Hitachi Wheel Type Excavator Troubleshooting Manual PDF

INTRODUCTION
TO THE READER
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX: 81-29-831-1162
E-mail: dc@hitachi-kenki.com
• This manual contains the revision information
to the 13, July 2009.
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 and the • Information included in the Workshop Manual:
Workshop Manual. technical information needed for maintenance
and repair of the machine, tools and devices
• Information included in the Technical Manual: needed for maintenance and repair, maintenance
technical information needed for redelivery and standards, and removal/installation and assem-
delivery, operation and activation of all devices ble/disassemble procedures.
and systems, operational performance tests, and
troubleshooting 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 : T 1-3-5
Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • CAUTION:

signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
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.
• NOTE:
To avoid injury and damage, be sure to use appropri-
Indicates supplementary technical information or
ate lifting techniques and equipment when lifting
know-how.
heavy parts.
UNITS USED
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION

• These are the SAFETY ALERT SYMBOLS.
• When you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
• Follow recommended precautions and safe operating
practices.
001-E01A-0001
SA-688
UNDERSTAND SIGNAL WORDS

• On machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or CAUTION
- are used with the safety alert symbol.
• DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
• WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
• CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
• DANGER or WARNING safety signs are located near spe-
cific hazards. General precautions are listed on CAUTION
safety signs.
• Some safety signs don’t use any of the designated signal
words above after the safety alert symbol are occasionally
used on this machine.
• To avoid confusing machine protection with personal safety

messages, a signal word IMPORTANT indicates a situation
which, if not avoided, could result in damage to the ma- SA-1223
chine.
• NOTE indicates an additional explanation for an element

of information.
002-E01A-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS

• Carefully read and follow all safety signs on the machine
and all safety messages in this manual.
• Safety signs should be installed, maintained and replaced
when necessary.
• If a safety sign or this manual is damaged or missing,
order a replacement from your authorized dealer in the
same way you order other replacement parts (be sure to
state machine model and serial number when ordering).
• Learn how to operate the machine and its controls correctly
and safely.
• Allow only trained, qualified, authorized personnel to oper- SA-003
ate the machine.
• Keep your machine in proper working condition.
• Unauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
• Do not modify any machine parts without authorization.
Failure to do so may deteriorate the part safety, func-
tion, and/or service life. In addition, personal accident,
machine trouble, and/or damage to material caused by
unauthorized modifications will void Hitachi Warranty
Policy.
• Do not use attachments and/or optional parts or equip-
ment not authorized by Hitachi. Failure to do so may
deteriorate the safety, function, and/or service life of the
machine. In addition, personal accident, machine trouble,
and/or damage to material caused by using unauthorized
attachments and/or optional parts or equipment will void
Hitachi Warranty Policy.
• The safety messages in this SAFETY chapter are intended to
illustrate basic safety procedures of machines. However it is
impossible for these safety messages to cover every hazard-
ous situation you may encounter. If you have any questions,
you should first consult your supervisor and/or your autho-
rized dealer before operating or performing maintenance
work on the machine.
003-E01B-0003
SA-2
SAFETY
PREPARE FOR EMERGENCIES

• Be prepared if a fire starts or if an accident occurs.
• Keep a first aid kit and fire extinguisher on hand.
• Thoroughly read and understand the label attached on
the fire extinguisher to use it properly.
• To ensure that a fire-extinguisher can be always used
when necessary, check and service the fire-extinguisher
at the recommended intervals as specified in the fire-
extinguisher manual.
• Establish emergency procedure guidelines to cope with
fires and accidents.
• Keep emergency numbers for doctors, ambulance service,
SA-437
hospital, and fire department posted near your tele-
phone.
004-E01A-0437
WEAR PROTECTIVE CLOTHING

• Wear close fitting clothing and safety equipment appropri-
ate to the job.
You may need:

A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavy gloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing for the
job. Do not take any chances.
• Avoid wearing loose clothing, jewelry, or other items that

can catch on control levers or other parts of the machine.
• Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating the machine.
005-E01A-0438
PROTECT AGAINST NOISE

• Prolonged exposure to loud noise can cause impairment or
loss of hearing.
• Wear a suitable hearing protective device such as ear-
muffs or earplugs to protect against objectionable or
uncomfortably loud noises.
006-E01A-0434
SA-434
SA-3
SAFETY
INSPECT MACHINE
• Inspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
• In the walk-around inspection be sure to cover all points
described in the “PRE-START INSPECTION” chapter in the
operator’s manual.
007-E01A-0435 SA-435
GENERAL PRECAUTIONS FOR CAB

• Before entering the cab, thoroughly remove all dirt and/
or oil from the soles of your work boots. If any controls
such as a pedal is operated while with dirt and/or oil on
the soles of the operator’s work boots the operator’s foot
may slip off the pedal, possibly resulting in a personal ac-
cident.
• Do not leave parts and/or tools lying around the operator’
s seat. Store them in their specified locations.
• Avoid storing transparent bottles in the cab. Do not at-
tach any transparent type window decorations on the
windowpanes as they may focus sunlight, possibly start-
ing a fire.
• Refrain from listening to the radio, or using music head-
phones 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 tem-
perature in the cab increases, the lighter may explode.
524-E01A-0000
SA-4
SAFETY
USE HANDHOLDS AND STEPS

• Falling is one of the major causes of personal injury.
• When you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount or dis-
mount a moving machine.
• Be careful of slippery conditions on platforms, steps, and
handrails when leaving the machine.
SA-439
008-E01A-0439
ADJUST THE OPERATOR'S SEAT

• A poorly adjusted seat for either the operator or for the
work at hand may quickly fatigue the operator leading to
misoperations.
• The seat should be adjusted whenever changing the op-
erator for the machine.
• The operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
• If not, move the seat forward or backward, and check
again.
• Adjust the rear view mirror position so that the best rear
SA-378
visibility is obtained from the operator’s seat. If the mirror
is broken, immediately replace it with a new one.
009-E01A-0462
ENSURE SAFETY BEFORE RISING FROM OR LEAV-

ING OPERATOR’S SEAT
• Before rising from the operator’s seat to open/close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with a
control lever, possibly resulting in serious personal injury or
death.
• 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-5
SAFETY
FASTEN YOUR SEAT BELT

• If the machine should overturn, the operator may become
injured and/or thrown from the cab. Additionally the opera-
tor may be crushed by the overturning machine, resulting in
serious injury or death.
• Prior to operating the machine, thoroughly examine web-
bing, buckle and attaching hardware. If any item is dam-
aged or worn, replace the seat belt or component before
operating the machine.
• Be sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to
minimize the chance of injury from an accident. SA-237
• We recommend that the seat belt be replaced every three

years regardless of its apparent condition.
010-E01A-0237
MOVE AND OPERATE MACHINE SAFELY

• Bystanders can be run over.
• Take extra care not to run over bystanders. Confirm the
location of bystanders before moving, swinging, or oper-
ating the machine.
• Always keep the travel alarm and horn in working condi-
tion (if equipped). It warns people when the machine
starts to move.
• Use a signal person when moving, swinging, or operating
the machine in congested areas. Coordinate hand signals
before starting the machine. SA-083
• Use appropriate illumination. Check that all lights are op-
erable before operating the machine. If any faulty illumi-
nation is present, immediately repair it.
011-E01A-0398
HANDLE STARTING AIDS SAFELY

Starting fluid:
• Starting fluid is highly flammable.

• Keep all sparks and flame away when using it.
• Keep starting fluid well away from batteries and cables.
• Remove container from machine if engine does not need
starting fluid.
• To prevent accidental discharge when storing a pressur-
ized container, keep the cap on the container, and store it
in a cool, well-protected location.
• Do not incinerate or puncture a starting fluid container.
SA-293
036-E01A-0293-3
SA-6
SAFETY
OPERATE ONLY FROM OPERATOR'S SEAT

• Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.
• Start the engine only when seated in the operator's seat.
• NEVER start the engine while standing on the track or on
ground.
• Do not start engine by shorting across starter terminals.
• Before starting the engine, confirm that all control levers
are in neutral.
• Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders.
SA-084
012-E01B-0431
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” chap-
ter 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
S013-E01A-0032
KEEP RIDERS OFF MACHINE

• Riders on machine are subject to injury such as being struck
by foreign objects and being thrown off the machine.
• Only the operator should be on the machine. Keep riders
off.
• Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.
014-E01B-0427
SA-091
SA-7
SAFETY
PRECAUTIONS FOR OPERATIONS

• Investigate the work site before starting operations.
• Be sure to wear close fitting clothing and safety equip-
ment appropriate for the job, such as a hard hat, etc.
when operating the machine.
• Clear all persons and obstacles from area of operation and
machine movement.
Always beware of the surroundings while operating.
When working in a small area surrounded by obstacles,
take care not to hit the upperstructure against obstacles.
• When loading onto trucks, bring the bucket over the truck
beds from the rear side. Take care not to swing the bucket
over the cab or over any person.
M202-05-014
SA-8
SAFETY
INVESTIGATE JOB SITE BEFOREHAND

• When working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
• Investigate the configuration and ground conditions of
the job site beforehand to prevent the machine from fall-
ing and to prevent the ground, stockpiles, or banks from
collapsing.
• Make a work plan. Use machines appropriate to the work
and job site.
• Reinforce ground, edges, and road shoulders as necessary.
Keep the machine well back from the edges of excava-
tions and road shoulders.
• When working on an incline or on a road shoulder, em- SA-085
ploy a signal person as required.
• Confirm that your machine is equipped a FOPS cab before
working in areas where the possibility of falling stones or
debris exist.
• When the footing is weak, reinforce the ground before
starting work.
• When working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
• Beware the possibility of fire when operating the machine
near flammable objects such as dry grass.
• Make sure the worksite has sufficient strength to firmly sup-
port the machine.
When working close to an excavation or at road shoulders,
operate the machine with the tracks positioned perpendicu-
lar 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 a soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm M202-05-015
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
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 ma-
chine movements.
SA-9
SAFETY
EQUIPMENT OF HEAD GUARD, ROPS, FOPS

In case the machine is operated in areas where the possibility
of falling stones or debris exist, equip a head guard, ROPS, or
FOPS according to the potential hazardous conditions. (The
standard cab for this machine corresponds to ROPS and FOPS.)
ROPS: Roll-Over Protective Structure

FOPS: Falling Object Protective Structure
SA-686
PROVIDE SIGNALS FOR JOBS INVOLVING MUL-

TIPLE NUMBERS OF MACHINES
• For jobs involving multiple numbers of machines, provide
signals commonly known by all personnel involved. Also,
appoint a signal person to coordinate the job site. Make
sure that all personnel obey the signal person’s directions.
018-E01A-0481
SA-481
CONFIRM DIRECTION OF MACHINE TO BE DRIVEN

• Incorrect steering wheel/forward/reverse pedal operation
may result in serious injury death.
• Before driving the machine, confirm the position of the
undercarriage in relation to the operator’s position. If the
travel motors are located in front of the cab, the machine
will move in reverse when steering wheel is operated to
the front.
SA-092
017-E01A-0491
SA-10
SAFETY
DRIVE MACHINE SAFELY

• Before driving the machine, always confirm that the steer-
ing wheel/forward/reverse switch direction corresponds to
the direction you wish to drive.
• Be sure to detour around any obstructions.
• Avoid traveling over obstructions. Soil, fragments of rocks,
and/or metal pieces may scatter around the machine. Do
not allow personnel to stay around the machine while
traveling.
• Driving on a slope may cause the machine to slip or over-

SA-090
turn, possibly resulting in serious injury or death.
• Never attempt to ascend or descend 35 degrees or steep-
er slopes.
• Be sure to fasten the seat belt.
• When driving up or down a slope, keep the bucket fac-
ing the direction of travel, approximately 0.5 to 1.0 m (A)
above the ground.
• If the machine starts to skid or becomes unstable, imme-
diately lower the bucket to the ground and stop.
SA-288
AVOID INJURY FROM ROLLAWAY ACCIDENTS

• Death or serious injury may result if you attempt to mount
or stop a moving machine.
To avoid rollaways:
• Select level ground when possible to park machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the ground.
• Place FNR switch in neutral, and put the brake switch in
the P (parking brake) position.
• Turn the auto-idle switch off.
• Run the engine at slow idle speed without load for 5 min-
utes to cool down the engine.
• Stop the engine and remove the key from the key switch.
• Pull the pilot control shut-off lever to LOCK position.
• Block both tires and lower the bucket to the ground.
Thrust the bucket teeth into the ground if you must park
on a grade.
SA-278
• Position the machine to prevent rolling.
• Park a reasonable distance from other machines.
020-E02A-0493
SA-11
SAFETY
AVOID INJURY FROM BACK-OVER AND SWING

ACCIDENTS
• If any person is present near the machine when backing or
swinging the upperstructure, the machine may hit or run
over that person, resulting in serious injury or death.
To avoid back-over and swing accidents:
• Always look around BEFORE YOU BACK UP AND SWING
THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE
CLEAR.
• Keep the travel alarm in working condition (if equipped).
ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE
WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN
BYSTANDERS BEFORE MOVING MACHINE.
• USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW SA-383
IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN
VIEW.
Use hand signals, which conform to your local regulations,
when work conditions require a signal person.
• No machine motions shall be made unless signals are
clearly understood by both signalman and operator.
• Learn the meanings of all flags, signs, and markings used
on the job and confirm who has the responsibility for
signaling.
• Keep windows, mirrors, and lights clean and in good con-
dition.
• Dust, heavy rain, fog, etc., can reduce visibility. As visibility SA-384
decreases, reduce speed and use proper lighting.

• Read and understand all operating instructions in the
021-E01A-0494
SA-12
SAFETY
KEEP PERSON CLEAR FROM WORKING AREA
• A person may be hit severely by the swinging front attach-
ment or counterweight and/or may be crushed against an
other object, resulting in serious injury or death.
• Keep all persons clear from the area of operation and
machine movement.
• Before operating the machine, set up barriers to the sides
and rear area of the bucket swing radius to prevent any-
one from entering the work area.
022-E01A-0386
M202-05-014
NEVER POSITION BUCKET OVER ANYONE

• Never lift, move, or swing bucket above anyone or a truck
cab.
Serious injury or machine damage may result due to bucket
load spill or due to collision with the bucket.
023-E01A-0487 SA-682
AVOID UNDERCUTTING
• Always confirm that ground conditions are strong enough
to support the machine weight when operating near a cliff.
Operate the machine with the chassis frame positioned
perpendicular to the cliff face so that the machine can more
easily evacuate if the cliff face collapses.
• If the footing starts to collapse and if retreat is not pos-
sible, do not panic. Often, the machine can be secured by
lowering the front attachment, in such cases.
024-E01A-0488 SA-683
SA-13
SAFETY
AVOID TIPPING
DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MA-
CHINE---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 ma-
SA-088
chine.
• 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.
• Be careful when working on frozen ground.

• Temperature increases will cause the ground to become
soft and make ground travel unstable.
025-E03B-0463
SA-684
NEVER UNDERCUT A HIGH BANK

• The edges could collapse or a land slide could occur causing
026-E01A-0519
SA-685
SA-14
SAFETY
DIG WITH CAUTION

• Accidental severing of underground cables or gas lines may
cause an explosion and/or fire, possibly resulting in serious
injury or death.
• Before digging check the location of cables, gas lines, and
water lines.
• Keep the minimum distance required, by law, from cables,
gas lines, and water lines.
• If a fiber optic cable should be accidentally severed, do
not look into the end. Doing so may result in serious eye
injury.
• Contact your local “diggers hot line” if available in your
area , and/or the utility companies directly.
Have them mark all underground utilities. SA-086
027-E01A-0382
OPERATE WITH CAUTION

• If the front attachment or any other part of the machine hits
against an overhead obstacle, such as a bridge, both the
machine and the overhead obstacle will be damaged, and
personal injury may result as well.
• Take care to avoid hitting overhead obstacles with the
boom or arm.
028-E01A-0389 SA-087
SA-15
SAFETY
AVOID POWER LINES

• Serious injury or death can result if the machine or front at-
tachments are not kept a safe distance from electric lines.
• When operating near an electric line, NEVER move any
part of the machine or load closer than 3 m plus twice the
line insulator length.
• Check and comply with any local regulations that may ap-
ply.
• Wet ground will expand the area that could cause any
person on it to be affected by electric shock. Keep all
bystanders or co-workers away from the site.
SA-089
029-E01A-0381
PRECAUTIONS FOR LIGHTENING

• The machine is vulnerable to lighting strikes.
• In the event of an electrical storm, immediately stop op-
eration, and lower the bucket to the ground. Evacuate to
a safe place far away from the machine.
• After the electrical storm has passed, check all of the
machine safety devices for any failure. If any failed safety
devices are found, operate the machine only after repair-
ing them.
SA-1241
OBJECT HANDLING
• If a lifted load should fall, any person nearby may be struck
by the falling load or may be crushed underneath it, result-
ing 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 sud-
denly.
• 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.
032-E01A-0132
SA-014
SA-16
SAFETY
PROTECT AGAINST FLYING DEBRIS

• If flying debris hit eyes or any other part of the body, serious
injury may result.
• Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
• Keep bystanders away from the working area before strik-
ing any object.
031-E01A-0432
SA-432
PARK MACHINE SAFELY

To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Place FNR switch in neutral, and put the brake switch in
the P (parking brake) position.
• Turn auto-idle switch OFF.
• Run engine at slow idle speed without load for 5 minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK position. SA-093
• Close windows, roof vent, and cab door.

• Lock all access doors and compartments.
HANDLE FLUIDS SAFELY−AVOID FIRES

• Handle fuel with care; it is highly flammable. If fuel ignites,
an explosion and/or a fire may occur, possibly resulting in
• Do not refuel the machine while smoking or when near
open flame or sparks.
• Always stop the engine before refueling the machine.
• Fill the fuel tank outdoors.
• All fuels, most lubricants, and some coolants are flammable.

SA-018
• Store flammable fluids well away from fire hazards.
• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn spontane-
ously.
• Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
SA-17
SAFETY
TRANSPORT SAFELY
• Take care the machine may turn over when loading or un-
loading the machine onto or off of a truck or trailer.
• Observe the related regulations and rules for safe trans-
portation.
• 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:
Less than 15°
1. Select solid and level ground.
2. Always use a ramp or deck strong enough to support the SA-094
machine weight.
3. Turn auto-idle switch OFF.
4. Always select the slow speed mode with the travel mode
switch.
5. Never load or unload the machine onto or off a truck or
trailer using the front attachment functions when driving
up or down the ramp.
6. Never steer the machine while on the ramp. If the travel-
ing direction must be changed while the ramp, unload
the machine from the ramp, reposition the machine on
the ground, then try loading again.
7. The top end of the ramp where it meets the flatbed is a Less than 15°
sudden bump. Take care when traveling over it.
SA-095
8. Place blocks in front of and behind the tires. Securely
hold the machine to the truck or trailer deck with wire
ropes.
Be sure to further follow the details described in the TRANS-

PORTING section.
035-E07A-0454
SA-18
SAFETY
PRACTICE SAFE MAINTENANCE

To avoid accidents:
• Understand service procedures before starting work.
• Keep the work area clean and dry.
• Do not spray water or steam inside cab.
• Never lubricate or service the machine while it is moving.
• Keep hands, feet and clothing away from power-driven
parts.
Before servicing the machine:

1. Park the machine on a level surface.
2. Lower the bucket to the ground.
3. Turn the auto-idle switch off.
4. Run the engine at slow idle speed without load for 5 min-
utes.
5. Turn the key switch to OFF to stop engine.
6. Relieve the pressure in the hydraulic system by moving SA-028
the control levers several times.
7. Remove the key from the switch.
8. Attach a “Do Not Operate” tag on the control lever.
9. Pull the pilot control shut-off lever to the LOCK position.
10. Allow the engine to cool.
• If a maintenance procedure must be performed with the

engine running, do not leave machine unattended.
• If the machine must be raised, maintain a 90 to 100˚ angle
between the boom and arm. Securely support any ma-
chine elements that must be raised for service work.
• Inspect certain parts periodically and repair or replace as
necessary. Refer to the section discussing that part in the SA-527
“MAINTENANCE” chapter in the operator’s manual.
• Keep all parts in good condition and properly installed.
• Fix damage immediately. Replace worn or broken parts.
Remove any buildup of grease, oil, or debris.
• When cleaning parts, always use nonflammable detergent
oil. Never use highly flammable oil such as fuel oil and
gasoline to clean parts or surfaces.
• Disconnect battery ground cable (−) before making
adjustments to electrical systems or before performing
welding on the machine.
500-E02C-0520
SA-19
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
WARN OTHERS OF SERVICE WORK

• Unexpected machine movement can cause serious injury.
• Before performing any work on the machine, attach a “Do
Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
501-E01A-0287
SS3076175 SS2045102
SUPPORT MACHINE PROPERLY

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

• Entanglement in moving parts can cause serious injury.
• To prevent accidents, care should be taken to ensure that
hands, feet, clothing, jewelry and hair do not become
entangled when working around rotating parts.
502-E01A-0026
SA-026
SA-20
SAFETY
PREVENT PARTS FROM FLYING

• Travel reduction gears are under pressure.
• As pieces may fly off, be sure to keep body and face away
from AIR RELEASE PLUG to avoid injury.
• GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually
loosen AIR RELEASE PLUG to release pressure.
503-E01B-0344
SA-344
STORE ATTACHMENTS SAFELY

• Stored attachments such as buckets, hydraulic hammers,
and blades can fall and cause serious injury or death.
• Securely store attachments and implements to prevent
falling. Keep children and bystanders away from storage
areas.
504-E01A-0034 SA-034
SUPPORT MAINTENANCE PROPERLY

• Explosive separation of a tire and rim parts can cause seri-
ous injury or death.
• Do not attempt to mount a tire unless you have the
proper equipment and experience to perform the job.
Have it done by your authorized dealer or a qualified
repair service.
• Always maintain the correct tire pressure. DO NOT inflate
tire above the recommended pressure.
• When inflating tires, use a chip-on chuck and exten-sion
hose long enough to allow you to stand to one side and
not in front of or over the tire assembly. Use a safety cage
it available.
• Inspect tires and wheels daily. Do not operate with low
pressure, cuts bubbles, damaged rims, or missing lug
bolts and nuts.
• Never cut or weld on an inflated tire or rim assembly. Heat
from welding could cause an increase in pressure and SA-249
may result in tire explosion.
521-E02A-0249
SA-21
SAFETY
PREVENT BURNS
Hot spraying fluids:
• After operation, engine coolant is hot and under pressure.

Hot water or steam is contained in the engine, radiator and
heater lines.
Skin contact with escaping hot water or steam can cause
severe burns.
• To avoid possible injury from hot spraying water. DO NOT
remove the radiator cap until the engine is cool. When
opening, turn the cap slowly to the stop. Allow all pres-
sure to be released before removing the cap.
SA-039
• The hydraulic oil tank is pressurized. Again, be sure to
release all pressure before removing the cap.
Hot fluids and surfaces:
• Engine oil, gear oil and hydraulic oil also become hot during
operation.
The engine, hoses, lines and other parts become hot as well.
• Wait for the oil and components to cool before starting
any maintenance or inspection work.
SA-225
505-E01B-0498
REPLACE RUBBER HOSES PERIODICALLY

• Rubber hoses that contain flammable fluids under pressure
may break due to aging, fatigue, and abrasion. It is very
difficult to gauge the extent of deterioration due to aging,
fatigue, and abrasion of rubber hoses by inspection alone.
• Periodically replace the rubber hoses. (See the page of
“Periodic replacement of parts” in the operator’s manual.)
• Failure to periodically replace rubber hoses may cause a fire,

fluid injection into skin, or the front attachment to fall on a
SA-019
person nearby, which may result in severe burns, gangrene,
or otherwise serious injury or death.
S506-E01A-0019
SA-22
SAFETY
AVOID HIGH-PRESSURE FLUIDS

• Fluids such as diesel fuel or hydraulic oil under pressure can
penetrate the skin or eyes causing serious injury, blindness
or death.
• Avoid this hazard by relieving pressure before disconnect-
ing hydraulic or other lines.
• Tighten all connections before applying pressure.
• Search for leaks with a piece of cardboard; take care to
protect hands and body from high-pressure fluids. Wear a
face shield or goggles for eye protection.
• If an accident occurs, see a doctor familiar with this type
of injury immediately. Any fluid injected into the skin
SA-031
must be surgically removed within a few hours or gan-
grene may result.
507-E03A-0499
SA-292
SA-044
SA-23
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.
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..
Clean up Flammables:
• Spilled fuel and oil, and trash, grease, debris, accumulated
coal dust, and other flammables may cause fires.
• Prevent fires by inspecting and cleaning the machine
daily and by removing spilled or accumulated flammables
immediately.
Check Key Switch:

• If a fire breaks out, failure to stop the engine will escalate
the fire, hampering fire fighting.
Always check key switch function before operating the ma-
chine every day:
1. Start the engine and run it at slow idle.
2. Turn the key switch to the OFF position to confirm that
the engine stops.
• If any abnormalities are found, be sure to repair them
before operating the machine.
508-E02B-0019
Check Heat Shields:

• Damaged or missing heat shields may lead to fires.
• Damaged or missing heat shields must be repaired or
replaced before operating the machine.
508-E02A-0393
SA-24
SAFETY
EVACUATING IN CASE OF FIRE

• If a fire breaks out, evacuate the machine in the following
way:
• Stop the engine by turning the key switch to the OFF
position if there is time.
• Use a fire extinguisher if there is time.
• Exit the machine.
• In an emergency, if the cab door or front window can not
be opened, break the front or rear window panes with the
emergency evacuation hammer to escape from the cab. SA-393
Refer the explanation pages on the Emergency Evacuation
Method.
18-E02B-0393
SS-1510
BEWARE OF EXHAUST FUMES

• Prevent asphyxiation. Engine exhaust fumes can cause sick-
ness or death.
• If you must operate in a building, be sure there is ad-
equate ventilation. Either use an exhaust pipe extension
to remove the exhaust fumes or open doors and windows
to bring enough outside air into the area.
509-E01A-0016
SA-016
PRECAUTIONS FOR WELDING AND GRINDING

• Welding may generate gas and/or small fires.
• Be sure to perform welding in a well ventilated and pre-
pared area. Store flammable objects in a safe place before
starting welding.
• Only qualified personnel should perform welding.
Never allow an unqualified person to perform welding.
• Grinding on the machine may create fire hazards. Store
flammable objects in a safe place before starting grinding.
• After finishing welding and grinding, recheck that there are
no abnormalities such as the area surrounding the welded
area still smoldering. SA-818
523-E01A-0818
SA-25
SAFETY
AVOID HEATING NEAR PRESSURIZED FLUID LINES

• Flammable spray can be generated by heating near pres-
surized fluid lines, resulting in severe burns to yourself and
bystanders.
• Do not heat by welding, soldering, or using a torch near
pressurized fluid lines or other flammable materials.
• Pressurized lines can be accidentally cut when heat goes
beyond the immediate flame area. Install temporary fire-
resistant guards to protect hoses or other materials before
engaging in welding, soldering, etc..
AVOID APPLYING HEAT TO LINES CONTAINING SA-030
FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that contain flam-
mable fluids.
• Clean them thoroughly with nonflammable solvent be-
fore welding or flame cutting them.
510-E01B-0030
REMOVE PAINT BEFORE WELDING OR HEATING

• Hazardous fumes can be generated when paint is heated by
welding, soldering, or using a torch. If inhaled, these fumes
may cause sickness.
• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated area. Dis-
pose of paint and solvent properly.
• Remove paint before welding or heating:

1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove stripper with
SA-029
soap and water before welding. Remove solvent or paint
stripper containers and other flammable material from
area. Allow fumes to disperse at least 15 minutes before
welding or heating.
511-E01A-0029
SA-26
SAFETY
BEWARE OF ASBESTOS DUST

• Take care not to inhale dust produced in the work site. Inha-
lation of asbestos fibers may be the cause of lung cancer.
• Depending on the wok site conditions, the risk of inhaling
asbestos fiber may exist. Spray water to prevent asbestos
from becoming airborne. Do not use compressed air.
• When operating the machine in a work site where asbes-
tos might be present, be sure to operate the machine
from the upwind side and wear a mask rated to prevent
the inhalation of asbestos.
• Keep bystanders out of the work site during operation.
• Asbestos might be present in imitation parts. Use only SA-029
genuine Hitachi Parts.
PREVENT BATTERY EXPLOSIONS

• Battery gas can explode.
• Keep sparks, lighted matches, and flame away from the
top of battery.
• Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
• Do not charge a frozen battery; it may explode. Warm the
battery to 16˚C ( 60˚ F ) first.
• Do not continue to use or charge the battery when elec-
trolyte level is lower than specified. Explosion of the bat-
tery may result.
• Loose terminals may produce sparks. Securely tighten all SA-032
terminals.
• Battery electrolyte is poisonous. If the battery should ex-

plode, battery electrolyte may be splashed into eyes, pos-
sibly resulting in blindness.
• Be sure to wear eye protection when checking electrolyte
specific gravity.
512-E01B-0032
SERVICE AIR CONDITIONING SYSTEM SAFELY

• If spilled onto skin, refrigerant may cause a cold contact
burn.
• Refer to the instructions described on the container for
proper use when handling the refrigerant.
• Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
• Never touch the refrigerant.
513-E01A-0405
SA-405
SA-27
SAFETY
HANDLE CHEMICAL PRODUCTS SAFELY

• Direct exposure to hazardous chemicals can cause serious
injury. Potentially hazardous chemicals used with your ma-
chine include such items as lubricants, coolants, paints, and
adhesives.
• A Material Safety Data Sheet (MSDS) provides specific de-
tails on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
• Check the MSDS before you start any job using a hazard-
ous chemical. That way you will know exactly what the
risks are and how to do the job safely. Then follow proce-
dures and use recommended equipment.
SA-309
• See your authorized dealer for MSDS’s (available only in
English) on chemical products used with your machine.
515-E01A-0309
DISPOSE OF WASTE PROPERLY

• Improperly disposing of waste can threaten the environ-
ment and ecology. Potentially harmful waste used with
HITACHI equipment includes such items as oil, fuel, coolant,
brake fluid, filters, and batteries.
• Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
• Do not pour waste onto the ground, down a drain, or into
any water source.
• Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to SA-226
recover and recycle used air conditioning refrigerants.

• Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.
516-E01A-0226
SA-28
SAFETY
BEFORE RETURNING THE MACHINE TO THE CUS-

TOMER
• After maintenance or repair work is complete, confirm that:
• The machine is functioning properly, especially the safety
systems.
• Worn or damaged parts have been repaired or replaced
S517-E01A-0435
SA-435
SA-29
SAFETY
(Blank)
SA-30
SECTION AND GROUP SECTION 4 OPERATIONAL PER-
CONTENTS FORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
TECHNICAL MANUAL
SECTION 5 TROUBLESHOOTING
(Troubleshooting)
Group 1 Diagnosing Procedure
Group 2 Monitor Unit
Group 3 Dr. ZX
Group 4 ICF
Group 5 Component Layout
Group 6 Troubleshooting A
Group 7 Troubleshooting B
Group 8 Electrical System Inspection
TECHNICAL MANUAL (Operational Principle)
SECTION 1 GENERAL SECTION 3 COMPONENT OPERATION
Group 1 Specifications Group 1 Pump Device
Group 2 Component Layout Group 2 Swing Device
Group 3 Component Specifications Group 3 Control Valve
SECTION 2 SYSTEM Group 4 Pilot Valve
Group 1 Controller Group 5 Electric Lever
Group 2 Control System Group 6 Transmission
Group 3 ECM System Group 7 Axle
All information, illustrations and speci- Group 4 Hydraulic System Group 8 Travel Motor
fications in this manual are based on Group 5 Electrical System Group 9 Signal Control Valve
the latest product information available Group 10 Steering Valve
at the time of publication. The right is Group 11 Brake Valve
reserved to make changes at any time Group 12 Others (Upperstructure)
without notice. Group 13 Others (Undercarriage)
COPYRIGHT(C)2007
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
←これ以下
記載しない
WORKSHOP MANUAL
SECTION 1 GENERAL INFORMATION SECTION 3 UNDERCARRIAGE
Group 1 Precautions for Disassem- Group 1 Swing Bearing
bling and Assembling Group 2 Travel Motor
Group 2 Tightening Torque Group 3 Center Joint
Group 3 Painting Group 4 Transmission
Group 4 Bleeding Air from Hydrau- Group 5 Axle
lic Oil Tank Group 6 Axle Lock Cylinder
SECTION 2 UPPERSTRUCTURE Group 7 Operate Check Valve
Group 1 Cab (Axle Lock Cylinder)
Group 2 Counterweight SECTION 4 FRONT ATTACHMENT
Group 3 Main Frame Group 1 Front Attachment
Group 4 Pump Device Group 2 Cylinder
Group 5 Control Valve Group 3 Hose Rupture Valve
Group 6 Swing Device Group 4 Operate Check Valve
Group 7 Pilot Valve (Blade/Outrigger)
Group 8 Electric Lever
Group 9 Pilot Shut-Off Solenoid Valve
Group 10 Signal Control Valve
Group 11 Travel Shockless Valve
Group 12 Swing Shockless Valve
Group 13 Solenoid Valve
Group 14 Steering Valve
Group 15 Brake Valve
Group 16 Accumulator Charging Valve
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction Group 5 Component Test
Operational Performance Tests ................... T4-1-1 Primary Pilot Pressure..................................T4-5-1
Preparation for Performance Tests .............. T4-1-2 Secondary Pilot Pressure.............................T4-5-3
Solenoid Valve Set Pressure ........................T4-5-4
Group 2 Standard
Main Pump Delivery Pressure......................T4-5-6
Performance Standard ................................. T4-2-1
Main Relief Set Pressure..............................T4-5-8
Main Pump P-Q Diagram............................. T4-2-6
Relief Pressure (When relieving Swing).... T4-5-10
Sensor Activating Range.............................. T4-2-8
Overload Relief Valve Set Pressure .......... T4-5-12
Group 3 Engine Test Main Pump Flow Rate Measurement ........ T4-5-14
Engine Speed............................................... T4-3-1 Swing Motor Drainage ............................... T4-5-24
Engine Compression Pressure .................... T4-3-4 Steering Valve Relief Pressure.................. T4-5-26
Valve Clearance ........................................... T4-3-6 Brake Pressure (Front and Rear) .............. T4-5-28
Lubricant Consumption ................................ T4-3-9 Brake Accumulated Pressure .................... T4-5-30
Brake Warning Set Pressure (Decrease) .. T4-5-32
Group 4 Excavator Test
Brake Warning Set Pressure (Increase).... T4-5-34
Travel Speed ................................................ T4-4-1
Service Brake Function................................ T4-4-3
Parking Brake Control Function................... T4-4-4
Swing Speed ................................................ T4-4-5
Swing Function Drift Check.......................... T4-4-6
Swing Motor Leakage .................................. T4-4-8
Maximum Swingable Slant Angle ................ T4-4-9
Swing Bearing Play.................................... T4-4-10
Hydraulic Cylinder Cycle Time ................... T4-4-12
Dig Function Drift Check ............................ T4-4-14
Control Lever Operating Force .................. T4-4-15
Control Lever Stroke .................................. T4-4-16
Combined Operation of Boom Raise/Swing
Function Check ........................................ T4-4-17
CEBT-4-1
(Blank)
CEBT-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedure to quan- The machine performance does not always deteriorate
titatively check all system and functions on the ma- as the working hours increase. However, the machine
chine. performance is normally considered to reduce in pro-
portion to the increase of the operation hours. Accord-
Purpose of Performance Tests ingly, restoring the machine performance by repair,
1. To comprehensively evaluate each operational adjustment, or replacement shall consider the number
function by comparing the performance test data of the machine’s working hours.
with the standard values.
2. According to the evaluation results, repair, adjust, Definition of “Performance Standard”
or replace parts or components as necessary to 1. Operation speed values and dimensions of the
restore the machine’s performance to the desired new machine.
standard. 2. Operational performance of new components
3. To economically operate the machine under op- adjusted to specifications. Allowable errors will be
timal conditions. indicated as necessary.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the op-
erational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to evalu-
ate the performance test data.
Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out

performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 300 m (984 ft 3 in), and to
make a full swing with the front attachment ex-
tended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork- T105-06-01-003
ers. Once the test is started, be sure to commu-
nicate with each other using these signals, and to
follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid 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
pipings.
MAKE PRECISE MEASUREMENT

1. Accurately calibrate test instruments in advance T212-07-01-003
to obtain correct data.

2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
T4-1-2
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 2 Standard
Performance Standard
The performance standard values are listed in the table * The standard measurement conditions are as follows.
below.  Engine Control Dial: Fast Idle
For details including measuring method, refer to T4-3  Power Mode Switch: P mode
onward.  Auto-Idle Switch: OFF
The value indicated in parentheses is only a reference.  Work Mode: Digging mode
 Engine Speed Control Mode Selection Switch: Dial
mode
 Hydraulic Oil Temperature: 50±5 ˚C (122±9 ˚F)
Performance Reference
Descriptions Remarks
Standard Page
ENGINE SPEED min-1 T4-3-1
Slow Idle Speed 900±100 Value indicated on Dr. ZX.
Fast Idle Speed 1700±50 
Fast Idle Speed (with ECO deactivated) 1800±50 
Fast Idle Speed (Relief operation) Arm roll-in relief control. Value
1800±50
indicated on Dr. ZX.
Fast Idle Speed (E mode) 1600±50 Value indicated on Dr. ZX.
Fast Idle Speed (HP mode, Relief operation) Arm roll-in relief control. Value
2000±50
indicated on Dr. ZX.
Slow Idle Speed (Pedal mode) Travel speed mode switch: Fast
speed
1100±50 Brake switch: OFF or Axle lock
Jack up and measure.
Value indicated on Dr. ZX.
Fast Idle Speed (Pedal mode, Working accelerator) FNR switch: N
Brake switch: OFF, Auto axle
2000±50
lock or Axle lock
Value indicated on Dr. ZX.
Fast Idle Speed (Pedal mode, Relief operation) Travel speed mode switch: Fast
speed
Brake switch: OFF, Auto axle
lock or Axle lock
2200±50
Depress the brake pedal,
perform travel relief or jack up
and measure.
Values indicated on Dr. ZX.
Auto-Idle Speed 1100±100 Value indicated on Dr. ZX.
Warming-Up Speed 1400±100 
ENGINE COMPRESSION PRESSURE 3.04±0.2 Engine speed: at 200 min-1 T4-3-4
MPa (kgf/cm2, psi) (31±2, 440)
VALVE CLEARANCE (IN, EX) mm 0.15 With engine cold T4-3-6
LUBRICANT CONSUMPTION Hour meter: 2000 hours or less T4-3-9
mL/h 30 or less
(Rated Output)
T4-2-1
Group 2 Standard
Descriptions Reference
Standard Page
TRAVEL SPEED km/h (100 m) T4-4-1
Fast Engine speed control mode
35.0+1.0-3.0 selection switch: Pedal mode,
Travel speed mode switch: Fast
Slow Engine speed control mode
selection switch: Pedal mode,
8.6±0.5
Travel speed mode switch:
Slow
Creeper ZX140W-3: Up to serial No
005000, ZX140W-3-AMS: Up to
2.2±0.3 serial No 050000
Engine speed control mode
selection switch: Creeper mode
ZX140W-3: Serial No 005001
and up, ZX140W-3-AMS: Serial
1.8±0.3 No 050001 and up
Engine speed control mode
selection switch: Creeper mode
SERVICE BRAKE FUNCTION N (kgf ) T4-4-3
Service Brake Tire
lock
Parking Brake Tire
lock
PARKING BRAKE FUNCTION mm/5 min (0) T4-4-4
SWING SPEED sec/3 rev 13.1±1.5 Bucket: empty T4-4-5
SWING FUNCTION DRIFT CHECK mm/90 ˚ 720 or less Bucket: empty T4-4-6
SWING MOTOR LEAKAGE mm/5 min 0 Bucket: loaded T4-4-8
MAXIMUM SWINGABEL SLANT ANGLE deg. 18 or more Bucket: loaded T4-4-9
SWING BEARING PLAY mm 0.2 to 1.25 Allowable limit: 2.0 to 3.05 T4-4-10
HYDRAULIC C YLINDER CYCLE TIME 2.52 m arm T4-4-12
sec 0.3 m3 (PCSA heaped) bucket,
Bucket: empty, Without HRV
Boom Raise (Monoblock Boom) 4.1±0.3 Without bucket: 3.9±0.3
Boom Lower (Monoblock Boom) 4.5±0.3 Without bucket: 4.3±0.3
Boom Raise (2-Piece Boom) 2.8±0.3 Without bucket: 3.1±0.3
Boom Lower (2-Piece Boom) 3.0±0.3 Without bucket: 3.3±0.3
Arm Roll-In 3.7±0.3 Without bucket: 3.9±0.3
Arm Roll-Out 3.1±0.3 Without bucket: 3.1±0.3
Bucket Roll-In 3.5±0.3 Without bucket: 3.9±0.3
Bucket Roll-Out 2.8±0.3 Without bucket: 2.9±0.3
Positioning Extend 7.6±0.5 Without bucket: 7.6±0.5
Positioning Retract 5.1±0.4 Without bucket: 5.1±0.4
Blade Raise 2.0±0.3
Blade Lower 2.5±0.3
Outrigger Raise 1.9±0.3
Outrigger Lower 1.9±0.3
fNOTE: HRV: Hose Rupture Valve
T4-2-2
Group 2 Standard
Standard Page
HYDRAULIC CYLINDER CYCLE TIME 2.52 m arm T4-4-12
sec 0.3 m3 (PCSA heaped) bucket,
Bucket: empty, With HRV
Boom Raise (Monoblock Boom) 4.1±0.3 Without bucket: 3.9±0.3
Boom Lower (Monoblock Boom) 3.0±0.3 Without bucket: 3.3±0.3
Boom Raise (2-Piece Boom) 4.5±0.3 Without bucket: 4.3±0.3
Boom Lower (2-Piece Boom) 3.2±0.3 Without bucket: 4.1±0.3
Arm Roll-In 3.9±0.3 Without bucket: 4.1±0.3
Arm Roll-Out 3.1±0.3 Without bucket: 3.1±0.3
Bucket Roll-In 3.5±0.3 Without bucket: 3.9±0.3
Bucket Roll-Out 2.8±0.3 Without bucket: 2.9±0.3
Positioning Extend 7.6±0.5 Without bucket: 7.6±0.5
Positioning Retract 5.3±0.4 Without bucket: 5.3±0.4
Blade Raise 2.0±0.3
Blade Lower 2.5±0.3
Outrigger Raise 1.9±0.3
Outrigger Lower 1.9±0.3
DIG FUNCTION DRIFT CHECK 2.52 m arm T4-4-14
(Maximum Reach Position) mm/5 min 0.3 m3 (PCSA heaped) bucket,
bucket loaded
Boom Cylinder 5 or less
Arm Cylinder 10 or less
Bucket Cylinder 15 or less
Positioning Cylinder 15 or less
Front Drift Amount (Bucket Bottom) 100 or less
CONTROL LEVER OPERATING FORCE N (kgf ) T4-4-15
Right Lever: Forward/Backward 15 (1.5) or less
Right Lever: Right/Left 15 (1.5) or less
Left Lever: Forward/Backward 15 (1.5) or less
Left Lever: Right/Left 15 (1.5) or less
Steering Wheel Turns (lock-to-lock) 20 (2.0) or less
CONTROL LEVER STROKE mm T4-4-16
Right Lever: Forward/Backward 62±10
Right Lever: Right/Left 62±10
Left Lever: Forward/Backward 74±10
Left Lever: Right/Left 74±10
Steering Wheel Turns (lock-to-lock) 7.0±0.5
2.52 m arm T4-4-17
COMBINED OPERATION OF BOOM
sec 3.6±0.3 0.3 m3 (PCSA heaped) bucket,
RAISE/SWING FUNCTION CHECK
Bucket: empty
Bucket Teeth Height: H mm 5500 or more
fNOTE: HRV: Hose Rupture Valve
T4-2-3
Group 2 Standard
Standard Page
HYDRAULIC SYSTEM
PRIMARY PILOT PRESSURE T4-5-1
MPa (kgf/cm2, psi)
4.0+1.0-0.5
Fast Idle
(41 -5, 581+145-73)
+10
SECONDARY PILOT PRESSURE 3.3 to 3.9 Value indicated on Dr. ZX. T4-5-3
(For Fast Idle, Slow Idle) (34 to 40, (Control lever: Full stroke)
MPa (kgf/cm2, psi) 480 to 567)
STEERING PUMP PRESSURE 2.5±1.0
MPa (kgf/cm2, psi) (26±10, 363±145)
SOLENOID VALVE SET PRESSURE T4-5-4
MPa (kgf/cm2, psi)
Solenoid Valve Unit Set Pressure (Value of Dr. ZX) ±0.2 Value indicated on Dr. ZX.
(2, 29)
MAIN PUMP DELIVERY PRESSURE 1.0+1.0-0.5 In neutral, Value indicated T4-5-6
MPa (kgf/cm2, psi) (10+10 , 145+145 ) on Dr. ZX
-5.0 -73
MAIN RELIEF VALVE RELIEF PRESSURE T4-5-8

MPa (kgf/cm2, psi)
Boom, Arm, Bucket (Relief operation for each) 34.3+1.2-0.8 Value indicated on Dr. ZX.
(350+12-8, 4980+175-115)
RELIEF PRESSURE
MPa (kgf/cm2, psi)
Relief operation of swing 33.4+2.3-0.5 Value indicated on Dr. ZX. T4-5-10
(340+23-5, 4860+335-73)
Relief operation of travel 35.3+2.0-1.0 Value indicated on Dr. ZX.
(360 -10, 5130 -145)
+20 +290
Relief operation of blade/outrigger raise 28.0+2.0-0 Value indicated on Dr. ZX.

(285+20-0, 4070+290-0)
Relief operation of blade/outrigger 28.0+2.0-1.0 Value indicated on Dr. ZX.
lower (285 -10, 4070 -145)
+20 +290
OVERLOAD RELIEF VALVE RELIEF PRESSURE T4-5-12

MPa (kgf/cm2, psi)
Boom (lower), Arm (roll-in), Bucket (roll-in), (Reference values at 50 L/
37.2 (379, 5410)
Blade/Outrigger (raise/lower) min)
Boom (raise), Arm (roll-out), Bucket (roll-out) (Reference values at 50 L/
39.2 (400, 5700)
min)
(Reference values at 135
Auxiliary 28.0 (285, 4070)
L/min)
T4-2-4
Group 2 Standard
Standard Page
MAIN PUMP FLOW RATE L/min - Refer to T4-2-6. T4-5-14
SWING MOTOR DRAINAGE L/min
With constant speed 0.2 to 0.3 T4-5-24
With motor relieved (2 to 5)
STEERING VALVE RELIEF PRESSURE 17.5±1.0 T4-5-28
MPa (kgf/cm2, psi) (179±10,
2540±145)
BRAKE PRESSURE (FRONT/REAR) 7.0±1.0 T4-5-30
(including work brake operating pressure) (70±10,
MPa (kgf/cm2, psi) 1020±145)
BRAKE ACCUMULATOR PRESSURE 17.7±1.0 T4-5-32
MPa (kgf/cm2, psi) (181±10,
2570±145)
BRAKE ALARM PRESSURE
MPa (kgf/cm2, psi)
Decrease 8.3±0.3 T4-5-34
(85±3, 1210±44)
9.0±0.3 T4-5-36
Increase
(92±3, 1310±44)
T4-2-5
Group 2 Standard
Main Pump P-Q Diagram

 Hydraulic P-Q Control (Torque Control)
(NOTE: Measured at Test Stand)
 Rated Pump Speed: 2200 min-1 (rpm)

 Hydraulic Oil Temperature: 50±5 °C (122±9 °F)
fNOTE: Refer to T4-5-14.
P-Q Point
Delivery Pressure Flow Rate
MPa (kgf/cm2, psi) L/min (gpm)
Pump 1: 220±3
A 3.9 (40, 570)
(58.0±0.8)
Pump 2: 165±3
A’ 3.9 (40, 570)
(43.5±0.8)
B 11.8 (120, 1720) Pump 1: [218 (57.5)]
B’ 16.7 (170, 2430) Pump 2: [163 (43.0)]
C 18.6 (190, 2700) 147±6 (38.8±1.6)
D 20.6 (210, 2990) [125 (33.0)]
E 22.5 (230, 3270) 110±6 (29.0±1.6)
F 34.3 (350, 4990) 53±10 (14.0±2.6)
The value indicated in parentheses is only a reference.
L/min A
B
A’ B’
D
Flow Rate
E
Delivery Pressure MPa (kgf/cm2) TCEB-04-02-001
T4-2-6
Group 2 Standard
 P-Q Control by Pump Control Pilot Pressure Signal

(NOTE: Measured at Test Stand)
 Rated Pump Speed: 2200 min-1 (rpm)

fNOTE: Refer to T4-5-16.
P-Q Point
Pump Control Pressure Flow Rate
MPa (kgf/cm2, psi) L/min (gpm)
1.9±0.05 (19±0.5, Pump 1: 91±2 (24.0±0.5)
A
276±7.3) Pump 2: 70±2 (18.5±0.5)
3.4±0.05 (35±0.5,
B 129±8 (34.0±2.1)
494±7.3)
Pump 1: 220±3
2.9+0.05-0.29 (58.0±0.8)
C
(30 -3, 422+7.3-42.2)
+0.5
Pump 2: 165±3
(43.5±0.8)
fNOTE: B: With flow rate limit control

C: Without flow rate limit control
L/min
Flow Rate
Pump Control Pressure MPa (kgf/cm2, psi) T1T1-04-02-001
T4-2-7
Group 2 Standard
Sensor Activating Range

1. Measuring Method
 Unless specified:
Power
Engine Auto-Idle
Mode Work Mode
Control Dial Switch
Switch
Fast Idle Digging
P OFF
Speed mode
 Monitor each sensor by using Dr. ZX.
2. Sensor Activating Range
Item Operation Standard

Slow Idle 0.3 to 1.0 V
Engine Control Dial
Fast Idle 4.0 to 4.7 V
Control lever: Neutral position 0 to 0.1 MPa
Pressure Sensor Pilot shut-off lever: LOCK position (0 to 1.0 kgf/cm2, 0 to 14.5 psi)
(Boom Raise, Arm Roll-In, Swing) Control lever: Full stroke 3.3 to 3.9 MPa
Pilot shut-off lever: UNLOCK position (34 to 40 kgf/cm2, 480 to 570 psi)
Control Lever: Neutral position 0 to 0.1 MPa
Pilot shut-off lever: LOCK position (0 to 1.0 kgf/cm2, 0 to 14.5 psi)
Pressure Sensor (Travel)
Control lever: Full stroke 2.7 to 3.3 MPa
Pilot shut-off lever: UNLOCK position (28 to 34 kgf/cm2, 390 to 480 psi)
0.7 to 1.3 MPa
Control lever: Neutral position
(7 to 13 kgf/cm2, 100 to 190 psi)
Pump Control Pressure Sensor
2.9 to 3.9 MPa
Control lever: Full stroke
(30 to 40 kgf/cm2, 420 to 570 psi)
Travel N Sensor 20 °C (GND to SIGNAL) 810±240 Ω
T4-2-8
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary:
1. Measure the engine speed by using the monitor
unit or Dr. ZX.
2. Measure the engine speeds in each mode.
NOTE: If the engine speed is not adjusted correctly,

all other performance data will be unreliable.
Consequently, measure the engine speed
before performing all other tests in order to
check that the engine speed meets
specification.
Preparations:
1. Select the service menu of monitor (In case of Dr.
ZX, install Dr. ZX first).
2. Warm up the machine until coolant temperature
reaches 50 °C (122 °F) or more, and hydraulic oil
temperature is 50±5 °C (122±9 °F).
T4-3-1
Measurement: Remedy:
1. Measure the engine speeds in the "dial mode" and Refer to Troubleshooting B in Group T5-7.
"pedal mode" positions for the engine speed
control mode selection switch.
NOTE: ECO stands for the auto engine speed
2. When measuring, set the switch and test condition -1
reduction system by 100 min .
as shown in the table below in response to the
engine speed to be measured.
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST /
Standard in Group T4-2.
• Engine Speed Control Mode Selection Switch: Dial mode

Engine Power Auto-
Item Control Mode Idle Work Mode Test Conditions
Dial Switch Switch
Slow Idle Digging Lever in neutral.
Slow Idle P OFF
mode
Fast Idle Check in the Dr. ZX special
(with ECO Digging functions with ECO deactivated.
Fast Idle P OFF
deactivated) mode Measure engine speed with the
lever in neutral.
Fast Idle Move the pilot shut-off lever to the
Digging
(Heater control Fast Idle P OFF UNLOCK position. Measure engine
mode
OFF) speed with the lever in neutral.
Fast Idle Digging Measure engine speed while
Fast Idle P OFF
(Relief operation) mode relieving the boom raise circuit.
Fast Idle Digging Lever in neutral.
Fast Idle E mode OFF
(E mode) mode
Fast Idle Digging Measure engine speed while
Fast Idle HP mode OFF
(HP mode) mode relieving the boom raise circuit.
Auto-Idle Measure engine speed 4 seconds
Digging
Fast Idle P ON after returning all control levers to
mode
neutral.
Warming-Up Engine speed can be measured
Digging
Slow Idle P OFF only when hydraulic oil
mode
temperature is 0 °C (32 °F) or less.
T4-3-2
• Engine Speed Control Mode Selection Switch: Pedal mode

Accelerator Power Mode Auto-Idle Work
Test Conditions
Pedal Switch Switch Mode
• FNR switch: (F or R)
Not Digging • Brake switch:
Slow Idle P OFF
depressed mode OFF or Axle lock
• Engine control dial: Slow
Max. Digging • FNR switch: N
Fast Idle P OFF
depressing mode • Work brake: Operable
• Travel speed mode switch: Fast
• Brake switch:
Fast Idle
Max. Digging OFF or Axle lock
(Relief P OFF
depressing mode • Raising Machine
operation)
• Travel operation with brake
depressed
Method Raising Machine:

As for a machine attached with an outrigger or a blade
in front and rear of the chassis, raise the machine off
the ground by using the outrigger or blade.
CAUTION: Securely support the raised

machine by using the blocks.
As for a machine attached with an outrigger or a blade

only in rear of the chassis, raise the machine by using
a front attachment as illustrated in the right.
Switch Panel: T1F3-04-02-002
Engine Control Monitor Unit:

Dial
Digging Mode
Travel Speed
Mode Switch
Engine Speed
Control Mode
Selection Switch
Power Mode
Switch
Auto-Idle
Switch TCJB-04-03-001
TCJB-05-02-064
T4-3-3
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders
and check for a decline in engine power.
2. Check exhaust gas color. Keep track of engine oil
consumption.
3. Check for abnormalities in the intake system,
including the air filter.
Preparation:
1. Confirm that valve clearances are correct.
2. Confirm that the batteries are charged properly.
3. Run the engine until the coolant temperature
gauge reaches the operating range.
4. Remove the negative terminal of the battery.
Remove all the glow plugs from each cylinder.
： 20 N⋅m (2.0 kgf⋅m, 14.8 lbf⋅ft)
IMPORTANT: If disconnecting the connector of Injector

injector, fuel cannot be jetted.
Therefore, ECM judges that the fuel
system is faulty and the fault code is
displayed. After measurement,
delete the displayed fault code.
5. Disconnect the connector of injector.

