PART NO. TT1V7-E-00 ZAXIS330-3 class HYDRAULIC EXCAVATOR Technical Manual Troubleshooting TECHNICAL MANUAL TROUBLESHOOTING 330-3 class 330-3•330LC-3 350H-3•350LCH-3 350LCK-3 350LC-3•350LCN-3 Hydraulic Excavator URL:http://www.hitachi-c-m.com Service Manual consists of the following separate Part No; Technical Manual (Operational Principle) : Vol. No.TO1V7-E Technical Manual (Troubleshooting) : Vol. No.TT1V7-E Workshop Manual : Vol. No.W1V7-E PRINTED IN JAPAN (E) 2006, 01 TM̲E(TT) Page 1 2006.1.
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.
INTRODUCTION SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. • 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.
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. 001-E01A-0001 SA-688 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.
SAFETY FOLLOW SAFETY INSTRUCTIONS • Carefully read and follow all safety signs on the machine and all safety messages in this manual. • Safety signs should be installed, maintained and replaced when necessary. • If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering). • Learn how to operate the machine and its controls correctly and safely.
SAFETY 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.
SAFETY PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing. • Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises. 006-E01A-0434 SA-434 INSPECT MACHINE • Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury.
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. Do not leave parts and/or tools lying around the operator's seat. Store them in their specified locations. Avoid storing transparent bottles in the cab.
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 hand-holds. • Never jump on or off the machine. Never mount or dismount a moving machine. • Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.
SAFETY ENSURE SAFETY BEFORE RISING FROM OR LEAVING OPERATOR'S SEAT • Before rising from the operator's seat to open/close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the pilot control shut-off lever to the LOCK position. Failure to do so may allow the machine to unexpectedly move when a body part unintentionally comes in contact with a control lever, possibly resulting in serious personal injury or death.
SAFETY MOVE AND OPERATE MACHINE SAFELY • Bystanders can be run over. • Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine. • Always keep the travel alarm and horn in working condition (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. • Use appropriate illumination.
SAFETY OPERATE SEAT ONLY FROM OPERATOR'S • Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. • Start the engine only when seated in the operator's seat. • 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 levers are in neutral.
SAFETY KEEP RIDERS OFF MACHINE • Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. • Only the operator should be on the machine. Keep riders off. • Riders also obstruct the operator's view, resulting in the machine being operated in an unsafe manner. 014-E01B-0427 SA-379 PRECAUTIONS FOR OPERATIONS • Investigate the work site before starting operations.
SAFETY INVESTIGATE JOB SITE BEFOREHAND • When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death. • Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing. • Make a work plan. Use machines appropriate to the work and job site. • Reinforce ground, edges, and road shoulders as necessary.
SAFETY EQUIPMENT OF HEAD GUARD, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.
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. • Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.
SAFETY DRIVE MACHINE SAFELY • Driving across the face of a slope or steering on a • • • • • • • slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation. Avoid swinging the upperstructure on slopes. Never attempt to swing the upperstructure downhill. The machine may tip over. If swinging uphill is unavoidable, carefully operate the upperstructure and boom at slow speed.
SAFETY • Use wood plates in order not to damage the road • • • • • • surface. Be careful of steering when operating on asphalt roads in summer. When crossing train tracks, use wood plates in order not to damage them. Do not make contact with electric wires or bridges. When crossing a river, measure the depth of the river using the bucket, and cross slowly. Do not cross the river when the depth of the river is deeper than the upper edge of the upper roller.
SAFETY AVOID INJURY FROM ROLLAWAY ACCIDENTS • Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: • Select level ground when possible to park 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. • 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.
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.
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.
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: • Be extra careful before operating on a grade. SA-012 • Prepare machine operating area flat. • Keep the bucket low to the ground and close to the machine.
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.
SAFETY AVOID POWER LINES • Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines. • When operating near an electric line, NEVER move any part of the machine or load 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.
SAFETY 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-432 PARK MACHINE SAFELY To avoid accidents: • Park machine on a firm, level surface. • Lower bucket to the ground. • Turn auto-idle switch and H/P mode switch OFF.
SAFETY TRANSPORT SAFELY • Take care the machine may turn over when loading or unloading the machine onto or off of a truck or trailer. • Observe the related regulations and rules for safe transportation. • Select an appropriate truck or trailer for the machine to be transported. • Be sure to use a signal person. • Always follow the following precautions for loading or unloading: 1. Select solid and level ground. 2. Always use a ramp or deck strong enough to support the machine weight. 3.
SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: • Understand service procedures before starting work. • Keep the work area clean and dry. • Do not spray water or steam inside cab. • Never lubricate or service the machine while it is moving. • Keep hands, feet and clothing away from power-driven parts. Before servicing the machine: 1. Park the machine on a level surface. 2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. 4. Run the engine at slow idle speed without load for 5 minutes.
SAFETY • 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 100° angle between the boom and arm. Securely support any machine elements that must be raised for service work. 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.
SAFETY 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.
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. • Never attempt to disassemble the track adjuster.
SAFETY PREVENT BURNS Hot spraying fluids: • After operation, engine coolant is hot and under pressure. 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. • The hydraulic oil tank is pressurized.
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 to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.
SAFETY PREVENT FIRES Check for Oil Leaks: • Fuel, hydraulic oil and lubricant leaks can lead to fires. • Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts. • Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts. • Do not bend or strike high-pressure lines. • Never install bent or damaged lines, pipes, or hoses.
SAFETY 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 cannot 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 in the operator's manual.
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..
SAFETY BEWARE OF ASBESTOS DUST • Take care not to inhale dust produced in the work site. Inhalation of asbestos fibers may be the cause of lung cancer. • Depending on the wok site conditions, the risk of inhaling asbestos fiber may exist. Spray water to prevent asbestos from becoming airborne. Don't use compressed air. • When operating the machine in a work site where asbestos might be present, be sure to operate the machine from the upwind side and wear a mask rated to prevent the inhalation of asbestos.
SAFETY SERVICE AIR CONDITIONING SYSTEM SAFELY • If spilled onto skin, refrigerant may cause a cold contact burn. • Refer to the instructions described on the container for proper use when handling the refrigerant. • Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere. • Never touch the refrigerant. 513-E01A-0405 SA-405 HANDLE CHEMICAL PRODUCTS SAFELY • Direct exposure to hazardous chemicals can cause serious injury.
SAFETY DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, 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.
SAFETY (Blank) SA-36
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 Diagnosing Procedure 2 Monitor Unit 3 Dr.
SECTION 4 OPERATIONAL PERFORMANCE TEST CONTENTS Group 1 Introduction Group 4 Excavator Test Operational Performance Tests ................T4-1-1 Travel Speed ............................................T4-4-1 Preparation for Performance Tests ...........T4-1-2 Track Revolution Speed............................T4-4-2 Mistrack Check.........................................T4-4-3 Group 2 Standard Travel Parking Leakage............................T4-4-4 Swing Speed ......................................
Group 5 Component Test Primary Pilot Pressure..............................T4-5-1 Secondary Pilot Pressure .........................T4-5-3 Solenoid Valve Set Pressure ....................T4-5-5 Main Pump Delivery Pressure ..................T4-5-8 Main Relief Set Pressure ..........................T4-5-9 Relief Pressure (When relieving Swing) .......................T4-5-13 Overload Relief Valve Set Pressure ........T4-5-14 Main Pump Flow Rate Measurement ......T4-5-17 Swing Motor Drainage ...................
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.
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.
OPERATIONAL PERFORMANCE TEST / Standard ZX330-3 CLASS OPERATIONAL PERFORMANCE STANDARD TABLE The standard Performance values are listed in the table below. Refer to the Group T4-3 to T4-5 for performance test procedures. Values indicated in parentheses are reference values.
OPERATIONAL PERFORMANCE TEST / Standard NOTE: 1 mm=0.03937 in PERFORMANCE TEST DESIGNATION TRAVEL SPEED sec/10 m Fast Speed Slow Speed TRACK REVOLUTION SPEED sec/3 rev Fast Speed Slow Speed MISTRACK mm/20 m (With fast and slow travel speed modes) TRAVEL MOTOR LEAKAGE mm/5 min SWING SPEED sec/3 rev SWING FUNCTION DRIFT CHECK mm /180° SWING MOTOR LEAKAGE mm/5 min MAXIMUM SWINGABLE SLANT ANGLE deg.
OPERATIONAL PERFORMANCE TEST / Standard PERFORMANCE TEST DESIGNATION DIG FUNCTION DRIFT CHECK (Mono Boom) Boom Cylinder (Maximum Reach Position) (Arm Roll-In position) Arm Cylinder (Maximum Reach Position) (Arm Roll-In position) Bucket Cylinder (Maximum Reach Position) (Arm Roll-In position) Bucket Bottom (Maximum Reach Position) (Arm Roll-In position) DIG FUNCTION DRIFT CHECK (2-Piece Boom) Boom Cylinder (Maximum Reach Position) (Arm Roll-In position) Arm Cylinder (Maximum Reach Position) (Arm Roll-In pos
OPERATIONAL PERFORMANCE TEST / Standard NOTE: 1 mm=0.03937 in PERFORMANCE TEST DESIGNATION ZX330-3 class (Performance Standard) CONTROL LEVER OPERATING FORCE Remarks Reference Page HITACHI lever pattern T4-4-16 HITACHI lever pattern T4-4-17 3.20 m arm 3 1.4 m (PCSA heaped) bucket, bucket: empty T4-4-18 3.20 m arm 3 1.4 m (PCSA heaped) bucket T4-4-19 N (kgf, lbf) Boom Lever 16 (1.6, 3.6) or less 13 (1.3, 2.9) or less 13 (1.3, 2.9) or less 16 (1.6, 3.6) or less 28 (2.8, 6.
OPERATIONAL PERFORMANCE TEST / Standard PERFORMANCE TEST DESIGNATION ZX330-3 class (Performance Standard) NOTE: 1 mm=0.03937 in Reference Remarks Page MAIN RELIEF VALVE PRESSURE T4-5-8 MPa (kgf/cm2, psi) Boom, Arm, Bucket (Relief operation for each) Relief operation of Positioning (2-piece boom only) Power Digging RELIEF PRESSURE MPa (kgf/cm2, psi) (Relief operation for Swing) +2.0 34.3 -0.5 +20 (350 -5, +284 4980 -71 ) +2.0 35.5 -0.5 +20 (362 -5, +284 5160 -71 ) +2.0 36.3 -1.
OPERATIONAL PERFORMANCE TEST / Standard MAIN PUMP P-Q DIAGRAM • • Points on P-Q Line P-Q Control (Torque Control) Delivery Pressure Flow Rate 2 MPa (kgf/cm , psi) L/min (gpm) A 4.9 (50, 710) 288±3 (76±0.8) B 18.6 (190, 2700) [285] ([75]) C 20.6 (210, 2995) 260±6 (69±1.6) D 23.5 (240, 3420) [220] ([58]) E 29.4 (300, 4275) 180±6 (47±1.6) F 34.3 (350, 4980) 150±6 (40±1.6) The value indicated in parentheses is only a reference value.
OPERATIONAL PERFORMANCE TEST / Standard • P-Q Control by Pump Control Pilot Pressure Signal • Points on P-Q Line ∗ (REFERENCE: Measured at Test Stand) Pump Control Pressure 2 MPa (kgf/cm , psi) • Rated Pump Speed: 1900 min-1 (rpm) Hydraulic Oil Temperature: 50±5 °C (122±41 °F) 1.67±0.05 A NOTE: Refer to T4-5-16. (17±0.5, 242±7) B 1.96 (20, 284) 2.94+0.05−0.29 C (30+0.5−3, 427+7−43) L/min Flow Rate L/min (gpm) 93±3 (25±0.8) [140] ([37]) 288±3 (76±0.
OPERATIONAL PERFORMANCE TEST / Standard SENSOR ACTIVATING RANGE 1. Checking Method • Hydraulic Oil Temperature: 50 ± 5 °C (122±41 °F) • Unless specified: Engine Power Work Mode Auto-Idle Control Mode Switch Switch Dial Switch Digging Fast Idle P Mode OFF Mode • Monitor each sensor by using Dr. ZX. 2.
OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE SPEED Summary 1. Measure the engine speed by using the monitor unit or Dr. ZX.) 2. Measure the engine speeds in each mode. NOTE: If the engine speed is not adjusted correctly, all other performance data will be unreliable. Consequently, measure the engine speed before performing all other tests in order to check that the engine speed meets specification. Preparation: 1. Select the service menu of monitor (In case of Dr. ZX, install Dr. ZX first). 2.
OPERATIONAL PERFORMANCE TEST / Engine Test Measurement: 1. Measure the items as shown in the table below. 2. When measuring, set the switch and test condition as shown in the table below in response to the engine speed to be measured. Evaluation: Refer to Operational Performance Standard in Group T4-2. Remedy: Refer to Troubleshooting B in Group T5-4. NOTE: ECO stands for the auto engine speed re-1 duction system by 100 min .
OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE COMPRESSION PRESSURE Summary: 1. Measure compression pressure in the cylinders and check for a decline in engine power. 2. Check exhaust gas color. Keep track of engine oil consumption. 3. Check for abnormalities in the intake system, including the air filter. Preparation: 1. Confirm that valve clearances are correct. 2. Confirm that the batteries are charged properly. 3. Run the engine until the coolant temperature gauge reaches the operating range. 4.
OPERATIONAL PERFORMANCE TEST / Engine Test VALVE CLEARANCE Terminal Nut Summary: 1. Perform the measurement when the engine is cold. 2. Before starting any work, clean the head cover mounting area and avoid contamination in the engine. Preparation: 1. Remove the head cover. 2. Remove the terminal nut which secures the harness to the injector. ： 2 N⋅m (0.2 kgf⋅m, 1.5 lbf⋅ft) 3. Remove the harness assembly from the injector. 4. Remove the leak off pipe. Harness ： 12 N⋅m (1.2 kgf⋅m, 8.9 lbf⋅ft) 5.
OPERATIONAL PERFORMANCE TEST / Engine Test Measurement: 1. Insert a thickness gauge into the clearance between rocker arm and bridge cap end and measure the valve clearance. Rocker Arm NOTE: The cylinders are aligned from No.1 to No.6 in that order, as viewed from the fan side. Injection Order: 1-5-3-6-2-4 2. When measurement is started from No.1 cylinder, perform the same measurement to all valves indicated with the mark “○” in the table below. (When measurement is started from No.
OPERATIONAL PERFORMANCE TEST / Engine Test Adjustment: If the measurement results are out of specification, adjust the valve clearance in the same order of measurement. Adjusting Screw Rocker Arm IMPORTANT: Touch the bridge to the end of valve heads (2 used) horizontally and adjust the valve clearance carefully. 1. Loosen the lock nuts (12 used) and adjusting screws (12 used), which secure the bridge and rocker arm. 2. Insert a thickness gauge into the clearance between rocker arm and bridge cap. 3.
OPERATIONAL PERFORMANCE TEST / Engine Test LUBRICANT CONSUMPTION Measuring Method 1. Place the machine on level firm ground and leave the machine for at least one hour in order to let the lubricant lower to the oil pan when the engine stops. At this time, confirm that the machine is level by using a leveler. 2. Record read-out A (unit: hour) of the hour meter. 3. Replenish the lubricant up to the high-level gauge. 4.
OPERATIONAL PERFORMANCE TEST / Engine Test (Blank) T4-3-8
OPERATIONAL PERFORMANCE TEST / Excavator Test TRAVEL SPEED Summary: Measure the time required for the excavator to travel a 20 m (65.6 ft) test track and check the performance of travel device systems (from main pump to travel motor). Preparation: 1. Adjust the track sag on both tracks equally. 2. Prepare a flat and solid test track 10 m (33 ft) in length with extra length of 3 to 5 m (9.8 to 16 ft) on both ends for machine acceleration and deceleration. 3.
OPERATIONAL PERFORMANCE TEST / Excavator Test TRACK REVOLUTION SPEED Summary: Measure the track revolution cycle time with the track raised off ground and check the performance of travel device systems (from main pump to travel motor). Preparation: 1. Adjust the track sag of both side tracks equally. 2. On the track to be measured, put the mark on one shoe by using a piece of chalk or cloth. 3. Jack up the track to be measured as illustrated.
OPERATIONAL PERFORMANCE TEST / Excavator Test MISTRACK CHECK Summary: 1. Allow the machine to travel 20 m (65.6 ft). Measure the maximum tread deviation from the tread chord line drawn between the travel start and end points and check the performance of travel device systems (from main pump to travel motor). 2. If measured on a concrete surface, the tread deviation has a trend to decrease. Preparation: 1. Adjust the track sag of both tracks equally. 2. Provide a flat, solid test yard 20 m (65.
OPERATIONAL PERFORMANCE TEST / Excavator Test TRAVEL PARKING LEAKAGE Summary: Measure the parking brake function on a specified slope. Preparation: 1. The surface of test slope shall be even with a gradient of 20 % (11.31°). 2. With the arm and bucket fully extended, hold the bucket 0.2 to 0.3 m (8 to 12 in) above the ground. 3. Maintain the hydraulic oil temperature at 50±5 °C (122±41 °F). 0.2 to 0.3 m Measurement: 1. Measure the travel parking brake slip amount while parked. 2.
OPERATIONAL PERFORMANCE TEST / Excavator Test SWING SPEED Summary: Measure the time required to swing three complete turns and check the performance of swing device systems (from main pump to swing motor). Preparation: 1. Check lubrication of the swing gear and swing bearing. 2. Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on slopes. 3.
OPERATIONAL PERFORMANCE TEST / Excavator Test SWING FUNCTION DRIFT CHECK Summary: 1. Measure the swing drift on swing bearing outer circumference when stopping after a 180° full-speed swing and check the performance of swing brake valve. 2. The mechanical brake for seing parking brake is equipped for the swing motor. Preparation: 1. Check lubrication of the swing gear and swing bearing. 2. Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on a slope. 3.
OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Select the following switch positions: Engine Con- Power Mode Auto-Idle Work Mode trol Dial Switch Switch Digging Fast Idle P Mode OFF Mode 2. Operate the swing control lever fully and return it to the neutral position when the mark on upperstructure aligns with that on track frame after swinging 180° . 3. Measure the distance between the two marks. 4. Align the marks again and swing 180°. Then test in the opposite direction. 5.
OPERATIONAL PERFORMANCE TEST / Excavator Test SWING MOTOR LEAKAGE Summary: Measure the upperstructure drift while suspending a load on a specified slope and check the performance of swing parking brake. (The mechanical brake for seing parking brake is equipped for the swing device.) Preparation: 1. Check lubrication of the swing gear and swing bearing. 2. Load bucket fully. In lieu of loading the bucket, weight (W) of the following specification can be used. Weight=2100 kg (4630 lb) 3.
OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Select the following switch position: Power Mode Auto-Idle Switch Work Mode Switch P Mode OFF Digging Mode Measure Difference Between Marks 2. Maintain the engine at slow idle. After five minutes, measure difference between the marks along bearing outer circumference and track frame. 3. Perform the measurement in both right and left swing directions. 4. Repeat the measurement three times in each direction and calculate the average values.
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. Measurement: 1. Select the following switch positions: Engine Power Mode Control Auto-Idle Switch Switch Dial Preparation: 1. Check lubrication of the swing gear and bearing. 2. Load the bucket fully. In lieu of loading the bucket, weight (W) of the following specification can be used.
OPERATIONAL PERFORMANCE TEST / Excavator Test (Blank) T4-4-11
OPERATIONAL PERFORMANCE TEST / Excavator Test SWING BEARING PLAY Summary: Measure the swing bearing play using a dial gauge and check the wear of bearing races and balls. Preparation: 1. Check the swing bearing mounting bolts for looseness. 2. Check lubrication of the swing bearing. Confirm that bearing rotation is smooth and without noise. 3. Install a dial gauge on the round trunk of track frame by using a magnetic base. 4.
OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. With the arm fully retracted and the bucket fully extended, hold the bucket 100 mm above the ground. Record dial gauge reading (h1). 2. Lower the bucket to the ground and raise the front idler 0.5 m (20 in) by using the front attachment. Record dial gauge reading (h2). 3. Calculate bearing play (H) from this data (h1 and h2) as follows: H=h2-h1 Evaluation: Refer to the Operational Performance Standard in Group T4-2.
OPERATIONAL PERFORMANCE TEST / Excavator Test HYDRAULIC CYLINDER CYCLE TIME Summary: 1. Measure the cycle time of boom, arm and bucket cylinders and check the performance of front attachment systems (from main pump to each cyliner). Preparation: 1. Mmeasure at the position as follows. • Measurement of the cycle time of boom cylinders: With the arm fully retracted and the bucket fully extended, lower the bucket to the ground.
OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Select the following switch positions: Engine Power Mode Control Auto-Idle Switch Switch Dial Fast Idle P Mode OFF Work Mode Digging Mode 2. Measure the cylinder cycle times as follows: (Cylinder full stroke includes cylinder cushioning zone.) • Boom cylinder: Operate the boom control lever to full stroke. Measure the time to raise and lower the boom. • Arm cylinder: Operate the arm control lever to full stroke.
OPERATIONAL PERFORMANCE TEST / Excavator Test DIG FUNCTION DRIFT CHECK • Maximum Reach Position Summary: 1. Measure dig function drift, which can be caused by oil leakage in the control valve and boom, arm and bucket cylinders, with the loaded bucket. 2. When testing the dig function drift just after cylinder replacement, slowly operate each cylinder for ten minutes to its stroke end and bleed air. Preparation: 1. Load the bucket fully.
OPERATIONAL PERFORMANCE TEST / Excavator Test • Arm Roll-In Position Summary: 1. Measure dig function drift, which can be caused by oil leakage in the control valve and boom, arm and bucket cylinders. 2. When testing the dig function drift just after cylinder replacement, slowly operate each cylinder for ten minutes to its stroke end and bleed air. Preparation: 1. The bucket must be empty. 2.
OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER OPERATING FORCE Summary: 1. Measure a play and operating condition of each control lever. 2. Measure the maximum operating force of 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±41 °F). CAUTION: Prevent personal injury.
OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Measure each control lever. 2. Select the following switch positions: Engine Power Mode Control Auto-Idle Switch Switch Dial Fast Idle P Mode OFF Work Mode Digging Mode 3. In case of boom (raise), arm and bucket lever, measure the maximum operating force for each with each actuator relieved. 4. In case of boom (lower) lever, measure the maximum operating force with the boom (lower) relieved by jacking up the machine in a safe area. 5.
OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER STROKE Summary: 1. Measure a play and operating condition of each control lever. 2. Measure the lever stroke at the grip center of each control lever. 3. In case lever stroke play is present in the neutral position, add half (1/2) the play present to both side lever strokes. Preparation: Maintain the hydraulic oil temperature at 50±5 °C (122±41 °F). Measurement: 1. Stop the engine. 2.
OPERATIONAL PERFORMANCE TEST / Excavator Test (Blank) T4-4-21
OPERATIONAL PERFORMANCE TEST / Excavator Test COMBINED OPERATION OF BOOM RAISE / SWING FUNCTION CHECK Summary: 1. Check boom raise and swing movement and speeds while operating both functions simultaneously. 2. Make sure that the cylinders do not hesitate while operating the cylinder with the engine running at fast idle. Preparation: 1. With the arm fully retracted and the bucket fully extended, lower the bucket onto the ground. The bucket must be empty. 2.
OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Select the following switch positions: Engine Power Mode Control Auto-Idle Switch Switch Dial Fast Idle P Mode OFF Work Mode Digging Mode 2. Raise the boom and roll the swing in full stroke at the same time. 3. When the upperstructure rotates 90°, release the control levers to stop both functions. Measure the time required to swing 90° and height (H) of the bucket teeth. (The bucket must be empty.) 4.
OPERATIONAL PERFORMANCE TEST / Excavator Test COMBINED OPERATION OF BOOM RAISE / ARM ROLL-IN FUNCTION CHECK Summary: 1. Check boom raise and arm roll-in movement and speeds while operating both functions simultaneously. 2. Make sure that the cylinders do not hesitate while operating the cylinder with the engine running at fast idle. Preparation: 1. With the arm fully retracted and the bucket fully extended, adjust the boom cylinder so that the bucket tooth tip height is 0.5 m (1 ft 8 in) above the ground.
OPERATIONAL PERFORMANCE TEST / Component Test PRIMARY PILOT PRESSURE Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and release any remaining pressure. 3. Remove the plug from the pilot filter. Install adapter (ST 6069) and pressure gauge (ST 6942) to the pressure check port. : 14 mm 4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±41 °F).
OPERATIONAL PERFORMANCE TEST / Component Test Primary Pilot Pressure Adjustment Procedure Adjustment: Adjust the relief valve set pressure if necessary. Relief Valve 1. Remove plug (1) from the relief valve. : 22 mm 2. Install the estimated number of shims (2). 3. After adjustment, tighten plug (1). +2 +0.2 +1.5 : 25 N⋅m (2.5 kgf⋅m, 18.4 lbf⋅ft) T178-03-07-001 1 2 4. After adjustment, check the set pressure.
OPERATIONAL PERFORMANCE TEST / Component Test SECONDARY PILOT PRESSURE Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and release any remaining pressure. 3. Measure pressure at the location between pilot valve and signal control valve. Remove the pilot hose from the circuit to be measured. Install the hose (9/16-18UNF, Length: approx. 400 mm (16 in)) to the signal control valve side.
OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Select the following switch positions: Engine Power Mode Auto-Idle Work Mode Control Dial Switch Switch Digging Fast Idle P Mode OFF Mode Digging Slow Idle P Mode OFF Mode 2. Measure pilot pressure by using a pressure gauge with the corresponding control lever operated to full stroke. 3. Repeat the measurement three times and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2.
OPERATIONAL PERFORMANCE TEST / Component Test SOLENOID VALVE SET PRESSURE Measure solenoid valve set pressure by using both Dr. ZX and the pressure gauge. Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and release any remaining pressure. 3. Remove the line from the solenoid valve to be measured. Install tee (ST 6451), hose (Parts Number: 4216453), adapter (ST 6461) and pressure gauge (ST 6942). : 17 mm, 19 mm, 22 mm Connect Dr.
OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Select the following switch positions: Engine Power Mode Auto-Idle Work Mode Control Dial Switch Switch Digging Fast Idle P Mode OFF Mode Digging Slow Idle P Mode OFF Mode SC SF SI SG 2. Operate as instructed below for each measuring solenoid valve: Solenoid Valve SG: Turn the power digging switch ON and OFF. Solenoid Valve SI: Travel: Stop Solenoid Valve SF: Relief combined operation of boom raise and arm roll-in.
OPERATIONAL PERFORMANCE TEST / Component Test Solenoid Valve Adjustment Procedure O-Ring 7 IMPORTANT: As O-ring is damaged and oil leakage may cause, do not loosen adjusting screw (8) excessively. Do not loosen adjusting screw (8) more than 2 turns. 1. Loosen lock nut (7). Turn adjusting screw (8) and adjust the set pressure. 2. After adjustment, tighten lock nut (7). : 10 mm : 3 mm : 3 N⋅m (0.3 kgf⋅m, 2.2 lbf⋅ft) 8 T1V1-04-05-004 2.0 mm (0.079 in) or less from end of Lock Nut 3.
OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP DELIVERY PRESSURE The main pump delivery pressure can also be measured by using Dr. ZX. Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and release any remaining pressure. 3. Remove the plug of pressure check port from the main pump delivery port. Install adapter (ST 6069), hose (ST 6943) and pressure gauge (ST 6941). : 6 mm Connect Dr. ZX and select the monitoring function. 4. Start the engine.
OPERATIONAL PERFORMANCE TEST / Component Test MAIN RELIEF SET PRESSURE Summary: Measure the main relief valve set pressure at the delivery port in main pump. (The main relief set pressure can also be measured by using Dr. ZX.) Preparation: 1. Stop the engine. 2. Push the air bleed valve on top of the hydraulic oil tank and release any remaining pressure. 3. Remove the plug of pressure check port from the main pump delivery port. Install adapter (ST 6069), hose (ST 6943) and pressure gauge (ST 6941).
OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Select the following switch positions: Engine Power Mode Auto-Idle Work Mode Control Dial Switch Switch Digging Fast Idle P Mode OFF Mode 2. First, slowly operate the bucket, arm and boom control levers to the stroke end and relieve each function. 3. As for the swing function, secure the upperstructure so it is immovable. Slowly operate the swing lever and relieve the swing function. 4.
OPERATIONAL PERFORMANCE TEST / Component Test Main Relief Pressure Adjustment Procedure Adjustment: In case of pressure adjustment during power digging operation, adjust the high-pressure side of main relief pressure. In case of pressure adjustment in normal, adjust the low-pressure side of main relief pressure. Main Relief Valve • High-Pressure Side of Main Relief Pressure Adjustment Procedure 1. Loosen lock nut (1). Lightly tighten plug (3) until plug (3) comes into contact with the end of piston (2).
OPERATIONAL PERFORMANCE TEST / Component Test • Low-Pressure Side of Main Relief Pressure Adjustment Procedure 1. Loosen lock nut (1). Turn plug (3) counterclockwise until the specified value is obtained. Tighten lock nut (1). : 27 mm : Lock Nut (1): 59 to 68 N⋅m (6 to 7 kgf⋅m, 43 to 51 lbf⋅ft) or less 2. After adjustment, check the set pressures. NOTE: Standard Change in Pressure (Reference) Plug Turns 1/4 1/2 3/4 Change in Relief MPa 7.1 14.2 21.3 2 Pressure: Plug (5) (kgf/cm ) 72.5 145 217.
