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TTJBM-EN-00
ZX
Additional References
Please refer to the other materials (operator’s manual,
parts catalog, engine technical material and Hitachi
training material etc.) in addition to this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop Information included in the Workshop Manual:
Manual and the Engine Manual. Technical information needed for maintenance and
repair of the machine, tools and devices needed for
Information included in the Technical Manual: maintenance and repair, maintenance standards, and
Technical information needed for redelivery and delivery, removal / installation and assemble / disassemble
operation and activation of all devices and systems, procedures.
operational performance tests, and troubleshooting
procedures. Information included in the Engine Manual:
Technical information needed for redelivery and delivery
and maintenance and repair of the machine, operation
and activation of all devices and systems, troubleshooting
and assemble / disassemble procedures.
Page Number
Each page has a number, located on the center lower part
of the page, and each number contains the following
information:
Example:
Technical Manual: T 1-3-5 Workshop Manual: W 1-3-2-5
T Technical Manual W Workshop Manual
1 Section Number 1 Section Number
3 Group Number 3 Group Number
5 Consecutive Page Number for Each Group 2 Sub Group Number
5 Consecutive Page Number for Each Group
IN-01
INTRODUCTION
Safety Alert Symbol and Headline Notations
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the potential dCAUTION:
for personal injury of machine damage. Indicates potentially hazardous situation which could, if
not avoided, result in personal injury or death.
d This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention to
component/part weights.
To avoid injury and damage, be sure to use appropriate
fNOTE:
Indicates supplementary technical information or know-
lifting techniques and equipment when lifting heavy
how.
parts.
Units Used
SI Units (International System of Units) are used in this Example: 24.5 MPa (250 kgf/cm2, 3560 psi)
manual. MKSA system units and English units are also
indicated in parentheses just behind SI units. A table for conversion from SI units to other system units
is shown below for reference purposes.
IN-02
SYMBOL AND ABBREVIATION
SY-1
SYMBOL AND ABBREVIATION
(Blank)
SY-2
SAFETY
SA-688
SA-1
SAFETY
SA-2
SAFETY
SA-3
SAFETY
SA-434
Inspect Machine
Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
In the walk-around inspection be sure to cover all points
described in the "Inspect Machine Daily Before Starting"
section in the operator’s manual.
SA-435
SA-4
SAFETY
General Precautions for Cab
Before entering the cab, thoroughly remove all dirt and/or
oil such as mud, grease, soil or stones that may mess up
the cab from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots, the operator’s foot
may slip off the pedal, possibly resulting in a personal
accident.
Do not mess up around the operator’s seat with parts,
tools, soil, stones, obstacles that may fold up or turn
over, cans or lunch box. The levers or pedals become
inoperable if obstacle jams in operation stroke of the
travel levers/pedals, pilot control shut-off lever or control
levers, which may result in serious injury or death.
Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
operating the machine.
Keep all flammable objects and/or explosives away from
the machine.
After using the ashtray, always cover it to extinguish the
match and/or tobacco.
Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
Use proper floor mat dedicated to the machine. If another
floor mat is used, it may be displaced and contact with
the travel pedals during operation, resulting in serious
injury or death.
SA-5
SAFETY
SA-6
SAFETY
Ensure Safety Before Rising from or Leaving
Operator’s Seat
Before rising from the operator’s seat to open/close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with
a control lever and/or pedal, possibly resulting in serious
personal injury or death.
Before leaving the machine, be sure to first lower the front
attachment to the ground and then move the pilot control
shut-off lever to the LOCK position. Turn the key switch OFF
to stop the engine.
Before leaving the machine, close all windows, doors, and
access covers and lock them up.
SA-7
SAFETY
SA-8
SAFETY
Jump Starting
Battery gas can explode, resulting in serious injury.
If the engine must be jump started, be sure to follow
the instructions shown in the “OPERATING THE ENGINE”
chapter in the operator’s manual.
The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
Never use a frozen battery.
Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SA-032
SA-379
SA-9
SAFETY
M178-05-007
SA-10
SAFETY
SA-11
SAFETY
Make sure the worksite has sufficient strength to firmly
support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks positioned
perpendicular to the cliff face with travel motors at the rear,
so that the machine can more easily evacuate if the cliff face
collapses.
If working on the bottom of a cliff or a high bank is required,
be sure to investigate the area first and confirm that no
danger of the cliff or bank collapsing exists. If any possibility
of cliff or bank collapsing exists, do not work on the area.
Soft ground may collapse when operating the machine on
it, possibly causing the machine to tip over. When working
on soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm
enough to easily support the machine.
Note that there is always a possibility of machine tipping
over when working on rough terrain or on slopes. Prevent M104-05-016
machine tipping over from occurring. When operating on
rough terrain or on slopes:
Reduce the engine speed.
Select slow travel speed mode.
Operate the machine slowly and be cautious with
machine movements.
SA-490
SA-12
SAFETY
SA-481
SA-491
SA-13
SAFETY
SA-441
WRONG
SA-590
SA-14
SAFETY
Avoid swinging the upperstructure on slopes. Never
attempt to swing the upperstructure downhill. The
machine may tip over. If swinging uphill is unavoidable,
carefully operate the upperstructure and boom at slow
speed.
If the engine stalls on a slope, immediately lower the
bucket to the ground. Return the control levers to neutral.
Then, restart the engine.
Be sure to thoroughly warm up the machine before
ascending steep slopes. If hydraulic oil has not warmed
up sufficiently, sufficient performance may not be Travel Motor
obtained.
Use a signal person when moving, swinging or operating M104-05-008
the machine in congested areas. Coordinate hand signals
before starting the machine.
Before moving machine, determine which way to move
travel pedals/levers for the direction you want to go.
When the travel motors are in the rear, pushing down
on the front of the travel pedals or pushing the levers
forward moves the machine forward, towards the idlers.
An arrow-mark seal is stuck on the inside surface of the
side frame to indicate the machine front direction.
Select a travel route that is as flat as possible. Steer the
Arrow -mark
machine as straight as possible, making small gradual
changes in direction. M178-03-001
Before traveling on them, check the strengths of bridges
and road shoulders, and reinforce if necessary.
Use wood plates in order not to damage the road surface.
Be careful of steering when operating on asphalt roads in
summer.
When crossing train tracks, use wood plates in order not
to damage them.
Do not make contact with electric wires or bridges.
When crossing a river, measure the depth of the river
using the bucket, and cross slowly. Do not cross the river
when the depth of the river is deeper than the upper
edge of the upper roller.
SA-011
When traveling on rough terrain, reduce engine speed.
Select slow travel speed. Slower speed will reduce
possible damage to the machine.
Avoid operations that may damage the track and
undercarriage components.
During freezing weather, always clean snow and ice from
track shoes before loading and unloading machine, to
prevent the machine from slipping.
SA-15
SAFETY
To avoid rollaways:
Select level ground when possible to park the machine.
Do not park the machine on a grade.
Lower the bucket and/or other work tools to the ground.
Turn the auto-idle switch OFF.
Run the engine at slow idle speed without load for 5
minutes to cool down the engine.
Stop the engine and remove the key from the key switch.
Pull the pilot control shut-off lever to LOCK position.
SA-391
Block both tracks and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must park
on a grade.
Position the machine to prevent rolling.
Park at a reasonable distance from other machines.
SA-2273
SA-16
SAFETY
SA-17
SAFETY
SA-386
SA-487
SA-18
SAFETY
Avoid Undercutting
In order to retreat from the edge of an excavation if the
footing should collapse, always position the undercarriage
perpendicular to the edge of the excavation with the travel
motors at the rear.
If the footing starts to collapse and if retreat is not
possible, do not panic. Often, the machine can be secured
by lowering the front attachment, in such cases.
SA-488
Avoid Tipping
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE
--- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT
MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP
FREE
FASTEN YOUR SEAT BELT
The danger of tipping is always present when operating on
a grade, possibly resulting in serious injury or death.
To avoid tipping:
Be extra careful before operating on a grade.
Prepare machine operating area flat.
Keep the bucket low to the ground and close to the SA-012
machine.
Reduce operating speeds to avoid tipping or slipping.
Avoid changing direction when traveling on grades.
NEVER attempt to travel across a grade steeper than 15
degrees if crossing the grade is unavoidable.
Reduce swing speed as necessary when swinging loads.
SA-440
SA-19
SAFETY
SA-489
SA-389
SA-20
SAFETY
SA-381
SA-21
SAFETY
Object Handling
If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed underneath it,
resulting in serious injury or death.
When using the machine for craning operations, be sure
to comply with all local regulations.
Do not use damaged chains or frayed cables, sables,
slings, or ropes.
Before craning, position the upperstructure with the
travel motors at the rear.
Move the load slowly and carefully. Never move it
suddenly.
Keep all persons well away from the load.
Never move a load over a person’s head.
Do not allow anyone to approach the load until it is safely
and securely situated on supporting blocks or on the
ground.
Never attach a sling or chain to the bucket teeth. They
may come off, causing the load to fall.
SA-014
SA-432
SA-22
SAFETY
SA-390
SA-019
SA-23
SAFETY
Transport Safely
Take care, the machine may turn over when loading or
unloading the machine onto or off of a truck or trailer.
Observe the related regulations and rules for safe
transportation.
Select an appropriate truck or trailer for the machine to
be transported.
Be sure to use a signal person.
Always follow the following precautions for loading or
unloading:
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the
machine weight. SA-395
SA-24
SAFETY
SA-25
SAFETY
Sufficiently illuminate the work site. Use a maintenance
work light when working under or inside the machine.
Always use a work light protected with a guard. In case
the light bulb is broken, spilled fuel, oil, antifreeze fluid, or
window washer fluid may catch fire.
SA-037
SS2045102
SA-26
SAFETY
SA-026
SA-2294
SA-27
SAFETY
SA-034
Prevent Burns
Hot spraying fluids:
Engine oil, gear oil and hydraulic oil also become hot during
operation.
The engine, hoses, lines and other parts become hot as well.
Wait for the oil and components to cool before starting
any maintenance or inspection work.
SA-225
SA-28
SAFETY
SA-292
SA-044
SA-29
SAFETY
Prevent Fires
Check for Oil Leaks:
Fuel, hydraulic oil and lubricant leaks can lead to fires.
Check for oil leaks due to missing or loose clamps, kinked
hoses, lines or hoses that rub against each other, damage
to the oil cooler, and loose oil cooler flange bolts.
Tighten, repair or replace any missing, loose or damaged
clamps, lines, hoses, oil cooler and oil cooler flange bolts.
Do not bend or strike high-pressure lines.
Never install bent or damaged lines, pipes, or hoses.
Replace fuel hoses and hydraulic hoses periodically even
if there is no abnormality in their external appearance.
SA-019
Check for Shorts:
Short circuits can cause fires.
Clean and tighten all electrical connections.
Check before each shift or after eight (8) to ten (10) hours
operation for loose, kinked, hardened or frayed electrical
cables and wires.
Check before each shift or after eight (8) to ten (10) hours
operation for missing or damaged terminal caps.
DO NOT OPERATE MACHINE if cable or wires are loose,
kinked, etc.
Never attempt to modify electric wirings.
SA-30
SAFETY
Clean up Flammable Materials:
Spilled fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammable materials may cause fires.
Prevent fires by inspecting and cleaning the machine
daily, and by removing adhered oil or accumulated
flammable materials immediately. Check and clean high
temperature parts such as the exhaust outlet and muffler
earlier than the normal interval.
Do not wrap high temperature parts such as a muffler or
exhaust pipe with oil absorbents.
Do not store oily cloths as they are vulnerable to catching
fire.
Keep flammable materials away from open flames.
Do not ignite or crush a pressurized or sealed container.
Wire screens may be provided on openings on the engine
compartment covers to prevent flammable materials
such as dead leaves from entering. However, flammable
materials which have passed through the wire screen
may cause fires. Check and clean the machine every
day and immediately remove accumulated flammable
materials.
SA-31
SAFETY
SS-1510
SA-016
SA-32
SAFETY
Precautions for Welding and Grinding
Welding may generate gas and/or small fires.
Be sure to perform welding in a well ventilated and
prepared area. Store flammable materials in a safe place
before starting welding.
Only qualified personnel should perform welding. Never
allow an unqualified person to perform welding.
Turn the battery disconnect switch to the OFF position
before operating the machine.
Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grinding.
After finishing welding and grinding, recheck that there are SA-818
no abnormalities such as the area surrounding the welded
area still smoldering.
SA-33
SAFETY
SA-030
SA-34
SAFETY
SA-35
SAFETY
SA-405
SA-36
SAFETY
SA-37
SAFETY
SA-38
SAFETY
Precautions for Communication Terminal
Equipment
This machine has a communication terminal equipment
emitting electrical waves installed inside a rear tray which
is situated at the back of the operator's seat. There is a
possibility that a medical device, including an implantable
device such as a cardiac pacemaker, would be affected and
would malfunction by the electrical waves emitted from the
communication terminal equipment.
Any person affixed with a medical device such as the above SA-2302
should not use this machine, unless the medical device and
the rear tray are at least 22 centimeters (8.7 inches) apart at
all times. If such condition cannot be met, please contact
your authorized dealer and have the person in charge stop
the communication terminal equipment from functioning
completely and confirm that it is not emitting electrical waves.
SA-39
SAFETY
Do not attempt to disassemble, repair, modify and displace
of the communication terminal, antenna and cables. Failure
to do so may cause damage or fire on the machine and the
communication terminal. (Before removing or installing the
communication terminal, consult your authorized dealer.)
SA-435
SA-40
SECTION AND GROUP SECTION 4 OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
TECHNICAL MANUAL Group 5 Component Test
Group 6 Adjustment
(Troubleshooting)
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Monitor
Group 3 e-Service
Group 4 Component Layout
Group 5 Troubleshooting A
Group 6 Troubleshooting B
Group 7 Air Conditioner
COPYRIGHT(C)2016
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
TECHNICAL MANUAL (Operational Principle) WORKSHOP MANUAL
SECTION 1 GENERAL SECTION 1 GENERAL INFORMATION
Group 1 Specification Group 1 Precautions for Disassembling and Assembling
Group 2 Component Layout Group 2 Tightening Torque
Group 3 Component Specifications Group 3 Painting
SECTION 2 SYSTEM Group 4 Bleeding Air
Group 1 Controller Group 5 Pressure Release Procedure
Group 2 Control System Group 6 Preparation
Group 3 ECM System SECTION 2 MAINTENANCE STANDARD
Group 4 Hydraulic System Group 1 Upperstructure
Group 5 Electrical System Group 2 Undercarriage
SECTION 3 COMPONENT OPERATION Group 3 Attachment
Group 1 Pump Device SECTION 3 UPPERSTRUCTURE
Group 2 Swing Device Group 1 Cab
Group 3 Control Valve Group 2 Counterweight
Group 4 Pilot Valve Group 3 Main Frame
Group 5 Travel Device Group 8 Pump Device
Group 6 Signal Control Valve Group 9 Control Valve
Group 7 Others (Upperstructure) Group 10 Swing Device
Group 8 Others (Undercarriage) Group 11 Pilot Valve
Group 12 Solenoid Valve
Group 13 Signal Control Valve
Group 14 Shockless Valve
Group 15 Fan Valve
Group 16 Fan Moter
SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
SECTION 5 ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
SECTION 4
JBMT-4-1
(Blank)
JBMT-4-2
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the
operational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to evaluate
the performance test data.
T4-1-1
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
THE MACHINE
1. Repair any defects and damage found, such as oil
or water leaks, loose bolts, cracks and so on, before
starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 20 m (65 ft 7 in), and to make a
full swing with the front attachment extended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to be
employed for communication among coworkers.
Once the test is started, be sure to communicate
with each other using these signals, and to follow
them without fail.
2. Operate the machine carefully and always give first
priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic T105-06-01-003
pipings.
T105-06-01-004
T4-1-2
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
Operational Performance Standard Table The standard measurement conditions are as followings
unless instructed in each performance test procedure:
The standard Performance values are listed in the table Test procedure:
below. Engine Control Dial: Fast Idle
The detailed measurement procedures are explained in Power Mode Switch: HP Mode
T4-3, T4-4, and T4-5. Refer to the reference page. Auto-Idle Switch: OFF
Values indicated in parentheses [ ] are reference values. Work Mode: Digging Mode
Hydraulic Oil Temperature: 50±5 °C
Performance Reference
Performance Test Unit Remark
Standard Page
ENGINE SPEED min-1 T4-3-1
Slow Idle Speed 900±50 Control Lever: Neutral
Fast Idle Speed (HP mode) 1650±50 Control Lever: Neutral
Fast Idle Speed (PWR mode) 1650±50 Control Lever: Neutral
Fast Idle Speed (ECO mode) 1630±50 Control Lever: Neutral
With boom raise relief
Fast Idle Speed
1819±50 operation, Fan maximum
(HP mode)
speed
Auto-Idle Speed 1180±50 Control Lever: Neutral
Refer to
2.84 (29) or
ENGINE COMPRESSION PRESSURE MPa (kgf/cm2) Engine speed: 200 min-1 Engine
more
Manual
Refer to
VALVE CLEARANCE (IN, EX) mm 0.4 With the engine cold Engine
Manual
LUBRICANT CONSUMPTION Hour meter: 2000 hours or
mL/h 100 or less
(Rated output) less
TRAVEL SPEED sec/20 m T4-4-1
Fast Speed Mode 15.5±2.0
Slow Speed Mode 22.9±2.0
TRACK REVOLUTION SPEED sec/3 rev T4-4-2
870LC-5A/890LCH-5A:
Fast Speed Mode 28.5±2.0
30.9±2.0
870LC-5A/890LCH-5A:
Slow Speed Mode 42.0±2.0
45.5±2.0
MISTRACK CHECK
mm/20 m 200 or less T4-4-3
(With fast and slow travel speed modes)
TRAVEL MOTOR LEAKAGE mm/5 min 0 T4-4-4
SWING SPEED sec/3 rev 23.7±1.5 Bucket: Empty T4-4-5
SWING FUNCTION DRIFT CHECK mm/180 ° 1510 or less Bucket: Empty T4-4-6
Bucket: Loaded
SWING MOTOR LEAKAGE mm/5 min 0 T4-4-7
Weight: 4650 kg
Bucket: Loaded
MAXIMUM SWINGABLE SLANT ANGLE deg. 15 or more T4-4-8
Weight: 4650 kg
SWING BEARING PLAY mm 0.4 to 1.6 Allowable limit: 3.6 to 4.8 T4-4-10
T4-2-1
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
Performance Reference
Performance Test Unit Remarks
Standard Page
8.4 m Boom
3.7 m Arm
HYDRAULIC CYLINDER CYCLE TIME
sec 3.5 m3 (PCSA heaped) T4-4-12
(Backhoe)
Bucket, Bucket empty
Weight: 4650 kg
Boom Raise 4.6±0.4
Boom Lower 2.9±0.4
Arm Roll-In 4.2±0.4
Arm Roll-Out 3.2±0.4
Bucket Roll-In 3.4±0.4
Bucket Roll-Out 2.8±0.4
8.4 m Boom
3.7 m Arm
DIG FUNCTION DRIFT CHECK
mm/5 min 3.5 m3 (PCSA heaped) T4-4-14
(Backhoe) (Maximum Reach Position)
Bucket, Bucket loaded
Weight: 4650 kg
Boom Cylinder 5 or less
Arm Cylinder 10 or less
Bucket Cylinder 15 or less
Bucket Bottom 100 or less
RADIATOR FAN MOTOR SPEED min-1 1110±50
OIL COOLER FAN MOTOR SPEED min-1 1110±50
T4-2-2
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
Performance Reference
Performance Test Unit Remarks
Standard Page
CONTROL LEVER OPERATING FORCE N (kgf ) T4-4-15
16.0 (1.6) or
Front and Rear at Right Side
less
13.0 (1.3) or
Right and Left at Left Side
less
13.0 (1.3) or
Right and Left at Right Side
less
16.0 (1.6) or
Front and Rear at Left Side
less
28.0 (2.9) or
Travel Control Lever
less
CONTROL LEVER STROKE mm T4-4-16
Front and Rear at Right Side 97±10
Right and Left at Left Side 82±10
Right and Left at Right Side 82±10
Front and Rear at Left Side 97±10
Travel Control Lever 120±10
COMBINED OPERATION OF BOOM RAISE 8.4 m Boom
AND SWING FUNCTION CHECK Backhoe: 3.7 m Arm
sec 4.9 or less
(The time required to swing the 3.5 m3 (PCSA heaped)
upperstructure 90 degrees) Bucket, Bucket empty
Bucket Teeth Height: H mm 7900 or more
HYDRAULIC SYSTEM
PRIMARY PILOT PRESSURE MPa (kgf/cm2) T4-5-1
Engine: Slow Idle Speed 3.9±0.5 (40±5)
3.91.00
Engine: Fast Idle Speed
(40+100)
SECONDARY PILOT PRESSURE MPa (kgf/cm2) 3.9±0.5 (40±5) (Lever: Full Stroke) T4-5-3
SOLENOID VALVE SET PRESSURE MPa (kgf/cm2) 3.9±0.5 (40±5) T4-5-4
T4-2-3
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
Performance Reference
Performance Test Unit Remarks
Standard Page
MAIN RELIEF SET PRESSURE MPa (kgf/cm2) T4-5-9
31.9+2.0−0.5
Boom Lower, Arm, Bucket
(325+20−5)
34.3+2.0−0.5
Power Digging
(350+20−5)
RELIEF PRESSURE MPa (kgf/cm2) T4-5-13
28.4 -0.5
+2.0
Relief Operation of Swing
(290+20-5)
34.3+2.0-0.5
Relief Operation of Travel
(350+20-5)
OVERLOAD RELIEF PRESSURE MPa (kgf/cm2) T4-5-15
35.3+1.00 Reference values at 110
Boom, Arm, and Bucket
(360+100) L/min
Boom (Lower) 11.8+2.0−0.5 Reference values at 210
(When operating boom mode selector) (120+20−5) L/min
MAIN PUMP FLOW RATE L/min - Refer to page T4-2-5 T4-5-18
FAN PUMP FLOW RATE L/min - Refer to page T4-2-6 T4-5-20
SWING MOTOR DRAINAGE
L/min 0.2 to 0.3 T4-5-30
With constant maximum speed
TRAVEL MOTOR DRAINAGE
L/min 5 or less Allowable limit: 10 T4-5-32
With the track raised off the ground
T4-2-4
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
L/min
700
600
500
Q 400
B
300 C
200
100
0
0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 MPa
(51) (102) (153) (204) (255) (306) (357) (kgf/cm2)
P TJBM-04-02-001
T4-2-5
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
L/min
150
125
A B
C
100
Q 75
50
25
0
0 5.0 10.0 15.0 20.0 MPa
(51) (102) (153) (204) (kgf/cm2)
TJBC-04-02-002
P
T4-2-6
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
L/min
150
125
A
100
75
50
25
0
200 300 400 500 600 700 mA
I TJBC-04-02-003
I- Fan Q- Flow Rate
T4-2-7
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
*: Reference Value
T4-2-8
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
T4-2-9
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
T4-2-10
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
T4-2-11
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
T4-2-12
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
T4-2-13
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
T4-2-14
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
T4-2-15
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
(Blank)
T4-2-16
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 3 Engine Test
Engine Speed
Summary:
1. Measure the engine speed by using the monitor
unit or MPDr..
2. Measure the engine speeds in each mode.
Preparation:
1. Select the service menu of the monitor or MPDr.. In
case of MPDr., install MPDr. first.
2. Warm up the machine until the coolant temperature
reaches 70 °C or more and the hydraulic oil
temperature is 50±5 °C.
T4-3-1
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 3 Engine Test
Measurement: Remedy:
1. Measure the items as shown in the table below. Refer to Troubleshooting B.
2. When measuring, set the switch and test condition
as shown in the table below in response to the
engine speed to be measured.
Evaluation:
Refer to Operational Performance Standard.