6. Install the negative terminal of the battery.
7. Turn the starter. Exhaust foreign subjects from the
cylinder.
8. Install a pressure gauge and an adaptor (Isuzu
5-8840-2815-0) to the glow plug mounting part.
(Sufficiently install them in order to prevent air
leakage.) T1T1-04-03-001
Glow Plug
Measurement:
1. Turn the starter and measure compression
pressure of each cylinder.
2. Repeat the measurement three times and
calculate the mean values.
Evaluation:
Refer to OERATIONAL PERFORMANCE TEST /
Remedy:
Refer to the engine shop manual.
T1T1-04-03-002
T4-3-4
(Blank)
T4-3-5
VALVE CLEARANCE
Injector
Summary:
1. Perform the measurement when the engine is
cold.
2. Before starting any work, clean the head cover
mounting area and avoid contamination in the
engine.
Preparation:
1. Disconnect the connector of inject.
2. Remove the leak off hose.
3. Remove the head cover.
4. Rotate the crank pulley. Align the top dead center
(TDC) mark on crank pulley with the top mark
located on timing gear case. Leak Off Hose T1T1-04-03-001
NOTE: When rotating the crank pulley, remove the

fan guard. Then, rotate the fan while
holding the fan belt. If it is difficult to rotate,
remove all glow plugs and release
compression pressure. Crank Pulley
5. Check if cylinder No.1 (or cylinder No.4) is now

positioned at the TDC in the compression stroke.
NOTE: When both intake and exhaust valve are
closed, this cylinder is positioned at TDC in
the compression stroke.
6. Start measurement from the cylinder No.1 (or Top Mark

cylinder No.4) positioned at TDC in the
compression stroke. T1T1-04-03-003
TDC Mark
T4-3-6
Measurement:
1. Insert a thickness gauge into the clearance
between rocker arm roller and cam shaft and A
measure the valve clearance.
A
NOTE: The cylinders are aligned from No.1 to A

No.4 in that order, as viewed from the fan A
side. Injection Order: 1-3-4-2 A
2. When measurement is started from No.1 cylinder, A

perform the same measurement to all valves A
○
indicated with the mark “ ” in the table below.
(When measurement is started from No.4 cylinder, A
T1T1-04-03-006
perform the measurement in the valves shown
with mark “×”.)
Cylinder No. No.1 No.2 No.3 No.4

Valve locations I E I E I E I E
When the measurement is
started from No.1 cylinder
○ ○ ○ ○
When the measurement is
× × × ×
started from No.4 cylinder
3. Rotate the crankshaft 360°. Align the TDC mark

with the pointer. Continue measurement of other Section A
valves in the same way.
Valve Clearance Caam Shaft Valve Clearance
Evaluation:
Refer to OERATIONAL PERFORMANCE TEST /
T1T1-04-03-005
Rocker Arm Roller
T4-3-7
Adjustment:
If the measurement results are out of specification,
adjust the valve clearance in the same order of
measurement.
Cam Shaft
1. Loosen the lock nuts (16 used) and adjusting
screws (16 used), which secure the rocker arm by
using adjust nut wrench (Isuzu 5-8840-2822-0).
2. Insert a thickness gauge into the clearance
between rocker arm roller and cam shaft.
3. Tighten the adjusting screw of rocker arm until Thickness
Gauge
condition for the thickness gauge is proper.
4. Tighten the lock nut of rocker arm.
: 18 N⋅m (1.8 kgf⋅m, 13.2 lbf⋅ft)
5. Check the valve clearance after the lock nuts are
tightened. T1T1-04-03-004
Adjust Nut Wrench Rocker Arm
Valve Clearance Cam Shaft Valve Clearance
T1T1-04-03-005
Rocker Arm Roller
T4-3-8
LUBRICANT CONSUMPTION
Measuring Method
1. Place the machine on level firm ground and leave
the machine for at least one hour in order to let
the lubricant lower to the oil pan when the engine
stops.
At this time, confirm that the machine is level by
using a leveler.
2. Record read-out A (unit: hour) of the hour meter.
3. Replenish the lubricant up to the high-level
gauge.
4. Operate the machine for at least 100 hours or
until the oil level lowers to the low-level gauge.
IMPORTANT: Keep the machine-leaving time in

Step 1 above.
5. Place the machine on level firm ground and leave
the machine for at least one hour in order to let
the lubricant lower to the oil pan when the engine
stops.
At this time, confirm that the machine is level by
using a leveler.
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.
NOTE: When measuring, use a high-precision
measuring cylinder or the like.
8. Determine lubricant consumption from the

following equation:
Oil replenishing volume (C) [mL] / Operating hours
(B-A) [hr]
Evaluation:
T4-3-9
(Blank)
T4-3-10
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
1. Measure the time required for the excavator to
travel a 100 m (328 ft) test track and check the
performance of travel device systems (from main
pump to travel motor).
Preparation:
CAUTION: Set the swing lock lever to the
LOCK position while traveling.
1. Adjust pressure of all tires equally.

2 End
Pressure: 650 kPa (6.5 kgf/cm , 94 psi)
2. Prepare a flat and solid test track 100 m (328 ft) 100 m
long, with an extra length of 400 m (1310 ft) on
both ends of the test track for machine Start
acceleration and deceleration. Acceleration Zone
400 m T1F3-04-04-003
NOTE: If it is difficult to prepare a test track 400 m

(1310 ft) long, set the travel speed mode
switch to slow idle before measurement.
NOTE: When measuring travel speed at slow idle

or creeper speed, prepare a test track 200
m (656 ft) long.
3. Position the front attachment as illustrated in the

4. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
T4-4-1
Measurement:
CAUTION: Do not measure travel speed
when traveling in reverse. (FNR Switch: F)
1. Measure at fast, slow and creeper speed.

2. Select the following switch positions:
Engine Travel Speed Engine Speed Control Accelerator Power Mode Auto-Idle
Work Mode
Control Dial Mode Switch Mode Selection Switch Pedal Switch Switch
Max.
Fast Slow idle Fast Pedal mode P Digging mode OFF
depressing
Max.
Slow Slow idle Slow Pedal mode P Digging mode OFF
depressing
Max.
Creeper Slow idle Slow Creeper mode P Digging mode OFF
depressing
3. Turn the FNR switch to the F (forward) position.

Depress the accelerator pedal to full stroke and
travel the machine from the acceleration zone.
4. Measure travel speed (second) in each mode.
5. Repeat the measurement three times. Calculate
the average values.
6. Convert the measured values to km/h.
Measured value (second) = S (sec)

Converted value (km per hour) = A (km/h)
A= 100 × 3600
S ×1000
Evaluation:
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B
in Group T5-7.
T4-4-2
SERVICE BRAKE FUNCTION
Summary: Evaluation:
1. Check the performance of hydraulic brake circuit Refer to OPERATIONAL PERFORMANCE TEST /
and brake. Standard in Group T4-2.
2. Brake control function is the safety item. Carry out
the performance test of brake certainly. Remedy:
Preparation: in Group T5-7.
CAUTION: Set the swing lock lever to the
LOCK position while traveling.
1. Adjust pressure of all tires equally.
Pressure: 650 kPa (6.5 kgf/cm2, 94 psi)
2. Prepare a dry and paved test track 200 m (656 ft)
long (acceleration zone 100 m (328 ft) and test
track 100 m (328 ft)). Determine the brake start
position.
(122±9 °F).
Measurement:
Stop Position
CAUTION: Do not measure travel speed Stop Distance
when traveling in reverse. (FNR Switch: F)
Brake
1. Measure travel speed in fast idle. Start Position (100 m Position)
T1F3-04-04-004
Travel Speed Engine Speed Control Accelerator Power Mode Auto-Idle

Work Mode
Mode Switch Mode  Selection Switch Pedal Switch Switch
Max. Digging
Fast Pedal P OFF
depressing mode
3. Turn the FNR switch to the F (forward) position.
Depress the accelerator pedal to full stroke and
travel the machine at fast.
4. Depress the brake pedal at the brake start
position and stop the machine completely.
5. Measure the distance from the brake start position
to the tread of a front tire.
the average values.
T4-4-3
PARKING BRAKE FUNCTION
Summary:
1. Measure the parking brake function on a specified
slope.
2. Brake control function is the safety item. Carry out
the performance test of brake certainly.
Preparation:
1. The surface of test slope shall be even paved
road with a gradient (11.31°).
(122±9 °F).
Measurement:
1. Climb a slope and set the brake switch to the P
(parking brake) position.
2. Stop the engine.
3. After the machine stops, put the mark (white line)
on the tire and slope.
4. After 5 minutes, measure the distance between
marks (white line) on the tire and slope.
T1F3-04-04-005
Evaluation:
T4-4-4
SWING SPEED
Summary:
Measure the time required to swing three complete
turns and check the performance of swing device
systems (from main pump to swing motor).
Preparation:
1. Check lubrication of the swing gear and swing
bearing.
2. Place the machine on flat, solid ground with
ample space for swinging. Do not conduct this test
on a slope.
3. With the arm cylinder fully retracted and the
bucket cylinder fully extended, hold the bucket so
that the height of the boom foot pin is the same as Height of the boom
foot pin is the
the arm tip pin. (The bucket must be empty.) same as the
4. Maintain hydraulic oil temperature at 50±5 °C arm tip pin
(122±9 °F).
T1F3-04-04-006
CAUTION: Prevent personal injury. Always

make sure that the area is clear and that
co-workers are out of the swing area before
starting the measurement.
Measurement:
Engine Power Mode Work Auto-Idle
Brake Switch Work Brake
Control Dial Switch Mode Switch
Digging Axle lock or
Fast idle P OFF Operable
mode Auto axle lock
2. Operate the swing control lever fully.
3. Measure the time required to swing three turns in
one direction.
4. Measure for the right and left swing.
the average values.
Evaluation:
Remedy:
in Group T5-7.
T4-4-5
SWING FUNCTION DRIFT CHECK
Summary:
1. Measure the swing drift on swing bearing outer
circumference when stopping after a 90°
full-speed swing and check the performance of
swing brake valve.
2. The mechanical brake for swing parking brake is
equipped for the swing motor.
Preparation:
bearing.
2. Place the machine on flat, solid ground with
ample space for swinging. Do not conduct this test
on a slope.
that the height of the boom foot pin is the same as
the arm tip pin. (The bucket must be empty.) Put the matching marks on swing
4. Put the matching marks on the swing bearing bearing outer circumference and
T202-07-03-005
outer circumference (upperstructure side) and the chassis.

chassis.
5. Set the marks on swing bearing and chassis with Before starting the measurement,
swing the upperstructure 90°
an angle of 90°.
(122±9 °F).

T1F3-04-04-007
T4-4-6
Measurement:
mode Auto axle lock
2. Operate the swing control lever fully. Return the
swing control lever to the neutral position when
the mark on upperstructure aligns with that on
chassis after swinging 90°.
3. After the upperstructure stops, measure the Measure the distance between the marks.
distance between the marks along swing bearing
outer circumference and chassis.
4. Measure for the right and left swing.
the average values.
Evaluation: Mark on Chassis

Standard in Group T4-2. Mark on Swing Bearing
T105-06-03-010
Remedy:
in Group T5-7.
T4-4-7
SWING MOTOR LEAKAGE

Summary: Evaluation:
1. Measure the upperstructure drift while keeping the Refer to OPERATIONAL PERFORMANCE TEST /
upperstructure with an angle of 90° relative to the Standard in Group T4-2.
slope on a 15±1° slope and check the
performance of swing parking brake. Remedy:
(The mechanical brake for swing parking brake is Refer to TROUBLESHOOTING / Troubleshooting B
equipped for the swing device.) in Group T5-7.
Preparation:
bearing.
2. Load a specified weight 750 kg (1660 lb) into the
bucket.
the arm tip pin.
4. The test slope angle shall be flat with a gradient
(15±1°).
5. Climb a slope and swing the upperstructure to
position it 90° relative to the slope. Put the
matching marks on the outer circumference of
swing bearing (upperstructure side) and chassis
by using the tape.
(122±9 °F).
T212-07-03-001
Measurement:
Slow idle P OFF Operable
mode Auto axle lock
2. Maintain the engine at slow idle. After five minutes,
measure the distance between the marks along
swing bearing outer circumference and chassis. Measure the distance between the marks.
3. Measure on the right and left swing.
4. Repeat the measurements three times. Calculate
the average values.
Mark on Chassis
Mark on Swing Bearing
T105-06-03-010
T4-4-8
MAXIMUM SWINGABLE SLANT ANGLE
CAUTION: As the machine may turn over

during swing operation, turn the brake switch
to the Axle Lock or Auto Axle Lock position.
Summary:
1. With the upperstructure swing 90° relative to the
slope, check the maximum slant angle on which
the upperstructure can swing to the uphill side.
Preparation:
bearing.
bucket.
the arm end pin.
4. Climb a slope and swing the upperstructure 90°
relative to the slope.
T212-07-03-001
(122±9 °F).
Measurement:
mode Auto axle lock
2. Operate the swing control lever to full stroke and
swing the upperstructure to the uphill side.
3. If the machine can swing, measure the cab floor
slant angle.
4. Increase the slope angle. Measure for the right
and left swing.
5. Repeat the measurement three times.
Evaluation:
Remedy:
in Group T5-7.
T4-4-9
SWING BEARING PLAY
Summary:
1. Measure the swing bearing play between inner
Dial Gauge
race and outer race and check the wear of swing
bearing races and balls.
Preparation:
1. Check the swing bearing mounting bolts for
looseness.
2. Check lubrication of the swing bearing. Check that
the swing bearing rotation is smooth and without
noise.
3. Secure a dial gauge on the round trunk of chassis
by using a magnetic base.
4. Position the upperstructure in the same direction
as traveling the chassis.
5. Position the dial gauge so that its needle point
comes into contact with the bottom surface of
swing bearing outer race. Magnetic T202-07-03-008
6. The bucket must be empty. Base
NOTE: The measured value will vary depending on Dial Gauge

where the magnet base is secured.
Secure the magnet base onto the round
trunk or in a position as close to the swing
bearing as possible.
Measurement: Round Trunk

bucket cylinder fully extended, hold the bucket Magnetic
Base
100 mm above the ground. Record dial gauge
reading (h1). T105-06-03-015
2. Lower the bucket to the ground and raise the front Measurement [h 1]
idler 0.5 m (20 in) by using the front attachment.
Record dial gauge reading (h2).
3. Calculate swing bearing play (H) from these data
(h1 and h2) as follows:
[H]=[h2]ー[h1]
Evaluation:
Refer to OPERATIONAL PERFORMANCE TEST / 100 mm
T212-07-05-003
Measurement [h 2]
T1F3-04-04-008
T4-4-10
(Blank)
T4-4-11
HYDRAULIC CYLINDER CYCLE TIME
Summary:
1. Measure the cycle time of boom, arm, bucket,
blade (optional) and outrigger (optional) cylinders
and check the performance of front attachment
systems (from main pump to each cylinder).
2. The bucket must be empty.
Preparation:
1. Measure at the position as follows.
1-1. Measurement of the cycle time of boom
cylinders:
With the arm cylinder fully retracted and the
bucket cylinder fully extended, lower the bucket
Boom Cylinder:
on to the ground.
1-2. Measurement of the cycle time of arm cylinder:
Retract or extend the bucket cylinder so that the
arm and bucket teeth are vertical to the ground.
Set the arm so that the center of arm operation
is vertical.
1-3. Measurement of the cycle time of bucket
cylinder: T202-07-03-012
Adjust each cylinder of boom and arm so that
Arm Cylinder:
the center of bucket full stroke is vertical.
1-4. Measurement of the cycle time of blade
cylinders:
Raise the machine by using the front
attachment in order to be able to move the
blade cylinder to fully stroke.
1-5. Measurement of the cycle time of outrigger
cylinders:
Raise the machine by using the front
attachment in order to be able to move the
outrigger cylinder to fully stroke.
0.5 m

(122±9 °F). T1V1-04-05-005
Bucket Cylinder:
T105-06-03-018
T4-4-12
Measurement:
Engine Power Mode Auto-Idle
Work Mode Work Brake
Control Dial Switch Switch
Digging
mode
2. Measure the cylinder cycle times as follows.
(Cylinder full stroke includes cylinder cushioning
Blade Cylinder:
zone.)
2-1. Boom cylinder:
Operate the boom control lever to full stroke.
Measure the time to raise and lower the boom.
2-2. Arm cylinder:
Operate the arm control lever to full stroke.
Measure the time to roll in and roll out the arm.
2-3. Bucket cylinder:
Operate the bucket control lever to full stroke.
Measure the time to roll in and roll out the
bucket.
2-4. Blade cylinder:
Operate the blade control lever to full stroke.
Measure the time to raise and lower the blade.
2-5. Outrigger cylinder:
Operate the outrigger control lever to full stroke. TCJB-04-04-001
Measure the time to raise and lower the NOTE: The illustration shows the rear blade.
outrigger. Measure the time for the cylinders
one by one. Outrigger Cylinder:

the average values.
Evaluation:
Remedy: TCJB-04-04-002
NOTE: The illustration shows the rear outrigger.
in Group T5-7.
T4-4-13
DIG FUNCTION DRIFT CHECK
• Maximum Reach Position

Summary:
1. Load a specified weight into the bucket. Measure
the cylinder rod drift and judge oil leakage in the
boom, arm and bucket cylinders, and the control
valve.
2. When measuring the drift just after cylinder
replacement, slowly operate the cylinder for ten
minutes and bleed air from the cylinder.
Preparations:
bucket.
Extended Distance
that the height of the boom foot pin is the same as Retracted Distance
the arm tip pin. Retracted
3. Position the arm and buckets cylinders with the Distance
rod 50 mm (2 in) retracted from the fully extended
position. Height of the
boom foot pin is
4. Maintain hydraulic oil temperature at 50±5 °C the same as the arm tip pin.
(122±9 °F).
Drift Amount
Measurement: T1F3-04-04-011
1. Stop the engine.

2. Five minutes after the engine has been stopped, Boom and Bucket Cylinder Retraction
measure the change in position of bottom of the
bucket, as well as the boom, arm and bucket Mark Mark
cylinders.
the average values.
Evaluation:
T110-06-03-002
Remedy:
Refer to TROUBLESHOOTING / Troubleshooting B Arm Cylinder Extension
in Group T5-7.
Mark
T110-06-03-001
T4-4-14
CONTROL LEVER OPERATING FORCE
Summary:
1. Measure a play and operating condition of each
control lever.
2. Measure the maximum operating force of front
attachment control lever.
3. Measure the operating force at the grip center of
each control lever.
Preparation:
(122±9 °F).
CAUTION: Prevent personal injury. Always T107-06-03-003

starting the measurement. Knob
Measurement:
1. Measure for each control lever.
2. Select the following switch positions: TCJB-04-04-003

Digging
mode
3. In case of boom (raise), arm and bucket control
lever, measure the maximum operating force for
each with each actuator relieved.
4. In case of boom (lower) control lever, measure the
maximum operating force with the boom (lower)
relieved by raising the machine in a safe area.
5. In case of swing control lever, measure the
maximum operating force with swing relieved after
securing the front attachment to prevent swinging.
6. In case of handle, measure the maximum
operating force by using a spring balance
attached to knob.
the average values.
Evaluation:
T4-4-15
CONTROL LEVER STROKE
Summary:
1. Check a play and operating condition of each
control lever and measure the stroke.
2. Measure the control lever stroke at the grip center Stroke Stroke
of each control lever.
3. In case control lever stroke play is present in the
neutral position, add half (1/2) the play present to
both side control lever strokes.
Neutral
Preparations:
1. Maintain hydraulic oil temperature at 50±5 °C T1F3-04-04-012
(122±9 °F).
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 number of rotation of handle from
right to left stroke end and from left to right stroke
end.
4. Measure the straight dimension.
the average values.
Evaluation:
T4-4-16
COMBINED OPERATION OF BOOM RAISE
/ SWING FUNCTION CHECK
Summary:
1. Check boom raise and swing movement and
speeds while operating both functions
simultaneously.
2. Check that the cylinders do not hesitate while
operating the cylinder with the engine running at
fast.
Preparation:
bucket cylinder fully extended, lower the bucket
onto the ground. (The bucket must be empty.)
2. Maintain hydraulic oil temperature at 50±5 °C T212-07-03-005
(122±9 °F).

Measurement: T212-07-03-006

Digging
mode
2. Raise the boom and roll the swing in full stroke at
the same time. When the upperstructure rotates
90°, release the control levers to stop both
functions. Measure the time required to swing 90°
and height (H) of the bucket teeth. (The bucket
must be empty.)
the average values.
H
Evaluation:
Remedy: 90° T212-07-03-007

in Group T5-7.
T4-4-17
(Blank)
T4-4-18
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Stop the engine.
2. Push the air bleed valve of the oil supply cap and
release any remaining pressure.
3. Remove the plug from the pilot filter. Install
adapter (ST 6069) and pressure gauge (ST 6942)
to the pressure check port.
: 14 mm
4. Start the engine. Check for any oil leaks at the
pressure gauge connection. Plug
(122±9 °F).
Measurement: T178-03-07-001
1. Select the following switch positions.
Power
Engine Auto-Idle
Mode Work Mode
Control Dial Switch
Switch
Digging
Fast idle P OFF
mode
Digging
Slow idle P OFF
mode
2. Measure pilot pressure in each specified setting
above without load by using a pressure gauge.
the average values.
Evaluation:
T4-5-1
Primary Pilot Pressure Adjustment Procedure
Adjustment:
Adjust the relief valve set pressure if necessary.
Relief Valve
1. Remove plug (1) from the relief valve.
: 22 mm
2. Install the estimated number of shims (2).
3. After adjustment, tighten plug (1).
+2 +0.2 +1.5
: 25 N⋅m (2.5 kgf⋅m, 18.4 lbf·ft) T178-03-07-001
4. After adjustment, check the set pressure.
1
NOTE: Standard Change in Pressure (Reference) 2
Shim Change in Pressure
Thickness
kPa (kgf/cm2) (psi)
(mm)
0.25 78 (0.8) (11)
0.5 157 (1.6) (23)
1.0 304 (3.1) (44)
T111-06-04-004
T4-5-2
SECONDARY PILOT PRESSURE
Preparation:
1. Stop the engine.
2. Push the air bleed valve of the oil supply cap and Pilot Valve Signal Control Valve
3. Measure pressure at the location between pilot Hose
valve and signal control valve. Remove the pilot
hose from the circuit to be measured. Install the Fitting
hose (9/16-18UNF, Length: approx. 400 mm (16
in)) to the signal control valve side. Install tee
(4351843), adapter (ST 6460), fitting (ST 6069),
coupling (ST 6332) and pressure gauge (ST 6315)
between the hoses. Pressure
Gauge
: 17 mm, 19 mm
Tee
Adapter
NOTE: When removing the lines from signal con-
trol valve, use tool (SNAP-ON
GAN850812B: size 19.05 mm) in order to
easily remove the lines.

pressure gauge connection.
(122±9 °F). T1F3-04-05-008
Measurement:
Power
Engine Auto-Idle
Mode Work Mode
Control Dial Switch
Switch
Digging
Fast idle P OFF
mode
Digging
Slow idle P OFF
mode
2. Measure pilot pressure by using a pressure gauge
with the corresponding control lever operated to
full stroke.
the average values.
Evaluation:
Remedy:
in Group T5-7.
T4-5-3
SOLENOID VALVE SET PRESSURE
Use both Dr. ZX and a pressure gauge.
Preparation:
1. Stop the engine.
Solenoid Valve Unit
3. Remove the line from the solenoid valve to be Pressure Gauge
measured. Install tee (ST 6451), hose (Parts
Number: 4216453), adapter (ST 6461) and pres-
sure gauge (ST 6942).
: 17 mm, 19 mm, 22 mm
4. Connect Dr. ZX and select the monitoring function.
6. Maintain hydraulic oil temperature at 50±5 °C Hose Tee Adapter
(122±9 °F). T157-05-04-002
Measurement:
Power
Engine Auto-Idle
Mode Work Mode
Control Dial Switch
Switch
Digging
Fast idle P OFF
mode
Digging
Slow idle P OFF
mode
2. Operate as instructed below for each measuring
solenoid valve:
• Solenoid Valve SI: SC SF SI
Set the brake switch to the Axle lock position.
• Solenoid Valve SF:
When setting the brake switch to the Axle lock or
Auto axle lock position and stopping the machine,
depress the brake pedal.
• Solenoid Valve SC:
Combined operation of swing and arm roll-in.
3. Read the values on both Dr. ZX and the pressure
gauge.
the average values. TCGB-03-12-001
Evaluation:
T4-5-4
Solenoid Valve Adjustment Procedure
7 O-Ring
IMPORTANT: As O-ring is damaged and oil leak-

8
age may cause, do not loosen ad-
justing screw (8) excessively.
Do not loosen adjusting screw (8)
more than 2 turns.
1. Loosen lock nut (7). Turn adjusting screw (8) and

adjust the set pressure.
2. After adjustment, tighten lock nut (7).
: 10 mm T1V1-04-05-004
: 5 N⋅m (0.5 kgf⋅m, 3.7 lbf·ft) 2.0 mm (0.079 in) or less

: 3 mm from end of Lock Nut
NOTE: Standard Change in Pressure (Reference)

Screw Turns 1/4 1/2 3/4 1
kPa 69 137 206 275 7
Change
(kgf/cm2) (0.7) (1.4) (2.1) (2.8)
in Pressure
(psi) (10) (20) (30) (40)
T1V1-04-05-003
7 8
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-5
MAIN PUMP DELIVERY PRESSURE
This pressure can also be measured by using Dr. ZX.
Preparation:
1. Stop the engine.
3. Remove the plug of pressure check port from the
main pump delivery port. Install adapter (ST 6069),
hose (ST 6943) and pressure gauge (ST 6941).
: 6 mm
4. Connect Dr. ZX and select the monitoring func-
tion.
(122±9 °F).
Measurement:
Power
Engine Auto-Idle
Mode Work Mode
Control Dial Switch
Switch T157-05-04-005
Digging
Fast idle P OFF
mode
2. Measure pressure with the control levers in neu-
tral without load.
the average values.
Evaluation:
Remedy:
in Group T5-7.
T4-5-6
(Blank)
T4-5-7
MAIN RELIEF SET PRESSURE
Summary:
Measure the main relief valve set pressure at the de-
livery port in main pump. (This pressure can also be
measured by using Dr. ZX.)
Preparation:
1. Stop the engine.
3. Remove the plug of pressure check port from
: 6 mm
4. Connect Dr. ZX and select the monitoring func-
tion.
(122±9 °F).
Measurement:
Power
Engine Auto-Idle
Mode Work Mode
Control Dial Switch T157-05-04-005
Switch
Digging
Fast idle P OFF
mode
2. First, slowly operate the bucket, arm and boom
control levers to the stroke end and relieve each
function.
3. As for the swing control function, secure the up-
perstructure so it is immovable. Slowly operate
the swing control lever and relieve the swing
function.
4. As for the travel function, secure the tracks
against an immovable object. Slowly operate the
travel control levers and relieve the travel function.
Evaluation:
T4-5-8
NOTE: If the measure pressures for all functions

are lower than the specified range, the
probable cause is a decrease of the main Main Relief
relief valve setting pressure. Valve
If the relief pressure of a particular function
is lower, the probable cause is other than
main relief valve.
Main Relief Pressure Setting Adjustment Proce-

dure
Adjustment:
1. Loosen lock nut (1).
: 17 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
2. Turn adjusting screw (2) to adjust the main relief

set pressure referring to the table below.
3. Retighten lock nut (1). T16W-03-03-032
4. Recheck the set pressures.

1 2

Plug Turns 1/4 1/2 3/4 1
Change in MPa 2.79 5.59 8.36 11.2
2
Relief (kgf/cm ) (28.5) (57) (85.2) (114)
Pressure (psi) (405) (811) (1212) (1620)
T176-03-03-010
Adjusting
Screw
Pressure Pressure
Increase Decrease
T105-06-05-002
T4-5-9
RELIEF PRESSURE (WHEN RELIEVING Swing Relief
SWING) Valve

: 24 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
2. Turn adjustiing screw (2) to adjust the swing relief

pressure setting referring to the table below.
: 8 mm
3. Retighten lock nut (1).
4. Recheck the set pressures.

Screw Turns 1/4 1/2 3/4 1
Change in MPa 0.9 2.0 2.9 3.9
2
Relief (kgf/cm ) (10) (20) (30) (40)
Pressure (psi) (142) (284) (427) (570)
T176-01-02-002
1 2
T176-04-04-004
Adjusting
Screw
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-10
(Blank)
T4-5-11
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary:
1. The circuit pressure must be increased by apply- 5. Maintain hydraulic oil temperature at 50±5 °C
ing an external force while blocking the return cir- (122±9 °F).
cuit from the control valve. This measuring
method is hazardous and the results obtained with Measurement:
this method are unreliable. 1. Select the following switch positions.
2. The oil flow rate used to set the overload relief Engine Power Mode Auto-Idle
Work Mode
pressure is far less than that used to set the main Control Dial Switch Switch
relief pressure. Therefore, measuring the overload Digging
pressure in the main circuit by increasing the main Fast idle P OFF
mode
relief set pressure more than the overload valve
set-pressure is not a proper method. In addition, in 2. Slowly operate the bucket, arm or boom control
case a main relief valve designed to leak a small levers to the stroke ends and relieve each func-
quantity of oil before reliving is used, its tion.
pre-leaking start pressure must be increased 3. Read pressures on the pressure gauge at this
more than the overload relief valve set pressure. time.
However, the pre-leaking start pressure is not al- 4. Perform the measurement for the bucket, arm and
ways increased more than the overload relief boom in that order.
valve set-pressure as the adjustable upper limit of 5. Repeat the measurement three times. Calculate
the main relief valve set pressure is provided. the average value for each.
Accordingly, the overload relief valve assembly
should be removed from the machine and
checked on a specified test stand at a correct oil
flow rate. Some overload relief valves come in
contact with the control valve body to block the oil
passage. When this type of overload relief valve is
checked, the control valve body must be precisely
finished as the test unit. Provide one control valve
other than that on the machine as a test kit.
3. If the overload relief valve performance must be
checked on the machine, however, measure the
main relief pressure while releasing each front
function respective to the measuring overload re-
lief valve. And, assume that the overload relief
valve is functioning correctly if the obtained main
relief pressure is within the specified value range.
Measure the main pressure of the front functions
by using Dr. ZX as follows.
Preparation:
1. Stop the engine.
2. Push the air bleed valve on top of the oil supply
cap and release any remaining pressure.
3. Remove the plug from pressure check port of
T157-05-04-005
: 6 mm
4. Connect Dr. ZX and select the monitoring function.

Start the engine. Check for any oil leaks at the
T4-5-12
Evaluation:
1. Performance of the overload relief valves are
normal if the measured main relief pressures are
within the specified value range.

Overload Relief Valve Pressure Adjustment Pro-

cedure
NOTE: In principle, adjust the overload relief valve
pressure on a test stand.
Loosen lock nut (1) and adjust pressure with adjust-

ing screw (2).

: 17 mm
2. Turn adjusting screw (2) in order to adjust pres- 1
sure.
: 6 mm
3. Tighten lock nut (1).
: 17 mm
: 29.5 N⋅m (3.0 kgf⋅m, 21.5 lbf·ft)
2
NOTE: Standard Change in Pressure (Reference) W107-02-05-128
Adjusting Screw (2)

1/4 1/2 3/4 1
Turns
MPa 5.2 10.6 15.9 21.1
Change 2
(kgf/cm ) (54) (108) (162) (216)
in Pressure 2
(psi) (770) (1540) (2300) (3070)
Pressure Pressure
Increase Decrease
W107-02-05-129
T4-5-13
MAIN PUMP FLOW RATE MEASUREMENT
• P-Q Control (Torque Control)

Summary:
Main pump performance is checked by measuring 5. Install a pressure gauge to the main pump to be
the pump flow rate by using a hydraulic tester in- measured. (Refer to “Main Relief Set Pressure”.)
stalled at the main pump delivery port (one side) to : 6 mm
be measured. Use Dr. ZX and a pressure gauge at 6. Remove pipe (13) from the regulator. Install plug
the same time. (G 1/4) to pipe (13) in the regulator.
: 17 mm
IMPORTANT: This measurement procedure is a 7. Remove the vacuum pump. Loosen plug (12) on
simple method. The measured data top of the pump casing. Bleed air from the casing
will be lower by approx. 5 % than the until oil only comes out.
accurately measured value. In order 8. Fully open the loading valve of hydraulic tester.
to measure accurately, disconnect 9. Start the engine. Check for any oil leaks at the
the return circuit from the control pressure gauge connection. Install Dr. ZX and
valve and connect it to the hydraulic select the monitoring function.
oil tank.
Measurement:
Preparation: 1. Maintain hydraulic oil temperature at 50±5 °C
1. Stop the engine. Push the air bleed valve and (122±9 °F).
bleed air. Install a vacuum pump to the oil filler 2. Measure the maximum flow rate.
port. 3. Select each switch position as follows.
NOTE: Operate the vacuum pump with the pump Engine Power Mode Auto-Idle
Work Mode
flow rate test line connected. Control Dial Switch Switch
2. Remove the delivery hose from main pump (one Digging
Fast idle P OFF
side) to be measured. Install pipe (1 or 2) by using mode
the split flanges and bolts which were used for the
removed delivery hose. 4. Adjust the relief set pressure of main relief valve in
: 41 mm control valve to each pressure point specified
: 10 mm along the main pump P-Q curve. (Refer to
3. Install pipe (1 or 2) to hydraulic tester (5) by using T4-2-13.) Slowly restrict the loading valve of hy-
test hose (3) and adapter (4). Install adapter (6), draulic tester while relieving pressure in the arm
joint (7), test hose (8) and flange (9) to hydraulic roll-in circuit. Measure the flow rates and engine
tester (5). speeds at each pressure point specified in the
: 41 mm P-Q curve.
: 10 mm 5. Repeat each measurement three times. Calculate
4. Install the delivery hose to flange (9) with split the average values.
flanges (10) and bolt (11).
: 10 mm
T4-5-14
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified pump speed by using the following for- Refer to OPERATIONAL PERFORMANCE TEST /
mulas: Standard in Group T4-2.
Qc = Ns×Q/Ne NOTE: When actually measuring, install pipe (1 or

2) only to the pump to be measured.
Qc : Converted Flow Rate
Q : Measured Flow Rate
-1
Ns : Specified Engine Speed: 2200 min
Ne : Measured Engine Speed:
Values indicated on Dr. ZX
1, 2 3 4 5 6 7 8 9 10 11
Delivery Hose
(To Control
Valve)
T173-04-04-002
13
12
TCEB-03-01-001
1 - Pipe E (ST 6144) 5- Hydraulic Tester (ST 6299) 8- Test Hose (ST 6320) 11 - Bolt (ST 6409) (4 Used)
2 - Pipe B (ST 6143) 6- Adapter PF1 × UNF1-7/8 9- Flange (ST 6118) 12 - Plug
(ST 6146)
3 - Test Hose (ST 6145) 7 - Joint (ST 6330) 10 - Split Flange (ST 6130) 13 - Pipe
4 - Adapter PF1 × UNF1-7/8
(ST 6146)
T4-5-15
• Pilot Pressure Characteristics
Summary:
Main pump performance is checked by measuring 5. Install hose (19) and adapter (20) to port T of
the pump flow rate by using a hydraulic tester in- pressure reducing valve (16). Remove plug L
stalled at the main pump delivery port (one side) to from the return pipe. Install hose (19).
be measured. Use Dr. ZX and a pressure gauge at : 19 mm, 22 mm
the same time. 6. Remove pipe (21) from the regulator. Install plug
(G 1/4) to the mounting hole for pipe (21) in the
IMPORTANT: This measurement procedure is a regulator.
simple method. The measured data : 17 mm
will be lower by approx. 5 % than the 7. Remove the vacuum pump. Loosen the plug from
accurately measured value. In order top of the pump casing. Bleed air from the pump
to measure accurately, disconnect casing until oil only comes out.
the return circuit from the control 8. Fully open the loading valve of hydraulic tester.
valve and connect it to the hydraulic 9. Start the engine. Check the connections for any
oil tank. oil leaks.
Preparation:
1. While referring to steps 1 to 4 on page T4-5-18.
Install a hydraulic tester to the main pump to be
measured.
2. Remove the hose from regulator port Pi of the
pump to be measured. Install plug (ST 6213) to
the removed hose.
: 6 mm, 19 mm
3. Install adapters (15) (3 used) to pressure reducing
valve (16). Remove plug M from the pilot filter.
Install adapter (13) and hose (14) to the pilot filter.
Install hose (14) to regulator port P1 on pressure
reducing valve (16).
: 19 mm
4. Install tee (17) to port P2 of pressure reducing
valve (16). Install pressure gauge (18) and hose
(14) to tee (17). Install hose (14) to the regulator.
: 19 mm
T4-5-16
1, 2 3 4 5 6 7 8 9 10 11
Delivery Hose
(To Control
Valve)
T173-04-04-002
21
12
Plug M
Port Pi
T178-03-07-001
TCEB-03-01-001
Pressure Reducing Valve Port Position

Pressure Reducing Return Pipe
Valve
T L
20
18
P1 P2 19
15
To Regulator To Pilot Filter

Port Pi
14 17 15 16 15 14 13
T178-04-04-004
1 - Pipe E (ST 6144) 7 - Joint (ST 6330) 12 - Plug M 17 - Tee UNF7/16×UNF7/16×
PF1/4 (ST 6451)
2 - Pipe B (ST 6143) 8 - Test Hose (ST 6320) 13 - Adaptor UNF7/16 18 - Pressure Gauge (ST
×PF1/4 (ST 6069) 6931)
3 - Test Hose (ST 6145) 9 - Flange (ST 6118) 14 - Hose UNF7/16× 19 - Hose UNF7/16×
UNF7/16(4334309) UNF7/16 (4334309)
4 - Adapter PF1 × UNF1-7/8 10 - Split Flange 15 - Adapter PF3/8×UNF7/16 20 - Adapter PF3/8×UNF7/16
(ST 6146) (ST 6130) (4200465) (4200465)
5 - Hydraulic Tester (ST 6299) 11 - Bolt (ST 6409) (4 Uded) 16 - Pressure Reducing Valve 21 - Pipe
(4325439)
(ST 6146)
T4-5-17
Measurement:
(122±9 °F).
2. Measure pump flow rate in response to the ex-
ternal command pilot pressure.
Power
Engine Auto-Idle
Mode Work Mode
Control Dial Switch
Switch
Digging
Fast idle P OFF
mode
4. Adjust the pressure reducing valve set pressure
to each pressure point specified along the main
pump P-Q curve. (Pilot Characteristics) (Refer to
T4-2-14.)
Measure the flow rates and engine speeds at the
pressure points specified in the P-Q curve.
the average values.
Evaluation:
1. Convert the measured flow rates to those at the
specified engine speed by using the following
formulas:
Qc = Ns×Q/Ne
Qc : Converted Flow Rate
Q : Measured Flow Rate
-1
Ns : Specified Engine Speed: 2200 min
Ne : Measured Engine Speed:
Values indicated on Dr. ZX
2. Standard Flow Rate

Refer to OPERATIONAL PERFORMANCE TEST
/ Standard in Group T4-2.
NOTE: When actually measuring, install pipe (1)

(ST 6144) or (2) (ST 6143) only to the
pump to be measured.
T4-5-18
1, 2 3 4 5 6 7 8 9 10 11
Delivery Hose
(To Control Valve)
T173-04-04-002
21
12
Plug M
Port Pi
T178-03-07-001
TCEB-03-01-001
Pressure Reducing Valve Port Position

Pressure Reducing Valve
Return Pipe
T L
20
18
P1 P2 19
15
To Regulator Port Pi To Pilot Filter
14 17 15 16 15 14 13
T178-04-04-004
1 - Pipe E (ST 6144) 7- Joint (ST 6330) 12 - Plug M 17 - Tee UNF7/16×UNF7/16×
PF1/4 (ST 6451)
2 - Pipe B (ST 6143) 8- Test Hose (ST 6320) 13 - Adaptor UNF7/16 18 - Pressure Gauge (ST
×PF1/4 (ST 6069) 6931)
3 - Test Hose (ST 6145) 9- Flange (ST 6118) 14 - Hose UNF7/16× 19 - Hose UNF7/16×
UNF7/16 (4334309) UNF7/16 (4334309)
4 - Adapter PF1 × UNF1-7/8 10 - Split Flange 15 - Adapter PF3/8×UNF7/16 20 - Adapter PF3/8×UNF7/16
(ST 6146) (ST 6130) (4200465) (4200465)
5 - Hydraulic Tester (ST 6299) 11 - Bolt (ST 6409) (4 Used) 16 - Pressure Reducing Valve 21 - Pipe
(4325439)
(ST 6146)
T4-5-19
Regulator Adjustment
6 5 1
2
10
4 3
7 8
T1V1-03-01-009
1 - Lock Nut (For Minimum 4 - Adjusting Screw (For 7 - Lock Nut (For P-Q 9 - Lock Nut (For P-Q
Flow Rate) Maximum Flow Rate) Control) Control)
2 - Adjusting Screw (For 5 - Lock Nut (For Pilot 8 - Adjusting Screw (For P-Q 10 - Adjusting Screw (For P-Q
Minimum Flow Rate) Pressure Characteristic) Control) Control)
3 - Lock Nut (For Maximum 6 - Adjusting Screw (For Pilot
Flow Rate) Pressure Characteristic)
Adjustment Item Adjustment Procedure Remarks

1. Minimum Flow Rate Loosen lock nut (1) and turn adjusting 1) Do not turn adjusting screw (2)
screw (2). more than two turn.
Rotating adjusting screw (2) 1/4 a 2) Securely tighten lock nut (1) after
turn clockwise increases the mini- adjustment.
mum pump flow rate by 6.56 cm3/rev.
3
(0.4 in /rev).
: 17 mm
: 19.6 N⋅m
(2 kgf⋅m, 14.5 lbf·ft)
2. Maximum Flow Rate Loosen lock nut (3) and turn adjusting 1) Do not turn adjusting screw (4)
screw (4). more than two turn.
Rotating adjusting screw (4) 1/4 a 2) Do not increase the maximum flow
turn clockwise decreases the maxi- rate.
mum pump flow rate by 8.22 cm3/rev. In other words, do not turn adjust-
3
(0.5 in /rev). ing screw (4) counterclockwise.
: 13 mm 3) Securely tighten lock nut (3) after
: 9.8 N⋅m (1 kgf⋅m, 7.2 lbf·ft) adjustment.
T4-5-20

3. Pilot Pressure Characteristics Loosen lock nut (5) and turn ad- 1) Do not turn adjusting screw (6) more
justing screw (6). than one turn.
Rotating adjusting screw (6) 1/4 2) When adjusting screw (6) is turned
a turn clockwise decreases the clockwise, the maximum flow rate
3
flow rate by 13.2 cm /rev. will also be decreased.
Q 3
(0.71 in /rev). In order to maintain the maximum
: 30 mm flow rate unchanged, turn adjusting
: 29.5 N⋅m screw (4) counterclockwise twice as
(3 kgf⋅m, 21.5 lbf⋅ft) much as adjusting screw (6) is
turned.
This ratio of 2 (adjusting screw (4)
counterclockwise turn) to 1 (adjust-
ing screw (6) clockwise turn) is to
Pi
counterbalance.
3) Securely tighten lock nut (5) after
adjustment.
4. P-Q Control A: Loosen lock nut (7) and turn 1) Do not turn the adjusting screws
(Torque Adjustment) adjusting screw (8). more than one turn.
Rotating adjusting screw (8) 2) Rotate the adjusting screws watch-
Q 1/4 a turn clockwise increases ing the engine performance.
3
the flow rate by 15.3 cm /rev. 3) Securely tighten lock nut (7) or (9)
3
A (0.93 in /rev.). after adjustment.
B: Loosen lock nut (9) and turn 4) Do not decrease the maximum flow
adjusting screw (10). rate. In other words, do not turn ad-
Rotating adjusting screw (10) justing screws (8, 10) counter-
1/4 a turn clockwise increases clockwise.
3
the flow rate by 3.60 cm /rev.
Pd 3
(0.22 in /rev).
Pd
T4-5-21
Adjustment of Maximum Pump 1 and 2 Flow Rate
Limit Control Solenoid Valve
Maximum Pump 2 Flow Rate Limit

Control Solenoid Valve
Torque Control
Solenoid Valve

TCEB-03-01-001

1. Flow Rate of Flow Rate Loosen lock nut (1) of the solenoid 1) Adjust only maximum pump 2 flow
Limit valve and turn adjusting screw (2). rate limit control solenoid valve at
(When using boom, arm, Rotating adjusting screw (2) 1/4 a the pump 2 side.
bucket, swing and attach- turn clockwise decreases the pump 2) Do not turn adjusting screw (2)
ment) flow rate by 13.2 cm3/rev. (0.8 more than one turn.
3
in /rev). 3) Securely tighten lock nut (1) after
: 10 mm adjustment.
Q
: 5.0 N⋅m (0.5 kgf⋅m, 3.7 lbf·ft)
Pi
T4-5-22
(Blank)
T4-5-23
SWING MOTOR DRAINAGE
Summary:
1. Measure amount of oil draining from the swing
motor while swinging the upperstructure and
check the swing motor performance.
2. Secure absolute safety for the measuring persons
as well as for the surrounding while measuring.
3. Keep oil temperature constant as the drain
amount from the swing motor is much influenced
by oil temperature.
Preparation:
(122±9 °F). Rotate the swing motor in order to
warm inside of the motor.
2. Stop the engine. Push air bleed valve (1) of the oil
supply cap and release any remaining pressure. 1
3. Remove drain hose (2) of the swing motor at the
hydraulic oil tank end. Install plug (ST 6213) to the
removed end on the hydraulic oil tank.
: 22 mm
: 39 N⋅m (4 kgf⋅m, 28.5 lbf·ft)

Also, take care not to fall off the machine T157-05-04-014
while the measurement.

2
Conditions for Measurement

Power
Engine Auto-Idle
Mode Work Mode
Control Dial Switch
Switch
Digging
Fast idle P OFF
mode
T178-04-04-005
T4-5-24
Measurement:

Also, take care not to fall off the machine
while the measurement.
Height of the boom
• Amount of Oil Drained While Swinging the Up- foot pin is the same
perstructure as the arm tip pin
1. Fully retract the arm cylinder. Fully extend the
bucket cylinder. Hold the boom so that the arm tip T212-07-04-001
pin height is the same as the boom foot pin height.

The bucket must be empty.
2. Start the engine. Operate and hold the swing
control lever to full stroke. After the swing speed
reaches a constant maximum speed, start drain-
ing oil measurement when drain oil starts coming
out of the drain hose end.
3. Repeat the measurement three times in both
clockwise and counterclockwise directions. Cal-
culate the average values.
4. The measuring time should be for more than 45
seconds.
T212-07-04-002
• Amount of Oil Drained While Relieving Swing
Motor Circuit
1. Thrust the bucket teeth into the ground so that the
upperstructure does not rotate. Set the swing lock
lever to the LOCK position so that the upper-
structure does not rotate.
2. Start the engine. Operate and hold the swing
control lever to full stroke. Start draining oil
measurement when drain oil starts coming out of
the drain hose end.
3. Repeat the measurement three times in both
clockwise and counterclockwise directions. Cal-
culate the average values.
4. The measuring time should be for more than 45
seconds. Swing Lock Lever M216-05-004
Evaluation:
∗ Conversion of amount of drain oil measured into the

per-minute value
First measure amount of drain oil by using a cali-
brated container. Then, convert the measured drain
oil into the per-minute value by using the formula
below:
∆Q = 60 × q / t
∆Q : Amount of drain oil per minute (L/min)
T107-06-05-008
t : Measured time (seconds)
q : Total amount of drain oil (L)
T4-5-25
STEERING VALVE RELIEF PRESSURE
Use both Dr. ZX and a pressure gauge.

CAUTION: If air is mixed in the brake system,
the brake function is reduced, and serious
hazard may occur. Bleed air from the brake
system after removing and installing the pipe
lines of steering and brake and replacing hy-
draulic oil.
(Refer to the TROUBLESHOOTING / Trouble-
shooting B group.)
Summary:
The steering circuit is provided with the steering relief
valve. When the steering relief valve is faulty, the
handle will turn heavily.
Preparation:
1. Stop the engine.
2. Push the air bleed valve (1) on top of the hydraulic
oil tank and release any remaining pressure. 1
3. Remove the hoe of steering filter outlet or inlet.
Install tee 3/4-16UNF (ST 6477), fitting (ST 6069)
and pressure gauge assembly (ST 6933) between
steering filter and hose.
: 22 mm, 24 mm
4. Connect Dr. ZX and monitor the pump 3 pressure.
(122±9 °F).
MCBB-07-025
Steering Filter
MCBB-07-027
T4-5-26
Measurement:
Engine Power Work Auto-Idle
Control Mode Mode Switch
Dial Switch
Digging
Fast idle P OFF
mode
2. Measure the steering pressure in the handle from
right to left stroke end and from left to right stroke
end by using a pressure gauge.
3. Repeat the measurements three times. Calculate
the average values.
Evaluation:
Remedy
The steering relief valve cannot be adjusted. If the
steering pressure does not meet standard value, re-
place the steering relief valve as an assembly.
T4-5-27
BRAKE PRESSURE (FRONT AND REAR)

the brake function is reduced and serious
hazard may occur. Bleed air from the brake
system after removing and installing the pipe
lines and replacing hydraulic oil.
(Refer to TROUBLESHOOTING / Trouble-
shooting B in Group T5-7.)
Summary:
Measure the brake pressure at the brake valve outlet
side. Measure the pressure when depressing the
brake pedal and applying the working brake.
Preparation:
CAUTION: Install the measuring equipment
under a machine. Install it on flat and solid SA-1140
ground after securing the front attachment in
order to prevent running away and an oper-
ating error.
1. Stop the engine.

release any remaining pressure from the hydraulic Front
oil tank. Axle
3. Depress the brake at least 50 strokes in order to
reduce the accumulated pressure left in the brake
circuit.
4. Install the measuring equipment to front and rear
wheel brake circuit.
4-1. Front wheel brake circuit pressure: Remove
front wheel brake hose (1). Install tee
9/16-18UNF (ST 6485), fitting (ST 6069) and
pressure gauge assembly (ST 6932) to the re- T1F3-04-05-003
moved hose.
: 19 mm, 22 mm 1
4-2. Rear wheel brake circuit pressure: Remove rear
wheel brake hose (2). Install tee 9/16-18UNF
(ST 6485), fitting (ST 6069) and pressure gauge
assembly (ST 6932) to the removed hose.
: 19 mm, 22 mm Rear
Axle
(122±9 °F).
T1F3-04-05-004
T4-5-28
Engine Power Mode Work Mode Auto-Idle FNR Brake
Control Dial Switch Switch Switch Switch
Fast idle P Digging mode OFF N OFF
Measurement:
1. Measure the pressure when fully depressing the
brake pedal.
2. Measure the pressure when the work brake is
operable.
the average values.
Evaluation:
Remedy
in Group T5-7.
Normally, the front and rear wheel brake pressures
become equal. If not, malfunction of the brake valve
and dirt caught in the valve are suspected.
T4-5-29
BRAKE ACCUMLATED PRESSURE

the brake function is reduced serious hazard
may occur. Bleed air from the brake system
after removing and installing the pipe lines
and replacing hydraulic oil.
Refer to TROUBLESHOOTING / Trouble-
shooting B group.
Summary:
The accumulated brake pressure is measured at
output port of the accumulator. The accumulated
brake pressure varies according to operation of the
brake. Record the maximum value.
Preparation:

under a machine. Install it on flat and solid
ating error.
1. Stop the engine.

