Está en la página 1de 344

-

--- - -

-
-

PDF created with pdfFactory Pro trial version www.pdffactory.com


PDF created with pdfFactory Pro trial version www.pdffactory.com
INTRODUCTION
TO THE READER
This manual is written for an experienced technician If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using Service Manual
Revision Request Form at the end of this man-
Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162

ADDITIONAL REFERENCES

Please refer to the materials listed below in addition Operation Manual of the Engine
to this manual. Parts Catalog of the Engine
Hitachi Training Material
The Operators Manual
The Parts Catalog

MANUAL COMPOSITION

This manual consists of three portions: the Techni- Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.

Information included in the Technical Manual Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redelivery and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.

IN-01

PDF created with pdfFactory Pro trial version www.pdffactory.com


INTRODUCTION
PAGE NUMBER
Each page has a number, located on the center
lower part of the page, and each number contains
the following information:

Example : T 1-3-5

Consecutive Page Number for Each Group


Group Number
Section Number
T: Technical Manual W: Workshop Manual

SAFETY ALERT SYMBOL AND HEADLINE


NOTATIONS
CAUTION:
In this manual, the following safety alert symbol and Indicated potentially hazardous situation which
signal words are used to alert the reader to the could, if not avoided, result in personal injury or
potential for personal injury of machine damage. death.

This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury. Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights. NOTE:
To avoid injury and damage, be sure to use appropri- Indicates supplementary technical information or
know-how.
ate lifting techniques and equipment when lifting
heavy parts.

IN-02

PDF created with pdfFactory Pro trial version www.pdffactory.com


INTRODUCTION
UNITS USED
2
SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.

To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature pC pF pCI1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque Nm kgf m 1.0197 mL/rev cc/rev 1.0
Nm lbf ft 0.7375

IN-03

PDF created with pdfFactory Pro trial version www.pdffactory.com


INTRODUCTION
(Blank)

IN-04

PDF created with pdfFactory Pro trial version www.pdffactory.com


SAFETY
RECOGNIZE SAFETY INFORMATION
This is the SAFETY ALERT SYMBOL.
When you see this symbol on your machine or in
this manual, be alert to the potential for personal
injury.
Follow recommended precautions and safe
operating practices.

001-E01A-0688

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.
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
DANGER or WARNING safety signs are
located near specific hazards. General
precautions are listed on CAUTION safety
signs.
Some safety signs dont use any of the
designated signal words above after the safety
alert symbol are occasionally used on this
machine. SA-1223

CAUTION also calls attention to safety messages in


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

NOTE indicates an additional explanation for an


element of information.
002-E01C-1223

SA-1

PDF created with pdfFactory Pro trial version www.pdffactory.com


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 author-
ized dealer in the same way you order other
replacement parts (be sure to state machine
model and serial number when ordering).
Learn how to operate the machine and its controls
correctly and safely.
Allow only trained, qualified, authorized personnel SA-003

to operate the machine.


Keep your machine in proper working condition.
Unauthorized modifications of the machine may
impair its function and/or safety and affect ma-
chine life.
The safety messages in this SAFETY chapter are
intended to illustrate basic safety procedures of
machines. However it is impossible for these safety
messages to cover every hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your au-
thorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003

SA-2

PDF created with pdfFactory Pro trial version www.pdffactory.com


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 at-
tached on the fire extinguisher to use it properly.
To ensure that a fire-extinguisher can be always
used when necessary, check and service the
fire-extinguisher at the recommended intervals as
specified in the fire-extinguisher manual.
Establish emergency procedure guidelines to
cope with fires and accidents.
Keep emergency numbers for doctors, ambu-
lance service, hospital, and fire department SA-437

posted near your telephone.

004-E01A-0437

WEAR PROTECTIVE CLOTHING

Wear close fitting clothing and safety equipment


appropriate to the job.
You may need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask. SA-438

Be sure to wear the correct equipment and clothing


for the job. Do not take any chances.
Avoid wearing loose clothing, jewelry, or other
items that can catch on control levers or other
parts of the machine.
Operating equipment safely requires the full
attention of the operator. Do not wear radio or
music headphones while operating the machine.

005-E01A-0438

SA-3

PDF created with pdfFactory Pro trial version www.pdffactory.com


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.
In the walk-around inspection be sure to cover all
points described in the PRE-START
INSPECTION chapter in the operators manual.

S007-E01A-0435

SA-435

SA-4

PDF created with pdfFactory Pro trial version www.pdffactory.com


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 operators
work boots the operators foot may slip off the
pedal, possibly resulting in a personal accident.
Dont leave parts and/or tools lying around the
operators seat. Store them in their specified lo-
cations.
Avoid storing transparent bottles in the cab. Dont
attach any transparent type window decorations
on the windowpanes as they may focus sunlight,
possibly starting a fire.
Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab
while operating the machine.
Keep all flammable objects and/or explosives
away from the machine.
After using the ashtray, always cover it to extin-
guish the match and/or tobacco.
Dont leave cigarette lighters in the cab. When
the temperature in the cab increases, the lighter
may explode.
524-E01A-0000

SA-5

PDF created with pdfFactory Pro trial version www.pdffactory.com


SAFETY
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal injury.
When you mounting and dismounting the ma-
chine, 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 mounting and dis-
mounting the machine.
SA-439

008-E01B-0439

ADJUST THE OPERATOR'S SEAT

A poorly adjusted seat for either the operator or for


the work at hand may quickly fatigue the operator
leading to misoperations.
The seat should be adjusted whenever changing
the operator for the machine.
The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
If not, move the seat forward or backward, and
check again.
SA-378

009-E01A-0378

SA-6

PDF created with pdfFactory Pro trial version www.pdffactory.com


SAFETY
FASTEN YOUR SEAT BELT
If the machine should overturn, the operator may
become injured and/or thrown from the cab.
Additionally the operator may be crushed by the
overturning machine, resulting in serious injury or
death.
Prior to operating the machine, thoroughly
examine webbing, buckle and attaching
hardware. If any item is damaged or worn,
replace the seat belt or component before
operating the machine.
Be sure to remain seated with the seat belt SA-237

securely fastened at all times when the machine


is in operation to minimize the chance of injury
from an accident.
We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.

010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY

Bystanders can be run over.


Take extra care not to run over bystanders.
Confirm the location of bystanders before moving,
swinging, or operating the machine.
Always keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the
machine. SA-426

011-E01A-0426

SA-7

PDF created with pdfFactory Pro trial version www.pdffactory.com


SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
Inappropriate engine starting procedures may
cause the machine to runaway, possibly resulting in
serious injury or death.
Start the engine only when seated in the
operator's seat.
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 SA-444

levers are in neutral.

012-E01B-0444

JUMP STARTING
Battery gas can explode, resulting in serious injury.
If the engine must be jump started, be sure to
follow the instructions shown in the OPERATING
THE ENGINE chapter in the operators manual.
The operator must be in the operators seat so
that the machine will be under control when the
engine starts. Jump starting is a two-person
operation.
Never use a frozen battery.
Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway SA-032

machine.

S013-E01A-0032

SA-8

PDF created with pdfFactory Pro trial version www.pdffactory.com


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 operators view, resulting
in the machine being operated in an unsafe
manner.

014-E01B-0379
SA-379

PROVIDE SIGNALS FOR FOBS INVOLV-


ING MULTIPLE NUMBERS OF MACHINES

For jobs involving multiple numbers of machines,


provide signals commonly known by all personnel
involved. Also, appoint a signal person to coordi-
nate the job site. Make sure that all personnel obey
the signal persons directions.

018-E01A-0481
SA-481

CONFIRM DIRECTION OF MACHINE TO


BE DRIVEN

Incorrect travel pedal/lever operation may result in


serious injury death.
Before driving the machine, confirm the position
of the undercarriage in relation to the operators
position. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.

017-E01A-0491
SA-491

SA-9

PDF created with pdfFactory Pro trial version www.pdffactory.com


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. Dont allow personnel to stay
around the machine while traveling.

SA-387

Driving on a slope may cause the machine to slip or


overturn, possibly resulting in serious injury or
death.
When driving up or down a slope, keep the
bucket facing the direction of travel, approxi-
mately 200 to 300 mm (A) above the ground.
If the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and
stop traveling.

SA-388

Driving across the face of a slope or steering on SA-441

a slope may cause the machine to skid or turn-


over. If the direction must be changed, move the
machine to level ground, then, change the direc- WRONG
tion to ensure sage operation.

019-E01D-0492

SA-590

SA-10

PDF created with pdfFactory Pro trial version www.pdffactory.com


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 / acceleration seleclter and the SA-391

H/P mode switch off.


Run the engine at slow idle speed without load
for 5 minutes to cool down the engine.
Stop the engine and remove the key from the key
switch.
Pull the pilot control shut-off lever to LOCK
position.
Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
Position the machine to prevent rolling.
Park a reasonable distance from other machines.
SA-392

020-E08A-0493

SA-11

PDF created with pdfFactory Pro trial version www.pdffactory.com


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 SA-383

equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
USE A SIGNAL PERSON WHEN BACKING UP
IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a
signal person.
No machine motions shall be made unless
signals are clearly understood by both signalman SA-384

and operator.
Learn the meanings of all flags, signs, and
markings used on the job and confirm who has
the responsibility for signaling.
Keep windows, mirrors, and lights clean and in
good condition.
Dust, heavy rain, fog, etc., can reduce visibility.
As visibility decreases, reduce speed and use
proper lighting.
Read and understand all operating instructions in
the operators manual.

S021-E01A-0494

SA-12

PDF created with pdfFactory Pro trial version www.pdffactory.com


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 SA-012

injury or death.

To avoid tipping:
Be extra careful before operating on a grade.
Prepare machine operating area flat.
Keep the bucket low to the ground and close to
the machine.
Reduce operating speeds to avoid tipping or
slipping.
Avoid changing direction when traveling on
grades.
NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is SA-440

unavoidable.
Reduce swing speed as necessary when
swinging loads.
Be careful when working on frozen ground.
Temperature increases will cause the ground to
become soft and make ground travel unstable.

S025-E01B-0495

SA-13

PDF created with pdfFactory Pro trial version www.pdffactory.com


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 (10 ft) plus twice the line insulator length.
Check and comply with any local regulations that
may apply.
Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site.
SA-381

029-E01A-0381

OBJECT HANDLING

If a lifted load should fall, any person nearby may


be struck by the falling load or may be crushed
underneath it, resulting in serious injury or death.
When using the machine for craning operations,
be sure to comply with all local regulations.
Do not use damaged chains or frayed cables,
sables, slings, or ropes.
Before craning, position the upperstructure with
the travel motors at the rear.
Move the load slowly and carefully. Never move it
suddenly.
Keep all persons well away from the load.
Never move a load over a person's head.
Do not allow anyone to approach the load until it
is safely and securely situated on supporting
SA-014
blocks or on the ground.
Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.

032-E01A-0014

SA-14

PDF created with pdfFactory Pro trial version www.pdffactory.com


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 / acceleration selector and H/P
mode switch off.
Run engine at slow idle speed without load for 5
minutes.
Turn key switch to OFF to stop engine.
Remove the key from the key switch.
Pull the pilot control shut-off lever to the LOCK
position. SA-390

Close windows, roof vent, and cab door.


Lock all access doors and compartments.

033-E09B-0390

SA-15

PDF created with pdfFactory Pro trial version www.pdffactory.com


SAFETY
HANDLE FLUIDS SAFELY AVOID FIRES
Handle fuel with care; it is highly flammable. If fuel
ignites, an explosion and/or a fire may occur,
possibly resulting in serious injury or death.
Do not refuel the machine while smoking or when
near open flame or sparks.
Always stop the engine before refueling the
machine.
Fill the fuel tank outdoors.

All fuels, most lubricants, and some coolants are


flammable. SA-018

Store flammable fluids well away from fire


hazards.
Do not incinerate or puncture pressurized
containers.
Do not store oily rags; they can ignite and burn
spontaneously.
Securely tighten the fuel and oil filler cap.

034-E01A-0496

SA-019

SA-16

PDF created with pdfFactory Pro trial version www.pdffactory.com


SAFETY
SAFETY TRANSPORTING
The danger of tipping is present when
loading/unloading the machine onto/from a truck or
trailer bed.
Be sure to observe local regulations when
transporting the machine on public roads.
Provide an appropriate truck or trailer for
transporting the machine.

Take the following precautions when loading /


unloading the machine:
1) Select firm level ground. SA-395

2) Be sure to use a loading dock or ramp.


3) Be sure to have a signal person when
loading/unloading the machine.
4) Always turn the auto-idle / acceleration selector
and the H/P mode switch OFF when loading or
unloading the machine, to avoid unexpected
speed increase due to unintentional operation
of a control lever.
5) Always select the slow speed mode with the
travel mode switches. In the high speed mode,
travel speed may automatically increase.
6) Avoid steering while driving up or down the
ramp as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify traveling direction, and begin to
drive again.
7) Do not operate any levers besides the travel
levers when driving up or down the ramp.
8) The top end of the ramp where it meets the
flatbed is a sudden bump. Take care when
traveling over it.
9) Prevent possible injury from machine tipping
while the upperstructure is rotating.
10) Keep the arm tucked under and rotate the
upperstructure slowly for best stability.
11) Securely fasten chain or cables to the machine
frame. Refer to "transporting" chapter in the
operator's manual for details.

S035-E08A-0395

SA-17

PDF created with pdfFactory Pro trial version www.pdffactory.com


SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:

Understand service procedures before doing


work.
Keep 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 / acceleration selecltor off.
4) Run the engine at slow idle speed without load
for 5 minutes.
5) Turn the key switch to OFF to stop engine.
6) Relieve the pressure in the hydraulic system by
moving the control levers several times.
7) Remove the key from the switch.
8) Attach a Do Not Operate tag on the control
lever.
9) Pull the pilot control shut-off lever to the LOCK
position.
10) Allow the engine to cool.

SA-18

PDF created with pdfFactory Pro trial version www.pdffactory.com


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
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
Never work under a machine raised by the boom.
Inspect certain parts periodically and repair or
replace as necessary. Refer to the section
discussing that part in the MAINTENANCE
chapter in the operators manual.
Keep all parts in good condition and properly
installed.
Fix damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or
debris.
When cleaning parts, always use nonflammable
SA-028
detergent oil. Never use highly frammable oil
such as fuel oil and gasoline to clean parts or
surfaces.
Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
Illuminate your work area adequately but safely.
Use a portable safety light for working inside or
under the machine.
Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
Sufficiently illuminate the work site. Use a
maintence work light when working under or SA-527

inside the machine.


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

S500-E02B-0497

SA-037

SA-19

PDF created with pdfFactory Pro trial version www.pdffactory.com


SAFETY
WARN OTHERS OF SERVICE WORK
Unexpected machine movement can cause serious
injury.
Before performing any work on the machine, at-
tach a Do Not Operate tag on the control lever.
This tag is available from your authorized dealer.

SS2045102

SUPPORT MACHINE PROPERLY


Never attempt to work on the machine without
securing the machine first.
Always lower the attachment to the ground
before you work on the machine.
If you must work on a lifted machine or
attachment, securely support the machine or
attachment. Do not support the machine on
cinder blocks, hollow tires, or props that may
crumble under continuous load. Do not work
under a machine that is supported solely by a
SA-527
jack.
519-E01A-0527

STAY CLEAR OF MOVING PARTS


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

502-E01A-0026

SA-026

SA-20

PDF created with pdfFactory Pro trial version www.pdffactory.com


SAFETY
PREVENT PARTS FROM FLYING
Grease in the track adjuster is under high pressure.
Failure to follow the precautions below may result in
serious injury, blindness, or death.
Do not attempt to remove GREASE FITTING or
VALVE ASSEMBLY.
As pieces may fly off, be sure to keep body and
face away from valve.
Travel reduction gears are under pressure.
As pieces may fly off, be sure to keep body and
face away from AIR RELEASE PLUG to avoid
injury. GEAR OIL is hot. SA-344

Wait for GEAR OIL to cool, then gradually loosen


AIR RELEASE PLUG to release pressure.

503-E01B-0344

STORE ATTACHMENTS SAFELY

Stored attachments such as buckets, hydraulic


hammers, and blades can fall and cause serious
injury or death.
Securely store attachments and implements to
prevent falling. Keep children and bystanders
away from storage areas.

504-E01A-0034 SA-034

USE TOOLS PROPERLY


Use tools appropriate for the work to be done.
Makeshift tools, parts, and procedures can create
safety hazards.
For loosening and tightening hardware, use the
correct size tools to avoid injury caused by
slipping wrenches.
Use only recommended replacement parts.
(See the parts catalog.)

SA-040
S522-E01A-0040

SA-21

PDF created with pdfFactory Pro trial version www.pdffactory.com


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. SA-039

The hydraulic oil tank is pressurized. Again, be


sure to release all pressure before removing the
cap.

Hot fluids and surfaces:


Engine oil, gear oil and hydraulic oil also become
hot during operation.
The engine, hoses, lines and other parts become
hot as well.
Wait for the oil and components to cool before
starting any maintenance or inspection work.

505-E01B-0498 SA-225

REPLACE RUBBER HOSES


PERIODICALLY

Rubber hoses that contain flammable fluids under


pressure may break due to aging, fatigue, and
abrasion. It is very difficult to gauge the extent of
deterioration due to aging, fatigue, and abrasion of
rubber hoses by inspection alone.
Periodically replace the rubber hoses. (See the
page of Periodic replacement of parts in the
operators manual.)
Failure to periodically replace rubber hoses may
cause a fire, fluid injection into skin, or the front SA-019

attachment to fall on a person nearby, which may


result in severe burns, gangrene, or otherwise
serious injury or death.

S506-E01A-0019

SA-22

PDF created with pdfFactory Pro trial version www.pdffactory.com


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 SA-031

goggles for eye protection.


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

SA-292

507-E03A-0499

SA-044

SA-23

PDF created with pdfFactory Pro trial version www.pdffactory.com


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 SA-019

hoses.

Check for Shorts:


Short circuits can cause fires.
Clean and tighten all electrical connections.
Check before starting work for loose, kinked,
hardened or frayed electrical cables and wires.
Check before starting work for missing or
damaged terminal caps.
DO NOT OPERATE MACHINE if cable or wires
are loose, kinked, etc..

Clean up Flammables:
Spilled fuel and oil, and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.
Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.

SA-24

PDF created with pdfFactory Pro trial version www.pdffactory.com


SAFETY
Check Key Switch:
If a fire breaks out, failure to stop the engine will
escalate the fire, hampering fire fighting.
Always check key switch function before
operating the machine every day:
1) Start the engine and run it at slow idle.
2) Turn the key switch to the OFF position to
confirm that the engine stops.
If any abnormalities are found, be sure to repair
them before operating the machine.

Check Emergency Engine Stop Switch:


If a fire breaks out, failure to release pressurized air
inside the hydraulic tank will escalate fire, hamper-
ing fire fighting.
Check the emergency engine stop switch func-
tion every 250 hours:
1) Start the engine and run it at slow Idle.
2) Turn the emergency engine stop switch to the
EMERG. STOP position.
3) Confirm that both engines stop and that
pressurized air inside the hydraulic oil tank is
released (a hissing sound should be heard).
If any abnormalities are found, be sure to repair
them before operating the machine.

Check Heat Shields:


Damaged or missing heat shields may lead to fires.
Damaged or missing heat shields must be
repaired or replaced before operating the
machine.

S508-E02B-0019

SA-25

PDF created with pdfFactory Pro trial version www.pdffactory.com


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 and/or the front SA-393

window cannot be opened, break the front or rear


window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on EMERGENCY
EXIT in Operators Manual.

518-E02B-0393

SS-1510

BEWARE OF EXHAUST FUMES


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

509-E01A-0016

SA-016

SA-26

PDF created with pdfFactory Pro trial version www.pdffactory.com


SAFETY
PRECAUTIONS FOR WELDING AND
GRINDING
Welding may generate gas and/or small fires.
Be sure to perform welding in a well ventilated
and prepared area. Store flammable objects in a
safe place before starting welding.
Only qualified personnel should perform welding.
Never allow an unqualified person to perform
welding.
Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before
starting grinding.
After finishing welding and grinding, recheck that SA-818

there are no abnormalities such as the area sur-


rounding the welded area still smoldering.
523-E01A-0818

AVOID HEATING NEAR PRESSURIZED


FLUID LINES

Flammable spray can be generated by heating near


pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
Do not heat by welding, soldering, or using a
torch near pressurized fluid lines or other
flammable materials.
Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area.
Install temporary fire-resistant guards to protect
hoses or other materials before engaging in
welding, soldering, etc.. SA-030

AVOID APPLYING HEAT TO LINES


CONTAINING FLAMMABLE FLUIDS

Do not weld or flame cut pipes or tubes that


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

SA-27

PDF created with pdfFactory Pro trial version www.pdffactory.com


SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
Avoid potentially toxic fumes and dust.
Do all such work outside or in a well-ventilated
area. Dispose of paint and solvent properly.

Remove paint before welding or heating:


1) If you sand or grind paint, avoid breathing the
dust. SA-029

Wear an approved respirator.


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

511-E01A-0029

PREVENT BATTERY EXPLOSIONS

Battery gas can explode.


Keep sparks, lighted matches, and flame away
from the top of battery.
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or hy-
drometer.
Do not charge a frozen battery; it may explode.
Warm the battery to 16 pC ( 60 pF ) first.
Do not continue to use or charge the battery
when electrolyte level is lower than specified. Ex-
plosion of the battery may result. SA-032

Loose terminals may produce sparks. Securely


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

512-E01C-0032

SA-28

PDF created with pdfFactory Pro trial version www.pdffactory.com


SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
If spilled onto skin, refrigerant may cause a cold
contact burn.
Refer to the freon container for proper use when
servicing the air conditioning system.
Use a recovery and recycling system to avoid
venting freon into the atmosphere.
Never let the freon stream make contact with the
skin.

SA-405
513-E01A-0405

HANDLE CHEMICAL PRODUCTS SAFELY

Direct exposure to hazardous chemicals can cause


serious injury. Potentially hazardous chemicals
used with your machine include such items as
lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides
specific details on chemical products: physical
and health hazards, safety procedures, and
emergency response techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know
exactly what the risks are and how to do the job SA-309

safely. Then follow procedures and use


recommended equipment.

S515-E01A-0309

SA-29

PDF created with pdfFactory Pro trial version www.pdffactory.com


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.
Air conditioning refrigerants escaping into the air
can damage the Earths atmosphere. SA-226

Government regulations may require a certified


air conditioning service center to recover and
recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of
waste from your local environmental or recycling
center.

S516-E01A-0226

BEFORE RETURNING THE MACHINE TO


THE CUSTOMER

After maintenance or repair work is complete,


confirm that:
The machine is functioning properly, especially
the safety systems.
Worn or damaged parts have been repaired or
replaced

S517-E01A-0435 SA-435

SA-30

PDF created with pdfFactory Pro trial version www.pdffactory.com


SECTION AND GROUP SECTION 4 OPERATIONAL PER-
CONTENTS FORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
TECHNICAL MANUAL
Group 6 Adjustment
(Troubleshooting) SECTION 5 TROUBLESHOOTING
Group 1 General
Group 2 Component Layout
Group 3 Troubleshooting A
Group 4 Troubleshooting B
Group 5 Troubleshooting C
Group 6 Electrical System Inspection
Group 7 ICX
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Control System Group 5 Travel Device
Group 2 Hydraulic System Group 6 Others (Upperstructure)
Group 3 Electrical System Group 7 Others (Undercarriage)
All information, illustrations and speci-
fications in this manual are based on WORKSHOP MANUAL
the latest product information available
SECTION 1 GENERAL INFORMA- SECTION 3 UNDERCARRIAGE
at the time of publication. The right is
reserved to make changes at any time TION Group 1 Swing Bearing
Group 1 Precautions for Disassem- Group 2 Travel Device
without notice.
bling and Assembling Group 3 Center Joint
Group 2 Tightening Torque Group 4 Track Adjuster
Group 3 Painting Group 5 Front Idler
SECTION 2 UPPERSTRUCTURE Group 6 Upper and Lower Roller
Group 1 Cab Group 7 Track
Group 2 Counterweight SECTION 4 FRONT ATTACHMENT
COPYRIGHT(C)2005
Group 3 Main Frame Group 1 Front Attachment
Hitachi Construction Machinery Co., Ltd.
Group 4 Pump Device Group 2 Cylinder
Group 5 Control Valve SECTION 5 ENGINE
Tokyo, Japan
Group 6 Swing Device
All rights reserved
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 9 Shockless Valve
Group 10 Solenoid Valve Unit

PDF created with pdfFactory Pro trial version www.pdffactory.com


PDF created with pdfFactory Pro trial version www.pdffactory.com
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
Operational Performance Swing Speed .............................................T4-4-5
Standard Table ...................................... T4-2-1 Swing Function Drift Check .......................T4-4-6
Main Pump P-Q Curve .............................. T4-2-6 Swing Motor Leakage................................T4-4-8
Injection Pump .......................................... T4-2-8 Maximum Swingable Slant Angle ..............T4-4-9
Dr.ZX Monitor Indicating Values .............. T4-2-9 Swing Bearing Play .................................T4-4-10
Sensor Activating Range ........................ T4-2-13 Hydraulic Cylinder Cycle Time ................T4-4-12
Dig Function Drift Check .........................T4-4-14
Group 3 Engine Test Control Lever Operating Force ................ T4-4-16
Engine Speed ........................................... T4-3-1 Control Lever Stroke ...............................T4-4-18
Engine Compression Pressure ................. T4-3-4 Combined Boom Raise/Swing
Valve Clearance Adjustment ..................... T4-3-5 Function Check .....................................T4-4-19
Nozzle Check............................................ T4-3-8 Combined Boom Raise and
Injection Timing....................................... T4-3-13 Arm Roll-In Operation ..........................T4-4-20
Lubricant Consumption ......................... T4-3-14

1HHT-4-1

PDF created with pdfFactory Pro trial version www.pdffactory.com


Group 5 Component Test
Primary Pilot Pressure .............................. T4-5-1
Secondary Pilot Pressure ......................... T4-5-3
Solenoid Valve Set Pressure..................... T4-5-4
Main Pump Delivery Pressure................... T4-5-7
Main Relief Valve Set Pressure................. T4-5-8
Relief Pressure (When relieving
Swing) ................................................. T4-5-11
Relief Pressure (When relieving
Travel) ................................................. T4-5-12
Overload Relief Valve Set Pressure ........ T4-5-16
Main Pump Flow Rate Measurement ...... T4-5-20
Swing Motor Drainage ............................ T4-5-27
Travel Motor Drainage ............................ T4-5-30

Group 6 Adjustment
Engine Speed Adjustment and
Engine Learning .................................... T4-6-1
Govenor Lever and Fuel
Cut Lever Position ................................. T4-6-4

1HHT-4-2

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedure to quan- The machine performance does not always deterio-
titatively check all system and functions on the ma- rate as the working hours increase. However, the
chine. machine performance is normally considered to re-
duce in proportion to the increase of the operation
Purpose of Performance Tests hours. Accordingly, restoring the machine perform-
1. To comprehensively evaluate each operational ance by repair, adjustment, or replacement shall con-
function by comparing the performance test data sider the number of the machines working hours.
with the standard values.
2. According to the evaluation results, repair, adjust, Definition of Performance Standard
or replace parts or components as necessary to 1. Operation speed values and dimensions of the
restore the machines performance to the desired new machine.
standard. 2. Operational performance of new components
3. To economically operate the machine under op- adjusted to specifications. Allowable errors will be
timal conditions. indicated as necessary.

Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the op-
erational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.

Performance Standards
Performance Standard is shown in tables to evalu-
ate the performance test data.

Precautions for Evaluation of Test Data


1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.

T4-1-1

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out
performance tests accurately and safely.

THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.

TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to
run straight more than 20 m (65 ft 7 in), and to
make a full swing with the front attachment ex-
tended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.

PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork-
ers. Once the test is started, be sure to commu-
nicate with each other using these signals, and to
follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid acci-
dents due to landslides or contact with
high-voltage power lines. Always confirm that
there is sufficient space for full swings.
4. Avoid polluting the machine and the ground with T105-06-01-003

leaking oil. Use oil pans to catch escaping oil.


Pay special attention to this when removing hy-
draulic pipings.

MAKE PRECISE MEASUREMENT


1. Accurately calibrate test instruments in advance
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.

T105-06-01-004

T4-1-2

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE STAN-
DARD TABLE
The standard performance values are listed in the ta- Engine Control Dial : Fast Idle
ble below. Refer to group T4-2 for performance test Power Mode Switch : P Mode
procedures. Values in parentheses are reference val- Auto-Idle / Acceleration Selector: OFF
ues. Work Mode Switch : Digging Mode
The following switch positions shall be selected and Hydraulic Oil Temperature
the hydraulic oil temperature shall be maintained as : 50o5 pC (122o9 pF)
indicated below when measuring performance unless
otherwise specified.

Performance Reference
PERFORMANCE TEST DESIGNATION Standard Remarks
page
ENGINE SPEED min-1 T4-3-1
Slow Idle Speed 1050+100-100 Value indicated on Dr. ZX.
Fast Idle (Normal) 2015+75-75
Fast Idle (With ECO deactivated) +100
2115 -100
Fast Idle (Relief operation) Boom Raise relief opera-
1850 to 2015 tion
Value indicated on Dr. ZX.
Fast Idle (E mode) 1920
+100
-100
Value indicated on Dr. ZX.
Fast Idle (HP mode) Boom Raise / Arm Roll-In
1950 to 2200 relief operations.
Value indicated on Dr. ZX.
Auto-idle Speed 1335+100-100 Value indicated on Dr. ZX.
Auto-Acceleration Speed 1675+100-100
Warming Up Speed +100
1190 -100
ENGINE COMPRESSION PRESSURE 2.5 (26, 370) After engine warm up. T4-3-4
MPa (kgf/cm2, psi)
VALVE CLEARANCE (IN, EX) mm 0.4 With engine cold. T4-3-5
NOZZULE INJECTION PRESSURE T4-3-8
MPa (kgf/cm2, psi)
First stage: 18.1
(185, 2630)
Second stage:
22.1
(225, 3200)
INJECTION TIMING (Degrees before TDC) deg. 9p T4-3-13
LUBRICANT CONSUMPTION mL/h Hour meter: 2000 hours or T4-3-14
70 or less
less
TRVEL SPPED sec/10 m T4-4-1
Fast Mode ZAXIS330, 330LC, 350LC, 350LCN, 6.6o0.6
350H, 350BEH:
ZAXIS370MTH: 6.9o0.6
ZAXIS380HH: 6.8o0.6
Slow Mode ZAXIS330, 330LC, 350LC, 350LCN, (10.0o1.0)
350H, 350BEH:
ZAXIS370MTH: (11.0o1.0)
ZAXIS380HH: (11.3o1.0)

T4-2-1

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Standard

Performance Reference
PERFORMANCE TEST DESIGNATION Standard Remarks
page
TRACK REVOLUTION SPEED sec/3 rev T4-4-2
Fast Mode ZX330, 350H, 350BEH: 27.3o2.0
ZX330LC, 350LC, 350LCN, 350LCH: 29.4o2.0
ZX370MTH: 35.0o2.0
ZX380HH: 32.6o2.0
Slow Mode ZX330, ZAXIS350H, 350BEH: 27.3o2.0
ZX330LC, 350LC, 350LCN, 350LCH: 29.4o2.0
ZX370MTH: 35.0o2.0
ZX380HH 32.6o2.0
MISTRACK mm/20 m
200 or less T4-4-3
(Both fast and slow travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0 T4-4-4
SWING SPEED sec/3 rev 15.5o1.0 Bucket empty T4-4-5
SWING FUNCTION DRIFT CHECK mm/180o 1706 or less 3.2 Arm T4-4-6
1.4 m3 (PCSA heaped)
Bucket, Bucket empty
SWING MOTOR LEAKAGE mm/5 min 3.2 Arm T4-4-8
0 1.4 m3 (PCSA heaped)
Bucket, Bucket loaded
MAXIMUM SWINGABLE SLANT ANGLE deg. 21.2 or possibly Bucket loaded T4-4-9
more
SWING BEARING PLAY mm 0.2 to 1.25 Allowable Limit: 2.0 to T4-4-10
3.05
HYDRAULIC CYLINDER CYCLE TIME sec 3.2 m Arm T4-4-12
1.4 m3 (PCSA heaped)
Bucket, Bucket empty
Boom Raise ZX330, 350LC, 350LCN: 3.4o0.3
ZX350H, 370MTH, 380HH: 3.6o0.3
ZX350BEH: 3.7o0.3
Boom Lower ZX330, 350LC, 350LCN: 2.4o0.3
ZX350H, 370MTH: 2.2o0.3
ZX380HH: 2.0o0.3
ZX350BEH: 2.9o0.3
Arm Roll-In ZX330, 350LC, 350LCN, 350H, 4.6o0.3
370MTH, 350BEH:
ZX380HH: 4.3o0.3
Arm Roll-Out 3.2o0.3
Bucket Roll-In ZX330, 350LC, 350LCN, 350H, 4.0o0.3
370MTH:
ZX380HH: 3.8o0.3
ZX350BEH: 4.3o0.3
Bucket Roll-Out ZX330, 350LC, 350LCN, 350H, 2.7o0.3
370MTH:
ZX380HH: 2.6o0.3
ZX350BEH: 2.8o0.3
DIG FUNCTION DRIFT CHECK mm/5 min 3.2 m Arm T4-4-14
1.4 m3 (PCSA heaped)
Bucket
Boom Cylinder (Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In Position) 5 or less Bucket empty
Arm Cylinder (Maximum Reach Position) 30 or less Bucket loaded
(Arm Roll-In Position) 15 or less Bucket empty
Bucket Cylinder (Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In Position) 10 or less Bucket empty
Bucket Bottom (Maximum Reach Position) 150 or less Bucket loaded
(Arm Roll-In Position) 110 or less Bucket empty

T4-2-2

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Standard

Performance Reference
PERFORMANCE TEST DESIGNATION Standard Remarks
page
CONTROL LEVER OPERATING FORCE HITACHI Lever Pattern
T4-4-16
N (kgf, lbf)
Boom Lever 18 (1.8, 13.0)
or less
Arm Lever (ISO Lever Pattern: Swing Lever) 15 (1.5, 10.8)
or less
Bucket Lever 15 (1.5, 10.8)
or less
Swing Lever (ISO Lever Pattern: Arm Lever) 18 (1.8, 13.0)
or less
Travel Lever 28 (2.8, 20.3)
or less
CONTROL LEVER STROKE mm HITACHI Lever Pattern T4-4-18
Boom Lever 105o10
Arm Lever (ISO Lever Pattern: Swing Lever) 84o10
Bucket Lever 84o10
Swing Lever (ISO Lever Pattern: Arm Lever) 105o10
Travel Lever 120o10
COMBINED BOOM RAISE/SWING FUNCTION 3.2 m Arm
Time to Swing 90p 1.4 m3 (PCSA heaped)
With bucket empty sec Bucket T4-4-19
ZX330, 350LC, 350LCN, 350H, 370MTH, 350BEH: 4.0o0.3
ZX380HH: 4.3o0.3
Bucket Teeth Height When Swinging 90p mm
ZAXIS330, 350LC, 350LCN: 7200 or more
ZAXIS350H, 370MTH, 380HH: 6500 or more
ZAXIS350BEH: 5500 or more
Boom Raise / Arm Roll-In sec 3.2 m Arm
5.9o0.3 1.4 m3 (PCSA heaped) T4-4-20
Bucket
PRIMARY PILOT PRESSURE MPa (kgf/cm2 , psi) 4.0+1.0-0.5 T4-5-1
Engine: Fast Idle (40+10-5 570+142-71)
Engine: Slow Idle 3.5+1.0-0
(35 -0, 500+142-0)
+10

SECONDARY PILOT PRESSURE MPa (kgf/cm2, psi) Value indicated on T4-5-3


Engine: Fast (Standard Mode) and Slow Idle 3.4 to 4.0 Dr.ZX.
(34 to 40, (With control lever fully
483 to 570) stroked)

T4-2-3

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Standard

Performance Reference
PERFORMANCE TEST DESIGNATION Standard Remarks
page
SOLENOID VALVE SET PRESSURE Value indicated On T4-5-4
2
MPa (kgf/cm , psi) Dr.ZXo0.2 (2, 28)
MAIN PUMP DELIVERY PRESSURE 2.0o1.0 Value indicated on T4-5-7
2
MPa (kgf/cm , psi) (20o10, 284o142) Dr.ZX.
MAIN RELIEF VALVE SET PRESSURE T4-5-8
2
MPa (kgf/cm , psi)
With Boom / Arm / Bucket Circuit relieved 31.4+2.0-0.5 Value indicated on
(320+20-5, Dr.ZX.
4550+284-71)
With Bucket Circuit relieved 32.4+2.0-0.5 Value indicated on
(330+20-5, Dr.ZX.
4690+284-71)
RELIEF PRESSURE 32.4+2.0-0.5 Value indicated on T4-5-11
(When relieving Swing) (330+20-5, Dr.ZX.
4690+284-71)
RELIEF PRESSURE T4-5-12
(When relieving Travel)
(When relieving both travel levers) 34.3+2.0-0.5 Value indicated on
(350+20-5, Dr.ZX.
4980+284-71)
(When relieving one travel lever) 35.3+2.0-0.5 Value indicated on
(360+20-10, Dr.ZX.
5120+284-142)
With Power Boost Circuit relieved +2.0
34.3 -1.0 Value indicated on
(Boom, Arm) (350+20-10, Dr.ZX.
4980+284-142)
With Power Boost Circuit relieved +2.0
35.3 -1.0 Value indicated on
(Bucket) (360+20-10, Dr.ZX.
5120+284-142)
OVERLOAD RELIEF VALVE SET PRESSURE (Reference Values T4-5-14
MPa (kgf/cm2,, psi) at
50L / min)
Boom (Raise/Lower), Arm (Roll-In), 33.4+1.0-0
Bucket (Roll-In) (340+10-0,
4830+142-0)
Arm (Roll-Out), Bucket (Roll-Out) 35.3+1.0-0
(360+10-0, 5120+142-0)
MAIN PUMP FLOW RATE TEST L/min Refer to T4-2-6 and T4-5-18
T4-2-7 Group.
SWING MOTOR DRAINAGE L/min T4-5-25
With constant maximum speed 0.2 to 0.3
With the motor relieved (2 to 5)
TRAVEL MOTOR DRAINAGE L/min T4-5-28
With the track jacked up 1.4 to 2.1 Allowable Limit: 2.6
With the motor relieved 1.4 to 4.0 Allowable Limit: 5.0

T4-2-4

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Standard
(Blank)

T4-2-5

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Standard
MAIN PUMP P-Q CURVE
Hydraulic P-Q Control (Torque Adjustment) Points on P-Q Line
(Reference: Measured at Test Stand) Delivery Pressure Flow Rate
MPa (kgf/cm2) L/min
Rated Pump Speed: 1900 min-1 (rpm) A 4.9 (50) 272o3
Hydraulic Oil Temperature: 50o5 pC B 18.0 (184) (269)
C 20.4 (208) 234o6
NOTE: Refer to page T4-5-18. D 22.1 (225) (210)
E 26.4 (269) 180o6
F 34.3 (350) 127o6
The values in parentheses are reference only.

(L/min)

300

A B
250

C
D
200

E
Flow Rate

150

100

50

0
4.9 (50) 9.8 (100) 14.7 (150) 19.6 (200) 24.5 (250) 29.4 (300) 34.3 (350)
T173-04-05-001

Delivery Pressure MPa (kgf/cm2)

T4-2-6

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Standard
P-Q Control by Pump Control Pilot Pressure Signal
(Pilot Pressure Characteristics) Points on P-Q Line
(Reference: Measured at Test Stand) Pump Control Pressure Flow Rate
MPa (kgf/cm2) L/min
Rated Pump Speed: 1900 min-1 (rpm) A 73o3
Hydraulic Oil Temperature: 50o5 pC B 0.78o0.05 (8.0o0.5) 93o3
C 2.94+0.05-0.29 (30+0.5-3) 272o3
NOTE: Refer to page T4-5-20.

(L/min)

200

Flow Rate B
100 A

MPa (kgf/cm2)
0 0.98(10) 1.96(20) 2.94(30)

Pump Control Pressure

T4-2-7

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Standard
INJECTION PUMP
Test Conditions:
1. Injection pump: PE6P120/721LS3000
2. Governor: EP/RSV 200-1350
3. Nozzle and nozzle holder assembly:
105780-8140 (Bosch No. EF8511/9A)
4. Nozzle: 105780-0000 (Bosch No. DN12SD12T)
5. Nozzle holder: 105780-2080 (Bosch No.
EF8511/9)
6. Nozzle opening pressure:
2
17.2 MPa (175 kgf/cm , 2490 psi)
7. Test fuel: ISO 4113 or SAE J967d
8. Transfer pump pressure:
255 kPa (2.6 kgf/cm2, 37 psi)
9. Injection pipe: Inner Dia. 3 mmIOuter Dia. 8
mm Length 600 mm (0.118I0.315 23.6 in)
10. Fuel temperature: 39 to 41 pC (109.2 to 114.8 pF)
11. Overflow valve opening pressure: 255 kPa (2.6
kgf/cm2, 37.0 psi)

NOTE: The nozzle test injection pressure is 17.2


2
MPa (175 kgf/cm , 2490 psi). However,
actual machine injection pressure at the
first / second stage are 18.1 MPa (185
kgf/cm2, 2630 psi) and 22.1 MPa (225
2
kgf/cm , 3200 psi) respectively.