OPERATIONAL PERFORMANCE TEST / Component Test RELIEF PRESSURE (WHEN RELIEVING SWING) Swing Relief Valve Loosen lock nut (2) and adjust pressure by using adjusting screw (1). 1. Loosen lock nut (2). :24 mm, 32 mm 2. Turn adjusting screw (1) in order to adjust pressure. 3. Tighten lock nut (2). : 24 mm, 32 mm : 177 N⋅m (18 kgf⋅m, 130 lbf⋅ft) 4. Check the set pressure. NOTE: Standard Change in Pressure (Reference) Adjusting Screw Turns Change in Pressure MPa (kgf/cm2) (psi) 1/4 1/2 3/4 1 2.5 (25.
OPERATIONAL PERFORMANCE TEST / Component Test OVERLOAD RELIEF VALVE SET PRESSURE 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.
OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Select the following switch positions: Engine Power Mode Auto-Idle Work Mode Control Dial Switch Switch Digging Fast Idle P Mode OFF Mode 2. Slowly operate the bucket, arm and boom control levers to the stroke ends and relieve each function. 3. Read pressures on the pressure gauge at this time. 4. Perform the measurement for the bucket, arm and boom in that order. 5. Repeat the measurement three times and calculate the average value for each.
OPERATIONAL PERFORMANCE TEST / Component Test Overload Relief Valve Pressure Adjustment Procedure NOTE: In principle, adjust the overload relief valve pressure on a test stand. Loosen lock nut (1) and adjust pressure by using adjusting screw (2). 1 1. Loosen lock nut (1). : 17 mm 2. Turn adjusting screw (2) in order to adjust pressure. : 6 mm 2 3. Tighten lock nut (1). : 17 mm : 29.5 N⋅m (3.0 kgf⋅m, 22 lbf⋅ft) W107-02-05-128 4. Check the set pressure.
OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP FLOW RATE MEASUREMENT •P-Q Control (Torque Control) Summary: Main pump performance is checked by measuring the pump flow rate by using a hydraulic tester installed at the main pump delivery port (one side) to be measured. Use Dr. ZX and a pressure gauge at the same time. IMPORTANT: This measurement procedure is a simple method. The measured data will be lower by approx. 5 % than the accurately measured value.
OPERATIONAL PERFORMANCE TEST / Component Test Evaluation: 1. Convert the measured flow rates to those at the specified pump speed by using the following formulas: 2. Standard Flow Rate Refer to Operational Performance Standard in Group T4-2. NOTE: When actually measuring, install pipe (1 or 2) only to the pump to be measured. Qc = (Ns × Q) ⁄ Ne Qc : Q: Ns : Ne : Converted Flow Rate Measured Flow Rate -1 Specified Engine Speed: 1900 min Measured Engine Speed: Values indicated on Dr.
OPERATIONAL PERFORMANCE TEST / Component Test •Pilot Characteristics Summary: Main pump performance is checked by measuring the pump flow rate by using a hydraulic tester installed at the main pump delivery port (one side) to be measured. Use Dr. ZX and a pressure gauge at the same time. IMPORTANT: This measurement procedure is a simple method. The measured data will be lower by approx. 5 % than the accurately measured value.
OPERATIONAL PERFORMANCE TEST / Component Test 1, 2 3 4 6 5 7 8 9 10 11 Delivery Hose (To Control Valve) Port Pi T173-04-04-002 12 Plug M T1V7-04-05-001 T178-03-07-001 Reducing Valve Port Position Reducing Valve Return Pipe T L 20 18 P2 P1 19 15 To Regulator Port Pi To Pilot Filter 14 17 15 16 15 14 13 T178-04-04-004 1 - Pipe E (ST 6144) 7 - Joint (ST6330) 12 - Plug M 2 - Pipe B (ST 6143) 8 - Test Hose (ST 6320) 3 - Test Hose (ST 6145) 9 - Flange (ST 6118) 4 - Adapter PF
OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Maintain the hydraulic oil temperature at 50±5 °C (122±41 °F) 2. Measure pump flow rate in response to the external command pilot pressure. 3. Select each switch position as follows: Engine Power Mode Auto-Idle Work Mode Control Dial Switch Switch Digging Fast Idle P Mode OFF Mode 4. Adjust the reducing valve set pressure to each pressure point specified along the main pump P-Q curve. (Pilot Characteristics) (Refer to T4-2-7.
OPERATIONAL PERFORMANCE TEST / Component Test Regulator Adjustment 6 5 1 3 2 4 10 9 7 1 - Lock Nut (For Minimum Flow Rate) 2 - Adjusting Screw (For Minimum Flow Rate) 3 - Lock Nut (For Maximum Flow Rate) 4 - Adjusting Screw (For Maximum Flow Rate) 5 - Lock Nut (For Pilot Pressure Characteristic) 6 - Adjusting Screw (For Pilot Pressure Characteristic) 7 - Lock Nut (For P-Q Control) 8 - Adjusting Screw (For P-Q Control) 8 T1HH-03-01-002 9 - Lock Nut (For P-Q Control) 10 - Adjusting Screw (For P-Q
OPERATIONAL PERFORMANCE TEST / Component Test Adjustment Item 3. Pilot Pressure Characteristics Q Pi 4. P-Q Control (Torque Adjustment) Q A Pd Adjustment Procedure Remarks Loosen lock nut (5) and turn ad- 1) Do not turn adjusting screw (6) more than one turn. justing screw (6). Rotating adjusting screw (6) 1/4 2) When adjusting screw (6) is turned clockwise, the maximum flow rate a turn clockwise decreases the 3 will also be decreased. flow rate by 19.0 cm /rev. (1.
OPERATIONAL PERFORMANCE TEST / Component Test SWING MOTOR DRAINAGE Summary: 1. Measure amount of oil draining from the swing motor while swinging the upperstructure and check the swing motor performance. 2. The amount of drain oil from the swing motor will change depending on hydraulic oil temperature. 1 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.
OPERATIONAL PERFORMANCE TEST / Component Test Preconditions for Measurement: 1. Select the following switch positions: Engine Power Mode Auto-Idle Work Mode Control Dial Switch Switch Digging Fast Idle P Mode OFF Mode Measurement: 1. Amount of Oil Drained While Swinging the Upperstructure (1) Fully retract the arm cylinder. Fully extend the bucket cylinder. Hold the boom so that the arm tip pin height is the same as the boom foot pin height. The bucket must be empty. (2) Start the engine.
OPERATIONAL PERFORMANCE TEST / Component Test Evaluation: Refer to the Performance Standard in Group T4-2. ∗ Conversion of amount of drain oil measured into the per-minute value First measure amount of drain oil by using a calibrated container.
OPERATIONAL PERFORMANCE TEST / Component Test TRAVEL MOTOR DRAINAGE Summary: 1. While rotating the travel motor with the track to be measured jacked up, measure amount of oil draining from the travel motor and check travel motor performance. 2. Judge travel motor performance from the results including travel speed, mistrack and so on overall. 3. The amount of drain oil from the travel motor will change depending on hydraulic oil temperature. 1 CAUTION:Prevent personal injury.
OPERATIONAL PERFORMANCE TEST / Component Test Measurement: CAUTION: When working around moving parts is unavoidable, pay special attention to ensure that hands, feet, and clothing do not become entangled. Securely support the raised track by using the blocks. (1) 90 to 110° Start the engine. Jack up the track to be measured. M104-07-067 (2) Rotate the track to be measured. Start drain oil measurement when drain oil starts coming out of the drain hose end.
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SECTION 5 TROUBLESHOOTING CONTENTS Group 1 Diagnosing Procedure Group 3 Dr. ZX Introduction ..............................................T5-1-1 Outline .....................................................T5-3-1 Diagnosing Procedure ..............................T5-1-2 Select Controller.......................................T5-3-6 Main Controller .........................................T5-3-7 Group 2 Monitor Unit Main Menu Monitor Display.......................T5-3-8 Outline .....................
Group 5 Component Layout Overload Alarm Enable / Disable Selection ....................T5-3-84 Main Components ....................................T5-5-1 Back Monitor Setting ..............................T5-3-86 Electrical System (Overview) ....................T5-5-3 Operating Condition Engine......................................................T5-5-8 Enable / Disable Selection ....................T5-3-90 Time Setting Function Pump Device ............................................
MC Fault Code 11410.............................T5-6-91 ECM, Communication System ECM Fault Codes 639.........................T5-6-122 CAN Data Reception Failure MC Fault Code 11910 ...........................T5-6-92 ICF, Satellite Terminal Fault Codes 14000 to 14003...................................T5-6-123 CAN Harness Check MC Fault Code 11910 ...........................T5-6-94 ICF, Satellite Terminal Fault Codes 14006, 14008, 14100 to 14106 ...........T5-6-127 MC Fault Code 11918..................
Group 8 Electrical System Inspection Precautions for Inspection and Maintenance...........................................T5-8-1 Instructions for Disconnecting Connectors .............................................T5-8-3 Fuse Inspection........................................T5-8-4 Fusible Link Inspection .............................T5-8-5 Battery Voltage Check ..............................T5-8-6 Alternator Check ......................................T5-8-7 Continuity Check .............................
TROUBLESHOOTING / Diagnosing Procedure INTRODUCTION Refer to the inspection and troubleshooting procedures after any machine trouble has occurred. The inspection and troubleshooting procedures are presented in an orderly fashion in this section to quickly find the cause of the machine trouble and solution. The troubleshooting section in this manual consists of 8 groups; Diagnosing Procedure, monitor unit, Dr.
TROUBLESHOOTING / Diagnosing Procedure 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. 2. Ask the operator Before inspecting, get the full malfunctions from the operator below.
TROUBLESHOOTING / Diagnosing Procedure 4. Operate the machine yourself Try to identify the trouble by operating machine yourself. If the trouble cannot be confirmed, stop engine and obtain further details of malfunction from the operator. Also, check for any incomplete connections of wire harnesses correponding to the trouble.
TROUBLESHOOTING / Diagnosing Procedure 5. Perform troubleshooting CAUTION: Do not disconnect harnesses or hydraulic lines while the engine is running. The machine may malfunction or pressurized oil may spout, possibly resulting in personal injury. Stop the engine before disconnecting harnesses or hydraulic lines. Perform diagnosis by connecting Palm to the machine or by using the service menu of monitor unit. In case any fault code has been displayed by diagnosis by using Dr.
TROUBLESHOOTING / Diagnosing Procedure 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.
TROUBLESHOOTING / Diagnosing Procedure (Blank) T5-1-6
TROUBLESHOOTING/ Monitor Unit OUTLINE Primary Screen Machine with Overload Alarm (Optional) Attached 1 2 3 4 5 6 7 8 9 22 10 11 12 13 14 15 21 20 19 18 17 16 T1V1-05-01-094 1 - Work Mode Display 2 - Auto-Idle Display 7 - Work Mode Display 8 - Hour Meter 13 - Fuel Consumption Gauge 14 - Clock 3 - ML Crane Display or Overload Alarm Display (Optional) 4 - Auxiliary 5 - Auxiliary 9 - ML Crane Display (Optional) 15 - Back-Screen Selection 10 - Fuel Gauge 11 - Mail Display (Optional) 16
TROUBLESHOOTING/ Monitor Unit • Display of Meters Work Mode Data to be displayed on each meter are received from other controllers (MC, ICF and ECM) by using CAN, and are displayed on the monitor unit. 1 Items to be displayed 1. Coolant Temperature Gauge 2. Hour Meter 3. Fuel Consumption Gauge 4. Clock 2 3 4 • Work Mode Display The attachments being used are displayed according to the signals received from MC by using CAN.
TROUBLESHOOTING/ Monitor Unit • Auto-Idle Display(1) When selecting auto-idle from the switch panel, the data according to the signals received from MC by using CAN is displayed. When the key is turned ON, the data blinks for 10 seconds. 1 2 • ML Crane or Overload Alarm Display (2) (optional) 3 4 ML Crane T1V1-05-02-001 When ML crane mode switch or travel suspended load mode switch is turned ON on the ML crane display, the data will be displayed.
TROUBLESHOOTING/ Monitor Unit • Fuel Sensor Error Display When the fuel sensor is faulty or if the harness between fuel sensor and monitor unit is broken, the data is displayed on the fuel gauge. Coolant Temperature Sensor Error Display Fuel Sensor Error Display • Coolant Temperature Sensor Error Display When the coolant temperature sensor is faulty or if the harness between coolant temperature sensor and monitor unit is broken, the data is displayed on the coolant temperature gauge.
TROUBLESHOOTING/ Monitor Unit • Troubleshooting This screen displays fault codes according to the signals received from ICF by using CAN. Fault Code Display T1V5-05-01-097 Controller Version Display T1V5-05-01-122 Monitoring Screen T1V5-05-01-087 Operating Conditions Screen T1V5-05-01-025 • Controller Version This screen displays the version of controller. • Monitoring This screen displays temperature and pressure data received from each controller by using CAN.
TROUBLESHOOTING/ Monitor Unit • Pump 2 Flow Rate Adjustment (Only machines equipped with optional parts) When using the attachments, fine adjust flow rate of pump 2 by keys 1 and 2 operation. The signals from the monitoring unit are sent to MC by using CAN. When breaker 1 or 2 is used, MC adjusts flow rate of pump 2 while controlling maximum pump 2 flow rate limit control solenoid valve.
TROUBLESHOOTING/ Monitor Unit • Attachment Selection (Only machines equipped with optional parts) On this screen. Select digging mode and attachment mode set by Dr. ZX. NOTE: In attachment mode, the following five modes are set at the time of shipping from the factory. 1 - Digging 2 - Breaker 1 3 - Breaker 2 4 - Pulverizer 1 1 5 - Crusher 1 2 3 4 5 Attachment Selection Screen NOTE: The items on monitor unit and HITACHI pattern are same.
TROUBLESHOOTING/ Monitor Unit • Back Monitor Settings By key operation, image display ON and OFF of Auto-Control for switching image of the back monitor while traveling pilot time and display format on the screen of the rear view camera can be set. IMPORTANT: the rear view camera is set in mirror image mode. Therefore, if image display is set as mirror image, normal image is displayed on the screen of monitor unit.
TROUBLESHOOTING/ Monitor Unit • Maintenance Settings This screen displays the hour meter reading at replacement time and the remaining hours until the next replacement. As the items to be replaced are displayed in a list, record performed replacement by selecting an item from the list. • Interval ON/OFF Settings Set change interval for each item to be replaced.
TROUBLESHOOTING/ Monitor Unit • Overload Alarm Alarm (Only machines equipped with optional parts) IMPORTANT: When using overload alarm, make overload alarm available by using Dr. ZX. The system measures load of the suspended load from bottom pressure of the boom cylinder. An alarm message is displayed and a buzzer is rung, if overload is detected. 1. If load of the suspended load becomes overloaded, the boom bottom pressure sensor (optional) sends a signal to MC. 2.
TROUBLESHOOTING/ Monitor Unit HOW TO USE SCREENS Displaying Primary Screen IMPORTANT: Start the engine after the primary screen is displayed. When the key switch is turned to the ON position, the starting screen appears for about two seconds and the primary screen appears. Key Switch: ON T1V1-05-01-115 Primary Screen T1V1-05-01-123 IMPORTANT: After the engine starts and the alternator starts generating power, alternator alarm is displayed on the primary screen.
TROUBLESHOOTING/ Monitor Unit Displaying Primary Screen by Password Input (Optional) IMPORTANT: Before performing this operation, make the password function available by using Dr. ZX. Starting Screen T1V1-05-01-115 Password Input Screen T1V5-05-01-093 1. When the key switch is turned to the ON position, the starting screen appears and the password input screen appears. 2. Input a password by using the keys located under the screen.
TROUBLESHOOTING/ Monitor Unit (Blank) T5-2-13
TROUBLESHOOTING/ Monitor Unit In Case of Inputting an Incorrect Password 1. If inputting an incorrect password, the message "password is incorrect." appears by pushing the confirm key. Password Input Screen Confirm Key Erase Key T1V5-05-01-093 T1V5-05-01-002 2. Return to the password input screen, by pushing the back key. NOTE: When inputting the password again, the entered characters can be erased by pushing the erase key.
TROUBLESHOOTING/ Monitor Unit 3. If inputting an incorrect password three times, a screen appears informing that the security lock has been applied, and a buzzer rings for thirty seconds. During that time, the buzzer does not stop ringing even if turning of the key switch ON/OFF. Security Lock Screen T1V5-05-01-005 Starting Screen T1V1-05-01-115 Password Input Screen T1V5-05-01-093 4.
TROUBLESHOOTING/ Monitor Unit Extending Password Duration Time IMPORTANT: This operation is applicable only to those machines that display the primary screen based upon password input. By using the password duration screen, password duration time can be set. When you restarting the machine, a password need not be input within that timeframe. 1. When turn the key switch to the OFF position, the monitor unit displays the password duration Ｋey 1 screen for ten seconds.
TROUBLESHOOTING/ Monitor Unit (Blank) T5-2-17
TROUBLESHOOTING/ Monitor Unit Password Change (Optional) 1. After the primary screen is displayed, push the menu key in order to display the main menu. Menu Key T1V5-05-01-123 Primary Screen 2. Select password change from main menu by using keys1 and 2. Push the confirm key. Then, the password change screen appears. Key 1 Key 2 T1V5-05-01-129 Confirm Key T1V5-05-01-041 Registered Password 3. Input the registered password and push the confirm key. 4.
TROUBLESHOOTING/ Monitor Unit NOTE: If inputting an incorrect password after pushing the confirm key, the message "Password is incorrect." appears. Push the back key and go back to the previous screen, Input the password again. Back Key T1V5-05-01-044 5. The message "Enter password to be registered." appears. Then, input a new password with three or four digits and push the confirm key. 6. If inputting the password again, push the erase key.
TROUBLESHOOTING/ Monitor Unit 7. The message "Re-enter password." appears. Then, input a new password again and push the confirm key. 8. If inputting the password again, push the erase key in order to erase the entered characters. T1V5-05-01-132 Confirm Key Erase Key T1V5-05-01-133 9. The message "New password has been registered." appears. This completes the password change process. T1V5-05-01-043 Key 6 10. Push key 6 and the primary screen appears.
TROUBLESHOOTING/ Monitor Unit PRIMARY SCREEN Machine with Overload Alarm (Optional) Attached 1 2 3 4 5 6 7 8 9 22 10 11 12 13 14 15 21 20 19 18 17 16 T1V1-05-01-094 1 - Work Mode Display 2 - Auto-Idle Display 7 - Work Mode Display 8 - Hour Meter 13 - Fuel Consumption Gauge 14 - Clock 3 - ML Crane Display or Overload Alarm Display (Optional) 4 - Auxiliary 5 - Auxiliary 9 - ML Crane Display (Optional) 15 - Screen Selection 10 - Fuel Gauge 11 - Mail Display (Optional) 16 - Menu 17 - A
TROUBLESHOOTING/ Monitor Unit SCREEN DISPLAY WHEN AN ALARM IS ISSUED When an alarm is issued, the alarm marks are displayed at the bottom of screen.
TROUBLESHOOTING/ Monitor Unit When an alarm is issued, if the key under a relevant alarm mark is pushed, the remedy against the alarm is displayed.
TROUBLESHOOTING/ Monitor Unit CONTENTS OF ALARMS Display Contents of Alarms Overheat Alarm Remedy Temperature of engine coolant is going up abnormally higher. Stop the work and turn the engine into low idle in order to lower the coolant temperature. Engine Warning Alarm Failure of the engine or its related parts. Please contact our authorized distributor or dealer. Engine Oil Pressure Alarm Pressure of engine lubricant oil is decreasing.
TROUBLESHOOTING/ Monitor Unit (Blank) T5-2-25
TROUBLESHOOTING/ Monitor Unit TROUBLESHOOTING 1. Displaying service menu Turn the key switch to the ON position while pushing the key at upper right corner of the monitor unit. Therefore, service menu is added to main menu. Turn key switch ON while pushing the key T1V1-05-01-115 2. When the primary screen appears, push the menu key and display main menu. Menu Key Primary Screen T1V1-05-01-123 3. Select service menu from main menu by using keys 1 and 2. Push the confirm key.
TROUBLESHOOTING/ Monitor Unit 4. Select troubleshooting by using keys 1 and 2. Push the confirm key. Then, the troubleshooting screen appears. 5. Results of trouble analyses for each controller are displayed on the screen. 6. Select abnormal of a faulty controller by using keys 1 and 2. Push the confirm key. Then, failure code screen appears. For details of trouble analyses, refer to "Troubleshooting A." IMPORTANT: Up to twenty failure codes can be displayed.
TROUBLESHOOTING/ Monitor Unit CONTROLLER VERSION 1. Displaying Service Menu Turn the key switch to the ON position while pushing the key at upper right of the monitor unit. Therefore, service menu is added to main menu. Turn the key switch ON while pushing the key T1V1-05-01-115 2. When primary screen appeared, push menu key to display main menu. Menu Key Primary Screen T1V1-05-01-123 3. Select service menu from main menu by using keys 1 and 2. Push the confirm key.
TROUBLESHOOTING/ Monitor Unit 4. Select controller version by using keys 1 and 2. Push the confirm key. Then, the controller version screen appears. NOTE: The version of ECM is not displayed. NOTE: When pushing the back key, return to the previous screen. Key 1 Key 2 Key 6 Confirm Key Back Key Back Key T1V5-05-01-083 T1V5-05-01-122 5. Push key 6, and the primary screen appears.
TROUBLESHOOTING/ Monitor Unit MONITORING 1. Displaying Service menu Turn the key switch to the ON position while pushing the key at upper right of the monitor unit. Therefore, the service menu is added to main menu. Turn the key switch ON while pushing the key T1V1-05-01-115 2. When the primary screen appeared, push the menu key and display main menu. Menu Key Primary Screen T1V1-05-01-123 3. Select service menu from main menu by using keys 1 and 2. Push the confirm key.
TROUBLESHOOTING/ Monitor Unit 4. Select monitoring by using keys 1 and 2. Push the confirm key. Then, the monitoring screen appears. For items to be monitored, refer to the next section. Key 1 Key 2 T1V5-05-01-083 Confirm Key 5. Select an item to be monitored by using keys 1 and 2. Push the confirm key. Then, the selected item is brought up to the top. 6. Push key 3, and the displayed data are put on hold. Push key 3 again, and the records are updated with the displayed data. 7.
TROUBLESHOOTING/ Monitor Unit A List of Items to be Monitored Items Engine Torque Coolant Temperature (E) Fuel Temperature Engine Oil Pressure Atmospheric Pressure Intake Air Temperature Boost Pressure Boost Temperature Coolant Temperature (M) Target Engine Speed Actual Engine Speed Pump 1 Delivery Pressure Pump 1 Pump Control Pressure Pump 1 Target Flow Rate Pump 2 Delivery Pressure Pump 2 Pump Control Pressure Pump 2 Target Flow Rate Front Attachment Control Pilot Pressure Boom Raise Control Pilot Pressur
TROUBLESHOOTING/ Monitor Unit DISPLAYING OPERATING CONDITIONS 1. When the primary screen appeared, push the menu key and display main menu. 2. Select operating conditions from main menu by using keys 1 and 2. Push the confirm key. Then, the operating conditions screen appears. 3. Push the reset key, and a screen appears to confirm if it's OK to reset data. If it’s OK to reset data, push the confirm key. Menu Key Primary Screen NOTE: When pushing the back key, return to the previous screen.
TROUBLESHOOTING/ Monitor Unit PUMP 2 FLOW RATE ADJUSTMENT (Only Machines Equipped with Optional Parts) IMPORTANT: This operation is effective when attachments are used. 1. When the primary screen appears, push the menu key and display main menu. 2. Select attachment adjustment from main menu by using keys 1 and 2. Push confirm key. Then, the attachment adjustment screen appears. Menu Key Primary Screen T1V1-05-01-123 3. Push key 2.
TROUBLESHOOTING/ Monitor Unit (Blank) T5-2-35
TROUBLESHOOTING/ Monitor Unit ATTACHMENT SELECTION (Only Machines Equipped with Optional Parts) IMPORTANT: Select the attachments from the work mode screen. In order to display the work mode screen, push key F1 after primary screen appears, or select from main menu. Selecting an Attachment by Using Key F1 1. When the primary screen appears, push key F1 and display the work mode screen. Key F1 Primary Screen T1V1-05-01-123 2.
TROUBLESHOOTING/ Monitor Unit Selecting an Attachment from Main Menu 1. When the primary screen appears, push the menu key and display main menu. 2. Select work mode from main menu by using keys 1 and 2. Push confirm key. Then, the work mode screen appears. 3. Push the relevant key under an attachment mark to be used in order to select the attachment. (In the right example, Crusher 1 is selected.) Menu Key Primary Screen NOTE: When selecting digging, return to main menu. T1V1-05-01-123 4.
TROUBLESHOOTING/ Monitor Unit Attachment Specification Screen Maximum Pump 2 Flow Rate Maximum Engine Speed Accumulator Control Solenoid Valve: OFF Secondary Hydraulic Relief Selector Control Solenoid Valve: ON Selector Valve Control Solenoid Valve: ON The selector valve is connected to the hydraulic oil.
TROUBLESHOOTING/ Monitor Unit Maximum Pump 1 and 2 Flow Rate Maximum Engine Speed Accumulator Control Solenoid Valve: OFF Secondary Hydraulic Relief Selector Control Solenoid Valve: OFF Selector Valve Control Solenoid Valve: OFF The selector valve is connected to the control valve.
TROUBLESHOOTING/ Monitor Unit TIME SET 1. When the primary screen appears, push the menu key and display main menu. Menu Key Primary Screen T1V1-05-01-123 2. Select time set from main menu by using keys 1 and 2. Push the confirm key. Then, the time set screen appears. Back Key Key 1 Key 2 T1V5-05-01-019 Confirm Key 3. On the time set screen, select the items to be set (Year, Month, Day and Time) by using keys 1 and 2, and set the figures by using keys 3 and 4. Move the item to this icon 4.
TROUBLESHOOTING/ Monitor Unit (Blank) T5-2-41
TROUBLESHOOTING/ Monitor Unit FUEL RATE DISPLAY/NO DISPLAY Fuel Rate Display 1. When the primary screen appears, push the menu key and display main menu. Menu Key Primary Screen T1V1-05-01-123 2. Select fuel rate display/no display from main menu by using keys 1 and 2. Push the confirm key. Then, the fuel rate display/no display screen appears. Key 1 Key 2 Confirm Key Back Key T1V5-05-01-118 3. Push the confirm key, and fuel rate display will be set to ON.
TROUBLESHOOTING/ Monitor Unit 4. Push key 6, and the fuel gauge will be added to primary screen.
TROUBLESHOOTING/ Monitor Unit Fuel Rate No Display 1. When the primary screen appears, push the menu key and display main menu. Fuel Gauge Menu Key Primary Screen T1V1-05-01-007 2. Select fuel rate display/no display from main menu by using keys 1 and 2. Push the confirm key. Then, the fuel rate display/no display screen appears. Key 1 Key 2 Confirm Key Back Key T1V5-05-01-118 3. Push the confirm key, and fuel rate display will be set to OFF.
TROUBLESHOOTING/ Monitor Unit 4. Push key 6, and return to the primary screen.
TROUBLESHOOTING/ Monitor Unit BACK MONITOR SETTINGS IMPORTANT: Image displayed on the back monitor is of auxiliary nature at best. When the machine is operated pay thorough attention to surrounding situation. Auto-Control: ON Image on the monitor unit when traveling is automatically switched to that of the back monitor. Menu Key 1. When the primary screen appears, push the menu key and display main menu. Primary Screen T1V1-05-01-123 2. Select back monitor settings from main menu by using keys 1 and 2.
TROUBLESHOOTING/ Monitor Unit Auto-Control: OFF Set automatic switching function of images between monitor unit and back monitor when traveling to OFF. 1. When the primary screen appears, push the menu key and display main menu. Menu Key Primary Screen T1V1-05-01-123 2. Select back monitor settings from main menu by using keys 1 and 2. Push the confirm key. Then, the back monitor settings screen appears.
TROUBLESHOOTING/ Monitor Unit Switching Image Display • From mirror image to normal image 1. When the primary screen appears, push the menu key and display main menu. Menu Key Primary Screen T1V1-05-01-123 2. Select back monitor settings from main menu by using keys 1 and 2. Push the confirm key. Then, the back monitor settings screen appears. Back Key Key 1 Key 2 Confirm Key T1V5-05-01-114 3. Select mirror image by using keys 1 and 2. Push the confirm key.
TROUBLESHOOTING/ Monitor Unit 4. Push the back monitor switching key, and normal image is displayed on the screen.
TROUBLESHOOTING/ Monitor Unit • From normal image to mirror image 1. When the primary screen appears, push the menu key and display main menu. Menu Key Primary Screen T1V1-05-01-123 2. Select back monitor settings from main menu by using keys 1 and 2. Push the confirm key. Then, the back monitor settings screen appears. Back Key Key 1 Key 2 Confirm Key T1V5-05-01-114 3. Select normal image by using keys 1 and 2. Push the confirm key. Then, the setting is switched to mirror image.
