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TO THE READER
This manual is written for an experienced technician
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition
to this manual.
MANUAL COMPOSITION
This manual consists of three portions: the Techni-
IN-01
INTRODUCTION
PAGE NUMBER
Each page has a number, located on the center
W: Workshop Manual
CAUTION:
Indicated potentially hazardous situation which
could, if not avoided, result in personal injury or
death.
IMPORTANT:
IN-02
NOTE:
Indicates supplementary technical information or
know-how.
INTRODUCTION
UNITS USED
Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
Quantity
Length
Volume
Weight
Force
Torque
To Convert
From
mm
mm
L
L
m3
kg
N
N
Nm
Nm
Into
in
ft
US gal
US qt
yd3
lb
kgf
lbf
kgfm
lbfft
Quantity
Multiply By
0.03937
0.003281
0.2642
1.057
1.308
2.205
0.10197
0.2248
1.0197
0.7375
Pressure
Power
Temperature
Velocity
Flow rate
IN-03
To Convert
From
MPa
MPa
kW
kW
C
km/h
min-1
L/min
mL/rev
Into
kgf/cm2
psi
PS
HP
F
mph
rpm
US gpm
cc/rev
Multiply By
10.197
145.0
1.360
1.341
C1.8+32
0.6214
1.0
0.2642
1.0
INTRODUCTION
(Blank)
IN-04
SAFETY
RECOGNIZE SAFETY INFORMATION
These are the SAFETY ALERT SYMBOLS.
When you see these symbols on your machine or in
this manual, be alert to the potential for personal injury.
SA-688
001-E01A-0001
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
SA-1
SA-1223
SAFETY
FOLLOW SAFETY INSTRUCTIONS
Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
SA-003
Learn how to operate the machine and its controls correctly and safely.
004-E01A-0437
SA-2
SA-437
SAFETY
WEAR PROTECTIVE CLOTHING
Wear close fitting clothing and safety equipment appropriate to the job.
SA-438
005-E01A-0438
SA-434
006-E01A-0434
INSPECT MACHINE
Inspect your machine carefully each day or shift by
007-E01A-0435
SA-3
SA-435
SAFETY
GENERAL PRECAUTIONS FOR CAB
Before entering the cab, thoroughly remove all dirt
and/or oil from the soles of your work boots. If any
controls such as a pedal is operated while with dirt
and/or oil on the soles of the 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 locations.
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.
524-E01A-0000
SA-4
SAFETY
USE HANDHOLDS AND STEPS
Falling is one of the major causes of personal injury.
When you get on and off the machine, always face
the machine and maintain a three-point contact with
the steps and handrails.
008-E01A-0439
The operator should be able to fully depress the pedals and to correctly operate the control levers with his
back against the seat back.
009-E01A-0378
SA-5
SA-378
SAFETY
FASTEN YOUR SEAT BELT
If the machine should overturn, the operator may be-
SA-237
Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate
hand signals before starting the machine.
011-E01A-0426
SA-6
SA-426
SAFETY
OPERATE ONLY FROM OPERATORS SEAT
Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury
or death.
SA-444
JUMP STARTING
Battery gas can explode, resulting in serious injury.
If the engine must be jump started, be sure to follow
the instructions shown in the OPERATING THE ENGINE chapter in the operator's manual.
SA-032
S013-E01A-0032
SA-379
014-E01B-0379
SA-7
SAFETY
INVESTIGATE JOB SITE BEFOREHAND
When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting
in serious injury or death.
SA-380
Beware the possibility of fire when operating the machine near flammable objects such as dry grass.
015-E01A-0380
SA-490
015-E01A-0380
SA-8
SAFETY
PROVIDE SIGNALS FOR JOBS INVOLVING
MULTIPLE NUMBERS OF MACHINES
For jobs involving multiple numbers of machines, pro-
018-E01A-0481
SA-481
SA-9
SAFETY
DRIVE MACHINE SAFELY
Before driving the machine, always confirm that the
SA-388
SA-441
SA-589
019-E01C-0492
SA-10
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCI-DENTS
Death or serious injury may result if you attempt to
mount or stop a moving machine.
To avoid rollaways:
Select level ground when possible to park machine.
Turn the auto-idle switch and the H/P mode switch off.
SA-391
Stop the engine and remove the key from the key
switch.
SA-11
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
If any person is present near the machine when backing
or swinging the upperstructure, the machine may hit or
run over that person, resulting in serious injury or death.
SA-383
SA-12
SA-384
SAFETY
KEEP PERSON CLEAR FROM WORKING
AREA
A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed
against an other object, resulting in serious injury or
death.
SA-386
022-E01A-0386
truck cab.
Serious injury or machine damage may result due to
bucket load spill or due to collision with the bucket.
023-E01A-0487
SA-487
AVOID UNDERCUTTING
In order to retreat from the edge of an excavation if the
footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with
the travel motors at the rear.
SA-488
024-E01A-0488
SA-13
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING
MACHINE --- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN
JUMP FREE
FASTEN YOUR SEAT BELT
To avoid tipping:
SA-012
SA-440
SA-489
026-E01A-0489
SA-14
SAFETY
DIG WITH CAUTION
Accidental severing of underground cables or gas lines
SA-382
028-E01A-0389
SA-389
Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.
SA-381
029-E01A-0381
SA-15
SAFETY
OBJECT HANDLING
If a lifted load should fall, any person nearby may be
SA-014
030-E01A-0014
031-E01A-0432
SA-16
SA-432
SAFETY
PARK MACHINE SAFELY
To avoid accidents:
Park machine on a level surface.
SA-390
tion.
033-E08B-0390
nites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.
SA-018
SA-019
034-E01A-0496
SA-17
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
Understand service procedures before doing work.
When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as
fuel oil and gasoline to clean parts or surfaces.
SA-18
SA-527
SAFETY
Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the
machine.
SA-037
501-E01A-0287
SS2045102
SA-527
519-E01A-0527
502-E01A-0026
SA-026
SA-19
SAFETY
PREVENT PARTS FROM FLYING
Grease in the track adjuster is under high pressure.
Failure to follow the precautions below may result in serious injury, blindness, or death.
SA-344
Securely store attachments and implements to prevent falling. Keep children and bystanders away from
storage areas.
SA-034
504-E01A-0034
SA-20
SAFETY
PREVENT BURNS
Hot spraying fluids:
sure. Hot water or steam is contained in the engine, radiator and heater lines.
Skin contact with escaping hot water or steam can
cause severe burns.
SA-039
Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot as
well.
SA-225
S506-E01A-0019
SA-21
SA-019
SAFETY
AVOID HIGH-PRESSURE FLUIDS
Fluids such as diesel fuel or hydraulic oil under pressure
can penetrate the skin or eyes causing serious injury,
blindness or death.
Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.
SA-031
SA-292
507-E03A-0499
SA-22
SA-044
SAFETY
PREVENT FIRES
Check for Oil Leaks:
Fuel, hydraulic oil and lubricant leaks can lead to fires.
Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler
flange bolts.
SA-019
508-E02B-0019
SA-23
SAFETY
Check Emergency Engine Stop Switch:
If a fire breaks out, failure to release pressurized air inside the hydraulic tank will escalate fire, hampering fire
fighting.
Check the emergency engine stop switch function
every 250 hours:
1)
2)
3)
Confirm that both engines stop and that pressurized air inside the hydraulic oil tank is released (a
hissing sound should be heard).
SA-393
518-E02B-0393
SS-1510
SA-24
SAFETY
PRECAUTIONS FOR WELDING AND GRINDING
Welding may generate gas and/or small fires.
Be sure to perform welding in a well ventilated and
prepared area. Store flammable objects in a safe
place before starting welding.
SA-818
523-E01A-0818
SA-25
SA-016
SAFETY
AVOID HEATING NEAR PRESSURIZED FLUID
LINES
Flammable spray can be generated by heating near
SA-030
SA-26
SAFETY
PREVENT BATTERY EXPLOSIONS
Battery gas can explode.
Keep sparks, lighted matches, and flame away from
the top of battery.
SA-032
512-E01B-0032
Refer to the freon container for proper use when servicing the air conditioning system.
Never let the freon stream make contact with the skin.
SA-405
513-E01A-0405
SA-27
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY
Direct exposure to hazardous chemicals can cause se-
A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques.
SA-309
516-E01A-0226
SA-28
SA-226
TECHNICAL MANUAL
(Troubleshooting)
1
2
3
4
5
Introduction
Standard
Engine Test
Excavator Test
Component Test
SECTION 5 TROUBLESHOOTING
Group
Group
Group
Group
Group
Group
Group
Group
1 General
2 Cross Reference Table
3 Component Layout
4 Troubleshooting A
5 Troubleshooting B
6 Troubleshooting C
7 Troubleshooting D
8 Electrical System Inspection
COPYRIGHT(C)2006
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
WORKSHOP MANUAL
SECTION 1 GENERAL INFORMATION
Group 1 Precautions for Disassembling and Assembling
Group 2 Tightening Torque
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
Group 3 Pump Device
Group 4 Control Valve
Group 5 Swing Device
Group 6 Pilot Valve
Group 7 Pilot Shut-Off Valve
Group 8 Shockless Valve
Group 9 Solenoid Valve
Group 10 Signal Control Valve
Group 11 Oil Cooler Fan Motor
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
Group 3 Bushing and Point
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction
Group 2 Standard
18ET-4-1
(Blank)
18ET-4-2
T4-1-1
FOR
PERFORMANCE
T4-1-2
T105-06-01-003
T105-06-01-004
PERFORMANCE
STAN-
The standard performance values are listen in the table below. Refer to the Groups 3 to 5 for performance
test procedures. Values indicated in parentheses are
reference values. The fuel lever shall be placed in the
fast idle position and the hydraulic oil temperature is
to be maintained at 50 5 C (122 9 F) unless otherwise specified.
EX1200-5C
(Standard
Performance)
Performance Test
ENGINE SPEED
Fast Idle Speed
Slow Idle Speed
Auto-Idle Speed
Quick Idle Speed
TRAVEL SPEED
Fast Speed Mode
Slow Speed Mode
TRACK REVOLUTION SPEED
Fast Speed Mode
Slow Speed mode
MISTRACK
(in both fast and slow mode)
TRAVEL MOTOR DRIFT
SWING SPEED
SWING FUNCTION DRIFT
(Backhoe)
(Loading Shovel)
SWING MOTOR DRIFT
MAXIMUM SWINGABLE SLANT ANGLE
min
Refer to T4-3-1
-1
185050
85050
1400100
85050
Refer to T4-4-1
sec /20 m
21.31.6
30.52.0
Refer to T4-4-2
sec /3 rev
42.04.0
61.04.0
mm /20 m
mm /5 min
sec /3 rev
200 or less
0
30.02.0
mm /180
mm /5 min
1100 or less
deg
(Backhoe)
Refer to T4-4-3
Refer to T4-4-4
Refer to T4-4-5
Refer to T4-4-6
Refer to T4-4-8
Refer to T4-4-9
12 or possibly
more
10 or possibly
more
(Loading Shovel)
SWING BEARING PLAY
Remarks
mm
2.0 or less
NOTE: BH: Backhoe: With 5.0 m3 (PCSA heaped) Bucket, 3.4 m Arm, 9.1 Boom
LD: Loading Shovel: With 6.5 m3 Bucket
T4-2-1
Performance Test
CYLINDER CYCLE TIME
(Backhoe)
Boom Raise
Boom Lower
Arm Roll-In
Arm Roll-Out
Bucket Roll-In
Bucket Roll-Out
(Loading Shovel)
Boom Raise
Boom Lower
Arm Extend
Arm Retract
Bucket Tilt-In
Bucket Tilt-Out
Bucket Open
Bucket Close
DIG FUNCTION DRIFT
(Backhoe)
Boom Cylinder
Arm Cylinder
Bucket Cylinder
Bucket Bottom
(Loading Shovel)
Boom Cylinder
Arm Cylinder
Bucket Cylinder
Bucket Bottom
CONTROL LEVER OPERATING FORCE
(HITACHI Control Pattern)
Boom Lever
Remarks
Refer to T4-4-12
sec
4.30.5
3.10.5
4.50.5
3.50.5
3.00.5
2.30.5
BE: 4.50.5
BE: 3.30.5
BE: 4.50.5
BE: 4.00.5
BE: 3.30.5
BE: 2.70.5
5.50.5
4.00.5
2.90.5
2.50.5
3.30.5
2.20.5
1.10.5
1.60.5
Refer to T4-4-14
mm/5 min
20 or less
20 or less
30 or less
300 or less
BE: 30 or less
BE: 30 or less
BE: 30 or less
BE: 400 or less
20 or less
20 or less
30 or less
300 or less
Refer to T4-4-15
N (kgf)
Travel Lever
19.7 (2.0) or
less
16.7 (1.7) or
less
16.7 (1.7) or
less
16.7 (1.7) or
less
19.7 (2.0) or
less
24.5 (2.5) or
less
T4-2-2
Performance Test
LEVER STROKE (HITACHI Control Pattern)
Boom Lever
Arm Lever
Refer to T4-4-16
mm
10510
8310
Bucket Lever
Swing Lever
8310
10510
Travel Lever
Bucket Open/Close Pedal
BOOM RAISE/SWING COMBINED OPERATION (with
Empty Bucket) Time
sec/90
Bucket Tooth Tip Height (H) from Ground
mm
2
HYDRAULIC COMPONENT
MPa (kgf/cm )
PRIMARY PILOT PRESSURE: Fast Idle
Slow Idle
SECONDARY PILOT PRESSURE
2
SOLENOID VALVE SET PRESSURE
MPa (kgf/cm )
Travel Mode Solenoid Valve
Flow Rate Reducing Solenoid Valve
Power Decrease Solenoid Valve
Power Increase Solenoid Valve
Oil Cooler Fan Control Solenoid Valve
2
MAIN PUMP DELIVERY PRESSURE
MPa (kgf/cm )
2
MAIN RELIEF PRESSURE
MPa (kgf/cm )
Boom, Arm, Bucket, and Bucket Open (LD)
11510
5.50.6
7300 or more
4.90.5 (505)
3.90.5 (405)
3.6 (37) or less
Power Boost
Travel
Swing
OVERLOAD RELIEF PRESSURE
Arm Roll-out (BH), Arm Retract (LD)
Remarks
Refer to T4-5-8
31.51.0
(32010)
33.31.0
(34010)
29.41.0
(30010)
29.41
(30010)
MPa (kgf/cm )
T4-2-3
34.31.0-0
(35010-0)
33.31.0-0
(34010-0)
17.71.0-0
(18010-0)
2 or less
5 or less
Refer to T4-5-12
P
MPa (kgf/cm2, psi)
8.4 (86, 1218)
15.7 (160, 2276)
33.3 (340, 4828)
12.6 (128, 1827)
19.9 (203,2885)
33.3 (340, 4828)
19.2 (196, 2784)
26.5 (270, 3842)
33.3 (340, 4828)
Q
(Flow
Rate)
L/min
Q
(Flow
Rate)
L/min
600
A
500
600
G
SP Mode Control
(Pz) = 3.30 MPa
500
400
400
300
200
H
300
E Mode Control
(PG) = 2.08 MPa
I
F
C
100
200
100
10
15
20
25
30
P (Pressure)
MPa
T183-04-04-005
B
C
10
15
20
25
30
P (Pressure)
MPa
T183-04-04-017
T4-2-4
T4-3-1
T4-3-2
Deceleration Zone
3 to 5 m
Finish
Track Sag
490 to 550 mm
(19 to 22 in)
Measurement:
1. Measure travel time at both fast and slow travel
speeds.
2. Engine Control Dial : Maximum Position
3. Start machine to travel from the rear end of the
acceleration zone by moving the travel levers full
stroke.
4. Measure the time required to travel the travel test
distance 20 m (65.5 ft).
5. After measuring the forward travel time, rotate
the machine upperstructure 180. Then, measure
the reverse travel time on the way back to the
starting position in the same method.
6. Repeat steps (4) and (5) three times and
calculate the average values.
Evaluation:
Refer to T4-2 Operational Performance Standard.
Remedy:
Refer to the T5-5 Troubleshooting B.
T4-4-1
T145-05-03-001
Start
Acceleration Zone
3 to 5 m
T142-05-03-001
T145-05-03-005
90 to 110
T142-05-03-011
Measurement:
1. Measure the track rotation time at both fast and
slow travel speeds.
2. Engine Control Dial : Maximum Position
3. Operate the travel control lever of the raised
track in full forward and reverse.
4. After the track revolution attains to constant
speed, measure the time required for the marked
shoe to rotate three times in both directions.
5. Raise the other side of the track and repeat the
procedure.
6. Repeat steps (3) and (4) three times and
calculate the average values.
Evaluation:
Refer to T4-2 Operational Performance Standard.
T142-05-03-012
Forward
Reverse
T145-05-03-001
Remedy:
Refer to the T5-5 Troubleshooting B.
T4-4-2
Measurement:
1. Measure the amount of mistracking in both fast
and slow travel speeds.
2. Engine Control Dial : Maximum Position
3. Start machine to travel from the rear end of the
acceleration zone by moving both travel levers
full stroke.
4. Draw a 20 m (65.5 ft) straight line along the rut
from the travel start point to the travel end point
as illustrated. Measure the maximum distance
between the rut and the straight line.
5. Conduct the measurement in both forward and
reverse travel operation in the same method.
6. Repeat steps (4) and (5) three times and
calculate the average values.
T145-05-03-005
T145-05-03-006
Deceleration Zone
3 to 5 m
Acceleration Zone
3 to 5 m
Evaluation:
Refer to T4-2 Operational Performance Standard.
T115-07-03-005
Remedy:
Refer to the T5-5 Troubleshooting B.
T4-4-3
Preparation:
1. The surface of the test slope shall be even with a
gradient of 20 % (11.31).
2. Hold the bucket 0.5 to 1.0 m (20 to 39 in) above
the ground with the arm and bucket fully rolled in.
3. Maintain the hydraulic oil temperature at 505 C
(1229 F).
T142-05-03-002
Measurement:
1. Climb the slope and place the travel levers in
neutral.
2. Stop the engine.
3. After the machine stops, put alignment marks on
a track link or shoe, and the track side frame.
4. After 5 minutes, measure the distance between
the marks on the track link or shoe and the track
side frame.
Evaluation:
Refer to T4-2 Operational Performance Standard.
0.5 to 1.0 m
T118-04-03-001
T4-4-4
T145-05-03-007
T145-05-03-008
3 Revolutions
T145-05-03-009
Remedy:
Refer to the T5-5 Troubleshooting B.
T4-4-5
T4-4-6
T145-05-03-007
T145-05-03-008
Return the
swing control
lever to the
neutral position.
Drift
Amount
Rotate 180
Evaluation:
Refer to T4-2 Operational Performance Standard.
Start Rotation
Remedy:
Refer to the T5-5 Troubleshooting B.
T142-05-03-003
T4-4-7
T4-4-8
T142-05-03-004
T4-4-9
T142-05-03-004
T4-4-10
Dial
Gauge
Round Trunk
Magnet
Base
T105-06-03-015
A
B
D
C
T145-05-03-023
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Backhoe
Measurement : (h1)
Measurement : (h2)
T142-05-03-006
Loading Shovel
Measurement : (h1)
Measurement : (h2)
T142-05-03-005
T4-4-11
Backhoe
Boom Cylinder
T145-05-03-012
Arm Cylinder
T118-04-03-003
Bucket Cylinder
T145-05-03-014
Loading Shovel
Boom Cylinder
T145-05-03-015
Arm Cylinder
T145-05-03-016
Bucket Cylinder
T145-05-03-017
Dump Cylinder
T145-05-03-018
T4-4-12
T4-4-13
T145-05-03-020
Mark
T110-06-03-002
Mark
Measurement:
1. Stop the engine.
2. After five minutes have passed, measure the retractions of the boom, arm, and bucket cylinders
as illustrated
3. Repeat step (2) three times and calculate the
average values.
T110-06-03-001
Evaluation:
Refer to T4-2 Operational Performance Standard.
Solution:
Refer to T5-5 Troubleshooting B.
T4-4-14
T145-05-03-021
T107-06-03-003
T4-4-15
T107-06-03-004
T4-4-16
T107-06-03-005
COMBINED
OP-
Summary:
1. Check the combined operation performance
while operating the boom raise and swing simultaneously.
2. Run the engine at full speed and check if the
boom cylinders move without hesitating.
T142-05-03-007
Preparation:
1. Empty the bucket and position the machine with
front attachment positioned as illustrated.
2. Maintain the hydraulic oil temperature at 50 5
C (122 9 F).
CAUTION: Prevent personal injury. Always
make sure that the area is clear and that
co-workers are out of the swing area before
starting the measurement.
T142-05-03-008
Measurement:
1. Run the engine at the maximum speed with the
auto idle switch OFF.
2. Operate the boom raise and swing levers full
stroke. Measure the time required for the machine to swing 90 and bucket tooth tip height H
raised while swinging.
3. Repeat the measurement in both directions three
times and calculate the average values.
T142-05-03-009
Evaluation:
Refer to T4-2 Operational Performance Standard.
Solution:
Refer to T5-5 Troubleshooting B.
T142-05-03-010
T4-4-17
T4-4-18
Pressure Gauge
T4-5-1
T142-05-04-001
T183-04-04-001
Plug
Shim
T111-06-04-004
T4-5-2
LD: Tilt-Out)
Preparation:
1. Stop the engine.
Boom 2 (Lower)
BH: Arm 1
(Roll-Out)
LD: Arm 1
(Roll-In)
Bucket 1
(BH: Roll-In,
LD: Tilt-In)
BH: Arm 2
(Roll-in)
LD: Arm 2
(Extend)
BH: Auxiliary
LD: Bucket
(Close)
Boom 2
(Raise)
Bucket 2
(BH: Roll-in,
LD: Tilt-in)
BH: Arm 1
(Roll-In) T183-03-03-027
LD: Arm 1
(Extend)
Boom 3
(Lower)
Swing (Left)
BH: Bucket 3 (Roll-Out)
LD: Bucket 3 (Tilt-Out)
T183-03-03-030
Evaluation:
Refer to the Operational Performance Standard
group (T4-2).