Injection rate adjustment


Average Injection Maximum Variance
Adjusting Pump Speed Rack Position Boost
Rate Between Cylinders Remarks
Point (mm-1) (mm) Pressure (kPa)
(cm3/1000 Stroke) (%)
A 1000 12.8 133.5o1 o3 More than 160 Basic
C 500 6.8 9.5o3.2 o15

Governor adjustment
Rack limit
Idle-sub spring setting
Above
Boost Compensator Stroke; 0.7o0.1 mm
Governor spring setting

Pack Position
(mm)

Above

Pump Speed min-1 (rpm) T1HH-04-05-001

T4-2-8

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Standard
DR. ZX MONITOR INDICATING VALUES
Unless specified, test under the following conditions. NOTE: Items marked ( ) are measurable with the
Engine Speed: Fast Idle built-in diagnostic system.
Work Mode Switch: Digging Mode
Items marked ( ) are measurable with the
Power Mode Switch: P mode
built-in diagnostic system. However, it may
Auto-Idle/Acceleration Selector: OFF
be difficult to read the measured value
while operating the machine.

Reference Measured Value


Item Remarks
Value First Second Third Average
PUMP 1 PRESSURE (MPa)
Control Lever in Neutral 2.2
Boom Raise 36.2 When relieving
Boom Lower -
Arm Roll-in 33.3 When relieving
Arm Roll-Out 33.6 When relieving
Bucket Roll-Out 33.3 When relieving
Bucket Roll-In* 35.0 When relieving
Boom Raise + Arm Roll-In
+ Bucket Roll-In Combined 33.1 When relieving
Operation
PUMP 2 PRESSURE (MPa)
Control Lever in Neutral 2.0
Boom Raise 35.7 When relieving
Boom Lower -
Arm Roll-in 33.6 When relieving
Arm Roll-Out 32.8 When relieving
Bucket Roll-Out 2.2 When relieving
Bucket Roll-In 2.2 When relieving
Boom Raise + Arm Roll-In
+ Bucket Roll-In Combined 32.6 When relieving
Operation

T4-2-9

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Standard

Reference Measured Value


Item Remarks
Value First Second Third Average
PUMP 1 PUMP CONTROL
PRESSURE (MPa)
Control Lever in Neutral 0
Boom Raise 3.38 When relieving
Boom Lower -
Arm Roll-in 3.38 When relieving
Arm Roll-Out 3.40 When relieving
Bucket Roll-Out 3.43 When relieving
Bucket Roll-In 3.40 When relieving
Boom Raise + Arm Roll-In
+ Bucket Roll-In Combined 3.36 When relieving
Operation
PUMP 2 PUMP CONTROL
PRESSURE (MPa)
Control Lever in Neutral 0
Boom Raise 3.50 When relieving
Boom Lower -
Arm Roll-in 3.50 When relieving
Arm Roll-Out 3.52 When relieving
Bucket Roll-Out 0.03 When relieving
Bucket Roll-In 0 When relieving
Boom Raise + Arm Roll-In +
Bucket Roll-In Combined 3.50 When relieving
Operation

T4-2-10

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Standard

Reference Measured Value


Item Remarks
Value First Second Third Average
TARGET ENGINE SPEED (min-1)
Fast Idle 1850
Fast Idle
1950
(When operating a control lever)
Fast Idle (HP Mode) 2050 With Boom
Raise relieved
Fast Idle (E Mode) 1750
Auto-Idle 1050
Slow Idle 850
ACTUAL ENGINE SPEED (min-1)
Fast Idle 2000
Fast Idle
1950
(When operating a control lever)
Fast Idle (HP Mode) 2070 With Boom
Raise relieved
Fast Idle (E Mode) 1910
Auto-Idle 1220
Slow Idle 1000
ENGINE SPEED DEVIATION
(min-1)
Fast Idle 162
Fast Idle
-4
(When operating a control lever)
Fast Idle (HP Mode) 14 With Boom
Raise relieved
Fast Idle (E Mode) 164
Auto-Idle 170
Slow Idle 152
EC ANGLE (Volt)
Minimum 2.55
Maximum 3.14
DIAL ANGLE (Volt)
Minimum 0.37
Maximum 4.17

T4-2-11

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Standard

Reference Measured Value


Item Remarks
Value First Second Third Average
BOOM RAISE PILOT
4.07 When relieving
CONTROL PRESSURE (MPa)
ARM ROLL-IN PILOT
4.07 When relieving
CONTROL PRESSURE (MPa)
SWING PILOT CONTROL
-
PRESSURE (MPa)
TRAVEL PILOT CONTROL
3.40
PRESSURE (MPa)
FRONT ATTACHMENT ON-OFF is dis-
-
CONTROL PRESSURE (MPa) played
PUMP 2 PROPORTIONAL
3.92
VALVE OUTPUT (MPa)
P TORQUE PROPORTION- Engine Slow
1.67
AL VALVE OUTP (MPa) Idle and Travel
ARE REGENERATIVE
PROPORTIONAL VALVE
OUTPUT (MPa)
Lever in Neutral 1.64
Swing, Arm Roll-In and
Boom Raise Combined 2.72
Operation
POWER DIGGING CONTROL
PRESSURE (MPa)
During Operation 2.92
When Relieving Boom Raise
2.92
Circuit
TRAVEL MOTOR CONTROL Travel and Travel
PRESSURE (MPa) 2.92 mode Switch
(fast)
EC MOTOR POSITION With Arm Roll-In
332
relieved

T4-2-12

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Standard
SENSOR ACTIVATING RANGE
1. Checking Method

Hydraulic Oil Temperature: 50 o 5 pC


Unless specified:
Auto-Idle
Engine Power
Work Mode Switch/Auto-Acc
Control Mode
Switch eleration
Dial Switch
Selector
Maximum Digging
P Mode OFF
Speed Mode

Monitor each sensor using Dr. ZX.

2. Sensor Activating Range

Sensor Operation Specification


Minimum Speed 0.3 to 1.0 V
Engine Control Dial
Maximum Speed 4.0 to 4.7 V
Minimum Speed 2.5 to 2.7 V
Maximum Speed (Power Mode Switch: P) 3.3 to 3.7 V
EC Sensor Maximum Speed (Power Mode Switch: Maximum Speed
HP) (Power Mode Switch: P) +0.2 V
or more
Control Lever: Neutral 2.0 o 1.0 MPa (20 o 10 kgf/cm2)
Pump Delivery
Arm Roll-In: Relief 31.4+2.0-0.5 MPa (320+20-5 kgf/cm2)
Pressure Sensor
Boom Raise: Relief 34.3+2.0-1.0 MPa (350+20-10 kgf/cm2)
Pressure Sensor Control Lever: Neutral 0 to 0.1 MPa (0 to 1.0 kgf/cm2)
Pilot Control Shut-Off Lever: LOCK
Control Lever: Full Stroke 3.3 to 3.9 MPa (34 to 40 kgf/cm2)
Pilot Control Shut-Off Lever: UNLOCK
2
Pump Control Control Lever: Neutral 1 to 1.6 MPa (10 to 16 kgf/cm )
Pressure Sensor
Jack-Up + Travel (Only one side): 2.9 to 3.9 MPa (30 to 40 kgf/cm2)
Full Stroke
N Sensor 20 pC (Between Ground to Signal) 810o240

T4-2-13

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Standard
(Blank)

T4-2-14

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary:
1. Measure the engine speed using the built-in di- 1
agnosing system (refer to TROUBLESHOOT-
ING/General group.) or Dr. ZX. If the built-in di- 2
agnosing system or Dr. ZX is not available, use
an engine speed meter.
2. Measure the engine speeds in each mode.
NOTE: Measure the engine speed before per-
forming all other tests to check that the
engine speed meets specification. Be-
cause, if the engine speed is not adjusted
correctly, all other performance data will be
unreliable.
3 T107-06-02-002

Preparation:
1. Select the monitor function of the built-in diag-
nosing system (or Dr.ZX). When using an engine
speed meter, install speed pickup (1) to injection
pipe (2).
2. Warm up the machine until the engine coolant
temperature reaches 50 pC (122 pF) or more, and
hydraulic oil is 50o5 pC (122o9 pF).

IMPORTANT: Never attempt to the readjust stop-


per (3) of the governor lever.

T1HH-04-02-002

T4-3-1

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Engine Test
Measurement: Evaluation:
1. Check engine speeds for auto-warm up (when Refer to T4-2 Operational Performance Standard.
starting the engine), auto-idle, slow idle, fast idle
(when normal), fast idle (when the ECO is deac- Remedy:
tivated), fast idle (in the E mode), and fast idle (in Refer to T5-4 Troubleshooting B.
the HP mode).
2. Select the switch positions and the test condi-
tions corresponding to the engine speed to be NOTE: ECO stands for the auto engine speed re-
measured as shown in the table below. duction system by 100 min-1.
Engine Power Auto-Idle/ Auto- Work
Control Mode Acceleration Mode Test Conditions
Dial Switch Selector Switch
Digging
Slow Idle Min. Speed P OFF
Mode
Fast Idle (Normal) Digging
Max. Speed P OFF
Mode
Fast Idle Check in the Dr. ZX special
Digging
(With ECO deac- Max. Speed P OFF functions with ECO deacti-
Mode
tivated) vated.
Fast Idle (Relief Digging Check the engine speed while
Max. Speed P OFF
operation) Mode relieving the boom raise circuit.
Fast Idle Digging
Max. Speed E Mode OFF
(E mode) Mode
Fast Idle Digging Check the engine speed while
Max. Speed HP Mode OFF
(HP mode) Mode relieving the boom raise circuit.
Check engine speed 4 seconds
Digging
Auto-Idle Max. Speed P Auto-Idle after returning all control levers
Mode
to neutral.
Check reduced engine speed
Digging
Auto-Acceleration Max. Speed P Auto-Acceleration within 3 seconds after returning
Mode
all control levers to neutral.
Digging Check only when oil tempera-
Warming Up Max. Speed P OFF
Mode ture is lower than 0 pC (32 pF).

T4-3-2

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Engine Test

Monitor Panel Switch Panel

Engine Con-
trol Dial

Auto-Idle/ Accelera-
tion Selector

Power Mode
Switch
Work Mode
Switch

T178-01-01-003 T178-01-01-004

T4-3-3

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders
to check for a decline in engine power.
2. Check exhaust gas color and the amount of
blow-by gas from the crankcase. Keep track of
engine oil consumption.
3. Check for abnormalities in the intake system, in-
cluding 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. Stop the engine. Remove glow plugs from each
cylinder.
NOTE: Unless the fuel delivery pipes are discon-
nected, fuel will ignite in the cylinders so
that pressure in the cylinders will increase. T1HH-04-02-003

5. Install an adapter (Isuzu 5-8840-2622-0) and


compression gauge in place of the glow plug in
one cylinder. (Be sure to sufficiently tighten the
adapter and compression gauge to prevent air
leakage.)

Measurement:
1. Turn the starter to crank the engine. Record the
compression pressure of each cylinder.
2. Repeat measurement three times for each cylin-
der and calculate the mean values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

Remedy
Refer to engine shop manual.

T4-3-4

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Engine Test
VALVE CLEARANCE ADJUSTMENT
Summary:
Perform the measurement when the engine is cool.
Pointer
Before starting work, clean the head cover mounting
area to avoid contaminating the engine.

Preparation:
1. Locate top dead center (TDC) in the compression
stroke.
While turning the crank shaft clockwise, align the
matching mark on the crank pulley with the
pointer located on the flywheel housing as illus-
trated.
When the S mark on the driving side flange of the
injection pump coupling aligns with the pointer,
piston No.1 (or piston No.6) is positioned at TDC
in the compression stroke.

2. Remove the head cover. Crank Pulley Matching Mark


T1HH-04-02-004

3. Move the intake and exhaust valve push rods on


cylinder No.1 up and down by hand. Pointer S Mark
If any clearance is present on both ends of the
push rods, piston No.1 is positioned at TDC in
the compression stroke.
Start measurement from cylinder (No.1 or No.6)
positioned at TDC in the compression stroke.

Measurement:
1. Insert a feeler gauge into the clearance between
the rocker arm and the valve stem end to meas-
ure the valve clearance.
T173-04-02-007
NOTE: Cylinder Nos. are designated from No.1 to
No.6 as viewed from the fan side.

T4-3-5

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Engine Test
2. When the measurement is started from cylinder
No.1, perform the same measurement to all
valves indicated with the mark in the table
below. (When the measurement is started from
cylinder No.6, perform the measurement on the
valves shown with the mark I.)

Cylinder NO. No.1 No.2 No.3 No.4 No.5 No.6


Valve I E I E I E I E I E I E
When starting meas-
urement from cylinder
No.1
When starting meas-
urement from cylinder I I I I I I
No.6

3. Turn the crankshaft 360p. Align the TC mark with


the pointer. Then, continue measurement of the
other valves in the same way.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

T4-3-6

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Engine Test
Adjustment:
If the measurement results are out of specification,
adjust the valve clearance in the same order of
measurement.

1. Loosen the adjusting screws (A) and (B) lock


nuts on the rocker arms.
Adjusting
Screw (A)
2. Insert the feeler gauge set at the specified di-
mension between the rocker arms and the valve Rocker Arm
stem, turn the adjusting screws (A).
Adjusting
3. After adjusting, retighten the lock nuts on adjust- Screw (B)
ing screws (A) to the specification.
: 22 N m (2.2 kgf m 16 lbf ft) Valve Stem

4. Tighten adjusting screws (B) completely with the


feeler gauge inserted.

5. Loosen gradually adjusting screws (B) until the


feeler gauge moves smoothly T1HH-04-02-005

6. After adjusting, retighten the lock nuts on adjust-


ing screws (B).
: 22 N m (2.2 kgf m 16 lbf ft)

T4-3-7

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Engine Test
NOZZLE CHECK
Summary:
1. Check the injection pressures and the spray pat-
terns at the first and second stages with a nozzle
tester.
Nozzle Nozzle
Holder
2. Before starting work, clean the nozzle holder
Retaining
mounting area to avoid contaminating the engine Nut
system.

Preparation:
1. Injection Pressure at First Stage:
1-1. Remove the nozzle holder, the fuel injection Injection Pressures T1HH-04-02-007
at First and Second
pipings and so on. Stages:
Retaining
1-2. Remove the retaining nut from the nozzle Nut (Tool) Nozzle
holder. Install the gasket (tool) and retaining
nut (tool) on the nozzle.
Gasket
Gasket (Tool): 157892-1500 (Bosch Automo- (Tool)
tive)
Retaining Nut (Tool): 157892-4000 (Bosch
Automotive)
: 34 N m (3.5 kgf m, 25.5 lbf ft)

1-3. Install the nozzle holder to the nozzle tester.

2. Injection Pressure at Second Stage: T1HH-04-02-008


2-1. Remove the retaining nut from the nozzle Injection Pressures at Second Stage:
holder. Install the gasket (tool) and the retain-
ing nut (tool) to the nozzle. Plug (Tool)

2-2. Install the gasket (tool) and the plug (tools) to Retaining Nut
the retaining nut (tool). (Tool) Gasket (Tool)
Gasket (Tool) :026508-1140 (Bosch Automo-
tive)
Plug (Tool): 157892-1600 (Bosch Automotive)

2-3. Install the holder (tools) to the nozzle holder.


Holder (Tool): 157892-4400 (Bosch Automo-
tive)
Injection Pressures at Second Stage:
Holder (Tool) T1HH-04-02-009

Nozzle Holder

T1HH-04-02-010

T4-3-8

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Engine Test
2-4. Install the nut (tool) to the holder (tool).
Nut (Tool): 157892-1000 (Bosch Automotive) Nut (Tool)

Holder (Tool)
2-5. Install the pin (tool) to the dial gauge (tool).
Dial Gauge (Tool): 157892-3800 (Bosch
Automotive)
Pin (Tool) (Length: 60 mm): 157892-5300
(Bosch Automotive)

2-6. Install the dial gauge assembly to the nozzle


holder so that the pin on the dial gauge comes
in contact with the first spring seat, and then
secure it with the nut.
T1HH-04-02-011

NOTE: Secure the dial gauge to measure the


stroke of 2 mm.
Dial Gauge
Check if the shaft of the dial gauge can (Tool)
move smoothly. Dial
Gauge
2-7. Install the nozzle holder to the nozzle tester Assembly Nut (Tool)
Pin (Tool)
and calibrate the dial gauge to zero.

2-8. Loosen the plug of the retaining nut to bleed


any air from inside the retaining nut. After that,
check any for fuel leaks.
Fast Spring
Seat

T1HH-04-02-012

Retaining Nozzle
Nut Tester

Plug
T1HH-04-02-013

T4-3-9

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Engine Test
Measurement
CAUTION: Never allow skin to contact the Injection Pressure at First Stage:
spray directly. The fuel spray from the nozzle
may penetrate the skin,
resulting in serious injury. If the fuel pene-
trates into the blood stream, it may cause
blood toxication. Nozzle Tester
IMPORTANT: Be sure to use clean diesel oil for
the test.

1. Injection Pressure at First Stage:


Operate the nozzle tester and make several
strong strokes of the tester to inject the fuel. Then,
while operating the tester at approx. 60 strokes a
T1HH-04-02-006

minute, measure the fuel injection pressure. Injection Pressure at Second Stage:
Dial Gauge
2. Injection Pressure at Second Stage:
2-1. Operate the nozzle tester in order to increase
the pressure inside the nozzle holder to 34.3
to 44.1 MPa (350 to 450 kgf/cm2, 4980 to
6400 psi). The nozzles needle valve should
move through its full stroke. Record full stroke Nozzle Tester
(L).

2-2. With the needle valve at full stroke, release


the nozzle tester handle.(The pressure inside
the nozzle holder will decrease and the needle T1HH-04-02-016
valve stroke as indicated on the dial gauge will
fall.)
Stroke of Needle Valve
2-3. Read needle valve stroke (M) from the dial
gauge indication (once the needle valve has L
descended). Refer to the set value as below.
2
Set Value: 18.1+1 MPa (185+10 kgf/cm ,
2630+142 psi)
NOTE: The valve indicated on the dial gauge M+0.05 mm
means pre-life value (M). M

Pressure

Injection Pressure Insertion Pressure 34.3 to 44.1 MPa


at First Stage at Second Stage (350 to 450 kgf/cm 2,
4980 to 6400 psi)

T4-3-10

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Engine Test
2-4. Operate the nozzle tester again in order to in-
crease the pressure inside the nozzle holder
to 34.3 to 44.1 MPa (350 to 450 kgf/cm2, 4980
to 6400 psi). Release the nozzle tester handle.
Holder will decrease (and the needle valve
stroke as indicated on the dial will fall.

2-5. Read the pressure at the moment when the


value indicated on the dial gauge points the
set value as below.
Set Value: Pre-lift value (M)+0.05 mm

T4-3-11

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Engine Test
3. Spray Pattern
Attach the nozzle holder to the nozzle tester.
Make several strong strokes of the tester and
check the fuel spray pattern. Be sure not to oper-
ate the pressure gauge.

4. Leak Condition
Be sure to keep the pressure as that just before Normal
the injection. Then, check for any oil leakage
around the nozzle.

Evaluation
1. Standard Injection Pressure:
Refer to T4-2 Operational Performance Standard
Table.
2. Spray Pattern
Large-size spray should not be visible to the na- T1HH-04-02-014

ked eye. Abnormal


No stray sideways sprays should be seen.
During initial injection stage, spray size should be
fine injected intermittently.
There should be no drips found.
Injection spray angle must be normal.

3. Oil Tight Condition


No fuel leaks.

Adjustment
1. Injection pressure at the first stage can be
changed in response to the first nozzle opening
pressure shim thickness.
T1HH-04-02-015
2. Injection pressure at the second stage can be
changed in response to the second nozzle open-
ing pressure shim thickness.

3. When adjusting the injection pressures at the first


Second Nozzle
and the second stages, its easier to adjust them Opening Pres-
referring to the record of shim thickness and the sure Shim
pressure.
NOTE: Use a micrometer to measure shim thick-
ness.

First Nozzle
Opening
Pressure
Shim

T1HH-04-02-007

T4-3-12

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Engine Test
INJECTION TIMING
Pointer

Inspection/Adjustment:
1. Position piston No.1 at TDC. Turn the crank shaft
clockwise to align the matching mark on the
crank pulley with the pointer on the housing.

2. Check if the mark on the coupling of the injection T1HH-04-02-004


pump aligns with the pointer on the housing side. Crank Pulley Matching Mark
NOTE: When the matching mark on the crank Injection Coupling Pointer
pulley aligns with the pointer on the hous- Pump
ing and the matching mark on the coupling
aligns with the pointer on the housing, the
injection timing is equal to the position at 9
before TDC.

3. If not, align them by loosening the adjusting bolt


on the coupling.

4. With the matching mark on the crank pulley


aligned with the pointer on the housing, the mark
on the coupling of the injection pump aligns with T1HH-04-02-017

the pointer on the housing, and then tighten the Adjusting


Coupling Bolt
adjusting bolt.
: 88 N m (91 kgf/cm2, 65 lbf ft)

T1HH-04-02-017
Coupling
Adjusting
Bolt

T1HH-04-02-018

T4-3-13

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Engine Test
LUBRICANT CONSUMPTION

Measuring Method
1. Place the machine on level firm ground, and
leave it for at least one hour to let the lubricant
lower to the oil pan.
At this time, confirm that the machine is level,
using a leveler.
2. Record the read-out A (unit: hour) of the hour
meter.
3. Replenish the lubricant up to the high-level
gauge.
4. Operate the machine for at least 100 hours or un-
til the oil level lowers to the low-level gauge.

IMPORTANT: Make sure to keep the ma-


chine-leaving time in Step 1 above.
5. Place the machine on level firm ground, and
leave it for at least one hour to let the lubricant
lower to the oil pan.
At this time, confirm that the machine is level,
using a leveler.
6. Record the read-out B (unit: hour) of the hour
meter.
7. Replenish the lubricant up to the high-level
gauge while measuring the oil-replenishing vol-
ume C.
NOTE: For measuring, use a high-precision
measuring cylinder or the like.

8. Determine lubricant consumption from the fol-


lowing equation:
Oil replenishing volume (C) [mL] / Operating
hours (B-A) [hr]

Evaluation:
Refer to T4-2 Operational Performance Standard.

T4-3-14

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary: Measurement:
Measure the time required for the excavator to travel 1. Measure both the slow and fast speeds of the
a 20 m (65.6 ft) test track. machine.
2. Select the following switch positions:
Preparation: Travel Engine Power Work Auto-Idle/
1. Adjust the track sag on both sidetracks equally. Mode Control Mode Mode Acceleration
2. Prepare a flat and solid test track 20 m (65.6 ft) in Switch Dial Switch Switch Selector
length with extra length of 3 to 5 m (9.8 to 16 ft) Slow Digging
on both ends for machine acceleration and de- Fast Idle P Mode OFF
Mode Mode
celeration. Fast Digging
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above Fast Idle P Mode OFF
Mode Mode
the ground with the arm and bucket rolled in.
4. Maintain hydraulic oil temperature at 50o5 pC 3. Start traveling the machine in the acceleration
(122o9 pF). zone with the travel levers to full stroke.
4. Measure the time required to travel 20 m (65.6
ft).
5. After measuring the forward travel speed, turn
the upperstructure 180p and measure the reverse
Arm Rolled-In, Bucket Rolled-In travel speed.
End 6. Repeat steps 4. to 5. three times in each direc-
Bucket Height: 0.3 to 0.5 m tion and calculate the average values.
Start
20 m Deceleration
Evaluation:
Zone Refer to the Operational Performance Standard in
3 to 5 m Group T4-2.
Acceleration
Zone
3 to 5 m Remedy:
Refer to the Troubleshooting B in Group T5-4.
T105-06-03-001

T4-4-1

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
TRACK REVOLUTION SPEED
Summary: Measurement:
Measure the track revolution cycle time with the NOTE: When jacking up one side track and rotat-
track raised off ground. ing it, the track doesnt rotate at fast speed
though the travel made switch is turned to
Preparation: Fast Mode.
1. Adjust the track sag of both side tracks to be (Refer to the Travel Motor Swash Angle
equal. Control of the SYSTEM / Control System
2. On the track to be measured, mark one shoe with group in the T/M (Operational Principle).)
chalk.
3. Swing the upperstructure 90p and lower the 1. Select the following switch positions:
bucket to raise the track off ground. Keep the Travel Engine Power Work Auto-Idle/
boom-arm angle between 90 to 110p as shown. Mode Control Mode Mode Acceleration
Place blocks under the machine frame. Switch Dial Switch Switch Selector
Slow Digging
Fast Idle P Mode OFF
Mode Mode
Fast Digging
Fast Idle P Mode OFF
Mode Mode
2. Operate the travel control lever of the raised
90 to 110p track to full stroke.
3. Measure the time required for 3 revolutions in
both directions after a constant track revolution
speed is obtained.
4. Raise the other side and repeat the above
Mark
M104-07-067
procedures.
5. Repeat steps 3. to 5. three times and calculate
CAUTION: Securely support the raised track the average values.
using wooden blocks.
Evaluation:
4. Maintain the hydraulic oil temperature at 50o5 pC Refer to the Operational Performance Standard
(122o9 pF). Table in Group T4-2.

NOTE: The measurement data obtained through


the raised track revolution test may have
wide variations. Therefore, the evaluation
based on the results obtained from the 20
m travel speed check described before is
more recommendable.

Remedy:
Refer to the Troubleshooting B in Group T5-4.

T4-4-2

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
MISTRACK CHECK
Summary: Measurement:
1. Allow the machine to travel 20 m (65.6 ft). 1. Measure the amount of mistracking in both fast,
Measure the maximum tread deviation from the and slow travel speeds.
tread chord line drawn between the travel start 2. Select the following switch positions:
and end points to check the performance Travel Engine Power Work Auto-Idle/
equilibrium between both sides of the travel Mode Control Mode Mode Acceleration
device systems (from the main pump to the travel Switch Dial Switch Switch Selector
motor). Slow Digging
2. If measured on a concrete surface, the tread Fast Idle P Mode OFF
Mode Mode
deviation has a trend to decrease. Fast Digging
Fast Idle P Mode OFF
Mode Mode
Preparation:
1. Adjust the track sag of both tracks to be equal. 3. Start traveling the machine in the acceleration
2. Provide a flat, solid test yard 20 m (65.6 ft) in zone with the travel levers at full stroke.
length, with extra length of 3 to 5 m (9.8 to 16 ft) 4. Measure the maximum distance between a
on both ends for machine acceleration and straight 20 m (65.6 ft) tread chord line and the
deceleration. tread made by the machine.
5. After measuring the tracking in forward travel,
turn the upperstructure 180p and measure in
Maximum Distance reverse travel.
6. Repeat steps 3. to 5. three times and calculate
the average values.
Acceleration
Zone: Evaluation:
3 to 5 m
20 m Refer to the Operational Performance Standard
Table in Group T4-2.

Remedy:
Refer to the Troubleshooting B in Group T5-4.
T105-06-03-022

3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above


the ground with the arm and bucket rolled in.
4. Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF).

T4-4-3

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL PARKING LEAKAGE
Summary:
To measure the parking brake function on a speci-
fied slope.

Preparation:
1. The surface of the test slope shall be even with a
gradient of 20 (11.31p).
0.2 to 0.3 m
2. Mark a white line on the travel device cover.
3. Hold the bucket 0.2 to 0.3 m (8 to 12 in) above
the ground with the arm and bucket fully rolled in.
4. Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF).
T105-06-03-004
Measurement:
1. Measure the travel parking brake slip amount
while parked.
2. Climb the slope and place the travel levers in
neutral.
3. Stop the engine.
4. After the machine stops, put alignment marks on
a track link or shoe, and the track side frame.
5. After 5 minutes, measure the distance between
the marks on the track link or shoe and the track
side frame.

Evaluation:
Refer to the Operational Performance Standard
Table in Group T4-2.
Alignment marks on the trackside
frame and shoe when the machine
comes to a stop.
Displacement measured
after 5 minutes.
T105-06-03-006

T4-4-4

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING SPEED
Summary:
Measure the time required to swing three complete CAUTION: Prevent personal injury. Always
turns. make sure that the area is clear and that
co-workers are out of the swing area before
starting the measurement.
Preparation:
1. Check the lubrication of the swing gear and
swing bearing. Measurement:
2. Place the machine on flat, solid ground with 1. Select the following switch positions:
ample space for swinging. Do not conduct this Auto-Idle/
Engine Con- Power Mode Work Mode
test on slopes. Acceleration
trol Dial Switch Switch
3. With the arm rolled out and bucket rolled in, hold Selector
the bucket so that the height of the bucket pin is Digging
Fast Idle P Mode OFF
the same as the boom foot pin. The bucket must Mode
be empty.
2. Operate swing control lever fully.
3. Measure the time required to swing 3 turns in
one direction.
4. Operate swing control lever fully in the opposite
direction and measure the time required for 3
turns.
The same height as the
5. Repeat steps 2. to 4. three times and calculate
boom foot pin height the average values.

T105-06-03-013 Evaluation:
Refer to the Operational Performance Standard in
NOTE: In case a sufficient space for the meas- Group T4-2.
urement is difficult to find, carry out the
measurement with the boom fully raised Remedy:
and the arm fully rolled-in. Refer to the Troubleshooting B in Group T5-4.

T178-04-03-001

4. Maintain the hydraulic oil temperature at 50o5 pC


(122o9 pF).

T4-4-5

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING FUNCTION DRIFT CHECK
Summary:
Measure the swing drift on the bearing outer
circumference when stopping after a 180p full-speed
swing.

Preparation:
1. Check the lubrication of the swing gear and
swing bearing.
2. Place the machine on flat, solid ground with
ample space for swinging. Do not conduct this Two Check Marks
test on a slope.
T105-06-03-008
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. The bucket must
be empty.
4. Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
5. Swing the upperstructure 180p.
6. Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF).

CAUTION: Prevent personal injury. Always


make sure that the area is clear and that T105-06-03-009

co-workers are out of the swing area before


starting the measurement.

T4-4-6

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Select the following switch positions:
Auto-Idle/
Engine Con- Power Mode Work Mode
Acceleration
trol Dial Switch Switch
Selector
Measure Difference Between Marks
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 the
upperstructure aligns with that on the track frame
after swinging 180p . Marking on the Track Frame
3. Measure the distance between the two marks.
Marking on the Swing Bearing
4. Align the marks again, swing 180p, then test in
the opposite direction.
5. Repeat steps 2. to 4. three times each and T105-06-03-010

calculate the average values.

Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.

Remedy:
Refer to the Troubleshooting B in Group T5-4.

T4-4-7

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING MOTOR LEAKAGE
Summary:
Check for upperstructure drift while suspending a
load on a slope.

Preparation:
1. Check the lubrication of the swing gear and
swing bearing.
2. Park the machine on a smooth slope with a
gradient of 26.8 % (15p).
3. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
W=1800 kg (3970 lb)
4. With the arm rolled out, and bucket rolled in,
position the arm top pin height to be level with the
boom foot pin.
5. Swing the upperstructure to position it 90p to the
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as T105-06-03-011
illustrated.
6. Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF).

Measurement:
1. Select the following switch position:
Auto-Idle/
Power Mode Work Mode
Acceleration Measure Difference Between Marks
Switch Switch
Selector
P Mode Digging Mode OFF

2. Maintain the engine at slow idle. After five


minutes, measure the difference between the
marks along the swing bearing periphery and the Marking on the Track Frame
track frame. Marking on the Swing Bearing
3. Perform the measurement in both right and left
swing directions.
T105-06-03-010
4. Perform the measurement three times in each
direction and calculate the average values.

Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.

Remedy:
Refer to the Troubleshooting B in Group T5-4.

T4-4-8

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
MAXIMUM SWINGABLE SLANT ANGLE
Summary: Measurement:
With the upperstructure swung 90p to the slope, 1. Select the following switch positions:
check the maximum slant angle on which the upper- Engine Auto-Idle/
Power Mode Work Mode
structure can swing to the uphill side. Control Acceleration
Switch Switch
Dial Selector
Preparation: Fast Idle P Mode Digging Mode OFF
1. Check that the swing gear and bearing are well
lubricated.
2. Load bucket fully. In lieu of loading the bucket, 2. Operate the swing lever to full stroke to swing the
weight (W) of the following specification can be upperstructure to the uphill side.
used. 3. If the machine can swing, measure the cab floor
W=1800 kg (3970 lb) slant angle.
3. With the arm cylinder fully retracted and the 4. Increase the slope angle and repeat steps 2. and
bucket cylinder fully extended, hold the arm top 3. Check both clockwise and counterclockwise.
pin to the position flush with the boom foot pin 5. Perform the measurement three times.
height.
4. Climb a slope and swing the upperstructure 90p Evaluation:
to the slope. Refer to the Operational Performance Standard in
5. Maintain the hydraulic oil temperature at 50o5 pC Group T4-2.
(122o9 pF).
Remedy:
Refer to the Troubleshooting B in Group T5-4.

T105-06-03-011

T4-4-9

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING BEARING PLAY
Summary:
Measure the swing bearing play using a dial gauge
to check the wear of bearing races and balls.

Preparation:
1. Check swing bearing mounting bolts for loose-
ness.
2. Check the lubrication of the swing bearing. Con-
firm that bearing rotation is smooth and without
noise.
3. Install a dial gauge on the track frame as shown, Magnetic Dial
using a magnetic base. Base Gauge
T105-06-03-014
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the front
idlers.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race.
6. Bucket should be empty.

NOTE: The measured value will vary depending Round Trunk


on where the magnet base is secured.
Secure the magnet base onto the round
trunk or in a position as close to the round
trunk as possible.
T105-06-03-015

T4-4-10

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. With the arm rolled out and bucket rolled in, hold
Measurement: (h1)
the bucket so that the height of the bucket pin is
the same as the boom foot pin. Record the dial
gauge reading (h1).
2. Lower the bucket to the ground and use it to
raise the front idler 0.5 m (20 in). Record the dial
gauge reading (h2).
3. Calculate bearing play (H) from this data (h1 and The same height
as the boom foot
h2) as follows: pin height
H=h2-h1

Evaluation: T105-06-03-007

Refer to the Operational Performance Standard in


Group T4-2. Measurement: (h2)

T105-06-03-017

T4-4-11

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
HYDRAULIC CYLINDER CYCLE TIME
1. Measure the cycle time of the boom, arm, and
bucket cylinders.
2. Be sure that the bucket is empty.

Preparation:
1. Be sure to measure at the position as follows.
To measure the cycle time of the boom cylinders:
With the arm rolled out and the empty bucket
rolled in, lower the bucket to the ground, as
shown. T105-06-03-018

To measure the cycle time of the arm cylinder:


With the empty bucket rolled in, position the arm
so that it is vertical to the ground. Lower the
boom until the bucket is 0.5 m (20 in) above the
ground.
To measure the cycle time of the bucket cylinder:
The empty bucket should be positioned at
mid-stroke between roll-in and roll-out, so that
0.5 m
the sideplate edges are vertical to the ground.
2. Maintain the hydraulic oil temperature at 50o5 pC
T105-06-03-019
(122o9 pF).

T105-06-03-020

T4-4-12

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Select the following switch positions:
Engine Auto-Idle/
Power Mode Work Mode
Control Acceleration
Switch Switch
Dial Selector
Fast Idle P Mode Digging Mode OFF

2. To measure cylinder cycle times:


(Cylinder full stroke includes cylinder cushioning
zone.)
Boom cylinders:
Measure the time it takes to raise the boom, and
the time it takes to lower the boom. To do so,
position the boom at one stroke end, then move
the control lever to the other stroke end as
quickly as possible.
Arm cylinder:
Measure the time it takes to roll in the arm, and
the time it takes to roll out the arm. To do so,
position the arm at one stroke end, then move
the control lever to the other stroke end as
quickly as possible.
Bucket cylinder:
Measure the time it takes to roll in the bucket,
and the time it takes to roll out the bucket. To do
so, position the bucket at one stroke end, then
move the control lever to the other stroke end as
quickly as possible.

3. Repeat each measurement three times and


calculate the average values.

Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.

Remedy:
Refer to the Troubleshooting B in Group T5-4.

T4-4-13

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
DIG FUNCTION DRIFT CHECK
Maximum Reach Position

Summary:
Measure dig function drift, which can be caused by
oil leakage in the control valve and boom, arm, and
bucket cylinders, with the loaded bucket.

NOTE: When testing the dig function drift just after


cylinder replacement, slowly operate each
Extended
cylinder for ten minutes to its stroke end to Retracted
Distance
Distance
purge air. Retracted
Distance
Preparation:
1. Load bucket fully. In lieu of loading the bucket, Same Height
weight (W) of the following specification can be
used.
W=1800 kg (3970 lb) Bucket Bottom
2. Position the arm cylinder with the rod 50 mm (2
in) extended from the fully retracted position.
3. Position the bucket cylinder with the rod 50 mm T105-06-03-021

(2 in) retracted from the fully extended position. Arm Cylinder Extension
4. With the arm rolled out and the bucket rolled in,
hold the bucket so that the height of the bucket
pin is the same as the boom foot pin.
5. Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF).
Mark

Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the bucket, as well as the boom, arm and
bucket cylinders.
3. Repeat step 2. three times and calculate the T110-06-03-001

average values. Boom and Bucket Cylinder Retraction

Evalution: Mark Mark


Refer to the Operational Performance Standard in
Group T4-2.

Remedy:
Refer to the Troubleshooting B in Group T5-4.

T110-06-03-002

T4-4-14

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
Arm Roll-In Position

Summary:
Measure dig function drift, which can be caused by
oil leakage in the control valve and boom, arm, and
bucket cylinders.

NOTE: When testing the dig function drift just after


cylinder replacement, slowly operate each
cylinder for ten minutes to its stroke end to
purge air.

Preparation:
1. The bucket must be empty.
2. Position the arm cylinder with the rod 50 mm (2
in) retracted from the fully extended position.
3. Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position.
4. With the arm rolled in and the bucket rolled in.
1m
Lower the boom until the arm tip is 1 m (40 in)
above the ground.
5. Maintain the hydraulic oil temperature at 50o5 pC T173-04-03-001

(122o9 pF).

Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the arm tip, as well as the boom, arm and
bucket cylinders. Cylinder Retraction
3. Repeat step 2. three times and calculate the
average values. Mark Mark

Evalution:
Refer to the Operational Performance Standard in
Group T4-2.

Remedy:
Refer to the Troubleshooting B in Group T5-4.

T110-06-03-002

T4-4-15

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER OPERATING FORCE
Summary:
1. Use a spring scale to measure the maximum
resistance of each control lever as illustrated.
2. Measure the maximum operating force of the
front attachment control lever.
3. Measure the operating force at the grip center of
each control lever.

Preparation:
Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF).

CAUTION: Prevent personal injury. Always T107-06-03-003

make sure that the area is clear and that


co-workers are out of the swing area before
starting the measurement.

T107-06-03-004

T4-4-16

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Measure each control lever.
2. Select the following switch positions:
Engine Auto-Idle/
Power Mode Work Mode
Control Acceleration
Switch Switch
Dial Selector
Fast Idle P Mode Digging Mode OFF

3. Operate each boom (raise), arm and bucket lever


to the fully and measure the maximum operating
force for each with each actuator relieved.
4. Operate boom (lower) lever and measure the
maximum operating force with the boom (lower)
relieved by jacking up the machine in a safe
area.
5. Operate swing lever and measure the maximum
operating force with swing relieved after securing
the front attachment to prevent swinging.
6. Lower the bucket to the ground to raise one track
off the ground. Operate the travel lever to full
stroke and measure the maximum operating
force required. When finished, lower the track
and then jack-up the other track.
7. Repeat steps 3. to 6. three times and calculate
the average values.

Evalution:
Refer to the Orerational Performance Standard in
Group T4-2.

T4-4-17

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER STROKE
Summary:
1. Measure each lever stroke at the lever top using
a ruler.
2. Measure the lever stroke at the grip center of
each control lever.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both
side lever strokes.

Preparation:
Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF).

Measurement: T107-06-03-005

1. Stop the engine.


2. Measure each lever stroke at the lever top from
neutral to the stroke end using a ruler.
3. Repeat step 2. three times and calculate the
average values.

Evalution:
Refer to the Orerational Performance Standard in
Group T4-2.

T4-4-18

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
COMBINED BOOM RAISE/SWING FUNC-
TION CHECK
Summary:
Check boom raise and swing movement and speeds
while operating both functions simultaneously.

Preparation:
1. Start the engine and run it at fast idle. Operate
the boom raise function and check to be sure that
the cylinder movement is smooth, with out stick-
ing. T107-06-03-009

2. With the arm fully rolled out and bucket fully


rolled in, lower the bucket to the ground. The
bucket must be empty.
3. Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF).

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.