Slow Idle Speed Min. Speed HP OFF Digging Pilot shut-off lever: LOCK position
Mode
Slow Idle Speed Min. Speed HP OFF Digging Pilot shut-off lever: UNLOCK position,
Mode Control lever in neutral
Fast Idle Speed Max. Speed HP OFF Digging Deactivate ECO by MPDr., Control lever
(With ECO Mode in neutral
deactivated)
Fast Idle Speed Max. Speed PWR OFF Digging Boom raise (Relief operation)
(Relief operation) Mode
Fast Idle Speed Max. Speed ECO OFF Digging
(ECO mode) Mode
Fast Idle Speed Max. Speed HP OFF Digging Boom raise (Relief operation)
(HP mode) Mode
Auto-Idle Speed Max. Speed HP ON Digging 3.5 seconds passed after returning the
Mode control levers to neutral
T4-3-2
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 3 Engine Test
TDAA-05-02-032 TDAA-05-02-060
3
T4-3-3
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 3 Engine Test
Lubricant Consumption
Measuring Method
1. Place the machine on the level, firm ground and
leave the machine for at least one hour in order to
return the lubricant to the oil pan after the engine
stops.
At this time, confirm that the machine is level by
using a leveler.
2. Record read-out A (unit: hour) of the hour meter.
3. Replenish the lubricant up to the high-level gauge.
4. Operate the machine for at least 100 hours or until
the oil level lowers to the low-level gauge.
5. Place the machine on the level, firm ground and
leave the machine for at least one hour in order to
return the lubricant to the oil pan after the engine
stops.
At this time, confirm that the machine is level by
using a leveler.
6. Record read-out B (unit: hour) of the hour meter.
7. Replenish the lubricant up to the high-level gauge
while measuring the oil-replenishing volume C.
Evaluation:
Refer to Operational Performance Standard.
T4-3-4
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Travel Speed
Summary:
1. Measure the time required for the machine to travel
a test track and check the performance of the travel
systems (from main pump to travel motor).
c
Preparation: a
Evaluation:
Refer to Operational Performance Standard.
Remedy:
Refer to Troubleshooting B.
T4-4-1
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Preparation:
1. Adjust track sag of both tracks to the nominal
dimension.
2. On the track to be measured, put a mark on one M104-07-067
shoe by using a piece of chalk or cloth.
a- 90 to 110 Degrees
3. Raise the track to be measured off the ground as
illustrated.
Measurement:
1. Measure on both tracks at slow and fast travel
modes with forward and reverse travel.
2. Select the following conditions.
Evaluation:
Refer to Operational Performance Standard.
f NOTE: When the measurement data obtained through
the track revolution test with the track raised off the
ground has wide variations, the evaluation based on
the results obtained from the 10 m travel speed check
described before is more recommendable.
Remedy:
Refer to Troubleshooting B.
T4-4-2
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Mistrack Check
Summary:
1. Allow the machine to travel 20 m. Measure the
maximum tread deviation from the tread chord
drawn between the travel start and end points and
check the performance of the travel system (from
main pump to travel motor).
2. If measured on a pavement surface, the tread
deviation has a trend to decrease.
Preparation: a
1. Adjust track sag of both tracks to the nominal
dimension.
2. Provide a flat, solid test yard 20 m in length, with b
extra length of 3 to 5 m on both ends for machine
acceleration and deceleration. c
Evaluation:
Refer to Operational Performance Standard.
Remedy:
Refer to Troubleshooting B.
T4-4-3
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
a
Preparation:
1. Measure on a flat slope with a gradient of 20 %
(11.31 degrees).
2. With the arm and bucket cylinders fully extended,
hold the bucket 0.2 to 0.3 m above the ground.
T105-06-03-004
3. Maintain the hydraulic oil temperature at 50±5 °C.
a- 0.2 to 0.3 m
Measurement:
1. Climb the slope and set the travel control lever in
neutral.
2. Stop the engine.
3. After the machine stops, put marks onto the track
link or the shoe, and the track side frame.
4. When five minutes passed, measure the distance
between marks on the track link or the shoe, and
the track frame.
Evaluation:
Refer to Operational Performance Standard.
TDAA-04-04-001
T4-4-4
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Swing Speed
Summary:
1. Measure the time required to swing three complete
turns and check the performance of the swing
system (from main pump to swing motor).
Preparation:
1. Check lubrication of the swing gear and the swing
bearing.
2. Place the machine on a flat and solid ground with
ample space for swinging. Do not conduct this test
on a slope. a
3. Fully retract the arm cylinder. Fully extend the
bucket cylinder. Adjust and hold the boom so that
the arm end pin height is the same as the boom T105-06-03-013
foot pin height. (Empty the bucket.) a- The same height as boom foot pin
Measurement:
1. Select the following conditions.
Evaluation:
Refer to Operational Performance Standard.
Remedy:
Refer to Troubleshooting B.
T4-4-5
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Preparation: a
1. Check lubrication of the swing gear and the swing T105-06-03-008
bearing. a- Put the marks on swing
bearing outer circumference
2. Place the machine on a flat and solid ground with and track frame.
ample space for swinging. Do not conduct this test
on a slope.
3. Fully retract the arm cylinder. Fully extend the
bucket cylinder. Adjust and hold the boom so that
the arm end pin height is the same as the boom
foot pin height. (Empty the bucket.)
4. Put marks onto the swing bearing outer
circumference (upperstructure side) and the track
frame.
5. Swing the upperstructure 180 degrees.
b
6. Maintain the hydraulic oil temperature at 50±5 °C.
T105-06-03-009
T4-4-6
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Measurement:
1. Select the following conditions.
Evaluation:
Refer to Operational Performance Standard.
Remedy:
Refer to Troubleshooting B.
T4-4-7
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Summary:
1. Set the machine on a specified slope and swing the
upperstructure 90 degrees to the slope. Measure
the upperstructure drift while suspending a load on
a specified slope and check the performance of the
swing parking brake.
(The mechanical brake for the swing parking brake
is equipped for the swing device.)
Preparation:
1. Check lubrication of the swing gear and the swing
bearing.
2. Load the bucket. (Refer to the Operational
performance Standard about the loading weight.) T105-06-03-011
T4-4-8
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Measurement:
1. Select the following conditions.
Remedy:
Refer to Troubleshooting B.
T4-4-9
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Summary:
1. With the upperstructure swung 90 degrees to the
slope, check the maximum slant angle on which the
upperstructure can swing to the uphill side.
Preparation:
1. Check lubrication of the swing gear and the swing
bearing.
2. Load the bucket. (Refer to the Operational
performance Standard about the loading weight.)
3. Fully retract the arm cylinder. Fully extend the
bucket cylinder. Adjust and hold the boom so that
the arm end pin height is the same as the boom
foot pin height. (Empty the bucket.) T105-06-03-011
4. Climb a slope and swing the upperstructure 90
degrees to the slope.
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T4-4-10
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Measurement:
1. Select the following conditions.
Evaluation:
Refer to Operational Performance Standard.
Remedy:
Refer to Troubleshooting B.
T4-4-11
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Preparation:
1. Check the swing bearing mounting bolts for 1 2
looseness. T105-06-03-014
1- Magnetic Base 2- Dial Gauge
2. Check lubrication of the swing bearing. Confirm
that bearing rotation is smooth without noise.
3. Secure dial gauge (2) on the round trunk (3) side of
the track frame by using magnetic base (1).
4. Position the upperstructure so that the boom aligns
with the tracks facing towards the front idlers.
5. Position dial gauge (2) so that its needle point
comes in contact with the bottom surface of the
swing bearing outer race. 3
6. Empty the bucket.
T4-4-12
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Measurement:
1. Fully retract the arm cylinder. Fully extend the
bucket cylinder. Adjust the boom so that the arm
end pin height is same as the boom foot pin height.
Record dial gauge reading (h1) of dial gauge (2).
a
T105-06-03-013
T4-4-13
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Summary:
1. Measure the cycle time of boom, arm, and bucket
cylinders, and check the performance of the front
attachment system (from main pump to each
cylinder).
2. Empty the bucket.
Preparation:
1. Measurement is made for the following positions.
Measurement of the cycle time of the boom cylinder:
With the bucket cylinder fully extended and the arm
cylinder fully retracted, lower the bucket onto the
ground.
T105-06-03-018
Measurement of the cycle time of the arm cylinder:
Retract or extend the bucket cylinder so that the arm
and the bucket teeth are vertical to the ground.
Set the arm so that the center of arm operation
is vertical. The bucket teeth clearance above the
ground is 0.5 m.
T105-06-03-020
T4-4-14
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Measurement:
1. Select the following conditions.
Evaluation:
Refer to Operational Performance Standard.
Remedy:
Refer to Troubleshooting B.
T4-4-15
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
T4-4-16
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Measurement:
1. Stop the engine. a
b b
2. When 5 minutes passed, measure the change in
position of bottom of the bucket, as well as the
boom, arm, and bucket cylinders.
Boom and Bucket Cylinders: Retracted
Distance: a
a=A-B
Arm Cylinder: Extended Distance: c
c=B-A T110-06-03-002
a- Boom and Bucket Cylinders: b- Mark
3. Repeat the measurement three times and calculate Retracted Distance
the mean values.
Evaluation: c
Refer to Operational Performance Standard.
d d
Remedy:
Refer to Troubleshooting B.
TDCY-04-04-001
T4-4-17
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Preparation:
1. Empty the bucket.
2. With the arm fully extended and the bucket fully
extended, hold the arm end 1 m above the ground.
3. Position the arm cylinder and the bucket cylinder
with the rod 50 mm away from the full stroke end
position.
4. Maintain the hydraulic oil temperature at 50±5 °C.
a
Measurement:
1. Stop the engine. T173-04-03-001
a- 1m
2. When 5 minutes passed, measure the change in
position of bottom of the arm tip, as well as the
boom, arm and bucket cylinders.
Cylinder: Retracted Distance: b
b=A-B b
Evaluation:
Refer to Operational Performance Standard.
Remedy:
Refer to Troubleshooting B.
T110-06-03-002
b- Cylinder: Retracted Distance c- Mark
T4-4-18
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Summary:
1. Check a play and operating condition and measure
the operating force.
2. Measure the maximum operating force of the front
attachment control lever.
3. Measure the lever stroke along the control lever
operation from the grip center of each control lever.
Preparation:
1. Maintain the hydraulic oil temperature at 50±5 °C.
TABA50-04-04-001
dCAUTION: Prevent personal injury. Always make
sure that the area is clear and that coworkers
are out of the swing area before starting the
measurement.
Measurement:
1. Measure the operating force of each control lever.
2. Select the following conditions.
Evaluation:
Refer to Operational Performance Standard.
T4-4-19
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Summary:
1. Check a play and operating condition and measure
each control lever stroke.
2. Measure the control lever stroke at the grip center
of each control lever.
3. In case the lever stroke play is present in the neutral
position, add half (1/2) the play present to both side
lever strokes.
Preparation:
1. Maintain the hydraulic oil temperature at 50±5 °C. T107-06-03-005
Measurement:
1. Stop the engine.
2. Measure each control lever stroke from neutral to
the stroke end of each control lever of boom, arm,
bucket, swing, and travel.
3. Measure the chord length from neutral to the stroke
end.
4. Repeat the measurement three times and calculate
the mean values.
Evaluation:
Refer to Operational Performance Standard.
T4-4-20
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
Summary:
1. Check the boom raise and swing movement
and speed while operating both functions
simultaneously.
2. Check if the cylinders do not hesitate while
operating the cylinder with the engine running at T107-06-03-009
fast idle.
Preparation:
1. With the arm cylinder fully retracted and the bucket
cylinder fully extended, lower the bucket onto the
ground. Lower the bucket onto the ground. (Empty
the bucket.)
2. Maintain the hydraulic oil temperature at 50±5 °C.
T107-06-03-010
Measurement:
1. Select the following conditions.
Evaluation:
Refer to Operational Performance Standard.
Remedy:
Refer to Troubleshooting B.
T4-4-21
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 4 Machine Performance Test
(Blank)
T4-4-22
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
j : 19 mm
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C.
Measurement:
1
1. Select the following conditions.
Evaluation:
Refer to Operational Performance Standard.
T4-5-1
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
Adjustment:
Adjust the relief valve (1) set pressure if necessary.
T111-06-04-004
T4-5-2
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
j : 19 mm, 22 mm
5
4. Start the engine. Confirm that no oil leakage is 4
observed at the pressure gauge (6) connection.
5. Maintain the hydraulic oil temperature at 50±5 °C.
3
Measurement:
1. Select the following conditions.
Evaluation:
Refer to Operational Performance Standard.
Remedy:
Refer to Troubleshooting B.
T4-5-3
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
Measurement:
1. Select the following conditions.
Evaluation:
Refer to Operational Performance Standard.
T4-5-4
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
Measurement:
1. Select the following conditions.
Evaluation:
Refer to the Operational Performance Standard.
T4-5-5
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
l : 3 mm 8 7
3. After the adjustment, check the set pressure.
7 8
b c
W107-02-05-129
T4-5-6
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
Preparation:
1. Stop the engine. 1 2
2. Push the air bleed valve on top of the hydraulic oil
tank and bleed air.
3. Remove the plug from the delivery pressure check
port of the main pump to be measured. Install
the adapter (ST 6069), the hose (ST 6943), and the
pressure gauge (ST 6941) to the delivery pressure
check port of the main pump to be measured.
j : 19 mm
l : 6 mm
Connect MPDr. and select the monitoring function.
4. Start the engine. Confirm that no oil leakage is TJBC-04-05-001
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C. 1- Pump 1 Delivery Pressure 2- Pump 2 Delivery Pressure
Check Port Check Port
Measurement:
1. Select the following conditions.
Evaluation:
Refer to Operational Performance Standard.
Remedy:
Refer to Troubleshooting B.
T4-5-7
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
j : 19 mm
l : 6 mm
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C.
Measurement:
1. Select the following conditions.
Evaluation:
Refer to the Operational Performance Standard.
Remedy:
Refer to the Troubleshooting B.
T4-5-8
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the hydraulic oil
tank and bleed air.
3. Remove the plug from the delivery pressure check
port of the main pump to be measured. Install
the adapter (ST 6069), the hose (ST 6943), and the
pressure gauge (ST 6941) to the delivery pressure
check port of the main pump to be measured.
j : 19 mm TJBC-04-05-001
l : 6 mm
1- Pump 1 Delivery Pressure 2- Pump 2 Delivery Pressure
Connect MPDr. and select the monitoring function. Check Port Check Port
T4-5-9
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
Measurement:
1. Select the following conditions.
Evaluation:
Refer to Operational Performance Standard.
T4-5-10
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
j : 22 mm, 30 mm 6
(Lock Nut (3))
m : 50 to 60 N·m (5 to 6 kgf·m)
2. Loosen lock nut (5). Turn sleeve (4) and adjust the
pressure until the specified pressure is obtained.
j : 27 mm, 41 mm
(Lock Nut (5))
2, 4
a b
W107-02-05-127
a- Pressure Increase b- Pressure Decrease
T4-5-11
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
j : 22 mm, 30 mm 6
m : 50 to 60 N·m (5 to 6 kgf·m)
4. After adjustment, check the set pressure.
2, 4
b
a
W107-02-05-127
a- Pressure Increase b- Pressure Decrease
T4-5-12
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
j : 38 mm
2. Turn adjusting plug (2) to adjust.
j : 30 mm
3. Tighten lock nut (3).
j : 38 mm
T16J-04-05-001
b
a
T157-05-04-023
T4-5-13
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
j : 19 mm
2. Turn adjusting screw (3) to adjust the pressure
setting, referring to the table below.
j : 6 mm
3. Retighten lock nut (2).
j : 19 mm
2 3
b
a
W107-02-05-129
T4-5-14
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
j : 19 mm
1 2
l : 6 mm
4. Connect MPDr. and select the monitoring function.
Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C.
TJBC-04-05-001
T4-5-15
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
Loosen lock nut (1) and adjust the set pressure of the
overload relief valve by using adjusting screw (2).
j : 19 mm 2
2. Turn adjusting screw (2) and adjust the set pressure. T162-04-04-004
j : 19 mm 1 2
T4-5-16
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
(Blank)
T4-5-17
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
fNOTE: Operate the vacuum pump while connecting the 1. Maintain the hydraulic oil temperature at 50±5 °C.
pump flow rate test line. 2. Measure the maximum flow rate.
2. Disconnect the delivery hose from the main pump
3. Select the following conditions.
to be measured. Connect pipe (1 or 2) to the
delivery port of the main pump with the split flange Engine Power Auto-Idle Work Mode
and bolts of the disconnected hose. Control Dial Mode Switch
j : 41 mm Fast Idle HP OFF Digging
Mode
l : 10 mm
4. Adjust the relief set pressure of main relief valve
3. Connect pipe (1 or 2) to hydraulic tester (5) by using in control valve to each pressure point specified
test hose (3) and adapter (4). Install adapter (6), test along the main pump P-Q curve. (Refer to T4-2-5)
hose (7) and flange (8) to hydraulic tester (5). Slowly restrict the loading valve of hydraulic tester
(5) while relieving pressure in the arm roll-in circuit.
j : 41 mm Measure the flow rates and engine speeds at each
l : 10 mm pressure point specified in the P-Q curve.
4. Connect the delivery hose to flange (8) with split 5. Repeat the measurement three times and calculate
flanges (9) and bolt (10). the average values.
l : 10 mm
5. Install a pressure gauge to the main pump to be
measured. (Refer to “Main Relief Set Pressure”.)
l : 6 mm
T4-5-18
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified pump speed by using the following
Refer to Operational Performance Standard.
formula.
fNOTE: When actually measuring, install pipe (1 or 2)
Qc = Q × Ns / Ne only to the pump to be measured.
1, 2 3 4 5 6 7 8 9 10
Delivery Hose
(To Control
Valve)
TJAA-04-05-004
12 11
TJBA-04-05-004
TJBG-04-05-001 13
1- Pipe F (ST 6138) 5- Hydraulic Tester (ST 6299) 9- Split Flange (4075853)
2- Pipe D (ST 6132) 6- Adapter G1 × UNF1-7/8 10- Bolt (J271245) (4 Used)
3- Test Hose (ST 6145) (ST 6146) 11- Port P1
4- Adapter G1 × UNF1-7/8 7- Test Hose (ST 6145) 12- Plug
(ST 6146) 8- Flange (ST 6140) 13- Plug (ST 6255)
T4-5-19
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
1. Stop the engine. Push the air bleed valve and bleed 4. Adjust the set pressure of relief valve in fan valve
air. Connect a vacuum pump to the oil filler port. to each pressure point specified along the fan
pump P-Q curve. (Refer to T4-2-6) Slowly restrict the
fNOTE: Operate the vacuum pump while connecting the loading valve of hydraulic tester (3). Measure the
flow rates and engine speeds at each pressure point
pump flow rate test piping.
2. Disconnect the delivery hose (7) from fan pump. specified in the P-Q curve.
Install the pipe (10) and the test hose (1) to the 5. Repeat the measurement three times and calculate
delivery port. the average values.
j : 36 mm, 41 mm
3. Connect test hose (1) to hydraulic tester (3) with
adapter (2). Install adapter (4), test hose (5) and
adapter (6) to hydraulic tester (3).
j : 41 mm
4. Connect the delivery hose (7) to adapter (6).
j : 41 mm
5. Disconnect the hose from the port Psv (8). Install
plug (ST 6204) to the port Psv (8).
j : 19 mm
6. Remove the vacuum pump. Loosen plug (9) on top
of the pump casing. Bleed air from the casing until
oil only comes out.
l : 6 mm
7. Fully open the loading valve of hydraulic tester (3).
8. Start the engine. Confirm that no oil leakage is
observed at the hydraulic tester (3) connection.
T4-5-20
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
Qc = Q × Ns / Ne
10 1 2 3 4 5 6
Delivery Hose
(To Control Valve)
TJBG-04-05-005
9
8
TJBA-04-05-002
1- Test Hose (ST 6145) 3- Hydraulic Tester (ST 6299) 5- Test Hose (ST 6145) 8- Port Psv
2- Adapter G1 × UNF1-7/8 4- Adapter G1 × UNF1-7/8 6- Adapter (ST 6025) 9- Plug
(ST 6146) (ST 6146) 7- Delivery Hose 10- Pipe (ST 6142)
T4-5-21
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
a b
3 4 5 6 TJBA-04-05-007
a- Flow Rate Increase b- Flow Rate Decrease
1- Adjusting Screw (For Minimum 3- Lock Nut (For Flow Rate 5- Lock Nut (For Minimum Flow
Flow Rate) Control) Rate)
2- Lock Nut (For Minimum Flow 4- Adjusting Screw (For Flow Rate 6- Adjusting Screw (For Minimum
Rate) Control) Flow Rate)
I
TJAA-04-05-007
T4-5-22
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
a b
1 2
1
3 4 5 6
TJBA-04-05-008
a- Flow Rate Decrease b- Flow Rate Increase
1- Adjusting Screw (For Minimum 3- Lock Nut (For Flow Rate 5- Lock Nut (For Minimum Flow
Flow Rate) Control) Rate)
2- Lock Nut (For Minimum Flow 4- Adjusting Screw (For Flow Rate 6- Adjusting Screw (For Minimum
Rate) Control) Flow Rate)
Q
I
TJAA-04-05-008
T4-5-23
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
a b
1
3
3 4 5 6
TJBA-04-05-007
a- Flow Rate Increase b- Flow Rate Decrease
1- Adjusting Screw (For Minimum 3- Lock Nut (For Flow Rate 5- Lock Nut (For Minimum Flow
Flow Rate) Control) Rate)
2- Lock Nut (For Minimum Flow 4- Adjusting Screw (For Flow Rate 6- Adjusting Screw (For Minimum
Rate) Control) Flow Rate)
I
TJAA-04-05-009
T4-5-24
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
(Blank)
T4-5-25
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
3 4
1 2
TJBA-04-05-009
1- Adjusting Screw (For 2- Lock Nut (For Maximum Flow 3- Lock Nut (For Minimum Flow 4- Adjusting Screw (For Minimum
Maximum Flow Rate) Rate) Rate) Flow Rate)
Q
Adjusting Screw (1) Turn 1/4
Flow Rate Change 3.1 L/min
Engine Speed 1800 min-1
I
TJBA-04-05-010
b
a
TJBA-04-05-006
T4-5-26
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
3 4
1 2
TJBA-04-05-009
1- Adjusting Screw (For 2- Lock Nut (For Maximum Flow 3- Lock Nut (For Minimum Flow 4- Adjusting Screw (For Minimum
Maximum Flow Rate) Rate) Rate) Flow Rate)
I
TJBA-04-05-011
a b
W107-02--05-129
a- Flow Rate Increase b- Flow Rate Decrease
T4-5-27
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
TJBA-04-05-009
Q
Adjusting Screw (3) Turn 1/4
Flow Rate Change 9.5 L/min
Engine Speed 1800 min-1
IMPORTANT: When adjusting the flow rate, the
maximum flow rate will also be changed.
There fore, adjust the maximum flow rate after
adjusting the flow rate.
I
TJBA-04-05-012
a b
W107-02--05-129
a- Flow Rate Decrease b- Flow Rate Increase
T4-5-28
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
(Blank)
T4-5-29
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F). Rotate the swing motor in order to warm
inside of the motor.
2. Stop the engine. Push air bleed valve (1) on top of
the hydraulic oil tank and release any remaining
pressure.
3. Disconnect right drain hose (1) at right side of tee
Machine
(A). Install plug (ST 6491) on the tee side. The drain Front Side 2 B
oil at the swing device (right) comes out from the
drain hose (1). T1JB-04-05-005
Disconnect drain hose (2) at left side of tee (B). 1- Drain Hose (Between Swing 2- Drain Hose (Return Hydraulic
Connect a test drain hose (3/4-16UN) to the motor Motor) Oil Tank)
side and plug (ST 6637) to drain hose (2). The drain
oil at the swing device (left) comes out from the test A- Right Side of Tee B- Left Side of Tee
drain hose.
j : 27 mm
T4-5-30
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
Measurement:
Evaluation:
Refer to Operational Performance Standard.