2. Push the air bleed valve on the oil supply cap and
release any remaining pressure in the hydraulic oil
tank.
circuit.
4. Remove the cover under the cab.
Remove brake hose (1).
Install tee (9/16-18UNF) (ST 6485), fitting (ST
6069) and pressure gauge assembly (ST 6932)
between the removed hoses.
: 19 mm, 22 mm
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T4-5-30
Engine Power Mode Work Mode Auto-Idle FNR Brake
Measurement:
1. When depressing the brake pedal slowly several
times, measure the maximum pressure.
the average values.
Evaluation:
Remedy
in Group T5-7.
T4-5-31
BRAKE WARNING SET PRESSURE
(DECREASE)

shooting B group.)
Summary:
When the warning buzzer sounds by reducing the
accumulated brake pressure, measure the pressure
at the output port of accumulator.
Preparation:

ating error.
1. Stop the engine.

tank.
circuit.
： 19 mm, 22 mm
(122±9 °F).
T4-5-32
Conditions for Measurement:
Forward/Reverse Lever Parking Brake Switch
N P (Parking Brake)
Measurement:
1. Stop the engine. Turn the key switch to ON posi-
tion.
2. Measure the pressure when warning buzzer
sounds by slowly depressing the brake pedal
several times.
the average values.
Evaluation:
Remedy:
in Group T5-7.
T4-5-33
BRAKE WARNING SET PRESSURE
(INCREASE)

shooting group.)
Summary:
When sounding of the warning buzzer stops by in-
creasing the accumulated brake pressure, measure
the pressure at the output port of accumulator.
Preparation:

ating error.
1. Stop the engine.

tank.
circuit.
： 19 mm, 22 mm
(122±9 °F).
T4-5-34

Engine Power Mode Auto-Idle FNR Brake
Work Mode
Measurement:
1. Stop the engine. Turn the key switch to ON posi-
tion.
2. Set the engine control dial to slow idle.
3. Depress the brake pedal several times and make
the warning buzzer sound.
4. Start the engine. Measure the pressure when
sounding of the warning buzzer stops. Notice that
it is difficult to read the gauge as the pressure in-
creases rapidly.
5. Repeat the measurement three times and calcu-
late the average values.
Evaluation:
Remedy:
in Group T5-7.
T4-5-35
(Blank)
T4-5-36
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SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 Diagnosing Procedure Group 4 ICF
Introduction........................................................................... T5-1-1 Outline..................................................................................... T5-4-1
Diagnosing Procedure....................................................... T5-1-2 List of Daily Report Data.................................................... T5-4-2
List of Frequency Distribution Data.............................. T5-4-5
Group 2 Monitor Unit
List of Total Operating Hours........................................... T5-4-6
Outline..................................................................................... T5-2-1 How to Download and
How to Use Screens..........................................................T5-2-17 Upload Data of ICF......................................................... T5-4-8
Screen Display When An Alarm Various Setup of ICF and
is Issued............................................................................T5-2-24 Satellite Communication Terminal
Contents of Alarms............................................................T5-2-26 by Using Dr. ZX..................................................................T5-4-11
Time Setting.........................................................................T5-2-29 List of Fault Code................................................................T5-4-23
Attachment Adjustment Satellite Communication System.................................T5-4-24
(Pump 2 Flow Rate Adjustment).............................T5-2-30
Displaying Operating Conditions................................T5-2-32 Group 5 Component Layout
Maintenance Settings......................................................T5-2-34 Main Component Layout.................................................. T5-5-1
Work Mode (Attachment Selection)...........................T5-2-40 Electrical Component Layout
Mail (Optional)....................................................................T5-2-44 (Overview)......................................................................... T5-5-6
Meter Display Selection...................................................T5-2-46 Electrical Component Layout
Password Change (Optional).........................................T5-2-48 (Monitors and Switches).............................................. T5-5-8
Back Monitor Settings......................................................T5-2-52 Electrical Component Layout
Language Settings............................................................T5-2-56 (Controllers and Relays).............................................T5-5-11
Meter Combination Settings.........................................T5-2-58 Engine....................................................................................T5-5-13
Unit Settings........................................................................T5-2-60 Pump Device.......................................................................T5-5-14
Service Menu (Built-In Diagnosing System) Swing Device.......................................................................T5-5-14
Operation........................................................................T5-2-63 Signal Control Valve..........................................................T5-5-14
Troubleshooting.................................................................T5-2-64 Control Valve.......................................................................T5-5-15
Monitoring...........................................................................T5-2-66 Brake Valve...........................................................................T5-5-15
Controller Version..............................................................T5-2-70 3-Spool Solenoid Valve Unit...........................................T5-5-15
Blade/Outrigger Settings................................................T5-2-72 Solenoid Valve Unit (for Electric Lever)......................T5-5-15
Keyless Hour Meter...........................................................T5-2-74 Travel Shockless Valve......................................................T5-5-16
List of Monitor Unit Sitting Function..........................T5-2-75 Transmission Changeover
Solenoid Valve...............................................................T5-5-16
Group 3 Dr. ZX
Travel Device.......................................................................T5-5-16
Outline..................................................................................... T5-3-1 Filter........................................................................................T5-5-16
MC Monitoring List.............................................................. T5-3-2 Components in Control Valve........................................T5-5-18
ECM Monitoring List........................................................... T5-3-5 Pilot Port................................................................................T5-5-32
Monitor Unit Monitoring List........................................... T5-3-6
Steering Column Monitor Group 6 Troubleshooting A
Monitoring List................................................................ T5-3-7 Troubleshooting A Procedure......................................... T5-6-1
Option Controller Monitoring List................................. T5-3-8 MC Fault Code List............................................................... T5-6-2
MC Adjustment List...........................................................T5-3-10 ECM Fault Code List...........................................................T5-6-24
MC Attachment Adjustment List..................................T5-3-12 ICF Fault Code List.............................................................T5-6-48
ICF Adjustment Item List.................................................T5-3-16 Satellite Terminal Fault Code List.................................T5-6-49
Option Controller Adjustment List..............................T5-3-18 Monitor Unit Fault Code List..........................................T5-6-49
Dr. ZX Operation Procedure...........................................T5-3-20 Option Controller Fault Code List................................T5-6-50
CEBT-5-1
Steering Column Monitor Option Controller Fault Code 15516........................ T5-6-152
Fault Code.......................................................................T5-6-68 Option Controller Fault Code 15517........................ T5-6-153
MC Fault Codes 11000 to 11002...................................T5-6-70 Option Controller Fault Code 15518........................ T5-6-154
MC Fault Code 11003.......................................................T5-6-71 Option Controller Fault Code 15519........................ T5-6-155
MC Fault Code 11004.......................................................T5-6-72 Option Controller Fault Code 15570........................ T5-6-156
CAN Harness Check...........................................................T5-6-73 Option Controller Fault Code 15571........................ T5-6-157
MC Fault Code 11100.................................................... T5-6-105 Option Controller Fault Code 15572........................ T5-6-158
MC Fault Code 11200.................................................... T5-6-107 Option Controller Fault Codes
MC Fault Code 11202.................................................... T5-6-108 15574-3 and 15578-3............................................... T5-6-160
MC Fault Code 11306.................................................... T5-6-116 20300 to 20303.......................................................... T5-6-164
MC Fault Codes 11910 to 11920................................ T5-6-128 Option Controller Fault Codes
MC Fault Code 11901.................................................... T5-6-129 15565 to 15577.......................................................... T5-6-176
ECM Fault Codes 100 to 190....................................... T5-6-130 Steering Column Monitor
ECM Fault Codes 628 to 1485..................................... T5-6-131 Fault Code 16000....................................................... T5-6-177
ECM Fault Codes 10001 to 10013.............................. T5-6-132
Group 7 Troubleshooting B
ICF Fault Codes 14000 to 14003................................ T5-6-133
Information C/U: Intialize............................................. T5-6-134 Troubleshooting B Procedure......................................... T5-7-1
Control Data: Intialize.................................................... T5-6-135 Relationship between Machine Trouble
Enter Model and Serial No........................................... T5-6-136 Symptoms and Related Parts..................................... T5-7-2
ICF Fault Codes 14006, 14008..................................... T5-6-137 Correlation between Trouble
Satellite Terminal Fault Codes Symptoms and Part Failures.....................................T5-7-22
14100 to 14106.......................................................... T5-6-138 Engine System Troubleshooting..................................T5-7-38
Monitor Unit Fault Code 13303................................. T5-6-139 All Actuator System Troubleshooting.........................T5-7-66
Monitor Unit Fault Code 13304................................. T5-6-140 Front Attachment System
Monitor Unit Fault Codes Troubleshooting...........................................................T5-7-74
13306 and 13308....................................................... T5-6-141 Swing System Troubleshooting....................................T5-7-88
Monitor Unit Fault Code 13310................................. T5-6-142 Travel System Troubleshooting....................................T5-7-90
Monitor Unit Fault Code 13311................................. T5-6-143 Brake System Troubleshooting.................................. T5-7-102
Pilot Shut-Off Lever Alarm........................................... T5-6-144 Steering System Troubleshooting............................ T5-7-105
Option Controller Fault Codes Other System Troubleshooting.................................. T5-7-106
15500 to 15504.......................................................... T5-6-145 Exchange Inspection..................................................... T5-7-126
Option Controller Fault Code 15505........................ T5-6-146 Bleeding Air from Transmission................................. T5-7-130
Option Controller Fault Code 15506........................ T5-6-147 Bleeding Air from Brake (Axle)................................... T5-7-131
Option Controller Fault Code 15510........................ T5-6-148 Emergency Boom Lowering Procedure
Option Controller Fault Code 15511........................ T5-6-149 (without Hose Rupture Valve)............................... T5-7-132
Option Controller Fault Code 15514........................ T5-6-150 Attachment Circuit Pressure Release
Option Controller Fault Code 15515........................ T5-6-151 Procedure..................................................................... T5-7-133
CEBT-5-2
Group 8 Electrical System Inspection
Precautions for Inspection and
Maintenance.................................................................... T5-8-1
Instructions for Disconnecting
Connectors....................................................................... T5-8-3
Fuse Inspection..................................................................... T5-8-4
Fusible Link Inspection...................................................... T5-8-6
Battery Voltage Check........................................................ T5-8-7
How to Check Alternator................................................... T5-8-8
Continuity Check................................................................. T5-8-9
Voltage and Current Measurement.............................T5-8-10
Check by False Signal.......................................................T5-8-17
Test Harness.........................................................................T5-8-18
CEBT-5-3
(Blank)
CEBT-5-4
TROUBLESHOOTING / Diagnosing Procedure
INTRODUCTION
Refer to the inspection and troubleshooting proce-

dures after any machine trouble has occurred. The
inspection and troubleshooting procedures are pre-
sented in an orderly fashion in this section to quickly
find the cause of the machine trouble and solution.
The troubleshooting section in this manual consists of

8 groups; Diagnosing Procedure, Monitor Unit, Dr. ZX,
ICF, Component Layout, Troubleshooting A (base
machine diagnosis by using fault codes), Trouble-
shooting B (base machine diagnosis starting with in-
spection of abnormal operational status) and Electrical
System Inspection.
• Diagnosing Procedure • Troubleshooting A (base machine diagnosis by

using fault codes)
• Monitor Unit Refer to these procedures if any fault codes are
Refer to this group as for the display screen and displayed when each controller (MC, ECM, ICF
operating procedures of monitor unit. and monitor unit) is diagnosed by using Dr. ZX (or
the service menu of monitor unit).
• Dr. ZX
This group contains the operating procedures for
Dr. ZX. IMPORTANT: ICF receives and retains a record of
the electrical signal system mal-
• ICF function of each controller in the
This group contains as follows. form of fault codes by using CAN
Download data from ICF and Upload communication. In addition, ICF
Procedures when starting satellite communication, self-diagnosing function records the
when installing the satellite communication con- electrical signal system malfunction
troller and when replacing ICF in the form of fault codes
Explanation for the satellite communication sys- Ex.) Fault Code 11004-2: Failure of CAN Com-
tem munication
• Component Layout • Troubleshooting B (base machine diagnosis start-

ing with inspection of abnormal operational
status)
Refer to these procedures when no fault codes
are displayed after diagnosing the machine with
Dr. ZX (or the service menu of monitor unit).
Ex.) Although the engine control dial is turned,
engine speed does not change.
• Electrical System Inspection

Refer to this group when required to obtain pre-
cautions and/or information for the electrical sys-
tem inspection.
Ex.) Fuse Check
T5-1-1
DIAGNOSING PROCEDURE
These six basic steps are essential for efficient

troubleshooting:
1. Study the System

Study the machine’s technical manuals. Know the
system and how it works, and what the
construction, functions and specifications of the
system components are.
2. Ask the operator

Before inspecting, get the full story of
malfunctions from the operator below.
T107-07-01-001
(a) How is the machine being used? (Find out if

the machine is being operated correctly)
(b) When was the trouble noticed, and what

types of work the machine doing at that
time?
(c) What are the details of the trouble? Is the

trouble getting worse, or did it appear
suddenly for the first time?
(d) Did the machine have any other troubles

previously? If so, which parts were repaired
before?
3. Inspect the machine

Before starting the troubleshooting procedure, T107-07-01-002
check the machine’s daily maintenance points, as
shown in the operator's manual.
Also, check the electrical system, including the

batteries, as troubles in the electrical system such
as low battery voltage, loose connections and
blown fuses will result in malfunction of the
controllers, causing total operational failure of the
machine.
If troubleshooting is started without checking for
blown fuses, a wrong diagnosis may result,
wasting time. Check for blown fuses before
troubleshooting. Even if a fuse looks normal by
visual inspection, a fine crack is difficult to find.
Always use a tester when checking the fuses.
T107-07-01-003
T5-1-2
4. Operate the machine yourself

Try to identify the trouble by operating the
machine yourself.
If the trouble cannot be confirmed, stop the
engine and obtain further details of the
malfunction from the operator.
Also, check for any incomplete connections of the
wire harnesses correponding to the trouble.
T5-1-3
5. Perform troubleshooting
CAUTION: Do not disconnect harnesses or

hydraulic lines while the engine is running.
The machine may malfunction or pressurized
oil may spout, possibly resulting in personal
injury. Stop the engine before disconnecting
harnesses or hydraulic lines.
Perform diagnosis by connecting Palm to the

machine or by using the service menu of monitor
unit. In case any fault code has been displayed by
diagnosis by using Dr. ZX (the service menu of T107-07-01-005
monitor unit), check the cause of the trouble by

referring to Troubleshooting A in this section. In
case any fault code has been displayed by diag-
nosis by using Dr. ZX (the service menu of moni-
tor unit), write the fault code. Delete the fault code
once and retry self-diagnosis again. If the fault
code is displayed again, check the cause of the
trouble by referring to Troubleshooting A in this
section. After the machine trouble has been cor-
rected, the fault code (displayed by the service
menu of monitor unit) will be deleted. Therefore,
in case the problems which are not easily
re-predicable are encountered, check the fault
code by using Dr. ZX.
In case the fault code is not displayed, check T107-07-01-006
operating condition of each component by refer-

ring to Troubleshooting B in this section and by
using Dr. ZX (the service menu of monitor unit).
NOTE: Note that the fault codes displayed do not

necessarily indicate machine trouble. The
controller stores even temporary electrical
malfunctions, such as a drop in battery
output voltage or disconnections of the
switches, sensors, etc., for inspections.
For this reason, the “RETRIAL” is required
to erase the accumulated fault codes from
the controller memory and to confirm if any T107-07-01-007
fault codes are indicated after the
“RETRIAL”.
T5-1-4
6. Trace possible causes

Before reaching a conclusion, check the most
likely causes again. Try to identify the actual
cause of the trouble.
Based on your conclusion, make a plan for
appropriate repairs to avoid consequent
malfunctions.
T5-1-5
(Blank)
T5-1-6
TROUBLESHOOTING / Monitor Unit
OUTLINE
Primary Screen
7
1 2 3 4 5 6 8
9
10
11
12
13
14
15
16
17
18
35 34
20 20 19
TCJB-05-02-043
33 32 31 30 29 28 27 26 25 24 23 22
1 - Work Mode Display 10 - Parking Brake Display 19 - Trip Meter Display 28 - Work Mode Display
2 - Auto-Idle Display 11 - Work Brake Display 20 - Odometer Display 29 - Auxiliary Selection
3 - Overload Alarm Display 12 - Axle Lock Display 21 - Hour Meter Display 30 - Coolant Temperature
(Optional) Gauge
4 - Auto Axle Lock Display 13 - Work Light Display 22 - Back Monitor Selection 31 - Work Mode Selection
5 - Auxiliary 14 - Auxiliary 2 (Positioning) 23 - Menu 32 - Return to Primary Screen
Selection Display
6 - Glow Signal Display 15 - Auxiliary 1 (Attachment) 24 - Meter Display Selection 33 - Brake Oil Pressure Gauge
Selection Display
7 - Trip Meter 16 - Blade/Outrigger Settings 25 - Fuel Gauge 34 - Speedometer
and Brake Mode Display
8 - Odometer 17 - Mail Display (Optional) 26 - Auxiliary 35 - Tachometer
9 - Hour Meter 18 - Clock 27 - Mail Selection (Optional)
T5-2-1
7
• Display of Meters
Data to be displayed on each meter are displayed on
the monitor unit according to the input signal from
sensor, the signal received from ICF by using CAN
and the internal data of monitor unit.
Items to be displayed 18
7. Trip Meter (Signal received from MC by using CAN)

8. Odometer (Signal received from MC by using CAN)
9. Hour Meter (Internal data of the monitor unit)
18. Clock (Signal received from ICF by using CAN)
25. Fuel Gauge (Input signal from the fuel sensor)
30. Coolant Temperature Gauge (Input signal from the
coolant temperature sensor) 8 TCJB-05-02-057
34 33 30 25
33. Brake Oil Pressure Gauge (Signal received from
MC by using CAN)
34. Speedometer (Signal received from MC by using
CAN)
35. Tachometer (Signal received through MC from
ECM by using CAN)
TCJB-05-02-056
9
TCJB-05-02-042
35 TCJB-05-02-041
T5-2-2
• Work Mode Display (1) 1 7
The attachments being used are displayed accord-
ing to the signals received from MC by using CAN.
Digging Mode
18
T1V1-05-01-108
Attachment Mode
Breaker
T1V1-05-01-104
Pulverizer
TCJB-05-02-057
34 33 30 25
T1V1-05-01-105
Crusher
T1V1-05-01-106
Vibrating Hammer
T1V1-05-01-107
Others
T1V1-05-02-003
NOTE: The items on monitor unit and HITACHI

pattern are same.
Monitor Unit HITACHI pattern
Breaker1 Hydraulic Breaker1
Pulverizer1 Secondary Crusher1
Crusher1 Primary Crusher1
T5-2-3
• Auto-Idle Display (2)
2 3 4 6
When the auto-idle switch on switch panel is turned
ON, the data is displayed.
When the key switch is turned ON with the auto-idle
switch ON, the data blinks for 10 seconds.
• Overload Alarm (3)
TCJB-05-02-061
The system measures the load of suspended load

from the boom cylinder bottom pressure sensor.
When overload is detected, an alarm is displayed.
(Refer to T5-2-15.)
• Auto Axle Lock Display (4)

The data is displayed when the brake switch in the TCJB-05-02-042
auto axle lock position.
• Glow Signal Display (5)

While ECM is supplying current to the glow plug, the
data is displayed according to the signal from ECM.
T5-2-4
• Fuel Gauge (25) 30 25
The data of fuel level is displayed.
• Coolant Temperature Gauge (30)

Temperature of engine coolant is displayed.
TCJB-05-02-064
• Brake Oil Pressure Gauge (33) 34 33

Pressure in the brake circuit is displayed.
• Speedometer (34)
Travel speed is displayed.
NOTE: When the machine travels forward and al-

though other setting on the monitor unit is
done, the primary screen is displayed.
(Screen Forcible Transition Control)
(Refer to the SYSTEM / Control System
group.)
TCJB-05-02-064
35
• Tachometer (35)
Engine speed is displayed.
NOTE: Speedometer (34) or tachometer (35) is

displayed on the monitor screen due to the
setting.
TCJB-05-02-065
T5-2-5
• Parking Brake Display (10)
When the parking brake is applied, the red indicator 4 10 11 12
lights.
(Brake Switch: P (Parking Brake) Position
• Work Brake Display (11)

When the work brake is applied (under the work
brake control), the red indicator lights.
(Refer to the SYSTEM/Control System group.)
• Axle Lock Display (12)

When the axle lock is operated, the red indicator
lights. (Brake Switch: Axle Lock or Auto Axle Lock
position)
(Refer to the SYSTEM/Control System group.)
NOTE: When the brake switch is in the auto axle

TCJB-05-02-042
lock position and the lever is in neural, auto
axle lock display (4) or axle lock display
(12) lights.
At this time, the accelerator pedal is de-
pressed, the axle lock is released by the
axle lock control and axle lock display (12)
goes off.
As the brake switch is in the auto axle lock
position, auto axle lock display (4) is kept to
light.
(Refer to the SYSTEM/Control System
group.)
T5-2-6
• Work Light Display (13)
The work light switch is turned ON, the green indi- 15 14
cator lights.
• Auxiliary 2 (Positioning) Selection Display (14) 13

When the auxiliary/positioning selection switch is in 16
the Positioning position, the green indicator lights.
• Auxiliary 1 (Attachment) Selection Display (15)

When the auxiliary/positioning selection switch is in
the Auxiliary (Attachment) position, the green indi-
cator lights.
• Blade/Outrigger Setup and Brake Mode Display (16)

The combination data of blade/outrigger is displayed.
When the parking brake, work brake or TCJB-05-02-042
blade/outrigger is operated, the green indicator re-
lated to the operated function lights.
When applying parking brake
NOTE: The illustration shows the screen on the
front outrigger and rear blade specification.
Green indicator
lights.
TCJB-05-02-074
When applying work brake
Green indicator Green indicator

lights. lights.
TCJB-05-02-075
When operating blade/outrigger
Green indicator Green indicator

lights. lights.
TCJB-05-02-102
T5-2-7
• Fuel Sensor Error Display Coolant Temperature Fuel Sensor Error
Sensor Error Display Display
TCJB-05-02-104
When the fuel sensor is faulty or if the harness be-

tween fuel sensor and monitor unit is open circuit,
the data is displayed on the fuel gauge.
• Coolant Temperature Sensor Error Display
TCJB-05-02-103
When the coolant temperature sensor is faulty, the

data is displayed on the coolant temperature gauge.
TCJB-05-02-045
• Alarm and Remedy Displays against Alarm

Alarm marks are displayed on bottom of the screen
according to the alarm signals from pilot shut-off
lever, overheat switch, fuel sensor, hydraulic oil filter,
alarm switch (optional), air cleaner restriction switch,
alternator, battery system and ECM and the alarm
signals received from MC by using CAN. The rem-
edy for each alarm is displayed by key operation.
Alarm Display TCJB-05-02-049
Remedy Display against T1V5-05-01-013
Alarm
T5-2-8
Main Menu
• Time Setting
Time is set. (Refer to T5-2-29.)
Time Set Screen T1V5-05-01-021
• Operating Conditions
This screen displays machine operating hour, fuel
usage and fuel consumption rate registered by the
monitor unit.
(Refer to T5-2-32.)
Operating Conditions Screen T1V5-05-01-025
• Attachment Selection (Work Mode)

(Only machines equipped with optional parts)
Selects digging mode and attachment mode set by
Dr. ZX on this screen.
(Refer to T5-2-40.)
NOTE: In attachment mode, the following four

modes are set by default.
1 - Digging
2 - Breaker 1
3 - Breaker 2
4 - Pulverizer 1
5 - Crusher 1
1 2 3 4 5 T1V5-05-01-109

pattern are same. Attachment Selection Screen
Pulverizer1 Secondary Crusher1
Crusher1 Primary Crusher1
T5-2-9
• Pump 2 Flow Rate Adjustment (Attachment Adjust- Figure 1
ment)
(Only machines equipped with optional parts)
When using the attachments, fine adjust flow rate of
pump 2 by keys 1 and 2 operation.
(Refer to T5-2-30.)
The signals from monitor unit are sent to MC by us-
ing CAN.
When breaker 1 or 2 is used, MC adjusts maximum
flow rate of pump 2 while controlling maximum pump
2 flow rate limit control solenoid valve. (Figure 1) Key 1
(Pump 2 Flow Rate Limit Control)
When pulverizer 1 or crusher 1 is used, MC adjusts Key 2
flow rate of pressure oil that flows from pump 2 to
pulverizer or crusher while controlling the auxiliary When using Breaker 1 T1V5-05-01-111
flow rate control solenoid valve. (Figure 2) (Pulver- Figure 2

izer / Crusher Control)
(Refer to the SYSTEM / Control System group.)
NOTE: When the 2-speed selector circuit is OFF,

maximum flow rate of pump 2 can be ad-
justed while controlling the maximum pump
2 flow rate limit control solenoid valve.
(Figure 1)
When the 2-speed selector circuit is ON, Key 1
flow rate of pressure oil that flows from
pump 2 to the attachments can be adjusted Key 2
while controlling the auxiliary flow rate con- T1V5-05-01-024
trol solenoid valve. (Figure 2) When using Pulverizer 1
The table blow shows the default.
Type of 2-Speed Valve Selector Accumulator Secondary

Attachments Display Selector Circuit Circuit Circuit Hydraulic
Relief Selector
Circuit
Breaker 1 Figure 1 OFF O/T OFF ON
Breaker 2 Figure 1 OFF O/T OFF OFF
Pulverizer 1 Figure 2 ON C/V OFF OFF
Crusher 1 Figure 2 ON C/V OFF OFF
NOTE: O/T: Hydraulic Oil Tank
C/V: Control Valve

pattern are same.
Breaker 1 Hydraulic Breaker 1
Breaker 2 Hydraulic Breaker 2
Pulverizer 1 Secondary Crusher 1
Crusher 1 Primary Crusher 1
T5-2-10
• Maintenance Settings
The data; date of the last replacement, hour meter,
the remaining hours until the next replacement and
the replacement interval are displayed.
As the items to be replaced are displayed in a list,
record performed replacement by selecting an item
from the list.
(Refer to T5-2-34.)
• Interval ON/OFF Settings

Set change interval for each item to be replaced.
• Items included in Maintenance Settings Maintenance Setup Screen T1V5-05-01-049

Engine Oil
Engine Oil Filter
Hydraulic Oil
Hydraulic Oil Pilot Filter
Hydraulic Oil Filter
Pump Transmission Oil
Swing Reduction Gear Oil
Swing Bearing Grease
Hydraulic Oil Brake Steering Filter
Travel Device Transmission Oil
Axle Gear Oil (Front, Rear, each Hub)
Drive Shaft Greasing
Front Axle King Pin Greasing
Front Axle Center Pin Greasing Interval ON/OFF Setup Screen T1V5-05-01-052
Wheel Nut Torque Check
Air Filter
Engine/Air Conditioner V-belt
Fuel Filter
Air Conditioner Filter
User Setting (TRIP 1)
T5-2-11
• Mail (Optional Function)
Sends requests such as general, fuel replenishment,
service maintenance and forwarding requests in the
mail switch screen.
Contents of mails are registered in ICF, and are sent
to the central server by a satellite terminal.
(Refer to T5-2-44.)
Mail Switch Screen T1V5-05-01-037
• Meter Display Selection (HOUR↔ODO↔TRIP)

The meter display; hour meter, odometer and trip
meter on primary screen is switched.
The selected item is displayed on the primary
screen.
When the key switch is turned OFF, the item is reset
into the meter combination setting.
(Refer to T5-2-46.)
Meter Display Selection Screen TCJB-05-02-072
• Back Monitor Settings

By key operation, image display ON/OFF of
Auto-Control for switching image of the back monitor
while the machine travels backward.
(Refer to T5-2-52.)
T1V5-05-01-173
T5-2-12
• Language Settings
Select a language to be used in screens from
among preset languages, according to work envi-
ronment. (Refer to T5-2-56.)
Language Setup Screen T1V1-05-01-137
• Meter Combination Settings (km/h↔min-1)

-1
Speedometer (km/h), tachometer (min ), hour meter,
odometer and trip meter on the primary screen are
combined and set respectively.
(Default: Speedometer+Hour Meter)
(Refer to T5-2-58.)
TCJB-05-02-068
Meter Combination Setup Screen
• Unit Setting (km↔mile)

The units; km and mile, in the primary screen are set.
(Refer to T5-2-60.)
TCJB-05-02-016
Unit Setup Screen
T5-2-13
• Service Menu (Built-In Diagnosing System)
• Troubleshooting
This screen displays the fault codes according to
the signals received from each controller by using
CAN.
(Refer to T5-2-64.)
Fault Code Display T1V5-05-01-097
• Monitoring
This screen displays temperature and pressure
data received from each controller by using CAN.
By key operation, the displayed data can be hold.
(Refer to T5-2-66.)
Monitoring Screen T1V5-05-01-087
• Controller Version
This screen displays the version of MC, ICF,
monitor unit, steering column monitor and option
controller.
(Refer to T5-2-70.)
NOTE: The version of ECM is not displayed.
Controller Version Display TCHB-05-02-008
• Blade/Outrigger Settings
Combination of blade and outrigger displayed on
the primary screen is set.
(Refer to T5-2-72.)
Blade/Outrigger Setup Screen TCHB-05-02-009
T5-2-14
• Overload Alarm
(Only the machines equipped with optional parts) Overload Alarm
IMPORTANT: When using overload alarm, make

overload alarm available by using Dr.
ZX.
1. MC detects load of the suspended load by the

signal from the boom bottom pressure sensor.
2. When the overload alarm switch (optional) is
turned ON and load of the suspended load be-
comes overloaded, the monitor unit displays an
alarm message on the primary screen and rings a
buzzer according to the signal from MC by using
CAN.
3. If overload of the suspended load is dissolved, the Primary Screen TCJB-05-02-042
alarm message disappears and the buzzer stops

Overload Alarm Switch
ringing. (Optional)
NOTE: Even if the work is done while displaying a

screen except the primary screen, when an
overload condition is reached, the screen
of monitor unit is switched to the primary
screen, an alarm message is displayed and
a buzzer is rung.
Even after the overload alarm is dissolved,
the monitor unit keeps on displaying the
primary screen without returning to the
screen while the work is done.
T1V1-05-02-004
T5-2-15
(Blank)
T5-2-16
HOW TO USE SCREENS
Displaying Primary Screen
IMPORTANT: Start the engine after the primary

screen is displayed.
When the key switch is turned to the ON position, the

starting screen appears for about two seconds and the
primary screen appears.
Key Switch: ON T1V1-05-01-115
Primary Screen TCJB-05-02-064
IMPORTANT: Until the alternator starts generating

power after the engine starts, alter-
nator alarm is displayed on the pri-
mary screen.
TCJB-05-02-050
Alternator Alarm
T5-2-17
Displaying Primary Screen by Password Input
(Optional)
IMPORTANT: Before performing this operation,

make the password function avail-
able by using Dr. ZX.
Starting Screen T1V1-05-01-115
1. When the key switch is turned to the ON position,

the starting screen appears and the primary Password
Icon
screen appears.
NOTE: Only the operations including the engine

start and key 1 on the monitor unit can be
done on this screen.
Key 1
2. When key 1 is pushed or the key switch is turned

to the START position, the password input screen
appears.
TCJB-05-02-054
Primary Screen
T1V5-05-01-093
Password Input Screen
T5-2-18
3. Input a password by using the keys located under
the screen. If pushing the confirm key, the monitor
unit matches the input password to the registered
one. If they match, the primary screen appears.
NOTE: When inputting the password again, the

entered characters can be erased by
pushing the erase key.
Confirm Key Erase Key

T1V5-05-01-002
T5-2-19
In Case of Inputting an Incorrect Password
1. If inputting an incorrect password, the message

“Password is incorrect.” appears by pushing the
confirm key.
Password Input Screen T1V5-05-01-093
T1V5-05-01-002
2. Return to the password input screen by pushing

the back key.
NOTE: When inputting the password again, the

entered characters can be erased by
pushing the erase key.
T1V5-05-01-004
Back Key
T1V5-05-01-093
T5-2-20
3. If inputting an incorrect password three times, a
screen appears informing that the security lock
has been applied, and a buzzer rings. While the
key switch is turned to the ON position, the buzzer
does not stop ringing. When the key switch is
turned to the OFF position, the security lock dis-
play disappears and the buzzer rings for thirty
seconds.
Security Lock Screen T1V5-05-01-005
4. If the key switch is turned to the ON position after

the buzzer stops ringing, the starting screen ap-
pears and the primary screen appears again.
Then a password can be input again. After that,
Password
when key 1 is pushed or the key switch is turned Icon
to the START position, the password input screen
appears and the password can be re-input. If in-
putting an incorrect password even once this time,
the security lock screen appears again and a
buzzer rings. While the key switch is turned to the
Key 1
ON position, the buzzer does not stop ringing.
When the key switch is turned to the OFF position,
the buzzer rings for thirty seconds.
5. After the buzzer stops ringing, a password can be

input. Turn the key switch to the ON position and
input a password after the password input screen
appears. (Refer to T5-2-20).
6. If inputting an incorrect password again, the se-

curity lock screen appears again and a buzzer
rings. While the key switch is turned to the ON
position, the buzzer does not stop ringing. When
the key switch is turned to the OFF position, the
buzzer rings for thirty seconds.
T1V5-05-01-093
Password Input Screen
T5-2-21
Extending Password Duration Time
IMPORTANT: This operation is applicable only to

those machines that display the
primary screen based upon pass-
word input.
By using the password duration screen, password

duration time can be set. When restarting the machine,
a password need not be input within that timeframe.
1. When the key switch is turned to the OFF position,

the monitor unit displays the password duration
screen for ten seconds.
Key 1 Key 2 Key 3 Key 4 Key 5 T1V1-05-01-012
2. While the password duration screen is still dis- Password Duration Screen (Key Switch: OFF)
played, push a relevant key, and password dura-
tion time is set.
Duration time assigned to each key is as follows:
key 1: 0 minute
key 2: 30 minutes
key 3: 60 minutes
key 4: 90 minutes
key 5: 120 minutes
NOTE: If password duration time is not set explic-

itly, 0 minute on duration time is assumed.
3. If the key switch is turning to the ON position

within password duration time, the monitor unit Key Switch: ON T1V1-05-01-115
displays the primary screen after the starting

screen.
T5-2-22
(Blank)
T5-2-23
SCREEN DISPLAY WHEN AN ALARM IS
ISSUED
When an alarm is issued, the alarm marks are dis-

played at the bottom of screen.
• When the number of alarm is three or less
TCJB-05-02-046
• When the number of alarm is four to five
TCJB-05-02-047
• When the number of alarm is six to seven
TCJB-05-02-048
• When the number of alarm is eight or more
TCJB-05-02-049
T5-2-24
When an alarm is issued, if the key under a relevant
alarm mark is pushed, the remedy against the alarm is
displayed.
Push a Relevant Key TCJB-05-02-046
T1V5-05-01-013
T5-2-25
CONTENTS OF ALARMS
Display Buzzer Contents of Alarms Remedy

Overheat Alarm Temperature of engine coolant is going up abnormally
Continuously higher.
sounds Stop the work. Run the engine at low idle in order to
M178-01-036 lower the coolant temperature.
Engine Warning Alarm Failure of the engine or its related parts.
Please contact our authorized distributor or dealer.
-
M183-01-080
Engine Oil Pressure Pressure of engine lubricant oil is decreasing.

Continuously Alarm Stop the engine immediately and inspect the engine oil
sounds system and oil level of the engine.
M178-01-037
Alternator Alarm The electrical system is faulty.

- Inspect the alternator and battery system.
M183-01-071
Fuel Level Alarm Level of remaining oil is becoming less.

Refuel oil earlier.
-
M178-01-034
Hydraulic Oil Filter The hydraulic oil filter is clogged.

- Alarm Clean or replace the hydraulic oil filter.
M1CC-01-039
Air Filter Restriction The air filter is clogged.

Alarm Clean or replace the air filter.
-
M183-01-067
Hydraulic Oil Tem- Hydraulic oil temperature is going up abnormally higher.

perature Alarm Stop operation. Run the engine at low idle in order to
- lower the oil temperature.
T1JB-05-02-001
T5-2-26
Display Buzzer Contents of Alarms Remedy

Brake Pressure Alarm Brake oil pressure is low.
Continuously Please contact our authorized distributor or dealer.
sounds
TCJB-05-02-032
Attachment Operating Attachment pedal operating signal is abnormal.

Intermittently Signal Alarm Please contact our authorized distributor or dealer.
sounds
TCJB-05-02-033
Blade/Outrigger Operat- Blade/outrigger operating signal is abnormal.

Intermittently ing Signal Alarm Please contact our authorized distributor or dealer.
sounds
TCJB-05-02-034
Assist Operating Signal Assist operating signal is abnormal.

Alarm Please contact our authorized distributor or dealer.
-
TCJB-05-02-035
Electric Lever Solenoid Electric lever solenoid valve output is abnormal.

Continuously Valve Output Alarm Please contact our authorized distributor or dealer.
sounds
TCJB-05-02-036
Network Alarm Network system is abnormal.

-
TCJB-05-02-037
Work Mode Alarm Network system is abnormal.

-
T1V1-05-01-102
Pilot Shut-Off Lever Alarm The pilot shut-off lever system is abnormal.
-
T1V1-05-01-103
T5-2-27
(Blank)
T5-2-28
TIME SETTING
1. When the primary screen appears, push the

menu key and display main menu.
Menu Key
TCJB-05-02-064
Primary Screen
2. Select time set from main menu by using keys 1
and 2. Push the confirm key. Then, the time setup
screen appears.
Back Key
T1V5-05-01-019
Key 1 Key 2 Confirm Key
3. On the time setup screen, select the items to be

set (Year, Month, Day and Time) by using keys 1
and 2 and set the figures by using keys 3 and 4. Move the
item to
4. By using key 2, move the item to . Push the this icon
confirm key. Then, system time is updated with
the values specified on the screen.
NOTE: When pushing the back key, return to the

previous screen.
Back Key
5. Push key 6, and return to the primary screen. T1V5-05-01-021
Key 1 Key 2 Key 3 Key 4 Confirm Key
Back Key
Key 6 T1V5-05-01-022
T5-2-29
ATTACHMENT ADJUSTMENT
(PUMP 2 FLOW RATE ADJUSTMENT)
NOTE: Only the machines equipped with optional

parts.
IMPORTANT: This operation is effective when at-

tachments are used.
When using breaker 1 or breaker 2

menu key and display main menu. Menu Key
TCJB-05-02-0064
Primary Screen
2. Select Attachment Adjustment from main menu
by using keys 1 and 2. Push the confirm key.
Then, the attachment adjustment screen appears.
3. Push key 2. Then, the attachment adjustment

screen for currently installed attachments ap-
pears.
T1V5-05-01-019
4. Adjust flow rate of pump 2 by using keys 1 and 2.

When breaker 1 or breaker 2 is used, pushing key
1 will decrease flow rate of pump 2 and pushing
key 2 will increase respectively.
NOTE: When pushing the back key, return to the T1V5-05-01-111

Key 1 Key 2 Back Key
previous screen.
5. Push key 6, and the primary screen appears.
T5-2-30

parts.
IMPORTANT: This operation is effective when at-

tachments are used.
When using pulverizer or crusher

2. Select attachment adjustment from main menu by

using keys 1 and 2. Push the confirm key. Then, Menu Key
the attachment adjustment screen appears. TCJB-05-02-0064
Primary Screen
3. Push key 2. Then, the attachment adjustment
screen for currently installed attachments ap-
pears.
T1V5-05-01-019
4. When the pulverizer or crusher is used, pushing

key 1 will increase flow rate of boom raise, arm
roll-out, swing or travel circuit sides.
Pushing key 2 will increase flow rate of attach-
ment side.

previous screen.
T1V5-05-01-024
Key 1 Key 6 Key 2 Back Key
T5-2-31
DISPLAYING OPERATING CONDITIONS

Menu Key
TCJB-05-02-064
Primary Screen
2. Select operating conditions from main menu by

using keys 1 and 2. Push the confirm key. Then,
the operating conditions screen appears.
T1V5-05-01-019
3. Push the reset key, and a screen appears in order
to confirm if it's OK to reset data.
If it’s OK to reset data, push the confirm key.

previous screen.
IMPORTANT: Total fuel consumption and fuel

consumption rate depend on the
operating environment and the op-
eration method of machine.
The values shown on the screen are
just for reference.
T1V5-05-01-025
There could arise ± 20% of differ- Reset Key Back Key
ences between actual fuel con-
sumption and fuel consumption
which is displayed by the monitor
unit.
Back Key
T1V5-05-01-026
Key 6 Confirm Key
T5-2-32
(Blank)
T5-2-33
MAINTENANCE SETTINGS

Menu Key
2. Select maintenance settings from main menu by

the maintenance settings screen appears.
T1V5-05-01-019
3. Select an item to be set from among the list of

maintenance settings screen by using keys 1 and
2. Push the confirm key. Then, the interval
ON/OFF setup screen appears.
(In the right example, Engine Oil is selected.)
T1V5-05-01-049
T5-2-34
Maintenance Information Display ON/OFF
Example: Maintenance Information Display OFF→ON
ON: When time comes to change, the informa-

tion message is displayed on the screen.
OFF: No information message is displayed.
1. Select maintenance information display by using

Key 1
keys 1 and 2. Confirm
Key
Key 2
2. Push the confirm key and select ON.
Key 6
Interval ON/OFF Setup Screen T1V5-05-01-052

3. In order to complete setting, push key 6. Then,
the primary screen appears.
T5-2-35
Change Interval Settings
IMPORTANT: Change interval can only be set

when maintenance information dis-
play is set to ON.
1. Select change interval by using keys 1 and 2.
2. Set time for change interval by using keys 3 and Key 1

4.
Key 2 Key 3 Key 4 T1V5-05-01-052
Interval ON/OFF Setup Screen
3. Select remaining hours by using keys 1 and 2 and

push the confirm key.
Key 1
T1V5-05-01-138
Key 2 Confirm Key
4. The message “Adjust remaining hours to new

change interval. OK?” appears. Then, push the
confirm key.
Key 6 Confirm Key T1V5-05-01-139
Menu Key
T5-2-36
Resetting Data
If data is reset, push key 5 on the interval ON/OFF

setup screen.
The message “Reset Data. OK?” appears. Then,
The value of remaining hours is reset to that of
change interval. The previous change date/hour is
updated with current date and time.
Key 5
Interval ON/OFF Setup Screen T1V5-05-01-052
Confirm Key T1V5-05-01-140
T5-2-37
Notice
Screen Display when Maintenance Information
Display is ON
• When only one item is displayed

1. If the key switch is turned to the ON position, the
primary screen appears. At this time, if mainte-
nance is required, the primary screen gives notice
of the maintenance item. In three seconds, the
maintenance information display screen is dis-
played automatically.
(In the right example, Hydraulic Oil is displayed.)
NOTE: As for a machine which the primary screen

is displayed according to a password on, Primary Screen TCJB-05-02-055
after the password is input successfully and
the confirm key is pushed. And then the
primary screen appears.
2. If data is reset, push the reset key while the

played.
push the confirm key. Back Key
change interval. The previous change date/hour
is updated with current date and time. Reset Key
NOTE: When pushing the back key while the Maintenance Information Display Screen T1V5-05-01-170
maintenance information display screen is

displayed, return to the primary screen.
NOTE: When pushing the back key while reset

screen is displayed, return to the mainte-
nance information display screen.
3. After the maintenance information display screen Back Key

is displayed for ten seconds, the primary screen is
displayed.
Confirm Key
T1V5-05-01-171
Reset Screen
TCJB-05-02-064
Primary Screen
T5-2-38
Notice
• When more than two items are displayed
1. If the key switch is turned to the ON position, the
primary screen appears. At this time, if mainte-
nance is required, the primary screen gives notice
of the maintenance item. In three seconds, the
played automatically.
(In the right example, Hydraulic Oil is displayed.)
NOTE: As for a machine which the primary screen

is displayed according to a password on,
after the password is input successfully and
the confirm key is pushed. And then the
primary screen appears. Primary Screen TCJB-05-02-055
2. If data is reset, while the scheduled maintenance

screen is displayed, select the required item by
the maintenance information display screen for
the selected item appears.
(In the right example, Hydraulic Oil is selected.)
Key 1 Back Key

NOTE: When pushing the back key while the
scheduled maintenance screen is dis-
played, the primary screen appears. Confirm
Key 2 Key
3. Push the reset key while the maintenance infor-
T1V5-05-01-169
mation display screen is displayed. Scheduled Maintenance Screen
change interval. The previous change date/hour
is updated with current date and time.
NOTE: When pushing the back key while the

maintenance information display screen is Back Key
displayed, return to the scheduled mainte-
nance screen.
Reset Key
NOTE: When pushing the back key while the reset
screen is displayed, return to the mainte-
Maintenance Information Display Screen TCHB-05-02-011
nance information display screen.
4. After the maintenance information display screen

is displayed for ten seconds, the primary screen is
displayed.
Back Key
Reset Screen T1V5-05-01-171
T5-2-39
WORK MODE (ATTACHMENT SELECTION)

parts.
IMPORTANT: Select the attachments from the

work mode screen.
In order to display the work mode
screen, push key F1 after the pri-
mary screen appears, or select from
main menu.
Selecting Attachment by Using Key F1

Key F1 TCJB-05-02-064
Primary Screen
1. When the primary screen appears, push key F1
and display the work mode screen.
2. Push a relevant key under an attachment mark to

be used in order to select the attachment.
(In the right example, Crusher 1 is selected.)
NOTE: When selecting Digging, return to the pri-

mary screen.
Digging
Back Key
Select Crusher Work Mode Screen T1V5-05-01-109

1
3. On the attachment specification screen, confirm if

specification of the installed attachment agrees
with that displayed on the screen.

previous screen.
4. Push the confirm key, and the primary screen

appears. Back Key
Confirm
Key
TCEB-05-02-008
Attachment Specification Screen
T5-2-40
Selecting Attachment from Main Menu

Menu Key
TCJB-05-02-064
Primary Screen
2. Select work mode from main menu by using keys
1 and 2. Push the confirm key. Then, the work
mode screen appears.
Back Key
TCHB-05-02-001
3. Push the relevant key under an attachment mark

to be used in order to select the attachment.
(In the right example, Crusher 1 is selected.)
NOTE: When selecting digging, return to main

menu.
4. On the attachment specification screen, confirm if

specification of the installed attachment agrees
with that displayed on the screen.
Digging
If they do not match, perform the setting of at-
tachment by using Dr. ZX. Back Key
For details of the attachment specification screen, Select T1V5-05-01-109
Crusher 1 Work Mode Screen
refer to T5-2-42 and 43.

previous screen.
5. Push the confirm key, and the primary screen

appears.
Back Key
Confirm
Key
Attachment Specification Screen TCEB-05-02-008
T5-2-41
Attachment Specification Screen
Maximum Pump 2 Flow Rate
Maximum Engine Speed
Accumulator Control Solenoid Valve:

OFF
Secondary Hydraulic Relief Selector

Control Solenoid Valve: ON
Selector Valve Control Solenoid Valve: ON

The selector valve is connected to the
hydraulic oil tank.
Auxiliary Flow Combiner Solenoid

Valve: OFF
TCEB-05-02-005

OFF

Control Solenoid Valve: OFF
Selector Valve Control Solenoid Valve: ON
The selector valve is connected to the
hydraulic oil tank.
Auxiliary Flow Combiner Solenoid Valve:

OFF
TCEB-05-02-006
T5-2-42
Maximum Pumps 1 and 2 Flow Rate

OFF
Selector Valve Control Solenoid Valve: OFF

The selector valve is connected to the control
valve.

ON
TCEB-05-02-007
Maximum Pumps 1 and 2 Flow Rate

OFF
Selector Valve Control Solenoid Valve: OFF

The selector valve is connected to the control
valve.

ON
TCEB-05-02-008
T5-2-43
MAIL (Optional)
IMPORTANT: This function is available only to a

machine equipped with a satellite
terminal.
When using the mail function, make
the mail function available by using
Dr. ZX.
1. When the primary screen appears, push key F3

and display the mail screen.
2. If a relevant request key is pushed, mail informa-

Key F3 Primary Screen
tion is sent to ICF. TCJB-05-02-044
1 - General Request
2 - Fuel Replenishment Request
3 - Service Maintenance Request
4 - Forwarding Request
T1V5-05-01-037
1 2 3 Mail Screen 4
3. While mail information is sent to ICF, the message
“Mail is being delivered.” is displayed on the
screen.
T1V5-05-01-038
4. When ICF completes receives mail information,

the message “Mail delivery successful.” is dis-
played on the screen.
When pushing the back key, return to the mail
screen.
5. Then, a mail is sent from the satellite terminal to

the central server via the satellite.
NOTE: Depending on machine operating envi-

ronment or position of the satellite on its
orbit, the mail may not be sent. Back Key
T1V5-05-01-039
T5-2-44
NOTE: When ICF could not receive the mail, the

message “Mail delivery failed.” is displayed
on the screen.
T1V5-05-01-040
T5-2-45
METER DISPLAY SELECTION
NOTE: The meter display selection screen is dis-

played by pushing key F4 or selecting main
menu after the primary screen is displayed.
Select Meter Display Selection from Key F4
1. After the primary screen is displayed, push key F4.

Then, the meter display selection screen is dis- Key F4
played.
NOTE: If key F4 is pushed for two seconds or more,

the meter display is changed on the primary Primary Screen TCJB-05-02-064
screen as follows.
Hour Meter → Odometer → Trip Meter
2. Select the meter by using keys 1 and 2. Push the Data Reset
confirm key. (In the right example, Trip Meter is Icon
selected.)

Key 1 Back Key
previous screen.
Key 6
Confirm
3. Only when the trip meter is selected, the data re- Key
set icon is displayed. If data is reset, push key 5.
Key 2 Key 5
Meter Display Selection Screen
4. The message “Reset Data. OK?” appears. Push TCJB-05-02-012
the confirm key.
5. Push key 6, and the primary screen is displayed.
NOTE: The contents which are set by the meter

display selection are available until the key
switch is turned OFF. When the key switch
is turned OFF, the contents are reset to
those by the meter combination settings. Back Key
Confirm
Key
Key 6
TCHB-05-02-006
T5-2-46
NOTE: The meter display selection screen is dis-

played by pushing key F4 or selecting main
menu after the primary screen is displayed.
Select Meter Display Selection from Main Menu
1. After the primary screen is displayed, push the

menu key. The main menu is displayed.
Primary Screen
2. Select HOUR ↔ ODO ↔ TRIP from main menu TCJB-05-02-069
by using keys 1 and 2. Push the confirm key. Then,

the meter display selection screen is displayed.
Back Key
Key 1 Key 2 Confirm Key TCHB-05-02-001
3. Select the meter by using keys 1 and 2. Push the

confirm key. (In the right example, Hour Meter is
selected.)

previous screen.
4. Push key 6, and the primary screen is displayed. Key 1

Back Key
NOTE: The contents which are set by the meter Key 2 Confirm
display selection are available until the key Key
switch is turned OFF. When the key switch Key 6
is turned OFF, the contents are reset to Meter Display Selection Screen TCJB-05-02-072
those by the meter combination settings.
T5-2-47
PASSWORD CHANGE (OPTIONAL)

Menu Key
2. Select password change from main menu by us-

ing keys 1 and 2. Push the confirm key. Then, the
password change screen appears.
T1V5-05-01-041
Registered Password
3. Input the registered password and push the con-
firm key.
4. If inputting the password again, the entered

characters can be erased by pushing the erase
key.
Confirm Key Erase Key T1V5-05-01-042
T5-2-48
NOTE: If inputting an incorrect password after

pushing the confirm key, the message
“Password is incorrect.” appears.
Push the back key and go back to the pre-
vious screen. Input the password again.
T1V5-05-01-044
Back Key
5. The message “Enter password to be registered.”

appears. Then, input a new password with three
or four digits and push the confirm key.
6. If inputting the password again, push the erase

key.
T1V5-05-01-130
A New Password
T1V5-05-01-131
T5-2-49
7. The message “Re-enter password.” appears.
Then, input a new password again and push the
confirm key.
8. If inputting the password again, push the erase

key in order to erase the entered characters.
T1V5-05-01-132
Confirm Key Erase Key T1V5-05-01-133
9. The message “New password has been regis-

tered.” appears. This completes the password
change process.
T1V5-05-01-043
Key 6
T5-2-50
(Blank)
T5-2-51
BACK MONITOR SETTINGS
IMPORTANT: Image displayed on the back monitor

is of auxiliary nature at best. When
the machine is operated, pay thor-
ough attention to surrounding situa-
tion.
Auto-Control: ON
When the FNR switch is turned to the R (reverse)

position, image on the monitor unit is automatically
switched to that of the back monitor. Menu Key
TCJB-05-02-064
Primary Screen
1. When the primary screen appears, push the menu
key and display main menu.
2. Select back monitor settings from main menu by

the back monitor settings screen appears.
Back Key
3. Push the confirm key. Then, auto-control is set to

ON.

previous screen.
4. Push key 6, and return to the primary screen.
Back Key
Key 1 Key 2 Confirm Key T1V5-05-01-173
Back Key
Key 6
T1V5-05-01-174
T5-2-52
5. When the FNR switch is turned to the R (reverse)
position, image on the monitor unit is switched to
rear view image.
NOTE: After rear view image is displayed on the

monitor unit screen and although the ac-
celerator pedal returns to the neutral posi-
tion, rear view image is displayed for three
seconds. If step 2 below is done in three
seconds after rear view image is displayed,
rear view image is not displayed on the
monitor unit screen.
1. Return rear view image to the primary
screen.
2. Turn the FNR switch to the R (reverse)
position.
(While the FNR switch is in the R (reverse)
position, rear view image is not displayed.)
If step 1 above is done in three seconds
after rear view image is displayed, rear view
image is displayed on the monitor unit
screen.
T5-2-53
Auto-Control: OFF
When the FNR switch is the R (reverse) position,

automatic switching function of images between
monitor unit and back monitor is set to OFF.