TROUBLESHOOTING/ Monitor Unit 4. Push the back monitor switching key, and mirror image is displayed on the screen.
TROUBLESHOOTING/ Monitor Unit Switching Image Format IMPORTANT: If changing the rear view camera to one with PAL image format, change the image format of the back monitor to PAL. 1. When the primary screen appears, push the menu key and display main menu. Menu Key Primary Screen T1V1-05-01-123 2. Select back monitor settings from main menu by using keys 1 and 2. Push the confirm key. Then, the back monitor settings screen appears. 3. Select "PAL" for image format by using keys 1 and 2.
TROUBLESHOOTING/ Monitor Unit (Blank) T5-2-53
TROUBLESHOOTING/ Monitor Unit MAINTENANCE SETTINGS 1. When the primary screen appears, push the menu key and display main menu. Menu Key Primary Screen T1V1-05-01-123 2. Select maintenance settings from main menu by using keys 1 and 2. Push the confirm key. Then, the maintenance settings screen appears. Key 1 Key 2 Confirm Key T1V5-05-01-019 Key 1 Key 2 Confirm Key T1V5-05-01-049 3. Select an item to be set from among the list of maintenance settings screen by using keys 1 and 2.
TROUBLESHOOTING/ Monitor Unit Change Interval Settings IMPORTANT: Change interval can only be set when maintenance information display is set to ON. 1. Select change interval by using keys 1 and 2. 2. Set time for change interval by using keys 3 and 4. Key 1 3. Select remaining hours by using keys 1 and 2, and push confirm key. 4. The message "Adjust remaining hours to new change interval. OK?" appears. Then, push the confirm key. Key 2 Interval ON/OFF Settings Screen T1V5-05-01-052 5.
TROUBLESHOOTING/ Monitor Unit Resetting Data If data is reset, push key 5 on the Interval ON/OFF settings screen. The message "Reset Data. OK?" appears. Then, push the confirm key. The value of remaining hours is reset to that of change interval. Previous change date/hour is updated with current date and time.
TROUBLESHOOTING/ Monitor Unit (Blank) T5-2-57
TROUBLESHOOTING/ Monitor Unit Screen Display when Maintenance Information Display is ON • When only one item applies 1. If turning the key switch to the ON position, the starting screen appears. Then, the scheduled maintenance screen for the item whose change interval has expired appears for three to ten seconds. Finally the primary screen appears. (In the right example, Hydraulic Oil applies.
TROUBLESHOOTING/ Monitor Unit • When more than two items apply 1. If turning the key switch to the ON position, the starting screen appears. Then, the scheduled maintenance screen for the items whose change interval has expired appears for three to ten seconds. Finally the primary screen appears.
TROUBLESHOOTING/ Monitor Unit LANGUAGE SETTINGS 1. When the primary screen appeared, push the menu key and display main menu. 2. Select language from main menu by using keys 1 and 2. Push the confirm key. Then, the language settings screen appears. 3. Select a desired language by using keys 1 and 2. Push the confirm key. Menu Key NOTE: Languages to be displayed on the screen of monitor unit have been selected from twelve languages, namely display languages 1 or 2, at the time of shipping from the factory.
TROUBLESHOOTING/ Monitor Unit Lists of Display Languages Display Languages 1 Language Screen Display Japanese T1V1-05-01-141 English T1V1-05-01-142 Chinese T1V1-05-01-143 Taiwanese T1V1-05-01-144 Korean T1V1-05-01-145 Indonesian T1V1-05-01-146 Thai T1V1-05-01-147 Vietnamese T1V1-05-01-148 Myanmarese T1V1-05-01-149 Arabic T1V1-05-01-150 Persian T1V1-05-01-151 Turkish T1V1-05-01-152 Display Languages 2 Language Screen Display English T1V1-05-01-142 Spanish T1V1-05-01-153 Italian T1V1-05-01-1
TROUBLESHOOTING/ Monitor Unit MAIL (Optional) IMPORTANT: This function is available only to a machine equipped with a satellite terminal. When using the mail function, make the mail function avaiable by using Dr. ZX. 1. When the primary screen appears, push key F3 and display mail screen. 2. If pushing a relevant request key, mail information is sent to ICF. 1 - General Request 2 - Fuel Replenishment Request 3 - Service Maintenance Request 4 - Forwarding Request Primary Screen Key F3 T1V1-05-01-123 3.
TROUBLESHOOTING/ Monitor Unit NOTE: When ICF could not receive the mail, the message "Mail delivery failed." is displayed on the screen.
TROUBLESHOOTING/ Monitor Unit (Blank) T5-2-64
TROUBLESHOOTING / Dr. ZX OUTLINE Dr. ZX is used for diagnosis of electrical system including MC, EMC, ICF and monitor unit. Dr. ZX is connected to ICF and failure of each controller and each sensor is displayed as a fault code. (Self-Fiagnostic Result) Dr. ZX displays the input status of sensors and switches connected to each controller and the output status to actuator including solenoid valve from controller with the machine operated in real time.
TROUBLESHOOTING / Dr. ZX Operation 1. Connect Palm (Dr. ZX) to the diagnosing connector in the cab by using the Hot Sync cable and connecting harness. 2. Turn the key switch ON or start the engine. 3. When turning Palm ON, the following screen is displayed on the display of Palm. 3-1. Initial Screen Select Dr. ZX icon. 3-2. Password Setup Screen (When the password has unset) Set the password. Dr. ZX Connector 3-3. Service Software Selection Screen + Select ZX-3 Mid. T1V1-05-07-001 3-4.
TROUBLESHOOTING / Dr. ZX Start Initial Screen Password Setup Screen • Input Password Input the former password (6 characters or more). Next time, input the same password in order to check and push OK.
TROUBLESHOOTING / Dr. ZX Self-Diagnostic Result The self-diagnostic result of each controller is displayed. After starting Dr. ZX, push Self-Diagnostic Result. T1V7-05-03-001 T1V7-05-03-008 Function Selection Screen NOTE: Main C/U: Engine C/U: Monitor Unit: Information C/U: T1V7-05-03-002 Controller Self- Diagnosis Screen MC ECM Monitor Unit ICF NOTE: Self-diagnosis of ICF controller is done on the next page.
TROUBLESHOOTING / Dr. ZX Self-Diagnosis After starting Dr. ZX, Self-Diagnostic Result. Push Fault of ICF Controller. In case of no faulty, No Fault is displayed. push To the lower T1V7-05-03-001 T1V7-05-03-002 T1V7-05-03-008 Controller Self- Diagnosis Screen Function Selection Screen By changing the page, the forward and backward fault Push Retry B and return to code is displayed. Controller Self-Diagnosis Screen after executing Retry B.
TROUBLESHOOTING / Dr. ZX SELECT CONTROLLER Select failure-diagnosis controller. After starting Dr. ZX, push Select Controller.
TROUBLESHOOTING / Dr. ZX MAIN CONTROLLER Main Menu • Monitor Display Displays the control signals of MC and the input signals from each switch and sensor. • Special Function Makes Special Function disable. • Setup Adjusts engine speed, pump delivery flow rate, solenoid valve output pressure and so on. Title Screen Recorded Data Displays data recorded in MC by one day by using Dr. ZX. Password Change Changes the password input when setting.
TROUBLESHOOTING / Dr. ZX MAIN MENU MONITOR DISPLAY Dr. ZX displays the input signals from switches and sensors and the control signals from MC.
TROUBLESHOOTING / Dr. ZX Item Data Selecting Type of Current ATT Monitoring Current ATT Type Communication from monitor unit Number of Current ATT Type of ATT1 Current ATT No. ATT1 Type Communication from monitor unit Communication from monitor unit Number of ATT1 Type of ATT2 ATT1 No. ATT2 Type Communication from monitor unit Communication from monitor unit Number of ATT2 Type of ATT3 ATT2 No.
TROUBLESHOOTING / Dr. ZX Item Selecting Boom Dampener Switch 1 (Optional) Boom Dampener Switch 2 (Optional) Low Vibration Switch Low Vibration Mode ON/OFF Switch ML Sensor Initial Setting Switch Digging Regenerative Proportional Valve Output Arm Regenerative Proportional Valve Output Power Digging Control Pressure Travel Mode Control Pressure ATT.
TROUBLESHOOTING / Dr.
TROUBLESHOOTING / Dr. ZX Monitor Display After starting Dr. ZX, push Select Controller. Push OK. Push Main C/U. To the lower T1V7-05-03-001 T1V7-05-03-009 Function Selection Screen Controller Selection Screen Push Start. Push Monitor Display. T1V7-05-03-010 Main Controller Screen To the lower T1V7-05-03-011 Title Screen T1V7-05-03-012 Main Menu Screen Input the model code and serial No. and push OK. Push ESC and return to Main Menu Screen. T1V7-05-03-065 Enter Model and Serial No.
TROUBLESHOOTING / Dr. ZX Push Rec. No. and the recording screen for Rec. No. is made. Push Record. To the lower T1V7-05-03-015 T1V7-05-03-096 Monitor Screen If Rec. No. has already been recorded and push Over Write, data is overwritten. Push ESC and return to Main Menu Screen. If Rec. No. has not been recorded yet and push Write, data is written to the recording screen. Push ESC and return to Main Menu Screen. Select Write Data-Bank Screen T1V7-05-03-097 Push Comment .
TROUBLESHOOTING / Dr. ZX SPECIAL FUNCTION Auto Warm-Up Control: Deactivation After starting Dr. ZX, push Select Controller. Push Main C/U. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 Function Selection Screen Controller Selection Screen Push Start. Push Special Function. T1V7-05-03-010 Main Controller Screen To the lower T1V7-05-03-011 T1V7-05-03-012 Title Screen Main Menu Screen Push WU Dectivation. Push ESC and return to Main Menu Screen. Push Exec.
TROUBLESHOOTING / Dr. ZX ECO Control: Deactivation After starting Dr. ZX, push Select Controller. Push Main C/U. Push OK. To the lower Function Selection Screen T1V7-05-03-001 Controller Selection Screen T1V7-05-03-009 T1V7-05-03-010 Main Controller Screen Push Special Function. Push Start. To the lower T1V7-05-03-011 T1V7-05-03-012 Title Screen Main Menu Screen Push ECO Deactivation. Push ESC and return to Main Menu Screen. Push Exec.
TROUBLESHOOTING / Dr. ZX SETTING Engine speed, pump delivery flow rate, solenoid valve output pressure and so on can be adjusted.
TROUBLESHOOTING / Dr. ZX Attachment Parameter Change Item ATT1 ATT1 ATT Type Attachment selection Data ATT1 ATT No.
TROUBLESHOOTING / Dr. ZX Item ATT3 ATT3 ATT Type Data Attachment selection ATT3 ATT No.
TROUBLESHOOTING / Dr. ZX Item ATT5 ATT5 ATT Type ATT5 ATT No.
TROUBLESHOOTING / Dr. ZX ADJUSTMENT DATA LIST ZX200-3 class Adjustment Data Li Speed WU Speed AI Speed Min. Adjustment Value -1 10 min -1 10 min -1 10 min Range Standard Adjustment 0 to 400 -450 to 200 -400 to 400 0 min -1 0 min -1 0 min 10 min -200 to 200 0 min 2.45 N⋅m -60 to 60 0 N⋅m 0.0196 MPa -0.9996 to 0.9996 0 MPa 0.0196 MPa -0.9996 to 0.9996 0 MPa 40 ms 0 to 3000 ms 0 ms 0.2 MPa -9.8 to 14.
TROUBLESHOOTING / Dr. ZX ZX240-3 class Adjustment Data Li Speed WU Speed AI Speed Min. Adjustment Value -1 10 min -1 10 min -1 10 min Range Standard Adjustment 0 to 400 -450 to 200 -400 to 400 0 min -1 0 min -1 0 min 10 min -200 to 100 0 min 2.45 N⋅m -60 to 60 0 N⋅m 0.0196 MPa -0.9996 to 0.9996 0 MPa 0.0196 MPa -0.9996 to 0.9996 0 MPa 40 ms 0 to 3000 ms 0 ms 0.2 MPa -9.8 to 14.
TROUBLESHOOTING / Dr. ZX ZX270-3 class Adjustment Data Li Speed WU Speed AI Speed Min. Adjustment Value -1 10 min -1 10 min -1 10 min Adjustable Range Range Standard Adjustment 0 to 400 -450 to 200 -400 to 400 0 min -1 0 min -1 0 min -1 -200 to 100 0 min -1 -400 to 400 0 min -1 -1 -1 P Speed 10 min Travel I Speed 10 min Travel P Speed 10 min -200 to 100 0 min 2.45 N⋅m -100 to 100 0 N⋅m 0.0196 MPa -0.9996 to 0.9996 0 MPa 0.0196 MPa -0.9996 to 0.
TROUBLESHOOTING / Dr.
TROUBLESHOOTING / DR.ZX ATTACHMENT ADJUSTMENT DATA LIST ZX200-3 class Adjustment Data ATT1 ATT1 ATT Type/No. ATT1 P1 Max Swash Angle Adjustment ATT1 P2 Max Swash Angle Adjustment ATT1 Engine Speed Increase/Decrease ATT1 Secondary Pilot Relief Pressure Selection ATT1 Selector Valve Selection ATT1 Accumulator Selection ATT1 2-Speed Selection ATT2 ATT2 ATT Type/No.
TROUBLESHOOTING / DR.ZX Adjustment Data Min. Adjustment Value Adjustable Range - 0 to 5 Primary Crusher 1 0.5 L/min 106 to 212 212 L/min 0.5 L/min 106 to 212 212 L/min 10 min -500 to 200 200 min - ON/OFF OFF - C/V or 0/T C/V - ON/OFF OFF - ON/OFF ON - 0 to 5 Unregistration 0.5 L/min 106 to 212 212 L/min 0.
TROUBLESHOOTING / DR.ZX ZX240-3 class Adjustment Data ATT1 ATT1 ATT Type/No. ATT1 P1 Max Swash Angle Adjustment ATT1 P2 Max Swash Angle Adjustment ATT1 Engine Speed Increase/Decrease ATT1 Secondary Pilot Relief Pressure Selection ATT1 Selector Valve Selection ATT1 Accumulator Selection ATT1 2-Speed Selection ATT2 ATT2 ATT Type/No.
TROUBLESHOOTING / DR.ZX Adjustment Data Min. Adjustment Value Adjustable Range - 0 to 5 Primary Crusher 1 0.5 L/min 112 to 224 224 L/min 0.5 L/min 112 to 224 224 L/min 10 min -500 to 100 100 min - ON/OFF OFF - C/V or 0/T C/V - ON/OFF OFF - ON/OFF ON - 0 to 5 Unregistration 0.5 L/min 112 to 224 224 L/min 0.
TROUBLESHOOTING / DR.ZX ZX270-3 class Adjustment Data ATT1 ATT1 ATT Type/No. ATT1 P1 Max Swash Angle Adjustment ATT1 P2 Max Swash Angle Adjustment ATT1 Engine Speed Increase/Decrease ATT1 Secondary Pilot Relief Pressure Selection ATT1 Selector Valve Selection ATT1 Accumulator Selection ATT1 2-Speed Selection ATT2 ATT2 ATT Type/No.
TROUBLESHOOTING / DR.ZX Adjustment Data Min. Adjustment Value Adjustable Range - 0 to 5 Primary Crusher 1 0.5 L/min 118 to 236 236 L/min 0.5 L/min 118 to 236 236 L/min 10 min -500 to 100 100 min - ON/OFF ON - C/V or 0/T C/V - ON/OFF OFF - ON/OFF ON - 0 to 5 Unregistration 0.5 L/min 118 to 236 236 L/min 0.
TROUBLESHOOTING/ Dr. ZX Setting • Parameter Change After starting Dr. ZX, push Select Controller. Push OK. Push Main C/U. To the lower T1V7-05-03-001 T1V7-05-03-009 Function Selection Screen Controller Selection Screen Push Start. Push Setup. T1V7-05-03-010 Main Controller Screen To the lower T1V7-05-03-011 T1V7-05-03-012 Title Screen Main Menu Screen Input the password and push OK. Push Cancel and return to Main Menu Screen. Push Parameter Change. Push ESC and return to Main Menu Screen.
TROUBLESHOOTING/ Dr. ZX Parameter Input Example: Li Speed Adjustment Input Value = Normal Value Input the value and push Exec. Push ESC and return to Parameter Change Selection Screen. Push Li Speed Adjustment. Check Adjustment and push Exec. Push ESC and return to Parameter Change Selection Screen. To the lower T1V7-05-03-105 Parameter Change Selection Screen T1V7-05-03-106 Parameter Input Screen Push ESC and return to Parameter Change Selection Screen.
TROUBLESHOOTING/ Dr. ZX Input Value = Current Value Input the value and push Exec. Push ESC and return to Parameter Change Selection Screen Push Li Speed Adjustment. Push Exec.
TROUBLESHOOTING/ Dr. ZX Input Value > Maximum Value (Input Value < Minimum Value) Input the value and push Exec. Push ESC and return to Parameter Change Selection Screen. Push Li Speed Adjustment. Push Re-Input and return to Parameter Input Screen. Push Max and the maximum value is input. Push ESC and return to Parameter Change Selection Screen. To the lower T1V7-05-03-105 Parameter Change Selection Screen Parameter Input Screen Push ESC and return to Parameter Change Selection Screen.
TROUBLESHOOTING/ Dr. ZX When the input value cannot be divided Input the value and push Exec. Push ESC and return to Parameter Change Selection Screen. Push Li Speed Adjustment. Push Re-Input and return to Parameter Input Screen. Push A or B and the value of A or B is input. Push ESC and return to Parameter Change Selection Screen. To the lower T1V7-05-03-105 Parameter Change Selection Screen Parameter Input Screen Push ESC and return to Parameter Change Selection Screen.
TROUBLESHOOTING/ Dr. ZX Status Selection Example: ATT Torque Reducing On/Off: Off Push ATT Torque Reducing On/Off. Push OFF and Push Exec. Push ESC and return to Parameter Change Selection Screen. Check OFF and push Exec. Push ESC and return to Parameter Change Selection Screen. To the lower T1V7-05-03-179 Parameter Change Selection Screen T1V7-05-03-111 Status Selection Screen Push ESC and return to Parameter Change Selection Screen.
TROUBLESHOOTING/ Dr. ZX • Attachment Parameter Change After starting Dr. ZX, push Select Controller. Push OK. Push Main C/U. To the lower T1V7-05-03-001 T1V7-05-03-009 Function Selection Screen Controller Selection Screen Push Start. Push Setup. T1V7-05-03-010 Main Controller Screen To the lower Title Screen T1V7-05-03-011 Input the password and push OK. Push ESC and return to Main Menu Screen. Main Menu Screen Push ATT Parameter Change. Push ESC and return to Main Menu Screen.
TROUBLESHOOTING/ Dr. ZX Attachment Parameter Input Input Value = Normal Value Push ATT1 Adjustment. Push ATT1. P1 Swash Angle Input the value and push Exec. Push ESC and return to Parameter Change Screen. To the lower T1V7-05-03-114 T1V7-05-03-115 Parameter Change Screen Check Adjustment and push Exec. Push ESC and return to Parameter Change Screen.. Push ESC and return to Parameter Change Screen.
TROUBLESHOOTING/ Dr. ZX Input Value = Current Value Push ATT1 Adjustment. Push ATT1. P1 Swash Angle Input the value and push Exec. Push ESC and return to Parameter Change Screen. To the lower T1V7-05-03-114 T1V7-05-03-115 Attachment Selection Screen Parameter Change Screen Push Exec. Push ESC and return to Parameter Chnage Screen. Push ESC and return to Parameter Change Screen.
TROUBLESHOOTING/ Dr. ZX Input Value > Maximum Value (Input Value < Minimum Value) Push ATT1 Adjustment. Push ATT1. P1 Swash Angle Input the value and push Exec. Push ESC and return to Parameter Change Screen. To the lower T1V7-05-03-114 T1V7-05-03-115 Attachment Selection Screen Parameter Change Screen Push Re-Input and return to Parameter Input Screen. Push Max and the maximum value is input. Push ESC and return to Parameter Change Screen. Push ESC and return to Parameter Change Screen.
TROUBLESHOOTING/ Dr. ZX When the input value cannot be divided Push ATT1 Adjustment. Push ATT1. P1 Swash Angle Input the value and push Exec. Push ESC and return to Parameter Change Screen. To the lower T1V7-05-03-114 T1V7-05-03-115 Attachment Selection Screen Parameter Change Screen Push Re-Input and return to Parameter Input Screen. Push A or B and the value of A or B is input. Push ESC and return to Parameter Change Screen. Push ESC and return to Parameter Change Screen.
TROUBLESHOOTING/ Dr. ZX Status Selection Example: ATT1, ATT No. Push ATT1. Push “5” and Push Exec. Push ESC and return to Parameter Change Selection Screen. Push ATT1 Number. To the lower T1V7-05-03-114 T1V7-05-03-115 Attachment Selection Screen Parameter Change Screen Check number and push Exec. Push ESC and return to ATT Parameter Change Selection Screen. Push ESC and return to Parameter Change Selection Screen.
TROUBLESHOOTING/ Dr. ZX Recorded Data Display After starting Dr. ZX, push Select Controller. Push OK. Push Main C/U. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-010 Function Selection Screen Controller Selection Screen Main Controller Screen Push Disp. Record. Push and select No. Push Regeneration and the recorded data is regenerated.Push DEL and data of selected No. is deleted. Push Hold and the monitor is stopped temporarily. Push Hold again and restart regeneration.
TROUBLESHOOTING/ Dr. ZX Password Change After starting Dr. ZX, push Select Controller. Push OK. Push Main C/U. To the lower Function Selection Screen T1V7-05-03-001 Controller Selection Screen T1V7-05-03-009 Input the registered Password and push OK. Push Password. Main Controller Screen T1V7-05-03-010 Input the new password and push OK. To the lower T1V7-05-03-011 T1V7-05-03-126 Title Screen Input the new password again and push OK. Push OK Screen.
TROUBLESHOOTING / Dr. ZX ATTACHMENT SETTING Monitor Unit When the attachment is set by Dr. ZX, the attachment specification screen can be selected and displayed on the work mode screen of monitor unit. (Push key 2 and select Breaker 1 in this group.) NOTE: Refer to the monitor unit group as for the display on work mode screen of monitor unit. When pushing key 6 and displaying the primary screen, the attachment mode which is selected on display the work mode is displayed.
TROUBLESHOOTING / Dr. ZX Five kinds attachment can be selected from Breaker 1 to 5, pulverizer 1 to 5, crusher 1 to 5, vibrating hammer 1 to 5 and others 1 to 5. (Refer to T5-3-17, 18.
TROUBLESHOOTING / Dr. ZX Attachment Setting Example: Set Pulverizer 5 to Attachment 1 Push PU and push Exec. Push ESC and return to ATT Parameter Change Selection Screen. Push ATT1 ATT Type. Push ATT 1. To the lower T1V7-05-03-114 T1V7-05-03-115 Attachment Selection Screen ATT Parameter Change Screen Status Selection Screen Check PU and push Exec. Push ESC and return to ATT Parameter Change Selection Screen. Push ESC and return to ATT Parameter Change Selection Screen. Push ATT 1 Number.
TROUBLESHOOTING / Dr. ZX When the work mode screen of monitor unit is displayed, Pulverizer 5 is displayed at Attachment 1. When pushing key 2, Pulverizer 5 is selected and the Pulverizer 5 specification screen is displayed.
TROUBLESHOOTING / Dr. ZX Attachment Non-Setting IMPORTANT: When the attachment is “non-setting”, the attachment cannot be selected on the monitor unit. Example: Set Attachment to Non-Setting Push Non and push Exec. Push ESC and return to ATT Parameter Change Selection Screen. Push ATT1 ATT Type. Push ATT 1. To the lower T1V7-05-03-114 T1V7-05-03-115 Attachment Selection Screen ATT Parameter Change Screen Check Non and push Exec. Push ESC and return to ATT Parameter Change Selection Screen.
TROUBLESHOOTING / Dr. ZX When the work mode of monitor unit is displayed, attachment 1 display disappears.
TROUBLESHOOTING / Dr. ZX ENGINE CONTROLLER Main Menu • Monitor Display Dr. ZX displays the input signals from sensors and the control signals of ECM. • Recorded Data Display Data recorded in ECM is displayed by one day by using Dr. ZX. Password Change The password can be changed.
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TROUBLESHOOTING / Dr. ZX Monitor Display After starting Dr. ZX, push Select Controller. Push OK. Push Engine C/U. To the lower T1V7-05-03-001 T1V7-05-03-009 Function Selection Screen Controller Selection Screen Push Start. Push Monitor Display. T1V7-05-03-010 Engine Controller Screen To the lower Title Screen T1V7-05-03-011 Input the model code and serial No. and push OK. Push ESC and return to Main Menu Screen. T1V7-05-03-130 T1V7-05-03-013 Main Menu Screen Enter Model and Serial No.
TROUBLESHOOTING / Dr. ZX Push Rec. No. and the recording screen for Rec. No. is made. Push Record. To the lower Monitor Screen T1V7-05-03-133 If Rec. No. has already been recorded and push Over Write, data is overwritten. Push ESC and return to Main Menu Screen. T1V7-05-03-134 If Rec. No. has not been recorded yet and push Write, data is written to the recording screen. Push ESC and return to Main Menu Screen. Select Write Data-Bank Screen T1V7-05-03-135 Push Comment.
TROUBLESHOOTING / Dr. ZX RECORED DATA DISPLAY After starting Dr. ZX, push Select Controller. Push OK. Push Engine C/U. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-010 Function Selection Screen Controller Selection Screen Engine Controller Screen Push Disp. Record. Push and select No. Push Regeneration and the recorded data is regenerated. Push DEL and data of selected No. is deleted. Push ESC and return to Main Menu Screen.
TROUBLESHOOTING / Dr. ZX PASSWORD CHANGE After starting Dr. ZX, push Select Controller. Push Engine C/U. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 Function Selection Screen Controller Selection Screen Push Password. Input the registered password and push OK. T1V7-05-03-010 Engine Controller Screen Input the new password and push OK. To the lower T1V7-05-03-011 T1V7-05-03-126 Title Screen Input the newpassword again and push OK. Push OK Screen.
TROUBLESHOOTING / Dr. ZX ICF CONTROLLER Main Menu • Information C/U Various Setup Initialization of information C/U, setting of model, serial No. and time, and initialization of control data can be done. • Data Download Daily report data, frequency distribution data, total operating hours, alarm and failure which are recorded in ICF can be downloaded to Dr. ZX.
TROUBLESHOOTING / Dr. ZX MAIN MENU INFORMATION C/U VARIOUS SETUP List of Controller Data Setting Item Item Information C/U: Initialize Enter Model and Serial No. Range of Data Model Serial No. Enter Date and Time YY MM DD HH MM Date Time Control Data: Initialize Satellite Terminal: Initialize Satelite Terminal No. Confirmation Communicating State Check ICF < = > Satellite Terminal Satellite Terminal Connect Comm. Power Comm.
TROUBLESHOOTING / Dr. ZX INFORMATION C/U: INITIALIZE After starting Dr. ZX, push Select Controller. Push Information C/U. Push OK. To the lower Function Selection Screen T1V7-05-03-001 Controller Selection Screen Push Information Setup. Push Start. C/U: T1V7-05-03-009 Various ICF Controller Screen T1V7-05-03-024 Push Information C/U: Initialize. To the lower Title Screen T1V7-05-03-025 Push Init and the controller operating data is initialied.
TROUBLESHOOTING / Dr. ZX ENTER MODEL AND SERIAL No. After starting Dr. ZX, push Select Controller. Push Information C/U. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-024 Function Selection Screen Controller Selection Screen ICF Controller Screen Push Start. Push Information Setup. Push Enter Model and Serial No. C/U: Various To the lower T1V7-05-03-025 T1V7-05-03-026 Title Screen Main Menu Screen Push Exec and model and serial No. can be input.
TROUBLESHOOTING / Dr. ZX ENTER DATE AND TIME After starting Dr. ZX, push Select Controller. Push Information C/U. Push OK. To the lower Function Selection Screen T1V7-05-03-001 T1V7-05-03-009 Controller Selection Screen Push Information Setup. Push Start. C/U: Various ICF Controller Screen T1V7-05-03-024 Push Enter Date and Time.
TROUBLESHOOTING / Dr. ZX CONTROL DATA: INITIALIZE After starting Dr. ZX, push Select Controller. Push OK. Push Information C/U. To the lower Function Selection Screen T1V7-05-03-001 T1V7-05-03-009 Push Information Setup. Push Start. C/U: T1V7-05-03-024 ICF Controller Screen Controller Selection Screen Various Push Control Data: Initialize. To the lower Title Screen T1V7-05-03-025 Push Init and the controller control data is initialied.
TROUBLESHOOTING / Dr. ZX SATELLITE TERMINAL: INITIALIZE After starting Dr. ZX, push Select Controller. Push OK. Push ICF Controller. To the lower T1V7-05-03-001 Function Selection Screen Push Start. T1V7-05-03-009 T1V7-05-03-024 Controller Selection Screen ICF Controller Screen Push Information Setup. Push T and move to the next screen of Information C/U: Various Setup Screen. Push Satellite Terminal: Initialize. C/U: Various To the lower Title Screen T1V7-05-03-025 Push Exec.
