” both stand for the color orange. 3) Wires with longitudinal stripes printed on them are not color coded. Be sure not to confuse them with color coded wires.

T5-8-1

TROUBLESHOOTING / Electrical System Inspection 3. Precautions for Connecting and Disconnecting Terminal Connectors 1) When disconnecting harnesses, grasp them by their connectors. Do not pull on the wire itself. Be sure to release the lock first before attempting to separate connectors, if a lock is provided. 2) Water-resistant connectors keep water out so that if water enters the connector, water will not easily drain. When checking water-resistant connectors, take extra care not to allow water to enter these types of connectors. In case water should enter this connector, reconnect only after thoroughly drying the connector. 3) Before connecting terminal connectors, check that no terminals are bent or missing. In addition, as most connectors are made of brass, check that no terminals are corroding. 4) When connecting terminal connectors provided with a lock, be sure to insert them together until the lock “clicks.” 4. Precaution for Using a Circuit Tester 1) Before using a circuit tester, refer to the instructions in the circuit tester manual. Then, set the circuit tester to meet the object to be measured, voltage range and current polarity. 2) Before starting the connector test, always check the connector terminal numbers, referring to the circuit diagram. When the connector size is very small, and the standard probe size is too large to be used for testing, wind a fine piece of sharpened wire or a pin around the probe to make the test easier.

T5-8-2

Correct

Incorrect

T107-07-06-001

Correct Rust Bending Separation T107-07-06-002

Wind wire around the probe.

Probe

Sharpen the tip of wire. T107-07-06-003

TROUBLESHOOTING / Electrical System Inspection INSPECTIONS CONNECTORS

FOR

DISCONNECTING

1. Push the lock to disconnect. NOTE: 1) Connectors may not be separated if the lock is pushed while the connectors are pulled. Be sure to push the lock first before pulling the connectors. 2) The lock is provided on the female connector (harness side).

T107-04-05-002

Locations of This Type Connector Hydraulic Oil Level Switch Proximity Switch Washer Boom Mode Selection Switch Air Conditioner Clutch Governor Actuator Monitor Controller Work Light Main Pump Delivery Pressure Sensor Oil Level Switch

Diode Front All Pressure Sensor Starter Relay 2 Buzzer Cancel Switch Air Conditioner Pressure Switch Air Conditioner Sensor Air Compressor Speaker Boost Pressure Sensor

Wiper Motor Flow Rate Decrease Solenoid Valve Travel Pressure Sensor Heavy Lift Switch Auto-Lubrication Timer Switch Air Conditioner Controller Air Conditioner Unit Ambient Air Temperature Sensor ECM Relay Exhaust Gas Temperature Sensor

Coolant Level Sensor Data Link Engine Diagnostic Switch Key Switch DC-DC Controller Room Light ECM Engine Speed Sensor Fuel Sensor

2. Pull to disconnect. Locations of This Type Connector Oil Pressure Sensor Air Vent Select Servo Motor Switch Box Frash Memory A/M Servo Motor Radio Fusible Link

Circulation Servo Motor Preheat Switch Power Transistor Hydraulic Oil Temperature Sensor Thermo-Guard Switch Step Light Switch Sun Exposure Sensor T107-04-05-004

3. Connector to pull apart Use a 10 mm wrench to tighten the screw until the torque mark (convex) appears when re-tightening.

Screw Convex

Locations of This Type Connector DLU

T107-04-05-005

T5-8-3

TROUBLESHOOTING / Electrical System Inspection FUSE INSPECTION Fuse failure is often caused by a fine crack in the fuse, and such fine cracks are very hard to detect by visual inspection. Checking fuse continuity with a tester is far superior to sight inspection.

3. Connect the negative probe to the vehicle ground, and touch the outside terminal of each fuse with the positive probe of the tester. When normal continuity of a fuse is intact, the tester will indicate 20 to 25 volts.

1. Turn the key switch ON In doing so, the battery relay is activated by the current from terminal M of the key switch, and electric power is supplied to all circuits except the No.19 fuse circuit and the No.20 fuse circuit.

NOTE: (a) All the inside terminals of the fuses in the fuse box are connected to the power source, while the outside terminals are connected to the accessories. Test all fuses using the same method, except the fuses for the No.19 fuse circuit and the No.20 fuse circuit. (b) To check the fuse for the No.19 fuse circuit and No.20 fuse circuit, turn the key switch to the START position and perform the test as described in (3).