Measurement:
1. Select the following switch positions: T107-06-03-010

Engine Auto-Idle/
Power Mode Work Mode
Control Acceleration
Switch Switch
Dial Selector
Fast Idle P Mode Digging Mode OFF

2. Raise the boom and swing simultaneously, both


at full stroke.
3. When the upperstructure rotates 90p, release the
control levers to stop both functions. Measure the H
time required to swing 90 and the height (H) of
the bucket teeth.
4. Repeat steps 2. to 3. three times and calculate
the average values.
T107-06-03-011

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

Remedy:
Refer to the Troubleshooting B in Group T5-4.

T4-4-19

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Excavator Test
COMBINED BOOM RAISE/ARM ROLL-IN
OPERATION
Summary:
1. Performance of boom raise and arm roll-in com-
bined operation is checked.
2. Make sure that the cylinders dont hesitate while
operating the cylinder with the engine running at
fast idle.

Preparation:
1. Fully retract the arm cylinder and fully extend the
bucket cylinder. Adjust the boom cylinder so that
the bucket tooth tip height is 0.5 m (1 ft 8 in)
above the ground. (Empty the bucket.)
2. Maintain the hydraulic oil temperature at 50 o 5
pC (122o9 pF). 0.5 m

Measurement: T107-06-03-006

1. Select the switch positions as follows.


Engine Auto-Idle/
Power Mode Work Mode
Control Acceleration
Switch Switch
Dial Selector
Fast Idle P Mode Digging Mode OFF

2. Raise the boom and roll the arm in full stroke at


the same time.
3. Measure the time required for the arm to reach
the stroke end with the bucket empty.
4. Repeat the measurement three times and calcu-
late the average value.

Evaluation:
Refer to T4-2 Operational Performance Standard.

Remedy:
Refer to T5-4 Troubleshooting B.
T107-06-03-008

T4-4-20

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove the plug from the pilot pump delivery
port. Install adapter (ST 6069) and pressure
gauge (ST 6942) on the port.
: 6 mm

4. Start the engine. Confirm that no oil leakage is


observed at the pressure gauge connection. Plug
5. Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF). T157-07-04-012

Measurement:
1. Select the following switch positions:
Power Auto-Idle/
Engine Con- Work Mode
Mode Acceleration
trol Dial Switch
Switch Selector
General
Fast Idle P Mode Purpose OFF
Mode
General
Slow Idle P Mode Purpose OFF
Mode

2. Measure the pilot pressure in each specified set-


ting above.
3. Repeat the measurement three times and calcu-
late the average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

T4-5-1

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
Primary Pilot Pressure Adjustment
1
Adjustment:
Adjust the set pressure of relief valve (1) as neces-
sary.
: 22 mm

T1HH-04-04-002

1. Remove plug (3). 2 3


2. Install the estimated necessary number of shims
(2).
3. Tighten plug (3).
: 24.5 N m (2.5 kgf m, 18 lbf ft)

4. Check the relief pressure of relief valve (1).

NOTE: Standard Change in Pressure (Reference)


Change in Relief Pres-
Shim Thickness (mm) sure
kPa (kgf/cm2) (psi) T157-05-04-007

0.25 78 (0.8) (11)


0.5 147 (1.5) (21)
1.0 294 (3.0) (43)

T4-5-2

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
SECONDARY PILOT PRESSURE
1
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Install pressure gauge (ST 6942) and tee (ST
6450) to the end of pilot line (1) at the respective
control valve spool end, as illustrated.
: 14 mm, 17 mm

4. Start the engine. Confirm that no oil leakage is


observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF).

Measurement:
1. Select the following switch positions:
Power Auto-Idle/
Engine Work Mode T1HH-04-04-003
Mode Acceleration
Control Dial Switch
Switch Selector
Digging
Fast Idle P Mode OFF
Mode
Digging
Slow Idle P Mode OFF
Mode

2. While operating the corresponding control lever


full stroke of the function to be measured, meas-
ure the pilot oil pressure.
3. Repeat the measurement three times and calcu-
late the average values.

Evaluation:
Refer to Performance Standard Table in Group T4-2.

Remedy: T157-05-04-011

Refer to Troubleshooting B in Group T5-4.

T4-5-3

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
SOLENOID VALVE SET PRESSURE
Measure the solenoid valve set pressure using both
Dr. ZX and a pressure gauge.

Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Disconnect line (1) from the solenoid valve to be
measured. Install hose (Parts Number: 4216453),
tee (ST 6451), adapter (ST 6461), and pressure
gauge (ST 6942) to the disconnected end at the
solenoid valve side, as illustrated.
: 17 mm, 19 mm, 22 mm
SC
Connect Dr. ZX. Select the monitor function.
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection. SI
5. Maintain the hydraulic oil temperature at 50o5 pC SG
(122o9 pF). T1HH-01-02-008

Pressure Gauge

Hose Piping

Tee Adapter

T173-04-04-006

Solenoid Valve Unit

T4-5-4

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions:
Power Auto-Idle/
Engine Work Mode
Mode Acceleration
Control Dial Switch
Switch Selector
Digging
Fast Idle P Mode OFF
Mode

2. Pull the pilot control shut-off lever to LOCK posi-


tion.
3. Operate as instructed below for each measuring
solenoid valve:
Solenoid Valve SG: Repeat pressing and releas-
ing of the power boost switch.
Solenoid Valve SC: Perform a combined opera-
tion of boom raise and arm roll-in.
Solenoid Valve SI: Drive the machine, then stop
the machine at the fast mode.
4. Read the values on both Dr. ZX and the pressure
gauge.
5. Repeat the measurement three times and calcu-
late the average values.

Evaluation:
The average value read on the pressure gauge shall
be within o0.2 MPa (o2 kgf/cm2, o28 psi) of the value
indicated on Dr. ZX.

T4-5-5

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
Solenoid Valve Set Pressure Adjustment Proce-
dure
7
IMPORTANT: Do not loosen the adjusting screw
excessively. 8
The O-ring on the threads may come
off the sealing surface, causing oil
leakage.
Be sure to turn the adjusting screw
less than 2 turns to loosen. T107-06-04-020
The distance between the
lock nut end and screw end
should be 2.0 mm (0.079 in)
1. Mark the end of the adjusting screw with a white or less.
marker for the record of the original position.
(Take care not to touch any part of the screw
threads with the white marker.)
2. Loosen lock nut (7). Turn adjusting screw (8) to
adjust the set pressure of the solenoid valve. 8
3. Retighten lock nut (7).
: 10 mm
: 3 mm
: 5 N m (0.5 kgf m, 3.6 lbf ft) 7

4. Check the set pressure of the solenoid valve. T107-06-05-001

NOTE: Standard Change in Pressure (Reference)


Screw Turns 1/4 1/2 3/4 1 Adjusting Screw
kPa 78 156 234 312
(kgf/cm2) (0.8) (1.6) (2.4) (3.2)
(psi) (11) (22) (34) (45)
Pressure Pressure
Increase Decrease

W107-02-05-129

T4-5-6

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
MAIN PUMP DELIVERY PRESSURE
The main pump delivery pressure can also be meas-
ured with the built-in diagnosing system or Dr.ZX.
1
Preparation:
1. Shut down the engine properly.
2. Press the air relief valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove plug (1) from the main pump delivery
port. Install adapter (ST 6069), hose (ST 6943)
and pressure gauge (ST 6941) on the port.
: 6 mm

Select the monitoring function of the built-in di-


agnostic system (or Dr. ZX).
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF).

Measurement:
1. Select the following switch positions: T1HH-04-04-005

Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Digging
Fast Idle P Mode OFF
Mode

2. Measure the pressure with the control levers in


neutral.
3. Repeat the measurement three times and calcu-
late the average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

Remedy:
Refer to the Troubleshooting B in Group T5-4.

T4-5-7

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
MAIN RELIEF VALVE SET PRESSURE
Possible to measure with the built-in diagnosing sys-
tem or Dr.ZX.

Summary:
Measure the main relief valve setting pressure at the
main pump delivery part. Pressure Check Ports
The main relief pressure can also be measured with
the built-in diagnosing system or Dr.ZX.

Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install adapter (ST 6069), hose (ST 6943)
and pressure gauge (ST 6941) on the port.
: 6 mm

Select the monitoring function of the built-in di-


agnostic system (or Dr. ZX).
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF).
T1HH-04-04-005

T4-5-8

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions:
Power Work Auto-Idle/
Engine
Mode Mode Acceleration
Control Dial
Switch Switch Selector
Dipping
Fast Idle P Mode Mode OFF

2. Slowly operate bucket, arm, and boom control


levers to the stroke ends to relieve each function
one at a time.
3. As for the swing function, secure the upperstruc-
ture so it is immovable. Slowly operate the swing
lever to relieve the swing function.
4. As for the travel function, secure the tracks
against an immovable object. Slowly operate the
travel levers to relieve the travel function.
5. Which power boost switch depressed, then
slowly operate bucket, arm and boom control
levers to the stroke ends to relieve to relieve
each function. (Measure within 8 seconds.)

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

NOTE: If the measured pressures in all circuits is


lower than the specified range, a decrease
in the set pressure of the main relief valve
may be the probable cause. In cases
where the relief pressure of a particular
circuit is lower, the probable cause may be
something other than the main relief valve.

T4-5-9

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
Main Relief Set Pressure Adjustment

IMPORTANT: When the high pressure main relief


set pressure is adjusted, the lower
pressure main relief set pressure is Main Relief Valve
changed. Therefore, check to
re-adjust the lower pressure main
relief set pressure after adjusting
the high pressure main relief set
pressure.

High Pressure Main Relief Set Pressure Adjustment


1. Loosen lock nut (1). Turn adjusting plug (2) to
adjust the set pressure. After adjusting, tighten
lock nut (1) so that adjusting plug (2) does not
turn.
: 32 mm (Lock Nut 1)
: 29 N m (3 kgf m, 22 lbf ft) T1HH-01-02-005

: 19 mm (Adjusting Plug 2)

Low Pressure Main Relief Set Pressure Adjustment 1 2 3 4


1. Loosen lock nut (3). Turn adjusting screw (4) to
adjust the set pressure. After adjusting, tighten
lock nut (3) so that adjusting screw (3) does not
turn.
: 22 mm (Lock Nut 3)
: 29 N m (3 kgf m, 22 lbf ft)
: 6 mm (Adjusting Screw 4)
T1HH-03-03-014
2. Recheck the set pressure.

NOTE: Standard Change in Pressure (Reference)


Adjusting Plug
(2) and Adjust-
1/4 1/2 3/4 1
ing Screw (4)
Turns Adjusting Plug
MPa 4.4 8.8 13.2 17.7 Adjusting Screw
(kgf/cm2) (45) (90) (135) (180)
(psi) (640) (1280) (1920) (2560)
Pressure Pressure
Increase Decrease

W107-02-05-129

T4-5-10

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
RELIEF PRESSURE (When relieving
Swing)
1. Loosen the lock nut to adjust the adjusting plug.

2. Loosen lock nut (2).


: 41 mm

3. Turn adjusting plug (1) to adjust. Swing Relief Valve


: 27 mm

4. Tighten lock nut (2).


: 41 mm
: 186 N m (19 kgf m, 137 lbf ft)

5. Check the set pressure.

T1HH-01-02-004

NOTE: Standard Change in Pressure (Reference)


1 2
Adjusting Plug
1/4 1/2 3/4 1
Turns
MPa 2.5 5.0 7.5 10.0
(kgf/cm2) (25.5) (51) (76.5) (102)
(psi) (363) (725) (1088) (1450)

T107-02-04-020

Adjusting Plug

Pressure Pressure
Increase Decrease

T157-05-04-023

T4-5-11

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
RELIEF PRESSURE (When relieving
Travel)
ZAXIS330, 350LC, 350LCN, 350H
(Up to serial No.31357)
1. Loosen the lock nut to adjust the adjusting plug.

2. Loosen lock not (2).


: 19 mm

3. Turn adjusting screw (1) to adjust.


: 6 mm

4. Tighten lock nut (2).


: 19 mm
: 49 N m (5 kgf m, 36 lbf ft)
Travel Relief Valve T1HH-01-02-006

2 1

T157-05-04-008

NOTE: Standard Change in Pressure (Reference)


Adjusting Screw
1/4 1/2 3/4 1
Turns
MPa 2.9 5.9 8.8 11.5
(kgf/cm2) (30) (60) (90) (120)
(psi) (427) (853) (1280) (1706)

Adjusting Screw

Pressure Pressure
Increase Decrease

W107-02-05-129

T4-5-12

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
ZAXIS330, 350LC, 350LCN, 350H
(Serial No.31358 and up)
1. Remove the travel relief valve.
: 36 mm

2. Remove sleeve (1) and poppet (3).

3. Install shims (5) between poppet (3) and spring


guide (4) to adjust the set-pressure.
Travel Relief
4. Install the travel relief valve. Valve
: 450 N m (46 kgf m, 330 lbf ft)

5. Check the set-pressure.


T155-01-01-006
NOTE: Standard Change in Pressure (Reference)
Shim Change in Relief
Thickness Parts No. Pressure 1 2 5
(mm) kPa (kgf/cm2) (psi)
0.5 A590103 900 (9.2) (130)

3 4
T135-06-04-001

T4-5-13

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
ZAXIS370MTH
1. Loosen the lock nut to adjust the adjusting plug. :
2. Loosen lock not (2).
: 19 mm

3. Turn adjusting screw (1) to adjust. Travel Relief


: 6 mm Valve

4. Tighten lock nut (2).


: 19 mm
: 49 N m (5 kgf m, 36 lbf ft)

T183-01-02-012

2 1

T142-05-04-007

NOTE: Standard Change in Pressure (Reference)


Adjusting Screw
1/4 1/2 3/4 1
Turns
MPa 1.96 3.92 5.88 7.85
(kgf/cm2) (20) (40) (60) (80)
(psi) (284) (569) (853) (1138)

Adjusting Screw

Pressure Pressure
Increase Decrease

W107-02-05-129

T4-5-14

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
(Blank)

T4-5-15

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary: Preparation:
1. The circuit pressure must be increased by apply- 1. Shut down the engine properly.
ing an external force while blocking the return cir- 2. Press the air relief valve on top of the hydraulic
cuit from the control valve. This measuring oil tank to release any remaining pressure.
method is hazardous and the results obtained 3. Remove the plug from the main pump delivery
with this method are unreliable. port. Install adapter (ST 6069) and pressure
2. The oil flow rate used to set the overload relief gauge (ST 6934) on the port.
pressure is far less than that used to set the main : 6 mm
relief pressure. Therefore, measuring the over- 4. Select the monitoring function of the built-in di-
load pressure in the main circuit by increasing agnosing system (or Dr.ZX). Start the engine.
the main relief set-pressure more than the over- Confirm that no oil leakage is observed at the
load valve set-pressure is not a proper method. pressure gauge connection.
In addition, in case a main relief valve designed 5. Maintain the hydraulic oil temperature at 50o5 pC
to leak a small quantity of oil before reliving is (122o9 pF).
used, its pre-leaking start pressure must be in-
creased more than the overload relief valve
set-pressure. However, the pre-leaking start
pressure is not always increased more than the
overload relief valve set-pressure as the adjust-
able upper limit of the main relief valve
set-pressure is provided. Accordingly, the over-
load relief valve assembly should be removed
from the machine and checked on a specified
test stand at a correct oil flow rate. Some over-
load relief valves come in contact with the control
valve body to block the oil passage. When this
type of overload relief valve is checked, the con-
trol valve body must be precisely finished as the
test unit. Provide one control valve other than
that on the machine as a test kit.
3. If the overload relief valve performance must be
checked on the machine, however, measure the
main relief pressure while releasing each front
function respective to the measuring overload re-
lief valve. And, assume that the overload relief
valve is functioning correctly if the obtained main
relief pressure is within the specified value range.
Measure the main pressure of the front functions
with the built-in diagnosing system or Dr.ZX as
follows:

T4-5-16

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
Measurement:
1. Select the following switch positions:
Auto-Idle/
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch Pressure
Selector
Check Ports
Digging
Fast Idle P Mode OFF
Mode

2. Slowly operate bucket, arm, and boom control


levers to the stroke ends to relieve each function
one at a time.
3. Read the pressures on the pressure gauge while
releasing the front functions.
4. Perform the measurement for the bucket, arm,
and boom, in that order.
5. Repeat the measurement three times and calcu-
late the average value for each front function.

Evaluation:
1. Performance of the overload relief valves are
normal if the measured main relief pressures are
T1HH-04-04-005
within the specified value range.

Refer to the Performance Standard Table in


Group T4-2.

T4-5-17

PDF created with pdfFactory Pro trial version www.pdffactory.com


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

NOTE: In principle, adjust the overload relief valve


set pressure on a test stand.

Adjustment:
Adjust the pressure setting of the overload relief
valve using adjusting screw (2) after loosening lock
nut (1).
1 2
1. Loosen lock nut (1).
: 22 mm

2. Turn adjusting screw (2) to adjust the pressure.


: 6 mm

3. Retighten lock nut (1). T1HH-03-03-018


: 22 mm
: 29.5 N m (30 kgf m, 21.5 lbf ft)

4. Recheck the set pressures.


Adjusting Screw

NOTE: Standard Change in Pressure (Reference)


Screw Turns 1/4 1/2 3/4 1
Change MPa 4.4 8.8 13.2 17.7
in Relief (kgf/cm2) (45) (90) (135) (180)
Pressure (psi) (640) (1280) (1920) (2560) Pressure Increase Pressure Decrease

W107-02-05-129

T4-5-18

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
(Blank)

T4-5-19

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
MAIN PUMP FLOW RATE MEASUREMENT
P-Q Control (Torque Control)
Summary:
Main pump performance is checked by measuring 6. Remove regulator pipe (14).
the pump flow rate with a hydraulic tester installed at Install hose (ST 6339) (13) to the port for regula-
the main pump delivery port (one side) to be meas- tor pipe (14) to be measured.
ured. Use Dr. ZX and a pressure gauge at the same Install plug (ST 6212) to the port for regulator
time. pipe (14) not to be measured.
7. Disconnect the N sensor connector.
IMPORTANT: This measurement procedure is a Connect the pulse counter to the N sensor.
simple method. The measured data 8. Disconnect the vacuum pump. Loosen plug (12)
will be lower by approx. 5 % than on the top of the pump casing to bleed the air
the accurately measured value. To from the casing until oil comes out.
measure accurately, disconnect the 9. Fully open the loading valve located on the port-
return circuit from the control valve able tester.
and connect it to the hydraulic oil 10. Disconnect the torque control solenoid valve
tank. connector.
11. Start the engine. Check for any oil leaks at con-
Preparation: nections to the pressure gauge. Connect Dr. ZX
1. Stop the engine. Push the air bleed valve to and select the monitoring function.
bleed air. Connect a vacuum pump to the oil filler
port.
Measurement:
1. Maintain the hydraulic oil temperature at 50o5 pC
NOTE: Operate the vacuum pump while connect-
(122 o 9pF)
ing the pump flow rate test line.
2. Measure the maximum flow rate.
3. Select each switch position as follows:
2. Disconnect the delivery hose from the main
Auto-Idle/
pump (one side) to be measured. Connect pipe Engine Power Mode Work Mode
Acceleration
(1 or 2) to the pump delivery port using the split Control Dial Switch Switch
Selector
flanges and bolts which were used to connect the
disconnected delivery hose. Digging
Fast Idle P Mode OFF
: 41 mm Mode
: 10 mm
3. Connect hose (1 or 2) to hydraulic tester (5) us- 4. Slowly close the loading valve of the hydraulic
ing test hose (3) and adapter (4). Connect tester while relieving the pressure. Measure the
adapter (6), joint (7), test hose (8) and flange (9) flow rates and engine speeds at the pressure
to hydraulic tester (5). points specified in the P-Q curve.
: 41 mm 5. Repeat each measurement three times and cal-
: 10 mm culate the average values.
4. Connect the delivery hose to flange (9) with split
flanges (10) and bolts (11).
: 10 mm
5. Install a pressure gauge to the main pump to be
measured. (Refer to T4-5-8 Main Relief Pressure
Check.)
: 6 mm

T4-5-20

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified pump speed using the following formu- Refer to T4-2 Operational Performance Standard.
las:

Qc = (Ns I Q) / Ne

Qc : Converted Flow Rate


Q: Measured Flow Rate
Ns : Specified Pump Speed (1900 min-1)
Ne : Measured Engine Speed
Pulse Number (Hz)I60/39

1, 2 3 4 5 6 7 8 9 10 11

Delivery Hose (To


Control Valve)

T173-04-04-002

Signal Control Valve


12
13

14

N sensor

T1HH-01-02-003

T1HH-04-04-010

1- Pipe E (ST 6144) 5- Hydraulic Tester (ST 6299) 9- Flange (ST 6118) 12 - Plug
2- Pipe B (ST 6143) 6- Adapter PF1IUNF1-7/8 10- Split Flange (ST 6130) 13 - Hose (ST 6339)
(ST 6146)
3- Test Hose (ST 6145) 7- Joint (ST 6330) 11- Bolt (ST 6409) (4 Used) 14- Pipe (2 Used)
4- Adapter PF1IUNF1-7/8 8- Test Hose (ST 6320)
(ST 6146)

T4-5-21

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONL PERFORMANCE TEST / Component Test
P-Q Control by Pump Control Pilot Pressure Signal
(Pilot Pressure Characteristics)
Summary:
To check the main pump performance, measure the 5. Connect hose (19) and adapter (20) to port T on
pump flow rate by connecting a portable tester at the reducing valve (16). Connect hose (19) after re-
delivery port of the main pump of which the flow rate moving plug L from the return pipe.
is to be measured. Dr.ZX or a pressure gauge is : 19 mm, 22 mm
used for pressure reading purpose in the measure-
ment. 6. Disconnect the N sensor connector.
Connect the pulse counter to the N sensor.
IMPORTANT: This measurement procedure is a
simple method. The measured data 7. Disconnect the vacuum pump. Loosen plug M
will be lower by approx. 5 % than (12) on the pump casing to bleed air from the
the accurately measured value. To casing until oil comes out.
measure accurately, disconnect the
return circuit from the control valve 8. Fully open the loading valve on the portable
and connect it to the hydraulic oil tester.
tank.
9. Disconnect the torque control solenoid valve
Preparation: connector.
1. Refer to steps 1 to 4 on page T4-5-18, connect a
portable tester to the main pump to be measured. 10. Start the engine. Check the pressure gauge con-
nections for any oil leakage.
2. Disconnect the hoses of port Pi at the regulator
on the main pump to be measured.
Attach plug (ST 6213) in the disconnected hose.
: 6 mm, 19 mm

3. Connect adapters (15) (3 used) to reducing valve


(16).
Disconnect hose M at port PC of the pilot filter.
Connect tee (17) to port PC of the pilot filter. Con-
nect hose M, adapter (13) and hose (14) to tee
(17). Connect hose (14) to port P1 on reducing
valve (16).
: 19 mm

4. Connect tee (17) to port P2 on reducing valve


(16). Connect pressure gauge (18) and hose (14)
to tee (17). Connect hose (14) to the port Pi on
the regulator.

T4-5-22

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Component Test

1, 2 3 4 5 6 7 8 9 10 11

Delivery Hose (To


Control Valve)

Port Pi
M T173-04-04-002

12

N sensor
T1HH-04-04-002

T1HH-04-04-009

Reducing Valve Position


Reducing Valve
Return Piping
T
L
20
18
M
P1 P2 19

15 17

To Port Pi on Regulator

14 17 15 16 15 14 13 To Port PC on
Pilot Filter
T1HH-04-04-008

1 - Pipe E (ST 6144) 6 - Adapter PF1IUNF1-7/ 8 11 - Bolt (ST 6409) (4 used) 16 - Reducing Valve (4325439)
(ST 6146)
2 - Pipe B (ST 6143) 7 - Joint (ST 6330) 12 - Plug M 17 - Tee UNF7/16IUNF 7/16
3 - Test Hose (ST 6145) 8 - Test Hose (ST 6320) 13 - Adapter UNF 7/16I 18 - Pressure Gauge (ST 6931)
PF 1/4 (ST 6069)
4 - Adapter PF1IUNF1-7 / 8 9 - Flange (ST 6118) 14 - Hose UNF7/16I 19 - Hose UNF 7/16I
(ST 6146) UNF7/16 (4334309) UNF 7/16 (4334309)
5 - Potable Tester (ST 6299) 10 - Split Flange (ST 6130) 15 - Adapter PF3/8I 20 - Adapter PF3/8I
UNF 7/16 (4200465) UNF 7/16 (4200465)

T4-5-23

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Component Test
Measurement: Evaluation:
1. Measure the main pump flow rate controlled by 1. Convert the measured pump flow rate into the
the pump control pilot pressure signal. one for the rated pump speed using the following
formula.
2. Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF).

3. Select the following switch positions: Qc = Ns I Q / Ne


Power Auto-Idle/
Engine Work Mode
Mode Acceleration Qc : Converted Flow Rate
Control Dial Switch
Switch Selector Q : Measured Flow Rate
-1
Ns : Rated Pump Speed (1900 min )
Digging Ne : Measured Engine Speed
Fast Idle P Mode OFF
Mode Pulse Number (Hz)I60/39

4. Adjust the reducing valve set pressure to the 2. Specified Pump Flow Rate
specified pressure shown on the P-Q diagram of Refer to the Performance Standard Table in
the main pump (Pilot Pressure Characteristics) Group T4-2.
on page T4-2-5.
Measure the flow rate and engine speed at each
specified pressure shown on the P-Q diagram.

5. Repeat the measurement three times and calcu-


late the average values.

T4-5-24

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Component Test
Regulator Adjustment

6 5

1
3

2
4

10

T1HH-03-01-002
7 8

1 - Lock Nut (For Minimum 4 - Adjusting Screw (For 7 - Lock Nut 9 - Lock Nut
Flow Adjustment) Maximum Flow Adjust- (For P-Q Line Adjustment) For P-Q Line Adjustment)
ment)
2 - Adjusting Screw (For 5 - Lock Nut 8 - Adjusting Screw 10 - Adjusting Screw
Minimum Flow Adjustment) (For Pilot Pressure Char- (For P-Q Line Adjustment) (For P-Q Line Adjustment)
acteristic Adjustment)
3 - Lock Nut (For Maximum 6 - Adjusting Screw
Flow Adjustment) (For Pilot Pressure Char-
acteristic Adjustment)

Adjustment Procedure Remarks


1. Minimum Flow Rate After loosening lock nut (1), turn 1) Do not tighten adjusting screw
Q adjusting screw (2). Tightening ad- (2) more than one and half
justing screw (2) 1/4 a turn in- turns.
creases the minimum pump flow 2) Securely retighten lock nut (1)
rate by 8.21 cm3/rev. after adjustment.

Pi

2. Maximum Flow Rate After loosening lock nut (3), turn 1) Do not tighten adjusting screw
Q adjusting screw (4). Tightening ad- (2) more than two turns.
justing screw (4) 1/4 a turn de- 2) Do not attempt to increase the
creases the maximum pump flow maximum flow rate. (Do not turn
rate by 10.00 cm3/rev. adjusting screw (4)
counter-clockwise.)
3) Securely retighten lock nut (3)
after adjustment.

Pd

T4-5-25

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Component Test

Adjustment Procedure Remarks


3. Pilot Control Characteris- After loosening lock nut (5), turn 1) Do not tighten adjusting screw
tics adjusting screw (6). Tightening ad- (6) more than one turn.
(Pi-Q Line) justing screw (6) 1/4 a turn de- 2) When adjusting screw (6) is
creases the pump flow rate by tightened, the maximum flow rate
Q 17.11 cm3/rev. decreases. Therefore, after tight-
ening adjusting screw (6), loosen
adjusting screw (4) by the ratio of
2 (adjusting screw (4) turn) to 1
(adjusting screw (6) turn) to
maintain the maximum flow rate
unchanged. The loosening vs.
tightening ratio of 2 to 1 should
Pi always be kept constant.
3) Securely retighten lock nut (5)
after adjustment.

4. Pump Output Torque A. After loosening lock nut (7), turn 1) Do not tighten adjusting screw
(P-Q Line) adjusting screw (8). Tightening (8) more than one turn.
Q adjusting screw (8) 1/4 a turn 2) Increase or decrease the flow
increases the pump flow rate by rate. So that the engine is not
A 19.85 cm3/rev. overloaded.
B. After loosening lock nut (9), turn 3) Securely retighten lock nut (3 or
Pd adjusting screw (10). Tightening 9) after adjustment.
Q adjusting screw (10) 1/4 a turn
increases the pump flow rate by
3.73 cm3/rev.
B
Pd

NOTE: The change in the pump flow rate shown in


the above table means the change value
per one turn of the engine output shaft.

T4-5-26

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Component Test
SWING MOTOR DRAINAGE
Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while
swinging the upperstructure.

NOTE: The amount of drain oil from the swing


motor will change depending on hydraulic
oil temperature.
Maintain hydraulic oil temperature at 50 5 1
C (122 9 F).

CAUTION: Prevent personal injury. Always


check that the area is clear and that
co-workers are out of the swing area before
starting the measurement.
Also, take care not to fall off the machine
while the measurement.

Preparation:
1. Maintain hydraulic oil temperature at 50o5 pC
(122o9 pF). Rotate the swing motor to warm the T157-05-04-014

inside of the motor. 2


2. Properly shut down the engine. Press the air re-
lease valve (1) on top of the hydraulic oil tank to
release any remaining pressure.
3. Disconnect the swing motor drain hose (2) at the
hydraulic oil tank end. Install plug (ST 6213) to
the disconnected end on the hydraulic oil tank.
: 22 mm
: 39 N m (4 kgf m, 29 lbf ft)

Preconditions for Measurement:


1. Select the following switch positions:
Power Auto-Idle /
Engine Work Mode
Mode Acceleration
Control Dial Switch
Switch Selector
Digging
Fast Idle P Mode OFF
Mode T1HH-04-04-006

T4-5-27

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Amount of Oil Drained While Swinging the Up-
perstructure
(1) Fully retract the arm cylinder. Fully extend the
bucket cylinder. Raise the boom so that the
arm tip pin height is the same as the boom
foot pin height. Check that the bucket is
empty.
(2) Start the engine. Operate and hold the swing The same height as
boom foot pin height
lever full stroke. Start draining oil measure-
ment after the swing speed reaches a con-
T105-06-03-013
stant maximum speed. The measuring time
should be more than 45 seconds.
(3) Repeat the measurement at least three times
in both clockwise and counterclockwise direc-
tions, and calculate the average values.

2. Amount of Oil Drained While Relieving Swing


Motor Circuit
(1) Thrust the bucket teeth into the ground as il-
lustrated so that the upperstructure does not
rotate when the swing lever is operated full
stroke.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start drain oil measurement
when drain oil starts coming out of the drain T107-06-06-005
hose end. The measuring time should be
more than 45 seconds.
(3) Repeat the measurement at least three times
in both clockwise and counterclockwise direc-
tions, and calculate the average values.

T4-5-28

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation:
Refer to the Performance Standard Table in group
T4-2.

Conversion of the amount of drain oil measured


into the per-minute value

First measure the amount of drain oil using a cali-


brated container. Then, convert the measured drain
oil into the per-minute value using the formula be-
low:

Q = 60 I q / t

Where:
Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
T107-06-05-008
q : Total amount of drain oil (L)

T4-5-29

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Component Test
TRAVEL MOTOR DRAINAGE
1
Summary:
To check travel motor performance, measure the
amount of oil draining from the travel motor while
rotating the travel motor with the measuring side
track jacked up.

NOTE: The amount of drain oil from the travel


motor will change depending on hydraulic
oil temperature.
Maintain hydraulic oil temperature at 50 5
C (122 9 F). T157-05-04-014

ZAXIS330, 350LC, 350LCN, 350H (Up to serial No.31357)


Preparation:
1. Main hydraulic oil temperature at 50o5 pC (122o9
2
pF). Rotate the travel motor to warm the inside of
the motor.
2. Properly shut down the engine. Press the air re-
lease valve (1) on top of the hydraulic oil tank to
release any remaining pressure.
3. Disconnect the travel motor drain hose (2) at the
travel motor end. Install plug (ST 6637) to the dis-
connected end. Connect the drain hose
(3/4-16UN) to the travel motor.
: 22 mm, 27 mm
: 93 N m (9.5 kgf m, 69 lbf ft)

Preconditions for Measurement:


1. Select the following switch positions: T1HH-04-04-007

Auto-Idle/ ZAXIS330, 350LC, 350LCN, 350H (Serial No.31358 and up)


Engine Con- Power Mode Work Mode
Acceleration
trol Dial Switch Switch
Selector 2
Fast Idle P Mode Digging OFF

ZAXIS370MTH:
T155-05-04-004
2

M183-01-001

T4-5-30

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Amount of Oil Drained While Rotating Travel
Motor
(1) Start the engine. Jack up the measuring side
track using the front attachment, as illustrated.
90 to 110p
CAUTION: Securely support the raised track
using wooden blocks. When working around
moving parts is unavoidable, pay special at-
tention to ensure that hands, feet, and cloth-
ing do not become entangled. M104-07-067

(2) Rotate the raised track with the travel lever


operated full stroke. Start drain oil measure-
ment after the track rotation speed reaches a
constant maximum speed. The measuring
time should be more than 45 seconds.

(3) Repeat the measurement at least three times


in both forward and reverse directions, and
calculate the average values.

Evaluation:
Refer to the Performance Standard Table in Group
T4-2.

Conversion of the amount of drain oil measured


into the per-minute value

First measure the amount of drain oil using a cali- T157-05-04-019


brated container. Then, convert the measured drain
oil into the per-minute value using the formula be-
low:

Q = 60 I q / t

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

T4-5-31

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)

T4-5-32

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Adjustment
ENGINE SPEED ADJUSTMENT AND
ENGINE LEARNING
After removing and/or replacing the components as
described below for repair and/or inspection, or if error
in engine speed is found, readjust engine speed and
perform engine learning.

Removal of the engine, engine control cable, or


EC motor
Replacement of MC

Adjustment of Engine Speed:


1. Turn the key switch to the START position to start
the engine.
NOTE: Turn the air conditioner OFF.

2. Rotate the engine control dial to the minimum


speed position. (The output voltage from the EC
sensor is 2.5 V.)

3. Deactivate the auto warming up and ECO control


systems by Dr. ZX.

4. When Dr. ZX is not available, keep the engine


running for about 15 minutes to warm coolant
temperature to more than 30 pC (86 Fp) until the
auto warming up control system is deactivated.

5. Loosen the bolt holding the control lever to the EC Holding Bolt
motor output shaft.
Control Lever T157-07-04-015
6. While monitoring the actual engine speed with Dr.
ZX or the engine speed meter, adjust the control
lever so that the minimum speed (slow idle)
matches the specification.
Specification: Refer to T4-2 OPERATIONAL PER
FORMANCE TEST.

7. Tighten the lever holding bolt to secure the control


lever to the motor output shaft.
: 13 N m (1.3 kgf m, 9.4 lbf ft)

NOTE: Dont lubricate the motor output shaft.

8. Perform engine learning.

T4-6-1

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Adjustment
Engine Learning:
1. Turn the key switch OFF
Learning
NOTE: In case the engine doesnt stop when the Switch
key switch is turned OFF, pull the handle
located under the seat to stop the engine.
Dr.ZX
2. Disconnect Dr. ZX. Wait for 5 seconds. Connector
to MC
3. Turn the learning switch ON.

4. Turn the key switch ON. Wait for 5 seconds.

5. Turn the key switch OFF. Wait for 5 seconds.

6. Turn the learning switch OFF.

7. Check the engine speed. T178-01-02-006

Learning Switch is
Turned to Stamp E

Learning Switch

Stamp

Learning Switch Dr.ZX Connector


to MC T1CC-05-01-001

T4-6-2

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Adjustment
(Blank)

T4-6-3

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Adjustment
GOVERNOR LEVER AND FUEL CUT
LEVER POSITION
Check the fuel cut lever position during cranking.
If the position is normal, the engine unit and/or
fuel system may have trouble.

Governor Lever and Fuel Cut Lever

1 2

T1HH-04-02-002

4 3

1 - Governor Cable (From EC Motor)


2 - Fuel Cut-Off Cable
(Fuel Cut-Off Handle)
3 - Fuel Cut Lever
4 - Governor Lever

T4-6-4

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Adjustment
Governor Lever Position

A - Key Switch OFF (Engine Stop Position)


B - Key Switch ON (Engine Start Position)

B
FULL
A: STOP
FULL
STOP

T1HH-04-02-002

Fuel Cut Lever Position

A - Fuel Cut-Off Handle Pulled Position


B - Fuel Cut-Off Handle Returned Position

B A

T1HH-04-02-002

T4-6-5

PDF created with pdfFactory Pro trial version www.pdffactory.com


OPERATIONAL PERFORMANCE TEST / Adjustment
(Blank)

T4-6-6

PDF created with pdfFactory Pro trial version www.pdffactory.com


MEMO

PDF created with pdfFactory Pro trial version www.pdffactory.com


MEMO

PDF created with pdfFactory Pro trial version www.pdffactory.com


SECTION 5
TROUBLESHOOTING

CONTENTS
Group 1 General Group 3 Troubleshooting A
Introduction............................................... T5-1-1 Troubleshooting A Procedure ....................T5-3-1
Diagnosing Procedure .............................. T5-1-2 Fault Code List ..........................................T5-3-2
Built-In Diagnosing System Operation ...... T5-1-6 Fault Code 01, 02, 03................................T5-3-3
Built-In Diagnosing Function Display List .. T5-1-7 Fault Code 04............................................T5-3-3
Dr. ZX Operation....................................... T5-1-8 Fault Code 06............................................T5-3-4
Dr. ZX Fault Code List............................. T5-1-10 Fault Code 07............................................T5-3-5
Dr. ZX Monitoring Item List ..................... T5-1-12 Fault Code 10, 11 ......................................T5-3-6
Dr. ZX Special Function .......................... T5-1-14 Fault Code 12, 13......................................T5-3-7
Dr. ZX Service Mode............................... T5-1-15 Fault Code 14, 15, 16, 18..........................T5-3-8
Adjustment Data List............................... T5-1-25 Fault Code 19............................................T5-3-9
Group 2 Component Layout
Main Component Layout ........................... T5-2-1
Electrical Component Layout (Overview) .. T5-2-2 Group 4 Troubleshooting B
Electrical System (Relays) ........................ T5-2-3 Troubleshooting B Procedure....................T5-4-1
Electrical System Relationship between Machine Trouble
(Monitors and Switches).......................... T5-2-4 Symptoms and Related Parts ..................T5-4-2
Engine ...................................................... T5-2-5 Correlation between Trouble
Pump Device ............................................ T5-2-5 Symptoms and Part Failures ................. T5-4-20
Swing Device ............................................ T5-2-5 Engine System Troubleshooting .............. T5-4-31
Control Valve ............................................ T5-2-6 All Actuator System Troubleshooting .......T5-4-52
Solenoid Valve Unit................................... T5-2-6 Front Attachment System
Travel Device ............................................ T5-2-6 Troubleshooting..................................... T5-4-59
Shockless Valve........................................ T5-2-6 Swing System Troubleshooting ...............T5-4-72
Positioning Control Valve ........................ T5-2-6 Travel System Troubleshooting ............... T5-4-75
Components in Control Valve.................... T5-2-8 Other System Troubleshooting ................ T5-4-82
Exchange Inspection ............................. T5-4-102
Emergency Boom Lowering
Procedure ........................................... T5-4-104

1HHT-5-1

PDF created with pdfFactory Pro trial version www.pdffactory.com


Group 5 Troubleshooting C Group 7 ICX
Troubleshooting C Procedure ................... T5-5-1 Outline ......................................................T5-7-1
Malfunction of Coolant ICX Fault Code List ...................................T5-7-8
Temperature Gauge ................................ T5-5-2 Satellite Terminal Fault Code List ..............T5-7-8
Malfunction of Fuel Gauge ........................ T5-5-4 Fault Code 1 to 6.......................................T5-7-9
Malfunction of Indicator Light Fault Code 7 to 10.....................................T5-7-9
Check System......................................... T5-5-6 Some Parts of Data in Daily Report,
Malfunction of Preheat Indicator ............... T5-5-7 Frequency Distribution, Cumulative
Malfunction of Engine Oil Level Operation Hours are not Recorded........T5-7-10
Indicator .................................................. T5-5-8
Malfunction of Coolant Level
Indicator ................................................ T5-5-10
Malfunction of Alternator Indicator .......... T5-5-12
Malfunction of Engine Oil Pressure
Indicator ................................................ T5-5-14
Malfunction of Overheat Indicator ........... T5-5-16
Malfunction of Air Filter Restriction
Indicator ................................................ T5-5-18
Malfunction of Buzzer ............................. T5-5-20
Malfunction of LCD ................................. T5-5-22
Malfunction of Hour Meter....................... T5-5-23
Malfunction of Hydraulic Oil Filter
Indicator (Optional) ............................... T5-5-24

Group 6 Electrical System Inspection


Precautions for Inspection and
Maintenance ........................................... T5-6-1
Instructions for Disconnecting
Connectors ............................................. T5-6-3
Fuse Inspection ........................................ T5-6-4
Fusible Link Inspection ............................. T5-6-5
Battery Voltage Check .............................. T5-6-6
How to Troubleshoot Alternator
Malfunctions............................................ T5-6-7
Continuity Check....................................... T5-6-8
Voltage and Current Measurement ......... T5-6-11
Check by False Signal ............................ T5-6-15
Test Harness........................................... T5-6-16

1HHT-5-2

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
INTRODUCTION
Refer to the inspection and troubleshooting proce- Troubleshooting B (base machine diagnosis start-
dures after any machine trouble has occurred. The ing with inspection of abnormal operational
inspection and troubleshooting procedures are pre- status)
sented in an orderly fashion in this section to quickly Refer to these procedures when no fault codes
find the cause of the machine trouble and solution. are displayed after diagnosing the machine with
Dr. ZX (or the built-in diagnosing system). Trace
The troubleshooting section in this manual consists of the cause of trouble based on the inspected re-
7 groups; General, Component Layout, Troubleshoot- sult of the abnormal symptom.
ing A (base machine diagnosis using fault codes),
Troubleshooting B (base machine diagnosis starting Example: Even if the engine control dial is oper-
with inspection of abnormal operational status), Trou- ated, engine speed remains unchanged.
bleshooting C (monitor diagnosis), Electrical System
Inspection, and ICX. Troubleshooting C (monitor diagnosis)
Refer to these procedures when gauges and/or
General indicators are malfunctioning.