T183-03-03-028
Left Travel
(Reverse)
Boom 1
(Raise)
BH: Arm 2
(Roll-Out)
LD: Arm 2
(Retract)
BH: Auxiliary
LD: Bucket (Open)
Boom 3 (Raise)
Swing (Right)
BH: Bucket 3 (Roll-In)
LD: Bucket 3 (Tilt-In)
BH: Arm 3 (Roll-In)
LD: Arm 3 (Extend)
T4-5-3
T183-03-03-031
Preparation:
1. Stop the engine.
Output Port
T183-05-04-019
2. Slowly loosen the cap to release air from the hydraulic oil tank.
3. Connect tee (ST 6450. For the power decrease
solenoid valve, power increase solenoid valve
and oil cooler fan control solenoid valve, use ST
6451) and pressure gauge (ST 6942) on the solenoid valve output port.
: 17 mm, 22 mm
Output Port
T183-05-04-018
4. Start the engine. Check the pressure gauge connection for oil leaks.
Output Port
T183-04-04-001
T4-5-4
Output Port
T183-04-04-001
Output Port
T183-05-04-017
Evaluation:
Refer to the Operational Performance Standard
group (T4-2).
Output Port
T183-05-04-016
Output Port
T4-5-5
T183-05-04-016
T4-5-6
Test Port
Test Port
Pressure Gauge
T183-04-04-002
Measurement:
1. Engine Control Dial : Maximum Speed
2. Measure the pressure with the control levers in
neutral.
3. Read the pressure gauge three times in total.
Calculate the average value.
Evaluation:
Refer to the Operational Performance Standard
group (T4-2).
Remedy:
Refer to the Troubleshooting B group (T5-5).
T4-5-7
T183-04-04-003
Test Port
Test Port
Pressure Gauge
T183-04-04-002
T183-04-04-003
Evaluation:
Refer to the Operational Performance Standard
group (T4-2).
T4-5-8
Pressure
Setting
Adjustment
Main Control Valve
Adjustment:
Adjust the main relief valve pressure settings using
plug (for the low-side main relief pressure) and
sleeve (for high-side main relief pressure) after
loosening lock nut (4).
High-Side
Main Relief
Adjustment Procedure
Pressure
Main Relief
Valve
Setting
T183-03-03-029
Main Relief
Valve
Low-Side
Main Relief
Adjustment Procedure
Pressure
Setting
Plug
T183-03-03-030
Lock Nut 2
Sleeve
Lock Nut 1
Piston
T162-04-04-010
Sleeve, Plug
Pressure
Increase
Pressure
Decrease
W107-02-05-127
T4-5-9
Adjustment:
Loosen the lock nut.
: 17 mm
1. Turn the adjusting screw to adjust the pressure
setting.
T142-01-02-011
Adjusting
Screw
Lock Nut
T142-02-02-006
Lock Nut
Pressure
Increase
Adjusting Screw
Pressure Decrease
T105-06-05-002
T4-5-10
Adjustment:
1. Loosen the lock nut.
: 19 mm
2. Turn the adjusting screw to adjust the pressure
setting.
: 6 mm
Travel Relief
Valve
T183-01-02-012
Lock Nut
Adjusting
Screw
T142-05-04-007
Lock Nut
Pressure
Increase
Adjusting Screw
Pressure
Decrease
W107-02-05-129
T4-5-11
RELIEF
VALVE
SET
Summary:
1. The circuit pressure must be increased by
applying an external force while blocking the
return circuit from the control valve. This
measuring method is hazardous and the results
obtained with this method are unreliable.
2. The oil flow rate used to set the overload relief
pressure is far less than that used to set the main
relief pressure. Therefore, measuring the overload pressure in the main circuit by increasing
the main relief set-pressure more than the overload valve set-pressure is not a proper method.
In addition, in case a main relief valve designed
to leak a small quantity of oil before reliving is
used, its pre-leaking start pressure must be increased more than the overload relief valve
set-pressure. However, the pre-leaking start
pressure is not always increased more than the
overload relief valve set-pressure as the adjustable upper limit of the main relief valve
set-pressure is provided. Accordingly, the overload relief valve assembly should be removed
from the machine and checked on a specified
test stand at a correct oil flow rate. Some overload relief valves come in contact with the control
valve body to block the oil passage. When this
type of overload relief valve is checked, the control valve body must be precisely finished as the
test unit. Provide one control valve other than
that on the machine as a test kit.
3. If the overload relief valve performance must be
checked on the machine, however, measure the
main relief pressure while releasing each front
function respective to the measuring overload
relief valve. And, assume that the overload relief
valve is functioning correctly if the obtained main
relief pressure is within the specified value range.
Measure the main pressure of the front functions
as follows:
T4-5-12
Lock Nut
Adjustment:
Adjust the pressure setting of the overload relief
valve using adjusting screw after loosening lock nut.
1. Loosen lock nut.
: 19 mm
2. Turn adjusting screw to adjust the pressure
setting referring to the table below.
: 6 mm
T162-04-04-004
Adjusting Screw
W107-02-05-129
Screw Turns
1/4
1/2
3/4
MPa
3.9
7.8
11.7
15.6
(kgf/cm )
(40)
(78)
(120)
(160)
(psi)
(566)
(1131)
(1697)
(2262)
Pressure Decrease
T4-5-13
Boom Mode
Selection
T183-03-03-028
Sleeve
Lock Nut
1/4
1/2
3/4
MPa
8.9
17.8
26.7
35.6
(kgf/cm )
(90)
(180)
(270)
(360)
(psi)
(1290)
(2581)
(3872)
(5162)
T183-04-04-007
Sleeve
Pressure
Increase
Pressure
Decrease
W107-02-05-127
T4-5-14
T4-5-15
to Main Pump 1,
2 and MC/V
to Main Pump 3
and SC/V
Delivery Hose
Split Flange
(ST 6133)
T183-04-04-013
Delivery Hose
Flange
(ST 6123)
Bolt
(ST 6458)
Test Hose
(ST 6145)
Main Pump
Test Hose
(ST 6145)
Split Flange
(ST 6133)
Bolt
(ST 6458)
Pipe
(ST 6132)
T183-04-04-014
Adapter
(ST 6069)
T4-5-16
T183-04-04-003
Port Psv
Port Pi
T183-01-02-006
Psv Pressure
Hose (ST 6961)
Tee (ST 6640)
Elbow (ST 6635)
Elbow (ST 6635)
T183-04-04-004
T4-5-17
T183-04-04-006
(Pump
Flow Rate)
Q
(Pump
Flow Rate)
Q
Pi
Pi
(Flow Rate Control
Pressure)
T4-5-18
2
3
4
5
T117-05-04-005
(Pump Delivery
Pressure)
T4-5-19
(Pump Delivery
Pressure)
1
2
T117-05-04-006
(Pump Flow
Rate)
Q
T4-5-20
P (Pump Delivery
Pressure)
T4-5-21
Delivery Hose
T183-04-04-015
Split Flange
(4506459)
Delivery Hose
Bolt
(ST 6408)
Adapter (ST 6146)
Test Hose
(ST 6145)
Test Hose
(ST 6145)
Flange(ST 6574)
Adapter(ST 6146)
Hydraulic Tester (ST 6299)
Bolt (ST 6408)
Split Flange
Pipe
(4506459)
(ST 6575)
Oil Cooler Fan
Motor Drive Pump
T183-04-04-018
T4-5-22
T183-04-04-019
Measurement:
1. Engine Control Dial: Maximum speed
T183-04-04-016
T4-5-23
NOTE: Turning adjusting screw (2) clockwise decreases the maximum flow rate, and turning counterclockwise increases. 1/4 turn of
adjusting screw (2) changes the flow rate
approx. 3 L/min (0.8 US gal/min).
Turning adjusting screw (4) clockwise increases the minimum flow rate, and turning counterclockwise decreases. 1/4 turn
of adjusting screw (4) changes the flow
rate approx. 3 L/min (0.8 US gal/min).
T183-03-01-003
(Pump
Flow Rate)
Q
(Pump
Flow Rate)
Q
Pi
Pi
(Flow Rate Control
Pressure)
T4-5-24
W117-02-02-017
(Pump Delivery
Pressure)
T4-5-25
1
2
T117-05-04-006
(Pump Flow
Rate)
Q
(Pump Flow
Rate)
Q
T4-5-26
P (Pump Delivery
Pressure)
T4-5-27
Cap
Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while
swinging the upperstructure.
Swing motor while swinging the upperstructure.
NOTE: The amount of drain oil from the swing
motor will change depending on hydraulic
oil temperature.
Maintain hydraulic oil temperature within
505 C (12241 F).
Preparation:
1. Maintain hydraulic oil temperature at 505 C
(12241 F). Rotate the swing motor to warm the
inside of the motor.
Drain Hose
M183-07-052
Front Side
T183-04-04-008
Drain Hose
T183-04-04-009
ST 6491
T183-04-04-010
T4-5-28
T145-05-03-007
T145-05-03-008
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Conversion of the amount of drain oil measured into
the per-minute value
First measure the amount of drain oil using a
calibrated container. Then, convert the measured
drain oil into the per-minute value using the formula
below:
Q = 60 q / t
T183-04-04-009
Where :
Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-29
Cap
Summary:
To check travel motor performance, measure the
amount of oil draining from the travel motor, while
rotating the travel motor with the measuring side
track jacked up.
Drain Hose
M183-07-052
M183-01-001
Drain Hose
Drain Hose
T157-05-04-019
ST 6637
T183-04-04-011
T4-5-30
T142-05-03-012
T4-5-31
T4-5-32
MEMO
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SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 General
Group 4 Troubleshooting A
Group 5 Troubleshooting B
18ET-5-1
Group 6 Troubleshooting C
Group 7 Troubleshooting D
Malfunction of Coolant
Temperature Gauge................................T5-6-2
Maintenance ...........................................T5-8-1
Inspections for Disconnecting
Indicator ...............................................T5-6-10
Connectors .............................................T5-8-3
Indicator ...............................................T5-6-18
18ET-5-2
TROUBLESHOOTING / General
INTRODUCTION
Refer to the inspection and troubleshooting procedures after any machine trouble has occurred. The
inspection and troubleshooting procedures are presented in an orderly fashion in this section to help you
quickly find the cause and solution of the machine
trouble.
The troubleshooting section in this manual consists of
8 groups; General, Cross Reference Table, Component Layout, Troubleshooting A (base machine diagnosis using the built-in diagnosing systems fault
codes), Troubleshooting B (base machine diagnosis
starting with inspection of abnormal operational
status), Troubleshooting C (monitor diagnosis), Troubleshooting D (engine diagnosis indicated by the
flashing pattern of indicator lights), and Electrical
System Inspection.
General
Cross Reference Table
Component Layout
Troubleshooting A (base machine diagnosis using the built-in diagnosing systems fault codes)
Troubleshooting B (base machine diagnosis
starting with inspection of abnormal operational
status)
Refer to these procedures when troubleshooting
by inspecting abnormal machine operational
status.
Example: Even if the fuel lever is operated, engine speed doesnt change.
Troubleshooting C (monitor diagnosis)
Refer to these procedures when gauges and/or
indicators are malfunctioning.
Example: The fuel gauge doesnt operate.
Troubleshooting D (engine diagnosis relies on
the flashing pattern of indicator lights)
The engine is diagnosed by referring to the flashing pattern of the engine warning indicator.
Electrical System Inspection
Refer to this group when required to obtain precautions and/or information for the electrical system
inspection.
Example: Fuse Inspection
T5-1-1
TROUBLESHOOTING / General
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient
troubleshooting:
1. Study the system
Study the machines technical manuals. Know the
system and how it works, and what the
construction, functions and specifications of the
system components are.
T107-07-01-001
T107-07-01-002
T5-1-2
T107-07-01-003
TROUBLESHOOTING / General
4. Operate the machine yourself
Try to identify the trouble by operating the
machine yourself.
If the trouble cannot be confirmed, stop the
engine and obtain further details of the
malfunction from the operator.
Also, check for any incomplete connections of
the wire harnesses.
5. Perform troubleshooting
T107-07-01-004
CAUTION: If a harness or pipe is disconnected with the engine running, the machine
may operate incorrectly, or high pressure oil
may spray, causing personal injury. Be sure
to disconnect harnesses or pipes after stopping the engine.
Perform self-diagnosis by operating the built-in
self-diagnosing system. In case any fault code
has been displayed by diagnosis using the
built-in self-diagnosing system, check the cause
of the trouble by referring to Troubleshooting A in
this section. After the machine trouble has been
corrected, the fault code will be deleted. If the
engine stop indicator and the engine warning indicator in the cab start flashing by the ECM diagnosis system, check the cause of the trouble
by referring to Troubleshooting D in this section.
Therefore, in case problems which are not easily
repredicable are encountered, use the built-in
self-diagnosing system and ECM diagnosis system to display the fault code. In case no fault
codes are displayed, check all related
parts/component operating condition using the
monitor function of the built-in self-diagnosing
system while referring to troubleshooting B in this
section.
T107-07-01-006
T5-1-3
TROUBLESHOOTING / General
BUILT-IN
DIAGNOSING
OPERATION
SYSTEM
Display
Selection Switch
SET Switch
Liquid Crystal
Display (LCD)
T183-01-02-013
Side Cover
M183-01-008
MC
Display
Selection
Switch
Machine
Front
ON
Neutral
OFF
T5-1-4
T183-05-01-001
TROUBLESHOOTING / General
(Blank)
T5-1-5
TROUBLESHOOTING / General
BUILT-IN
DIAGNOSING
DISPLAY LIST
Main Controller A
Display
Description
Order
1.
Hour Meter
2.
Trip1
3.
Trip2
4.
Engine Actual Speed
5.
Hydraulic Oil Temperature
6.
7.
8.
Fault Code *
9.
Main Pump 1 Pressure
10.
Main Pump 2 Pressure
11.
Main Pump 3 Pressure
12.
Front Operation Pressure
13.
Travel Operation Pressure
Engine Exhaust Gas
14.
Temperature
15.
FUNCTION
Monitored
Result
Unit
{{{{{ h
{{{{{ h
{{{{{ h
n {{{{
{{{
L1 {{
L2 {{{
0
{{
1
{{{{
2
{{{{
3
{{{{
4
{{{{
5
{{{{
6
0
min-1
C
MPa
MPa
MPa
MPa
MPa
C
EC Angle
Digital Input 0
7
8
{{{{
{{
Digital Input 1
{{
Digital Input 2
{{
Digital Input 3
{{
Digital Output
{{
Proportional Valve
ON/OFF Output
{{
{{{{
V
2 Digits displayed in
Hexadecimal Number
**
2 Digits displayed in
Hexadecimal Number
**
2 Digits displayed in
Hexadecimal Number
**
2 Digits displayed in
Hexadecimal Number
**
2 Digits displayed in
Hexadecimal Number
**
2 Digits displayed in
Hexadecimal Number
**
mA
{{{{
mA
16.
17.
18.
19.
20.
21.
22.
23.
T5-1-6
Remarks
Standard Mode
Standard Mode (Subtraction)
Standard Mode (Subtraction)
Possible to display
Possible to display
Display Purpose Only
Display Purpose Only
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Fixed by 0 C (32 F)
(Not used for the CUMMINS
engine)
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
TROUBLESHOOTING / General
Main Controller B
Display
Description
Order
1.
Hour Meter
2.
Trip1
3.
Trip2
4.
Engine Actual Speed
5.
Hydraulic Oil Temperature
6.
7.
8.
Fault Code *
9.
Digital Input 0
Monitored
Result
{{{{{ h
{{{{{ h
{{{{{ h
n {{{{
{{{
L1 {{
L2 {{{
0
{{
1
{{
10.
Digital Input 1
{{
11.
Digital Input 2
{{
12.
Digital Input 3
{{
13.
Digital Output 1
{{
14.
Proportional Valve
ON/OFF Output
{{
15.
Auto-Lubrication Status 1
{{
16.
Auto-Lubrication Status 2
(upper 4 bits)
Auto-Lubrication Status 2
(lower 4 bits)
Auto-Lubrication Interval
Selection
{{{{
{{{{
{{
Digital Output 2
(upper 4 bits)
Digital Output 2
(lower 4 bits)
{{{{
{{{{
17.
18.
19.
20.
21.
22.
23.
NOTE:
Unit
min-1
C
2 Digits displayed in
Hexadecimal Number
**
2 Digits displayed in
Hexadecimal Number
**
2 Digits displayed in
Hexadecimal Number
**
2 Digits displayed in
Hexadecimal Number
**
2 Digits displayed in
Hexadecimal Number
**
2 Digits displayed in
Hexadecimal Number
**
2 Digits displayed in
Hexadecimal Number
**
4 Digits displayed in
Binary Number ***
4 Digits displayed in
Binary Number ***
2 Digits displayed in
Hexadecimal Number
**
4 Digits displayed in
Binary Number ***
4 Digits displayed in
Binary Number ***
d
E
F
T5-1-7
Remarks
Standard Mode
Standard Mode (Subtraction)
Standard Mode (Subtraction)
Possible to display
Possible to display
Display Purpose Only
Display Purpose Only
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
Possible to display
TROUBLESHOOTING / General
Hexadecimal Number and 2 Digits Display
Correspondence Chart between
Number and Binary Number
Hexadecimal
Number
Binary Number
Hexadecimal
0000
0001
0010
0011
0100
0101
0110
0111
1000
1001
1010
1011
1100
1101
1110
1111
8
Upper
7
6
5
4
3
2
1
0
0
1
1
0
0
0
0
0
Main Controller A
bit Status of
Main Controller
(0)
Contact Terminal is
GND
Opened
Current
(1)
Contact Terminal
is Closed
3. If the value is "1", the terminal point corresponding the bit is closed. The contact terminal is connected to ground, so that power flows.
If the value is "0", the terminal point is opened, so
that current does not flow. (Refer to Diagram 1)
From the above information, it becomes apparent
that the engine oil level indicator on the monitor is
switched on, the heavy lift switch is turned on,
and the checker is disconnected.
4. Convert the value for digital input 1, digital input 2,
digital input 3 of the main controller A, and digital
input 0, digital input 1, digital input 2 and digital
input 3 of the main controller B. Then, calculate
the corresponding bit values.
T5-1-8
GND
TROUBLESHOOTING / General
In Case of Digital Output of Main Controller A
(Ex.) Monitor Display
51
c
Upper
bit
bit
bit
bit
bit
bit
bit
1
0
1
0
0
0
1
6
5
4
3
2
1
0
Main Controller A
bit Status of Main Controller
Current
Vcc
Load
(1)
GND
Vcc
Load
(0)
GND
T5-1-9
TROUBLESHOOTING / General
Correspondence Chart between Hexadecimal Number and Binary Number
Hexadecimal
Number
Binary Number
0000
0001
0010
0011
0100
0101
0110
0111
1000
1001
1010
1011
1100
1101
1110
1111
d
Upper
0
1
bit 5
bit
bit
bit
bit
bit
0
0
0
0
0
4
3
2
1
0
T5-1-10
Main Controller A
bit Status of Main Controller
Current
Solenoid Valve
(1) Energized
Solenoid Valve
(0) De-energized
TROUBLESHOOTING / General
BINARY NUMBER BIT LIST
Upper
Lower
Hexadecimal
Number
Binary
Number
bit 7
Main Controller A
Display
Description
Order
16
Digital Input 0
17
Digital Input 1
18
Digital Input 2
bit 6
bit
Digital Input 3
Digital Output
21
Proportional
Valve ON/OFF
Output
bit 3
bit 2
bit 1
Upper
bit 0
bit
Lower
3
2
1
0
3
2
1
0
3
0
1
Blank = 0
Blank = 0
3
2
1
0
Blank = 0
Blank = 0
Blank = 0
Blank = 0
2
1
0
3
2
Blank = 0
Engine Stop Output
Auto-Idle Output
Blank = 0
Blank = 0
Blank = 0
Blank = 0
7
6
5
4
7
20
bit 4
7
6
5
4
7
6
5
4
7
5
4
19
bit 5
6
5
4
7
6
5
4
T5-1-11
TROUBLESHOOTING / General
Upper
Lower
Hexadecimal
Number
Binary
Number
bit 7
Main Controller B
Display
Description
Order
bit 6
bit
bit 5
bit 4
bit 3
bit 2
bit 1
Upper
bit 0
bit
Lower
Digital Input 0
10
Digital Input 1
6
5
4
7
2
1
0
3
11
Digital Input 2
6
5
4
7
Blank = 0
Travel Mode Switch
Auto-Lubrication Timer Switch (B)
Blank = 1
2
1
0
3
12
Digital Input 3
13
Digital
1
6
5
4
7
6
5
4
7
2
1
0
3
2
1
0
3
14
Proportional
Valve ON/OFF
Output
Blank = 0
Auto-Lubrication Interval Set (B)
Auto-Lubrication Cycle Switch (B)
Hydraulic Oil Level Alarm Output
Load Dump Prevention Output
Step Light Output
Auto-Lubrication Relay Output
Boom Mode Selection Solenoid
Valve Output
Travel Mode Control Solenoid Valve
Output
Blank = 0
Blank = 0
Auto-Lubrication Activating
Auto-Lubrication Indication
Auto-Lubrication Error Occurrence
Blank = 0
Blank = 0
1
0
3
2
1
0
Blank = 0
Blank = 0
Blank = 0
Blank = 0
Lubrication Selection
Lubrication Selection
15
Output
Auto-Lubricatio
n Status 1
7
6
5
4
7
3
2
1
0
3
6
5
4
7
6
5
4
Auto-Lubrication
T5-1-12
TROUBLESHOOTING / General
NOTE: No need to convert to binary number.