TROUBLESHOOTING / Dr. ZX SATELLITE TERMINAL No. CONFIRMATION After starting Dr. ZX, push Select Controller. Push OK. Push Information C/U. To the lower T1V7-05-03-001 Function Selection Screen Push Start. T1V7-05-03-009 T1V7-05-03-024 Controller Selection Screen ICF Controller Screen Push Information Setup. Push T and move to the next screen of Information C/U: Various Setup Screen. Push Satellite Terminal No. Confirmation.
TROUBLESHOOTING / Dr. ZX COMMUNICATING STATE CHECK After starting Dr. ZX, push Select Controller. Push Information C/U. Push OK. To the lower Function Selection Screen T1V7-05-03-001 Controller Selection Screen Push Information Setup. Push Start. C/U: T1V7-05-03-009 Various ICF Controller Screen T1V7-05-03-024 Push T and move to the next screen of Information C/U: Various Setup Screen. Push Communicating State Check.
TROUBLESHOOTING / Dr. ZX ENTER SATELLITE COMM. START / STOP After starting Dr. ZX, push Select Controller. Push OK. Push Information C/U. To the lower T1V7-05-03-001 Function Selection Screen T1V7-05-03-009 Controller Selection Screen Push Information Setup. Push Start. C/U: Various ICF Controller Screen T1V7-05-03-024 Push T and move to the next screen of Information C/U: Various Setup Screen. Push Enter Satellite Comm. Start/Stop.
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TROUBLESHOOTING / Dr. ZX DATE DOWNLOAD After starting Dr. ZX, push Select Controller. Push Information C/U. Push OK. To the lower Function Selection Screen T1V7-05-03-001 Push Start. Controller Selection Screen T1V7-05-03-009 ICF Controller Screen T1V7-05-03-024 While downloading data, Download Screen is displayed. Push Data Download. To the lower Title Screen T1V7-05-03-025 When downloading is completed normally, Normal End Screen is displayed. Push OK and return to Main Menu Screen.
TROUBLESHOOTING / Dr. ZX SAVE DATA CHECK After starting Dr. ZX, push Select Controller. Push Information C/U. Push OK. To the lower T1V7-05-03-001 Function Selection Screen Push Start. T1V7-05-03-009 T1V7-05-03-024 Controller Selection Screen ICF Controller Screen Push Save Data Check. Data saved in ICF is displayed. Push OK and return to Main Menu Screen.
TROUBLESHOOTING / Dr. ZX PASSWORD CHANGE After starting Dr. ZX, push Select Controller. Push OK. Push Information C/U. To the lower Function Selection Screen T1V7-05-03-001 Controller Selection Screen T1V7-05-03-009 Input the registered password and push OK. Push Password. ICF Controller Screen T1V7-05-03-024 Input the new password and push OK. To the lower T1V7-05-03-025 T1V7-05-03-126 Title Screen Input the new password again and push OK. Push OK Screen.
TROUBLESHOOTING / Dr. ZX MONITOR CONTROLLER Main Menu • Monitoring Dr. ZX displays the control signals of each controller and the input signals from each sensor. • Various Settings Dr. ZX can set optional function setting, back monitor setting, operating condition enable/ disable, time set function enable / disable, maintenance setting, inner hour meter synchronization and fuel consumption gauge display ON/OFF selection. Password Change The password can be changed.
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TROUBLESHOOTING / Dr. ZX Monitor Switch Condition Check After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower Function Selection Screen T1V7-05-03-001 Controller Selection Screen T1V7-05-03-009 Push item for monitoring and push OK. Push ESC and return to Main Menu Screen. Push Monitoring. Push Start. T1V7-05-03-041 Monitor Controller Screen To the lower T1V7-05-03-025 Title Screen T1V7-05-03-042 Push ESC and return to Main Menu Screen.
TROUBLESHOOTING / Dr. ZX Other Monitoring After starting Dr. ZX, push Select Controller. Push OK. Push Monitor Unit. To the lower T1V7-05-03-001 Function Selection Screen Push Start. T1V7-05-03-009 T1V7-05-03-041 Controller Selection Screen Monitor Controller Screen Push Monitoring. Push item for monitoring and push OK. Refer to T5-3-73 as for the monitoring item. Push ESC and return to Main Menu Screen.
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TROUBLESHOOTING / Dr. ZX OPTIONAL FUNCTION ALLOCATION Example: Allocate ML Crane for Menu 7 After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 Function Selection Screen Controller Selection Screen Push Start. Push Various Setup. Monitor Controller Screen T1V7-05-03-041 To the lower T1V7-05-03-025 Title Screen Push Next. Push ESC and return to Main Menu Screen.
TROUBLESHOOTING / Dr. ZX Move the item by using T and push Menu 7. To the lower T1V7-05-03-153 Push ML Crane. T1V7-05-03-050 T1V7-05-03-051 Option Function Allocate Execution Screen is displayed. Push ESC and return to Various Setup Item Screen. Push Exec.
TROUBLESHOOTING / Dr. ZX Allocate Mail for Menu 3 After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower Function Selection Screen T1V7-05-03-001 Controller Selection Screen T1V7-05-03-009 Push Various Setup. Push Start. Monitor Controller Screen T1V7-05-03-041 Push Option Function Allocate. To the lower T1V7-05-03-025 T1V7-05-03-042 Title Screen Main Menu Screen Push Next. Push ESC and return to Main Push Next.
TROUBLESHOOTING / Dr. ZX Push Menu 3. Push Exec. Push Mail. To the lower T1V7-05-03-155 T1V7-05-03-152 Option Function Allocate Screen T1V7-05-03-153 Option Function Allocate Execution Screen is displayed. Push ESC and return to Various Setup Item Screen. T1V7-05-03-154 Option Function Allocate Execution Screen T1V7-05-03-046 Various Setup Item Screen Mail is displayed on the monitor unit screen. When pushing key F3, Mail Screen is displayed.
TROUBLESHOOTING / Dr. ZX Allocate ML Crane for Menu 2 After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-041 Function Selection Screen Controller Selection Screen Monitor Controller Screen Push Start. Push Various Setting. Push Option Function Allocate. To the lower Title Screen T1V7-05-03-025 Push Next. Push ESC and return to Main Menu Screen.
TROUBLESHOOTING / Dr. ZX Push Menu 2. Push ML Crane. Push Exec. To the lower Option Function Allocate Screen T1V7-05-03-155 T1V7-05-03-159 Option Function Allocate Screen T1V7-05-03-157 Option Function Allocate Execution Screen is displayed. Push ESC and return to Various Setup Item Screen. T1V7-05-03-158 Option Function Allocate Execution Screen T1V7-05-03-046 Various Setup Item Screen ML Crane is displayed on the monitor unit screen.
TROUBLESHOOTING / Dr. ZX Make ML Crane for Menu 2 Disable After starting Dr. ZX, push Select Controller. Push OK. Push Monitor Unit. To the lower Function Selection Screen T1V7-05-03-001 Push Start. Controller Selection Screen T1V7-05-03-009 Monitor Controller Screen T1V7-05-03-041 Push Option Function Allocate. Push Various Setting. To the lower Title Screen T1V7-05-03-025 Push Next. Push ESC and return to Main Menu Screen.
TROUBLESHOOTING / Dr. ZX Push Unset. Push Menu 2. Push Exec. To the lower T1V7-05-03-157 T1V7-05-03-156 Option Function Allocate Screen T1V7-05-03-155 Option Function Allocate Screen Option Function Allocate Execution Screen is displayed. Push ESC and return to Various Setup Item Screen. T1V7-05-03-160 Option Function Allocate Execution Screen Various Setup Item Screen T1V7-05-03-046 ML Crane is disappeared on the monitor unit screen.
TROUBLESHOOTING / Dr. ZX OVERLOAD ALARM ENABLE / DISABLE SELECTION Overload Alarm: Enable After starting Dr. ZX, push Select Controller. IMPORTANT: In case ML Crane is set to any one of Menu 1 to 9 of Option Function Allocate, make ML Crane disable. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-041 Function Selection Screen Controller Selection Screen Monitor Controller Screen Push Start. Push Various setting. Push Overload Disable.
TROUBLESHOOTING / Dr. ZX Overload Alarm: Disable After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-041 Function Selection Screen Controller Selection Screen Monitor Controller Screen Push Start. Push Various setting. Push Overload Disable. warnig Enable/ To the lower T1V7-05-03-025 T1V7-05-03-042 Title Screen Main Menu Screen Push Disable and push Exec. Push ESC and return to the former screen.
TROUBLESHOOTING / Dr. ZX BACK MONITOR SETTING Back Monitor Function: Enable After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-041 Function Selection Screen Controller Selection Screen Monitor Controller Screen Push Start. Push Various setting. Push Back Monitor Setup.
TROUBLESHOOTING / Dr. ZX Back Monitor Function: Disable After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-041 Function Selection Screen Controller Selection Screen Monitor Controller Screen Push Start. Push Various setting. Push Back Monitor Setup. To the lower T1V7-05-03-025 T1V7-05-03-042 T1V7-05-03-046 Title Screen Main Menu Screen Various Setup Item Screen Push Back Monitor Function Enable / Disable.
TROUBLESHOOTING / Dr. ZX Back Monitor Function: Normal After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-041 Function Selection Screen Controller Selection Screen Monitor Controller Screen Push Start. Push Various setting. Push Back Monitor Setup. To the lower T1V7-05-03-025 T1V7-05-03-042 T1V7-05-03-046 Title Screen Main Menu Screen Various Setup Item Screen Push Back Monitor Display Normal / Filip Vartical.
TROUBLESHOOTING / Dr. ZX Back Monitor Display: Flip Vertical After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-041 Function Selection Screen Controller Selection Screen Monitor Controller Screen Push Start. Push Various setting. Push Back Monitor Setup.
TROUBLESHOOTING / Dr. ZX OPERATING CONDITION DISABLE SELECTION ENABLE / Operating Condition: Enable After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-041 Function Selection Screen Controller Selection Screen Monitor Controller Screen Push Start. Push Various setting. Push Overload Disable. warnig Enable/ To the lower T1V7-05-03-025 T1V7-05-03-042 Main Menu Screen Push Enable and push Exec.
TROUBLESHOOTING / Dr. ZX Operating Condition: Disable After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-041 Function Selection Screen Controller Selection Screen Monitor Controller Screen Push Start. Push Various setting. Push Overload Disable. warnig Enable/ To the lower T1V7-05-03-025 T1V7-05-03-042 Main Menu Screen Push Enable and push Exec. Push ESC and return to the former screen.
TROUBLESHOOTING / Dr. ZX TIME SETTING FUNCTION ENABLE / DISABLE SELECTION Time Setting Function: Enable After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 Function Selection Screen Push Start. T1V7-05-03-009 T1V7-05-03-041 Controller Selection Screen Monitor Controller Screen Push Various setting. Move the item by using T and push Time Set Func Enable/Disable.
TROUBLESHOOTING / Dr. ZX Time Setting Function: Disable After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 Function Selection Screen Push Start. T1V7-05-03-009 T1V7-05-03-041 Controller Selection Screen Monitor Controller Screen Push Various setting. Move the item by using T and push Time Set Func Enable/Disable. To the lower T1V7-05-03-025 Various Setup Item Screen Main Menu Screen Push Disable and push Exec.
TROUBLESHOOTING / Dr. ZX MAINTENANCE SETTING MAINTENANCE OPERATION ALLOW / NOT ALLOW SELECTION Maintenance Operation: Allow After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-041 Function Selection Screen Controller Selection Screen Monitor Controller Screen Push Start. Push Various setting. Move the item by using T and push Maintenance Setup.
TROUBLESHOOTING / Dr. ZX Maintenance Operation: Not Allow After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-041 Function Selection Screen Controller Selection Screen Monitor Controller Screen Push Start. Push Various setting. Move the item by using T and push Maintenance Setup. To the lower T1V7-05-03-025 Title Screen Push Maintenance Allow/Not Allow.
TROUBLESHOOTING / Dr. ZX NOTIFICATION FUNCTION DISABLE SELECTION ENABLE / Notification Function: Enable After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-041 Function Selection Screen Controller Selection Screen Monitor Controller Screen Push Start. Push Various setting. Move the item by using T and push Maintenance Setup. To the lower T1V7-05-03-025 Title Screen Push Maintenance Allow/Not Allow.
TROUBLESHOOTING / Dr. ZX Notification Function: Disable After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-041 Function Selection Screen Controller Selection Screen Monitor Controller Screen Push Start. Push Various setting. Move the item by using T and push Maintenance Setup. To the lower T1V7-05-03-025 Title Screen Push Notification Enable/Disable. function Various Setup Item Screen Push Disable and push Exec.
TROUBLESHOOTING / Dr. ZX MAINTENANCE DISPLAY ITEM ON/OFF SELECTION Maintenance Display Item: ON After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-041 Function Selection Screen Controller Selection Screen Monitor Controller Screen Push Start. Push Various setting. Move the item by using T and push Maintenance Setup.
TROUBLESHOOTING / Dr. ZX Push the displayed item and finally push OK. Push All Sel and select all the items. To the lower T1V7-05-03-078 T1V7-05-03-080 T1V7-05-03-081 Display Item Selection Screen Push ESC and return Maintenance Set Item Screen.
TROUBLESHOOTING / Dr. ZX Maintenance Display Item: ON After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-041 Function Selection Screen Controller Selection Screen Monitor Controller Screen Push Start. Push Various setting. Move the item by using T and push Maintenance Setup.
TROUBLESHOOTING / Dr. ZX Push the item of which the display is turned into OFF and finally push OK Push ESC and return Maintenance Set Item Screen.
TROUBLESHOOTING / Dr. ZX INTERNAL HOUR SYNCHRONIZATION After starting Dr. ZX, push Select Controller. METER Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-041 Function Selection Screen Controller Selection Screen Monitor Controller Screen Push Start. Push Various setting. Move the item by using T and push Maintenance Setup. To the lower T1V7-05-03-025 T1V7-05-03-063 T1V7-05-03-042 Various Setup Item Screen Title Screen Main Menu Screen Push Sync.
TROUBLESHOOTING / Dr. ZX FUEL CONSUMPTION GAUGE DISPLAY ENABLE / DIABLE SELECTION Fuel Consumption Gauge Display: Enable After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 Function Selection Screen Push Start. T1V7-05-03-009 T1V7-05-03-041 Controller Selection Screen Monitor Controller Screen Push Various setting. Move the item by using T and push Fuel cost meter display Enable/Disable.
TROUBLESHOOTING / Dr. ZX Fuel Consumption Gauge Display: Disable After starting Dr. ZX, push Select Controller. Push OK. Push Monitor Unit. To the lower T1V7-05-03-001 Function Selection Screen Push Start. T1V7-05-03-009 T1V7-05-03-041 Controller Selection Screen Monitor Controller Screen Push Various setting. Move the item by using T and push Fuel cost meter display Enable/Disable. To the lower T1V7-05-03-025 T1V7-05-03-042 Title Screen Main Menu Screen Push Disable and push Exec.
TROUBLESHOOTING / Dr. ZX PASSWORD CHANGE After starting Dr. ZX, push Select Controller. Push Monitor Unit. Push OK. To the lower T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-041 Function Selection Screen Controller Selection Screen Monitor Controller Screen Push Password. Input the registered password and push OK. Input the new password and push OK. To the lower T1V7-05-03-025 T1V7-05-03-126 Title Screen Main Menu Screen Input the new password again and push OK. Push OK Screen.
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TROUBLESHOOTING / e-Shovel OUTLINE ICF (Information Controller) saves the input signals from various sensors and switches of the machine as data. Various input signals are recorded as “list of daily report data”, “list of frequency distribution data”, “list of total operating hours”, “list of alarm” and “list of failure” in ICF. The recorded data is downloaded to the personal computer and is uploaded to the center server via LAN, so that the data can be used as “e-Service”.
TROUBLESHOOTING / e-Shovel LIST OF DAILY REPORT DATA Data which can be downloaded by Palm Item Details Date Date of daily report data Time when key switch is first turned ON during a day Start: Time (Time is recorded by key switch ON signal.) Time when key switch is last turned OFF during a day Stop: Time (Time is recorded by key switch ON signal.) The value of the final remained fuel during a day Fuel Level (Value is recorded by fuel sensor data from monitor unit.
TROUBLESHOOTING / e-Shovel Item Details Total machine’s waiting hours during a day No Load Time (Hours are recorded by each pressure sensor information from MC.) The highest radiator coolant temperature during a day Radiator Coolant Temperature (Value is recorded from monitor unit.) The highest hydraulic oil temperature during a day Hydraulic Oil Temperature (Value is recorded from MC.) The highest intake air temperature during a day Intake Air Temperature (Value is recorded from ECM.
TROUBLESHOOTING / e-Shovel Data which can be sent by Satellite Communication Item Details Date Date of daily report data The value of the final remained fuel during a day Fuel Level (Value is recorded by fuel sensor data from monitor unit.) The value of fuel used during a day Fuel Usage Amount (Value is calculated and recorded by accumulated fuel usage amount from ECM.) Hour meter cumulative hours Machine Hour Meter (Hours are recorded by hour meter from monitor unit.
TROUBLESHOOTING / e-Shovel LIST OF FREQUENCY DISTRIBUTION DATA Item Details Frequency distribution of fuel temperature Frequency distribution of average pump delivery pressure of pumps 1 Pump Load and 2 Average Pump Delivery Pressure in Frequency distribution of average delivery pressure from pumps during Digging Operation digging operation Average Pump Delivery Pressure in Frequency distribution of average delivery pressure from pumps during Travel Operation travel operation Radiator Coolant Temperature F
TROUBLESHOOTING / e-Shovel LIST OF TOTAL OPERATING HOURS Item Details Inner Hour Meter Hour meter’s value accumulated inside ICF Machine Hour Meter Hour meter’s value accumulated in machine’s monitor Engine Hour Operating HP Mode Hours Total engine operating hours selecting HP mode P Mode Hours Total engine operating hours selecting P mode E Mode Hours Total engine operating hours selecting E mode Auto-Idle Switch ON Time Hours when auto-idle switch is turned ON Fast Idle (Hi) Total operating
TROUBLESHOOTING / e-Shovel (Blank) T5-4-7
TROUBLESHOOTING / e-Shovel HOW TO DOWNLOAD AND UPLOAD DATA OF ICF Rear Console After the data saved in ICF is downloaded to Palm (Dr. ZX), is uploaded to the personal Computer, and is uploaded to the center server by using LAN, the data can be used as “e-Service”. How to Download Data from Machine to Palm 1. Connect the Dr. ZX connectors in Palm and machine by using the Hot Sync cable and connecting harness. 2. Turn Palm ON and start downloading the data. (Refer to the next page.
TROUBLESHOOTING / e-Shovel Data Download After starting Dr. ZX, push Select Controller. Select Function + Select failure-diagnosis controller Self-Diagnostic Result + Push OK. Push ICF Controller. Select Controller + Engine Controller + Main Controller + Monitor Controller + ICF Controller ESC ・ ICF controller Ver.: XXYY ・ Satellite terminal Controller Ver.: XXYY Is it correct? ESC OK ESC Function Selection Screen Controller Selection Screen ICF Controller Screen Push Start.
TROUBLESHOOTING / e-Shovel How to Upload Data from Palm to Personal Computer 1. Set Palm to the cradle. Connect the USB cable to the personal computer. 2. Push the Hot Sync button. NOTE: When pushing the Hot Sync button and uploading the data to the personal computer, the Palm Desktop software attached with Palm need to be installed.
TROUBLESHOOTING / e-Shovel VARIOUS SETUP OF ICF AND SATELLITE COMMUNICATION TERMINAL BY USING Dr. ZX Before starting satellite communication, installing the satellite communication terminal and replacing ICF, perform the following procedures by using Dr. ZX. ICF Setup Procedures Start Dr. ZX 1.1 Select Information Controller 1.2 Select Information C/U: Various Setup 1.3 Enter Date and Time 1.4 Enter Model and Serial No. 1.5 Information C/U: Initialize Communication No Communication 1.
TROUBLESHOOTING / e-Shovel 1.1 Select Information Controller 1.2 Select Information C/U: Various Setup 1.1 Select Information Controller After starting Dr. ZX, push Select Controller. Push ICF Controller. Push OK. Select failure-diagnosis controller Select Function + Self-Diagnostic Result + Select Controller + Engine Controller + Main Controller + Monitor Controller + ICF Controller ESC Function Selection Screen ・ ICF Controller Ver.: XXYY ・ Satellite Terminal Controller Ver.
TROUBLESHOOTING / e-Shovel 1.3 Enter Date and Time Push Enter Date and Time. Push ESC and return to Main Menu Screen. Push Set and the focused item is YY. Push ESC and return to Information C/U: Various Setup Screen. Enter Date and Time Select Item + Information C/U: Initialize YY 2004 MM 01 + HH 01 01 + Enter Model and Serial No.
TROUBLESHOOTING / e-Shovel 1.4 Enter Model and Serial No. Push Enter Model and Serial No. Select Item + Information C/U: Initialize + + Enter Model and Serial No. Enter Date and Time + Control Data: Initialize To the lower ESC Information C/U: Various Setup Screen After inputting model and serial No., push OK and return to Enter Model and Serial No. Screen. Push ESC and return to Information C/U: Various Setup Screen. Push Exec, and model and serial No. can be input.
TROUBLESHOOTING / e-Shovel 1.5 Information C/U: Initialize Push Information C/U: Initialize. Select Item + Information C/U: Initialize + + Enter Model and Serial No. Enter Date and Time + Control Data: Initialize To the lower ESC Information C/U: Various Setup Screen Push Init and the controller operating data is initialized. Push ESC and return to Information C/U: Various Setup Screen. Push OK and return to Information C/U: Various Setup Screen.
TROUBLESHOOTING / e-Shovel 1.6 Satellite Terminal: Initialize Display the next screen of Information C/U: Various Setup Screen. Push Satellite Terminal: Initialize. Push ESC and return to Main Menu Screen. Select Item Select Item + Information C/U: Initialize + + Enter Model and Serial No. + Enter Date and Time + + Control Data: Initialize + + Information C/U: Various Setup Screen Satellite Terminal: Initialize Satellite Terminal: Initialize Satellite Terminal No.
TROUBLESHOOTING / e-Shovel 1.7 Satellite Terminal Serial No. Check Push Satellite Terminal No. Confirmation. Push ESC and return to Main Menu Screen. Select Item + + + + Satellite Terminal: Initialize Satellite Terminal No. Confirmation Communicating State Check Enter Satellite Comm. Start/Stop Confirm serial no. (12 digits). Push ESC and return to Information C/U: Various Setup Screen. Satellite Terminal No. Confirmation Select Item + + Serial No.
TROUBLESHOOTING / e-Shovel 1.8 Satellite Check Terminal, Push Communicating State Check. Push ESC and return to Main Menu Screen. Select Item + + + + Satellite Terminal: Initialize Satellite Terminal No. Confirmation Communicating State Check Enter Satellite Comm. Start/Stop Communicating State Check communicating state. Communicating State Check ICF⇔Satellite Terminal Conn UnCon ・ Conn ・ Comm. OK NG Satellite Terminal ON OFF ・ Power ・ Comm.
TROUBLESHOOTING / e-Shovel 1.9 Enter Satellite Comm. Start/Stop Push ▼ and move to the next screen of Information C/U: Various Setup Screen. Push Enter Satellite Comm. Start/Stop. Select Item + + + + Satellite Terminal: Initialize Satellite Terminal No. Confirmation Communicating State Check Enter Satellite Comm. Start/Stop To the lower ESC Information C/U: Various Setup Screen When starting Satellite Comm., push Start and push Exec. When stopping Satellite Comm., push Stop and push Exec.
TROUBLESHOOTING / e-Shovel 1.10 Control Data: Initialize Push Control Data: Initialize. Select Item + Information C/U: Initialize + + Enter Model and Serial No. Enter Date and Time + Control Data: Initialize ESC Information C/U: Various Setup Screen Push Init and the controller operating data is initialized. Push ESC and return to Information C/U: Various Setup Screen. Push OK and return to Information C/U: Various Setup Screen. Push ESC and return to Main Menu Screen.
TROUBLESHOOTING / e-Shovel (Blank) T5-4-21
TROUBLESHOOTING / e-Shovel 2. Self-Diagnosing After starting Dr. ZX, Self-Diagnostic Result. Push Fault of ICF Controller. If there is no trouble, No Problem is displayed. push Self-diagnosing of controllers below hasn completed.
TROUBLESHOOTING / e-Shovel LIST OF FAULT CODE Fault Code Details Remedy 14000-2 Abnormal CAN Communication 14001-2 ICF: Flash Memory: Read / Write Execute retry B in self-diagnosing and execute the following Error item. Execute 1.5 Information C/U: Initialize (T5-4-15). ICF: External RAM: Read / Write Error 14002-2 14003-2 ICF: EEPROM: Sum Check Error Execute retry B in self-diagnosing. If this error code is displayed after re-try, check the following item.
TROUBLESHOOTING / e-Shovel SATELLITE COMMUNICATION SYSTEM The satellite communication system is used for maintenance of the machine, “e-Service” by transmitting various data of the machine regularly via a low earth orbit satellite. GPS Aerial Communication Aerial NOTE: Depending on the circumstances of the machine (ex. in the constructions, in the tunnel, affected by the surrounding building and affected of noise), the data transfer rate may become slower, or the communication might not be established.
TROUBLESHOOTING / e-Shovel On the machine equipped with the satellite communication system, the data are sent according to the condition as follows: Kinds of data sent from the machine by using satellite communication: Items Kinds of Data Periodical Daily Report Data, Latest Transmission Information, Fuel Level Condition The data are sent once a day. In order to avoid congested traffic in the communication line, the data is sent randomly between 0:00 and 02:00.
TROUBLESHOOTING / e-Shovel (Blank) T5-4-26
TROUBLESHOOTING / Component Layout MAIN COMPONENTS 2 3 1 24 4 5 6 7 8 9 23 10 22 11 21 12 20 19 14 18 12- Bucket Cylinder Arm Cylinder 34- Boom Cylinder Center Joint 56- Swing Bearing Swing Device 7 - Fuel Tank 8 - Hydraulic Oil Tank 9 - Control Valve 10 - Pilot Filter/ Pilot Relief Valve 11 - Pump Device 12 - Engine 17 16 13 15 T1V1-01-02-013 13 - Intercooler 14 - Air Conditioner Condenser 19 - Fuel Cooler 20 - Air Cleaner 15 - Radiator 16 - Battery 21 - Signal Control Valve 22
TROUBLESHOOTING / Component Layout Front Attachment (2-Piece Boom) 3 4 5 6 2 7 8 1 9 11 T1V1-01-02-006 10 1- Bucket 23- Bucket Cylinder Arm 4 - Hose Rupture Valve (Arm Cylinder) 5 - Arm Cylinder 6 - Upper Boom 7- Hose Rupture Valve (Positioning Cylinder) 8 - Positioning Cylinder 9 - Bottom Boom T5-5-2 10 - Hose Rupture Valve (Boom Cylinder) 11 - Boom Cylinder
TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM (OVERVIEW) Pump Device • Pump 1,2 Delivery Pressure Sensors • Pumps 1, 2 Control Pressure Sensors • Torque Control Solenoid Valve • Maximum Pump 2 Flow Rate Limit Control Solenoid Valve Refer to T5-5-9.
TROUBLESHOOTING / Component Layout Electrical System (In Cab) Refer to Rear Tray (T5-5-5). 2 Refer to Switch Panel (T5-5-6).
TROUBLESHOOTING / Component Layout Electrical System (Rear Tray) 1 2 3 T1V1-01-02-007 4 5 8 9 10 11 7 12 6 13 14 T1V1-01-02-009 19 123- MC (Main Controller) Fuse Box Dr.