Component Layout Example: Malfunction of fuel gauge

Troubleshooting A (base machine diagnosis using Electrical System Inspection


fault codes) Refer to this group when required to obtain pre-
Refer to these procedures if any fault codes are cautions and/or information for the electrical sys-
displayed when the main controller (MC) is diag- tem inspection.
nosed with Dr. ZX (or the built-in diagnosing sys-
tem). Example: Fuse Inspection
(MC self-diagnosing function retains a record of
the electrical signal system malfunction in the ICX
form of fault codes.) Refer to these procedures after any fault code is
displayed after diagnosing ICX (Information Con-
Example: Fault Code 06: Abnormal EC Sensor troller) or the satellite terminal (optional) with Dr.
ZX. (The controller self-diagnosing function re-
tains a record of the electrical signal system mal-
function in the form of fault codes.)

Example: ICX Fault Code 7: MC Communication


Time Out

In addition, information on the following items is


described in this group.
1. Trouble shooting and setting procedures of
ICX and satellite terminal using Dr. ZX.
2. Information on the satellite communication
system

T5-1-1

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient
troubleshooting:

1. Study the System


Study the machines 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 T107-07-01-001

Before inspecting, get the full story of


malfunctions from the operator below.

(a) How is the machine being used? (Find out if


the machine is being operated correctly)

(b) When was the trouble noticed, and what


types of work the machine doing at that
time?

(c) What are the details of the trouble? Is the


trouble getting worse, or did it appear
suddenly for the first time?

(d) Did the machine have any other troubles


previously? If so, which parts were repaired
before?

T107-07-01-002

T5-1-2

PDF created with pdfFactory Pro trial version www.pdffactory.com


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

Also, check the electrical system, including the


batteries, as troubles in the electrical system
such as low battery voltage, loose connections
and blown fuses will result in malfunction of the
controllers, causing total operational failure of the
machine.
If troubleshooting is started without checking for
blown fuses, a wrong diagnosis may result,
wasting time. Be sure to check for blown fuses
before troubleshooting. Even if a fuse looks
normal by visual inspection, a fine crack is
difficult to find. Always use a tester when
checking the fuses. T107-07-01-003

4. Operate the machine yourself


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

T5-1-3

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
5. Perform troubleshooting
CAUTION: Never attempt to disconnect
harnesses or hydraulic lines while the engine
is running. The machine may malfunction or
pressurized oil may spout, possibly resulting
in personal injury. Be sure to stop the engine
before disconnecting harnesses or hydraulic
lines.

Perform diagnosis by connecting Dr. ZX to the


machine or by operating the built-in diagnosing
system. In case any fault code has been dis-
played by diagnosis using Dr. ZX (or the built-in
diagnosing system), delete the fault code once T107-07-01-005

and retry self-diagnosis again. If the fault code is


displayed again, check the cause of the trouble
by referring to Troubleshooting A in this section.
After the machine trouble has been corrected, the
fault code (displayed by the built-in diagnosing
function) will be deleted. Therefore, in case prob-
lems, which are not easily re-predicable are
encountered, use Dr. ZX to display the fault code.
In case no fault codes are displayed, check all re-
lated parts/component operating condition using
the monitor function of Dr. ZX (or the built-in di-
agnosing system) while referring to troubleshoot-
ing B in this section.

Note that the fault codes displayed do not


necessarily indicate machine trouble. The T107-07-01-006
controller stores even temporary electrical
malfunctions, such as a drop in battery output
voltage or disconnections of the switches,
sensors, etc., for inspections.
For this reason, the RETRIAL is required to
erase the accumulated fault codes from the
controller memory and to confirm if any fault
codes are indicated after the RETRIAL.

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 T107-07-01-007

appropriate repairs to avoid consequent


malfunctions.

T5-1-4

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
(Blank)

T5-1-5

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
BUILT-IN DIAGNOSING SYSTEM OPERA-
TION
IMPORTANT: This system is to be operated by the
HITACHI Dealer Only. Dont explain
this system function to the cus-
tomer.

In the service mode, the monitor LCD displays the


diagnosing items, fault codes and monitored results
(not all of them) without using Dr. ZX.

Built-In Diagnosing System Activation


1. While pressing the monitor SET switch, turn the
key switch ON.
Display Selection
Switch
Built-In Diagnosing System Operation
1. Each time the display selection switch is pressed,
SET Switch
the displayed item will be changed as shown on
next page.

NOTE: The fault code is indicated in the display


order 8. All fault codes (Dr. ZX fault code
list) can be indicated. In case more than LCD
one fault code is indicated, they will be dis-
played with an interval of 1 second in order.
After the machine malfunction has been
repaired, the fault codes are automatically
deleted. Accordingly, if any trouble, which
is not reproducible, is encountered, it is
recommended to use Dr. ZX.
The built-in diagnosing system displays only the
item No. on the left and the monitored result on the T178-01-01-003

right. The item description is not displayed.

T5-1-6

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
BUILT-IN DIAGNOSING FUNCTION DISPLAY LIST

Display
Description Monitored Result Unit Remarks
Order
1 Hour Meter h Standard Mode
2 Trip 1 h Standard Mode (Subtraction)
3 Trip 2 h Standard Mode (Subtraction)
4 Engine Actual Speed n -1
min User Mode (Required to set
in the Dr. ZX service mode)
5 Hydraulic Oil Tempera- pC User Mode (Required to set
ture in the Dr. ZX service mode)
6 L1 Display Purpose Only
7 Overload Alarm L2 % European Spec. Only
8 Fault Code* 0
9 ML Switch** 1 0: Switch OFF
1: Switch ON
10 Pump 1 Delivery Pres- 2 MPa
sure
11 Pump 2 Delivery Pres- 3 MPa
sure
12 Pump 1 Pump (Flow) 4 MPa
Control Pressure
13 Pump 2 Pump (Flow) 5 MPa
Control Pressure
-1
14 Engine Target Speed 6 min
15 EC Angle 7 V
16 Dial Angle 8 V
17 Boom Raise Pilot Pres- 9 MPa
sure
18 Arm Roll-In Pilot Pres- A MPa
sure
19 Swing Control Pilot b MPa
Pressure
20 Travel Control Pilot c MPa
Pressure
21 Front Att. Operation d 0: Not Operating
1: Operating
22 Att. Control Pressure E MPa
23 Work Mode F 0: Digging
1: Breaker
2: Secondary
Crusher
(Demolisher)
3: Crusher
4: Vibro-Hammer

NOTE: *: Refer to T5-1-10 for the Fault Codes.


**: ML specification is only available in Japanese domestic market.

T5-1-7

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
Dr. ZX OPERATION
Rear Console
Dr. ZX is a troubleshooting tool to diagnose the elec- Fuse Box
tronic control system including the MC (main Control-
ler) and ICX (Information Controller). When Dr. ZX is Dr. ZX
connected to either the MC or the ICX, it displays Connector
whether the controllers and sensors operate normally (MC)
in the form of fault codes (Self-Diagnosing Result Dis-
play Function).
In addition, Dr. ZX can display the inputs from sensors
and switches to the MC and/or the outputs to actua-
tors such as solenoid valves from the MC in real time
while operating the machine (Monitor Display Func-
tion).

NOTE: This group describes how to operate Dr.


ZX connected to the MC. Refer to Group 7
ICX for operation of Dr. ZX connected to Dr. ZX Connector (ICX)
the ICX. (Located at Backside of
Sheet)
T178-01-02-006

Palm
Dr. ZX

Hot Sync Cable

Battery Box
Cable

T178-05-01-167

T5-1-8

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
Operation
1. Connect palm (Dr. ZX) to the diagnosis connec-
tors (MC and ICX) located in the cab, using Hot Start
Sync cable and battery box cable.

2. Turn the key switch ON, or start the engine.


3. When the palm power is turned ON, palm dis- Title Screen
plays the following screens in order.
3-1. Title Screen
Select the Dr. ZX icon
3-2. Select Kind Screen Cannot Select Kind
Communicate Screen
+ Select the EPVC-Mid
3-3. Menu Screen
Check harness
Select the Start. Check fuse
3-4. Model Name Screen Menu Screen
(Example) Model: ZX330
3-5. Function Selection Screen
+ Self-Diagnostic Results
Model Name
+ Monitor Display Confirmation
+ Special Function
NOTE: Special functions allow the ECO and WU NOT OK
deactivation. (Refer to T5-1-14) OK ?

4. Select Self-Diagnostic Results. Then, continue to OK


Replace software
operate palm by following instructions to be dis-
played at the screen bottom hereafter.
Self-Diagnosing
NOTE: Refer to the Dr. ZX Operation Manual for Result Display Special
Function Select Monitor Function
the detailed operation of Dr. ZX.
function

Self-diagnostic
Result by control- Enter model
ler is displayed Record
code and serial
No.

Retry B
Select data to
be monitored

Self-diagnostic
Result is displayed Monitored data
is displayed

T5-1-9

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
DR. ZX FAULT CODE LIST

Fault Code Trouble Cause


01 Abnormal EEPROM Faulty MC
02 Abnormal RAM
03 Abnormal A/D Conversion
04 Abnormal Sensor Voltage Faulty MC
Faulty Harness
Faulty Sensor
06 Abnormal EC Sensor Faulty MC
Faulty Harness
Faulty EC Sensor
07 Abnormal Engine Control Dial Angle Faulty MC
Faulty Harness
Faulty Engine Control Dial
10 Abnormal Pump 1 Delivery Pressure Faulty MC
11 Abnormal Pump 2 Delivery Pressure Faulty Harness
Faulty Pump Delivery Pressure Sensor
12 Abnormal Pump1 Pump Control Pressure Faulty MC
13 Abnormal Pump2 Pump Control Pressure Faulty Harness
Faulty Pump Control Pressure Sensor
14 Abnormal Swing Pilot Pressure Faulty MC
15 Abnormal Boom Raise Pilot Pressure Faulty Harness
16 Abnormal Arm Roll-In Pilot Pressure Faulty Pilot Pressure Sensor
18 Abnormal Travel Pilot Pressure
19 Abnormal Hydraulic Oil Temperature Faulty MC
Faulty Harness
Faulty Hydraulic Oil Temperature Sensor

T5-1-10

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
(Blank)

T5-1-11

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
Dr. ZX MONITORING ITEM LIST
Dr. ZX displays the input signals from the switches
and sensors to the MC and the control signals to the
actuators from the MC.

Item Data Unit


Pump 1 Delivery Pressure Input signals from pump 1 delivery pressure sensor MPa
Pump 1 Pump (Flow) Con- Input signals from pump 1 control pressure sensor MPa
trol Pressure
Pump 2 Delivery Pressure Input signals from pump 2 delivery pressure sensor MPa
Pump 2 Pump (Flow) Con- Input signals from pump 2 control pressure sensor MPa
trol Pressure
Pump 2 Max. Displacement cm3
Engine Target Speed Target speed when loaded. Approx. 150 min differs min-1
-1

from speed when unloaded.


-1
Engine Actual Speed Input signal from N sensor min
Deviation in Engine Speed Calculated Value min-1
(Engine Speed Differential) (Target Engine Speed - Actual Engine Speed)
EC Angle Input signal from EC sensor V
Dial Angle Input signal from engine control dial V
Boom Raise Pilot Pressure Input signal from pressure sensor (boom raise) MPa
Arm Roll-In Pilot Pressure Input signal from pressure sensor (Arm Roll-In) MPa
Swing Control Pressure Input signal from pressure sensor (swing) MPa
Travel Control Pressure Input signal from pressure sensor (travel) MPa
Front Att. Operation Input signal from pressure sensor (front att.) FR
Hydraulic Oil Temperature Input signal from oil temperature sensor pC
E/P/HP Mode Switch Power mode switch selection status E, P, HP
Auto-Idle/Auto-Accel Auto-Idle/Acceleration selection status AI, AA
Switch
Travel Mode Travel mode switch selection status Lo, Hi
Power Digging (Boost) Power digging switch status Pd
Switch
Key Switch Key switch selection status Ky
Work mode Work mode switch selection status
ATT. Mode
Engine Learning Status Done, Undone,
Aborted Ky
Pump 2 Proportional Sole- Control signal to max. pump 2 flow rate limit solenoid MPa
noid Valve Output valve
Pump Torque Proportional Control signal to torque control solenoid valve MPa
Solenoid Valve Output
Arm Regenerative Propor- Control signal to solenoid valve SC MPa
tional Solenoid Valve Out-
put
Power Digging (Boost) Control signal to solenoid valve SG MPa
Control Pressure
Travel Motor Control Pres- Control signal to solenoid valve SI MPa
sure
EC Motor Position step

T5-1-12

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General

Optional
Item Data Unit
Optional Pump 3 Delivery Pressure Input signal from pump 3 delivery pressure sen- MPa
sor
Boom Cylinder Bottom Pressure MPa
Boom Cylinder Rod Pressure MPa
ATT. Control Pressure Input signal from pressure sensor (auxiliary) MPa
Boom Angle V
Arm Angle V
Pump 1 Max. Displacement cm3
Pump 1 Proportional Solenoid Valve Control signal to pump 1 flow rate control sole- MPa
Output noid valve
Travel/Swing/Overload Alarm Tr, Sw, Load
Initial ML Setting Unf, Done, Abrt,
Und
Initial Boom-Angle Setting Unf, Done, Abrt,
Und

NOTE: ML specification is only available in Japa-


nese domestic market.

T5-1-13

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
Dr. ZX SPECIAL FUNCTION
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS330.

Start the service software in the Select a special function


operation mode
If the following screen appears, Select the function you want to
you are in the operation mode. execute.
Select Special Function.

Fig. A T178-05-01-013 Fig. B T178-05-01-168


Select ESC to return
to Fig. A.

Special function

Select Execute to execute the


function.

WU deactivation ECO control deactivation

Execute Execute

T178-05-01-030 T178-05-01-031 T178-05-01-032 T178-05-01-033


Select ESC to return Select ESC to return Select ESC to return Select ESC to return
to Fig. B. to Fig. B. to Fig. B. to Fig. B.

T5-1-14

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
Dr. ZX SERVICE MODE
Dr. ZX has three (3) modes, learning value display, Engine
parameter change, and monitor display information Learning
Switch
setting.

Learning Value Display


Displays the values set by learning function. Dr. ZX
Connector
to MC
Parameter Change
Engine speed, pump delivery flow rate, and solenoid
valve output pressure can be adjusted.

Monitor Display Information Setting


Items to be displayed on the monitor LCD can be
added.

Accessing Service Mode T178-01-02-006


1. After turning the key switch OFF, wait for more
than 10 seconds.
2. Connect Dr. ZX to the connector to MC on the
The learning switch is
base machine. turned to the stamped
3. Turn the engine learning switch to the learning mark E
position (the stamped mark E side). Engine Learning Switch
4. Turn the key switch ON. Dont start the engine at
this time.
5. Turn Dr. ZX switch ON.

Stamped
Mark E

T1CC-05-01-001

T5-1-15

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General

Item Data
Learning Data Display
EC Motor Stop Position Display of the engine stop value in engine learning
EC Motor Maximum Speed Position Display of max. engine speed valve in engine learning
Boom Angle Sensor Correction Value Display of boom angle sensor correction value
Arm Angle Sensor Correction Value Display of arm angle sensor correction value
Parameter Change
Li Speed Adjustment Adjustment of minimum engine speed
WU Speed Adjustment Adjustment of warming up engine speed
AI Speed Adjustment Adjustment of auto-idle engine speed
E Speed Adjustment Adjustment of E-mode engine speed
P Speed Adjustment Adjustment of P-mode engine speed
Breaker Engine Speed Adjustment Adjustment of breaker operation engine speed
Secondary Crusher (Demolisher) Engine Adjustment of secondary crusher (demolisher) operation
Speed Adjustment engine speed
Crusher Engine Speed Adjustment Adjustment of crusher operation engine speed
Vibro-Hammer Speed Adjustment Adjustment of vibratory hammer operation engine speed
Hyd. Breaker P1 Max Swash Angle Adjustment of lowest pump 1 max. flow rate in breaker
Adjustment operation
Secondary Crusher (Demolisher) P1 Max Adjustment of lowest pump 1 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P1 Max Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in crusher
operation
Vibro P1 Max Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in vibratory
hammer operation
Hyd. Breaker P2 Max Swash Angle Adjustment of lowest pump 2 max. flow rate in breaker
Adjustment operation
Secondary Crusher (Demolisher) P2 Max Adjustment of lowest pump 2 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P2 Max Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in crusher
operation
Vibro P2 Max Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in vibratory
hammer operation
Pump PQ Base Torque Correction Adjustment of pump P-Q curve
ATT Speed Increase Down Waiting Time Setting of time required for engine speed increase
Min, Boom CYL. Bottom Pressure Over
Balance
Monitor Display Change
Engine Actual Speed Display/Non-display Monitor setting of display/no-display of actual engine speed
Hydraulic Oil Temperature Display/No-display Monitor setting of display/no-display of hydraulic oil
temperature
Hydraulic Oil Filter LED Display/No-display Monitor setting of ON/OFF of hydraulic oil filter LED.
NOTE: ML specification is only available in Japanese domestic market.

T5-1-16

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
(Blank)

T5-1-17

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
Displaying Engine Learning Data and Angle Sensor Correction Valve

NOTE: The following explanation exemplifies the transition diagrams for ZAXIS330.

Start the service software in The service software will


the service mode start in the service mode
Select Start from the Press Correct if the Confirm that you are in the Select Special Function.
EPVC_Mid software menu. displayed model name is service mode, and select
correct. Rechecked.

Fig. A T178-05-01-006 Fig. B T1HH-05-01-001 Fig.C T178-05-01-034 Fig. D T178-05-01-035


Select ESC to return Select ESC to return Select ESC to return
to Fig. A. to Fig. A. to Fig. A.

Select the function you Learning data items will


want to execute be displayed
The menu will be displayed. Select the item you want to
Select Learning Data Display execute.
from the menu.

Fig. E T178-05-01-036 Fig. F T178-05-01-037


Select ESC to return Select ESC to return
to Fig. D. to Fig. F.

T5-1-18

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General

EC Motor stop position EC Motor Maximum Boom angle sensor Arm angle sensor correction
engine speed position correction value value

T178-05-01-038 T178-05-01-039 T178-05-01-040 T178-05-01-041


Select ESC to return Select ESC to return Select ESC to return Select ESC to return
to Fig. F. to Fig. F. to Fig. F. to Fig. F.

T5-1-19

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
Changing Parameters In The Controller

NOTE: The following explanation exemplifies the transition diagrams for ZAXIS330.
Start the service mode on the condition that the engine learning switch is turned on.
To change the parameter, it is necessary to enter the password. To change the password, refer to the Changing the password
section.

Start the service software in The service software will start in


the service mode the service mode
Select Start from the Press Correct if the displayed Confirm that you are in the Select Special Function.
EPVC_Mid software menu. model name is correct. service mode, and select
Rechecked.

Fig. A T178-05-01-006 Fig. C T178-05-01-034 Fig. D T178-05-01-035


Fig. B T1HH-05-01-001 Select ESC to return
Select ESC to return Select ESC to return
to Fig. A. to Fig. A
to Fig. A.

Execute the parameter Select a parameter change


change Enter the password
item

The menu will be displayed. Enter the password to change Select the item you want to change. The
Select Parameter Change from the parameter. up- and down-arrow buttons can be
the menu. used to scroll through the item list.

Fig. F
Fig. E T178-05-01-042
T178-05-01-043
Fig. G
Select ESC to return T178-05-01-044
Select ESC to return to Fig. E. Select ESC to return
to Fig. D. to Fig. E.

T5-1-20

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General

Enter the new value Confirm the new value Parameter adjustment
result
Enter the new value in the The new value will be displayed
The adjusted value will be
Adjustment space, and press in the Adjustment space. Select
displayed.
Execution. Execute to change to this value.

T178-05-01-045 T178-05-01-046 T178-05-01-047


Select ESC to return Select ESC to return Select ESC to return
to Fig. G. to Fig. G. to Fig. G.

T5-1-21

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
Changing The User Mode Display on The Monitor Panel

NOTE: The following explanation exemplifies the transition diagrams for ZAXIS330.
Start the service mode on the condition that the engine learning switch is turned on.

Start the service software in The service software will start in


the service mode the service mode
Select Start from the Press Correct if the displayed Confirm that you are in the
EPVC_Mid software menu. model name is correct. service mode, and select Select Special Function.
Rechecked.

Fig. A T178-05-01-006 Fig. B T1HH-05-01-001 Fig. C T178-05-01-034 Fig. D T178-05-01-035


Select ESC to return Select ESC to return Select ESC to return
to Fig. A. to Fig. A. to Fig. A.

Execute the monitor display Select a display change Select Display or


change item No Display
The menu will be displayed. Select the monitor display Select Disp or No Disp.
Select Monitor Display from change item you want to
the menu. execute.

Fig. E T178-05-01-042 Fig. F T178-05-01-048 Fig. G T178-05-01-049


Select ESC to return Select ESC to return Select ESC to return
to Fig. D. to Fig. E. to Fig. F.

T5-1-22

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General

Confirm Disp/No Disp Confirm the result


Confirm that the Monitor space
shows Disp or No Disp. If it is It has been changed as shown
correctly displayed, select on-screen. Select ESC.
Execute.

Fig. H T178-05-01-050 Fig. I T178-05-01-051

Select ESC to return Select ESC to return to Fig. F.


to Fig.F.

T5-1-23

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General

Operational Performance Check After Adjustment


(Check that pump flow rate and engine speed
have been changed.)

IMPORTANT: After adjusting the engine speed and


flow rate to the attachment, turn the
engine learning switch to neutral. If
the engine is started with the engine
learning switch in the engine
learning position, the MC will not
control the engine, pumps, and
valves so that change in the pump
flow rate and the engine speed
cannot be checked.

1. Turn the key switch OFF.


2. Wait approx. 10 seconds.
3. Turn the engine learning switch to neutral.
4. Disconnect the Dr. ZX. connector (When
monitoring with Dr. ZX, pass this step.)
5. Turn the key switch ON.
6. Start the engine.
7. Check operational performances of the machine.

T5-1-24

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
ADJUSTMENT DATA LIST

Min. Adjustable Range


Standard
Adjustment Data Adjustment Remarks
Model Range Adjustment
Value
Li Speed 10 min-1 ZX330 0 to 120 0 min-1
WU Speed 10 min-1 ZX330 -120 to 120 0 min-1
AI Speed 10 min-1 ZX330 -120 to 120 0 min-1
-1 -1
E Speed 10 min ZX330 -120 to 120 0 min
-1 -1
P Speed 10 min ZX330 -120 to 120 0 min
Breaker Speed 10 min-1 ZX330 -500 to 100 0 min-1
Secondary Crusher
10 min-1 ZX330 -500 to 100 100 min-1
(Demolisher) Speed
Crusher Speed 10 min-1 ZX330 -500 to 100 100 min-1
Vibro-Hammer Speed 10 min-1 ZX330 -500 to 100 0 min-1
Hyd. Breaker P1 Max 3 3
1 cm /rev ZX330 73 to 145 145 cm /rev
Swash Angle
Secondary (Demolisher) P1
1 cm3/rev ZX330 73 to 145 145 cm3/rev
Max Crusher Swash Angle
Crusher P1 Max Swash
1 cm3/rev ZX330 73 to 145 145 cm3/rev
Angle
Vibro Swash Angle 1 cm3/rev ZX330 73 to 145 145 cm3/rev
Hyd. Breaker P2 Max
1 cm3/rev ZX330 73 to 145 145 cm3/rev
Swash Angle
Secondary Crusher
(Demolisher) P2 Max 1 cm3/rev ZX330 73 to 145 145 cm3/rev
Swash Angle
Crusher P2 Max Swash
1 cm3/rev ZX330 73 to 145 145 cm3/rev
Angle
Vibro P2 Max Swash Angle 1 cm3/rev ZX330 73 to 145 145 cm3/rev
Pump PQ Base Torque
2.45 N m ZX330 -78.4 to 0 0Nm
Adjustment
ATT Speed Increase Down
500 ms ZX330 0 to 3000 3000 ms
Wait Time
Min Boom CYL Bottom
0.1 MPa ZX330 -9.81 to 9.81 0 MPa
Pressure Over Balance
NOTE: 1 MPa=10.197 kgf/cm2
2
1 kgf/cm =0.098 MPa

T5-1-25

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / General
(Blank)

T5-1-26

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Component Layout
MAIN COMPONENT LAYOUT

1
3

4
5
6
7
8
9

21

10
11
12
13
20 14
15
19 16

18 17 T1HH-01-02-001

1- Bucket Cylinder 7- Fuel Tank 13- Intercooler 19- Pilot Shut-Off Valve
2- Arm Cylinder 8- Hydraulic Oil Tank 14- Radiator 20- Travel Pilot Valve
3- Boom Cylinder 9- Control Valve 15- Oil Cooler 21- Front Attachment/Swing
Pilot Valve
4- Center Joint 10- Pilot Filter and Pilot Relief Valve 16- Battery
5- Swing Bearing 11- Pump Device 17- Travel Device
6- Swing Device 12- Engine 18- Shockless Valve

T5-2-1

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Component Layout
ELECTRICAL COMPONENT LAYOUT
(Overview)

1 2

Pressure Sensor
(Front Attachment)
Pressure Sensor
(Travel)
Refer to the Control Valve
group.

6, 7
15

14

13
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
N Sensor
12 Refer to the Pump Device group.

8
11
Coolant Temperature Switch
(Engine Preheat Circuit)
Engine Oil Pressure Switch
*Engine Oil Level Switch
Coolant Temperature Sensor
Overheat Switch
10 Refer to the Engine group
9
T1HH-01-02-002
1 - Wiper Motor 5 - Pump 1 Control Pressure 9 - Battery Relay 13 - Starter Relay
sensor (4-Spool Side)
2 - Horn 6 - EC Motor 10 - Ambient Temperature Sensor 14 - Air Cleaner Restriction Switch
3 - Work Light 7 - EC Sensor 11 - *Coolant Level Switch 15 - Pressure Sensor (Boom Raise)
4 - Fuel Sensor 8 - Pump 2 Control Pressure 12 - Battery Pressure Sensor (Arm Roll-In)
sensor (5-Spool Side) Pressure Sensor (Swing)
Torque Control Solenoid Valve
Pump 2 Flow Rate Control
Solenoid Valve
NOTE: *Up to serial No.030652

T5-2-2

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM (Relays)
Rear Deck
5
4
3 6
2

8
9

10

T178-01-02-006

15
14

19

18 13

17 12
16 11

T178-01-02-007

1 - GPS ON/OFF Switch 6 - Fuse Box 11 - Load Damp Relay (R1) 16 - Wiper Relay A (R6)
(Satellite Navigation System
Equipped Machines only)
2 - QOS Controller 7 - Learning Switch 12 - Washer Relay (R2) 17 - Wiper Relay B1 (R7)
3 - ICX (Information Controller) 8 - Dr. ZX Connector to MC 13 - Work Light Relay 2 (R3) 18 - Wiper Relay B2 (R8)
4 - MC (Main Controller) 9 - Download Connector 14 - Work Light Relay 1 (R4) 19 - Wiper Relay B3 (R9)
(Not connected in Satellite
Terminal equipped machines)
5 - Satellite Terminal (Optional) 10 - Dr. ZX Connector to ICX 15 - Horn Relay (R5)

T5-2-3

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Component Layout
ELECTRICAL SYSTEM
(Monitors and Switches)

1 2

20

19
21
18
3
17
22
16 4

15
23
5

14 24
6
13 7
12 8
25
11
9
10

T178-01-01-003
T178-01-01-004

1 - Coolant Temperature 8 - Alternator Indicator 14 - Overheat Indicator 20 - Engine Control Dial


Gauge
2 - Fuel Gauge 9 - Hydraulic Oil Filter 15 - Digging Mode Indicator 21 - Auto-Idle/Acceleration
Indicator (Optional) Selector
3 - Display Selection Switch 10 - *Coolant Level Indicator 16 - Attachment Mode Indicator 22 - Power Mode Switch
4 - SET Switch 11 - *Engine Oil Level Indicator 17 - Liquid Crystal Display 23 - Travel Mode Switch
5 - Work Mode Switch 12 - Engine Oil Pressure 18 - Auto-Idle Indicator 24 - Work Light Switch
Indicator
6 - Fuel Level Indicator 13 - Preheat Indicator 19 - Auto-Acceleration Indicator 25 - Wiper/Washer Switch
7 - Air Filter Restriction
Indicator
NOTE: *Up to serial No.030652

T5-2-4

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Component Layout
ENGINE
1 2
3 4

M1HH-07-001
5

M1HH-07-012

SWING DEVICE
PUMP DEVICE

7 8 9
6

14
10

11

13

12 T1HH-01-02-003

T1HH-01-02-004

1 - Coolant Temperature Switch 5 - Engine Oil Level Switch 9 - N Sensor 12 - Pump 1 Delivery Pressure
(Engine Preheat Circuit) Sensor
2 - Engine Oil Pressure Switch 6 - Regulator (Pump 2) 10 - Regulator (Pump 1) 13 - Pump 2 Delivery Pressure
Sensor
3 - Overheat Switch 7 - Pump 2 11 - Pump 1 14 - Swing Relief Valve
4 - Coolant Temperature Sensor 8 - Pilot Pump

T5-2-5

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Component Layout
CONTROL VALVE TRAVEL DEVICE
(ZAXIS330, 330LC, 350LC, 350LCN, 350H,
350LCH)

1 2
T1HH-01-02-005

TRAVEL DEVICE
(ZAXIS370MTH) 3 4
T1HH-01-02-006

SOLENOID VALVE UNIT

6
T183-01-02-012 7
SHOCKLESS VALVE T1HH-01-02-008

9 10
POSITIONING CONTROL VALVE
8 (2-piece Boom Only)
11

T173-03-06-001

T178-03-03-068

1 - Pressure Sensor (Front) 4 - Travel Relief Valve 7 - Solenoid Valve Unit (SG) 9 - Pressure Sensor (Boom Raise)
2 - Pressure Sensor (Travel) 5 - Solenoid Valve Unit (SC) 8 - Pressure Sensor 10 - Pressure Sensor (Swing)
3 - Counterbalance Valve 6 - Solenoid Valve Unit (SI) (Arm Roll-In) 11 - Overload Relief Valve
(Positioning)

T5-2-6

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Component Layout
(Blank)

T5-2-7

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Component Layout
COMPONENTS IN CONTROL VALVE 1 2 3 4 5 6 7
Travel Motor (Left)

Travel Motor (Right)

8
9
39
38 10
11

Bucket
Cylinder
37 12
36 13
35 14
Arm
Cylinder
34

Boom
Cylinder
15
16
17
33 32 31 30 18

19

20

29 28 27 26 25 24 23 22 21
Swing Motor

Pump 2 Pump 1

T1HH-03-03-001

34 22 Machine Front
23
11 Machine Front
20 15
3 30
9

35
7 29
27
5

32
33
14 36
24, 25 21 12 T173-03-03-050 1 39 38 T173-03-03-051

T5-2-8

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Component Layout

Machine Front

A
B
C

T1HH-03-03-002

Section A Section B Section C

Travel (Left) Travel (Right)

5
6 1

4
2
38

39
3 7
T1HH-03-03-003

T1HH-03-03-004

1 - Pump Control Valve 11 - Overload Relief Valve 21 - Load Check Valve 31 - Arm Anti-Drift Valve:
(In 5-Spool Section) (Bucket) (Arm 2 Tandem Passage) Bottom Side (Switch Valve)
2 - Check Valve 12 - Load Check Valve 22 - Needle Valve 32 - Arm Anti-Drift Valve:
(Main Relief Circuit) (Boom 1 Parallel Passage) Bottom Side (Check Valve)
3 - Main Relief Valve 13 - Boom Regenerative Valve 23 - Boom Anti-Drift Valve 33 - Arm Anti-Drift Valve:
(Switch Valve) Bottom Side (Relief Valve)
4 - Check Valve 14 - Boom Anti-Drift Valve 24 - Orifice 34 - Overload Relief Valve
(Main Relief Circuit) (Check Valve) (Arm)
5 - Flow Combiner Valve 15 - Overload Relief Valve 25 - Load Check Valve 35 - Arm Anti-Drift Valve:
(Boom) (Arm 2 Parallel Passage) Rod Side (Check Valve)
6 - Check Valve (Flow 16 - Arm Regenerative Valve 26 - Load Check Valve 36 - Load Check Valve
Combiner Valve Circuit) (Arm 1 Parallel Passage) (Boom 2 Parallel Passage)
7 - Check Valve With Orifice 17 - Check Valve (Arm 27 - Orifice 37 - Load Check Valve
(Bucket Combination) Regenerative Valve Circuit) (Aux. Parallel Passage)
8 - Bucket Flow Rate Control 18 - Bucket Flow Rate Control 28 - Load Check Valve 38 - Travel Flow Rate Control
Valve (Poppet Valve) Valve (Switch Valve A) (Arm 1 Tandem Passage) Valve
9 - Bucket Flow Rate Control 19 - Bypass Shut-Out Valve 29 - Load Check Valve (Swing) 39 - Load Check Valve
Valve (Switch Valve B) (Travel Tandem Passage)
10 - Bucket Regenerative Valve 20 - Pump Control Valve 30 - Arm Anti-Drift Valve:
(In 4-Spool Section) Rod Side (Switch Valve)

T5-2-9

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Component Layout
1 2 3 4 5 6 7
Travel Motor (Left)

Travel Motor (Right)

8
9
39
10
38
11

Bucket
Cylinder
37 12
36 13
35 14
Arm
Cylinder
34

Boom
Cylinder
15
16
17
33 32 31 30 18

19

20

29 28 27 26 25 24 23 22 21
Swing Motor

Pump 2 Pump 1

Section D Section E T1HH-03-03-001

Boom 2 Boom 1
Auxiliary Bucket 22
11 23
15
8
37
9 14

36 12

9
13
10
15
11
T1HH-03-03-006
T1HH-03-03-005

T5-2-10

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Component Layout

Section F Section G

Arm 1 Arm 2 Swing


19
30
34

20
35 16
26 17
32 31
27 24, 25

29
21

34

T1HH-03-03-008
33 28 18
T1HH-03-03-007

1 - Pump Control Valve 11 - Overload Relief Valve 21 - Load Check Valve 31 - Arm Anti-Drift Valve:
(In 5-Spool Section) (Bucket) (Arm 2 Tandem Passage) Bottom Side (Switch Valve)
2 - Check Valve 12 - Load Check Valve 22 - Needle Valve 32 - Arm Anti-Drift Valve:
(Main Relief Circuit) (Boom 1 Parallel Passage) Bottom Side (Check Valve)
3 - Main Relief Valve 13 - Boom Regenerative Valve 23 - Boom Anti-Drift Valve 33 - Arm Anti-Drift Valve:
(Switch Valve) Bottom Side (Relief Valve)
4 - Check Valve 14 - Boom Anti-Drift Valve 24 - Orifice 34 - Overload Relief Valve
(Main Relief Circuit) (Check Valve) (Arm)
5 - Flow Combiner Valve 15 - Overload Relief Valve 25 - Load Check Valve 35 - Arm Anti-Drift Valve:
(Boom) (Arm 2 Parallel Passage) Rod Side (Check Valve)
6 - Check Valve (Flow 16 - Arm Regenerative Valve 26 - Load Check Valve 36 - Load Check Valve
Combiner Valve Circuit) (Arm 1 Parallel Passage) (Boom 2 Parallel Passage)
7 - Check Valve With Orifice 17 - Check Valve (Arm 27 - Orifice 37 - Load Check Valve
(Bucket Combination) Regenerative Valve Circuit) (Aux. Parallel Passage)
8 - Bucket Flow Rate Control 18 - Bucket Flow Rate Control 28 - Load Check Valve 38 - Travel Flow Rate Control
Valve (Poppet Valve) Valve (Switch Valve A) (Arm 1 Tandem Passage) Valve
9 - Bucket Flow Rate Control 19 - Bypass Shut-Out Valve 29 - Load Check Valve (Swing) 39 - Load Check Valve
Valve (Switch Valve B) (Travel Tandem Passage)
10 - Bucket Regenerative Valve 20 - Pump Control Valve 30 - Arm Anti-Drift Valve:
(In 4-Spool Section) Rod Side (Switch Valve)

T5-2-11

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Component Layout
2-piece Boom (Optional)

T1HH-03-03-046
1 - Load Check Valve 2- Overload Relief Valve 3 - Overload Relief 4- Load Check Valve
(Positioning Circuit) (Positioning: Rod Side) Valve (Positioning Parallel Circuit)
(Positioning: Bottom
Side)

T5-2-12

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Component Layout

Positioning Control Valve


(2-piece Boom Only)

D
4

Section D-D
1
T178-03-03-067
3
T178-03-03-066

T5-2-13

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Component Layout
(Blank)

T5-2-14

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault
codes are displayed after diagnosing the main con-
troller (MC) using the built-in diagnosing system or Dr.
ZX.

How to Read Troubleshooting Flow Charts

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

Instructions, reference, and/or inspection methods and/or measurements are occasionally


described under the box. If incorrectly checked or measured, not only will troubleshooting
Key switch: ON be unsuccessful but also damage to the components may result.

Refer to Electrical System Inspection Group (Group 6) for descriptions in the dotted-line
box.

Use Dr. EX (or the built-in diagnosing system) for descriptions in the double-line box.

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

NOTE: All harness end connectors are seen from


the open end side.

Harness

Open End
Side
Harness End Connector

T158-05-03-001

T5-3-1

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting A
FAULT CODE LIST
Fault code Problem Cause
01 Abnormal EEPROM Faulty MC
02 Abnormal RAM
03 Abnormal A/D Conversion
04 Abnormal Sensor Voltage Faulty MC
Faulty Harness
Faulty Sensor
06 Abnormal EC Sensor Faulty MC
Faulty Harness
Faulty EC Sensor
07 Abnormal Engine Control Dial Angle Faulty MC
Faulty Harness
Faulty Engine Control Dial
10 Abnormal Pump 1 Delivery Pressure Faulty MC
11 Abnormal Pump 2 Delivery Pressure Faulty Harness
Faulty Pump Deliver Pressure Sensor
12 Abnormal Pump1 Pump Control Pressure Faulty MC
13 Abnormal Pump2 Pump Control Pressure Faulty Harness
Faulty Pump Control Pressure Sensor
14 Abnormal Swing Lever Stroke Faulty MC
15 Abnormal Boom Raise Lever Stroke Faulty Harness
16 Abnormal Arm Roll-In Lever Stroke Faulty Pilot Pressure Sensor
18 Abnormal Travel Lever Stroke
19 Abnormal Oil Temperature Faulty MC
Faulty Harness
Faulty Oil Temperature Sensor

NOTE: In case all fault codes from 06 to 19 are


displayed, one of the sensors may be
short-circuited. Disconnect all sensors.
Then, reconnect sensors one at a time.
When the connected sensor is normal, the
corresponding fault code will disappear.
When the short-circuited sensor is recon-
nected, all fault codes are displayed again
thus revealing the faulty sensor.

T5-3-2

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting A
FAULT CODE 01 (ABNORMAL EEPROM)
FAULT CODE 02 (ABNORMAL RAM)
FAULT CODE 03
(ABNORMAL A/D CONVERSION)

YES * Faulty MC.

Check if engine and machine Refer to T4-6-1.


actuators operate normally.
Faulty MC.
NO
Refer to T4-6-1.
* Even if any fault codes are still displayed after re-
trying, as long as the engine and machine operate
normally, the machine can be operated as it is.

FAULT CODE 04
(ABNORMAL SENSOR VOLTAGE)

YES Faulty sensor.

Disconnect connectors from


all sensors relating to the in- Short-circuited harness be-
dicated fault code, and retry. YES tween MC and sensor in
Does fault code 04 disappear? Disconnect all con- section where continuity is
nectors from MC. present.
NOTE: If fault code 04 Is there continuity be-
(abnormal sensor NO tween terminals #1 and
voltage) appears, #3 of harness at each
sensor? Faulty MC.
other fault codes NO
appear at the same Key switch: OFF
Refer to T4-6-1.
time.