Display
Description
Upper
Data Set Value
Order
(Long, Middle, Short) =
0
(80, 70, 60) min
Selection of
(Long, Middle, Short) =
18
Auto-Lubrication
1
(50, 40, 30) min
Interval
(Long, Middle, Short) =
2
(30, 20, 10) min
Lower
Interval Value
Long
Middle
Short
bit 3
Main Controller B
Display
Description
Order
16
Auto-Lubrication
Status 2
(upper 4 bits)
17
Auto-Lubrication
Status 2
(lower 4 bits)
19
Digital Output 2
(upper 4 bits)
20
Digital Output 2
(lower 4 bits)
bit 2
bit 1
bit 0
bit
3
2
1
0
3
2
1
0
3
2
1
0
3
2
1
0
Auto-Lubrication Activating
Auto-Lubrication Indicator
Auto-Lubrication Error Occurrence
Blank = 0
Blank = 0
Blank = 0
Lubrication Selection
Lubrication Selection
Hydraulic Oil Level Indicator
Load Dump Prevention Output
Step Light Output
Auto-Lubrication Relay Output
Auto-Lubrication Indicator Output
Blank = 0
Blank = 0
Blank = 0
T5-1-13
TROUBLESHOOTING / General
MAIN CONTROLLER FAULT CODE LIST
Main Controller A
Fault Code
Trouble
00
Normal
01
Abnormal EEPROM
02
Abnormal RAM
03
Abnormal A/D Conversion
04
Abnormal Sensor Voltage
05
Abnormal Engine Speed
06
07
08
09
10
11
12
13
14
25
Cause
Faulty Main Controller A
T5-1-14
TROUBLESHOOTING / General
Main Controller B
Fault code
Trouble
30
Normal
31
Abnormal EEPROM
32
Abnormal RAM
33
Abnormal A/D Conversion
34
Abnormal Sensor Voltage
37
Abnormal Main Controller B Reception
(Between Main Controller B and Built-In
Diagnosing System)
Cause
Faulty Main Controller B
Faulty Main Controller B
Faulty Main Controller B
Faulty Harness
T5-1-15
TROUBLESHOOTING / General
(Blank)
T5-1-16
Position
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
017
018
019
020
021
022
023
024
025
026
027
028
029
030
031
032
033
1G
1G
2G
1H
2K
2B
4C
4I
5C
5F
6H
6H
6I
5J
8C
7C
7C
7D
7D
7D
7D
7E
7E
7E
8D
8D
8D
8D
8D
8D
8D
8D
8D
Component Name
Work Light (on Cab Roof)
Work Light (at the right side of Frame)
Work Light (Under Cab Floor)
Horn
Fresh Air Sensor (Air Conditioner)
DLU (Cummins)
Data Link Connector
RADIO
DLU (Mitsubishi)
Sunlight Sensor
Wiper Relay (Low)
Wiper Relay (High 1)
Wiper Relay (High 2)
Air Conditioner Unit
Monitor
Coolant Temperature Gauge
Fuel Gauge
Liquid Crystal Display (LCD)
Switch Panel 1
Auto-Idle Indicator
Quick-Idle Indicator
Lubrication Mode Indicator (OFF)
Lubrication Mode Indicator (Manual)
Lubrication Mode Indicator (Auto)
Overheat Indicator (L1)
Air Filter Restriction Indicator (L2)
Fuel Level Indicator (L3)
Preheat Indicator (L4)
Download Indicator (L5)
Alternator Indicator (L6)
Engine Oil Pressure Indicator (L7)
Pump Transmission Oil Pressure Indicator (L8)
Exhaust Gas Temperature Indicator (L9)
T5-2-1
Page
T5-3-2
T5-3-2
T5-3-2
T5-3-2
T5-3-2
T5-3-4
T5-3-3
T5-3-4
T5-3-2
T5-3-4
T5-3-4
T5-3-4
T5-3-2
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
Item
Number
1
4
31
8
10
10
10
32
26
25
24
2
14
15
33
16
34
35
32
32
32
30
31
17
28
29
18
27
26
19
Note
No.
Position
034
035
036
037
038
039
040
041
044
045
046
047
048
049
050
051
052
053
054
055
056
057
058
059
060
061
062
063
064
065
8D
8D
8D
8E
8E
8E
8I
8G
10G
10G
9L
9L
9L
9L
10K
10K
11K
11K
11K
12K
14K
11D
11F
12F
11G
11H
14D
14D
14D
14D
Component Name
Engine Oil Level Indicator (L10)
Coolant Level Indicator (L11)
Hydraulic Oil Level Indicator (L12)
Auto-Lubrication Indicator (L13)
Engine Stop Indicator (L14)
Engine Warning Indicator (L15)
Travel Alarm Stop Switch (Option)
Washer Relay (R3)
Work Light Relay 1 (R5)
Quick Idle Relay (R9)
Heavy Lift Solenoid Valve (SC)
Travel Mode Control Solenoid Valve (ST)
Oil Cooler Fan Control Solenoid Valve (SF)
Power Increase Solenoid Valve (ST)
Oil Pressure Sensor 3
Oil Pressure Sensor 2
Oil Pressure Sensor 1
Hydraulic Oil Temperature Sensor
Pilot Pressure Sensor (Travel)
Pilot Pressure Sensor (All)
Solenoid Valve Unit
Quick Idle Switch
Horn Switch
Horn Relay (R6)
Power Transistor Unit 2
Power Transistor Unit 1
Auto-Idle Switch
Work Light Switch
Wiper/Washer Switch
Engine Control Dial
T5-2-2
Page
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-9
T5-3-3
T5-3-4
T5-3-4
T5-3-4
T5-3-2
T5-3-2
T5-3-10
T5-3-10
T5-3-2
T5-3-2
T5-3-2
T5-3-2
T5-3-2
T5-3-2
T5-3-2
T5-3-2
T5-3-2
T5-3-4
T5-3-4
T5-3-4
T5-3-9
T5-3-9
T5-3-9
T5-3-9
Item
Number
25
22
20
24
23
21
5
23
28
2
25
24
12
11
22
22
22
26
27
23
16
3
30
27
13
14
4
7
8
3
Note
No.
Position
066
067
068
069
070
071
072
073
074
075
076
077
078
079
080
081
082
083
084
085
086
087
088
089
091
092
093
094
095
096
097
14D
14D
13F
14F
13H
16A
16C
16D
16H
15K
16K
17F
17F
17F
17F
18H
18I
17K
18K
18H
19H
20K
17C
18C
18G
19G
19B
20C
22B
21C
21F
Component Name
Travel Mode Switch
Power Mode Switch
Auto-Idle Relay (R6)
Engine Protection Relay (R27)
Flow Rate Decrease Solenoid Valve Relay (R7)
Fuse Box 1
Fuse Box 2
DC/DC Converter
MC Display Selection Switch
Flow Rate Decrease Solenoid Valve
Pump Transmission Oil Pressure Switch
Boom Mode Selection Switch
Buzzer Cancel Switch
Heavy Lift Switch
Entrance Light Switch
Power Transistor Unit 3
Main Controller B (MCX-B)
Hydraulic Oil Level Switch1
Hydraulic Oil Level Switch2
Auto-Lubrication Relay (R11)
Auto-Lubrication (ALU) Timer Switch
Air Cleaner Restriction Switch
Entrance Light Relay
Load Dump Relay
Preheat Indicator Relay (R13)
Coolant Level Sensor Relay (R30)
Key Switch
Engine Stop Relay
Engine Stop Solenoid Relay (R18)
Entrance Light
Engine Warning Indicator Relay (R15)
T5-2-3
Page
T5-3-9
T5-3-9
T5-3-4
T5-3-4
T5-3-4
T5-3-4
T5-3-4
T5-3-2
T5-3-3
T5-3-10
T5-3-10
T5-3-9
T5-3-3
T5-3-9
T5-3-9
T5-3-4
T5-3-4
T5-3-2
T5-3-2
T5-3-4
T5-3-9
T5-3-2
T5-3-4
T5-3-4
T5-3-9
T5-3-4
T5-3-2
T5-3-4
Item
Number
6
5
6
7
1
17
18
29
3
14
5
13
4
12
36
12
16
28
28
3
11
14
20
4
9
21
33
9
Note
No.
Position
098
099
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
21G
21I
21I
22I
22I
23B
22F
25B
25B
25B
25B
25C
25C
25C
25C
26E
25F
26B
28C
28C
29D
29F
Component Name
Engine Stop Indicator Relay (R16)
Cummins Indicator Panel
Protction Indicator (L3)
Stop Indicator (L2)
Warning Indicator (L1)
Starter Relay (R19)
ECM Relay (R17)
Fusible Link 1 (45A)
Fusible Link 2 (75A)
Fusible Link 3 (75A)
Fusible Link 4 (45A)
Fusible Link 5 (250A)
Fusible Link 6 (100A)
Fusible Link 7 (125A)
Fusible Link 8 (125A)
Auto-Lubrication Device
Fuel Level Sensor
1 Pole Junction
Battery Relay 2
Battery Relay 1
Battery (12Vx2)
Alternator
T5-2-4
Page
T5-3-4
T5-3-6
T5-3-4
T5-3-6
T5-3-6
T5-3-6
T5-3-6
T5-3-6
T5-3-6
T5-3-6
T5-3-6
T5-3-1
T5-3-2
T5-3-6
T5-3-6
T5-3-6
T5-3-1
T5-3-8
Item
Number
8
2
11
13
12
11
10
4
9
7
8
10
9
6
5
3
8
2
Note
No.
Position
120
121
122
123
124
125
126
127
128
129
130
29G
29G
29H
31F
30F
30G
31H
29J
9G
9I
27F
Component Name
Engine Oil Level Switch
Grid Heater Relay 1
Grid Heater Relay 2
Coolant Temperature Sensor
Starter 2
Starter 1
Engine Speed Sensor (Pump)
ECM (Cummins)
Work Light Relay 2 (R4)
Main Controller A (MCX-A)
Coolant Level Sensor
Page
T5-3-8
T5-3-8
T5-3-2
T5-3-2
T5-3-2
T5-3-8
T5-3-4
T5-3-4
T5-3-2
T5-2-5
Item
Number
6
5
15
15
19
1
22
15
12
Note
Position
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
017
018
1G, H
1I
1J
3C, E
3D
4H
5K
4I
2K
4B
4B
3D
4G
5J
019
020
021
022
023
024
025
026
027
028
029
030
7D
6D
9F
8G
9H
10B
10F
10F
11F
11F
11G
10K
Component Name
Front / Swing Pilot Valve
Travel Pilot Valve
Accumulator
Boom Cylinder
Bucket Cylinder
Shuttle Valve (Bucket Roll-In)
Shock Reducing Valve
Shuttle Valve (Pilot Pressure Control)
Pilot Shut-Off Valve
Oil Cooler
Oil Cooler Fan Motor
Arm Cylinder
Hydraulic Oil Tank
Shuttle Valve
(For Switching Pump 3 Control Pressure)
Swing Device
Travel Device
Brake Release Pressure Switch Valve
Shuttle Valve (Boom Raise Priority)
Signal Control Valve
Main Control Valve
Heavy Lift Solenoid Valve
Reducing Valve
Shuttle Valve (Swing Brake Release)
Travel Mode Control Solenoid Valve
Shuttle Valve (Auxiliary Circuit)
Arm Preference Valve
T5-2-6
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-30
T5-3-30
T5-3-30
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-30
Item
Number
6
30
29
5
1
18
16
17
27
13
14
3
7
10
T5-3-1
T5-3-1
T5-3-30
T5-3-30
T5-3-1
T5-3-1
T5-3-30
T5-3-30
T5-3-30
T5-3-30
T5-3-30
T5-3-30
11
21
6
9
19
12
4
3
7
5
2
11
Page
Note
No.
Position
031
032
033
034
035
036
037
038
039
040
041
042
043
044
045
046
047
048
12I
12K
15K
14K
16G
15I
16I
16I
17I
17I
18I
18H
20H
20H
20H
19I
19J
19J
Component Name
Swing Control Valve
Pump 3 Control Valve
Shockless Valve
Shuttle Valve (Swing Make-Up)
Engine
Main Pump 3
Main Pump 2
Oil Cooler Fan Motor Drive Pump
Pilot Pump
Transmission Lubrication Oil Pump
Main Pump 1
Flow Rate Decrease Solenoid Valve
Power Decrease Solenoid Valve (SA)
Power Decrease Solenoid Valve (SB)
Boom Mode Selection Solenoid Valve (SC)
Power Increase Solenoid Valve (ST)
Oil Cooler Fan Control Solenoid Valve (SF)
Pilot Filter
T5-2-7
Page
T5-3-1
T5-3-30
T5-3-30
T5-3-30
T5-3-1
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
Item
Number
24
13
14
15
17
10
8
4
7
6
3
14
16
17
18
11
12
13
Note
Position
001
002
003
004
005
006
007
008
009
010
011
012
013
014
015
016
017
018
1F, G
1H
1H
1I
1J
2C, E
2C, D
2D
3D
4H
5K
4I
2K
4B
4B
4D
4G
5J
019
020
021
022
023
024
025
026
027
028
029
030
7D
6D
9F
8G
9H
10B
10F
10F
11F
11F
11G
10K
Component Name
Front / Swing Pilot Valve
Pilot Valve (Bucket Open)
Travel Pilot Valve
Pilot Valve (Bucket Close)
Accumulator
Boom Cylinder
Bucket Cylinder
Dump Cylinder
Level Cylinder
Shuttle Valve (Bucket Roll-In)
Shock Reducing Valve
Shuttle Valve (Pilot Pressure Control)
Pilot Shut-Off Valve
Oil Cooler
Oil Cooler Fan Motor
Arm Cylinder
Hydraulic Oil Tank
Shuttle Valve
(For Switching Pump 3 Control Pressure)
Swing Device
Travel Device
Brake Release Pressure Switch Valve
Shuttle Valve (Boom Raise Priority)
Signal Control Valve
Main Control Valve
Heavy Lift Solenoid Valve
Reducing Valve
Shuttle Valve (Swing Brake Release)
Travel Mode Control Solenoid Valve
Shuttle Valve (Auxiliary Circuit)
Arm Preference Valve
T5-2-8
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-30
T5-3-30
T5-3-30
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-1
T5-3-30
Item
Number
6
33
30
34
29
5
1
35
32
18
16
17
27
13
14
3
7
10
T5-3-1
T5-3-1
T5-3-30
T5-3-30
T5-3-1
T5-3-1
T5-3-30
T5-3-30
T5-3-30
T5-3-30
T5-3-30
T5-3-30
11
21
6
9
19
12
4
3
7
5
2
11
Page
Note
No.
Position
031
032
033
034
035
036
037
038
039
040
041
042
043
044
045
046
047
048
12I
12K
15K
14K
16G
15I
16I
16I
17I
17I
18I
18H
20H
20H
20H
19I
19J
19J
Component Name
Swing Control Valve
Pump 3 Control Valve
Shockless Valve
Shuttle Valve (Swing Make-Up)
Engine
Main Pump 3
Main Pump 2
Oil Cooler Fan Motor Drive Pump
Pilot Pump
Transmission Lubrication Oil Pump
Main Pump 1
Flow Rate Decrease Solenoid Valve
Power Decrease Solenoid Valve (SA)
Power Decrease Solenoid Valve (SB)
Boom Mode Selection Solenoid Valve (SC)
Power Increase Solenoid Valve (ST)
Oil Cooler Fan Control Solenoid Valve (SF)
Pilot Filter
T5-2-9
Page
T5-3-1
T5-3-30
T5-3-30
T5-3-30
T5-3-1
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
T5-3-10
Item
Number
24
13
14
15
17
10
8
4
7
6
3
14
16
17
18
11
12
13
Note
T5-2-10
2
1
5
6
7
8
9
10
36
37
11
12
31
13
14
15
16
30
29
28
27
Loading Shovel
26
25
5
32
24
3
2
35
31
17
23
18
22
6 21
19
20
30
33
34
T183-01-02-016
1 - Bucket Cylinder
2 - Arm
11 - Swing Device
12 - Main Control Valve
21 - Travel Device
22 - Upper Roller
3 - Arm Cylinder
13 - Oil Cooler
23 - Lower Roller
4 - Boom
5 - Boom Cylinder
15 - Intercooler
25 - Center Joint
678910 -
16 17 18 19 20 -
26 27 28 29 30 -
Radiator
Engine
Pump Device
Signal Control Valve
Swing Bearing
T5-3-1
Track Adjuster
Pilot Shut-Off Valve
Front Idler
Accumulator
Travel Pilot Valve
31 - Bucket
32 - Level Cylinder
(Loading Shovel Only)
33 - Pilot Valve (Bucket Open)
(Loading Shovel Only)
34 - Pilot Valve (Bucket Close)
(Loading Shovel Only)
35 - Dump Cylinder
(Loading Shovel Only)
36 - Condenser (Air Conditioner)
37 - Fuel Cooler
7
8
11
9
10
34
12
(Refer to T5-3-4)
(Refer to T5-3-11)
13
33
32
14
31
30
29
15
16 (Refer to T5-3-10)
(Refer to T5-3-3)
28
17 (Refer to T5-3-10)
18 (Refer to T5-3-10)
(Refer to T5-3-30) 27
26
25
19 (Refer to T5-3-8)
24
(Refer to T5-3-30) 23
1 - Work Light (on Cab Roof)
20
22
21
2 - Monitor
4 - Work Light
(at the right side of Frame)
5 - Starter Relay 1
6 - Battery
15 - Starter 1,2
7 - Battery Relay
8 - Horn
T5-3-2
T18E-01-02-009
1
6
T18E-01-02-010
2
4
M18E-01-009
T18E-01-02-013
1 - 12 V Power Source
Terminal
2 - DC-DC Converter
6-
3 - MC Display Selection
Switch
T5-3-3
8-
9-
10
28
27
26
25
11
24
23
22
21
20
19
18
17
16
15
14
13
12
T18E-01-02-003
15 - Main Controller A
(MCX-A)
16 - Main Controller B
(MCX-B)
17 - Fuse Box 1
18 - Fuse Box 2
NOTE: The items with mark * are not used for the machine equipped with CUMMINS engine.
T5-3-4
T5-3-5
12 13
10 11
3
4
5
6
1234-
567-
Battery Relay 2
1 Pole Junction
Fusible Link 7 (125A)
T183-01-02-015
T5-3-6
Fusible Link 2
Fusible Link 3
Fusible Link 4
Fusible Link 5
Fusible Link 6
Fusible Link 7
Fusible Link 8
Circuit
Monitor, Back up Power Circuit
Main Controller B, DLU Main Power Circuit
ECM Power Circuit
Work Light Relays 1, 2 Power Circuit
Washer Relay, Wiper Relay (L, H1, H2),
Wiper Motor Power Circuit
Air Conditioner Power Circuit
Auto-Lubrication Solenoid Valve Relay, Flow Rate
Decrease Solenoid Valve Relay, Power Transistors 1, 2
and 3
DC-DC Converter Power Circuit
Main Controller A, B Solenoid Power Circuit
Travel Alarm Power Circuit
Monitor, Main Controller A Main Power circuit
Step Light Relay Power Circuit
Air Conditioner
Air Heater Signal Relay Power Circuit
Starter Relay Power Circuit
Alternator
Preheat Relay 1 Power Circuit
Preheat Relay 2 Power Circuit
T5-3-7
Connected
Fuse Box 1 (#1, #2)
Fuse Box 2 (#1)
Fuse Box 2 (#1114)
5
9
11
10
12
T18E-01-02-011
1 - ECM (Cummins)
2 - Alternator
3 - Engine Speed Sensor 1
(ECM)
4-
7-
Preheat Relay
8-
Starter
9-
Coolant Temperature
Sensor (ECM)
T5-3-8
14
15
1
35
34
16
33
32
31
3
30
29
28
5
6
27
26
7
8
25
17
18
19
20
T183-01-02-013
24 23
22 21
10
13
12
11
36
M183-01-035
T183-01-02-010
1 - Monitor Panel
2 - Quick Idle Switch
3 - Engine Control Dial
4 - Auto-Idle Switch
16 - Switch Panel 1
8 - Wiper/Washer Switch
9 - Key Switch
NOTE: The Item with mark * is not used for the machine equipped with CUMMINS engine.