* Conversion of amount of measured drain oil into
the per-minute value
First measure the amount of drain oil by using a
calibrated container. Then, convert the measured
drain oil into the per-minute value by using the
following formula.
Q =60×q/t
Q : Amount of drain oil per minute (L/min)
t : Measured time (seconds)
q : Total amount of drain oil (L)
T107-06-05-008
T4-5-31
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
M183-01-001
Preparation:
1. Adjust track sag.
Track sag specification: 450 to 500 mm
2. Main hydraulic oil temperature at 50±5 °C (122±9
°F). Rotate the travel motor and warm inside of the
motor. 2
j : 27 mm
T157-05-04-019
m : 93 N·m (9.5 kgf·m)
T183-04-04-011
T4-5-32
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
Measurement:
Evaluation:
Refer to Operational Performance Standard.
Q =60×q/t
Q : Amount of drain oil per minute (L/min)
t : Measured time (seconds) T157-05-04-019
q : Total amount of drain oil (L)
T4-5-33
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 5 Component Test
(Blank)
T4-5-34
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 6 Adjustment
PUMP LEARNING
(Pump Regulator Pressure Learning)
T4-6-1
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 6 Adjustment
TORQUE ADJUSTMENT
Adjust pump drive torque, sum of main pumps 1, 2, by
using MPDr. (Refer to the T/M (SYSTEM) section.)
IMPORTANT: These procedures are for only
adjustment without repair. When main pump
drive torque need to increase or decrease, do
these procedures.
Adjustment Start Condition:
MC, ECM: No breakdown and No malfunction (by
using MPDr.)
Engine output horsepower: Normal
Hydraulic oil temperature: 50±5 °C (122±9 °F)
T4-6-2
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 6 Adjustment
CONNECTION
1. Connect MPDr. to the MPDr. connector by using the
USB serial cable, the inter link cross cable, and the MPDr. Connector 1
connecting harness.
2. Turn the key switch ON or start the engine.
Inter Link
Cross cable
TJAA-01-02-018
USB Serial
Cable
Connecting
Harness
T1T1-06-01-001
1- MPDr. Connector
T4-6-3
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 6 Adjustment
(Blank)
T4-6-4
MEMO
MEMO
SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 Diagnosing Procedure 4-Spool Solenoid Valve Unit...........................................T5-4-17
Introduction........................................................................... T5-1-1 2-Spool Solenoid Valve Unit...........................................T5-4-17
Diagnosis Procedure........................................................... T5-1-2 Layout of Control Valve....................................................T5-4-18
Electrical System Inspection............................................ T5-1-5 Pilot Port (Signal Control Valve)....................................T5-4-34
Precautions for Inspection and Maintenance............ T5-1-6
Group 5 Troubleshooting A
Instructions for Disconnecting Connectors............... T5-1-8
Troubleshooting A (Base Machine Diagnosis By
Fuse Inspection...................................................................T5-1-10
Using Fault Codes) Procedure.................................... T5-5-1
Fusible Link Inspection....................................................T5-1-13
MC Fault Code List............................................................... T5-5-3
Battery Voltage Check......................................................T5-1-14
ECM Fault Code List...........................................................T5-5-22
Alternator Check................................................................T5-1-15
Monitor Controller (Monitor) Fault Code List..........T5-5-27
Continuity Check...............................................................T5-1-16
Monitor Controller (Information) Fault Code List...T5-5-28
Voltage and Current Measurement.............................T5-1-18
Air Conditioner Controller Fault Code List................T5-5-31
Check by False Signal.......................................................T5-1-25
Communication Terminal Fault Code List.................T5-5-32
Test Wire Harness...............................................................T5-1-26
MC Fault Codes 11000 to 11002...................................T5-5-33
Group 2 Monitor MC Fault Code 11003.......................................................T5-5-34
Outline..................................................................................... T5-2-1 MC Fault Codes 11006, 11007,11009
Operating Procedures of Service Menu....................... T5-2-2 Monitor Controller (Monitor) Fault Codes
Setting Menu.......................................................................T5-2-39 13002, 13003, 13005...................................................T5-5-37
Inspection of Engine Oil Level, Coolant Level, Hour CAN0 Harness Check........................................................T5-5-38
Meter, and Fuel Gauge...............................................T5-2-41 MC Fault Codes 11008, 11010
Fuel Gauge and Coolant Temperature Gauge.........T5-2-42 Monitor Controller (Monitor) Fault Codes
13004, 13006, 13007...................................................T5-5-41
Group 3 e-Service CAN1 Harness Check........................................................T5-5-42
Outline..................................................................................... T5-3-1 MC Fault Code 11100.......................................................T5-5-45
List of Operation Data........................................................ T5-3-2 MC Fault Code 11101.......................................................T5-5-46
Snapshot Data....................................................................... T5-3-6 MC Fault Codes 11200, 11202.......................................T5-5-47
Communication System.................................................... T5-3-7 MC Fault Codes 11301, 11302.......................................T5-5-48
Group 4 Component Layout MC Fault Code 11303.......................................................T5-5-49
Main Component................................................................. T5-4-1 MC Fault Codes 11304, 11325.......................................T5-5-50
Radiator/Oil Cooler/Inter Cooler.................................... T5-4-2 MC Fault Code 11405.......................................................T5-5-51
Electrical System (Overview)........................................... T5-4-3 MC Fault Code 11408.......................................................T5-5-52
Fuel Pump............................................................................... T5-4-4 MC Fault Code 11412.......................................................T5-5-53
Electrical System (Rear Tray)............................................. T5-4-5 MC Fault Code 11428.......................................................T5-5-54
Electrical System (Switch Panel)..................................... T5-4-6 MC Fault Code 11802.......................................................T5-5-55
Electrical System (Cab Behind Side).............................. T5-4-7 MC Fault Code 11901.......................................................T5-5-56
Battery Disconnect Switch............................................... T5-4-8 MC Fault Codes 11942, 11944.......................................T5-5-57
Around Horn.......................................................................... T5-4-9 MC Fault Codes 11945......................................................T5-5-58
Boom Upper Side...............................................................T5-4-10 MC Fault Code 11948.......................................................T5-5-59
Electric Grease Gun...........................................................T5-4-10 MC Fault Code 11950.......................................................T5-5-60
Engine....................................................................................T5-4-11 MC Fault Code 11951.......................................................T5-5-61
Pump Device.......................................................................T5-4-12 MC Fault Code 11953.......................................................T5-5-62
Control Valve.......................................................................T5-4-13 MC Fault Codes 11978, 11979.......................................T5-5-63
Check Valve..........................................................................T5-4-14 MC Fault Code 11981.......................................................T5-5-64
Signal Control Valve..........................................................T5-4-14 MC Fault Code 11982.......................................................T5-5-65
MC Fault Codes 11985, 11986.......................................T5-5-66
JBMT-5-1
MC Fault Code 11989.......................................................T5-5-67
MC Fault Codes 11992, 11994.......................................T5-5-68
MC Fault Codes 11995, 11997.......................................T5-5-69
MC Fault Code 11998.......................................................T5-5-70
MC Fault Codes 20062......................................................T5-5-71
Monitor Controller (Information) Fault Codes
13304, 13310..................................................................T5-5-72
Monitor Controller (Information) Fault Code
13311................................................................................T5-5-73
Monitor Controller (Information) Fault Codes
20100 to 20104, 20106...............................................T5-5-74
Monitor Controller (Information) Fault Codes
20107, 20109, 20110, 20114, 20146, 20149........T5-5-75
Air Conditioner Controller Fault Codes 11 to 22.....T5-5-76
Air Conditioner Controller Fault Codes 43 to 92.....T5-5-77
Group 6 Troubleshooting B
Troubleshooting B (Machine Diagnosis by
Using Trouble Symptom) Procedure....................... T5-6-1
Relationship between Machine Trouble
Symptoms and Related Parts..................................... T5-6-3
Correlation Between Trouble Symptoms and Part
Failures.............................................................................T5-6-29
Engine System Troubleshooting..................................T5-6-47
All Actuator System Troubleshooting.........................T5-6-53
Front Attachment System Troubleshooting.............T5-6-62
Swing System Troubleshooting....................................T5-6-75
Travel System Troubleshooting....................................T5-6-78
Other System Troubleshooting.....................................T5-6-82
Exchange Inspection........................................................T5-6-89
How to Lowering Boom When Emergency and
When Engine Stops.....................................................T5-6-92
Group 7 Air Conditioner
Outline..................................................................................... T5-7-1
Functions of Main Parts..................................................... T5-7-4
Troubleshooting................................................................... T5-7-9
Air Conditioner Controller Fault Code List................T5-7-10
Air Conditioner Controller Fault Codes 11 to 22.....T5-7-11
Air Conditioner Controller Fault Codes 43 to 92.....T5-7-12
Work after Replacing Components.............................T5-7-34
Refill Compressor Oil........................................................T5-7-35
Charge Air Conditioner with Refrigerant..................T5-7-36
Hose and Pipe Tightening Torque................................T5-7-44
JBMT-5-2
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Introduction
Refer to the inspection and troubleshooting procedures
after any machine trouble has occurred. The inspection
and troubleshooting procedures are presented in an
orderly fashion in this section to quickly find the cause of
the machine trouble and solution.
7. Air Conditioner
This group explains air conditioner system,
troubleshooting, and procedure of charging
refrigerant to the air conditioner.
T5-1-1
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Diagnosis Procedure
These six basic steps are essential for efficient
troubleshooting:
T107-07-01-003
T5-1-2
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
5. Perform troubleshooting
T5-1-3
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
7. Maintenance mode
Before checking the electrical system such
T107-07-01-007
as disconnecting the connector, select the
maintenance mode on the monitor. (Refer to
Monitor.)
T5-1-4
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
T5-1-5
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Code R W L G Y B
Color Red White Blue Green Yellow Black
Code Or Lg Br P Gr V
Color Orange Light Brown Pink Gray Violet
green
fNOTE:
Code BW indicates a black base wire harness with
white fine-line marking.
Initials "O" and "Or" both stand for the color orange.
Longitudinal stripes printed on wires are not color
code and indicate the kinds of wires.
T5-1-6
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
T5-1-7
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
T107-04-05-002
T107-04-05-003
T5-1-8
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
TDAA-05-08-005
B TDAA-05-08-006
T5-1-9
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Fuse Inspection
Cracks in a fuse are so fine that it is very difficult or
impossible to find by visual inspection. Use a circuit tester
fNOTE: Check the starter circuit fuse with the key switch
set in the START position and follow the procedure in step
in order to correctly inspect fuse continuity by following 3.
the instructions described below.
b a b
1. Set the key switch to the ON position. When the
key switch is in the ON position, current from key
switch terminal M turns ON the battery relay so that
electric power is supplied to all circuits except the
starter circuit. (Refer to the circuit diagram.)
2. Remove the fuse box cover. Set a circuit tester.
(Measurement Range: 0 to 30 V)
3. Ground the negative probe of circuit tester to the
body. Touch the terminals located (b) away from
center of the fuse box with the positive probe of
circuit tester one at a time. When the circuit tester
indicates 20 to 25 V (battery voltage), the fuse is
normal.
M178-07-034
10 20 30 40
9 19 29 39
8 18 28 38
7 17 27 37
6 16 26 36
5 15 25 35
4 14 24 34
3 13 23 33
2 12 22 32
1 11 21 31
M178-07-034 M178-07-034
T5-1-10
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
T5-1-11
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
T5-1-12
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Replacement
1. Turn OFF the battery disconnect switch.
2. Pull out fusible link (2, 3). Replace fusible link (2, 3).
3. Turn ON the battery disconnect switch.
M1JB-07-012
T111-04-05-015
T5-1-13
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
T162-05-06-005
T5-1-14
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Alternator Check
Generally, if the alternator has generated electricity,
alternator alarm (1) will disappear. If alternator alarm (1)
is displayed while the engine is running, the alternator
might be defective.
T16J-05-06-001
T5-1-15
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Continuity Check
IMPORTANT: Before continuity check, set the key
switch to the OFF position. A a
T107-07-05-005
T5-1-16
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
(Blank)
T5-1-17
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
24-Volt Circuit
Start checking the circuit in order up to the location to be measured from either power source or actuator side.
Thereby, the faulty location in the circuit will be found.
Black (negative) probe terminal of circuit tester: To the body (to ground)
Red (Positive) probe terminal of circuit tester: To touch the location to be measured
T5-1-18
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
g
h 12 13 i
11
1 2 3 4 5 6
c j
d e f
14
n
10
a k
7
8
19 18 17 16 15
9
b
TJAE-05-01-001
T5-1-19
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
T5-1-20
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
27
20 26
c d 28
k g
a 25 f
21 A16
22
23 29
24
b 30
33
h
32
31 E4
j
134
i
TJAE-05-01-001
T5-1-21
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
T5-1-22
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
34 a b c d
38
35
36
37
TJAE-05-01-001
T5-1-23
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
5-Volt Circuit
Voltage between terminal #1 and the body Two Polarities
Disconnect the connector with the key switch OFF.
Measure voltage between terminal #1 (5 V power supply) 1 2
on the body harness end connector and the body
(ground).
Key Switch: ON
Black (negative) probe terminal of circuit tester: To
the body (to ground)
Red (positive) probe terminal of circuit tester:
Terminal #1
T107-07-05-006
If the measuring voltage is within 5 ± 0.5 volts, the circuit
up to terminal #1 is normal. Three Polarities
1 2 3
Key Switch: ON
Black (negative) probe terminal of circuit tester: To
ground terminal (Terminal #2 or #3)
Red (positive) probe terminal of circuit tester:
Terminal #1
Three Polarities
1 2 3
T107-07-05-009
T5-1-24
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
T107-07-05-010
IMPORTANT: Do not connect terminal #1 or #2
to terminal #3 or to the body (ground) when
Three Polarities
checking a three-polarity connector.
fNOTE: Some kinds of sensors can be monitored by the 1 2 3
service menu of the monitor.
T107-07-05-011
T5-1-25
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
4
Parts Number (ST 7226) 3 50
Use in order to check the solenoid valve unit circuits.
150 50 50
1 2 2 1
When the corresponding control lever or switch is
operated: Light is ON. T107-07-06-015
TDAA-05-06-003
T5-1-26
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
2 3 TDAA-05-06-002
2 3 4
TDAA-05-06-003
T5-1-27
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
(Blank)
T5-1-28
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
Outline
Basic Screen
1 2 3 4
5
6
7
8
19
18
9
17
16
15
10
14
11
13 12
MJAE-01-012
1- Work Mode Display 6- Fan Reverse Display (Option) 11- Logo Display/ Operation 15- Auxiliary
2- Auto-Idle Display 7- Glow Signal Display Display/ No Display/ Rear View 16- Auxiliary
3- Power Mode Display 8- Seat Belt Display Monitor Display 17- Travel Mode Display
4- Clock, Hour Meter 9- Fuel Gauge 12- Radio Display 18- Auto Shut-Down Display
5- Auto-Lubrication Display 10- Sub Meter 13- Air Conditioner Display 19- Auxiliary
(Option) 14- Coolant Temperature Gauge
T5-2-1
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
Troubleshooting:
Fault code is displayed.
Monitoring:
A part of monitor items for MPDr. is displayed.
Controller Version:
The controller version is displayed.
Issued Warning Record:
Ten alarms which were issued recently are displayed.
Operation:
Total operating hours of various hour meters are
displayed.
Communication Terminal Status:
Information of the communication terminal is
displayed.
Machine Setting:
The settings are adjusted.
Monitor Setting:
All item operations displayed on the monitor are set
to enable/disable.
Engine Setting:
Fault Code Clear is set.
Maintenance Mode:
ON/OFF of the maintenance mode is set.
f NOTE: Machine Setting and Monitor Setting are not
displayed in initialization. When displaying Machine
Setting and Monitor Setting, make enable by function
settings of MPDr..
T5-2-2
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
TDC1-05-02-014EN TDC1-05-02-010EN
T5-2-3
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
Troubleshooting
1 2
1. Turn select/set switch (3) and select
Troubleshooting (4) on Service Menu. When
pushing select/set switch (3), the Troubleshooting
screen appears. (Figure A)
3
2. Turn select/set switch (3) and select the controller.
When pushing select/set switch (3), the self-
diagnostic result of selected controller (fault code) is
displayed. (Figure B)
TDAA-05-02-030
fNOTE: Main (MC) (5) is selected as an example here.
A
3. The past fault codes as well as the current ones are
displayed at this time.
4. Turn select/set switch (3), select CLEAR (6), and push
select/set switch (3). 4
5
5. The past fault codes are deleted and only the
current fault codes which have been generated
newly can be displayed. (Figure C)
6. When pushing back switch (1), the previous screen
appears.
7. When pushing return to basic screen switch (2), the
basic screen appears. TDC1-05-02-010EN TDC1-05-02-024EN
B C
TDC1-05-02-025EN TDC1-05-02-031EN
T5-2-4
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
(Blank)
T5-2-5
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
Monitoring 1 2
B C
5
6
TDAA-05-02-016EN TDC1-05-02-017EN
T5-2-6
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
D E
fNOTE: Even if the key switch is set to OFF position, the
selected monitoring item has been stored. If the selected
monitoring item is required to release, select CLEAR 7
(HOLD) (6) on the Monitoring screen and push select/set
switch (3) for a while until START (5) and CLEAR (HOLD)
(6) disappear.
TDC1-05-02-019EN TDC1-05-02-018EN
5
6
TDC1-05-02-017EN
T5-2-7
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
T5-2-8
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
T5-2-9
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
T5-2-10
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
T5-2-11
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
T5-2-12
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
T5-2-13
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
Wiper/Light Controller
Item Unit Data
Wiper 1 Input V Input signal from wiper switch
Wiper 2 Input V Input signal from overhead window wiper switch
Washer 1 Switch OFF/ON Washer switch ON/OFF status
Washer 2 Switch OFF/ON Washer switch ON/OFF status
Work Light 1 Switch OFF/ON Work light switch 1 ON/OFF status
Work Light 2 Switch OFF/ON Work light switch 2 ON/OFF status
Cab Light Switch OFF/ON Cab light switch ON/OFF status
Wiper 1 Output OFF/ON Wiper relay ON/OFF status
Wiper 2 Output OFF/ON Overhead window wiper relay ON/OFF status
Washer 1 Output OFF/ON Washer relay ON/OFF status
Washer 2 Output OFF/ON Washer relay ON/OFF status
Work Light 1 Output OFF/ON Work light relay 1 ON/OFF status
Work Light 2 Output OFF/ON Work light relay 2 ON/OFF status
Cab Light 1 Output OFF/ON Cab light ON/OFF status
Cab Light 2 Output OFF/ON Cab light ON/OFF status
T5-2-14
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
Controller Version
1 2
1. Turn select/set switch (3) and select Controller
Version (4) on Service Menu.
2. When pushing select/set switch (3), the version of
each controller appears. (Figure A)
3
3. When pushing back switch (1), the previous screen
appears.
4. When pushing return to basic screen switch (2), the
basic screen appears. TDAA-05-02-030
TDC1-05-02-010EN TDC1-05-02-009EN
T5-2-15
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
B C
TDC1-05-02-022EN TDC1-05-02-023EN
T5-2-16
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
List of Alarm
M183-01-075
Overheat Alarm Coolant Temperature Is Abnormally High. Stop Refer to
Operation. Run The Engine At Slow Idle To Cool Coolant Troubleshooting
Temperature. A.
MDAA-01-067
Coolant Level Alarm Check Coolant Level And Add Coolant If Required. Follow Trouble
Screen on the
monitor.
MDAA-01-065
Overheat Alarm Coolant Temperature Is Abnormally High. Stop Refer to
Operation. Run The Engine At Slow Idle To Cool Coolant Troubleshooting
Temperature. A.
MDAA-01-067
Hydraulic Oil Overheat Hydraulic Oil Temperature Is Abnormally High. Stop Refer to
Alarm Operation, Check Hydraulic Oil Level And Any Oil Leaks Troubleshooting
From Hydraulic Circuit. A.
MDAA-01-068
Engine Trouble Alarm Engine Or Accessory Are Abnormal. Contact Your Refer to Engine
Nearest Authorized Dealer. Troubleshooting
Manual.
MDAA-01-069
T5-2-17
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
MDAA-01-028
Alternator Alarm Electrical System Is Abnormal. Check Alternator And Refer to
Battery Systems. Troubleshooting
A.
M183-01-071
*Fuel Level Alarm Fuel Level Is Low. Refer to
Troubleshooting
A.
M178-01-034
T5-2-18
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
M183-01-067
Fuel Filter Restriction Fuel Filter Is Clogged. Replace Fuel Filter Element. Refer to
Alarm Troubleshooting
A.
M1U1-01-116
System Failure Alarm Machine Network System Is Abnormal. Contact Your Refer to
Nearest Authorized Dealer. Troubleshooting
A.
MDAA-01-034
Pilot Control Shut-Off Pilot Control Shut-Off Lever System Is Abnormal. Refer to
Lever Alarm Contact Your Nearest Authorized Dealer. Troubleshooting
A.
MDAA-01-036
T5-2-19
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
Operation
1 2
1. Turn select/set switch (3) and select Operation (4)
on Service Menu. When pushing select/set switch
(3), the Operation screen appears. (Figure A)
2. The hour meters are displayed.
3
3. When pushing back switch (1), the previous screen
appears.
4. When pushing return to basic screen switch (2), the
basic screen appears. TDAA-05-02-030
TDC1-05-02-010EN TDC1-05-02-020EN
T5-2-20
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
TDC1-05-02-011EN TDC1-05-02-034EN
T5-2-21
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
T5-2-22
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
Machine Setting
1 2
fNOTE: Machine Setting is not displayed in initialization.
When displaying Machine Setting, make Machine
Setting enable with MPDr..
3
Constant Change
1. Turn select/set switch (3) and select Machine
Setting (4) on Service Menu. When pushing select/
set switch (3), the Machine Setting screen appears.
