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ADDITIONAL REFERENCES
Please refer to the materials listed below in addition Operation Manual of the Engine
to this manual. Parts Catalog of the Engine
Hitachi Training Material
The Operators Manual
The Parts Catalog
MANUAL COMPOSITION
This manual consists of three portions: the Techni- Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
Information included in the Technical Manual Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redelivery and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
IN-01
Example : T 1-3-5
This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury. Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights. NOTE:
To avoid injury and damage, be sure to use appropri- Indicates supplementary technical information or
know-how.
ate lifting techniques and equipment when lifting
heavy parts.
IN-02
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature pC pF pCI1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque Nm kgf m 1.0197 mL/rev cc/rev 1.0
Nm lbf ft 0.7375
IN-03
IN-04
001-E01A-0688
SA-688
SA-1
SA-2
004-E01A-0437
005-E01A-0438
SA-3
006-E01A-0434
SA-434
INSPECT MACHINE
S007-E01A-0435
SA-435
SA-4
SA-5
008-E01B-0439
009-E01A-0378
SA-6
010-E01A-0237
011-E01A-0426
SA-7
012-E01B-0444
JUMP STARTING
Battery gas can explode, resulting in serious injury.
If the engine must be jump started, be sure to
follow the instructions shown in the OPERATING
THE ENGINE chapter in the operators manual.
The operator must be in the operators seat so
that the machine will be under control when the
engine starts. Jump starting is a two-person
operation.
Never use a frozen battery.
Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway SA-032
machine.
S013-E01A-0032
SA-8
014-E01B-0379
SA-379
018-E01A-0481
SA-481
017-E01A-0491
SA-491
SA-9
SA-387
SA-388
019-E01D-0492
SA-590
SA-10
To avoid rollaways:
Select level ground when possible to park
machine.
Do not park the machine on a grade.
Lower the bucket and/or other work tools to the
ground.
Turn the auto-idle / acceleration seleclter and the SA-391
020-E08A-0493
SA-11
equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
USE A SIGNAL PERSON WHEN BACKING UP
IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEP THE SIGNAL PERSON IN VIEW.
Use hand signals, which conform to your local
regulations, when work conditions require a
signal person.
No machine motions shall be made unless
signals are clearly understood by both signalman SA-384
and operator.
Learn the meanings of all flags, signs, and
markings used on the job and confirm who has
the responsibility for signaling.
Keep windows, mirrors, and lights clean and in
good condition.
Dust, heavy rain, fog, etc., can reduce visibility.
As visibility decreases, reduce speed and use
proper lighting.
Read and understand all operating instructions in
the operators manual.
S021-E01A-0494
SA-12
injury or death.
To avoid tipping:
Be extra careful before operating on a grade.
Prepare machine operating area flat.
Keep the bucket low to the ground and close to
the machine.
Reduce operating speeds to avoid tipping or
slipping.
Avoid changing direction when traveling on
grades.
NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is SA-440
unavoidable.
Reduce swing speed as necessary when
swinging loads.
Be careful when working on frozen ground.
Temperature increases will cause the ground to
become soft and make ground travel unstable.
S025-E01B-0495
SA-13
029-E01A-0381
OBJECT HANDLING
032-E01A-0014
SA-14
031-E01A-0432
SA-432
033-E09B-0390
SA-15
034-E01A-0496
SA-019
SA-16
S035-E08A-0395
SA-17
SA-18
S500-E02B-0497
SA-037
SA-19
SS2045102
502-E01A-0026
SA-026
SA-20
503-E01B-0344
504-E01A-0034 SA-034
SA-040
S522-E01A-0040
SA-21
505-E01B-0498 SA-225
S506-E01A-0019
SA-22
SA-292
507-E03A-0499
SA-044
SA-23
hoses.
Clean up Flammables:
Spilled fuel and oil, and trash, grease, debris,
accumulated coal dust, and other flammables may
cause fires.
Prevent fires by inspecting and cleaning the
machine daily and by removing spilled or
accumulated flammables immediately.
SA-24
S508-E02B-0019
SA-25
518-E02B-0393
SS-1510
509-E01A-0016
SA-016
SA-26
SA-27
511-E01A-0029
512-E01C-0032
SA-28
SA-405
513-E01A-0405
S515-E01A-0309
SA-29
S516-E01A-0226
S517-E01A-0435 SA-435
SA-30
CONTENTS
Group 1 Introduction Group 4 Excavator Test
Operational Performance Tests................. T4-1-1 Travel Speed .............................................T4-4-1
Preparation for Performance Tests............ T4-1-2 Track Revolution Speed ............................T4-4-2
Mistrack Check..........................................T4-4-3
Group 2 Standard Travel Parking Leakage ............................T4-4-4
Operational Performance Swing Speed .............................................T4-4-5
Standard Table ...................................... T4-2-1 Swing Function Drift Check .......................T4-4-6
Main Pump P-Q Curve .............................. T4-2-6 Swing Motor Leakage................................T4-4-8
Injection Pump .......................................... T4-2-8 Maximum Swingable Slant Angle ..............T4-4-9
Dr.ZX Monitor Indicating Values .............. T4-2-9 Swing Bearing Play .................................T4-4-10
Sensor Activating Range ........................ T4-2-13 Hydraulic Cylinder Cycle Time ................T4-4-12
Dig Function Drift Check .........................T4-4-14
Group 3 Engine Test Control Lever Operating Force ................ T4-4-16
Engine Speed ........................................... T4-3-1 Control Lever Stroke ...............................T4-4-18
Engine Compression Pressure ................. T4-3-4 Combined Boom Raise/Swing
Valve Clearance Adjustment ..................... T4-3-5 Function Check .....................................T4-4-19
Nozzle Check............................................ T4-3-8 Combined Boom Raise and
Injection Timing....................................... T4-3-13 Arm Roll-In Operation ..........................T4-4-20
Lubricant Consumption ......................... T4-3-14
1HHT-4-1
Group 6 Adjustment
Engine Speed Adjustment and
Engine Learning .................................... T4-6-1
Govenor Lever and Fuel
Cut Lever Position ................................. T4-6-4
1HHT-4-2
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the op-
erational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
Performance Standard is shown in tables to evalu-
ate the performance test data.
T4-1-1
THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to
run straight more than 20 m (65 ft 7 in), and to
make a full swing with the front attachment ex-
tended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork-
ers. Once the test is started, be sure to commu-
nicate with each other using these signals, and to
follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid acci-
dents due to landslides or contact with
high-voltage power lines. Always confirm that
there is sufficient space for full swings.
4. Avoid polluting the machine and the ground with T105-06-01-003
T105-06-01-004
T4-1-2
Performance Reference
PERFORMANCE TEST DESIGNATION Standard Remarks
page
ENGINE SPEED min-1 T4-3-1
Slow Idle Speed 1050+100-100 Value indicated on Dr. ZX.
Fast Idle (Normal) 2015+75-75
Fast Idle (With ECO deactivated) +100
2115 -100
Fast Idle (Relief operation) Boom Raise relief opera-
1850 to 2015 tion
Value indicated on Dr. ZX.
Fast Idle (E mode) 1920
+100
-100
Value indicated on Dr. ZX.
Fast Idle (HP mode) Boom Raise / Arm Roll-In
1950 to 2200 relief operations.
Value indicated on Dr. ZX.
Auto-idle Speed 1335+100-100 Value indicated on Dr. ZX.
Auto-Acceleration Speed 1675+100-100
Warming Up Speed +100
1190 -100
ENGINE COMPRESSION PRESSURE 2.5 (26, 370) After engine warm up. T4-3-4
MPa (kgf/cm2, psi)
VALVE CLEARANCE (IN, EX) mm 0.4 With engine cold. T4-3-5
NOZZULE INJECTION PRESSURE T4-3-8
MPa (kgf/cm2, psi)
First stage: 18.1
(185, 2630)
Second stage:
22.1
(225, 3200)
INJECTION TIMING (Degrees before TDC) deg. 9p T4-3-13
LUBRICANT CONSUMPTION mL/h Hour meter: 2000 hours or T4-3-14
70 or less
less
TRVEL SPPED sec/10 m T4-4-1
Fast Mode ZAXIS330, 330LC, 350LC, 350LCN, 6.6o0.6
350H, 350BEH:
ZAXIS370MTH: 6.9o0.6
ZAXIS380HH: 6.8o0.6
Slow Mode ZAXIS330, 330LC, 350LC, 350LCN, (10.0o1.0)
350H, 350BEH:
ZAXIS370MTH: (11.0o1.0)
ZAXIS380HH: (11.3o1.0)
T4-2-1
Performance Reference
PERFORMANCE TEST DESIGNATION Standard Remarks
page
TRACK REVOLUTION SPEED sec/3 rev T4-4-2
Fast Mode ZX330, 350H, 350BEH: 27.3o2.0
ZX330LC, 350LC, 350LCN, 350LCH: 29.4o2.0
ZX370MTH: 35.0o2.0
ZX380HH: 32.6o2.0
Slow Mode ZX330, ZAXIS350H, 350BEH: 27.3o2.0
ZX330LC, 350LC, 350LCN, 350LCH: 29.4o2.0
ZX370MTH: 35.0o2.0
ZX380HH 32.6o2.0
MISTRACK mm/20 m
200 or less T4-4-3
(Both fast and slow travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0 T4-4-4
SWING SPEED sec/3 rev 15.5o1.0 Bucket empty T4-4-5
SWING FUNCTION DRIFT CHECK mm/180o 1706 or less 3.2 Arm T4-4-6
1.4 m3 (PCSA heaped)
Bucket, Bucket empty
SWING MOTOR LEAKAGE mm/5 min 3.2 Arm T4-4-8
0 1.4 m3 (PCSA heaped)
Bucket, Bucket loaded
MAXIMUM SWINGABLE SLANT ANGLE deg. 21.2 or possibly Bucket loaded T4-4-9
more
SWING BEARING PLAY mm 0.2 to 1.25 Allowable Limit: 2.0 to T4-4-10
3.05
HYDRAULIC CYLINDER CYCLE TIME sec 3.2 m Arm T4-4-12
1.4 m3 (PCSA heaped)
Bucket, Bucket empty
Boom Raise ZX330, 350LC, 350LCN: 3.4o0.3
ZX350H, 370MTH, 380HH: 3.6o0.3
ZX350BEH: 3.7o0.3
Boom Lower ZX330, 350LC, 350LCN: 2.4o0.3
ZX350H, 370MTH: 2.2o0.3
ZX380HH: 2.0o0.3
ZX350BEH: 2.9o0.3
Arm Roll-In ZX330, 350LC, 350LCN, 350H, 4.6o0.3
370MTH, 350BEH:
ZX380HH: 4.3o0.3
Arm Roll-Out 3.2o0.3
Bucket Roll-In ZX330, 350LC, 350LCN, 350H, 4.0o0.3
370MTH:
ZX380HH: 3.8o0.3
ZX350BEH: 4.3o0.3
Bucket Roll-Out ZX330, 350LC, 350LCN, 350H, 2.7o0.3
370MTH:
ZX380HH: 2.6o0.3
ZX350BEH: 2.8o0.3
DIG FUNCTION DRIFT CHECK mm/5 min 3.2 m Arm T4-4-14
1.4 m3 (PCSA heaped)
Bucket
Boom Cylinder (Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In Position) 5 or less Bucket empty
Arm Cylinder (Maximum Reach Position) 30 or less Bucket loaded
(Arm Roll-In Position) 15 or less Bucket empty
Bucket Cylinder (Maximum Reach Position) 20 or less Bucket loaded
(Arm Roll-In Position) 10 or less Bucket empty
Bucket Bottom (Maximum Reach Position) 150 or less Bucket loaded
(Arm Roll-In Position) 110 or less Bucket empty
T4-2-2
Performance Reference
PERFORMANCE TEST DESIGNATION Standard Remarks
page
CONTROL LEVER OPERATING FORCE HITACHI Lever Pattern
T4-4-16
N (kgf, lbf)
Boom Lever 18 (1.8, 13.0)
or less
Arm Lever (ISO Lever Pattern: Swing Lever) 15 (1.5, 10.8)
or less
Bucket Lever 15 (1.5, 10.8)
or less
Swing Lever (ISO Lever Pattern: Arm Lever) 18 (1.8, 13.0)
or less
Travel Lever 28 (2.8, 20.3)
or less
CONTROL LEVER STROKE mm HITACHI Lever Pattern T4-4-18
Boom Lever 105o10
Arm Lever (ISO Lever Pattern: Swing Lever) 84o10
Bucket Lever 84o10
Swing Lever (ISO Lever Pattern: Arm Lever) 105o10
Travel Lever 120o10
COMBINED BOOM RAISE/SWING FUNCTION 3.2 m Arm
Time to Swing 90p 1.4 m3 (PCSA heaped)
With bucket empty sec Bucket T4-4-19
ZX330, 350LC, 350LCN, 350H, 370MTH, 350BEH: 4.0o0.3
ZX380HH: 4.3o0.3
Bucket Teeth Height When Swinging 90p mm
ZAXIS330, 350LC, 350LCN: 7200 or more
ZAXIS350H, 370MTH, 380HH: 6500 or more
ZAXIS350BEH: 5500 or more
Boom Raise / Arm Roll-In sec 3.2 m Arm
5.9o0.3 1.4 m3 (PCSA heaped) T4-4-20
Bucket
PRIMARY PILOT PRESSURE MPa (kgf/cm2 , psi) 4.0+1.0-0.5 T4-5-1
Engine: Fast Idle (40+10-5 570+142-71)
Engine: Slow Idle 3.5+1.0-0
(35 -0, 500+142-0)
+10
T4-2-3
Performance Reference
PERFORMANCE TEST DESIGNATION Standard Remarks
page
SOLENOID VALVE SET PRESSURE Value indicated On T4-5-4
2
MPa (kgf/cm , psi) Dr.ZXo0.2 (2, 28)
MAIN PUMP DELIVERY PRESSURE 2.0o1.0 Value indicated on T4-5-7
2
MPa (kgf/cm , psi) (20o10, 284o142) Dr.ZX.
MAIN RELIEF VALVE SET PRESSURE T4-5-8
2
MPa (kgf/cm , psi)
With Boom / Arm / Bucket Circuit relieved 31.4+2.0-0.5 Value indicated on
(320+20-5, Dr.ZX.
4550+284-71)
With Bucket Circuit relieved 32.4+2.0-0.5 Value indicated on
(330+20-5, Dr.ZX.
4690+284-71)
RELIEF PRESSURE 32.4+2.0-0.5 Value indicated on T4-5-11
(When relieving Swing) (330+20-5, Dr.ZX.
4690+284-71)
RELIEF PRESSURE T4-5-12
(When relieving Travel)
(When relieving both travel levers) 34.3+2.0-0.5 Value indicated on
(350+20-5, Dr.ZX.