T5-3-9
Pump Device
10
9
8
7
4
18
Solenoid Valve
Unit
T183-01-02-006
11
17
16
12
15
Front
13
14
T183-01-02-007
6 - Transmission Lubrication
Oil Pump
7 - Pilot Pump
3 - Main Pump 1
8 - Main Pump 2
10 - Main Pump 3
T5-3-10
T18E-01-02-012
T5-3-11
Auxiliary: BH
Bucket
Open/Close: LD
10
34
Arm 1
Arm 2
11
33
Boom 2
Boom 1
12
32
13
14
31
Bucket 2
15
Bucket 1
16
30
17
18
Left Travel
29
28
19
Right Travel
27
26
25
24
23
22 21
20
T18E-03-03-001
T5-3-12
15, 16 18
E
Section A
26
27
25
10
Front
27
26
31
29
24
33
Section B
T183-03-03-003
23
T183-03-03-002
Section C
36
35
Right Travel
39
Bucket 1
Left Travel
40
Bucket 2
18
29
17
19
28
21
20
18
29
T183-03-03-004
37
T183-03-03-005
38
41
42
T5-3-13
Auxiliary: BH
Bucket
Open/Close: LD
10
34
Arm 1
Arm 2
11
33
Boom 2
Boom 1
12
32
13
14
31
Bucket 2
15
Bucket 1
16
30
17
Left Travel
18
29
28
19
Right Travel
27
26
25
24
23
22 21
20
T18E-03-03-001
T5-3-14
Section D
44
Boom 1
Section E
47
48
Boom 2
Arm 2
16
31
33
Arm 1
12
34
15
13
30
6
3
14
2
11
31
T183-03-03-007
32
49
46
50
T183-03-03-006
45
51
Auxiliary (BH)
Bucket Open/Close (LD)
Section F
10
Section G
11
T183-03-03-009
9
34
52
T183-03-03-008
T5-3-15
11
Boom 3
10
Swing
Bucket 3
Arm 3
7 - Check Valve
(Arm 3)
8 - Make-Up Valve
(Arm 3)
9 - Overload Relief Valve
(Swing)
T5-3-16
T18E-03-03-002
Section A
14
16
18
1
B
10
T183-03-03-011
13
Section B
15
T183-03-03-012
19
14
Section C
11
17
Swing
Boom 3
3
2
10
11
15
T183-03-03-013
13
T5-3-17
T183-03-03-014
11
Boom 3
10
Swing
Bucket 3
Arm 3
12-
4-
7-
Check Valve
(Arm 3)
8 - Make-Up Valve
(Arm 3)
9 - Overload Relief Valve
(Swing)
T5-3-18
T18E-03-03-002
18
Section D
Section E
Bucket 3
Arm 3
5
4
T183-03-03-015
17
19
T183-03-03-016
Section F
T183-03-03-017
T5-3-19
T5-3-20
Pilot Valve
Side
T178-03-06-016
Shockless Valve
Auxiliary
Auxiliary
Priority Valve
T178-03-06-002
T5-3-21
Connecting to
Right Pilot Valve
Right Pilot Valve
Left Pilot Valve
Port D
Port E
Port F
Port G
Port H
Port I
Port J
Port K
Port L
Port M
Port N
Port SA
Port SB
Port PI
Port PH
Port SH
Port DF
T5-3-22
Note
Boom Raise Pilot Pressure
Boom Lower, Bucket Roll-Out Pilot Pressure
Arm Roll-Out Pilot Pressure (BH)
Arm Roll-In Pilot Pressure (LD)
Boom Raise Pilot Pressure
Returning to Hydraulic Oil Tank
Arm Roll-Out Pilot Pressure (BH)
Arm Roll-In Pilot Pressure (LD)
Arm Roll-In Pilot Pressure (BH)
Arm Roll-Out Pilot Pressure (LD)
Bucket Roll-In Pilot Pressure
Left Travel Forward Pilot Pressure
Left Travel Forward Pilot Pressure
Right Travel Forward Pilot Pressure
Right Travel Forward Pilot Pressure
Auxiliary Pilot Valve (BH)
Bucket Open Pilot Valve (LD)
Auxiliary Pilot Valve (BH)
Bucket Open Pilot Valve (LD)
Pump 1 and 2 Control Pressure
Plug
Primary Pilot Pressure
Primary Pilot Pressure (Heat Circuit)
Plug
Returning to Hydraulic Oil Tank
PH
A
E
M
D
H
B
SB
G
PI
Pilot Valve
Side
I
SH
J
DF
SA
L
T178-03-06-016
T5-3-23
Connecting to
Control Valve
Control Valve
Port 7
Control Valve
Port 8
Port 9
Port 10
Port 11
Port 12
Port 13
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Port 14
Control Valve
Port SE
Port SM
Port SN
Port SP
Port SL
Port SK
Shuttle Valve
Shuttle Valve
Shuttle Valve
Shuttle Valve
Control Valve
T5-3-24
Note
Boom Raise Pilot Pressure
Plug
Plug
Plug
Plug
Arm Roll-Out Pilot Pressure (BH)
Arm Roll-In Pilot Pressure (LD)
Arm Roll-In Pilot Pressure (BH)
Arm Roll-Out Pilot Pressure (LD)
Bucket Roll-In Pilot Pressure
Left Travel Forward Pilot Pressure
Left Travel Reverse Pilot Pressure
Right Travel Forward Pilot Pressure
Right Travel Reverse Pilot Pressure
Auxiliary Close Pilot Pressure (BH)
Bucket Close Pilot Pressure (LD)
Auxiliary Open Pilot Pressure (BH)
Bucket Open Pilot Pressure (LD)
Boom Raise Priority Pilot Pressure
Auxiliary
Swing Brake Release
Swing Brake Release
Combiner Valve Shifting Pressure
Plug
3
5
1
13
2
SK
4
SE
8
S3
14
Control Valve
Side
7
9
6
10
SN
SL
11
12
T5-3-25
SP
T178-03-06-015
Priority Valve
{
{
{
{
{
{
{
{
{
T5-3-26
Boom
Bucket
Left Travel
Right Travel
Shockless Valve
6
Arm Flow Rate Control
Valve
P1 and P2 Pump Flow
Rate Control Valve
Flow Combiner Valve
Control Spool
Priority Valve
T183-03-06-001
17 16 15 14 13 12
1 - Auxiliary (BH), Bucket
Open/Close (LD)
6 - Right Travel
8 - Boom, Arm,
Bucket, Right
Travel
9 - Left Travel
11 10
7
14 - Boom, Arm, Bucket
T5-3-27
Swing Arm
Boom
Left Travel
Bucket
Right Travel
Shockless Valve
6
Arm Flow Rate
Control Valve
P1 and P2 Pump Flow
Rate Control Valve
Flow Combiner Valve
Control Spool
Priority Valve
T183-03-06-001
17 16 15 14 13 12
11 10
T5-3-28
Pilot Valve
Side
T178-03-06-016
7
16
17
15
13
11
14
10
12
4
2
T178-03-06-009
6 - Right Travel
8 - Boom, Arm,
Bucket, Right
Travel
9 - Left Travel
T5-3-29
Swing Device
20
19
9
4
Front
Side
8
5
T142-01-02-011
T183-01-02-008
Travel Device
Valves (2)
10
11
21
12
18
22
17
16
13
Valves (1)
15
14
T18E-01-02-002
T183-01-02-012
7 - Shuttle Valve
(Swing Brake Release)
8 - Pilot Pressure Sensor (All)
(Front Operation)
9 - Shuttle Valve
(Boom Raise Priority)
10 - Shuttle Valve
(For Switching Pump 3
Control Pressure)
11 - Arm Preference Valve
17 - Shuttle Valve
(Pilot Pressure Control)
T5-3-30
18 - Shuttle Valve
(Bucket Roll-In)
19 - Swing Parking Brake
Release Valve
20 - Swing Relief Valve
21 - Counterbalance Valve
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
Refer to troubleshooting A procedure in case any fault
codes are displayed after diagnosing the main
controller A and/or B using the built-in diagnosing
system.
YES (OK)
(2)
(1)
NO (NOT OK)
Key switch: ON
(3)
Refer to "Electrical System Inspection" group (Group 8) for descriptions in the dotted-line
box.
Use the built-in diagnosing system for descriptions in the double-line box.
Causes of machine problems are stated in the thick-line box. Scanning quickly through
the thick-line boxes allows you to estimate the possible causes before actually following
the flow chart.
Harness
Open End
Side
T5-4-1
TROUBLESHOOTING / Troubleshooting A
MAIN CONTROLLER FAULT CODE LIST
Main Controller A
Fault Code
Trouble
00
Normal
01
Abnormal EEPROM
02
Abnormal RAM
03
Abnormal A/D Conversion
04
Abnormal Sensor Voltage
05
Abnormal Engine Speed
06
Cause
08
09
10
11
12
13
25
07
T5-4-2
TROUBLESHOOTING / Troubleshooting A
Main Controller B
Fault Code
Trouble
Cause
30
Normal
31
Abnormal EEPROM
Faulty Main Controller B
32
Abnormal RAM
33
Abnormal A/D Conversion
34
Abnormal Sensor Voltage
Faulty Main Controller B
37
Abnormal Main Controller B Reception
Faulty Main Controller B
(Between Main Controller B and Built-In Faulty Harness
Diagnosing System)
T5-4-3
TROUBLESHOOTING / Troubleshooting A
MAIN CONTROLLER A
FAULT CODE 01
ABNORMAL EEPROM
FAULT CODE 02
ABNORMAL RAM
FAULT CODE 03
ABNORMAL A/D CONVERSION
YES
NO
NO
YES
FAULT CODE 04
ABNORMAL SENSOR VOLTAGE
YES
Faulty alternator.
NO
T5-4-4
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 05
ABNORMAL ENGINE SPEED
Disconnect connector
from engine speed
sensor 1. Check if
resistance between
sensor end connector
terminals #1 and #2
matches specification.
Specification: 200 to 300
NO
Main Controller A
Connector D
D14
Broken harness
between main
YES
controller A and
engine speed sensor
1 (terminal #1).
NO
Broken harness
between main
controller A and
engine speed sensor
1 (terminal #2).
Faulty engine speed
sensor 1.
NO
D13
YES
T183-05-04-009
T18E-05-04-001
T5-4-5
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 06
ABNORMAL MAIN CONTROLLER A
RECEPTION
(BETWEEN MAIN CONTROLLER A AND
MAIN CONTROLLER B)
Exchange main
controller A and main
controller B.
Turn off MC display
selection switch to
change the monitor
display to main controller
B.
Display the faulty code.
Check if Code 37 is
displayed.
YES
NO
D9
T183-05-04-009
Main Controller B
Connector D
D10
T183-05-04-009
T5-4-6
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 07
ABNORMAL MAIN CONTROLLER A
RECEPTION
(BETWEEN MAIN CONTROLLER A AND
DLU, OR BETWEEN MAIN CONTROLLER
A AND BUILT-IN DIAGNOSING SYSTEM)
Between Main Controller A and DLU
YES
Disconnect joining
connector between
DLU and main
controller A.
Check for continuity
between DLU harness
end connector 76B
terminal #32 and
joining connector DLU
end terminal #2.
YES
Faulty DLU.
NO
YES
Key Switch: ON
NO
Reconnect connector
D to main controller A.
Connect DLU harness
end connector 76B
terminals #41 and #33
with a clip.
and
NO
Check harness
between DLU harness
end connector 76B
terminal #41 and
connector D harness
end terminal #D11 for
breakage or short
circuit.
Broken harness
between DLU harness
YES end connector 76B
terminal #41 and
connector D terminal
#D11.
NO
Built-In
Broken harness
between main controller
A and monitor
controller.
YES
Check harness
between main
controller A connector
harness end terminal
#D10 and monitor
controller connector B
harness end terminal
#B1 for breakage or
short circuit.
Broken harness
between DLU harness
end connector 76B
terminal #33 and
connector D terminal
#D12.
NO
Connector
DLU
Main Controller
Connector D
Connector 76B
D10
D11
Monitor Controller
Connector B
D12
B1
Joining Connector
(Between DLU and
Main Controller A)
T18E-05-04-003
T183-05-04-013
T18E-05-04-002
T183-05-04-009
T5-4-7
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 08
ABNORMAL FRONT PILOT PRESSURE
FAULT CODE 09
ABNORMAL TRAVEL PILOT PRESSURE
Disconnect connectors
from all operation
pressure sensor and
NO travel pressure sensor.
Check if voltage
between harness end
connector terminals #1
and #3 is 50.5 V.
Key switch: ON
Check if fault codes are
switched after switching
all operation pressure
sensor with travel
pressure sensor and
retrying.
Check if voltage
between all operation
pressure sensor (or
travel pressure sensor)
harness end connector
NO terminal #1 and vehicle
frame matches
specification.
Key switch: ON
Specification: 50.5 V
C1
C23
C31
NO
Broken harness
between main
YES controller A and all
operation pressure
sensor or travel
pressure sensor
(terminal #3).
NO
Broken harness
between main
controller A and all
operation pressure
sensor or travel
pressure sensor
(terminal #1).
Faulty pressure
sensor.
YES
C1
Broken harness
between main
YES
controller A and all
operation pressure
sensor or travel
pressure sensor.
T5-4-8
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-4-9
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 10
ABNORMAL ENGINE
ANGLE
CONTROL
DIAL
Disconnect ECM
connector 31 poles.
Check harness
YES
between connector 31
poles harness end
terminal #5 and switch
box terminal #3 for
breakage or short
circuit.
Key switch: ON
NO
Disconnect ECM
connector 31 poles.
Check for continuity
between switch box
harness end
connector terminal #4
and ECM harness
end connector
terminal #6.
NO
NO
Faulty harness
between switch box
and engine control
dial.
Broken harness
between ECM and
engine control dial
(terminal #4).
NO
Switch Box
#4
#3
#2
T18E-05-04-004
T5-4-10
TROUBLESHOOTING / Troubleshooting A
YES
NO
Faulty ECM.
Broken harness
between ECM and
engine control dial
(terminal #2).
T5-4-11
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 11
ABNORMAL PUMP 1 DELIVERY
PRESSURE
FAULT CODE 12
ABNORMAL PUMP 2 DELIVERY
PRESSURE
FAULT CODE 13
ABNORMAL PUMP 3 DELIVERY
PRESSURE
Disconnect pump
delivery pressure
NO sensor. Check if
voltage between
harness end connector
terminals #1 and #3 is
50.5 V.
Key switch: ON
Check harness
between main
controller A connector
C (connector 31P)
harness end terminals
YES #C4 (pump 1), #C5
(pump 2) or #C6
(pump 3) and pump
delivery pressure
sensor terminal #2 for
breakage or short
circuit.
NO
Check if voltage
between pump delivery
pressure sensor
harness end connector
terminal #1 and vehicle
frame matches
specification.
Key switch: ON
Specification: 50.5 V
C23
C5
NO
Broken harness
between main
YES controller A and
pump delivery
pressure sensor
(terminal #3).
NO
Broken harness
between main
controller A and
pump delivery
pressure sensor
(terminal #1).
Faulty pump delivery
pressure sensor.
YES
C1
Broken harness
YES between main
controller A and
pump delivery
pressure sensor.
C6
C10
C31
T146-05-03-006
T5-4-12
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 25
ABNORMAL OIL TEMPERATURE SENSOR
Connect oil
temperature sensor
harness end connector
terminals #1 and #2
YES with a clip.
Remove connector B
and connector C from
main controller A.
Check for continuity
between connector B
harness end terminal
#B22 and connector C
terminal #C24.
Disconnect oil
temperature sensor.
Check if sensor end
connector resistance
matches specification.
NO
B19
B25
B22
Connector C
C10
C1
C23
C31
C24
Broken harness
between main
YES controller A and oil
temperature sensor
(terminal #1).
NO
Broken harness
between main
controller A and oil
temperature sensor
(terminal #2).
Faulty oil temperature
sensor.
NO
B1
YES
T5-4-13
TROUBLESHOOTING / Troubleshooting A
MAIN CONTROLLER B
IMPORTANT: The fault code is displays on the
monitor by the fault signal from
main controller B which comes via
main controller A.
Check that main controller A
operates
normally
before
performing troubleshooting of main
controller B.
FAULT CODE 31
ABNORMAL EEPROM
FAULT CODE 32
ABNORMAL RAM
FAULT CODE 33
ABNORMAL A/D CONVERSION
YES
YES
FAULT CODE 34
ABNORMAL SENSOR VOLTAGE
YES
NO
NO
T5-4-14
TROUBLESHOOTING / Troubleshooting A
FAULT CODE 37
ABNORMAL MAIN CONTROLLER B
RECEPTION
(BETWEEN MAIN CONTROLLER B AND
BUILT-IN DIAGNOSING SYSTEM)
YES
NO
T5-4-15
TROUBLESHOOTING / Troubleshooting A
SENSOR ACTIVATING RANGE
1. Checking Method
Power
Mode
Switch
Auto-Idle
Switch
S/P
OFF
Maximum
Speed
Pressure Sensor
Operation
Maximum Speed
Minimum Speed
Control Lever: Neutral
Pilot Control Shut-Off Lever: LOCK
Control Lever: Full Stroke
Pilot Control Shut-Off Lever: UNLOCK
T5-4-16
Specification
0.3 to 1.0 V
4.0 to 4.7 V
0 to 0.10 MPa
(0 to 1.0 kgf/cm2)
3.3 to 3.9 MPa
(34 to 40 kgf/cm2)
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when diagnosing
from the fault phenomenon.
On the front section pages of this group T5-5, there
are tables indicating the relationship between machine trouble symptoms and related parts which may
cause such trouble if failed.
Start the troubleshooting with more probable causes
selected by referring to these tables.
(2)
After checking or measuring item (1), select YES (OK) or NO (NOT OK)
and proceed to item (2) or (3), as appropriate.
(1)
NO(NOT OK)
Key switch: ON
(3)
Special instructions, or reference item are indicated in the spaces under the box. Incorrect
measuring or checking methods will render troubleshooting impossible, and may damage
components as well.
Use the built-in diagnosing system for descriptions in the double-line box.
Causes are stated in the thick-line box. Scanning through the thick-line boxes, possible
causes can be seen without going through the flow chart.
Harness
T5-5-1
TROUBLESHOOTING / Troubleshooting B
CORRELATION
BETWEEN
TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine
troubles and parts contributing to the cause of the
trouble if failed.
Engine System Troubleshooting
Trouble Symptom
Main Controller A
ECM
Monitor Controller
Switch Box
Pilot Pressure Sensor
Quick-Idle Switch
Auto-Idle Switch
Battery Relay
Starter Relay
Starter Relay 1
Starter Relay 2
Flow Rate Decrease Solenoid Valve Relay
Preheat Relay 1
Preheat Relay 2
Power Transistor 1
Power Transistor 2
Flow Rate Decrease Solenoid Valve
Power Decrease Solenoid
Valve
Engine Speed Sensor 1
Pump 1 and 2 Control
Valve (Signal Control
Valve)
E-1
E-2
z
z
z
z
z
z
z
z
Shuttle Valve
(Swing Make-Up)
Shockless Valve
(Pump 2 Regulator Pressure Pi Circuit Side)
Starter Motor
Engine Unit
Main Pump / Regulator
Shuttle Valve
E-3
Even if engine control
dial is rotated, engine
speed remains unchanged.
z
z
T5-5-2
E-4
Even if key switch is
turned OFF, engine
does not stop.
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.
E-5
Engine speed is slow,
or does not increase.
E-6
Quick-idle system is
inoperable.
z
z
E-7
E-8
E-9
z
z
z
z
z
z
T5-5-3
TROUBLESHOOTING / Troubleshooting B
Trouble Symptom
E-10
Engine stalls.
Main Controller A
ECM
Monitor Controller
Switch Box
Pilot Pressure Sensor
Quick-Idle Switch
Auto-Idle Switch
Battery Relay
Starter Relay
Starter Relay 1
Starter Relay 2
Flow Rate Decrease
Solenoid Valve Relay
Preheat Relay 1
Preheat Relay 2
Power Transistor 1
Power Transistor 2
Flow Rate Decrease
Solenoid Valve
Power Decrease
Solenoid Valve
Engine Speed Sensor 1
Pump 1 and 2 Control
Valve
(Signal Control Valve)
Shuttle Valve
(Swing Make-Up)
Shockless Valve (Pump 2
Regulator Pressure Pi
Circuit Side)
Starter Motor
Engine Unit
Main Pump / Regulator
Shuttle Valve
Air Heater (1)
Air Heater (2)
E-11
Even if preheat switch
is pressed, air heater
does not operate (Engine is difficult to start).
z
z
z
z
z
z
z
z
z
z
z
z
z
T5-5-4
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-5-5
TROUBLESHOOTING / Troubleshooting B
A-2
All actuators are inoperable.
A-3
A-4
SP mode is inoperable.
Parts
Main Controller A
Switch Box
Flow Rate Decrease Solenoid Valve
Power Decrease Solenoid
Valve
Power Increase Solenoid
Valve
Engine Speed Sensor 1
Spool
Main Relief Valve
Main Pump / Regulator
Pilot Pump
Pilot Valve
Pilot Relief Valve
Shuttle Valve
(Swing Make-Up)
Shockless Valve (Pump 2
Regulator Pressure Pi
Circuit Side)
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
T5-5-6
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.
A-5
E mode is inoperable.
z
z
T5-5-7
TROUBLESHOOTING / Troubleshooting B
F-1
F-2
F-3
F-4
Front attachment
moves slightly to the
opposite direction
against the lever operation (boom raise, arm
roll-out (BH), arm retract (LD) or bucket
close (LD)).
Parts
Main Controller A
Main Controller B
Heavy Lift Switch
Boom Mode Selection
Switch
Flow Rate Decrease Solenoid Valve Relay
Power Transistor 1
Heavy Lift Solenoid Valve
Boom Mode Selection
Solenoid Valve
Flow Rate Decrease Solenoid Valve
Spool
Overload Relief Valve
Load Check Valve
Shuttle Valve
Main Relief Valve
Boom Overload Relief
Change Valve
Main Pump / Regulator
Pilot Valve
Cylinder
Slow-Return Valve
Shockless Valve (Signal
Control Valve)
Arm Flow Rate Control
Valve (Signal Control
Valve)
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
T5-5-8
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.
F-5
F-6
F-7
F-8
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
T5-5-9
TROUBLESHOOTING / Troubleshooting B
S-1
Swing is unmoving,
slow or weak in power.
S-2
Swing drift is large
when stopping.
T-1
Both right and left
tracks do not rotate or
rotate slowly.
T-2
Fast travel is inoperable.
Parts
Main Controller B
Switch Box
Travel Mode Control Solenoid Valve
Main Pump / Regulator
Spool
Overload Relief Valve
Load Check Valve
Flow Combiner Valve
Shuttle Valve (Swing
Brake Release)
Pump 3 Control Valve
Reducing Valve
Priority Valve (Signal
Control Valve)
Flow Combiner Valve
Selection Spool (Signal
Control Valve)
Counterbalance Valve
Pilot Valve
Shuttle Valve (Pilot Selection)
Shuttle Valve (Swing
Make-Up)
Shockless Valve (Pump 2
Regulator Pressure Pi
Circuit Side)
Swing Motor
Swing Parking Brake Release Valve
Swing Reduction Gear
Swing Relief Valve
Travel Parking Brake
Travel Motor
Travel Reduction Gear
Travel Relief Valve
Center Joint
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
z
T5-5-10
TROUBLESHOOTING / Troubleshooting B
In case more than one trouble occurs at
the same time, find out all faulty components while checking all suspected components in each trouble symptom.
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.
T-3
Slow travel is inoperable.
T-4
T-5
T-6
Machine mistracks
during combined travel
and front attachment
operation.
z
z
z
z
z
z
z
z
z
z
z
z
z
T5-5-11
TROUBLESHOOTING / Troubleshooting B
O-1
O-2
O-3
O-4
Parts
Main Controller A
Main Controller B
Auto-Lubrication Selection Switch
Proximity Switch
Step Light Switch
Auto-Lubrication Relay
Step Light Relay
Power Transistor 3
Oil Cooler Fan Control
Solenoid Valve
Grease Pump
Oil Cooler Fan Motor
Drive Pump
Oil Cooler Fan Motor
Step Light
Follow Plate
z
z
z
z
z
z
z
z
z
z
T5-5-12
TROUBLESHOOTING / Troubleshooting B
NOTE: The trouble symptoms in this table are described provided that each trouble occurs
independently.
O-5
Step light does not
come ON.
O-6
Even if step light switch
is turned OFF, step light
does not come OFF
after 60 seconds.