2. Remove the fuse box cover and set the correct voltage measurement range of the tester. (Measurement range: 0 to 30 V)

No.20 Fuse Circuit

No.19 Fuse Circuit

Accessory (Outside)

－

+

Accessory (Outside)

Power Source (Inside)

T142-06-06-004

T5-8-4

TROUBLESHOOTING / Electrical System Inspection Connection in Fuse Box 1 Fuse No.

Description

Capacity

Connected to

Remarks

1

Backup

5A

Monitor Controller, DLU

Backup power source,

2

Controller

5A

Main Controller B

Main power source Power source ON sig.

Power source 3

Power ON SIG.

5A

Main Controller A, Main Controller B

4

DC-DC Converter

20 A

DC-DC Converter

Power source

5

MCX SOL

10 A

Main Controller A, Main Controller B

Power source

6

Travel Alarm

5A

Travel Alarm (Optional)

Power source

7

Switch Box

5A

Monitor Controller, Main Controller A

Main power source

8

Step Light

5A

Step Light Relay

Power source Power source

9

Air Conditioner

5A

Air Conditioner

10

BATT

5A

Battery Relay, Battery Relay 2

Power source

11

Light

20 A

Work Light Relay 1, Work Light Relay 2

Power source

12

Wiper

20 A

Washer Relay, Wiper Motor

Power source

13

Air Conditioner

20 A

Power source

14

Solenoid

15 A

Air Conditioner (Heater) Flow Rate Decrease Solenoid Valve Relay, Power Transistor 1, Power Transistor 2, Power Transistor 3, Auto-Lubrication Relay, Solenoid Valve Relay

Power source

15

Radio

5A

Radio, Monitor Controller

Power source

16

Lighter

10 A

Lighter

Power source

17

Room Lamp

5A

Room Lamp

Power source

18

Horn

10 A

Horn Relay

Power source

19

Start Repeating Relay

5A

Starter Relay 1

Power source

20

ECM. ENG. Start, SIG

5A

T18E-01-02-003

20

19

18 17 16 15 14 13 12 11

T18E-05-08-002

10

9

8

7

6

T5-8-5

5

4

3

2

1

TROUBLESHOOTING / Electrical System Inspection Fuse Box 2

T18E-01-02-003

9

5

8

4

3

7

6

2

T18E-05-08-001

1

Connection in Fuse Box 2 Fuse No. 1

Description ECM Main Power Source

Capacity 20 A

Connected to

Remarks

ECM

Main power source

2

Preheat Switch

5A

3

Preheat Relay

5A

Preheat Relay 1

Power source

ECM

Power source

DOWN LOAD PC, Satellite Communication Controller

Power source

4

ECM

5A

5

DLU Main Power Source

5A

6

DOWN LOAD PC

5A

7

OPT5

20 A

8

OPT6

20 A

9

Coolant Level Switch

5A

T5-8-6

TROUBLESHOOTING / Electrical System Inspection FUSIBLE LINK INSPECTION • Fusible Link 1 to 4

Pull off the fusible links to visually inspect.

Fusible Link 1 to 4

Fusible Link 5 to 8

• Fusible Link 5 to 8

Check continuity between both ends of the fusible link.

T183-01-02-015

T183-05-08-001

T5-8-7

TROUBLESHOOTING / Electrical System Inspection BATTERY VOLTAGE CHECK 1. Turn the key switch OFF. Check voltage between the battery positive terminal and the vehicle. V

Normal Voltage: 24 V NOTE: If voltage is abnormal, recharge or replace the battery. 2. Start the engine. Check voltage between the battery positive terminal and the vehicle. Normal Voltage: 26 to 28 V NOTE: If voltage is abnormal, check the charging system.

ALTERNATOR CHECK T142-06-06-002

In general, the alternator indicator remains off when the alternator is generating power. If the alternator indicator comes on while the engine is running, the alternator might be defective.

Terminal R

Terminal B

Generating Voltage Measurement 1. Measure voltages at terminals R and B after starting the engine. Specification: Terminal R: More than 21 V Terminal B: Approx. 28 V

T18E-05-08-004

T5-8-8

TROUBLESHOOTING / Electrical System Inspection (Blank)

T5-8-9

TROUBLESHOOTING / Electrical System Inspection VOLTAGE CHECK Operate the key switch and the engine control dial as specified to apply voltage to the point to be measured. Check if the specified (standard) voltage is obtained at each point.