4980+284-71)
(When relieving one travel lever) 35.3+2.0-0.5 Value indicated on
(360+20-10, Dr.ZX.
5120+284-142)
With Power Boost Circuit relieved +2.0
34.3 -1.0 Value indicated on
(Boom, Arm) (350+20-10, Dr.ZX.
4980+284-142)
With Power Boost Circuit relieved +2.0
35.3 -1.0 Value indicated on
(Bucket) (360+20-10, Dr.ZX.
5120+284-142)
OVERLOAD RELIEF VALVE SET PRESSURE (Reference Values T4-5-14
MPa (kgf/cm2,, psi) at
50L / min)
Boom (Raise/Lower), Arm (Roll-In), 33.4+1.0-0
Bucket (Roll-In) (340+10-0,
4830+142-0)
Arm (Roll-Out), Bucket (Roll-Out) 35.3+1.0-0
(360+10-0, 5120+142-0)
MAIN PUMP FLOW RATE TEST L/min Refer to T4-2-6 and T4-5-18
T4-2-7 Group.
SWING MOTOR DRAINAGE L/min T4-5-25
With constant maximum speed 0.2 to 0.3
With the motor relieved (2 to 5)
TRAVEL MOTOR DRAINAGE L/min T4-5-28
With the track jacked up 1.4 to 2.1 Allowable Limit: 2.6
With the motor relieved 1.4 to 4.0 Allowable Limit: 5.0
T4-2-4
T4-2-5
(L/min)
300
A B
250
C
D
200
E
Flow Rate
150
100
50
0
4.9 (50) 9.8 (100) 14.7 (150) 19.6 (200) 24.5 (250) 29.4 (300) 34.3 (350)
T173-04-05-001
T4-2-6
(L/min)
200
Flow Rate B
100 A
MPa (kgf/cm2)
0 0.98(10) 1.96(20) 2.94(30)
T4-2-7
Governor adjustment
Rack limit
Idle-sub spring setting
Above
Boost Compensator Stroke; 0.7o0.1 mm
Governor spring setting
Pack Position
(mm)
Above
T4-2-8
T4-2-9
T4-2-10
T4-2-11
T4-2-12
T4-2-13
T4-2-14
Preparation:
1. Select the monitor function of the built-in diag-
nosing system (or Dr.ZX). When using an engine
speed meter, install speed pickup (1) to injection
pipe (2).
2. Warm up the machine until the engine coolant
temperature reaches 50 pC (122 pF) or more, and
hydraulic oil is 50o5 pC (122o9 pF).
T1HH-04-02-002
T4-3-1
T4-3-2
Engine Con-
trol Dial
Auto-Idle/ Accelera-
tion Selector
Power Mode
Switch
Work Mode
Switch
T178-01-01-003 T178-01-01-004
T4-3-3
Preparation:
1. Confirm that valve clearances are correct.
2. Confirm that the batteries are charged properly.
3. Run the engine until the coolant temperature
gauge reaches the operating range.
4. Stop the engine. Remove glow plugs from each
cylinder.
NOTE: Unless the fuel delivery pipes are discon-
nected, fuel will ignite in the cylinders so
that pressure in the cylinders will increase. T1HH-04-02-003
Measurement:
1. Turn the starter to crank the engine. Record the
compression pressure of each cylinder.
2. Repeat measurement three times for each cylin-
der and calculate the mean values.
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy
Refer to engine shop manual.
T4-3-4
Preparation:
1. Locate top dead center (TDC) in the compression
stroke.
While turning the crank shaft clockwise, align the
matching mark on the crank pulley with the
pointer located on the flywheel housing as illus-
trated.
When the S mark on the driving side flange of the
injection pump coupling aligns with the pointer,
piston No.1 (or piston No.6) is positioned at TDC
in the compression stroke.
Measurement:
1. Insert a feeler gauge into the clearance between
the rocker arm and the valve stem end to meas-
ure the valve clearance.
T173-04-02-007
NOTE: Cylinder Nos. are designated from No.1 to
No.6 as viewed from the fan side.
T4-3-5
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-3-6
T4-3-7
Preparation:
1. Injection Pressure at First Stage:
1-1. Remove the nozzle holder, the fuel injection Injection Pressures T1HH-04-02-007
at First and Second
pipings and so on. Stages:
Retaining
1-2. Remove the retaining nut from the nozzle Nut (Tool) Nozzle
holder. Install the gasket (tool) and retaining
nut (tool) on the nozzle.
Gasket
Gasket (Tool): 157892-1500 (Bosch Automo- (Tool)
tive)
Retaining Nut (Tool): 157892-4000 (Bosch
Automotive)
: 34 N m (3.5 kgf m, 25.5 lbf ft)
2-2. Install the gasket (tool) and the plug (tools) to Retaining Nut
the retaining nut (tool). (Tool) Gasket (Tool)
Gasket (Tool) :026508-1140 (Bosch Automo-
tive)
Plug (Tool): 157892-1600 (Bosch Automotive)
Nozzle Holder
T1HH-04-02-010
T4-3-8
Holder (Tool)
2-5. Install the pin (tool) to the dial gauge (tool).
Dial Gauge (Tool): 157892-3800 (Bosch
Automotive)
Pin (Tool) (Length: 60 mm): 157892-5300
(Bosch Automotive)
T1HH-04-02-012
Retaining Nozzle
Nut Tester
Plug
T1HH-04-02-013
T4-3-9
minute, measure the fuel injection pressure. Injection Pressure at Second Stage:
Dial Gauge
2. Injection Pressure at Second Stage:
2-1. Operate the nozzle tester in order to increase
the pressure inside the nozzle holder to 34.3
to 44.1 MPa (350 to 450 kgf/cm2, 4980 to
6400 psi). The nozzles needle valve should
move through its full stroke. Record full stroke Nozzle Tester
(L).
Pressure
T4-3-10
T4-3-11
4. Leak Condition
Be sure to keep the pressure as that just before Normal
the injection. Then, check for any oil leakage
around the nozzle.
Evaluation
1. Standard Injection Pressure:
Refer to T4-2 Operational Performance Standard
Table.
2. Spray Pattern
Large-size spray should not be visible to the na- T1HH-04-02-014
Adjustment
1. Injection pressure at the first stage can be
changed in response to the first nozzle opening
pressure shim thickness.
T1HH-04-02-015
2. Injection pressure at the second stage can be
changed in response to the second nozzle open-
ing pressure shim thickness.
First Nozzle
Opening
Pressure
Shim
T1HH-04-02-007
T4-3-12
Inspection/Adjustment:
1. Position piston No.1 at TDC. Turn the crank shaft
clockwise to align the matching mark on the
crank pulley with the pointer on the housing.
T1HH-04-02-017
Coupling
Adjusting
Bolt
T1HH-04-02-018
T4-3-13
Measuring Method
1. Place the machine on level firm ground, and
leave it for at least one hour to let the lubricant
lower to the oil pan.
At this time, confirm that the machine is level,
using a leveler.
2. Record the read-out A (unit: hour) of the hour
meter.
3. Replenish the lubricant up to the high-level
gauge.
4. Operate the machine for at least 100 hours or un-
til the oil level lowers to the low-level gauge.
Evaluation:
Refer to T4-2 Operational Performance Standard.
T4-3-14
T4-4-1
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-2
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T105-06-03-022
T4-4-3
Preparation:
1. The surface of the test slope shall be even with a
gradient of 20 (11.31p).
0.2 to 0.3 m
2. Mark a white line on the travel device cover.
3. Hold the bucket 0.2 to 0.3 m (8 to 12 in) above
the ground with the arm and bucket fully rolled in.
4. Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF).
T105-06-03-004
Measurement:
1. Measure the travel parking brake slip amount
while parked.
2. Climb the slope and place the travel levers in
neutral.
3. Stop the engine.
4. After the machine stops, put alignment marks on
a track link or shoe, and the track side frame.
5. After 5 minutes, measure the distance between
the marks on the track link or shoe and the track
side frame.
Evaluation:
Refer to the Operational Performance Standard
Table in Group T4-2.
Alignment marks on the trackside
frame and shoe when the machine
comes to a stop.
Displacement measured
after 5 minutes.
T105-06-03-006
T4-4-4
T105-06-03-013 Evaluation:
Refer to the Operational Performance Standard in
NOTE: In case a sufficient space for the meas- Group T4-2.
urement is difficult to find, carry out the
measurement with the boom fully raised Remedy:
and the arm fully rolled-in. Refer to the Troubleshooting B in Group T5-4.
T178-04-03-001
T4-4-5
Preparation:
1. Check the lubrication of the swing gear and
swing bearing.
2. Place the machine on flat, solid ground with
ample space for swinging. Do not conduct this Two Check Marks
test on a slope.
T105-06-03-008
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. The bucket must
be empty.
4. Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
5. Swing the upperstructure 180p.
6. Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF).
T4-4-6
Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-7
Preparation:
1. Check the lubrication of the swing gear and
swing bearing.
2. Park the machine on a smooth slope with a
gradient of 26.8 % (15p).
3. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
W=1800 kg (3970 lb)
4. With the arm rolled out, and bucket rolled in,
position the arm top pin height to be level with the
boom foot pin.
5. Swing the upperstructure to position it 90p to the
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as T105-06-03-011
illustrated.
6. Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF).
Measurement:
1. Select the following switch position:
Auto-Idle/
Power Mode Work Mode
Acceleration Measure Difference Between Marks
Switch Switch
Selector
P Mode Digging Mode OFF
Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-8
T105-06-03-011
T4-4-9
Preparation:
1. Check swing bearing mounting bolts for loose-
ness.
2. Check the lubrication of the swing bearing. Con-
firm that bearing rotation is smooth and without
noise.
3. Install a dial gauge on the track frame as shown, Magnetic Dial
using a magnetic base. Base Gauge
T105-06-03-014
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the front
idlers.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race.
6. Bucket should be empty.
T4-4-10
Evaluation: T105-06-03-007
T105-06-03-017
T4-4-11
Preparation:
1. Be sure to measure at the position as follows.
To measure the cycle time of the boom cylinders:
With the arm rolled out and the empty bucket
rolled in, lower the bucket to the ground, as
shown. T105-06-03-018
T105-06-03-020
T4-4-12
Evaluation:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-13
Summary:
Measure dig function drift, which can be caused by
oil leakage in the control valve and boom, arm, and
bucket cylinders, with the loaded bucket.
(2 in) retracted from the fully extended position. Arm Cylinder Extension
4. With the arm rolled out and the bucket rolled in,
hold the bucket so that the height of the bucket
pin is the same as the boom foot pin.
5. Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF).
Mark
Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the bucket, as well as the boom, arm and
bucket cylinders.
3. Repeat step 2. three times and calculate the T110-06-03-001
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T110-06-03-002
T4-4-14
Summary:
Measure dig function drift, which can be caused by
oil leakage in the control valve and boom, arm, and
bucket cylinders.
Preparation:
1. The bucket must be empty.
2. Position the arm cylinder with the rod 50 mm (2
in) retracted from the fully extended position.
3. Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position.
4. With the arm rolled in and the bucket rolled in.
1m
Lower the boom until the arm tip is 1 m (40 in)
above the ground.
5. Maintain the hydraulic oil temperature at 50o5 pC T173-04-03-001
(122o9 pF).
Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the arm tip, as well as the boom, arm and
bucket cylinders. Cylinder Retraction
3. Repeat step 2. three times and calculate the
average values. Mark Mark
Evalution:
Refer to the Operational Performance Standard in
Group T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T110-06-03-002
T4-4-15
Preparation:
Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF).
T107-06-03-004
T4-4-16
Evalution:
Refer to the Orerational Performance Standard in
Group T4-2.
T4-4-17
Preparation:
Maintain the hydraulic oil temperature at 50o5 pC
(122o9 pF).
Measurement: T107-06-03-005
Evalution:
Refer to the Orerational Performance Standard in
Group T4-2.
T4-4-18
Preparation:
1. Start the engine and run it at fast idle. Operate
the boom raise function and check to be sure that
the cylinder movement is smooth, with out stick-
ing. T107-06-03-009
Measurement:
1. Select the following switch positions: T107-06-03-010
Engine Auto-Idle/
Power Mode Work Mode
Control Acceleration
Switch Switch
Dial Selector
Fast Idle P Mode Digging Mode OFF
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-4-19
Preparation:
1. Fully retract the arm cylinder and fully extend the
bucket cylinder. Adjust the boom cylinder so that
the bucket tooth tip height is 0.5 m (1 ft 8 in)
above the ground. (Empty the bucket.)
2. Maintain the hydraulic oil temperature at 50 o 5
pC (122o9 pF). 0.5 m
Measurement: T107-06-03-006
Evaluation:
Refer to T4-2 Operational Performance Standard.
Remedy:
Refer to T5-4 Troubleshooting B.
T107-06-03-008
T4-4-20
Measurement:
1. Select the following switch positions:
Power Auto-Idle/
Engine Con- Work Mode
Mode Acceleration
trol Dial Switch
Switch Selector
General
Fast Idle P Mode Purpose OFF
Mode
General
Slow Idle P Mode Purpose OFF
Mode
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-5-1
T1HH-04-04-002
T4-5-2
Measurement:
1. Select the following switch positions:
Power Auto-Idle/
Engine Work Mode T1HH-04-04-003
Mode Acceleration
Control Dial Switch
Switch Selector
Digging
Fast Idle P Mode OFF
Mode
Digging
Slow Idle P Mode OFF
Mode
Evaluation:
Refer to Performance Standard Table in Group T4-2.
Remedy: T157-05-04-011
T4-5-3
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Disconnect line (1) from the solenoid valve to be
measured. Install hose (Parts Number: 4216453),
tee (ST 6451), adapter (ST 6461), and pressure
gauge (ST 6942) to the disconnected end at the
solenoid valve side, as illustrated.
: 17 mm, 19 mm, 22 mm
SC
Connect Dr. ZX. Select the monitor function.
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection. SI
5. Maintain the hydraulic oil temperature at 50o5 pC SG
(122o9 pF). T1HH-01-02-008
Pressure Gauge
Hose Piping
Tee Adapter
T173-04-04-006
T4-5-4
Evaluation:
The average value read on the pressure gauge shall
be within o0.2 MPa (o2 kgf/cm2, o28 psi) of the value
indicated on Dr. ZX.
T4-5-5
W107-02-05-129
T4-5-6
Measurement:
1. Select the following switch positions: T1HH-04-04-005
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Digging
Fast Idle P Mode OFF
Mode
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-5-7
Summary:
Measure the main relief valve setting pressure at the
main pump delivery part. Pressure Check Ports
The main relief pressure can also be measured with
the built-in diagnosing system or Dr.ZX.
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install adapter (ST 6069), hose (ST 6943)
and pressure gauge (ST 6941) on the port.