T5-3-3

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting A
FAULT CODE 06
(ABNORMAL EC SENSOR) YES Faulty harness be-
Check harness be-
tween MC and EC
tween MC connector
sensor.
YES C (31P) terminal #18
and EC sensor ter-
minal #2 for breakage
or short circuit. Faulty MC.
Disconnect EC sen- NO
sor. Check if voltage
Disconnect EC sensor. YES between harness end Refer to T4-6-1.
Check if resistance be- connectors #1 and #3
tween sensor side is 5o0.5 V. Check if voltage be- YES Broken harness be-
tween MC and EC
connector terminals #1 tween EC sensor
Key switch: ON sensor terminal #3.
and #3 is less than harness end connec-
2.0o0.4 k . Connect test tor terminal #1 and
harness between EC NO vehicle frame
sensor and base ma- Broken harness be-
matches specification.
chine side harness. tween MC and EC
Key switch: ON NO sensor terminal #1.
Check if voltage changes
in accordance with speci- Specification: 5o0.5 V
fications when engine
control dial is rotated. Faulty EC sensor.
Test Harness: ST 7129 NO
Specification: See table be- Refer to T4-6-1.
low.

EC Sensor Specification
Minimum Speed 2.5 to 2.7 V
Maximum Speed (HP 3.3 to 3.7 V
mode Switch: OFF)
Maximum Speed (HP Voltage at Maximum Speed
mode Switch: ON) (HP Mode Switch: OFF) plus
0.2 V or more

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

MC Connector C

C1 C10

C23 C31
#18
EC Sensor

1 2 3

T5-3-4

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting A
FAULT CODE 07
(ABNORMAL ENGINE CONTROL DIAL
ANGLE) Faulty harness be-
Check harness be- YES
tween MC connector C tween MC and engine
(31P) harness end ter- control dial.
YES
minal #6 and switch
panel terminal #3 for
breakage or short cir- Faulty MC.
Disconnect switch cuit.
NO
panel. Check if voltage Refer to T4-6-1.
YES between harness end
Disconnect switch panel. connector terminals #2 Broken harness be-
Check if resistance be- and #4 is 5o0.5 V. YES tween MC and engine
Check if voltage be-
tween switch panel side control dial terminal
Key switch: ON tween switch panel
connector terminals #2 and #4.
harness end connec-
#4 is 5o0.5 k . tor terminal #2 and
Reconnect switch panel. NO Broken harness be-
vehicle frame
Insert tester probe into tween MC and engine
matches specification.
connector terminal #3 from NO control dial terminal
the reverse side. Check if Key switch: ON #2.
voltage varies as specified Specification: 5o0.5 V
when engine control dial is
turned. Faulty engine control
Specification: See table NO dial.
below.

Engine Control Dial Specification


Minimum Speed 0.3 to 1.0 V
Maximum Speed 4.0 to 4.7 V

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

MC Connector C
#6
C1 C10

C23 C31

Switch Panel

#4 #3 #2

T5-3-5

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting A
FAULT CODE 10
(ABNORMAL PUMP 1 DELIVERY PRES-
SURE)
FAULT CODE 11
(ABNORMAL PUMP 2 DELIVERY PRES-
SURE)
Checking Instruction
Both pump 1 and pump 2 delivery pressure sen-
sors seldom fail at the same time. Accordingly, if
both fault codes 10 and 11 are displayed simulta-
neously, faulty harness may be the cause of this
problem. Faulty harness be-
Check harness be-
YES tween MC and pump
tween MC connector C
delivery pressure
(31P) harness end ter-
sensor.
YES minal #1 (pump 1) or
#4 (pump 2) and pump
delivery pressure sen- Faulty MC.
Disconnect pump de- sor terminal #2 for
livery pressure sensor. breakage or short cir- NO
NO Check if voltage be- Refer to T4-6-1.
tween harness end
connector terminals #1 Broken harness be-
and #3 is 5o0.5 V Check if voltage be- YES tween MC and pump
tween pump delivery delivery pressure
Check if fault codes are pressure sensor har-
Key switch: ON sensor terminal #3.
switched after switching ness end connector
pump 1 delivery pressure NO terminal #1 and vehi-
sensor with pump 2 de- Broken harness be-
cle frame matches tween MC and pump
livery pressure sensor specification.
and retrying. NO delivery pressure
Key switch: ON sensor terminal #1.
Specification: 5o0.5 V
Faulty pump delivery
YES pressure sensor.

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

MC Connector C
#1 #4
C1 C10

C23 C31

Pump Delivery Pressure Sensor

3 2 1

T5-3-6

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting A
FAULT CODE 12
(ABNORMAL PUMP 1 CONTROL PRES-
SURE)
FAULT CODE 13
(ABNORMAL PUMP 2 CONTROL PRES-
SURE)
Checking Instruction
Both pump 1 and pump 2 control pressure sen-
sors seldom fail at the same time. Accordingly, if
both fault codes 12 and 13 are displayed simul-
taneously, faulty harness may be the cause of
this problem.

Check harness be- Faulty harness be-


tween MC connector C YES tween MC and pump
(31P) harness end ter- control pressure sen-
sor.
YES minal #7 (pump 1) or
#13 (pump 2) and
pump control pressure
Disconnect pump con- sensor terminal #2 for Faulty MC.
breakage or short cir- NO
trol pressure sensor. Refer to T4-6-1.
NO Check if voltage be- cuit.
tween harness end Broken harness be-
connector terminals #1 tween MC and pump
Check if voltage be- YES
and #3 is 5o0.5 V control pressure sen-
tween pump control
Key switch: ON pressure sensor har- sor terminal #3.
Check if fault codes are ness end connector
switched after switching NO terminal #1 and vehicle Broken harness be-
pump 1 control pressure frame matches specifi- tween MC and pump
sensor with pump 2 con- cation. NO control pressure sen-
trol pressure sensor and sor terminal #1.
Key switch: ON
retrying. Specification: 5o0.5 V
Faulty pump control
YES pressure sensor.

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

MC Connector C
#13 #7
C1 C10

C23 C31

Pump Control Pressure Sensor

1 2 3

T5-3-7

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting A
FAULT CODE 14
(ABNORMAL SWING PILOT PRESSURE)
FAULT CODE 15
(ABNORMAL BOOM RAISE PILOT
PRESSURE)
FAULT CODE 16
(ABNORMAL ARM ROLL-IN PILOT
PRESSURE) Check harness be- Faulty harness be-
FAULT CODE 18 tween MC connector C
YES tween MC and
(ABNORMAL TRAVEL PILOT PRESSURE) (31P) harness end pressure sensor.
YES each corresponding
Checking Instruction terminal and pressure
All pressure sensors seldom fail at the same time. sensor terminal #2 for
Faulty MC.
breakage or short cir-
Accordingly, if fault codes 14, 15, 16, and 18 are cuit. NO
displayed simultaneously, faulty harness may be Refer to T4-6-1.
Connector C Terminal:
the cause of this problem. #14: Pressure Sensor (Swing)
Disconnect pressure #2: Pressure Sensor
sensor. Check if volt- (Boom Raise)
age between harness #5: Pressure Sensor
NO end connector termi-
(Arm Roll-In)
nals #1 and #3 is 5o0.5 #3: Pressure Sensor
V. (Travel)
Key switch: ON
Broken harness be-
Check if fault code dis- tween MC and
appears after switching Check if voltage be- YES
pressure sensor ter-
pressure sensor with an- tween pressure minal #3.
other pressure sensor sensor harness end
and retrying. connector terminal #1
NO and vehicle frame Broken harness be-
Fault Code: matches specification. tween MC and
14: Pressure Sensor (Swing) NO pressure sensor ter-
Key switch: ON minal #1.
15: Pressure Sensor Specification: 5o0.5 V
(Boom Raise)
16: Pressure Sensor
(Arm Roll-In) Faulty pressure sen-
18: Pressure Sensor YES sor.
(Travel)

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

MC Connector C
#2 #3 #5

C1 C10

C23 C31
#14

Pilot Pressure Sensor

1 2 3

T5-3-8

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting A
FAULT CODE 19
(ABNORMAL OIL TEMPERATURE)

Connect oil tempera-


YES Faulty MC.
ture sensor harness
end connector terminal
#1 to #2 with a clip. Refer to T4-6-1.
Remove connector B
YES (25P) and connector C Connect MC connec- Broken harness be-
(31P) from MC. Check tor B (25P) harness YES tween MC and oil
for continuity between end terminal #22 to temperature sensor
connector B harness vehicle frame. Check terminal #1.
end terminal #22 and for continuity between
Disconnect oil tempera-
connector C terminal NO oil temperature sensor
ture sensor. Check if Broken harness be-
#24. harness end connec-
sensor side connector tween MC and oil
tor terminal #2 and
resistance matches NO temperature sensor
vehicle frame.
specification. terminal #2.
Specification: See table
below.
Faulty oil temperature
NO sensor.

Oil Temperature Specification


Oil Temperature Resistance
(pC) (k )
20 16.2o1.6
0 (5.88)
20 2.45o0.24
40 (1.14)
60 (0.534)
80 0.322

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

MC Connector B
B1 B8

B19 B25
#22

MC Connector C

C1 C10

C23 C31
#24

Oil Temperature Sensor

1 2

T5-3-9

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting A
(Blank)

T5-3-10

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code
is displayed on the Dr.ZX (or the built-in diagnosing
system) although the machines operation is abnor-
mal.
On the front section pages of this group T5-4, are ta-
bles indicating the relationship between machine trou-
ble symptoms and related parts which may cause
such trouble if failed.
Start the troubleshooting with more probable causes
selected by referring to these tables.

How to Read the Troubleshooting Flow Charts

YES (OK)
(2)
After checking or measuring item (1), select either YES (OK) or
(1) NO (NOT OK) and proceed to item (2) or (3), as appropriate.

(3)
NO (NOT OK)

Special instructions or reference item are indicated in the spaces under the box.
Incorrect measuring or checking methods will render troubleshooting impossible,
Key switch: ON and may damage components as well.

Explanation of how to use test harness kit required. Refer to Electrical System
Inspection Group (Group 6) in this section.

Use Dr.ZX (or the built-in diagnosing system) function.

Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.

T5-4-1

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
RELATIONSHIP BETWEEN MACHINE
TROUBLE SYMPTOMS AND RELATED
PARTS
This table indicates the relationship between machine
trouble symptoms and the potential problem parts,
which may cause trouble if failed, and the evaluation
methods of these components.
Parts
EC Motor EC Sensor
Moves governor. Detects minimum governor speed position (2.5 V) only when
key switch is turned ON.
Detects minimum and maximum speed position when engine
learning is conducted.
Function

Governor lever doesnt move. Engine speed is controlled based on idle position set when
key switch is turned ON. Therefore, engine speed is always
Symptoms in control controlled with error in idle position setting if set incorrectly.
system when trouble
occurs.

Even if engine control dial is Error in setting will seldom occur so that change in machine
turned, engine speed doesnt in- operation will not be noticed.
crease from slow idle speed. In case error is set on lower side, engine speed changes but
Engine start may be difficult runs slower than normal through the full range when engine
though starter rotates. control dial is turned. (Note: In case error is set on upper
Engine will stall if discontinuity side, EC motor is driven so that it runs faster than the control
occurs in EC motor while engine range. However, motor, a worm gear type, holds governor
is running at more than a speci- lever at maximum constant position, preventing engine stall.
fied speed. When engine control dial is turned to minimum speed posi-
Engine will become uncontrolla- tion, governor lever is returned to idle position.)
Symptoms in machine ble if discontinuity occurs in EC When starting engine, engine speed fluctuates.
operation when trouble motor while engine is running at Starting engine is occasionally difficult.
lower than a specified speed.
occurs. Engine cannot be stopped with
key switch.

By Fault Fault code 06 is displayed.


Code
Monitor Item: EC Angle (Displayed by built-in diagnosing sys-
By Monitor tem)
Evalua- Function
tion Install lamp harness (ST 7125) to
Using Test check EC output signal and har-
Harness ness for any abnormality.

Others
Engine is stopped by EC motor. If EC sensor is faulty, engine learning is not performed.
(Engine stop motor is not pro-
vided.)
NOTE Fuel cut-off cable is provided.

Descriptions of Control T2-1 T2-1


(Operational Principle
Section in T/M)

T5-4-2

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Engine Control Dial Pump Control Pressure Sensor Pump 1 Delivery Pressure Sensor
Indicates governor lever position (engine Monitors pump control pressure to con- Monitors pump delivery pressure to con-
target speed). trol auto-acceleration system and travel trol HP mode, auto-acceleration, slow
motor swash angle controls. speed torque increase, auto power lift
and travel motor swash angle controls.

Engine speed doesnt change even if No signals arrive to MC If pump delivery pressure sensor output
engine control dial is turned. is 0 or 5 V, following symptoms will be
If discontinuity or short circuit occurs in presented by back-up mode function.
engine control dial, target speed of 1600
-1
min is used as back-up value.

Engine speed is kept unchanged from Auto-acceleration control is inoperable HP mode is inoperable.
-1
1600 min . (Auto-idle system functions. (but not noticeable). Auto-acceleration control is inoperable.
Engine can be stopped by key switch.) Travel speed is kept in slow mode, not Machine mistakes occasionally when
allowing to automatically change to fast traveling at slow idle speed.
mode. Boom raise power is weak during digging
operation.
Travel speed is kept in slow mode, not
allowing to automatically change to fast
mode.

Fault code 07 is displayed. Fault codes 12 and 13 are displayed. Fault codes 10 is displayed.

Monitor Item: Engine Target Speed, Dial An- Monitor Item: Pump 1 and 2 pump control Monitor Item: Pump 1 delivery pressure
gle (Displayed by built-in diagnosing sys- pressure (Displayed by built-in diagnosing (Displayed by built-in diagnosing system)
tem) system)

Evaluation by Dr. ZX
Broken Circuit: 0.25 V or less
Short Circuit: 4.75 V or more

T2-1 T2-1 T2-1

T5-4-3

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Parts Pump 3 Delivery Pressure Sensor


Pump 2 Delivery Pressure Sensor
(Optional)
Monitors pump delivery pressure to control HP Monitors pump delivery pressure to control
mode, auto-acceleration, slow speed torque in- pump 3 torque decrease control.
crease, arm regenerative and travel motor
swash angle control.
Function

Symptoms in control If pump delivery pressure sensor output is 0 or Engine stalls if pump torque is increased.
5 V, following symptoms will be presented by
system when trouble back-up mode function.
occurs.
HP mode is inoperable. Engine stalls if pump torque is increased.
Auto-acceleration control is inoperable.
Machine mistakes occasionally when traveling
at slow idle speed.
Arm is slow when arm roll-in and swing com-
bined operation is made.
Travel speed is kept in slow mode, not allowing
to automatically change to fast mode.
Symptoms in machine
operation when trouble
occurs.

By Fault Fault codes 11 is displayed.


Code
Monitor Item: Pump 2 delivery pressure (Displayed
by built-in diagnosing system)
By Monitor
Function
Evaluation

Using Test
Harness
Others

NOTE

Descriptions of Control T2-1 T2-1


(Operational Principle
Section in T/M)

T5-4-4

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Pressure Sensor
Pressure Sensor (Travel) Pressure Sensor (Swing)
(Front Attachment)
Monitors travel pilot pressure to control Monitors front attachment pilot pressure Monitors swing pilot pressure to control
auto-idle, auto-acceleration, idle to control auto-idle, and idle speed-up arm regenerative system.
speed-up, slow speed torque increase, systems.
and travel motor swash angle controls.

No signals arrive to MC No signals arrive to MC No signals arrive to MC

Engine speed doesnt increase even if Engine speed doesnt increase even if Since arm regenerative function is inop-
auto-idle/auto-acceleration selector is any front attachment actuator is operated erable, when swing/arm roll-in combined
auto-idle position. with auto-idle/auto-acceleration selector operation is made, initial arm moving
Engine speed doesnt increase even if is auto-idle position. speed is slow. (Not remarkable)
auto-idle/auto-acceleration selector is Occasionally, engine speed hunts while During arm level crowding operation, arm
auto-acceleration position. operating front attachment at slow idle. speed is slightly slow.
Occasionally, engine speed hunts while
traveling at slow idle.
If there is a difference in delivery flow rate
between pumps 1 and 2, machine may
mistrack when traveling at minimum
speed. (Not remarkable)
Fast travel mode cannot be selected
even if travel mode switch is turned to the
FAST position.

Fault code 18 is displayed. Fault code 14 is displayed.

Monitor Item: Travel Control Pressure (dis- Monitor Item: Front Attachment Operation Monitor Item: Swing Control Pressure (dis-
played built-in diagnosing system). (displayed built-in diagnosing system). played built-in diagnosing system).
Monitor pressure change while traveling Monitor pressure change while operating Monitor pressure change while swinging
machine. front attachment. upperstructure.

Judge if pressure sensor is faulty or port Judge if pressure sensor is faulty or port Judge if pressure sensor is faulty or port
is clogged by switching pressure sensor is clogged by switching pressure sensor is clogged by switching pressure sensor
with another pressure sensor. with another pressure sensor. with another pressure sensor.

T2-1 T2-1 T2-1

T5-4-5

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Parts Pressure Sensor Pressure Sensor


(Boom Raise) (Arm Roll-In)
Monitors boom raise pilot pressure to control HP Monitors arm roll-in pilot pressure to control HP
mode, auto-acceleration, arm regenerative, and mode, auto-acceleration, and arm regenerative
auto-power lift controls. controls.

Function

Symptoms in control No signals arrive to MC No signals arrive to MC


system when trouble
occurs.
Even if boom is raised with HP mode switch ON, Even if arm is rolled in with HP mode switch ON,
engine speed doesnt increase. engine speed doesnt increase.
Even if boom is raised with Even if arm is rolled in with
auto-idle/auto-acceleration selector is auto-idle/auto-acceleration selector is
auto-acceleration position, engine speed auto-acceleration position, engine speed
doesnt increase. doesnt increase.
Arm roll-in speed becomes slightly slower than Arm speed is slow in arm level crowd operation.
normal in boom raise and arm roll-in combined
operation as arm regenerative system doesnt
Symptoms in machine work. (Not remarkable)
operation when trouble Arm roll-in and boom raise speeds become
occurs. slightly slower at the beginning stage of arm
level crowd operation.
Boom raise power is weak. (Not remarkable)

By Fault Fault Code 15 is displayed. Fault code 16 is displayed.


Code
Monitor Item: Boom Raise Pilot Pressure (dis- Monitor Item: Arm Roll-In Pilot Pressure (displayed
played built-in diagnosing system). built-in diagnosing system).
By Monitor Monitor pressure change while raising boom. Monitor pressure change while rolling arm in.
Function
Evaluation

Using Test
Harness
Others
Judge if pressure sensor is faulty or port is Judge if pressure sensor is faulty or port is
clogged by switching pressure sensor with an- clogged by switching pressure sensor with an-
other pressure sensor. other pressure sensor.

NOTE

Descriptions of Control T2-1 T2-1


(Operational Principle
Section in T/M)

T5-4-6

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Pressure Sensor (Auxiliary)


Torque Control Solenoid Valve Solenoid Valve Unit (SG)
(Optional)
Monitors attachment pilot pressure when Supplies control pressure to pumps 1 and Temporarily increases main relief valve
attachment is installed to control attach- 2 to control speed sensing and slow set-pressure when operating machine
ment operation speed increase, and speed torque increase controls. either in power digging and auto-power
pump 1 and pump 2 flow rate limit. lift mode.

No signals arrive to MC If torque control solenoid valve is not ac- In case solenoid valve unit (SG) is not
tivated, output pressure from solenoid activated, pressure at port SG becomes
valve is 0 MPa (0 kgf/cm2). 0 MPa (0 kgf/cm2).

Engine speed doesnt increase when at- Even if speed sensing system doesnt In case solenoid valve unit (SG) is closed:
tachment is operated. work, upper limit power is restricted so Relief pressure stays at normal 31.4 MPa
When attachment is operated, operation that machine is operable. 2
(320 kfg/cm ). Even if power digging
speed increases. Machine may occasionally mistrack when switch is pressed, relief pressure doesnt
traveling at slow idle speed. increase. Power doesnt increase.

In case solenoid valve unit (SG) is open:


The pressure always increases, all op-
eration makes the force increase.

Monitor Item: ATT Control Pressure (dis- Monitor Item: Pump Torque Proportional Monitor Item: Power Digging (Boost) Control
played built-in diagnosing system). Solenoid Valve Output Pressure
Monitor pressure change while operating
attachment.

Install lamp harness (ST 7123) to check


output signals from MC and harness
condition.

Judge if pressure sensor is faulty or port Proportional solenoid valve is used as an


is clogged by switching pressure sensor ON/OFF valve. Therefore, even if power
with another pressure sensor. digging switch is pressed or released,
lamp will come ON when normal. In case
lamp goes OFF, it may be due to broken
harness.

T2-1 T2-1 T2-1

T5-4-7

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Parts
Solenoid Valve Unit (SC) Solenoid Valve Unit (SI)
Routes return oil from arm cylinder rod side to When pump delivery pressure is low in fast
bottom side when rolling arm in to increase travel mode, travel motor swash angle is re-
arm speed. duced to increase travel speed.

Function

In case solenoid valve unit (SC) is not acti- Fast travel mode cannot be selected.
vated, pressure at port SC becomes 0 MPa (0
kgf/cm2). Arm regenerative valve will not oper-
Symptoms in control sys- ate at this time.
tem when trouble occurs.

In case solenoid valve unit (SC) is closed: In case solenoid valve unit (SI) is closed:
Arm speed is slow in arm level crowd opera- Even if travel mode switch is turned to FAST
tion. position, fast travel mode cannot be selected.
In case solenoid valve unit (SC) is open: In case solenoid valve unit (SI) is open:
Arm speed is fast because arm regeneration is Fast travel mode is always selected.
always operated.

Symptoms in machine
operation when trouble
occurs.

By Fault
Code
By Monitor Monitor Item: Arm Regenerative Proportional Sol. Monitor Item: Travel Motor Control Pressure
Valve Output
Function

Evaluation

Using Test Install lamp harness (ST 7123) to check output Install lamp harness (ST 7123) to check output
signals from MC and harness condition. signals from MC and harness condition.
Harness
Others

NOTE

Descriptions of Control T2-1 T2-1


(Operational Principle
Section in T/M)

T5-4-8

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Max. Pump 1 Flow Rate Limit Solenoid Max. Pump 2 Flow Rate
Valve (Optional) Limit Solenoid Valve N Sensor
When operating attachment, limits maxi- When operating attachment, limits Monitors engine speed to operate en-
mum pump 1 flow rate. maximum pump 2 flow rate. gine speed sensing control.

In case max. pump 1 flow rate limit solenoid In case max. pump 2 flow rate limit so- Speed sensing control is inoperable.
valve is not activated, pressure at output lenoid valve is not activated, pressure at
port becomes 0 MPa (0 kgf/cm2). output port becomes 0 MPa (0 kgf/cm2).

In case max. pump 1 flow rate limit solenoid In case max. pump 2 flow rate limit sole- Engine stalls under adverse operating
valve is closed: noid valve is closed: conditions such as at high altitude.
When operating attachment, operating When operating attachment, operating
speed doesnt decrease. speed doesnt decrease.
In case max. pump 1 flow rate limit solenoid In case max. pump 2 flow rate limit sole-
valve is open: noid valve is open:
Right travel, bucket, arm and boom speeds Left travel, arm, boom and swing
are slow because maximum flow rate of speeds are slow because maximum
pump 1 decrease. flow rate of pump 2 decreases.
Machine mistracks to the right when travel- Machine mistracks to the left when trav-
ing. eling.

Monitor Item: Actual engine speed (If N


sensor fails, engine speed is not meas-
ured.)

Even if signals from N sensor are not


delivered due to broken circuit or poor
sensor installation, few changes in op-
erational performance occur, making
troubleshooting difficult. Use monitor
function.

T2-1 T2-1 T2-1

T5-4-9

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Parts
Hydraulic Oil Temperature Sensor Engine Learning Switch
Monitors hydraulic oil temperature to control Starts engine learning.
auto-warming up and arm regenerative control. ON: 0V Learning
OFF: 5V Normal Control
Function

If circuit breakage occurs, system operates as if Engine learning is not performed.


hydraulic oil temperature is 40 pC (Dr. ZX or
monitor will not indicate 40 pC in diagnosis
Symptoms in control operation).
system when trouble
occurs.

Even if oil temperature is lower than 0 pC, Machine will operate normally problem is
auto-warming up control doesnt operate so that caused by broken circuit or discontinuity of
engine runs at idle speed when engine is switch. (Only learning cannot be performed.)
started. If short circuit occurs, learning mode operation
When oil temperature is lower than 10 pC, arm starts when key switch is turned ON. Therefore,
regenerative control is inoperable. engine will stall at 2 second or 20 seconds after
engine starts.

Symptoms in machine
operation when trouble
occurs.

Fault code 19 is displayed.


By Fault
Code
Monitor Item: Hydraulic Oil Temperature Monitor Item: Engine Learning
By Monitor
Evaluation Function
Using Test
Harness
Others

NOTE

T2-1 T2-1
Descriptions of Control
(Operational Principle
Section in T/M)

T5-4-10

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Power Digging Switch Travel Mode Selector MC


Activates power digging control. Changes travel mode. Controls engine, pump, and valve opera-
ON: 0V Increasing Pressure Fast Mode: 0V tion.
OFF: 5V Not Increasing Pressure Slow Mode: 5V

Broken Circuit: Pressure doesnt in- Broken Circuit in Switch: Travel speed Depending on trouble situations, control
crease. remains unchanged in slow mode (5V). system malfunction may differ. (The fol-
Short Circuit: Pressure increases for 8 Short Circuit in Switch: lowing symptoms in machine operation
seconds after turning key switch and Travel speed remains unchanged in fast indicates that MC logic circuit has failed.)
stops increasing. mode (0V).

Power digging control doesnt operate if Even if travel mode selector is turned to Even if key switch is turned ON, EC mo-
broken circuit or short circuit occurs. the FAST position, fast travel mode can- tor will not move to the START position
not be selected. so that engine cannot start. Even though
Even if travel mode selector is turned to engine starts, speed stays slow.
the SLOW position, fast travel mode is Since pump displacement is held at
operated. minimum, all actuator speeds are slow.

Fault codes 01, 02, and 03 are displayed.


Other fault codes may be displayed.

Monitor Item: Power Digging (Boost) Switch Monitor Item: Travel Mode

Before suspecting a failure in MC, be


sure to check the fuses in control system.
If any sensor in 5 V system is
short-circuited, all sensor fault codes will
be displayed.

T2-1 T2-1 T2-1

T5-4-11

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Parts Auto-Idle/Auto-Acceleration Selector Auto-Idle/Auto-Acceleration Selector


(Auto-Idle) (Auto-Acceleration)
Activates auto-idle control. Activates auto-acceleration control.
ON: 0 V Auto-idle is operable. ON: 0 V Auto-acceleration is operable.
OFF: 5 V Inoperable. OFF: 5 V Inoperable.
Function

Broken Circuit: Auto-idle system is inoperable. Broken Circuit: Auto-acceleration control is in-
Short Circuit: Even if auto-idle/auto-acceleration operable.
selector is OFF, auto-idle control is always per- Short Circuit: Even if auto-idle/auto-acceleration
formed. selector is OFF, auto-acceleration control is al-
Symptoms in control ways performed.
system when trouble
occurs.

Same as described above. Same as described above.

Symptoms in machine
operation when trouble
occurs.

By Fault
Code
Monitor Item: Auto-Idle/Auto-Accel Switch Monitor Item: Work Mode Switch
By Monitor
Evaluation Function
Using Test
Harness
Others

NOTE

Descriptions of Control T2-1 T2-1


(Operational Principle
Section in T/M)

T5-4-12

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Power Mode Switch Power Mode Switch


Work Mode Switch (Digging Mode)
(HP Mode) (E Mode)
Activates HP mode control. Selects E mode. Allows normal control to be performed.
ON: 0 V HP mode is operable. ON: 0 V E mode
OFF: 5 V Inoperable. OFF: 5 V Normal

Broken Circuit: Even if HP mode is se- Broken Circuit: Even if E mode is se-
lected, HP mode is inoperable. lected, engine speed doesnt decrease.
Short Circuit: Even if HP mode switch is Short Circuit: Engine speed doesnt in-
turned OFF, HP mode system is not de- crease to the maximum. Auto-idle control
activated. Attachment speed increase is inoperable.
control (optional) becomes inoperable.

Same as described above. Same as described above

Monitor Item: E/P/HP Mode Switch Monitor Item: E/P/HP Mode Switch Monitor Item: Work Mode Switch

T2-1 T2-1 T2-1

T5-4-13

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Parts Auxiliary Mode Switch (Optional)


Work Mode Switch (Attachment Mode)
Functions only when optional attachment kit is Functions only when optional attachment kit is
equipped. (Attachment operation speed in- equipped. (Attachment operation speed in-
crease/limit control) crease/limit control)
Function

When operating attachment, engine speed is When operating attachment, engine speed is
not controlled. not controlled.

Symptoms in control
system when trouble
occurs.

Even if auxiliary valve is operated, engine Even if auxiliary valve is operated, engine
speed doesnt increase. speed doesnt increase.
Even if attachment mode is selected, maximum Even if attachment mode is selected, maximum
engine speed doesnt decrease. engine speed doesnt decrease.

Symptoms in machine
operation when trouble
occurs.

By Fault
Code
Monitor Item: Work Mode Switch
By Monitor
Evaluation Function
Using Test
Harness
Others

NOTE

Descriptions of Control T2-1 T2-1


(Operational Principle
Section in T/M)

T5-4-14

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Flow Combiner Valve Travel Flow Control Valve Bucket Flow Control Valve
Supplies hydraulic oil to both right and To ensure pressure oil to raise boom To restrict the bucket circuit to assist
left travel spools from pump 1 during when travel and boom raise functions are boom to raise when a combined opera-
combined operation of travel and operated at the same time. tion of bucket, arm roll-in, and boom raise
front/swing. is made.

During combined operation of travel and Oil flow is not restricted properly. Always restrict the bucket circuit if switch
front/swing, insufficient oil is supplied to valve is seized in operation.
left travel spool.

While traveling, when front/swing lever is If fully closed, shock increases when Bucket speed decreases if poppet valve
operated, machine mistracks to the left. travel combined operation is made. is seized or switch valve is seized so that
If fully opened, boom is not raised when the poppet valve is closed.
the combined operation of travel down a Boom does not rise when the combined
slope and boom raise with bucket loaded operation of bucket, arm roll-in, and
is made. (Boom raise single operation boom raise is made with poppet valve
can be achieved.) fully opened, or if switch valve is seized
so that poppet valve is fully opened.

T3-3 T3-3 T3-3

T5-4-15

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Parts Boom Regenerative Arm Regenerative Bucket Regenerative


Control Valve Control Valve Valve
To prevent boom cylinder When the valve is switched by To prevent bucket cylinder
hesitation by allowing the re- pilot pressure oil led from sole- hesitation by allowing the re-
turn oil from the boom cylin- noids valve unit (SC). turn oil from the bucket cyl-
der bottom side to flow into To increase arm speed by al- inder rod side to flow into the
the boom cylinder rod side. lowing the return oil from the bucket cylinder bottom side.
arm cylinder rod side to flow
Function into the arm cylinder bottom
side.

The same as described be- Arm regenerative function does The same as described be-
low. not operate. low.
Symptoms in control
system when trouble
occurs.

If check valve is kept closed, Arm speed is very slow when If check valve is kept closed,
boom lower speed decreases. leveling. bucket is not smoothly rolled
If check valve is kept opened, in.
jacking up the machine using If check valve is kept opened,
the front attachment is diffi- bucket power is weak.
cult.

Symptoms in machine
operation when trouble
occurs.

By Fault
Code
By Monitor
Evalua- Function
tion
Using Test
Harness
Others

NOTE

Descriptions of Control T3-3 T3-3 T3-3


(Operational Principle
Section in T/M)

T5-4-16

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Arm Anti-Drift Valve Arm Anti-Drift Valve


Boom Anti-Drift Valve
(Rod Side) (Bottom Side)
To prevent the arm drift caused by inner To prevent the arm drift caused by inner To prevent the boom drift caused by inner
leakage of hydraulic oil in control valve. leakage of hydraulic oil in control valve. leakage of hydraulic oil in control valve.
Only when arm is rolled in, anti-drift valve Only when arm is rolled out, anti-drift Only when boom is lowered, anti-drift
(check valve) in the arm cylinder return valve (check valve) in the arm cylinder valve (check valve) in the boom cylinder
circuit is forcibly opened so that arm is return circuit is forcibly opened so that return circuit is forcibly opened so that
rolled in. arm is rolled out. boom is lowered.

Check valve does not open if switch Check valve does not open if switch Check valve does not open if switch
valve is seized. valve is seized. valve is seized.

If check valve does not open, arm roll-in If check valve does not open, arm roll-out If check valve does not open, boom is not
speed decreases. speed decreases. lowered.
If check valve is kept opened, arm drift If check valve is kept opened, arm drift If check valve is kept opened, boom drift
increases due to the control valve inner increases due to the control valve inner increases due to the control valve inner
leakage. leakage. leakage.
According to the degree of seizure in According to the degree of seizure in According to the degree of seizure in
check valve, arm roll-in operation be- check valve, arm roll-out operation be- check valve, boom lower operation be-
comes jerky, or slower. comes jerky, or slower. comes jerky, or slower.

T3-3 T3-3 T3-3

T5-4-17

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Parts
Pump Control Valve
Bypass Shut-Off Valve
(4-Spool Side)
Supplies pressure oil from pump 1 to auxiliary Operating boom raise/lower, arm roll-in/out,
spool when auxiliary spool is operated. bucket roll-in/out, right travel and auxiliary, flow
rate control pressure Pi is supplied to pump 1
regulator in response to the operation.
Function

The same as described below. Pump control pressure of pump 1 doesnt


change if pump control valve (4-spool side)
spools are seized and the spring is broken.

Symptoms in control
system when trouble
occurs.

If spool is bound in the fully opened position, Seized in neutral, pump 1 is turned the
single attachment operation speed becomes maximum swash angle though the control lever
slow. is in neutral. (If the travel lever is kept at half
If spool is bound in the fully closed position, stroke, the machine mistracks to the left.)
main relief valve continues to relieve with all Seized in neutral, pump 1 control pressure
control levers positioned in neutral. sensor indicates the maximum pressure.
If pump 1 control pressure is monitored, it indi- Seized with pump control valve operated, pump
cates the maximum value. 1 is kept at the minimum swash angle, operating
If spool is bound in opened position, when all the control lever.
control levers are in neutral, pump 1 pressure is (Right travel is in operable in single travel
higher than pump 2 pressure. operation. Bucket speed is very slow.)
Symptoms in machine
operation when trouble
occurs.

By Fault
Code
Monitor Item: Pump 1 Delivery Pressure, Pump 1 Monitor Item: Pump 1 Control Pressure.
By Monitor Control Pressure.
Evaluation Function
Using Test
Harness
Others

NOTE
T3-3 T3-3
Descriptions of Control
(Operational Principle
Section in T/M)

T5-4-18

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Bucket Flow Rate Control Bucket Flow Rate Control


Pump Control Valve Swing Parking Brake
Valve (Switch Valve A Valve (Switch Valve B
(5-Spool Side) Release Spool
Spool) Spool)
Operating boom raise/lower Supplies swing parking brake Supplies boom raise pilot Reduces flow rate to bucket
arm roll-in/out, swing right/left release pressure when pressure to the switch valve cylinder when shifted by
and left travel, flow rate con- shifted by boom, arm, bucket, B of bucket flow rate control boom raise pilot pressure.
trol pressure Pi is supplied to or swing pilot pressure. valve when shifted by arm
pump 2 regulator in response roll-in pilot pressure.
to the operation.

Pump control pressure of If spool is bound in the fully If spool is bound in the fully If spool is bound in the fully
pump 2 doesnt change if opened position, swing park- opened position, bucket opened position, boom
pump control valve (5-spool ing brake is kept released. speed becomes slow when doesnt raise during
side) spool are seized and (Machine vibrates while trav- boom raise and bucket com- 3-combined operation of
the spring is broken. eling.) bined operation is made. bucket, arm roll-in and boom
If spool is bound in the fully (Bucket flow rate control is raise.
closed position, swing park- inoperable.) If spool is bound in the fully
ing brake is kept applied. If spool is bound in the fully closed position, bucket speed
(Dragging is felt.) closed position, boom doesnt becomes slow in bucket sin-
raise during 3-combined op- gle operation. (Bucket flow
eration of bucket, arm roll-in, rate control is always effec-
and boom raise. tive.)

Seized in neutral, pump 2 is Same as described above. Same as described above. Same as described above.
turned the maximum swash
angle though the control lever
is in neutral. (If the travel
lever is kept at half stroke,
the machine mistracks to the
right.)
Seized in neutral, pump 2
control pressure sensor indi-
cates the maximum pressure.
Seized with pump control
valve operated, pump 2 is
kept at the minimum swash
angle, operating the control
lever.
(Left travel is inoperable in
single travel operation. Swing
speed is very slow.)

Monitor Item: Pump 2 Control Monitor Item: Pump 2 Control


Pressure. Pressure.

T3-3 T3-3

T5-4-19

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine
troubles and parts contributing to the cause of the
trouble if failed.
Engine System Troubleshooting
E-1 E-2 E-3
Starter doesnt rotate Although starter ro- When engine control dial is fully rotated, en-
Trouble tates, engine doesnt gine stalls. Occasionally engine stalls during
Symptom start. operation with engine control dial fully rotated
and auto-idle ON. Engine speed is slower than
specification in all operating range. Idle speed
is faster or slower than specification.

Parts
MC (Main Controller)
QOS Controller
EC Motor
EC Sensor
Pump 1 Delivery Pressure
Sensor
Pump 2 Delivery Pressure
Sensor
Pump 1 Control Pressure
Sensor
Pump 2 Control Pressure
Sensor
Pressure Sensor (Travel)
Pressure Sensor
(Front Attachment)
Pressure Sensor (Swing)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Auxiliary)
N Sensor
Hyd. Oil Temperature Sensor
Coolant Temperature Sensor
Key Switch
Engine Control Dial
Auto-Idle/Acceleration Selector
Power Mode Switch
Work Mode Switch
Auxiliary Mode Switch
Engine Learning Switch
Battery Relay
Glow Relay
Engine Electrical Equipment
Engine Unit
Governor
Check batteries. Check fuel system Check fuel cut-off handle and engine control
(filters and piping). cable. Be sure to perform engine learning after
Remarks replacing engine.

T5-4-20

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.

E-4 E-5 E-6 E-7 E-8


Even if engine control Engine speed doesnt Faulty HP mode. Even if key switch is Faulty auto-idle system.
dial is rotated, engine increase after engine is turned OFF, engine
speed remains un- started. doesnt stop.
changed.

Check engine control


cable.

: 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.

T5-4-21

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

E-9 E-10 E-11


Faulty E mode. Faulty auto-acceleration When traveling or operating
Trouble system. front attachment with en-
Symptom gine running at slow idle,
engine hunts.

Parts

MC (Main Controller)
QOS Controller
EC Motor
EC Sensor
Torque Control Solenoid Valve
Pump 1 Delivery Pressure
Sensor
Pump 2 Delivery Pressure
Sensor
Pump 1 Control Pressure
Sensor
Pump 2 Control Pressure
Sensor
Pressure Sensor (Travel)
Pressure Sensor
(Front Attachment)
Pressure Sensor (Swing)

Pressure Sensor (Boom Raise)

Pressure Sensor (Arm Roll-In)


Pressure Sensor (Auxiliary)
N Sensor
Hyd. Oil Temperature Sensor
Coolant Temperature Switch
Key Switch
Engine Control Dial

Auto-Idle/Acceleration Selector

Power Mode Switch


Work Mode Switch
Auxiliary Mode Switch
Engine Learning Switch
Battery Relay
Glow Relay
Engine Electrical Equipment
Engine Unit
Governor
Pump Regulator

Remarks

T5-4-22

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.

E-12 E-13 E-14 E-15 E-16


Engine speed doesnt When attachment mode Engine stalls within sev- Engine stalls during op- Engine is difficult to start
increase even if attach- is selected, engine eral seconds after engine eration under adverse at low temperature.
ment is operated in at- speed doesnt decrease. has started. condition such as at high
tachment mode. altitude.

Check fuel system for Check batteries.


clogging.

: 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.

T5-4-23

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

All Actuator System Troubleshooting


A-1 A-2 A-3
All actuator speeds are Left travel is inoperable Right travel is inoperable
Trouble slow. during single travel opera- during single travel opera-
Symptom tion. Single swing operation tion. Single bucket opera-
speed is slow. Arm is tion speed is slow. Boom is
slightly slow during arm not raised properly during
level crowding. arm level crowding.