(Figure A) TDAA-05-02-030
TDC1-05-02-071EN TDC1-05-02-072EN
T5-2-23
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
T5-2-24
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
T5-2-25
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
T5-2-26
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
TDAA-05-02-074EN TDAA-05-02-075EN
TDAA-05-02-026EN TDAA-05-02-076EN
T5-2-27
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
T5-2-28
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
ATT1
Item Unit Minimum Adjustable Initial Value
Adjustment Range
ATT1 Type 0 to 7 - 0 to 7 1
ATT1 No. 1 to 5 - 1 to 5 1
ATT1 Pump 1 Maximum Flow Rate L/min 0.5 100 to 542 542
ATT1 Pump 2 Maximum Flow Rate L/min 0.5 100 to 542 260
ATT1 Engine Speed min-1 10 -500 to 100 100
ATT1 Relief Valve 0 to 2 - 0 to 2 2
ATT1 Selector Valve*2 0, 1 - 0, 1 1
ATT1 Auxiliary Flow Combiner Valve*1 0, 1 - 0, 1 0
ATT2
Item Unit Minimum Adjustable Initial Value
Adjustment Range
ATT2 Type 0 to 7 - 0 to 7 1
ATT2 No. 1 to 5 - 1 to 5 2
ATT2 Pump 1 Maximum Flow Rate L/min 0.5 100 to 542 542
ATT2 Pump 2 Maximum Flow Rate L/min 0.5 100 to 542 300
ATT2 Engine Speed min-1 10 -500 to 100 100
ATT2 Relief Valve 0 to 2 - 0 to 2 2
ATT2 Selector Valve*2 0, 1 - 0, 1 1
ATT2 Auxiliary Flow Combiner Valve*1 0, 1 - 0, 1 0
T5-2-29
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
ATT3
Item Unit Minimum Adjustable Initial Value
Adjustment Range
ATT3 Type 0 to 7 - 0 to 7 1
ATT3 No. 1 to 5 - 1 to 5 3
ATT3 Pump 1 Maximum Flow Rate L/min 0.5 100 to 542 542
ATT3 Pump 2 Maximum Flow Rate L/min 0.5 100 to 542 320
ATT3 Engine Speed min-1 10 -500 to 100 100
ATT3 Relief Valve 0 to 2 - 0 to 2 2
ATT3 Selector Valve*2 0, 1 - 0, 1 1
ATT3 Auxiliary Flow Combiner Valve*1 0, 1 - 0, 1 0
ATT4
Item Unit Minimum Adjustable Initial Value
Adjustment Range
ATT4 Type 0 to 7 - 0 to 7 1
ATT4 No. 1 to 5 - 1 to 5 4
ATT4 Pump 1 Maximum Flow Rate L/min 0.5 100 to 542 542
ATT4 Pump 2 Maximum Flow Rate L/min 0.5 100 to 542 350
ATT4 Engine Speed min-1 10 -500 to 100 100
ATT4 Relief Valve 0 to 2 - 0 to 2 2
ATT4 Selector Valve*2 0, 1 - 0, 1 1
ATT4 Auxiliary Flow Combiner Valve*1 0, 1 - 0, 1 0
T5-2-30
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
ATT5 to 11
Item Unit Minimum Adjustable Initial Value
Adjustment Range
ATT5 Type 0 to 7 - 0 to 7 0
ATT5 No. 1 to 5 - 1 to 5 1
ATT5 Pump 1 Maximum Flow Rate L/min 0.5 100 to 542 542
ATT5 Pump 2 Maximum Flow Rate L/min 0.5 100 to 542 542
ATT5 Engine Speed min-1 10 -500 to 100 100
ATT5 Relief Valve 0 to 2 - 0 to 2 2
ATT5 Selector Valve*2 0, 1 - 0, 1 1
ATT5 Auxiliary Flow Combiner Valve*1 0, 1 - 0, 1 0
T5-2-31
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
Monitor Setting 1 2
Operation Permission
1. Turn select/set switch (3) and select Monitor TDAA-05-02-030
Setting (4) on Service Menu. When pushing select/
set switch (3), the Monitor Setting screen appears. A
(Figure A)
2. Turn select/set switch (3) and select Operation
Permission. When pushing select/set switch (3), the
setting screen for selected item appears. (Figure B)
(Refer to List of Monitor Setting Item.)
3. When pushing select/set switch (3), the color of
selected item data is changed. Turn select/set
switch (3), change the data, and push select/set
switch (3). (Figure C) 4
5
6
TDC1-05-02-052EN TDC1-05-02-051EN
T5-2-32
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
Maintenance Items 1 2
1. Turn select/set switch (3) and select Monitor
Setting (4) on Service Menu. When pushing select/
set switch (3), the Monitor Setting screen appears. 3
(Figure A)
2. Turn select/set switch (3) and select the item to
change the setting. When pushing select/set switch
(3), the setting screen for selected item appears. TDAA-05-02-030
A
(Figure B) (Refer to List of Monitor Setting Item.)
TDC1-05-02-049EN TDC1-05-02-050EN
TDC1-05-02-079EN TDC1-05-02-080EN
T5-2-33
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
T5-2-34
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
T5-2-35
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
T5-2-36
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
Engine Setting
1 2
1. Turn select/set switch (3) and select Engine Setting
(4) on Service Menu. When pushing select/set
switch (3), the Engine Setting screen appears.
(Figure A)
3
2. Turn select/set switch (3) and select the item to
change the setting. When pushing select/set switch
(3), the setting screen for selected item appears.
(Figure B)
TDAA-05-02-030
fNOTE: Fault Code Clear (5) is selected as an example
here. A
TDAA-05-02-054EN
T5-2-37
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
Maintenance Mode 1 2
TDC1-05-02-205EN
TDBL-05-02-004
T5-2-38
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
Setting Menu
When logging on the service menu, The following items
are added to the setting menu.
T5-2-39
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
Breaker Alarm(Option)
1 2
1. Turn select/set switch (3) and select Breaker Alarm
(4) on the setting menu. When pushing select/set
switch (3), the Breaker Alarm screen appears. (Figure
A)
3
2. Push select/set switch (3) and turn Breaker Alarm
ON.
3. Turn select/set switch (3) and select Setting Time (5).
Push select/set switch (3).
TDAA-05-02-030
4. Turn select/set switch (3) and set the setting time
until Breaker Alarm is activated. When pushing A
select/set switch (3), the setting is completed.
TDAA-05-02-029EN TDAA-05-02-013EN
T5-2-40
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
MJAA-03-001
TDAA-05-02-081EN
T5-2-41
SECTION 5 TROUBLESHOOTING
Group 2 Monitor
TDAA-05-02-082
Coolant Temperature Gauge No. Coolant Temperature (ºC) Coolant Temperature Sensor (kΩ)
E
A 25 7.6±0.76
F B 40 4.0±0.35
C 50 2.7±0.22
D 80 0.92±0.07
D 95 0.56±0.04
E 105 0.42±0.03
D F 120 0.28±0.01
B
A
TJBG-05-02-084
T5-2-42
SECTION 5 TROUBLESHOOTING
Group 3 e-Service
Outline
Controller saves the input signals from various sensors
and switches of the machine as data. Various input signals
are recorded as Operation Data in monitor controller.
T5-3-1
SECTION 5 TROUBLESHOOTING
Group 3 e-Service
Item Details
Date Date of daily report data.
Time Final time when the engine is operated during a day.
Fuel Level The value of the final remained fuel during a day. (Value is recorded by fuel
sensor data from monitor controller.)
Fuel Usage Amount The value of fuel used during a day. (Value is calculated and recorded by
accumulated fuel usage amount from ECM.)
Machine Hour Meter Hour meter cumulative hours. (Hours are recorded by hour meter from monitor
controller.)
Engine HP Mode Hours Total engine operating hours selecting HP mode during a day. (Hours are
Operating recorded by power mode switch information from MC.)
Hours PWR Mode Hours Total engine operating hours selecting PWR mode during a day. (Hours are
recorded by power mode switch information from MC.)
ECO Mode Hours Total engine operating hours selecting ECO mode during a day. (Hours are
recorded by power mode switch information from MC.)
Auto-Idle Switch ON Time Hours when auto-idle switch is turned ON during a day. (Hours are recorded by
switch from MC.)
Travel Fast (Hi) Traveling Total operating hours of travel mode Fast (Hi) during a day. (Hours are recorded
Operating Hours by travel mode switch information from MC.)
Hours Slow (Lo) Traveling Total operating hours of travel mode Slow (Lo) during a day. (Hours are recorded
Hours by travel mode switch information from MC.)
Swing Operating Hours Total swing operating hours during a day. (Hours are recorded by swing pressure
sensor information from MC.)
Digging Operating Hours Total front attachment operating hours during a day. (Hours are recorded by
front attachment pressure sensor information from MC.)
T5-3-2
SECTION 5 TROUBLESHOOTING
Group 3 e-Service
Item Details
Attachment Breaker Operating Total operating hours selecting breaker during a day. (Hours are recorded by
Operating Hours Hours attachment information from MC.)
Pulverizer Total operating hours selecting pulverizer during a day. (Hours are recorded by
Operating Hours attachment information from MC.)
Crusher Operating Total operating hours selecting hydraulic crusher during a day. (Hours are
Hours recorded by attachment information from MC.)
Vibrating Hammer Total operating hours selecting vibrating hammer during a day. (Hours are
Operating Hours recorded by attachment information from MC.)
Bucket Operating Total operating hours selecting bucket during a day. (Hours are recorded by
Hours or Others attachment information from MC.)
No Load Time Total machine’s waiting hours during a day. (Hours are recorded by each
pressure sensor information from MC.)
Engine Operating Hour Distribution Engine operating hour distribution during a day. (Operating hours are recorded
Data when the condition that the engine is operated continues over 5 minutes.)
Loaded Time Distribution Data Machine operating hour distribution during a day. (Operating hours are
recorded only when operating pressure is continuously detected for more than
5 minutes while the engine runs.)
Latitude Final position during a day. (Signal from GPS antenna.)
Longitude Final position during a day. (Signal from GPS antenna.)
T5-3-3
SECTION 5 TROUBLESHOOTING
Group 3 e-Service
Item Details
Pump Load Frequency distribution of average pump delivery pressure of pumps 1 and 2
Average Pump Delivery Pressure in Frequency distribution of average delivery pressure from pumps during digging
Digging Operation operation
Average Pump Delivery Pressure in Frequency distribution of average delivery pressure from pumps during travel
Travel Operation operation
Radiator Coolant Temperature (79 °C Total hours when coolant temperature is less than 80 °C during a day.
or less)
Radiator Coolant Temperature (80 to Total hours when coolant temperature is 80 °C or more and less than 94 °C
93 °C) during a day.
Radiator Coolant Temperature (94 to Total hours when coolant temperature is 94 °C or more and less than 105 °C
104 °C) during a day.
Radiator Coolant Temperature (105 °C Total hours when coolant temperature is 105 °C or more during a day.
or more)
Hydraulic Oil Temperature (49 °C or Total hours when hydraulic oil temperature is less than 50 °C during a day.
less)
Hydraulic Oil Temperature (50 to 89 Total hours when hydraulic oil temperature is 50 °C or more and less than 90 °C
°C) during a day.
Hydraulic Oil Temperature (90 to 99 Total hours when hydraulic oil temperature is 90 °C or more and less than 100 °C
°C) during a day.
Hydraulic Oil Temperature (100 °C or Total hours when hydraulic oil temperature is 100 °C or more during a day.
more)
T5-3-4
SECTION 5 TROUBLESHOOTING
Group 3 e-Service
Item Details
Hour Meter End Machine hour meter’s value
Engine HP Mode Hours Total engine operating hours selecting HP mode
Operating
Hour PWR Mode Hours Total engine operating hours selecting PWR mode
ECO Mode Hours Total engine operating hours selecting ECO mode
Auto-Idle Switch ON Time Total hours when auto-idle switch is turned ON
Travel Fast (Hi) Traveling Total operating hours of travel mode Fast (Hi)
Operating Hours
Hour Slow (Lo) Traveling Total operating hours of travel mode Slow (Lo)
Hours
Swing Operating Hour Total swing operating hours
Front Attachment Operating Hour Total front attachment operating hours
Attachment Breaker Operating Total operating hours selecting breaker during daily operation
Operating Hours
Hour Pulverizer Operating Total operating hours selecting pulverizer during daily operation
Hours
Hydraulic Crusher Total operating hours selecting hydraulic crusher during daily operation
Operating Hours
Vibrating Hammer Total operating hours selecting vibrating hammer during daily operation
Operating Hours
Bucket Operating Total operating hours selecting bucket during daily operation
Hours or Others
No Load Time Total machine’s waiting hours
MC Communication Error Time Total hours of MC communication error
ECM Communication Time Out Time Total hours of ECM communication time out
T5-3-5
SECTION 5 TROUBLESHOOTING
Group 3 e-Service
Snapshot Data
Item Details
Serial No. - Machine serial no.
Snapshot Model 1 Difference of large-sized crawler, middle-sized crawler, wheeled excavator, and
wheel loader
Model 2 Detail difference on model 1
DTC Code Fault code and frequency of occurrence
Priority -
Hour Meter Machine hour meter at a time when trouble occurred
Occurrence: Year Year at a time when trouble occurred
Occurrence: Date Date at a time when trouble occurred
Occurrence: Time Time at a time when trouble occurred
SA -
SPN Version 001: Version 1
010: Version 2
011: Version 3
100: Version 4
111: Missing version
T5-3-6
SECTION 5 TROUBLESHOOTING
Group 3 e-Service
Communication System
The communication system is used for maintenance of
the machine: “e-Service” by transmitting various data of
the machine regularly via the communication terminal.
Communication Terminal:
Receives the data from monitor controller and GPS
antenna, and sends the data to the communication
antenna.
GPS Antenna:
Receives location information of the machine.
Communication Antenna:
Communicates the data.
T5-3-7
SECTION 5 TROUBLESHOOTING
Group 3 e-Service
(Blank)
T5-3-8
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
Main Component
26
2
3
4
5
6
7
8
25 9
27
24 10
11
12
23
13
22
21
20
19
18
17 14
16 MJAE-07-045
15
1- Arm Cylinder 9- Signal Control Valve 16- Shockless Valve (Refer to 23- Travel Pilot Valve
2- Washer Tank 10- Oil Cooler Fan Motor T5-4-2.) 24- Front Attachment/Swing Pilot
3- Swing Bearing 11- Expantion Tank 17- Pilot Filter/Pilot Relief Valve Valve
4- Center Joint 12- Radiator Fan Motor 18- Drain Filter 25- Boom Cylinder
5- Swing Device 13- Engine 19- Check Valve (Refer to T5-4-14.) 26- Bucket Cylinder
6- Fuel Tank 14- Pump Device 20- Hydraulic Oil Tank 27- Radiator/Oil Cooler/Inter
7- Control Valve 15- Travel Device 21- Track Adjuster Cooler (Refer to T5-4-2)
8- Air Cleaner 22- Pilot Shut-Off Solenoid Valve
T5-4-1
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
TJBM-01-02-002
5 10 4 9
Shockless Valve
6
TJAA-01-02-008
1- Inter Cooler 4- Air Conditioner Condenser 7- Control Valve 10- Receiver Tank
2- Oil Cooler 5- Radiator 8- Shocklesss Valve
3- Fuel Cooler 6- Signal Control Valve 9- Ambient Temperature Sensor
T5-4-2
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
5
4 6
3
7
2
8
1
9
10
11
17
16
15 12
13
14 TJBM-01-02-010
1- Monitor 6- Components Related with 12- Components Related with 16- Components Related with
2- GPS Aerial Signal Control Valve (Refer to Engine (Refer to T5-4-11.) Check Valve (Refer to T5-4-14.)
3- Around Horn (Refer to T5-4-9.) T5-4-14.) 13- Components Related with 17- Electrical System (Cab Behind
4- Electric Grease Gun (Refer to 7- Fuel Sensor Pump Device (Refer to T5-4- Side) (Refer to T5-4-7.)
T5-4-10.) 8- Fuel Pump (Refer to T5-4-4.) 12.)
5- Components Related with 9- Air Cleaner Restriction Switch 14- 4-Spool Solenoid Valve Unit
Control Valve (Refer to T5-4- 10- Coolant Level Switch 15- Hydraulic Oil Temperature
13.) 11- Rear View Camera Sensor
T5-4-3
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
Fuel Pump
1 2
TJBC-01-02-005
T5-4-4
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
22 23 24 25
1 3
TJAA-01-02-004
7
10 11 12 13
9
14
8
15
16
21 20 19 18 17 T1V1-01-02-009
1- Monitor Controller 7- Wiper/Light Controller 14- Horn Relay (R10) 21- Load Damp Relay (R1)
2- GSM (Option) 8- Wiper Relay (R6) 15- Security Relay (R5) 22- Auto Lubrication Relay (R15)
3- MC (Main Controller) 9- Work Light Relay 1 (R7) 16- Starter Cut Relay (R4) 23- Fuel Pump Relay (R16)
4- MPDr. Connector (Download 10- ACC Cut Relay (R12) 17- Key Switch ON Cut Relay (R13) 24- Work Light Relay 3 (R17)
Connector Using Conbinedly) 11- Work Light Relay 2 (R8) 18- Security Horn Relay (R3) 25- Pump Regulator Pressure
5- Fuse Box 1 12- Auto Shut-Down Relay (R11) 19- ECM Main Relay (R14) Learning Switch
6- Fuse Box 2 13- Washer Relay (R9) 20- Pilot Shut-Off Relay (R2)
T5-4-5
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
1 2
16
4
15
13 14 7
24
23
22
21
12 11 10
20
19
17 18
TJAA-01-02-003 TDAA-05-02-059
1- Return to Previous Screen 7- Auto-Idle Switch 15- AUTO/OFF Switch/Blower 21- Overload Alarm Switch
Switch (Monitor) 8- Travel Mode Switch Switch (Air Conditioner) (Option)
2- Return to Basic Screen Switch 9- Work Light Switch 16- Temperature Control Switch/ 22- Swing Alarm Cancel Switch
(Monitor) 10- Power Mode Switch MODE Switch (Air Conditioner) (Option)
3- Selector/Set Switch (Monitor) 11- Key Switch 17- Travel Alarm Cancel Switch 23- Rear Work Light Switch
4- AM·FM Switch/Tuning Switch 12- TEN-key Switch (Option) (Option)
(Radio) 13- Overhead Window Wiper/ 18- Seat Heat Switch (Option) 24- Beacon Light Switch (Option)
5- Power Switch/Volume Control Overhead Window Washer 19- Boom Mode Selector Switch
Switch (Radio) Switch (Option) 20- Auto-Lubrication Switch
6- Engine Control Dial 14- Wiper/Washer Switch (Option)
T5-4-6
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
2 1
TJBG-01-02-005
3 4 8 5 6 7
M1JB-07-012
T5-4-7
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
TJBE-01-02-005
1
1 TJBE-01-02-006
T5-4-8
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
Around Horn
T1J7-01-02-004
3 TJBC-01-02-011
T5-4-9
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
2
1 TJBC-01-02-006 TJBC-01-02-007
T5-4-10
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
Engine
4 3 2 TJBG-01-02-007
12 13 14
5 15
11
9
10
TJBG-01-02-008 TJBG-01-02-010
1- Injector 5- Common Rail Pressure Sensor 9- Engine Oil Level Switch 13- Glow Plug
2- Boost Pressure Sensor 6- Crank Speed Sensor 10- Supply Pump 14- Coolant Temperature Sensor
3- Boost Temperature Sensor 7- Engine Oil Pressure Sensor 11- Cam Angle Sensor 15- Intake-Air Temperature Sensor
4- EGR Valve 8- Fuel Temperature Sensor 12- Overheat Switch
T5-4-11
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
Pump Device
1 2 3 4
7 5
6 B
TJBC-01-02-008
View B
8 9
10
11
TJBC-01-02-009
1- Pump 1 5- Pump 2 Delivery Pressure 8- Pump 1 Control Pressure 11- Pump 1 Control Solenoid Valve
2- Fan Pump Sensor Sensor
3- Fan Pump Control Solenoid 6- Pump 1 Delivery Pressure 9- Pump 2 Control Pressure
Valve Sensor Sensor
4- Pump 2 7- Pilot Pump 10- Pump 2 Control Solenoid Valve
T5-4-12
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
Control Valve
5
TJAA-01-02-015
2 3 4
7 TJAG-01-02-016
TJAG-01-02-101
1- Main Relief valve 3- Pressure Sensor (Boom Raise) 5- 2-Spool Solenoid Valve Unit 7- Pressure Sensor (Boom Lower)
2- Pressure Sensor (Bucket Roll- 4- Pressure Sensor (Arm Roll-out) (Refer to T5-4-17.) 8- Pressure Sensor (Bucket
Out) 6- Pressure Sensor (Arm Roll-In) Roll-In)
T5-4-13
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
Check Valve
1
5
TJAA-01-02-017
TJAA-03-06-003
T5-4-14
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
TJAA-03-06-004
Section A-A
7 2
6 3
5 4
T178-03-06-002
1- Shockless Valve 3- Pump 1 Flow Rate Control 5- Swing Parking Brake Release 7- Auxiliary
2- Arm Flow Rate Control Valve Valve Spool
Control Spool 4- Flow Combiner Valve Control 6- Pump 2 Flow Rate Control
Spool Valve
T5-4-15
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
Swing Device
1 TJBG-05-04-007
Travel Device
2
M1J1-07-048
T5-4-16
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
5 6
1 2 3 4
TJAA-01-02-102 TJAA-01-02-103
1- 4-Spool Solenoid Valve Unit 3- 4-Spool Solenoid Valve Unit 5- 2-Spool Solenoid Valve Unit
(SC) (SI) (SC)
2- 4-Spool Solenoid Valve Unit 4- 4-Spool Solenoid Valve Unit 6- 2-Spool Solenoid Valve Unit
(SF) (SG) (SI)
T5-4-17
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
c a a c
1 2 3 4 5 6 7 8 9
52
10
11
51
12
50
49 13
48 14
47
46 15
45 16
17
55
44
43
18
42 19
41 20
40
21
39
38 22
28
37
23
36
24
35
25
26
31 30
34 33 32 29 27
TJBM-03-03-001
54 53
T5-4-18
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
A Side
g c a
14
13
11
7
d 6 10 8 9 TJAG-03-03-002
b
a- Machine Upper Side c- Machine Lower Side d- Arm Roll-In Pressure Sensor g- Bucket Roll-In Pressure Sensor
b- Machine Front Side Connecting Position Connecting Position
1- Load Check Valve (Travel (Left) 16- Boom Flow Rate Control Valve 31- Auxiliary Flow Combiner Valve 44- Boost Check Valve (Boom
Parallel Circuit) (Poppet Valve) (Selector Valve) Regenerative Back Pressure
2- Bypass Shut-Out Valve (B side) 17- Boom Lower Meter-In Cut 32- Auxiliary Flow Combiner Valve Valve)
3- Check Valve (Bucket Flow Valve (Poppet Valve) 45- Overload Relief Valve (Boom 2:
Combiner Circuit) 18- Boom 1 Anti-Drift Valve 33- Swing Flow Rate Control Valve Rod Side)
4- Check Valve (Bucket Flow (Selector Valve) (Selector Valve) 46- Boom 2 Anti-Drift Valve
Combiner Circuit) 19- Boom 1 Anti-Drift Valve (Check 34- Swing Flow Rate Control Valve (Selector Valve)
5- Check Valve (Main Relief Valve) (Poppet Valve) 47- Boom 2 Anti-Drift Valve (Check
Circuit) 20- Overload Relief Valve (Boom 1: 35- Arm 1 Flow Rate Control Valve Valve)
6- Flow Combiner Valve Bottom Side) (Selector Valve) 48- Overload Relief Valve
7- Check Valve (Flow Combiner 21- Overload Relief Valve (Low 36- Arm 1 Flow Rate Control Valve (Auxiliary)