Tester Probes: Black (-) Probe :To vehicle (Grounding) Red (+) Probe :To the point to be measured.

24 Voltage Circuits For each 24 voltage circuit, start checking either from the power source side or the actuator side. Thereby, the failed part in each circuit can be located, if any. Engine Power Source Circuit Stopped Stopped Stopped Stopped Stopped Starting Circuit Cranking Cranking Cranking Cranking Cranking Cranking Accessory Circuit Stopped Stopped Stopped Stopped Charging Circuit Running Running Running Running Surge Voltage Prevention Circuit Running-Stopped Running-Stopped

Key Switch

Check Point

Standard

OFF OFF OFF OFF OFF

Between (2) and (1): One Battery Between (3) and (2): One Battery Between (3) and (1): Two Battery Between (4) and (E): Power Source Between (5) and (E): Fusible Link

10 to 12.5 V 10 to 12.5 V 20 to 25 V 20 to 25 V 20 to 25 V

START START START START START START

Between (6) and (E) : Key Switch Between (7) and (E) : Fuse Between (8) and (E) : Starter Relay 1 (Coil) Between (9) and (E) : Starter Relay 1 (Switch) Between (10) and (E): Starter Relay 2 (S) Between (11) and (E): Starter Motor (C)

20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V

ACC ACC ACC ACC

Between (12) and (E): Radio Between (13) and (E): Cigar Lighter Between (14) and (E): Room Light Between (15) and (E): Horn

20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V

ON ON ON ON

Between (16) and (E): Alternator (B) Between (17) and (E): Battery Relay 1 (B) Between (18) and (E): Alternator (R) Between (19) and (E): Monitor Controller

26 to 30 V 20 to 25 V 20 to 25 V 20 to 25 V

ON-OFF ON-OFF

Between (20) and (E): Load Dump Relay (Coil) Between (21) and (E): Battery Relay (Coil)

20 to 25 V 20 to 25 V

T5-8-10

TROUBLESHOOTING / Electrical System Inspection Power Circuit

Fuse Box 1

Key Switch

DLU

5 Fusible Link

4

Battery Relay 2 Fuse Box 2

Load Damp Relay Battery Battery Relay 1

Monitor Controller

3 ECM

2

1

Main Controller B

T18E-02-03-007

T5-8-11

TROUBLESHOOTING / Electrical System Inspection Starting Circuit Key Switch

Fusible Link 1 Fuse Box 1

1 Pole Junction

6

Battery Relay 2

Fusible Link 5

7

Fusible Link 6 Fusible Link 7

Battery Relay 1

Fusible Link 8

Battery

Fuse Box 2

Alternator

9

Starter Relay

Starter Motor 2

Safety Relay 2

10

8

ECM

Starter Motor 1

Safety Relay 1

11

T5-8-12

T18E-02-03-010

TROUBLESHOOTING / Electrical System Inspection Accessory Circuit 12 13 Fuse Box 1 Radio

Key Switch

Fusible Link #1

Cigar Lighter Cab Light Horn

14 15 Battery Relay 2

Battery Relay 1

Battery T18E-02-03-009

T5-8-13

TROUBLESHOOTING / Electrical System Inspection Charging Circuit Key Switch

Fusible Link 1 Fuse Box 1

Fusible Link 2

17 1 pole Junction

Battery Relay 2

Fusible Link 3

Fusible Link 4 Battery Relay 1 Fusible Link 5 Battery

Fusible Link 6

Fuse Box 2

Fusible Link 7

16

Alternator

Fusible Link 8

18

Starter Relay

Air Heater 2 Air Heater 1

19

Monitor Controller

T18E-02-03-011

T5-8-14

TROUBLESHOOTING / Electrical System Inspection Surge Voltage Prevention Circuit

Key Switch

Fuse Box 1 Fusible link 1 1 Pole Junction

Battery Relay 2

Fusible link 3

Battery Relay 1

20 Load Damp Relay Power Transistor 3

21

Fusible link 5

Battery

Fusible link 6 Fusible link 7

Alternator

Fusible link 8 Main Controller B Monitor Controller

Safety Relay 2

Safety Relay 1

T18E-02-03-012

T5-8-15

TROUBLESHOOTING / Electrical System Inspection 5-Volt Circuit

Power Source 1

• Voltage between Terminal #1 and Vehicle Frame Turn the key switch OFF. After disconnecting the sensor connector, measure the voltage between machine side harness end connector terminal #1 (5 V power) and the vehicle frame (ground) under the following conditions.