Parts
MC (Main Controller)
Torque Control Solenoid Valve
N Sensor
Spool
Main Relief Valve
Main Pump
Regulator
Pilot Pump
Pilot Valve
Pilot Relief Valve
Pump Control Valve
(4-Spool Side)
Pump Control Valve
(5-Spool Side)

Remarks

T5-4-24

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

NOTE: The trouble symptoms in this table are de-


scribed provided that each trouble occurs
independently. In case more than one trou-
ble occurs at the same time, find out all
faulty components while checking all sus-
pected components in each trouble symp-
tom.

A-4 A-5
Actuator doesnt stop Actuator speed is faster
even if control lever is than normal. Machine
returned to neutral. mistracks when travel
lever is operated at the
half stroke.
Precise control can not
be performed.

: 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.

T5-4-25

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Front Attachment System Troubleshooting


F-1 F-2 F-3 F-4 F-5
All front attach- Even if power dig- Some cylinders During the com- Arm speed is slow
Trouble ment actuator ging switch is are inoperable or bined operation of in a combined op-
Symptom power is weak. pressed, power speeds are slow. travel and boom eration. Arm speed
doesnt increase. raise, boom does is slow during arm
Boom raise power not rise. level crowding.
is weak when dig-
ging.

Parts

MC (Main Controller)
Solenoid Valve Unit (SG)
Solenoid Valve Unit (SC)
Pump 1 Delivery Pressure
Sensor
Pump 2 Delivery Pressure
Sensor
Pressure Sensor
(Swing)
Pressure Sensor
(Boom Raise)
Pressure Sensor
(Arm Roll-In)
Oil Temperature Sensor
Power Digging Switch
Spool
Main Relief Valve
Overload Relief Valve
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve
Bucket Regenerative Valve
Travel Flow Rate Control
Valve
Bucket Flow Rate Control
Valve
Boom Anti-Drift Valve
Arm Anti-Drift Valve
Needle Valve
Shockless Valve
Pilot Valve
Cylinder

Remarks

T5-4-26

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.

F-6 F-7 F-8 F-9 F-10


Bucket is slow in bucket When starting to move in Boom starting speed is When operating the con- Front attachment cylinder
roll-in single operation. combined operation, arm slow and/or jerky during trol lever to raise boom drift is large.
Bucket doesnt move doesnt smoothly move. combined operations. or to roll-out arm, boom
smoothly in bucket roll-in Arm starts to move slow During boom lower sin- or arm starts to move
single operation. slightly in arm roll-in sin- gle operation, boom after slightly moving in
gle operation. These speed is slightly slow. the reverse direction.
troubles often occur when
oil temperature is low.

: 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.

T5-4-27

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Swing/Travel/Other System Troubleshooting


S-1 T-1 T-2 T-3 T-4
Swing speed is Both right and left When a com- One side track During a com-
Trouble slow or swing travel side tracks bined operation does not move or bined operation
Symptom function does not do not move or with boom raise move slowly, or of travel and front
operate. move slowly. is made, a large the machine can- function, the ma-
shock is felt. not travel straight chine mistracks.
(Mistracks).

Parts

MC (Main Controller)
Torque Control Solenoid
Valve
Solenoid Valve Unit (SI)
Pump 1 Delivery Pressure
Sensor
Pump 2 Delivery Pressure
Sensor
Pump 1 Control Pressure
Sensor

Pump 2 Control Pressure Sensor

Pressure Sensor (Travel)


Pressure Sensor (Swing)
Pressure Sensor (Arm Roll-In)
Travel Mode Switch
Pump Device
Spool
Load Check Valve
Travel Flow Rate Control
Valve
Swing Relief Valve
Flow Combiner Valve
Pump Control Valve
(4-Spool Side)
Pump Control Valve
(5-Spool Side)
Swing Device
Travel Device
Center Joint
Pilot Valve
Also, refer to T-7 In case either
bucket or swing is
also slow, refer to
Remarks A-2 or A-3.

T5-4-28

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
T-5 T-6 T-7 O-1 O-2
Occasionally, machine mis- No steering force and no Fast travel is inoperable. Wiper is inoperable or Air Conditioner mal-
tracks when traveling with gradeability when travel Travel mode does not not retracted. function
engine running at slow mode is fast. change from slow mode
speed. to fast mode.

: 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.

T5-4-29

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-4-30

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter doesnt rotate.

Related Fault Code: None

This trouble has nothing to do with the electronic


control system such as the MC.
Check for loose harness connections before-
hand. Faulty starter or faulty
harness between
YES starter and battery re-
Check if voltage at lay.
battery relay terminal A
YES is 24 V.

Faulty battery relay.


Check if both voltages
at key switch terminal NO
YES #5 and #6 are 24 V.

YES Faulty key switch.


Check for continuity
Check if battery voltage between battery posi-
and electrolyte density is Key switch: START
tive terminal and key
normal, and fusible link switch terminal #1.
NO Faulty harness be-
(40 A) is not blown.
tween battery and key
switch.
NO

Voltage: More than 24 V


Density: More than 1.25 Faulty battery or fusible
to 1.28 link.
NO

Key Switch Battery Relay


Terminal A

T178-05-04-001
T105-07-04-002

T5-4-31

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
E-2 Although starter rotates, engine doesnt
start.

Related Fault Code: None

Check the fuel cut lever position during cranking.


If the position is normal, the engine unit and/or
fuel system may have trouble.
Check for loose harness connections before-
hand.

Faulty engine.
YES

Check if governor lever Refer to Engine Shop Manual.


moves to the START position
when key switch is turned ON.

Key switch: ON
Check EC motor drive circuit.
NO

Test Harness: 4274589


(ST 7125)

Governor Lever and Fuel Cut Lever


2
1

T1HH-04-02-002

4 3

1 - Governor Cable (From EC Motor)


2 - Fuel Cut-Off Cable
(Fuel Cut-Off Handle)
3 - Fuel Cut Lever
4 - Governor Lever

T5-4-32

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
Governor Lever Position

A - Key Switch OFF (Engine Stop Position)


B - Key Switch ON (Engine Start Position)

B
FULL
A: STOP
FULL
STOP

T1HH-04-02-002

Fuel Cut Lever Position

A - Fuel Cut-Off Handle Pulled Position


B - Fuel Cut-Off Handle Returned Position

B A

T1HH-04-02-002

T5-4-33

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
E-3 When engine control dial is fully rotated,
engine stalls.
Occasionally engine stalls during operation
with engine control dial fully rotated and
auto-idle ON.
Engine speed is slower than specification in
all operating ranges.
Idle speed is faster or slower than specifica-
tion.

Related Fault Code: 06

In case engine learning has not been performed Refer to pages for Engine Learning in the SYS-
or engine learning has been incorrectly per- TEM/Control System group in the T/M (Opera-
formed, engine speed becomes slower than tional Principle).
specification across the operating range. Check for loose harness connections before-
In case the EC sensor is faulty, engine speed is hand.
controlled based on the governor lever position,
which is judged as the idle position when the key
switch is turned ON. Accordingly, discrepancies
in engine speed from specification will result.
Depending on where the governor lever is posi-
tioned when the key switch is turned ON, dis-
crepancy will differ, causing this trouble to be not
reproducible.

Return fuel cut


lever to original po-
YES sition.

Check if fuel cut


lever has been
moved up to half YES Faulty EC sensor.
way stroke.

Check if fault code Refer to T4-6-1.


06 is displayed.
NO YES End.
Check if problem is
corrected after en-
gine learning.
NO

NO Monitor engine
Refer to T4-6-1 for learning status.
engine learning
procedures.
Monitor item: En-
gine learning con-
trol

T5-4-34

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Faulty engine and/or fuel sys-


YES tem.

Check if governor lever


OK comes in contact with stopper
when performing engine Faulty control cable and/or in-
learning. correctly adjusted engine gov-
ernor lever.
NO

Adjust engine speed.


(Refer to T4-6-1.)

Faulty MC, faulty learning


switch, or broken harness be-
tween learning switch and MC.
NOT OK

Refer to T4-6-1.

T5-4-35

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
E-4 Even if engine control dial is rotated, engine
speed remains unchanged.

Related Fault Code: 07

If the EC fails, the engine will not stop with the


key switch OFF.
Check for loose harness connections before-
hand.

Faulty engine control dial or


broken harness between en-
gine control dial and MC.
YES
Check if fault code 07 is dis-
played. Using Dr. ZX, monitor
engine control dial angles
(standard voltages). Check if
voltages are normal. Faulty EC motor.
YES
Install test harness (ST 7125)
to EC motor. Check if lamp
comes ON while turning en- Refer to T4-6-1.
gine control dial.
Standard voltages NO
Slow idle position: 0.3 to 1 V Faulty MC or broken harness
Fast idle position: 4.4 to 4.7 V between MC and EC motor.
Possible to display with built-in
diagnosing system. NO

Refer to T4-6-1.

T5-4-36

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
E-5 Engine speed doesnt increase after engine
is started.

Related Fault Code: 19

Refer to the pages for the Auto Warming Up Con-


trol in the SYSTEM / Control System group in the
T/M (Operational Principle).
Check for loose harness connections before-
hand.

More than 0 pC
when starting Normal.

Monitor oil tem-


NO perature.

Faulty key switch or


broken harness be-
Monitor item: Hydraulic oil
YES tween key switch and
temperature Monitor key switch. MC.
Possible to display with Check if displayed
built-in diagnosing system ky is highlighted in
response to key
switch operation.
Check if fault code
19 is displayed. Lower than 0 pC
when starting Faulty MC.
NO
Refer to T4-6-1.
Monitor item: Key
switch
Faulty hyd. oil tem-
perature sensor or
broken harness be-
tween oil tempera-
ture sensor and MC.
YES

T5-4-37

PDF created with pdfFactory Pro trial version www.pdffactory.com


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 Fault Codes: 10, 11, 15, and 16

Sensors detect the conditions necessary to oper- Refer to the pages for HP Mode Control in the
ate the HP mode. Therefore, if any of these sen- SYSTEM / Control System group in the T/M (Op-
sor fails, the HP mode becomes inoperable. erational Principle).
Pressure sensors (arm roll-in and boom raise) Check for loose harness connections before-
and pump 1 and 2 delivery pressure sensors are hand.
also engaged in the HP mode control. However, if
these sensors fail, other operating functions will
be also affected. (Refer to the relationship be-
tween machine trouble symptoms and related
parts on page T5-4-2.)
Faulty power mode
switch or broken
harness between
NO power mode switch
and MC.
Monitor power mode
switch. Check if indica-
tion HP is highlighted
when power mode
NO switch is turned to HP Check if governor
mode. lever comes in contact YES Faulty engine.
with full-side stopper
while relieving boom
raise circuit pressure.
YES
Check if any fault Faulty MC.
codes are displayed. Monitor item: E/P/HP
mode switch NO
Refer to T4-6-1.

Faulty corresponding
sensor or broken
harness between
sensor and MC.
YES

Fault codes:
Pump 1 delivery pressure sensor: 10
Pump 2 delivery pressure sensor: 11
Pilot pressure sensor (boom raise): 15
Pilot pressure sensor (arm roll-in): 16

T5-4-38

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
Although the power mode switch isnt turned to the
HP mode position, 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
broken at the same time.
Short circuited harness
between MC and power
YES mode switch.

Monitor the power


Check if the symp- End.
mode switch. Check Check if the governor YES
tom disappears after
if HP is displayed. lever comes in contact completing engine
with full side stopper YES learning.
when the key switch is Faulty MC.
turned ON (engine not
running) and the engine NO
Monitor item: E/P/HP control dial is turned to Refer to T4-6-1.
mode switch NO
Fast Idle.
Power mode switch:
P mode Faulty engine.
NO

T5-4-39

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
E-7 Even if key switch is turned OFF, engine
doesnt stop. (In case the engine doesnt
stop, stop the engine by pulling the engine
stop handle located under the seat stand.
Then, begin inspection.)

Related Fault Codes: 06 and 07

Probably 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 will come up. Per-
form troubleshooting for these symptoms.

T5-4-40

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
E-8 Faulty auto-idle system

Even if control lever is turned to neutral. Auto-idle


system is inoperable.

Related Fault Code: 18

In case trouble symptoms E1 to E7 are recog- Refer to the pages for Auto-Idle Control in the
nized, perform the troubleshooting of these trou- SYSTEM / Control System group in the T/M (Op-
bles beforehand. erational Principle).
Although the failure in pressure sensors (travel Check for loose harness connections before-
and front attachment) will have relevance to mal- hand.
function of the auto-idle control. However, if these
sensors fail, other operating functions will also be
affected. (Refer to the relationship between ma- Normal (Turn power
chine trouble symptoms and related parts on mode switch to a posi-
page T5-4-2.) YES tion other than the E
mode.)

Check if power mode


switch is in the E
YES mode position.

Monitor auto-idle switch.


Check if displayed AI is
turned OFF or ON in re-
sponse to auto-idle / Faulty MC.
auto- acceleration selec-
tor operation. NO
Refer to T4-6-1.

Faulty auto-idle / auto-


acceleration selector
Monitor item:
or broken harness
Auto-idle / auto-accel
between auto-idle
switch
switch and MC.
NO

Although the auto-idle / auto-acceleration selector is


turned OFF, the auto-idle control is operated.

Be sure to separate auto-idle control from Short circuited harness


auto-acceleration control. between MC and auto-idle
/ auto-acceleration selec-
YES tor.
Monitor auto-idle /
auto-acceleration se-
lector. Check if AI is
displayed.

Faulty MC.

Monitor item: Auto-idle / NO


auto-accel switch
Auto-idle / Refer to T4-6-1.
auto-acceleration selec-
tor: OFF

T5-4-41

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
E-9 Faulty E mode

Even if power mode switch is turned to the E mode


position, engine speed remains unchanged. (En-
gine speed doesnt decrease.)

Related Fault Code: None

In case trouble symptoms E-1 to E-8 are recog-


nized, perform the troubleshooting of these trou-
bles beforehand.
Refer to the pages for E Mode Control in the
SYSTEM / Control System group in the T/M (Op-
erational Principle).
Check for loose harness connections before-
hand. Faulty power mode switch or
broken harness between
NO power mode switch and MC.
Monitor power mode switch.
Check if displayed E Mode is
turned OFF or ON in re-
sponse to power mode switch
operation.

Faulty MC.

YES
Monitor item: Refer to T4-6-1.
E/P/HP mode switch

Although power mode switch isnt turned into E


mode, engine speed decrease.

Short circuited harness be-


tween MC and power mode
YES
switch.
Monitor power mode switch.
Check if E is displayed.

Faulty MC.
Monitor item: E/P/HP switch NO
Power mode switch: P mode
Refer to T4-6-1.

T5-4-42

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
E-10 Faulty auto-acceleration system

Auto-acceleration system is inoperable.

Related Fault Code: 10, 11, 12, 13, 14, 15, 16, and
18

In case trouble symptoms E-1 to E-9 are recog- Refer to the pages for Auto-Acceleration Control
nized, perform the troubleshooting of these trou- in the SYSTEM / Control System group in the
bles beforehand. T/M (Operational Principle).
Although the failure in pressure sensors (travel,
swing, boom raise, and arm roll-in), pump 1 and
2 delivery pressure sensors, and pump 1 and 2
control pressure sensors will have relevance to
malfunction of the auto-acceleration control.
However, if these sensors fail, other operating
functions will also be affected. (Refer to the rela-
tionship between machine trouble symptoms and
related parts on page T5-4-2.) Faulty auto-idle /
auto-acceleration selector or
broken harness between
Monitor auto-idle / auto-acceleration switch and MC.
NO
auto-acceleration selector.
Check if displayed AA is
turned OFF or ON in response
to auto-acceleration switch
operation.
Faulty MC.

YES
Refer to T4-6-1.
Monitor item:
Auto-idle/auto-accel
switch

Although auto-idle / acceleration selector is turned


OFF, the auto-idle acceleration control is operated.

Be sure to separate the auto-idle control from the


auto-acceleration control. Short circuited harness between
MC and auto-idle /
YES auto-acceleration selector.
Monitor auto-idle / accelera-
tion selector.
Check if AA is displayed.

Faulty MC.
Monitor item: Auto-idle / NO
auto-accel switch
Auto-idle / auto-acceleration se- Refer to T4-6-1.
lector:
Auto-idle position

T5-4-43

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
E-11 When traveling or operating front attach-
ment with engine running at slow idle, en-
gine hunts.

Related Fault Code: 18

Although the failure in pressure sensors (travel


and front attachment) will have relevance to mal-
function of the engine speed increase control.
However, if these sensors fail, other operating
functions will also be affected. (Refer to the rela-
tionship between machine trouble symptoms and
related parts on page T5-4-2.)
Refer to the pages for Idle Speed-Up Control in
the SYSTEM / Control System group in the T/M
(Operational Principle).

YES Faulty engine.

Check if engine speed is


faster than increased idle Refer to the Engine Shop
speed. Manual.

Faulty MC.
Monitor item: NO
Engine target speed
Possible to display with built-in Refer to T4-6-1.
diagnosing system

T5-4-44

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
E-12 Engine speed doesnt increase even if at-
tachment is operated in attachment mode.

Related Fault Code: None

In case trouble symptoms E-1 to E-11 are recog- Refer to the pages for Attachment Operation
nized, perform the troubleshooting of these trou- Speed Increase Control in the SYSTEM / Control
bles beforehand. System group in the T/M (Operational Principle).
Although the failure in pressure sensor (auxiliary) Check for loose harness connections before-
and power mode switch will have relevance to hand.
the malfunction of the attachment operation
speed increase control. However, if these sensor
and switches fail, other operating functions will
also be affected. (Refer to the relationship be-
tween machine trouble symptoms and related
parts on page T5-4-2.)
Normal (Set to In-
NO crease (+).)
Check if attachment
speed adjustment
has been set to In-
NO crease (+) in Dr. ZX Monitor attachment
service mode. pilot pressure. Check YES
if pressure varies in To A
response to lever
Check if P speed ad-
stroke.
justment has been YES
set to Decrease in Faulty auxiliary pres-
Dr. ZX service mode. sure sensor.
NO

Monitor item: Att. con-


trol pilot pressure Normal (If set to De-
crease, this control
system is deacti-
YES vated.)

YES Faulty MC.


Monitor work mode
switch. Check if display
switches in response Refer to T4-6-1.
to work mode switch
A operation.

Faulty work mode


switch.
NO
Monitor item:
Work mode switch

T5-4-45

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
E-13 When attachment mode is selected, engine
speed doesnt decrease.

Related Fault Code: None

In case trouble symptoms E-1 to E-11 are recog-


nized, perform the troubleshooting of these trou-
bles beforehand.
Refer to the pages for Attachment Operation
Speed Limit Control in the SYSTEM / Control
System group in the T/M (Operational Principle).
Check for loose harness connections before-
hand.

YES Faulty MC.


Monitor work mode
switch. Check if dis-
play switches in re-
sponse to work mode Refer to T4-6-1.
YES switch operation.

Check if attachment Faulty work mode switch.


speed adjustment has NO
been set to Decrease
(-) in Dr. ZX service Monitor item:
mode. Work mode switch

Normal (Set to Increase


(+).)
NO

T5-4-46

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
E-14 Engine stalls within several seconds after
engine has started.

Related Fault Code: None

Refer to the pages for Engine Learning Control in


the SYSTEM / Control System group in the T/M
(Operational Principle).
If the engine-learning switch is turned to the
learning position, the engine will stall in 5 sec-
onds after the engine starts.
Check for loose harness connections before-
hand.

Normal (Return switch to


YES neutral.)

Check if engine learn-


ing switch is turned to
the learning position.
Faulty learning switch, or
short-circuited harness be-
tween learning switch and
MC, or check fuel system for
clogging.
NO

T5-4-47

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
E-15 Engine stalls during operation under ad-
verse condition such as at high altitude.

Related Fault Code: 05

If speed-sensing control is inoperable, the engine


will stall under adverse operating conditions.
Check for loose harness connections before-
hand.

Disconnect torque control


solenoid valve. Connect
test harness (ST 7123)
Monitor torque control sole- between solenoid valve
noid valve output. Install NO and harness. Check if
pressure gauge to output port test harness lamp comes To A
so that pressure can be ON.
measured by pressure gauge
and Dr. ZX. Check if both
NO measured pressure values by
pressure gauge and Dr. ZX
vary identically.

Disassemble to check
regulator.
YES
Monitor actual engine
speed. Check if engine
speed is abnormal. Monitor item: Pump torque
proportional solenoid valve
output
Refer to the Operational Per-
Monitor item: formance Test section.
Engine actual speed Faulty N sensor, or faulty
harness between N
sensor and MC.
YES

Faulty torque control


YES solenoid valve.

A
Broken harness be-
tween torque control so-
lenoid valve and MC.
NO

T5-4-48

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-4-49

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
E-16 Engine is difficult to start at low tempera-
ture. (During cold weather or in cold dis-
tricts, the engine is difficult to start or
doesnt start although pre-heated.)

Related Fault Code: None

Check if electricity is routed to the glow plugs. Check battery at the same time.
Check the glow plugs for any abnormality. Check for loose harness connections before-
The pre-heat system operates only when coolant hand.
temperature is below 10 pC (50 pF). When cool-
ant temperature is higher than 10 pC (50 pF), the
pre-heat system doesnt operate.

Faulty coolant temperature


YES switch.

Disconnect coolant tempera-


ture switch. Check if voltage at
glow plug is 20 to 24 V.
YES Faulty QOS controller.
Disconnect QOS controller.
Ground harness end connector
Key switch: ON terminal #4 to vehicle frame.
Check if problem is corrected.
NO
Measure each glow plug re-
sistance.
Using a clip, ground from the NO
reverse side of the connector
without disconnecting. Key switch: OFF
Before measuring, remove
copper plates connecting
each glow plug.

Measurement of Glow Plug Voltage and Resistance


Voltage Check
Resistance Check

Remove
the
copper
plate.

Specification: 20 to 24 V
Specification: Below 10
T105-07-04-006

T105-07-04-007

T5-4-50

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Faulty glow plug.

Faulty glow relay, or broken


NO harness between glow plug
Disconnect glow relay. relay and glow plug.
Connect harness end
connector terminal #4 to
YES vehicle frame. Check if
voltage is 20 to 24 V.

Broken harness between glow


relay and QOS controller or
Disconnect glow relay. Key switch: ON YES faulty engine unit.
Check if voltage at glow
plug relay harness end
connector terminals #1 or Refer to the engine shop manual.
#3 is 20 to 24 V.
Below 10
In case voltage at terminal #1
is 0 V, harness between glow
relay and batteries is broken.
Key switch: ON In case voltage at terminal #3
is 0 V, harness between glow
relay and key switch terminal
NO M is broken.

Verify that fuse #19 is normal.

T5-4-51

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
ALL ACTUATOR SYSTEM TROUBLE-
SHOOTING
A-1 All actuator speeds are slow.

Related Fault Code: None

Reduction in pump 1 and 2 flow rate due to some Although speed is satisfactory, in case power is
reasons or faulty pilot system may cause this weak, refer to the troubleshooting for faulty relief
trouble. valve (F-1).
Also, check for fuse of the torque control solenoid Check for loose harness connections before-
valve. hand.

Faulty pilot pump or


YES clogged pilot filter.
Check if same
symptom still ap-
pears after disas-
NO sembling, cleaning,
and adjusting pilot
relief valve.
End.
NO

Check if primary
pilot pressure is Faulty N sensor or
normal. broken harness in N
YES sensor circuit.

Fully boom raised or arm


roll-in Monitor actual en-
Monitor item: Boom gine speed. Check
Raise Pilot Pressure, Arm if abnormal speed
YES
Roll-In Pilot Pressure YES is indicated. Monitor torque con-
trol solenoid valve
output. Check if
Monitor item: Engine torque control sole-
Actual Speed noid valve output is
Possible to display NO normal.
with monitor service
mode.

Monitor item:
Pump torque NO
proportional solenoid
valve output
Refer to the opera-
tional performance
Test section

T5-4-52

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Pressure Gauge
Mounting Port Torque Control
Solenoid Valve

Pilot Filter

T1HH-03-06-003

T173-03-01-001

Faulty pump device.


Install pressure YES
gauge between
YES torque control sole-
noid valve and regu- Faulty torque control solenoid
Check if harness
lator. Check if the valve.
between MC and
pressure changes. NO
torque control so-
lenoid valve is
normal

Faulty harness between torque


control solenoid valve and MC.
Key Switch: OFF NO

Faulty MC.

Refer to T4-6-6.

T5-4-53

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
A-2 Left travel is inoperable during single travel
operation. Single swing operation speed is
slow. Arm is slightly slow during arm level
crowding. (All problems occur at the same
time.)

Related 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.
Pressure oil from pump 1 is also routed to the
arm and boom cylinders so that the arm and
boom can move at a slightly slow speed in single
operation. However, in level crowd operation,
pressure oil is routed to the boom prior to the arm
so that arm speed becomes very slow.
Refer to the SYSTEM / Hydraulic System group
in the T/M (Operational Principle).

YES Faulty pump 2 regulator.


Monitor pump 2 pump
control pressure. Check
if pressure increases in
proportion to left travel
lever stroke.
Bound pump control valve
(5-spool side) spool in con-
trol valve.
NO
Monitor item: Pump 2
flow control pressure
Possible to display with
built-in diagnosing sys-
tem.

T5-4-54

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
A-3 Right travel is inoperable during single
travel operation. Single bucket operation
speed is slow. Boom is not raised properly
during arm level crowding. (All problems
occur at the same time.)

Related 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.
Pressure oil from pump 2 is also routed to the
arm and boom cylinders so that the arm and
boom can move at a slightly slow speed in single
operation. However, in level crowd operation,
pressure oil is routed to the arm prior to the boom
so that boom is scarcely raised.
Refer to the SYSTEM / Hydraulic System group
in the T/M (Operational Principle).

YES Faulty pump 1 regulator.

Monitor pump 1 pump


control pressure. Check if
pressure increases in
proportion to right travel
lever stroke. Bound pump control valve
(4-Spool side) spool in con-
trol valve.
NO

Monitor item: Pump 1 flow


control pressure
Possible to display with
built-in diagnosing sys-
tem.

T5-4-55

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
A-4 Actuator doesnt stop even if control lever
is returned to neutral.

Related 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 neu-


Check if actuator stops when tral, pilot pressure is routed to
pilot control shut-off lever is spool end in control valve.
raised.

Faulty control valve.

NO
Although pilot pressure is not
routed to spool end in control
valve, spool is kept opened
due to binding of spool.

T5-4-56

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-4-57

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
A-5 Actuator speed is faster than normal
Machine mistracks when travel lever is op-
erated at half stroke. Precise control cannot
be performed.

Related 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
doesnt reach the full stroke.
The pressure oil from pump 1 makes right travel
perform, and the pressure oil from pump 2 makes
left travel. Perform on the single travel operation.
Different flow rates between pump 1 and pump 2
occur, and the machine mistracks. When the
travel lever is operated at half stroke.
Refer to the SYSTEM / Hydraulic System group
in the T/M (Operational Principle).

Faulty pump regulator.


YES
Monitor pump control pressure
of pump 1 and 2. Check if the
pressure changes in response
to the lever operation.

Bound pump control valve


spool in control valve.
NO
Pump 1: Bucket operation
Pump 2: Swing operation
Monitor item: Pump 1 and 2
pump control pressures
Possible to display with built-in
diagnosing system.

T5-4-58

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
F-1 All front attachment actuator power is weak.

Related Fault Code: None

In case operating speeds are extremely slow,


pump control may be malfunctioning (A-2 and/or
A-3). Faulty pilot system may also cause this
trouble.
Main relief valve should be
31.4+2.0-0.5 MPa normal. Find out cause of trou-
+20 2
(320 -5 kgf/cm ) ble by tracing other trouble
symptoms.

Monitor pump 1 and 2 delivery


pressures.

Monitor item: Pump 1 and 2 de-


livery pressure Adjust main relief valve.
Possible to display with built-in
diagnosing system Less than 31.4 MPa
2
Relieve boom, arm, and bucket (Less than 320 kgf/cm )
circuits.
Power mode switch: OFF
Work mode: Digging

T5-4-59

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

F-2 Even if power digging switch is pressed,


power doesnt increase. Boom raise power
is weak when digging.

Related fault Code: None

Refer to the pages for the Power Digging Control


and the Auto-Power Lift Control in the SYSTEM /
Control System group in the T/M (Operational
Principle).
Check for loose harness connections before-
hand.

Normal (Possibly, Faulty power digging


Pressure Increases. HP mode is taken switch or broken har-
2
Less than 31.4 MPa (320 kgf/cm ) for power digging ness between power
NO
2
mode.) digging switch and MC.
34.3 MPa (350 kgf/cm )

Monitor pump 1
and 2 delivery
pressures. Monitor power
digging switch.
Check if indication Remains unchanged.
Pressure Pd is turned ON
Monitor item: doesnt or OFF in response Check pressure at
Pump 1 and 2 Deliv- increase. to power digging solenoid valve unit
ery Pressure switch operation. YES (SG) port.
Possible to display
with built-in diagnos-
tic system
Check pump delivery Check pressure
pressure change change while pressing Changes.
Monitor item: power digging switch. 2
while pressing power 0.49 MPa (5 kgf/cm ) or less
Power Digging (Boost) Measurement: Refer to
digging switch.
Switch the Operational Per- 2
0.98 MPa (10 kgf/cm ) or less
Proceed to YES if boom formance Test section.
raise power is weak in
digging operation.

T5-4-60

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Disconnect solenoid
valve unit (SG). Con-
nect test harness (ST Faulty solenoid valve unit
7123) between sole- YES
(SG).
noid valve unit and
harness. Check if test
harness lamp comes
ON.
Faulty harness between so-
lenoid valve unit (SG) and
NO MC.
Power Digging Switch:
ON

Faulty main relief valve.

T5-4-61

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
F-3 Some cylinders are inoperable or speeds
are slow.

Related Fault Code: None

When other actuators (travel and swing motors) In case single arm roll-in operation speed is slow,
operate normally, the pilot pump (primary pilot refer to F-7.
pressure) is considered to be normal. In case single boom lower operation speed is
In case single bucket operation speed is slow, slow, refer to F-8.
refer to F-6. Faulty cylinder (faulty
YES
Monitor pump con- seal kit).
trol pressure. Check Check if overload
if pump control pres- YES relief pressure is
sure changes normal.
smoothly while mov- Faulty overload relief
Monitor or meas- ing control lever valve.
ure secondary pilot YES slowly. NO
pressure. Check if
secondary pilot
pressure is normal. Bound control valve
Monitor item: spool.
Pump 1 flow control NO
pressure, pump 2 flow
Secondary pilot pres- control pressure
sure: Possible to display with
built-in diagnosing sys- Faulty pilot valve.
Refer to Operational YES
Performance Test Sec- tem.
tion. Check if secondary
Monitor item: Boom pilot pressure is cor-
raise pilot pressure, NO rect at the inlet port of Bound shockless
arm roll-in pilot pressure the shockless valve. valve spool.
Possible to display with NO
built-in diagnosing sys-
tem
In case of boom lower, Check only when
bucket roll-out/in and arm is not
arm roll-out, connect rolled-out. In case
the pressure gauge to cylinders other than
the pilot port in control arm roll-out are ab-
valve. normal, skip this
step and proceed to
the NO line.

Shockless Valve
2 1
3
4
5
6
7
8

1- From Swing Left Pilot Valve


2- From Swing Right Pilot Valve
3- From Bucket Roll-Out Pilot Valve
4- From Bucket Roll-In Pilot Valve
5- From Boom Raise Pilot Valve
6- From Boom Lower Pilot Valve
7- From Arm Roll-Out Pilot Valve
8- From Arm Roll-In Pilot Valve

T1HH-03-06-001

T5-4-62

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
F-4 During the Combined Operation of Travel
and Boom Raise, Boom does not Rise.

Related Fault Code: None


During the combined operation of travel and
boom raise, the travel flow rate control valve sup-
plies the pump flow rate for boom raise. If the
boom does not rise during the combined opera-
tion of travel and boom raise, faulty travel flow
rate control valve may be the cause of the trou-
ble.
Refer to the COMPONENT OPERATION/Control
Valve group in the T/M (Operational Principle).

T5-4-63

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
F-5 Arm speed is slow in a combined operation.
Arm speed is slow during arm level crowd-
ing.

Related Fault Codes: 11, 14, 15, and 16

Refer to the pages for the Arm Regenerative


Control in the SYSTEM / Control System group in
the T/M (Operational Principle).
Disconnect solenoid
valve unit (SC). Con-
nect test harness (ST Faulty solenoid valve
Monitor output from 7123) between sole- YES unit (SC).
solenoid valve unit noid valve unit (SC)
(SC). Install pressure and harness. Check if
gauge to port SC. NO
test harness lamp
Compare pressure comes ON. Broken harness be-
measured by Dr. ZX tween solenoid valve
with that measured by NO unit (SC) and MC.
pressure gauge. Check
NO if both pressure values
vary identically. Perform boom raise and
arm roll-in combined
operation.

YES
Monitor item:
Arm Regenerative Pro-
Check if any fault portional Solenoid Valve
codes are dis- Output
played. Perform boom raise and
arm roll-in combined op-
eration.
Refer to the Operational
Performance Test.
Fault Codes:
11: Pump 2 Delivery
Pressure Sensor Faulty corresponding
14: Pressure Sen- sensor or faulty MC, or
sor (Swing) broken harness be-
15: Pressure Sen- tween MC and sensor.
sor (Boom Raise) YES
16: Pressure Sen-
sor (Arm Roll-In)

NOTE: In case other fault


codes are displayed,
perform trouble-
shooting corre-
sponding to the dis-
played fault code.

T5-4-64

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Faulty arm regen-


YES erative valve.

Check if arm regen- Faulty check valve


erative valve in YES and orifice
4-spool section of (4-spool).
control valve is
scored or bound. Check if check valve
and orifice in control YES
valve (4-spool) parallel Faulty orifice
NO circuit are scored, (5-spool).
seized or blocked. Check if orifice in con-
trol valve (5-spool) arm
NO 1 parallel circuit is
blocked.
Find out cause of
trouble by tracing
NO other trouble symp-
toms.

T5-4-65

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
F-6 Bucket is slow in bucket roll-in single op-
eration. Bucket doesnt move smoothly in
bucket roll-in single operation.

Related Fault Code: None

Faulty bucket flow rate control valve or bucket Faulty bucket regen-
regenerative valve may cause this trouble. erative valve (Disas-
Refer to the COMPONENT OPERATION / Con- semble and clean, or
YES replace.)
trol Valve group in the T/M (Operational Princi-
ple).
Disconnect pipe SL and adapter
connected bucket flow rate control Check if bucket re-
valve (switch valve B) in the con- YES generative valve in
trol valve from bucket flow rate bucket spool is Find out cause of trou-
control valve (switch valve A). bound or scored. ble by tracing other
Connect adapters (PF 1/4) (2 NO trouble symptoms.
used), hoses (2 used), a tee and a
pressure gauge between bucket
NO flow rate control valve (switch
valve A and B).
Check if relief pressure is approx.
2
Check if bucket flow 3.9 MPa (40 kgf/cm ) while per-
forming 3-function combined op- Bound bucket flow rate
rate control valve
eration of boom raise, arm roll-in, control valve (switch
(switch valve B) in
and bucket roll-in. NO valve A) control spool
control valve is
in signal control valve.
bound or scored.

Faulty bucket flow rate


control valve (switch
YES valve B). (Disassem-
ble and clean, or re-
place.)

Bucket Flow Rate


Control Valve
(Switch Valve B)

T1HH-05-04-001

Pipe (SL) Bucket Flow Rate


Control Valve
(Switch Valve A)

T5-4-66

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
F-7 When starting to move in combined opera-
tion, arm doesnt smoothly move. Arm starts
to move slightly slow in arm roll-in single
operation. These troubles often occur when
oil temperature is low.

Related Fault Code: None

Refer to the COMPONENT OPERATION / Con-


trol Valve group in the T/M (Operational Princi-
ple).
Faulty arm regenerative valve
(Disassemble to clean, or
replace.)
YES
Check if arm regenera-
tive valve is bound or
NO scored.
Check if arm anti-drift valve is Find out cause of trouble by
bound or scored. tracing other trouble symp-
toms.
NO

Be sure to check both rod Faulty arm anti-drift valve


side and bottom side. (Disassemble to clean, or
replace.)
YES

T5-4-67

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
F-8 Boom Starting Speed is Slow and/or Jerky
During Combined Operations. During Boom
Lower Single Operation, Boom Speed is
Slightly Slow.

Related Fault Code: None


Refer to the boom regenerative valve and the
boom anti-drift valve in COMPONENT OPERA-
TION / Control Valve group in T/M (Operational
Principle).

Trace the cause of the


trouble by checking
NO other symptoms.

Check if boom regen-


NO erative valve is seized
or scored. Faulty boom regenera-
tive valve. (Clean or
replace boom regenera-
Check if boom YES tive valve.)
anti-drift valve is
seized or scored.

YES Faulty boom anti-drift


valve. (Clean or replace
boom anti-drift valve.)

T5-4-68

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
F-9 When Operating the Control Lever to Raise
Boom or to Roll-out Arm, Boom or Arm
Starts to Move after Slightly Moving in the
Reverse Direction.

Related Fault Code: None

Faulty anti-drift valve.


YES
Check if anti-drift valve for
arm or boom is seized or
YES scored.

Check if load check valve Cylinder internal leakage.


in control valve operates
correctly. NO

Faulty load check valve.


Disassemble and visu-
NO
ally check.

NOTE: 1. During the initial stage of operation, oil


pressure and flow rate from the pump is
low. Therefore, if the load check valve
is malfunctioning, the oil in the bottom
(B)
side of the boom cylinder flows back
into the circuit through the load check
valve, causing the boom cylinder to When the load check
valve is malfunctioning:
temporarily retract. (A)
2. If the clearance between the piston and
the cylinder barrel is poor, oil pressure
in the bottom side (A) leaks to rod side
(B). As oil pressure and flow rate from
the pump is low during the initial stage
of operation, and if the amount of oil
leaking through the gap between the
piston and the barrel is large, the
cylinder is temporarily retracted. In T105-07-04-012

addition, cylinder force is reduced. In


this case, the cylinder drift is also
increased.

T5-4-69

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
F-10 Front Attachment Cylinder Drift is Large.

Related Fault Code: None

YES Normal.

Check if each front NO Close needle valve.


attachment cylin- Check if needle valve
der drift is within in boom 1 section in
the specified value. 4-spool control valve is
NO Check if the symptom
completely closed.
is deleted when the
Check if the cylinder overload valve is tem-
drift is reduced when porarily switched with
pilot shut-off valve is YES one in an other cylin-
closed. der circuit.
NO

Faulty pilot valve.


YES

Needle Valve
Lock Nut

M1HH-05-001

T5-4-70

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Scored spool or damaged


NO spring in control valve or
loose spool end.
Check if internal leak-
NO age exists in cylinder.

Faulty cylinder. (Replace seal


Check if boom or arm kit.)
NO anti-drift valve is seized
or clogged. YES

Faulty anti-drift valve. (Clean


or replace anti-drift valve.)
YES

Faulty overload relief valve.


YES

Boom Cylinder Internal Leakage Check

1. With the bucket cylinder fully retracted and the


arm cylinder slightly extended from the fully
retracted position, lower the bucket tooth tips
onto the ground.

2. Disconnect hoses to the boom cylinder rod side.


Then, drain oil from hoses and cylinders. (Plug
the disconnected hose ports.)

3. Retract the arm cylinder to lift the bucket above


the ground.

At this time, if oil flows out of the pipes from T105-07-04-009

which the hoses were disconnected and the


boom cylinder is retracted, internal leakage in the
boom cylinder exists.
If no oil flows out of the pipes from which the
hoses were disconnected but the boom cylinder
is retracted, internal leakage in the control valve
exists.

T5-4-71

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
SWING SYSTEM TROUBLESHOOTING
S-1 Swing Speed is Slow or Swing Function
Does not Operate.

Related Fault Code: None


Check whether the pilot system is malfunctioning
or the main hydraulic system is malfunctioning.
If other functions (front attachment or travel)
operate normally, the pilot pump is considered to
be normal. If the pilot system is malfunctioning,
the cause of the trouble may exist in the pilot
system after the pilot valve.
When the left travel speed is also slow, refer to
A-2.

Check if swing motor


oil drain amount is
YES normal.

Check if swing relief Measurement: Refer


pressure is normal. to Operational Per-
YES formance Test sec-
Monitor the pump con- tion.
trol pressure. While
slowly operating the Swing relief pressure Faulty swing relief
YES control lever, check if Monitor item: valve.
the pump control pres- Pump 2 delivery pressure NO
sure changes smoothly. Specification:
Refer to Operational Per-
formance Test section.
Possible to display with Seized pump control
Check if the pilot
built-in diagnosing system. valve (5-spool) spool in
secondary pressure Monitor item:
is normal. Pump 2 pump control NO control valve.
pressure
Possible to display
with built-in diagnosing
Specification: system. Faulty pilot valve.
Refer to Operational
Performance Test NO
section.
Monitor item: Swing
control pressure
Possible to display
with built-in diagnos-
ing system.

T5-4-72

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Faulty swing reduction


device.
NO
Check if the switch
valve for swing motor
YES parking brake release
is scored or seized.
Faulty the switch valve
for swing motor parking
YES brake release.

Faulty swing motor.