Circuit) Pressure) (Boom 1: Rod Side) (Poppet Valve) 49- Load Check Valve (Auxiliary
8- Check Valve (Main Relief 22- Boom Overload Relief Selector 37- Load Check Valve (Arm 1 Tandem Circuit)
Circuit) Valve Tandem Circuit) 50- Overload Relief Valve
9- Main Relief valve 23- Load Check Valve (Arm 2 38- Load Check Valve (Boom 2 (Auxiliary)
10- Load Check Valve (Bucket Tandem Circuit) Parallel Circuit) 51- Load Check Valve (Auxiliary
Parallel Circuit) 24- Arm 2 Flow Rate Control Valve 39- Check Valve (Boom 2 Parallel Circuit)
11- Bucket Regeneration Cut Valve (Selector Valve) Regenerative Circuit) 52- Load Check Valve (Travel (Left)
12- Bucket Regenerative Valve 25- Arm 2 Flow Rate Control Valve 40- Overload Relief Valve (Arm: Tandem Circuit)
13- Overload Relief Valve (Bucket: (Poppet Valve) Bottom Side) 53- Pump 1
Rod Side) 26- Check Valve (Arm Make-Up) 41- Arm Rod Anti-Drift Valve 54- Pump 2
14- Overload Relief Valve (Bucket: 27- Bypass Shut-Out Valve (A side) (Selector Valve) 55- Boom Regenerative Valve
Bottom Side) 28- Arm Regenerative Valve 42- Arm Rod Anti-Drift Valve
15- Boom Flow Rate Control Valve 29- Arm Regenerative Cut Valve (Check Valve)
(Selector Valve) 30- Check Valve (Auxiliary Flow 43- Overload Relief Valve (Arm:
Combiner Circuit) Rod Side)
T5-4-19
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
c a a c
1 2 3 4 5 6 7 8 9
52
10
11
51
12
50
49 13
48 14
47
46 15
45 16
17
55
44
43
18
42 19
41 20
40
21
39
38 22
28
37
23
36
24
35
25
26
31 30
34 33 32 29 27
TJBM-03-03-001
54 53
T5-4-20
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
B Side
a c
44 1 50 46, 47 49 52 2 39 45 48
TJAA-03-03-007
b
a- Machine Upper Side c- Machine Lower Side e- Boom Lower Pressure Sensor
b- Machine Front Side Connecting Position
1- Load Check Valve (Travel (Left) 16- Boom Flow Rate Control Valve 31- Auxiliary Flow Combiner Valve 44- Boost Check Valve (Boom
Parallel Circuit) (Poppet Valve) (Selector Valve) Regenerative Back Pressure
2- Bypass Shut-Out Valve (B side) 17- Boom Lower Meter-In Cut 32- Auxiliary Flow Combiner Valve Valve)
3- Check Valve (Bucket Flow Valve (Poppet Valve) 45- Overload Relief Valve (Boom 2:
Combiner Circuit) 18- Boom 1 Anti-Drift Valve 33- Swing Flow Rate Control Valve Rod Side)
4- Check Valve (Bucket Flow (Selector Valve) (Selector Valve) 46- Boom 2 Anti-Drift Valve
Combiner Circuit) 19- Boom 1 Anti-Drift Valve (Check 34- Swing Flow Rate Control Valve (Selector Valve)
5- Check Valve (Main Relief Valve) (Poppet Valve) 47- Boom 2 Anti-Drift Valve (Check
Circuit) 20- Overload Relief Valve (Boom 1: 35- Arm 1 Flow Rate Control Valve Valve)
6- Flow Combiner Valve Bottom Side) (Selector Valve) 48- Overload Relief Valve
7- Check Valve (Flow Combiner 21- Overload Relief Valve (Low 36- Arm 1 Flow Rate Control Valve (Auxiliary)
Circuit) Pressure) (Boom 1: Rod Side) (Poppet Valve) 49- Load Check Valve (Auxiliary
8- Check Valve (Main Relief 22- Boom Overload Relief Selector 37- Load Check Valve (Arm 1 Tandem Circuit)
Circuit) Valve Tandem Circuit) 50- Overload Relief Valve
9- Main Relief valve 23- Load Check Valve (Arm 2 38- Load Check Valve (Boom 2 (Auxiliary)
10- Load Check Valve (Bucket Tandem Circuit) Parallel Circuit) 51- Load Check Valve (Auxiliary
Parallel Circuit) 24- Arm 2 Flow Rate Control Valve 39- Check Valve (Boom 2 Parallel Circuit)
11- Bucket Regeneration Cut Valve (Selector Valve) Regenerative Circuit) 52- Load Check Valve (Travel (Left)
12- Bucket Regenerative Valve 25- Arm 2 Flow Rate Control Valve 40- Overload Relief Valve (Arm: Tandem Circuit)
13- Overload Relief Valve (Bucket: (Poppet Valve) Bottom Side) 53- Pump 1
Rod Side) 26- Check Valve (Arm Make-Up) 41- Arm Rod Anti-Drift Valve 54- Pump 2
14- Overload Relief Valve (Bucket: 27- Bypass Shut-Out Valve (A side) (Selector Valve) 55- Boom Regenerative Valve
Bottom Side) 28- Arm Regenerative Valve 42- Arm Rod Anti-Drift Valve
15- Boom Flow Rate Control Valve 29- Arm Regenerative Cut Valve (Check Valve)
(Selector Valve) 30- Check Valve (Auxiliary Flow 43- Overload Relief Valve (Arm:
Combiner Circuit) Rod Side)
T5-4-21
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
c a a c
1 2 3 4 5 6 7 8 9
52
10
11
51
12
50
49 13
48 14
47
46 15
45 16
17
55
44
43
18
42 19
41 20
40
21
39
38 22
28
37
23
36
24
35
25
26
31 30
34 33 32 29 27
TJBM-03-03-001
54 53
T5-4-22
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
A B Section A-A
C
C
D
D
E c a
E
F
F
G 12
G
H
H
6 b 9
A B
J TJAA-03-03-008
TJAA-03-03-009
1- Load Check Valve (Travel (Left) 16- Boom Flow Rate Control Valve 31- Auxiliary Flow Combiner Valve 44- Boost Check Valve (Boom
Parallel Circuit) (Poppet Valve) (Selector Valve) Regenerative Back Pressure
2- Bypass Shut-Out Valve (B side) 17- Boom Lower Meter-In Cut 32- Auxiliary Flow Combiner Valve Valve)
3- Check Valve (Bucket Flow Valve (Poppet Valve) 45- Overload Relief Valve (Boom 2:
Combiner Circuit) 18- Boom 1 Anti-Drift Valve 33- Swing Flow Rate Control Valve Rod Side)
4- Check Valve (Bucket Flow (Selector Valve) (Selector Valve) 46- Boom 2 Anti-Drift Valve
Combiner Circuit) 19- Boom 1 Anti-Drift Valve (Check 34- Swing Flow Rate Control Valve (Selector Valve)
5- Check Valve (Main Relief Valve) (Poppet Valve) 47- Boom 2 Anti-Drift Valve (Check
Circuit) 20- Overload Relief Valve (Boom 1: 35- Arm 1 Flow Rate Control Valve Valve)
6- Flow Combiner Valve Bottom Side) (Selector Valve) 48- Overload Relief Valve
7- Check Valve (Flow Combiner 21- Overload Relief Valve (Low 36- Arm 1 Flow Rate Control Valve (Auxiliary)
Circuit) Pressure) (Boom 1: Rod Side) (Poppet Valve) 49- Load Check Valve (Auxiliary
8- Check Valve (Main Relief 22- Boom Overload Relief Selector 37- Load Check Valve (Arm 1 Tandem Circuit)
Circuit) Valve Tandem Circuit) 50- Overload Relief Valve
9- Main Relief valve 23- Load Check Valve (Arm 2 38- Load Check Valve (Boom 2 (Auxiliary)
10- Load Check Valve (Bucket Tandem Circuit) Parallel Circuit) 51- Load Check Valve (Auxiliary
Parallel Circuit) 24- Arm 2 Flow Rate Control Valve 39- Check Valve (Boom 2 Parallel Circuit)
11- Bucket Regeneration Cut Valve (Selector Valve) Regenerative Circuit) 52- Load Check Valve (Travel (Left)
12- Bucket Regenerative Valve 25- Arm 2 Flow Rate Control Valve 40- Overload Relief Valve (Arm: Tandem Circuit)
13- Overload Relief Valve (Bucket: (Poppet Valve) Bottom Side) 53- Pump 1
Rod Side) 26- Check Valve (Arm Make-Up) 41- Arm Rod Anti-Drift Valve 54- Pump 2
14- Overload Relief Valve (Bucket: 27- Bypass Shut-Out Valve (A side) (Selector Valve) 55- Boom Regenerative Valve
Bottom Side) 28- Arm Regenerative Valve 42- Arm Rod Anti-Drift Valve
15- Boom Flow Rate Control Valve 29- Arm Regenerative Cut Valve (Check Valve)
(Selector Valve) 30- Check Valve (Auxiliary Flow 43- Overload Relief Valve (Arm:
Combiner Circuit) Rod Side)
T5-4-23
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
c a a c
1 2 3 4 5 6 7 8 9
52
10
11
51
12
50
49 13
48 14
47
46 15
45 16
17
55
44
43
18
42 19
41 20
40
21
39
38 22
28
37
23
36
24
35
25
26
31 30
34 33 32 29 27
TJBM-03-03-001
54 53
T5-4-24
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
i
26 37 40
28
55 33
a c
27 34
TJBA-03-03-006
TJAA-03-03-011
b
a- Machine Upper Side b- Machine Front Side c- Machine Lower Side i- Swing
1- Load Check Valve (Travel (Left) 16- Boom Flow Rate Control Valve 31- Auxiliary Flow Combiner Valve 44- Boost Check Valve (Boom
Parallel Circuit) (Poppet Valve) (Selector Valve) Regenerative Back Pressure
2- Bypass Shut-Out Valve (B side) 17- Boom Lower Meter-In Cut 32- Auxiliary Flow Combiner Valve Valve)
3- Check Valve (Bucket Flow Valve (Poppet Valve) 45- Overload Relief Valve (Boom 2:
Combiner Circuit) 18- Boom 1 Anti-Drift Valve 33- Swing Flow Rate Control Valve Rod Side)
4- Check Valve (Bucket Flow (Selector Valve) (Selector Valve) 46- Boom 2 Anti-Drift Valve
Combiner Circuit) 19- Boom 1 Anti-Drift Valve (Check 34- Swing Flow Rate Control Valve (Selector Valve)
5- Check Valve (Main Relief Valve) (Poppet Valve) 47- Boom 2 Anti-Drift Valve (Check
Circuit) 20- Overload Relief Valve (Boom 1: 35- Arm 1 Flow Rate Control Valve Valve)
6- Flow Combiner Valve Bottom Side) (Selector Valve) 48- Overload Relief Valve
7- Check Valve (Flow Combiner 21- Overload Relief Valve (Low 36- Arm 1 Flow Rate Control Valve (Auxiliary)
Circuit) Pressure) (Boom 1: Rod Side) (Poppet Valve) 49- Load Check Valve (Auxiliary
8- Check Valve (Main Relief 22- Boom Overload Relief Selector 37- Load Check Valve (Arm 1 Tandem Circuit)
Circuit) Valve Tandem Circuit) 50- Overload Relief Valve
9- Main Relief valve 23- Load Check Valve (Arm 2 38- Load Check Valve (Boom 2 (Auxiliary)
10- Load Check Valve (Bucket Tandem Circuit) Parallel Circuit) 51- Load Check Valve (Auxiliary
Parallel Circuit) 24- Arm 2 Flow Rate Control Valve 39- Check Valve (Boom 2 Parallel Circuit)
11- Bucket Regeneration Cut Valve (Selector Valve) Regenerative Circuit) 52- Load Check Valve (Travel (Left)
12- Bucket Regenerative Valve 25- Arm 2 Flow Rate Control Valve 40- Overload Relief Valve (Arm: Tandem Circuit)
13- Overload Relief Valve (Bucket: (Poppet Valve) Bottom Side) 53- Pump 1
Rod Side) 26- Check Valve (Arm Make-Up) 41- Arm Rod Anti-Drift Valve 54- Pump 2
14- Overload Relief Valve (Bucket: 27- Bypass Shut-Out Valve (A side) (Selector Valve) 55- Boom Regenerative Valve
Bottom Side) 28- Arm Regenerative Valve 42- Arm Rod Anti-Drift Valve
15- Boom Flow Rate Control Valve 29- Arm Regenerative Cut Valve (Check Valve)
(Selector Valve) 30- Check Valve (Auxiliary Flow 43- Overload Relief Valve (Arm:
Combiner Circuit) Rod Side)
T5-4-25
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
c a a c
1 2 3 4 5 6 7 8 9
52
10
11
51
12
50
49 13
48 14
47
46 15
45 16
17
55
44
43
18
42 19
41 20
40
21
39
38 22
28
37
23
36
24
35
25
26
31 30
34 33 32 29 27
TJBM-03-03-001
54 53
T5-4-26
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
j 29 k 42 41 18 19 l 44 m 46
20
47
24
38
55
25
23 32 28 36 35 17 16 21 39 45
TJBA-03-03-013 TJBA-03-03-014
1- Load Check Valve (Travel (Left) 16- Boom Flow Rate Control Valve 31- Auxiliary Flow Combiner Valve 44- Boost Check Valve (Boom
Parallel Circuit) (Poppet Valve) (Selector Valve) Regenerative Back Pressure
2- Bypass Shut-Out Valve (B side) 17- Boom Lower Meter-In Cut 32- Auxiliary Flow Combiner Valve Valve)
3- Check Valve (Bucket Flow Valve (Poppet Valve) 45- Overload Relief Valve (Boom 2:
Combiner Circuit) 18- Boom 1 Anti-Drift Valve 33- Swing Flow Rate Control Valve Rod Side)
4- Check Valve (Bucket Flow (Selector Valve) (Selector Valve) 46- Boom 2 Anti-Drift Valve
Combiner Circuit) 19- Boom 1 Anti-Drift Valve (Check 34- Swing Flow Rate Control Valve (Selector Valve)
5- Check Valve (Main Relief Valve) (Poppet Valve) 47- Boom 2 Anti-Drift Valve (Check
Circuit) 20- Overload Relief Valve (Boom 1: 35- Arm 1 Flow Rate Control Valve Valve)
6- Flow Combiner Valve Bottom Side) (Selector Valve) 48- Overload Relief Valve
7- Check Valve (Flow Combiner 21- Overload Relief Valve (Low 36- Arm 1 Flow Rate Control Valve (Auxiliary)
Circuit) Pressure) (Boom 1: Rod Side) (Poppet Valve) 49- Load Check Valve (Auxiliary
8- Check Valve (Main Relief 22- Boom Overload Relief Selector 37- Load Check Valve (Arm 1 Tandem Circuit)
Circuit) Valve Tandem Circuit) 50- Overload Relief Valve
9- Main Relief valve 23- Load Check Valve (Arm 2 38- Load Check Valve (Boom 2 (Auxiliary)
10- Load Check Valve (Bucket Tandem Circuit) Parallel Circuit) 51- Load Check Valve (Auxiliary
Parallel Circuit) 24- Arm 2 Flow Rate Control Valve 39- Check Valve (Boom 2 Parallel Circuit)
11- Bucket Regeneration Cut Valve (Selector Valve) Regenerative Circuit) 52- Load Check Valve (Travel (Left)
12- Bucket Regenerative Valve 25- Arm 2 Flow Rate Control Valve 40- Overload Relief Valve (Arm: Tandem Circuit)
13- Overload Relief Valve (Bucket: (Poppet Valve) Bottom Side) 53- Pump 1
Rod Side) 26- Check Valve (Arm Make-Up) 41- Arm Rod Anti-Drift Valve 54- Pump 2
14- Overload Relief Valve (Bucket: 27- Bypass Shut-Out Valve (A side) (Selector Valve) 55- Boom Regenerative Valve
Bottom Side) 28- Arm Regenerative Valve 42- Arm Rod Anti-Drift Valve
15- Boom Flow Rate Control Valve 29- Arm Regenerative Cut Valve (Check Valve)
(Selector Valve) 30- Check Valve (Auxiliary Flow 43- Overload Relief Valve (Arm:
Combiner Circuit) Rod Side)
T5-4-27
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
c a a c
1 2 3 4 5 6 7 8 9
52
10
11
51
12
50
49 13
48 14
47
46 15
45 16
17
55
44
43
18
42 19
41 20
40
21
39
38 22
28
37
23
36
24
35
25
26
31 30
34 33 32 29 27
TJBM-03-03-001
54 53
T5-4-28
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
n 11 o 50 p 1 q
13
10 52
12
14 48 49
TJAA-03-03-014 TJAA-03-03-015
1- Load Check Valve (Travel (Left) 16- Boom Flow Rate Control Valve 31- Auxiliary Flow Combiner Valve 44- Boost Check Valve (Boom
Parallel Circuit) (Poppet Valve) (Selector Valve) Regenerative Back Pressure
2- Bypass Shut-Out Valve (B side) 17- Boom Lower Meter-In Cut 32- Auxiliary Flow Combiner Valve Valve)
3- Check Valve (Bucket Flow Valve (Poppet Valve) 45- Overload Relief Valve (Boom 2:
Combiner Circuit) 18- Boom 1 Anti-Drift Valve 33- Swing Flow Rate Control Valve Rod Side)
4- Check Valve (Bucket Flow (Selector Valve) (Selector Valve) 46- Boom 2 Anti-Drift Valve
Combiner Circuit) 19- Boom 1 Anti-Drift Valve (Check 34- Swing Flow Rate Control Valve (Selector Valve)
5- Check Valve (Main Relief Valve) (Poppet Valve) 47- Boom 2 Anti-Drift Valve (Check
Circuit) 20- Overload Relief Valve (Boom 1: 35- Arm 1 Flow Rate Control Valve Valve)
6- Flow Combiner Valve Bottom Side) (Selector Valve) 48- Overload Relief Valve
7- Check Valve (Flow Combiner 21- Overload Relief Valve (Low 36- Arm 1 Flow Rate Control Valve (Auxiliary)
Circuit) Pressure) (Boom 1: Rod Side) (Poppet Valve) 49- Load Check Valve (Auxiliary
8- Check Valve (Main Relief 22- Boom Overload Relief Selector 37- Load Check Valve (Arm 1 Tandem Circuit)
Circuit) Valve Tandem Circuit) 50- Overload Relief Valve
9- Main Relief valve 23- Load Check Valve (Arm 2 38- Load Check Valve (Boom 2 (Auxiliary)
10- Load Check Valve (Bucket Tandem Circuit) Parallel Circuit) 51- Load Check Valve (Auxiliary
Parallel Circuit) 24- Arm 2 Flow Rate Control Valve 39- Check Valve (Boom 2 Parallel Circuit)
11- Bucket Regeneration Cut Valve (Selector Valve) Regenerative Circuit) 52- Load Check Valve (Travel (Left)
12- Bucket Regenerative Valve 25- Arm 2 Flow Rate Control Valve 40- Overload Relief Valve (Arm: Tandem Circuit)
13- Overload Relief Valve (Bucket: (Poppet Valve) Bottom Side) 53- Pump 1
Rod Side) 26- Check Valve (Arm Make-Up) 41- Arm Rod Anti-Drift Valve 54- Pump 2
14- Overload Relief Valve (Bucket: 27- Bypass Shut-Out Valve (A side) (Selector Valve) 55- Boom Regenerative Valve
Bottom Side) 28- Arm Regenerative Valve 42- Arm Rod Anti-Drift Valve
15- Boom Flow Rate Control Valve 29- Arm Regenerative Cut Valve (Check Valve)
(Selector Valve) 30- Check Valve (Auxiliary Flow 43- Overload Relief Valve (Arm:
Combiner Circuit) Rod Side)
T5-4-29
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
c a a c
1 2 3 4 5 6 7 8 9
52
10
11
51
12
50
49 13
48 14
47
46 15
45 16
17
55
44
43
18
42 19
41 20
40
21
39
38 22
28
37
23
36
24
35
25
26
31 30
34 33 32 29 27
TJBM-03-03-001
54 53
T5-4-30
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
Section H-H
7 6 2
TJAA-03-03-016
1- Load Check Valve (Travel (Left) 16- Boom Flow Rate Control Valve 31- Auxiliary Flow Combiner Valve 44- Boost Check Valve (Boom
Parallel Circuit) (Poppet Valve) (Selector Valve) Regenerative Back Pressure
2- Bypass Shut-Out Valve (B side) 17- Boom Lower Meter-In Cut 32- Auxiliary Flow Combiner Valve Valve)
3- Check Valve (Bucket Flow Valve (Poppet Valve) 45- Overload Relief Valve (Boom 2:
Combiner Circuit) 18- Boom 1 Anti-Drift Valve 33- Swing Flow Rate Control Valve Rod Side)
4- Check Valve (Bucket Flow (Selector Valve) (Selector Valve) 46- Boom 2 Anti-Drift Valve
Combiner Circuit) 19- Boom 1 Anti-Drift Valve (Check 34- Swing Flow Rate Control Valve (Selector Valve)
5- Check Valve (Main Relief Valve) (Poppet Valve) 47- Boom 2 Anti-Drift Valve (Check
Circuit) 20- Overload Relief Valve (Boom 1: 35- Arm 1 Flow Rate Control Valve Valve)
6- Flow Combiner Valve Bottom Side) (Selector Valve) 48- Overload Relief Valve
7- Check Valve (Flow Combiner 21- Overload Relief Valve (Low 36- Arm 1 Flow Rate Control Valve (Auxiliary)
Circuit) Pressure) (Boom 1: Rod Side) (Poppet Valve) 49- Load Check Valve (Auxiliary
8- Check Valve (Main Relief 22- Boom Overload Relief Selector 37- Load Check Valve (Arm 1 Tandem Circuit)
Circuit) Valve Tandem Circuit) 50- Overload Relief Valve
9- Main Relief valve 23- Load Check Valve (Arm 2 38- Load Check Valve (Boom 2 (Auxiliary)
10- Load Check Valve (Bucket Tandem Circuit) Parallel Circuit) 51- Load Check Valve (Auxiliary
Parallel Circuit) 24- Arm 2 Flow Rate Control Valve 39- Check Valve (Boom 2 Parallel Circuit)
11- Bucket Regeneration Cut Valve (Selector Valve) Regenerative Circuit) 52- Load Check Valve (Travel (Left)
12- Bucket Regenerative Valve 25- Arm 2 Flow Rate Control Valve 40- Overload Relief Valve (Arm: Tandem Circuit)
13- Overload Relief Valve (Bucket: (Poppet Valve) Bottom Side) 53- Pump 1
Rod Side) 26- Check Valve (Arm Make-Up) 41- Arm Rod Anti-Drift Valve 54- Pump 2
14- Overload Relief Valve (Bucket: 27- Bypass Shut-Out Valve (A side) (Selector Valve) 55- Boom Regenerative Valve
Bottom Side) 28- Arm Regenerative Valve 42- Arm Rod Anti-Drift Valve
15- Boom Flow Rate Control Valve 29- Arm Regenerative Cut Valve (Check Valve)
(Selector Valve) 30- Check Valve (Auxiliary Flow 43- Overload Relief Valve (Arm:
Combiner Circuit) Rod Side)
T5-4-31
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
c a a c
1 2 3 4 5 6 7 8 9
52
10
11
51
12
50
49 13
48 14
47
46 15
45 16
17
55
44
43
18
42 19
41 20
40
21
39
38 22
28
37
23
36
24
35
25
26
31 30
34 33 32 29 27
TJBM-03-03-001
54 53
T5-4-32
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
TJAA-03-03-017 T450-03-03-008
1- Load Check Valve (Travel (Left) 16- Boom Flow Rate Control Valve 31- Auxiliary Flow Combiner Valve 44- Boost Check Valve (Boom
Parallel Circuit) (Poppet Valve) (Selector Valve) Regenerative Back Pressure
2- Bypass Shut-Out Valve (B side) 17- Boom Lower Meter-In Cut 32- Auxiliary Flow Combiner Valve Valve)
3- Check Valve (Bucket Flow Valve (Poppet Valve) 45- Overload Relief Valve (Boom 2:
Combiner Circuit) 18- Boom 1 Anti-Drift Valve 33- Swing Flow Rate Control Valve Rod Side)
4- Check Valve (Bucket Flow (Selector Valve) (Selector Valve) 46- Boom 2 Anti-Drift Valve
Combiner Circuit) 19- Boom 1 Anti-Drift Valve (Check 34- Swing Flow Rate Control Valve (Selector Valve)
5- Check Valve (Main Relief Valve) (Poppet Valve) 47- Boom 2 Anti-Drift Valve (Check
Circuit) 20- Overload Relief Valve (Boom 1: 35- Arm 1 Flow Rate Control Valve Valve)
6- Flow Combiner Valve Bottom Side) (Selector Valve) 48- Overload Relief Valve
7- Check Valve (Flow Combiner 21- Overload Relief Valve (Low 36- Arm 1 Flow Rate Control Valve (Auxiliary)
Circuit) Pressure) (Boom 1: Rod Side) (Poppet Valve) 49- Load Check Valve (Auxiliary
8- Check Valve (Main Relief 22- Boom Overload Relief Selector 37- Load Check Valve (Arm 1 Tandem Circuit)
Circuit) Valve Tandem Circuit) 50- Overload Relief Valve
9- Main Relief valve 23- Load Check Valve (Arm 2 38- Load Check Valve (Boom 2 (Auxiliary)
10- Load Check Valve (Bucket Tandem Circuit) Parallel Circuit) 51- Load Check Valve (Auxiliary
Parallel Circuit) 24- Arm 2 Flow Rate Control Valve 39- Check Valve (Boom 2 Parallel Circuit)
11- Bucket Regeneration Cut Valve (Selector Valve) Regenerative Circuit) 52- Load Check Valve (Travel (Left)
12- Bucket Regenerative Valve 25- Arm 2 Flow Rate Control Valve 40- Overload Relief Valve (Arm: Tandem Circuit)
13- Overload Relief Valve (Bucket: (Poppet Valve) Bottom Side) 53- Pump 1
Rod Side) 26- Check Valve (Arm Make-Up) 41- Arm Rod Anti-Drift Valve 54- Pump 2
14- Overload Relief Valve (Bucket: 27- Bypass Shut-Out Valve (A side) (Selector Valve) 55- Boom Regenerative Valve
Bottom Side) 28- Arm Regenerative Valve 42- Arm Rod Anti-Drift Valve
15- Boom Flow Rate Control Valve 29- Arm Regenerative Cut Valve (Check Valve)
(Selector Valve) 30- Check Valve (Auxiliary Flow 43- Overload Relief Valve (Arm:
Combiner Circuit) Rod Side)
T5-4-33
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
T5-4-34
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
PH
C A
D M
H
B
F SB
G
PI
N
K
I
J
SH
DF
SA L TJAA-03-06-002
SM 3
1 5
13 4
2 SE
SK 8
S3
14
6
7
9 SN
11
10
SL
TJAA-03-06-003
TR 12 SP
T5-4-35
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
T5-4-36
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
PH
C A
D M
H
B
F SB
G
PI
N
K
I
J
SH
DF
SA L TJAA-03-06-002
SM 3
1 5
13 4
2 SE
SK 8
S3
14
6
7
9 SN
11
10
SL
TJAA-03-06-003
TR 12 SP
T5-4-37
SECTION 5 TROUBLE SHOOTING
Group 4 Component Layout
(Blank)
T5-4-38
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
1
2
T6L4-05-03-001
T5-5-1
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
Contents of Diagnosis
Fault Code
Preparation
Procedure:
1. Check an applicable line depending on displayed fault cord (A).
2. After checking or measuring on Inspection Method (C), refer to
Evaluation (D) and judge the results.