: 6 mm
T4-5-8
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
T4-5-9
: 19 mm (Adjusting Plug 2)
W107-02-05-129
T4-5-10
T1HH-01-02-004
T107-02-04-020
Adjusting Plug
Pressure Pressure
Increase Decrease
T157-05-04-023
T4-5-11
2 1
T157-05-04-008
Adjusting Screw
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-12
3 4
T135-06-04-001
T4-5-13
T183-01-02-012
2 1
T142-05-04-007
Adjusting Screw
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-14
T4-5-15
T4-5-16
Evaluation:
1. Performance of the overload relief valves are
normal if the measured main relief pressures are
T1HH-04-04-005
within the specified value range.
T4-5-17
Adjustment:
Adjust the pressure setting of the overload relief
valve using adjusting screw (2) after loosening lock
nut (1).
1 2
1. Loosen lock nut (1).
: 22 mm
W107-02-05-129
T4-5-18
T4-5-19
T4-5-20
Qc = (Ns I Q) / Ne
1, 2 3 4 5 6 7 8 9 10 11
T173-04-04-002
14
N sensor
T1HH-01-02-003
T1HH-04-04-010
1- Pipe E (ST 6144) 5- Hydraulic Tester (ST 6299) 9- Flange (ST 6118) 12 - Plug
2- Pipe B (ST 6143) 6- Adapter PF1IUNF1-7/8 10- Split Flange (ST 6130) 13 - Hose (ST 6339)
(ST 6146)
3- Test Hose (ST 6145) 7- Joint (ST 6330) 11- Bolt (ST 6409) (4 Used) 14- Pipe (2 Used)
4- Adapter PF1IUNF1-7/8 8- Test Hose (ST 6320)
(ST 6146)
T4-5-21
T4-5-22
1, 2 3 4 5 6 7 8 9 10 11
Port Pi
M T173-04-04-002
12
N sensor
T1HH-04-04-002
T1HH-04-04-009
15 17
To Port Pi on Regulator
14 17 15 16 15 14 13 To Port PC on
Pilot Filter
T1HH-04-04-008
1 - Pipe E (ST 6144) 6 - Adapter PF1IUNF1-7/ 8 11 - Bolt (ST 6409) (4 used) 16 - Reducing Valve (4325439)
(ST 6146)
2 - Pipe B (ST 6143) 7 - Joint (ST 6330) 12 - Plug M 17 - Tee UNF7/16IUNF 7/16
3 - Test Hose (ST 6145) 8 - Test Hose (ST 6320) 13 - Adapter UNF 7/16I 18 - Pressure Gauge (ST 6931)
PF 1/4 (ST 6069)
4 - Adapter PF1IUNF1-7 / 8 9 - Flange (ST 6118) 14 - Hose UNF7/16I 19 - Hose UNF 7/16I
(ST 6146) UNF7/16 (4334309) UNF 7/16 (4334309)
5 - Potable Tester (ST 6299) 10 - Split Flange (ST 6130) 15 - Adapter PF3/8I 20 - Adapter PF3/8I
UNF 7/16 (4200465) UNF 7/16 (4200465)
T4-5-23
4. Adjust the reducing valve set pressure to the 2. Specified Pump Flow Rate
specified pressure shown on the P-Q diagram of Refer to the Performance Standard Table in
the main pump (Pilot Pressure Characteristics) Group T4-2.
on page T4-2-5.
Measure the flow rate and engine speed at each
specified pressure shown on the P-Q diagram.
T4-5-24
6 5
1
3
2
4
10
T1HH-03-01-002
7 8
1 - Lock Nut (For Minimum 4 - Adjusting Screw (For 7 - Lock Nut 9 - Lock Nut
Flow Adjustment) Maximum Flow Adjust- (For P-Q Line Adjustment) For P-Q Line Adjustment)
ment)
2 - Adjusting Screw (For 5 - Lock Nut 8 - Adjusting Screw 10 - Adjusting Screw
Minimum Flow Adjustment) (For Pilot Pressure Char- (For P-Q Line Adjustment) (For P-Q Line Adjustment)
acteristic Adjustment)
3 - Lock Nut (For Maximum 6 - Adjusting Screw
Flow Adjustment) (For Pilot Pressure Char-
acteristic Adjustment)
Pi
2. Maximum Flow Rate After loosening lock nut (3), turn 1) Do not tighten adjusting screw
Q adjusting screw (4). Tightening ad- (2) more than two turns.
justing screw (4) 1/4 a turn de- 2) Do not attempt to increase the
creases the maximum pump flow maximum flow rate. (Do not turn
rate by 10.00 cm3/rev. adjusting screw (4)
counter-clockwise.)
3) Securely retighten lock nut (3)
after adjustment.
Pd
T4-5-25
4. Pump Output Torque A. After loosening lock nut (7), turn 1) Do not tighten adjusting screw
(P-Q Line) adjusting screw (8). Tightening (8) more than one turn.
Q adjusting screw (8) 1/4 a turn 2) Increase or decrease the flow
increases the pump flow rate by rate. So that the engine is not
A 19.85 cm3/rev. overloaded.
B. After loosening lock nut (9), turn 3) Securely retighten lock nut (3 or
Pd adjusting screw (10). Tightening 9) after adjustment.
Q adjusting screw (10) 1/4 a turn
increases the pump flow rate by
3.73 cm3/rev.
B
Pd
T4-5-26
Preparation:
1. Maintain hydraulic oil temperature at 50o5 pC
(122o9 pF). Rotate the swing motor to warm the T157-05-04-014
T4-5-27
T4-5-28
Q = 60 I q / t
Where:
Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
T107-06-05-008
q : Total amount of drain oil (L)
T4-5-29
ZAXIS370MTH:
T155-05-04-004
2
M183-01-001
T4-5-30
Evaluation:
Refer to the Performance Standard Table in Group
T4-2.
Q = 60 I q / t
Where:
Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-5-31
T4-5-32
5. Loosen the bolt holding the control lever to the EC Holding Bolt
motor output shaft.
Control Lever T157-07-04-015
6. While monitoring the actual engine speed with Dr.
ZX or the engine speed meter, adjust the control
lever so that the minimum speed (slow idle)
matches the specification.
Specification: Refer to T4-2 OPERATIONAL PER
FORMANCE TEST.
T4-6-1
Learning Switch is
Turned to Stamp E
Learning Switch
Stamp
T4-6-2
T4-6-3
1 2
T1HH-04-02-002
4 3
T4-6-4
B
FULL
A: STOP
FULL
STOP
T1HH-04-02-002
B A
T1HH-04-02-002
T4-6-5
T4-6-6
CONTENTS
Group 1 General Group 3 Troubleshooting A
Introduction............................................... T5-1-1 Troubleshooting A Procedure ....................T5-3-1
Diagnosing Procedure .............................. T5-1-2 Fault Code List ..........................................T5-3-2
Built-In Diagnosing System Operation ...... T5-1-6 Fault Code 01, 02, 03................................T5-3-3
Built-In Diagnosing Function Display List .. T5-1-7 Fault Code 04............................................T5-3-3
Dr. ZX Operation....................................... T5-1-8 Fault Code 06............................................T5-3-4
Dr. ZX Fault Code List............................. T5-1-10 Fault Code 07............................................T5-3-5
Dr. ZX Monitoring Item List ..................... T5-1-12 Fault Code 10, 11 ......................................T5-3-6
Dr. ZX Special Function .......................... T5-1-14 Fault Code 12, 13......................................T5-3-7
Dr. ZX Service Mode............................... T5-1-15 Fault Code 14, 15, 16, 18..........................T5-3-8
Adjustment Data List............................... T5-1-25 Fault Code 19............................................T5-3-9
Group 2 Component Layout
Main Component Layout ........................... T5-2-1
Electrical Component Layout (Overview) .. T5-2-2 Group 4 Troubleshooting B
Electrical System (Relays) ........................ T5-2-3 Troubleshooting B Procedure....................T5-4-1
Electrical System Relationship between Machine Trouble
(Monitors and Switches).......................... T5-2-4 Symptoms and Related Parts ..................T5-4-2
Engine ...................................................... T5-2-5 Correlation between Trouble
Pump Device ............................................ T5-2-5 Symptoms and Part Failures ................. T5-4-20
Swing Device ............................................ T5-2-5 Engine System Troubleshooting .............. T5-4-31
Control Valve ............................................ T5-2-6 All Actuator System Troubleshooting .......T5-4-52
Solenoid Valve Unit................................... T5-2-6 Front Attachment System
Travel Device ............................................ T5-2-6 Troubleshooting..................................... T5-4-59
Shockless Valve........................................ T5-2-6 Swing System Troubleshooting ...............T5-4-72
Positioning Control Valve ........................ T5-2-6 Travel System Troubleshooting ............... T5-4-75
Components in Control Valve.................... T5-2-8 Other System Troubleshooting ................ T5-4-82
Exchange Inspection ............................. T5-4-102
Emergency Boom Lowering
Procedure ........................................... T5-4-104
1HHT-5-1
1HHT-5-2
T5-1-1
T107-07-01-002
T5-1-2
T5-1-3
T5-1-4
T5-1-5
T5-1-6
Display
Description Monitored Result Unit Remarks
Order
1 Hour Meter h Standard Mode
2 Trip 1 h Standard Mode (Subtraction)
3 Trip 2 h Standard Mode (Subtraction)
4 Engine Actual Speed n -1
min User Mode (Required to set
in the Dr. ZX service mode)
5 Hydraulic Oil Tempera- pC User Mode (Required to set
ture in the Dr. ZX service mode)
6 L1 Display Purpose Only
7 Overload Alarm L2 % European Spec. Only
8 Fault Code* 0
9 ML Switch** 1 0: Switch OFF
1: Switch ON
10 Pump 1 Delivery Pres- 2 MPa
sure
11 Pump 2 Delivery Pres- 3 MPa
sure
12 Pump 1 Pump (Flow) 4 MPa
Control Pressure
13 Pump 2 Pump (Flow) 5 MPa
Control Pressure
-1
14 Engine Target Speed 6 min
15 EC Angle 7 V
16 Dial Angle 8 V
17 Boom Raise Pilot Pres- 9 MPa
sure
18 Arm Roll-In Pilot Pres- A MPa
sure
19 Swing Control Pilot b MPa
Pressure
20 Travel Control Pilot c MPa
Pressure
21 Front Att. Operation d 0: Not Operating
1: Operating
22 Att. Control Pressure E MPa
23 Work Mode F 0: Digging
1: Breaker
2: Secondary
Crusher
(Demolisher)
3: Crusher
4: Vibro-Hammer
T5-1-7
Palm
Dr. ZX
Battery Box
Cable
T178-05-01-167
T5-1-8
Self-diagnostic
Result by control- Enter model
ler is displayed Record
code and serial
No.
Retry B
Select data to
be monitored
Self-diagnostic
Result is displayed Monitored data
is displayed
T5-1-9
T5-1-10
T5-1-11
T5-1-12
Optional
Item Data Unit
Optional Pump 3 Delivery Pressure Input signal from pump 3 delivery pressure sen- MPa
sor
Boom Cylinder Bottom Pressure MPa
Boom Cylinder Rod Pressure MPa
ATT. Control Pressure Input signal from pressure sensor (auxiliary) MPa
Boom Angle V
Arm Angle V
Pump 1 Max. Displacement cm3
Pump 1 Proportional Solenoid Valve Control signal to pump 1 flow rate control sole- MPa
Output noid valve
Travel/Swing/Overload Alarm Tr, Sw, Load
Initial ML Setting Unf, Done, Abrt,
Und
Initial Boom-Angle Setting Unf, Done, Abrt,
Und
T5-1-13
Special function
Execute Execute
T5-1-14
Stamped
Mark E
T1CC-05-01-001
T5-1-15
Item Data
Learning Data Display
EC Motor Stop Position Display of the engine stop value in engine learning
EC Motor Maximum Speed Position Display of max. engine speed valve in engine learning
Boom Angle Sensor Correction Value Display of boom angle sensor correction value
Arm Angle Sensor Correction Value Display of arm angle sensor correction value
Parameter Change
Li Speed Adjustment Adjustment of minimum engine speed
WU Speed Adjustment Adjustment of warming up engine speed
AI Speed Adjustment Adjustment of auto-idle engine speed
E Speed Adjustment Adjustment of E-mode engine speed
P Speed Adjustment Adjustment of P-mode engine speed
Breaker Engine Speed Adjustment Adjustment of breaker operation engine speed
Secondary Crusher (Demolisher) Engine Adjustment of secondary crusher (demolisher) operation
Speed Adjustment engine speed
Crusher Engine Speed Adjustment Adjustment of crusher operation engine speed
Vibro-Hammer Speed Adjustment Adjustment of vibratory hammer operation engine speed
Hyd. Breaker P1 Max Swash Angle Adjustment of lowest pump 1 max. flow rate in breaker
Adjustment operation
Secondary Crusher (Demolisher) P1 Max Adjustment of lowest pump 1 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P1 Max Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in crusher
operation
Vibro P1 Max Swash Angle Adjustment Adjustment of lowest pump 1 max. flow rate in vibratory
hammer operation
Hyd. Breaker P2 Max Swash Angle Adjustment of lowest pump 2 max. flow rate in breaker
Adjustment operation
Secondary Crusher (Demolisher) P2 Max Adjustment of lowest pump 2 max. flow rate in secondary
Swash Angle Adjustment crusher operation
Crusher P2 Max Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in crusher
operation
Vibro P2 Max Swash Angle Adjustment Adjustment of lowest pump 2 max. flow rate in vibratory
hammer operation
Pump PQ Base Torque Correction Adjustment of pump P-Q curve
ATT Speed Increase Down Waiting Time Setting of time required for engine speed increase
Min, Boom CYL. Bottom Pressure Over
Balance
Monitor Display Change
Engine Actual Speed Display/Non-display Monitor setting of display/no-display of actual engine speed
Hydraulic Oil Temperature Display/No-display Monitor setting of display/no-display of hydraulic oil
temperature
Hydraulic Oil Filter LED Display/No-display Monitor setting of ON/OFF of hydraulic oil filter LED.
NOTE: ML specification is only available in Japanese domestic market.
T5-1-16
T5-1-17
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS330.
T5-1-18
EC Motor stop position EC Motor Maximum Boom angle sensor Arm angle sensor correction
engine speed position correction value value
T5-1-19
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS330.
Start the service mode on the condition that the engine learning switch is turned on.
To change the parameter, it is necessary to enter the password. To change the password, refer to the Changing the password
section.
The menu will be displayed. Enter the password to change Select the item you want to change. The
Select Parameter Change from the parameter. up- and down-arrow buttons can be
the menu. used to scroll through the item list.
Fig. F
Fig. E T178-05-01-042
T178-05-01-043
Fig. G
Select ESC to return T178-05-01-044
Select ESC to return to Fig. E. Select ESC to return
to Fig. D. to Fig. E.