TROUBLESHOOTING / Component Layout Electrical System (Switch Panel) 3 4 2 5 1 6 T1V1-04-02-001 12- Wiper / Washer Switch Working Light Switch 3 - Engine Control Dial 4 - Auto-Idle Switch 5 - Power Mode Switch T5-5-6 6- Travel Mode Switch
TROUBLESHOOTING / Component Layout Electrical System (Utility Space) Front 2 1 Air Cleaner 3 4 T1V1-01-02-012 Electrical System (Relays) 5 6 T1V1-01-02-018 7 1- Atmospheric Pressure Sensor 2 - Intake-Air Temperature Sensor 3 - Fresh Air Pressure Sensor 5 - Battery Relay 4 - Starter Relay 2 6 - Glow Relay T5-5-7 7 - Fusible Link
TROUBLESHOOTING / Component Layout ENGINE 3 4 5 1 2 6 T1V1-01-02-017 T1V1-01-02-016 9 10 11 12 8 7 9 T1V1-01-02-015 13 1- Cam Angle Sensor 5- Fuel Temperature Sensor Overheat Switch Coolant temperature sensor 4 - Common Rail Pressure Sensor 67- Crank Speed Sensor Supply Pump Actuator 23- 8- Hydraulic Oil Pressure Sensor 9 - Injector 10 - EGR (Exhaust Gas Recirculation) Valve T5-5-8 11 - Boost Temperature Sensor 12 - Boost Pressure Sensor 13 - Glow Plug
TROUBLESHOOTING / Component Layout PUMP DEVICE 1 2 8 3 7 6 9 5 4 T178-03-01-003 T178-03-01-001 SWING DEVICE ZX270-3 class ZX200-3 class, ZX240-3 class Front 10 11 11 T1V1-01-02-005 1- Pilot Pump 4 - Pump 1 Delivery Pressure Sensor 2- Pump 2 3- Pump 1 5 - Pump 2 Delivery Pressure Sensor 6 - Torque Control Solenoid Valve 7 - Maximum Pump 2 Flow Rate Limit Control Solenoid Valve 8 - Pump 2 Control Pressure Sensor 9 - Pump 1 Control Pressure Sensor T5-5-9 T1V1-01-02-004 10 - Swing Rel
TROUBLESHOOTING / Component Layout CONTROL VALVE 1 Main Relief Valve 2 T1V1-03-03-073 SIGNAL CONTROL VALVE 3 4 T1V1-01-02-014 1- Pressure Sensor (Arm Roll-In) 2- Pressure Sensor (Boom Raise) 3- T5-5-10 Pressure Sensor (Swing) 4- Pressure Sensor (Travel)
TROUBLESHOOTING / Component Layout SOLENOID VALVE UNIT 1 2 3 4 T1V1-03-07-007 TRAVEL DEVICE ZX200-3 class, ZX240-3 class ZX270-3 class 5 5 5 6 T1HD-01-02-001 T178-01-02-014 6 5 1 - Solenoid Valve Unit SC 2 - Solenoid Valve Unit SF 34- Solenoid Valve Unit SI Solenoid Valve Unit SG 5- T5-5-11 Counterbalance Valve 6 - Travel Relief Valve
TROUBLESHOOTING / Component Layout Layout of Control Valve Machine Lower 1 Machine Upper 2 3 Machine Lower Machine Upper 4 5 6 7 8 9 10 11 12 42 13 14 41 15 40 16 39 17 38 18 19 20 37 36 35 21 34 22 23 33 24 32 31 30 29 28 27 26 25 T1V1-03-03-021 T5-5-12
TROUBLESHOOTING / Component Layout 4-Spool Section Arm Roll-In Pressure Sensor 18 19, 22 13 10, 11 23 15, 17 16 7 Boom Raise Pressure Sensor 1- Load Check Valve (Left Travel Parallel Circuit) 2 - Check Valve (Main Relief Circuit) 3 - Main Relief Valve 4- Check Valve (Auxiliary Combining Valve Circuit) 5 - Auxiliary Flow Combiner Valve 6 - Check Valve (Flow Combiner Valve Circuit) 7 - Flow Combiner Valve 8- Load Check Valve (Orifice) (Bucket) 9 - Check Valve (Main Relief Circuit) 10 - Bucket Flo
TROUBLESHOOTING / Component Layout Machine Lower 1 2 3 Machine Lower Machine Upper Machine Upper 4 5 6 7 8 9 10 11 12 42 13 14 41 15 40 16 39 17 38 18 19 20 37 36 35 21 34 22 23 33 24 32 31 30 29 28 27 26 25 T1V1-03-03-021 T5-5-14
TROUBLESHOOTING / Component Layout 5-Spool Section 3 37 34, 36 1 30, 32 5 40, 41 1- Load Check Valve (Left Travel Parallel Circuit) 2 - Check Valve (Main Relief Circuit) 3 - Main Relief Valve 4- Check Valve (Auxiliary Combining Valve Circuit) 5 - Auxiliary Flow Combiner Valve 6 - Check Valve (Flow Combiner Valve Circuit) 7 - Flow Combiner Valve 8- Load Check Valve (Orifice) (Bucket) 9 - Check Valve (Main Relief Circuit) 10 - Bucket Flow Rate Control Valve (Poppet Valve) 11 - Bucket Flow Rate Cont
TROUBLESHOOTING / Component Layout Machine Lower 1 2 3 Machine Lower Machine Upper Machine Upper 4 5 6 7 8 9 10 11 12 42 13 14 41 15 40 16 39 17 38 18 19 20 37 36 35 21 34 22 23 33 24 32 31 30 29 28 27 26 25 T1V1-03-03-021 T5-5-16
TROUBLESHOOTING / Component Layout 3 A B Cross Section C-C C C D D E E F F G G H H I I J J 4 5 7 A Cross Section B-B Cross Section A-A 3 T1V1-03-03-003 T1V1-03-03-026 B 2 12 28 9 21 27 29 T1V1-03-03-002 T1V1-03-03-001 1- Load Check Valve (Left Travel Parallel Circuit) 2 - Check Valve (Main Relief Circuit) 3 - Main Relief Valve 4- Check Valve (Auxiliary Combining Valve Circuit) 5 - Auxiliary Flow Combiner Valve 6 - Check Valve (Flow Combiner Valve Circuit) 7 - Flow Combiner
TROUBLESHOOTING / Component Layout Machine Lower 1 2 3 Machine Lower Machine Upper Machine Upper 4 5 6 7 8 9 10 11 12 42 13 14 41 15 40 16 39 17 38 18 19 20 37 36 35 21 34 22 23 33 24 32 31 30 29 28 27 26 25 T1V1-03-03-021 T5-5-18
TROUBLESHOOTING / Component Layout Cross Section D-D Cross Section E-E Travel (left) Travel (right) Auxiliary Bucket 13 10 41 11 14 40 12 T1V1-03-03-004 1- Load Check Valve (Left Travel Parallel Circuit) 2 - Check Valve (Main Relief Circuit) 3 - Main Relief Valve 4- Check Valve (Auxiliary Combining Valve Circuit) 5 - Auxiliary Flow Combiner Valve 6 - Check Valve (Flow Combiner Valve Circuit) 7 - Flow Combiner Valve 8- Load Check Valve (Orifice) (Bucket) 9 - Check Valve (Main Relief Circuit) 10
TROUBLESHOOTING / Component Layout Machine Lower 1 Machine Upper 2 3 Machine Lower Machine Upper 4 5 6 7 8 9 10 11 12 42 13 14 41 15 40 16 39 17 38 18 19 20 37 36 35 21 34 22 23 33 24 32 31 30 29 28 27 26 25 T1V1-03-03-021 T5-5-20
TROUBLESHOOTING / Component Layout Cross Section F-F Cross Section G-G Boom 2 Boom 1 22 37 19 39 16 17 15 38 21 28 20 T1V1-03-03-006 1- Load Check Valve (Left Travel Parallel Circuit) 2 - Check Valve (Main Relief Circuit) 3 - Main Relief Valve 4- Check Valve (Auxiliary Combining Valve Circuit) 5 - Auxiliary Flow Combiner Valve 6 - Check Valve (Flow Combiner Valve Circuit) 7 - Flow Combiner Valve 8- Load Check Valve (Orifice) (Bucket) 9 - Check Valve (Main Relief Circuit) 10 - Bucket Flow Rat
TROUBLESHOOTING / Component Layout Machine Lower 1 Machine Upper 2 3 Machine Lower Machine Upper 4 5 6 7 8 9 10 11 12 42 13 14 41 15 40 16 39 17 38 18 19 20 37 36 35 21 34 22 23 33 24 32 31 30 29 28 27 26 25 T1V1-03-03-021 T5-5-22
TROUBLESHOOTING / Component Layout Cross Section I-I Cross Section H-H Arm 1 34 Swing Arm 2 18 27 36 32 30 35 1- Load Check Valve (Left Travel Parallel Circuit) 2 - Check Valve (Main Relief Circuit) 3 - Main Relief Valve 4- Check Valve (Auxiliary Combining Valve Circuit) 5 - Auxiliary Flow Combiner Valve 6 - Check Valve (Flow Combiner Valve Circuit) 7 - Flow Combiner Valve 8- Load Check Valve (Orifice) (Bucket) 9 - Check Valve (Main Relief Circuit) 10 - Bucket Flow Rate Control Valve (Poppet Va
TROUBLESHOOTING / Component Layout Machine Upper Machine Lower 1 2 3 4 Machine Lower Machine Upper 5 6 7 8 9 10 11 12 42 13 14 41 15 40 16 39 17 38 18 19 20 37 36 35 21 34 22 23 33 24 32 31 30 29 28 27 26 25 T1V1-03-03-021 T5-5-24
TROUBLESHOOTING / Component Layout Cross Section J-J 25 K K L L M M T1V1-03-03-010 T1V1-03-03-027 Cross Section K-K Cross Section L-L 8 6 N N Cross Section N-N Cross Section M-M 42 Bo T1V1-03-03-028 T1V1-03-03-022 1 - Load Check Valve (Left Travel Parallel Circuit) 2 - Check Valve (Main Relief Circuit) 3 - Main Relief Valve 4 - Check Valve (Auxiliary Combining Valve Circuit) 5 - Auxiliary Flow Combiner Valve 6 - Check Valve (Flow Combiner Valve Circuit) 7 - Flow Combiner Valve 8 - Load Check
TROUBLESHOOTING / Component Layout Layout of Positioning Control Valve (2-Piece Boom) 1 2 4 3 T1V1-03-03-019 T5-5-26
TROUBLESHOOTING / Component Layout Cross Section X-X X 2 1 4 3 T178-03-03-070 X 1- Load Check Valve (Positioning Tandem Circuit) T198-03-03-003 2- Overload Relief Valve (Positioning: Rod Side) 3- T5-5-27 Overload Relief Valve (Positioning: Bottom Side) 4- Load Check Valve (Positioning Parallel Circuit)
TROUBLESHOOTING / Component Layout PILOT PORT (Signal Control Valve) Pilot Valve 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 T5-5-28
TROUBLESHOOTING / Component Layout Pilot Valve Side Port Name Port A Port B Port C Port D Port E Port F Port G Port H Port I Port J Port K Port L Port M Port N Port SA Port SB Port PI Port PH Port SH Port DF Connecting to Right Pilot Valve Right Pilot Valve Left Pilot Valve Left Pilot Valve Left Pilot Valve Left Pilot Valve Right Pilot Valve Right Pilot Valve Travel Pilot Valve Travel Pilot Valve Travel Pilot Valve Travel Pilot Valve Auxiliary Pilot Valve Auxiliary Pilot Valve Pump 1 Regulator Pump 2 Regul
TROUBLESHOOTING / Component Layout Control Valve Side SM 3 5 1 13 2 4 SK SE 8 Pressure Sensor (Swing) 14 Control Valve Side 7 9 6 10 SN SL 11 Pressure Sensor (Travel) 12 T5-5-30 SP T178-03-06-015
TROUBLESHOOTING / Component Layout Control Valve Side Port Name Port 1 Port 2 Port 3 Port 4 Port 5 Port 6 Port 7 Port 8 Port 9 Port 10 Port 11 Port 12 Port 13 Port 14 Port SE Port SM Port SN Port SP Port SL Port SK Connecting to Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Hydraulic Oil Tank Hydraulic Oil Tank Control Valve Control Valve Remar
TROUBLESHOOTING / Component Layout (Blank) T5-5-32
TROUBLESHOOTING / Troubleshooting A TROUBLESHOOTING A PROCEDURE Refer to troubleshooting A procedure in case any fault codes are displayed after diagnosing by using Dr. ZX or the service menu of monitor unit. • 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).
TROUBLESHOOTING / Troubleshooting A FAULT CODE LIST MC Controller Hardware Failure Fault Trouble Code 11000-2 Abnormal EEPROM 11001-2 Abnormal RAM 11002-2 Abnormal A/D Conversion 11003-3 Abnormal Sensor Voltage 11004-2 Abnormal CAN Communication Cause Influenced Control Faulty MC Faulty MC Faulty MC Faulty MC All Control All Control All Control All Control Faulty MC • Heater Control • Speed Sensing Control • Attachment Operation Speed Increase Control • Attachment Operation Speed Limit Control • Att
TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Occurs. Although the engine control dial is operated, engine speed does not change. • Machine movement is slow. • The work mode alarm is displayed on the monitor unit. Remedy for Dr.
TROUBLESHOOTING / Troubleshooting A Engine Failure Fault Trouble Code 11100-2 Abnormal Engine Speed Cause Engine Speed: Less than 4000 -1 min Influenced Control Speed Sensing Control 11101-3 Abnormal Engine Control Dial Voltage: 4.78 V or higher Sensor High Voltage Engine Control Dial Control 11101-4 Abnormal Engine Control Dial Voltage: Less than 0.
TROUBLESHOOTING / Troubleshooting A Symptoms in Machine OperaRemedy for Dr. ZX tion When Trouble Occurs. Machine movement is slow. Retrial B (During speed sensing, torque is reduced.) • Trouble condition with the Retrial B key ON: Engine speed is kept at idle speed. • Trouble condition with the key ON: engine speed is kept at speed immediately before trouble. • Trouble condition with the Retrial B key ON: Engine speed is kept at idle speed.
TROUBLESHOOTING / Troubleshooting A Pump Failure Fault Trouble Cause Code 11200-3 Abnormal Pump 1 Delivery Voltage: 4.
TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Remedy for Dr. ZX Trouble Occurs. • Combined operation of arm roll-in and Retrial B boom raise or combined operation of arm-roll-in and swing: Arm speed is slow. • Single operation of boom raise: Lifting force is weak. • Travel: Slow speed Remark • Check Harness • Replace Pump 1 Delivery Pressure Sensor • Combined operation of arm roll-in and Retrial B boom raise or combined operation of arm-roll-in and swing: Arm speed is slow.
TROUBLESHOOTING / Troubleshooting A Pilot Failure Fault Trouble Cause Code 11301-3 Abnormal Swing Pilot Pressure Voltage: 4.75 V or higher Sensor High Voltage Influenced Control • Arm Regenerative Control • Attachment Flow Rate Control • Swing Alarm Control 11301-4 Abnormal Swing Pilot Pressure Voltage: Less than 0.25 V Sensor Low Voltage • Arm Regenerative Control • Attachment Flow Rate Control • Swing Alarm Control 11302-3 Abnormal Boom Raise Pilot Pressure Sensor High Voltage Voltage: 4.
TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Occurs. • Combined operation of arm-roll-in and swing: Arm speed is slow. • In case of the machine equipped with the swing alarm (optional) and when swing alarm is effective, swing alarm continues to ring. • Combined operation of arm-roll-in and swing: Arm speed is slow. • In case of the machine equipped with the swing alarm (optional) and when swing alarm is effective, swing alarm continues to ring.
TROUBLESHOOTING / Troubleshooting A Fault Code 11304-3 Trouble Cause Influenced Control Abnormal Travel Pilot Pressure Voltage: 4.
TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Remedy for Dr. ZX Trouble Occurs. • When traveling at idle speed, engine Retrial B speed does not increase to the specification. • When traveling, speed does not return from auto idle speed. • When traveling, speed does not return from ECO speed. • Travel: Slow speed • When operating ATT, the machine mistracks. • In case of the machine equipped with the travel alarm (optional), travel alarm continues to ring.
TROUBLESHOOTING / Troubleshooting A Proportional Solenoid Valve Failure Fault Trouble Code 11400-2 Abnormal Current Feedback of Maximum Pump 2 Flow Rate Limit Control Solenoid Valve 11400-3 Abnormal Feedback High Current of Maximum Pump 2 Flow Rate Limit Control Solenoid Valve 11400-4 11401-2 11401-3 11401-4 11402-2 11402-3 11402-4 11403-2 11403-3 Cause Influenced Control Current: Both of Higher Pump 2 Flow Rate Limit Control than 920mA or Less than 60 mA Current: Higher than Pump 2 Flow Rate Li
TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Occurs. Remedy for Dr. ZX Retrial B • Check Harness Actual Operation of Proportional Valve during High Current: • Travel mistakes. • Boom raise operation is slow. • Arm operation is slow. • Swing operation is slow. Actual Operation of Proportional Valve during Low Current: • In case ATT flow rate is limited, it cannot be limited. Retrial B • Check Harness Retrial B • Check Harness Machine overall operation is slow.
TROUBLESHOOTING / Troubleshooting A Fault Code 11405-2 11405-3 11405-4 11410-2 11410-3 11410-4 Trouble Cause Influenced Control Abnormal Current Feedback of Solenoid Valve Unit (SI) (Travel Motor Fast Speed Selection) Abnormal Feedback High Current of Solenoid Valve Unit (SI) (Travel Motor Fast Speed Selection) Abnormal Feedback Low Current of Solenoid Valve Unit (SI) (Travel Motor Fast Speed Selection) Abnormal Current Feedback of Maximum Pump 1 Flow Rate Limit Control Solenoid Valve (Optional) Ab
TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Occurs. Remedy for Dr. ZX Retrial B • Check Harness Operation of Proportional Valve during High Current: • Travel motor is always slow. Retrial B • Check Harness Operation of Proportional Valve during Low Current: • Travel motor is always slow. Retrial B • Check Harness In case ATT flow rate is limited, it cannot be limited.
TROUBLESHOOTING / Troubleshooting A CAN Data Reception Failure Fault Trouble Code 11910-2 Actual Engine Speed Received from ECM Cause Influenced Control Faulty Harness • Speed Sensing Control • Send to ICF • Attachment Operation Speed Increase Control • Attachment Operation Speed Limit Control • Attachment Pump Torque Decrease Control • Pump 1 Flow Rate Limit Control • Pump 2 Flow Rate Limit Control • Attachment Flow Rate Control • Attachment Valve Selection (Optional) Theft Prevention Engine Speed, Eng
TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Occurs. Remedy for Dr. ZX Retrial B Machine operation speed is slow. (During speed sensing, torque is decreased.) During e-service, the engine is stalled. Retrial B • Digging Mode: Lock In case flow rate is decreased and speed decreases during ATT, stop this control, or Digging is not changed into ATT mode. • Work Mode Alarm is displayed on the monitor unit.
TROUBLESHOOTING / Troubleshooting A Other Failures Fault Trouble Code 11901-3 Hydraulic Oil Temperature Sensor High Voltage Cause Voltage: 4.52 V or higher 11901-4 Hydraulic Oil Temperature Sensor Low Voltage Voltage: Less than 0.23 V 11905-3 Abnormal Boom Bottom Pres- Voltage: 4.5 V or higher sure Sensor High Voltage (Optional) 11905-4 Abnormal Boom Bottom Pres- Voltage: Less than 0.
TROUBLESHOOTING / Troubleshooting A Symptoms in Machine Operation When Trouble Occurs. Remedy for Dr. ZX Retrial B • Check Harness When temperature is low (hydraulic oil temperature is less than 0 °C), the auto-warming up control is inoperable. Retrial B • Check Harness When overload alarm is used. • Overload alarm buzzer rings. • The overload alarm is displayed on the monitor unit.
TROUBLESHOOTING / Troubleshooting A ECM Sensor System Fault Trouble Code 636-2 Abnormal Cam Angle Sensor (No Signal) 636-2 723-2 723-2 636-7 172-3 172-4 110-3 110-4 Abnormal Cam Angle Sensor (Abnormal Signal) Abnormal Crank Speed Sensor (No Signal) Abnormal Crank Speed Sensor (Abnormal Signal) Phase Mismatch of Cam Angle Sensor Abnormal Intake-Air Temperature (Abnormal High Voltage) Abnormal Intake-Air Temperature (Abnormal Low Voltage) Abnormal Coolant Temperature (Abnormal High Voltage) Abnormal Coolan
TROUBLESHOOTING / Troubleshooting A Presumptive Symptoms in Real Machine Operation • While the engine runs, there is nothing abnormal with machine operation. • After the engine is stalled, the re-start is impossible. • The output power may decrease, white smoke may occur and vibration may occur. • The engine may be stalled. (If the cam senor is normal, the engine can re-start.) • While the engine runs, there is nothing abnormal with machine operation.
TROUBLESHOOTING / Troubleshooting A Fault Code 157-3 157-3 100-4 100-3 105-3 105-4 Trouble Abnormal Common Rail Pressure (Abnormal High Voltage) Abnormal Common Rail Pressure (Abnormal Low Voltage) Abnormal Engine Oil Pressure (Abnormal High Voltage) Abnormal Engine Oil Pressure (Abnormal Low Voltage) Abnormal Boost Temperature (Abnormal High Voltage) Cause Sensor Sensor Sensor Sensor Sensor Abnormal Boost Temperature Sensor (Abnormal Low Voltage) Voltage at the common rail pressure sensor is beyond 4
TROUBLESHOOTING / Troubleshooting A Presumptive Symptoms in Real Machine Operation The engine may be stalled. The output power decreases. Assumptive Conditions at Backup The supply pump can not be controlled. Fault Code (Tech 2) P0193 P0192 There is no influence when operating the ma- Nothing special chine. P0523 P0522 There is no influence when operating the ma- Nothing special chine.
TROUBLESHOOTING/ Troubleshooting A Fault Code 636-2 636-2 723-2 723-2 636-7 172-3 172-4 110-3 110-4 102-4 102-3 10001-3 108-4 108-3 174-3 174-4 157-3 157-4 100-4 100-3 Influence to Engine Performance (Presumption) Abnormal Cam Angle Sensor (No No influence during operationg Signal) Abnormal Cam Angle Sensor After stopping, the re-start is impossible.
TROUBLESHOOTING/ Troubleshooting A Fault Code 105-3 105-4 Influence to Engine Operating Rank Performance (Current State) (Presumption) output power Abnormal Boost Temperature Sensor No ○ change (Abnormal High Voltage) Abnormal Boost Temperature Sensor ○ (Abnormal Low Voltage) Trouble Operating Rank A: Diggings operable. B: Machine can travel with boom raised. (Steering is impossible.) C: The engine only runs. (Travel, digging and operation with light load are impossible.
TROUBLESHOOTING/ Troubleshooting A External Device System Fault Code Trouble Cause 10002-2 Abnormal EGR valve control Difference between the target valve lift and actual position isbeyond 20%. 1347-0 Open circuit in suction control valve The suctioncontrol valve drive current is beyond 2400 mA or drive system, Shorted circuit in + B or below 50 mA. Or, difference between the tartget current and GND actual current is 1000 mA or more.
TROUBLESHOOTING/ Troubleshooting A Presumptive Symptoms in Real Machine Operation Assumptive Conditions at Backup Fault Code (Tech 2) There is influence to exhaust gas. EGR cannot be controlled. As exhaust gas becomes bad, EGR stops. P0488 The engine may be stalled and the rotation speed increases automatically and abnormally according to open or shorted circuitc ondition. Dark smoke occurs. Output power is too large. The supply pump cannot be controlled.
TROUBLESHOOTING/ Troubleshooting A Fuel System Fault Code Trouble Cause 157-0 Abnormal common (First stage) rail pressure Common rail pressure is beyond 185 Mpa. 157-0 Abnormal commo rail pressure (Second stage) The first stage “Abnormal common rail presure” approveand commonrail pressure is beyond 190 Mpa.
TROUBLESHOOTING/ Troubleshooting A Presumptive Symptoms in Real Machine Operation Assumptive Conditions at Backup Fault Code (Tech 2) Vibration of the engine may be large, Rough idle, Prevention the junection system (pump) from output power decrease may occur, faulty damage increasing of rotation speed, dark smoke may (Protect the RP sensor by over-pressure) occur, output power may be too large.
TROUBLESHOOTING/ Troubleshooting A Fault Code Influence to Engine Performance (Presumption) Trouble Operating Rank (Current) A B C Remark D 10002-2 Abnormal EGR valve control 1347-0 651-3 652-3 653-3 654-3 655-3 656-3 Fault Code 157-0 157-0 157-2 633-7 1240-1 1239-1 No output power ○ change Open circuit in suction control valve Output power drive system, Shorted circuit in + B or decrease: 50% ○ GND power Open circuit in injection nozzle ＃ 1 Output ○ decrease: 15% drive system Open circuit in in
TROUBLESHOOTING/ Troubleshooting A (Blank) T5-6-31
TROUBLESHOOTING/ Troubleshooting A Fault Code Trouble Cause 110-0 Overheating Coolant temperature is beyond 120 °C (248 °F) when operating the engine. 190-0 Overrunning In case the engine speed is beyond 2500 min Fault Code Trouble -1 Cause 987-3 Abnormal check engine lamp No monitor signal of the check engine lamp 1485-2 Abnormal main relay system Voltage in the main relay system is 1 V or less with the main relay coil output ON.
TROUBLESHOOTING/ Troubleshooting A Presumptive Symptoms in Real Machine Operation Assumptive Conditions at Backup Fault Code (Tech 2) There is no influence when operating the Nothing special (The history of overheating is machine. recorded.) P1173 Engine speed of the excavator may not increase Mistake of gear change, etc. -1 2500 min or more. P0219 Presumptive Symptoms in Real Machine Operation Assumptive Conditions at Backup There is no influence when operating the Nothing special machine.
TROUBLESHOOTING/ Troubleshooting A Fault Code Trouble 110-0 Overheating 190-0 Overrunning Fault Code 987-3 Influence to Engine Performance (Presumption) No output change No output change Trouble Abnormal check engine lamp 1485-2 Abnormal main relay system power power Influence to Engine Performance (Presumption) No output power change The engine stops. Nothing (The engine cannot re-start according to battery voltage.) Operating Rank A: Diggings operable. B: Machine can travel with boom raised.
TROUBLESHOOTING/ Troubleshooting A (Blank) T5-6-35
TROUBLESHOOTING/ Troubleshooting A Internal Circuit System Fault Code Trouble Cause 10005-1 Abnormal Charge Circuit (Bank 1) In case volate at bank 1 of charge circuit in ECM is low 10006-1 Abnormal Charge Circuit (Bank 2) In case volate at bank 2 of charge circuit in ECM is low 10008-2 Abnormal A/D Conversion A/D conversion cannot be done. 10007-2 Abnormal CPU Within 100 msec after the key switch is turned ON, failure of main CPU is detected by sub CPU. (Sub CPU resets CPU.
TROUBLESHOOTING/ Troubleshooting A Presumptive Symptoms in Real Machine Operation Assumptive Conditions at Backup Vibration of the engine may be large, Rough idle, output power decrease may occur, faulty increasing of rotation speed may occur, the engine may be stalled. The injector cannot be controlled. → Stop output of drive signal at broken common side (Protect the engine from damage) P0612 Output power decrease, dark smoke occur. All analogue sensor cannot be used.
TROUBLESHOOTING/ Troubleshooting A Fault Code Trouble 10005-1 10006-1 Abnormal Charge Circuit Abnormal Charge Circuit 10008-2 Abnormal A/D Conversion 10007-2 Abnormal CPU (Bank 1) (Bank 2) 1077-2 Abnormal IC for CPU watching 628-2 10013-2 Abnormal ROM Abnormal EEPROM 1079-2 1080-2 Abnormal 5 V Power Source 1 Voltage Abnormal 5 V Power Source 2 Voltage 10009-2 Abnormal 5 V Power Source 3 Voltage 10010-2 Abnormal 5 V Power Source 4 Voltage 10011-2 Abnormal 5 V Power Source 5 Voltage 1000
TROUBLESHOOTING/ Troubleshooting A (Blank) T5-6-39
TROUBLESHOOTING/ Troubleshooting A Communication System Fault Code Trouble Cause 639-2 Abnormal CAN Bus Line Detect the bus line off.
TROUBLESHOOTING/ Troubleshooting A Presumptive Symptoms in Real Machine Operation Speed is turnd into idle speed. Assumptive Conditions at Backup CAN communication is operable.
TROUBLESHOOTING/ Troubleshooting A Fault Code Trouble 639-2 639-3 Abnormal CAN Bus Line Abnormal CAN Time Out Influence to Engine Performance (Presumption) Idle speed T5-6-42 Operating Rank (Current) A B C D ○ ○ Remark
TROUBLESHOOTING/ Troubleshooting A (Blank) T5-6-43
TROUBLESHOOTING/ Troubleshooting A ICF Fault Code Trouble Cause 14000-2 Abnormal CAN Communication Data cannot be received due to the noise on the CAN bus line.
TROUBLESHOOTING/ Troubleshooting A Fault Code Remedy 14000-2 Check for CAN communication bus line. 14001-2 After initializng the information C/U by using Dr. ZX, re-try in the troubleshooting. If the error code is displayed after re-try, ICF may be broken. Replace ICF. NOTE: When initialising the information C/U, all stored data is deleted. 14002-2 After initializng the information C/U by using Dr. ZX, re-try in the troubleshooting. If the error code is displayed after re-try, ICF may be broken.
TROUBLESHOOTING/ Troubleshooting A Satellite Terminal Fault Code Trouble Cause 14100-2 Satellite Communication Terminal: Data cannot be received due to the noise on the CAN bus Abnormal EEPROM line.
TROUBLESHOOTING/ Troubleshooting A Fault Code Remedy 14100-2 Replace the controller. 14101-2 Replace the controller. 14102-2 Replace the controller. 14103-2 Replace the controller. 14104-2 Replace the controller. 14105-2 Replace the controller. 14106-2 Replace the controller.
TROUBLESHOOTING/ Troubleshooting A Monitor Unit Fault Code Trouble Cause 13303-2 13304-2 13305-2 13306-2 13308-2 13310-2 Abnormal Thermister Temperature Abnormal REG Input H Level Abnormal Manual Glow EXT Output Abnormal EEPROM Abnormal CAN Communication Shorted circuit in Coolant Temperature Sensor Shorted circuit in Fuel Leverl Sensor Open circuit in Fuel Leverl Sensor Thermister temperature is 85 °C (185 °F) or higher.