O-7
Air conditioner.
T5-5-13
TROUBLESHOOTING / Troubleshooting B
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter does not rotate even if key switch is
turned to START position.
This problem is contributed to by many different
causes. Diagnose the power system and the relay
system separately to locate the cause of the problem.
(2)
To Relay System
Troubleshooting
(T5-5-16)
24 V
Key switch: ON
(1)
NO
To Power System
Troubleshooting
(T5-5-15)
Terminal B
Terminal C
Terminal M
T18E-05-05-010
T5-5-14
TROUBLESHOOTING / Troubleshooting B
(1) Power System Troubleshooting
(1)
Key switch: ON
Check if voltage at
battery relay terminal A is 24 V or
over.
NO
NO
Broken harness
between battery
relay terminal S
and fuse #10.
Broken harness
between battery
relay terminal A
and battery.
Broken harness
between battery
relay terminal B
and starter terminal
B.
YES
Connector
Battery Relay
T146-05-04-018
T5-5-15
TROUBLESHOOTING / Troubleshooting B
(2) Relay System Troubleshooting
Check if voltage
YES at starter relay 1
and 2 terminal S
is beyond 24V.
Disconnect starter
relay 1 and 2 terYES minal E. Check for
continuity between
harness end terminal E and vehicle
frame.
Broken harness
YES between starter relay 1 and starter
YES Check for continumotor 1 or starter
ity between terrelay 2 and starter
minal B and C.
motor 2.
NO
NO
Check if voltage
at starter relay
connector terminal #1 is beyond
24V.
Key switch: START
Check if voltage at
starter relay 1 and 2
NO output side is beyond 24V.
Broken harness
YES Remove starter
between starter
relay and starter
relay 1 and 2 terrelay 1 or 2.
minal #2. Check
for continuity between terminal #2 YES Faulty starter relay.
and vehicle frame.
NO
Faulty ground of
starter relay termiNO nal #2.
NO
Connector
Starter Relay 1
Starter Relay 2
Starter Relay 1
Starter Relay 2
T18E-05-05-002
T146-05-04-009
T18E-05-05-004
T18E-05-05-003
T5-5-16
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-5-17
TROUBLESHOOTING / Troubleshooting B
E-2 Although starter rotates, engine does not
start.
YES
YES
YES
Remove connector
31 poles. Check if
voltage at harness
end connector terminal #1 is 24V.
NO
Key switch: ON
YES
Check if voltage at
input side of fuse
NO box 2 terminal #3 is
24V.
Key switch: ON
Remove ECM
connector 21
poles.
Check if voltage
at harness end
connector terminals #G and #D is
24V respectively.
NO
YES
NO
Faulty engine.
(Refer to the Engine
Manual)
Check if voltage at
fuse box terminal #2
is 24V.
NO
Connector
ECM Connector 21 Poles
#D
#1
T18E-05-05-005
T5-5-18
T18E-05-04-004
TROUBLESHOOTING /Troubleshooting B
(Blank)
T5-5-19
TROUBLESHOOTING /Troubleshooting B
E-3 Even if engine control dial is rotated, engine
speed remains unchanged.
T5-5-20
TROUBLESHOOTING /Troubleshooting B
E-4 Even if key switch is turned OFF, engine
does not stop.
T5-5-21
TROUBLESHOOTING /Troubleshooting B
E-5 Engine speed is slow, or does not increase.
YES
YES
NO
Resistance specification:
50.5 k
Voltage specification:
0.3 to 1 V
NO
T5-5-22
TROUBLESHOOTING /Troubleshooting B
YES
NO
NO
NO
Connector
(Harness End Connector Viewed from the Open End
Side)
Switch Box
T183-05-04-004
T18E-05-04-004
T5-5-23
TROUBLESHOOTING /Troubleshooting B
E-6 Quick-idle system is inoperable.
YES
Faulty quick-idle
switch.
Disconnect
quick-idle switch.
Connect harness
end connector terminals with a clip.
Check if quick-idle
system is operated.
Engine: Running
Control lever: Neutral
NO
Disconnect monitor
controller connector
YES
C.
Check for continuity
between monitor controller terminal #C3
Disconnect monitor
controller connector
B.
Check for continuity
between monitor
controller harness
end connector terminal #B11 and
quick-idle switch
end terminal.
NO
NO
Connector C
C3
T183-05-04-014
B11
T183-05-04-013
T5-5-24
Connector
Monitor Controller
Connector B
Disconnect ECM
connector 31 poles.
Check for continuity
YES between monitor controller connector terminal #C3 and ECM
connector 31 poles
harness end terminal
#19.
TROUBLESHOOTING /Troubleshooting B
Broken harness
between ECM and
monitor controller.
NO
Faulty ECM.
YES
19
T18E-05-04-004
T5-5-25
TROUBLESHOOTING /Troubleshooting B
E-7 Auto-idle system is inoperable.
Connect connector.
Disconnect main
controller A conYES nector B.
Check for continuity between
harness end
connector terminal #B16 and vehicle frame.
Connect connector.
Disconnect main
controller A conYES nector A.
Check for continuity
between main controller terminal #A29
and vehicle frame.
Disconnect ECM
YES Faulty ECM.
connector 31
poles.
Connect main
controller conYES nector A terminal
#A29 to vehicle
frame.
Check for continuity between ECM
connector 31
Broken harness
poles terminal #20
between main conand vehicle frame.
NO troller and ECM.
NO
Broken harness
between main controller A and switch
box.
NO
Connector
Main Controller A
Connector A
B16
Connector B
#20
Switch Box
T183-05-04-004
A29
T183-05-04-005
T18E-05-04-004
T5-5-26
TROUBLESHOOTING /Troubleshooting B
(Blank)
T5-5-27
TROUBLESHOOTING /Troubleshooting B
E-8 Even if control lever is operated, speed does
not increase.
(with auto-idle ON)
The pilot sensor (front attachment), main controller A and/or harness may have trouble. In either
cases, fault code 08 is displayed on the built-in
diagnosing system.
Refer to Troubleshooting A.
T5-5-28
TROUBLESHOOTING /Troubleshooting B
E-9 Engine speed does not increase when a particular function is operated
(with auto-idle ON)
T5-5-29
TROUBLESHOOTING /Troubleshooting B
E-10 Engine stalls.
Install pressure gauge
on hose entering flow
YES rate decrease solenoid
valve input port.
Measure the pressure.
The engine speed sensor 1 and/or main controller A may have trouble. In either cases, fault code
05 is displayed on the built-in diagnosing system.
Refer to Troubleshooting A.
Check for loose harness connections beforehand.
Disconnect lines from
flow rate decrease solenoid valve. Check if
engine stalls when disconnected lines are
connected each other
directly.
YES
Check if output to flow
rate decrease solenoid valve is
normal.
Around
850 min-1
Check engine
speed.
Below
1400 min-1
Over
1400 min-1
NO
Connector
Main Controller A
Connector A
A19
A20
Connector D
Power Transistor 1
T183-05-04-011
A14
T183-05-04-010
T183-05-04-008
T183-05-04-009
D14
T5-5-30
TROUBLESHOOTING /Troubleshooting B
Faulty pump 1 and/or 2
flow rate control valve in
signal control valve.
Check if voltage at
flow rate decrease
solenoid valve relay connector terYES
minals #1 and #3
are 24 V.
NO
Check if voltage at
flow rate decrease
solenoid valve relay
YES connector terminal
#2 is 24 V.
NO
YES
(1)
Broken harness between
flow rate decrease solenoid valve and flow rate
decrease solenoid valve
relay.
Faulty regulator.
NO
YES
Input
Port
T183-05-04-010
T183-05-04-003
T183-05-04-012
T5-5-31
T146-05-03-006
TROUBLESHOOTING /Troubleshooting B
(1)
YES
NO
Check if engine
stalls after switching
power transistor 1
with power transistor
2 or power transistor
3.
T5-5-32
TROUBLESHOOTING /Troubleshooting B
(Blank)
T5-5-33
TROUBLESHOOTING /Troubleshooting B
E-11 Preheat does not operate.
(Engine is difficult to start)
YES
YES
Check voltage at
preheat signal
relay terminal #5
is 24V.
Broken harness
between ECM terminal #1 and preheat signal relay
terminal #1.
YES
Disconnect ECM
connector 2
poles.
Check voltage at
NO ECM end connector terminal
#1 is 24V.
Broken harness
between battery
and preheat signal
relay, or broken
fusible link 4.
Faulty preheat signal relay terminal
#2 ground.
NO
Faulty ECM.
NO
Conector
Preheat Signal Relay
(A)
ECM
5
T146-05-04-009
T18E-05-05-002
M
T183-05-04-102
1 To ECM
2 To GND
T183-05-04-102
T5-5-34
TROUBLESHOOTING /Troubleshooting B
YES
Check voltage at
YES
preheat relay
terminal M is
24V.
Check voltage at
YES
preheat relay
terminal B is 24V.
Check for contiYES nuity between
preheat relay
terminal #2 and
vehicle frame.
(A)
Check voltage at
preheat relay
terminal #1 is
24V.
NO
NO
Broken harness
between preheat
relay terminal #1
and preheat signal
relay terminal #5.
NO
YES
(B)
NO
(B)
Broken harness
between preheat
relay and air
heater.
NO
T5-5-35
TROUBLESHOOTING / Troubleshooting B
ALL ACTUATOR
SHOOTING
SYSTEM
TROUBLE-
YES
Check if output to
YES flow rate decrease
solenoid valve is
normal.
Built-in diagnosing system: Main controller A
Monitor item: Proportional valve ON/OFF
output: bit 6: #1, 2 pump
NO
power decrease solenoid valve output
Faulty main controller
NO
A.
NO
T5-5-36
TROUBLESHOOTING / Troubleshooting B
Output Port
To Main Pump 2 Regulator
Port Pi
Shuttle Valve
(Swing Make-Up)
Power
Decrease
Solenoid
Valve SB
Power Decrease
Solenoid Valve SA
Flow Rate
Decrease
Solenoid Valve
T183-05-04-026
Shockless Valve
T183-05-04-015
YES
Disconnect power
decrease solenoid
valve (SA, SB) output port. Place a
plug on port. Disconnected line is
left open to atmosphere.
Check if symptom
appears.
NO
NO
YES
Only main pump
2 output volume
decreases.
NO
T5-5-37
TROUBLESHOOTING / Troubleshooting B
A-2 All actuators are inoperable.
YES
NO
End
NO
T5-5-38
TROUBLESHOOTING / Troubleshooting B
A-3 Actuator does not stop even if lever is returned to neutral.
YES
T5-5-39
TROUBLESHOOTING / Troubleshooting B
A-4 SP mode is inoperable.
Faulty power increase solenoid valve ST and engine speed sensor 1 are suspected.
YES
Check if swing, travel right
YES and travel left single operation speed changes
when SP mode switch is
turned ON and OFF.
NO
Check if current at
power increase solenoid valve ST changes
in range of 255 to 416
mA.
NO
SP mode switch: ON
Turn engine control dial
to change engine
speed, then observe
pilot pressure change.
YES
Output Port
Power
Increase
Solenoid
Valve ST
Connector
Main Controller A
Connector A
A3
A4
T183-05-04-016
T183-05-04-008
T5-5-40
TROUBLESHOOTING / Troubleshooting B
YES
NO
NO
YES
Disconnect switch box.
Check for continuity between switch box end conYES nector terminals #6 and
#15.
SP mode switch: ON
NO
Connector
Switch Box
T183-05-04-004
T5-5-41
TROUBLESHOOTING / Troubleshooting B
A-5 E mode is inoperable.
NO
YES
Check if E mode
switch is normal.
E mode switch: ON
Built-in diagnosing system: Main controller A:
Monitor item: Digital
input: bit 3: E mode SW
Check if output to
power decrease solenoid valve is normal.
E mode switch: ON
Built-in diagnosing system: Main controller A
monitor item: Proportional valve ON/OFF
output: bit 6: #1, 2
Pump power decrease
solenoid valve output
YES
YES
Connector
Main Controller A
Connector A
A14
Connector B
B2
T183-05-04-005
T5-5-42
T183-05-04-010
TROUBLESHOOTING / Troubleshooting B
YES
Disconnect power decrease solenoid valve (SA)
from line, then connect
disconnected line directly.
Check if each operation
speed increases.
NO
Output Port
Input Port
T18E-05-05-001
T5-5-43
TROUBLESHOOTING / Troubleshooting B
FRONT ATTACHMENT SYSTEM TROUBLESHOOTING
F-1 Some front attachment movement is slow,
or is inoperable.
Measurement: Refer to
the OPERATIONAL
PERFORMANCE TEST
section.
Built-in diagnosing system: Main controller A
Monitor item: Main
pump 1
NO
YES
Faulty corresponding
overload relief valve.
Bound shockless valve
spool in signal control
valve (at boom raise
only).
Check if secondary
NO pressure at signal control valve inlet is normal.
NO
T5-5-44
TROUBLESHOOTING / Troubleshooting B
F-2 Front attachment drifts remarkably.
YES
Faulty corresponding
control valve (broken
spring, loose spool
NO
end).
Check if corresponding
overload relief valve is
NO normal.
Measurement: Refer
to the OPERATIONAL
PERFORMANCE
TEST section.
NO
Faulty corresponding
overload relief valve.
T5-5-45
TROUBLESHOOTING / Troubleshooting B
F-3 Front attachment moves slightly to the opposite direction against the lever operation
(boom raise, arm roll-out (BH), arm retract
(LD) or bucket close (LD).
NOTE: BH: Backhoe
LD: Loading Shovel
YES
YES
Check if corresponding
load check valve in control valve is normal.
Disassemble / Visual
Inspection
Check if slow-return
valve of corresponding cylinder is normal.
NO
Faulty corresponding
slow-return valve.
NO
T5-5-46
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-5-47
TROUBLESHOOTING / Troubleshooting B
F-4 Boom raise is slow at combined arm roll-out
(BH)/arm retract (LD) and boom raise operation.
NOTE: BH: BH: Backhoe
LD: Loading Shovel
The arm flow rate control valve in the signal control valve is switched at combined boom raise
and arm roll-out (BH)/arm retract (LD) operation,
so that pilot pressure is applied on both sides of
the arm 2 spool. Therefore, the arm 2 spool becomes neutral.
Check if secondary
pressures at signal
control valve inlet
ports D, A and F are
normal.
NO
NO
Port A
Port #1
Port D
Port SE
Port F
Control
Valve Side
Pilot Valve
Side
T178-03-06-016
T5-5-48
T178-03-06-015
TROUBLESHOOTING / Troubleshooting B
YES
T5-5-49
TROUBLESHOOTING / Troubleshooting B
F-5 Arm cylinder moves unevenly at combined
arm roll-out (BH)/arm retract (LD) and
bucket roll-in (BH)/bucket tilt-in (LD), boom
raise or swing operation.
NOTE: BH: Backhoe
LD: Loading Shovel
The arm preference valve is switched at combined arm roll-out (BH)/arm retract (LD) and
bucket roll-in (BH)/bucket tilt-in (LD), boom raise
or swing operation, so that the pilot pressure to
the arm 3 is blocked. Therefore, the arm 3 spool
does not move.
YES
YES
NO
NO
T5-5-50
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-5-51
TROUBLESHOOTING / Troubleshooting B
F-6 Single arm roll-in (BH)/arm extend (LD),
bucket roll-in (BH)/bucket tilt-in (LD) or
boom raise operation is slow.
NOTE: BH: Backhoe
LD: Loading Shovel
NO
YES
Check if pump 3 control valve is bound or
scored.
YES
T5-5-52
TROUBLESHOOTING / Troubleshooting B
YES
T5-5-53
TROUBLESHOOTING / Troubleshooting B
F-7 Heavy lift function does not operate.
NO
NO
NO
YES
NO
YES
T183-05-04-017
Connector
Heavy Lift Switch
Main Controller A
Connector A
A6
A7
Connector B
B11
T183-05-04-101
T5-5-54
T183-05-04-005
TROUBLESHOOTING / Troubleshooting B
YES
NO
T5-5-55
TROUBLSHOOTING / Troubleshooting B
F-8 Boom mode selection function does not
operate.
YES
Check if output to
boom mode selection
solenoid valve is
normal.
Boom mode selection
switch: ON
Built-in diagnosing system: Main controller B
Monitor item: Proportional valve ON/OFF
output: bit 7: Boom
mode selection solenoid valve output
NO
Interchange boom
mode selection
switch with heavy lift
switch and check if
system operates
properly.
Boom mode selection switch: ON
Disconnect boom
mode selection switch
and main controller B
connector B.
Check for continuity
NO between boom mode
selection switch harness end connector
terminal #3 and connector B harness end
connector terminal
#B12.
YES
NO
YES
Connector
Boom Mode Selection
Switch
Main Controller B
Connector A A3
A4
Connector B
B12
T183-05-04-010
T183-05-04-005
T183-05-04-101
T5-5-56
TROUBLSHOOTING / Troubleshooting B
NO
NO
YES
Boom Mode
Selection Solenoid
Valve SC
Front
T183-05-04-015
T5-5-57
TROUBLSHOOTING / Troubleshooting B
SWING SYSTEM TROUBLESHOOTING
S-1 Swing is unmoving, slow or weak in power.
NO
Check if swing
YES motor relief
pressure is
normal.
Built-in diagnosing
system: Main controller A
Monitor item: Main
pump pressure
Measurement:
Refer to the OPERATIONAL
PERFORMANCE
TEST section.
Faulty swing
control valve
spool.
Check if single
YES boom, bucket,
arm and swing
operations are
slower than
specification.
Check if shuttle
valve (pilot selection) or shuttle
valve (pump 3
control valve selection) is bound or
scored.
Check if shuttle
valve (pilot selection) is bound
or scored.
NO
Port Pi
T183-01-02-006
T5-5-58
TROUBLSHOOTING / Troubleshooting B
YES
YES
Check if swing parking
brake release valve is
NO bound or scored.
NO
YES
YES
NO Check if shuttle valve
(swing make-up) is
bound or scored.
Check if main
NO pump 2 delivery
pressure is normal.
Built-in diagnosing
system: Main controller A
Monitor item: Main
pump 2 pressure
YES
NO
Check if shockless
valve plunger is
NO bound.
YES
Check if pump 3 conYES trol valve is bound.
NO
T5-5-59
TROUBLSHOOTING / Troubleshooting B
S-2 Swing drift is large when stopping
Check if secondary
pilot pressure is 0
2
YES MPa (0 kgf/cm )
when swing lever is in
neutral.
NO
YES
NO
T5-5-60
TROUBLSHOOTING / Troubleshooting B
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Both right and left tracks do not rotate or
rotate slowly.
YES
Install tee to line of
travel parking brake release pressure port,
then install pressure
gauge.
Check if travel parking
brake release pressure
is normal.
Specification: 1.8 MPa (18
kgf/cm2) or over.
Measure pressure in jacking
up either side of track.
YES
T183-05-04-100
T5-5-61
TROUBLSHOOTING / Troubleshooting B
T-2 Fast travel is inoperable.
Travel mode
switch: ON
Faulty reducing
valve.
Measure pressure.
0 MPa
(0 kgf/cm2)
Disconnect switch
box and main controller B connector B.
Check for continuity
between switch box
harness end connector terminal #5
and connector B
harness end connector terminal #B13.
NO
Connector
(Harness End Connector Viewed from the Open End
Side)
Travel Mode Control
Solenoid Valve
(Lower Side)
Reducing Valve
Output Port
Main Controller B
Connector B B13
T183-05-04-021
T183-05-04-022
T183-05-04-020
Switch Box
Output Port
T183-05-04-019
T183-05-04-004
T5-5-62
TROUBLSHOOTING / Troubleshooting B
T-3 Slow travel is inoperable.
YES
NO
Disconnect main
controller B connector B.
Check for continuity
between connector B
harness end connector terminal #B13
and vehicle frame.
3.9 MPa
(40 kgf/cm2)
1.8 MPa
(18 kgf/cm2)
Disconnect line from
reducing valve output
port, then install pressure gauge on the port.
Measure pressure.
Travel mode switch:
OFF
3.9 MPa
(40 kgf/cm2)
Connector
(Harness End Connector Viewed from the Open End
Side)
Travel Mode Control
Solenoid Valve
(Lower Side)
Reducing Valve
(Travel Parking Brake)
Main Controller B
Connector B
Output Port
T183-05-04-021
Output Port
T183-05-04-020
T183-05-04-019
T5-5-63
TROUBLSHOOTING / Troubleshooting B
T-4 One side track does not move, moves
slowly or mistracks.
Check if secondary
travel pressure is normal.
Built-in diagnosing system: Main controller A
Monitor item: Travel
operation pressure
Measurement: Refer to
the OPERATIONAL
PERFORMANCE
TEST section.
Check if symptom is
YES reversed when right
and left travel line
hoses are switched
each other at the top
of center joint.
YES
NO
NO
Check if symptom is
reversed after switching
forward travel relief
valve with reverse travel
one, or right travel relief
valve with left one.
Measurement: Refer to
the OPERATIONAL
PERFORMANCE
TEST section.
Seal Location
2
2
Left Travel
(Forward)
4
Right Travel
(Reverse)
Left Travel
(Reverse)
6
7
Right Travel
(Forward)
T5-5-64
W183-03-08-001
TROUBLSHOOTING / Troubleshooting B
NO
Disassemble travel
motor counterbalance
valve.
YES Check for faulty parts.
NO
YES
YES
NO
2
3
W142-03-03-002
T5-5-65
TROUBLSHOOTING / Troubleshooting B
T-5 Travel motor runs excessively fast when
combined left travel and front attachment
operation is performed with left track off the
ground.
If the priority valve (travel motor overrun protection) in the signal control valve is stuck, the flow
combiner valve switches without right travel operating.
Same phenomenon can be observed when the
flow combiner valve is bound.
T5-5-66
TROUBLSHOOTING / Troubleshooting B
T-6 Machine mistracks during combined travel
and front attachment operation.
YES
YES
NO
NO
YES
NO
Control Valve
Side
Hose (G)
T183-05-04-025
T5-5-67
TROUBLSHOOTING / Troubleshooting B
OTHER SYSTEM TROUBLESHOOTING
0-1 Auto-lubrication indicator comes ON.