T5-1-20
Enter the new value Confirm the new value Parameter adjustment
result
Enter the new value in the The new value will be displayed
The adjusted value will be
Adjustment space, and press in the Adjustment space. Select
displayed.
Execution. Execute to change to this value.
T5-1-21
NOTE: The following explanation exemplifies the transition diagrams for ZAXIS330.
Start the service mode on the condition that the engine learning switch is turned on.
T5-1-22
T5-1-23
T5-1-24
T5-1-25
T5-1-26
1
3
4
5
6
7
8
9
21
10
11
12
13
20 14
15
19 16
18 17 T1HH-01-02-001
1- Bucket Cylinder 7- Fuel Tank 13- Intercooler 19- Pilot Shut-Off Valve
2- Arm Cylinder 8- Hydraulic Oil Tank 14- Radiator 20- Travel Pilot Valve
3- Boom Cylinder 9- Control Valve 15- Oil Cooler 21- Front Attachment/Swing
Pilot Valve
4- Center Joint 10- Pilot Filter and Pilot Relief Valve 16- Battery
5- Swing Bearing 11- Pump Device 17- Travel Device
6- Swing Device 12- Engine 18- Shockless Valve
T5-2-1
1 2
Pressure Sensor
(Front Attachment)
Pressure Sensor
(Travel)
Refer to the Control Valve
group.
6, 7
15
14
13
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
N Sensor
12 Refer to the Pump Device group.
8
11
Coolant Temperature Switch
(Engine Preheat Circuit)
Engine Oil Pressure Switch
*Engine Oil Level Switch
Coolant Temperature Sensor
Overheat Switch
10 Refer to the Engine group
9
T1HH-01-02-002
1 - Wiper Motor 5 - Pump 1 Control Pressure 9 - Battery Relay 13 - Starter Relay
sensor (4-Spool Side)
2 - Horn 6 - EC Motor 10 - Ambient Temperature Sensor 14 - Air Cleaner Restriction Switch
3 - Work Light 7 - EC Sensor 11 - *Coolant Level Switch 15 - Pressure Sensor (Boom Raise)
4 - Fuel Sensor 8 - Pump 2 Control Pressure 12 - Battery Pressure Sensor (Arm Roll-In)
sensor (5-Spool Side) Pressure Sensor (Swing)
Torque Control Solenoid Valve
Pump 2 Flow Rate Control
Solenoid Valve
NOTE: *Up to serial No.030652
T5-2-2
8
9
10
T178-01-02-006
15
14
19
18 13
17 12
16 11
T178-01-02-007
1 - GPS ON/OFF Switch 6 - Fuse Box 11 - Load Damp Relay (R1) 16 - Wiper Relay A (R6)
(Satellite Navigation System
Equipped Machines only)
2 - QOS Controller 7 - Learning Switch 12 - Washer Relay (R2) 17 - Wiper Relay B1 (R7)
3 - ICX (Information Controller) 8 - Dr. ZX Connector to MC 13 - Work Light Relay 2 (R3) 18 - Wiper Relay B2 (R8)
4 - MC (Main Controller) 9 - Download Connector 14 - Work Light Relay 1 (R4) 19 - Wiper Relay B3 (R9)
(Not connected in Satellite
Terminal equipped machines)
5 - Satellite Terminal (Optional) 10 - Dr. ZX Connector to ICX 15 - Horn Relay (R5)
T5-2-3
1 2
20
19
21
18
3
17
22
16 4
15
23
5
14 24
6
13 7
12 8
25
11
9
10
T178-01-01-003
T178-01-01-004
T5-2-4
M1HH-07-001
5
M1HH-07-012
SWING DEVICE
PUMP DEVICE
7 8 9
6
14
10
11
13
12 T1HH-01-02-003
T1HH-01-02-004
1 - Coolant Temperature Switch 5 - Engine Oil Level Switch 9 - N Sensor 12 - Pump 1 Delivery Pressure
(Engine Preheat Circuit) Sensor
2 - Engine Oil Pressure Switch 6 - Regulator (Pump 2) 10 - Regulator (Pump 1) 13 - Pump 2 Delivery Pressure
Sensor
3 - Overheat Switch 7 - Pump 2 11 - Pump 1 14 - Swing Relief Valve
4 - Coolant Temperature Sensor 8 - Pilot Pump
T5-2-5
1 2
T1HH-01-02-005
TRAVEL DEVICE
(ZAXIS370MTH) 3 4
T1HH-01-02-006
6
T183-01-02-012 7
SHOCKLESS VALVE T1HH-01-02-008
9 10
POSITIONING CONTROL VALVE
8 (2-piece Boom Only)
11
T173-03-06-001
T178-03-03-068
1 - Pressure Sensor (Front) 4 - Travel Relief Valve 7 - Solenoid Valve Unit (SG) 9 - Pressure Sensor (Boom Raise)
2 - Pressure Sensor (Travel) 5 - Solenoid Valve Unit (SC) 8 - Pressure Sensor 10 - Pressure Sensor (Swing)
3 - Counterbalance Valve 6 - Solenoid Valve Unit (SI) (Arm Roll-In) 11 - Overload Relief Valve
(Positioning)
T5-2-6
T5-2-7
8
9
39
38 10
11
Bucket
Cylinder
37 12
36 13
35 14
Arm
Cylinder
34
Boom
Cylinder
15
16
17
33 32 31 30 18
19
20
29 28 27 26 25 24 23 22 21
Swing Motor
Pump 2 Pump 1
T1HH-03-03-001
34 22 Machine Front
23
11 Machine Front
20 15
3 30
9
35
7 29
27
5
32
33
14 36
24, 25 21 12 T173-03-03-050 1 39 38 T173-03-03-051
T5-2-8
Machine Front
A
B
C
T1HH-03-03-002
5
6 1
4
2
38
39
3 7
T1HH-03-03-003
T1HH-03-03-004
1 - Pump Control Valve 11 - Overload Relief Valve 21 - Load Check Valve 31 - Arm Anti-Drift Valve:
(In 5-Spool Section) (Bucket) (Arm 2 Tandem Passage) Bottom Side (Switch Valve)
2 - Check Valve 12 - Load Check Valve 22 - Needle Valve 32 - Arm Anti-Drift Valve:
(Main Relief Circuit) (Boom 1 Parallel Passage) Bottom Side (Check Valve)
3 - Main Relief Valve 13 - Boom Regenerative Valve 23 - Boom Anti-Drift Valve 33 - Arm Anti-Drift Valve:
(Switch Valve) Bottom Side (Relief Valve)
4 - Check Valve 14 - Boom Anti-Drift Valve 24 - Orifice 34 - Overload Relief Valve
(Main Relief Circuit) (Check Valve) (Arm)
5 - Flow Combiner Valve 15 - Overload Relief Valve 25 - Load Check Valve 35 - Arm Anti-Drift Valve:
(Boom) (Arm 2 Parallel Passage) Rod Side (Check Valve)
6 - Check Valve (Flow 16 - Arm Regenerative Valve 26 - Load Check Valve 36 - Load Check Valve
Combiner Valve Circuit) (Arm 1 Parallel Passage) (Boom 2 Parallel Passage)
7 - Check Valve With Orifice 17 - Check Valve (Arm 27 - Orifice 37 - Load Check Valve
(Bucket Combination) Regenerative Valve Circuit) (Aux. Parallel Passage)
8 - Bucket Flow Rate Control 18 - Bucket Flow Rate Control 28 - Load Check Valve 38 - Travel Flow Rate Control
Valve (Poppet Valve) Valve (Switch Valve A) (Arm 1 Tandem Passage) Valve
9 - Bucket Flow Rate Control 19 - Bypass Shut-Out Valve 29 - Load Check Valve (Swing) 39 - Load Check Valve
Valve (Switch Valve B) (Travel Tandem Passage)
10 - Bucket Regenerative Valve 20 - Pump Control Valve 30 - Arm Anti-Drift Valve:
(In 4-Spool Section) Rod Side (Switch Valve)
T5-2-9
8
9
39
10
38
11
Bucket
Cylinder
37 12
36 13
35 14
Arm
Cylinder
34
Boom
Cylinder
15
16
17
33 32 31 30 18
19
20
29 28 27 26 25 24 23 22 21
Swing Motor
Pump 2 Pump 1
Boom 2 Boom 1
Auxiliary Bucket 22
11 23
15
8
37
9 14
36 12
9
13
10
15
11
T1HH-03-03-006
T1HH-03-03-005
T5-2-10
Section F Section G
20
35 16
26 17
32 31
27 24, 25
29
21
34
T1HH-03-03-008
33 28 18
T1HH-03-03-007
1 - Pump Control Valve 11 - Overload Relief Valve 21 - Load Check Valve 31 - Arm Anti-Drift Valve:
(In 5-Spool Section) (Bucket) (Arm 2 Tandem Passage) Bottom Side (Switch Valve)
2 - Check Valve 12 - Load Check Valve 22 - Needle Valve 32 - Arm Anti-Drift Valve:
(Main Relief Circuit) (Boom 1 Parallel Passage) Bottom Side (Check Valve)
3 - Main Relief Valve 13 - Boom Regenerative Valve 23 - Boom Anti-Drift Valve 33 - Arm Anti-Drift Valve:
(Switch Valve) Bottom Side (Relief Valve)
4 - Check Valve 14 - Boom Anti-Drift Valve 24 - Orifice 34 - Overload Relief Valve
(Main Relief Circuit) (Check Valve) (Arm)
5 - Flow Combiner Valve 15 - Overload Relief Valve 25 - Load Check Valve 35 - Arm Anti-Drift Valve:
(Boom) (Arm 2 Parallel Passage) Rod Side (Check Valve)
6 - Check Valve (Flow 16 - Arm Regenerative Valve 26 - Load Check Valve 36 - Load Check Valve
Combiner Valve Circuit) (Arm 1 Parallel Passage) (Boom 2 Parallel Passage)
7 - Check Valve With Orifice 17 - Check Valve (Arm 27 - Orifice 37 - Load Check Valve
(Bucket Combination) Regenerative Valve Circuit) (Aux. Parallel Passage)
8 - Bucket Flow Rate Control 18 - Bucket Flow Rate Control 28 - Load Check Valve 38 - Travel Flow Rate Control
Valve (Poppet Valve) Valve (Switch Valve A) (Arm 1 Tandem Passage) Valve
9 - Bucket Flow Rate Control 19 - Bypass Shut-Out Valve 29 - Load Check Valve (Swing) 39 - Load Check Valve
Valve (Switch Valve B) (Travel Tandem Passage)
10 - Bucket Regenerative Valve 20 - Pump Control Valve 30 - Arm Anti-Drift Valve:
(In 4-Spool Section) Rod Side (Switch Valve)
T5-2-11
T1HH-03-03-046
1 - Load Check Valve 2- Overload Relief Valve 3 - Overload Relief 4- Load Check Valve
(Positioning Circuit) (Positioning: Rod Side) Valve (Positioning Parallel Circuit)
(Positioning: Bottom
Side)
T5-2-12
D
4
Section D-D
1
T178-03-03-067
3
T178-03-03-066
T5-2-13
T5-2-14
YES(OK)
2
After completing the checking and/or measuring procedures in box (1),
1 select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
3
NO(NOT OK)
Refer to Electrical System Inspection Group (Group 6) for descriptions in the dotted-line
box.
Use Dr. EX (or the built-in diagnosing system) for descriptions in the double-line box.
Causes of machine problems are stated in the thick-line box. Scanning quickly through the
thick-line boxes allows you to estimate the possible causes before actually following the
flow chart.
Harness
Open End
Side
Harness End Connector
T158-05-03-001
T5-3-1
T5-3-2
FAULT CODE 04
(ABNORMAL SENSOR VOLTAGE)
T5-3-3
EC Sensor Specification
Minimum Speed 2.5 to 2.7 V
Maximum Speed (HP 3.3 to 3.7 V
mode Switch: OFF)
Maximum Speed (HP Voltage at Maximum Speed
mode Switch: ON) (HP Mode Switch: OFF) plus
0.2 V or more
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
C1 C10
C23 C31
#18
EC Sensor
1 2 3
T5-3-4
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#6
C1 C10
C23 C31
Switch Panel
#4 #3 #2
T5-3-5
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#1 #4
C1 C10
C23 C31
3 2 1
T5-3-6
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#13 #7
C1 C10
C23 C31
1 2 3
T5-3-7
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector C
#2 #3 #5
C1 C10
C23 C31
#14
1 2 3
T5-3-8
Connector (Harness End Connector Viewed from the Open End Side)
MC Connector B
B1 B8
B19 B25
#22
MC Connector C
C1 C10
C23 C31
#24
1 2
T5-3-9
T5-3-10
YES (OK)
(2)
After checking or measuring item (1), select either YES (OK) or
(1) NO (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO (NOT OK)
Special instructions or reference item are indicated in the spaces under the box.
Incorrect measuring or checking methods will render troubleshooting impossible,
Key switch: ON and may damage components as well.
Explanation of how to use test harness kit required. Refer to Electrical System
Inspection Group (Group 6) in this section.
Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
T5-4-1
Governor lever doesnt move. Engine speed is controlled based on idle position set when
key switch is turned ON. Therefore, engine speed is always
Symptoms in control controlled with error in idle position setting if set incorrectly.
system when trouble
occurs.
Even if engine control dial is Error in setting will seldom occur so that change in machine
turned, engine speed doesnt in- operation will not be noticed.
crease from slow idle speed. In case error is set on lower side, engine speed changes but
Engine start may be difficult runs slower than normal through the full range when engine
though starter rotates. control dial is turned. (Note: In case error is set on upper
Engine will stall if discontinuity side, EC motor is driven so that it runs faster than the control
occurs in EC motor while engine range. However, motor, a worm gear type, holds governor
is running at more than a speci- lever at maximum constant position, preventing engine stall.
fied speed. When engine control dial is turned to minimum speed posi-
Engine will become uncontrolla- tion, governor lever is returned to idle position.)
Symptoms in machine ble if discontinuity occurs in EC When starting engine, engine speed fluctuates.
operation when trouble motor while engine is running at Starting engine is occasionally difficult.
lower than a specified speed.
occurs. Engine cannot be stopped with
key switch.
Others
Engine is stopped by EC motor. If EC sensor is faulty, engine learning is not performed.
(Engine stop motor is not pro-
vided.)
NOTE Fuel cut-off cable is provided.
T5-4-2
Engine Control Dial Pump Control Pressure Sensor Pump 1 Delivery Pressure Sensor
Indicates governor lever position (engine Monitors pump control pressure to con- Monitors pump delivery pressure to con-
target speed). trol auto-acceleration system and travel trol HP mode, auto-acceleration, slow
motor swash angle controls. speed torque increase, auto power lift
and travel motor swash angle controls.