Signal or Ground 2

Two Polarities

V

Key Switch: ON Black Probe (Minus) of Tester: Vehicle Frame (Ground) Red Probe (Plus) of Tester: Terminal #1

T107-07-05-006

When the voltage matches 5 ± 0.5 V, the circuit up to terminal #1 is normal.

Power Source Signal Ground 1 3 2 Three Polarities

V

• Voltage between Terminal #1 and Ground Terminal Turn the key switch OFF. After disconnecting the sensor connector, measure the voltage between machine side harness end connector terminal #1 (5 V power) and the ground terminal (terminal #2 for two polarities, terminal #3 for three polarities) under the following conditions.

T107-07-05-007

1

2

Two Polarities

V

Key Switch: ON Black Probe (Minus) of Tester: Ground Terminal (Terminal #2 or #3) Red Probe (Plus) of Tester: Terminal #1 T107-07-05-008

When the voltage matches 5 ± 0.5 V, the circuit up to terminal #1 or the ground terminal is normal.

1

2

3

Three Polarities

V

T107-07-05-009

T5-8-16

TROUBLESHOOTING / Electrical System Inspection CONTINUITY CHECK Harness

Single-line continuity check Disconnect both end connectors of the harness and check continuity between both ends: If the ohm-meter reading is: 0 Ω = Continuity ∞ Ω = Discontinuity NOTE: When the one end connector is far apart from the other, connect one end of connector (A) to the machine chassis using a clip. Then, check continuity of the harness through the vehicle frame as illustrated.

A

Ω

Connect to the vehicle frame.

Ω

NOTE: By conducting the multi-line continuity check twice, it is possible to find out which line is discontinued. With terminals (A) and (C) short-circuited, check continuity between terminals (a) and (c). If the ohm-meter reading is: 0 Ω = Line (B) - (b) has discontinuity. ∞ Ω = Line (A) - (a) has discontinuity. Multi-line short-circuit check Disconnect both end connectors of the harness, and check continuity between terminals (A) and (B) or (C). If the ohm-meter reading is: 0 Ω = Short-circuit exists between the lines. ∞ Ω = No short-circuit exists between the lines.

T5-8-17

a

A

Single-line short-circuit check Disconnect both end connectors of the harness and check continuity between one end connector of the harness and the vehicle frame: If the ohm-meter reading is: 0 Ω = Short circuit is present. ∞ Ω = No short circuit is present. Multi-line continuity check Disconnect both end connectors of the harness, and short-circuit two terminals, (A) and (B), at one end connector, as illustrated. Then, check continuity between terminals (a) and (b) at the other connector. If the ohm-meter reading is ∞ Ω, either line (A) - (a), or (B) - (b) is in discontinuity. To find out which line is discontinued, conduct the single line continuity check on both lines individually, or, after changing the short-circuit terminals from (A) - (B) to (A) - (C), check continuity once more between terminals (a) and (c).

a

A

Connect to the vehicle frame.

If the ohm-meter reading is: 0 Ω = Continuity ∞ Ω = Discontinuity

a

×

Short-circuit between the harness and the vehicle frame

Ω

T107-07-05-003

First short-circuit

A B C

a b c

Second short-circuit

Ω

T107-07-05-004

Short-circuit between harnesses. A B C

×

a b c

Ω

T107-07-05-005

TROUBLESHOOTING / Electrical System Inspection (Blank)

T5-8-18

MEMO ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ 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MEMO ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ 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Hitachi Construction Machinery Co. Ltd Attn: Publications, Marketing & Product Support Fax: 81-29-831-1162

Hitachi Ref. No.

SERVICE MANUAL REVISION REQUEST FORM NAME OF COMPANY:

MODEL: PUBLICATION NO.:

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THE ATTACHED DIAGRAM LIST (The following diagrams are attached to this manual.) EX1200-5C ELECTRICAL CIRCUIT DIAGRAM (CUMMINS ENGINE SPECIFICATION) EX1200-5C CONNECTORS EX1200-5C BACKHOE HYDRAULIC CIRCUIT DIAGRAM EX1200-5C LOADING SHOVEL HYDRAULIC CIRCUIT DIAGRAM