Menu Key
TCJB-05-02-064
Primary Screen
2. Select back monitor settings from main menu by

the back monitor settings screen appears.
Key 1 Key 2 Confirm Key Back Key TCHB-05-02-003
3. Push the confirm key. Then, auto-control is set to

OFF.

previous screen.
4. Push key 6, and return to the primary screen.
Confirm Key Back Key T1V5-05-01-174
Back Key
Key 6
T1V5-05-01-173
T5-2-54
(Blank)
T5-2-55
LANGUAGE SETTINGS

Menu Key
TCJB-05-02-064
Primary Screen
2. Select language from main menu by using keys 1

and 2. Push the confirm key. Then, the language
settings screen appears.
TCHB-05-02-003
Key 1 Key 2 Confirm Key Back Key
3. Select a desired language by using keys 1 and 2.
Push the confirm key.
NOTE: Languages to be displayed on the screen

of monitor unit have been selected from
twelve languages, namely display lan-
guages 1 or 2, as default.
(Refer to the next page.)

previous screen.
Back Key
T1V1-05-01-137
Key 1 Key 6 Key 2 Confirm Key
T5-2-56
Lists of Display Languages
Display Languages 1
Language Screen Display
Japanese
T1V1-05-01-141
English
T1V1-05-01-142
Chinese
T1V1-05-01-143
Taiwanese
T1V1-05-01-144
Korean
T1V1-05-01-145
Indonesian
T1V1-05-01-146
Thai
T1V1-05-01-147
Vietnamese
T1V1-05-01-148
Myanmarese
T1V1-05-01-149
Arabic
T1V1-05-01-150
Persian
T1V1-05-01-151
Turkish
T1V1-05-01-152
Display Languages 2
Language Screen Display
English
T1V1-05-01-142
Spanish
T1V1-05-01-153
Italian
T1V1-05-01-154
French
T1V1-05-01-155
German
T1V1-05-01-156
Netherlandish
T1V1-05-01-157
Russian
T1V1-05-01-158
Portugese
T1V1-05-01-159
Finlandish
T1V1-05-01-160
Swedish
T1V1-05-01-161
Norwegean
T1V1-05-01-162
Danish
T1V1-05-01-163
T5-2-57
METER COMBINATION SETTINGS

Menu Key
TCJB-05-02-064
Primary Screen
-1
2. Select km/h ↔ min from main menu by using
keys 1 and 2. Push the confirm key. Then, the
meter combination setup screen is displayed.
NOTE: If mile is selected by unit settings (km ↔

-1
mile), mph ↔ min is displayed.
TCHB-05-02-003
3. Select the meter combination by using keys 1 and

2. Push the confirm key.

previous screen.
4. Push key 6, and the primary screen is displayed. Key 1 Back Key
Key 2 Confirm
Key
Key 6
Meter Combination Setup Screen TCJB-05-02-015
Key 1 Back Key
Key 2 Confirm
Key
Key 6
Meter Combination Setup Screen TCJB-05-02-068
T5-2-58
NOTE: Examples of combination

Odometer
• When selecting km (speedometer) and odometer
Speedometer
(km)
TCJB-05-02-069
• When selecting min-1 (tachometer) and hour me- Hour Me-

ter
ter
Tachometer
TCJB-05-02-065
Trip
Meter
• When selecting mph (speedometer) and trip me-
ter
(Unit: When selecting mile)
Speedometer
(mile)
TCJB-05-02-070
T5-2-59
UNIT SETTINGS

Menu Key
2. Select km/h ↔ mile from main menu by using

keys 1 and 2. Push the confirm key. Then, the unit
combination setup screen is displayed.
3. Select the unit by using keys 1 and 2. Push the

confirm key.

previous screen.
4. Push key 6, and the primary screen is displayed. Key 1 Back Key
Key 2 Confirm
Key
Key 6
Unit Setup Screen TCJB-05-02-016
T5-2-60
NOTE: Examples
• When selecting km
TCJB-05-02-069
• When selecting mile
TCJB-05-02-070
T5-2-61
(Blank)
T5-2-62
SERVICE MENU (BUILT-IN DIAGNOSING
SYSTEM) OPERATION
IMPORTANT: This system is to be operated by the

HITACHI dealer only. Do not explain
this system function to the cus-
tomer.
Although Dr.ZX id not used, the following items can be

displayed on the monitor unit.
• Troubleshooting:
The fault code is displayed.
• Monitoring: T1V1-05-01-115
A part of monitor items of Dr.ZX is displayed. Turn key switch ON while pushing the key
• Controller Version:
Each controller version is displayed.
• Blade/Outrigger Settings:
The blade/outrigger settings are changed.
1. Turn the key switch to the ON position while

pushing the key at upper right corner of the
monitor unit. Therefore, service menu is added to
main menu.

Menu Key
TCJB-05-02-064
3. Select service menu from main menu by using Primary Screen
service menu screen appears.

previous screen.
Key 1 Key 2 Confirm Back Key TCHB-05-02-005

Key
Back Key TCHB-05-02-007
T5-2-63
TROUBLESHOOTING
1. Displaying Service Menu

Turn the key switch to the ON position while
pushing the key at upper right corner of the
monitor unit. Therefore, service menu is added to
main menu.
T1V1-05-01-115
Turn key switch ON while pushing the key

Menu Key
TCJB-05-02-064
Primary Screen
3. Select service menu from main menu by using


previous screen.

Key
T5-2-64
4. Select troubleshooting by using keys 1 and 2.
Push the confirm key. Then, the troubleshooting
screen appears.
5. Results of trouble analyses for each controller are A figure enclosed in ( ) indicates the number of fault codes.
displayed on the screen.
Displayed Controller:
• Main Controller
• Engine Governor Controller
• Monitor Controller
• ICF Controller
• Steering Column Monitor
• Option Controller
6. Select Abnormal of a faulty controller by using

keys 1 and 2. Push the confirm key. Then, fault
code is displayed. Key 1 Key 2 Confirm Key Back Key T1V5-05-01-085
As for details of trouble analyses, refer to “Trou-

bleshooting A.”
IMPORTANT: Up to twenty fault codes can be dis-

played. But, one screen can contain
only ten fault codes maximum.
If the screen is fully filled with ten
items, push key 1 and check other
fault codes on the next page.
When returning to the previous page,
push key 2.

previous screen. Key 1 Key 6 Key 2 Back Key T1V5-05-01-097
T5-2-65
MONITORING

pushing the key at upper right corner of the moni-
tor unit. Therefore, service menu is added to main
menu.
T1V1-05-01-115
Turn the key switch ON while pushing the key
2. When the primary screen appeared, push the

Menu Key
TCJB-05-02-064
Primary Screen


previous screen.

Key
T5-2-66
4. Select monitoring by using keys 1 and 2. Push the
confirm key. Then, the monitoring screen appears.
As for items to be monitored, refer to the next
page.
TCHB-05-02-007
5. Select an item to be monitored by using keys 1
and 2. Push the confirm key. Then, the selected
item is brought up to the top.
NOTE: When the key switch is turned OFF, the

order of items to be monitored is reset to
the initial state.
6. Push key 3, and the displayed data are put on

hold.
Push key 3 again, and the records are updated
Back Key
with the displayed data.
T1V5-05-01-087
Key 1 Key 2 Key 3 Key 4 Confirm Key
7. The order of items to be monitored is reset to the
initial state by pushing key 4.
When key 4 is pushed and a confirmation mes-
sage appears, push the confirm key.

previous screen.
Back Key
T1V5-05-01-088
Key 6 Confirm Key
T5-2-67
A List of Items to be Monitored
Items Units Remarks

Engine Torque %
Coolant Temperature (E) °C Input signal to the monitor unit from ECM by
using CAN
Fuel Temperature °C
Engine Oil Pressure kPa
Atmospheric Pressure kPa
Intake Air Temperature °C
Boost Pressure kPa
Boost Temperature °C
Coolant Temperature (M) °C Directly Input signal to the monitor unit from
the coolant temperature sensor (coolant
temperature gauge)
Target Engine Speed min−1
Actual Engine Speed min−1
Pump 1 Delivery Pressure MPa
Pump 1 Pump Control Pressure MPa
Target Pump 1 Flow Rate L/min
Pump 2 Delivery Pressure MPa
Pump 2 Pump Control Pressure MPa
Target Pump 2 Flow Rate L/min
Swing/Front Attachment Control Pilot Pressure MPa
Boom Up Pilot Pressure MPa
Arm In Pilot Pressure MPa
Swing Pilot Pressure MPa
Forward Travel Pilot Pressure MPa
Reverse Travel Pilot Pressure MPa
EC Dial Angle V
Hydraulic Oil Temperature (Tank) °C Signal from main hydraulic oil temperature
sensor
Pump Torque Proportional Valve MPa
Arm Regeneration Proportional Valve MPa
Power Digging Control Pressure MPa 0 MPa is displayed.
Power Mode E/P/HP
Power Digging Switch OFF/ON OFF is displayed.
Radio Signal strength ×/○
T5-2-68
Items Units Remarks

Speed km/h Although mile is selected from main menu, travel
speed (km/h) is displayed.
Travel Motor Over Speed (Count)
Brake Pressure MPa
Emergency Stop OFF/ON
Attachment1/Positioning1 Signal V
Attachment2/Positioning2 Signal V
Blade1/Outrigger1 Signal V
Blade2/Outrigger2 Signal V
Assist1 Signal V
Assist2 Signal V
Assist3 Signal V
Assist4 Signal V
Hydraulic Oil Temperature (Pilot) °C Signal from pilot hydraulic oil temperature sensor
Assist1 Proportional Valve MPa
Positioning1 Proportional Valve MPa
Positioning2 Proportional Valve MPa
Blade1/Outrigger1 Proportional Valve MPa
Blade2/Outrigger2 Proportional Valve MPa
Assist3 Proportional Valve MPa “-” is displayed as default.
Assist4 Proportional Valve MPa “-” is displayed as default.
T5-2-69
CONTROLLER VERSION

menu.
T1V1-05-01-115

Menu Key
TCJB-05-02-064
Primary Screen

NOTE: When pushing the back key, return back to

the previous screen.

Key
T5-2-70
4. Select controller version by using keys 1 and 2.
Push the confirm key. Then, the controller version
screen appears.
NOTE: The version of ECM is not displayed.

previous screen.
TCHB-05-02-007
TCHB-05-02-008
Key 6 Back Key
T5-2-71
BLADE/OUTRIGGER SETTINGS

menu.
T1V1-05-01-115

Menu Key
TCJB-05-02-064
Primary Screen

NOTE: When pushing the back key, return back to

the previous screen.

Key
T5-2-72
4. Select blade/outrigger settings by using keys 1
and 2. Push the confirm key. Then, the
blade/outrigger setup screen appears.
5. Select the screen corresponded to the combina-

tion by using keys 1 and 2.

previous screen.
Key 1
Back Key
Key 2
Key 6
Blade/Outrigger Setup Screen TCHB-05-02-009
Display the
Selected
Screen
Screen Transition TCJB-05-02-067
6. Push key 6, and the primary screen is displayed.

The last screen is displayed as the primary
screen. TCJB-05-02-064
Primary Screen
NOTE: the blade/outrigger during operation is dis-

played in green on the primary screen.
T5-2-73
KEYLESS HOUR METER
When the key switch is turned OFF, the following items

can be displayed on the monitor unit screen.
• Hour Meter
• Odometer
• Fuel Gauge
When the back monitor selection key is

pushed for one second or more, the keyless
hour meter screen is displayed. Back Monitor
Selection Key
NOTE: While the back monitor selection key is
pushed, the keyless hour meter screen is
displayed. T1V1-05-01-010
Hour Meter
Odometer
Fuel Gauge
Back Monitor
Selection Key
Keyless Hour Meter Screen TCJB-05-02-001
2. When the back monitor selection key is released,

the keyless hour meter screen disappears.
T5-2-74
LIST OF MONITOR UNIT SETTING FUNC-
TION
○: with setting function

×: without setting function
Setting Function
Function Item Monitor Default
Dr.ZX
Unit
Alarm Check alarms while trouble occurs ○ ○(Troubleshooting) －
Security Password function Enable/Disable × ○(Security) Disable
Password change ○ × 0000
Permission/no permission of password change on the
× ○(Security) Permission
monitor
Max.
Maximum password digit change × ○(Security)
4 digits
Password check × ○(Security) －
Extending function Enable/Disable × ○(Security) Enable
Selection on extra time ○ × －
Time Setting Time set function Enable/Disable × ○(Monitor Controller) Enable
Time change ○ ○(ICF) －
Operating Operational condition Enable/Disable × ○(Monitor Controller) Enable
Condition Operational condition reset ○ × －
Maintenance Maintenance operation Allow/Not Allow × ○(Monitor Controller) Allow
Setting Maintenance display items ON/OFF × ○(Monitor Controller) ON
Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Engine Oil Change interval ○ × 500 hours
Remaining hours data reset ○ × －
Previous change Date/Hour Meter check ○ × －
Maintenance display items ON/OFF × ○(Monitor Controller) ON
Engine Oil
Change interval ○ × 500 hours
Filter
Hydraulic
Change interval × × 5000 hours
Oil
Hydraulic Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Oil Pilot Change interval × × 1000 hours
Filter Remaining hours data reset ○ × －
T5-2-75
Setting Function
Dr.ZX
Unit
Maintenance Maintenance display items ON/OFF × ○(Monitor Controller) ON
Setting Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Hydraulic
Oil Filter
Pump Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Transmission Change interval × × 1000 hours
Oil Remaining hours data reset ○ × －
Swing Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Reduction Change interval × × 1000 hours
Gear Remaining hours data reset ○ × －
Swing Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Bearing Change interval × × 500 hours
Grease Remaining hours data reset ○ × －
Hydraulic
Oil Brake
Steering
Travel Device Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Transmission Change interval × × 500 hours
Oil Remaining hours data reset ○ × －
Axle Gear
Oil
(Front, Rear,
each Hub) Remaining hours data reset ○ × －
T5-2-76
Setting Function
Dr.ZX
Unit
Setting Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Drive Shaft
Greasing
Front Axle Notification function Enable/Disable ○ ○(Monitor Controller) Enable
King Pin Change interval × × 30 days
Greasing Remaining hours data reset ○ × －
Front Axle Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Center Pin Change interval × × 250 hours
Greasing Remaining hours data reset ○ × －
Wheel Nut Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Torque Change interval × × 250 hours
Check Remaining hours data reset ○ × －
Air Filter Change interval × × 1500 hours
Engine / Air Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Conditioner Change interval × × 1000 hours
V-belt Remaining hours data reset ○ × －
Fuel Filter Change interval × × 500 hours
T5-2-77
Setting Function
Dr.ZX
Unit
Setting Air Notification function Enable/Disable ○ ○(Monitor Controller) Enable
Conditioner Change interval × × 3000 hours
Maintenance display items ON/OFF × × ON
Notification function Enable/Disable ○ × Disable
User Setting
Change interval ○ × 5000 hours
(TRIP 1)
Remaining hours data reset × × －
Optional Work mode function Set/Unset × ○(Monitor Controller) Set
Function Mail function Set/Unset × ○(Monitor Controller) Unset
Send the mail ○ × －
Overload
Overload alarm Enable/Disable × ○(Monitor Controller) Disable
Alarm
Back Monitor Back monitor function Enable/Disable × ○(Monitor Controller) Enable
Setting Auto-display/no auto-display of camera image during No auto
○ ×
travel reverse operation (auto-control) display
Back monitor display Normal/Flip Vertical × ○(Monitor Controller) Normal
Selection of NTSC/PAL (image method) × ○(Monitor Controller) NTSC
Meter Setting Meter setup function Enable/Disable × ○(Monitor Controller) Enable
Speedometer
Meter combination setting change ○ × +
Hour Meter
Unit Setting Unit setup function Enable/Disable × ○(Monitor Controller) Enable
Unit Change ○ × km
Language Select language ○ × English
Setting Register/delete language × × －
Registered language check ○ × －
Trouble- Check alarms while trouble occurs ○ ○(Troubleshooting) －
shooting Check alarms which occurred × ○(Troubleshooting) －
Clear fault code (Retry B) × ○(Troubleshooting) －
Monitoring Item order change ○ × －
Reset item order to default ○ × －
Blade / Out-
Blade/Outrigger setting change ○ × 1/12
rigger Setting
T5-2-78
TROUBLESHOOTING / Dr. ZX
OUTLINE
Dr. ZX is a tool used for troubleshooting of the

electronic control system of MC, ECM, ICF, monitor
unit, steering column monitor and option controller.
It displays the fault code of each controller or sensor by
connecting Dr. ZX to ICF. (Display of Troubleshooting
Result)
Dr. ZX also displays input status of sensor and switch

that connected to each controller and output status of
actuators from controllers to solenoid valves in real
time while it's running. (Controller Troubleshooting)
NOTE: For operation detail about Dr. ZX, refer to

separated "Dr. ZX Manual".
T5-3-1
MC MONITORING LIST
Dr. ZX displays the input signals from switches and
sensors to MC and the control signals to the actuators
from MC.
Item
Unit Data
Selecting Monitoring
-1
Requested Engine Speed Req. Eng min Input signal from engine control dial
-1
Actual Engine Speed Actual Speed min Input signal from ECM
-1
Engine Speed Deviation Eng Speed Deviat min A value subtracted required engine speed from actual engine speed
Vehicle Speed Vehicle Speed km/h Input value from travel N sensor
Pump 1 Delivery Pressure P1 Delivery Pres MPa Input signal from pump 1 delivery pressure sensor
Pump 1 Flow Control Pressure PC 1 Pressure MPa Input signal from pump 1 control pressure sensor
Pump 1 Flow Rate Limit P/S/V Out P1 P/S Valve MPa Control instruction signal to maximum pump 1 flow rate limit control solenoid
valve
Pump 1 Upper Limit Displacement P1 Pres Maxq cm3 Calculation from engine speed and pump 1 delivery pressure
(With attachment only)
Pump 1 Target Flow Rate P1 Set Flow Rate L/min Control instruction signal to maximum pump 1 flow rate limit control solenoid
valve
Pump 2 Delivery Pressure P2 Delivery Pres MPa Input signal from pump 2 delivery pressure sensor
Pump 2 Flow Control Pressure PC 2 Pressure MPa Input signal from pump 2 control pressure sensor
Pump 2 Flow Rate Limit P/S/V Out P2 P/S Valve MPa Control instruction signal to maximum pump 2 flow rate limit control solenoid
valve
Pump 2 Upper Limit Displacement P2Maxq cm3 Calculation from engine speed and pump 2 delivery pressure
(With attachment only)
Pump 2 Target Flow Rate P2 Set Flow Rate L/min Control instruction signal to maximum pump 2 flow rate limit control solenoid
valve
Pump Torque P/S Valve Output P Torque P/S/V MPa Control instruction signal to torque control solenoid valve
Pump 3 Delivery Pressure P3 Pressure MPa Input signal from steering pump delivery pressure sensor
Pump 4 Delivery Pressure P4 Pressure MPa Input signal from pump 4 delivery pressure sensor
Front Pilot Pressure Fr Pilot Press MPa Input signal from pressure sensor (front)
Boom Raise Pilot Pressure Boom Raise MPa Input signal from pressure sensor (boom raise)
Arm Roll-In Pilot Pressure Arm Roll-In MPa Input signal from pressure sensor (arm roll-in)
Arm Roll-Out Pilot Pressure Arm Roll-Out MPa Input signal from pressure sensor (arm roll-out)
Swing Pilot Pressure SW Pilot Press MPa Input signal from pressure sensor (swing)
Travel Forward Pilot Pressure Tr F Pilot Press MPa Input signal from pressure sensor (travel forward)
Travel Reverse Pilot Pressure Tr R Pilot Pilot Press MPa Input signal from pressure sensor (travel reverse)
ATT Control Pilot Pressure ATT Pilot Press MPa Input signal from pressure sensor (auxiliary)
EC Dial Angle Dial Angle V Input signal from engine control dial
Boom Bottom Pressure Bm Bottom Press MPa Input signal from boom bottom pressure sensor
Brake Remain Pressure Brake Remain P MPa Input signal from brake remaining pressure sensor
Brake Pressure Brake Pressure MPa Input signal from brake pressure sensor
E/P SW E/P SW E, P Power mode switch selection status
HP Mode SW HP Mode SW ON, OFF Power mode switch selection status
Auto-Idle SW AI SW AI Auto-idle switch selection status
NOTE: BR: Breaker

PU: Pulverizer
CR: Crusher
VI: Vibrating hammer
Un: Other
ATT: Attachment
OPT: Optional
T5-3-2
Item
Unit Data
Power Boost SW Power Boost SW ON, OFF Power digging switch ON/OFF selection status
Key SW Key SW ON, OFF Key switch ON/OFF selection status
Slight Travel SW Slight Travel SW ON, OFF Engine control mode selection switch (creeper) ON/OFF selection
status
Pedal EC SW Pedal EC SW ON, OFF Engine control mode selection switch (pedal) ON/OFF selection
status
Implement Brake Deactive Imp Brk Release ON, OFF Work brake release switch ON/OFF selection status
Parking Brake SW Parking Brake SW ON, OFF Brake switch (parking brake) ON/OFF selection status
Transmission H/L SW T/M H/L SW Lo, Hi Travel speed mode switch ON/OFF selection status
FNR (R) SW FNR (R) SW ON, OFF FNR switch (R) ON/OFF selection status
Arm Regenerative P/S Valve Output Am Regen P/S/V MPa Control instruction signal to solenoid valve unit (SC)
Power Boost Control Pressure PD Ctrl Pressure MPa Control instruction signal to solenoid valve unit (SG)
ATT P/S Valve Output ATT P/S Valve MPa Control instruction signal to auxiliary flow rate control solenoid valve
Pump 1 Flow Rate Limit P/S/V Out FB P1 Flow P/V FB mA Feedback from maximum pump 1 flow rate limit solenoid valve output
Pump 2 Flow Rate Limit P/S/V Out FB P2 Flow P/V FB mA Feedback from maximum pump 2 flow rate limit control solenoid valve
output
Pump Torque P/S/V Output FB P Torque P/V FB mA Feedback from torque control solenoid valve output
ATT P/S Valve Output FB ATT P/S/V FB mA Feedback from auxiliary flow rate control solenoid valve output
Arm Regenerative P/S/V Output FB Am Rege P/V FB mA Feedback from solenoid valve unit (SC) output
Power Boost chg. Over Pressure FB PD Ctrl Puress FB mA Feedback from solenoid valve unit (SG) output
Travel Motor Swash Angle P/V Valve TrM Swash Angle P/V Out MPa Control instruction signal to travel motor displacement angle control
Output solenoid valve
Travel Makeup P/S/V Output Travel Makeup P/S/V Out MPa Control instruction signal to travel make-up solenoid valve
Implement Brake P/S/V Output Implement Brake P/S/V MPa Control instruction signal to solenoid valve unit (SF)
Axle Lock Output Axle Lock Output MPa Control instruction signal to solenoid valve unit (SI)
Travel Motor Swash Angle P/V FB TrM Swash Angle P/V FB mA Feedback from travel motor displacement angle control solenoid
valve output
Travel Makeup P/S/V FB Travel Makeup P/S/V FB mA Feedback from travel make-up solenoid valve output
Axle Lock Output FB Axle Lock Output FB mA Feedback from solenoid valve unit (SI) output
Implement Brake FB Implement Brake FB mA Feedback from solenoid valve unit (SF) output
Travel Alarm Travel Alarm Action/ Action/No Action status of travel alarm
No Action
Swing Alarm Swing Alarm Action/ Action/No Action status of swing alarm
No Action
Hydraulic Oil Temperature (HOT) Hyd Oil Temp. °C Input signal from hydraulic oil temperature sensor
T/M Change (Low Speed) T/M Change (Low Speed) ON, OFF Travel mode selector solenoid valve (slow) ON/OFF selection status
T/M Change (High Speed) T/M Change (High Speed) ON, OFF Travel mode selector solenoid valve (fast) ON/OFF selection status
Axle Lock Control State Axle Lock Control State ON, OFF Brake switch (axle lock) ON/OFF selection status
Implement Brake State Implement Brake State ON, OFF Work brake ON/OFF selection status
Travel Motor Over Rotation Count TrM Over Rotation Count Count Input value from travel N sensor
NOTE: BR: Breaker

PU: Pulverizer
CR: Crusher
Un: Other
ATT: Attachment
OPT: Optional
T5-3-3
Item
Unit Data
Speed Meter Auto Change Flag Speed Meter Auto Change Flag ON, OFF Speed meter auto switch ON/OFF selection status
Current ATT Type Current ATT Type BR, PU, CR, VI, Un Communication from monitor unit
Current ATT No. Current ATT No. 1, 2, 3, 4, 5 Communication from monitor unit
ATT1 Type ATT1 Type BR, PU, CR, VI, Un Communication from monitor unit
ATT1 No. ATT1 No. 1, 2, 3, 4, 5 Communication from monitor unit
Trip Meter Trip Meter km Unit setting status for monitor unit
Odo Meter Odo Meter km Unit setting status for monitor unit
(German) Specifications Change SW (German) Specifications Change ON, OFF German specification selection switch ON/OFF selection status
SW
FNR (F) SW FNR (F) SW ON, OFF FNR switch (Forward) ON/OFF selection status
NOTE: BR: Breaker

PU: Pulverizer
CR: Crusher
Un: Other
ATT: Attachment
OPT: Optional
T5-3-4
ECM MONITORING LIST
Item
Unit Data
Engine Torque Engine Torque ％ Input signal from ECM
Actual Engine Speed
Act. Eng Speed min-1 Input signal from crank speed sensor and cam angle sensor
(Engine Speed)
Target Engine Speed Tar. Eng Speed min-1 Input signal from engine control dial
Glow Signal Glow Signal OFF, ON Glow Plug Relay ON/OFF selection status
Coolant Temperature (Engine) Coolant Temp. °C Input signal from coolant temperature sensor
Fuel Temperature Fuel Temp. °C Input signal from fuel level sensor
Engine Oil Pressure Eng Oil Pressure kPa Input signal from engine oil pressure sensor
Fuel Flow Fuel Flow L/h Input signal from ECM
Barometric Pressure Barome. Press kPa Input signal from atmospheric pressure sensor
Intake Air Temperature Intake Air Temp. °C Input signal from intake air temperature sensor
Boost Pressure Boost Pressure kPa Input signal from boom boost pressure sensor
Boost Temperature Boost Temp. °C Input signal from boom boost temperature sensor
Battery Voltage Battery Volt V Input signal from ECM
Total Used Fuel Total Used Fuel L Input signal from ECM
T5-3-5
MONITOR UNIT MONITORING LIST
Item
Unit Data
Monitor SW Status Check Monitor SW Status Check − Monitor unit switch status
Coolant Temperature Coolant Temp. °C Input signal from coolant temperature sensor
Fuel Level Fuel Level % Input signal from fuel level sensor
Security Signal Security Signal OFF, ON Communication from monitor unit
Mail SW Mail SW OFF Mail Operation Status
Fuel
Forward
Repair
General
T5-3-6
STEERING COLUMN MONITOR MONITORING LIST
Item
Unit Data
Speed Pulse Speed Pulse Hz Communication from MC
Vehicle Speed Pulse Vehicle Speed Pulse Hz Communication from MC
T5-3-7
OPTION CONTROLLER MONITORING LIST
Item
Unit Data
Att SW Operation (Proportional SW) Att SW Ope (Prop) V Input signal from attachment switch
Auxiliary Operation (Proportional SW) Aux Ope (Prop SW) V Input signal from attachment switch
Positioning/Att 1 Operation Posn/Att 1 Ope V Input signal from attachment pedal
Positioning/Att 2 Operation Posn/Att 2 Ope V Input signal from attachment pedal
Outrigger/Blade 1 Operation OR/BL1 Ope V Input signal from blade/outrigger lever
Outrigger/Blade 2 Operation OR/BL2 Ope V Input signal from blade/outrigger lever
Posn/Att SW Pilot Monitor Pressure Posn/Att SW P Press MPa Input signal from pressure sensor (positioning, attachment)
Outrgr/Blade/Att Pilot Montr Pressr OR/BL/Att P Press MPa Input signal from pressure sensor (blade/outrigger, auxiliary)
Hydraulic Oil Temperature (OPT) Hyd Oil Temp. °C Input signal from pilot oil temperature sensor
Boom Bottom Pressure Bm Bottom Press MPa Input signal from boom bottom pressure sensor
Gate Lock Signal Gate Lock Signal Up, Down Pilot shut-off lever up/down status (Pilot shut-off switch
ON/OFF selection status)
Att SW & Aux (Main SW) Att SW & Aux (Main SW) ON, OFF Electric operation main switch ON/OFF selection status
Att Selection SW Att Selection SW Aux, Posn Attachment selection switch ON/OFF selection status
Att SW 1 Operation Att SW 1 Operation ON, OFF Attachment switch ON/OFF selection status
Att SW 2 Operation Att SW 2 Operation ON, OFF Attachment switch ON/OFF selection status
Outrigger Control SW1 Outrigger Control SW1 ON, OFF Outrigger selection switch ON/OFF selection status
Swing Parking Release Swing Parking MPa Control instruction signal to swing parking brake release
solenoid valve
Att 1 P/S/V Att 1 P/S/V MPa Control instruction signal to auxiliary solenoid valve
Att 2 P/S/V Att 2 P/S/V MPa Control instruction signal to auxiliary solenoid valve
Blade 1/Outrigger 1 P/S/V BL1/OR1 P/V MPa Control instruction signal to blade/outrigger solenoid valve
Blade 2/Outrigger 2 P/S/V BL2/OR2 P/V MPa Control instruction signal to blade/outrigger solenoid valve
Positioning 1 P/S/V Posn 1 P/V MPa Control instruction signal to positioning solenoid valve
Positioning 2 P/S/V Posn 2 P/V MPa Control instruction signal to positioning solenoid valve
Att SW 1 P/S/V Att SW 1 P/S/V MPa Control instruction signal to attachment solenoid valve
T5-3-8
Item
Unit Data
Swing Parking Release FB Swing Parking FB mA Feedback from swing parking brake release solenoid valve
output
Att 1 P/S/V FB Att 1 P/S/V FB mA Feedback from auxiliary solenoid valve output
Att 2 P/S/V FB Att 2 P/S/V FB mA Feedback from auxiliary solenoid valve output
Blade 1/Outrigger 1 P/S/V FB BL1/OR1 P/V FB mA Feedback from blade/outrigger solenoid valve output
Blade 2/Outrigger 2 P/S/V FB BL2/OR2 P/V FB mA Feedback from blade/outrigger solenoid valve output
Positioning 1 P/S/V FB Posn 1 P/V FB mA Feedback from positioning solenoid valve output
Positioning 2 P/S/V FB Posn 2 P/V FB mA Feedback from positioning solenoid valve output
Att SW 1 P/S/V FB Att SW 1 P/V FB mA Feedback from attachment solenoid valve output
Outrigger Control Outrigger Control ON, OFF Outrigger main relay 2 ON/OFF selection status
Valve Selector Valve Selector ON, OFF Selector valve control solenoid valve ON/OFF selection status
2nd Relief Selector 2nd Relief Selector ON, OFF Secondary pilot relief pressure control solenoid valve ON/OFF
selection status
Acc Change Acc Change ON, OFF Accumulator control solenoid valve ON/OFF selection status
Electric Lever Pilot Cut Electric Lever Pilot Cut ON, OFF Outrigger selection switch (pilot cut) ON/OFF selection status
Load Alarm On/Off SW Load Alarm On/Off SW ON, OFF Overload alarm switch ON/OFF selection status
T5-3-9
MC ADJUSTMENT LIST
Engine speed, pump delivery flow rate, solenoid valve
output pressure and so on can be adjusted.
Adjustment Item List

Item Unit Data
-1
Li Speed Adjustment min Adjustment of minimum engine speed
-1
Travel Li Speed Adjustment min Adjustment of minimum engine speed when traveling
-1
WU Speed Adjustment min Adjustment of warming up engine speed
-1
AI Speed Adjustment min Adjustment of auto-idle engine speed
E Speed Adjustment min-1 Adjustment of E-mode engine speed
-1
P Speed Adjustment min Adjustment of P-mode engine speed
Travel P Speed Adjustment min-1 Adjustment of pedal mode speed
PQ Torque Control N⋅m Adjustment of pump P-Q curve
Pump 2 P/S Valve Adjustment MPa Adjustment of maximum pump 2 flow rate limit control solenoid valve
Tr Motor Swash Angle P/V Adjust MPa Adjustment of travel motor displacement angle control solenoid valve
Pump 1 P/S Valve Adjustment MPa Adjustment of maximum pump 1 flow rate limit control solenoid valve
Pump Torque P/S/V Adjustment MPa Adjustment of torque control solenoid valve
ATT P/S Valve Adjustment MPa Adjustment of auxiliary flow rate control solenoid valve
Arm Regenerative P/S/V Adjustment MPa Adjustment of solenoid valve unit (SC)
Slight Travel Flow Adjustment cm3 Adjustment of maximum pump 1 flow rate upper level
Front P1 Control Flow Adjustment cm3 Adjustment of pump 1 delivery flow rate
Front P2 Control Flow Adjustment cm3 Adjustment of pump 2 delivery flow rate
Implement Brake Lock Pressure MPa Adjustment of solenoid valve unit (SF)
ATT Torque Reducing On/Off ON, OFF ON/OFF of torque down control, when a front attachment is operated
ECO Mode On/Off ON, OFF ECO control ON/OFF
HP Mode On/Off ON, OFF HP mode control ON/OFF
Coolant Temp. WU_B Mode On/Off ON, OFF Coolant temperature warming-up control ON/OFF
Engine Burglar Proof On/Off ON, OFF Engine Control Theft Prevention Selection ON/OFF
Pump Burglar Proof On/Off ON, OFF Pump Control Theft Prevention Selection ON/OFF
Heater Mode On/Off ON, OFF Heater control ON/OFF
ATT Mode On/Off ON, OFF Attachment Mode ON/OFF
New E-mode Fix Control Change ON, OFF E-mode control ON/OFF
Speed Meter Auto Change On/Off ON, OFF Speed meter auto switch ON/OFF
ATT Speed Increase Down Waiting Time ms Setting of time required for engine speed decrease
Axle Lock Timer s Time setting for axle lock release (auto axle lock)
Travel Motor Over Rotation Count Times Setting for travel motor over rotation counter
T5-3-10
Adjustment List
Item Unit Minimum Adjustment Adjustable Range Initial Value
Li Speed Adjustment min-1 10 0 to 400 0
-1
Travel Li Speed Adjustment min 10 0 to 400 0
-1
WU Speed Adjustment min 10 -600 to 200 0
-1
AI Speed Adjustment min 10 -300 to 400 0
-1
E Speed Adjustment min 10 Temporarily release 0
(valid only when key is ON)
-1
P Speed Adjustment min 10 -200 to 200 0
Travel P Speed Adjustment min-1 10 -200 to 300 0
PQ Torque Control N⋅m 2.45 -60 to 60 0
Pump 2 P/S Valve Adjustment MPa 0.0196 -1 to 1 0
Tr Motor Swash Angle P/V Adjust MPa 0.0196 -1 to 1 0
Pump 1 P/S Valve Adjustment MPa 0.0196 -1 to 1 0
Pump Torque P/S/V Adjustment MPa 0.0196 -1 to 1 0
ATT P/S Valve Adjustment MPa 0.0196 -1 to 1 0
Arm Regenerative P/S/V Adjustment MPa 0.0196 -1 to 1 0
Slight Travel Flow Adjustment cm3 0.5 32.5 to 100.0 65.0
Front P1 Control Flow Adjustment cm3 0.5 32.5 to 100.0 58.5
Front P2 Control Flow Adjustment cm3 0.5 32.5 to 100.0 58.5
Implement Brake Lock Pressure MPa 0.02394 4.7 to 8.0 6.6
ATT Torque Reducing On/Off ON, OFF - ON/OFF ON
ECO Mode On/Off ON, OFF - ON/OFF ON
HP Mode On/Off ON, OFF - ON/OFF ON
Coolant Temp. WU_B Mode On/Off ON, OFF - ON/OFF ON
Engine Burglar Proof On/Off ON, OFF - ON/OFF OFF
Pump Burglar Proof On/Off ON, OFF - ON/OFF OFF
Heater Mode On/Off ON, OFF - - -
ATT Mode On/Off ON, OFF - ON/OFF OFF
New E-mode Fix Control Change ON, OFF - ON/OFF OFF
Speed Meter Auto Change On/Off ON, OFF - ON/OFF ON
ATT Speed Increase Down Waiting Time ms 40 0 to 3000 0
Axle Lock Timer s 0.5 0 to 10 0
Travel Motor Over Rotation Count Times 1 0 to 253 0
T5-3-11
MC ATTACHMENT ADJUSTMENT LIST

Item Unit Data
ATT1
ATT1 ATT Type BR PU CR VI Un Non Attachment selection
ATT1 ATT No. 12345 Attachment setting number selection
ATT1 P1 Swash Angle Adjustment L/min Adjustment of lower limit of maximum pump 1 flow rate when using attachment
-1
ATT1 Engine Speed Adjustment min Adjustment of engine speed when using attachment
ATT1 2nd Relief Selector (OPT) ON OFF Secondary pilot relief pressure control valve ON/OFF selection
ATT1 Valve Selector (OPT) ON OFF Selector valve ON/OFF selection
ATT1 Accumulator Change (OPT) ON OFF Accumulator control valve ON/OFF selection
ATT1 2-Speed Change (OPT) ON OFF 2-speed selection ON/OFF selection
ATT2
ATT2 Engine Speed Adjustment min-1 Adjustment of engine speed when using attachment
ATT3
NOTE: ATT: Attachment

BR: Breaker
PU: Pulverizer
CR: Crusher
Un: Other attachment
Non: No setting for attachment
T5-3-12
Item Unit Data

ATT4
-1
ATT4 Engine Speed Adjustment min Adjustment of engine speed when using attachment
ATT5
T5-3-13
Adjustment Value List

Adjustment Data Minimum Adjustment Adjustable Range Initial Value Remark
ATT1
ATT1 ATT Type - BR PU CR VI Un Non BR
ATT1 ATT No. - 1 to 5 1
ATT1 P1 Swash Angle Adjustment 0.5 L/min 52.8 to 105.6 L/min 105.6 L/min
-1 -1 -1
ATT1 Engine Speed Adjustment 10 min -500 to 200 min 0 min
ATT1 2nd Relief Selector (OPT) - ON/OFF ON
ATT1 Valve Selector (OPT) - C/V or O/T O/T
ATT1 Accumulator Change (OPT) - ON/OFF OFF
ATT1 2-Speed Change (OPT) - ON/OFF OFF
ATT2
ATT2 ATT Type - BR PU CR VI Un Non BR
ATT2 Engine Speed Adjustment 10 min-1 -500 to 200 min-1 0 min-1
ATT2 2nd Relief Selector (OPT) - ON/OFF OFF
ATT2 Valve Selector (OPT) - C/V or O/T O/T
ATT2 2-Speed Change (OPT) - ON/OFF OFF
ATT3
ATT3 ATT Type - BR PU CR VI Un Non PU
ATT3 Valve Selector (OPT) - C/V or O/T C/V
ATT3 2-Speed Change (OPT) - ON/OFF ON

BR: Breaker
PU: Pulverizer
CR: Crusher
T5-3-14
Adjustment Data Minimum Adjustment Adjustable Range Initial Value Remark

ATT4
ATT4 ATT Type - BR PU CR VI Un Non CR
-1 -1 -1
ATT4 Engine Speed Adjustment 10 min -500 to 200 min 200 min
ATT4 Valve Selector (OPT) - C/V or O/T C/V
ATT4 2-Speed Change (OPT) - ON/OFF ON
ATT5
ATT5 ATT Type - BR PU CR VI Un Non Unregistration
ATT5 ATT No. - 1 to 5 Unregistration
ATT5 2nd Relief Selector (OPT) - ON/OFF Unregistration
ATT5 Valve Selector (OPT) - C/V or O/T Unregistration
ATT5 Accumulator Change (OPT) - ON/OFF Unregistration
ATT5 2-Speed Change (OPT) - ON/OFF Unregistration

BR: Breaker
PU: Pulverizer
CR: Crusher
T5-3-15
ICF ADJUSTMENT ITEM LIST

Item Data Range
Information C/U: Initialization Initialization/End
Model Number Setting Model ASCII (4 characters) 0 to 9, A to Z
Machine Nos. 000000 to 999999
Time Setting Year 2000 to 2100
Date Month 1 to 12
Day 1 to 31
Hour 0 to 23
Time
Minutes 0 to 59
Control Data: Initialization Initialization/End
Satellite Terminal: Initialization Erase/End
Satellite Terminal Serial Number Verification 12 digits from 0 to 9 and A to Z
Check for Communication Status Connection Connected/Not-connected
ICF↔ Satellite Terminal
Communication OK/NG
Power Source ON/OFF
Satellite Terminal Satellite Transmission available/Not available
Communication
Rod Antenna OK/NG
GPS Antenna OK/NG
Wave Signal Status ON/OFF
Number of Unsent Data 0 to 99
Time of Previous Transmission YYYY/MM/DD hh:mm:ss
Satellite Communication, Sent/Stop Setting Start/Stop
T5-3-16
(Blank)
T5-3-17
OPTION CONTROLLER ADJUSTMENT LIST

Item Unit Data
Att Ope 1 P/S/V Adjustment MPa Adjustment of auxiliary solenoid valve
Att Ope 2 P/S/V Adjustment MPa Adjustment of auxiliary solenoid valve
Blade/OR Ope 1 P/S/V Adjustment MPa Adjustment of blade/outrigger solenoid valve
Blade/OR Ope 2 P/S/V Adjustment MPa Adjustment of blade/outrigger solenoid valve
Att SW Ope 1 P/S/V Adjustment MPa Adjustment of attachment solenoid valve
Positioning Ope 1 P/S/V Adjustment MPa Adjustment of positioning solenoid valve
Positioning Ope 2 P/S/V Adjustment MPa Adjustment of positioning solenoid valve
Attachment Function Enable/Disable Auxiliary operation enable/disable
Outrigger/Blade Function Enable/Disable Blade/Outrigger operation enable/disable
Positioning Function Enable/Disable Positioning operation enable/disable
Att SW Function (Proportional SW) Enable/Disable Attachment operation enable/disable
Att SW Function Enable/Disable Attachment operation enable/disable
Aux Assignment (Proportional SW) 0, 1, 2, 3, 4 Left grip assignment
Load Alarm Min Bottom Pressure kgf/cm2 Setting for boom cylinder minimum bottom pressure
Pressure Alarm Dtrmn Empty Load kgf/cm2 Setting for empty bucket judgment pressure
T5-3-18
Adjustment List
Item Unit Minimum Adjustment Adjustable Range Initial Value
Att Ope 1 P/S/V Adjustment MPa 0.0196 -0.5 to 0.5 0
Att Ope 2 P/S/V Adjustment MPa 0.0196 -0.5 to 0.5 0
Blade/OR Ope 1 P/S/V Adjustment MPa 0.0196 -0.5 to 0.5 0
Blade/OR Ope 2 P/S/V Adjustment MPa 0.0196 -0.5 to 0.5 0
Att SW Ope 1 P/S/V Adjustment MPa 0.0196 -0.5 to 0.5 0
Positioning Ope 1 P/S/V Adjustment MPa 0.0196 -0.5 to 0.5 0
Positioning Ope 2 P/S/V Adjustment MPa 0.0196 -0.5 to 0.5 0
Attachment Function Enable/Disable - - Disable
Outrigger/Blade Function Enable/Disable - - Enable
Positioning Function Enable/Disable - - Enable
Att SW Function (Proportional SW) Enable/Disable - - Disable
Att SW Function Enable/Disable - - Disable
Aux Assignment (Proportional SW) 0, 1, 2, 3, 4 - - 0 (Disable)
Load Alarm Min Bottom Pressure kgf/cm2 2 -100 to 170 0
Pressure Alarm Dtrmn Empty Load kgf/cm2 2 0 to 100 80
T5-3-19
Dr. ZX OPERATION PROCEDURE
Some examples are explained here. As for other Dr.

ZX Operation Procedure, refer to the extra volume, Dr.
ZX Manual.
Parameter Change (Option Controller)

As for the machine equipped with each attachment of
auxiliary, blade/outrigger, positioning and attachment,
the operation item should be selected into
Enable/Disable according to the machine specification.
If the operation item is selected into Enable, the
corresponding attachment can be operated.
IMPORTANT: If the operation item is not selected

into Enable, the corresponding
attachment cannot be operated.
In addition, make the item for the
unnecessary attachment disable.
Example:
• Machine equipped with 2-piece boom, 4 outrigger:
• Attachment Function: Disable
• Outrigger/Blade Function: Enable
• Positioning Function: Enable
• Att SW Function (Proportional SW): Disable
• Att SW Function: Disable
• Machine equipped with monoblock boom, auxiliary,

rear blade
• Attachment Function Enable
• Outrigger/Blade Function: Enable
• Positioning Function: Disable
• Att SW Function (Proportional SW): Disable
• Att SW Function: Disable
T5-3-20
Example: Outrigger/Blade Function: Enable
Push Parameter Change of option Push Enable and Push Exec. Push
controller. Push ESC and return to ESC and return to Parameter
Main Menu screen. Push Outrigger/Blade Function. Change Selection screen.
Select item Select item Outrigger/Blade Function
+ Parameter Change + Attachment Function

Status: Disable
To the
+ ML Parameter Change + Outrigger/Blade
lower
Function
+ All Parameter Positioning Enable Disable
+
initialize Function
+ Att SW Function
(Proportional SW)
ESC ESC Exec ESC
Setup Item Selection Screen Parameter Change Selection Setup Selection Screen
Screen
Push Exec. Push ESC and return

to Parameter Change Selection
screen.
*Adjust Data Confirm*
Adjusting Deviation Data Name

Outrigger/Blade Function
Adjustment: Disable
Data has changed
Current: Enable
Exec ESC ESC
Adjust Data Confirm Screen
T5-3-21
Parameter Change
(Aux Assignment (Proportional SW))
The initial setting of the left proportional switch is in

Disable. If one of the listed operations on the screen is
assigned to the left proportional switch by using Dr. ZX,
the operation can be performed with the left
proportional switch. At this time, the originally assigned
operation cannot be performed.
Example: When assigning attachment function:

• Attachment function with left proportional switch is
enable.
• Furthermore, the assigned operation cannot be
performed by the electric lever/pedal.
As for Parameter Change item,

Push Parameter Change of option refer to Adjustment Item List. Items
controller. Push ESC and return to are displayed by pushing a skip Push Aux Assignment
Main Menu screen. mark. (Proportional SW).
Select item Select item Select item
+ Parameter Change + Attachment Function + Positioning

Function
To the
+ ML Parameter Change + Outrigger/Blade Att SW Function
+ lower
Function (Proportional SW)
+ All Parameter + Positioning Att SW Function
+
initialize Function
Aux Assignment
+ Att SW Function + (Proportional SW)
(Proportional SW)
ESC ESC ESC
Setup Item Selection Screen Parameter Change Selection Parameter Change Selection
Screen Screen
Select assigned function and push

Exec. Push ESC and return to Push Exec. Push ESC and return
Parameter Change Selection to Parameter Change Selection
screen. screen.
Aux Assignment (Proportional SW) *Adjust Data Confirm*
Current: 0: Disable Adjusting Deviation Data Name

0: Disable Aux Assignment (Proportional SW)
1: Att Ope
Current: 0: Disable Data has changed
2: OR/BL Ope
Adjustment: 1: Att Ope
3: Positioning Ope
4: Att SW Ope
Exec ESC Exec ESC ESC
Operation Selection Screen Adjust Data Confirm Screen
T5-3-22
TROUBLESHOOTING / ICF
OUTLINE
ICF (Information Controller) saves the input signals

from various sensors and switches of the machine as
data.
Various input signals are recorded as “list of daily re-
port data”, “list of frequency distribution data”, “list of
total operating hours”, “list of alarm,” and “list of fail-
ure” in ICF.
The recorded data is downloaded to the personal

computer and is uploaded to the center server via
LAN, so that the data can be used as “e-Service”.
The machine equipped with the satellite communica-
tion terminal (optional) sends the data to center server
by using satellite communication. (As for the satellite
communication system, refer to T5-4-24.
T5-4-1
LIST OF DAILY REPORT DATA
Data which can be downloaded by Palm

Item Details
Date Date of daily report data
Time when key switch is first turned ON during a day
Start: Time
(Time is recorded by key switch ON signal.)
Time when key switch is last turned OFF during a day
Stop: Time
(Time is recorded by key switch ON signal.)
The value of the final remained fuel during a day
Fuel Level
(Value is recorded by fuel sensor data from monitor unit.)
The value of fuel used during a day
Fuel Usage Amount (Value is calculated and recorded by accumulated fuel usage amount
from ECM.)
Hour meter cumulative hours
Machine Hour Meter
(Hours are recorded by hour meter from monitor unit.)
Total engine operating hours selecting HP mode during a day
HP Mode Hours
(Hours are recorded by power mode switch information from MC.)
Engine Operating Total engine operating hours selecting P mode during a day
P Mode Hours
Hours (Hours are recorded by power mode switch information from MC.)
Total engine operating hours selecting E mode during a day
E Mode Hours
(Hours are recorded by power mode switch information from MC.)
Hours when auto-idle switch is turned ON during a day
Auto-Idle Switch ON Time
(Hours are recorded by switch from MC.)
Fast Idle (Hi) Trav- Total operating hours of travel mode (Hi) during a day
Travel Operating eling Hours (Hours are recorded by travel mode switch information from MC.)
Hours Slow Idle (Lo) Trav- Total operating hours of travel mode (Lo) during a day
eling Hours (Hours are recorded by travel mode switch information from MC.)
Total swing operating hours during a day
Swing Operating Hours
(Hours are recorded by swing pressure sensor information from MC.)
Total operating hours selecting front attachment during a day
Digging Operating Hours (Hours are recorded by front attachment pressure sensor information
from MC.)
Breaker Operating Total operating hours selecting breaker during a day
Hours (Hours are recorded by attachment information from MC.)
Secondary Crusher Total operating hours selecting secondary crusher during a day
Operating Hours (Hours are recorded by attachment information from MC.)
Attachment Operat- Hydraulic Crusher Total operating hours selecting hydraulic crusher during a day
ing Hours Operating Hours (Hours are recorded by attachment information from MC.)
Vibrating Hammer Total operating hours selecting vibrating hammer during a day
Operating Hours (Hours are recorded by attachment information from MC.)
Bucket Operating Total operating hours selecting bucket during a day
Hours or Others (Hours are recorded by attachment information from MC.)
T5-4-2
Item Details
Total machine’s waiting hours during a day
No Load Time
(Hours are recorded by each pressure sensor information from MC.)
The highest radiator coolant temperature during a day
Radiator Coolant Temperature
(Value is recorded from monitor unit.)
The highest hydraulic oil temperature during a day
Hydraulic Oil Temperature
(Value is recorded from MC.)
The highest intake air temperature during a day
Intake Air Temperature
(Value is recorded from ECM.)
Engine operating hour distribution during a day
Engine Operating Hour Distribution Data (Operating hours are recorded only when alternator output signal is
continuously delivered for more than 10 minutes.)
Machine operating hour distribution during a day
Loaded Time Distribution Data (Operating hours are recorded only when operating pressure is con-
tinuously detected for more than 5 minutes while the engine runs.)
NOTE: The daily operation in this table is equiva-

lent to the hours between 0:00 and
23:59:59 counted by the ICX built-in clock.
In case the engine is kept operated beyond
0:00, such data are recorded as those for
the following day.
T5-4-3
Data which can be sent by satellite communication

Item Details
Date Date of daily report data
The value of the final remained fuel during a day
Fuel Level
(Value is recorded by fuel sensor data from monitor unit.)
The value of fuel used during a day
Fuel Usage Amount (Value is calculated and recorded by accumulated fuel usage amount
from ECM.)
Hour meter cumulative hours
Machine Hour Meter
(Hours are recorded by hour meter from monitor unit.)
Total engine operating hours during daily operation
Engine Operating Hours
(Hours are recorded with alternator signal ON.)
Travel Operating Hours Total travel operating hours during daily operation
Swing Operating Hours Total swing operating hours during daily operation
Front Attachment Operating Hours Total front attachment operating hours during daily operation
Attachment Operating Hours Total attachment operating hours during daily operation
No Load Time Total machine’s waiting hours during daily operation
Radiator Coolant Temperature The highest radiator coolant temperature during a day
Hydraulic Oil Temperature The highest hydraulic oil temperature during a day
Intake Air Temperature The highest intake air temperature during a day
Engine Operating Hour Distribution Data Engine operating hour distribution during daily operation
(Operating hours are recorded only when alternator output signal is
continuously delivered for more than 10 minutes.)
Loaded Time Distribution Data Machine operating hour distribution during daily operation
(Operating hours are recorded only when operating pressure is
continuously detected for more than 5 minutes while the engine runs.)
NOTE: The daily operation in this table is equiva-

lent to the hours between 0:00 and
23:59:59 counted by the ICX built-in clock.
In case the engine is kept operated beyond
0:00, such data are recorded as those for
the following day.
T5-4-4
LIST OF FREQUENCY DISTRIBUTION DATA
Item Details
Fuel Temperature Frequency distribution of fuel temperature
Frequency distribution of average pump delivery pressure of pumps 1
Pump Load
and 2
Average Pump Delivery Pressure in Frequency distribution of average delivery pressure from pumps during
Digging Operation digging operation
Average Pump Delivery Pressure in Frequency distribution of average delivery pressure from pumps during
Travel Operation travel operation
Radiator Coolant Temperature Frequency information of coolant temperature
Hydraulic Oil Temperature Frequency information of hydraulic oil temperature
Radiator Coolant Temperature － Intake Frequency information on temperature in which intake air temperature is
Air Temperature pulled from coolant temperature
Hydraulic Oil Temperature － Intake Air Frequency information on temperature in which intake air temperature is
Temperature pulled from hydraulic oil temperature
Frequency information of engine speed and average load rate (average
Pump Load Rate
of pump 1 load rate and pump 2 load rate)
Engine Load Rate Frequency information of engine speed and engine torque
Radiator Coolant Temperature/Intake Air
Frequency information of coolant temperature and intake air temperature
Temperature
Hydraulic Oil Temperature/Intake Air Frequency information of hydraulic oil temperature and intake air tem-
Temperature perature
T5-4-5
LIST OF TOTAL OPERATING HOURS
Item Details
Inner Hour Meter Hour meter’s value accumulated inside ICF
Machine Hour Meter Hour meter’s value accumulated in machine’s monitor
HP Mode Hours Total engine operating hours selecting HP mode
Engine Operating
P Mode Hours Total engine operating hours selecting P mode
Hour
E Mode Hours Total engine operating hours selecting E mode
Auto-Idle Switch ON Time Total hours when auto-idle switch is turned ON
Fast Idle (Hi) Travel-
Total operating hours of travel mode (Hi)
Travel Operating ing Hours
Hour Slow Idle (Lo) Trav-
Total operating hours of travel mode (Lo)
eling Hours
Swing Operating Hour Total swing operating hours during
Front Attachment Operating Hour Total front attachment operating hours
Breaker Operating
Total operating hours selecting breaker during daily operation
Hours
Secondary Crusher Total operating hours selecting secondary crusher during daily opera-
Operating Hours tion
Attachment Operat- Hydraulic Crusher Total operating hours selecting hydraulic crusher during daily opera-
ing Hour Operating Hours tion
Vibrating Hammer Total operating hours selecting vibrating hammer during daily opera-
Operating Hours tion
Bucket Operating
Total operating hours selecting bucket during daily operation
Hours or Others
No Load Time Total machine’s waiting hours
T5-4-6
(Blank)
T5-4-7
HOW TO DOWNLOAD AND UPLOAD DATA Satellite
OF ICF Rear Console Terminal
After the data saved in ICF is downloaded to Palm (Dr.