Engine speed doesnt change even if No signals arrive to MC If pump delivery pressure sensor output
engine control dial is turned. is 0 or 5 V, following symptoms will be
If discontinuity or short circuit occurs in presented by back-up mode function.
engine control dial, target speed of 1600
-1
min is used as back-up value.
Engine speed is kept unchanged from Auto-acceleration control is inoperable HP mode is inoperable.
-1
1600 min . (Auto-idle system functions. (but not noticeable). Auto-acceleration control is inoperable.
Engine can be stopped by key switch.) Travel speed is kept in slow mode, not Machine mistakes occasionally when
allowing to automatically change to fast traveling at slow idle speed.
mode. Boom raise power is weak during digging
operation.
Travel speed is kept in slow mode, not
allowing to automatically change to fast
mode.
Fault code 07 is displayed. Fault codes 12 and 13 are displayed. Fault codes 10 is displayed.
Monitor Item: Engine Target Speed, Dial An- Monitor Item: Pump 1 and 2 pump control Monitor Item: Pump 1 delivery pressure
gle (Displayed by built-in diagnosing sys- pressure (Displayed by built-in diagnosing (Displayed by built-in diagnosing system)
tem) system)
Evaluation by Dr. ZX
Broken Circuit: 0.25 V or less
Short Circuit: 4.75 V or more
T5-4-3
Symptoms in control If pump delivery pressure sensor output is 0 or Engine stalls if pump torque is increased.
5 V, following symptoms will be presented by
system when trouble back-up mode function.
occurs.
HP mode is inoperable. Engine stalls if pump torque is increased.
Auto-acceleration control is inoperable.
Machine mistakes occasionally when traveling
at slow idle speed.
Arm is slow when arm roll-in and swing com-
bined operation is made.
Travel speed is kept in slow mode, not allowing
to automatically change to fast mode.
Symptoms in machine
operation when trouble
occurs.
Using Test
Harness
Others
NOTE
T5-4-4
Pressure Sensor
Pressure Sensor (Travel) Pressure Sensor (Swing)
(Front Attachment)
Monitors travel pilot pressure to control Monitors front attachment pilot pressure Monitors swing pilot pressure to control
auto-idle, auto-acceleration, idle to control auto-idle, and idle speed-up arm regenerative system.
speed-up, slow speed torque increase, systems.
and travel motor swash angle controls.
Engine speed doesnt increase even if Engine speed doesnt increase even if Since arm regenerative function is inop-
auto-idle/auto-acceleration selector is any front attachment actuator is operated erable, when swing/arm roll-in combined
auto-idle position. with auto-idle/auto-acceleration selector operation is made, initial arm moving
Engine speed doesnt increase even if is auto-idle position. speed is slow. (Not remarkable)
auto-idle/auto-acceleration selector is Occasionally, engine speed hunts while During arm level crowding operation, arm
auto-acceleration position. operating front attachment at slow idle. speed is slightly slow.
Occasionally, engine speed hunts while
traveling at slow idle.
If there is a difference in delivery flow rate
between pumps 1 and 2, machine may
mistrack when traveling at minimum
speed. (Not remarkable)
Fast travel mode cannot be selected
even if travel mode switch is turned to the
FAST position.
Monitor Item: Travel Control Pressure (dis- Monitor Item: Front Attachment Operation Monitor Item: Swing Control Pressure (dis-
played built-in diagnosing system). (displayed built-in diagnosing system). played built-in diagnosing system).
Monitor pressure change while traveling Monitor pressure change while operating Monitor pressure change while swinging
machine. front attachment. upperstructure.
Judge if pressure sensor is faulty or port Judge if pressure sensor is faulty or port Judge if pressure sensor is faulty or port
is clogged by switching pressure sensor is clogged by switching pressure sensor is clogged by switching pressure sensor
with another pressure sensor. with another pressure sensor. with another pressure sensor.
T5-4-5
Function
Using Test
Harness
Others
Judge if pressure sensor is faulty or port is Judge if pressure sensor is faulty or port is
clogged by switching pressure sensor with an- clogged by switching pressure sensor with an-
other pressure sensor. other pressure sensor.
NOTE
T5-4-6
No signals arrive to MC If torque control solenoid valve is not ac- In case solenoid valve unit (SG) is not
tivated, output pressure from solenoid activated, pressure at port SG becomes
valve is 0 MPa (0 kgf/cm2). 0 MPa (0 kgf/cm2).
Engine speed doesnt increase when at- Even if speed sensing system doesnt In case solenoid valve unit (SG) is closed:
tachment is operated. work, upper limit power is restricted so Relief pressure stays at normal 31.4 MPa
When attachment is operated, operation that machine is operable. 2
(320 kfg/cm ). Even if power digging
speed increases. Machine may occasionally mistrack when switch is pressed, relief pressure doesnt
traveling at slow idle speed. increase. Power doesnt increase.
Monitor Item: ATT Control Pressure (dis- Monitor Item: Pump Torque Proportional Monitor Item: Power Digging (Boost) Control
played built-in diagnosing system). Solenoid Valve Output Pressure
Monitor pressure change while operating
attachment.
T5-4-7
Parts
Solenoid Valve Unit (SC) Solenoid Valve Unit (SI)
Routes return oil from arm cylinder rod side to When pump delivery pressure is low in fast
bottom side when rolling arm in to increase travel mode, travel motor swash angle is re-
arm speed. duced to increase travel speed.
Function
In case solenoid valve unit (SC) is not acti- Fast travel mode cannot be selected.
vated, pressure at port SC becomes 0 MPa (0
kgf/cm2). Arm regenerative valve will not oper-
Symptoms in control sys- ate at this time.
tem when trouble occurs.
In case solenoid valve unit (SC) is closed: In case solenoid valve unit (SI) is closed:
Arm speed is slow in arm level crowd opera- Even if travel mode switch is turned to FAST
tion. position, fast travel mode cannot be selected.
In case solenoid valve unit (SC) is open: In case solenoid valve unit (SI) is open:
Arm speed is fast because arm regeneration is Fast travel mode is always selected.
always operated.
Symptoms in machine
operation when trouble
occurs.
By Fault
Code
By Monitor Monitor Item: Arm Regenerative Proportional Sol. Monitor Item: Travel Motor Control Pressure
Valve Output
Function
Evaluation
Using Test Install lamp harness (ST 7123) to check output Install lamp harness (ST 7123) to check output
signals from MC and harness condition. signals from MC and harness condition.
Harness
Others
NOTE
T5-4-8
Max. Pump 1 Flow Rate Limit Solenoid Max. Pump 2 Flow Rate
Valve (Optional) Limit Solenoid Valve N Sensor
When operating attachment, limits maxi- When operating attachment, limits Monitors engine speed to operate en-
mum pump 1 flow rate. maximum pump 2 flow rate. gine speed sensing control.
In case max. pump 1 flow rate limit solenoid In case max. pump 2 flow rate limit so- Speed sensing control is inoperable.
valve is not activated, pressure at output lenoid valve is not activated, pressure at
port becomes 0 MPa (0 kgf/cm2). output port becomes 0 MPa (0 kgf/cm2).
In case max. pump 1 flow rate limit solenoid In case max. pump 2 flow rate limit sole- Engine stalls under adverse operating
valve is closed: noid valve is closed: conditions such as at high altitude.
When operating attachment, operating When operating attachment, operating
speed doesnt decrease. speed doesnt decrease.
In case max. pump 1 flow rate limit solenoid In case max. pump 2 flow rate limit sole-
valve is open: noid valve is open:
Right travel, bucket, arm and boom speeds Left travel, arm, boom and swing
are slow because maximum flow rate of speeds are slow because maximum
pump 1 decrease. flow rate of pump 2 decreases.
Machine mistracks to the right when travel- Machine mistracks to the left when trav-
ing. eling.
T5-4-9
Parts
Hydraulic Oil Temperature Sensor Engine Learning Switch
Monitors hydraulic oil temperature to control Starts engine learning.
auto-warming up and arm regenerative control. ON: 0V Learning
OFF: 5V Normal Control
Function
Even if oil temperature is lower than 0 pC, Machine will operate normally problem is
auto-warming up control doesnt operate so that caused by broken circuit or discontinuity of
engine runs at idle speed when engine is switch. (Only learning cannot be performed.)
started. If short circuit occurs, learning mode operation
When oil temperature is lower than 10 pC, arm starts when key switch is turned ON. Therefore,
regenerative control is inoperable. engine will stall at 2 second or 20 seconds after
engine starts.
Symptoms in machine
operation when trouble
occurs.
NOTE
T2-1 T2-1
Descriptions of Control
(Operational Principle
Section in T/M)
T5-4-10
Broken Circuit: Pressure doesnt in- Broken Circuit in Switch: Travel speed Depending on trouble situations, control
crease. remains unchanged in slow mode (5V). system malfunction may differ. (The fol-
Short Circuit: Pressure increases for 8 Short Circuit in Switch: lowing symptoms in machine operation
seconds after turning key switch and Travel speed remains unchanged in fast indicates that MC logic circuit has failed.)
stops increasing. mode (0V).
Power digging control doesnt operate if Even if travel mode selector is turned to Even if key switch is turned ON, EC mo-
broken circuit or short circuit occurs. the FAST position, fast travel mode can- tor will not move to the START position
not be selected. so that engine cannot start. Even though
Even if travel mode selector is turned to engine starts, speed stays slow.
the SLOW position, fast travel mode is Since pump displacement is held at
operated. minimum, all actuator speeds are slow.
Monitor Item: Power Digging (Boost) Switch Monitor Item: Travel Mode
T5-4-11
Broken Circuit: Auto-idle system is inoperable. Broken Circuit: Auto-acceleration control is in-
Short Circuit: Even if auto-idle/auto-acceleration operable.
selector is OFF, auto-idle control is always per- Short Circuit: Even if auto-idle/auto-acceleration
formed. selector is OFF, auto-acceleration control is al-
Symptoms in control ways performed.
system when trouble
occurs.
Symptoms in machine
operation when trouble
occurs.
By Fault
Code
Monitor Item: Auto-Idle/Auto-Accel Switch Monitor Item: Work Mode Switch
By Monitor
Evaluation Function
Using Test
Harness
Others
NOTE
T5-4-12
Broken Circuit: Even if HP mode is se- Broken Circuit: Even if E mode is se-
lected, HP mode is inoperable. lected, engine speed doesnt decrease.
Short Circuit: Even if HP mode switch is Short Circuit: Engine speed doesnt in-
turned OFF, HP mode system is not de- crease to the maximum. Auto-idle control
activated. Attachment speed increase is inoperable.
control (optional) becomes inoperable.
Monitor Item: E/P/HP Mode Switch Monitor Item: E/P/HP Mode Switch Monitor Item: Work Mode Switch
T5-4-13
When operating attachment, engine speed is When operating attachment, engine speed is
not controlled. not controlled.
Symptoms in control
system when trouble
occurs.
Even if auxiliary valve is operated, engine Even if auxiliary valve is operated, engine
speed doesnt increase. speed doesnt increase.
Even if attachment mode is selected, maximum Even if attachment mode is selected, maximum
engine speed doesnt decrease. engine speed doesnt decrease.
Symptoms in machine
operation when trouble
occurs.
By Fault
Code
Monitor Item: Work Mode Switch
By Monitor
Evaluation Function
Using Test
Harness
Others
NOTE
T5-4-14
Flow Combiner Valve Travel Flow Control Valve Bucket Flow Control Valve
Supplies hydraulic oil to both right and To ensure pressure oil to raise boom To restrict the bucket circuit to assist
left travel spools from pump 1 during when travel and boom raise functions are boom to raise when a combined opera-
combined operation of travel and operated at the same time. tion of bucket, arm roll-in, and boom raise
front/swing. is made.
During combined operation of travel and Oil flow is not restricted properly. Always restrict the bucket circuit if switch
front/swing, insufficient oil is supplied to valve is seized in operation.
left travel spool.
While traveling, when front/swing lever is If fully closed, shock increases when Bucket speed decreases if poppet valve
operated, machine mistracks to the left. travel combined operation is made. is seized or switch valve is seized so that
If fully opened, boom is not raised when the poppet valve is closed.
the combined operation of travel down a Boom does not rise when the combined
slope and boom raise with bucket loaded operation of bucket, arm roll-in, and
is made. (Boom raise single operation boom raise is made with poppet valve
can be achieved.) fully opened, or if switch valve is seized
so that poppet valve is fully opened.
T5-4-15
The same as described be- Arm regenerative function does The same as described be-
low. not operate. low.
Symptoms in control
system when trouble
occurs.
If check valve is kept closed, Arm speed is very slow when If check valve is kept closed,
boom lower speed decreases. leveling. bucket is not smoothly rolled
If check valve is kept opened, in.
jacking up the machine using If check valve is kept opened,
the front attachment is diffi- bucket power is weak.
cult.
Symptoms in machine
operation when trouble
occurs.
By Fault
Code
By Monitor
Evalua- Function
tion
Using Test
Harness
Others
NOTE
T5-4-16
Check valve does not open if switch Check valve does not open if switch Check valve does not open if switch
valve is seized. valve is seized. valve is seized.
If check valve does not open, arm roll-in If check valve does not open, arm roll-out If check valve does not open, boom is not
speed decreases. speed decreases. lowered.
If check valve is kept opened, arm drift If check valve is kept opened, arm drift If check valve is kept opened, boom drift
increases due to the control valve inner increases due to the control valve inner increases due to the control valve inner
leakage. leakage. leakage.
According to the degree of seizure in According to the degree of seizure in According to the degree of seizure in
check valve, arm roll-in operation be- check valve, arm roll-out operation be- check valve, boom lower operation be-
comes jerky, or slower. comes jerky, or slower. comes jerky, or slower.
T5-4-17
Parts
Pump Control Valve
Bypass Shut-Off Valve
(4-Spool Side)
Supplies pressure oil from pump 1 to auxiliary Operating boom raise/lower, arm roll-in/out,
spool when auxiliary spool is operated. bucket roll-in/out, right travel and auxiliary, flow
rate control pressure Pi is supplied to pump 1
regulator in response to the operation.
Function
Symptoms in control
system when trouble
occurs.
If spool is bound in the fully opened position, Seized in neutral, pump 1 is turned the
single attachment operation speed becomes maximum swash angle though the control lever
slow. is in neutral. (If the travel lever is kept at half
If spool is bound in the fully closed position, stroke, the machine mistracks to the left.)
main relief valve continues to relieve with all Seized in neutral, pump 1 control pressure
control levers positioned in neutral. sensor indicates the maximum pressure.
If pump 1 control pressure is monitored, it indi- Seized with pump control valve operated, pump
cates the maximum value. 1 is kept at the minimum swash angle, operating
If spool is bound in opened position, when all the control lever.
control levers are in neutral, pump 1 pressure is (Right travel is in operable in single travel
higher than pump 2 pressure. operation. Bucket speed is very slow.)