NO

T5-4-73

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-4-74

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Both Right and Left Travel Side Tracks Do
Not Move or Move Slowly.

Related Fault Code: None

Checking Instructions

Pilot valves, travel motors, control valve spools in


both right and left travel systems are unlikely to
be faulty at the same time.
If both travel systems do not operate, the pilot
system, which is applied to both side travel
motors, may be faulty. If the pilot primary pump
delivery pressure is lower than specification, the
front attachment does not operate as well. Refer
to A-1.
If the travel doesnt change into the fast speed,
refer to T-7.

T-2 When a Combined Operation with Boom


Raise is Made, a Large Shock is Felt.

Related Fault Code: None

Checking Instructions

Travel flow control valve might be seized.


Refer to the Travel Flow Rate Control Vavle in
COMPONENT OPERATION / Control Valve
group in T/M (Operational Principle).

T5-4-75

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
T-3 One Side Track does not Move or Move
Slowly, or the Machine cannot Travel
Straight (Mistracks).

Related Fault Code: None

Checking Instructions
Check if the slack of both track is epual.
If one side system only does not operate, pilot Check if travel motor oil
valve, control valve, travel motor, or center joint YES drain amount is normal.
might be faulty.
Mistracks occur due to faulty pump control. In Check if travel relief
this case, a symptom such as bucket or swing pressure in slow speed Specification: Refer to
function speed is slow in single operation, or arm side system is normal. Operational Perform-
roll-in or boom raise speed is slow is recognized. NO ance Test section.
Refer to A-2 and A-3 if a symptom and mistracks
occur at the same time.
Check if the symptom Relieve travel system.
is reversed when right Monitor item: Pump 1 Switch rear and front or
and left travel line and 2 delivery pres- right and left travel relief
YES hoses connected to top sure valves with each other.
of center joint are Specification: Refer to Check if symptom is
Check if travel pilot switched with each Operational Perform- reversed.
secondary pressure NO
other. ance Test section.
is normal. Possible to display
with built-in diagnosing
system. Bound control valve
spool.
Monitor item: Travel YES
control pressure
Possible to display
with built-in diag- Faulty pilot valve.
nosing system.
NO

Relationship between Faulty Seal Location Seal Location


and Mistrack Direction
Seal When traveling When pivot turn
No. straight: is performed: 1
External Oil
1 Leak
2 2
3
Left Travel Right
3 (Reverse) Travel
(Reverse)
4
Left Travel 5 Right
4 (Forward) Travel
(Forward)
6
5 7

6 T105-07-04-015

External Oil
7 Leak

T5-4-76

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Faulty travel motor.


NO

Disassemble and clean YES Faulty travel reduction


travel motor servo pis- gear.
YES ton. Check if same
Disassemble and clean problem occurs again.
Faulty travel motor
travel motor counter-
servo piston.
balance. Check if same
problem occurs again. NO
YES
Faulty counterbalance
valve.
NO

Faulty center joint.


NO

Faulty travel relief


valve.
YES

Pipe Layout

1 2 Front

5 4 W157-03-03-003

1 - Left Travel (Forward) 3 - Pilot 5 - Left Travel (Reverse) 6 - Drain


2 - Right Travel (Forward) 4 - Right Travel (Reverse)

T5-4-77

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
T-4 During a Combined Operation of Travel and
Front Function, the Machine Mistracks.

Related Fault Code: None Faulty load check valve.


YES
Check if load check
YES valve is normal.
Check if flow com- Trace the cause of the
biner valve in con- trouble by checking other
trol valve is normal. NO symptoms.

Faulty flow combiner valve.

NO

T-5 Occasionally, machine mistracks when


traveling with engine running at slow speed.

Related Fault Codes: 10, 11, and 18

Refer to the pages for the Slow Speed Torque In-


crease Control in the SYSTEM / Control System
group in the T/M (Operational Principle).
Check for loose harness connections before-
hand. Faulty corresponding
sensor or broken har-
ness between MC and
YES corresponding sensor.

Check is any fault Monitor output pressure


code is displayed. from torque control sole-
Faulty pump device.
noid valve. Install pres- YES
sure gauge to torque
control solenoid valve
Fault Codes: output port. Check if both
10: Pump 1 Deliv- pressures measured by Faulty torque control
ery Pressure Sen- pressure gauge and Dr. solenoid valve or MC, or
NO ZX varies identically by
sor YES broken harness between
approx. 1.5 MPa (15 Monitor travel pilot torque control solenoid
11: Pump 2 Deliv- 2
kgf/cm ) when travel op- pressure. Check if valve and MC.
ery Pressure Sen-
eration is made. pressure varies in
sor
response to travel
18: Pressure Sen-
NO lever operation.
sor (Travel)
Possible to display
with built-in diag- Faulty pressure sensor
nosing system (travel).
NO
Monitor item: Monitor item:
Pump Torque Propor- Travel Control Pilot
tional Solenoid Valve Pressure
Output
Engine:
Running at slow idle
speed

T5-4-78

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
T-6 No steering force and no grade ability when
travel mode is Fast.

Related Fault Code: None

Monitor travel motor swash


angle control. Find out cause of trouble
Connect a pressure gauge to NO by other symptoms.
port SI in solenoid valve unit
and operate travel and travel
relief.
Check if the pressure
changes with both pressures
of Dr.ZX and the pressure
gauge are equal. Seized solenoid valve unit
(SI).
YES

Monitor item: Travel motor


control pressure
Travel mode: Fast
How to Travel: Refer to Opera-
tional Performance Test.

T5-4-79

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
T-7 Fast travel is inoperable.
Travel mode doesnt change from slow
mode to fast mode.

Related Fault Codes: 10, 11, 12, and 13

Refer to the pages for the Travel Motor Swash


Angle Control in the SYSTEM / Control section in
the T/M (Operational Principle).
Check for loose harness connections before- Faulty travel mode switch or
hand. broken harness between
travel mode switch and MC.
NO

Monitor travel mode


switch. Check if dis- Check if symptom is re-
played indication is versed when pressure sen-
highlighted in response NO sor (travel) is switched with
NO to travel mode switch another pressure sensor.
operation.

Monitor pressure sen-


sor (travel). Check if
Monitor: Travel mode pressure varies in
response to travel Monitor travel motor
YES lever operation. swash angle. Install pres-
sure gauge to solenoid
Check if any fault valve unit (SI) output port.
codes are displayed. Check if pressure meas-
Monitor: Travel control ured by Dr. ZX varies iden-
pressure tically with pressure
Possible to display with measured by pressure
built-in diagnosing sys- YES gauge while repeating to
tem. travel and stop.

Monitor:
Travel motor control pres-
sure
Travel mode: Fast
Measurement: Refer to
OPERATIONAL PER-
FORMANCE TEST section.

Faulty corresponding sen-


sor or broken harness be-
YES tween MC and sensor.

Fault Codes:
10: Pump 1 Delivery Pressure Sensor
11: Pump 2 Delivery Pressure Sensor
12: Pump 1 Control Pressure Sensor
(4-Spool)
13: Pump 2 Control Pressure Sensor
(5-Spool)

NOTE: In case other fault codes


are displayed, perform
troubleshooting corre-
sponding to the displayed
fault code.

T5-4-80

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Faulty pressure sensor


YES (travel).

Broken harness between


travel pressure sensor
(travel) and MC.
NO

Disconnect solenoid
valve unit (SI). Connect Faulty solenoid valve unit
YES (SI).
test harness (ST 7123)
between solenoid valve
NO unit (SI) and harness.
Check if test harness Broken harness between
lamp comes ON. solenoid valve and MC.
NO

YES Faulty travel motor swash


Travel Mode: Fast angle control valve.
Check if travel motor
YES swash angle control
valve is bound or Faulty travel motor or travel
scored. NO reduction gear.

T5-4-81

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
OTHER SYSTEM TROUBLESHOOTING
O-1 Wiper is inoperable or not retracted.

Related Fault Code: None

Checking Instructions

The wiper is driven by electric power routed via If the front window is open, the wiper wont oper-
the relay circuit controlled by the monitor assem- ate. Check that the front window is securely
bly. In case the wiper is inoperable, first check closed.
the wiper motor and links for any abnormality us-
ing an auxiliary electric power and the test har-
ness. Faulty front window
open/close switch or
short-circuited harness
between front window
YES open/close switch and
monitor.

Disconnect front win-


dow open / close Remove test harness
switch. Check if wiper and reconnect circuit to
YES Faulty wiper relay.
operates. the original position.
Replace wiper relay
Connect test harness YES one at a time to see if
(ST 7227) between wiper operates.
auxiliary electric power
Key switch: ON
(fuse box #19) and To A
wiper motor as illus- NO
trated to the right.
Check if wiper oper-
NO Key switch: ON
ates.

Faulty wiper motor or


links.
NO or test har-
Key switch: ON
ness lamp doesnt
light normally.
NOTE: When the wiper motor
is normal, lamp S lights while
the wiper is moving within the
operating range. Both lamps B
and S light for a moment at the YES End (Faulty monitor).
Replace monitor as-
same time only when the wiper sembly to see if wiper
reaches the intermittent stop A operates.
position.
Faulty cab harness.
NO

T5-4-82

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Test Harness Application Circuit


Fuse Box #19

Lamp S
M B 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

T5-4-83

PDF created with pdfFactory Pro trial version www.pdffactory.com


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 be-
low: 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 Fahr-
enheit Temperature Indication.

Normal Operation

Turn key switch ON while pressing air


conditioner switch and mode switch.

Keep pressing OFF switch


for more than 3 seconds. STEP 0
Check Model Confirmation

Press lower side fan switch. Press upper side fan switch.
Keep pressing OFF switch STEP 1
for more than 3 seconds. Display Function Con-
firmation

Press lower side fan switch. Press upper side fan switch.
Keep pressing OFF switch STEP 2
for more than 3 seconds. Present Trouble
Diagnosing

Press lower side fan switch. Press upper side fan switch.

Keep pressing OFF switch STEP 3 Keep pressing air conditioner


for more than 3 seconds. Past Trouble Di- switch for more than 3 seconds.
agnosing

Press lower side fan switch. Press upper side fan switch.
Keep pressing OFF switch
for more than 3 seconds. STEP 4
Sensing Temperature
Display

Press lower side fan switch. Press upper side fan switch.
Keep pressing OFF switch
for more than 3 seconds. STEP 5
Component Operation Check

Press AUTO switch and Press AUTO Press A/C Press A/C switch and
lower side fan switch. Switch and switch and upper side fan switch.
upper side lower side
fan switch. fan switch.
Keep pressing OFF switch STEP 6-1 STEP 6-2
for more than 3 seconds. Correction of the Set Selection of Celsius and Fahrenheit
Temperature Temperature Indication
Keep pressing OFF switch
for more than 3 seconds.

Self-Diagnosis

T5-4-84

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
Self-Diagnostic System Activation
Fan Switch LCD Air Conditioner Switch
Turn the key switch ON while pressing the air condi-
tioner switch and mode switch on air conditioner
control panel.

STEP 0 Check Model Confirmation


The liquid crystal display (LCD) indicates the ma-
chine model name this system can diagnose. T178-05-08-001

Mode Switch OFF Switch


The LCD will indicate Sd as the check model
name.
(ZAXIS330, 350H, 350K and 370MTH)
Select next step to be performed by operating the
switch as described below.
Upper side fan switch: To proceed to Step 1
Keep pressing OFF switch for more than 3 sec-
onds: To return to normal operation
NOTE: The system operation will automatically
proceed to STEP 1 after 5 seconds have
passed after the check model is displayed.

STEP 1 Display Function Confirmation


Turn all indicators ON to check indicator bulbs.

The LCD panel and all switch indicators light.


Select the next step to be performed by operating
the switches as follows:
Press the upper side of the fan switch: To pro-
ceed to STEP 2.
Press the lower side of the fan switch: To return
to STEP 0.
Keep pressing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed)

T5-4-85

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
STEP 2 Present Trouble Diagnosing
The LCD indicates the fault codes for present ab-
Fan Switch LCD
normalities of the mix door, mode encoder, and/or
sensors.

In case any abnormalities are present, the LCD in-


dicates the fault codes. If more than one fault code
is detected, the following fault code is displayed af-
ter flashing (0.5 seconds) twice.
Fault Code T178-05-08-001
Breakage Short Circuit OFF Switch
Mix Door 21 21
Mode Encoder 22
In-Cab Ambient 23 23
Temperature Sen-
sor
Outdoor Ambient 24 24
Temperature Sen-
sor
Coolant Tempera- 25 25
ture Sensor
Solar Radiation 26 26
Sensor
: When solar radiation is shaded, the solar radiation
sensor indicates the fault code of breakage.
Select the next step to be performed by operating
the switches as follows:
Press the upper side of the fan switch: To pro-
ceed to STEP 3.
Press the lower side of the fan switch: To return
to STEP 1.
Keep pressing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed)

T5-4-86

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
STEP 3 Past Trouble Diagnosing
The LCD indicates the fault codes for past abnor-
Fan Switch LCD Air Conditioner Switch
malities of the mix door, mode encoder, and/or sen-
sors.
The past stored fault codes are deleted.

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 dis-
played after flashing (0.5 seconds) twice. T178-05-08-001
Fault Code OFF Switch
Breakage Short Circuit
Mix Door 21 21
Mode Encoder 22
In-Cab Ambient
Temperature Sen- 23 23
sor
Outdoor Ambient
Temperature Sen- 24 24
sor
Coolant Tempera- 25 25
ture Sensor
Solar Radiation 26
Sensor
When the air conditioner switch is kept pressed for
more than 3 seconds, failure records are deleted.
After this operation, the air conditioner switch indi-
cator flashes 5 times. Then, the self-diagnosing
system is deactivated. (Normal functions are re-
sumed.)
Select the next step to be performed by operating
the switches as follows:
Press the upper side of the fan switch: To pro-
ceed to STEP 4.
Press the lower side of the fan switch: To return
to STEP 2.
Keep pressing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed)

T5-4-87

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
STEP 4 Sensing Temperature Display
The LCD indicates the sensing temperature detected
Fan Switch Fan Mark LCD Air Conditioner Switch
by each temperature sensor (excluding the insulation
sensor).

The sensing temperature detected by the in-cab


ambient temperature sensor, outdoor ambient tem-
perature sensor, and coolant temperature sensor
are displayed on the LCD in real time. (Figures less
than the decimal point are not displayed.) T178-05-08-001

NOTE: The coolant temperature sensor indicates Fresh Air Vent Switch OFF Switch
H when coolant temperature is more than
21 C (70 F) and L when coolant tem-
perature is less than 21 C (70 F).
Sensing temperature detected by each sensor is
automatically displayed on the LCD and is cycled at
an interval of 3 seconds with the timer. The timer is
turned ON or OFF by operating the fresh air vent
switch.
Referring to the fan mark can check which sensing
temperature is displayed.
Select the next step to be performed by operating
the switches as follows:
Press the upper side of the fan switch: To pro-
ceed to STEP 5.
Press the lower side of the fan switch: To return
to STEP 3.
Keep pressing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed)

T5-4-88

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
STEP 5 Component Operation Check Air Conditioner
Fan Switch LCD Switch AUTO Switch
Each component operation is checked by performing
pattern operation.

Each time the fresh air vent switch is pressed, the


component to be checked is selected in order.
Check which component has been selected by re-
ferring to No. indicated on the LCD. (See table 1.)
Operating pattern of the selected component is T178-05-08-001
shifted at an interval of 10 seconds. Operating pat-
Fresh Air Vent switch OFF Switch
tern is cycled. (See table 1.)
NOTE: The components other than selected oper-
ate under the standard conditions (shown
by marks* in table 1).
Select the next step to be performed by operating
the switches as follows:
Press the AUTO switch and upper side of the fan
switch: To proceed to STEP 6-1.
Press the A/C switch and upper side of the fan
switch: To proceed to STEP 6-2.
Press the lower side of the fan switch: To return
to STEP 4.
Keep pressing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed)

Table 1
Component Indication Operation Pattern Remarks
on LCD
Air Mix Damper 51 Controls opening extent of air mix 0%, 50%, 100%: C, 5, and H are
damper: 0% (fully closed) indicated next to the decimal point
50%* 100% (fully opened) respectively.
Fan 52 Controls air flow volume: Lo Indicators corresponding to air flow vol-
M(Lo) M(Hi) Hi ume light.
Air Vent Loca- 53 Selects air vent: Front* Indicator corresponding to selected air
tion Front/Rear Front/Foot Foot vent lights.
Fresh/Circula-tio 54 Select Ventilation Mode: Circula- Indicator corresponding to selected
n Air Vent Selec- tion* Fresh mode light.
tion
Air Conditioner 55 Turns air conditioner switch: ON* ON: Indicator lights.
OFF OFF: Indicator is extinguished.

T5-4-89

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
STEP 6-1 Correction of the Set Temperature
Fine correction of the set temperature. Temperature
Fan Switch LCD Control Switch AUTO Switch

Each time when the top or bottom of the tempera-


ture control switch is pressed, temperature correc-
tion, displayed on the LCD window, can be
changed.
Actually controlled temperature is the normally set
temperature plus the set temperature correction.
For instance, when the normally set temperature is T178-05-08-001

25C (77 F) and set temperature correction is -1C OFF Switch


(-34 F), the actually controlled temperature be-
comes 24C (75 F).
Select the next step to be performed by operating
the switches as follows:
Press the AUTO switch and lower side of the fan
switch: To return to STEP 5.
Keep pressing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed)

T5-4-90

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
STEP 6-2 Selection of Celsius and Fahrenheit
Temperature Indication
Fan Switch LCD Air Conditioner Switch
Selection of Celsius and Fahrenheit Temperature In-
dication.
Each time when the fresh air vent switch is pressed,
Celsius or Fahrenheit temperature may be dis-
played alternately.
Temperature is displayed at the top of the LCD
window as follows.
(C: Celsius, F: Fahrenheit) T178-05-08-001

C F Fresh Air Vent Switch OFF Switch

Select the next step to be performed by operating


the switches as follows:
Press the Air Conditioner Switch and lower side
of the fan switch: To return to STEP 5.
Keep pressing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed)

T5-4-91

PDF created with pdfFactory Pro trial version www.pdffactory.com


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 machines air conditioning system.
AIR CONDITIONER TROUBLE REPORT File No
(1) What
Checked by:
Model (Serial No. )
Operation Type Manual Semi-Auto Full-Auto
Delivery Date Year Month
(2) When
Date Year Month Day Operating Hour ( h)
Time Morning Daytime Evening Night
Frequency Every Day Once a Week Once a Month Times per
(3) Where
Job Site Address State County Town
Access Road Condition Paved Not Paved (Gravel Sand Soil)
(4) How (Operating Conditions)
Weather Fine Cloudy Rain Snow
Atmospheric Temperature Very Hot Hot Cold Very Cold
Operating Conditions Parking Traveling Working
Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when
full-auto operation
A/C ON OFF
Control Air Induction Re-Circulation Fresh Air Circulation
Panel AUTO ON OFF Not Available
Fill following items when operated in manual mode or when manual control type unit is used.
Vent Position Front Front / Rear Foot Front / Rear and Foot
Fan First Second Third Fourth Fifth Sixth
(5) How (Problem Symptom)
Abnormal Compressor Operation
Symptom Not turned ON Check Result
Not turned OFF (1) Is problem reproducible ?
Others Reproducible
Uncontrollable air temperature Not reproducible
Symptom No cool air (2) Pressure (To be measured at gauge manifold)
Low Pressure
No warm air
High Pressure
Others
(3) Which parts have been replaced ?
Uncontrollable air volume
1
Symptom Air flows in Hi mode only
No air flows
2
Small air volume
Others
Before replacing the control amplifier, be sure to
Uncontrollable vent hole
check that the connectors are correctly connected
Symptom Vent hole isnt selected
while repeatedly disconnecting and reconnecting
Others connectors.
Abnormal panel indication
Faulty Indicator Vent Hole
A/C
AUTO
Fresh Air Circulation
Fan OFF
Fan (Lo Hi)
Temperature Control
Symptom Stays OFF
Stays ON
Blinks
Others

T5-4-92

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Refrigerant Quantity ....................... 1100o50 g


Compressor Oil Quantity................ 210 cm3

T5-4-93

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Refrigerant pressure Bubbles can be seen in sight Piping and/or parts are stained with oil,
in both high and glass. respond to gas detector.
low-pressure sides is
low.
No oil stain is found or gas detector
doesnt respond. Refrigerant has not
been refilled for longer than one sea-
son.
No bubbles are seen in sight
glass.

After cooling at fast speed continu-


ously, cooling power is reduced. Air
flow volume remains unchanged.

Air flow volume is reduced.

Refrigerant pressure
in low-pressure side Bubbles can be seen in sight Compressor cylinder is extremely hot,
Insuffi- is high. glass. emitting a smell.
cient
Cooling
Power
Refrigerant pressure in Compressor cylinder is extremely hot,
high-pressure side is low. emitting a smell.

Heater unit emits hot air.

Refrigerant pressure
in high-pressure side Bubbles can be seen in sight Refrigerant pressure in low-pressure
is high. glass. side is low.

Condenser is stained and clogged.

Even if condenser is sprayed with water, few bubbles appear. Receiver dryer tem-
perature is low.

After cooling at fast speed continu-


ously, cooling power is reduced. Air Frost forms. Thermistor doesnt cool.
flow volume is reduced.

Thermistor cools.

T5-4-94

PDF created with pdfFactory Pro trial version www.pdffactory.com


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 Readjust or replace expansion valve.


valve.

Clogged expansion valve. Remove clog, or replace receiver and/or expansion


valve.

Clogged low-pressure circuit and/or evaporator. Remove clog, or replace parts.

Frozen expansion valve or water in circuit. After evacuation, refill refrigerant and/or replace re-
ceiver dryer.

Gas leaks from case. Seal gaps using vinyl tape or packing compound.

Poor contact of expansion valve temperature sensing cylinder. Make good contact. Replace temperature sensing
stay.

Improper adjustment (excessive open) of expansion valve. Readjust or replace.

Insufficient compressor discharge (faulty gasket and/or valve). Replace.

Improper water stop valve wire adjustment and/or faulty stop


valve. Check and readjust or replace.

Poor airtight fitting of outside air damper (outside air induction


Repair.
type).

Clogged high-pressure circuit before receiver dryer. Remove clog, or replace parts.

Clean Condenser.

Excessive refrigerant. Remove excessive refrigerant to proper level.

After evacuation, refill refrigerant and/or replace re-


Air is mixed in system.
ceiver dryer.

Incorrect thermistor location. Correct thermistor location.

Gas leaks from case. Seal gaps using vinyl tape or packing compound.

Faulty thermistor (stays ON). Disconnected thermistor cord.

Even if function and performance are normal, when Instruct user on correct air-conditioner operation.
air-conditioner is kept operated for a long time with thermistor (Reset thermistor to either minimum or middle cooling
in max. cooling position and air flow in M or L mode, frost may position or increase air flow.)
form.

T5-4-95

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
Cooling Circuit

Case connection. Louver resonance.

Fan contacts case, or foreign matter enters case.


Blower fan connection.
Brush friction noise, metal and/or thrust washer con-
tact noise.

Gas blowing sound (roaring). Gas vibration noise (compressor discharge and/or
suction gas noise).

Expansion valve connection, whistle Abnormal noise from expansion valve (Expansion
Noise sound, gas blowing sound. valve is normally functioning.).

Faulty clutch bearing, and/or idle pulley bearing.

Clutch disengaging sound.


Contact of clutch amature due to resonance, or loose
belt and/or screws.

Noisy compressor.
Compressor rotating sound.
Vibration and/or loose screws due to excessive drive
belt looseness.

Broken heater core and/or hose.


Water leak and/or splash.
Clogged case drain port and/or drain hose.
Others

Absorbed cigarette and dust smell on evaporator fins.


Abnormal smell.

T5-4-96

PDF created with pdfFactory Pro trial version www.pdffactory.com


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. 1500 min in
L mode for more than 10 minutes, flush smell out by condensed water.

T5-4-97

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
Compressor

Compressor doesnt rotate. Clutch terminal voltage is normal 24 V.

Inoperable
cooling Clutch terminal voltage is low.
system.

Clutch terminal voltage is 0 V.

Bubbles exist even after refrigerant is refilled.

Both high and


low side Check for oil and refrigerant leaks from parts other than
pressures are compressor and pipe joints using gas detector.
low.
Both com- Check for oil and refrigerant leaks from compressor (no
pressor and leaks from parts other than compressor) using gas de-
blower mo- tector. (Refer to NOTE 2 on page T5-4-101.)
tor rotate.
Stain on exterior.
(Refer to NOTE 1
on page T5-4-101.)

Refrigerant has not been refilled for longer


than one season.

Refrigerant is discharged within 1 to 2


months after being recharged. Check for
refrigerant leaks using gas detector.

Refrigerant is kept charged for longer than


2 years.

Compressor cylinder is not hot. (Refrigerant returns to com-


High pressure side is pressor in liquid form.)
slightly low and low pres-
sure side is high.
No refrigerant returns in liquid form. High pressure side is low.

Bubbles can be seen through Others


sight glass.
High pressure side is high.
Refer to the Cooling Circuit Troubleshooting
Table on page T5-4-94.
Temperature is not cooled when compressor is
operated at fast speed continuously.

Air flow from blower is insufficient.

T5-4-98

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Seized clutch. Replace.

Improper gap between amature and rotor (improper air gap).


Replace.
Broken or short-circuited core cable.

Shaft doesnt 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. Replace.

Normal leaks from hoses. Charge refrigerant.

No leaks (normal).

Refer to the Cooling Circuit Troubleshooting Table on page T5-4-101.

Broken valve (See NOTE 3 on page T5-4-101.)

Replace.
Blown gasket (See NOTE 3 on page T5-4-101.)

Check and adjust


Excessive oil. oil level.

T5-4-99

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
Compressor

Compressor rotation is abnormally draggy.


Overheating
is susceptible
to occur.

Trouble other than compressor. Refer to the Cooling Circuit Troubleshooting Ta-
ble on page T5-4-94.

Noise is heard when clutch is OFF.

Abnormal
noise

Noise is heard when clutch is ON.

T5-4-100

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Broken clutch bearing due to overly tightened belt. Replace.

Shaft doesnt 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


Saggy belt. Troubleshooting Table on
page T5-4-94.

Loose screws.

Broken valve.

Replace.
Blown gasket.

Abnormal internal noise. Replace.

Vibration due to saggy belt.


Refer to the Cooling Circuit
Troubleshooting Table on
Loose screws. page T5-4-94.

NOTE:
1. Dont quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A
slight oil seepage will appear due to the seal construction. However, this oil seepage will not
cause malfunction. Be sure to accurately check whether oil is leaking or seeping only.
2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose sur-
face may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
2
high-pressure side and low-pressure side is 0.49 MPa (5 kgf/cm ) or less. When the clutch is
turned OFF, the pressure difference between high-pressure side and low-pressure side will dis-
appear within about 10 seconds.

T5-4-101

PDF created with pdfFactory Pro trial version www.pdffactory.com


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.
Pump 2 Pump 1
Many sensors and solenoid valves used on this ma- (5-Spool (4-Spool
chine are identical. Therefore, using this switch-check Section) Section)
method, faulty part /component, and/or harness can
be easily found.
PP2 PP1
Example: Abnormal pump 1 delivery pressure (Fault
code: 10)

Check Method:
1. Switch two delivery pressure sensors located as
Figure A
shown in figure A to figure B.
2. Retry troubleshooting. T157-07-04-006

Result:
In case the pump 2 delivery pressure is abnormal
(fault code 11), the pump 1 delivery pressure sensor
is considered to be faulty.

In case the pump 1 delivery pressure is abnormal Pump 2 Pump 1


(5-Spool (4-Spool
(fault code 10), the pump 1 delivery pressure sensor Section) Section)
harness is considered to be faulty.

PP1 PP2

Figure B T157-07-04-006

T5-4-102

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B

Applicability of Switch-Check Method


Fault Code Trouble Applicability
01 Abnormal EEPROM Not Applicable
02 Abnormal RAM
03 Abnormal A/D Conversion
04 Abnormal Sensor Voltage
06 Abnormal EC Angle Sensor Not Applicable
07 Abnormal EC Dial Not Applicable
08 Abnormal Boom Angle Sensor Not Applicable
10 Abnormal Pump 1 Delivery Pressure Applicable (Harness)
11 Abnormal Pump 2 Delivery Pressure
12 Abnormal Pump 1 Control Pressure Applicable (Harness)
13 Abnormal Pump 2 Control Pressure
14 Abnormal Swing Pilot Pressure Applicable (Harness/Sensor)
15 Abnormal Boom Raise Pilot Pressure
16 Abnormal Arm Roll-In Pilot Pressure
18 Abnormal Travel Pilot Pressure
19 Abnormal Hydraulic Oil Temperature Not Applicable
Sensor

T5-4-103

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting B
EMERGENCY BOOM LOWERING PRO-
CEDURE 2

If the engine stalls and cannot be restarted, lower the


boom to lower the bucket to the ground referring to
the emergency boom lowering procedure stated be-
low.

1. Loosen lock nut (1).


: 17 mm

CAUTION: Gradually loosen the needle


valve checking the front attachment, other-
wise the boom falls down.
Be sure not to loosen it more than 4 turns, or
the hydraulic oil spurts. Front
2. Gradually loosen needle valve (2) checking the Attachment Side
front attachment. T1HH-01-02-005

: 6 mm
2 1
3. After the front attachment is lowered completely,
tighten needle valve (2).
: 6 mm
: 7.9 N m (0.8 kgf m, 5.8 lbf ft)

4. Tighten lock nut (1).


: 17 mm
: 41 N m (4.2 kgf m, 30 lbf ft)

M1HH-05-001

T5-4-104

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C (TROUBLE-
SHOOTING FOR MONITOR) PROCEDURE
Use troubleshooting C when any monitors, such as
gauges or indicators malfunction.

How to Read Troubleshooting Flow Charts

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

NO (NOT OK) (3)

Instructions, reference, and/or instruction methods on inspection and/or measurements


are occasionally described under the box. If incorrectly checked or measured, not only
Key switch: ON will troubleshooting be unsuccessful but also damage to components may result.

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

NOTE: All harness end connector are seen from


the open-end side.

Wire Harness Side

Open End
Side
Harness End Connector
T158-05-03-001

T5-5-1

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF COOLANT TEM-
PERATURE GAUGE
Check for loose harness connections beforehand.

Disconnect coolant Faulty coolant temperature


YES sensor.
temperature sensor.
Ground harness end
Gauge pointer terminal to vehicle
doesnt move frame. Check if pointer Without connecting coolant
at all. swings to (H) side. temperature sensor, remove Faulty monitor.
connector B (20P) from moni- YES
tor. Check for continuity be-
tween monitor harness end
connector terminal #18 and
NO coolant temperature sensor Broken harness between
Key switch: ON terminal. monitor and sensor.
NO

Faulty coolant temperature


YES sensor.
Disconnect coolant
Gauge pointer temperature sensor.
swings over Check if pointer returns Without connecting coolant Short-circuited harness be-
scale. to zero. temperature sensor, remove tween monitor and sensor.
YES
connector B (20P) from moni-
tor. Check for continuity be-
tween monitor harness end
terminal #18 and vehicle
NO
frame. Faulty monitor.
Key switch: ON
NO

Disconnect coolant
temperature sensor. Faulty coolant temperature
YES sensor.
Ground harness end
Gauge pointer terminal to vehicle
keeps moving frame, Check if pointer
unstably. swings and is stabi-
lized to (H) side.

Faulty monitor.
NO

Key switch: ON

T5-5-2

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C

Coolant Temperature Gauge Board

105 C
(95

70 C

T157-07-05-001

Coolant Temperature Sensor

Coolant Temperature Resistance (k )


pC (pF)
25 (77) 7.6o0.76
40 (104) 4.0o0.35
50 (122) 2.7o0.22
80 (176) 0.92o0.07
95 (203) 0.56o0.04
105 (221) 0.42o0.03
120 (248) 0.28o0.01

Connector (Harness end connector terminals seen


from the open end side)
Monitor Connector B (20P)

10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11

T5-5-3

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF FUEL GAUGE
Check for loose harness connections beforehand.

Disconnect fuel sensor. YES Faulty fuel sensor.


Connect harness end con-
nector terminal #1 to
Fuel gauge terminal #2 using jumper
pointer doesnt wire such as clip. Check if Without connecting fuel
move at all. pointer swings to (FULL) sensor, remove connec-
side. tor B (20P) from monitor. YES Faulty monitor.
Check for continuity be-
tween monitor terminal
#19 and fuel sensor ter-
NO minal #1. Broken harness between
monitor and sensor.
Key switch: ON NO

YES Faulty fuel sensor.

Disconnect fuel sensor.


Fuel gauge pointer Check if pointer returns to Without connecting fuel
swings over scale. zero. sensor, remove connector Short-circuited harness be-
B (20P) from monitor. YES tween monitor and sensor.
Check for continuity be-
tween monitor harness
Key switch: ON end terminal #19 and ve-
NO hicle frame.
Faulty monitor.
NO

Disconnect fuel sensor.


Connect harness end con- YES Faulty fuel sensor.
nector terminal #1 to
Fuel gauge pointer terminal #2 using jumper
keeps moving un- wire such as clip. Check if
stably. pointer swings and is stabi-
lized to (FULL) side.

Faulty monitor.
NO

Key switch: ON

T5-5-4

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C

Fuel Sensor

Float

FULL

R381.9 mm

257 mm 3/4

93 mm

70.5 mm

1/2
204 mm

338 mm 1/4

EMPTY
T178-05-05-001

NOTE: 1 mm = 0.03937 in

Float Position Resistance ( )


Upper Limit (FULL) 10+0-4
3/4 26
1/2 38o5
1/4 53
Warning Level 85o3
Lower Limit (EMPTY) 90+10-0

Connector (Harness end connector terminals seen


from the open end side)

Monitor Connector B (20P) Fuel Sensor

10 9 8 7 6 5 4 3 2 1
1 2
20 19 18 17 16 15 14 13 12 11

T5-5-5

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF INDICATOR LIGHT
CHECK SYSTEM
Check for loose harness connections beforehand.
Burnt fuse or faulty monitor.
Disconnect monitor con- YES
nector C. Check if there is
continuity between harness
YES end connector terminal
#1(power input) and fuse
Indicator doesnt box terminal #5(switch box). Broken harness between
light when indicator Check if all in- fuse and monitor.
light check operation dicators dont
is performed. light. NO

Conduct troubleshooting of
each indicator, which does
NO not light.

Connector (Harness end connector terminals seen


from the open end side)

Monitor Connector C (20P)

10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11

T5-5-6

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF PREHEAT INDICATOR
The preheat system operates only when coolant In case the preheat system malfunctions, refer to
temperature is below 10 pC (50 pF), lighting the the troubleshooting B for E-16 Engine is difficult to
preheat indicator for 8 seconds. (Refer to the start at low temperature.
SYSTEM /Electrical Circuit group.) Check for loose harness connections beforehand.

Remove connector
(with black and Faulty coolant tem-
white cables) from YES perature switch.
Preheat indicator
coolant tempera-
lights even though
ture switch. Check
preheat system
if indicator goes Faulty QOS con-
doesnt operate YES
OFF by grounding troller.
(coolant tempera-
harness end con-
ture is more than
nector to vehicle Without connecting
10 pC (50 pF)).
frame. Disconnect QOS QOS controller, re-
move connector B Short-circuited har-
controller. Check if
(20P) from monitor. ness between QOS
indicator goes YES
Check for continuity controller and moni-
OFF.
NO between monitor tor.
harness end con-
NO nector terminal #20
and vehicle frame.
Key switch: ON
Key switch: ON Faulty monitor.
NO

Remove connector Faulty coolant tem-


Preheat indicator YES perature switch.
doesnt light al- (with black and
though preheat white cables) from
system operates coolant tempera-
ture switch. Check YES Faulty QOS control-
(coolant tempera-
if indicator comes ler.
ture is lower than Disconnect QOS
10 pC (50 pF)). ON. controller. Check if
indicator comes Ground monitor
ON by grounding connector B (20P) Broken harness
harness end con- terminal #20 to ve- between QOS con-
hicle frame. Check YES
nector terminal #6 troller and monitor.
NO to vehicle frame. if indicator comes
ON.
Key switch: ON NO
Faulty monitor.
NO
Key switch: ON
Without discon-
necting connector,
ground connector
Connector (Harness end connector terminals seen to vehicle frame
using jumper wire
from the open end side)
such as clip from
reverse side of
Monitor Connector B (20P) QOS Controller connector.

10 9 8 7 6 4 3 2 1 1 2 3
20 19 18 17 14 13 12 11 4 5 6

T5-5-7

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE OIL LEVEL
INDICATOR
(Up to serial No. 030652)

Check that indicator light is not burned out.


Check that all other indicators work correctly.
Check that machine is parked on level surface.
Check for loose harness connections beforehand.

Without connecting
connector to engine oil Short-circuited harness be-
level switch, remove tween engine oil level switch
YES and monitor.
connector B (20P) from
monitor. Check for con-
Check if indicator NO tinuity between monitor
lights by removing harness end connector
connector (with terminal #8 and vehicle
Indicator doesnt frame. Faulty monitor.
light even if engine black and white ca-
ble) from engine oil NO
oil level is lower
than specification. level switch.

Faulty engine oil level switch.


YES

Without connecting
connector to engine oil
level switch, remove
connector B (20P) from
monitor. Check for con-
Remove connector tinuity between monitor
(with black and white NO harness end connector To A
cables) from engine oil terminal #8 and engine
Lower than 3.5 mm level switch. Check if oil level switch connec-
below LOW level mark indicator goes OFF by tor.
on oil level gauge grounding harness
end connector to vehi-
cle frame.
Indicator comes ON
even if engine oil
level matches Check oil level with
specification. oil level gauge. Faulty engine oil level switch.
YES

Normal (Lack of engine oil).


Above 3.5 mm
below LOW level mark
on oil level gauge

YES Faulty monitor.

A
Broken harness between en-
gine oil level switch and moni-
NO tor.

T5-5-8

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C

Engine Oil Level Switch


Oil Level
Gauge Engine Oil Level
Switch

ON

H A (Indicator ON)

L
(Indicator OFF)

OFF
A: 3.5 mm
T107-04-03-010

Connector (Harness end connector terminals seen


from the open end side)

Monitor Connector B (20P)

10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11

T5-5-9

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF COOLANT LEVEL IN-
DICATOR
(Up to serial No. 030652)

Check that indicator light is not burned out.


Check that all other indicators work correctly.
Check that machine is parked on level surface.
Check for loose harness connections beforehand.
Without connecting
connector to coolant Short-circuited harness be-
level switch, remove tween coolant level switch and
connector B (20P) YES
monitor.
from monitor. Check
NO for continuity between
Check if indicator monitor harness end
Indicator doesnt lights by removing connector terminal #9
light even if coolant connector (with and vehicle frame. Faulty monitor.
level is lower than gray cable) from NO
specification. coolant level switch.

Faulty coolant level switch.


YES

Without connecting
connector to coolant
level switch, remove
connector B (20P) from
monitor. Check for con-
tinuity between monitor
Remove connector NO harness end connector
(with gray cables) from terminal #9 and coolant To A
coolant level switch. level switch connector.
Check if indicator goes
OFF by grounding
harness end connec-
NO tor terminal #1 to vehi-
cle frame.

Indicator comes ON Check if coolant


even if coolant level level in coolant res-
matches specifica- ervoir is lower than
tion. LOW mark. Faulty coolant level switch.
YES

Normal (Lack of coolant).


YES

YES Faulty monitor.

A
Broken harness between
coolant level switch and moni-
NO tor.

T5-5-10

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C

Coolant Level Switch

Reserve Tank

ON
FULL

LOW

Radiator OFF

Coolant Level Switch


T107-04-03-012

Connector (Harness end connector terminals seen


from the open end side)

Coolant Level Switch


Monitor Connector B (20P)

10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 1 2

T5-5-11

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ALTERNATOR INDI-
CATOR
Check for loose harness connections beforehand. NOTE: *Regulator terminals L are water-resistant
type connectors so that it is not practical to
measure voltage at these terminals.
Measure voltage at starter relay terminal R
instead. Check for continuity between
starter relay terminal R and regulator
terminal L beforehand.

Between 13 V
and 33.5 V Faulty monitor.
Measure voltage at
Between 13 V monitor connector A
and 33.5 V (16P) terminal #2.
Broken harness between
Alternator indicator regulator terminal L and
stays ON after en- Measure voltage at monitor.
Engine: Running
gine is started. regulator terminal L.* Less than 13 V or
higher than 33.5 V

Faulty regulator or alter-


Engine: Running nator.
Less than 13 V or
higher than 33.5 V

Between 10 V
and 33.5 V Faulty monitor.
Measure voltage at
YES regulator terminal L.*
Although alternator
output is low, alter- Check if indicator Faulty regulator.
nator indicator lights when key Key switch: ON
Engine: Stopped Less than 10 V or
doesnt light. switch is turned ON. higher than 33.5 V

Burned indicator light.