3. In case the results are satisfied with Evaluation (D), the trouble cause is
Cause (E).
In case the results are not satisfied with Evaluation (D), go to the next
procedure, Inspection Method (F).
A connection point of the test harness and a point to check are explained.
(Only Pressure Sensor System Troubleshooting)
T5-5-2
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-3
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-4
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
Engine Failure
Fault Code Trouble Cause Symptoms in Machine Remedy
Operation When Trouble
Occurs
11100-2 Abnormal Engine Engine speed: 4000 The machine operation Check the crank speed
Speed min-1 or more speed is slow. (During sensor.
speed sensing, the torque is Check the cam angle sensor.
decreased.) (Refer to the engine manual.)
11101-3 Abnormal Engine Voltage: more than Trouble condition with the Check the wire harness.
Control Angle 4.75 V key switch ON: The engine Replace the engine control
Sensor High Input speed is kept at slow idle dial.
speed.
Trouble condition during
operation: The engine speed
is kept at the speed just
before trouble occurs.
11101-4 Abnormal Engine Voltage: less than Trouble condition with the Check the wire harness.
Control Angle 0.25 V key switch ON: The engine Replace the engine control
Sensor Low Input speed is kept at slow idle dial.
speed.
Trouble condition during
operation: The engine speed
is kept at the speed just
before trouble occurs.
T5-5-5
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
Pump Failure
Fault Code Trouble Cause Symptoms in Machine Operation Remedy
When Trouble Occurs
11200-3 Pump 1 Delivery Voltage: more Combined operation of arm roll- Check the wire harness.
Pressure Sensor than 4.75 V in and boom raise or combined Replace the pump 1 delivery
Circuit High Input operation of arm roll-in and swing: pressure sensor.
Arm roll-in speed becomes slow.
Single operation of boom raise:
Lifting force is weak.
Machine is kept to travel at slow
speed.
11200-4 Pump 1 Delivery Voltage: less Combined operation of arm roll- Check the wire harness.
Pressure Sensor than 0.25 V in and boom raise or combined Replace the pump 1 delivery
Circuit Low Input operation of arm roll-in and swing: pressure sensor.
Arm roll-in speed becomes slow.
Single operation of boom raise:
Lifting force is weak.
Machine is kept to travel at slow
speed.
11202-3 Pump 2 Delivery Voltage: more Combined operation of arm roll- Check the wire harness.
Pressure Sensor than 4.75 V in and boom raise or combined Replace the pump 2 delivery
Circuit High Input operation of arm roll-in and swing: pressure sensor.
Arm roll-in speed becomes slow.
Machine is kept to travel at slow
speed.
11202-4 Pump 2 Delivery Voltage: less Combined operation of arm roll- Check the wire harness.
Pressure Sensor than 0.25 V in and boom raise or combined Replace the pump 2 delivery
Circuit Low Input operation of arm roll-in and swing: pressure sensor.
Arm roll-in speed becomes slow.
Machine is kept to travel at slow
speed.
T5-5-6
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
Pilot Failure
Fault Code Trouble Cause Symptoms in Machine Operation Remedy
When Trouble Occurs
11301-3 Swing Pilot Pressure Voltage: more Swing speed becomes slow. Check the wire harness.
Sensor Circuit High than 4.75 V Combined operation of swing, arm Replace the swing pilot
Input roll-in, and boom raise: Boom does pressure sensor.
not raise easily and arm speed
becomes fast.
Swing alarm (optional) continues
to sound.
11301-4 Swing Pilot Pressure Voltage: less Swing speed becomes slow. Check the wire harness.
Sensor Circuit Low than 0.1 V Combined operation of swing, arm Replace the swing pilot
Input roll-in, and boom raise: Boom does pressure sensor.
not raise easily and arm speed
becomes fast.
Swing alarm (optional) continues
to sound.
11302-3 Boom Raise Pilot Voltage: more When operating boom raise, Check the wire harness.
Pressure Sensor than 4.75 V engine speed does not increase. Replace the boom raise pilot
Circuit High Input Combined operation of swing, arm pressure sensor.
roll-in, and boom raise: Boom does
not raise easily.
Single operation of boom raise:
Lifting force is weak.
11302-4 Boom Raise Pilot Voltage: less When operating boom raise, Check the wire harness.
Pressure Sensor than 0.1 V engine speed does not increase. Replace the boom raise pilot
Circuit Low Input Combined operation of swing, arm pressure sensor.
roll-in, and boom raise: Boom does
not raise easily.
Single operation of boom raise:
Lifting force is weak.
11303-3 Arm Roll-in Pilot Voltage: more When operating arm roll-in, Check the wire harness.
Pressure Sensor than 4.75 V engine speed does not increase. Replace the arm roll-in pilot
Circuit High Input Arm speed becomes fast. pressure sensor.
11303-4 Arm Roll-in Pilot Voltage: less When operating arm roll-in, Check the wire harness.
Pressure Sensor than 0.1 V engine speed does not increase. Replace the arm roll-in pilot
Circuit Low Input Arm speed becomes fast. pressure sensor.
T5-5-7
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-8
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-9
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-10
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-11
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
Other Failures
Fault Code Trouble Cause Symptoms in Machine Remedy
Operation When Trouble
Occurs
11802-3 Boom Bottom Voltage: more than 4.75 V The buzzer sounds. Check the wire
Pressure Sensor Circuit harness
High Input (Option) Replace the boom
bottom pressure
sensor
11802-4 Boom Bottom Voltage: less than 0.25 V The buzzer sounds. Check the wire
Pressure Sensor Circuit harness
High Input (Option) Replace the boom
bottom pressure
sensor
11901-3 Hyd. Oil Temp Sensor Voltage: more than 4.35 V Fan rotation speed is Check the wire
Circuit High Input kept at the maximum harness
speed. Pump driving
torque is reduced.
11901-4 Hyd. Oil Temp Sensor Voltage: less than 0.1 V Fan rotation speed is Check the wire
Circuit Low Input kept at the maximum harness
speed. Pump driving
torque is reduced.
T5-5-12
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-13
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-14
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-15
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-16
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-17
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-18
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-19
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-20
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-21
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-22
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-23
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-24
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-25
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-26
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-27
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-28
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-29
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-30
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-31
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-32
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-33
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
2
3
4
5
18
6
17 7
8
9
16 10
11
15
12
13 TJBG-05-05-001
1- MC 7- Pressure Sensor (Bucket Roll- 12- Pressure Sensor (Attachment) 16- Pump 1 Control Pressure
2- Pressure Sensor (Boom Raise) Out) (Option) Sensor
3- Pressure Sensor (Boom Lower) 8- Pressure Sensor (Swing) 13- Bottom Pressure Sensor 17- Pump 2 Delivery Pressure
4- Pressure Sensor (Arm Roll-In) 9- Pressure Sensor (Travel) (Option) Sensor
5- Pressure Sensor (Arm Roll-Out) 10- Pressure Sensor (4-Spool Side) 15- Pump 1 Delivery Pressure 14- Pump 2 Control Pressure
6- Pressure Sensor (Bucket 11- Pressure Sensor (5-Spool Side) Sensor Sensor
Roll-In)
T5-5-34
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TJBG-05-05-011
TJBG-05-05-010
Switch Panel
(Engine Control Dial)
TJBG-05-05-016
T5-5-35
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
(Blank)
T5-5-36
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
fNOTE: IC and ICF are the Information Control Unit of Monitor Controller.
T5-5-37
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
Evaluation
Continuity (0 Ω) Discontinuity (∞ Ω)
Continuity check Correct Incorrect (open
(open circuit) circuit)
Discontinuity check Incorrect (short Correct
(short circuit) circuit)
T5-5-38
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-39
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TDAB-05-06-011
TJBG-05-05-005
TJBG-05-05-006 TJBG-05-05-012
MC-F Connector
TJBG-05-05-007
ECM-2 Connector
TJBG-05-05-021
T5-5-40
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
fNOTE: IC and ICF are the Information Control Unit of Monitor Controller.
T5-5-41
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
Evaluation
Continuity (0 Ω) Discontinuity (∞ Ω)
Continuity check Correct Incorrect (open
(open circuit) circuit)
Discontinuity check Incorrect (short Correct
(shorted circuit) circuit)
T5-5-42
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-43
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TDAB-05-06-018
TJBG-05-05-005
TDAB-05-06-019
TJBG-05-05-006
TDAB-05-06-010
TJBG-05-05-007
TDAB-05-06-011 TDAB-05-06-008
TDAB-05-06-009
TJBG-05-05-012
T5-5-44
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-45
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TJBG-05-05-016
T5-5-46
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
C B A
TDAA-05-06-003
T5-5-47
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
C B A
TDAA-05-06-003
T5-5-48
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
C B A
TDAA-05-06-003
T5-5-49
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
C B A
TDAA-05-06-003
T5-5-50
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TJBG-05-05-003
T5-5-51
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TJBG-05-05-003
T5-5-52
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TJBG-05-05-003
T5-5-53
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TJBG-05-05-003
T5-5-54
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
C B A
TDAA-05-06-003
T5-5-55
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TDAB-05-06-023
T5-5-56
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
C B A
TDAA-05-06-003
T5-5-57
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
C B A
TDAA-05-06-003
T5-5-58
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TJBG-05-05-003
T5-5-59
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TJBG-05-05-003
T5-5-60
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TJBG-05-05-003
T5-5-61
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TJBG-05-05-003
T5-5-62
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
C B A
TDAA-05-06-003
T5-5-63
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TJBG-05-05-003
T5-5-64
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TJBG-05-05-003
T5-5-65
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TJBG-05-05-003
T5-5-66
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TJBG-05-05-003
T5-5-67
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
C B A
TDAA-05-06-003
T5-5-68
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
C B A
TDAA-05-06-003
T5-5-69
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
C B A
TDAA-05-06-003
T5-5-70
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-71
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TDAB-05-06-011
fNOTE:
Coolant Temperature Gauge No. Coolant Temperature (ºC) Coolant Temperature Sensor (kΩ)
E
A 25 7.6±0.76
F
B 40 4.0±0.35
C 50 2.7±0.22
D 80 0.92±0.07
D 95 0.56±0.04
E 105 0.42±0.03
D F 120 0.28±0.01
B
A
TJBG-05-02-084
T5-5-72
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
fNOTE:
Fuel Gauge No. Fuel Level (%) Fuel Sensor (Ω)
A A 100 (FULL) 100-4
B
B 75 19
C
C 50 32±5
D
D 25 49.3
E 6 -
E
F 0 (EMPTY) 80+12+2
TDAA-05-02-082
TDCD-05-06-010
T5-5-73
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
TDAB-05-06-011
T5-5-74
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
Monitor Controller (Information) Fault Codes 20107, 20109, 20110, 20114, 20146, 20149
T5-5-75
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-76
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
T5-5-77
SECTION 5 TROUBLESHOOTING
Group 5 Troubleshooting A
(Blank)
T5-5-78
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Diagnosis Procedure
Perform diagnosis by using MPDr. or the service
menu of monitor first.
When the fault code is displayed, refer to the
troubleshooting A group and diagnose.
In case any fault code has not been displayed by
diagnosis, perform inspection according to the
procedures in this group when diagnosing.
On the front section pages of this group, there are
the tables indicating the relationship between
machine trouble symptoms and related parts
which may cause such trouble if failed. Start the
troubleshooting with more probable causes selected
by referring to these tables.
f NOTE: All connector images in this section are viewed
from the open end side of wire harness end.
1
2
T6L4-05-03-001
T5-6-1
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Contents of Diagnosis
Trouble Symptom
Preparation
Inspection
Procedure Condition Evaluation Cause
Method
(A) (B) (C) (D) (E)
(F) (G) (H) (I) (J)
A, F: Inspection order
B, G: Inspection method for trouble cause
C, H: Conditions for inspection
D, I: Evaluation specification of check results
E, J: Trouble cause for trouble symptom
Procedure:
1. Perform inspection according to Inspection Method (B) and Condition (C) of
Procedure (A).
2. In case the results are applied to Evaluation (D), the trouble cause is Cause (E).
In case the results are not applied to Evaluation (D), go to the next, Procedure (F).
T5-6-2
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Item
Function MC controls the engine, pump, Engine control dial instructs target This switch activates auto-idle
and valve. engine speed. control.
ON: 0 VAuto-idle control is
activated.
OFF: 5 VAuto-idle control is
not activated.
Symptoms Depending on trouble situations, Even if engine control dial is Open circuit: Auto-idle is not
in control control system malfunction may operated, engine speed does not activated.
system when differ. (The following symptoms in change. Short circuit: Even if auto-idle
machine operation indicate that
trouble occurs switch is in OFF position, auto-
MC logic circuit has failed.) idle control is always activated.
Symptoms Even if engine starts, engine Engine speed is fixed at 1200 min . Same as shown above
-1
T5-6-3
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Parts Power Mode Switch (ECO Mode) Travel Mode Switch Boom Mode Selector Switch
Item
Function This switch shifts power mode This switch shifts 4-spool This switch reduces overload
switch to ECO mode. solenoid valve unit (SC) and relief pressure at the boom
ON: 0 VECO mode control is changes travel speed. cylinder rod side.
operated.
OFF: 5 VNormal.
Symptoms Open circuit: Even if ECO mode is Open circuit: Travel speed Open circuit: Boom mode
in control selected, engine speed does not remains unchanged in slow selector control is not performed.
system when decrease with the control lever in speed. Short circuit: Overload relief
trouble occurs neutral. Short circuit: Even if travel mode pressure at the boom cylinder
Short circuit: Even if power mode switch is in slow idle position, rod side remains low constantly
is set to PWR mode or HP mode machine travels at fast speed. and machine cannot be raised
from ECO mode with the control off the ground with front
lever in neutral and the engine attachment.
control dial in fast idle position,
engine speed does not increase.
Symptoms Same as shown above Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by MC: Power Mode Switch MC: Travel Mode SW MC: Boom Mode Switch
Monitoring
Evaluation - - -
by using Test
Harness
Note - - -
Descriptions T2-2 T2-2 T2-2
of Control
(Operational
Principle
Section in
T/M)
T5-6-4
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-5
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-6
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-7
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Item
Function This valve opens and closes pilot This sensor monitors hydraulic oil
circuit. temperature.
Symptoms When close: All actuators are not MC recognizes that hydraulic oil
in control activated. (Pilot pressure oil is not temperature is 120 °C when an
system when supplied to pilot valve.) open circuit occurs. (Hydraulic
trouble occurs When open: Pilot pressure oil is oil temperature: 120 °C is not
always supplied to pilot valve. displayed on monitoring.)
Symptoms Same as shown above The fan speed is fixed to the
in machine maximum value.
operation
when trouble
occurs
Evaluation by - 11901
Fault Code
Evaluation by - MC: Hydraulic Oil Temperature
Monitoring
Evaluation - -
by using Test
Harness
Note - -
Descriptions T2-5 T2-2
of Control
(Operational
Principle
Section in
T/M)
T5-6-8
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Item
Function This sensor detects pump 1 This sensor detects pump 2
delivery pressure. delivery pressure.
Symptoms When output is 0 V or 5 V, the When output is 0 V or 5 V, the
in control following symptoms occur. following symptoms occur.
system when
trouble occurs
Symptoms HP Mode cannot be set. HP Mode cannot be set.
in machine As the pump 1 delivery flow rate As the pump 2 delivery flow rate
operation is restricted, operation speed is restricted, operation speed
when trouble of the boom, arm, and bucket of the boom, arm, and swing
occurs becomes slower. becomes slower.
The engine becomes easily The engine becomes easily
stalled. stalled.
As the machine is kept to travel As the machine is kept to travel
at slow speed, speed does not at slow speed, speed does not
change into fast. change into fast.
Evaluation by 11200 11202
Fault Code
Evaluation by MC: Pump 1 Delivery Pressure MC: Pump 2 Delivery Pressure
Monitoring
Evaluation - -
by using Test
Harness
Note Possible to judge if sensor or Possible to judge if sensor or
harness is faulty by switching harness is faulty by switching
pressure sensor with other pressure sensor with other
delivery pressure sensor. delivery pressure sensor.
Descriptions T2-2 T2-2
of Control
(Operational
Principle
Section in
T/M)
T5-6-9
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Item
Function This sensor detects pump control This sensor detects pump control
pressure of pump 1. pressure of pump 2.
Symptoms When output is 0 V or 5 V, the When output is 0 V or 5 V, the
in control following symptoms occur. following symptoms occur.
system when
trouble occurs
Symptoms Engine speed does not decrease Engine speed does not decrease
in machine when operating bucket and when operating travel (left) at
operation travel (right) at ECO mode. ECO mode.
when trouble Fast travel cannot be selected Fast travel cannot be selected
occurs easily when travering. easily when travering.
Evaluation by 11994 11992
Fault Code
Evaluation by MC: Pump 1 Control Pressure MC: Pump 2 Control Pressure
Monitoring
Evaluation - -
by using Test
Harness
Note Possible to judge if sensor or wire Possible to judge if sensor or wire
harness is faulty by switching harness is faulty by switching
pressure sensor with other pump pressure sensor with other pump
control pressure sensor. control pressure sensor.
Descriptions T2-2 T2-2
of Control
(Operational
Principle
Section in
T/M)
T5-6-10
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Parts Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Pressure Sensor (Arm Roll-In)
Item
Function This sensor monitors boom raise This sensor monitors Boom Lower This sensor monitors arm roll-in
pilot pressure. pilot pressure. pilot pressure.
Symptoms When output is 0 V or 5 V, the When output is 0 V or 5 V, the When output is 0 V or 5 V, the
in control following symtoms occur. following symtoms occur. following symtoms occur.
system when
trouble occurs
Symptoms Engine speed is difficult to Engine speed is difficult to Engine speed is difficult to
in machine increase when performing increase when performing increase when performing
operation digging operation. digging operation. digging operation.
when trouble Arm roll-in speed is slow during Boom lower speed is slow when Arm roll-in speed is slow during
occurs combined operation of arm roll- performing combined operation combined operation of arm roll-
in and boom raise. of swing, arm roll-in, and boom in and boom raise.
During boom raise single lower. Arm roll-in speed is fast during
operation, power is weak. arm level crowding operation.
Boom raise speed is slow during Attachment and boom raise
combined operation of swing, speed are slow when performing
arm roll-in, and boom raise. combined operation of arm roll-
in, boom raise, and attachment.
Evaluation by 11302 11998 11303
Fault Code
Evaluation by MC: Boom Raise Pilot Pressure MC: Bm Lower Pilot Pressure MC: Arm Roll-In Pilot Pressure
Monitoring
Evaluation - - -
by using Test
Harness
Note Possible to judge if pressure Possible to judge if pressure Possible to judge if pressure
sensor is faulty or port is clogged sensor is faulty or port is clogged sensor is faulty or port is clogged
by switching pressure sensor with by switching pressure sensor with by switching pressure sensor with
other pressure sensor. other pressure sensor. other pressure sensor.
Descriptions T2-2 T2-2 T2-2
of Control
(Operational
Principle
Section in
T/M)
T5-6-11
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Parts Pressure Sensor (Arm Roll-Out) Pressure Sensor (Bucket Roll-In) Pressure Sensor (Bucket Roll-Out)
Item
Function This sensor monitors arm roll-out This sensor monitors bucket roll- This sensor monitors bucket roll-
pilot pressure. in pilot pressure. out pilot pressure.
Symptoms When output is 0 V or 5 V, the When output is 0 V or 5 V, the When output is 0 V or 5 V, the
in control following symtoms occur. following symtoms occur. following symtoms occur.
system when
trouble occurs
Symptoms Engine speed is difficult to Engine Speed is difficult to Bucket speed is slow when
in machine increase when performing arm increase when performing performing light digging
operation roll-out operation. digging operation. operation.
when trouble Arm roll-out speed is slow. Bucket speed is slow when
occurs performing light digging
operation.
Evaluation by 11995 11325 11997
Fault Code
Evaluation by MC: Arm Roll-Out Pilot Pressure MC: Bucket Roll-In Pilot Pressure MC: Bucket Roll-Out Pilot Pressure
Monitoring
Evaluation - - -
by using Test
Harness
Note Possible to judge if pressure Possible to judge if pressure Possible to judge if pressure
sensor is faulty or port is clogged sensor is faulty or port is clogged sensor is faulty or port is clogged
by switching pressure sensor with by switching pressure sensor with by switching pressure sensor with
other pressure sensor. other pressure sensor. other pressure sensor.
Descriptions T2-2 T2-2 T2-2
of Control
(Operational
Principle
Section in
T/M)
T5-6-12
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Item
Function This sensor monitors travel pilot This sensor monitors swing pilot
pressure. pressure.
Symptoms When output is 0 V or 5 V, the When output is 0 V or 5 V, the
in control following symtoms occur. following symtoms occur.
system when
trouble occurs
Symptoms Even if the machine travels, When performing combined
in machine engine speed is kept at auto-idle operation of swing and boom
operation speed. raise, engine speed does not
when trouble Even if the machine travels with increase.
occurs the engine running at slow idle Boom raise speed is slow and
speed, engine speed does not arm roll-in speed is fast when
increase. performing combined operation
As the machine is kept to travel of swing, arm roll-in, and boom
at slow speed, speed does not raise.
change into fast. Swing speed acceleration
When performing combined becomes bad and swing
operation of attachment and operation at constant speed is
travel, the machine mistracks. slow.
Travel alarm (option) continues to Swing alarm (option) continues
sound. to sound.
Evaluation by 11304 11301
Fault Code
Evaluation by MC: Travel Pilot Pressure MC: Swing Pilot Pressure
Monitoring
Evaluation - -
by using Test
Harness
Note Possible to judge if pressure Possible to judge if pressure
sensor is faulty or port is clogged sensor is faulty or port is clogged
by switching pressure sensor with by switching pressure sensor
other pressure sensor. with other pressure sensor.
Descriptions T2-2 T2-2
of Control
(Operational
Principle
Section in
T/M)
T5-6-13
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Item
Function This sensor monitors control This sensor monitors control valve
valve 4-spool side pilot pressure. 5-spool side pilot pressure.