Symptoms in machine
operation when trouble
occurs.
By Fault
Code
Monitor Item: Pump 1 Delivery Pressure, Pump 1 Monitor Item: Pump 1 Control Pressure.
By Monitor Control Pressure.
Evaluation Function
Using Test
Harness
Others
NOTE
T3-3 T3-3
Descriptions of Control
(Operational Principle
Section in T/M)
T5-4-18
Pump control pressure of If spool is bound in the fully If spool is bound in the fully If spool is bound in the fully
pump 2 doesnt change if opened position, swing park- opened position, bucket opened position, boom
pump control valve (5-spool ing brake is kept released. speed becomes slow when doesnt raise during
side) spool are seized and (Machine vibrates while trav- boom raise and bucket com- 3-combined operation of
the spring is broken. eling.) bined operation is made. bucket, arm roll-in and boom
If spool is bound in the fully (Bucket flow rate control is raise.
closed position, swing park- inoperable.) If spool is bound in the fully
ing brake is kept applied. If spool is bound in the fully closed position, bucket speed
(Dragging is felt.) closed position, boom doesnt becomes slow in bucket sin-
raise during 3-combined op- gle operation. (Bucket flow
eration of bucket, arm roll-in, rate control is always effec-
and boom raise. tive.)
Seized in neutral, pump 2 is Same as described above. Same as described above. Same as described above.
turned the maximum swash
angle though the control lever
is in neutral. (If the travel
lever is kept at half stroke,
the machine mistracks to the
right.)
Seized in neutral, pump 2
control pressure sensor indi-
cates the maximum pressure.
Seized with pump control
valve operated, pump 2 is
kept at the minimum swash
angle, operating the control
lever.
(Left travel is inoperable in
single travel operation. Swing
speed is very slow.)
T3-3 T3-3
T5-4-19
Parts
MC (Main Controller)
QOS Controller
EC Motor
EC Sensor
Pump 1 Delivery Pressure
Sensor
Pump 2 Delivery Pressure
Sensor
Pump 1 Control Pressure
Sensor
Pump 2 Control Pressure
Sensor
Pressure Sensor (Travel)
Pressure Sensor
(Front Attachment)
Pressure Sensor (Swing)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Auxiliary)
N Sensor
Hyd. Oil Temperature Sensor
Coolant Temperature Sensor
Key Switch
Engine Control Dial
Auto-Idle/Acceleration Selector
Power Mode Switch
Work Mode Switch
Auxiliary Mode Switch
Engine Learning Switch
Battery Relay
Glow Relay
Engine Electrical Equipment
Engine Unit
Governor
Check batteries. Check fuel system Check fuel cut-off handle and engine control
(filters and piping). cable. Be sure to perform engine learning after
Remarks replacing engine.
T5-4-20
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
T5-4-21
Parts
MC (Main Controller)
QOS Controller
EC Motor
EC Sensor
Torque Control Solenoid Valve
Pump 1 Delivery Pressure
Sensor
Pump 2 Delivery Pressure
Sensor
Pump 1 Control Pressure
Sensor
Pump 2 Control Pressure
Sensor
Pressure Sensor (Travel)
Pressure Sensor
(Front Attachment)
Pressure Sensor (Swing)
Auto-Idle/Acceleration Selector
Remarks
T5-4-22
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
T5-4-23
Parts
MC (Main Controller)
Torque Control Solenoid Valve
N Sensor
Spool
Main Relief Valve
Main Pump
Regulator
Pilot Pump
Pilot Valve
Pilot Relief Valve
Pump Control Valve
(4-Spool Side)
Pump Control Valve
(5-Spool Side)
Remarks
T5-4-24
A-4 A-5
Actuator doesnt stop Actuator speed is faster
even if control lever is than normal. Machine
returned to neutral. mistracks when travel
lever is operated at the
half stroke.
Precise control can not
be performed.
T5-4-25
Parts
MC (Main Controller)
Solenoid Valve Unit (SG)
Solenoid Valve Unit (SC)
Pump 1 Delivery Pressure
Sensor
Pump 2 Delivery Pressure
Sensor
Pressure Sensor
(Swing)
Pressure Sensor
(Boom Raise)
Pressure Sensor
(Arm Roll-In)
Oil Temperature Sensor
Power Digging Switch
Spool
Main Relief Valve
Overload Relief Valve
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve
Bucket Regenerative Valve
Travel Flow Rate Control
Valve
Bucket Flow Rate Control
Valve
Boom Anti-Drift Valve
Arm Anti-Drift Valve
Needle Valve
Shockless Valve
Pilot Valve
Cylinder
Remarks
T5-4-26
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
T5-4-27
Parts
MC (Main Controller)
Torque Control Solenoid
Valve
Solenoid Valve Unit (SI)
Pump 1 Delivery Pressure
Sensor
Pump 2 Delivery Pressure
Sensor
Pump 1 Control Pressure
Sensor
T5-4-28
NOTE: The trouble symptoms in this table are de- In case more than one trouble occurs at
scribed provided that each trouble occurs the same time, find out all faulty compo-
independently. nents while checking all suspected com-
ponents in each trouble symptom.
T-5 T-6 T-7 O-1 O-2
Occasionally, machine mis- No steering force and no Fast travel is inoperable. Wiper is inoperable or Air Conditioner mal-
tracks when traveling with gradeability when travel Travel mode does not not retracted. function
engine running at slow mode is fast. change from slow mode
speed. to fast mode.
T5-4-29
T5-4-30
T178-05-04-001
T105-07-04-002
T5-4-31
Faulty engine.
YES
Key switch: ON
Check EC motor drive circuit.
NO
T1HH-04-02-002
4 3
T5-4-32
B
FULL
A: STOP
FULL
STOP
T1HH-04-02-002
B A
T1HH-04-02-002
T5-4-33
In case engine learning has not been performed Refer to pages for Engine Learning in the SYS-
or engine learning has been incorrectly per- TEM/Control System group in the T/M (Opera-
formed, engine speed becomes slower than tional Principle).
specification across the operating range. Check for loose harness connections before-
In case the EC sensor is faulty, engine speed is hand.
controlled based on the governor lever position,
which is judged as the idle position when the key
switch is turned ON. Accordingly, discrepancies
in engine speed from specification will result.
Depending on where the governor lever is posi-
tioned when the key switch is turned ON, dis-
crepancy will differ, causing this trouble to be not
reproducible.
NO Monitor engine
Refer to T4-6-1 for learning status.
engine learning
procedures.
Monitor item: En-
gine learning con-
trol
T5-4-34
Refer to T4-6-1.
T5-4-35
Refer to T4-6-1.
T5-4-36
More than 0 pC
when starting Normal.
T5-4-37
Sensors detect the conditions necessary to oper- Refer to the pages for HP Mode Control in the
ate the HP mode. Therefore, if any of these sen- SYSTEM / Control System group in the T/M (Op-
sor fails, the HP mode becomes inoperable. erational Principle).
Pressure sensors (arm roll-in and boom raise) Check for loose harness connections before-
and pump 1 and 2 delivery pressure sensors are hand.
also engaged in the HP mode control. However, if
these sensors fail, other operating functions will
be also affected. (Refer to the relationship be-
tween machine trouble symptoms and related
parts on page T5-4-2.)
Faulty power mode
switch or broken
harness between
NO power mode switch
and MC.
Monitor power mode
switch. Check if indica-
tion HP is highlighted
when power mode
NO switch is turned to HP Check if governor
mode. lever comes in contact YES Faulty engine.
with full-side stopper
while relieving boom
raise circuit pressure.
YES
Check if any fault Faulty MC.
codes are displayed. Monitor item: E/P/HP
mode switch NO
Refer to T4-6-1.
Faulty corresponding
sensor or broken
harness between
sensor and MC.
YES
Fault codes:
Pump 1 delivery pressure sensor: 10
Pump 2 delivery pressure sensor: 11
Pilot pressure sensor (boom raise): 15
Pilot pressure sensor (arm roll-in): 16
T5-4-38
T5-4-39
T5-4-40
In case trouble symptoms E1 to E7 are recog- Refer to the pages for Auto-Idle Control in the
nized, perform the troubleshooting of these trou- SYSTEM / Control System group in the T/M (Op-
bles beforehand. erational Principle).
Although the failure in pressure sensors (travel Check for loose harness connections before-
and front attachment) will have relevance to mal- hand.
function of the auto-idle control. However, if these
sensors fail, other operating functions will also be
affected. (Refer to the relationship between ma- Normal (Turn power
chine trouble symptoms and related parts on mode switch to a posi-
page T5-4-2.) YES tion other than the E
mode.)
Faulty MC.
T5-4-41
Faulty MC.
YES
Monitor item: Refer to T4-6-1.
E/P/HP mode switch
Faulty MC.
Monitor item: E/P/HP switch NO
Power mode switch: P mode
Refer to T4-6-1.
T5-4-42
Related Fault Code: 10, 11, 12, 13, 14, 15, 16, and
18
In case trouble symptoms E-1 to E-9 are recog- Refer to the pages for Auto-Acceleration Control
nized, perform the troubleshooting of these trou- in the SYSTEM / Control System group in the
bles beforehand. T/M (Operational Principle).
Although the failure in pressure sensors (travel,
swing, boom raise, and arm roll-in), pump 1 and
2 delivery pressure sensors, and pump 1 and 2
control pressure sensors will have relevance to
malfunction of the auto-acceleration control.
However, if these sensors fail, other operating
functions will also be affected. (Refer to the rela-
tionship between machine trouble symptoms and
related parts on page T5-4-2.) Faulty auto-idle /
auto-acceleration selector or
broken harness between
Monitor auto-idle / auto-acceleration switch and MC.
NO
auto-acceleration selector.
Check if displayed AA is
turned OFF or ON in response
to auto-acceleration switch
operation.
Faulty MC.
YES
Refer to T4-6-1.
Monitor item:
Auto-idle/auto-accel
switch
Faulty MC.
Monitor item: Auto-idle / NO
auto-accel switch
Auto-idle / auto-acceleration se- Refer to T4-6-1.
lector:
Auto-idle position
T5-4-43
Faulty MC.
Monitor item: NO
Engine target speed
Possible to display with built-in Refer to T4-6-1.
diagnosing system
T5-4-44
In case trouble symptoms E-1 to E-11 are recog- Refer to the pages for Attachment Operation
nized, perform the troubleshooting of these trou- Speed Increase Control in the SYSTEM / Control
bles beforehand. System group in the T/M (Operational Principle).
Although the failure in pressure sensor (auxiliary) Check for loose harness connections before-
and power mode switch will have relevance to hand.
the malfunction of the attachment operation
speed increase control. However, if these sensor
and switches fail, other operating functions will
also be affected. (Refer to the relationship be-
tween machine trouble symptoms and related
parts on page T5-4-2.)
Normal (Set to In-
NO crease (+).)
Check if attachment
speed adjustment
has been set to In-
NO crease (+) in Dr. ZX Monitor attachment
service mode. pilot pressure. Check YES
if pressure varies in To A
response to lever
Check if P speed ad-
stroke.
justment has been YES
set to Decrease in Faulty auxiliary pres-
Dr. ZX service mode. sure sensor.
NO
T5-4-45
T5-4-46
T5-4-47
Disassemble to check
regulator.
YES
Monitor actual engine
speed. Check if engine
speed is abnormal. Monitor item: Pump torque
proportional solenoid valve
output
Refer to the Operational Per-
Monitor item: formance Test section.
Engine actual speed Faulty N sensor, or faulty
harness between N
sensor and MC.
YES
A
Broken harness be-
tween torque control so-
lenoid valve and MC.
NO
T5-4-48
T5-4-49
Check if electricity is routed to the glow plugs. Check battery at the same time.
Check the glow plugs for any abnormality. Check for loose harness connections before-
The pre-heat system operates only when coolant hand.
temperature is below 10 pC (50 pF). When cool-
ant temperature is higher than 10 pC (50 pF), the
pre-heat system doesnt operate.
Remove
the
copper
plate.
Specification: 20 to 24 V
Specification: Below 10
T105-07-04-006
T105-07-04-007
T5-4-50
T5-4-51
Reduction in pump 1 and 2 flow rate due to some Although speed is satisfactory, in case power is
reasons or faulty pilot system may cause this weak, refer to the troubleshooting for faulty relief
trouble. valve (F-1).
Also, check for fuse of the torque control solenoid Check for loose harness connections before-
valve. hand.
Check if primary
pilot pressure is Faulty N sensor or
normal. broken harness in N
YES sensor circuit.
Monitor item:
Pump torque NO
proportional solenoid
valve output
Refer to the opera-
tional performance
Test section
T5-4-52
Pressure Gauge
Mounting Port Torque Control
Solenoid Valve
Pilot Filter
T1HH-03-06-003
T173-03-01-001
Faulty MC.
Refer to T4-6-6.
T5-4-53
T5-4-54
T5-4-55
NO
Although pilot pressure is not
routed to spool end in control
valve, spool is kept opened
due to binding of spool.
T5-4-56
T5-4-57
T5-4-58
T5-4-59
Monitor pump 1
and 2 delivery
pressures. Monitor power
digging switch.
Check if indication Remains unchanged.
Pressure Pd is turned ON
Monitor item: doesnt or OFF in response Check pressure at
Pump 1 and 2 Deliv- increase. to power digging solenoid valve unit
ery Pressure switch operation. YES (SG) port.
Possible to display
with built-in diagnos-
tic system
Check pump delivery Check pressure
pressure change change while pressing Changes.
Monitor item: power digging switch. 2
while pressing power 0.49 MPa (5 kgf/cm ) or less
Power Digging (Boost) Measurement: Refer to
digging switch.
Switch the Operational Per- 2
0.98 MPa (10 kgf/cm ) or less
Proceed to YES if boom formance Test section.
raise power is weak in
digging operation.
T5-4-60
Disconnect solenoid
valve unit (SG). Con-
nect test harness (ST Faulty solenoid valve unit
7123) between sole- YES
(SG).
noid valve unit and
harness. Check if test
harness lamp comes
ON.
Faulty harness between so-
lenoid valve unit (SG) and
NO MC.
Power Digging Switch:
ON
T5-4-61
When other actuators (travel and swing motors) In case single arm roll-in operation speed is slow,
operate normally, the pilot pump (primary pilot refer to F-7.
pressure) is considered to be normal. In case single boom lower operation speed is
In case single bucket operation speed is slow, slow, refer to F-8.
refer to F-6. Faulty cylinder (faulty
YES
Monitor pump con- seal kit).
trol pressure. Check Check if overload
if pump control pres- YES relief pressure is
sure changes normal.
smoothly while mov- Faulty overload relief
Monitor or meas- ing control lever valve.
ure secondary pilot YES slowly. NO
pressure. Check if
secondary pilot
pressure is normal. Bound control valve
Monitor item: spool.