(Grease pump does not operate.)
(Empty grease in pump)
YES
Disconnect grease
pump.
Check if voltage at harness end connector terminal #1 is 24 V.
Key switch: ON
During grease pump
operation
YES
Disconnect
auto-lubrication relay.
Check if voltage between
NO harness end connector
terminals #1 and #3 is 24
V.
Reposition follow plate.
Disconnect grease pump air
lubrication hose at quick coupler.
Screw in and position follow
plate.
NO
T5-5-68
TROUBLSHOOTING / Troubleshooting B
NO
Connect connector.
Check if grease
pump operates afYES
ter switching power
transistor 3 with
power transistor 1
or power transistor
2.
Disconnect power
transistor 3.
Check if voltage at
harness end connector terminal #5 is 24 V.
YES
NO
NO
YES
NO
Connector
Auto-Lubrication Relay
Power Transistor 3
Main Controller B
Connector A
T183-05-04-011
T183-05-04-003
A26
T5-5-69
T183-05-04-008
TROUBLSHOOTING / Troubleshooting B
O-2 Grease pump operates excessively slow.
YES
NO
Check if coefficient of
grease viscosity becomes high due to winter or cold environment.
YES
YES
Check if manual/auto
selection valve near
grease pump is in
MANUAL position.
End
T5-5-70
TROUBLSHOOTING / Troubleshooting B
Connector
(Harness End Connector Viewed from the Open End
Side)
Proximity Switch
Power Transistor 3
#2
T183-05-04-011
T183-05-04-003
Main Controller B
Connector A
A26
Connector B
T183-05-04-005
B10
YES
NO
Disconnect power
transistor 3 and main
controller B connector
Connect proximity
YES A.
switch harness end
Check for continuity
connector terminal #2
between connector A
and vehicle frame with
harness end terminal
a clip.
#A26 and power tranNO
Disconnect main consistor 3 harness end
troller B connector B.
connector terminal #2.
Check for continuity
between main controller B harness conNO
nector terminal #B10
and vehicle frame.
Connect disconnected
YES connector.
Disconnect
auto-lubrication relay.
Check for continuity
between
auto-lubrication relay
terminals #3 and #5.
NO
Check if grease
pump stops after
switching power
transistor 3 with
NO
power transistor 1 or
power transistor 2.
YES
T5-5-71
(1)
TROUBLSHOOTING / Troubleshooting B
Proximity Switch Adjustment Procedure
1. Loosen the nut.
: 17 mm
2. Slowly tighten the proximity switch by hand until
the end of the proximity switch touches the protrusion.
3. Loosen the proximity switch 1/2 to 1 turn. Be sure
that the indicator faces in the direction of as the
figure on the right.
Indictor
Proximity Switch
Nut
T142-06-04-024
Proximity Switch
Nut
Adapter
Protrusion
T142-06-04-025
Pin
YES
(1)
Faulty main controller B.
NO
T5-5-72
TROUBLSHOOTING / Troubleshooting B
(Blank)
T5-5-73
TROUBLSHOOTING / Troubleshooting B
O-4 Fan motor does not rotate at speed corresponding to hydraulic oil temperature or
fuel temperature. Fan motor does not rotate
at all.
Connector
Main Controller A
B
T146-05-04-012
C10
T146-05-04-012
C23
NO
NO
C
C1
B22
C31
C24
T5-5-74
TROUBLSHOOTING / Troubleshooting B
YES
NO
Broken harness between oil cooler fan control solenoid valve and
main controller A.
Fan Control Solenoid Valve
Tester
A
Delivery Port
T183-05-04-023
T5-5-75
Fan Motor
Speed Mode
LowMiddle
MiddleHigh
MiddleLow
High Middle
TROUBLESHOOTING / Troubleshooting B
O-5 Step light does not come ON.
Check for loose harness connections beforehand.
YES
YES
Check if step light
comes ON after switching step light relay with
other general-purpose
relay.
NO
Step Light
NO
M183-01-036
Connector
Step Light Relay
Main Controller B
Connector A
Connector B
T183-05-04-003
A27
B11
T183-05-04-024
T5-5-76
T183-05-04-005
TROUBLESHOOTING / Troubleshooting B
YES
NO
Check if voltage at
NO
step light relay harness end connector
terminal #3 is 24 V.
Connect connector.
Disconnect step light
YES
terminal.
Check if voltage at
harness end terminal
is 24 V.
NO
YES
NO
YES
T5-5-77
TROUBLESHOOTING / Troubleshooting B
O-6 Even if step light switch is turned OFF, step
light does not come OFF after 60 seconds.
Check for loose harness connections beforehand.
YES
NO
YES
NO
T5-5-78
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-5-79
TROUBLESHOOTING / Troubleshooting B
O-7 Malfunction of Air Conditioner
The air conditioner has a self-diagnosis function.
The self-diagnosis functions to:
1) Display Fault Codes
2) Change Displayed Fault Codes
3) Delete Fault Code
4) End Fault Code Display
Temperature
Control Switch
LCD
M178-01-017
Fault
Code
E11
E12
Cause
Broken circuit in air circulation
sensor
Short-circuited circulation air
sensor
Broken circuit in fresh air sensor
Short-circuited fresh air sensor
E13
E14
Abnormal solar
radiation sensor
E18
E21
E22
Abnormal damper
E43
E44
E45
Water temperature
sensor
E15
E16
Abnormal refrigerant
E51
T5-5-80
Symptom
Y value (air flow-in temperature) cannot
be adjusted in response to the
set-temperature.
Operation is controlled under such circumstance as no fresh air sensor is provided.
Operation is controlled under such circumstance as no solar radiation sensor is
provided.
Operation is controlled under such circumstance as the evaporator temperature
is set to 10 C (50 F).
Corresponding damper servo becomes
inoperable.
TROUBLESHOOTING / Troubleshooting B
Change Displayed Fault Code
Temperature
Control Switch
LCD
LCD
M178-01-017
Circulation
Air Switch
Fresh Air
Switch
M178-01-017
Fan Switch
T5-5-81
M178-01-017
TROUBLESHOOTING / Troubleshooting B
Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to Hitachi Tsuchiura Works Quality Assurance Dept. after
experiencing a problem with your 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
Air Induction
Re-Circulation
Fresh Air Circulation
Control
Panel
AUTO
ON
OFF
Not Available
Fill following items when operated in manual mode or when manual control type unit is used.
Vent Position
Front
Front / Rear
Foot
Front / Rear and Foot
Fan
First
Second
Third
Fourth
Fifth
Sixth
(5) How (Problem Symptom)
Abnormal Compressor Operation
<Check Result>
Symptom
Not turned ON
(1) Is problem reproducible ?
Not turned OFF
Reproducible
Others
Not
reproducible
Uncontrollable air temperature
(2) Pressure (To be measured at gauge manifold)
Symptom
No cool air
Low Pressure
No warm air
High Pressure
Others
(3) Which parts have been replaced ?
Uncontrollable air volume
1
Symptom
Air flows in Hi mode only
No air flows
2
Small air volume
Others
Before replacing the control amplifier, be sure to
Uncontrollable vent hole
check that the connectors are correctly connected
Symptom
Vent hole 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
T5-5-82
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-5-83
TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Refrigerant pressure
in both high and low
pressure sides is low.
Frost
forms.
T5-5-84
TROUBLESHOOTING / Troubleshooting B
Refill refrigerant.
Readjust or replace.
Replace.
Repair.
Excessive refrigerant.
T5-5-85
TROUBLESHOOTING / Troubleshooting B
Cooling Circuit
Case connection.
Louver resonance.
Fan contacts case, or foreign matter enters case.
Noise
Abnormal smell.
T5-5-86
TROUBLESHOOTING / Troubleshooting B
Repair or replace.
Remove foreign matter. Readjust fan motor location.
Slight noise is unavoidable.
Replace if loud.
Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.
Replace.
Repair or replace clutch. Re-tighten screws.
Repair or replace.
Re-adjust drive belt.
Replace.
Clean.
Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in
L mode for more than 10 minutes, flush smell out by condensed water.
T5-5-87
TROUBLESHOOTING / Troubleshooting B
Compressor
Compressor doesnt rotate.
Inoperable
cooling
system.
Both compressor
and blower
motor rotate.
Check for oil and refrigerant leaks from parts other than
compressor and pipe joints using gas detector.
Others
T5-5-88
TROUBLESHOOTING / Troubleshooting B
Seized clutch.
Replace.
Replace.
Replace.
Charge
refrigerant.
No leaks (normal).
Check and
adjust oil level.
Excessive oil.
Broken clutch bearing due to overly tightened belt.
Replace.
T5-5-89
TROUBLESHOOTING / Troubleshooting B
Compressor
Abnormal
noise
T5-5-90
TROUBLESHOOTING / Troubleshooting B
Saggy belt.
Loose screws.
Broken valve.
Replace.
Blown gasket.
Abnormal internal noise.
Replace.
Loose screws.
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 surface may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
high pressure side and low pressure side is 0.49 MPa (5 kgf/cm2) or less. When the clutch is
turned OFF, the pressure difference between high pressure side and low pressure side will disappear within about 10 seconds.
T5-5-91
TROUBLESHOOTING / Troubleshooting B
WORK AFTER
NENTS
REPLACING
COMPO-
T5-5-92
TROUBLESHOOTING / Troubleshooting B
CHARGE AIR
REFRIGERANT
CONDITIONER
WITH
Necessity of Purging
Be sure to purge the air conditioner circuit with a
vacuum before charging with refrigerant (R134a)
because the following problems can arise if air or
other gases remain in the A/C circuit.
1. Pressure rise in the high pressure side
Air
W115-02-10-001
2. Metal corrosion
If air remains in the air conditioner circuit, a
chemical reaction between refrigerant and
moisture in the air takes place, and as a result,
hydrochloric acid, that corrodes metals such as
aluminum, copper and iron, is produced.
Hydrochloric acid
corrodes metals if
moisture exists
Hydrochloric acid
W115-02-10-002
Metal corrosion
Plugged refrigerant
flow
W115-02-10-003
Low cooling
efficiency
T5-5-93
TROUBLESHOOTING / Troubleshooting B
Purging Procedure
Gauge Manifold
Adapter
Low Pressure
Valve
Low Pressure
Charge Hose
High Pressure
Valve
High Pressure
Charge Hose
Center Pressure
Charge Hose
Vacuum Pump
(Parts
W115-02-10-005
Low Pressure
Side
S
Compressor
D
High Pressure
Side
T142-02-05-018
Fully Open
Fully Open
In Operation
W115-02-10-005
T5-5-94
TROUBLESHOOTING / Troubleshooting B
IMPORTANT: If the pointer returns to 0, retighten
the line connections and perform
purging again.
3. When the low pressure gauge reading falls
below-755 mmHg, stop the vacuum pump and
close the high and low pressure valves. Wait for
approximately five minutes and confirm that the
pointer does not return to 0.
Close
Close
In Operation
W115-02-10-005
Refrigerant Container
W115-02-10-007
Loosen
Open
W115-02-10-007
T5-5-95
TROUBLESHOOTING / Troubleshooting B
IMPORTANT: Always stop the engine when
charging the air conditioner with
refrigerant. Never position the
refrigerant container upside down
during charging operation. When
changing the refrigerant container
during charging operation, be sure
to purge air from the charge hose,
as shown in step 10.
6. Fully tighten the charge hose connection to the
gauge manifold. Open the high pressure valve
and refrigerant container valve to charge with
refrigerant (R134a).
Close the high pressure valve and refrigerant
container valve when the high pressure gauge
reading reaches 98 kPa (1 kgf/cm2, 14 psi).
NOTE: Use warm water of 40 C (104 F) or less
to warm the refrigerant container to aid in
charging operation.
T5-5-96
High
Pressure
Gauge
Tighten
Open
Open
W115-02-10-007
W115-02-10-008
TROUBLESHOOTING / Troubleshooting B
8. Confirm that the
high pressure and low
pressure valves in the gauge manifold and the
refrigerant container valve are closed.
Start the engine and operate the air conditioner.
Operating Conditions of the Air Conditioner:
Engine Speed : Slow Idle
Cab Window : Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum
IMPORTANT: Never open the high pressure valve
in the gauge manifold.
9. Open the low pressure valve in the gauge
manifold and the refrigerant container valve to
charge with refrigerant until the bubbles seen in
the receiver/drier sight glass disappear.
Open
Open
W115-02-10-007
Close
Close
W115-02-10-007
T5-5-97
TROUBLESHOOTING / Troubleshooting B
IMPORTANT: If the air conditioner is operated
with very low refrigerant, a bad load
will be exerted on the compressor. If
the air conditioner is overcharged
with refrigerant, cooling efficiency
will lower and abnormal high
pressure will arise in the air
conditioner circuit, causing danger.
12. Start the engine and operate the air-conditioner
again.
Observe the sight glass of the receiver/drier to
check refrigerant quantity.
Operating Conditions of the Air Conditioner:
Engine Speed : Slow Idle
Cab Window : Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum
NOTE: As the bubbles in the sight glass vary
depending on the ambient temperature,
check refrigerant quantity confirming the
changes in pressure .
Sight Glass
Receiver/Drier
W115-02-10-009
(approx. 1 mm after)
Adequate
W115-02-10-016
Overcharged
W115-02-10-017
Bubbles are seen continuously after the air conditioner is turned ON.
Not Enough
W115-02-10-018
W115-02-10-019
115-02-10-021
Milk white:
Refrigerant flow shows thin milk white
as oil and refrigerant are separated.
T5-5-98
TROUBLESHOOTING / Troubleshooting B
Warm-up Operation
After charting the air conditioner, carry out warm-up
operation five minute to lubricate system with
compressor oil.
Operating Conditions of the Air Conditioner
Engine Speed : Slow Idle
Cab Window
: Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum
Inspection
After warm-up operation, carry out gas leak check
and performance check.
CAUTION: Refrigerant
will
produce
poisonous material if exposed to heat of
1000 C (1800 F) or more. Never bring
refrigerant close to a fire.
1. Check the air conditioner for gas leaks using a
leak tester.
(1) Perform checking under well-ventilated
conditions.
(2) Thoroughly wipe off dust from the charge
hose connections of the compressor.
(3) Pay special attention to check the line
connections.
(4) If any gas leaks are found, retighten the line
connections.
2. Performance Check
Carry out performance check of the air
conditioner after checking each air conditioner
component.
(1) Check each component for abnormalities.
(2) Carry out ON-OFF check of the compressor
clutch.
(3) Check compressor fan belt tension.
(4) Check the coolant level in the radiator.
(5) Operate the air conditioner and check the
performance.
T5-5-99
Leak Tester
W115-02-10-013
Retighten Line
Connection
W115-02-10-014
TROUBLESHOOTING / Troubleshooting B
3. The checklist before the summer season is as
follows:
(1) Check each air conditioner component for
abnormalities.
(2) Check the line connections for oil leaks.
(3) Check refrigerant quantity.
(4) Check the engine cooling circuit.
(5) Check belts for wear. Replace if necessary.
4. Off-Season Maintenance
(1) During off-season, operate the idler pulley
and compressor at least once a month for a
short time to check for any abnormal
sounds.
(2) Do not remove the compressor belts during
off-season.
Operate
the
compressor
occasionally at slow speed for 5 to 10
minutes with the belt slightly loosened in
order to lubricate the machine parts.
T5-5-100
TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C (TROUBLESHOOTING FOR MONITOR) PROCEDURE
Use troubleshooting C when any monitors, such as
gauges or indicators, malfunction.
(2)
(1)
NO(NOT OK)
Key switch: ON
(3)
Causes of machine problems are stated in the thick-line box. Scanning quickly through
the thick-line boxes allows you to estimate the possible causes before actually following
the flow chart.
Harness
T158-05-03-001
T5-6-1
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF
PERATURE GAUGE
COOLANT
TEM-
This troubleshooting procedures should be performed after checking that the other instruments
are performing correctly.
Check for loose harness connections beforehand.
Gauge Pointer Does Not Move At All
YES
Key switch: ON
NO
Key switch: ON
Connect terminal from the
rear of connector using a
piece of clip with connector
connected.
YES
Key switch: ON
NO
Connect disconnected
terminal. Disconnect
monitor controller connector B. Check if
pointer returns to zero.
NO
NO
T5-6-2
TROUBLESHOOTING / Troubleshooting C
NO
YES
Resistance (k)
7.6
4.00.32
2.70.22
0.98
0.6
0.45
0.30.02
Connector
Monitor Controller
Connector B
T183-05-04-013
B18
T5-6-3
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF FUEL GAUGE
Connector
Monitor Controller
Connector B
Fuel Sensor
T183-05-04-013
B19
YES
Disconnect fuel sensor from
connector. Ground harness
end connector terminal #2 to
vehicle frame. Check if pointer
swings to the right side.
Key switch: ON
NO
Key switch: ON
Connect terminal from the
rear of connector using a
piece of clip with connector
connected.
YES
Key switch: ON
NO
Connect disconnected
connector.
Disconnect monitor controller connector B.
Check if pointer returns
to zero.
NO
YES
Disconnect fuel sensor from
connector. Ground harness
end connector terminal #2 to
vehicle frame.
Check if pointer swings and is
stabilized to the right side.
Key switch: ON
NO
T5-6-4
TROUBLESHOOTING / Troubleshooting C
Fuel Gauge
Upper Limit
1/2
Lower Limit
NO
M183-01-011
Fuel Sensor
Float
FULL
YES
3/4
257 mm
138.5 mm
R370
22
33
70.5 mm
228 mm
1/2
27
28
338 mm
Electric Resistance
1/4
EMPTY
T107-04-03-020
T5-6-5
Float Position
Resistance ()
10+1.0-0.5
3/4
(19)
1/2
323
1/4
(49.5)
80+12+2
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF INDICATOR LIGHT
CHECK SYSTEM
Check for loose harness connections beforehand.
YES
Indicator does not
come ON when
indicator light
check operation is
performed.
NO
Connector
Monitor Controller
Connector C
C1
T183-05-04-014
T5-6-6
TROUBLESHOOTING / Troubleshooting C
(Blank)
T5-6-7
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF OVERHEAT INDICATOR
Check for loose harness connections beforehand.
NOTE: Overheat Switch Operating Temperature:
100 C (212 F) or more
Indicator Does Not Come ON Even If Engine
Overheats
Faulty monitor controller
or burnt indicator light.
NO
NO
Disconnect DLU connector
D.
Disconnect monitor controller connector B.
Check for continuity beYES tween DLU connector D
terminal #66 and monitor
controller terminal #B6.
NO
Connector
DLU Connector D
DLU Connector C
#D
T18E-05-06-002
#66
#51
#52
T5-6-8
T18E-05-06-004
T18E-05-06-003
TROUBLESHOOTING / Troubleshooting C
Indicator Comes ON Even If Coolant Temperature
Is Low
YES
Faulty engine.
Disconnect ECM
connector 9 poles.
Check if indicator
goes OFF.
YES
NO
Faulty DLU.
Broken monitor.
NO
Monitor Connector
#6
T183-05-04-013
T5-6-9
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF AIR CLEANER RESTRICTION INDICATOR
Check for loose harness connections beforehand.
YES
YES
Check if indicator
comes ON when key
switch is turned ON.
NO
NO
YES
Check if indicator
goes OFF when air
cleaner restriction
switch is disconnected.
YES
Key switch: ON
NO
T5-6-10
TROUBLESHOOTING / Troubleshooting C
YES
NO
Pressure
5.0 kPa
(50848 mmH2O) or lower
5.0 kPa
(50848 mmH2O) or more
Operation
OFF
ON
Connector
Monitor Controller
Connector B
B7
T183-05-04-013
Short-circuited harness
between monitor controller and air cleaner
restriction switch.
T5-6-11
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF FUEL LEVEL INDICATOR
Check for loose harness connections beforehand.
YES
YES
NO
NO
YES
Indicator comes ON
even if fuel still remains.
Disconnect fuel
sensor from connector. Check if
indicator goes
OFF.
Key switch: ON
YES
Disconnect fuel level sensor
and monitor controller connector B.
Check for continuity beNO tween monitor controller
harness end connector terminal #B19 and vehicle
frame.
NO
T5-6-12
TROUBLESHOOTING / Troubleshooting C
YES
NO
Connector
Faulty fuel sensor.
Fuel Sensor
Short-circuited harness
between monitor controller and fuel sensor.
T183-05-04-010
Monitor Controller
Connector B
T183-05-04-013
B19
T5-6-13
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF PREHEAT INDICATOR
Check that all other indicators work correctly.
Check for loose harness connections beforehand.
Indicator Does Not Come ON Even If Air Heater Is
Operating
Faulty preheat indicator
relay.
YES
Check if indicator
comes ON after
switching preheat
indicator relay and
other general-purpose relay.
Disconnect preheat indicator relay from connector.
NO Check if voltage at harness end connector terminal #1 is 24 V.
Connect disconnected
connector.
Disconnect monitor
YES controller connector B.
Check for continuity
between harness end
connector terminal #B20
and vehicle frame.
NO
Disconnect monitor
controller connector B.
Check if indicator
comes ON.
Short-circuited harness
between monitor controller and preheat indicator relay.
YES
Disconnect preheat indicator relay.
Check for continuity beNO tween harness end connector terminal #3 and
vehicle frame.
Connect connector.
Check if indicator
comes ON after switchNO ing preheat indicator
relay and other general-purpose relay.
Connector
Monitor Controller
Connector B
B20
T183-05-04-003
T5-6-14
T183-05-04-014
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF DOWNLOAD INDICATOR
Check for loose harness connections beforehand.
Indicator Does Not Come ON Even If DLU Data
Memory Is Full
YES
Disconnect monitor
controller connector
C.
Check for continuity
between terminal
#C20 and vehicle
frame.
YES
Faulty DLU.
NO
YES
Disconnect DLU
connector D.
Check if indicator
goes OFF.
Short-circuited harness
between DLU and
monitor controller.
YES
Connector
Monitor Controller
Connector C
DLU Connector D
#56
T183-05-04-014
T18E-05-06-002
T5-6-15
C20
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ALTERNATOR INDICATOR
Check for loose harness connections before-
Connector
hand.