TROUBLESHOOTING / Troubleshooting A Fault Code Remedy 13303-2 Cool the monitor unit and so on until temperature inside the monitor unit is less than 85 °C (185 °F). 13304-2 (Refer to the Troubleshooting flow chart.) 13306-2 If this fault code is displayed after retarial, replace the monitor unit. 13308-2 Refer to “Check CAN Harness” on page T5-6-52. 13310-3 Check coolant temperature sensor and harness. 13311-3 Check fuel level sensor and harness. 13311-4 Check fuel level sensor and harness.
TROUBLESHOOTING / Troubleshooting A CONTROLLER HARDWARE FAILURE MC FAULT CODE 11000 to 11002 Fault Code 11000-2 11001-2 11002-2 Trouble Abnormal EEPROM Abnormal RAM Abnormal A/D Conversion Cause Faulty MC Faulty MC Faulty MC YES Influenced Control All Control All Control All Control *Faulty MC Check if operation of engine and machine is normal. Faulty MC NO * When the fault code is displayed in the result of retrial and If operation of engine and machine is normal, the machine can be used.
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11003 Fault Code 11003-3 Trouble Abnormal Sensor Voltage Cause Influenced Control All Control Faulty MC YES Disconnect connectors of all sensors corresponding to the displayed fault code and retry. Check if fault code 11003-3 disappears. NO Faulty sensor Disconnect all connectors at MC end. Check for continuity between terminals #1 and #3 of harness end connector of each sensor.
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11004 Fault Code 11004-2 Trouble Cause Abnormal CAN Faulty MC Communication • • • • • • • • • • Influenced Control Heater Control Speed Sensing Control Attachment Operation Speed Increase Control Attachment Operation Speed Limit Control Attachment Pump Torque Decrease Control Pump 1 Flow Rate Limit Control Pump 2 Flow Rate Limit Control Attachment Flow Rate Control (Optional) Attachment Valve Selection (Optional) CAN Cycle Data Communication Dr.
TROUBLESHOOTING / Troubleshooting A (Blank) T5-6-53
TROUBLESHOOTING / Troubleshooting A CAN HARNESS CHECK • Check the wiring connections first. NO Check for continuity in YES CAN harness between MC and ECM. · Key switch: OFF · Refer to “CAN Harness Continuity Check” on T5-6-58. Check for continuity in YES CAN harness between MC and ICF. · Key switch: OFF · Refer to “CAN Harness Continuity Check” on T5-6-58. Retry by using Dr. ZX. Check if fault code 11004-2 is displayed. NO Open circuit in CAN harness between MC and ECM.
TROUBLESHOOTING / Troubleshooting A Disconnect all connectors in MC, ICF, ECM and monitor unit. YES Check for continuity between CAN circuit and ground circuit in MC, ICF, ECM and monitor unit. Short-circuited CAN harness between ground circuit and CAN circuit YES · Key switch: OFF NO · Refer to “Discontinuity Check between CAN Circuit and Ground Circuit” on T5-6-61 to 64.
TROUBLESHOOTING / Troubleshooting A Short-circuited CAN harness. YES A Connect connector YES in MC. Check if fault code 11004-2 is displayed. Connect all connectors except connector MC-C in MC. Check if resistance between terminals #C4 and #C15 of NO harness end of connector MC-C is within 60±10 Ω. · Key switch: ON · Key switch: OFF NO Connect connector in MC. Disconnect connector ICF-C in ICF. Check if resistance between terminals #C5 and #C11 of harness end of connector is within 60±10 Ω.
TROUBLESHOOTING / Troubleshooting A Adjust the connection of ECM and connector. NO Faulty ECM. YES YES Connect connector in monitor unit. Check if fault code 11004-2 is displayed. · Key switch: ON NO Check the connection of monitor unit and connector. Faulty monitor unit. YES Failure in any controller of MC, ICF, ECM and monitor unit.
TROUBLESHOOTING / Troubleshooting A Continuity Check in CAN Harness IMPORTANT: Before continuity check, turn the key switch OFF. • Between MC and ECM CAN Harness (High Side) Check for continuity between terminal #C4 of harness end of connector MC-C in MC and terminal #18 of harness end of connetor in ECM. CAN Harness (Low Side) Check for continuity between terminal #C15 of harness end of connector MC-C in MC and terminal #37 of harness end of connetor in ECM.
TROUBLESHOOTING / Troubleshooting A • Between MC and ICF CAN Harness (High Side) Check for continuity between terminal #C4 of harness end of connector MC-C in MC and terminal #C5 of harness end of connetor ICF-C in ICF. CAN Harness (Low Side) Check for continuity between terminal #C15 of harness end of connector MC-C in MC and terminal #C11 of harness end of connetor ICF-C in ICF.
TROUBLESHOOTING / Troubleshooting A • Between MC and Monitor Unit CAN Harness (High Side) Check for continuity between terminal #C4 of harness end of connector MC-C in MC and terminal #B7 of harness end of connetor monitor-B in the monitor unit. CAN Harness (Low Side) Check for continuity between terminal #C15 of harness end of connector MC-C in MC and terminal #B6 of harness end of connetor monitor-B in the monitor unit.
TROUBLESHOOTING / Troubleshooting A Discontinuity Check between CAN Circuit and Ground Circuit IMPORTANT: Before continuity check, turn the key switch OFF. • In case of continuity, the circuit between CAN circuit and ground circuit is shorted. • In case of discontinuity, the circuit is normal.
TROUBLESHOOTING / Troubleshooting A Between CAN Circuit (Low Side) and Ground Circuit Check for continuity between terminal #C5 of harness end of connector MC-C and terminal #A2 of harness end of connetor in MC-A. Connector Check for continuity between terminal #C15 of harness end of connector MC-C and terminal #A13 of harness end of connetor in MC-A. Check for continuity between terminal #C15 of harness end of connector MC-C and terminal #B8 of harness end of connetor in MC-B.
TROUBLESHOOTING / Troubleshooting A • ECM Between CAN Circuit (High Side) and Ground Circuit Check for continuity between terminals #18 and #1 of harness end of connector. ECM Connector (Harness end) #18 #43 Check for continuity between terminals #18 and #3 of harness end of connector. #4 #3 Check for continuity between terminals #18 and #4 of harness end of connector. #62 Check for continuity between terminals #18 and #43 of harness end of connector.
TROUBLESHOOTING / Troubleshooting A • ICF Between CAN Circuit (High Side) and Ground Circuit Check for continuity between terminals #C5 and #C14 of harness end of connector ICF-C. ICF Connector ICF-C (Harness end) #C5 Check for continuity between terminals #C5 and #C15 of harness end of connector ICF-C. #C14 Between CAN Circuit (Low Side) and Ground Circuit Check for continuity between terminals #C11 and #C14 of harness end of connector ICF-C.
TROUBLESHOOTING / Troubleshooting A Discontinuity Check between CAN Circuit and Power Circuit Connector IMPORTANT: Before continuity check, turn the key switch OFF. • In case of continuity, the circuit between CAN circuit and power circuit is shorted. • In case of discontinuity, the circuit is normal.
TROUBLESHOOTING / Troubleshooting A Between CAN Circuit (Low Side) and Power Circuit Check for continuity between terminal #C15 of harness end of connector MC-C and terminal #A2 of harness end connector MC-A. Connector Connector MC-C (Harness end) Check for continuity between terminal #C15 of harness end of connector MC-C and terminal #A12 of harness end connector MC-A. C1 Check for continuity between terminal #C15 of harness end of connector MC-C and terminal #B7 of harness end connector MC-B.
TROUBLESHOOTING / Troubleshooting A • ECM Between CAN Circuit (High Side) and Power Circuit Check for continuity between terminals #18 and #2 of harness end of connector. ECM Connector (Harness end) #18 #5 Check for continuity between terminals #18 and #5 of harness end of connector. #2 Between CAN Circuit (Low Side) and Power Circuit Check for continuity between terminals #37 and #2 of harness end of connector.
TROUBLESHOOTING / Troubleshooting A • Monitor Unit Between CAN Circuit (High Side) and Power Circuit Check for continuity between terminal #B7 of harness endo of connector in the monitor unit and terminal #A16 of harness endo of connector monitor-A in the monitor unit.
TROUBLESHOOTING / Troubleshooting A Discontinuity Check between CAN Circuit and Key Signal Circuit Connector IMPORTANT: Before continuity check, turn the key switch OFF. • In case of continuity, the circuit between CAN circuit and key signal circuit is shorted. • In case of discontinuity, the circuit is normal.
TROUBLESHOOTING / Troubleshooting A • ECM Between CAN Circuit (High Side) and Key Signal Circuit Check for continuity between terminals #18 and #24 of harness end of connector. ECM Connector (Harness end) #18 #24 T1GR-05-04-002 Between CAN Circuit (Low Side) and Key Signal Circuit Check for continuity between terminals #37 and #24 of harness end of connector.
TROUBLESHOOTING / Troubleshooting A • Monitor Unit Between CAN Circuit (High Side) and Power Circuit Check for continuity between terminal #B7 of harness end of connector in the monitor unit and terminal #A7 of harness end of connector monitor-A in the monitor unit.
TROUBLESHOOTING / Troubleshooting A Discontinuity Check in CAN Harness IMPORTANT: Before continuity check, turn the key switch OFF. • In case of continuity, the circuit between CAN (high side) circuit and CAN (low side) circuit is shorted. • In case of discontinuity, the circuit is normal. • Connector MC-C Check for continuity between terminals #C4 and #C15 of harness end of connector MC-C in MC.
TROUBLESHOOTING / Troubleshooting A • Connector ICF-C Check for continuity between terminals #C5 and #C11 of harness end of connector ICF-C in ICF. ICF Connector ICF-C (Harness end) #C5 #C11 • Connector Monitor-B in Monitor Unit Check forcontinuity between terminals #B6 and #B7 of harness end of connector monitor-B in the monitor unit.
TROUBLESHOOTING / Troubleshooting A ENGINE FAILURE MC FAULT CODE 11100 Fault Code Trouble 11100-2 Abnormal Engine Speed Cause -1 Engine Speed: 4000 min or faster • ECM sends by using CAN bus line. The actual engine speed is abnormal. Perform self-diagnosis of ECM.
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11101 Fault Code Trouble Cause 11101-3 Abnormal Engine Control Dial Voltage: 4.78 V or higher Sensor High Voltage 11101-4 Abnormal Engine Control Dial Voltage: Less than 0.22 V Sensor Low Voltage Disconnect connector of switch panel. Check if voltage between terminals #2 YES and #4 of harness end of connector is 5±0.5 V. Disconnect connector of switch panel. Check fi resistance between terminals #2 and #4 of switch panel end of connector is 5±0.5 kΩ.
TROUBLESHOOTING / Troubleshooting A PUMP FAILURE MC FAULT CODE 11200 Fault Code 11200-3 Trouble Cause Abnormal Pump 1 Delivery Voltage: 4.5 V or higher Pressure Sensor High Voltage Influenced Control • HP Mode Control • Travel HP Mode Control • E Mode Control • Travel Torque-Up Control • Arm Regenerative Control • Digging Regenerative Control • Auto-Power Lift Control • Travel Motor Swash Angle Selection Control 11200-4 Abnormal Pump 1 Delivery Voltage: Less than 0.
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11202 Fault Code 11202-3 Trouble Cause Abnormal Pump 2 Delivery Voltage: 4.5 V or higher Pressure Sensor High Voltage Influenced Control • HP Mode Control • Travel HP Mode Control • E Mode Control • Travel Torque-Up Control • Arm Regenerative Control • Digging Regenerative Control • Travel Motor Swash Angle Selection Control 11202-4 Abnormal Pump 2 Delivery Voltage: Less than 0.
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11206 Fault Code 11206-3 Trouble Cause Abnoraml Pump 1 Control Voltage: 4.75 V or higher Pressure Sensor High Voltage 11206-4 Abnormal Pump 1 Control Voltage: Less than 0.
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11208 Fault Code 11208-3 Trouble Cause Abnormal Pump 2 Control Voltage: 4.75 V or higher Pressure Sensor High Voltage 11208-4 Abnormal Pump 2 Control Voltage: Less than 0.
TROUBLESHOOTING / Troubleshooting A PILOT FAILURE MC FAULT CODE 11301 Fault Code 11301-3 Trouble Cause Abnormal Swing Pilot Voltage: 4.75 V or higher Pressure Sensor High Voltage 11301-4 Abnormal Swing Pilot Voltage: Less than 0.25 V Pressure Sensor Low Voltage Check if harnes YES between terminal #C13 of harness end of connector MC-C in MC and terminal #2 in pressure sensor is open or shorted. Disconnect connector of pressure sensor.
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11302 Fault Code 11302-3 Trouble Cause Abnormal Boom Raise Voltage: 4.75 V or higher Pilot Pressure Sensor High Voltage 11302-4 Abnormal Boom Raise Voltage: Less than 0.25 V Pilot Pressure Sensor Low Voltage Check if harnes between terminal #D15 of harness end of YES connector MC-D in MC and terminal #2 in pressure sensor is open or shorted. Disconnect connector of pressure sensor.
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11303 Fault Code 11303-3 Trouble Cause Abnormal Arm Roll-In Voltage: 4.75 V or higher Pilot Pressure Sensor High Voltage 11303-4 Abnormal Arm Roll-In Voltage: Less than 0.25 V Pilot Pressure Sensor Low Voltage Check if harnes between terminal #C3 YES of harness end of connector MC-C in MC and terminal #2 in pressure sensor is open or shorted. Disconnect connector of pressure sensor.
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11304 Fault Code 11304-3 Trouble Cause Abnormal Travel Pilot Voltage: 4.75 V or higher Pressure Sensor High Voltage Influenced Control • Auto-Idle Control • Idle Speed-Up Control • ECO Control • Travel HP Mode Control • Heater Control • Travel Torque-Up Control • Pump 1 Flow Rate Limit Control • Pump 2 Flow Rate Limit Control • Travel Motor Swash Angle Control 11304-4 Abnormal Travel Pilot Voltage: Less than 0.
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11307 Fault Code 11307-3 Trouble Cause Abnormal Front Attachment Voltage: 4.75 V or higher Pilot Pressure Sensor High Voltage 11307-4 Replace Front Pilot Pressure Voltage: Less than 0.
TROUBLESHOOTING / Troubleshooting A PROPORTIONAL SOLENOID VALVE FAILURE MC FAULT CODE 11400 Fault Code 11400-2 11400-3 11400-4 Trouble Abnormal Current Feedback of Maximum Pump 2 Flow Rate Limit Control Solenoid Valve Abnormal Feedback High Current of Maximum Pump 2 Flow Rate Limit Control Solenoid Valve Abnormal Feedback Low Current of Maximum Pump 2 Flow Rate Limit Control Solenoid Valve YES Check for continuity in harness between MC and maximum pump2 flow rate limit control solenoid valve.
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11401 Fault Code 11401-2 11401-3 11401-4 Trouble Cause Influenced Control Abnormal Current Feedback of Current: Both of Higher than • Speed Sensing Control Torque Control Solenoid Valve 920mA or Less than 60 mA • Travel Torque-Up Control • Attachment Pump Torque Decrease Control Abnormal Feedback High Current: Higher than 920mA • Speed Sensing Control Current of Torque Control • Travel Torque-Up Control Solenoid Valve • Attachment Pump Torque Decrease Con
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11402 Fault Code 11402-2 11402-3 11402-4 Trouble Abnormal Current Feedback of Solenoid Valve Unit (SF) (Digging Regeneration) Abnormal Feedback High Current of Solenoid Valve Unit (SF) (Digging Regeneration) Abnormal Feedback Low Current of Solenoid Valve Unit (SF) (Digging Regeneration) YES Check for continuity in harness between MC and solenoid valve unit (SF) (digging regeneration).
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11403 Fault Code 11403-2 11403-3 11403-4 Trouble Abnormal Current Feedback of Solenoid Valve Unit (SC) (Arm Regeneration) Abnormal Feedback High Current of Solenoid Valve Unit (SC) (Arm Regeneration) Abnormal Feedback Low Current of Solenoid Valve Unit (SC) (Arm Regeneration) YES Check for continuity in harness between MC and solenoid valve unit (SC) (arm regeneration).
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11404 Fault Code 11404-2 11404-3 11404-4 Trouble Abnormal Current Feedback of Solenoid Valve Unit (SG) (Relief Pressure Control) Abnormal Feedback High Current of Solenoid Valve Unit (SG) (Relief Pressure Control) Abnormal Feedback Low Current of Solenoid Valve Unit (SG) (Relief Pressure Control) YES Check for continuity in harness between MC and solenoid valve unit (SG) (relief pressure control).
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11405 Fault Code 11405-2 11405-3 11405-4 Trouble Abnormal Current Feedback of Solenoid Valve Unit (SI) (Travel Motor Fast Speed Selection) Abnormal Feedback High Current of Solenoid Valve Unit (SI) (Travel Motor Fast Speed Selection) Abnormal Feedback Low Current of Solenoid Valve Unit (SI) (Travel Motor Fast Speed Selection) YES Check for continuity in harness between MC and solenoid valve unit (SI) (travel motor fast speed selection).
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11410 Fault Code 11410-2 11410-3 11410-4 Trouble Abnormal Current Feedback of Maximum Pump 1 Flow Rate Limit Control Solenoid Valve (Optional) Abnormal Feedback High Current of Maximum Pump 1 Flow Rate Limit Control Solenoid Valve (Optional) Abnormal Feedback Low Current of Maximum Pump 1 Flow Rate Limit Control Solenoid Valve (Optional) Current: Higher than 920mA • Pump 1 Flow Rate Limit Control • Travel Pump Flow Rate Current: Less than 56 mA • Pump
TROUBLESHOOTING / Troubleshooting A CAN DATA RECEPTION FAILURE MC FAULT CODE 11910 Fault Code 11910-2 Trouble Actual Engine Speed Received from ECM Cause Faulty CAN Harness Influenced Control • Speed Sensing Control • Send to ICF Dr.
TROUBLESHOOTING / Troubleshooting A (Blank) T5-6-93
TROUBLESHOOTING / Troubleshooting A CAN HARNESS CHECK MC FAULT CODE 11910 • Check the wiring connections first. YES Check for continuity in YES CAN harness between MC and ECM. Disconnect all connectors of MC, ICF, ECM and monitor unit. YES Check for continuity between ground circuit (MC, ICF, ECM, monitor unit) and CAN circuit. · Key switch: OFF · Refer to “Discontinuity Check between CAN Circuit and Ground Circuit”. · Key switch: OFF · Refer to “Continuity Check in CAN Harness”. Retry by using Dr. ZX.
TROUBLESHOOTING / Troubleshooting A Shorted circuit in CAN harness between power circuit and CAN circuit. YES Shorted circuit in CAN harness between key signal circuit and CAN circuit. YES Check for continuity between key signal circuit (MC, ICF, NO ECM, monitor unit) and CAN circuit. YES · Key switch: OFF · Refer to “Discontinuity Check between CAN Circuit and Key Signal Circuit”. NO Check for continuity between High side and Low side in CAN harness.
TROUBLESHOOTING / Troubleshooting A Connect connector in MC. Check if fault code 11004-2 is displayed. A · Key switch: ON Connect connector in ECM. YES Check if fault code 11004-2 is displayed. · Key switch: ON B Connect connector in ECM. Disconnect connector ICF-C in ICF. Check if resistance NO between terminals #C5 and #C11 of harness end of connector is within 60±10 Ω. · Key switch: OFF NO Check the connections of MC and connector. Faulty MC. YES NO Check the connections of ECM and connector.
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11918 Fault Code 11918-2 Trouble Cause Work Mode Faulty CAN Harness Received from Monitor Unit Influenced Control • Attachment Operation Speed Increase Control • Attachment Operation Speed Limit Control • Attachment Pump Torque Decrease Control • Pump 1 Flow Rate Limit Control • Pump 2 Flow Rate Limit Control • Attachment Flow Rate Control • Attachment Valve Selection Control Dr.
TROUBLESHOOTING / Troubleshooting A CAN HARNESS CHECK MC FAULT CODE 11918 • Check the wiring connections first. Disconnect all connectors of MC, ICF, ECM and monitor unit. YES Check for continuity between ground circuit (MC, ICF, ECM, monitor unit) and CAN circuit. Check for continuity in YES CAN harness between MC and monitor unit. · Key switch: OFF · Refer to “Discontinuity Check between CAN Circuit and Ground Circuit”. · Key switch: OFF · Refer to “Continuity Check in CAN Harness”. Retry by using Dr.
TROUBLESHOOTING / Troubleshooting A Shorted circuit in CAN harness between power circuit and CAN circuit. YES Shorted circuit in CAN harness between key signal circuit and CAN circuit. YES Check for continuity between key signal circuit (MC, ICF, NO ECM, monitor unit) and CAN circuit. · Key switch: OFF · Refer to “Discontinuity Check between CAN Circuit and Key Signal Circuit”. YES NO Check for continuity between High side and Low side in CAN harness.
TROUBLESHOOTING / Troubleshooting A NO Check the connections of MC and connector. Connect connector in MC. Check if fault code 11004-2 is displayed. A Faulty MC. · Key witch: ON YES Connect connector in the monitor unit. YES Check if fault code 11004-2 is displayed. NO Check the connections of monitor unit and connector. Faulty monitor unit. YES · Key witch: ON B Connect connector in the monitor unit. Disconnect connector ECM.
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11911 Fault Code Trouble 11911-2 Security Signal Received from Monitor Unit Cause Faulty CAN Harness Influenced Control Theft Prevention Engine Speed, Engine Torque Dr.
TROUBLESHOOTING / Troubleshooting A CAN HARNESS CHECK MC FAULT CODE 11911 • Check the wiring connections first. Disconnect all connectors of MC, ICF, ECM and monitor unit. YES Check for continuity between ground circuit (MC, ICF, ECM, monitor unit) and CAN circuit. · Key switch: OFF · Refer to “Discontinuity Check between CAN Circuit and Ground Circuit”. YES Check for continuity in CAN harness between MC and monitor unit. · Key switch: OFF · Refer to “Continuity Check in CAN Harness”. Retry by using Dr.
TROUBLESHOOTING / Troubleshooting A Shorted circuit in CAN harness between power circuit and CAN circuit. YES Shorted circuit in CAN harness between key signal circuit and CAN circuit. YES Check for continuity between key signal circuit (MC, ICF, NO ECM, monitor unit) and CAN circuit. · Key switch: OFF · Refer to “Discontinuity Check between CAN Circuit and Key Signal Circuit”. YES NO Check for continuity between High side and Low side in CAN harness.
TROUBLESHOOTING / Troubleshooting A Connect connector in MC. Check if fault code 11004-2 is displayed. A · Key switch: ON Connect connector in the monitor unit. YES Check if fault code 11004-2 is displayed. · Key switch: ON B Connect connector in the monitor unit. Disconnect connector ECM. Check if resistance NO between terminals #18 and #37 of harness end of connector is within 120±10 Ω. · Key switch: OFF NO Check the connections of MC and connector. Faulty MC.
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11920 Fault Code Trouble Cause 11920-2 Fuel Flow Rate Received from Faulty CAN Harness ECM Influenced Control Fuel Flow Rate Dr.
TROUBLESHOOTING / Troubleshooting A CAN HARNESS CHECK MC FAULT CODE 11920 • Check the wiring connections first. Disconnect all connectors of MC, ICF, ECM and monitor unit. YES Check for continuity between ground circuit (MC, ICF, ECM, monitor unit) and CAN circuit. YES Check for continuity in CAN harness between MC and ECM. · Key switch: OFF · Refer to “Discontinuity Check between CAN Circuit and Ground Circuit”. · Key switch: OFF · Refer to “Continuity Check in CAN Harness”. Retry by using Dr. ZX.
TROUBLESHOOTING / Troubleshooting A Shorted circuit in CAN harness between power circuit and CAN circuit. YES Shorted circuit in CAN harness between key signal circuit and CAN circuit. YES Check for continuity between key signal circuit (MC, ICF, NO ECM, monitor unit) and CAN circuit. YES · Key switch: OFF · Refer to “Discontinuity Check between CAN Circuit and Key Signal Circuit”. NO Check for continuity between High side and Low side in CAN harness.
TROUBLESHOOTING / Troubleshooting A Connect connector in MC. Check if fault code 11004-2 is displayed. A · Key switch: ON Connect connector in ECM. YES Check if fault code 11004-2 is displayed. NO Check the connections of MC and connector. Faulty MC. YES NO Check the connections of ECM and connector. Faulty ECM. YES · Key switch: ON B Connect connector in ECM. Disconnect connector ICF-C in ICF. Check if resistance NO between terminals #C5 and #C11 of harness end of connector is within 60±10 Ω.
TROUBLESHOOTING / Troubleshooting A MC FAULT CODE 11914 Fault Code Trouble Cause 11914-2 Radiator Coolant Temperature Faulty Harness Received from ECM Influenced Control Heater Control Dr.
TROUBLESHOOTING / Troubleshooting A CAN HARNESS CHECK MC FAULT CODE 11914 • Check the wiring connections first. Check for continuity in YES CAN harness between MC and ECM. Disconnect all connectors of MC, ICF, ECM and monitor unit. YES Check for continuity between ground circuit (MC, ICF, ECM, monitor unit) and CAN circuit. · Key switch: OFF · Refer to “Discontinuity Check between CAN Circuit and Ground Circuit”. · Key switch: OFF · Refer to “Continuity Check in CAN Harness”. Retry by using Dr. ZX.
TROUBLESHOOTING / Troubleshooting A Shorted circuit in CAN harness between power circuit and CAN circuit. YES Shorted circuit in CAN harness between key signal circuit and CAN circuit. YES Check for continuity between key signal circuit (MC, ICF, NO ECM, monitor unit) and CAN circuit. YES · Key switch: OFF · Refer to “Discontinuity Check between CAN Circuit and Key Signal Circuit”. NO Check for continuity between High side and Low side in CAN harness.
TROUBLESHOOTING / Troubleshooting A Connect connector in MC. Check if fault code 11004-2 is displayed. A · Key switch: ON Connect connector in ECM. YES Check if fault code 11004-2 is displayed. NO Check the connections of MC and connector. Faulty MC. YES NO Check the connections of ECM and connector. Faulty ECM. YES · Key switch: ON B Connect connector in ECM. Disconnect connector ICF-C in ICF. Check if resistance NO between terminals #C5 and #C11 of harness end of connector is within 60±10 Ω.
TROUBLESHOOTING / Troubleshooting A OTHER FAILURES MC FAULT CODE 11901 Fault Code Trouble Cause 11901-3 Hydraulic Oil Temperature Voltage: 4.52 V or higher Sensor High Voltage 11901-4 Hydraulic Oil Temperature Voltage: Less than 0.23 V Sensor Low Voltage Disconnect connector of hydraulic oil temperature sensor. Check if resistance at sensor end connector is specification. · Specification: Refer to the table below.