ZX), is uploaded to the personal computer, and is up-
loaded to the center server by using LAN, the data
can be used as “e-Service”.
Dr. ZX
Connector
How to Download Data from Machine to Palm
1. Connect the Dr. ZX connectors in Palm and the
machine by using the Hot Sync cable and the
connecting harness.
2. Turn Palm ON and start downloading the data.
(Refer to the next page.)
ICF
TCJB-05-04-001
Palm
(Dr. ZX)
Hot Sync
Cable
Connecting
Harness
T1V1-05-07-002
T5-4-8
Data Download
After starting Dr. ZX, push Select

Controller. Push ICF Controller. Push OK.
Select Function Select failure-diagnosis control-
ler
+ Self-Diagnostic Result ・ ICF
+ Engine Controller controller Ver.: XXYY To the
+ Select Controller ・ Satellite terminal Controller lower
+ Main Controller Ver.: XXYY
+ Monitor Controller Is it correct?
+ ICF Controller
ESC ESC OK ESC
Function Selection Screen Controller Selection Screen ICF Controller Screen
While downloading data,

Push Start. Push Date Download. Download Screen is displayed.
Select Item Data Download
Password
+ Information C/U: Various Downloading.
Setup Do not turn off the Palm or To the
Dr. ZX SerVice Soft + Data Download disconnect the download ca- lower
(C)Hitachi Construction ble.
Machinery Co., ltd + Save Data Check
27%
+
Op. Manual
Start Back ESC Cancel
Title Screen Main Menu Screen Data Download Screen
When downloading is completed

normally, Normal End Screen is If pushing Cancel on Data
displayed. Download Screen, Alarm Screen
Push OK and return to Main Menu is displayed. Push OK and return Push ESC and return to Title
Screen. to Main Menu Screen. Screen.
Select Item
+ Information C/U: Various

CAUTION Setup
Initialization has been Initialization has been
completed. completed. + Data Download
i The download is com- The download has been inter-
pleted. rupted.
+ Save Data Check
You may disconnect the No data has been trans-
ferred to the Dr. ZX +
download cable.
OK OK ESC
Normal End Screen Alarm Screen Main Menu Screen
T5-4-9
How to Upload Data from Palm to Personal
Computer
1. Set Palm to the cradle. Connect the USB cable to

the personal computer. Palm
2. Push the Hot Sync button.
NOTE: When pushing the Hot Sync button and
uploading the data to the personal com-
puter, the Palm (or CLIE) Desktop software
with Palm attached need to be installed.
Cradle
Hot Sync
Button
T178-05-07-033
T5-4-10
VARIOUS SETUP OF ICF AND SATELLITE
COMMUNICATION TERMINAL BY USING
Dr. ZX
Before starting satellite communication, installing the

satellite communication terminal and replacing ICF,
perform the following procedures by using Dr. ZX.
ICF Setup Procedures
Start Dr. ZX
1.1 Select Information Controller
1.2 Select Information C/U: Various Setup
1.3 Enter Date and Time
1.4 Enter Model and Serial No.
1.5 Information C/U: Initialize
Communication No Communication
1.6 Satellite Terminal: Initialize
1.7 Satellite Terminal Serial No. Check
1.8 Satellite Terminal, Communicating State Check
2. Self-Diagnosing
T5-4-11

Controller. Push ICF Controller. Push OK.
Select Function Select failure-diagnosis control-
ler
+ Self-Diagnostic Result ・ ICF
+ Engine Controller Controller Ver.: XXYY To the
+ Select Controller ・ Satellite Terminal lower
+ Main Controller Controller Ver.: XXYY
+ Monitor Controller Is it correct?
+ ICF Controller
ESC ESC OK ESC

Push Information C/U: Various
Push Start. Setup.
Select Item Select Item
Password
+ Information C/U: Various + Information C/U: Initialize
Setup
Dr. ZX SerVice Soft + Data Download + Enter Model and Serial
(C)Hitachi Construction No.
Machinery Co., ltd + Save Data Check + Enter Date and Time
+ + Control Data: Initialize
Op. Manual
Start Back ESC ESC
Title Screen Main Menu Screen Information C/U: Various Setup

Screen
T5-4-12
1.3 Enter Date and Time
Push Set and the focused item is
YY.
Push Enter Date and Time. Push ESC and return to Information
Push ESC and return to Main C/U: Various Setup Screen.
Menu Screen.
Select Item Enter Date and Time

YY, MM, DD, HH, and MM
+ Information C/U: Initialize YY 2004 MM 01 DD 01 The focused item is displayed reversely.
At first, the focused item is YY.
+ Enter Model and Serial HH 01 MM 01
No.
+ Enter Date and Time
+ Control Data: Initialize
－＋ YY, MM, DD, HH, and MM

Move the focused item.
ESC Set ESC No repeat input.
Information C/U: Various Setup Enter Date and Time Screen
Screen
－＋
YY, MM, DD, HH, and MM
Value of the focused item is increased or de-
creased one by one.
In case value is beyond maximum one: Change
Select Item value into the minimum one
Information C/U: Various In case value is below minimum one: Change
+ value into the maximum one
Setup
No repeat input.
+ Data Download
+ Save Data Check
ESC
Main Menu Screen
T5-4-13
1.4 Enter Model and Serial No.
Push Enter Model and Serial No.
Select Item
+ Information C/U: Initialize

Enter Model and Serial To the
+ lower
No.
ESC
Information C/U: Various Setup

Screen
After inputting model and serial

Push Exec, and model and serial No., push OK and return to Enter
No. can be input. Model and Serial No. Screen.
Push ESC and return to Informa- Push ESC and return to Informa-
tion C/U: Various Setup Screen. tion C/U: Various Setup Screen. Push ESC and return to Main
Menu Screen.
Enter Model and Serial No. Enter Model and Serial No. Select Item
Model 01J1 + Information C/U: Initialize

Model |
Ex. Mach.No.(HCM1J1⋅⋅⋅12 Enter Model and Serial
3456) Model(01J1) +
Exec ESC No.
Serial No. 123456 Serial No.
ESC OK
Ex. Mach.No.(HCM1J1⋅⋅⋅12 + Control Data: Initialize
3456) Serial No.(123456)
Exec ESC OK ESC ESC
Enter Model and Serial No. Information C/U: Various Setup

Screen
T5-4-14
1.5 Information C/U: Initialize
Push Information C/U: Initialize.
Select Item
+ Enter Model and Serial To the

No. lower
ESC

Screen
Push Init and the controller oper-

ating data is initialized.
Push ESC and return to Informa- Push OK and return to Informa-
tion C/U: Various Setup Screen. Push ESC and return to Main
tion C/U: Various Setup Screen. Menu Screen.
Information C/U: Initialize Select Item

Is operation data erased? Initialization has been
completed. + Enter Model and Serial
Init i Initialization has been No.
completed.
ESC
+ Control Data: initialize
Init ESC OK ESC
Information C/U: Initialize Screen Information C/U: Various Setup

Screen
T5-4-15
1.6 Satellite Terminal: Initialize
Push Exec.
Display the next screen of Infor- Push Satellite Terminal: Initialize. Push ESC and return to Informa-
mation C/U: Various Setup Screen. Push ESC and return to Main tion C/U: Various Setup Screen.
Menu Screen.
Select Item Select Item Satellite Terminal: Initialize
+ Information C/U: Initialize + Satellite Terminal: Initialize

Satellite Terminal No.
+ Enter Model and Serial Confirmation To the
+ Is Un-Transmit data erased?
No. Communicating State lower
+ Enter Date and Time + Check
Enter Satellite Comm.
+ Control Data: Initialize + Start/Stop
ESC ESC Exec ESC
Information C/U: Various Setup Next Screen of Information C/U: Satellite Terminal: Initialize Screen
Screen Various Setup Screen
Push OK and return to Information

C/U: Various Setup Screen.
Satellite Terminal: Initialize Select Item Select Item
+ Satellite Terminal: Initialize + Information C/U: Various

Satellite Terminal No. Setup
Un-Transmit data is erased. Confirmation Data Download
+ +
Communicating State
+ Check + Save Data Check
+ Start/Stop +
OK ESC ESC
Information C/U: Various Setup Main Menu Screen

Screen
T5-4-16
1.7 Satellite Terminal Serial No. Check
Push Satellite Terminal No. Confir- Confirm serial No. (12 digits). Push
mation. ESC and return to Information C/U:
Push ESC and return to Main Various Setup Screen.
Menu Screen.
Select Item Satellite Terminal No. Confirma- Select Item

tion
+ Satellite Terminal: Initialize + Satellite Terminal: Initialize
Satellite Terminal No. Satellite Terminal No.
+ Confirmation + Confirmation
Communicating State Serial No. 8GBDA701862 Communicating State
+ Check + Check
Enter Satellite Comm. Enter Satellite Comm.
+ Start/Stop + Start/Stop
ESC ESC ESC
Information C/U: Various Setup Information C/U: Various Setup

Screen Screen
Select Item
+ Information C/U: Various

Setup
+ Data Download
+ Save Data Check
ESC
Main Menu Screen
T5-4-17
1.8 Satellite Terminal, Communicating State
Check
Push Communicating State
Check.
Push ESC and return to Main
Menu Screen. Check communicating state.
Select Item Communicating State Check
Satellite Terminal: Initialize ICF⇔Satellite Terminal Check the enclosed state.
+
Satellite Terminal No. ・ Conn Un- Un-
Confirmation Uncon: Faulty harness
+ ・ Comm. OK NG
Communicating State NG: Faulty harness for Comm.
Check Satellite Terminal
+ OFF: Faulty harness, Faulty controller
Enter Satellite Comm. ・ Power ON OFF
Stop: 1.9 Enter Satellite Comm. Start/Stop
+ Start/Stop ・ Comm. Enable Stop
ESC ESC
Information C/U: Various Setup Communicating State Check

Screen
Rod Aerial OK NG
When electrical wave of the satellite is caught,
GPS Aerial OK NG the items are turned into OK.
Wave State ON OFF IMPORTANT: Check this with the key of the
machine ON in outdoor.
Un Transmit Data Number According to state of electrical
0 wave, it may take a little longer
time.
Last Transmitting Time
2004/07/01 13：50：00
ESC
Select Item Select Item
+ Information C/U: Various + Satellite Terminal: Initialize

Setup Satellite Terminal No.
Data Download Confirmation
+ +
Communicating State
+ Save Data Check + Check
+ + Start/Stop
ESC ESC
Main Menu Screen Information C/U: Various Setup

Screen
T5-4-18
1.9 Enter Satellite Comm. Start/Stop
Push ▼ and display to the next
screen of Information C/U: Various
Setup Screen.
Push Enter Satellite Comm.
Start/Stop.
Select Item
+ Satellite Terminal: Initialize

Confirmation To the
+ lower
Communicating State
+ Check
+ Start/Stop
ESC

Screen
When starting Satellite Comm.,

push Start and push Exec.
When stopping Satellite Comm.,
push Stop and push Exec.
Push ESC and return to Informa- Push OK and return to Information
C/U: Various Setup Screen. Push ESC and return to Main
tion C/U: Various Setup Screen.
Menu Screen.
Enter Satellite Comm. Start/Stop Satellite Terminal UnTrasmit Select Item

State
+ Satellite Terminal: Initialize
Confirmation
+
Exec Communicating State
Start Stop Setting has been completed + Check
ESC Enter Satellite Comm.
+ Start/Stop
Exec ESC OK ESC

Screen
T5-4-19
1.10 Control Data: Initialize
Push Control Data: Initialize.
Select Item
To the
+ Enter Model and Serial lower
No.
ESC

Screen
Push Init and the controller oper-

ating data is initialized.
Push ESC and return to Informa- Push OK and return to Information
tion C/U: Various Setup Screen. C/U: Various Setup Screen. Push ESC and return to Main
Menu Screen.
Control Data: Initialize Select Item

Is control data initialized? Initialization has been
completed. + Enter Model and Serial
Init i Initialization has been No.
completed. Enter Date and Time
+
ESC
Init ESC OK ESC
Control Data: Initialize Screen Information C/U: Various Setup

Screen
T5-4-20
(Blank)
T5-4-21
2. Self-Diagnosing
Push Fault of ICF Controller. If
After starting Dr. ZX, push there is no trouble, No Problem is
Self-Diagnostic Result. displayed.
Select Function Self-diagnosing of controllers

below hasn completed.
+ Self-Diagnostic Result
Engine Controller No Problem
+ To the
Select Controller
Main Controller Fault lower
Self-Diagnosing
Monitor Controller No Problem
ICF Controller Fault
ESC ESC ESC
Function Selection Screen Controller Self-Diagnosing Screen

Change the page and
the fault code in back
and forth is displayed.
Push Retry B and return to Controller
Push Details, and Details and Self-Diagnosing Screen after controller
Corrective Action are displayed. self-diagnsing.
Push ESC and Retry B Screen is Push ESC and Retry B Screen is Push ESC and return to Controller
displayed. displayed. Self-Diagnosing Screen.
ICF Controller Fault Code 14000-2

Problem was detected.
Details Retry B
14000 14001 Details CAN Communication Error
Do you want to escape?

Corrective Action
1)Retry B
ESC 2)Check Harness ESC
3)
ESC ESC Retry B ESC

Details
Fault Code Screen Retry B Screen
Self-diagnosing of controllers
below hasn completed.
Execute
Engine Controller No Problem
Retry B
Main Controller Fault
ESC Monitor Controller No Problem
ICF Controller Fault
ESC
Controller Self-Diagnosing Screen
T5-4-22
LIST OF FAULT CODE
Fault Code Trouble Remedy
14000-2 Abnormal CAN Communication Execute retry B in self-diagnosing.

If this fault code is displayed after re-try, check the following
item.
Check the CAN communication line (check the harness).
14001-2 ICF: Flash Memory: Read / Write Execute retry B in self-diagnosing and execute the following
Error item.
Execute 1.5 Information C/U: Initialize (T5-4-15).
14002-2 ICF: External RAM: Read / Write
Error
14003-2 ICF: EEPROM: Sum Check Error Execute retry B in self-diagnosing.

If this fault code is displayed after re-try, check the following
item.
1. Execute 1.10 Control Data: Initialize (T5-4-20).
2. Execute 1.4 Enter Model and Serial No. (T5-4-14).
Then, execute self-diagnosing and execute retry B.
14006-2 ICF: Satellite Communication Ter- Execute retry B in self-diagnosing.

minal: Communication Error If this fault code is displayed after re-try, check the following
item.
Check the communication line.
Check the power source line of satellite terminal.
Check the fuse.
14008-2 ICF: Abnormal Internal RAM Execute retry B in self-diagnosing.

If this fault code is displayed after re-try, replace the control-
14100-2 Satellite Communication Terminal: ler.
Abnormal EEPROM
14101-2 Satellite Communication Terminal:
Abnormal IB/OB Queue
Abnormal Local Loup Back
The satellite is not found.
Fail 1 of Remote Loup Back
Fail 2 of Remote Loup Back
Sending and receiving data are un-
matched.
T5-4-23
SATELLITE COMMUNICATION SYSTEM
The satellite communication system is used for main- GPS Aerial

tenance of the machine, “e-Service” by transmitting
various data of the machine regularly via a low earth Communication
Aerial
orbit satellite.
NOTE: Depending on the circumstances of the

machine (ex. in the constructions, in the
tunnel, affected by the surrounding building
and affected of noise), the data transfer
rate may become slower, or the communi-
cation might not be established.
The satellite communication system using
a low earth orbit satellite transmits digital
data through the radio wave. If there is ex-
cessively noise or use of electrical equip- T1V1-05-07-003
ment which causes noise near the machine, Satellite

Rear Console Terminal
they cause reduces data transfer rate or
communication might not be established at
worst.
The satellite communication system consists of satel-

lite communication terminal, GPS aerial and commu-
nication aerial. The mail function of monitor unit be-
comes effective.
The functions of each equipment are:
• Satellite Communication Terminal

Receives the data from ICF, GPS aerial and
monitor unit, and sends the data to the commu-
nication aerial. ICF
• GPS Aerial TCJB-05-04-001
Receives location information of the machine

from a low earth orbit satellite. Monitor Unit
• Communication Aerial
Communicates the data with a low earth orbit
satellite.
• Monitor Unit
Sends the mail when pushing the key corre-
sponding to requirement.
1. General Requirement
2. Fuel Replenishing Requirement
3. Service Maintenance Requirement
4. Forwarding Requirement
1 2 3 4 T1V5-05-01-037
Mail Screen
T5-4-24
On the machine equipped with the satellite communi-
cation system, the data are sent according to the con-
dition as follows:
Kinds of data sent from the machine by using satellite

communication:
Items Kinds of Data Condition

Periodical Daily Report Data, Latest Location Infor-
The data are sent once a day. In order to
Transmission mation, Fuel Level avoid congested traffic in the communi-
cation line, the data is sent randomly
between 0:00 and 02:00.
Transmitting Data at Latest Location Information The data is sent only when the machine
Engine Start is moved more than 5 km from the place
where it is recorded lastly.
Emergency Alarm and Error Information The transmission starts immediately
Transmission when the alarm and error occurs.
Hour Meter 100 Hours Frequency Distribution Information The data is sent when the hour meter
Transmission exceeds every 100 hours.
Transmission by Mail General Requirement, Fuel Replenishing The transmission starts when the key on
Requirement, Service Maintenance Re- monitor unit corresponding to require-
quirement and Forwarding Requirement ment is pushed.
T5-4-25
(Blank)
T5-4-26
Section 5 TROUBLESHOOTING
Main Component Layout

Upperstructure (1)
1 2 3
8
9
10
11
12
13
14
15
24 16
23 17
22 18
21
20 19 TCEB-01-02-002
1- Rear Camera 8- Battery 14- Travel Shockless Valve 20- Steering Valve
2- Radiator 9- Fuel Cooler 15- Pilot Valve (Left) 21- Brake Valve
3- Inter Cooler 10- Washer Tank 16- Pilot Shut-Off Solenoid Valve 22- Travel Pilot Valve
4- Reserve Tank 11- ECM (Engine Controller) 17- Center Joint 23- Pilot Valve (Right)
5- Air Conditioner Condenser 12- Solenoid Valve Unit (For 18- Accumulator Charging Valve 24- Blade / Outrigger Electric
6- Receiver Drier Electric Lever) 19- Auxiliary / Positioning Electric Lever
7- Air Cleaner 13- Oil Cooler Lever
T5-5-1
Upperstructure (2)
42
41
40
38
37
36
35
34
33
32
31
30
29 28 27 26 25 TCEB-01-02-003
25- Positioning Control Valve 30- Automatic Fueling Switch 35- Engine Oil Filter 40- Steering Filter
26- Shuttle Valve 31- Control Valve 36- Pump Device 41- Pilot Filter
27- Signal Control Valve 32- Automatic Fueling Pump 37- Fuel Pre Filter 42- Engine
28- Heat Circuit Cut Solenoid Valve 33- 3-Spool Solenoid Valve Unit 38- Fuel Main Filter
29- Swing Shockless Valve 34- Swing Device 39- Solenoid Pump
T5-5-2
Undercarriage
ZX140W-3: Up to serial No 005000
ZX140W-3-AMS: Up to serial No 050000
1 2
3
9
8
7 6
TCEB-01-02-001
1- Blade Cylinder 3- 2-Spool Solenoid Valve Unit 5- Front Axle 8- Transmission

2- Rear Axle (Blade / Outrigger Cylinder) 6- Outrigger Cylinder 9- Transmission Changeover
4- Axle Lock Cylinder 7- Travel Motor Solenoid Valve
T5-5-3
Undercarriage
ZX140W-3: Serial No 005001 and up
ZX140W-3-AMS: Serial No 050001 and up
1
2
3
8
7
6
TCJB-01-02-011
1- Blade Cylinder 3- 2-Spool Solenoid Valve Unit 5- Front Axle 8- Transmission

2- Rear Axle (Blade / Outrigger Cylinder) 6- Outrigger Cylinder 9- Transmission Changeover
4- Axle Lock Cylinder 7- Travel Motor Solenoid Valve
T5-5-4
Front Attachment
 2-Piece Boom  Monoblock Boom
3 1
2
7
5 7
1
6 4
T1F3-01-02-003 6 T1F3-01-02-004
1- Bucket Cylinder 3- Positioning Cylinder 5- Hose Rupture Valve 6- Hose Rupture Valve (Boom)
2- Arm Cylinder 4- Boom Cylinder (Positioning) 7- Hose Rupture Valve (Arm)
T5-5-5
Electrical Component Layout (Overview)
Pump Device (Refer to T5-5-14.)

· Pump 1 Delivery Pressure Sensor
· Pump 2 Delivery Pressure Sensor
· Pump 1 Control Pressure Sensor
· Pump 2 Control Pressure Sensor Filter (Refer to T5-5-16.)
· Pump 1 Maximum Flow Rate Limit · Steering Pump Delivery Pressure Sensor
· Pump 2 Maximum Flow Rate Limit
Control Solenoid Valve Engine (Refer to T5-5-13.)
· Torque Control Solenoid Valve
2
3
4
5
6
8 7
9
10
11 TCEB-01-02-002
Travel Shockless Valve
(Refer to T5-5-16.)
Brake Valve (Refer to T5-5-15.) · Pressure Sensor (Travel Forward)
· Brake Pressure Sensor · Pressure Sensor (Travel Reverse)
· Work Brake Release Switch
· Brake Remain Pressure Sensor
1- Fresh Air Temperature Sensor 5- Battery 8- Solenoid Valve Unit (For 11- Pilot Shut-Off Solenoid Valve
2- Starter Relay 6- ECM Electric Lever) 12- Fuel Sensor
3- Battery Relay 7- Intake Air Temperature Sensor 9- Atmosphere Pressure Sensor 13- Hydraulic Oil Temperature
4- Glow Plug Relay 10- Air Cleaner Restriction Switch Sensor (Main)
T5-5-6
Swing Device
(Refer to T5-5-14.)
· Pressure Sensor (Front)
14
15
16
Control Valve (Refer to T5-5-15.) 17
· Pressure Sensor (Boom Raise)
· Pressure Sensor (Arm Roll-In) TCEB-01-02-003
Signal Control Valve (Refer to T5-5-14.)

· Pressure Sensor (Swing)
· Pressure Sensor (Auxiliary)
14- Horn 16- Pressure Sensor (Positioning) 18- 3-Spool Solenoid Valve Unit
15- Slip Ring 17- Heat Circuit Cut Solenoid Valve
T5-5-7
Electrical Component Layout (Monitors and

Switches)
5 6 7
4 2
3 12
TCJB-01-02-006 TCJB-01-02-014
11 10 9 8
14
22
15 23
16 24
34
13
25
26
27
33
28
17
18 32
19 31 30 29 TCJB-01-02-007
20
21
TCJB-01-02-008
1- Monitor Unit (Refer to T5-5-9.) 9- Brake Pedal 17- Hazard Switch 26- Travel Speed Mode Switch
2- Swing Lock Lever 10- Steering Column Monitor 18- Electrical Control Main Switch 27- Engine Speed Control Mode
3- Blade/Outrigger Lever (Refer to T5-5-10.) (Optional) Selection Switch
4- Pilot Shut-Off Lever 11- Auxiliary/Positioning Pedal 19- Blade/Outrigger Front-Rear 28- Power Mode Switch
5- Engine Stop Switch (Optional) Selector Switch 29- Key Switch
6- Combination Switch 12- Horn Switch 20- Outrigger Left-Right Selector 30- Blade/Outrigger Selector
· Turn Signal Switch 13- Left Analog Switch (Auxiliary) Switch Switch
· Light Switch 14- Horn Switch 21- Heater Seat Switch (Optional) 31- Auto-Idle Switch
· Dimmer Switch 15- Positioning Pedal Selection 22- FNR Switch 32- Work Light Switch
· Passing Switch Switch 23- Auxiliary 33- Wiper/Washer Switch
7- Brake Switch 16- Auxiliary Pedal Selection 24- Auxiliary 34- Right Analog Switch (Assist)
8- Accelerator Pedal Switch 25- Engine Control Dial (Optional)
T5-5-8
Monitor Unit
1 2 3 4 5 6 8
9
10
11
12
13
14
15
16
17
18
34
35
21 20 19
TCJB-05-02-043
33 32 31 30 29 28 27 26 25 24 23 22
1- Work Mode Display 10- Parking Brake Display 17- Mail Display (Optional) 27- Mail Selection (Optional)
2- Auto-Idle Display 11- Work Brake Display 18- Clock 28- Work Mode Display
3- Overload Alarm Display 12- Axle Lock Display 19- Trip Meter Display 29- Auxiliary Selection
(Optional) 13- Work Light Display 20- Odometer Display 30- Coolant Temperature Gauge
4- Auto Axle Lock Display 14- Auxiliary 2 (Positioning) 21- Hour Meter Display 31- Work Mode Selection
5- Auxiliary Selection Display 22- Back Monitor Selection 32- Return to Primary Screen
6- Glow Signal Display 15- Auxiliary 1 (Attachment) 23- Menu 33- Brake Oil Pressure Gauge
7- Trip Meter Selection Display 24- Meter Display Selection 34- Speedometer
8- Odometer 16- Blade/Outrigger Settings and 25- Fuel Gauge 35- Tachometer
9- Hour Meter Brake Mode Display 26- Auxiliary
T5-5-9
Steering Column Monitor
1 2
12
3
11 4
10 6
9 7
TCJB-02-01-008
8
1- Travel Forward Indicator 5- Travel Reverse Indicator 8- Travel Slow Speed Indicator 12- Turn Signal Indicator (Left)
2- Turn Signal Indicator (Right) 6- Hazard Light Indicator 9- Auxiliary
3- Neutral Indicator 7- Auto-Cruise Indicator 10- Clearance Light Indicator
4- Pilot Cut Indicator (Optional) 11- High Beam Indicator
T5-5-10
Electrical Component Layout (Controllers

and Relays)
1 2
7 3
TCJB-01-02-015
6 5
1- MC (Main Controller) 3- Fuse Box 5- Option Controller

2- Satellite Communication 4- Dr.ZX Connector (Use as 6- ICF (Information Controller)
Terminal (Optional) Download Connector) 7- Flasher
T5-5-11
Relays Position
TCJB-01-02-009
Option Controller
Dr.ZX Connector Fuse Box TCJB-01-02-010
1- High Beam Relay 19- Pilot Shut-Off Relay 33- Heater Seat Relay (OP) 45- Twin Wiper Relay 3 (OP)
2- Clearance Light Relay (Left) 20- Security Horn Relay 34- Room Lamp Controller Relay 46- Twin Wiper Relay 4 (OP)
3- Clearance Light Relay (Right) 21- Starter Cut Relay (OP) 47- Twin Wiper Relay 5 (OP)
4- Head Light Relay (Left) 22- Security Relay 35- Assist Relay 1 (OP) 48- Twin Wiper Relay 6 (OP)
5- Head Light Relay (Right) 23- Travel Fast Selection Relay 36- Assist Relay 2 (OP) 49- Swing Alarm Relay (OP)
6- Travel Slow Selection Relay 24- Blade/Outrigger Relay (Rear) 37- Assist Flow Rate Control Relay 50- Rear Head Light Relay (OP)
7- Compressor Relay (A/C) 25- Blade/Outrigger Relay (Front) (OP) 51- Additional Front Head Light
8- Heater Relay (A/C) 26- Blade/Outrigger Relay (Rear- 38- Blank (OP)
9- MAX-Hi Relay (A/C) Right) 39- Auxiliary/Positioning Selection 52- Additional Front Head Light
10- ECM Main Relay 27- Blade/Outrigger Relay (Rear- Relay 1 (OP) (OP)
11- Turn Signal Light Relay (Left) Left) 40- Auxiliary/Positioning Selection 53- Revolving Light Relay (OP)
12- Turn Signal Light Relay (Right) 28- Blade/Outrigger Relay (Main 2) Relay 2 (OP) 54- Immobilizer 1 (OP)
13- Wiper Relay 29- Blade/Outrigger Relay (Front- 41- Auxiliary/Positioning Selection 55- Immobilizer 2 (OP)
14- Boom Light Relay Right) Relay 3 (OP) 56- Immobilizer 3 (OP)
15- Stop Light Relay 30- Blade/Outrigger Relay (Front- 42- Auxiliary/Positioning Selection
16- Washer Relay Left) Relay 4 (OP)
17- Horn Relay 31- Blade/Outrigger Relay (Main 1) 43- Twin Wiper Relay 1 (OP)
18- Load Dump Relay 32- Auto-Cruise Relay (OP) 44- Twin Wiper Relay 2 (OP)
fNOTE: OP: Optional
T5-5-12
Engine
1
2
T1T1-01-02-005 5 6
3 4
7
8
13
T1T1-01-02-003 T1T1-01-02-004
12 11 10
1- EGR Valve 5- Overheat Switch 9- Common Rail Pressure Sensor 13- Supply Pump Actuator
2- Glow Plug 6- Injector 10- Crank Speed Sensor
3- Cam Angle Sensor 7- Boost Pressure Sensor 11- Engine Oil Pressure Sensor
4- Coolant Temperature Sensor 8- Boost Temperature Sensor 12- Fuel Temperature Sensor
T5-5-13
Pump Device
5 6
2 1
11
10
9 8
TCEB-03-01-003 TCEB-03-01-001
4 3
Swing Device Signal Control Valve
13
12 19
18
14
15
17 16
TCEB-01-02-005
TCEB-01-02-004
1- Pump 1 6- Steering Pump 10- Torque Control Solenoid Valve 16- Heat Circuit Cut Solenoid Valve
2- Pump 2 7- Pump 2 Control Pressure 11- Pump 2 Maximum Flow Rate 17- Swing Shockless Valve
3- Pump 1 Delivery Pressure Sensor Limit Control Solenoid Valve 18- Pressure Sensor (Swing)
Sensor 8- Pump 1 Control Pressure 12- Pressure Sensor (Front) 19- Pressure Sensor (Auxiliary)
4- Pump 2 Delivery Pressure Sensor 13- Signal Control Valve
Sensor 9- Pump 1 Maximum Flow Rate 14- Pressure Sensor (Positioning)
5- Pilot Pump Limit Control Solenoid Valve 15- Shuttle Valve
T5-5-14
Control Valve Brake Valve
1 2 4
6
TCGB-01-02-003
3 TCJB-01-02-017
3-Spool Solenoid Valve Unit Solenoid Valve Unit (For Electric Lever)
9 10 11
20 12
19 13
18 14
17 15
TCGB-03-12-001
16
TCJB-01-02-018
1- Main Relief Valve 7- Brake Pressure Sensor 13- Auxiliary Solenoid Valve 17- Blade / Outrigger Solenoid
2- Pressure Sensor (Arm Roll-In) 8- Brake Valve 14- Blade / Outrigger Solenoid Valve
3- Pressure Sensor (Boom Raise) 9- Solenoid Valve Unit (SC) Valve 18- Auxiliary Solenoid Valve
4- Accumulator Charging Valve 10- Solenoid Valve Unit (SF) 15- Travel Make-Up Solenoid Valve 19- Positioning / Assist Solenoid
5- Brake Remain Pressure Sensor 11- Solenoid Valve Unit (SI) 16- Hydraulic Oil Temperature Valve
6- Stop Light / Work Brake 12- Positioning / Assist Solenoid Sensor (For Electric Lever) 20- Swing Parking Brake Release
Release Switch Valve Solenoid Valve
T5-5-15
Travel Shockless Valve Transmission Changeover Solenoid Valve
2 5 6
TCJB-01-02-019 TCJB-05-07-002
4
Travel Device Filter

11 12 13
7 8
10 9 TCJB-01-02-020 15 14
TCEB-01-02-006
1- Pressure Sensor (Travel 4- Pressure Sensor (Travel 8- Transmission 12- Steering Filter
Forward) Reverse) 9- Travel N Sensor 13- Pilot Filter
2- Travel Forward Pi Cut Solenoid 5- Travel Mode Selector Solenoid 10- Travel Motor Displacement 14- Fuel Pre Filter
Valve Valve Control Solenoid Valve 15- Fuel Main Filter
3- Travel Reverse Pi Cut Solenoid 6- Pressure Reducing Valve 11- Steering Pump Delivery
Valve 7- Travel Motor Pressure Sensor
T5-5-16
(Blank)
T5-5-17
Components in Control Valve
1 2 3 4 5 6 7 8 9 10
41
40 11
12
39 13
38
37 14
15
16
36
35 17
34
33
32
18
31
19
30
29
28
20
21
27 26 25 24 23 22
T16W-03-03-018
T5-5-18
11
4 14
41
18
35, 36
Front
T16W-03-03-030
1- Load Check Valve (Blade/ 12- Make-Up Valve (Travel Forward 23- Bypass Shut-Out Valve 34- Load Check Valve (Boom 2
Outrigger Tandem Circuit) Side) 24- Check Valve (Orifice) (Arm 2 Parallel Circuit)
2- Load Check Valve (Blade/ 13- Bucket Regenerative Circuit Parallel Circuit) 35- Aux. Flow Rate Control Valve
Outrigger Parallel Circuit) 14- Overload Relief Valve (Bucket 25- Load Check Valve (Arm 1 (Poppet Valve)
3- Check Valve (Main Relief Rod Side) Parallel Circuit) 36- Aux. Flow Rate Control Valve
Circuit) 15- Overload Relief Valve (Bucket 26- Load Check Valve (Arm 1 (Selector Valve)
4- Main Relief Valve Bottom Side) Tandem Circuit) 37- Overload Relief Valve
5- Auxiliary Flow Combiner Valve 16- Load Check Valve (Boom 1 27- Load Check Valve (Swing (Auxiliary)
6- Check Valve (Auxiliary Flow Parallel Circuit) Circuit) 38- Overload Relief Valve
Combiner Circuit) 17- Boom Regenerative Circuit 28- Arm Regenerative Valve (Auxiliary)
7- Check Valve (Main Relief 18- Overload Relief Valve (Boom (Selector Valve) 39- Load Check Valve (Bucket
Circuit) Bottom Side) 29- Arm Regenerative Circuit Parallel Circuit)
8- Check Valve (Flow Combiner 19- Overload Relief Valve (Boom 30- Overload Relief Valve (Arm 40- Overload Relief Valve (Blade/
Circuit) Rod Side) Bottom Side) Outrigger Rod Side)
9- Bucket Flow Rate Control Valve 20- Boom Anti-Drift Valve (Check 31- Overload Relief Valve (Arm 41- Overload Relief Valve (Blade/
(Selector Valve) Valve) Rod Side) Outrigger Bottom Side)
10- Bucket Flow Rate Control Valve 21- Boom Anti-Drift Valve (Selector 32- Arm Anti-Drift Valve (Check
(Poppet Valve) Valve) Valve)
11- Make-Up Valve (Travel Reverse 22- Load Check Valve (Arm 2 33- Arm Anti-Drift Valve (Selector
Side) Tandem Circuit) Valve)
T5-5-19
1 2 3 4 5 6 7 8 9 10
41
40 11
12
39 13
38
37 14
15
16
36
35 17
34
33
32
18
31
19
30
29
28
20
21
27 26 25 24 23 22
T16W-03-03-018
T5-5-20
19 15 9, 10 12
39
6
23
Front T16W-03-03-031
30 37 40 5
T5-5-21
1 2 3 4 5 6 7 8 9 10
41
40 11
12
39 13
38
37 14
15
16
36
35 17
34
33
32
18
31
19
30
29
28
20
21
27 26 25 24 23 22
T16W-03-03-018
T5-5-22
A B
C
C
D
D
E E
F F
G G
H
H
A B T16W-03-03-002
Cross Section A-A Cross Section B-B

8
13
Blade/
Outrigger Travel
Auxiliary Bucket
Boom 2
Boom 1
Arm 1
Arm 2
Swing
17
28
29 T16W-03-03-008 TCHB-03-03-001
T5-5-23
1 2 3 4 5 6 7 8 9 10
41
40 11
12
39 13
38
37 14
15
16
36
35 17
34
33
32
18
31
19
30
29
28
20
21
27 26 25 24 23 22
T16W-03-03-018
T5-5-24
Cross Section C-C Cross Section D-D
Blade/ Travel
Outrigger
4 7 41 11
3 1
5
8 8 6 39
T16W-03-03-014 T16W-03-03-013
40 12
T5-5-25
1 2 3 4 5 6 7 8 9 10
41
40 11
12
39 13
38
37 14
15
16
36
35 17
34
33
32
18
31
19
30
29
28
20
21
27 26 25 24 23 22
T16W-03-03-018
T5-5-26
Cross Section E-E Cross Section F-F
Boom 2 Boom 1
Auxiliary Bucket
38 14 31 21
20
35 10
9 34
36 16
17
T16W-03-03-012 T16W-03-03-011
37 15 19
T5-5-27
1 2 3 4 5 6 7 8 9 10
41
40 11
12
39 13
38
37 14
15
16
36
35 17
34
33
32
18
31
19
30
29
28
20
21
27 26 25 24 23 22
T16W-03-03-018
T5-5-28
Cross Section G-G Cross Section H-H
Arm 1 Arm 2
Swing
33 18
28
32
22
25 27
26
24
29
23
T16W-03-03-010 T16W-03-03-009
30
T5-5-29
Layout of Positioning Control Valve (2-Piece Boom)
3 2
Positioning TCEB-03-03-001
Control Valve
T5-5-30
Cross Section X-X

X
X T178-03-03-070 T198-03-03-003
1- Load Check Valve (Positioning 2- Load Check Valve (Positioning 3- Overload Relief Valve 4- Overload Relief Valve
Parallel Circuit) Tandem Circuit) (Positioning: Bottom Side) (Positioning: Rod Side)
T5-5-31
Pilot Port Pilot Valve Side

C
PH
E
A
D
M
B
H
SB
F G
P1
N
Pilot Valve Side
K I
SH J
DF
T178-03-06-016
SA L
Pilot Valve Side
Port Name Connecting to Remark
Port A Right Pilot Valve Boom Raise Pilot Pressure
Port B Right Pilot Valve Boom Lower Pilot Pressure
Port C Swing Shockless Valve (Left Pilot Valve) Arm Roll-Out Pilot Pressure
Port D Swing Shockless Valve (Left Pilot Valve) Arm Roll-In Pilot Pressure
Port E Swing Shockless Valve (Left Pilot Valve) Left Swing Pilot Pressure
Port F Swing Shockless Valve (Left Pilot Valve) Right Swing Pilot Pressure
Port G Right Pilot Valve Bucket Roll-In Pilot Pressure
Port H Right Pilot Valve Bucket Roll-Out Pilot Pressure
Port I - Plug
Port J - Plug
Port K Travel Shockless Valve (Travel Pilot Valve) Travel Reverse Pilot Pressure
Port L Travel Shockless Valve (Travel Pilot Valve) Travel Forward Pilot Pressure
Port M Blade/Outrigger Solenoid Valve Blade/Outrigger Pilot Pressure
Port N Auxiliary Solenoid Valve Auxiliary Pilot Pressure
Port SA Pump 1 Regulator Pump 1 Control Pressure
Port SB Pump 2 Regulator Pump 2 Control Pressure
Port PI Pilot Shut-Off Solenoid Valve Primary Pilot Pressure
Port PH Pilot Shut-Off Solenoid Valve Primary Pilot Pressure (Heat Circuit)
Port SH Swing Parking Brake Brake Release Pressure
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank
T5-5-32
Control Valve Side
1 3
Pressure Sensor (Auxiliary)

13 5
2 4
SK
Pressure Sensor (Swing) SE
8
14
Control Valve Side

7
6
9
10 SN
SL 11
T1F3-03-06-003
12 SP
Control Valve Side

Port Name Connecting to Remark
Port 1 Control Valve Boom Raise Pilot Pressure
Port 2 Control Valve Boom Lower Pilot Pressure
Port 3 Control Valve Arm Roll-Out Pilot Pressure
Port 4 Control Valve Arm Roll-In Pilot Pressure
Port 5 Control Valve Left Swing Pilot Pressure
Port 6 Control Valve Right Swing Pilot Pressure
Port 7 Control Valve Bucket Roll-In Pilot Pressure
Port 8 Control Valve Bucket Roll-Out Pilot Pressure
Port 9 Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port 10 - Plug
Port 11 Control Valve Travel Reverse Pilot Pressure
Port 12 Control Valve Travel Forward Pilot Pressure
Port 13 - Plug
Port 14 - Plug
Port SE - Plug
Port SN - Plug
Port SP Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port SL - Plug
Port SK Control Valve Bucket Flow Rate Control Valve Control Pressure
2-Piece Boom Specification Machine

Port SP Positioning Solenoid Valve Pump 1 Control Pressure
T5-5-33
fNOTE: Machine with front attachment (pulverizer 1 to 5

and crusher 1 to 5) attached.
Control Valve Side
14
Control Valve Side
SN
T1F3-03-06-003
Control Valve Side

Port Name Connecting to Note
Port 14 Auxiliary Flow Combiner Contorl Solenoid Valve Auxiliary Flow Combiner Valve Control Pressure
Port SN Pressure Reducing Valve Auxiliary Flow Combiner Valve Control Pressure
fNOTE: The auxiliary flow combiner control solenoid

valve and pressure reducing valve are installed only on
the machines equipped with the optional parts.
T5-5-34
TROUBLESHOOTING / Troubleshooting A
Symptoms in Machine Operation When

Remedy by Dr. ZX Remedy
Trouble Occurs.
- Retrial B Replace MC.
Although the engine control dial is Retrial B • Check the sensor connected to MC.
operated, the engine speed does not • Check the harness.
change. • Replace MC.
• The machine movement is slow. Retrial B • Check the CAN harness.
• The work brake is not operated. • Replace MC.
• The work mode alarm is displayed on
the monitor unit.
T1V1-05-01-102
• The travel speed does not change.
T5-6-3
Engine Failure
Fault Code Trouble Cause Influenced Control
11100-2 Abnormal Engine Speed Engine Speed: more than Speed Sensing Control
-1
4000 min
11101-3 Abnormal Engine Control Dial Voltage: more than 4.78 V Engine Control Dial Control
Sensor High Voltage
11101-4 Abnormal Engine Control Dial Voltage: less than 0.22 V Engine Control Dial Control
Sensor Low Voltage
T5-6-4

Trouble Occurs.
The machine movement is slow. Retrial B • Check the crank speed sensor.
(During speed sensing, the torque is • Check the cam angle sensor.
reduced.)
• Trouble condition with the key ON: Retrial B • Check the harness.
The engine speed is kept at idle • Replace the engine control dial.
speed.
• Trouble condition during operation:
The engine speed is kept at the
speed immediately before trouble.
• Trouble condition with the key ON: Retrial B • Check the harness.
The engine speed is kept at idle • Replace the engine control dial.
speed.
• Trouble condition during operation:
The engine speed is kept at the
speed immediately before trouble.
T5-6-5
Pump Failure
11200-3 Abnormal Pump 1 Delivery Voltage: more than 4.5 V • HP Mode Control
Pressure Sensor High Voltage • Travel Accelerator Control
• E Mode Control
• Arm Regenerative Control
• Auto-Power Lift Control
11200-4 Abnormal Pump 1 Delivery Voltage: less than 0.25 V • HP Mode Control
Pressure Sensor Low Voltage • Travel Accelerator Control
• E Mode Control
11202-3 Abnormal Pump 2 Delivery Voltage: more than 4.5 V • HP Mode Control
Pressure Sensor High Voltage • E Mode Control
11202-4 Abnormal Pump 2 Delivery Voltage: less than 0.25 V • HP Mode Control
Pressure Sensor Low Voltage • E Mode Control
11203-3 Abnormal Pump 3 Delivery Voltage: more than 4.5 V • Steering Pump Torque
Pressure Sensor High Voltage Reduction Control
11203-4 Abnormal Pump 3 Delivery Voltage: less than 0.25 V • Steering Pump Torque
Pressure Sensor Low Voltage Reduction Control
11206-3 Abnormal Pump 1 Pump Control Voltage: more than 4.75 V • E Mode Control
Pressure Sensor High Voltage • Heater Control
11206-4 Abnormal Pump 1 Pump Control Voltage: less than 0.25 V • E Mode Control
Pressure Sensor Low Voltage • Heater Control
11208-3 Abnormal Pump 2 Pump Control Voltage: more than 4.75 V • E Mode Control
Pressure Sensor High Voltage • Heater Control
11208-4 Abnormal Pump 2 Pump Control Voltage: less than 0.25 V • E Mode Control
Pressure Sensor Low Voltage • Heater Control
T5-6-6

Trouble Occurs.
• Combined operation of arm roll-in and Retrial B • Check the harness.
boom raise or combined operation of • Replace the pump 1 delivery
arm-roll-in and swing: Arm speed is pressure sensor.
slow.
• Single operation of boom raise: Lifting
force is weak.
slow.
force is weak.
slow.
slow.
• The steering pump torque decrease Retrial B • Check the harness.
control is inactive. • Replace the steering pump delivery
pressure sensor.
• The steering pump torque decrease Retrial B • Check the harness.
control is inactive. • Replace the steering pump delivery
pressure sensor.
• Although speed normally returns to P Retrial B • Check the harness.
speed when lever is operated in E • Replace the pump 1 control
mode, speed stays at P speed in this pressure sensor.
failure.
failure.
failure.
failure.
T5-6-7
Pilot Failure
11301-3 Abnormal Swing Pilot Pressure Voltage: more than 4.75 V • Arm Regenerative Control
Sensor High Voltage • Attachment Flow Rate Control
(Optional)
• Swing Alarm Control (Optional)
11301-4 Abnormal Swing Pilot Pressure Voltage: less than 0.25 V • Arm Regenerative Control
Sensor Low Voltage • Attachment Flow Rate Control
(Optional)
• Swing Alarm Control (Optional)
11302-3 Abnormal Boom Raise Pilot Voltage: more than 4.75 V • HP Mode Control
Pressure Sensor High Voltage • Arm Regenerative Control
• Attachment Flow Rate Control
(Optional)
11302-4 Abnormal Boom Raise Pilot Voltage: less than 0.25 V • HP Mode Control
Pressure Sensor Low Voltage • Arm Regenerative Control
(Optional)
11303-3 Abnormal Arm Roll-In Pilot Voltage: more than 4.75 V • HP Mode Control
Pressure Sensor High Voltage • Arm Regenerative Control
11303-4 Abnormal Arm Roll-In Pilot Voltage: less than 0.25 V • HP Mode Control
Pressure Sensor Low Voltage • Arm Regenerative Control
T5-6-8

Trouble Occurs.
• Combined operation of arm-roll-in and Retrial B • Check the harness.
swing: Arm speed is slow. • Replace the swing pilot pressure
• In case of the machine equipped with sensor.
the swing alarm (optional) and when
swing alarm is effective, swing alarm
continues to sound even in no
swinging.
• Combined operation of arm-roll-in and Retrial B • Check the harness.
swing: Arm speed is slow. • Replace the swing pilot pressure
• In case of the machine equipped with sensor.
the swing alarm (optional) and when
swing alarm is effective, swing alarm
continues to sound even in no
swinging.
• During HP control, engine speed does Retrial B • Check the harness.
not increase in boom raise operation. • Replace the boom raise pilot
• Combined operation of arm roll-in and pressure sensor.
boom raise: Arm speed is slow.
force is weak.
not increase in boom raise operation. • Replace the boom raise pilot
boom raise: Arm speed is slow.
force is weak.
not increase in arm-roll-in operation. • Replace the arm roll-in pilot
swing: Arm speed is slow.
not increase in arm-roll-in operation. • Replace the arm roll-in pilot
swing: Arm speed is slow.
T5-6-9
11305-3 Abnormal Travel Voltage: more than 4.75 V • Auto-Idle Control

Forward Pilot • Idle Speed-Up Control
Pressure Sensor • ECO Control
• Travel Accelerator Control
High Voltage • Heater Control
• Speed Sensing Control (Normal)
• Travel Speed Sensing Control
• Pump 1 and 2 Flow Rate Limit Control
• Travel Motor Displacement Angle Control
• Travel Motor Excessive Rotation Control
• Auto Axle Lock Control
• Forward/Reverse Shifting Limit Control
• Attachment Flow Rate Limit Control
• Travel Alarm Control (Optional)
• Auto-Cruise Control (Optional)
11305-4 Abnormal Travel Voltage: less than 0.25 V • Auto-Idle Control
Forward Pilot • Idle Speed-Up Control
Pressure Sensor Low • ECO Control
Voltage • Heater Control
• Auto-Cruise Control (Optional)
11306-3 Abnormal Travel Voltage: more than 4.75 V • Auto-Idle Control
Reverse Pilot • Idle Speed-Up Control
Pressure Sensor • ECO Control
High Voltage • Heater Control
11306-4 Abnormal Travel Voltage: less than 0.25 V • Auto-Idle Control
Reverse pilot • Idle Speed-Up Control
• ECO Control
Pressure Sensor Low • Travel Accelerator Control
Voltage • Heater Control
T5-6-10

Trouble Occurs.
• When traveling forward at idle speed, Retrial B • Check the harness.
engine speed does not increase to the idle • Replace the travel forward pilot
speed-up speed. pressure sensor.
• When traveling forward, engine speed does
not return from auto idle speed.
not return from ECO speed.
• When operating the attachment with
traveling forward, the machine mistracks.
• In case of the machine equipped with the
travel alarm (optional), travel alarm
continues to sound even in no traveling.
• When traveling forward at idle speed, Retrial B • Check the harness.

engine speed does not increase. • Replace the travel forward pilot
• When traveling forward, engine speed does pressure sensor.
traveling forward, the machine mistracks.
• When traveling reverse at idle speed, Retrial B • Check the harness.

engine speed does not increase to the idle • Replace the travel reverse pilot
• When traveling reverse, engine speed does
traveling reverse, the machine mistracks.
• When traveling reverse at idle speed, Retrial B • Check the harness.

engine speed does not increase to the idle • Replace the travel reverse pilot
traveling reverse, the machine mistracks.
T5-6-11

11307-3 Abnormal Front Attachment Pilot Voltage: more than 4.75 V • Auto-Idle Control
Pressure Sensor High Voltage • Idle Speed-Up Control
• ECO Control
• Pump 1 and 2 Flow Rate Limit
Control
• Heater Control
• Parking Brake Alarm Control
11307-4 Abnormal Front Attachment Pilot Voltage: less than 0.25 V • Auto-Idle Control
Pressure Sensor Low Voltage • Idle Speed-Up Control
• ECO Control
Control
• Heater Control
• Parking Brake Alarm Control
11310-3 Abnormal Brake Pressure Voltage: more than 4.50 V • Work Brake Control
Sensor High Voltage • Auto-Cruise Control
(Optional)
11310-4 Abnormal Brake Pressure Voltage: less than 0.25 V • Work Brake Control
Sensor Low Voltage • Auto-Cruise Control
(Optional)
11311-3 Abnormal Brake Remaining Voltage: more than 4.50 V • Travel Mode Selection Control
Pressure Sensor High Voltage
11311-4 Abnormal Brake Remaining Voltage: less than 0.25 V • Travel Mode Selection Control
Pressure Sensor Low Voltage
T5-6-12

Trouble Occurs.
• When operating the front attachment at Retrial B • Check the harness.
idle speed, engine speed does not • Replace the front attachment pilot
increase to the idle speed-up speed. pressure sensor.
• When operating the front attachment,
engine speed does not return from
auto idle speed.
ECO speed.
• Although the front attachment is
operated while parking brake is
activated, buzzer does not sound.
• When operating the front attachment at Retrial B • Check the harness.
idle speed, engine speed does not • Replace the front attachment pilot
increase to the idle speed-up speed. pressure sensor.
auto idle speed.
ECO speed.
• Although the front attachment is
operated while parking brake is
activated, buzzer does not sound.
• Work brake is not does not work. Retrial B • Check the harness.
• Auto-cruise control cannot be • Replace the brake pressure sensor.
released.
• Work brake is not does not work. Retrial B • Check the harness.
• Auto-cruise control cannot be • Replace the brake pressure sensor.
released.
• After releasing the parking brake, Retrial B • Check the harness.
shifting fast/slow of the transmission • Replace the brake remaining
does not work. pressure sensor.
• After releasing the parking brake, Retrial B • Check the harness.
shifting fast/slow of the transmission • Replace the brake remaining
does not work. pressure sensor.
T5-6-13
Proportional Solenoid Valve Failure
11400-2 Abnormal Current Feedback of Current: Both of Higher Pump 2 Flow Rate Limit Control
Maximum Pump 2 Flow Rate Limit than 920 mA or Less
Control Solenoid Valve than 60 mA
11400-3 Abnormal Feedback High Current of Current: Higher than Pump 2 Flow Rate Limit Control
Maximum Pump 2 Flow Rate Limit 920 mA
11400-4 Abnormal Feedback Low Current of Current: Less than 56 Pump 2 Flow Rate Limit Control
Maximum Pump 2 Flow Rate Limit mA
11401-2 Abnormal Current Feedback of Current: Both of Higher • Speed Sensing Control
Torque Control Solenoid Valve than 920 mA or Less • Steering Pump Torque Decrease
than 60 mA Control
11401-3 Abnormal Feedback High Current of Current: Higher than • Speed Sensing Control
Torque Control Solenoid Valve 920 mA • Steering Pump Torque Decrease
Control
11401-4 Current: Less than 56 • Speed Sensing Control

Abnormal Feedback Low Current of
Torque Control Solenoid Valve mA • Steering Pump Torque Decrease
Control
11403-2 Abnormal Current Feedback of Current: Both of Higher Arm Regenerative Control
Solenoid Valve Unit (SC) (Arm than 920 mA or Less
Regeneration) than 60 mA
11403-3 Abnormal Feedback High Current of Current: Higher than Arm Regenerative Control
Solenoid Valve Unit (SC) (Arm 920 mA
Regeneration)
11403-4 Abnormal Feedback Low Current of Current: Less than 56 Arm Regenerative Control
Solenoid Valve Unit (SC) (Arm mA
Regeneration)
11404-2 Abnormal Current Feedback of Current: Both of Higher • Power Digging Control
Solenoid Valve Unit (SG) (Relief than 920mA or Less • Auto-Power Lift Control
Pressure Control) than 60 mA
11404-3 Abnormal Feedback High Current of Current: Higher than • Power Digging Control
Solenoid Valve Unit (SG) (Relief 920 mA • Auto-Power Lift Control
Pressure Control)
11404-4 Abnormal Feedback Low Current of Current: Less than 56 • Power Digging Control
Solenoid Valve Unit (SG) (Relief mA • Auto-Power Lift Control
Pressure Control)
T5-6-14

Trouble Occurs.
In case the attachment flow rate is Retrial B • Check the harness.
limited, it cannot be limited.
Operation during abnormal high current: Retrial B • Check the harness.