Monitor Controller
Connector A
A2
T183-05-05-001
Alternator indicator
stays ON after engine is started.
Engine: Running
Disconnect alternator
terminal R, then ground
the terminal to vehicle
frame.
Disconnect connector A
of monitor controller.
Check for continuity between alternator relay
harness end connector
terminal #A2 and vehicle
frame.
YES
Faulty alternator.
NO
Less than 10 V
Faulty alternator.
Turn key switch
ON. Check if indicator comes ON.
10 V or more
NO
T5-6-16
TROUBLESHOOTING / Troubleshooting C
(Blank)
T5-6-17
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR
Check for restricted oil filter.
Check for loose harness connections beforehand.
NO
Key switch: ON
NO
Faulty DLU.
NO
Broken or short-circuited
CAN harness.
YES
NO
Short-circuited harness
between monitor and
DLU.
Broken monitor.
NO
T5-6-18
TROUBLESHOOTING / Troubleshooting C
Connector
DLU Connector 76D
#55
T18E-05-06-002
#51
#52
#5
T18E-05-06-004
T18E-05-06-003
T5-6-19
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF PUMP TRANSMISSION
OIL PRESSURE INDICATOR
Check for loose harness connections beforehand.
Indicator does not come ON even if pump transmission oil pressure is insufficient.
YES
YES
Disconnect pump
transmission oil pressure switch. Ground
harness end terminal
#M4 to vehicle frame.
Check if indicator
comes ON.
Key switch: ON
NO
Connect disconnected
terminal.
Ground monitor controller
connector A terminal #A13
to vehicle frame.
Check if indicator comes
ON.
Key switch: ON
Connect terminal from the
rear of connector using a
piece of clip with connector connected.
Key switch: ON
NO
NO
T5-6-20
TROUBLESHOOTING / Troubleshooting C
YES
Connector
Monitor Controller
Connector A
T183-05-05-001
A13
YES
Short-circuited harness
between monitor controller and pump transmission oil pressure
switch.
T5-6-21
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE OIL LEVEL
INDICATOR
Check that all other indicators work correctly.
Check that machine is parked on level surface.
Check for loose harness connections beforehand.
Indicator Does Not Come ON Even If Oil Level is
Normal
YES
NO
YES
NO
YES
NO
NO
YES
T5-6-22
TROUBLESHOOTING / Troubleshooting C
YES
Connector
Monitor Controller
Connector B
NO
B8
T183-05-04-013
YES
Short-circuited harness
between monitor controller and engine oil
level switch.
Normal.
T5-6-23
T18E-05-06-006
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF COOLANT LEVEL INDICATOR
Check that all other indicators work correctly.
Check that machine is parked on level surface.
Check for loose harness connections beforehand.
Indicator Does Not Come ON Even If Coolant
Level Is Lower than Low
Check if fault cod 235 is displayed on the engine
fault code monitor beforehand.
If fault code 235 is displayed, the following troubles may occur.
Faulty engine (coolant level sensor or ECM)
Broken or short -circuited harness between ECM
and coolant level sensor.
NO
YES
YES
Disconnect monitor
controller connector B.
Disconnect DLU connector 76D.
Check for continuity
between DLU terminals #76 to 57D and
vehicle frame.
NO
Disconnect DLU
connector 76D.
Check for continuity
between DLU end
terminal 76-57D and
vehicle frame.
NO
Disconnect monitor
controller connector B.
Check for
short-circuited harness
between DLU terminals #76 to 57 and
monitor controller terminal B9.
NO
Disconnect coolant
level sensor connector
and ECM connector
21 poles. Check for
broken or
short-circuited harness
between terminals below.
NO
Broken or short-circuited
harness between DLU and
ECM.
NO
YES
Broken or short-circuited
harness between ECM and
coolant level sensor.
Faulty engine. (coolant level
sensor or ECM)
NO
T5-6-24
Broken or short-circuited
harness between DLU and
monitor controller.
TROUBLESHOOTING / Troubleshooting C
Monitor Controller
Connector B
#57
B9
T18E-05-06-002
T183-05-04-013
#C
T18E-05-06-007
T18E-05-06-003
T5-6-25
#51
#52
T18E-05-06-004
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF
LEVEL INDICATOR
HYDRAULIC
OIL
YES
Connect disconnected
connector.
Disconnect hydraulic
oil level switch 2.
NO Ground harness end
connector terminal to
vehicle frame. Check if
indicator comes ON
after 5 seconds.
Key switch: ON
NO
NO
Connect disconnected
connector.
Disconnect main controller B connector B.
Check for continuity
between harness end
connector terminal
#B15 and vehicle
frame.
NO
YES
T5-6-26
TROUBLESHOOTING / Troubleshooting C
Connector
Monitor Controller
Connector C
Main Controller B
Connector B
T183-05-04-010
T183-05-04-014
C14
B23
B15
T183-05-04-021
YES
Check for continuity
YES between harness end
connector terminal
#B16 and vehicle
frame.
NO
NO
YES
Check if indicator
comes ON after
YES switching hydraulic oil
level switch 1 and hydraulic oil level switch
2.
NO
Disconnect hydraulic
oil level switch 1.
Check for continuity
between main controller B harness end
connector terminal
#B15 and hydraulic oil
level switch 2 harness
end connector terminal #1.
NO
YES
Disconnect hydraulic
oil level switch 1.
Ground harness end
connector terminal to
vehicle frame.
Check if indicator
comes ON after 5
seconds.
YES
NO
T5-6-27
TROUBLESHOOTING / Troubleshooting C
Indicator Comes ON Even If Hydraulic Oil Level
Is Normal
YES
Disconnect hydraulic
oil level switch 1.
Check if indicator
goes OFF.
NO
Connect disconnected
connectors.
Disconnect main conNO troller B connector B.
Check for continuity
between harness end
connector terminals
#B15, B16 and vehicle
frame.
NO
Disconnect monitor
controller connector C.
Check for continuity
between connector C
harness end terminal
#C14 and connector B
harness end terminal
#B23.
Short-circuited harness
between hydraulic oil
YES level switch 1, 2 and
main controller B.
YES
Connector
Monitor Controller
Connector C
Main Controller B
Connector B
T183-05-04-010
T183-05-04-014
C14
B23
B15
T183-05-04-021
T5-6-28
TROUBLESHOOTING / Troubleshooting C
YES
NO
Short-circuited harness
between monitor controller
and main controller B.
T5-6-29
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF AUTO-LUBRICATION
INDICATOR
Check for loose harness connections beforehand.
24 V
NO
T5-6-30
TROUBLESHOOTING / Troubleshooting C
Connector
Monitor Controller
Connector C
Main Controller B
Connector A
T183-05-04-014
C15
YES
A29
0V
T5-6-31
T183-05-04-008
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE STOP INDICATOR
Check for loose harness connections beforehand.
Even If Engine is Normal, Indicator comes ON.
Check if fault code corresponding to ECM is not
displayed beforehand.
NO
YES
Disconnect DLU connector 76D.
Check if voltage between
YES DLU terminals #76 to #64
and vehicle frame is 24V.
Faulty DLU.
Faulty monitor.
NO
NO
YES
NO DLU
Disconnect
connector 76D.
NO Check if voltage between terminals #8
and #9 is 24V.
NO Faulty DLU.
Faulty DLU.
T5-6-32
TROUBLESHOOTING / Troubleshooting C
Connector
DLU Connector D
DLU Connector A
#64
Monitor Connector C
#8
#9
T18E-05-06-008
T18E-05-06-002
#67
T5-6-33
T18E-05-06-009
#19
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE WARNING
INDICATOR
Check for loose harness connections beforehand.
YES
Disconnect monitor controller connector C.
Check for continuity for
vehicle frame and terminal
#16.
YES
Faulty ECM.
NO
NO
T5-6-34
TROUBLESHOOTING / Troubleshooting C
Connector
Engine Warning Indicator Relay
Monitor Controller
Connector C
#17
T183-05-04-014
T183-05-04-003
C16
T18E-05-04-004
T5-6-35
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF QUICK-IDLE INDICATOR
Check for loose harness connections beforehand.
Connector
Monitor Controller
Connector B
T183-05-04-013
Connector C
C3
T183-05-04-014
NO
Short-circuited harness
between quick-idle
switch and monitor controller.
T5-6-36
TROUBLESHOOTING / Troubleshooting C
YES
T5-6-37
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF AUTO-IDLE INDICATOR
Check for loose harness connections beforehand.
Connector
Switch Box
T183-05-04-004
Monitor Controller
Connector B
B10
T183-05-04-013
YES
Disconnect monitor controller connector B.
Check if voltage at harness end connector terminal #B10 is 24 V.
NO
YES
YES
NO
Short-circuited harness
between switch box and
monitor controller.
Disconnect monitor
controller connector B.
Check if indicator
comes ON.
T5-6-38
TROUBLESHOOTING / Troubleshooting C
(Blank)
T5-6-39
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF HOURMETER
Check for loose harness connections beforehand.
Hourmeter Does Not Operate When Engine Is
Running
Less than 13 V
or 33.5 V or more
13 V or more
less than
33.5 V
NO Measure voltage at
alternator terminal L.
Engine speed:
900 min-1 (rpm)
or more.
0V
YES
Connector
Monitor Controller
Connector A
Faulty alternator.
A2
T183-05-05-001
T5-6-40
TROUBLESHOOTING / Troubleshooting C
(Blank)
T5-6-41
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF BUZZER
Check for loose harness connections beforehand.
Buzzer sounds continuously key switch is turned
ON without starting engine.
10 V or more
Measure voltage at
monitor controller
connector A terminal
#A2.
Key switch: ON
without starting engine
Faulty alternator.
Faulty monitor
controller.
Less than
10 V
Check if pump
transmission oil
pressure indicator
comes ON.
Faulty pump
transmission oil
pressure system.
YES
NO
Check if engine
stop indicator
comes ON.
NO
Buzzer does not sound even if pump transmission oil pressure indicator or engine stop indicator comes ON.
Check if buzzer
stops by pressing
buzzer cancel
switch.
Normal (Engine
speed is too slow).
NO
Check if alternator
indicator comes ON.
Measure voltage at
regulator terminal
R.
YES
Engine: Running
T5-6-42
TROUBLESHOOTING / Troubleshooting C
Connector
Starter Relay 2
(Harness End)
Monitor Controller
Connector A (Harness End)
A2
1
2
T183-05-05-001
YES
Normal.
less than
13 V
Disconnect alternator
terminal R and monitor
controller connector A.
Check for continuity between terminals R and
#A2.
YES
Faulty alternator.
NO
T5-6-43
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION
DISPLAY (LCD)
OF
LIQUID
CRYSTAL
Fault Code
Main Pump 1 Pressure
Main Pump 2 Pressure
Main Pump 3 Pressure
Front Attachment Operation Pressure
Travel Operation Pressure
Engine Exhaust Gas
Temperature
EC Angle
Digital Input 0
Digital Input 1
Digital Input 2
Digital Input 3
Digital Output
Proportional Valve
ON/OFF Output
Hydraulic Oil Cooling
Output Current
Power Increase Output
Current
Causes
Refer to T5-6-40
Faulty monitor.
Faulty sensor system detecting corresponding signal. (There should be
some abnormality with the machine control. Refer to Troubleshooting
B).
T5-6-44
TROUBLESHOOTING / Troubleshooting C
17
18
19
20
21
22
23
Fault Code
Digital Input 0
Digital Input 1
Digital Input 2
Digital Input 3
Digital Output
Proportional
Valve
ON/OFF Output
Auto-Lubrication Status
1
Auto-Lubrication Status
2
(upper 4 bits)
Auto-Lubrication Status
2
(lower 4 bits)
Auto-Lubrication Interval
Selection
Digital Output 2
(upper 4 bits)
Digital Output 2
(lower 4 bits)
Causes
Refer to T5-6-40.
Faulty monitor.
Faulty sensor system detecting corresponding signal. (There should be
some abnormality with the machine control. Refer to Troubleshooting
B).
T5-6-45
TROUBLESHOOTING / Troubleshooting C
MALFUNCTION OF ENGINE TROUBLESHOOTING OPERATION
Check for loose harness connections beforehand.
NO
Check for continuity beYES tween harness end terminal #2 and vehicle
frame.
NO
Connector
ECM Connector 31 Poles
#18
1
2
3
T18E-05-06-010
#12
T18E-05-04-004
#13
T5-6-46
TROUBLESHOOTING / Troubleshooting C
Even if some troubles occur in the engine and
engine fault diagnosing switch B is switched, the
previous or following fault code is not displayed.
NOTE: If only one trouble occurs in the engine
and engine fault diagnosing switch B is
switched, the fault code does not change.
YES
YES
Key switch: ON
Engine fault diagnosing
switch A: ON
NO
T5-6-47
Faulty ECM.
TROUBLESHOOTING / Troubleshooting C
(Blank)
T5-6-48
TROUBLESHOOTING / Troubleshooting D
TROUBLESHOOTING D PROCEDURES
Refer to Troubleshooting D if the engine stop indicator
and the engine warning indicator in the cab start flashing by the ECM diagnosis system. Refer to the System section in the Technical Manual (Operational
Principle).
T5-7-1
TROUBLESHOOTING / Troubleshooting D
Inspection Method
When any trouble occurs in the engine control system,
one of the following indicators come ON:
Monitor Panel
Overheat Indicator
Engine Oil Pressure Indicator
Coolant Level Indicator
Engine Warning Indicator 1
Engine Stop Indicator 1
4
T183-01-02-013
T141-05-03-002
M18E-01-009
T5-7-2
TROUBLESHOOTING / Troubleshooting D
FAULT CODE INDICATION BY INDICATOR
BLINKING PATTERN
The fault code is indicated by the blinking pattern of
the engine warning indicator 2 and engine stop indicator 2 if the engine fault diagnosing switch A and/or B
is operated.
NOTE: The engine warning indicator 1 and engine
stop indicator 1 on the monitor panel may
blink when the fault diagnosing switch A
and/or B is operated. This does not indicate the fault code.
Fault Diagnosing Switch
There are two diagnostic switches: A and B. These
switches are used to indicate the fault codes.
Both diagnostic switches are self-return type, so a
fault code is indicated while switches are pressed up
or down.
Switch A: The fault code is indicated by pressing the
switch upward.
Switch B: This is used when more than one fault code
is memorized. The next fault code is displayed when
pressing the switch up once, and previous fault code
is displayed when pressing the switch down once.
Troubleshooting Procedure
1. Turn key switch to ON position. (Engine: Stop)
When Fault Code is Not Memorized:
The engine warning indicator 2, engine stop indicator 2 and engine protection indicator come
ON in sequence. Then, all three indicators go
OFF.
When Faulty Code is Memorized:
The engine warning indicator 2, engine stop indicator 2 and engine protection indicator come
ON in sequence. Then, all three indicators go
OFF. After that, the indicator corresponding to the
fault level stays ON.
T5-7-3
Fault Diagnosing
Switch B
Fault Diagnosing
Switch A
M18E-01-009
TROUBLESHOOTING / Troubleshooting D
2. Turn the engine fault diagnosing switch A ON
(press upward). The engine warning indicator 2
and engine stop indicator 2 blink in the following
sequence. (Three indicators stay ON when no
fault code is memorized).
The engine warning indicator 2 blinks once.
After approx. one seconds, the engine stop indicator 2 blinks. The blinking number indicates the
hundredth digit.
After approx. one seconds, the engine stop indicator 2 blinks. The blinking number indicates the
tenth digit.
After approx. one seconds, the engine stop indicator 2 blinks. The blinking number indicates the
first digit.
Finally, the engine warning indicator 2 blinks
once.
3. The fault code is indicated repeatedly in the
above sequence.
tenth
number
first
number
ON
OFF
T5-7-4
one
second
one
second
T141-05-03-004
TROUBLESHOOTING / Troubleshooting D
FAULT CODES FOR QUANTUM ENGINES
S020
3
114
Yellow
QSK60
113
Yellow
QSK45
635
7
QST30
S020
7
QSK23
112
Red
QSK19
QSX15
629
12
QSM11
S254
12
DESCRIPTION
QSL9
111
Red
FMI
QSC
SID(S)
PID(P)
FMI
QSB
SPN
FAULT
CODE/
LAMP
635
3
S020
4
635
4
115
Red
P190
2
190
2
116
Red
P156
3
156
3
Engine Speed/Position Sensor Circuit lost both of two signals from the
magnetic pickup sensor
Fuel Timing Pressure Sensor Circuit shorted high
117
Red
P156
4
156
4
118
Yellow
P135
3
119
Yellow
X
X
135
3
P135
4
135
4
121
Yellow
P190
10
190
10
122
Yellow
P102
3
102
3
Engine Speed/Position Sensor Circuit lost one of two signals from the
magnetic pickup sensor
Intake Manifold Pressure Sensor #1
Circuit - shorted high
123
Yellow
P102
4
102
4
124*
Yellow
102
16
125*
None
102
18
126*
Yellow
1129
16
127*
None
1129
18
T5-7-5
TROUBLESHOOTING / Troubleshooting D
QSK45
QSK60
129*
None
1129
4
QSX15
QSL9
1129
3
QSC
128*
None
DESCRIPTION
QSB
QST30
FMI
QSK23
SPN
QSK19
SID(S)
PID(P)
FMI
QSM11
FAULT
CODE/
LAMP
131
Red
P091
3
091
3
132
Red
P091
4
091
4
133
Red
P029
3
974
3
133
Red
P029
3
29
3
134
Red
P029
4
974
4
134
Red
P029
4
29
4
135
Yellow
P100
3
100
3
136*
None
1208
3
137*
None
1208
4
X
X
P100
4
100
4
143
Yellow
P100
1
100
18
143
White
P100
1
100
1
144
Yellow
P110
3
110
3
145
Yellow
P110
4
110
4
146
Yellow
P110
0
110
16
T5-7-6
141
Yellow
X
X
X
X
TROUBLESHOOTING / Troubleshooting D
SID(S)
PID(P)
FMI
QSB
QSC
QSL9
QSM11
QSX15
QSK19
QSK23
QST30
QSK45
QSK60
SPN
FAULT
CODE/
LAMP
147
Red
P091
8
091
8
148
Red
P091
8
091
8
151
Red
P110
0
110
0
151
White
P110
0
110
0
153
Yellow
P105
3
105
3
154
Yellow
P105
4
105
4
155
Red
P105
0
105
0
155
White
P105
0
105
0
156*
Yellow
1131
3
157*
Yellow
FMI
DESCRIPTION
X
X
1131
4
158*
White
1131
0
159*
Yellow
1132
3
161*
Yellow
1132
4
162*
White
1132
0
163*
Yellow
1133
3
164*
Yellow
1133
4
165*
White
1133
0
T5-7-7
X
X
TROUBLESHOOTING / Troubleshooting D
172
Red
S023
6
638
6
173
Yellow
S023
7
638
7
184
Yellow
S233
2
609
2
185
Yellow
S231
2
639
2
187
Yellow
S232
4
620
4
211
None
S216
11
1484
31
175
3
175
3
175
4
175
4
175
0
175
0
211*
None
212
Yellow
613
14
P175
3
212*
Yellow
213
Yellow
P175
4
213*
Yellow
214
Red
P175
0
214*
White
219
Maint
P17
1
1380
17
219
White
P17
1
1380
1
221
Yellow
P108
3
108
3
T5-7-8
QSK60
733
4
QST30
S024
4
QSK23
167
Yellow
QSK19
QSX15
QSM11
733
3
QSL9
S024
3
DESCRIPTION
QSC
166
Yellow
FMI
QSB
SID(S)
PID(P)
FMI
QSK45
SPN
FAULT
CODE/
LAMP
X
X
TROUBLESHOOTING / Troubleshooting D
SPN
225
Yellow
S086
4
1266
4
227
Yellow
S232
3
620
3
231
Yellow
P109
3
109
3
232
Yellow
P109
4
109
4
233
Yellow
P109
1
109
18
233
White
P109
1
109
1
234
Red
P190
0
190
0
235
Red
P111
1
111
1
235
White
P111
1
111
1
237
Yellow
S030
2
644
2
241
Yellow
P084
2
084
2
242
Yellow
P084
10
084
10
243
Yellow
P121
4
513
4
245
Yellow
S033
4
647
4
252
Yellow
P098
2
098
2
T5-7-9
QSK60
1265
4
QSK45
S085
4
QST30
223
Yellow
QSK19
QSX15
108
4
QSM11
P108
4
DESCRIPTION
QSL9
222
Yellow
FMI
QSC
SID(S)
PID(P)
FMI
QSB
FAULT
CODE/
LAMP
X
X
X
X
X
X
TROUBLESHOOTING / Troubleshooting D
254
None
S017
4
632
4
255
Yellow
S017
3
632
3
259
Red
S017
7
632
7
261
Yellow
P174
0
174
16
261
White
P174
0
174
0
263
Yellow
P174
3
174
3
264
Yellow
P174
11
174
11
265
Yellow
P174
4
174
4
268
Yellow
P094
2
271
Yellow
X
X
QSK60
632
4
QSK45
S017
4
QST30
254
Red
QSK19
QSX15
098
1
QSM11
P098
1
DESCRIPTION
QSL9
253
White
FMI
QSC
SID(S)
PID(P)
FMI
QSB
SPN
FAULT
CODE/
LAMP
X
X
X
X
X
X
94
2
S126
4
1347
4
272
Yellow
S126
3
1347
3
273
Yellow
S127
4
1348
4
274
Yellow
S127
3
1348
3
275
Yellow
S126
7
1347
7
276
Yellow
S018
3
633
3
T5-7-10
TROUBLESHOOTING / Troubleshooting D
278
Yellow
P073
11
1075
11
279
Yellow
S018
4
633
4
281
Yellow
S126
7
282
Yellow
QSC
QSL9
X
1347
7
S127
7
1348
7
283
Yellow
S221
3
1043
3
284
Yellow
S221
4
1043
4
285
Yellow
S231
9
639
9
286
Yellow
S231
13
639
13
287
Red
P091
2
91
19
288
Red
P029
2
974
19
292
White
P223
14
1083
14
293
Yellow
S441
3
441
3
293
Yellow
P223
3
1083
3
293
Yellow
S154
3
1083
3
294
Yellow
S441
4
441
4
294
Yellow
P223
4
1083
4
T5-7-11
QSB
X
X
QSK60
QSK45
633
7
QST30
S018
7
DESCRIPTION
QSK19
277
Yellow
FMI
QSX15
SID(S)
PID(P)
FMI
QSM11
SPN
FAULT
CODE/
LAMP
TROUBLESHOOTING / Troubleshooting D
295
Yellow
P108
2
108
2
296
Red
P223
14
1387
14
296
White
P223
14
1084
14
297
Yellow
P223
3
1387
3
297
Yellow
P223
3
1084
3
298
Yellow
P223
4
1387
4
298
Yellow
P223
4
1084
4
299
None
S117
14
1384
31
299
Yellow
S117
11
1384
31
311
Yellow
S001
6
651
6
312
Yellow
S005
6
655
6
313
Yellow
S003
6
653
6
314
Yellow
S006
6
656
6
315
Yellow
S002
6
652
6
316
Yellow
S078
3
931
3
318
Yellow
S078
7
931
7
QSK60
QSK45
QST30
QSK19
QSX15
1083
4
QSL9
S154
4
DESCRIPTION
QSC
294
Yellow
FMI
QSB
SID(S)
PID(P)
FMI
QSM11
SPN
FAULT
CODE/
LAMP
X
X
T5-7-12
TROUBLESHOOTING / Troubleshooting D
322
Yellow
S001
5
651
5
323
Yellow
S005
5
655
5
324
Yellow
S003
5
653
5
325
Yellow
S006
5
656
5
328
Yellow
S152
7
1348
7
329
Yellow
S233
14
1077
14
331
Yellow
S002
5
652
5
332
Yellow
S004
5
654
5
341
Yellow
S253
2
630
2
342
Red
S253
13
630
13
343
Yellow
S254
12
629
12
346
Yellow
S253
12
630
12
349
Yellow
P191
0
191
16
349
Yellow
P191
0
191
0
352
Yellow
S232
4
1079
4
T5-7-13
QSK60
654
6
QSK45
S004
6
QST30
321
Yellow
QSX15
QSM11
251
2
QSL9
P251
2
DESCRIPTION
QSC
319
Maint
FMI
QSB
SID(S)
PID(P)
FMI
QSK19
SPN
FAULT
CODE/
LAMP
X
X
X
X
TROUBLESHOOTING / Troubleshooting D
1076
4
363
Yellow
S251
7
1076
7
364
Yellow
S233
9
1077
9
365
Yellow
S233
4
1077
4
366
Yellow
S233
2
1077
2
367
Yellow
P190
11
1078
11
368
Yellow
S254
8
1078
8
369
Yellow
P190
2
1078
2
372
Yellow
S233
11
1077
11
373
Red
S233
3
1077
3
374
Yellow
S233
12
1077
12
375
Yellow
S254
2
629
2
376
Yellow
S233
13
1077
13
377
Yellow
S233
7
1077
7
378
Yellow
S018
5
633
5
379
Yellow
S018
6
633
6
T5-7-14
QSK60
S251
4
QSK45
362
Yellow
QST30
QSX15
QSM11
1076
3
QSL9
S251
3
DESCRIPTION
QSC
361
Red
FMI
QSB
SID(S)
PID(P)
FMI
QSK19
SPN
FAULT
CODE/
LAMP
TROUBLESHOOTING / Troubleshooting D
382
Yellow
S237
11
626
11
384
Yellow
S237
11
626
11
385
Yellow
S232
3
620
3
386
Yellow
S232
3
1079
3
387
Yellow
S221
3
1043
3
389
Yellow
S033
11
647
11
391
Yellow
S017
11
632
11
394
Yellow
S020
5
635
5
395
Yellow
S020
6
635
6
396
Yellow
S083
5
1244
5
397
Yellow
S083
6
1244
6
398
Yellow
S084
5
1245
5
399
Yellow
S084
6
1245
6
414*
Yellow
S250
9
608
9
415
Red
P100
1
100
1
415
White
P100
1
100
1
T5-7-15
QSK60
QSK45
QST30
626
11
QSK19
QSL9
S237
11
DESCRIPTION
QSX15
QSC
381
Yellow
FMI
QSM11
SID(S)
PID(P)
FMI
QSB
SPN
FAULT
CODE/
LAMP
X
X
X
X
TROUBLESHOOTING / Troubleshooting D
1319
2
P111
2
111
2
423
Yellow
P156
2
156
2
426
None
S231
2
639
2
426
Yellow
S231
2
639
2
639
2
426*
None
X
X
X
S231
639
9
428
Yellow
P097
3
97
3
429
Yellow
P097
4
097
4
431
Yellow
S230
2
558
2
431
Yellow
P091
2
91
2
432
Red
S230
13
558
13
432
Red
P091
13
91
13
433
Yellow
P102
2
102
2
434
Yellow
S251
2
627
2
435
Yellow
P100
2
100
2
T5-7-16
427
None
QST30
QSK19
QSK60
QSK45
097
15
QSX15
422
Yellow
DESCRIPTION
QSM11
P097
0
FMI
QSL9
418
WIF /
Maint.