TROUBLESHOOTING / Troubleshooting A ECM, SENSOR SYSTEM ECM FAULT CODES 100, 102, 105, 108, 110, 157, 172 Fault Code Trouble 100-3 Abnormal Engine Oil Pressure Sensor (Abnormal Low Voltage) Abnormal Engine Oil Pressure Sensor (Abnormal High Voltage) Abnormal Boost Pressure Sensor (Abnormal Low Voltage) Abnormal Boost Pressure Sensor (Abnormal High Voltage) 100-4 102-3 102-4 105-3 105-4 108-3 Fault Code (Tech 2) P0522 Reference Page on Engine Troubleshooting Manual 1E-403 P0523 1E-409 P0237 1E-341
TROUBLESHOOTING / Troubleshooting A ECM FAULT CODES 174, 636, 723, 10001 Fault Code 174-3 174-4 636-2 636-2 636-7 723-2 723-2 10001-3 Trouble Fault Code (Tech 2) Abnormal Fuel Temperature Sensor (Abnormal P0183 High Voltage) Abnormal Fuel Temperature Sensor (Abnormal P0182 Low Voltage) Abnormal Cam Angle Sensor (No Signal) P0340 Reference Page on Engine Troubleshooting Manual 1E-280 1E-274 1E-368 Abnormal Cam Angle Sensor (Abnormal P0341 Signal) Phase Mismatch of Cam Angle Sensor P1345 1E-375 Abnorm
TROUBLESHOOTING / Troubleshooting A ECM, EXTERNAL DEVICE SYSTEM ECM FAULT CODES 651, 652, 653, 654, 655, 656, 1347, 10002 Fault Code Trouble 651-3 Open Circuit in Injection Nozzle ＃1 Drive System Open Circuit in Injection Nozzle ＃2 Drive System Open Circuit in Injection Nozzle ＃3 Drive System Open Circuit in Injection Nozzle ＃4 Drive System Open Circuit in Injection Nozzle ＃5 Drive System Open Circuit in Injection Nozzle ＃6 Drive System Open Circuit in Suction Control Valve Drive System, Shorted Circuit
TROUBLESHOOTING / Troubleshooting A ECM, FUEL SYSTEM ECM FAULT CODES 157, 633, 1239, 1240 Fault Code Trouble 157-0 Abnormal Common Rail Pressure (First Stage) Abnormal Common Rail Pressure (Second Stage) Abnormal Common Rail Pressure (Pump Over-Pressure) Pressure Limiter Open No Pressure to Pump (Fuel Leakage) No Pressure to Pump (Fuel Leakage) 157-0 157-2 633-7 1239-1 1240-1 Fault Code (Tech 2) P0088 Reference Page on Engine Troubleshooting Manual 1E-215 P0088 1E-215 P0089 1E-220 P1095 P0087 P10
TROUBLESHOOTING / Troubleshooting A ECM, ENGINE PROTECTION ECM FAULT CODES 110, 190 Fault Code 110-0 190-0 Trouble Overheating Overrunning Fault Code (Tech 2) P1173 P0219 T5-6-118 Reference Page on Engine Troubleshooting Manual 1E-466 1E-339
TROUBLESHOOTING / Troubleshooting A ECM, ENGINE PROTECTION ECM FAULT CODES 987, 1485 Fault Code 987-3 1485-2 Trouble Abnormal Check Engine Lamp Abnormal Main Relay System (None) Fault Code (Tech 2) P0650 P1625 T5-6-119 Reference Page on Engine Troubleshooting Manual 1E-429 1E-529
TROUBLESHOOTING / Troubleshooting A ECM, INTERNAL CIRCUIT SYSTEM ECM FAULT CODES 628, 1077, 1079, 1080, 10003, 10004, 10005 Fault Code Trouble 628-2 1077-2 1079-2 1080-2 10003-2 Abnormal ROM Abnormal IC for CPU Watching Abnormal 5 V Power Source 1 Voltage Abnormal 5 V Power Source 2 Voltage Abnormal Injection Nozzle Common 1 Drive System Abnormal Injection Nozzle Common 2 Drive System Abnormal Charge Circuit (Bank 1) 10004-2 10005-1 Fault Code (Tech 2) P0601 P0606 P1631 P1632 P1261 Reference Page on E
TROUBLESHOOTING / Troubleshooting A ECM FAULT CODES 10006, 10007, 10008, 10009, 10010, 10011, 10013 Fault Code Trouble Fault Code (Tech 2) 10006-1 10007-2 10008-2 10009-2 10010-2 10011-2 10013-2 Abnormal Charge Circuit (Bank 2) Abnormal CPU Abnormal A/D Conversion Abnormal 5 V Power Source 3 Voltage Abnormal 5 V Power Source 4 Voltage Abnormal 5 V Power Source 5 Voltage Abnormal EEPROM P0612 P0606 P1630 P1633 P1634 P1635 P0603 T5-6-121 Reference Page on Engine Troubleshooting Manual 1E-426 1E-421 1E-
TROUBLESHOOTING / Troubleshooting A ECM, COMMUNICATION SYSETEM ECM FAULT CODE 639 Fault Code 639-2 639-3 Trouble Abnormal CAN Bus Line Abnormal CAN Time Out Fault Code (Tech 2) U2104 U2106 T5-6-122 Reference Page on Engine Troubleshooting Manual 1E-553 1E-558
TROUBLESHOOTING / Troubleshooting A ICF, SATELLITE TERMINAL FAULT CODES 14000 to 14003 Fault Code Trouble 14000-2 Abnormal CAN Communication 14001-2 14002-2 14003-2 Remedy Execute retry B in self-diagnosing. If this error code is displayed after re-try, check the following item. • Check the CAN communication line (harness). ICF: Flash Memory: Read / Write Error Execute retry B in self-diagnosing and execute the following ICF: External RAM: Read / Write Error item. • Execute “Information C/U: Initialize”.
TROUBLESHOOTING / Troubleshooting A Information C/U: Initialize After starting Dr. ZX, push Select Controller. Push ICF Controller. Push OK. Select failure-diagnosis controller Select Function + Self-Diagnostic Result + Select Controller + Engine Controller + Main Controller + Monitor Controller + ICF Controller ESC ・ ICF Controller Ver.: XXYY ・ Satellite Terminal Controller Ver.
TROUBLESHOOTING / Troubleshooting A Control Data: Initialize After starting Dr. ZX, push Select Controller. Push ICF Controller. Push OK. Select failure-diagnosis controller Select Function + Self-Diagnostic Result + Select Controller + Engine Controller + Main Controller + Monitor Controller + ICF Controller ESC ・ ICF Controller Ver.: XXYY ・ Satellite Terminal Controller Ver.
TROUBLESHOOTING / Troubleshooting A Enter Model and Serial No. After starting Dr. ZX, push Select Controller. Push ICF Controller. Push OK. Select failure-diagnosis controller Select Function + Self-Diagnostic Result + Select Controller + Engine Controller + Main Controller + Monitor Controller + ICF Controller ESC ・ ICF Controller Ver.: XXYY ・ Satellite Terminal Controller Ver.
TROUBLESHOOTING / Troubleshooting A ICF, SATELLITE TERMINAL FAULT CODES 14006, 14008, 14100 to 14106 Fault Code Trouble Remedy 14006-2 ICF: Satellite Communication Execute retry B in self-diagnosing. Terminal: Communication Error If this error code is displayed after re-try, check the following item. Check the communication line. Check the power source line of satellite terminal. Check the fuse. 14008-2 ICF: Abnormal Internal RAM Then, execute self-diagnosing and execute retry B.
TROUBLESHOOTING / Troubleshooting A Fault Codes 14102-2, 14103-2 Communication Aerial (GPS Aerial) Satellite Terminal T1V1-05-07-001 Communication Aerial (GPS Aerial) T1V1-05-06-004 T5-6-128
TROUBLESHOOTING / Troubleshooting A MONITOR UNIT FAULT CODE 13303 Fault Code 13303-2 Trouble Remedy Abnormal Thermister Temperature Cool the monitor unit until temperature inside the monitor unit becomes less than 85 ℃. The screen of monitor unit becomes dark. YES YES Normal. Cool monitor unit. Check if the screen of monitor unit becomes normal. Faulty monitor unit. Check if temperature around monitor unit is high. NO Faulty monitor unit.
TROUBLESHOOTING / Troubleshooting A MONITOR UNIT FAULT CODE 13304 Fault Code Trouble 13304-2 Abnormal REG Input H Level • Check the wiring connections first. Remedy Refer to the following. NOTE: As terminal L in the regulator is a waterproof type connector, it is difficult to measure voltage. Measure voltage at terminal R in starter relay 2. Check for continuity at terminal R in starter relay 2 and terminal L in regulator. Less than 33.5 V Less than 33.
TROUBLESHOOTING / Troubleshooting A MONITOR UNIT FAULT CODES 13306, 13308 Fault Code Trouble 13306-2 Abnormal EEPROM 13308-2 Abnormal CAN Communication Remedy If this error code is displayed after re-try, replace the monitor unit. Refer to “Check CAN Harness” (T5-6-54).
TROUBLESHOOTING / Troubleshooting A MONITOR UNIT FAULT CODE 13310 Fault Code 13310-2 Trouble Shorted Circuit Temperature Sensor Remedy in YES Check if resistance of coolant temperature sensor is specification. Coolant Check the coolant temperature sensor and harness. With terminal of coolant temperature sensor disconnected, disconnect connector monitor-C in monitor unit. Check for continuity between terminal #C8 of harness end of connector in monitor unit and machine.
TROUBLESHOOTING / Troubleshooting A MONITOR UNIT FAULT CODE 13311 Fault Code Trouble Remedy 13311-3 13311-4 Shorted Circuit in Fuel Level Sensor Open Circuit in Fuel Level Sensor Check the fuel level sensor and harness. Check the fuel level sensor and harness. With connector of fuel level sensor disconnected, disconnect connector monitor-C in YES monitor unit. Check for continuity between terminal #C2 of harness end of connector in monitor unit and machine.
TROUBLESHOOTING / Troubleshooting A PILOT SHUT-OFF LEVER ALARM Pilot shut-off lever alarm is displayed on the monitor unit screen. YES Faulty pilot shut-off switch. Check if pilot shut-off switch is bent or damaged. Faulty harness.
TROUBLESHOOTING / Troubleshooting B TROUBLESHOOTING B PROCEDURE Apply troubleshooting B procedure when no fault code is displayed on the service menu (built-in diagnosing system) in monitor unit and Dr.ZX although the machine operation is abnormal. On the front section pages of this group are the tables indicating the relationship between machine trouble symptoms and related parts which may cause such trouble if failed.
TROUBLESHOOTING / Troubleshooting B RELATIONSHIP BETWEEN MACHINE TROUBLE SYMPTOMS AND RELATED PARTS This table indicates the relationship between machine trouble symptoms and the potential problem parts, which may cause trouble if failed, and the evaluation methods of these components. Parts Engine Control Dial Pump Control Pressure Sensor Pump 1 Delivery Pressure Sensor • Instructs engine target • Monitors pump control pres- • Monitors pump delivery • Engine speed does not • No signals arrive to MC.
TROUBLESHOOTING / Troubleshooting B Pump 2 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor (Optional) Pressure Sensor (Travel) • Monitors pump delivery pressure in order • Monitors pump delivery pressure in order • If pump delivery pressure sensor output • Engine stalls if pump torque is increased. • No signals arrive to MC. • HP mode is inoperable. • At P and HP mode, auto-acceleration • Engine stalls if pump torque is increased.
TROUBLESHOOTING / Troubleshooting B Parts Pressure Sensor (Front Attachment) • Monitors front attachment • Monitors swing pilot pressure • Monitors boom raise pilot • No signals arrive to MC. • No signals arrive to MC. • No signals arrive to MC. • Engine speed does not in- • As arm regenerative function • Even if boom is raised with pilot pressure in order to control auto-idle, and idle speed-up, and engine speed automatic increase at travel (ZX270-3 class only) controls.
TROUBLESHOOTING / Troubleshooting B Pressure Sensor (Arm Roll-In) Pressure Sensor (Auxiliary) (Optional) Torque Control Solenoid Valve • Monitors arm roll-in pilot pressure in or- • Monitors attachment pilot pressure when • Supplies control pressure to pumps 1 • No signals arrive to MC. • No signals arrive to MC.
TROUBLESHOOTING / Troubleshooting B Parts Function Symptoms in control system when trouble occurs. Symptoms in machine operation when trouble occurs.
TROUBLESHOOTING / Troubleshooting B Max. Pump 1 Flow Rate Limit Solenoid Valve (Optional) Max. Pump 2 Flow Rate Limit Solenoid Valve • When pump delivery pressure is low in • Limits maximum pump 1 flow rate when • Limits maximum pump 2 flow rate when • Fast travel mode cannot be selected. • If max. pump 1 flow rate limit solenoid • If max. pump 2 flow rate limit solenoid Solenoid valve unit (SI) is closed: Max.
TROUBLESHOOTING / Troubleshooting B Parts Auxiliary Flow Rate Control Solenoid Valve (Optional) Auxiliary Flow Combining Solenoid Valve (Optional) • Restricts oil flow to auxiliary • activates during auxiliary op- • Monitors hydraulic oil tem- • If auxiliary flow rate control • If auxiliary flow combining • If discontinuity occurs, sys- • If valve is bound fully closed, • Speed does not increase • Even if oil temperature is spool during combined operation and improves operability.
TROUBLESHOOTING / Troubleshooting B Power Digging Switch Travel Mode Switch MC • Activates power digging control. • Changes travel mode. • Controls engine, pump and valve opera- • Open circuit: Pressure does not in- • Open circuit in switch: Travel speed re- • Depending on trouble situations, control • • ON: 0V→Increasing Pressure OFF: 5V→ Not Increasing Pressure crease. Shorted circuit: Pressure increases for 8 seconds after turning key switch and stops increasing.
TROUBLESHOOTING / Troubleshooting B Auto-Idle Switch Parts Power Mode Switch (E Mode) • Activates auto-idle control. • Activates HP mode control. • Selects E mode. • Open circuit: Auto-idle sys- • Open circuit: Even if HP • Open circuit: Even if E mode • • ON: 0 V → Auto-idle control is operable. OFF: 5 V → Inoperable. Function • Symptoms in control system when trouble occurs. tem is inoperable. Shorted circuit: Even if auto-idle switch is OFF, auto-idle control is always activated.
TROUBLESHOOTING / Troubleshooting B Arm 2 Flow Rate Control Valve • Be shifted by pilot pressure from sole• noid valve unit (SC). Ensures boom raise speed. Flow Combiner Valve • Supplies hydraulic oil to both right and left travel spools from pump 1 during combined operation of travel and front/swing. Arm 1 Flow Rate Control Valve • Be shifted by pilot pressure from arm • flow rate control valve in signal control valve. Ensures swing power.
TROUBLESHOOTING / Troubleshooting B Parts Bucket Flow Rate Control Valve • Be shifted by pilot pressure • Routes return oil from boom • If switch valve is bound with • If spool is bound or spring is • If check valve is kept closed, during 3-combined operation of bucket, arm roll-in and boom raise, and allows boom to raise. switch valve activated, bucket circuit is always restricted. Symptoms in control system when trouble occurs.
TROUBLESHOOTING / Troubleshooting B Arm Regenerative Valve • Be shifted by pilot pressure from sole• noid valve unit (SC). Routes return oil from arm cylinder rod side to bottom side and increases arm speed. • Arm regenerative function is inoperable. Bucket Regenerative Valve • Routes return oil from bucket cylinder rod • Forcibly open check valve in arm roll-in side to bottom side and prevents bucket cylinder hesitation.
TROUBLESHOOTING / Troubleshooting B Parts Boom Anti-Drift Valve • Forcibly open check valve in boom lower return circuit and allows boom to move only when boom is lowered. Prevents boom from drifting due to oil leaks in control valve. Function • If switch valve is bound, check valve does not open. Auxiliary Flow Combining Valve • Be shifted by pilot pressure • from auxiliary flow combining solenoid valve. Supplies pressure oil from pump 1 to auxiliary spool.
TROUBLESHOOTING / Troubleshooting B Flow Combiner Valve Control Spool Pump 1 Flow Rate Control Valve Pump 2 Flow Rate Control Valve • Supplies flow rate control pressure Pi to • Supplies flow rate control pressure Pi to • Be shifted by right travel pilot pres- • If spool is bound at fully open, even if con- • If spool is bound at fully open, even if con- • If spool is bound at fully open, when pump 1 regulator in response to lever stroke when boom (raise/lower), arm (roll-out/in), bucket (roll-out
TROUBLESHOOTING / Troubleshooting B Parts Swing Parking Brake Release Spool Bucket Flow Rate Control Valve Control Spool • Be shifted by boom, arm, bucket or swing pilot • Be shifted by arm roll-in pilot pressure and pressure and supplies swing parking brake release pressure. supplies boom raise pilot pressure to bucket flow rate control valve as control pressure. Function • If spool is bound at fully open, swing parking • Symptoms in control system when trouble occurs.
TROUBLESHOOTING / Troubleshooting B Arm Flow Rate Control Valve Control Spool • Be shifted by arm roll-in pilot pressure and supplies to arm flow rate control valve 1 on 5-spool side in control valve as control pressure. • If spool is bound at fully • open, arm speed decreases during single arm operation. (Arm flow rate control is always operable.) If spool is bound at fully closed, swing power becomes insufficient during combined operation of swing and arm roll-in.
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. z : Related, required to check { : Related. However, in case this component fails, other trouble symptom will be more noticeable so that this component will not be the direct cause of the trouble concerned.
TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently. E-4 Even if engine control dial is rotated, engine speed remains unchanged. z E-5 Engine speed does not increase when engine starts. 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-6 Faulty HP mode. z { E-7 Faulty Travel HP mode.
TROUBLESHOOTING / Troubleshooting B z : Related, required to check { : Related. However, in case this component fails, other trouble symptom will be more noticeable so that this component will not be the direct cause of the trouble concerned. Trouble Symptom E-8 Even if key switch is turned OFF, engine does not stop. E-9 Faulty auto-idle system. E-10 Faulty E mode.
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. E-11 When traveling or operating front attachment with engine running at slow idle, engine hunts. E-12 Engine speed does not increase even if attachment is operated in attachment mode.
TROUBLESHOOTING / Troubleshooting B Trouble Symptom E-15 Engine stalls during operation under adverse condition such as at high altitude. E-16 Engine is difficult to start at low temperature.
TROUBLESHOOTING / Troubleshooting B (Blank) T5-7-23
TROUBLESHOOTING / Troubleshooting B All Actuator System Troubleshooting Trouble Symptom A-1 All actuator speeds are slow. A-2 All actuators are not operated. A-3 Left travel is inoperable during single travel operation. Single swing operation speed becomes slow. Arm speed is slightly slow during arm level crowding.
TROUBLESHOOTING / Troubleshooting B A-4 Right travel is inoperable during single travel operation. Single bucket operation speed becomes slow. Boom is not raised properly during arm level crowding. A-5 Actuator does not stop even if control lever is turned to neutral. A-6 Occasionally, swing or arm roll-in speed becomes slow during combined operation of swing and arm roll-in. A-7 Actuator speed is faster than normal. Machine mistracks when travel lever is operated at half stroke.
TROUBLESHOOTING / Troubleshooting B Front Attachment System Troubleshooting Trouble Symptom F-1 All front attachment actuator power is weak. F-2 Even if power digging switch is pushed, power does not increase. Boom raise power is weak when digging. F-3 Some cylinder are inoperable or speeds are slow.
TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently. F-4 Arm speed is slow during combined operation. During combined operation of boom raise and arm roll-in, boom raise speed is slow. Arm speed is slow during arm level crowding. F-5 Arm roll-in speed is slow when digging.
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. Front Attachment System Troubleshooting Trouble Symptom F-9 When boom raise or arm roll-out is operated, boom or arm starts to move after slightly moving downward. F-10 Front attachment drifts remarkably.
TROUBLESHOOTING / Troubleshooting B (Blank) T5-7-29
TROUBLESHOOTING / Troubleshooting B Swing/Travel/Other System Troubleshooting Trouble Symptom S-1 Swing is slow or unmoving.
TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently. T-3 Machine mistracks during combined operation of travel and front attachment. T-4 Occasionally, machine mistracks when traveling with engine running at slow speed. 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. O-2 T-5 O-1 Fast travel is inoperable.
TROUBLESHOOTING / Troubleshooting B ENGINE SYSTEM TROUBLESHOOTING E-1 Starter does not rotate. Related MC Fault Code: None IMPORTANT: As electric current from the key switch is not routed to starter relay 2 with the pilot shut-off lever in ON position, the starter does not rotate. (Refer to “Electrical System”.) • This trouble has nothing to do with the electronic control system such as MC. • Check the wiring connections first. YES Switch starter cut relay YES with other general relay.
TROUBLESHOOTING / Troubleshooting B YES Check if voltage at terminal A in battery relay is 24 V. Disconnect connector of starter relay 2. Connect terminal S of harness end of conYES nector to machine. Check for continuity between terminal #4 of harness end of connector in starter cut relay and machine. Check if voltage at YES terminal #2 of harness end of connector in starter cut relay is 0 V. Faulty starter, or faulty YES harness between starter and battery relay. Faulty battery relay.
TROUBLESHOOTING / Troubleshooting B E-2 Even if starter rotates, engine does not start. Related MC Fault Code: None • Check the wiring connections first. Faulty ECM main relay. YES Switch ECM main relay with other general relay. Check if engine starts. Disconnect ECM main relay from connector. Check if voltage beNO tween terminal #3 of harness end of connector and machine is specification. · Specification: 24V Connect terminal #4 of harness end of connector in ECM main relay to machine.
TROUBLESHOOTING / Troubleshooting B Check if voltage YES between terminal #24 of harness Check for contiend of connector nuity between in ECM and machine is specificaYES terminal #2 of harness end of tion. connector in ECM · Key switch: ON main relay and · Specification: 24 machine. V Disconnect con- YES Open circuit in harness between key switch and nector ICF-C in monitor unit. ICF. Check if voltage between YES Check if fuse #18 is blown.
TROUBLESHOOTING / Troubleshooting B E-3 When engine control dial is fully rotated, engine stalls. When engine control dial is fully rotated, engine speed becomes slow. Related MC Fault Code: 11003-3, 11004-2 • Check the wiring connections first. YES Faulty MC, or faulty CAN between MC and ECM. Check if fault code is displayed. · Fault code 11003-3: Abnormal sensor voltage 11004-2: Abnormal CAN communication Refer to engine troubleshooting manual.
TROUBLESHOOTING / Troubleshooting B E-4 Even if engine control dial is rotated, engine speed remains unchanged. Related MC Fault Code: 11004-2, 11101-3, 11101-4 • Check the wiring connections first. Faulty engine control dial, or open circuit in harness between engine control dial and MC. YES Check if fault code 11101-3 or 11101-4 is displayed. Monitor engine control dial angle (standard voltage) by using Dr. ZX. Check if voltage is normal. · Standard voltage Slow idle position: 0.
TROUBLESHOOTING / Troubleshooting B E-5 Engine speed does not increase when engine starts. Related MC Fault Code: 11004-2, 11901-3, 11901-4 • Refer to the pages for the Auto Warming Up Control in the SYSTEM / Control System group in the T/M (Operational Principle). • Check the wiring connections first. 0 °C or higher when starting NO Normal. Monitor oil temperature.
TROUBLESHOOTING / Troubleshooting B (Blank) T5-7-39
TROUBLESHOOTING / Troubleshooting B E-6 Faulty HP mode • Even if power mode switch is turned to the HP mode position, HP mode is inoperable. (General mode normally operates.) Related MC Fault Codes: 11004-2, 11200-3, 11200-4, 11202-3, 11202-4, 11302-3, 11302-4, 11303-3, 11303-4 • The sensors detect the conditions necessary to • Refer to the pages for HP Mode Control in the operate HP mode. Therefore, if any of these sensors fails, HP mode becomes inoperable.
TROUBLESHOOTING / Troubleshooting B • Even if the power mode switch is not turned to HP mode, HP mode is operable. • Boom raise and arm roll-in must be operated when the average delivery pressures of pump 1 and 2 are high, if HP mode control is performed. The sensors related to this condition may not be faulty at the same time. Short circuit in harness between MC and power mode switch. YES Monitor the power mode switch. Check if “HP” is displayed.
TROUBLESHOOTING / Troubleshooting B E-7 Faulty Travel HP mode • Even if the travel mode switch is turned to FAST during single travel operation, travel HP mode is inoperable. Related MC Fault Code: 11004-2, 11200-3, 11200-4, 11202-3, 11202-4, 11304-3, 11304-4 • The sensors detect the conditions necessary to • Refer to the pages for Travel HP Mode Control in operate travel HP mode. Therefore, if any of these sensors fails, travel HP mode becomes inoperable.
TROUBLESHOOTING / Troubleshooting B • Even if the travel mode switch is not turned to FAST, travel mode becomes fast idle. • Travel must be operated when the average delivery pressures of pump 1 and 2 are high, if travel HP mode control is performed. The sensors related to this condition may not be faulty at the same time. Short circuit in harness between MC and travel mode switch. YES Monitor travel mode switch. Check if FAST is displayed.
TROUBLESHOOTING / Troubleshooting B E-8 Even if key switch is turned OFF, engine does not stop. (In case engine does not stop, stop engine by pulling engine stop handle located under seat stand. Then, begin inspection.) Related MC Fault Codes: 11101-3, 11101-4 • Probably the symptoms such as “Engine speed is slower than specification in all operating ranges” or “Even if engine control dial is rotated, engine speed remains unchanged” may come up. Perform troubleshooting for these symptoms.
TROUBLESHOOTING / Troubleshooting B (Blank) T5-7-45
TROUBLESHOOTING / Troubleshooting B E-9 Faulty auto-idle system • Even if control lever is turned to neutral, auto-idle system is inoperable. Related MC Fault Code: 11004-2, 11304-3, 11304-4, 11307-3, 11307-4 • Refer to the pages for Auto-Idle Control in the • In case trouble symptoms E1 to E8 are recognized, perform the troubleshooting of these troubles first. • Even if failure in pressure sensors (travel and front attachment) may have relevance to malfunction of the auto-idle control.
TROUBLESHOOTING / Troubleshooting B • Even if auto-idle switch is turned OFF, auto-idle is operable. Shorted circuit in harness between MC and auto-idle switch. YES Disconnect connector monitor-B in monitor unit. Check for continuity between terminal #B18 of harness end of connector and machine. · Auto idle switch: OFF YES NO Faulty CAN between MC and ECM. Check if fault code 11004-2 is displayed. Faulty MC.
TROUBLESHOOTING / Troubleshooting B E-10 Faulty E mode • Even if power mode switch is turned to the E mode position, engine speed remains unchanged. (Engine speed does not decrease.) Related MC Fault Code: 11004-2, 11200-3, 11200-4, 11202-3, 11202-4, 11206-3, 11206-4, 11208-3, 11208-4 • In case trouble symptoms E-1 to E-9 are recog- • Pump 1, 2 control pressure sensors and pump 1, nized, perform the troubleshooting of these troubles first. • The sensors detect the conditions necessary to operate E mode.
TROUBLESHOOTING / Troubleshooting B • Even if power mode switch is not turned to E mode, engine speed decreases. • Required engine speed from the engine control -1 dial must be beyond 1800 min when the pump control pressures of pump 1 and 2 are low or the average delivery pressures of pump 1 and 2 are high, if E mode control is performed. The sensors related to this condition may not be faulty at the same time. Shorted circuit in harness between MC and power mode switch. NO Monitor power mode switch.
TROUBLESHOOTING / Troubleshooting B E-11 When traveling or operating front attachment with engine running at slow idle, engine hunts. Related MC Fault Code: 11004-2, 11304-3, 11304-4, 11307-3, 11307-4 • Even if the failure in pressure sensors (travel and front attachment) may have relevance to malfunction of the engine speed increase control. However, if these sensors fail, other operating functions will also be affected.
TROUBLESHOOTING / Troubleshooting B E-12 Engine speed does not increase even if attachment is operated in attachment mode. Related MC Fault Code: 11004-2, 11918-2 • In case trouble symptoms E-1 to E-11 are recog- • Refer to the pages for Attachment Operation nized, perform the troubleshooting of these troubles first. • Even ifh the failure in pressure sensor (auxiliary) and power mode switch may have relevance to the malfunction of attachment operation speed increase control.
TROUBLESHOOTING / Troubleshooting B E-13 When attachment mode is selected, engine speed does not decrease. Related MC Fault Code: 11004-2, 11918-2 • In case trouble symptoms E-1 to E-11 are recognized, perform the troubleshooting of these troubles beforehand. • Refer to the pages for Attachment Operation Speed Limit Control in the SYSTEM / Control System group in the T/M (Operational Principle). • Check the wireing connections first. YES YES Faulty CAN between MC and ECM.
TROUBLESHOOTING / Troubleshooting B E-14 Engine stalls within several seconds after engine has started. Related MC Fault Code: None • Refer to the Engine Troubleshooting Manual.
TROUBLESHOOTING / Troubleshooting B E-15 Engine stalls during operation under adverse condition such as at high altitude. Test Harness (ST 7226) When operating corresponding control lever and switch: ON Related MC Fault Code: 11004-2, 11100-2, 11910-2, 11401-2, 11401-3, 11401-4 • If speed sensing control is inoperable, the engine 4 will stall under adverse operating conditions. • Check the wiring connections first. 3 1 2 150 50 50 50 2 1 T107-07-06-015 NO Monitor actual engine speed.
TROUBLESHOOTING / Troubleshooting B YES Faulty torque control solenoid valve. Open circuit in harness between torque control solenoid valve and MC.
TROUBLESHOOTING / Troubleshooting B E-16 Engine is difficult to start at low temperature. (During cold weather or in cold districts, engine is difficult to start or does not start even if pre-heated.) Related MC Fault Code: None • Check if electricity is routed to the glow plugs. Check the glow plugs for any abnormality. • The pre-heat system operates only when coolant temperature is below 10 °C (50 °F). When coolant temperature is higher than 10 °C (50 °F), the pre-heat system does not operate.
TROUBLESHOOTING / Troubleshooting B ∞Ω Faulty glow plug. NO YES Connect connector in glow relay. Connect terminal #4 of harness end of connector to machine. Check if voltage at glow plug is 20 to 24 V. · Key switch: ON YES Below 10 Ω Faulty glow relay, or faulty harness between glow relay and glow plug. Open circuit in harness between glow relay and ECM. Disconnect connector in glow relay. Check if voltages at terminals #1 and #3 of harness end of connector in glow relay are 20 to 24 V.
TROUBLESHOOTING / Troubleshooting B ALL ACTUATOR SHOOTING SYSTEM TROUBLE- A-1 All actuator speeds are slow. Related MC Fault Code: 11004-2, 11100-2, 11910-2, 11401-2, 11401-3, 11401-4 • Even if speed is satisfactory, in case power is • Reduction in pump 1 and 2 flow rate due to some weak, refer to the troubleshooting for faulty main relief valve (F-1). • Check the wiring connections first. reasons or faulty pilot system (A-2) may cause this trouble. • Check fuse of the torque control solenoid valve.
TROUBLESHOOTING / Troubleshooting B (Blank) T5-7-59
TROUBLESHOOTING / Troubleshooting B A-2 All actuator are not operated. Related MC Fault Code: None • The pilot shut-off circuit may be faulty. • Check the wiring connections first. • When the key switch is turned to the START position with the pilot shut-off lever in the ON position, the starter does not rotate. • When the key switch is turned to the START position with the emergency switch and the pilot shut-off lever in the ON position, the starter rotates.
TROUBLESHOOTING / Troubleshooting B Check if voltage YES between terminal #1 of harness end of connector in pilot shut-off relay and machine is 24 V. Check for continuity between terminal #3 YES of harness end of Connect terminal #5 of connector in security harness end of conrelay and machine. nector in pilot shut-off relay to machine. YES Disconnect security relay. Check for continuity between terminal #4 of harness end of connector and machine.