• Travel mistakes.
• Boom raise operation is slow.
• Arm operation is slow.
• Swing operation is slow.
Operation during abnormal low current: Retrial B • Check the harness.
• In case the attachment flow rate is
Machine overall operation is slow. Retrial B • Check the harness.

• The engine is stalled at slow idle.
• Engine speed: Middle to Fast: Engine
stall or large lug down
• Machine overall operation is slow.
Combined operation of boom raise and Retrial B • Check the harness.

arm roll-in with the front attachment
over ground, the boom is not raised
smoothly and the arm roll-in full-speed
is slow.
• Digging force (arm) becomes weak.

• Combined operation of boom raise
and arm roll-in with the front
attachment over ground, the boom is
not raised smoothly and the arm
roll-in full-speed is slow.
Pressure does not increase even if Retrial B • Check the harness.
power digging switch is on.

• Pressure always increases.

• Pressure does not increase even if
power digging switch is on.
T5-6-15
11410-2 Abnormal Current Feedback of Current: Both of Higher • Pump 1 Flow Rate Limit Control
Maximum Pump 1 Flow Rate Limit than 920 mA or Less When Traveling At Creeper Mode
Control Solenoid Valve than 60 mA • Pump 1 Flow Rate Limit Control
• Attachment Flow Rate Limit
Control
11410-3 Abnormal Feedback High Current of Current: Higher than • Pump 1 Flow Rate Limit Control
Maximum Pump 1 Flow Rate Limit 920 mA When Traveling At Creeper Mode
Control Solenoid Valve • Pump 1 Flow Rate Limit Control
Control
11410-4 Abnormal Feedback Low Current of Current: Less than 56 • Pump 1 Flow Rate Limit Control
Maximum Pump 1 Flow Rate Limit mA When Traveling At Creeper Mode
Control Solenoid Valve • Pump 1 Flow Rate Limit Control
Control
11422-2 Abnormal Current Feedback of Current: Both of Higher • Travel Motor Displacement Angle
Travel Motor Displacement Angle than 920 mA or Less Control
Control Solenoid Valve than 60 mA • Travel Motor Excessive Rotation
Control
11422-3 Abnormal Feedback High Current of Current: Higher than • Travel Motor Displacement Angle
Travel Motor Displacement Angle 920 mA Control
Control Solenoid Valve • Travel Motor Excessive Rotation
Control
11422-4 Abnormal Feedback Low Current of Current: Less than 56 • Travel Motor Displacement Angle
Travel Motor Displacement Angle mA Control
Control Solenoid Valve • Travel Motor Excessive Rotation
Control
11423-2 Abnormal Current Feedback of Current: Both of Higher -
Travel Make-Up Solenoid Valve than 920 mA or Less
than 60 mA
11423-3 Abnormal Feedback High Current of Current: Higher than -
Travel Make-Up Solenoid Valve 920 mA
11423-4 Abnormal Feedback Low Current of Current: Less than 56 -

Travel Make-Up Solenoid Valve mA
T5-6-16

Trouble Occurs.





T5-6-17
11424-2 Abnormal Current Feedback of Current: Both of Higher • Auto Axle Lock Control
Solenoid Valve Unit (SI) (Axle Lock than 920 mA or Less
Selection) than 60 mA
11424-3 Abnormal Feedback High Current Current: Higher than • Auto Axle Lock Control
of Solenoid Valve Unit (SI) (Axle 920 mA
Lock Selection)
11424-4 Abnormal Feedback Low Current Current: Less than 56 • Auto Axle Lock Control
of Solenoid Valve Unit (SI) (Axle mA
Lock Selection)
11425-2 Abnormal Current Feedback of Current: Both of Higher • ECO Control
Solenoid Valve Unit (SF) (Work than 920 mA or Less • Idle Speed-Up Control
Brake) than 60 mA • Speed Sensing Control
• Brake Dragging Prevention
Control
• Work Brake Control
11425-3 Abnormal Feedback High Current Current: Higher than • ECO Control
of Solenoid Valve Unit (SF) (Work 920 mA • Idle Speed-Up Control
Brake) • Speed Sensing Control
Control
11425-4 Abnormal Feedback Low Current Current: Less than 56 • ECO Control
of Solenoid Valve Unit (SF) (Work mA • Idle Speed-Up Control
Brake) • Speed Sensing Control
Control
T5-6-18

Trouble Occurs.



T5-6-19
CAN Data Reception Failure
11910-2 Actual Engine Speed Faulty harness • Speed Sensing Control

Sent from: ECM • Send to ICF
11911-2 Security Signal Faulty harness Theft Prevention Engine Speed,

Sent from: Monitor Unit Engine Torque
11914-2 Radiator Coolant Temperature Faulty harness Heater Control

Sent from: ECM
11915-2 Gate Lock Signal Faulty harness Heater Control
Sent from: Option Controller
11918-2 Work Mode Faulty harness • Attachment Operation Speed
Sent from: Monitor Unit Increase Control
• Attachment Operation Speed
Limit Control
• Attachment Pump Torque
Decrease Control
Control
(Optional)
• Breaker/Pulverizer/Crusher
Control (Optional)
11920-2 Fuel Flow Rate Faulty harness Fuel Flow Rate
Sent from: ECM
T5-6-20

Trouble Occurs.
Machine operation speed is slow. Retrial B • Check the harness.
(During speed sensing, torque is
decreased.)
Engine stall is displayed on e-Service.
When theft prevention is ON set by Dr. Retrial B • Check the harness.
ZX,
Engine speed = Slow idle
Pump torque = Minimum displacement
angle
Those values are fixed.
Heater control is inactive. Retrial B • Check the harness.
Heater control is inactive. Retrial B • Check the harness.
• Work Mode: Digging mode is fixed. Retrial B • Check the harness.

In case decreasing flow rate and speed
are set in ATT mode, stop this mode
control, or Work mode is not changed
from Digging mode to ATT mode.
• Work Mode Alarm is displayed on the
monitor unit.
T1V1-05-01-102
When fuel rate display is set on Retrial B • Check the harness.

monitor, "---" is displayed.
T5-6-21
Other Failures
*11502-2 Travel Motor Excessive Rotation Transmission rotation keeps -
over its threshold value for 2.0
sec.
11901-3 Hydraulic Oil Temperature Voltage: more than 4.52 V • Auto-Warming Up Control
Sensor High Voltage • Arm Regenerative Control
11901-4 Hydraulic Oil Temperature Voltage: less than 0.23 V • Auto-Warming Up Control
Sensor Low Voltage • Arm Regenerative Control
11921-2 Incorrect Odometer Value Faulty MC -
NOTE: *: Fault code 11502 is shown when travel

motor overturns.
Select the MC monitor item on Dr. ZX.
Check the counted travel motor excessive
rotations. (The travel motor is not faulty.)
Select retrial in order to erase the displayed
fault code.
T5-6-22
TROUBLESHOOTING/ Troubleshooting A
Symptoms in Machine Operation When Trouble Remedy by

Remedy
Occurs. Dr. ZX
- - -
In low temperature (Hydraulic oil temperature is less Retrial B • Check the harness.
than 0 °C (32 °F)), auto-warming up control is
impossible.
In low temperature (Hydraulic oil temperature is less Retrial B • Check the harness.
than 0 °C (32 °F)), auto-warming up control is
impossible.
Odometer value may increase after the key switch is Retrial B • Replace MC.
OFF.
T5-6-23
ECM FAULT CODE LIST
Sensor System
Fault
Trouble Cause
Code
636-2 Abnormal Cam Angle Sensor (No Signal) Although the crank signal is present, the cam signal is
not present.
636-2 Abnormal Cam Angle Sensor (Abnormal The pulse of cam signal is not matched.
Signal)
723-2 Abnormal Crank Speed Sensor (No Although the cam signal is present, the crank signal is
Signal) not present.
723-2 Abnormal Crank Speed Sensor The pulse of crank signal is not matched.
(Abnormal Signal)
636-7 Phase Mismatch of Cam Angle Sensor The right cam pulse is not present at the gap in the
crank.
172-3 Abnormal Intake Air Temperature Sensor Voltage at the intake air temperature sensor is beyond
(Abnormal High Voltage) 4.95 V in 3 minutes after the engine starts.
172-4 Abnormal Intake Air Temperature Sensor Voltage at the intake-air temperature sensor is below
(Abnormal Low Voltage) 0.1 V.
110-3 Abnormal Coolant Temperature Sensor Voltage at the coolant temperature sensor is beyond
(Abnormal High Voltage) 4.85 V in 3 minutes after the engine starts.
110-4 Abnormal Coolant Temperature Sensor Voltage at the coolant temperature sensor is below 0.1
(Abnormal Low Voltage) V
102-4 Abnormal Boost Pressure Sensor Voltage at the boost pressure sensor is beyond 4.9 V.
(Abnormal High Voltage)
102-3 Abnormal Boost Pressure Sensor Voltage at the boost pressure sensor is below 0.1 V
(Abnormal Low Voltage)
10001-3 Abnormal EGR Position (Brushless spec.) The condition which the output signal of EGR position
cannot be present in.
108-4 Abnormal Atmospheric Pressure Sensor Voltage at the atmospheric pressure sensor is beyond
(Abnormal High Voltage) 3.8 V.
108-3 Abnormal Atmospheric Pressure Sensor Voltage at the atmospheric pressure sensor is below
174-3 Abnormal Fuel Temperature Sensor Voltage at the fuel temperature sensor is beyond 4.85
(Abnormal High Voltage) V in 3 minutes after the engine starts.
174-4 Abnormal Fuel Temperature Sensor Voltage at the fuel temperature sensor is below 0.1 V.
T5-6-24
Presumptive Symptoms in Real Machine Fault Code

Assumptive Conditions at Backup
Operation (Tech 2)
• While the engine runs, there is nothing While the engine runs, operate according to P0340
abnormal with machine operation. standard of the crank sensor. When the engine
• After the engine is stalled, the re-start is stops, the start is impossible (in order to P0341
impossible. prevent the engine from damaging).
• The output power may decrease, white smoke Operate according to standard of the cam P0335
may occur and vibration may occur. sensor.
• The engine may be stalled. (If the cam senor is P0336
normal, the engine can re-start.)
• While the engine runs, there is nothing The timing chain and the belt does not turn P1345
abnormal with machine operation. smoothly but turn in reverse.
• After the engine is stalled, the re-start is
impossible.
Nothing special When starting: -10 °C (14 °F) (Start the engine P0113
although what state.)
When operating: 25 °C (77 °F) (Operate P0112
normally.)
Normal temperature: When starting, dark smoke When starting: -20 °C (-4 °F) (Start the engine P0118
may occur and engine combustion sound may be although what state.)
become loud. When operating: 80 °C (176 °F) (Operate P0117
While warming up with fresh air in low normally.)
temperature: Rough idle, engine stall or while
smoke may be occur.
Dark smoke occurs. Boost pressure cannot be corrected. P0238
P0237
There is influence to exhaust gas. As the sensor input is not certain, it cannot be P0487
controlled. Exhaust gas becomes bad.
Operate the engine with EGR valve fully open.
2
Dark smoke occurs at high altitude. Atmospheric pressure 80 kPa (0.8 kgf/cm , 12 P0108
psi) (2000 m above the sea)
P0107
Nothing special. When starting: -20 °C (-4 °F) (Start the engine P0183
although what state.)
When operating: 70 °C (158 °F) (Operate P0182
normally.)
T5-6-25
Fault
Trouble Cause
Code
157-3 Abnormal Common Rail Pressure Sensor Voltage at the common rail pressure sensor is beyond
157-3 Abnormal Common Rail Pressure Sensor Voltage at the common rail pressure sensor is below
100-4 Abnormal Engine Oil Pressure Sensor Voltage at the engine oil pressure sensor is beyond
100-3 Abnormal Engine Oil Pressure Sensor Voltage at the engine oil pressure sensor is below 0.1
(Abnormal Low Voltage) V.
105-3 Abnormal Boost Temperature Sensor Voltage at the boost temperature sensor is beyond
(Abnormal High Voltage) 4.95 V over 5 minutes after the engine starts or when
coolant temperature is beyond 50 °C (122 °F).
105-4 Abnormal Boost Temperature Sensor Voltage at the boost temperature sensor is below 0.1
(Abnormal Low Voltage) V.
T5-6-26

Operation (Tech 2)
The engine may be stalled. The output power The supply pump can not be controlled. P0193
decreases.
P0192
There is no influence when operating the Nothing special. P0523

machine.
P0522
There is no influence when operating the Nothing special. P1113

machine.
P1112
T5-6-27
Influence to Engine Operating Rank

Fault Code Trouble Performance (Current State) Remedy
(Presumption) A B C D
636-2 Abnormal Cam Angle Sensor (No No influence during
○ ○
Signal) operating
636-2 Abnormal Cam Angle Sensor After stopping, the
○ ○
(Abnormal Signal) re-start is impossible.
723-2 Abnormal Crank Speed Sensor (No No output power
○
Signal) decrease
723-2 Abnormal Crank Speed Sensor
○
(Abnormal Signal)
636-7 Phase Mismatch of Cam Angle No influence during
Sensor operating
○ ○
After stopping, the
re-start is impossible.
172-3 Abnormal Intake Air Temperature No output power
○
Sensor (Abnormal High Voltage) decrease
172-4 Abnormal Intake Air Temperature
○
Sensor (Abnormal Low Voltage)
110-3 Abnormal Coolant Temperature No output power
○
110-4 Abnormal Coolant Temperature
○
102-4 Abnormal Boost Pressure Sensor No output power
○
(Abnormal High Voltage) decrease
102-3 Abnormal Boost Pressure Sensor
○
10001-3 Abnormal EGR Position (Brushless No output power
○
spec.) change
108-4 Abnormal Atmospheric Pressure No output power
○
108-3 Abnormal Atmospheric Pressure
○
174-3 Abnormal Fuel Temperature Sensor No output power
○
(Abnormal High Voltage) decrease
174-4 Abnormal Fuel Temperature Sensor
○
157-3 Abnormal Common Rail Pressure Output power
○
Sensor (Abnormal High Voltage) decrease: 70%
157-4 Abnormal Common Rail Pressure
○
100-4 Abnormal Engine Oil Pressure No output power
○
Sensor (Abnormal High Voltage) change
100-3 Abnormal Engine Oil Pressure
○
T5-6-28
Influence to Engine
Fault Operating Rank
Trouble Performance Remedy
Code (Current State)
(Presumption)
105-3 Abnormal Boost Temperature Sensor No output power
○
(Abnormal High Voltage) change
105-4 Abnormal Boost Temperature Sensor
○
Operating Rank
A: Digging is operable.
B: Machine can travel with the boom raised.
(Steering is impossible.)
C: The engine only runs. (Travel, digging and
operation are impossible even in light load.)
D: The engine cannot stop / start.
IMPORTANT: When fault code 723-2 (abnormal

crank speed sensor) is displayed
and the engine does not start, the
cam angle sensor is faulty although
fault codes 636-2 (abnormal cam
angle sensor) and 636-7 (phase
mismatch of cam angle sensor) are
not displayed.
T5-6-29
External Device System
Fault Code Trouble Cause
10002-2 Abnormal EGR Valve Control Difference between the target valve lift and actual position is
beyond 20%.
1347-0 Open Circuit in Suction Control Valve The suction control valve drive current is beyond 2400 mA or
Drive System, Shorted Circuit In + B below 50 mA. Or, difference between the tartget current and
or GND actual current is 1000 mA or more.
651-3 Open Circuit in Injection Nozzle #1 No input signal of injector 1 monitor.

Drive System
Drive System
Drive System
654-3 Open Circuit In Injection Nozzle #4 No input signal of injector 4 monitor.
Drive System
T5-6-30

Operation (Tech 2)
There is influence to exhaust gas. EGR cannot be controlled. P0488
As exhaust gas becomes bad, EGR stops.
The engine may be stalled and the rotation The supply pump cannot be controlled. P0090
speed increases automatically and abnormally → Prevent the engine from increasing the rotation
according to open or shorted circuit condition. speed automatically and abnormally (Protect the
Dark smoke occurs. Output power is too large. engine).
Vibration of the engine is large, rough idle, #1 injector cannot be controlled. P0201
output power decrease, faulty increasing of → Stop drive pulse output of #1 injector.
rotation speed, output power decrease.
#2 injector cannot be controlled. P0202
→ Stop drive pulse output of #2 injector.
T5-6-31
Fuel System
157-0 Abnormal Common Rail Pressure Common rail pressure is beyond 185 MPa.
(First Stage)
157-0 Abnormal Common Rail Pressure The first stage “Abnormal common rail pressure” is approved
(Second Stage) common rail pressure is beyond 190 MPa.
157-2 Abnormal Common Rail Pressure When duty factor to the suction control valve is 40 % or more,
3
(Pump Over-Pressure) or target pressure to the suction control valve is 90 mm /sec
2
or less, actual rail pressure is 40 MPa (410 kgf/cm , 5820 psi)
higher than the target rail pressure.
633-7 Pressure Limiter Open The pressure limiter is open.
1240-1 No Pressure to Pump (Fuel Leakage) When duty factor to the suction control valve is 33 % or less,
3
or pressure to the suction control valve is 28000 mm /sec or
-1
more and engine speed is 1200 min , actual rail pressure is
2
50 MPa (510 kgf/cm , 7270 psi) lower than the target rail
pressure.
-1
1239-1 No Pressure to Pump (Fuel Leakage) When engine speed 900 min , actual rail pressure is 15 MPa
2
(150 kgf/cm , 2180 psi) or less.
T5-6-32

Operation (Tech 2)
Vibration of the engine may be large, rough idle, Prevention the injection system (pump) from P0088
output power decrease may occur, faulty damage
increasing of rotation speed, dark smoke may (Protect the rail pressure sensor by
occur, output power may be too large. over-pressure)
Vibration of the engine may be large, rough idle, Prevention the injection system from damage P0088
output power decrease may occur, faulty (Pressure is too much as rail is clogged.)
increasing of rotation speed, dark smoke may
occur, output power may be too large.
Vibration of the engine may be large, rough idle, Prevention the injection system (pump) from P0089
output power decrease may occur, faulty damage
increasing of rotation speed, dark smoke may (Protect the rail pressure sensor by
occur, output power may be too large. over-pressure)
Output power decrease. Rail pressure is beyond the allowable pressure. P1095
Vibration of the engine may be large, rough idle, Fuel leakage is too much. P1093
output power decrease may occur, faulty Difference between target rail pressure and actual
increasing of rotation speed, dark smoke may rail pressure is larger than the specification.
occur, output power may be too large. (Large deflection)
Vibration of the engine may be large, rough idle, Fuel leakage is too much. P0087
output power decrease may occur, faulty Actual rail pressure does not increase to the
increasing of rotation speed, dark smoke may required pressure.
occur, output power may be too large.
T5-6-33

Fault (Current)
Code
10002-2 Abnormal EGR Valve Control No output power
○
change
1347-0 Open Circuit in Suction Control Valve Output power
Drive System, Shorted Circuit in + B or decrease: 50% ○
GND
651-3 Open Circuit in Injection Nozzle #1 Output power
○
Drive System decrease: 15%
652-3 Open Circuit in Injection Nozzle #2 (Five cylinders drive.)
○
Drive System
653-3 Open Circuit in Injection Nozzle #3
○
Drive System
○
Drive System
○
Drive System
○
Drive System
Operating Rank
Influence to Engine (Current)
Fault
Code
157-0 Abnormal Common Rail Pressure (First Output power
○
Stage) decrease: 50%
○
(Second Stage) decrease: 50%
○
(Pump Over-Pressure) decrease: 50%
633-7 Pressure Limiter Open Output power
○
decrease: 50%
1240-1 No Pressure to Pump (Fuel Leakage) Output power ○
1239-1 No Pressure to Pump (Fuel Leakage) decrease: 50% ○
Operating Rank
B: Machine can travel with boom raised. (Steering is
impossible.)
T5-6-34
(Blank)
T5-6-35

110-0 Overheating Coolant temperature is beyond 120 °C (248 °F) when running
engine.
190-0 Overrunning -1
In case the engine speed is beyond 2500 min .
Fault code Trouble Cause

987-3 Abnormal Check Engine Lamp No monitor signal of the check engine lamp.
1485-2 Abnormal Main Relay System (ON is Voltage in the main relay system is 1 V or less with the main
impossible.) relay coil output ON
Although the main relay coil output is OFF, the main relay is
kept ON.
T5-6-36

Operation (Tech 2)
There is no influence when operating the Nothing special (The history of overheating is P1173
machine. recorded.)
Engine speed of the excavator may not increase Nothing special P0219
-1
2500 min or more.

Operation (Tech 2)
There is no influence when operating the Nothing special
machine. P0650
The engine cannot start. Nothing
P1625
Electrical power is kept supplying to the Nothing
machine.
T5-6-37
Operating Rank
Influence to Engine (Current)
Fault
Code
110-0 Overheating No output power

○
change
190-0 Overrunning No output power
○
change

Fault (Current)
Code
987-3 Abnormal Check Engine Lamp No output power
○
change
1485-2 Abnormal Main Relay System (ON is The engine stops. ○
impossible.) Nothing (The engine
cannot re-start
○ ○
according to battery
voltage.)
Operating Rank
impossible.)
T5-6-38
(Blank)
T5-6-39
Internal Circuit System
10005-1 Abnormal Charge Circuit (Bank 1) In case voltage at bank 1 of charge circuit in ECM is low.
10006-1 Abnormal Charge Circuit (Bank 2) In case voltage at bank 2 of charge circuit in ECM is low.
10008-2 Abnormal A/D Conversion A/D conversion cannot be done.

10007-2 Abnormal CPU Within 100 msec after the key switch is turned ON, failure of
main CPU is detected by sub CPU.
(Sub CPU resets CPU.)
1077-2 Abnormal IC for CPU Watching No change of RUN-SUB pulse in 20 msec.
628-2 Abnormal ROM ROM is broken.
10013-2 Abnormal EEPROM EEPROM is broken.
1079-2 Abnormal 5 V Power Source 1 When battery voltage is between 16 V and 32 V, voltage of
Voltage key switch power source is 5.5 V or more or 4.5 V or less.
10003-2 Abnormal Injection Nozzle Common No monitor signals of injectors 1, 3, 5.

1 Drive System
10004-2 Abnormal Injection Nozzle Common No monitor signals of injectors 2, 4, 6.
2 Drive System
T5-6-40

Operation (Tech 2)
Vibration of the engine may be large, rough idle, The injector cannot be controlled. P0611
output power decrease may occur, faulty → Stop output of drive signal at failed common
increasing of rotation speed may occur, the side
engine may be stalled. (Protect the engine from damage) P0612
Output power decrease, dark smoke occurs. All analogue sensor cannot be used. P1630
Output power decrease. CPU is broken. P0606
The engine cannot start. P0606
Output power decrease. Sub CPU is broken. P0601

The engine stops. Data of ROM cannot be read. P1603
There is no influence when operating the Data cannot be written to EEPROM. P1631
machine.
No backup. ← P1632
Same as Abnormal atmospheric and in-take ← P1633

temperature sensors.
Same as Abnormal coolant temperature, fuel ← P1634

temperature and hydraulic oil pressure sensors.
Same as Abnormal boost pressure and boost ← P1635

temperature sensors.
Same as Abnormal rail pressure and EGR ← P1261

position sensors.
Vibration of the engine may be large, rough idle, The injector cannot be controlled. P1262
output power decrease may occur, faulty → Stop output of drive signal at failed common
increasing of rotation speed may occur, the side
engine may be stalled. (Protect the engine from damage)
T5-6-41

Fault Code Trouble Performance (Current) Remedy
10005-1 Abnormal Charge Circuit (Bank 1) Output power ○ ○
10006-1 Abnormal Charge Circuit (Bank 2) decrease: 60%
(Three cylinders in ○ ○
operation.)
10008-2 Abnormal A/D Conversion Output power
○
decrease: 50%
10007-2 Abnormal CPU Output power
○
decrease: 50%
The engine cannot
○
start.
1077-2 Abnormal IC for CPU Watching Output power
○
decrease: 50%
628-2 Abnormal ROM The engine stops. ○
10013-2 Abnormal EEPROM No output power
○
decrease
1079-2 Abnormal 5 V Power Source 1 Voltage Idle Speed Operation ○
1080-2 Abnormal 5 V Power Source 2 Voltage No output power
○
decrease
○
change
○
decrease
10011-2 Abnormal 5 V Power Source 5 Voltage Output power
○ ○
decrease: 50%
10003-2 Abnormal Injection Nozzle Common 1 Output power
○ ○
Drive System decrease: 60%
10004-2 Abnormal Injection Nozzle Common 2 (Three cylinders in
○ ○
Drive System operation.)
Operating Rank
impossible.)
T5-6-42
(Blank)
T5-6-43
Communication System
639-2 Abnormal CAN Bus Line Detect the Bus Line OFF
639-3 Abnormal CAN Time Out In case the CAN data reception is impossible for
predetermined time.
T5-6-44
Presumptive Symptoms in Real Machine Fault code

Operation (Tech2)
The engine runs at idle speed. CAN communication is impossible. U2104
U2106
T5-6-45

Fault (Current)
Code
639-2 Abnormal CAN Bus Line ○
Idle Speed
639-3 Abnormal CAN Time Out ○
T5-6-46
(Blank)
T5-6-47
ICF FAULT CODE LIST
Fault Code Trouble Cause Remedy
14000-2 Abnormal CAN Data cannot be received Check for CAN communication bus line.
Communication due to the noise on the
CAN bus line.
14001-2 Flash Memory: The internal memory is After initializing the information C/U by using Dr.
Read / Write Error abnormal when the key ZX, retry in the troubleshooting.
switch is ON. If the error code is displayed after retry, ICF may
be broken.
Replace ICF.
NOTE: When initializing the information C/U,
all stored data is deleted.
14002-2 External RAM: The internal memory is After initializing the information C/U by using Dr.
Read / Write Error abnormal when the key ZX, retry in the troubleshooting.
switch is ON. If the error code is displayed after retrial, ICF may
be broken.
Replace ICF.
NOTE: When initializing the information C/U,
all stored data is deleted.
14003-2 EEPROM: Sum The internal memory is Retry in the troubleshooting by using Dr. ZX.
Check Error abnormal when the key If the error code is displayed after retrial, ICF may
switch is ON. be broken.
Replace ICF.
14006-2 Satellite Communication to the Check for the items below.
Communication satellite terminal cannot be 1. Check if the communication line is abnormal.
Terminal: done over 30 seconds. 2. Check if the electrical power source of
Communication communication terminal is abnormal.
Error • Electrical power source
• Fuses
3. Check if the satellite terminal is broken.
14008-2 Abnormal Internal The internal memory is Retry in the troubleshooting by using Dr. ZX.
RAM abnormal when the key If the error code is displayed after retrial, ICF may
switch is ON. be broken.
Replace ICF.
T5-6-48
SATELLITE TERMINAL FAULT CODE LIST

14100-2 Abnormal EEPROM Internal memory is abnormal. Replace the controller.
14101-2 Abnormal IB/OB Queue Internal memory is abnormal. Replace the controller.
14102-2 Abnormal Local Loop Back Data can not be received from Check the communication
satellite. antenna for satellite.
14103-2 Satellite cannot be found. Satellite can not be caught. Check the communication
antenna for satellite.
14104-2 Remote Loop Back Failure 1 Communication with satellite Replace the controller.
base station is impossible.
14105-2 Remote Loop Back Failure 2 Communication with satellite Replace the controller.
base station is impossible.
14106-2 Received data is not same with Received data is not same with Replace the controller.
sent data. sent data.
MONITOR UNIT FAULT CODE LIST
13303-2 Abnormal Thermistor Thermistor temperature is 85 °C Cool the monitor unit and so on
Temperature (185 °F) or more. until the internal temperature of
monitor unit is less than 85 °C
(185 °F).
13304-2 Abnormal REG Input H Level REG input level is H. Refer to the Troubleshooting flow
chart.
13306-2 Abnormal EEPROM EEPROM reading failure occurs. Replace the monitor unit when
displaying the fault code after
retrial.
13308-2 Abnormal CAN Communication Bus OFF occurs 5 times or Refer to CAN Harness Check
more. (T5-6-73 to 104).
13310-3 Shorted Circuit in Coolant Input 105±30 Ω or less continues Check coolant temperature
Temperature Sensor for 60 seconds. sensor and harness.
13311-3 Shorted Circuit in Fuel Level Input 3±1 Ω or less continues for Check fuel level sensor and
Sensor 60 seconds. harness.
13311-4 Open Circuit in Fuel Level Input 135±20 Ω or less continues Check fuel level sensor and
Sensor for 60 seconds. harness.
T5-6-49
OPTION CONTROLLER FAULT CODE LIST
Controller Hardware Failure

15500-4 Abnormal External Reference Faulty controller All Controls
Voltage
15501-2 Abnormal Read Of Initial Setting Faulty controller All Controls
Value (EEPROM)
15502-2 Abnormal EEPROM Faulty controller All Controls
15503-2 Abnormal RAM Faulty controller All Controls
15504-2 Abnormal A/D Conversion Faulty controller All Controls
15505-2 Abnormal CAN Communication Faulty controller • All Controls
Faulty CAN harness • Pulverizer/Crusher Control
• CAN Cycle Data Communication
15506-3 Abnormal Sensor Voltage Faulty controller All Controls
Faulty sensor
Faulty harness
T5-6-50
Symptoms in Machine Operation

When Trouble Occurs.
- Retrial B Replace the controller.

- Retrial B Check CAN harness.
Replace the controller.
T5-6-51
Pilot Pressure Failure
15510-3 Abnormal Assist Stroke 1 Sensor Voltage: more than 4.65 V Assist Control
High Voltage
15510-4 Abnormal Assist Stroke 1 Sensor Voltage: less than 0.35 V Assist Control
Low Voltage
15511-3 Abnormal Assist Stroke 2 Sensor Voltage: more than 4.65 V Assist Control
High Voltage
15511-4 Abnormal Assist Stroke 2 Sensor Voltage: less than 0.35 V Assist Control
Low Voltage
15514-3 Abnormal Positioning/Auxiliary Voltage: more than 4.55 V • Auxiliary Selection Switch: ON
Stroke 1 Sensor High Voltage Auxiliary Control
• Auxiliary Selection Switch: OFF
Positioning Control
15514-4 Abnormal Positioning/Auxiliary Voltage: less than 0.45 V • Auxiliary Selection Switch: ON
Stroke 1 Sensor Low Voltage Auxiliary Control
Positioning Control
15515-3 Abnormal Positioning/Auxiliary Voltage: more than 4.85 V • Auxiliary Selection Switch: ON
Stroke 2 Sensor High Voltage Auxiliary Control
Positioning Control
15515-4 Abnormal Positioning/Auxiliary Voltage: less than 0.15 V • Auxiliary Selection Switch: ON
Stroke 2 Sensor Low Voltage Auxiliary Control
Positioning Control
T5-6-52
Remedy by
Symptoms in Machine Operation When Trouble Occurs. Remedy
Dr. ZX
• Stop assist operation. Retrial B Check the harness.
• Display "Abnormal assist operation signal warning" on the monitor unit.
• If positioning and auxiliary stroke 2 is neutral, positioning and auxiliary Retrial B Check the harness.
operation stops.
• If positioning and auxiliary stroke 2 is not neutral, positioning and auxiliary
operation is active with pressure decreasing by 40%.
• Display "Abnormal attachment operation signal warning" on the monitor
unit.
• Buzzer (intermittent sound) sounds.
operation stops.
unit.
operation stops.
unit.
operation stops.
unit.
T5-6-53

15516-3 Abnormal Positioning/Assist Pi Pressure Voltage: more than 4.60 V • Positioning Control
Sensor High Voltage • Assist Control
15516-4 Abnormal Positioning/Assist Pi Pressure Voltage: less than 0.40 V • Positioning Control
Sensor Low Voltage • Assist Control
15517-3 Abnormal Outrigger/Blade/Auxiliary Pi Voltage: more than 4.60 V • Outrigger/Blade Control

Pressure Sensor High Voltage • Auxiliary Control
15517-4 Abnormal Outrigger/Blade/Auxiliary Pi Voltage: less than 0.40 V • Outrigger/Blade Control

Pressure Sensor Low Voltage • Auxiliary Control
15518-3 Abnormal Outrigger/Blade Stroke 1 Voltage: more than 4.55 V Outrigger/Blade Control
Sensor High Voltage
15518-4 Abnormal Outrigger/Blade Stroke 1 Voltage: less than 0.45 V Outrigger/Blade Control
Sensor Low Voltage
15519-3 Abnormal Outrigger/Blade Stroke 2 Voltage: more than 4.85 V Outrigger/Blade Control
Sensor High Voltage
15519-4 Abnormal Outrigger/Blade Stroke 2 Voltage: less than 0.15 V. Outrigger/Blade Control
Sensor Low Voltage
T5-6-54
Remedy by
Dr. ZX
• All proportional solenoid valve outputs stop by shutting off pilot pressure. Retrial B Check the harness.
• Display "Abnormal electric lever solenoid valve output warning" on the
monitor unit.
• Buzzer (continuous sound) sounds.
monitor unit.
monitor unit.
monitor unit.
• If outrigger/blade stroke 2 is neutral, Retrial B Check the harness.
outrigger/blade operation stops.
• If outrigger/blade stroke 2 is not neutral,
outrigger/blade operation is active with pressure decreasing by 40%.
• Display "Abnormal outrigger/blade operation signal warning" on the monitor
unit.
unit.
unit.
unit.
T5-6-55
Proportional Solenoid Valve Control Failure
15570-2 Abnormal When meeting the following conditions, • Outrigger/Blade Control
Outrigger/Blade/Auxiliary outrigger/blade/auxiliary pilot pressure is more • Auxiliary Control
Neutral than 1.2 MPa.
(Conditions)
• Outrigger/blade 1 and 2 solenoid valve
output is less than 0.5 MPa
• Auxiliary solenoid valve 1 and 2 output is
less than 0.5 MPa
15571-2 Abnormal When meeting either of the following • Outrigger/Blade Control
Outrigger/Blade/Auxiliary conditions, outrigger/blade/auxiliary pilot • Auxiliary Control
Operation pressure is less than 1.0 MPa.
(Conditions)
output is more than 2.2 MPa
• Auxiliary solenoid valve 1 and 2 output is
more than 2.2 MPa
15572-2 Abnormal When meeting the following conditions, • Positioning Control
Positioning/Assist Neutral positioning/assist pilot pressure is more than • Assist Control
1.2 MPa.
(Conditions)
• Positioning 1 and 2 solenoid valve output is
less than 0.5 MPa
• Assist 1 and 2 solenoid valve output is less
than 0.5 MPa
15573-2 Abnormal When meeting either of the following • Positioning Control
Positioning/Assist conditions, positioning/assist pilot pressure is • Assist Control
Operation less than 1.0 MPa.
(Conditions)
• Positioning 1 and 2 solenoid valve output is
more than 2.2 MPa
• Assist 1 and 2 solenoid valve output is more
than 2.2 MPa
15574-3 Abnormal Positioning/auxiliary stroke 1 +• Positioning Control
Positioning/Auxiliary Sum positioning/auxiliary stroke 2 is more than 9.0 • Auxiliary Control
Signal Critical High V
Voltage
15574-4 Abnormal Positioning/auxiliary stroke 1 + • Positioning Control
Positioning/Auxiliary Sum positioning/auxiliary stroke 2 is less than 0.5 V • Auxiliary Control
Signal Critical Low
Voltage
15575-3 Abnormal Outrigger/Blade Outrigger/blade stroke 1 + outrigger/blade Outrigger/Blade Control
Sum Signal Critical High stroke 2 is more than 9.0 V
Voltage
Sum Signal Critical Low stroke 2 is less than 0.5 V
Voltage
T5-6-56
Remedy by
Dr. ZX
monitor unit.
• Outrigger/blade operation is active with pressure decreasing by 40%. Retrial B Check the harness.
• Positioning and auxiliary 1 operation is active with pressure decreasing by 40%.
• Display "Abnormal electric lever solenoid valve output warning" on the monitor
unit.
• Positioning 1 operation is active with pressure decreasing by 40%. Retrial B Check the harness.
• Assist 1 operation is active with pressure decreasing by 40%.
• Positioning control: Positioning operation stops. Retrial B Check the harness.

• Auxiliary control: Auxiliary operation stops.
• Display "Abnormal attachment operation signal warning" on the monitor unit.
• Positioning control: Positioning operation stops. Retrial B Check the harness.
• Auxiliary control: Auxiliary operation stops.
• Outrigger/blade operation stops. Retrial B Check the harness.
• Display "Abnormal outrigger/blade operation signal warning" on the monitor unit.
• Outrigger/blade operation stops. Retrial B Check the harness.
T5-6-57

Positioning/Auxiliary Sum positioning/auxiliary stroke 2 is more than 5.4 • Auxiliary Control
Signal High Voltage V and less than or equal to 9.0 V

Positioning/Auxiliary Sum positioning/auxiliary stroke 2 more than or • Auxiliary Control
Signal Low Voltage equal to 0.5 V and is less than 4.6 V

Sum Signal High Voltage stroke 2 is more than 5.4 V and less than or
equal to 9.0 V

Sum Signal Low Voltage stroke 2 more than or equal to 0.5 V and is
less than 4.6 V
20300-2 Abnormal Positioning And Abnormal positioning/auxiliary stroke 1, or • Auxiliary Selection

Auxiliary Operation Signal Abnormal positioning/auxiliary stroke 2, or Switch: ON
Warning Abnormal sum of positioning/auxiliary 1 and 2 Auxiliary Control
• Auxiliary Selection
Switch: OFF
Positioning Control
20301-2 Abnormal Outrigger/Blade Abnormal outrigger/blade stroke 1 or Outrigger/Blade Control
Operation Signal Warning Abnormal outrigger/blade stroke 2 or
Abnormal sum of outrigger/blade 1 and 2
20302-2 Abnormal Warning On Abnormal assist stroke 1 or Assist 1 Control

Assist Related Operation Abnormal assist stroke 2 All Electric Lever Control
Signal (Assist 2)
20303-2 Electric Lever Pilot Cut Some electric lever controls are abnormal in All Controls
Warning monitoring neutral.
T5-6-58
Remedy by
Dr. ZX
• If positioning and auxiliary stroke 2 is not neutral, positioning operation is active Retrial B Check the harness.
with pressure decreasing by 40 %.
• If positioning and auxiliary stroke 2 is neutral, positioning operation stops.
• If positioning and auxiliary stroke 2 is not neutral, positioning operation is active Retrial B Check the harness.
with pressure decreasing by 40 %.
• If positioning and auxiliary stroke 2 is neutral, positioning operation stops.
• If outrigger/blade stroke 2 is not neutral, outrigger/blade operation is active with Retrial B Check the harness.
pressure decreasing by 40 %.
• If outrigger/blade stroke 2 is neutral, outrigger/blade operation stops.
• If outrigger/blade stroke 2 is not neutral, outrigger/blade operation is active with Retrial B Check the harness.
pressure decreasing by 40 %.
• If outrigger/blade stroke 2 is neutral, outrigger/blade operation stops.
• Display "Abnormal attachment operation signal warning" on the monitor unit. Retrial B Check the harness.
• Display "Abnormal outrigger/blade operation signal warning" on the monitor unit. Retrial B Check the harness.
• Display "Abnormal assist operation signal warning" on the monitor unit. Retrial B Check the harness.
• Front attachment operation completely stops. Retrial B Check the harness.

monitor unit.
T5-6-59
Proportional Solenoid Valve Failure
15520-2 Invalid and Abnormal Current Feedback Current: Both of Higher than Auxiliary Control
Value of Auxiliary 1 Proportional Valve 920 mA or Less than 60 mA
15520-3 Abnormal Feedback Value High Current of Current: Higher than 920 Auxiliary Control
Auxiliary 1 Proportional Valve mA
15520-4 Abnormal Feedback Value Low Current of Current: Less than 56 mA Auxiliary Control
Auxiliary 1 Proportional Valve
15521-2 Invalid and Abnormal Current Feedback Current: Both of Higher than Auxiliary Control
Value of Auxiliary 2 Proportional Valve 920 mA or Less than 60 mA
15521-3 Abnormal Feedback Value High Current of Current: Higher than 920 Auxiliary Control
Auxiliary 2 Proportional Valve mA
15521-4 Abnormal Feedback Value Low Current of Current: Less than 56 mA Auxiliary Control
15522-2 Invalid and Abnormal Current Feedback Current: Both of Higher than Outrigger/Blade Control
Value of Outrigger/Blade 1 Proportional 920 mA or Less than 60 mA
Valve
15522-3 Abnormal Feedback Value High Current of Current: Higher than 920 Outrigger/Blade Control
Outrigger/Blade 1 Proportional Valve mA
15522-4 Abnormal Feedback Value Low Current of Current: Less than 56 mA Outrigger/Blade Control
Outrigger/Blade 1 Proportional Valve
15523-2 Invalid and Abnormal Current Feedback Current: Both of Higher than Outrigger/Blade Control
Value of Outrigger/Blade 2 Proportional 920 mA or Less than 60 mA
Valve
15523-3 Abnormal Feedback Value High Current of Current: Higher than 920 Outrigger/Blade Control
Outrigger/Blade 2 Proportional Valve mA
15523-4 Abnormal Feedback Value Low Current of Current: Less than 56 mA Outrigger/Blade Control
15524-2 Invalid and Abnormal Current Feedback Current: Both of Higher than • Positioning Control
Value of Swing Parking Release 920 mA or Less than 60 mA • Assist 1 Control
Proportional Valve • Assist Switch Control
15524-3 Abnormal Feedback Value High Current of Current: Higher than 920 • Positioning Control
Swing Parking Release Proportional Valve mA • Assist 1 Control
• Assist Switch Control
15524-4 Abnormal Feedback Value Low Current of Current: Less than 56 mA • Positioning Control
Swing Parking Release Proportional Valve • Assist 1 Control
• Assist Switch Control
T5-6-60

Remedy
Occurs. Dr. ZX
Auxiliary operation stops. Retrial B Check the harness.
Outrigger/blade operation stops. Retrial B Check the harness.
Swing parking release is impossible. Retrial B Check the harness.
Swing parking is always released. Retrial B Check the harness.
Swing parking release is impossible. Retrial B Check the harness.
T5-6-61

15525-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 Assist 1 Control
Value of Assist 1 Proportional Valve mA or Less than 60 mA
15525-3 Abnormal Feedback Value High Current Current: Higher than 920 mA Assist 1 Control
of Assist 1 Proportional Valve
15525-4 Abnormal Feedback Value Low Current Current: Less than 56 mA Assist 1 Control
15526-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 Assist 1 Control
15526-3 Abnormal Feedback Value High Current Current: Higher than 920mA Assist 1 Control
15526-4 Abnormal Feedback Value Low Current Current: Less than 56 mA Assist 1 Control
15527-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 Assist Switch Control
15527-3 Abnormal Feedback Value High Current Current: Higher than 920 mA Assist Switch Control
15527-4 Abnormal Feedback Value Low Current Current: Less than 56 mA Assist Switch Control
15528-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 Assist Switch Control
15528-3 Abnormal Feedback Value High Current Current: Higher than 920 mA Assist Switch Control
15528-4 Abnormal Feedback Value Low Current Current: Less than 56 mA Assist Switch Control
T5-6-62

Remedy
Occurs. Dr. ZX
Assist 1 operation stops. Retrial B Check the harness.
Assist switch operation stops. Retrial B Check the harness.
T5-6-63

15529-2 Invalid and Abnormal Current Feedback Current: Both of higher than 920 Positioning Control
Value of Positioning 1 Proportional mA or Less than 60 mA
Valve
15529-3 Abnormal Feedback Value High Current Current: Higher than 920mA Positioning Control
of Positioning 1 Proportional Valve
15529-4 Abnormal Feedback Value Low Current Current: Less than 56 mA Positioning Control
of Positioning1 Proportional Valve
15530-2 Invalid and Abnormal Current Feedback Current: Both of higher than 920 Positioning Control
Value of Positioning 2 Proportional mA or Less than 60 mA
Valve
15530-3 Abnormal Feedback Value High Current Current: Higher than 920mA Positioning Control
15530-4 Abnormal Feedback Value Low Current Current: Less than 56 mA Positioning Control
T5-6-64
Symptoms in Machine Operation When Trouble Remedy by Remedy

Occurs. Dr. ZX
Positioning operation stops. Retrial B Check the harness.
T5-6-65
CAN Data Reception Failure
Fault code Trouble Cause Influenced Control

15565-2 Unreceived Work Mode Unreceived for 2000 ms • Pulverizer Control
Sent from: MC • Crusher Control
15566-2 Unreceived ATT 1 and 2 Optional Unreceived for 10 sec • Pulverizer Control
Selection • Crusher Control
Sent from: MC
15567-2 Unreceived ATT 3 and 4 Optional Unreceived for 10 sec • Pulverizer Control
Selection • Crusher Control
Sent from: MC
15568-2 Unreceived ATT 5 Optional Selection Unreceived for 10 sec • Pulverizer Control
Sent from: MC • Crusher Control
15577-2 Unreceived Actual Engine Speed Unreceived for 10 sec All Electric Lever Control
Sent from: ECM
T5-6-66
Remedy by
Symptoms in Machine Operation When Trouble Occurs Remedy
Dr. ZX
Work mode control is inactive (Always digging mode). Retrial B Check the harness.
• Secondary pilot relief control solenoid valve: Always Retrial B Check the harness.
OFF
• Selector valve control solenoid valve: Always OFF
• Accumulator control solenoid valve: Always OFF
OFF
OFF
• Electric lever: Engine stop control Retrial B Check the harness.
T5-6-67
STEERING COLUMN MONITOR FAULT CODE
Symptoms in
Influenced Machine Remedy
Control Operation When by Dr. ZX
Trouble Occurs.
16000-2 Abnormal CAN Faulty steering - - Retrial B Check the CAN
communication column monitor harness.
Faulty CAN harness
T5-6-68
(Blank)
T5-6-69
MC FAULT CODES 11000 TO 11002

11000-2 Abnormal EEPROM Faulty MC
11001-2 Abnormal RAM Faulty MC
11002-2 Abnormal A/D Convesion Faulty MC
YES * Faulty MC.
Check if engine and machine

operate normally.
Faulty MC.
NO
* After retrial, if the engine and the machine operate

normally with the fault code shown, the machine can
be operated.
T5-6-70
MC FAULT CODE 11003

11003-3 Abnormal Sensor Voltage Faulty MC
IMPORTANT: Fault code 11003-3 (Abnormal sen-

sor voltage) is shown with other
fault code, diagnose fault code
11003-3 first.
YES Faulty sensor.
Disconnect all sensor

connectors for displayed
Shorted circuit in harness with
fault code and retry. Disconnect all con- YES continuity between MC and
Check if fault code nectors at MC side. sensor.
11003-3 disappears. Check for continuity
between terminals
NO #1 and #3 (harness
end) of connector.
Faulty MC.
NO
· Key switch: OFF
Connector (Harness end of connector viewed from the

open end side)
• Pressure Sensor (Boom Raise, Arm Roll-Out, • Pump 1 Delivery Pressure Sensor
(Optional)/Arm Roll-In, Front Attachment, Swing, • Pump 2 Delivery Pressure Sensor
Travel Forward/Reverse, Auxiliary (Optional), Po- • Steering Pump Delivery Pressure Sensor
sitioning (Optional))
• Pump 1 Control Pressure Sensor
• Pump 2 Control Pressure Sensor
T1V1-05-07-101
T1V1-05-07-102
T5-6-71
MC FAULT CODE 11004

11004-2 Abnormal CAN Communication Faulty MC
Dr.ZX
Satellite Terminal
(Optional)
Monitor Unit
ICF
Option MC
Controller
CAN Harness
Steering
Column ECM
Monitor
TCJB-02-01-001
• Check the CAN harness between the controllers.

(Refer to CAN Harness Check on T5-6-73 to 104.)
T5-6-72
CAN HARNESS CHECK
• Check the wiring connections first.
Open circuit in CAN

NO harness between
MC and ECM.
YES Check for continuity in
CAN harness between
MC and ECM. Check for continuity
· Key switch: OFF in CAN harness be-
tween MC and To A
· Refer to CAN Har- YES
Check for continuity in ness Continuity monitor unit.
YES CAN harness between
Check on T5-6-78.
MC and ICF. · Key switch: OFF
· Refer to CAN Har-
· Key switch: OFF ness Continuity
· Refer to CAN Har- Check on T5-6-80.
ness Continuity
Retry by using Dr. ZX. Check on T5-6-79. Open circuit in CAN
Check if fault code harness between
11004-2 is displayed. NO MC and ICM.
Normal.
NO
T5-6-73
YES
YES Check for continuity in
CAN harness between
MC and option con-
troller. Open circuit in CAN
harness between
Check for continuity in · Key switch: OFF MC and option con-
NO
CAN harness between · Refer to CAN Har- troller.
YES ness Continuity
MC and steering col-
umn monitor. Check on T5-6-82.
· Key switch: OFF Open circuit in CAN

· Refer to CAN Har- harness between
ness Continuity MC and steering
A Check on T5-6-81. NO
column monitor.
Open circuit in CAN

harness between
NO MC and monitor unit.
T5-6-74
Shorted circuit in
CAN harness be-
YES tween ground circuit
and CAN circuit.
Disconnect all con-
nectors of MC, ICF,
ECM, monitor unit, Shorted circuit in
steering column CAN harness be-
YES
monitor and option tween electric power
controller. circuit and CAN cir-
Check for continuity cuit.
Check for continuity
between power cir-
between ground cir-
cuit and CAN circuit
cuit and CAN circuit NO Shorted circuit in
of each controller. of MC, ICF, ECM,
Check for continuity YES CAN harness be-
monitor unit, steering
column monitor and between key signal tween electric
· Key switch: OFF option controller. circuit and CAN cir- key-signal circuit and
· Refer to Discontinuity cuit of MC, ICF, CAN circuit.
Check between CAN · Key switch: OFF NO ECM, monitor unit,
Circuit and Ground · Refer to Discontinuity steering column
Check between CAN Check for continuity
Circuit on T5-6-84 to monitor and option
Circuit and Power between High and
91. controller.
Low sides of CAN To B
Circuit on T5-6-92 to NO
99. · Key switch: OFF harness.
· Refer to Discontinuity
Check between CAN · Key switch: OFF
Circuit and Key Signal · Refer to Discontinu-
Circuit on T5-6-100 to ity Check in CAN
103. Harness on
T5-6-104.
T5-6-75
YES Shorted circuit in

CAN harness.
YES Faulty MC.

B
Connect all MC
connectors except
connector MC-C.
Check if resistance
NO between terminals YES Faulty ICF.
#C4 and #C15 of
harness end of con-
nector MC-C is within
Connect MC con-
60±10 Ω.
nector.
· Key switch: OFF Disconnect connec-
tor ICF-C in ICF.
NO Check if resistance YES Faulty ECM.
between terminals
#C5 and #C11 of Connect ICF con-
harness end is within nector.
60±10 Ω. Disconnect ECM
connector.
Check if resistance Connect ECM con-
· Key switch: OFF NO nector.
Connector between terminals
#18 and #37 of har- Disconnect connec-
MC Connector MC-C tor monitor-B in
ness end is within
(Harness end) 120±10 Ω. monitor unit.
#C4 #C15 NO Check if resistance
· Key switch: OFF between terminals
C1 C10
#B6 and #B7 of har-
ness end is within
120±10 Ω.
C23 C31 · Key switch: OFF
ICF Connector ICF-C

#C5
(Harness end)
#C11 T1V1-05-04-002
Monitor Unit Connector Monitor-B
(Harness end)
ECM Connector
#B7 #B6
(Harness end) #18 #37
T1GR-05-04-002 T183-05-04-013
T5-6-76
YES
Faulty monitor unit.
YES
Faulty steering column
Connect monitor unit monitor.
connector.
Disconnect connector 2
in steering column
NO monitor.
Connect steering col-
Check if resistance be- YES
umn monitor connector. Faulty option control-
tween terminals #1 and
Disconnect connector C ler.
#9 of harness end is
in option controller.
within 60±10 Ω.
Check if resistance be-
NO tween terminals #C10
· Key switch: OFF
and #C22 of harness
end is within 60±10 Ω. Failure in any control-
NO
ler.
· Key switch: OFF
Steering Column Monitor Connector 2 Option Controller Connector C

(Harness end) (Harness end)
C1 C10
#9 #C10
#1 #C22
TCJB-05-06-001
C23 C31
T5-6-77
CAN Harness Continuity Check
IMPORTANT: Before continuity check, trun the

key switch OFF.
• Between MC and ECM

• CAN Harness (High Side)
Check for continuity between terminal #C4 (har-
ness end) of connector MC-C in MC and terminal
#18 (harness end) of connector in ECM.
• CAN Harness (Low Side)

Check for continuity between terminal #C15
(harness end) of connector MC-C in MC and ter-
minal #37 (harness end) of connector in ECM.
Connector
MC Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
ECM Connector
(Harness end)
#18 #37
T1GR-05-04-002
T5-6-78
• Between MC and ICF
#C5 (harness end) of connector ICF-C in ICF.

minal #C11 (harness end) of connector ICF-C in
ICF.
Connector
MC Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
ICF Connector ICF-C

(Harness end) #C5
T1V1-05-04-002
#C11
T5-6-79
• Between MC and Monitor Unit
#B7 (harness end) of connector monitor-B in the
monitor unit.

minal #B6 (harness end) of connector monitor-B
in the monitor unit.
Connector
MC Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31

(Harness end)
#B7 #B6
T183-05-04-013
T5-6-80
• Between MC and Steering Column Monitor
#1 (harness end) of connector 2 in the steering
column monitor.

minal #9 (harness end) of connector 2 in the
steering column monitor.
Connector
MC Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
Steering Column Monitor Connector 2

(Harness end)
#9
#1
TCJB-05-06-001
T5-6-81
• Between MC and Option Controller
#C10 (harness end) of connector C in the option
controller.

minal #C22 (harness end) of connector C in the
option controller.
Connector
MC Connector MC-C
(Harness end)
#C4 #C15
C1 C10
C23 C31
Option Controller Connector C

(Harness end)
C1 C10
#C10
#C22
C23 C31
T5-6-82
(Blank)
T5-6-83
Discontinuity Check between CAN Circuit and
Ground Circuit Connector
Connector MC-C
IMPORTANT: Before continuity check, turn the key (Harness end)
switch OFF.
#C4
In case of continuity, the circuit be- C1 C10
tween CAN circuit and ground cir-
cuit is shorted.
In case of discontinuity, the circuit is
normal. C23 C31
• MC
Between CAN Circuit (High Side) and Ground Cir- Connector MC-A
cuit (Harness end)
• Check for continuity between terminal #C4 (har- #A2
ness end) of connector MC-C and terminal #A2
(harness end) of connector MC-A.
• Check for continuity between terminal #C4 (har-

(harness end) of connector MC-A. #A13
T183-05-04-008

ness end) of connector MC-C and terminal #B8
(harness end) of connector MC-B. Connector MC-B
(Harness end)
• Check for continuity between terminal #C4 (har- #B8
(harness end) of connector MC-B.
#B18
T183-05-04-021
T5-6-84
• MC
Between CAN Circuit (Low Side) and Ground Circuit Connector
• Check for continuity between terminal #C15 Connector MC-C
(harness end) of connector MC-C and terminal (Harness end)
#A2 (harness end) of connector MC-A.
#C15
• Check for continuity between terminal #C15 C1 C10
(harness end) of connector MC-C and terminal
• Check for continuity between terminal #C15 C23 C31

#B8 (harness end) of connector MC-B. Connector MC-A
(Harness end)
• Check for continuity between terminal #C15 #A2
#B18 (harness end) of connector MC-B.
#A13
T183-05-04-008
Connector MC-B
(Harness end)
#B8
#B18
T183-05-04-021
T5-6-85
• ECM
Between CAN Circuit (High Side) and Ground Cir- ECM Connector
cuit (Harness end)
• Check for continuity between terminals #18 and #18 #43
#1 (harness end).
#4
• Check for continuity between terminals #18 and #3

#3 (harness end).