419
Yellow
SPN
QSC
SID(S)
PID(P)
FMI
QSB
FAULT
CODE/
LAMP
X
X
X
X
X
X
TROUBLESHOOTING / Troubleshooting D
441
None
P168
1
168
1
442
Yellow
P168
0
168
16
442
Yellow
P168
0
168
0
443
Yellow
S221
4
1043
4
444
Yellow
S232
1
620
18
446*
None
N/A
447*
None
N/A
448*
None
N/A
DESCRIPTION
QST30
QSK60
QSK45
QSX15
QSM11
168
18
QSL9
P168
1
QSC
441
Yellow
FMI
QSB
SID(S)
PID(P)
FMI
QSK19
SPN
FAULT
CODE/
LAMP
X
X
X
X
449
Yellow
P094
0
094
16
451
Yellow
P157
3
157
3
451
Red
P157
3
157
3
452
Yellow
P157
4
157
4
452
Red
P157
4
157
4
455
Red
S018
3
633
3
466
Yellow
S032
4
1188
4
467
Yellow
S020
2
635
2
T5-7-17
TROUBLESHOOTING / Troubleshooting D
471
Maint.
P098
1
98
1
472
Maint.
P017
2
1380
2
473
Yellow
P017
2
1380
2
1318
9
479*
None
094
18
483
Yellow
P129
3
1349
3
484
Yellow
P129
4
1349
4
485
Yellow
P129
0
1349
16
486
Yellow
P129
1
1349
18
487
None
S237
1
626
1
488
Yellow
P105
0
105
16
489
Yellow
P191
1
191
18
489
Yellow
P191
1
191
1
493
S018
1076
13
13
Error
S221
11
1043
11
T5-7-18
P094
1
482
Yellow
496
Yellow
QSK60
98
17
QSK45
P098
1
QST30
471
Maint.
QSK19
QSX15
633
2
QSM11
S018
2
DESCRIPTION
QSL9
468
Yellow
FMI
QSC
SID(S)
PID(P)
FMI
QSB
SPN
FAULT
CODE/
LAMP
X
X
TROUBLESHOOTING / Troubleshooting D
497
Yellow
S114
2
1377
2
498
Yellow
P098
3
098
3
499
Yellow
P098
4
514
Red
QSK60
X
098
4
S018
7
633
7
515
Yellow
P091
3
091
3
516
Yellow
P091
4
091
4
517
Yellow
S251
12
1076
12
524
Yellow
P113
2
113
2
527
Yellow
P154
3
702
3
527
Yellow
S040
3
702
3
528
Yellow
P093
2
093
2
529
Yellow
S051
3
703
3
539
Yellow
S018
11
633
11
546
Yellow
P094
3
94
3
547
Yellow
P094
4
94
4
551
Yellow
S230
4
558
4
551
Red
P091
4
091
4
553
Yellow
P157
0
157
16
T5-7-19
QST30
QSX15
QSL9
QSC
DESCRIPTION
QSB
QSK45
FMI
QSK19
SID(S)
PID(P)
FMI
QSM11
SPN
FAULT
CODE/
LAMP
X
X
X
X
X
X
X
X
TROUBLESHOOTING / Troubleshooting D
QSK60
X
554
Yellow
P157
2
157
2
555
Yellow
P022
0
1264
16
555
White
P022
0
1264
0
581
Yellow
P015
3
1381
3
582
Yellow
P015
4
1381
4
583
Yellow
P015
1
1381
18
595
Yellow
P103
0
103
16
596
Yellow
P167
0
167
16
597
Yellow
P167
1
167
18
598
Red
P167
1
167
1
599
Red
S025
14
640
14
611
None
S151
11
1383
31
611
None
S151
14
1383
31
612*
Red
99
1
616*
None
1173
16
617*
None
1172
0
621*
Yellow
1137
18
X
X
T5-7-20
QST30
QSK19
X
QSX15
QSM11
157
0
QSL9
P157
0
DESCRIPTION
QSC
553
Red
FMI
QSB
SID(S)
PID(P)
FMI
QSK45
SPN
FAULT
CODE/
LAMP
TROUBLESHOOTING / Troubleshooting D
SPN
QSK45
QSK60
623*
Yellow
1139
18
624*
Yellow
1140
18
625*
Yellow
1141
18
626*
Yellow
1142
18
627*
Yellow
1143
18
628*
Yellow
1144
18
631*
Yellow
1143 (45)
1145 (60)
18
1329
1
1144 (45)
1146 (60)
18
1329
1
1145 (45)
1147 (60)
18
1329
1
1146 (45)
1148 (60)
18
1329
1
631*
Yellow
632*
Yellow
632*
Yellow
633*
Yellow
633*
Yellow
634*
Yellow
634*
Yellow
T5-7-21
QSX15
QSL9
1138
18
QSC
622*
Yellow
DESCRIPTION
QSB
QST30
FMI
QSK19
SID(S)
PID(P)
FMI
QSM11
FAULT
CODE/
LAMP
TROUBLESHOOTING / Troubleshooting D
QSK60
QST30
QSK19
QSX15
QSM11
DESCRIPTION
QSL9
FMI
QSK45
635*
Yellow
SPN
QSC
SID(S)
PID(P)
FMI
QSB
FAULT
CODE/
LAMP
1147 (45)
1149 (60)
18
1329
1
636*
Yellow
1148 (45)
1150 (60)
18
1329
1
637*
Yellow
1151
18
638*
Yellow
1152
18
641*
Red
1137
0
642*
Red
1138
0
643*
Red
1139
0
644*
Red
1140
0
645*
Red
1141
0
646*
Red
1142
0
647*
Red
1143
0
648*
Red
1144
0
635*
Yellow
636*
Yellow
649
None
S153
0
1378
0
649
White
S153
11
1378
31
T5-7-22
X
X
TROUBLESHOOTING / Troubleshooting D
QST30
QSK45
QSK60
X
651*
Red
657*
Red
1143
1145
0
1144
1146
0
1145
1147
0
1146
1148
0
1147
1149
0
1148
1149
0
1150
0
(30,45)
(60)
658*
Red
1151
0
652*
Red
(30,45)
(60)
653*
Red
(30,45)
(60)
654*
Red
(30,45)
(60)
655*
Red
(30,45)
(60)
656*
Red
(30,45)
(60)
659*
None
QSX15
QSL9
QSC
649*
None
DESCRIPTION
QSK19
FMI
QSM11
SPN
SID(S)
PID(P)
FMI
QSB
FAULT
CODE/
LAMP
661*
Yellow
1137
16
661*
Yellow
1323
0
662*
Yellow
1138
16
662*
Yellow
1324
0
663*
Yellow
1139
16
T5-7-23
TROUBLESHOOTING / Troubleshooting D
QSK45
QSK60
QST30
QSK19
QSX15
DESCRIPTION
QSM11
FMI
QSL9
SPN
QSC
SID(S)
PID(P)
FMI
QSB
FAULT
CODE/
LAMP
663*
Yellow
1325
0
664*
Yellow
1140
16
664*
Yellow
1326
0
665*
Yellow
1141
16
665*
Yellow
1327
0
666*
Yellow
1142
16
666*
Yellow
1328
0
667*
Yellow
1143
16
668*
Yellow
1144
16
669*
None
671*
None
1137
4
672*
None
1138
4
673*
None
1139
4
674*
None
1140
4
675*
None
1141
4
676*
None
1142
4
677*
None
1143
4
678*
None
1144
4
T5-7-24
TROUBLESHOOTING / Troubleshooting D
QSK60
QSK19
QSX15
QSK45
Change Coolant
QST30
679*
None
DESCRIPTION
QSM11
FMI
QSL9
SPN
QSC
SID(S)
PID(P)
FMI
QSB
FAULT
CODE/
LAMP
691*
None
1172
3
692*
None
1172
4
694*
None
1173
3
695*
None
1174
4
711*
Yellow
1143 (45)
1145 (60)
16
1329
0
1144 (45)
1146 (60)
16
1330
0
1145 (45)
1147 (60)
16
1331
0
1146 (45)
1148 (60)
16
1332
0
1147 (45)
1148 (60)
16
1333
0
1148 (45)
1149 (60)
16
711*
Yellow
712*
Yellow
712*
Yellow
713*
Yellow
713*
Yellow
714*
Yellow
714*
Yellow
715*
Yellow
715*
Yellow
716*
Yellow
T5-7-25
TROUBLESHOOTING / Troubleshooting D
QSK60
QSK45
QST30
QSK19
QSX15
DESCRIPTION
QSM11
FMI
QSL9
SPN
QSC
SID(S)
PID(P)
FMI
QSB
FAULT
CODE/
LAMP
716*
Yellow
1334
0
717*
Yellow
1150
0
718*
Yellow
1151
0
1264
3
719
Yellow
P022
3
721*
None
727*
None
1143
1145
4
1144
1146
4
1145
1147
4
1146
1148
4
1147
1149
4
1148
1150
4
1151
4
728*
None
722*
None
723*
None
724*
None
725*
None
726*
None
729
Yellow
P022
4
(30,45)
(60)
(30,45)
(60)
(30,45)
(60)
(30,45)
(60)
(30,45)
(60)
(30,45)
(60)
1152
4
1264
4
747*
None
748*
None
749*
None
T5-7-26
TROUBLESHOOTING / Troubleshooting D
755
Yellow
157
7
QSK60
QST30
QSK19
QSK45
754*
None
QSX15
723
2
DESCRIPTION
QSM11
S064
2
FMI
QSL9
753
None
SPN
QSC
SID(S)
PID(P)
FMI
QSB
FAULT
CODE/
LAMP
756*
None
757*
None
758
Yellow
P129
7
1349
7
772
Yellow
S118
11
1657
11
773
Yellow
S119
11
1658
11
768
Yellow
S009
11
923
11
777
Yellow
P173
0
1180
0
779
Yellow
S051
11
703
11
951
None
P166
2
166
2
1000*
None
X
X
2154*
None
611
3
2155*
None
611
4
2194
Yellow
P223
11
1387
11
2195
Red
S051
14
703
14
T5-7-27
TROUBLESHOOTING / Troubleshooting D
(Blank)
T5-7-28
Color
Red
White
Blue
Green
Yellow
Black
Code
Or
Lg
Br
Gr
Color
Orange
Brown
Pink
Gray
Violet
Light
Green
T5-8-1
T5-8-2
Correct
Incorrect
T107-07-06-001
Correct
Rust
Bending
Separation
T107-07-06-002
Probe
FOR
DISCONNECTING
T107-04-05-002
Diode
Front All Pressure Sensor
Starter Relay 2
Buzzer Cancel Switch
Air Conditioner
Pressure Switch
Air Conditioner Sensor
Air Compressor
Speaker
Boost Pressure Sensor
Wiper Motor
Flow Rate Decrease Solenoid Valve
Travel Pressure Sensor
Heavy Lift Switch
Auto-Lubrication Timer Switch
Air Conditioner Controller
Air Conditioner Unit
Ambient Air Temperature Sensor
ECM Relay
Exhaust Gas Temperature Sensor
2. Pull to disconnect.
Locations of This Type Connector
Oil Pressure Sensor
Air Vent Select Servo Motor
Switch Box
Frash Memory
A/M Servo Motor
Radio
Fusible Link
Screw
Convex
T107-04-05-005
T5-8-3
Accessory (Outside)
Accessory (Outside)
Power Source
(Inside)
T142-06-06-004
T5-8-4
Description
Capacity
Connected to
Remarks
Backup
5A
Controller
5A
Main Controller B
Power source
3
Power ON SIG.
5A
DC-DC Converter
20 A
DC-DC Converter
Power source
MCX SOL
10 A
Power source
Travel Alarm
5A
Power source
Switch Box
5A
Step Light
5A
Power source
Power source
Air Conditioner
5A
Air Conditioner
10
BATT
5A
Power source
11
Light
20 A
Power source
12
Wiper
20 A
Power source
13
Air Conditioner
20 A
Power source
14
Solenoid
15 A
Power source
15
Radio
5A
Power source
16
Lighter
10 A
Lighter
Power source
17
Room Lamp
5A
Room Lamp
Power source
18
Horn
10 A
Horn Relay
Power source
19
5A
Starter Relay 1
Power source
20
5A
T18E-01-02-003
20
19
18 17 16 15 14 13 12 11
T18E-05-08-002
10
T5-8-5
T18E-01-02-003
T18E-05-08-001
Description
ECM Main Power Source
Capacity
20 A
Connected to
Remarks
ECM
Preheat Switch
5A
Preheat Relay
5A
Preheat Relay 1
Power source
ECM
Power source
Power source
ECM
5A
5A
DOWN LOAD PC
5A
OPT5
20 A
OPT6
20 A
5A
T5-8-6
Fusible Link 1 to 4
Fusible Link 5 to 8
Fusible Link 5 to 8
T183-01-02-015
T183-05-08-001
T5-8-7
Normal Voltage: 24 V
NOTE: If voltage is abnormal, recharge or replace
the battery.
2. Start the engine. Check voltage between the
battery positive terminal and the vehicle.
Normal Voltage: 26 to 28 V
NOTE: If voltage is abnormal, check the charging
system.
ALTERNATOR CHECK
T142-06-06-002
Terminal R
Terminal B
T18E-05-08-004
T5-8-8
T5-8-9
Tester Probes:
Black (-) Probe :To vehicle (Grounding)
Red (+) Probe :To the point to be measured.
24 Voltage Circuits
For each 24 voltage circuit, start checking either
from the power source side or the actuator side.
Thereby, the failed part in each circuit can be
located, if any.
Engine
Power Source Circuit
Stopped
Stopped
Stopped
Stopped
Stopped
Starting Circuit
Cranking
Cranking
Cranking
Cranking
Cranking
Cranking
Accessory Circuit
Stopped
Stopped
Stopped
Stopped
Charging Circuit
Running
Running
Running
Running
Surge Voltage
Prevention Circuit
Running-Stopped
Running-Stopped
Key Switch
Check Point
Standard
OFF
OFF
OFF
OFF
OFF
10 to 12.5 V
10 to 12.5 V
20 to 25 V
20 to 25 V
20 to 25 V
START
START
START
START
START
START
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
ACC
ACC
ACC
ACC
20 to 25 V
20 to 25 V
20 to 25 V
20 to 25 V
ON
ON
ON
ON
26 to 30 V
20 to 25 V
20 to 25 V
20 to 25 V
ON-OFF
ON-OFF
20 to 25 V
20 to 25 V
T5-8-10
Fuse Box 1
Key Switch
DLU
5
Fusible Link
Battery
Relay 2
Fuse Box 2
Load Damp
Relay
Battery
Battery
Relay 1
Monitor
Controller
3
ECM
Main
Controller B
T18E-02-03-007
T5-8-11
Fusible Link 1
Fuse
Box 1
1 Pole
Junction
Battery
Relay 2
Fusible Link 5
Fusible
Link 6
Fusible
Link 7
Battery
Relay 1
Fusible
Link 8
Battery
Fuse
Box 2
Alternator
Starter Relay
Starter Motor 2
Safety Relay 2
10
ECM
Starter Motor 1
Safety Relay 1
11
T5-8-12
T18E-02-03-010
Key Switch
Fusible
Link #1
Cigar
Lighter
Cab
Light
Horn
14
15
Battery Relay 2
Battery Relay 1
Battery
T18E-02-03-009
T5-8-13
Fusible Link 1
Fuse Box 1
Fusible Link 2
17
1 pole
Junction
Battery Relay 2
Fusible Link 3
Fusible Link 4
Battery Relay 1
Fusible Link 5
Battery
Fusible
Link 6
Fuse Box 2
Fusible
Link 7
16
Alternator
Fusible Link 8
18
Starter Relay
Air Heater 2
Air Heater 1
19
Monitor
Controller
T18E-02-03-011
T5-8-14
Key Switch
Fuse
Box 1
Fusible link 1
1 Pole
Junction
Battery Relay 2
Fusible link 3
Battery Relay 1
20
Load
Damp
Relay
Power
Transistor 3
21
Fusible link 5
Battery
Fusible
link 6
Fusible
link 7
Alternator
Fusible link 8
Main
Controller B
Monitor
Controller
Safety Relay 2
Safety Relay 1
T18E-02-03-012
T5-8-15
Power
Source
1
Signal or Ground
2
Two Polarities
Key Switch: ON
Black Probe (Minus) of Tester: Vehicle Frame
(Ground)
Red Probe (Plus) of Tester:
Terminal #1
T107-07-05-006
Power
Source Signal Ground
1
3
2
Three Polarities
T107-07-05-007
Two Polarities
Key Switch: ON
Black Probe (Minus) of Tester: Ground Terminal
(Terminal #2 or #3)
Red Probe (Plus) of Tester: Terminal #1
T107-07-05-008
Three Polarities
T107-07-05-009
T5-8-16
Connect to
the vehicle
frame.
T5-8-17
Connect to
the vehicle
frame.
Short-circuit
between the
harness and
the vehicle
frame
T107-07-05-003
First short-circuit
A
B
C
a
b
c
Second short-circuit
T107-07-05-004
a
b
c
T107-07-05-005
T5-8-18
MEMO
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MODEL:
PUBLICATION NO.:
YOUR NAME:
DATE:
FAX:
PAGE NO.:
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