Key switch: ON
NO

Connector (Harness end connector terminals seen


from the open end side)

Starter Relay Monitor Connector A (16P)

E
8 7 6 5 4 3 2 1
S R 16 15 14 13 12 11 10 9

T5-5-12

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C
(Blank)

T5-5-13

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE OIL PRES-
SURE INDICATOR
Check for loose harness connections beforehand. NOTE: During one or two minutes after the engine
is stopped, engine oil pressure may still
exist. When the engine is restarted under
this condition, the indicator may not light.

Disconnect engine oil Faulty engine oil pressure


YES switch.
pressure switch. Check
if indicator lights when
harness end connector
terminal #1 (white and
red cable) is grounded Reconnect engine oil pres-
YES to vehicle frame. sure switch. Check if indica-
tor lights when monitor con-
nector C (20P) terminal #18
is grounded to vehicle frame.
To A
NO
Indicator doesnt Check if indicator
light even if engine lights when key Key switch: ON
oil pressure is low. switch is turned ON. Key switch: ON
Without disconnecting con-
nector, ground connector to
vehicle frame using such
Key switch: ON jumper wire as clip from re-
Engine: Stopped verse side of connector.

Burned indicator light.


NO

Broken harness between


monitor and engine oil pres-
YES
sure switch.

Faulty monitor.
NO

Faulty engine oil pressure


switch or engine oil pressure
YES system, or clogged oil filter.
Check if indicator
goes OFF when
Indicator stays ON engine oil pressure
after engine is switch is discon- Reconnect engine oil
started. nected. pressure switch and re- Short-circuited harness be-
move connector C (20P) tween monitor and engine oil
from monitor. Check for YES
pressure switch.
continuity between har-
Check oil filter for ness end connector ter-
clogging. minal #18 and vehicle
Key switch: ON NO frame.
Engine: Stopped
Faulty monitor.
NO

T5-5-14

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C

Engine Oil Pressure Switch


Pressure Operation
Approx. 98 kPa
(1.0 kgf/cm2, 14.22 psi) ON
or less
Approx. 98 kPa
(1.0 kgf/cm2, 14.22 psi) OFF
or higher

Connector (Harness end connector terminals seen


from the open end side)

Monitor Connector C (20P)

10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11

T5-5-15

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF OVERHEAT INDICA-
TOR
Check for loose harness connections beforehand.

Faulty overheat switch.


Remove connector (red YES
and blue cable) from
overheat switch. Check
if indicator lights when
harness end terminal is
Reconnect overheat switch.
YES grounded to vehicle Check if indicator lights when
frame.
monitor connector B (20P)
terminal #6 is grounded to
vehicle frame.
To A
NO
Indicator doesnt Check if indicator Key switch: ON
light even if engine lights when key
overheats. switch is turned ON. Key switch: ON
Without disconnecting con-
nector, ground connector to
vehicle frame using such
jumper wire as clip from re-
Key switch: ON
verse side of connector.

Burned indicator light.


NO

Broken harness between


YES monitor and overheat switch.

Faulty monitor.
NO

Faulty overheat switch.


YES

Check if indicator
Indicator lights even
goes OFF when
if coolant tempera-
overheat switch is Disconnect overheat
ture is low.
disconnected. switch. Remove con- Short-circuited harness be-
YES tween monitor and overheat
nector B (20P) from
monitor. Check for con- switch.
Key switch: ON tinuity between connec-
Engine: Stopped tor terminal #6 and vehi-
NO cle frame.
Faulty monitor.
NO

T5-5-16

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C

Overheat Switch
Coolant Temperature Operation
Lower than 105 pC OFF
(221 pF)
105 pC (221 pF) or ON
higher

Connector (Harness end connector terminals seen


from the open end side)

Monitor Connector B (20P)

10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11

T5-5-17

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF AIR FILTER RESTRIC-
TION INDICATOR
Check for loose harness connections beforehand.

Disconnect air filter re- Faulty air filter restriction


striction switch at plug YES switch.
receptacle with green
and blue cable. Check if
indicator lights when
harness end plug con-
Reconnect air filter restriction
YES nector is grounded to
switch. Remove connector B
vehicle frame.
(20P) from monitor. Check
for continuity between moni-
tor harness end connector
To A
Even if air filter is Check if indicator NO terminal #7 and vehicle
clogged, indicator lights when key frame.
doesnt light. switch is turned ON.
Key switch: ON

Key switch: ON
Burned indicator light.
NO

YES Faulty monitor.

A
Broken harness between
monitor and air filter restriction
switch.
NO

Faulty air filter restriction


YES
switch.
Check if indicator
goes OFF when air Disconnect air filter re-
Although air filter is filter restriction
not clogged, indi- striction switch at plug
switch is discon- receptacle with green
cator lights. nected. Short-circuited harness be-
and blue cable and re-
YES tween monitor and air filter
move connector B (20P)
restriction switch.
from monitor. Check for
Disassemble and continuity between con-
visually inspect. Key switch: ON nector terminal #7 and
Verify that air filter NO vehicle frame.
is not moist. Faulty monitor.
NO

T5-5-18

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C

Air Filter Restriction Switch


Pressure Operation
5.1 kPa (520 mmH2O) OFF
6.2 kPa (630 mmH2O) ON

Connector (Harness end connector terminals seen


from the open end side)

Monitor Connector B (20P)

10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11

T5-5-19

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF BUZZER
Check for loose harness connections beforehand. NOTE: *Regulator terminals L are water-resistant
type connectors so that it is not practical to
measure voltage at these terminals.
Measure voltage at starter relay terminal R
instead. Check for continuity between
starter relay terminal R and regulator ter-
minal L beforehand.

Buzzer continues to Faulty regulator.


sound when key 13 V or more
Measure voltage at
switch is turned ON monitor connector A
without starting en- (16P) terminal #2.
gine.
Faulty monitor.
Less than 13V
Key switch: ON
(without starting
engine)

Faulty engine oil pres-


YES sure system.

Buzzer continues to Check if engine oil


sound when engine pressure indicator
is started. lights. YES Overheat of engine.
Check if overheat in-
dicator lights.
NO
Faulty monitor.
NO

Buzzer doesnt NO Normal.


sound even if en-
gine oil pressure Check if engine
-1
indicator or over- speed is 900 min
heat indicator lights (rpm) or faster. NO Perform troubleshooting
with engine running. of indicator staying ON.
Check if alternator in-
dicator lights.
YES
Measure voltage at regu-
lator terminal L.*
YES

Engine speed: 900 min-1


(rpm) or faster.

T5-5-20

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C

Connector (Harness end connector terminals seen


from the open end side)

Monitor Connector A (16P) Starter Relay

8 7 6 5 4 3 2 1 E
16 15 14 13 12 11 10 9 S R

Lower than 13 V or
more than 33.5 V Faulty regulator and alterna-
tor.

Lower than 13 V or Broken harness between


higher than 33.5 V regulator terminal L and
monitor.
Measure voltage at monitor
connector A (16P) terminal #2.
Between 13 V Faulty monitor.
and 33.5 V -1
Engine speed: 900 min Between 13 V
(rpm) or faster and 33.5 V

T5-5-21

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF LCD
The following items are described:
1 to 3: To be displayed in the standard mode.
4 to 8: To be displayed in the users mode.
9 to 24: To be displayed with built-in diagnosing
system
In case only LCD is abnormal, the machine will
normally operate.

Display
Description Cause of Trouble
Order
1 Hour Meter Refer to the next page.
2 Trip 1 Faulty Monitor.
3 Trip 2
4 Actual Engine Speed In case Dr. ZX can display data, monitor is abnormal or communication
5 Hydraulic Oil Tempera- between monitor and MC is interrupted. In case Dr. ZX doesnt display
ture data, corresponding signal sensor is faulty. (The machine must have
any abnormality in the control system. Refer to Troubleshooting B.)
6 Faulty monitor or interrupted communication between ML controller and
7 Load Alarm monitor.
8 Hydraulic Oil Filter Faulty monitor or interrupted communication between ICX controller
and monitor.
9 Fault Code In case Dr. ZX can display data, monitor is abnormal or communication
10 ML Switch between monitor and MC is interrupted. In case Dr. ZX doesnt display
11 Pump 1 Delivery Pres- data, corresponding signal sensor is faulty. (The machine must have
sure any abnormality in the control system. Refer to Troubleshooting B.)
12 Pump 2 Delivery Pres-
sure
13 Pump 1 Control Pres-
sure
14 Pump 2 Control Pres-
sure
15 Target Engine Speed
16 EC Angle
17 Dial Angle
18 Boom Raise Lever
Stroke
19 Arm Roll-In Lever Stroke
20 Swing Lever Stroke
21 Travel Lever Stroke
22 Front Attachment Lever
Stroke
23 Attachment Lever Stroke
24 Work Mode

T5-5-22

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HOUR METER
Check for loose harness connections beforehand. NOTE: Regulator terminals L are water-resistant
type connectors so that it is not practical to
measure voltage at these terminals. Meas-
ure voltage at starter relay terminal R in-
stead. Check for continuity between starter
relay terminal R and regulator terminal L
beforehand.

Lower than 13 V or Faulty regulator or


higher than 33.5 V alternator.
Hour meter doesnt
count operating
hours with engine Measure voltage at Between 13V
running. regulator terminal L. and 33.5 V
Measure voltage Faulty monitor.
at monitor con-
-1
nector A (16P)
Engine speed: 900 min terminal #2.
Engine: Running (rpm) or faster Between 13V Broken harness be-
and 33.5 V tween regulator ter-
minal L and monitor.
Lower than 13 V or
higher than 33.5 V

Connector (Harness end connector terminals seen


from the open end side)

Monitor Connector A Starter Relay

8 7 6 5 4 3 2 1 E
16 15 14 13 12 11 10 9 S R

T5-5-23

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HYDRAULIC OIL FIL-
TER INDICATOR (Optional)
Check for loose harness connections beforehand.
Faulty hydraulic oil filter restric-
Disconnect hydraulic oil YES tion switch.
filter restriction switch at
plug receptacle with
white and blue cable.
Check if indicator lights Reconnect hydraulic oil filter
when harness end plug restriction switch. Check if
YES
connector is grounded indicator lights when monitor
to vehicle frame. connector C (16P) terminal
#14 is grounded to vehicle To A
frame.
NO

Even if hydraulic oil Check if indicator


filter is clogged, in- lights when key
dicator doesnt light. switch is turned ON. Key switch: ON Key switch: ON
Without disconnecting con-
nector, ground connector to
vehicle frame using jumper
Key switch: ON wire such as clip from reverse
side of connector.

Burned indicator light.


NO

Broken harness between moni-


YES tor and hydraulic oil filter restric-
tion switch.

A
Faulty monitor.
NO

Faulty hydraulic oil filter restric-


YES
tion switch.
Check if indicator
Although hydraulic goes OFF when
oil filter is not Disconnect hydraulic oil
hydraulic oil filter
clogged, indicator filter restriction switch at
restriction switch is
lights. plug receptacle with white Short-circuited harness between
disconnected.
and blue cable and re- YES monitor and hydraulic oil filter
move connector C (16P) restriction switch.
from monitor. Check for
continuity between con-
Key switch: ON nector terminal #14 and
Engine: Stopped NO vehicle frame.
Faulty monitor.
NO

Connector (Harness end connector terminals seen


from the open end side)
Monitor Connector C (16P)

8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9

T5-5-24

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.
Be sure to remove the negative terminals from
the batteries first when taking wire harnesses
and connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses, and fusible links and, in some
cases, cause fire due to short circuiting.
2. Color coding of wire harnesses. Code Color Code Color
The color codes of the wire harnesses in the R Red W White
electrical system are shown in the table on the L Blue G Green
right. Or Orange Lg Light
In cases on the design sheet where two colors green
are indicated for one wire, the left initial stands Y Yellow B Black
for the base color, while the right initial stands for Br Brown P Pink
the marking color.
Gr Gray V Violet

NOTE: 1) Code BW indicates a black base wire


with white fine-line marking.
2) Initials O and Or both stand for the
color orange.
3) Wires with longitudinal stripes printed
on them are not color coded. Be sure
not to confuse them with color coded
wires.

T5-6-1

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Electrical System Inspection
3. Precautions for connecting and disconnecting
terminal connectors.
1) When disconnecting harnesses, grasp them
Right Wrong
by their connectors. Do not pull on the wire
itself. Be sure to release the lock first before
attempting to separate connectors, if a lock
is provided. (Refer to Instructions for
Disconnecting Connector on page T5-6-3.)
2) Water-resistant connectors keep water out T107-07-06-001

so that if water enters them, water will not


easily drain from them. When checking
water-resistant connectors, take extra care
not to allow water to enter the connectors. In
case water should enter the connectors,
reconnect only after the connectors are Right
thoroughly dried.
Rust
3) Before connecting terminal connectors,
check that no terminals are bent or coming Wrong
(Deformation)
off. In addition, as most connectors are
made of brass, check that no terminals are Wrong
rusting. (Separation)
4) When connecting terminal connectors T107-07-06-002
provided with a lock, be sure to insert them
together until the lock clicks.
5) Pull the harness near the connector to
check if it is correctly connected.

4. Precaution for using a circuit tester.


1) Before using a circuit tester, refer to the
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object
Wind a Piece of Wire Tester Probe
to be measured, voltage range and current
polarity.
2) Before starting the connector test, always
check the connector terminal numbers,
referring to the circuit diagram. Sharpen the end of the Wire
When the connector size is very small, and T107-07-06-003

the standard probe size is too large to be


used for testing, wind a fine piece of
sharpened wire or a pin around the probe to
make the test easier.
3) When performing the connector test with the
circuit tester, be sure to insert the tester
probe from the connector harness side in
order not to damage the terminals in the
connector.

T5-6-2

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Electrical System Inspection
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
Push to Unlock and Separate Type

NOTE: Connectors will not be easily separated


even if the lock is pushed while being
pulled. Push the lock first before pulling the
connectors.
The lock is located on female side con-
nector (harness end side). T107-04-05-002

Locations of This Type Connector


Fuel Gauge N Sensor Engine Oil Level Switch* Radio
Hydraulic Oil Level Switch EC Motor Coolant Level Switch* Speaker
Horn EC Sensor Diode Learning Switch
Cab Harness Pump Delivery Pressure Sensor Key Switch Wiper
Pressure Sensor General Relay Engine Control Dial Monitor
Washer Solenoid Valve

NOTE: * Up to serial No.030652

Pull Up to Unlock and Separate Type

Locations of This Type Connector


Starter Relay

Pull to Separate Type T107-04-05-003

IMPORTANT: Generally, the solenoid valve con-


nector has a lock. Always pull to
separate the connector only after
unlocking using a tool such as a
pair of needle nose pliers.

Locations of This Type Connector


Oil Temperature Sensor
Dr. ZX T107-04-05-004

T5-6-3

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Electrical System Inspection
FUSE INSPECTION
Cracks in a fuse are so fine that it is very difficult or NOTE: All terminals located along the lengthwise
impossible to find by visual inspection. Use a tester to centerline of the fuse box are connected to
correctly inspect fuse continuity by following the in- the power source, while terminals located
structions described below. away from the center of the fuse box are
connected to loads (accessories). There-
1. Turn Key Switch ON fore, test all fuses in the same method ex-
When the key switch is turned ON, current from cept for the glow plug relay circuit fuse.
key switch terminal M activates the battery relay Check the glow plug relay circuit fuse with
so that electric power is supplied to all circuits the key switch turned to the ON position
except the glow plug relay circuit. (Refer to the then follow the procedure in step 3.
circuit diagram.)
2. Remove the fuse box cover. Set the tester volt-
age to meet the circuit specification to be meas-
ured. (Measurement Range: 0 to 30 V) 10 20
3. Ground the negative probe of the tester to the 9 19
vehicle frame. Touch the terminals located away
from the center of the fuse box with the positive 8 18
probe of the tester one at a time. When normal 7 17
continuity of a fuse is intact, the tester will indi-
cate 20 to 25 V (battery voltage). 6 16
5 15
4 14
3 13
2 12
1 11

M178-07-034

Fuse Fuse
Capacity Connected to Capacity Connected to
No. No.
1 5A Radio, Monitor (Backup 11 20 A Work Light Relays 1 and 2
Power), ICX (Main Power)
2 5A MC (Main Power) 12 10 A Wiper Relays A, B, and C,
Wiper Motor, Washer Relay
3 10 A MC (EC Motor Power) 13 20 A Heater (Air Conditioner Unit)
4 10 A MC (Solenoid Valve Power) 14 10 A Horn Relay
5 5A Monitor 15 5A Radio
6 5A MC, ICX (Power ON Signal) 16 10 A Cigarette Lighter
7 5A Air Conditioner Unit 17 5A Room Light
8 5A Optional 1 18 10 A Auxiliary
9 10 A Optional 2 19 5A QOS Controller, Glow Plug
Relay
10 5A Optional 3 20 10 A Lubricator (Optional)

T5-6-4

PDF created with pdfFactory Pro trial version www.pdffactory.com


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 to move the cable out of the
way of the front cover.
3. Open the fusible link box front cover and visually
inspect the fusible link.

Fusible Link M178-07-049

Fusible Link Cover

Replacement

1. Check that the negative cable is removed from


the battery.
2. Remove bolt M8 to take the fusible link off the T178-05-06-002

battery relay.
3. Open the upper and bottom side covers of the
fusible link box. Remove screws M6 (2 used).
4. Take out the fusible link to replace it. Battery
Relay
5. Retighten screws M6 (2 used). Bolt M8
6. Install the fusible link box and the cable to the
battery relay.
7. Reconnect the negative cable to the battery.

Cable Screw M6

T107-04-05-008

T5-6-5

PDF created with pdfFactory Pro trial version www.pdffactory.com


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 V


system.

T157-07-06-007

T5-6-6

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Electrical System Inspection
HOW TO TROUBLESHOOT ALTERNATOR
MALFUNCTIONS
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. Stop the engine. Turn the key switch to the ON


position. Confirm that the alternator indicator
comes on.

2. Measure the voltage between teminals B and E


terminals of the alternator. If the measured
voltage is around 24 V, the alternator circuit can
A
be considered normal. If the measured voltage
is low, a shortage in battery capacity or
looseness of the wire connectors of the alternator
A
circuit might be the cause of the malfunction.
When the voltage is 0 V, the wiring between the
fuse box and alternator might be loose or
disconnected.
Also, the alternator cannot generate electricity if
the ground line is disconnected.

3. Next, start the engine and measure the voltage M1HH-07-001

generated while as the alternator rotates.


As described above, measure the voltage Alternator seen from A-A
between terminals B and E on the side of the
Terminal B
alternator. If the voltage is around 28 V, the
alternator is operating normally.
If the rated voltage is not being generated, there
is some trouble with the alternator or the regula-
tor.

Terminal E

T1HH-05-06-001

T5-6-7

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Electrical System Inspection
CONTINUITY CHECK
Harness
Single-line continuity check A a
Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 Continuity
Discontinuity

NOTE: When the one end connector is far apart


from the other, connect one end of Connect to
A a
connector (A) to the machine chassis the vehicle
using a clip. Then, check continuity of the frame.
harness through the vehicle frame as
illustrated.
Connect to
the vehicle
If the ohm-meter reading is: 0 Continuity frame.
Discontinuity
A a
Single-line short-circuit check
Disconnect both end connectors of the harness and I Short-circuit
check continuity between one end connector of the between the
harness and
harness and the vehicle frame: the vehicle
If the ohm-meter reading is: frame.
0 Short circuit is present.
No short circuit is present.
T107-07-05-003

T5-6-8

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Electrical System Inspection
Multi-line continuity check
Disconnect both end connectors of the harness, First short-circuit
and short-circuit two terminals, (A) and (B), at one
end connector, as illustrated. Then, check continuity
A a
between terminals (a) and (b) at the other connector. B b
If the ohm-meter reading is , either line (A) - (a), C c
or (B) - (b) is in discontinuity. To find out which line
is discontinued, conduct the single line continuity Second short-circuit
check on both lines individually, or, after changing
the short-circuit terminals from (A) - (B) to (A) - (C),
check continuity once more between terminals (a)
and (c).

NOTE: By conducting the multi-line continuity T107-07-05-004


check twice, it is possible to find out which
line is discontinued. With terminals (A) and
(C) short-circuited, check continuity
between terminals (a) and (c).
If the ohm-meter reading is:
0 Line (B) - (b) has discontinuity.
Line (A) - (a) has discontinuity.

Multi-line short-circuit check


Disconnect both end connectors of the harness,
and check continuity between terminals (A) and (B)
or (C).
If the ohm-meter reading is:
0 Short-circuit exists between the lines.
No short-circuit exists between the lines.

Short-circuit between harnesses.

A a
B I
b
C c

T107-07-05-005

T5-6-9

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Electrical System Inspection
(Blank)

T5-6-10

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Electrical System Inspection
VOLTAGE AND CURRENT MEASURE-
MENT
Turn key switch ON so that the specified voltage (cur-
rent) is supplied to the location to be measured.
Judge if the circuit is normal by evaluating whether
the measured voltage (current) matches the specifica-
tion.

24-Volt Circuit
Start checking the circuit in order up to the loca-
tion to be measured from either power source or
actuator side. Thereby, the faulty location in the
circuit will be found.
Black Probe (Minus) of Tester : To ground to the vehi-
cle frame
Red Probe (Plus) of Tester : To touch the location
to be measured

T5-6-11

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Electrical System Inspection

Engine Key Switch Location to be Measured Specification


Power Source
Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (2): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and Ground: Battery Power 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 20 to 25 V
Stopped OFF Between (1) and Ground: Backup Current* 6 mA
Preheat Circuit
Stopped ON or START Between (6) and Ground: Key Switch 20 to 25 V
Stopped ON or START Between (7) and Ground: Glow Plug 20 to 25 V
Starting Circuit
Started START Between (8) and Ground: Key Switch 20 to 25 V
Started START Between (9) and Ground: Battery Relay (Coil) 20 to 25 V
Started START Between (10) and Ground: Battery Relay (Switch) 20 to 25 V
Started START Between (11) and Ground: Starter (B) 20 to 25 V
Started START Between (12) and Ground: Starter (C) 20 to 25 V
Started START Between (13) and Ground: Starter Relay (S) 20 to 25 V
Charging Circuit
Fast Speed ON Between (14) and Ground: Alternator (B) / Generating 26 to 30 V
Voltage
Fast Speed ON Between (10) and Ground: Battery Relay / Generating 26 to 30 V
Voltage
Fast Speed ON Between (15) and Ground: Fuse Box 26 to 30 V
Between (16) and Ground: Generating Voltage
Fast Speed ON Between (17) and Ground: Monitor 13 to 30 V
Fast Speed ON 13 to 30 V
Surge Voltage
Prevention Circuit
Slow Idle ON Between (14) and Ground: Alternator (B) 26 to 30 V
Slow Idle ON Between (16) and Ground: Starter Relay (R) 13 to 30 V
Slow Idle ON Between (18) and Ground: Load Damp Relay 26 to 30 V
Slow Idle ON Between (10) and Ground: Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (19) and Ground: Auxiliary 20 to 25 V
Stopped ON Between (20) and Ground: Room light 20 to 25 V
Stopped ON Between (21) and Ground: Cigar Lighter 20 to 25 V
Stopped ON Between (22) and Ground: Radio 20 to 25 V
Stopped ON Between (23) and Ground: Horn 20 to 25 V
Stopped ON Between (9) and Ground: Battery Relay 20 to 25 V

NOTE: *Measure after disconnecting the negative


cable from the battery.

T5-6-12

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Electrical System Inspection

Key Switch

Battery
6 8
1 2 3 5 4 9

15
Battery Relay

Fuse
10 Box
Starter
18 Load
Damp
Relay
11

12 23 22 21 20 19 17

13 Monitor
Starter Relay
16
Alternator
Glow
Plug
Relay

14

Glow Plug
T178-05-06-001

T5-6-13

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Electrical System Inspection
5 Voltage Circuit
Power Signal or
Voltage between terminal #1 and the vehicle Two Polarities Source Ground
frame (ground) 1 2
With the key switch turned OFF, disconnect the
sensor connector.
Measure the voltage between terminal #1 on the
machine harness side connector and the vehicle
(ground) under the following conditions.
V
Key switch position: ON
Tester black terminal (negative):
Connected to the vehicle (ground)
Tester red terminal (positive):
T107-07-05-006
Connected to terminal #1
Power
Three Polarities
Source Signal Ground
Evaluation: 1 2 3
If the measuring voltage is within 5o0.5 volts, the
circuit up to terminal #1 is normal.

Voltage between terminal #1 and the ground T107-07-05-007

terminal
With the key switch turned OFF, disconnect the Two Polarities
1 2
sensor connector.
Measure the voltage between terminal #1 on the
machine harness side connector and the ground
terminal (terminal #2 for two polarities, or terminal
#3 for three polarities) under the following V
conditions.

Key switch position: ON


Tester black terminal (negative):
Connected to the ground terminal
(terminal #2 or 3) T107-07-05-008
Tester red terminal (positive):
Connected to terminal #1 Three Polarities
1 2 3
Evaluation:
If the measuring voltage is within 5o0.5 volts, the
circuit up to terminal #1 or the ground terminal is
normal.
V

T107-07-05-009

T5-6-14

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Electrical System Inspection
CHECK BY FALSE SIGNAL
Two Polarities
Turn the key switch OFF. After disconnecting the sen- (Oil Temperature)
sor connector, turn the key switch ON. Then, connect (N Sensor)
1 2
machine side harness end connector terminal #1
(power) to terminal #2 (signal). (Power voltage is used
as a false signal.) Check the controller using Dr. ZX
monitor function under this condition. When the
maximum value is displayed, the MC and the circuit
up to the machine side harness end connector are
normal. When the pressure switch circuits are normal, Connect
Dr. ZX displays ON.

IMPORTANT: Dont connect terminal #1 or #2 to


terminal #3 or to the vehicle frame Three Polarities
T107-07-05-010

(ground) when checking a


three-polarity connector. (Pressure Sensor)
(Pump Delivery Pressure Sensor)
(Pump Control Pressure Sensor) 1 2 3
NOTE: Some kinds of sensors can be monitored (EC Sensor)
by the built-in diagnosing system. (Refer to
the TROUBLESHOOTING / General
group.)

Connect

T107-07-05-011

T5-6-15

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Electrical System Inspection
TEST HARNESS
With a test harness installed between connectors, the
circuit condition is checked depending on whether the
test harness lamp lights or extinguishes during opera-
tion.

Parts Number 4283594 (ST 7126)


Use to check a single-line (discontinuity and/or volt-
age).
To Location to be Measured.
During Operation: Lamp is ON. To Ground
T107-07-05-012
Parts Number 4283594 (ST 7126)

Parts Number (ST 7123)


Use to check the solenoid valve unit circuits.
When the corresponding control lever or switch is 4
operated: Lamp is ON. 3 50
(Refer to T5-4-46, 57, 60 and 79.) 150 50 50
1 2 2 1

T107-07-06-015
Parts Number (ST 7123)

Parts Number 4274589 (ST 7125)


Use to check the EC motor circuit.
(Refer to T5-4-32 and 36.) 5
6
EC Motor Circuit 50

When the engine control dial is rotated: 1 2 2 1


150 50
Both lamps ON: Normal 50
Only one lamp ON: Check for continuity of the 4 3 4 3
circuit connected to the lamp OFF. 7 50
Both lamps OFF: Check the harness together 8
with the relay.

Parts Number 4274589 (ST 7125) T107-07-06-024

T5-6-16

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Electrical System Inspection
Parts Number 4284347 (ST 7129)
Use to measure the EC sensor circuit signal line
voltage (between terminals #2 and #3).
(Red)
(Refer to T5-3-4.)

(Black)

Parts Number 4284347 (ST 7129) T107-07-03-009

Parts Number (ST 7227)


Use to check the wiper circuit. 2
5 1
(Refer to T5-4-80.)
2 4 7
1

Parts Number (ST 7227) T178-05-06-003

T5-6-17

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / Electrical System Inspection
(Blank)

T5-6-18

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / ICX
OUTLINE
The ICX (information controller) stores signals from
various kinds of sensors and switches provided on the
machine as data. The various input signals are
grouped into Daily Report Data List, Frequency Dis-
tribution Data List, Cumulative Operation Hour List,
Alarm List, and Trouble List and are recorded in
the ICX.

T5-7-1

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / ICX
Daily Report Data List

Data Details
1 Key Switch ON Time Time when key switch is first turned ON during daily operation
(Time is recorded by key switch ON signal.)

2 Key Switch OFF Time Time when key switch is last turned OFF during daily operation
(Time is recorded by key switch ON signal.)

3 Engine Start Time Time when engine is first started during daily operation
(Time is recorded by alternator output signal.)

4 Engine Stop Time Time when engine is last stopped during daily operation
(Time is recorded by alternator output signal.)

5 Hour Meter Hour meter cumulative hours


(Hours are recorded by hour meter signal from monitor.)

6 Fuel Level The value of the final remained fuel during a day
(Value is recorded by fuel sensor signal from monitor.)

7 Engine Operating Hours Total engine operating hours during daily operation
(Hours are recorded by alternator output signal.)

8 Swing Operating Hours Total swing operating hours during daily operation
(Hours are recorded by signals from swing pressure sensor.)

9 Travel Operating Hours Total travel operating hours during daily operation
(Hours are recorded by signals from travel pressure sensor.)

10 Front Attachment Operat- Total front attachment operating hours during daily operation
ing Hours (Hours are recorded by signals from front attachment pressure sensor.)

11 Breaker Operating Hours Total breaker operating hours during daily operation
(Hours are recorded by signals from auxiliary pressure sensor and attach-
ment mode switch.)

12 Auxiliary Attachment Ex- Total auxiliary attachment except for breaker operating hours during daily
cept for Breaker Operating operation
Hours (Hours are recorded by signals from auxiliary pressure sensor and attach-
ment mode switch.)

T5-7-2

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / ICX

Data Details
13 *ML Operating Hours Total *ML crane operating hours during daily operation
(Hours are recorded by signals from crane mode switch.)

14 Engine Operating Hour Engine operating hour distribution during daily operation
Distribution (Operating hours are recorded only when alternator output signal is con-
tinuously delivered for more than 10 minutes.)

NOTE: The daily operation in this table is equiva- *ML specification is only available in Japa-
lent to the hours between 0:00 and nese domestic market.
23:59:59 counted by the ICX built-in clock.
In case the engine is kept operated be-
yond 0:00, such data are recorded as
those for the following day.

Frequency Distribution Data List

Data Details
1 Engine Speeds Frequency distribution of engine speeds
(Speeds are recorded by signals from N sensor.)

2 Hydraulic Oil Tem- Frequency distribution of hydraulic oil temperature


perature (Temperatures are recorded by signals from hydraulic oil temperature sensor.)

3 Coolant Temperature Frequency distribution of coolant temperature


in Radiator (Temperatures are recorded by signals from coolant temperature sensor.)

4 Average Pump Deliv- Frequency distribution of average delivery pressure from pumps 1 and 2
ery Pressure (Average pressures are recorded by signals from delivery pressure sensors of
pumps 1 and 2.)

5 Average Pump Deliv- Frequency distribution of average delivery pressure from pumps during digging
ery Pressure in Dig- operation
ging Operation (Average pressures are recorded by signals from arm roll-in pressure sensor.)

6 Average Pump Deliv- Frequency distribution of average delivery pressure from pumps during travel
ery Pressure in Travel operation
Operation (Average pressures are recorded by signals from travel pressure sensor.)

T5-7-3

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / ICX
Cumulative Operation Hour List

Data Details
1 Engine Operation Hour Cumulative engine operation hours
(Hours are recorded by alternator output signal.)

2 Swing Operation Hour Cumulative swing operation hours


(Hours are recorded by signals from swing pressure sensor.)

3 Travel Operation Hour Cumulative travel operation hours


(Hours are recorded by signals from travel pressure sensor.)

4 Front Attachment Cumulative front attachment operation hours


Operation Hour (Hours are recorded by signals from front attachment pressure sensor.)

5 Breaker Operation Cumulative breaker operation hours


Hour (Hours are recorded by signals from auxiliary pressure sensor and attachment
mode switch.)

6 Auxiliary Attachment Cumulative attachment operation hours except for breaker operation hours
Except for Breaker (Hours are recorded by signals from auxiliary pressure sensor and auxiliary
Operation Hour mode switch.)

7 *ML Operation Hour Cumulative *ML operation hours


(Hours are recorded by signals from crane mode switch.)

NOTE: ML specification is only available in Japa-


nese domestic market.

T5-7-4

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / ICX
Alarm List

Code Data Details


81 Engine Oil Level Date and time when engine oil level indicator lighted are recorded
by signals from engine oil level switch.

85 Coolant in Radiator Date and time when coolant level indicator lighted are recorded by
signals from coolant level switch.

86 Hydraulic Oil Filter Date and time when hydraulic oil filter indicator lighted are recorded
by signals from hydraulic oil filter restriction switch.

89 Overheat Date and time when overheat indicator lighted are recorded by sig-
nals from overheat switch.

90 Engine Oil Pressure Date and time when engine oil pressure indicator lighted are re-
corded by signals from engine oil pressure switch.

93 Air Filter Restriction Date and time when air filter restriction indicator lighted are re-
corded by signals from air filter restriction switch.

94 Alternator Indicator Date and time when alternator indicator lighted are recorded by sig-
nals from monitor controller.

NOTE: In case the above alarms are recorded,


check individual item. If malfunction of the
monitor is found, refer to troubleshooting
C.

NOTE: The monitors mounted on the machines


(Up to serial No.030652) indicate the fail-
ure codes 81 (engine oil level) and 85 (ra-
diator coolant).

T5-7-5

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / ICX
Trouble List

Fault
Trouble Details
Code
01 Abnormal EEPROM Occurrence time and date of fault code 01

02 Abnormal RAM Occurrence time and date of fault code 02

03 Abnormal A/D Conversion Occurrence time and date of fault code 03

04 Abnormal Sensor Voltage Occurrence time and date of fault code 04

06 Abnormal EC Sensor Occurrence time and date of fault code 06

07 Abnormal Engine Control Dial Occurrence time and date of fault code 07

10 Abnormal Pump 1 Delivery Pressure Occurrence time and date of fault code 10

11 Abnormal Pump 2 Delivery Pressure Occurrence time and date of fault code 11

12 Abnormal Pump 1 Control Pressure Occurrence time and date of fault code 12

13 Abnormal Pump 2 Control Pressure Occurrence time and date of fault code 13

14 Abnormal Swing Lever Stroke Occurrence time and date of fault code 14

15 Abnormal Boom Raise Lever Stroke Occurrence time and date of fault code 15

16 Abnormal Arm Roll-In Lever Stroke Occurrence time and date of fault code 16

18 Abnormal Travel Lever Stroke Occurrence time and date of fault code 18

19 Abnormal Oil Temperature Sensor Occurrence time and date of fault code 19

64 MC Communication Error Time and date when communication error between MC


and ICX occurred.

65 Monitor Communication Error Time and date when communication error between
monitor and ICX occurred.

66 Satellite Terminal Communication Error Time and date when communication error between sat-
ellite terminal and ICX occurred.

NOTE: In case the above fault codes are recorded,


refer to troubleshooting A.

T5-7-6

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / ICX
(Blank)

T5-7-7

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / ICX
ICX FAULT CODE LIST

Fault
Trouble Remarks
Code
1 Abnormal Internal RAM In case of SAM error

2 Abnormal Flush Memory In case of SAM error

3 Abnormal Exterior In case of SAM error or read-write error

4 Abnormal EEPROM In case of SAM error

6 Abnormal Time In case RTC data was other than figures.

7 MC Communication Timeout (For ZAXIS) In case MC communication didnt last for more than 7
seconds.

8 Monitor Communication Timeout In case monitor communication didnt last for more than
24 seconds.

9* MC Communication Timeout (For EX5) In case MC communication didnt last for more than 20
seconds.

10 Satellite Terminal Communication Timeout In case satellite communication didnt last for more than
1 minute.

NOTE * Fault code 9 may be displayed on only the


machine (Type: EX5 with minor change), to
which the ICX is installed later.

SATELLITE TERMINAL FAULT CODE LIST

Fault
Trouble Remarks
Code
101 Satellite Terminal: Internal Error Abnormal EEPROM

102 Satellite Terminal: Internal Error Abnormal sent data

103 Satellite Terminal: Internal Error In case reception is difficult.

104 Satellite Terminal: Communication Error In case satellite communication cannot be accom-
plished.

105 Satellite Terminal: Internal Error In case sending retry over occurred or local loop back
test failed with power ON.

106 Satellite Terminal: Communication Error In case sending retry over occurred.

107 Satellite Terminal: Abnormal Harness In case reception data doesnt match sending data.

T5-7-8

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / ICX
FAULT CODE 1 TO 4 AND 6

YES *Faulty ICX.

Check if all data are normally


cumulated.

Faulty ICX.
NO

*Even if the fault code remains displayed after retrying,


the machine can be operated as it is when data re-
cord is normally cumulated.

FAULT CODE 7 TO 10

Check for continuity between Faulty ICX.


ICX and corresponding com- YES
ponent while referring to the
following table.
Broken harness between ICX
and corresponding compo-
NO nent.

Fault code ICX terminal # Corresponding component terminal #


7 Connector C terminal #11 MC connector D terminal #10

8 Connector B terminal #1 Monitor connector B terminal #3

10 Connector B terminal #5 Satellite terminal DSUb9 pin terminal #2

T5-7-9

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / ICX
SOME PARTS OF DATA IN DAILY REPORT,
FREQUENCY DISTRIBUTION, CUMULA-
TIVE OPERATION HOURS ARE NOT RE-
CORDED
All necessary data signals may not be input into
the ICX. Individual signals are utilized to record
more than one data. While referring to the table
below, check the corresponding system for any
abnormality.

Related Data Input Signal


Key switch ON and OFF time Key switch

Engine start and stop time, Engine operating hours (Daily report and cumulative Alternator
operation hour), Engine operating hour distribution

Hour meter Monitor controller

Coolant temperature distribution in radiator Coolant temperature sen-


sor
Remaining fuel level (detected at regular data sending time) Fuel level sensor

Travel operating hours (Daily report and cumulative operation hour), Average Travel pressure sensor
pump delivery pressure distribution in travel operation

Front attachment operating hours (Daily report and cumulative operation hour) Front attachment pressure
sensor
Swing operating hours (Daily report and cumulative operation hour) Swing pressure sensor

Average pump delivery pressure distribution in digging operation Arm roll-in pressure sen-
sor
Breaker operating hours (Daily report and cumulative operation hour), Auxiliary Auxiliary pressure sensor
attachment except for breaker operating hours (Daily report and cumulative op-
eration hour)

Distribution of average pump delivery pressure, average pump delivery pressure Pump 1 delivery pressure
in digging operation and travel operation sensor

Distribution of average pump delivery pressure, average pump delivery pressure Pump 2 delivery pressure
in digging operation and travel operation sensor

Engine speed distribution N sensor

Breaker operating hours (Daily report and cumulative operation hour) Attachment mode switch

Auxiliary attachment except for breaker operating hours (Daily report and cumula- Auxiliary mode switch
tive operation hour)

*ML operating hours (Daily report and cumulative operation hour) Crane mode switch

NOTE: *ML specification is available only in Japa-


nese domestic market.

T5-7-10

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / ICX

Corrective Action Remarks


Check harness between ICX terminal A5 and key In case engine doesnt start, refer to troubleshooting B.
switch terminal M.
Check harness between ICX terminal A2 and alter- In case alternator indicator malfunctions, refer to trou-
nator terminal L. bleshooting C.

Check harness between ICX terminal B1 and monitor In case hour meter malfunctions, refer to trouble-
terminal B3. shooting C.
Check harness between ICX terminal B1 and monitor In case coolant temperature gauge malfunctions, refer
terminal B3. to troubleshooting C.
Check harness between ICX terminal B1 and monitor In case fuel gauge malfunctions, refer to troubleshoot-
terminal B3. ing C.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.

Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.

Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.

Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.

Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.

Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.

T5-7-11

PDF created with pdfFactory Pro trial version www.pdffactory.com


TROUBLESHOOTING / ICX
(Blank)

T5-7-12

PDF created with pdfFactory Pro trial version www.pdffactory.com


MEMO

PDF created with pdfFactory Pro trial version www.pdffactory.com


MEMO

PDF created with pdfFactory Pro trial version www.pdffactory.com


Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162

SERVICE MANUAL REVISION REQUEST FORM

NAME OF COMPANY: MODEL:


PUBLICATION NO.:
YOUR NAME: (Located at the right top corner in the cover page)

DATE: PAGE NO.:


(Located at the bottom center in the page. If two or more revi-
FAX: sions are requested, use the comment column)

YOUR COMMENTS / SUGGESTIONS:


Attach photo or sketch if required.
If your need more space, please use another sheet.

REPLY:

(Copy this form for usage)

PDF created with pdfFactory Pro trial version www.pdffactory.com


THE ATTACHED DIAGRAM LIST

(The following diagrams are attached to this manual.)

ZAXIS330 ELECTRICAL CIRCUIT DIAGRAM

ZAXIS330 CONNECTORS

ZAXIS 330 CAB HARNESS

ZAXIS330 ENGINE HARNESS

ZAXIS330 MONITOR HARNESS

ZAXIS330 HYDRAULIC CIRCUIT DIAGRAM

PDF created with pdfFactory Pro trial version www.pdffactory.com