T1GR-05-04-002
#4 (harness end).
• Check for continuity between terminals #18 and

#43 (harness end).

#62 (harness end).
• ECM
Between CAN Circuit (Low Side) and Ground Circuit
#1 (harness end).

#3 (harness end). ECM Connector
(Harness end)
#37 #43
#4 (harness end). #4
#3
#43 (harness end).
T1GR-05-04-002
#62 (harness end).
T5-6-86
• ICF
Between CAN Circuit (High Side) and Ground Cir- ICF Connector ICF-C
cuit (Harness end) #C5
• Check for continuity between terminals #C5 and
#C14 (harness end) of connector ICF-C.

#C15 (harness end) of connector ICF-C. T1V1-05-04-002
#C14 #C15
• ICF
Between CAN Circuit (Low Side) and Ground Circuit ICF Connector ICF-C
• Check for continuity between terminals #C11 and (Harness end)

#C15 (harness end) of connector ICF-C. T1V1-05-04-002
#C14 #C15 #C11
• Monitor Unit
Between CAN Circuit (High Side) and Ground Circuit Monitor Unit Connector Monitor-B
• Check for continuity between terminals #B7 and (Harness end)
#B11 (harness end) of connector monitor unit-B.
#B7
• Monitor Unit #B11

T183-05-04-013
Between CAN Circuit (Low Side) and Ground Circuit

• Check for continuity between terminals #B6 and
#B11 (harness end) of connector monitor unit-B.
(Harness end)
#B6
T183-05-04-013
#B11
T5-6-87
Between CAN Circuit (High Side) and Ground Cir- Steering Column Monitor Connector 1
cuit (Harness end)
• Check for continuity between terminal #1 (har-
ness end) of connector 2 and terminal #1 (har-
ness end) of connector 1.
#7
• Check for continuity between terminal #1 (har- #1

TCJB-05-06-002

Between CAN Circuit (Low Side) and Ground Circuit Steering Column Monitor Connector 2
• Check for continuity between terminal #9 (har- (Harness end)
#9
#1
ness end) of connector 1. TCJB-05-06-001
T5-6-88
(Blank)
T5-6-89
Between CAN Circuit (High Side) and Ground Cir- Connector
cuit Connector C
• Check for continuity between terminal #C10 (Harness end)
(harness end) of connector C and terminal #A2
(harness end) of connector A. C1 C10
#C10
• Check for continuity between terminal #C10
(harness end) of connector A. C23 C31

(harness end) of connector C and terminal #A25 Connector A
(harness end) of connector A. (Harness end)
#A2
(harness end) of connector C and terminal #B8
(harness end) of connector B.

#A13
(harness end) of connector C and terminal #B18 T183-05-04-008
• Check for continuity between terminal #C10 Connector B

(harness end) of connector C and terminal #B25 (Harness end)
(harness end) of connector B. #B8
#B25
#B18
T183-05-04-021
T5-6-90
Between CAN Circuit (Low Side) and Ground Circuit Connector
• Check for continuity between terminal #C22 Connector C
(harness end) of connector C and terminal #A2 (Harness end)
(harness end) of connector A.
C1 C10
(harness end) of connector C and terminal #A13 #C22
C23 C31
(harness end) of connector A. Connector A
(Harness end)

(harness end) of connector C and terminal #B18 #A25
#A13
(harness end) of connector B. T183-05-04-008

(harness end) of connector C and terminal #B25 Connector B
(harness end) of connector B. (Harness end)
#B8
#B25
#B18
T183-05-04-021
T5-6-91
Power Circuit Connector
Connector MC-C
switch OFF. #C4
tween CAN circuit and power circuit
is shorted.
normal. C23 C31
• MC
Between CAN Circuit (High Side) and Power Circuit Connector MC-A
• Check for continuity between terminal #C4 (har- (Harness end)

T183-05-04-008

(harness end) of connector MC-B. Connector MC-B
(Harness end)
#B7
#B17
T183-05-04-021
T5-6-92
• MC
Between CAN Circuit (Low Side) and Power Circuit Connector
• Check for continuity between terminal #C15 Connector MC-C
(harness end) of connector MC-C and terminal (Harness end)
#A1 (harness end) of connector MC-A. #C15
C1 C10
C23 C31
#B7 (harness end) of connector MC-B. Connector MC-A
(Harness end)
(harness end) of connector MC-C and terminal #A1
#A12
T183-05-04-008
Connector MC-B
(Harness end)
#B7
#B17
T183-05-04-021
T5-6-93
• ECM
Between CAN Circuit (High Side) and Power Circuit ECM Connector
• Check for continuity between terminals #18 and (Harness end)
#2 (harness end). #18 #5

#5 (harness end).
• ECM #2
T1GR-05-04-002
Between CAN Circuit (Low Side) and Power Circuit

#2 (harness end).
ECM Connector
(Harness end)
#5 (harness end).
• ICF
Between CAN Circuit (High Side) and Power Circuit
• Check for continuity between terminals #C5 and #2
T1GR-05-04-002

ICF Connector ICF-C
(Harness end)
#C5
• ICF #C2
Between CAN Circuit (Low Side) and Power Circuit #C1
T1V1-05-04-002
ICF Connector ICF-C

(Harness end)
#C2
#C1
T1V1-05-04-002
#C11
T5-6-94
• Monitor Unit
Between CAN Circuit (High Side) and Power Circuit Monitor Unit Connector Monitor-B
• Check for continuity between terminal #B7 (har- (Harness end)
ness end) of connector monitor-B and terminal
#A16 (harness end) of connector monitor-A. #B7
T183-05-04-013
Monitor Unit Connector Monitor-A

(Harness end)
• Monitor Unit
Between CAN Circuit (Low Side) and Power Circuit T183-05-05-001
• Check for continuity between terminal #B6 (har- #A16

ness end) of connector monitor-B and terminal
#A16 (harness end) of connector monitor-A.

(Harness end)
#B6
T183-05-04-013

(Harness end)
T183-05-05-001
#A16
T5-6-95
Between CAN Circuit (High Side) and Power Circuit Steering Column Monitor Connector 2

ness end) of connector 2 and terminal #12 (har- #1
TCJB-05-06-001

(Harness end)
#12
#6
• Steering Column Monitor TCJB-05-06-002
Between CAN Circuit (Low Side) and Power Circuit

#9
TCJB-05-06-001

(Harness end)
#12
#6
TCJB-05-06-002
T5-6-96
(Blank)
T5-6-97
Between CAN Circuit (High Side) and Power Circuit Connector
C1 C10
• Check for continuity between terminal #C10 #C10
C23 C31
Connector A
(harness end) of connector B. #A1

T183-05-04-008
Connector B
(Harness end)
#B7
#B17
#B24 T183-05-04-021
T5-6-98
Between CAN Circuit (Low Side) and Power Circuit Connector
C1 C10
(harness end) of connector C and terminal #A12 #C22
C23 C31
(harness end) of connector B. Connector A
(Harness end)

(harness end) of connector C and terminal #B24 #A12
T183-05-04-008
Connector B
(Harness end)
#B7
#B17
#B24 T183-05-04-021
T5-6-99
Key Signal Circuit Connector
Connector MC-C
switch OFF. #C4
tween CAN circuit and key signal
circuit is shorted.
normal. C23 C31
• MC
Between CAN Circuit (High Side) and Key Signal Connector MC-B
Circuit (Harness end)
• Check for continuity between terminal #C4 (har- #B16
T183-05-04-021
• MC Connector
Between CAN Circuit (Low Side) and Key Signal Connector MC-C
• Check for continuity between terminal #C15 #C15
(harness end) of connector MC-C and terminal C1 C10
C23 C31
Connector MC-B
(Harness end)
#B16
T183-05-04-021
T5-6-100
• ECM
Between CAN Circuit (High Side) and Key Signal ECM Connector
#18 #24
#24 (harness end) of connector.
T1GR-05-04-002
• ECM ECM Connector

Between CAN Circuit (Low Side) and Key Signal
(Harness end)
Circuit #37 #24
#24 (harness end) of connector.
T1GR-05-04-002
• ICF
Between CAN Circuit (High Side) and Key Signal ICF Connector ICF-C
Circuit (Harness end) #C5
#C7 (harness end) of connector ICF-C. #C7
T1V1-05-04-002
• ICF
Between CAN Circuit (Low Side) and Key Signal ICF Connector ICF-C
#C7
T1V1-05-04-002
#C11
T5-6-101
• Monitor Unit
Between CAN Circuit (High Side) and Key Signal Monitor Unit Connector Monitor-B
• Check for continuity between terminal #B7 (har-
ness end) of connector monitor-B and terminal #B7
T183-05-04-013

(Harness end)
#A7
T183-05-05-001
• Monitor Unit
Between CAN Circuit (Low Side) and Key Signal Monitor Unit Connector Monitor-B
• Check for continuity between terminal #B6 (har-
ness end) of connector monitor-B and terminal #B6
T183-05-04-013

(Harness end)
#A7
T183-05-05-001
T5-6-102
Between CAN Circuit (High Side) and Key Signal Connector
Circuit Connector C
(harness end) of connector B. C1 C10
#C10
C23 C31
Connector B
(Harness end)
#B16
T183-05-04-021
• Option Controller Connector

Between CAN Circuit (Low Side) and Key Signal Connector C
(harness end) of connector C and terminal #B16 C1 C10
#C22
C23 C31
Connector B
(Harness end)
#B16
T183-05-04-021
T5-6-103
Discontinuity Check in CAN Harness
IMPORTANT: Before continuity check, turn the key

switch OFF.
In case of continuity, the circuit be-
tween CAN (High side) circuit and
CAN (Low side) circuit is shorted.
normal.
• Connector MC-C • Connector Monitor Unit-B

Check for continuity between terminals #C4 and Check for continuity between terminals #B6 and
#C15 (harness end) of connector MC-C in MC. #B7 (harness end) of connector monitor B in the
monitor unit.

MC Connector MC-C (Harness end)
(Harness end)
#B7 #B6
#C4 #C15
C1 C10
C23 C31 T183-05-04-013
• Connector 2 of Steering Column Monitor

• Connector ECM
Check for continuity between terminals #1 and #9
Check for continuity between terminals #18 and
(harness end) of connector 2.
#37 (harness end) of connector ECM.
ECM Connector (Harness end)
(Harness end)
#18 #37
#9
#1
TCJB-05-06-001
T1GR-05-04-002 • Connector C of Option Controller

Check for continuity between terminals #C10 and
• Connector ICF-C #C22 (harness end) of connector C.
Check for continuity between terminals #C5 and
#C11 (harness end) of connector ICF-C in ICF. Option Controller Connector C
(Harness end)
ICF Connector ICF-C

(Harness end) #C5 C1 C10
#C10
#C22
C23 C31
T1V1-05-04-002
#C11
T5-6-104
MC FAULT CODE 11100

-1
11100-2 Abnormal Engine Speed Engine speed: 4000 min or more
• Actual engine speed which ECM sends by using

CAN bus line.
Diagnose ECM.
T5-6-105
MC FAULT CODE 11101

11101-3 Abnormal Engine Control Dial Voltage: more than 4.78 V
Sensor High Voltage
11101-4 Abnormal Engine Control Dial Voltage: less than 0.22 V
Sensor Low Voltage
Open circuit in har-
Disconnect connector NO ness between MC
MC-C of MC. and engine control
YES Check for continuity dial.
between terminal #C1
(harness end) of
Check if voltage be- connector and termi- To A
1. With connector of switch
panel connected, insert tween terminals #1 and nal #2 (harness end) YES
of switch panel.
a test probe into the YES #3 (harness end) of
back side of connector connector of switch Open circuit in har-
in terminal #2. panel is 5±0.5 V. Check if voltage be- ness between MC
YES and engine control
When rotating engine tween terminal #1
control dial, check if · Key switch: ON (harness end) of dial (terminal #3).
voltage becomes speci- connector of switch
fication. panel and machine
NO
2. Disconnect connector of becomes specifica- Open circuit in har-
switch panel. Check if tion. ness between MC
resistance between ter- NO and engine control
minals #1 and #3 (switch · Key switch: ON dial (terminal #1).
panel end) of connector · Specification: 5±0.5 V
is 5±0.5 kΩ.
Faulty engine control
NO dial.
· Specification: Refer to
the following table.
Specification of Engine Control Dial

YES Faulty MC.
Slow Idle 0.3 to 1.0 V Check if voltage between
Fast Idle 4.0 to 4.7 V terminal #C1 (harness
A end) of connector MC-C
Connector (Harness end of connector viewed from the and machine is 0 V.
Shorted circuit in
open end side) harness between MC
MC Connector MC-C · Key switch: ON NO and engine control
dial.
#C1
C1 C10
C23 C31
Switch Panel
#3 #2 #1
T5-6-106
MC FAULT CODE 11200

11200-3 Abnormal Pump 1 Delivery Pressure Voltage: more than 4.5 V
Sensor High Voltage
11200-4 Abnormal Pump 1 Delivery Pressure Voltage: less than 0.25 V
Sensor Low Voltage
Disconnect connector
MC-D of MC. Open circuit in har-
Check for continuity be- ness between MC
NO
tween terminal #D10 and pump 1 delivery
(harness end) of con- pressure sensor.
YES nector and terminal #2
(harness end) of con-
nector of pump 1 delivery
Disconnect connector pressure sensor. To A
of pump 1 delivery YES
pressure sensor. Check if voltage be-
NO Check if voltage be- Open circuit in har-
tween terminal #1 (har-
tween terminals #1 and ness end) of connector ness between MC
#3 (harness end) of YES and pump 1 delivery
of pump 1 delivery
connector is 5±0.5 V. pressure sensor and pressure sensor
Switch pump 1 delivery (terminal #3).
pressure sensor with machine becomes
pump 2 delivery pres- NO specification.
sure sensor and retry. · Key switch: ON Open circuit in har-
Check if fault code is ness between MC
switched. · Key switch: ON NO and pump 1 delivery
· Specification: 0.25 V or more, pressure sensor
4.5 V or less (terminal #1).
Faulty pump 1 deliv-

YES ery pressure sensor.
YES Faulty MC.

Check if voltage between
terminal #D10 (harness
A end) of connector MC-D
and machine is 0 V.
Shorted circuit in
harness between MC
· Key switch: ON NO and pump 1 delivery
pressure sensor.
Connector (Harness end of connector viewed from the open end side)
MC Connector MC-D Pump 1 Delivery Pressure Sensor
#D10
3 2 1
T183-05-04-009
T5-6-107
MC FAULT CODE 11202

Sensor High Voltage
Sensor Low Voltage
MC-D of MC.
NO ness between MC
between terminal #D4
and pump 2 delivery
pressure sensor.
nector of pump 2 deliv-
ery pressure sensor. To A
Disconnect connector YES
NO of pump 2 delivery Check if voltage be- Open circuit in har-
pressure sensor. tween terminal #1 ness between MC
Check if the voltage (harness end) of YES and pump 2 delivery
between terminal #1 connector of pump 2 pressure sensor
and #3 (harness end) delivery pressure (terminal #3).
Switch pump 1 delivery of connector is 5±0.5 sensor and machine
pressure sensor with V. NO becomes specifica- Open circuit in har-
pump 2 delivery pres- tion. ness between MC
sure sensor and retry. · Key switch: ON
NO and pump 2 delivery
Check if fault code is
· Key switch: ON pressure sensor
switched.
· Specification: 0.25 V or more, (terminal #1).
4.5 V or less
YES ery pressure sensor.
YES Faulty MC.

terminal #D4 (harness end)
A of connector MC-D and
machine is 0 V.
Shorted circuit in
harness between MC
pressure sensor.
MC Connector MC-D o Pump 2 Delivery Pressure Sensor
#D4
3 2 1
T183-05-04-009
T5-6-108
MC FAULT CODE 11203

Sensor High Voltage
Sensor Low Voltage
Check for continuity NO ness between MC
between terminal #D3 and pump 3 delivery
YES
nector and terminal #2
Disconnect connector nector of pump 3 deliv- To A
of pump 3 delivery ery pressure sensor. YES
pressure sensor.
NO Check if voltage be- Check if voltage be- Open circuit in har-
tween terminals #1 and tween terminal #1 ness between MC
Switch pump 3 delivery (harness end) of con-
pressure sensor with #3 (harness end) of YES and pump 3 delivery
connector is 5±0.5 V. nector of pump 3 de- pressure sensor
pump 2 delivery pres- livery pressure sensor
sure sensor and retry. (terminal #3).
and machine becomes
Check if fault code is · Key switch: ON NO specification. Open circuit in har-
switched.
ness between MC
and pump 3 delivery
NO
· Key switch: ON pressure sensor
4.5 V or less
ery pressure sensor.
YES
YES Faulty MC.

terminal #D3 (harness end)
A of connector MC-D and
machine is 0 V.
Shorted circuit in
harness between MC
pressure sensor.
MC Connector MC-D Pump 3 Delivery Pressure

Sensor
#D3
3 2 1
T183-05-04-009
T5-6-109
MC FAULT CODE 11206

11206-3 Abnormal Pump 1 Control Pressure Voltage: more than 4.75 V.
Sensor High Voltage
11206-4 Abnormal Pump 1 Control Pressure Voltage: less than 0.25 V.
Sensor Low Voltage
between terminal #D11 and pump 1 control
Disconnect connector nector of pump 1 con-
of pump 1 control trol pressure sensor. To A
pressure sensor. YES
tween terminals #1 and tween terminal #1 ness between MC
#3 (harness end) of (harness end) of YES and pump 1 control
connector is 5±0.5 V. connector of pump 1 pressure sensor
Switch pump 1 control control pressure (terminal #3).
pressure sensor with sensor and machine
pump 2 control pressure · Key switch: ON
NO becomes specifica- Open circuit in har-
sensor and retry. Check tion. ness between MC
if fault code is switched. and pump 1 control
NO pressure sensor
· Key switch: ON (Terminal #1).
· Specification: 0.25 V or more,
4.75 V or less
Faulty pump 1 control
YES pressure sensor.
YES Faulty MC.

and machine is 0 V.
Shorted circuit in
harness between MC
· Key switch: ON NO and pump 1 control
pressure sensor.
MC Connector MC-D Pump 1 Control Pressure Sensor
1 2 3
#D11
T183-05-04-009
T5-6-110
MC FAULT CODE 11208

11208-3 Abnormal Pump 2 Control Pressure Voltage: more than 4.75 V
Sensor High Voltage
11208-4 Abnormal Pump 2 Control Pressure Voltage: less than 0.25 V
Sensor Low Voltage
Check for continuity ness between MC
NO
between terminal #D14 and pump 2 control
Disconnect connector nector for pump 2 con- To A
of pump 2 control trol pressure sensor.
Switch pump 1 control tween terminals #1 and ness between MC
tween terminal #1
pressure sensor with #3 (harness end) of YES and pump 2 control
(harness end) of
pump 2 control pressure connector is 5±0.5 V. pressure sensor
connector of pump 2
sensor and retry. Check control pressure (terminal #3).
if fault code is switched. · Key switch: ON sensor and machine
NO becomes specifica- Open circuit in har-
tion. ness between MC
and pump 2 control
NO pressure sensor
· Key switch: ON
4.75 V or less
Faulty pump 2 control
YES pressure sensor.
YES Faulty MC.

and machine is 0 V.
Shorted circuit in
harness between MC
· Key switch: ON NO and pump 2 control
pressure sensor.
MC Connector MC-D Pump 2 Control Pressure Sensor
#D14
1 2 3
T183-05-04-009
T5-6-111
MC FAULT CODE 11301

11301-3 Abnormal Swing Pilot Pressure Voltage: more than 4.75 V
Sensor High Voltage
11301-4 Abnormal Swing Pilot Pressure Voltage: less than 0.25 V
Sensor Low Voltage
MC-C of MC.
between terminal #C13 Open circuit in har-
NO ness between MC
nector and terminal #2 and pressure sensor.
YES (harness end) of con-
nector of pressure
sensor.
Disconnect connector To A
of pressure sensor. YES
Check if voltage be-
tween terminals #1 and
NO
#3 (harness end) of Check if voltage be-
connector is 5±0.5 V. tween terminal #1 Open circuit in har-
(harness end) of ness between MC
· Key switch: ON connector of pressure YES and pressure sensor
sensor and machine (terminal #3).
Switch pressure sensor becomes specifica-
with other pressure tion.
sensor and retry. Check NO Open circuit in har-
if fault code disappears.
ness between MC
and pressure sensor
· Key switch: ON NO
(terminal #1).
4.75 V or less
Faulty pressure sen-
YES sor.
YES Faulty MC.

terminal #C13 (harness
and machine is 0 V.
Shorted circuit in
harness between MC
· Key switch: ON and pressure sensor.
NO
MC Connector MC-C Pressure Sensor (Swing)

#C13
C1 C10
1 2 3
C23 C31
T5-6-112
MC FAULT CODE 11302

11302-3 Abnormal Boom Raise Pilot Pres- Voltage: more than 4.75 V
sure Sensor High Voltage
11302-4 Abnormal Boom Raise Pilot Pres- Voltage: less than 0.25 V
sure Sensor Low Voltage
Disconnect connector Open circuit in har-

MC-C of MC. NO ness between MC
Check for continuity and pressure sensor.
YES between terminal #D15
Disconnect connector (harness end) of con- To A
of pressure sensor. nector of pressure YES
Check if voltage be- sensor.
tween terminal #1 and
NO #3 (harness end) of
connector is 5±0.5 V. Check if voltage be-
tween terminal #1 Open circuit in har-
(harness end) of
· Key switch: ON YES ness between MC
connector of pressure and pressure sensor
sensor and machine (terminal #3).
with other pressure NO tion.
sensor and retry. Check Open circuit in har-
if fault code disappears. ness between MC
NO and pressure sensor
· Key switch: ON
(terminal #1).
4.75 V or less
YES sor.
YES Faulty MC.

and machine is 0 V.
Shorted circuit in
· Key switch: ON NO harness between MC
and pressure sensor.
MC Connector MC-D Pressure Sensor (Boom Raise)
1 2 3
#D15
T183-05-04-009
T5-6-113
MC FAULT CODE 11303

11303-3 Abnormal Arm Roll-in Pilot Pressure Voltage: more than 4.75 V
Sensor High Voltage
11303-4 Abnormal Arm Roll-in Pilot Pressure Voltage: less than 0.25 V
Sensor Low Voltage

YES between terminal #C3
(harness end) of con- To A
Disconnect connector nector of pressure
of pressure sensor. YES
sensor.
NO tween terminal #1 and
#3 (harness end) of
connector is 5±0.5 V. Check if voltage be-
tween terminal #1
(harness end) of Open circuit in har-
· Key switch: ON connector of pressure YES ness between MC
sensor and machine and pressure sensor
becomes specifica- (terminal #3).
Switch pressure sensor
sensor and retry. Check ness between MC
if fault code disappears. and pressure sensor
· Key switch: ON NO
(terminal #1).
4.75 V or less
YES sor,
YES Faulty MC,

and machine is 0 V.
Shorted circuit in
harness between MC
· Key switch: ON NO and pressure sensor.
MC Connector MC-C Pressure Sensor

(Arm Roll-In)
#C3
C1 C10
1 2 3
C23 C31
T5-6-114
MC FAULT CODE 11305

11305-3 Abnormal Travel Forward Pilot Voltage: more than 4.75 V
11305-4 Abnormal Travel Forward Pilot Voltage: less than 0.25 V

YES
(harness end) of con- To A
nector of pressure YES
Disconnect connector sensor.
of pressure sensor.
Check if voltage be- Open circuit in har-
NO Check if voltage be-
tween terminal #1 and YES ness between MC
#3 (harness end) of tween terminal #1 and pressure sensor
connector is 5±0.5 V. (harness end) of (terminal #3).
Switch pressure sensor connector of pressure
with other pressure · Key switch: ON NO sensor and machine
sensor and retry. Check becomes specifica- Open circuit in har-
if fault code disappears. tion. ness between MC
NO and pressure sensor
· Key switch: ON
4.75 V or less
YES sor.
YES Faulty MC.

and machine is 0 V.
Shorted circuit in
harness between MC
MC Connector MC-C Pressure Sensor (Travel Forward)

#C2
C1 C10
1 2 3
C23 C31
T5-6-115
MC FAULT CODE 11306

11306-3 Abnormal Travel Reverse Pilot Voltage: more than 4.75 V
11306-4 Abnormal Travel Reverse Pilot Voltage: less than 0.25 V
MC-C of MC.
Check for continuity Open circuit in har-
NO ness between MC
(harness end) of con- and pressure sensor.
nector of pressure
To A
sensor.
Disconnect connector YES
of pressure sensor. Check if voltage be- Open circuit in har-
NO Check if voltage between terminal #1 ness between MC
tween terminal #1 and (harness end) of YES
#3 (harness end) of and pressure sensor
connector of pressure (terminal #3).
connector is 5±0.5 V. sensor and machine
sensor and retry. Check · Key switch: ON Open circuit in har-
if fault code disappears. ness between MC
· Key switch: ON NO and pressure sensor
4.75 V or less
YES sor.
YES Faulty MC.

terminal #C11 (harness end)
A of connector MC-C and
machine is 0 V.
Shorted circuit in
harness between MC
MC Connector MC-C Pressure Sensor (Travel Reverse)
C1 C10
1 2 3
#C11
C23 C31
T5-6-116
MC FAULT CODE 11307

11307-3 Abnormal Front Attachment Pilot Voltage: more than 4.75 V
Pressure Sensor High voltage
11307-4 Abnormal Front Attachment Pilot Voltage: less than 0.25 V
Pressure Sensor Low voltage
MC-C of MC. Open circuit in har-
between terminal #C12 and pressure sensor.
YES (harness end) of con-
Disconnect connector nector of pressure To A
of pressure sensor. sensor. YES
tween terminal #1 and
NO
#3 (harness end) of
connector is 5±0.5 V.
· Key switch: ON YES ness between MC
tween terminal #1 and pressure sensor
(harness end) of con- (terminal #3).
nector of pressure
Switch pressure sensor NO sensor and machine
with other pressure becomes specification. Open circuit in har-
sensor and retry. Check ness between MC
if fault code disappears. NO and pressure sensor
· Key switch: ON
4.75 V or less
YES sor.
YES Faulty MC.

and machine. Shorted circuit in
Check if the voltage is 0 V. harness between MC
NO and pressure sensor.
· Key switch: ON
MC Connector MC-C Pressure Sensor (Front Attachment)
#C12
C1 C10
1 2 3
C23 C31
T5-6-117
MC FAULT CODE 11310

11310-3 Abnormal Brake Pressure Sensor Voltage: more than 4.75 V
High Voltage
11310-4 Abnormal Brake Pressure Sensor Voltage: less than 0.25 V
Low Voltage
MC-C of MC. Open circuit in har-
Check for continuity NO
ness between MC
between terminal #D12 and brake pressure
YES (harness end) of con- sensor.
Disconnect the connec- nector of brake pres- To A
tor of brake pressure sure sensor. YES
sensor. Check if voltage
NO between terminal #1
and #3 (harness end) Check if voltage be- Open circuit in har-
of connectoris 5±0.5 V. tween terminals #1 ness between MC
YES
(harness end) of con- and brake pressure
nector of brake pres- sensor (terminal #3).
· Key switch: ON sure sensor and ma-
Switch brake pressure
sensor with pump 1 de- NO chine becomes speci-
livery pressure sensor fication. Open circuit in har-
and retry. Check if fault ness between MC
NO and brake pressure
code is switched. · Key switch: ON sensor (terminal #1).
4.5 V or less
Faulty brake pressure
YES sensor.
YES Faulty MC.

and machine is 0 V.
Shorted circuit in
harness between MC
· Key switch: ON NO and brake pressure
sensor.
MC Connector MC-D Brake Pressure Sensor
#D12
3 2 1
T183-05-04-009
T5-6-118
MC FAULT CODE 11311

11311-3 Abnormal Brake Remaining Pres- Voltage: more than 4.75 V
sure Sensor High Voltage
11311-4 Abnormal Brake Remaining Pres- Voltage: less than 0.25 V
sure Sensor Low Voltage
MC-C of MC.
Check for continuity Open circuit in har-
between terminal #C24 NO ness between MC
(harness end) of con- and brake remaining
YES nector and terminal #2 pressure sensor.
Disconnect connector nector of brake remain-
of brake remaining ing pressure sensor. To A
NO Check if voltage be- Open circuit in har-
tween terminals #1 and Check if voltage be-
ness between MC
#3 (harness end) of tween terminal #1
(harness end) of con- YES and brake remaining
connector is 5±0.5 V. pressure sensor
Replace brake remain- nector of brake re-
(terminal #3).
ing pressure sensor with maining pressure
· Key switch: ON sensor and machine
pump 1 delivery pres- NO Open circuit in har-
sure sensor and retry. becomes specification.
ness between MC
Check if fault code is and brake remaining
switched. · Key switch: ON NO pressure sensor
4.5 V or less
Faulty brake remain-

YES ing pressure sensor.
YES Faulty MC.

and machine is 0 V.
Shorted circuit in
harness between MC
· Key switch: ON NO and brake remaining
pressure sensor.
MC Connector MC-C Brake Remaining Pressure Sensor
C1 C10
3 2 1
C23 C31
#C24
T5-6-119
MC FAULT CODE 11400

11400-2 Abnormal Current Feedback of Current: Both of Higher than
Maximum Pump 2 Flow Rate Limit 920 mA or Less than 60 mA
11400-3 Abnormal Feedback High Current of Current: Higher than 920 mA
11400-4 Abnormal Feedback Low Current of Current: Less than 56 mA
Switch connectors of Faulty maximum pump 2

maximum pump 2 flow NO
flow rate limit control
rate limit control solenoid valve.
YES solenoid valve and
torque control solenoid
valve.
Faulty MC.
Check if fault code of
torque control solenoid YES
Check for continuity in
harness between MC valve is displayed.
and maximum pump 2
solenoid valve.
· Between terminal #A22
of connector MC-A in
MC and terminal #1 of Open circuit in harness.
connector in maximum NO
pump 2 flow rate limit
control solenoid valve.
MC and terminal #2 of
connector in maximum
control solenoid valve

open end side)
MC
Connector MC-A
#A16 #A22
T183-05-04-008
T1V1-05-04-003
T5-6-120
MC FAULT CODE 11401

Torque Control Solenoid Valve 920 mA or Less than 60 mA
Torque Control Solenoid Valve
Switch connectors of
torque control solenoid NO Faulty torque control
valve and maximum solenoid valve.
YES control solenoid valve.
maximum pump 2 flow Faulty MC.
rate limit control solenoid YES
Check for continuity in valve is displayed.
harness between MC
and torque control
solenoid valve.
connector in torque Open circuit in harness.
control solenoid valve. NO
connector in torque

open end side)
MC
Connector MC-A
#A19
#A30
T183-05-04-008
T1V1-05-04-003
T5-6-121
MC FAULT CODE 11403

Solenoid Valve Unit (SC) (Arm 920 mA or Less than 60 mA
Regeneration)
Solenoid Valve Unit (SC) (Arm
Regeneration)
Solenoid Valve Unit (SC) (Arm
Regeneration)
solenoid valve unit (SC) NO Faulty solenoid valve unit
(arm regeneration) and (SC) (arm regeneration).
YES other solenoid valve
unit (SF, SG or SI).
Check if fault code of Faulty MC.
switched solenoid valve
unit is displayed. YES
harness between MC
and solenoid valve unit
(SC) (arm regeneration).
Open circuit in harness.
connector in solenoid
valve unit (SC) (arm NO
regeneration)
valve unit (SC) (arm
regeneration)

open end side)
MC
Connector MC-A
#A24
#A18
T183-05-04-008
Solenoid Valve Unit (SC)

(Arm Regeneration)
T1V1-05-04-003
T5-6-122
MC FAULT CODE 11404

Solenoid Valve Unit (SG) (Relief 920 mA or Less than 60 mA
Pressure Control)
Solenoid Valve Unit (SG) (Relief
Pressure Control)
Solenoid Valve Unit (SG) (Relief
Pressure Control)
Switch connectors of Faulty solenoid valve unit

solenoid valve unit NO
(SG) (relief pressure
(SG) (relief pressure control).
YES control) and other
solenoid valve unit (SF,
SC or SI).
Faulty MC.
switched solenoid valve YES
unit is displayed.
harness between MC
(SG) (relief pressure
control).
of connector MC-A in Open circuit in harness.
connector in solenoid NO
valve unit (SG) (relief
pressure control)
valve unit (SG) (relief
pressure control)

open end side)
Connector MC-A of MC
#A4 #A8
T183-05-04-008
Solenoid Valve Unit (SG)

(Relief Pressure Control)
T1V1-05-04-003
T5-6-123
MC FAULT CODE 11410

Maximum Pump 1 Flow Rate Limit 920 mA or Less than 60 mA
Switch connectors of Faulty maximum pump 1

maximum pump1 flow NO
rate limit control solenoid valve.
YES solenoid valve and
torque control solenoid
valve.
Faulty MC.
torque control solenoid YES
harness between MC valve is displayed.
and maximum pump 1
solenoid valve.
MC and terminal #1 of Open circuit in harness.
connector in maximum NO
connector in maximum

open side)
MC
Connector MC-A
#A5
#A31
T183-05-04-008
T1V1-05-04-003
T5-6-124
MC FAULT CODE 11422

Travel Motor Displacement Angle 920 mA or Less than 60 mA
Travel Motor Displacement Angle
NO Faulty travel motor

Disassemble and check displacement angle
travel motor displacement control solenoid valve.
YES angle control solenoid
valve.
Check for continuity in Check for abnormality. Faulty MC.
harness between MC YES
and travel motor
displacement angle
connector in travel Open circuit in harness.
motor displacement
NO
angle control solenoid
valve.
connector in travel
motor displacement
angle control solenoid
valve

open end side)
MC Connector MC-A
T183-05-04-008
#A29 #A32
Travel Motor Displacement Angle Control Solenoid Valve
TCJB-05-06-004
T5-6-125
MC FAULT CODE 11424

Solenoid Valve Unit (SI) (Axle Lock 920 mA or Less than 60 mA
Selection)
Solenoid Valve Unit (SI) (Axle Lock
Selection)
Solenoid Valve Unit (SI) (Axle Lock
Selection)
solenoid valve unit (SI) Faulty solenoid valve unit
NO
(axle lock selection) (SI) (axle lock selection).
and other solenoid
YES valve unit (SF, SC or
SG).
switched solenoid valve YES
Check for continuity in unit is displayed.
harness between MC
(SI) (axle lock selection).
valve unit (SI) (axle lock NO
selection).
valve unit (SI) (axle lock
selection).

open end side)
MC Connector MC-A
#A14
#A21 T183-05-04-008
Solenoid Valve Unit (SI)

(Axle Lock Selection)
T1V1-05-04-003
T5-6-126
MC FAULT CODE 11425

Solenoid Valve Unit (SF) (Work 920 mA or Less than 60 mA
Brake)
Solenoid Valve Unit (SF) (Work
Brake)
Solenoid Valve Unit (SF) (Work
Brake)
solenoid valve unit (SF) NO Faulty solenoid valve unit
(Work Brake) and other (SF) (work brake).
YES solenoid valve unit (SC,
SG or SI).
Check for continuity in switched solenoid valve
unit is displayed. YES
harness between MC
(SF) (work brake).
valve unit (SF) (work
brake). NO
valve unit (SF) (work
brake).

open end side)
MC Connector MC-A
#A9
#A15
T183-05-04-008
Solenoid Valve Unit (SF)

(Work Brake)
T1V1-05-04-003
T5-6-127
MC FAULT CODES 11910 TO 11920

11910-2 Actual Engine Speed Faulty harness
Sent from: ECM
11911-2 Security Signal Faulty harness
Sent from: Monitor Unit
11914-2 Radiator Coolant Temperature Faulty harness
Sent from: ECM
11915-2 Gate Lock Signal Faulty harness
Sent from: Option Controller
11918-2 Work Mode Faulty harness
Sent from: Monitor Unit
11920-2 Fuel Flow Rate Faulty harness
Sent from: ECM
NOTE: If fault codes 11910 to 11920 are displayed,

the CAN harness between MC and source
controller may be faulty.
Refer to CAN Harness Check on T5-6-73
to 104 and check the CAN harness.
T5-6-128
MC FAULT CODE 11901

11901-3 Hydraulic Oil Temperature Sensor Voltage: more than 4.52 V
High Voltage
11901-4 Hydraulic Oil Temperature Sensor Voltage: less than 0.23 V
Low Voltage
Connect terminals #1
YES Faulty MC.
and #2 (harness end)
of connector in
hydraulic oil
temperature sensor by Connect terminal #D6
YES using a clip. Open circuit in harness
(harness end) of YES between MC and
Disconnect connector connector MC-D in
MC-D from MC. hydraulic oil temperature
MC to machine. sensor (terminal #1).
Check for continuity Check for continuity
Disconnect connector of between terminals #D2
hydraulic oil temperature NO between terminals #2
and #D6 (harness end) (harness end) of
sensor. Open circuit in harness
of connector MC-D.
Check if resistance at connector in hydraulic between MC and
oil temperature NO hydraulic oil temperature
sensor end connector is
specification. sensor and machine. sensor (terminal #2).
the table below. Faulty hydraulic oil
NO temperature sensor.
Specification of Hydraulic Oil Temperature Sensor

Hydraulic Oil Resistance (kΩ)
Temperature
°C (°F)
-20 (-4) 16.2±1.6
0 (32) (5.88)
20 (68) 2.45±0.24
40 (104) (1.14)
60 (140) (0.534)
80 (176) 0
MC Connector MC-D
#D2
Hydraulic Oil Temperature Semsor
1 2
#D6 T183-05-04-009
T5-6-129
ECM FAULT CODES 100 TO 190
NOTE: If ECM fault code is displayed, refer to the

other manual "Engine Troubleshooting
Manual" and check the engine.
Engine
Fault Code Troubleshooting
Fault Code Trouble
(TECH2) Manual
Reference Page
Abnormal Engine Oil Pressure Sensor (Abnormal Low
100-3 P0522 1E-393
Voltage)
Abnormal Engine Oil Pressure Sensor (Abnormal High
100-4 P0523 1E-399
Voltage)
102-3 Abnormal Boost Pressure Sensor (Abnormal Low Voltage) P0237 1E-331
102-4 Abnormal Boost Pressure Sensor (Abnormal High Voltage) P0238 1E-339
Abnormal Boost Temperature Sensor (Abnormal High 1E-450
105-3 P1113
Voltage)
105-4 Abnormal Boost Temperature Sensor (Abnormal Low Voltage) P1112 1E-443
Abnormal Atmospheric Pressure Sensor (Abnormal Low
108-3 P0107 1E-228
Voltage)
Abnormal Atmospheric Pressure Sensor (Abnormal High
108-4 P0108 1E-235
Voltage)
110-0 Overheating P1173 1E-456
Abnormal Coolant Temperature Sensor (Abnormal High
110-3 P0118 1E-261
Voltage)
Abnormal Coolant Temperature Sensor (Abnormal Low
110-4 P0117 1E-255
Voltage)
157-0 Abnormal Common Rail Pressure (First stage) P0088 1E-212
157-0 Abnormal Common Rail Pressure (Second stage) P0088 1E-212
157-2 Abnormal Common Rail Pressure (Pump Over-Pressure) P0089 1E-217
Abnormal Common Rail Pressure Sensor (Abnormal High
157-3 P0193 1E-287
Voltage)
Abnormal Common Rail Pressure Sensor (Abnormal Low
157-4 P0192 1E-281
Voltage)
Abnormal Intake Air Temperature Sensor (Abnormal High
172-3 P0113 1E-247
voltage)
Abnormal Intake Air Temperature Sensor (Abnormal Low
172-4 P0112 1E-241
Voltage)
174-3 Abnormal Fuel Temperature Sensor (Abnormal High Voltage) P0183 1E-274
174-4 Abnormal Fuel Temperature Sensor (Abnormal Low Voltage) P0182 1E-268
190-0 Overrunning P0219 1E-329
T5-6-130
Engine
Fault Code Troubleshooting
Fault Code Trouble
(TECH2) Manual
Reference Page
628-2 Abnormal ROM P0601 1E-407
633-7 Pressure Limiter Open P1095 1E-433
636-2 Abnormal Cam Angle Sensor (No Signal) P0340 1E-358
636-2 Abnormal Cam Angle Sensor (Abnormal Signal) P0341 1E-365
636-7 Phase Mismatch of Cam Angle Sensor P1345 1E-512
639-2 Abnormal CAN Bus Line U2104 1E-541
639-3 Abnormal CAN Time Out U2106 1E-546
651-3 Open Circuit in Injection Nozzle #1 Drive System P0201 1E-294
723-2 Abnormal Crank Speed Sensor (No Signal) P0335 1E-346
723-2 Abnormal Crank Speed Sensor (Abnormal Signal) P0336 1E-352
987-3 Abnormal Check Engine Lamp P0650 1E-419
1077-2 Abnormal IC for CPU Watching P0606 1E-411
1079-2 Abnormal 5 V Power Source 1 Voltage P1631 1E-526
1080-2 Abnormal 5 V Power Source 2 Voltage P1632 1E-529
1239-1 No pressure to pump (Fuel leakage) P0087 1E-204
1240-1 No pressure to pump (Fuel leakage) P1093 1E-424
Open Circuit in Suction Control Valve Drive System,
1347-0 P0090 1E-222
Shorted circuit in +B or GND.
1485-2 Abnormal Main Relay System (ON is impossible.) P1625 1E-517
IMPORTANT: When fault code 723-2 (abnormal

crank speed sensor) is displayed
and the engine does not start, the
cam angle sensor is faulty although
fault codes 636-2 (abnormal cam
angle sensor) and 636-7 (phase
mismatch of cam angle sensor) are
not displayed.
T5-6-131
Engine Troubleshooting
Fault Code
Fault Code Trouble Manual
(TECH2)
Reference Item
10001-3 Abnormal EGR Position (Brushless spec.) P0487 1E-381
10002-2 Abnormal EGR Valve Control P0488 1E-387
10003-2 Abnormal Injection Nozzle Common 1 Drive System P1261 1E-466
10004-2 Abnormal Injection Nozzle Common 2 Drive System P1262 1E-476
10005-1 Abnormal Charge Circuit (Bank 1) P0611 1E-413
10006-1 Abnormal Charge Circuit (Bank 2) P0612 1E-416
10007-2 Abnormal CPU P0606 1E-411
10008-2 Abnormal A/D Conversion P1630 1E-524
10009-2 5 V Power Source 3 Voltage P1633 1E-532
10013-2 Abnormal EEPROM P0603 1E-409
T5-6-132
ICF FAULT CODES 14000 TO 14003

14000-2 Abnormal CAN Communication Execute retry B in self-diagnosing.
If this error code is displayed after retrial, check the following
item.
• Check the CAN communication line (harness).
14001-2 Flash Memory: Read / Write Error Execute retry B in self-diagnosing and execute the following
14002-2 External RAM: Read / Write Error item.
• Execute “Information C/U: Initialize”.
14003-2 EEPROM: Sum Check Error Execute retry B in self-diagnosing.
If this error code is displayed after retrial, check the following
item.
• Execute “Control Data: Initialize”.
• Execute “Enter Model and Serial No.”.
T5-6-133
INFORMATION C/U: INITIALIZE

Controller. Push Information C/U. Push OK.
To the
lower
T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-024


Push Start. Setup. Push Information C/U: Initialize.
To the
lower
T1V7-05-03-025 T1V7-05-03-026 T1V7-05-03-027

Screen
Push Init and the controller
operating data is initialied. Push
ESC and return to Information C/U: Push OK and return to Information Push ESC and return to Main
Various Setup Screen. C/U: Various Setup Screen. Menu Screen.
Init
ESC
T1V7-05-03-028 T1V7-05-03-029 T1V7-05-03-027
Information C/U: Initialize Screen Information C/U: Various Setup

Screen
T5-6-134
CONTROL DATA: INITIALIZE

To the
lower
T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-024


Push Start. Setup. Push Control Data: Initialize.
To the
lower
T1V7-05-03-025 T1V7-05-03-026 T1V7-05-03-027

Screen
Push Init and the controller control
data is initialied. Push ESC and
return to Information C/U: Various Push OK and return to Information Push ESC and return to Main
Setup Screen. C/U: Various Setup Screen. Menu Screen.
Init
ESC
T1V7-05-03-033 T1V7-05-03-034 T1V7-05-03-027

Control Data: Initialize Screen Information C/U: Various Setup
Screen
T5-6-135
ENTER MODEL AND SERIAL No.

To the
lower
T1V7-05-03-001 T1V7-05-03-009 T1V7-05-03-024


Push Start. Setup. Push Enter Model and Serial No.
To the
lower
T1V7-05-03-025 T1V7-05-03-026 T1V7-05-03-027

Screen
Push OK after inputting model and
Push Exec and model and serial serial No. and return to Enter
No. can be input. Model and Serial No. Screen.
Push ESC and return to Push ESC and return to
Information C/U: Various Setup Information C/U: Various Setup Push ESC and return to Main
Screen. Screen. Menu Screen.
Exes ESC
ESC
OK
T1V7-05-03-030 T1V7-05-03-031 T1V7-05-03-027

Enter Model and Serial No. Screen Information C/U: Various Setup
Screen
T5-6-136
ICF FAULT CODES 14006, 14008

14006-2 ICF: Satellite Communication Execute retry B in self-diagnosing.
Terminal: Communication Error If this error code is displayed after retrial, check the following
item.
• Check the communication line.
• Check the power source line of satellite terminal.
• Check the fuse.

14008-2 ICF: Abnormal Internal RAM Execute retry B in self-diagnosing.
If this error code is displayed after retrial, replace the
controller.
Fault Code 14006-2 Connector (Harness end of connector viewed from the
• Check the communication line open end side)
1. Check for continuity between terminal #A8
(harness end) of connector ICF-A in ICF and
terminal #10 (harness end) of connector A in
satellite terminal. ICF
Connector ICF-A
2. Check for continuity between terminal #A9 #A8
(harness end) of connector ICF-A in ICF and #A9
satellite terminal.
#A31
3. Check for continuity between terminal #A31
(harness end) of connector ICF-A in ICF and Satellite Terminal
Connector A
terminal #2 (harness end) of connector B in
satellite terminal.
10 9 8 7 6 5 4 3 2 1
• Check the power source line of satellite terminal 20 19 18 17 16 15 14 13 12 11
1. Check the battery power
Check if voltage between terminal #2 (harness Satellite Terminal
end) of connector A in satellite terminal and Connector B
machine is 24 V.
2. Check the main power 8 7 6 5 4 3 2 1
With the key switch ON, check if voltage between 16 15 14 13 12 11 10 9
satellite terminal and machine is 24 V.
3. Check the ground circuit
Check for continuity between terminals #11 and
#12 (harness end) of connector A in satellite
terminal.
T5-6-137
SATELLITE TERMINAL FAULT CODES 14100 TO 14106

14100-2 Abnormal EEPROM Execute retry B in self-diagnosing.
14101-2 Abnormal IB/OB Queue If this error code is displayed after retrial, replace the
controller.
14102-2 Abnormal Local Loop Back Check the communication antenna of satellite terminal.
14103-2 Satellite cannot be found.
14104-2 Remote Loop Back Failure 1 Execute retry B in self-diagnosing.
14105-2 Remote Loop Back Failure 2 If this error code is displayed after retrial, replace the
controller.
14106-2 Received data is not same with sent
data.
• Fault Codes 14102-2 and 14103-2 Satellite Terminal
TCJB-05-04-001
Communication
Antenna
GPS Antenna
T1V1-05-06-004
T5-6-138
MONITOR UNIT FAULT CODE 13303

13303-2 Abnormal Thermistor Temperature Cool the monitor unit and so on until the internal temperature
of monitor unit is less than 85 °C (185 °F).
• The screen of monitor unit becomes dark.
YES Normal.
Cool monitor unit. Check

YES
if the screen of monitor
unit becomes normal.
Check if temperature
NO
around monitor unit is
high.

NO
T5-6-139

13304-2 Abnormal REG Input H Level Refer to the following.
NOTE: *As terminal L in the regulator is a

waterproof type connector, it is difficult to
measure voltage.
Measure voltage at terminal R in starter
relay.
Check for continuity at terminal R in starter
relay and terminal L in the regulator in
advance.
Less than 33.5 V Faulty monitor unit.

Less than Measure voltage at
33.5 V terminal #C7 of
connector monitor-C.
Open circuit in harness
· Engine: Running between terminal L in
Measure voltage at 33.5 V or higher regulator and monitor
terminal L *in unit.
regulator.
Faulty regulator or faulty
alternator.
33.5 V or higher

open end)
Starter Relay
E
S R
Monitor Unit
Connector Monitor-C
6 1
12 7
#C7
T5-6-140
MONITOR UNIT FAULT CODES 13306 AND 13308

13306-2 Abnormal EEPROM Replace the monitor unit when displaying the fault code after
retrial.
13308-2 Abnormal CAN Communication Refer to CAN Harness Check (T5-6-73 to 104).
T5-6-141

13310-2 Shorted Circuit in Coolant Check the coolant temperature sensor and harness.
Temperature Sensor
With terminal of coolant

temperature sensor Shorted circuit in harness
YES YES between monitor unit and
disconnected, disconnect
connector monitor-C in sensor.
monitor unit.
Check for continuity between
terminal #C8 (harness end) of Faulty monitor unit.
Check if resistance of connector in monitor unit and NO
coolant temperature machine.
sensor is specification.
Faulty coolant temperature
NO sensor.
Coolant Temperature Sensor

Coolant Temperature °C Resistance
(°F) (kΩ)
25 (77) 7.6±0.76
40 (104) 4.0±0.35
50 (122) 2.7±0.22
80 (176) 0.92±0.07
95 (203) 0.56±0.04
105 (221) 0.42±0.03
120 (248) 0.28±0.01

open end side)
Monitor Unit
Connector Monitor-C
6 1
12 7
#C8
T5-6-142

13311-3 Shorted Circuit in Fuel Level Sensor Check fuel level sensor and harness.
13311-4 Open Circuit in Fuel Level Sensor Check fuel level sensor and harness.
YES Shorted circuit in harness

between monitor unit and
sensor.
With connector of fuel
level sensor
YES disconnected, disconnect
connector monitor-C in
monitor unit.
Check for continuity Connect terminal #1
between terminal #C2 (harness end) of YES Faulty monitor unit.
(harness end) of connector in fuel level
NO sensor to machine.
connector in monitor unit
and machine. Check for continuity
Check if resistance of between terminal #C2
fuel level sensor is (harness end) of Open circuit in harness
specification. connector in monitor unit NO between monitor unit and
and machine. sensor.
Faulty fuel level sensor.