Symptoms When output is 0 V ro 5 V, the When output is 0 V ro 5 V, the
in control following symptoms occur. following symptoms occur.
system when
trouble occurs
Symptoms Boom operation speed is slow. Boom operation speed is slow.
in machine Arm operation speed is slow. Arm operation speed is slow.
operation Bucket operation speed is slow. Swing speed is slow. The machine
when trouble The machine mistracks. mistracks.
occurs
Evaluation by - -
Fault Code
Evaluation by MC: Signal C/V SA Port Pressure MC: Signal C/V SB Port Pressure
Monitoring
Evaluation 11945 11944
by using Test
Harness
Note Possible to judge if pressure Possible to judge if pressure
sensor is faulty or port is clogged sensor is faulty or port is clogged
by switching pressure sensor by switching pressure sensor with
with other pressure sensor. other pressure sensor.
Descriptions T2-2 T2-2
of Control
(Operational
Principle
Section in
T/M)
T5-6-14
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-15
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Item
Function This valve changes pump 1 This valve changes pump 2
displacement angle displacement angle
Symptoms High current: Pump 1 High current: Pump 2
in control displacement angle is held at displacement angle is held at
system when maximum. The engine stalls or maximum. The engine stalls or
trouble occurs engine lug-down is remarkable engine lug-down is remarkable at
at high loaded. high loaded.
Low current: Pump 1 Low current: Pump 2
displacement angle is held displacement angle is held
at minimum. Machine overall at minimum. Machine overall
operation is slow operation is slow.
Symptoms Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by 11951 11950
Fault Code
Evaluation by MC: Pump 1 (4 Units) P/S Output, MC: Pump 2 (5 Units) P/S Output,
Monitoring Pump 1 (4 Units) P/S O/P FB Pump 2 (5 Units) P/S O/P FB
Evaluation - -
by using Test
Harness
Note - -
Descriptions T2-2 T2-2
of Control
(Operational
Principle
Section in
T/M)
T5-6-16
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Parts Fan Speed Control Solenoid Valve Reverse Rotation Control Reverse Rotation Control
Solenoid Valve 1 (Option) Solenoid Valve 2 (Option)
Item
Function This fan controls fan rotation This fan controls fan rotation This fan controls fan rotation
speed. direction. direction.
Symptoms High current: The fan speed is High current: The fan rotation High current: The fan rotation
in control fixed to the minimum value. direction is fixed to the normal direction is fixed to the normal
system when Low current: The fan speed is direction. direction.
trouble occurs fixed to the maximum value. Low current: The fan rotation Low current: The fan rotation
direction is fixed to the normal direction is fixed to the normal
direction. direction.
Symptoms Same as shown above Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by 11412 11982 11981
Fault Code
Evaluation by MC: Fan Sp Cont P/S 2 O/P, Fan Sp MC: Fan Dir Cont P/S 1 O/P, Fan MC: Fan Sp Cont P/S 2 O/P, Fan Sp
Monitoring Cont P/S 2 O/P FB Dir Cont P/S 1 O/P FB Cont P/S 2 O/P FB
Evaluation - - -
by using Test
Harness
Note - - -
Descriptions T2-2 T2-2 T2-2
of Control
(Operational
Principle
Section in
T/M)
T5-6-17
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Parts 4-Spool Solenoid Valve Unit (SI) 4-Spool Solenoid Valve Unit (SG)
Item
Function This valve temporally increase This valve shifts selector valve of
main relief valve relief pressure. arm 2 flow rate control valve.
Symptoms High current: Pressure increases High current: As arm 2 flow rate
in control constantly. control valve (selector valve) is
system when Low current: Pressure does not restricted constantly, the arm
trouble occurs increase constantly. speed becomes slow.
Low current: As arm 2 flow rate
control valve (selector valve) is
opened constantly, operability
of arm combined operation
becomes worse.
Symptoms Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by 11948 11428
Fault Code
Evaluation by MC: Main Relief Boost Press MC: Arm 2 Flw Cont P/S Output,
Monitoring Output, Main Relief Boost Press Arm 2 Flw Cont P/S O/P FB
O/P FB
Evaluation Install light harness (ST 7226). Install light harness (ST 7226).
by using Test Check output signals from MC Check output signals from MC
Harness and wire harness condition. and wire harness condition.
Note - -
Descriptions T2-2 T2-2
of Control
(Operational
Principle
Section in
T/M)
T5-6-18
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Parts 4-Spool Solenoid Valve Unit (SC) 2-Spool Solenoid Valve Unit (SC) 2-Spool Solenoid Valve Unit (SI)
Item
Function This valve decreases angle of This valve shifts boom overload This valve shifts swing flow rate
travel motor to the minimum and relief valve. control valve.
increases travel speed.
Symptoms High current: Machine is kept to High current: Shifts boom High current: Shifts swing flow
in control travel at fast speed. overload relief selector valve rate control valve constantly.
system when Low current: Machine is kept to constantly. Machine cannot raise Swing speed becomes slow.
trouble occurs travel at slow speed. the track off the ground. Low current: As swing flow rate
Low current: Since boom control valve does not shift,
overload relief selector does not boom raise speed is slow when
shift, Machine may be able to performing combined operation
raise the track off the ground. of swing and boom raise.
Symptoms Same as shown above Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by 11405 11989 11953
Fault Code
Evaluation by MC: Travel Mode C/V Output, MC: Boom Mode Cont P/S O/P, MC: Swing Flw Cont P/S Output,
Monitoring Travel Mode C/V Output FB Boom Mode Cont P/S O/P FB Swing Flw Cont P/S O/P FB
Evaluation Install light harness (ST 7226). Install light harness (ST 7226). Install light harness (ST 7226).
by using Test Check output signals from MC Check output signals from MC Check output signals from MC
Harness and wire harness condition. and wire harness condition. and wire harness condition.
Note - - -
Descriptions T2-2 T2-2 T2-2
of Control
(Operational
Principle
Section in
T/M)
T5-6-19
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Item
Function This valve shifts bypass shut-out This valve prevent pressure
valve. in pump 1 and 2 circuits from
exceeding the set pressure when
the control lever is operated.
Symptoms High current: Machine mistracks If valve is stuck in fully
in control to the right when performing closed position, hose of front
system when travel operation. attachment may be damaged.
trouble occurs Low current: Bucket speed is If valve is stuck in fully open
slow when performing bucket position, power is weak when
single operation. performing digging and climbing
operation.
Symptoms Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by 11408 -
Fault Code
Evaluation by Bypass Cut Cout P/S, Bypass Cut -
Monitoring cout P/S FB
Evaluation Install light harness (ST 7226). -
by using Test Check output signals from MC
Harness and wire harness condition.
Note - -
Descriptions T2-2 T3-3
of Control
(Operational
Principle
Section in
T/M)
T5-6-20
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Parts Overload Relief Valve Boom Anti-Drift Valve Arm Anti-Drift Valve (Rod Side)
Item
Function This valve prevents actuator This valve forcibly opens the This valve forcibly opens check
circuit pressure generated by check valve in boom lower return valve in arm roll-in return circuit
external force from exceeding circuit and lowers boom, only and rolls arm in only when
the set pressure with the control when performing boom lower performing arm roll-in operation.
lever set in neutral. operation. The valve prevents The valve prevents arm from
boom from drifting due to oil drifting due to oil leaks in control
leaks in control valve. valve.
Symptoms If valve is stuck in fully If check valve is kept closed, If check valve is kept closed, arm
in control closed position, hose of front boom does not lower smoothly. roll-in speed becomes slow.
system when attachment may be damaged by If check valve is kept open, If check valve is kept open, front
trouble occurs external force. machine cannot be raised off the attachment drift increases due to
If valve is stuck in fully open ground. oil leaks in control valve.
position, power is weak when
performing digging operation.
Symptoms Same as shown above Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by - - -
Monitoring
Evaluation - - -
by using Test
Harness
Note - - -
Descriptions T3-3 T3-3 T3-3
of Control
(Operational
Principle
Section in
T/M)
T5-6-21
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Item
Function This valve supplies pressure oil to
both right and left travel spools
from pump 1 when performing
combined operation of travel and
front attachment/swing.
Symptoms If valve is stuck in fully closed
in control position, machine mistracks
system when to the left when performing
trouble occurs combined operation of travel and
front attachment/swing.
If valve is stuck in fully open
position, machine mistracks to
the right when performing travel
single operation.
Symptoms Same as shown above
in machine
operation
when trouble
occurs
Evaluation by -
Fault Code
Evaluation by -
Monitoring
Evaluation -
by using Test
Harness
Note -
Descriptions T3-3
of Control
(Operational
Principle
Section in
T/M)
T5-6-22
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Parts Arm Regenerative Valve Bucket Regenerative Valve Bucket Regeneration Cut Valve
Item
Function This valve supplies returning This valve supplies returning oilThis valve decreases pressure
oil from arm cylinder rod side from bucket cylinder rod side in bucket cylinder rod side
to bottom side and prevents to bottom side and prevents and improves digging force
cylinder hesitation. cylinder hesitation. when performing bucket roll-in
operation at heavy load.
Symptoms If valve is kept closed, arm If check valve is kept closed, If valve is stuck in fully closed
in control regeneration is not done and arm bucket digging speed becomes position, power is weak when
system when roll-in speed becomes slow. slow, or bucket cylinder performing bucket digging
trouble occurs If valve is kept open, oil from hesitation occurs. operation.
pump 2 flow back through arm If check valve is kept open, power If valve is stuck in fully open
2 spool, and arm roll-in speed is weak. position, bucket digging speed
becomes slow. becomes slow.
Symptoms Same as shown above Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by - - -
Monitoring
Evaluation - - -
by using Test
Harness
Note - - -
Descriptions T3-3 T3-3 T3-3
of Control
(Operational
Principle
Section in
T/M)
T5-6-23
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Parts Arm 1 Flow Rate Control Valve Arm 2 Flow Rate Control Valve Swing Flow Rate Control Valve
Item
Function This valve is shifted by swing pilot This valve is shifted by pilot This valve is shifted by pilot
pressure. The valve restricts arm pressure from 4-spool solenoid pressure from 2-spool solenoid
1 circuit and secures swing speed valve unit (SG). The valve valve unit (SI). The valve restricts
when performing combined restricts arm 2 circuit and keepsswig circuit and secures boom
operation of swing and arm roll- bucket speed when performing or arm speed when performing
in. combined operation of arm roll- combined operation of swing
in and bucket. and boom raise or swing and arm
roll-out.
Symptoms If poppet valve or selector valve is If poppet valve or selector valve is If poppet valve or selector valve
in control stuck in fully closed position, arm stuck in fully closed position, arm is stuck in fully closed position,
system when roll-in speed becomes slow. roll-in speed becomes slow. swing speed becomes slow.
trouble occurs If poppet valve or selector valve If poppet valve or selector valve If poppet valve or selector valve
is stuck in fully open position, is stuck in fully open position, is stuck in fully closed position,
swing speed becomes slow when bucket roll-in speed becomes boom raise or arm roll-out speed
performing combined operation slow when performing combined becomes slow when performing
of swing and arm roll-in. operation of arm roll-in and combined operation of swing
bucket roll-in. and boom raise or swing and arm
roll-out.
Symptoms Same as shown above Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by - - -
Monitoring
Evaluation - - -
by using Test
Harness
Note - - -
Descriptions T3-3 T3-3 T3-3
of Control
(Operational
Principle
Section in
T/M)
T5-6-24
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Parts Boom Flow Rate Control Valve Auxiliary Flow Combiner Valve Bypass Shut-Out Valve
(Option)
Item
Function This valve is shifted by boom This valve is shifted by pilot This valve is shifted by pilot
lower pilot pressure. It restricts pressure from auxiliary flow pressure from 4-spool solenoid
boom 1 circuit to prioritize other combiner solenoid valve (option). valve unit (SF) and increases
actuators. Supplies pressure oil from pump pressure of pump 2 circuit.
to auxiliary spool.
Symptoms If poppet valve or selector valve If valve is stuck in fully closed If valve is stuck in fully closed
in control is stuck in fully closed position, position, attachment speed does position, main relief valve (P2)
system when boom lower speed becomes not increase when performing continues to be relieved with all
trouble occurs fast when performing combined combined operation of control levers set in neutral.
operation. attachment.
If poppet valve or selector valve If valve is stuck in fully open
is stuck in fully open position, the position, travel speed becomes
track can not be raised off the slow when performing combined
ground. operation of attachment and
travel.
Symptoms Same as shown above Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by - - -
Monitoring
Evaluation - - -
by using Test
Harness
Note - - -
Descriptions T3-3 T3-3 T3-3
of Control
(Operational
Principle
Section in
T/M)
T5-6-25
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Parts Boom Lower Meter-In Cut Valve Travel Motor Displacement Angle Pump 1 Flow Rate Control Valve
Control Valve
Item
Function This valve is shifted by returning This valve is shifted by pilot This valve supplies flow rate
oil from boom cylinder bottom pressure from 5-spool solenoid control pressure Pi according to
side. The valve lowers boom valve unit (SC). The valve shifts lever stroke to pump 1 regulator
due to own weight by the travel speed. when operating boom, arm,
boom regenerative circuit bucket , travel (right).
when performing boom lower
operation above ground, and
gives priority to operate other
actuators. When machine is
raised off the ground, the valve
gives priority to operate boom
and increses the force to raise the
machine.
Symptoms If valve is stuck in fully closed If valve is stuck in fully closed If valve is stuck in fully closed
in control position, boom lower speed position, machine is kept to travel position, pump 1 displacement
system when becomes fast when performing at slow speed. angle is held at minimum
trouble occurs combined operation. If valve is stuck in fully open when operating control lever.
If valve is stuck in fully open position, machine travels at fast Travel (right) is not operated
position, machine cannot be speed with travel mode switch when performing travel single
raised off ground. set in slow speed position. operation. Bucket speed
becomes extremely slow.
If valve is stuck in fully open
position, pump 1 displacement
angle is held at maximum with
control lever in neutral. Machine
mistracks to the left when travel
control lever is operated at half
stroke. Pump 1 control pressure
sensor detects maximum
pressure.
Symptoms Same as shown above Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by - - -
Monitoring
Evaluation - - -
by using Test
Harness
Note - - -
Descriptions T3-3 T3-5 T3-6
of Control
(Operational
Principle
Section in
T/M)
T5-6-26
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Parts Pump 2 Flow Rate Control Valve Arm Flow Rate Control Valve Swing Parking Brake Release
Control Spool Spool
Item
Function This valve supplies flow rate This valve is shifted by arm roll-in This spool is shifted by pilot
control pressure according to pilot pressure. The valve supplies pressure of boom, arm, bucket or
pilot pressure to pressure sensor swing pilot pressure to arm 1 swing. The spool supplies release
when operating boom, arm, flow rate control valve in control pressure to swing parking brake.
swing and travel (left). valve.
Symptoms If valve is stuck in fully closed If valve is stuck in fully closed If spool is stuck in fully closed
in control position, pump 2 displacement position, swing speed is slow position, swing parking brake is
system when angle is held at minimum when performing combined kept applied. (Dragging is felt.)
trouble occurs when operating control lever. operation of swing and arm roll- Even if control lever is operated
Travel (left) is not operated in. at auto-idle control, engine speed
when performing travel single If valve is stuck in fully open does not increase as pressure
operation. position, swing speed is slow sensors (boom, arm, and bucket)
If valve is stuck in fully open when performing combined are always OFF.
position, pump 2 displacement operation of swing and arm roll- If spool is stuck in fully open
angle is held at maximum with out position, swing parking brake is
control lever in neutral. Machine kept released. (Machine vibrates
mistracks to the right when travel when traveling.) Even if control
control lever is operated at half lever is set to neutral with auto-
stroke. Pump 2 control pressure idle switch ON, engine speed
sensor detects maximum does not decrease as pressure
pressure. sensors (boom, arm, and bucket)
are always ON.
Symptoms Same as shown above Same as shown above Same as shown above
in machine
operation
when trouble
occurs
Evaluation by - - -
Fault Code
Evaluation by - - -
Monitoring
Evaluation - - -
by using Test
Harness
Note - - -
Descriptions T3-6 T3-6 T3-6
of Control
(Operational
Principle
Section in
T/M)
T5-6-27
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-28
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-29
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-30
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Parts
MC
ECM
Monitor Controller
Monitor
Key Switch
Engine Control Dial
Auto-Idle Switch
Power Mode Switch (ECO)
Travel Mode Switch
Pilot Shut-Off Relay
Starter Cut Relay
Security Relay
Auto Shut-Down Relay
ACC Cut Relay
Key Switch ON Cut Relay
ECM Main Relay
Engine Stop Switch
Fuse Box 1
Pilot Shut-Off Switch
MPDr.
Battery
Starter Relay 1
Battery Relay
Engine Unit
Starter
Overheat Switch
Coolant Temperature Sensor
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pump 1 Control Pressure Sensor
Pump 2 Control Pressure Sensor
Pressure Sensor (Boom Raise)
Pressure Sensor (Boom Lower)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Arm Roll-Out)
Pressure Sensor (Bucket Roll-In)
Pressure Sensor (Bucket Roll-Out)
Pressure Sensor (Swing)
Pressure Sensor (Travel)
Pressure Sensor (4-spool side)
Pressure Sensor (5-spool side)
Pressure Sensor (Attachment) (OP)
Remark
T5-6-31
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-32
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-33
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
A-4 A-5
Trouble Symptom
Travel (left) operation speed is slow Actuator does not stop even if
when performing travel single control lever is set to neutral.
Parts
operation.
MC
ECM
Monitor Controller
Key Switch
Engine Control Dial
Pilot Shut-Off Relay
Security Horn Relay
Starter Cut Relay
Security Relay
Key Switch ON Cut Relay
Fuse Box 1
Pilot Shut-Off Switch
Pilot Shut-Off Solenoid Valve
Hydraulic Oil Temperature Sensor
Battery
Starter Relay 1
Main Pump 1
Main Pump 2
Pilot Pump
Pump 1 Regulator
Pump 2 Regulator
Pump 1 Control Solenoid Valve
Pump 2 Control Solenoid Valve
Spool
Pilot Valve
Pump 1 Flow Rate Control Valve
Pump 2 Flow Rate Control Valve
Shuttle Valve (Signal Control Valve)
Pilot Filter
Pilot Relief Valve
Remark
T5-6-34
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-35
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-36
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-37
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-38
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
F-11 F-12
Trouble Symptom F-10
Front attachment drifts remarkably. Boom lower speed above ground Arm speed is slow when performing
is faster than other actuators when arm level crowding operation. Arm
performing combined operation. power is weak when performing
Machine cannot be raised off the digging operation.
Parts
ground.
MC
Power Mode Switch
Pilot Shut-Off Solenoid Valve
Main Pump 1
Main Pump 2
Pilot Pump
Pump 1 Regulator
Pump 2 Regulator
Pump 1 Delivery Pressure Sensor
Pump 2 Delivery Pressure Sensor
Pump 1 Control Solenoid Valve
Pump 2 Control Solenoid Valve
Main Relief Valve
Boom Anti-Drift Valve
Arm Anti-Drift Valve (Rod Side)
Arm Regenerative Cut Valve
Bucket Regenerative Valve
Bucket Regeneration Cut Valve
Arm 1 Flow Rate Control Valve
Arm 2 Flow Rate Control Valve
Bypass Shut-Out Valve
Boom Lower Meter-In Cut Valve
Boom Overload Relief Selection Valve
Load Check Valve
Spool
Pressure Sensor (Boom Raise)
Pressure Sensor (Boom Lower)
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Arm Roll-Out)
Pressure Sensor (Bucket Roll-In)
Pressure Sensor (Bucket Roll-Out)
Cylinder
Pilot Valve
Shockless Valve (Signal Control Valve)
Shuttle Valve (Signal Control Valve)
Pressure Sensor (Travel)
Pressure Sensor (Swing)
Pressure Sensor (4-Spool Side)
Pressure Sensor (5-Spool Side)
Swing Flow Rate Control Valve
4-Spool Solenoid Valve Unit (SG)
4-Spool Solenoid Valve Unit (SI)
4-Spool Solenoid Valve Unit (SF)
4-Spool Solenoid Valve Unit (SC)
2-Spool Solenoid Valve Unit (SC)
2-Spool Solenoid Valve Unit (SI)
Pilot Filter
Pilot Relief Valve
Remark
T5-6-39
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-40
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-41
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-42
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-43
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-44
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-45
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-46
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Check that the pilot shut-off lever is in the LOCK In case the radio with the key switch set in the ACC
position. position and the horn with the key switch set in
This trouble is not related to the electronic control the OFF position are operated normally, the wire
system such as MC. harness between battery and key switch terminal B
Check the wiring connections first. is considered normal.
TJAE-05-06-001
TJAE-05-06-002
b- Terminals
TJAE-05-06-004
TJAE-05-06-003
T5-6-47
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Check that the engine stop switch is in the OFF
position.
Check that fuses #8 and #17 are normal.
Check the wiring connections first.
T5-6-48
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Check the wiring connections first.
T5-6-49
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Specification Remark
(min−1)
Fast Idle Speed 1730±50
(ECO mode)
Preparation
In case other trouble symptoms occur, perform Pump 1, 2 control pressure sensors, pump 1, 2
troubleshooting of these troubles first. delivery pressure sensors are also related to the ECO
The sensors detect the conditions necessary to mode control. However, if these sensors fail, other
operate ECO mode. Therefore, if any of these sensors operating functions will be also affected.
fails, ECO mode becomes ineffective. Refer to SYSTEM/Control System/ECO Mode Control.
Check the wiring connections first.
MC-F Connector
TJBG-05-05-007
T5-6-50
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Specification Remark
(min−1)
Auto-Idle Speed 1180±50
Preparation
In case other trouble symptoms occur, perform Refer to SYSTEM/Control System/Auto-Idle Control.
troubleshooting of these troubles first. Check the wiring connections first.
Failure in pressure sensors (boom raise, boom lower,
arm roll-in, arm roll-out, bucket roll-in, bucket
roll-out, swing, travel, 4-spool side, 5-spool side,
attachment (option)) may related to malfunction of
the auto-idle control. However, if these sensors fail,
other operating functions will be also affected.
Preparation
Check the wiring connections first.
MC-F Connector
TJBG-05-05-007
T5-6-51
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Refer to SYSTEM/Control System and SYSTEM/
Electric System/Auto Shut-Down Control.
Check the wiring connections first.
T5-6-52
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
The pilot shut-off circuit may be faulty. Refer to SYSTEM/Electric System.
Even if the key switch is set to the START position Check the wiring connections first.
with the pilot shut-off lever in the UNLOCK position,
the starter does not rotate.
Even if the key switch is set to the START position
with the engine stop switch is in the ON position and
the pilot shut-off lever is in the UNLOCK position, the
starter rotates.
T5-6-53
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T1V1-05-04-003
TDC1-05-06-005
T5-6-54
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Specification Remark
(MPa)
Primary Pilot 3.9+1.0-0 Engine Control
Pressure Dial: Fast Idle
Preparation
Decrease of pump 1, 2 flow rate due to some reasons
or faulty pilot system (A-1) may cause this trouble.
Even if speed is satisfactory, in case power is weak,
refer to the troubleshooting for faulty main relief
valve (F-1).
Check the wiring connections first.
T5-6-55
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
The pump 1 flow rate is minimized due to some
reasons. Travel (right) and bucket, which are driven
by pressure oil from pump 1, move very slowly.
Refer to SYSTEM /Control System, Hydraulic System.
T5-6-56
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-57
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Stuck spool in the pilot valve or stuck main spool in
the control valve is suspected.
T5-6-58
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Check the wiring connections first.
T5-6-59
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-60
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-61
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
If operating speeds are extremely slow, pump control
may be faulty (A-3, A-4). Faulty pilot system may also
cause this trouble.
T5-6-62
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Refer to SYSTEM/Control System/Power Digging
Control and Auto-Power Lift Control.
Check the wiring connections first.
T5-6-63
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
When other actuators (travel and swing motors) are
operated normally, the pilot pump (primary pilot
pressure) is considered to be normal.
T5-6-64
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Refer to SYSTEM/Hydraulic System/Bucket
Regenerative Cut Circuit.
Check the wiring connections first.