Pump 1 flow control NO
pressure, pump 2 flow
Secondary pilot pres- control pressure
sure: Possible to display with
built-in diagnosing sys- Faulty pilot valve.
Refer to Operational YES
Performance Test Sec- tem.
tion. Check if secondary
Monitor item: Boom pilot pressure is cor-
raise pilot pressure, NO rect at the inlet port of Bound shockless
arm roll-in pilot pressure the shockless valve. valve spool.
Possible to display with NO
built-in diagnosing sys-
tem
In case of boom lower, Check only when
bucket roll-out/in and arm is not
arm roll-out, connect rolled-out. In case
the pressure gauge to cylinders other than
the pilot port in control arm roll-out are ab-
valve. normal, skip this
step and proceed to
the NO line.
Shockless Valve
2 1
3
4
5
6
7
8
T1HH-03-06-001
T5-4-62
T5-4-63
YES
Monitor item:
Arm Regenerative Pro-
Check if any fault portional Solenoid Valve
codes are dis- Output
played. Perform boom raise and
arm roll-in combined op-
eration.
Refer to the Operational
Performance Test.
Fault Codes:
11: Pump 2 Delivery
Pressure Sensor Faulty corresponding
14: Pressure Sen- sensor or faulty MC, or
sor (Swing) broken harness be-
15: Pressure Sen- tween MC and sensor.
sor (Boom Raise) YES
16: Pressure Sen-
sor (Arm Roll-In)
T5-4-64
T5-4-65
Faulty bucket flow rate control valve or bucket Faulty bucket regen-
regenerative valve may cause this trouble. erative valve (Disas-
Refer to the COMPONENT OPERATION / Con- semble and clean, or
YES replace.)
trol Valve group in the T/M (Operational Princi-
ple).
Disconnect pipe SL and adapter
connected bucket flow rate control Check if bucket re-
valve (switch valve B) in the con- YES generative valve in
trol valve from bucket flow rate bucket spool is Find out cause of trou-
control valve (switch valve A). bound or scored. ble by tracing other
Connect adapters (PF 1/4) (2 NO trouble symptoms.
used), hoses (2 used), a tee and a
pressure gauge between bucket
NO flow rate control valve (switch
valve A and B).
Check if relief pressure is approx.
2
Check if bucket flow 3.9 MPa (40 kgf/cm ) while per-
forming 3-function combined op- Bound bucket flow rate
rate control valve
eration of boom raise, arm roll-in, control valve (switch
(switch valve B) in
and bucket roll-in. NO valve A) control spool
control valve is
in signal control valve.
bound or scored.
T1HH-05-04-001
T5-4-66
T5-4-67
T5-4-68
T5-4-69
YES Normal.
Needle Valve
Lock Nut
M1HH-05-001
T5-4-70
T5-4-71
T5-4-72
NO
T5-4-73
T5-4-74
Checking Instructions
Checking Instructions
T5-4-75
Checking Instructions
Check if the slack of both track is epual.
If one side system only does not operate, pilot Check if travel motor oil
valve, control valve, travel motor, or center joint YES drain amount is normal.
might be faulty.
Mistracks occur due to faulty pump control. In Check if travel relief
this case, a symptom such as bucket or swing pressure in slow speed Specification: Refer to
function speed is slow in single operation, or arm side system is normal. Operational Perform-
roll-in or boom raise speed is slow is recognized. NO ance Test section.
Refer to A-2 and A-3 if a symptom and mistracks
occur at the same time.
Check if the symptom Relieve travel system.
is reversed when right Monitor item: Pump 1 Switch rear and front or
and left travel line and 2 delivery pres- right and left travel relief
YES hoses connected to top sure valves with each other.
of center joint are Specification: Refer to Check if symptom is
Check if travel pilot switched with each Operational Perform- reversed.
secondary pressure NO
other. ance Test section.
is normal. Possible to display
with built-in diagnosing
system. Bound control valve
spool.
Monitor item: Travel YES
control pressure
Possible to display
with built-in diag- Faulty pilot valve.
nosing system.
NO
6 T105-07-04-015
External Oil
7 Leak
T5-4-76
Pipe Layout
1 2 Front
5 4 W157-03-03-003
T5-4-77
NO
T5-4-78
T5-4-79
Monitor:
Travel motor control pres-
sure
Travel mode: Fast
Measurement: Refer to
OPERATIONAL PER-
FORMANCE TEST section.
Fault Codes:
10: Pump 1 Delivery Pressure Sensor
11: Pump 2 Delivery Pressure Sensor
12: Pump 1 Control Pressure Sensor
(4-Spool)
13: Pump 2 Control Pressure Sensor
(5-Spool)
T5-4-80
Disconnect solenoid
valve unit (SI). Connect Faulty solenoid valve unit
YES (SI).
test harness (ST 7123)
between solenoid valve
NO unit (SI) and harness.
Check if test harness Broken harness between
lamp comes ON. solenoid valve and MC.
NO
T5-4-81
Checking Instructions
The wiper is driven by electric power routed via If the front window is open, the wiper wont oper-
the relay circuit controlled by the monitor assem- ate. Check that the front window is securely
bly. In case the wiper is inoperable, first check closed.
the wiper motor and links for any abnormality us-
ing an auxiliary electric power and the test har-
ness. Faulty front window
open/close switch or
short-circuited harness
between front window
YES open/close switch and
monitor.
T5-4-82
Lamp S
M B S
L E
Ground
T178-05-04-004
Retracted Position
Operating Range
T178-05-04-005
Lamp S
T157-07-04-004
T5-4-83
Normal Operation
Press lower side fan switch. Press upper side fan switch.
Keep pressing OFF switch STEP 1
for more than 3 seconds. Display Function Con-
firmation
Press lower side fan switch. Press upper side fan switch.
Keep pressing OFF switch STEP 2
for more than 3 seconds. Present Trouble
Diagnosing
Press lower side fan switch. Press upper side fan switch.
Press lower side fan switch. Press upper side fan switch.
Keep pressing OFF switch
for more than 3 seconds. STEP 4
Sensing Temperature
Display
Press lower side fan switch. Press upper side fan switch.
Keep pressing OFF switch
for more than 3 seconds. STEP 5
Component Operation Check
Press AUTO switch and Press AUTO Press A/C Press A/C switch and
lower side fan switch. Switch and switch and upper side fan switch.
upper side lower side
fan switch. fan switch.
Keep pressing OFF switch STEP 6-1 STEP 6-2
for more than 3 seconds. Correction of the Set Selection of Celsius and Fahrenheit
Temperature Temperature Indication
Keep pressing OFF switch
for more than 3 seconds.
Self-Diagnosis
T5-4-84
T5-4-85
T5-4-86
T5-4-87
NOTE: The coolant temperature sensor indicates Fresh Air Vent Switch OFF Switch
H when coolant temperature is more than
21 C (70 F) and L when coolant tem-
perature is less than 21 C (70 F).
Sensing temperature detected by each sensor is
automatically displayed on the LCD and is cycled at
an interval of 3 seconds with the timer. The timer is
turned ON or OFF by operating the fresh air vent
switch.
Referring to the fan mark can check which sensing
temperature is displayed.
Select the next step to be performed by operating
the switches as follows:
Press the upper side of the fan switch: To pro-
ceed to STEP 5.
Press the lower side of the fan switch: To return
to STEP 3.
Keep pressing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed)
T5-4-88
Table 1
Component Indication Operation Pattern Remarks
on LCD
Air Mix Damper 51 Controls opening extent of air mix 0%, 50%, 100%: C, 5, and H are
damper: 0% (fully closed) indicated next to the decimal point
50%* 100% (fully opened) respectively.
Fan 52 Controls air flow volume: Lo Indicators corresponding to air flow vol-
M(Lo) M(Hi) Hi ume light.
Air Vent Loca- 53 Selects air vent: Front* Indicator corresponding to selected air
tion Front/Rear Front/Foot Foot vent lights.
Fresh/Circula-tio 54 Select Ventilation Mode: Circula- Indicator corresponding to selected
n Air Vent Selec- tion* Fresh mode light.
tion
Air Conditioner 55 Turns air conditioner switch: ON* ON: Indicator lights.
OFF OFF: Indicator is extinguished.
T5-4-89
T5-4-90
T5-4-91
T5-4-92
T5-4-93
Refrigerant pressure
in low-pressure side Bubbles can be seen in sight Compressor cylinder is extremely hot,
Insuffi- is high. glass. emitting a smell.
cient
Cooling
Power
Refrigerant pressure in Compressor cylinder is extremely hot,
high-pressure side is low. emitting a smell.
Refrigerant pressure
in high-pressure side Bubbles can be seen in sight Refrigerant pressure in low-pressure
is high. glass. side is low.
Even if condenser is sprayed with water, few bubbles appear. Receiver dryer tem-
perature is low.
Thermistor cools.
T5-4-94
Gas leaks from pipe joints and/or parts. Re-tighten or replace parts.
Frozen expansion valve or water in circuit. After evacuation, refill refrigerant and/or replace re-
ceiver dryer.
Gas leaks from case. Seal gaps using vinyl tape or packing compound.
Poor contact of expansion valve temperature sensing cylinder. Make good contact. Replace temperature sensing
stay.
Clogged high-pressure circuit before receiver dryer. Remove clog, or replace parts.
Clean Condenser.
Gas leaks from case. Seal gaps using vinyl tape or packing compound.
Even if function and performance are normal, when Instruct user on correct air-conditioner operation.
air-conditioner is kept operated for a long time with thermistor (Reset thermistor to either minimum or middle cooling
in max. cooling position and air flow in M or L mode, frost may position or increase air flow.)
form.
T5-4-95
Gas blowing sound (roaring). Gas vibration noise (compressor discharge and/or
suction gas noise).
Expansion valve connection, whistle Abnormal noise from expansion valve (Expansion
Noise sound, gas blowing sound. valve is normally functioning.).
Noisy compressor.
Compressor rotating sound.
Vibration and/or loose screws due to excessive drive
belt looseness.
T5-4-96
Repair or replace.
Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.
Replace.
Repair or replace.
Replace.
Clean.
-1
Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min in
L mode for more than 10 minutes, flush smell out by condensed water.
T5-4-97
Inoperable
cooling Clutch terminal voltage is low.
system.
T5-4-98
Oil and refrigerant leaks from front housing, and/or cylinder block joint. Replace.
No leaks (normal).
Replace.
Blown gasket (See NOTE 3 on page T5-4-101.)
T5-4-99
Trouble other than compressor. Refer to the Cooling Circuit Troubleshooting Ta-
ble on page T5-4-94.
Abnormal
noise
T5-4-100
Loose screws.
Broken valve.
Replace.
Blown gasket.
NOTE:
1. Dont quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A
slight oil seepage will appear due to the seal construction. However, this oil seepage will not
cause malfunction. Be sure to accurately check whether oil is leaking or seeping only.
2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose sur-
face may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
2
high-pressure side and low-pressure side is 0.49 MPa (5 kgf/cm ) or less. When the clutch is
turned OFF, the pressure difference between high-pressure side and low-pressure side will dis-
appear within about 10 seconds.
T5-4-101
Check Method:
1. Switch two delivery pressure sensors located as
Figure A
shown in figure A to figure B.
2. Retry troubleshooting. T157-07-04-006
Result:
In case the pump 2 delivery pressure is abnormal
(fault code 11), the pump 1 delivery pressure sensor
is considered to be faulty.
PP1 PP2
Figure B T157-07-04-006
T5-4-102
T5-4-103
: 6 mm
2 1
3. After the front attachment is lowered completely,
tighten needle valve (2).
: 6 mm
: 7.9 N m (0.8 kgf m, 5.8 lbf ft)
M1HH-05-001
T5-4-104
YES (OK)
(2)
After completing the checking and/or measuring procedures in box
(1) (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).
Causes of machine problems are stated in the thick-line box. Scanning quickly through
the thick-line boxes, allows you to estimate the possible causes before actually following
the flow chart.
Open End
Side
Harness End Connector
T158-05-03-001
T5-5-1
Disconnect coolant
temperature sensor. Faulty coolant temperature
YES sensor.
Ground harness end
Gauge pointer terminal to vehicle
keeps moving frame, Check if pointer
unstably. swings and is stabi-
lized to (H) side.
Faulty monitor.
NO
Key switch: ON
T5-5-2
105 C
(95
70 C
T157-07-05-001
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-3
Faulty monitor.
NO
Key switch: ON
T5-5-4
Fuel Sensor
Float
FULL
R381.9 mm
257 mm 3/4
93 mm
70.5 mm
1/2
204 mm
338 mm 1/4
EMPTY
T178-05-05-001
NOTE: 1 mm = 0.03937 in
10 9 8 7 6 5 4 3 2 1
1 2
20 19 18 17 16 15 14 13 12 11
T5-5-5
Conduct troubleshooting of
each indicator, which does
NO not light.
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-6
Remove connector
(with black and Faulty coolant tem-
white cables) from YES perature switch.
Preheat indicator
coolant tempera-
lights even though
ture switch. Check
preheat system
if indicator goes Faulty QOS con-
doesnt operate YES
OFF by grounding troller.
(coolant tempera-
harness end con-
ture is more than
nector to vehicle Without connecting
10 pC (50 pF)).
frame. Disconnect QOS QOS controller, re-
move connector B Short-circuited har-
controller. Check if
(20P) from monitor. ness between QOS
indicator goes YES
Check for continuity controller and moni-
OFF.
NO between monitor tor.
harness end con-
NO nector terminal #20
and vehicle frame.
Key switch: ON
Key switch: ON Faulty monitor.
NO
10 9 8 7 6 4 3 2 1 1 2 3
20 19 18 17 14 13 12 11 4 5 6
T5-5-7
Without connecting
connector to engine oil Short-circuited harness be-
level switch, remove tween engine oil level switch
YES and monitor.
connector B (20P) from
monitor. Check for con-
Check if indicator NO tinuity between monitor
lights by removing harness end connector
connector (with terminal #8 and vehicle
Indicator doesnt frame. Faulty monitor.
light even if engine black and white ca-
ble) from engine oil NO
oil level is lower
than specification. level switch.
Without connecting
connector to engine oil
level switch, remove
connector B (20P) from
monitor. Check for con-
Remove connector tinuity between monitor
(with black and white NO harness end connector To A
cables) from engine oil terminal #8 and engine
Lower than 3.5 mm level switch. Check if oil level switch connec-
below LOW level mark indicator goes OFF by tor.
on oil level gauge grounding harness
end connector to vehi-
cle frame.
Indicator comes ON
even if engine oil
level matches Check oil level with
specification. oil level gauge. Faulty engine oil level switch.