TROUBLESHOOTING / Troubleshooting B Faulty monitor unit, or shorted circuit in harness between monitor unit and security relay. YES A NO Check for continuity YES between terminals #B19 and #B12 of harness end of conConnect terminal #2 of nector monitor-B. harness end of connector in pilot shut-off relay to machine. Disconnect connector monitor-B in monitor unit. Check for continuity between terminal #2 of harness end of connector and machine. Connect connector monitor-B.
TROUBLESHOOTING / Troubleshooting B (Blank) T5-7-63
TROUBLESHOOTING / Troubleshooting B A-3 Left travel is inoperable during single travel operation. Single swing operation speed becomes slow. Arm speed is slightly slow during arm level crowding. (All problems occur at the same time.) Related MC Fault Code: None • The pump 2 flow rate is minimized (approx. 20 L/min) due to some reasons. Accordingly, the left travel and swing motors, which are driven by pressure oil from pump 2, moves very slow.
TROUBLESHOOTING / Troubleshooting B A-4 Right travel is inoperable during single travel operation. Single bucket operation speed becomes slow. Boom is not raised properly during arm level crowding. (All problems occur at the same time.) Related MC Fault Code: None • The pump 1 flow rate is minimized (approx. 20 L/min) due to some reasons. Accordingly, the right travel motor and bucket cylinder, which are actuated by pressure oil from pump 1, moves very slow.
TROUBLESHOOTING / Troubleshooting B A-5 Actuator does not stop even if control lever is turned to neutral. Related MC Fault Code: None • Bound spool in the pilot valve or bound main spool in the control valve is suspected. Faulty pilot valve. YES · When control lever is in neutral, pilot pressure is routed to spool end in control valve. Check if actuator stops when pilot shut-off lever is turned to OFF position. Faulty control valve.
TROUBLESHOOTING / Troubleshooting B A-6 Occasionally, swing or arm roll-in speed becomes slow during combined operation of swing and arm roll-in. Related MC Fault Code: 11202-3, 11202-4, 11301-3, 11301-4, 11303-3, 11303-4 • The arm 1 flow rate control valve may be faulty. • Refer to the pages for the SYSTEM / Control System group in the T/M (Operational Principle). NO Check if fault code is displayed.
TROUBLESHOOTING / Troubleshooting B A-7 Actuator speed is faster than normal Machine mistracks when travel lever is operated at half stroke. Precise control cannot be performed. Related MC Fault Code: None • The pump 1 or 2 flow rate is maximized due to some reasons. Therefore, the maximum flow rate is supplied and actuator speed is faster though the control lever does not reach the full stroke.
TROUBLESHOOTING / Troubleshooting B (Blank) T5-7-69
TROUBLESHOOTING / Troubleshooting B FRONT ATTACHMENT SYSTEM TROUBLESHOOTING F-1 All front attachment actuator power is weak. Related MC Fault Code: None • In case operating speeds are extremely slow, pump control may be malfunctioning (A-3 and/or A-4). Faulty pilot system may also cause this trouble. 34.3 to 36.3 MPa 2 (350 to 370 kgf/cm ) Main relief valve should be normal. Find out cause of trouble by tracing other trouble symptoms. Monitor pump 1 and 2 delivery pressures.
TROUBLESHOOTING / Troubleshooting B F-2 Even if power digging switch is pushed, power does not increase. Boom raise power is weak when digging. Related MC fault Code: 11404-2, 11404-3, 11404-4 • Refer to the pages for the SYSTEM / Power Digging Control and Auto-Power Lift Control group in the T/M (Operational Principle). • Check the wiring connections first. Faulty solenoid valve unit (SG), open circuit in harness between solenoid valve unit (SG) and MC. YES Check if fault code is displayed.
TROUBLESHOOTING / Troubleshooting B F-3 Some cylinders are inoperable or speeds are slow. Related MC Fault Code: None • When other actuators (travel and swing motors) operate normally, the pilot pump (primary pilot pressure) is considered to be normal. • In case single bucket operation speed is slow, refer to F-6. • In case single arm roll-in operation speed is slow, refer to F-7. • In case single boom lower operation speed is slow, refer to F-8.
TROUBLESHOOTING / Troubleshooting B (Blank) T5-7-73
TROUBLESHOOTING / Troubleshooting B F-4 Arm speed is slow during combined operation. During combined operation of boom raise and arm roll-in, boom raise speed is slow. Arm speed is slow during arm level crowding. • Refer to the pages for the SYSTEM / Arm Re- Related MC Fault Codes: 11200-3, 11200-4, 11202-3, 11202-4, 11303-3, 11303-4, 11301-3, 11301-4, 11302-3, 11302-4, 11403-2, 11403-3, 11403-4 generative Control group in the T/M (Operational Principle). Faulty corresponding sensor, or faulty MC.
TROUBLESHOOTING / Troubleshooting B Section A-A A B B Arm Regenerative Valve A T1V1-03-03-002 Faulty arm regenerative valve. YES YES NO T1V1-03-03-026 Check if arm 2 flow rate control valve at 4-spool side in control valve is stuck or bound. NO Faulty arm 2 flow rate control valve. Find out cause of trouble by tracing other trouble symptoms.
TROUBLESHOOTING / Troubleshooting B F-5 Arm roll-in speed is slow when digging. Related MC Fault Codes: 11200-3, 11200-4, 11202-3, 11202-4, 11301-3, 11301-4, 11302-3, 11302-4, 11402-2, 11402-3, 11402-4 • Refer to the pages for the SYSTEM / Control System group / Digging Regenerative Control in the T/M (Operational Principle). Faulty corresponding sensor, or faulty MC.
TROUBLESHOOTING / Troubleshooting B F-6 Bucket is slow during bucket roll-in single operation. Bucket does not move smoothly during bucket roll-in single operation. Related MC Fault Code: None • Bucket flow rate control valve or bucket regenerative valve may be faulty. • Refer to the COMPONENT OPERATION / Control Valve group in the T/M (Operational Principle). YES NO Check if bucket flow rate control valve in control valve is bound or scored.
TROUBLESHOOTING / Troubleshooting B F-7 When starting to move during combined operation, arm does not smoothly move. Arm starts to move slightly slow during arm roll-in single operation. These troubles often occur when temperature is low. Related MC Fault Code: None • Refer to the COMPONENT OPERATION / Control Valve group in the T/M (Operational Principle). YES NO Check if arm regenerative valve is bound or scored. NO Check if arm anti-drift valve is bound or scored. Faulty arm regenerative valve.
TROUBLESHOOTING / Troubleshooting B F-9 When boom raise or arm roll-out is operated, boom or arm starts to move after moving slightly downward. Related MC Fault Code: None YES Faulty anti-drift valve. YES Check if anti-drift valves (arm and boom) are bound or scored. Oil leaks in cylinder. NO Check if load check valve in control valve is normal. · Disassemble / Visual Inspection Faulty load check valve. NO NOTE: 1. During the initial stage of operation, oil pressure and flow rate from the pump is low.
TROUBLESHOOTING / Troubleshooting B F-10 Front attachment drifts remarkably. Related MC Fault Code: None YES Normal NO Check if each front attachment cylinder drift is within specification. NO NO Check if emergency valve at boom 1 section in control valve 4-spool side is correctly adjusted. Check if cylinder drift is reduced when pilot shut-off valve is closed. YES Correctly adjust emergency valve and lock it up.
TROUBLESHOOTING / Troubleshooting B Emergency Valve NO Scored control valve spool, broken spring, or loose spool end. NO Check if oil leaks in cylinders. YES Faulty cylinder. (Replace seal kit.) T1V1-05-04-005 YES Faulty overload relief valve. Emergency Valve 1 2 T178-05-04-003 Adjustment Procedure: Loosen (1) and tighten (2). Tightening Torque: (1)- 13 N⋅m (1.3 kgf⋅m) (2)- 7 N⋅m (0.
TROUBLESHOOTING / Troubleshooting B F-11 Boom lower is faster than other actuators during combined operation. Related MC Fault Code: None • Boom lower meter-in cut valve or boom flow rate control valve may be faulty. • Refer to the pages for the SYSTEM / Hydraulic System group and the COMPONENT OPERATION / Control Valve group in the T/M (Operational Principle). • In case boom lower single operation is slow, refer to F-8. YES Faulty boom lower meter-in cut valve.
TROUBLESHOOTING / Troubleshooting B F-12 Machine cannot be raised off ground. Related MC Fault Code: None • Boom lower meter-in cut valve or boom flow rate control valve may be faulty. • Refer to the pages for the SYSTEM / Hydraulic System group and the COMPONENT OPERATION / Control Valve group in the T/M (Operational Principle). • In case boom lower single operation is slow, refer to F-8. YES Faulty boom lower meter-in cut valve. Check if boom lower meter-in cut valve is bound or scored.
TROUBLESHOOTING / Troubleshooting B SWING SYSTEM TROUBLESHOOTING S-1 Swing is slow or unmoving. Related MC Fault Code: None • 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 trouble may exist in the circuit after pilot valve. • In case left travel speed is also slow, refer to A-3.
TROUBLESHOOTING / Troubleshooting B YES Faulty swing reduction gear. YES Check if swing motor drain oil amount is normal. NO · Measurement: Refer to Operational Performance Test Section. Check if swing relief pressure is normal. · Relieve swing circuit. · Monitor item: Pump 2 delivery pressure · Possible to display by service menu and monitoring in monitor unit · Specification: Refer to Operational Performance Test Section. Faulty swing motor. NO Faulty swing relief valve.
TROUBLESHOOTING / Troubleshooting B S-2 Swing is slow (weak in power) during combined operation of swing and arm roll-in. Swing does not start smoothly. Swing power is weak. Related MC Fault Codes: 11202-3, 11202-4, 11301-3, 11301-4, 11303-3, 11303-4 • Refer to the pages for the SYSTEM / Hydraulic System group / Valve Control Circuit in the T/M (Operational Principle). • Check the wiring connections first. Faulty corresponding sensor, or faulty MC. Open circuit in harness between MC and sensor.
TROUBLESHOOTING / Troubleshooting B (Blank) T5-7-87
TROUBLESHOOTING / Troubleshooting B TRAVEL SYSTEM TROUBLESHOOTING T-1 Both right and left tracks do not rotate or rotate slowly. Related MC Fault Code: None • 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.
TROUBLESHOOTING / Troubleshooting B (Blank) T5-7-89
TROUBLESHOOTING / Troubleshooting B T-2 One side track does not rotate or rotates slowly. Machine mistracks. Related MC Fault Code: None • Check that both side track sags are equally ad- • In one side track only does not rotate, the pilot justed. valve, control valve, travel motor, or center joint may be faulty. • Faulty pump control will cause the machine to mistrack.
TROUBLESHOOTING / Troubleshooting B NO Faulty travel motor. Faulty travel reduction gear. YES Disassemble and clean travel motor servo piston. Check if same symptom occurs. YES YES Disassemble and clean travel motor counterbalance valve. Check if same symptom occurs. Faulty travel motor servo piston. NO Faulty counterbalance valve. NO NO Faulty center joint. Faulty travel relief valve.
TROUBLESHOOTING / Troubleshooting B T-3 Machine mistracks during combined operation of travel and front attachment. Related Fault Code: None Faulty flow combiner valve control spool in signal control valve. YES Disconnect hose (SL) from signal control valve to flow combiner valve. NO Install a pressure gauge. Check if signal pressure is approx. 3.9 MPa (40 2 kgf/cm ). YES NO Check flow combiner valve in control valve for any abnormality. Check load check valve for any abnormality.
TROUBLESHOOTING / Troubleshooting B T-4 Occasionally, machine mistracks when traveling with engine running at slow speed. Related MC Fault Codes: 11200-3, 11200-4, 11202-3, 11202-4, 11304-3, 11304-4, 11401-2, 11401-3, 11401-4 • Refer to the pages for the SYSTEM / Control System group / Travel Torque-Up Control in the T/M (Operational Principle). • Check the wiring connections first. Faulty corresponding sensor, or open circuit in harness between MC and corresponding sensor.
TROUBLESHOOTING / Troubleshooting B T-5 Fast travel is inoperable. Travel mode does not change from slow mode to fast mode. Related MC Fault Codes: 11200-3, 11200-4, 11202-3, 11202-4, 11206-3, 11206-4, 11208-3, 11208-4, 11405-2, 11405-3, 11405-4 • Refer to the pages for the SYSTEM / Control sec- • If the maximum speed cannot reach at the fast tion / Travel Motor Swash Angle Control in the T/M (Operational Principle). • Check the wiring connections first.
TROUBLESHOOTING / Troubleshooting B YES Faulty pressure sensor (travel). Open circuit in harness between pressure sensor (travel) and MC, or clogged shuttle valve in signal control valve. NO Faulty travel motor swash angle control valve. YES Faulty travel motor, or travel reduction gear.
TROUBLESHOOTING / Troubleshooting B OTHER SYSTEM TROUBLESHOOTING O-1 Wiper is inoperable or not retracted. Related MC Fault Code: None Checking Instructions • The wiper is driven by electric power routed via • If the front window is open, the wiper does not the relay circuit controlled by the monitor assembly. In case the wiper is inoperable, first check the wiper motor and links for any abnormality by using an auxiliary electric power and the test harness. operate.
TROUBLESHOOTING / Troubleshooting B Test Harness Application Circuit Fuse Box #15 M B Lamp S S Lamp B Wiper Motor L E Ground T178-05-04-004 Wiper Operating Range Intermittent Stop Position Retracted Position Operating Range T178-05-04-005 Test Harness Connection Method Wiper Motor Lamp B Lamp S Test Harness Fuse Box T157-07-04-004 T5-7-97
TROUBLESHOOTING / Troubleshooting B O-2 Air Conditioner Malfunction The air conditioner operation system has a self-diagnosing function. This system performs the diagnosis by 8-steps as shown in the flow chart below: Check Model Confirmation, Display Function Confirmation, Present Trouble Diagnosing, Past Trouble Diagnosing, Sensing Temperature Display, and Component Operation Check, Correction of the Set Temperature and Selection of Celsius and Fahrenheit Temperature Indication.
TROUBLESHOOTING / Troubleshooting B Self-Diagnostic System Activation Fan Switch Turn the key switch ON while pushing the air conditioner switch and mode switch on air conditioner control panel. LCD Air Conditioner Switch STEP 0 Check Model Confirmation The liquid crystal display (LCD) indicates the machine model name this system can diagnose. • The LCD will indicate “Sd” as the check model name. • Select next step in order to be performed by operating the switch as described below.
TROUBLESHOOTING / Troubleshooting B STEP 2 Present Trouble Diagnosing The LCD indicates the fault codes for present abnormalities of the mix door, mode encoder, and/or sensors. Fan Switch LCD • In case any abnormalities are present, the LCD indicates the fault codes. If more than one fault code is detected, the following fault code is displayed after flashing (0.5 seconds) twice.
TROUBLESHOOTING / Troubleshooting B STEP 3 Past Trouble Diagnosing The LCD indicates the fault codes for past abnormalities of the mix door, mode encoder, and/or sensors. The past stored fault codes are deleted. Fan Switch LCD Air Conditioner Switch • In case any abnormalities occurred in the past, the LCD indicates the fault codes. If more than one fault code is detected, the following fault code is displayed after flashing (0.5 seconds) twice.
TROUBLESHOOTING / Troubleshooting B STEP 4 Sensing Temperature Display The LCD indicates the sensing temperature detected by each temperature sensor (excluding the insulation sensor). Fan Mark Fan Switch LCD Air Conditioner Switch • The sensing temperature detected by the in-cab ambient temperature sensor, outdoor ambient temperature sensor and coolant temperature sensor are displayed on the LCD in real time. (Figures less than the decimal point are not displayed.
TROUBLESHOOTING / Troubleshooting B STEP 5 Component Operation Check Each component operation is checked by performing pattern operation. Fan Switch LCD Air Conditioner Switch AUTO Switch • Each time the fresh air vent switch is pushed, the component to be checked is selected in order. Check which component has been selected by referring to No. indicated on the LCD. (Refer to table 1.) • Operating pattern of the selected component is shifted at an interval of 10 seconds. Operating pattern is cycled.
TROUBLESHOOTING / Troubleshooting B STEP 6-1 Correction of the Set Temperature Fine correction of the set temperature. Fan Switch LCD Temperature Control Switch AUTO Switch • Each time when the top or bottom of temperature control switch is pushed, temperature correction, displayed on the LCD window, can be changed. • Actually controlled temperature is the normally set temperature plus the set temperature correction.
TROUBLESHOOTING / Troubleshooting B STEP 6-2 Selection of Celsius and Fahrenheit Temperature Indication Selection of Celsius and Fahrenheit Temperature In- Fan Switch LCD Air Conditioner Switch dication. • Each time when the fresh air vent switch is pushed, Celsius or Fahrenheit temperature may be displayed alternately. • Temperature is displayed at the top of LCD window as follows.
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.
TROUBLESHOOTING / Troubleshooting B Refrigerant Quantity....................... 850±50 g 3 Compressor Oil Quantity................
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 does not 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.
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.
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.).
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. -1 Clean evaporator. When humidity is high, open door. While rotating fan at approx.
TROUBLESHOOTING / Troubleshooting B Compressor Compressor does not 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 by using gas detector.
TROUBLESHOOTING / Troubleshooting B Seized clutch. Replace. Improper gap between amature and rotor (improper air gap). Replace. Open or shorted circuit in core cable. Shaft does not rotate (internally locked). Replace. Faulty Electrical System. Faulty Electrical System. Oil leaks from 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.
TROUBLESHOOTING / Troubleshooting B Compressor Compressor rotation is abnormally draggy. Overheating is susceptible to occur. Trouble other than compressor. Noise is heard when clutch is OFF. Abnormal noise Noise is heard when clutch is ON. T5-7-114 Refer to the Cooling Circuit Troubleshooting Table on page T5-7-100.
TROUBLESHOOTING / Troubleshooting B Broken clutch bearing due to overly tightened belt. Replace. Shaft does n’o rotate. Replace. Shaft rotates draggy. 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 T5-7-100. Saggy belt. Loose screws. Broken valve. Replace. Blown gasket. Abnormal internal noise. Replace. Vibration due to saggy belt.
TROUBLESHOOTING / Troubleshooting B EXCHANGE INSPECTION Exchange inspection method is a troubleshooting method to find the trouble location by exchanging the suspected part / component with another part /component having identical characteristics. Many sensors and solenoid valves used on this machine are identical. Therefore, by using this switch-check method, faulty part /component, and/or harness can be easily found.
TROUBLESHOOTING / Troubleshooting B Applicability of Switch-Check Method Fault Code 11000-2 11001-2 11002-2 11003-2 11004-2 11100-2 11101-3 11101-4 11200-3 11200-4 11202-3 11202-4 11206-3 11206-4 11208-3 11208-4 11301-3 11301-4 11302-3 11302-4 11303-3 11303-4 11304-3 11304-4 11307-3 11307-4 11400-2 11400-3 Trouble Abnormal EEPROM Abnormal RAM Abnormal A/D Conversion Abnormal Sensor Voltage Abnormal CAN Communication Abnormal Engine Speed Abnormal Engine Control Dial Sensor High Voltage Abnormal Engine C
TROUBLESHOOTING / Troubleshooting B Fault Code Trouble 11400-4 Abnormal Feedback Low Voltage of Maximum Pump 2 Flow Rate Limit Control Solenoid Valve Abnormal Feedback Current of Torque Control Solenoid Valve Abnormal Feedback High Voltage of Torque Control Solenoid Valve Abnormal Feedback Low Voltage of Torque Control Solenoid Valve Abnormal Feedback Current of Solenoid Valve Unit (SF) Abnormal Feedback High Voltage of Solenoid Valve Unit (SF) Abnormal Feedback Low Voltage of Solenoid Valve Unit (SF) Ab
TROUBLESHOOTING / Troubleshooting B EMERGENCY BOOM LOWERING PROCEDURE CAUTION: Prevent personal injury. Confirm that no one is under the front attachment before starting the procedure below. Emergency Valve If the engine stalls and cannot be restarted, lower the boom to the ground referring to the emergency boom lowering procedure stated below. 1. Loosen lock nut (1) in the control valve at the right. Loosen screw (2) one half of a turn.
TROUBLESHOOTING / Troubleshooting B ONE PART OF DATA, “DAILY REPORT DATA”, “DISTRIBUTION DATA” AND TOTAL OPERATING HOURS” IN NOT RECORDED • The required signal for data may not be sent to ICF. As each signal is used for some data, check the corresponding signal system according to the table below. Data Daily report data is not recorded.
TROUBLESHOOTING / Troubleshooting B Position to be checked Key signal line, alternator signal line Remedy Check terminal #C7 (power ON signal line) of connector ICF-C in ICF. Communication line between monitor unit and Check terminals #C5, #C11 of connector ICF-C in ICF and ICF (CAN bus line) terminals #18, #38 of connector in ECM. Communication line between ECM and ICF Check terminals #C5, #C11 of connector ICF-C in ICF and (CAN bus line) terminals #18, #38 of connector in ECM.
TROUBLESHOOTING / Troubleshooting B Data Input Signal Breaker Operating Attachment information sent from MC Hours Secondary Crusher Attachment information sent from MC Operating Hours Attachment Operating Primary Crusher Oper- Attachment information sent from MC Hours ating Hours Vibrating Hammer Op- Attachment information sent from MC erating Hours Bucket Operating Attachment information sent from MC Hours or Others No Load Time Pressure sensor information sent from MC Radiator Coolant Temperature Radia
TROUBLESHOOTING / Troubleshooting B Position to be checked Communication line between MC and ICF (CAN bus line) Communication line between MC and ICF (CAN bus line) Communication line between MC and ICF (CAN bus line) Communication line between monitor unit and ICF (CAN bus line) Communication line between MC and ICF (CAN bus line) Communication line between ECM and ICF (CAN bus line) Remedy Check terminals #C5, #C11 of connector ICF-C in ICF minals #C4, #C15 of connector MC-C in MC.
TROUBLESHOOTING / Troubleshooting B (Blank) T5-7-124
TROUBLESHOOTING / Electrical System Inspection PRECAUTIONS FOR INSPECTION AND MAINTENANCE 1. Disconnect the power source. Remove the harness from the negative terminal side in battery 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 circuiting. 2. Color coding of wire harnesses.
TROUBLESHOOTING / Electrical System Inspection 3. Precautions for connecting and disconnecting terminal connectors. 1) When disconnecting the harnesses, grasp them by their connectors. Do not pull on the wire itself. Release the lock first before attempting to separate connectors, if a lock is provided. (Refer to “Instructions for Disconnecting Connector” on page T5-8-3.) 2) The water-resistant connectors keep water out. If water enters them, water will not easily drain from them.
TROUBLESHOOTING / Electrical System Inspection INSTRUCTIONS CONNECTORS • FOR DISCONNECTING Push, Unlock and Separate Type NOTE: 1. Connectors will not be easily separated even if the lock is pushed while being pulled. Push the lock first before pulling the connectors. 2. The lock is located on female side connector (harness end side).
TROUBLESHOOTING / Electrical System Inspection FUSE INSPECTION Cracks in a fuse are so fine that it is very difficult or impossible to find by visual inspection. Use a tester in order to correctly inspect fuse continuity by following the instructions described below. NOTE: All terminals located along the lengthwise centerline of the fuse box are connected to the power source, while terminals located away from center of the fuse box are connected to loads (accessories).
TROUBLESHOOTING / Electrical System Inspection FUSIBLE LINK INSPECTION Battery Relay Inspection 1. Remove the negative cable from the battery. 2. Loosen bolt M8 holding the cable routed in front of the fusible link box. Slide the cable out of the way of the front cover. 3. Open the front cover of fusible link box and visually inspect the fusible link. Fusible Link Fusible Link M178-07-049 Cover Replacement 1. Check that the negative cable is removed from the battery. 2. Remove bolt M8.
TROUBLESHOOTING / Electrical System Inspection BATTERY VOLTAGE CHECK 1. Turn the key switch OFF. Check voltage between the battery positive terminal and the vehicle frame. 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 frame. Normal Voltage: 26 to 28 V NOTE: If voltage is abnormal, check the charging system.
TROUBLESHOOTING / Electrical System Inspection ALTERNATOR CHECK In general, the alternator indicator remains off when the alternator is generating power. If the alternator indicator comes on while the engine is running, the alternator might be defective. How to check the circuit 1. Turn the key switch to the ON position. Confirm that the alternator alarm is displayed. 2. Measure voltage between teminals B and E of the alternator.
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.
TROUBLESHOOTING / Electrical System Inspection 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.
TROUBLESHOOTING / Electrical System Inspection VOLTAGE MENT AND CURRENT MEASURE- Turn key switch ON so that the specified voltage (current) is supplied to the location to be measured. Judge if the circuit is normal by evaluating whether the measured voltage (current) matches the specification. 24-Volt Circuit Start checking the circuit in order up to the location to be measured from either power source or actuator side. Thereby, the faulty location in the circuit will be found.
TROUBLESHOOTING / Electrical System Inspection Power Source Circuit Preheat Circuit Charging Circuit Surge Voltage Prevention Circuit Accessory Circuit Key Switch Battery 1 2 3 5 4 17 10 6 Starter 9 B C 13 B Load Damp Relay Fuse Box S E R 16 15 14 11 B 12 Glow Relay L C7 8 7 Glow Plug Monitor Unit T5-8-11 T1V1-05-06-001
TROUBLESHOOTING / Electrical System Inspection Engine Starting Circuit Started Started Started Started Started Started Started Started Started Started Started Started Started Started Started Key Switch START START START START START START START START START START START START START START START Location to be Measured Between (18) and Ground: Key Switch Between (19) and Ground: Battery Relay (Coil) Between (20) and Ground: Battery Relay (Switch) Between (21) and Ground: Starter (B) Between (22) and Ground: St
TROUBLESHOOTING / Electrical System Inspection Starting Circuit Key Switch 19 20 Starter Cut Relay 18 26 Battery 25 Battery Relay Starter 21 22 24 23 Starter Relay 2 R 27 C7 ECM Main Relay 31 28 32 ECM MC Monitor Unit A7 B16 1-24 29 30 T1V1-05-06-002 T5-8-13
TROUBLESHOOTING / Electrical System Inspection Engine Pilot Shut-Off Circuit Stopped Stopped Stopped Stopped Stopped Key Switch ON ON ON ON ON Location to be Measured Between (33) and Ground: Fuse Box Between (34) and Ground: Pilot Shut-Off Relay Between (35) and Ground: Pilot Shut-Off Solenoid Valve Between (36) and Ground: Pilot Shut-Off Relay Between (37) and Ground: Security Relay NOTE: *Before measurement, disconnect the negative cable from the battery.
TROUBLESHOOTING / Electrical System Inspection Pilot Shut-Off Circuit Key Switch Starter Cut Relay #6 33 Battery Battery Relay Starter Fuse Box Starter Relay 2 Security Relay 37 Pilot Shut-Off Lever Pilot Shut-Off Relay 36 35 34 Pilot Shut-Off Solenoid Valve Monitor Unit T1V1-05-06-003 T5-8-15
TROUBLESHOOTING / Electrical System Inspection 5 Voltage Circuit • Voltage between terminal #1 and the vehicle Signal or Ground Power Source 1 Two Polarities frame Disconnect the connector with the key switch OFF. Measure voltage between terminal #1 on the machine harness end connector and the vehicle frame (ground).
TROUBLESHOOTING / Electrical System Inspection CHECK BY FALSE SIGNAL Two Polarities Turn the key switch OFF. Disconnect the sensor connector. Turn the key switch ON. Connect terminal #1 (power source) of machine harness end connector to terminal #2 (signal). (Power voltage is used as a false signal.) Check this state by using the monitor function of Dr. ZX. When the maximum value is displayed, MC and the circuit up to the machine harness end connector are normal.
TROUBLESHOOTING / Electrical System Inspection TEST HARNESS Install a test harness between connectors. Check the circuit condition depending on whether the test harness lamp lights or extinguishes during operation. Parts Number 4283594 (ST 7126) Use in order to check a single-line (discontinuity and/or voltage). During Operation: Lamp is ON. To Location to be Measured. To Ground T107-07-05-012 Parts Number 4283594 (ST 7126) Parts Number (ST 7226) Use in order to check the solenoid valve unit circuits.
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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.: YOUR NAME: DATE: FAX: (Located at the right top corner in the cover page) PAGE NO.: (Located at the bottom center in the page. If two or more revisions are requested, use the comment column) YOUR COMMENTS / SUGGESTIONS: Attach photo or sketch if required.
THE ATTACHED DIAGRAM LIST (The following diagrams are attached to this manual.) 1. ZAXIS200-3 CLASS/240-3 CLASS/270-3 CLASS/330-3 CLASS ELECTRICAL CIRCUIT DIAGRAM 2. ZAXIS200-3 CLASS/240-3 CLASS/270-3 CLASS/330-3 CLASS CONNECTORS 3. ZAXIS330-3 CLASS ENGINE HARNESS 1 4. ZAXIS200-3 CLASS/240-3 CLASS/270-3 CLASS/330-3 CLASS ENGINE HARNESS 2 ZAXIS200-3 CLASS/240-3 CLASS/270-3 CLASS/330-3 CLASS MONITOR UNIT HARNESS 5. ZAXIS200-3 CLASS/240-3 CLASS/270-3 CLASS/330-3 CLASS CAB HARNESS 6.