T5-6-65
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Refer to SYSTEM/Control System/Boom Mode
Selector Control
Check the wiring connections first.
T5-6-66
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
In case other trouble symptoms occur, perform
troubleshooting of these troubles first.
Refer to SYSTEM/Hydraulic System/Swing Flow Rate
Control Circuit.
T5-6-67
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Refer to COMPONENT OPERATION/Control Valve
T5-6-68
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Refer to COMPONENT OPERATION/Control Valve
T5-6-69
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
(B)
When start to operate control lever, oil pressure
and flow rate from the pump is low. Therefore, if
the load check valve is faulty, the load on the boom (A)
cylinder is applied, the oil in the bottom side of the
boom cylinder flows back into the circuit through
the load check valve. Therefore, the boom cylinder is
temporarily retracted.
As oil pressure and flow rate from the pump is
low, if oil leaks from bottom side (A) to rod side
(B) due to faulty boom cylinder piston or cylinder
tube, the boom cylinder is temporarily retracted
when performing the initial stage of operation. The
T105-07-04-012
cylinder becomes the lack of force. The cylinder drift
increases in this case.
T5-6-70
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-71
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
The boom lower meter-in cut valve or boom flow
rate control valve may be faulty.
Refer to SYSTEM/Hydraulic System and COMPONENT
OPERATION/Control Valve.
In case boom lower single operation speed is slow,
also refer to F-8.
In case machine cannot be raised off the ground, also
check boom mode selector control (F-5).
T5-6-72
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Refer to SYSTEM/Hydraulic System/Arm Regenerative
Cut Circuit.
T5-6-73
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-74
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Specification Remark
(sec/3 rev)
Swing Speed 23.7±1.5 The bucket
should be empty
Preparation
Check whether the pilot system is faulty or the main
circuit is faulty.
If other functions (front attachment and travel) are
operated normally, the pilot pump (primary pilot
pressure) and pump flow rate control are considered
to be normal. If the pilot system is faulty, the cause
of trouble may exist in the circuit downstream of the
pilot valve.
T5-6-75
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Refer to SYSTEM/Control System/Swing High
Pressure Power Decrease Control.
T5-6-76
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
In case other trouble symptoms occur, perform
troubleshooting of these troubles first.
Refer to SYSTEM/Hydraulic System/Arm 1 Flow Rate
Control Circuit.
TJAA-05-07-002
T5-6-77
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Both right and left pilot valves, travel motors, and/or
control valve spools are unlikely to be faulty at the
same time.
If both travel systems are not operated, the pilot
system, which is applied to both side travel motors,
may be faulty. If the primary pilot pressure is lower
than specification, the front attachment operating
speed becomes slow as well. Refer to A-2.
If the fast travel mode cannot be selected, refer to
T-4.
T5-6-78
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
In only one side track does not rotate, the pilot valve,
Preparation
the control valve, the travel motor, or the center joint
Check that both side track sags are equally adjusted. may be faulty.
Faulty pump control will cause the machine to
mistrack. Refer to A-3 or A-4.
T5-6-79
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
TJAA-05-07-002
T5-6-80
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Refer to SYSTEM/Control System/Travel Motor
Displacement Angle Control.
Check the wiring connections first.
T5-6-81
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Check that the work lights are not broken.
Refer to SYSTEM/Electrical System.
Check the wiring connections first.
T5-6-82
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Check that the boom lights are not broken.
Refer to SYSTEM/Electrical System.
Check the wiring connections first.
T5-6-83
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Refer to SYSTEM/Electrical System.
Check the wiring connections first.
T5-6-84
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
The wiper is driven by electric power routed via the
When the front window is open, the wiper is not
relay circuit. The relay circuit is controlled by the
operated. Check that the front window is closed
wiper/light controller.
securely.
When the wiper is not operated, first check if the
When the washer is also not operated, check fuse #2.
wiper relay is activated. Next, check if electric power
is routed to the wiper motor.
3 T1V1-05-07-004
T5-6-85
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Refer to SYSTEM/Electrical System.
Check the wiring connections first.
T5-6-86
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Preparation
Refer to SYSTEM/Control System/Auto-Lubrication
Control.
Check the wiring connections first.
T5-6-87
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-88
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
Exchange Inspection
Exchange inspection method is a troubleshooting
method to find the trouble location by exchanging
the suspected part/component with another part /
component having identical characteristics.
Result:
In case abnormal pump 2 delivery pressure high voltage
(MC fault code 11202-3) is displayed, the pump 1 delivery
pressure sensor is considered to be faulty.
T5-6-89
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-90
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
T5-6-91
SECTION 5 TROUBLESHOOTING
Group 6 Troubleshooting B
TJAA-04-05-003
Lock Nut (1)
j : 10 mm 3- Emergency Valve
TJAA-05-07-001
T5-6-92
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
Outline
Configuration layout of the air conditioning system is The vents (operator’s front/rear vent, foot vent, and the
illustrated below. front window) can be simultaneously or independently
Either fresh or re-circulated air is induced into the air selected by air vent damper servo motor (1) in accordance
conditioner unit by operating fresh/re-circulated air with the set-ventilation mode.
damper servo motor (6). The front widow and operator’s front vents are manually
The induced air flows out of the vents through evaporator selectable. The air conditioning controller controls the
(5) or heater (15) by blower motor (11). Evaporator (5) is air conditioning system. The air conditioner controller
a device used to cool the air. Heater (15) is a device used controls the damper operation by corresponding to the
to warm the air. In the air conditioning system, after the job site conditions such as atmospheric and cab inside
refrigerant is compressed by the compressor, it is sent to air temperatures, coolant temperature, operator’s set-
evaporator (5) in which the refrigerant expands to cool temperature, and the set-ventilation mode. In addition,
the air. Heater (15) warms air by absorbing heat from the air conditioning controller displays the air conditioner
warmed engine coolant. The temperature is kept at the system operation status on the monitor.
set temperature by adjusting evaporator (5) and heater
(15).
8
7
1 5
10 9
2 3
16
TDAA-05-07-001
15 14 13 12 11
1- Air Vent Damper Servo Motor 6- Fresh/Re-circulated Air 9- Re-circulated Air Filter 13- Frost Sensor
2- Defroster Vent Damper Servo Motor 10- Re-circulated Air Induction 14- Air Mix Damper Servo Motor
3- Rear Vent 7- Re-circulated Air Temperature Port 15- Heater Core
4- Front Vent Sensor 11- Blower Motor 16- Foot Vent
5- Evaporator 8- Fresh Air Induction Port 12- Power Transistor
T5-7-1
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
Component Layout
1 2
3
4
5
6
7
10
8
TDAA-05-07-027
11
12
27
TJBA-05-07-001
14 13 TJBM-05-07-001
1- Solar Radiation Sensor 4- AUTO/OFF Switch / Blower 8- Air Conditioner Unit 13- Air Conditioner Condenser
2- Monitor Switch 9- Fresh Air Filter 14- Receiver Tank
3- Temperature Control Switch/ 5- Engine Control Dial 10- Air Conditioner Controller 27- Compressor
Mode Switch 6- Key Switch 11- Ambient Temperature Sensor
7- Monitor Controller 12- High/Low Pressure Switch
T5-7-2
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
19
18
17
16
15
20
21
22
23
24
25
TDAA-05-07-028
26
15- Re-circulated Air Filter 18- Fresh/Re-circulated Air 21- Heater Core 25- Power Transistor
16- Compressor Relay Damper Servo Motor 22- Air Mix Damper Servo Motor 26- Blower Motor
17- Re-circulated Air Temperature 19- Frost Sensor 23- Air Vent Damper Servo Motor
Sensor 20- Evaporator 24- Blower Motor Relay
T5-7-3
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
Controller
The controller controls the air conditioning system. The
controller has the following functions.
The operator’s instructions are input by the switches.
The air and coolant temperature are detected by the
sensors.
Input the air conditioner unit conditions.
The blower motor and compressor are controlled by
operating the relays.
The air conditioner operating conditions are TDC1-05-07-002
displayed on the monitor panel.
TDC1-05-07-003
T5-7-4
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
T5-7-5
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
TDC1-05-07-011
T5-7-6
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
T5-7-7
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
T5-7-8
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
Troubleshooting
IMPORTANT:
When replacing the compressor due to the
breakage of compressor from internal lock,
sufficiently clean the air conditioner circuit or
replace all the parts.
When cleaning is insufficient or all the parts are
not replaced, the air conditioner may be broken
due to contaminants remaining in the circuit.
Using deteriorated LLC (coolant) or low-
concentration LLC, the heater core will receive
a bad influence and it may lead water leaks
and shorten the service life of machine.
Replace coolant and manage LLC concentration
according to the Operator's Manual.
fNOTE: The fault code of the air conditioner controller
is displayed only on the monitor. It is not displayed on
MPDr..
T5-7-9
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
T5-7-10
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
T5-7-11
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
T5-7-12
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
(Blank)
T5-7-13
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
Condition:
Fault code: Un-displayed
Airflow volume: faulty
Blower motor Normal speed Clogged re-circulated air filter Filter cleaning
rotates Clogged fresh air filter Filter cleaning
Obstacles are found in inlet area Remove obstacles
Deformation or breakage of blower Replace the blower
Frosted evaporator Go to A
Adhered dirt on evaporator surface Evaporator surface cleaning
Slow speed Power source voltage decreases Check the battery charging
system
Poor battery terminal contact Repair
Faulty blower motor Replace
Faulty power transistor Replace
Blower motor Faulty blower motor relay Replace
does not rotate Faulty blower motor Replace
Faulty power transistor Replace
Blower interferes with case Repair
Faulty controller Replace the controller
Faulty ground in body Make sure to ground
Faulty wire harness, disconnection of connector Check the wire harness
Blowout of power transistor thermal fuse due to locked motor Replace the motor
Blowout of fuse Replace with the Blower motor is locked Replace the blower motor
same capacity fuse Faulty wire harness Refer to wire harness
diagram and check
Short circuit Check the wire harness
T5-7-14
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
A: Frosted evaporator
Frosted evaporator Stop air conditioner and melt ice
With voltage applied to Faulty magnet clutch Check of clutch circuit Replace the clutch relay
magnet clutch circuit
Faulty wire harness of Short circuit check Repair
frost sensor
Faulty frost sensor Characteristic check Replace the frost
characteristics sensor.
Frost sensor is out Reinsert (floating distance from evaporator is 3
of evaporator (faulty mm or less)
sensitivity)
No voltage applied to magnet clutch Faulty magnet clutch Replace the magnet
clutch
T5-7-15
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
Condition:
Fault Code: Un-displayed
Airflow volume: Normal
Compressor: Compressor rotates normally
Compressor pressure: Normal
Fresh air enters Close the window and door.
Readjust the fresh/re-circulated
air selection damper.
Disconnection of Air Set the link again.
Mix link
T5-7-16
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
(Blank)
T5-7-17
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
Condition:
Fault Code: Un-displayed
Airflow volume: Normal
Compressor: Compressor rotates normally
Compressor pressure: Abnormal
Pressure on low- Overcharge of air Remove refrigerant thoroughly and recharge refrigerant to proper
pressure side is too conditioner with refrigerant level after purging
high (approx. 0.29 Faulty compressor Breakage of head gasket Replace the compressor.
MPa or more) Breakage of inlet valve Replace the compressor.
Foreign matter is caught in inlet Replace the compressor.
valve
Excessive open of Faulty valve Replace the valve.
expansion valve
Pressure on high- Abnormally low ambient temperature
pressure side is too Lack of refrigerant To B
low (pressure is not Faulty compressor Swash plate shoe is locked Replace the compressor.
approx. 0.98 MPa or Piston is locked Replace the compressor.
more) Faulty suction discharge valve Replace the compressor.
Faulty expansion valve Clogged valve (foreign matter) Replace the valve
Temporary clogged due to freezing Thoroughly perform purging
valve (moisture in the system) after replacing valve and
receiver.
Pressure on low- Abnormally low ambient temperature
pressure side is too Lack of refrigerant Go to B
low (pressure is Clogged in refrigeration cycle Go to C
approx. 0.05 MPa or Faulty expansion valve Go to D
less) Frosted evaporator Go to A
Pressure is high on Lack of condenser cooling Clogged fin with dirt or mud Cleaning of fin (washing)
both sides of high- Overcharge of air Discharge refrigerant thoroughly and recharge refrigerant to proper
pressure and low- conditioner with refrigerant level after purging.
pressure
Pressure is low on Lack of refrigerant
both sides of high-
pressure and low-
pressure
T5-7-18
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
A: Frosted evaporator
Frosted evaporator Stop air conditioner and melt ice.
With voltage applied to Faulty magnet clutch Check of clutch circuit Replace the clutch relay
magnet clutch circuit
Faulty wiring of frost Short circuit check Repair
sensor
Faulty frost sensor Characteristic check Replace the frost sensor
characteristics
Frost sensor is out Reinsert (floating distance from evaporator is 3
of evaporator (faulty mm or less)
sensitivity)
No voltage applied to magnet clutch Faulty magnet clutch Replace the magnet
clutch.
B: Lack of refrigerant
Lack of refrigerant Lack of refrigerant quantity Charge refrigerant to proper level.
Gas leak Check leak and charge with refrigerant
after repairing faulty.
T5-7-19
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
Condition:
Fault Code: Un-displayed
Airflow volume: Normal
Compressor: Compressor does not rotate normally
Broken V belt or slipping Replace V belt.
Faulty compressor (locked) Replace
Faulty magnet Repair or Open circuit in stator coil Replace
clutch replace Air gap between rotor and stator is too large Repair or
Replacement
Clutch slipping Slip caused by key breakage or inserting no key Replace the key.
Greasy clutch surface Remove oil.
Layer short of coil Replace
Battery voltage drop Charge
Caught foreign matter between rotor and stator Overhaul
Clutch does Check Faulty controller Replace the
not operate wiring controller.
due to faulty Faulty compressor clutch relay Replace
electrical Faulty frost sensor Replace
system Faulty high/low refrigerant pressure switch Replace
Abnormal high Too high Abnormally high ambient temperature
pressure (2.54 MPa or Lack of Clogged fin with Cleaning of fin
more) condenser dirt or mud (washing)
cooling
Overcharge air Discharge refrigerant thoroughly and
conditioner with recharge refrigerant to proper level
refrigerant after purging.
Air mixed in Discharge refrigerant thoroughly and
refrigeration recharge refrigerant to proper level
cycle after purging.
Too low Abnormally low ambient temperature
(0.98 MPa or Lack of refrigerant Go to B
less) Clogged during refrigeration cycle Go to C
Faulty expansion valve Go to D
Frosted evaporator Go to A
T5-7-20
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
A: Frosted evaporator
Frosted evaporator Stop air conditioner and melt ice.
With voltage applied to Faulty magnet clutch Check of clutch circuit Replace the clutch relay
magnet clutch circuit
Faulty wiring of frost Short circuit check Repair
sensor
Faulty frost sensor Characteristic check Replace the frost sensor
characteristics
Frost sensor is out Reinsert (floating distance from evaporator is 3
of evaporator (faulty mm or less).
sensitivity)
No voltage applied to magnet clutch Faulty magnet clutch Replace the magnet
clutch.
B: Lack of refrigerant
Lack of refrigerant Lack of refrigerant quantity Charge refrigerant to proper level.
Gas leak Check leak and charge with refrigerant
after repairing faulty.
T5-7-21
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
Condition:
Fault Code: 44 (Abnormal air mix damper servo motor)
Faulty wiring, open Wirings inspection
circuit, disconnection of
connector
Faulty servo motor Replace
Caught foreign matter Remove foreign matter.
Condition:
Fault Code: 51 (Abnormal high/low refrigerant pressure)
High pressure cut is Abnormally high ambient temperature
operated Lack of condenser Clogged fin with dirt or mud Cleaning of fin (washing)
cooling
Overcharge air Discharge refrigerant thoroughly and recharge refrigerant to
conditioner with proper level after purging
refrigerant
Air mixed in refrigeration Discharge refrigerant thoroughly and recharge refrigerant to
cycle proper level after purging
Low pressure cut is Abnormally low ambient temperature
operated Lack of refrigerant Lack of refrigerant quantity Charge refrigerant to proper
level.
Gas leak Check leak and charge with
refrigerant after repairing faulty.
Faulty compressor Swash plate shoe is locked Replace the compressor.
Piston is locked Replace the compressor.
Faulty suction discharge valve Replace the compressor.
Faulty expansion valve Clogged valve (foreign matter) Replace the valve.
Temporary clogged due to Thoroughly perform purging
freezing valve (moisture in the after replacing valve and
system) receiver.
T5-7-22
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
(Blank)
T5-7-23
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
Condition:
Fault code: Un-displayed
Faulty air flow Blower motor Normal speed Clogged re-circulated air filter Filter cleaning
volume rotates. Clogged fresh air filter Filter cleaning
Obstacles are found in inlet area Remove obstacles.
Deformation or breakage of blower Replacement of blower
Frosted evaporator Go to A
Adhered dirt on evaporator surface Evaporator surface
cleaning
Slow speed Power source decreases. Check battery charging
system.
Poor battery terminal contact Repair
Faulty blower motor Replace
Faulty power transistor Replace
Blower motor Blowout of fuse Replace with the Blower motor is Replace the blower
does not rotate. same capacity fuse, locked, motor.
Faulty wire harness Refer to wire harness
diagram and check.
Short circuit Check the wire harness.
Faulty blower motor relay Replace
Faulty blower motor Replace
Faulty power transistor Replace
Blower interferes with case Repair
Faulty controller Replace the controller.
Faulty ground in body Make sure to ground.
Faulty wire harness, disconnection of connector Check the wire harness.
Blowout of power transistor thermal fuse due to locked Replace the motor.
motor
Air flow volume Coolant temperature is low.
is normal Coolant Disconnection of air mix damper link Set the link again.
temperature is Air incorporation in hot-water circuit Bleed air from the circuit.
normal. Clogging, breakage, and bending of piping Repair or replace
Extremely low ambient temperature
Lack of engine coolant Charge engine coolant
to proper level.
Broken heater core Replace the heater core.
T5-7-24
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
A: Frosted evaporator
Frosted evaporator Stop air conditioner and melt ice
With voltage applied to Faulty magnet clutch Check of clutch circuit Replace the clutch
magnet clutch circuit relay.
Faulty wiring of frost Short circuit check Repair
sensor
Faulty the frost sensor Characteristic check Replace the frost
characteristics sensor.
Frost sensor is out Reinsert (floating distance from evaporator is 3
of evaporator (faulty mm or less)
sensitivity)
No voltage applied to magnet clutch Faulty magnet clutch Replace the magnet
clutch.
T5-7-25
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
Condition:
Fault Code: 44 (Abnormal air mix damper servo motor)
Caught foreign matter Remove foreign
matter.
Faulty wire harness, open circuit, Check the wire
disconnection of connector harness.
Faulty air mix damper servo motor Replace
T5-7-26
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
Others
T5-7-27
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
Noise
Related parts of case Louver resonance Repair or replace.
Related parts of blower fan motor Fan contacts case, Foreign matter Remove foreign matter. Readjust fan
enters case motor location.
Brush friction noise, metal and/or Slight noise is unavoidable. Replace if
thrust washer contact loud.
Gas blowing sound (roaring) Gas vibration noise (compressor No functional problem exists.
discharge and/or suction gas noise)
Expansion valve connection, Whistle Abnormal noise from expansion Replace expansion valve if whistle
sound, Gas blowing sound. valve, Expansion valve is normally sound is heard. Gas flow noise can be
functioning slightly heard.
Clutch disengaging sound Faulty clutch bearing, and/or idle Replace
pulley bearing
Contact of clutch amature due to Repair or replace the clutch. Re-tighten
resonance. Loose belt, Loose screws screws.
Compressor rotating sound Noisy compressor Repair or replace
Vibration due to V belt looseness, Re-adjust the belt. Re-tighten screws.
Loose screws
Others
Water leak, Water splash Broken heater core, Broken hose Replace
Clogged case drain port and/or drain Clean
hose
Abnormal smell Absorbed cigarette and dust smell on Clean the evaporator. When humidity
evaporator fins is high, open door. While rotating fan
at approx. 1500 min-1 in L mode for
more than 10 minutes, flush smell out
by condensed water.
T5-7-28
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
(Blank)
T5-7-29
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
TDC1-05-07-014 TDAB-05-07-027
Power Transistor
TDAB-05-07-028
T5-7-30
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
TDAB-05-07-019 TDAB-05-07-024
T5-7-31
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
Condition:
Engine Speed: 1500 min-1
Cab Window: Fully Open
Air Conditioner: ON
Airflow volume: Maximum
Temperature Control Switch: Maximum cool
Fresh/re-circulated air selection: Re-circulated Air
Air conditioner inlet temperature: 30 to 35 °C
1. In normal
Low-pressure side pressure: 0.15 to 0.25 MPa
High-pressure side pressure: 1.37 to 1.57 MPa
f NOTE: The reading of manifold gauge may depend on
conditions.
TDAA-05-07-018
TDAA-05-07-019
T5-7-32
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
TDAA-05-07-024
TDAA-05-07-025
T5-7-33
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
T5-7-34
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
1 2
TDAA-05-07-015
T5-7-35
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
2. Metal corrosion
If air remains in the air conditioner circuit, a chemical
reaction between refrigerant and moisture in the
air takes place, and as a result, hydrochloric acid is
produced. Hydrochloric aid corrodes metals such as
aluminum, copper and iron.
W115-02-10-002
W115-02-10-003
T5-7-36
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
W115-02-10-005
W115-02-10-005
T5-7-37
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
W115-02-10-005
4. With high pressure valve (2) and low pressure valve
(7) on manifold gauge (1) closed, connect charge
hose (5) to refrigerant container (8). 7 1
Refrigerant
Specification Part No. Volume (g)
R134a 4333767 200 2
4454005 250
4351827 300
8
5. Open valve (9) of refrigerant container (8). Push air
bleed valve (10) on manifold gauge (1) to purge
W115-02-10-007
air in charge hose (5) with the refrigerant pressure.
When draining refrigerant, immediately release air
bleed valve (10).
10 1
5
9
W115-02-10-007
T5-7-38
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
IMPORTANT:
Always stop the engine when charging the air
conditioner with refrigerant.
Do not position the refrigerant container upside
down during charging operation.
When changing the refrigerant container during
charging operation, be sure to perform the
procedure in step 10.
Charge the low-pressure side hose first.
6. Fully tighten charge hose (5) to manifold gauge
(1). Open high pressure valve (2) and valve (9) of
refrigerant container (8). Charge with refrigerant
(R134a). Close high pressure valve (2) and valve
(9) of refrigerant container (8) when high pressure
gauge (11) reading reaches 98 kPa. W115-02-10-008
11
2
5
9
W115-02-10-007
T5-7-39
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
W115-02-10-007
IMPORTANT: Do not open high pressure valve (2) on
manifold gauge (1).
9. Open low pressure valve (7) on manifold gauge (1)
1
and valve (9) of refrigerant container (8) to charge
with refrigerant. 7
T5-7-40
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
T5-7-41
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
Warm-up Operation
After charging air conditioner with specified volume
of refrigerant, carry out warm-up operation for five
minutes to lubricate system with compressor oil.
Inspection
After warm-up operation, carry out gas leak check and
performance check.
W115-02-10-014
T5-7-42
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
T5-7-43
SECTION 5 TROUBLESHOOTING
Group 7 Air Conditioner
TDAA-05-07-017
T5-7-44
MEMO
MEMO
Hitachi Construction Machinery Co., Ltd. Hitachi Ref. No.
Attn: Technical Information Center
Tel: 81-29-832-7084
Fax: 81-29-831-1162
E-mail: HCM-TIC-GES@hitachi-kenki.com
REPLY:
2. CONNECTORS
3. CAB HARNESS
MAIN HARNESS
4. ENGINE HARNESS
PUMP HARNESS
6. MONITOR HARNESS
KEY SWITCH HARNESS
11. BOOM MODE SWITCH AND SEAT HEATER SWITCH HARNESS (OPTION)