YES
A
Broken harness between en-
gine oil level switch and moni-
NO tor.
T5-5-8
ON
H A (Indicator ON)
L
(Indicator OFF)
OFF
A: 3.5 mm
T107-04-03-010
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-9
Without connecting
connector to coolant
level switch, remove
connector B (20P) from
monitor. Check for con-
tinuity between monitor
Remove connector NO harness end connector
(with gray cables) from terminal #9 and coolant To A
coolant level switch. level switch connector.
Check if indicator goes
OFF by grounding
harness end connec-
NO tor terminal #1 to vehi-
cle frame.
A
Broken harness between
coolant level switch and moni-
NO tor.
T5-5-10
Reserve Tank
ON
FULL
LOW
Radiator OFF
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 1 2
T5-5-11
Between 13 V
and 33.5 V Faulty monitor.
Measure voltage at
Between 13 V monitor connector A
and 33.5 V (16P) terminal #2.
Broken harness between
Alternator indicator regulator terminal L and
stays ON after en- Measure voltage at monitor.
Engine: Running
gine is started. regulator terminal L.* Less than 13 V or
higher than 33.5 V
Between 10 V
and 33.5 V Faulty monitor.
Measure voltage at
YES regulator terminal L.*
Although alternator
output is low, alter- Check if indicator Faulty regulator.
nator indicator lights when key Key switch: ON
Engine: Stopped Less than 10 V or
doesnt light. switch is turned ON. higher than 33.5 V
E
8 7 6 5 4 3 2 1
S R 16 15 14 13 12 11 10 9
T5-5-12
T5-5-13
Faulty monitor.
NO
T5-5-14
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-15
Faulty monitor.
NO
Check if indicator
Indicator lights even
goes OFF when
if coolant tempera-
overheat switch is Disconnect overheat
ture is low.
disconnected. switch. Remove con- Short-circuited harness be-
YES tween monitor and overheat
nector B (20P) from
monitor. Check for con- switch.
Key switch: ON tinuity between connec-
Engine: Stopped tor terminal #6 and vehi-
NO cle frame.
Faulty monitor.
NO
T5-5-16
Overheat Switch
Coolant Temperature Operation
Lower than 105 pC OFF
(221 pF)
105 pC (221 pF) or ON
higher
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-17
Key switch: ON
Burned indicator light.
NO
A
Broken harness between
monitor and air filter restriction
switch.
NO
T5-5-18
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T5-5-19
T5-5-20
8 7 6 5 4 3 2 1 E
16 15 14 13 12 11 10 9 S R
Lower than 13 V or
more than 33.5 V Faulty regulator and alterna-
tor.
T5-5-21
Display
Description Cause of Trouble
Order
1 Hour Meter Refer to the next page.
2 Trip 1 Faulty Monitor.
3 Trip 2
4 Actual Engine Speed In case Dr. ZX can display data, monitor is abnormal or communication
5 Hydraulic Oil Tempera- between monitor and MC is interrupted. In case Dr. ZX doesnt display
ture data, corresponding signal sensor is faulty. (The machine must have
any abnormality in the control system. Refer to Troubleshooting B.)
6 Faulty monitor or interrupted communication between ML controller and
7 Load Alarm monitor.
8 Hydraulic Oil Filter Faulty monitor or interrupted communication between ICX controller
and monitor.
9 Fault Code In case Dr. ZX can display data, monitor is abnormal or communication
10 ML Switch between monitor and MC is interrupted. In case Dr. ZX doesnt display
11 Pump 1 Delivery Pres- data, corresponding signal sensor is faulty. (The machine must have
sure any abnormality in the control system. Refer to Troubleshooting B.)
12 Pump 2 Delivery Pres-
sure
13 Pump 1 Control Pres-
sure
14 Pump 2 Control Pres-
sure
15 Target Engine Speed
16 EC Angle
17 Dial Angle
18 Boom Raise Lever
Stroke
19 Arm Roll-In Lever Stroke
20 Swing Lever Stroke
21 Travel Lever Stroke
22 Front Attachment Lever
Stroke
23 Attachment Lever Stroke
24 Work Mode
T5-5-22
8 7 6 5 4 3 2 1 E
16 15 14 13 12 11 10 9 S R
T5-5-23
A
Faulty monitor.
NO
8 7 6 5 4 3 2 1
16 15 14 13 12 11 10 9
T5-5-24
T5-6-1
T5-6-2
T5-6-3
M178-07-034
Fuse Fuse
Capacity Connected to Capacity Connected to
No. No.
1 5A Radio, Monitor (Backup 11 20 A Work Light Relays 1 and 2
Power), ICX (Main Power)
2 5A MC (Main Power) 12 10 A Wiper Relays A, B, and C,
Wiper Motor, Washer Relay
3 10 A MC (EC Motor Power) 13 20 A Heater (Air Conditioner Unit)
4 10 A MC (Solenoid Valve Power) 14 10 A Horn Relay
5 5A Monitor 15 5A Radio
6 5A MC, ICX (Power ON Signal) 16 10 A Cigarette Lighter
7 5A Air Conditioner Unit 17 5A Room Light
8 5A Optional 1 18 10 A Auxiliary
9 10 A Optional 2 19 5A QOS Controller, Glow Plug
Relay
10 5A Optional 3 20 10 A Lubricator (Optional)
T5-6-4
Inspection
Replacement
battery relay.
3. Open the upper and bottom side covers of the
fusible link box. Remove screws M6 (2 used).
4. Take out the fusible link to replace it. Battery
Relay
5. Retighten screws M6 (2 used). Bolt M8
6. Install the fusible link box and the cable to the
battery relay.
7. Reconnect the negative cable to the battery.
Cable Screw M6
T107-04-05-008
T5-6-5
Normal Voltage: 24 V
Normal Voltage: 26 to 28 V
T157-07-06-007
T5-6-6
Terminal E
T1HH-05-06-001
T5-6-7
T5-6-8
A a
B I
b
C c
T107-07-05-005
T5-6-9
T5-6-10
24-Volt Circuit
Start checking the circuit in order up to the loca-
tion to be measured from either power source or
actuator side. Thereby, the faulty location in the
circuit will be found.
Black Probe (Minus) of Tester : To ground to the vehi-
cle frame
Red Probe (Plus) of Tester : To touch the location
to be measured
T5-6-11
T5-6-12
Key Switch
Battery
6 8
1 2 3 5 4 9
15
Battery Relay
Fuse
10 Box
Starter
18 Load
Damp
Relay
11
12 23 22 21 20 19 17
13 Monitor
Starter Relay
16
Alternator
Glow
Plug
Relay
14
Glow Plug
T178-05-06-001
T5-6-13
terminal
With the key switch turned OFF, disconnect the Two Polarities
1 2
sensor connector.
Measure the voltage between terminal #1 on the
machine harness side connector and the ground
terminal (terminal #2 for two polarities, or terminal
#3 for three polarities) under the following V
conditions.
T107-07-05-009
T5-6-14
Connect
T107-07-05-011
T5-6-15
T107-07-06-015
Parts Number (ST 7123)
T5-6-16
(Black)
T5-6-17
T5-6-18
T5-7-1
Data Details
1 Key Switch ON Time Time when key switch is first turned ON during daily operation
(Time is recorded by key switch ON signal.)
2 Key Switch OFF Time Time when key switch is last turned OFF during daily operation
(Time is recorded by key switch ON signal.)
3 Engine Start Time Time when engine is first started during daily operation
(Time is recorded by alternator output signal.)
4 Engine Stop Time Time when engine is last stopped during daily operation
(Time is recorded by alternator output signal.)
6 Fuel Level The value of the final remained fuel during a day
(Value is recorded by fuel sensor signal from monitor.)
7 Engine Operating Hours Total engine operating hours during daily operation
(Hours are recorded by alternator output signal.)
8 Swing Operating Hours Total swing operating hours during daily operation
(Hours are recorded by signals from swing pressure sensor.)
9 Travel Operating Hours Total travel operating hours during daily operation
(Hours are recorded by signals from travel pressure sensor.)
10 Front Attachment Operat- Total front attachment operating hours during daily operation
ing Hours (Hours are recorded by signals from front attachment pressure sensor.)
11 Breaker Operating Hours Total breaker operating hours during daily operation
(Hours are recorded by signals from auxiliary pressure sensor and attach-
ment mode switch.)
12 Auxiliary Attachment Ex- Total auxiliary attachment except for breaker operating hours during daily
cept for Breaker Operating operation
Hours (Hours are recorded by signals from auxiliary pressure sensor and attach-
ment mode switch.)
T5-7-2
Data Details
13 *ML Operating Hours Total *ML crane operating hours during daily operation
(Hours are recorded by signals from crane mode switch.)
14 Engine Operating Hour Engine operating hour distribution during daily operation
Distribution (Operating hours are recorded only when alternator output signal is con-
tinuously delivered for more than 10 minutes.)
NOTE: The daily operation in this table is equiva- *ML specification is only available in Japa-
lent to the hours between 0:00 and nese domestic market.
23:59:59 counted by the ICX built-in clock.
In case the engine is kept operated be-
yond 0:00, such data are recorded as
those for the following day.
Data Details
1 Engine Speeds Frequency distribution of engine speeds
(Speeds are recorded by signals from N sensor.)
4 Average Pump Deliv- Frequency distribution of average delivery pressure from pumps 1 and 2
ery Pressure (Average pressures are recorded by signals from delivery pressure sensors of
pumps 1 and 2.)
5 Average Pump Deliv- Frequency distribution of average delivery pressure from pumps during digging
ery Pressure in Dig- operation
ging Operation (Average pressures are recorded by signals from arm roll-in pressure sensor.)
6 Average Pump Deliv- Frequency distribution of average delivery pressure from pumps during travel
ery Pressure in Travel operation
Operation (Average pressures are recorded by signals from travel pressure sensor.)
T5-7-3
Data Details
1 Engine Operation Hour Cumulative engine operation hours
(Hours are recorded by alternator output signal.)
6 Auxiliary Attachment Cumulative attachment operation hours except for breaker operation hours
Except for Breaker (Hours are recorded by signals from auxiliary pressure sensor and auxiliary
Operation Hour mode switch.)
T5-7-4
85 Coolant in Radiator Date and time when coolant level indicator lighted are recorded by
signals from coolant level switch.
86 Hydraulic Oil Filter Date and time when hydraulic oil filter indicator lighted are recorded
by signals from hydraulic oil filter restriction switch.
89 Overheat Date and time when overheat indicator lighted are recorded by sig-
nals from overheat switch.
90 Engine Oil Pressure Date and time when engine oil pressure indicator lighted are re-
corded by signals from engine oil pressure switch.
93 Air Filter Restriction Date and time when air filter restriction indicator lighted are re-
corded by signals from air filter restriction switch.
94 Alternator Indicator Date and time when alternator indicator lighted are recorded by sig-
nals from monitor controller.
T5-7-5
Fault
Trouble Details
Code
01 Abnormal EEPROM Occurrence time and date of fault code 01
07 Abnormal Engine Control Dial Occurrence time and date of fault code 07
10 Abnormal Pump 1 Delivery Pressure Occurrence time and date of fault code 10
11 Abnormal Pump 2 Delivery Pressure Occurrence time and date of fault code 11
12 Abnormal Pump 1 Control Pressure Occurrence time and date of fault code 12
13 Abnormal Pump 2 Control Pressure Occurrence time and date of fault code 13
14 Abnormal Swing Lever Stroke Occurrence time and date of fault code 14
15 Abnormal Boom Raise Lever Stroke Occurrence time and date of fault code 15
16 Abnormal Arm Roll-In Lever Stroke Occurrence time and date of fault code 16
18 Abnormal Travel Lever Stroke Occurrence time and date of fault code 18
19 Abnormal Oil Temperature Sensor Occurrence time and date of fault code 19
65 Monitor Communication Error Time and date when communication error between
monitor and ICX occurred.
66 Satellite Terminal Communication Error Time and date when communication error between sat-
ellite terminal and ICX occurred.
T5-7-6
T5-7-7
Fault
Trouble Remarks
Code
1 Abnormal Internal RAM In case of SAM error
7 MC Communication Timeout (For ZAXIS) In case MC communication didnt last for more than 7
seconds.
8 Monitor Communication Timeout In case monitor communication didnt last for more than
24 seconds.
9* MC Communication Timeout (For EX5) In case MC communication didnt last for more than 20
seconds.
10 Satellite Terminal Communication Timeout In case satellite communication didnt last for more than
1 minute.
Fault
Trouble Remarks
Code
101 Satellite Terminal: Internal Error Abnormal EEPROM
104 Satellite Terminal: Communication Error In case satellite communication cannot be accom-
plished.
105 Satellite Terminal: Internal Error In case sending retry over occurred or local loop back
test failed with power ON.
106 Satellite Terminal: Communication Error In case sending retry over occurred.
107 Satellite Terminal: Abnormal Harness In case reception data doesnt match sending data.
T5-7-8
Faulty ICX.
NO
FAULT CODE 7 TO 10
T5-7-9
Engine start and stop time, Engine operating hours (Daily report and cumulative Alternator
operation hour), Engine operating hour distribution
Travel operating hours (Daily report and cumulative operation hour), Average Travel pressure sensor
pump delivery pressure distribution in travel operation
Front attachment operating hours (Daily report and cumulative operation hour) Front attachment pressure
sensor
Swing operating hours (Daily report and cumulative operation hour) Swing pressure sensor
Average pump delivery pressure distribution in digging operation Arm roll-in pressure sen-
sor
Breaker operating hours (Daily report and cumulative operation hour), Auxiliary Auxiliary pressure sensor
attachment except for breaker operating hours (Daily report and cumulative op-
eration hour)
Distribution of average pump delivery pressure, average pump delivery pressure Pump 1 delivery pressure
in digging operation and travel operation sensor
Distribution of average pump delivery pressure, average pump delivery pressure Pump 2 delivery pressure
in digging operation and travel operation sensor
Breaker operating hours (Daily report and cumulative operation hour) Attachment mode switch
Auxiliary attachment except for breaker operating hours (Daily report and cumula- Auxiliary mode switch
tive operation hour)
*ML operating hours (Daily report and cumulative operation hour) Crane mode switch
T5-7-10
Check harness between ICX terminal B1 and monitor In case hour meter malfunctions, refer to trouble-
terminal B3. shooting C.
Check harness between ICX terminal B1 and monitor In case coolant temperature gauge malfunctions, refer
terminal B3. to troubleshooting C.
Check harness between ICX terminal B1 and monitor In case fuel gauge malfunctions, refer to troubleshoot-
terminal B3. ing C.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
Check harness between ICX terminal C11 and MC In case machine control system malfunctions, refer to
terminal D10. troubleshooting B.
T5-7-11
T5-7-12
REPLY:
ZAXIS330 CONNECTORS