NO
Fuel Sensor
Float Float Position Resistance (Ω)

Upper Limit (FULL) 10+0-4
3/4 26
FULL
1/2 38±5
R381.9 1/4 53
257 mm
Alarm Level 85±3
3/4
Lower Limit (EMPTY) 90+10-0
93 mm
70.5 mm
open end side)
204 mm 1/2
Monitor Unit
Connector Monitor-C
Fuel Sensor
1/4
338 mm
1 2
#C2
EMPTY
T178-05-05-001
6 1
12 7
T5-6-143
PILOT SHUT-OFF LEVER ALARM
Pilot shut-off lever alarm is displayed on the

monitor unit screen.
YES Faulty pilot shut-off

switch.
Check if pilot shut-off
switch is bent or
damaged.
Faulty harness.
NO
Pilot Shut-Off Pilot Shut-Off

Lever Switch
T1V1-05-06-005
T5-6-144
OPTION CONTROLLER FAULT CODES 15500 TO 15504

15500-4 Abnormal External Reference Voltage Faulty controller
15501-2 Abnormal Read of Initial Setting Value Faulty controller
(EEPROM)
15502-2 Abnormal EEPROM Faulty controller
15503-2 Abnormal RAM Faulty controller
15504-2 Abnormal A/D Conversion Faulty controller
YES * Faulty option controller.
Check if engine and machine

operate normally
Faulty option controller.
NO
* After retrial, if the engine and the machine operate

normally with the fault code shown, the machine
can be operated.
T5-6-145
OPTION CONTROLLER FAULT CODE 15505

15505-2 Abnormal CAN Communication Faulty controller
Faulty CAN harness
NOTE: If fault code 15505 is displayed, the CAN

harness between MC and source controller
may be faulty.
T5-6-146

15506-3 Abnormal Sensor Voltage Faulty controller
Faulty sensor
Faulty harness
YES Faulty sensor.
Disconnect all sensor

connectors for displayed
fault code and retry.
Check if fault code Disconnect all YES
15506-3 disappears. Shorted circuit in harness with
connectors at option continuity between option
controller side. controller and sensor.
NO between terminals #1
and #3 (harness end) of
connector. Faulty option controller.
NO
· Key switch: OFF

open end side)
• Pressure Sensor (Positioning) (Optional) • Electric Lever (Blade/Outrigger,
• Pressure Sensor (Auxiliary) (Optional) Auxiliary/Positioning)
T1V1-05-07-102
TCJB-05-06-005
T5-6-147

15510-3 Abnormal Assist Stroke 1 Sensor High Voltage: more than 4.65 V
Voltage
15510-4 Abnormal Assist Stroke 1 Sensor Low Voltage: less than 0.35 V
Voltage
Check if voltage
between terminal # C YES Faulty option
20 (harness end) of controller.
YES connector C of option
Disconnect connector controller and machine
C of option controller. 0 V. Shorted circuit in
Check for continuity harness between
YES between terminal #C1 NO option controller and
(harness end) of · Key switch: ON right grip (assist
connector and terminal switch).
#7 (harness end) of
connector of right grip. Open circuit in
Disconnect connector of harness between
right grip. option controller and
Check if voltage NO
right grip (assist
between terminals #5 switch).
connector is 5±0.5 V. Open circuit in
Check if voltage
between terminal #7 YES harness between
· Key switch: ON
(harness end) of option controller and
connector for right grip right grip (assist
and machine is switch) (terminal #5).
NO specification.
Open circuit in
harness between
· Key switch: ON option controller and
NO
· Specification: 0.25 V or more, right grip (assist
4.75 V or less switch) (terminal #7).
Right Grip Connector

#C20
#C1 C1 C10
C23 C31
TCJB-05-06-006
T5-6-148

15511-3 Abnormal Assist Stroke 2 Sensor High Voltage: more than 4.65 V
Voltage
15511-4 Abnormal Assist Stroke 2 Sensor Low Voltage: less than 0.35 V
Voltage
Check if voltage
between terminal #C6 YES Faulty option
(harness end) of controller.
controller and machine
is 0 V. Shorted circuit in
C of option controller.
Check for continuity harness between
YES between terminal #C NO option controller and
· Key switch: ON right grip (assist
(harness end) of
connector and terminal switch).
#7 (harness end) of
connector of right grip. Open circuit in
Disconnect connector of harness between
right grip. option controller and
Check if voltage NO
right grip (assist
between terminals #5 switch).
Check if voltage Open circuit in
· Key switch: ON between terminals #7 YES harness between
(harness end) of option controller and
connector of right grip right grip (assist
and machine is switch) (terminal #5).
NO specification.
Open circuit in
harness between
· Key switch: ON NO option controller and
· Specification: 0.25 V or more, right grip (assist
4.75 V or less switch) (terminal #7).
Right Grip Connector

#C6
#C1 C1 C10
C23 C31
TCJB-05-06-006
T5-6-149

15514-3 Abnormal Positioning/Auxiliary Stroke 1 Voltage: more than 4.55 V
Sensor High Voltage
15514-4 Abnormal Positioning/Auxiliary Stroke 1 Voltage: less than 0.45 V
Sensor Low Voltage
Check if voltage
YES Faulty option controller.
between terminal
#C19 (harness end) of
Disconnect connector C YES connector C option
of option controller. controller and machine Shorted circuit in
Check for continuity 0 V. harness between
between terminal #C1 option controller and
YES (harness end) of NO electric lever
· Key switch: ON (auxiliary/positioning).
connector and terminal
#2 (harness end) of
Disconnect connector connector of electric Open circuit in harness
of electric lever lever between option
(auxiliary/positioning). (auxiliary/positioning). controller and electric
Check if voltage NO lever
between terminals #2 (auxiliary/positioning).
of connector is 5±0.5 V. Check if voltage Open circuit in between
between terminal #2 option controller and
(harness end) of YES electric lever
· Key switch: ON
connector of electric (auxiliary/positioning)
lever (terminal #4).
(auxiliary/positioning)
and machine is
NO
specification. Open circuit in n
harness between
· Specification: 0.25 V or more, electric lever
4.75 V or less (auxiliary/positioning)
(terminal #2).
Option Controller Connector C Electric Lever (Auxiliary/Positioning)
#C19
#C1 C1 C10
C23 C31
TCJB-05-06-005
T5-6-150

15515-3 Abnormal Positioning/Auxiliary Stroke 2 Voltage: more than 4.85 V
Sensor High Voltage
15515-4 Abnormal Positioning/Auxiliary Stroke 2 Voltage: less than 0.15 V
Sensor Low Voltage
Check if voltage
between terminals YES Faulty option controller.
Disconnect connector C YES connector C of option
of option controller. controller and Shorted circuit in
Check for continuity machine. harness between
between terminal #C1 Check if voltage is 0 V. option controller and
YES (harness end) of NO electric lever
connector and terminal · Key switch: ON (auxiliary/positioning).
#2 (harness end) of
Disconnect connector connector of electric Open circuit in harness
of electric lever lever between option
(auxiliary/positioning). (auxiliary/positioning). controller and electric
Check if voltage NO lever
between terminals #2 (auxiliary/positioning).
Check if voltage
connector is 5±0.5 V. Open circuit in harness
between terminal #2
(harness end) of between option
· Key switch: ON connector of electric YES controller and electric
lever lever
(auxiliary/positioning) (auxiliary/positioning)
and machine is (terminal #4).
NO specification.
between option
· Key switch: ON NO controller and electric
lever
4.75 V or less
(auxiliary/positioning)
(terminal #2).
Option Controller Connector C Electric Lever (Auxiliary/Positioning)
#C17
#C1 C1 C10
C23 C31 TCJB-05-06-005
T5-6-151

15516-3 Abnormal Positioning/Assist Pi pressure Voltage: more than 4.60 V
Sensor High Voltage
15516-4 Abnormal Positioning/Assist Pi pressure Voltage: less than 0.40 V
Sensor Low Voltage

Disconnect connector C NO
of option controller. between option
Check for continuity controller and pressure
YES sensor.
(harness end) of
connector and terminal To A
#2 (harness end) of YES
of pressure sensor.
connector of pressure
Check if voltage
sensor.
between terminals #1
NO and #3(harness end) of
Check if voltage
· Key switch: ON between terminal #1 YES Open circuit in harness
(harness end) of between option
Switch pressure sensor connector of pressure controller and pressure
with other pressure sensor and machine is sensor (terminal #3).
sensor and retry. Check NO specification.
if fault code disappears. Open circuit in harness
between option
· Key switch: ON NO controller and pressure
· Specification: 0.25 V or more, sensor (terminal #1).
4.75 V or less
Faulty pressure
YES sensor.

A end) of connector C and
machine is 0 V.
Shorted circuit in
harness between
pressure sensor.
Option Controller Connector C Pressure Sensor (Positioning)
#C16
C1 C10
T1V1-05-07-102
C23 C31
T5-6-152

15517-3 Abnormal Outrigger/Blade/Auxiliary Pi Voltage: more than 4.60 V
15517-4 Abnormal Outrigger/Blade/Auxiliary Pi Voltage: is less than 0.40 V

Disconnect connector C NO between option
of option controller. controller and pressure
Check for continuity sensor.
YES
(harness end) of
Disconnect connector connector and terminal To A
of pressure sensor. #2 (harness end) of YES
Check if voltage connector of pressure
between terminals #1 sensor.
NO and #3 (harness end)
of connector is 5±0.5
V. Open circuit in harness
Check if voltage between option
· Key switch: ON between terminal #1 YES controller and pressure
(harness end) of sensor (terminal #3).
connector of pressure
Switch pressure sensor sensor and machine is
NO specification. Open circuit in harness
with other pressure
sensor and retry. Check if between option
fault code disappears. · Key switch: ON NO controller and pressure
· Specification: 0.25 V or more, sensor (terminal #1).
4.75 V or less
Faulty pressure
YES sensor.

end) of connector C and
A machine is 0 V.
Shorted circuit in
harness between
pressure sensor.
Option Controller Connector C Pressure Sensor (Auxiliary)

#C15
C1 C10
T1V1-05-07-102
C23 C31
T5-6-153

15518-3 Abnormal Outrigger/Blade Stroke 1 Sensor Voltage: more than 4.55 V
High Voltage
15518-4 Abnormal Outrigger/Blade Stroke 1 Sensor Voltage: less than 0.45 V
Low Voltage
Check if voltage
between terminal YES Faulty option controller.
Disconnect connector C YES connector C of option
Check for continuity is 0 V. harness between option
between terminal #C1 controller and electric
YES (harness end) of NO lever (blade/outrigger).
connector and terminal · Key switch: ON
#2 (harness end) of
connector of electric
Disconnect connector lever (blade/outrigger). Open circuit in harness
of electric lever between option
(blade/outrigger). NO controller and electric
Check if voltage lever (blade/outrigger).
and #4 (harness end) of Open circuit in harness
connector is 5±0.5 V. Check if voltage
between terminal #2 between option
· Key switch: ON (harness end) of YES controller and electric
connector of electric lever (blade/outrigger)
lever (blade/outrigger) (terminal #4).
and machine is
NO specification.
between option
· Key switch: ON NO controller and electric
· Specification: 0.25 V or more, lever (blade/outrigger)
4.75 V or less (terminal #2).
Option Controller Connector C Electric Lever (Blade/Outrigger)
#C18
#C1 C1 C10
C23 C31 TCJB-05-06-005
T5-6-154

15519-3 Abnormal Outrigger/Blade Stroke 2 Sensor Voltage: more than 4.85 V
High Voltage
15519-4 Abnormal Outrigger/Blade Stroke 2 Sensor Voltage: less than 0.15 V
Low Voltage
Check if voltage
YES Faulty option
between terminal
#C28 (harness end) of controller.
Disconnect connector C
Check for continuity is 0 V. harness between
between terminal #C1 option controller and
YES NO electric lever
(harness end) of · Key switch: ON
connector and terminal (blade/outrigger).
#2 (harness end) of
connector of electric Open circuit in
Disconnect connector of lever (blade/outrigger). harness between
electric lever option controller and
(blade/outrigger). NO electric lever
Check if voltage (blade/outrigger).
and #4 (harness end) of Open circuit in
connector is 5±0.5 V. harness between
Check if voltage YES option controller and
· Key switch: ON between terminal #2 electric lever
(harness end) of (blade/outrigger)
connector of electric (terminal #4).
lever (blade/outrigger)
NO
and machine is Open circuit in
specification. harness between
· Specification: 0.25 V or more, electric lever
4.75 V or less (blade/outrigger)
(terminal #2).
Option Controller Connector C Electric Lever (Blade/Outrigger)
#C1 C1 C10
C23 C31 TCJB-05-06-005

#C28
T5-6-155

15570-2 Abnormal Outrigger/Blade/Auxiliary Neutral When meeting the any following conditions,
outrigger/blade/auxiliary pilot pressure is
more than 1.2 MPa.
(Conditions)
• Auxiliary solenoid valve 1 and 2 output
is less than 0.5 MPa
YES Faulty auxiliary solenoid valve

1 or 2 (stuck spool).
YES Disassemble and check

auxiliary solenoid valve
1 or 2.
Check for abnormality. Faulty blade/outrigger solenoid
Set pilot shut-off lever
to LOCK position and NO valve 1 or 2 (stuck spool).
retry.
Check if fault code
disappears.
· Engine: Running YES Faulty pressure sensor.
Switch pressure
sensor with other
pressure sensor and
NO retry. Check if fault
code disappears.
NO
T5-6-156

15571-2 Abnormal Outrigger/Blade/Auxiliary When meeting either of the any following
Operation condition, outrigger/blade/auxiliary pilot
pressure is less than 1.0 MPa.
(Conditions)
• Auxiliary solenoid valve 1 and 2 output
is more than 2.2 MPa
• All of auxiliary solenoid valves 1, 2 and

blade/outrigger solenoid valves 1, 2 may not
become faulty at the same time.
• Therefore when the fault code is displayed, the
pressure sensor or the controller may be faulty.
• Refer to "FAULT CODE 15517".
T5-6-157

15572-2 Abnormal Positioning/Assist Neutral When meeting the any following conditions,
positioning/assist pilot pressure is more than
1.2 MPa.
(Conditions)
• Positioning 1 and 2 solenoid valve
• Assist 1 and 2 solenoid valve output
is less than 0.5 MPa
YES Faulty assist solenoid valve 1

or 2 (stuck spool).
YES Disassemble and check

assist solenoid valve 1
or 2.
Check for abnormality. Faulty positioning solenoid
Set pilot shut-off lever valve 1 or 2 (stuck spool).
to LOCK position and NO
retry.
Check if fault code
disappears.
· Engine: Running YES Faulty pressure sensor.

Switch pressure
sensor with other
pressure sensor and
NO retry.
Check if fault code
disappears.
NO
T5-6-158

15573-2 Abnormal Positioning/Assist Operation When meeting either of the following
conditions, positioning/assist pilot pressure
is less than 1.0 MPa.
(Conditions)
• Positioning 1 and 2 solenoid valve
• Assist 1 and 2 solenoid valve output
is more than 2.2 MPa
• All of assist solenoid valves 1, 2 and positioning

solenoid valves 1, 2 may not become faulty at the
same time.
• Therefore when the fault code is displayed, the
pressure sensor or the controller may be faulty.
• Refer to "FAULT CODE 15516".
T5-6-159
OPTION CONTROLLER FAULT CODES 15574-3 AND 15578-3

15574-3 Abnormal Positioning/Auxiliary Sum Signal Positioning/auxiliary stroke 1 + positioning/
Critical High Voltage auxiliary stroke 2 is more than 9.0 V
High Voltage auxiliary stroke 2 is more than 5.4 V and
less than or equal to 9.0 V
YES Faulty electric lever.

of electric lever
(auxiliary/positioning).
Connect terminal #2
of connector by using a
clip or others and retry.
Check if fault code YES Shorted circuit in harness with
Disconnect connector C
disappears. continuity.
of option controller.
between following
NO terminals (harness end)
of connector.
· Between terminal #C19 of NO
connector C and terminal #3
of connector of electric lever
· Between terminal #C17 of
connector C and terminal #1
of connector of electric lever
Electric Lever Option Controller Connector C

(Auxiliary/Positioning)
#C17 #C19
C1 C10
TCJB-05-06-005
C23 C31
T5-6-160

Critical Low Voltage auxiliary stroke 2 is less than 0.5 V
15578-4 Abnormalr Positioning/Auxiliary Sum Signal Positioning/auxiliary stroke 1 + positioning/

Low Voltage auxiliary stroke 2 is more than or equal to
0.5 V and less than 4.6 V

Disconnect connector of
electric lever
(auxiliary/positioning).
Connect terminals #2 and
#1 (harness end) of
connector by using a clip
or others. Disconnect connector C
Connect terminals #2 and of option controller and
#3 (harness end) of connector of electric YES Faulty option controller.
connector by using a clip lever
or others. Retry and (auxiliary/positioning).
Check if fault code Check for continuity
disappears. between following
NO
terminals (harness end)
of connector. Open circuit in harness without
NO continuity.
· Between terminal #C19
of connector C and
terminal #3 of connector
of electric lever
of connector C and
of electric lever

#C17 #C19
C1 C10
C23 C31
TCJB-05-06-005
T5-6-161

15575-3 Abnormal Outrigger/Blade Sum Signal Outrigger/blade stroke 1 + outrigger/blade
Critical High Voltage stroke 2 is more than 9.0 V
High Voltage stroke 2 is more than 5.4 V and less than or
equal to 9.0 V
of electric lever
(blade/outrigger).
of connector by using
a clip or others.
Retry and Check if Disconnect connector C YES Shorted circuit in with
fault code disappears. of option controller. continuity.
between following
NO terminals (harness end)
of connector.
· Between terminal #C18 of NO
connector C and terminal
#3 of connector of electric
lever
· Between terminal #C28 of
connector C and terminal
#1 of connector of electric
lever

(Blade/Outrigger)
#C18
C1 C10
C23 C31
TCJB-05-06-005 #C28
T5-6-162

Critical Low Voltage stroke 2 is less than 0.5 V
15579-4 Abnormal Outrigger/Blade Sum Signal Low Outrigger/blade stroke 1 + outrigger/blade
Voltage stroke 2 is more than or equal to 0.5 V and
less than 4.6 V

electric lever
(blade/outrigger).
#1 (harness end) of
or others.
#3 (harness end) of Disconnect connector C
of option controller and YES Faulty option controller.
or others. connector of electric
Retry and check if fault lever (blade/outrigger).
code disappears. Check for continuity
NO between following
terminals (harness end)
of connector. Open circuit in without
NO continuity.
of connector C and
of electric lever
of connector C and
of electric lever

#C18
C1 C10
C23 C31
TCJB-05-06-005
#C28
T5-6-163

20300-2 Abnormal Positioning/Auxiliary Operation Abnormal positioning/auxiliary stroke 1, or
Signal Warning Abnormal positioning/auxiliary stroke 2, or
Abnormal sum of positioning/auxiliary 1 and 2
20301-2 Abnormal Outrigger/Blade Operation Abnormal outrigger/blade stroke 1 or
Signal Warning Abnormal outrigger/blade stroke 2 or
Abnormal sum of outrigger/blade 1 and 2
20302-2 Abnormal Warning on Abnormal assist stroke 1 or Abnormal assist
Assist Related Operation Signal stroke 2
20303-2 Electric Lever Pilot Some electric lever controls are abnormal in
Cut Warning monitoring neutral.
• If this fault code is displayed, all related fault

codes are displayed at the same time.
• Refer to all fault codes and check them.
T5-6-164
TROUBLEHOOTING / Troubleshooting A

15520-2 Invalid and Abnormal Current Feedback Current: Both of Higher than 920 mA or Less
Value of Auxiliary 1 Proportional Valve than 60 mA
15520-3 Abnormal Feedback Value High Current of Current: Higher than 920 mA
15520-4 Abnormal Feedback Value Low Current of Current: Less than 56 mA
Switch connector of NO Faulty auxiliary solenoid

auxiliary solenoid valve 1 valve 1.
YES with connector of auxiliary
solenoid valve 2.
Check if fault code for
auxiliary solenoid valve 2 Faulty option controller.
is displayed. YES
Check for continuity of
harness between option
controller and auxiliary
solenoid valve 1.
of connector A of option
controller and terminal
#1 of connector of
auxiliary solenoid valve 1 NO
#2 of connector of
auxiliary solenoid valve 1

open end side)
Option Controller Connector A
#A19 #A22
T183-05-04-008
Auxiliary Solenoid Valve 1
T1V1-05-04-003
T5-6-165

Value of Auxiliary 2 Proportional Valve than 60 mA
Switch connector of NO Faulty auxiliary solenoid

auxiliary solenoid valve 2 valve 2.
YES with connector of auxiliary
solenoid valve 1.
auxiliary solenoid valve 1 Faulty option controller.
is displayed. YES
controller and auxiliary
solenoid valve 2.
controller and terminal #1
of connector of auxiliary
solenoid valve 2 NO
of connector of auxiliary
solenoid valve 2

open end side)
#A15 #A23
T183-05-04-008
Auxiliary Solenoid Valve 2
T1V1-05-04-003
T5-6-166

Value of Outrigger/Blade 1 Proportional than 60 mA
Valve
Switch connector of
NO Faulty blade/outrigger
blade/outrigger solenoid solenoid valve 1.
valve 1 with connector
YES of blade/outrigger
solenoid valve 2. Check
if the fault code for Faulty option controller.
blade/outrigger solenoid
valve 2 is displayed. YES
controller and
valve 1.
· Between terminal #A32 of
connector A of option Open circuit in harness.
of connector of NO
valve 1
connector A of option
of connector of
valve 1

open end side)
Option Controller Connector A Blade/Outrigger Solenoid Valve 1
#A7
T1V1-05-04-003
#A32
T183-05-04-008
T5-6-167

Value of Outrigger/Blade 2 Proportional than 60 mA
Valve
Switch connector of NO Faulty blade/outrigger

blade/outrigger solenoid solenoid valve 2.
valve 2 with connector of
YES blade/outrigger solenoid
valve 1.
Check if fault code for Faulty option controller.
blade/outrigger solenoid YES
Check for continuity of valve 1 is displayed.
controller and
valve 2.
connector A of option Open circuit in harness.
of connector of NO
valve 2
of connector of
valve 2

open end side)
Option Controller Connector A Blade/Outrigger Solenoid Valve 2
#A4
#A24 T1V1-05-04-003
T183-05-04-008
T5-6-168

Value of Swing Parking Release than 60 mA
Proportional Valve
Swing Parking Release Proportional Valve
Swing Parking Release Proportional Valve
Faulty swing parking

Switch connector of NO brake release solenoid
swing parking brake valve.
YES release solenoid valve
with connector of
valve 1. Faulty option controller.
Check for continuity of Check if fault code for YES
harness between option blade/outrigger solenoid
controller and swing valve 1 is displayed.
parking brake release
solenoid valve.
controller and terminal #1 Open circuit in harness.
of connector of swing NO
solenoid valve
of connector of swing
solenoid valve

open end side)
Option Controller Connector A Swing Parking Brake Release Solenoid Valve
#A17
T1V1-05-04-003
#A31 T183-05-04-008
T5-6-169

Value of Assist 1 Proportional Valve than 60 mA
Assist 1 Proportional Valve
Switch connector of assist NO Faulty assist solenoid

solenoid valve 1 with valve 1.
YES connector of assist
solenoid valve 2.
assist solenoid valve 2 is Faulty option controller.
displayed. YES
controller and assist
solenoid valve 1.
#1 of connector of Open circuit in harness.
assist solenoid valve 1 NO
#2 of connector of

open end side)
#A16
#A30 T183-05-04-008
Assist Solenoid Valve 1
T1V1-05-04-003
T5-6-170

Switch connector of assist NO Faulty assist solenoid

solenoid valve 2 with valve 2.
solenoid valve 1.
assist solenoid valve 1 is Faulty option controller.
displayed. YES
solenoid valve 2.
· Between terminal
#A21 of connector A of
option controller and
terminal #1 of
connector of assist NO
solenoid valve 2
of connector A of
terminal #2 of
connector of assist
solenoid valve 2

open end side)
#A5 #A21
T183-05-04-008
T1V1-05-04-003
T5-6-171

NO Faulty assist solenoid

Switch connector of assist valve 3.
solenoid valve 3 with
YES
connector of assist
solenoid valve 4.
assist solenoid valve 4 is YES
Check for continuity of displayed.
solenoid valve 3.
#1 of connector of Open circuit in harness.
assist solenoid valve 3 NO
#2 of connector of

open end side)
#A10
#A29 T183-05-04-008
T1V1-05-04-003
T5-6-172

NO Faulty assist solenoid

Switch connector of assist valve 4.
solenoid valve 4 with
solenoid valve 3.
assist solenoid valve 3 is YES
Check for continuity of displayed.
solenoid valve 4.
of connector A of
terminal #1 of Open circuit in harness.
connector of assist NO
solenoid valve 4
· Between terminal
#A14 of connector A of
terminal #2 of
connector of assist
solenoid valve 4

open end side)
#A14 #A8
#A29 T183-05-04-008
T1V1-05-04-003
T5-6-173

Value of Positioning 1 Proportional Valve than 60 mA
Positioning 1 Proportional Valve
Switch connector of NO Faulty positioning

positioning solenoid solenoid valve 1.
YES positioning solenoid
valve 2.
positioning solenoid YES
controller and
positioning solenoid
valve 1.
of connector of positioning NO
solenoid valve 1
of connector of positioning
solenoid valve 1

open end side)
#A6
#A11
T183-05-04-008
Positioning Solenoid Valve 1
T1V1-05-04-003
T5-6-174

Value of Positioning 2 Proportional Valve than 60 mA
Switch connector of NO Faulty positioning

positioning solenoid solenoid valve 2.
YES positioning solenoid
valve 1.
positioning solenoid YES
controller and
positioning solenoid
valve 2.
of connector of positioning NO
solenoid valve 2
of connector of positioning
solenoid valve 2

open end side)
#A3 #A9
T183-05-04-008
Positioning Solenoid Valve 2
T1V1-05-04-003
T5-6-175

15565-2 Unreceived Work Mode Unreceived for 2000 ms
Sent from: MC
15566-2 Unreceived ATT 1 and 2 Optional Selection Unreceived for 10 sec
Sent from: MC
15567-2 Unreceived ATT 3 and 4 Optional Selection Unreceived for 10 sec

Sent from: MC
15568-2 Unreceived ATT 5 Optional Selection Unreceived for 10 sec

Sent from: MC
15577-2 Unreceived Actual Engine Speed Unreceived for 10 sec

Sent from: ECM
NOTE: If fault codes 15565 to 15577 are displayed,

the CAN harness between MC and source
controller may be faulty.
Refer to CAN Harness Check o T5-6-73 to
104 and check the CAN harness.
T5-6-176
STEERING COLUMN MONITOR FAULT CODE 16000

16000-2 Abnormal CAN Communication Faulty steering column monitor
Faulty CAN harness
NOTE: If fault code 16000-2 is displayed, the CAN

harness between MC and source controller
may be faulty.
T5-6-177
(Blank)
T5-6-178
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
Apply troubleshooting B procedure when no fault code

is displayed on the service menu (built-in diagnosing
system) in monitor unit and the diagnosing by Dr. ZX
although the machine operation is abnormal. When
the fault code is displayed, refer to the troubleshooting
A group and diagnose.
On the front section pages of this group are the tables
indicating the relationship between machine trouble
symptoms and related parts which may cause such
trouble if failed.
Start the troubleshooting with more probable causes
selected by referring to these tablesHow to Read the
Troubleshooting Flow Charts
• How to read troubleshooting flowchart

YES (OK)
(2)
• After checking or measuring item (1), select either YES (OK)
・ (1) or NO (NOT OK) and proceed to item (2) or (3), as appropriate.
(3)
NO (NOT OK)
• Special instructions or reference item are indicated in the spaces under the box.
・ Incorrect measuring or checking methods will render troubleshooting impossible,
and may damage components as well.
· Key switch: ON
• Explanation of how to use test harness kit required. Refer to “Electrical System
・
Inspection” Group (Group 8) in this section.
・ • Use the service menu (built-in diagnosing system) in the monitor unit or the
diagnosing system / monitor function in Dr. ZX.
・ • Causes are stated in a thick-line box. Scanning through thick-line boxes, possible
causes can be seen without going through the flow chart.
NOTE: For all connector shown in this group,

harness end connector viewed from the
open end side are shown
Harness
Harness End
Connector
Open End Side T6L4-05-03-001
T5-7-1
RELATIONSHIP BETWEEN MACHINE .
TROUBLE SYMPTOMS AND RELATED
PARTS
This table indicates the relationship between machine
trouble symptoms and the potential problem parts,
which may cause trouble if failed, and the evaluation
methods of these components.
Parts Pump 1 Delivery
Item Engine Control Dial Pump Control Pressure Sensor
Pressure Sensor
• Instructs engine target • Monitors pump control pressure • Monitors pump
speed. in order to control E mode control. delivery pressure in
order to control HP
mode, auto-power lift
Function and travel accelera-
tion controls.
• As below • No signals arrive to MC. • If pump delivery

pressure sensor
Symptoms in control output is 0 or 5 V, fol-
system when trouble lowing symptoms will
be presented by
occurs. back-up mode func-
tion.
• Trouble when starting • Although operating lever at E • HP mode is
engine: Engine speed is kept mode, engine speed does not reach inoperable.
at slow idle speed. (Engine P speed. • Boom raise
can top by key switch.) power is weak during
• Trouble when running digging operation.
engine: • During com-
Engine speed is kept at bined operation of
speed just before trouble. arm roll-in and swing,
arm speed is slow.
Symptoms in machine
operation when trouble
occurs.
By Fault Code 11101 11206, 11208 11200

Monitor Item: Requested Engine Monitor Item: Pump 1 Flow Control Monitor Item: Pump 1
Speed, EC Dial Angle (Possible Pressure, Pump 2 Flow Control Pres- Delivery Pressure (Pos-
By Monitor to display by built-in diagnosing sure (Possible to display by built-in di- sible to display by
Evalua- Function system) agnosing system) built-in diagnosing sys-
tem)
tion
By Using Test
- - -
Harness
Others - - -
• Evaluation by Dr. ZX • Possible to
• 0.25 or less: open circuit in judge if sensor is
harness malfunction or har-
NOTE - • 4.75 or more: shorted circuit in ness is faulty by
harness switching pump 2
and 3 sensors.
Descriptions of Control T2-2 T2-2 T2-2
(Operational Principle
Section in T/M)
T5-7-2
Pump 2 Delivery Steering Pump Delivery Pressure Sensor Pressure Sensor

Pressure Sensor Pressure Sensor (Travel Forward) (Travel Reverse)
• Monitors pump delivery • Monitors pump delivery • Monitors travel for- • Monitors travel for-
pressure in order to control HP pressure in order to control ward pilot pressure in or- ward pilot pressure in or-
mode, and arm regenerative steering pump torque decrease der to control auto-idle, der to control auto-idle,
controls. control. idle speed-up, travel idle speed-up, travel
acceleration, speed acceleration, speed
sensing, forward/reverse sensing, forward/reverse
selection controls. selection controls.
• If pump delivery pressure • As below • No signals arrive to • No signals arrive to
sensor output is 0 or 5 V, fol- MC. MC.
lowing symptoms will be pre-
sented by back-up mode func-
tion.
• HP mode is inoperable. • Engine stalls if pump torque • Although accelerator • Although accelerator
• During combined opera- is increased. pedal is fully depressed pedal is fully depressed
tion of arm roll-in and swing, and machine travels for- and machine travels re-
arm speed is slow. ward, engine speed does verse, engine speed does
not increase. not increase.
• Although machine • Although machine
travels forward with travels reverse with
auto-idle switch ON, en- auto-idle switch ON, en-
gine speed does not in- gine speed does not in-
crease. crease.
• Although operating • Although operating
pedal with engine speed pedal with engine speed
control mode selection control mode selection
switch in pedal position, switch in pedal position,
engine speed does not in- engine speed does not in-
crease. crease.
• When machine trav- • When machine trav-
els at slow idle speed, en- els at slow idle speed, en-
gine may hunt. gine may hunt.
• Although machine • Although machine
travels forward at slow travels reverse at slow
idle, engine speed does idle, engine speed does
not increase. not increase.
11202 11203 11305 11306
Monitor Item: Pump 2 Delivery Monitor Item: Pump 3 Delivery Monitor Item: Travel Forward Monitor Item: Travel Reverse
Pressure (Possible to display by Pressure Pilot Pressure (Possible to Pilot Pressure (Possible to
built-in diagnosing system) display built-in diagnosing display built-in diagnosing
system). system).
Monitor pressure change Monitor pressure change
while traveling forward. while traveling reverse.
- - - -
- - - -
• Possible to judge if sen- • Possible to judge if sensor • Possible to judge if • Possible to judge if
sor is malfunction or harness is is malfunction or harness is faulty pressure sensor is faulty or pressure sensor is faulty or
faulty by switching pump 1 and by switching pump 1 and 2 sen- port is clogged by switch- port is clogged by switch-
3 sensors. sors. ing pressure sensor with ing pressure sensor with
another pressure sensor. another pressure sensor.
T2-2 T2-2 T2-2 T2-2
T5-7-3
Parts Pressure Sensor Pressure Sensor

Item Pressure Sensor (Swing)
(Front Attachment) (Boom Raise)
• Monitors front attachment • Monitors swing pilot pressure • Monitors boom raise pilot
pilot pressure in order to in order to control arm re- pressure in order to control
control auto-idle, idle generative control. HP mode, arm regenerative
speed-up and parking brake and auto power lift controls.
Function alarm controls.
• When pressure sensor (front • No signals arrive to MC. • No signals arrive to MC.
attachment) or harness be-
Symptoms in control tween pressure sensor and
system when trouble MC is faulty, MC judges that
pressure sensor (front at-
occurs. tachment) is ON.
• Although any front attach- • During arm level crowding • Although boom is raised at
ment is operated with operation, arm speed is HP mode, engine speed
auto-idle switch is ON, en- slightly slow. does not increase.
gine speed does not in- • Arm speed becomes slightly
crease. slower than normal in boom
• When front attachment is raise and arm roll-in opera-
operated at slow idle speed, tion as arm regenerative
engine may hunt. control does not work. (Not
• When parking brake is ap- remarkable)
Symptoms in machine plied and when front at- • Arm roll-in and boom raise
operation when trouble tachment is operated, buzzer speeds become slightly
occurs. does not sound. slower at the beginning
stage of arm level crowding
operation.
• Boom raise power is weak.
(Not remarkable)
By Fault Code 11307 11301 11302

Monitor Item: Front Pilot Pres- Monitor Item: Swing Pilot Monitor Item: Boom Raise Pilot
sure (Possible to display built-in Pressure (Possible to display Pressure (Possible to display
diagnosing system). built-in diagnosing system) built-in diagnostic system).
By Monitor Monitor pressure change while Monitor pressure change while Monitor pressure change while
Function operating front attachment. swinging upper-structure. operating front attachment.
Evalua-
tion
By Using Test
Harness - - -
Others - - -
• Possible to judge if pressure • Possible to judge if pressure • Possible to judge if pressure
sensor is faulty or port is sensor is faulty or port is sensor is faulty or port is
NOTE clogged by switching pres- clogged by switching pres- clogged by switching pres-
sure sensor with another sure sensor with another sure sensor with another
pressure sensor. pressure sensor. pressure sensor.

(Operational Principle Sec-
tion in T/M)
T5-7-4
Pressure Sensor Pressure Sensor Pressure Sensor

Brake Pressure Sensor
(Arm Roll-In) (Auxiliary) (Optional) (Positioning) (Optional)
• Monitors arm roll-in pilot • Monitors attachment pilot • Monitors attachment pilot • Monitors bake operating
pressure in order to control pressure when attachment is pressure when attachment is pressure in order to control
HP mode, arm regenerative installed in order to control installed in order to control work brake.
and auto power lift controls. attachment operation speed positioning and assist con-
increase, pump 1 and pump trols
2 flow rate limit and auxiliary
flow rate controls.
• No signals arrive to MC. • No signals arrive to MC and • No signals arrive to option • No signals arrive to MC.
option controller. Electric controller. Electric lever pilot
lever pilot cut-off control is cut-off control is done by op-
done by option controller. tion controller.
• Although arm is • When attachment is • When positioning or • Work brake is inoper-

rolled-in at HP mode, en- operated, engine speed does assist is operated, engine able.
gine speed does not in- not increase. speed does not increase.
crease. • When attachment is • When attachment is
• Arm speed is slow in operated, operation speed operated, operation speed
arm level crowding opera- decreases. decreases.
tion. • All operations are inop- • All operations are inop-
erable except travel opera- erable except travel opera-
tion. tion.
• Electric Lever Solenoid • Electric Lever Solenoid
Valve Output Warning is dis- Valve Output Warning is dis-
played on monitor unit. played on monitor unit.
• Buzzer sounds con- • Buzzer sounds con-
tinuously. tinuously.
11303 11517 11516 11310

Monitor Item: Arm Roll-In Pilot Monitor Item: ATT Control Pilot Monitor Item: Posn/Assist Pilot Monitor Item: Brake Pressure
Pressure (Possible to dis- Pressure (Possible to display Monitor Pressure (Possible to (Possible to display built-in di-
played built-in diagnosing built-in diagnosing system). display built-in diagnosing sys- agnosing system)
system). Monitor pressure change while tem) Monitor pressure change while
Monitor pressure change while operating attachment. Monitor pressure change while depressing brake pedal.
rolling arm in. operating attachment.
- - - -
- - - -
• Possible to judge if • Possible to judge if • Possible to judge if • Possible to judge if
pressure sensor is faulty or pressure sensor is faulty or pressure sensor is faulty or pressure sensor is faulty or
port is clogged by switching port is clogged by switching port is clogged by switching port is clogged by switching
pressure sensor with an- pressure sensor with another pressure sensor with another brake pressure sensor with
other pressure sensor. pressure sensor. pressure sensor. pump 1, 2, 3 delivery pres-
sure sensors.
T2-2 T2-2 T2-2 T2-2
T5-7-5
Parts Brake Remaining Boom Bottom

Item Pressure Sensor Solenoid Valve Unit (SF)
Pressure Sensor
• Monitors accumulated • Monitors Boom cylinder • Shifts bake valve by pilot
pressure of accumulator for bottom pressure in order to pressure in order to control
brake in order to control control (overload alarm con- work brake control.
travel motor selection control. trol (optional).
Function
• No signals arrive to MC. • No Signal arrive to MC. • Ifsolenoid valve unit (SF) is
not activated, pressure at
Symptoms in control port SE becomes 0 MPa (0
system when trouble kgf/cm2).
occurs.
• Parking brake cannot be re- • Condition is always overload. Abnormal low current:
leased. • Overload alarm is displayed • Work brake does not operate.
• Travel speed is turned to on monitor unit.
fast/slow speed. • Overload alarm sounds. Abnormal high current:
• Work brake is kept applied.
• Machine cannot travel.
Symptoms in machine
occurs.
By Fault Code 11311 11425 -

Monitor Item: Brake Remain Monitor Item: Implement Brake Monitor Item: Boom Bottom
By Monitor Pressure P/S/V Output Pressure
Function
Evalua-
tion • Install lamp harness (ST
By Using Test 7226). Check output signals
- from MC and harness condi- -
Harness tion.
Others - - -
• Possible to judge if
pressure sensor is faulty or
port is clogged by switching
NOTE brake pressure sensor with
- -
pump 1, 2, 3 delivery pres-
sure sensors.
T2-2 T2-2 T2-2
Descriptions of Control
Section in T/M)
T5-7-6
Max. Pump 1 Flow Rate Max. Pump 2 Flow Rate

Solenoid Valve Unit (SC) Solenoid Valve Unit (SI) Limit Control Solenoid Valve Limit Control Solenoid
• Routes return oil from arm cylin- • Is shifted when axle lock or • When machine is traveling • Limits maximum
V l flow rate
der rod side to bottom side when auto axle lock is selected by in travel creeper mode, or of pump 2 when operating
rolling arm in order to increase brake switch. Shifts operat- when attachment and front front attachment.
arm speed. ing check valve of axle lock attachment are operated,
cylinder in order to control maximum flow rate of pump
auto axle lock control. 1 is restricted in order to
control pump 1 flow rate
limit control in travel creeper
speed mode, pump 1 flow
rate limit and attachment
flow rate limit control.
• If solenoid valve unit (SC) is not • If solenoid valve unit (SI) is · If max. pump 1 flow rate limit • If max. pump 2 flow rate
activated, pressure at port SC not activated, pressure at control solenoid valve is not limit control solenoid valve
becomes 0 MPa (0 kgf/cm2). Arm port SI becomes 0 MPa (0 activated, pressure at output is not activated, pressure at
regenerative control will not op- kgf/cm2). port becomes 0 MPa (0 output port becomes 0 MPa
erate at this time. kgf/cm2). (0 kgf/cm2).
Abnormal low current: Abnormal low current: Abnormal low current: Abnormal low current:
• All operation speeds become • Axle lock is not released. • When attachment, front at- • When front and front at-
slow. tachment and superfine tachment are operated, op-
Abnormal high current: travel are operated, operat- erating speed becomes
Abnormal high current: • Axle lock is kept in released ing speed becomes fast. fast.
• Arm speed becomes fast as arm condition.
regenerative control is always • Condition when front at- Abnormal high current: Abnormal high current:
operated. tachment is operated is un- • Travel, bucket, arm and • Arm, boom and swing
stable. boom speeds become slow speeds become slow as
as maximum flow rate of maximum flow rate of pump
pump 1 decreases. 2 decreases.
11403 11424 11410 11400

Monitor Item: Arm Regenerative P/S Monitor Item: Axle Lock Output Monitor Item: Pump 1 Flow Monitor Item: Pump 2 Flow
Valve Output (Possible to display by Rate Limit P/S/V Out Rate Limit P/S/V Out
built-in diagnosing system)
• Install
lamp harness (ST 7226). • Install lamp harness (ST
Check output signals from MC 7226). Check output signals
and harness condition. from MC and harness con- - -
dition.
- - - -
- - - -
T2-2 T2-2 T2-2 T2-2
T5-7-7
Parts Torque Control Pilot Shut-Off

Solenoid Valve Auxiliary Solenoid Valve
Item Solenoid Valve
• Supplies control pressure to • Opens and closes pilot cir- • Is operated by signal from
pumps 1 and 2 in order to do cuit. option controller and sup-
speed sensing control. plies pressure oil from pilot
Function pump to control valve spool
in order to control auxiliary
control.
• If torque control solenoid • As below • When trouble occurs, sole-

valve is not activated, output noid valve output is 0 by
pressure of solenoid valve is electric lever pilot cut-off
Symptoms in control sys- 0 MPa (0 kgf/cm2). control. When operating
tem when trouble occurs. auxiliary, operating speed
becomes slow.
Abnormal low current: Solenoid valve is closed: Abnormal low current:

• All operation speeds become • All actuators are not oper- • When operating auxiliary,
slow. ated. (Pilot pressure oil is operating speed becomes
not supplied to pilot value.) slow.
Abnormal high current:
• Engine may stall while travel- Solenoid valve is open: Abnormal high current:
ing at slow idle speed. • Pilotpressure oil is always • All operations are inoper-
supplied to pilot value. able except travel operation.
• Alarm is displayed on
Symptoms in machine op- monitor unit and buzzer
eration when trouble oc- sounds.
curs.
By Fault Code 11401 15520, 15521 -

Monitor Item: Pump Torque P/S Monitor Item: Posn/Aux 1, 2
Valve Output (Possible to display Operation, Aux 1, 2 P/S/V
by built-in diagnosing system) (Possible to display by built-in
diagnosing system)
By Monitor Monitor voltage and pressure -
Evalua- Function changes while operating lever.
tion
By Using Test
- - -
Harness
Others - - -
NOTE - - -

Section in T/M)
T5-7-8
Blade/Outrigger Swing Parking Brake

Positioning Solenoid Valve Assist Solenoid Valve Release Solenoid Valve
Solenoid Valve
• Is operated by signal from option • Is operated by signal from • Is operated by signal from • Is operated by signal from
controller and supplies pressure option controller and sup- option controller and sup- option controller and sup-
oil from pilot pump to control plies pressure oil from pilot plies pressure oil from pilot plies pressure oil from pilot
valve spool in order to control pump to control valve spool pump to control valve spool pump to control valve spool
positioning control. in order to control in order to control assist in order to control position-
blade/outrigger control. control. ing and assist controls.
• When trouble occurs, solenoid • When trouble occurs, sole- • When trouble occurs, sole- • When trouble occurs, sole-
valve output is turned OFF by noid valve output is turned noid valve output is turned noid valve output is turned
electric lever pilot cut-off control. OFF by electric lever pilot OFF by electric lever pilot OFF by electric lever pilot
When operating positioning, op- cut-off control. When op- cut-off control. When op- cut-off control.
erating speed becomes slow. erating blade/outrigger, operating assist, operating
erating speed becomes speed becomes slow.
slow.
Abnormal low current: Abnormal low current: Abnormal low current: • All operations are inoper-
• When operating positioning, op- • When operating • When operating assist, op- able except travel opera-
erating speed becomes slow. blade/outrigger, operating erating speed becomes tion.
speed becomes slow. slow. • Alarm is displayed on
Abnormal high current: monitor unit and buzzer
• All operations are inoperable Abnormal high current: Abnormal high current: sounds.
except travel operation. • All operations are inoper- • All operations are inoper-
• Alarm is displayed on monitor able except travel opera- able except travel opera-
unit and buzzer sounds. tion. tion.
• Alarm is displayed on • Alarm is displayed on
monitor unit and buzzer monitor unit and buzzer
sounds. sounds.
15529, 15530 15522, 15523 15525, 15526 15524

Monitor Item: Posn/Aux 1, 2 Opera- Monitor Item: Outrigger/Blade Monitor Item: Assist 1, 2 Op- Monitor Item: Swing Parking
tion, Positioning 1, 2 P/S/V (Possi- 1, 2 Operation, Blade 1, eration, Assist 1, 2 P/S/V Release
ble to display by built-in diagnosing 2/Outrigger 1, 2 P/S/V (Possi- (Possible to display by built-in Monitor voltage and pressure
system) ble to display by built-in diag- diagnosing system) change while operating lever.
Monitor voltage and pressure nosing system) Monitor voltage and pressure
changes while operating lever. Monitor voltage and pressure changes while operating lever.
changes while operating lever.
- - - -
- - - -
- - - -
T2-2 T2-2 T2-2 T2-2
T5-7-9
Parts Auxiliary Flow Rate Control Auxiliary Flow Combiner Selector Valve Control
Item Solenoid Valve (Optional) Solenoid Valve (Optional) Solenoid Valve (Optional)
• Restricts flow rate to auxiliary • Activates during auxiliary op- • Activates when attachment
spool during combined operation and shifts spool in “selector valve returning to
eration and improves oper- auxiliary flow combining hydraulic oil tank” is selected
ability. valve. and shifts selector valve
spool.
Function
• Ifauxiliary flow rate control • If auxiliary flow combiner so- • If selector valve control so-
solenoid valve is not acti- lenoid valve is not activated, lenoid valve is not activated,
Symptoms in control vated, pressure at output port pressure at output port be- pressure at output port be-
system when trouble becomes 0 MPa (0 kgf/cm2). comes 0 MPa (0 kgf/cm2) comes 0 MPa (0 kgf/cm2)
when operating attachment. when attachment “selector
occurs. valve returning to hydraulic
oil tank” is selected.
Abnormal low current: • Speed does not increase • Breaker stroke becomes few.
• If valve is bound fully open, during single operation of at-
boom does not raise during tachment.
3-combined operation of
boom raise.
Abnormal high current:
• If valve is bound fully closed,
attachment speed becomes
slow during single operation.
Symptoms in machine
occurs.
By Fault Code - - -
By Monitor
- - -
Evalua- Function
tion Using Test
- - -
Harness
Others - - -
When pedal is depressed,
pressure in the right piping hose
NOTE - - occurs.

Section in T/M)
T5-7-10
Secondary Pilot Relief Pressure Hydraulic Oil Travel Speed

Travel N Sensor
Control Solenoid Valve (Optional) Temperature Sensor Mode Switch
• Activates when attachment • Detects travel motor speed • Monitors hydraulic oil tem- • Shifts fast/slow speed selec-
“secondary pilot relief pres- and sends a signal to speed perature in order to control tion solenoid valve by shifting
sure ON” is selected and display meter. auto-warming up and arm travel speed mode switch
shifts secondary pilot relief • Travel motor speed is de- regenerative controls. (Fast/Slow) in order to control
pressure control valve spool. tected to activate the super- travel speed mode selection
fine travel speed, to prevent control.
travel motor from excessive
rotation, and/or to restrict
forward/reverse shifting.
• If secondary pilot relief pres- • Speed display meter does not • If circuit breakage occurs, • When open or shorted circuit
sure control solenoid valve is operate. system operates as if hydrau- occurs in switch, fast/slow
not activated, pressure at • Travel speed, travel motor lic oil temperature is 120 °C speed selection solenoid
output port becomes 0 MPa excessive rotation, and/or the (Dr. ZX or monitor will not in- valve is held in either fast or
(0 kgf/cm2) when attachment forward/reverse shifting re- dicate 120 °C in diagnosis slow position.
“secondary pilot relief pres- striction control is inoperable. operation).
sure ON” is selected.
• Relief set pressure in auxiliary • Speed display meter does not • Although oil temperature is • Although travel speed mode
circuit does not decrease. operate. lower than 0 °C, switch is in fast position,
• When descending a slope, auto-warming up control does travel speed dose not change
engine speed is not reduced. not operate so that engine into Fast.
runs at idle speed when en- • Although travel speed mode
gine is started. switch is in slow position,
• When hydraulic oil tempera- travel speed dose not change
ture is lower than 10 °C, arm into Slow.
regenerative control is inop-
erable.
- - 11901 -
Monitor Item: Vehicle Speed Monitor Item: Hydraulic Oil Monitor Item: Transmission H/L
(Possible to display by built-in Temperature (HOT) SW
-
diagnosing system) (Possible to display by built-in
diagnosing system)
- - - -
- - - -
• If temperature is extremely
low (below -20°C), control
- - system is in-operable. -
T2-2 T2-2 T2-2 T2-2
T5-7-11
Parts Engine Speed Control

Item FNR Switch Brake Switch
Mode Selection Switch
• Shifts travel forward/reverse • Shifts engine speed control • Shifts parking brake, axle
Pi cut-off solenoid valve by mode by operating switch in lock, auto axle lock and
shifting FNR switch in order order to control engine con- OFF operating brake switch.
to control travel for- trol dial, accelerator pedal
Function ward/reverse selection limit and travel creeper speed
and travel pilot pressure controls.
controls.
• When open or shorted cir- • Depending on failure of • Depending on failure of
cuit occurs in switch, FNR switch, engine control mode switch, brake mode is held
Symptoms in control switch is held in N position. is held. (Engine control dial, (parking brake, axle lock,
system when trouble pedal and creeper modes) auto axle lock and OFF)
occurs.
• Although FNR switch is in N • Although engine speed • Although parking brake po-
position, indicator (N) on control mode selection sition is selected, the park-
steering column monitor switch is turned to pedal ing brake is not operable.
does not light. mode, engine speed cannot • Although axle lock position
• Although FNR switch is in F be controlled by accelerator is selected, axle cylinder is
or R position, machine does pedal. not locked.
not travel. • Although engine speed • Although machine travels in
• Although FNR switch is in R control mode selection auto axle lock position, axle
position, back light does not switch is turned to creeper lock cylinder is not released.
Symptoms in machine light. mode, travel creeper speed • Although OFF position is
operation when trouble mode is not operable. selected, either parking
brake or axle lock is oper-
occurs. able.
By Fault Code - - -
Monitor Item: Slight Travel SW, Monitor Item: Parking Brake Monitor Item: Transmission
By Monitor Pedal EC SW SW, Axle Lock Control State H/L SW
Evalua- Function
tion
By Using Test
- - -
Harness
Others - - -
NOTE - - -
T2-2 T2-2 T2-2

Section in T/M)
T5-7-12
Power Mode Switch Power Mode Switch

MC Auto-Idle Switch
(HP Mode) (E Mode)
• Controls engine, pump and • Activates auto-idle control. • Activates HP mode. • Selects E mode.
valve operation. ON: 0 V → Auto-idle is operable. ON: 0 V → HP mode control ON: 0 V → E mode
OFF: 5 V → Inoperable. OFF: 5 V → Normal OFF: 5 V → Normal
• Depending on trouble situa- • As below • As below • As below

tions, control system mal-
function may differ. (The fol-
lowing symptoms in machine
operation indicates that MC
logic circuit has failed.)
• Although engine starts, speed Open circuit: Open circuit: Open circuit:
stays slow. • Auto-idle is inoperable. • Although HP mode is se- • Even if E mode is selected,
• As pump displacement is held Shorted circuit: lected, HP mode is inoper- engine speed doesn’t de-
at minimum, all actuator • Although auto-idle switch is able. crease.
speeds are slow. OFF, auto-idle control is al- Shorted Circuit: Shorted Circuit:
ways done. • Although HP mode switch is • Engine speed does not in-
turned OFF, HP mode is not crease to the maximum.
deactivated. Attachment Auto-idle control is inoper-
speed increase control (op- able.
tional) becomes inoperable.
11000, 11001, 11002. Other fault

codes may be displayed. - - -
Monitor Item: Auto-Idle SW Monitor Item: HP Mode SW Monitor Item: E/P SW
-
- - - -
- - - -
• Before suspecting a failure in
MC, be sure to check fuses in
control system. If any sensor - - -
in 5 V system is shorted, fault
code11003 will be displayed.
T2-1 T2-2 T2-2 T2-2
T5-7-13
Parts Work Brake Release Outrigger Selection Pilot Shout-Off

Item Switch Switch
• Release work brake and • Shifts blade/outrigger main • Activates pilot shut-off sole-
makes machine travel in order relay 1 and pilot shut-off so- noid valve.(Turns pilot shut-off
to control work brake control. lenoid valve by shifting switch relay ON.)
Function in order to control ON: Pump control (positive con-
blade/outrigger, pilot cut-off trol) of pumps 1, 2 is activated.
controls. OFF: Minimum pump flow rate
• No signals arrive to MC. • Depending on failure of • As below

switch, each mode (OFF, pilot
Symptoms in control cut-off, ON) is held.
system when trouble
occurs.
• Although brake pedal is de- • When outrigger selection Open circuit:

pressed during work brake switch is turned to OFF or pi- • Pilot shout-off switch is al-
operation, work brake is not lot cut-off position, and when ways OFF.
released. lever is operated, • Pilot shut-off solenoid valve is
blade/outrigger is activated. not shifted.
• When outrigger selection • Although lever is operated
switch is turned to pilot cut-off with pilot shut-off lever in
position, and when lever is UNLOCK position, all actuator
operated, front attachment or are not operated.
Symptoms in machine blade/outrigger is activated. Short Circuit:
operation when trouble • When outrigger selection • Pilot shout-off switch is al-
switch is turned to ON posi- ways ON.
occurs. tion, blade/outrigger is not ac- • Engine does not start.
tivated. • If shorted circuit occurs while
starting engine, operate lever
with pilot shut-off lever in
LOCK position so actuator is
operated.
By Fault
- - -
Code
By Monitor Monitor Item: Electric Lever Pilot Monitor Item: Gate Lock Signal Monitor Item: E/P SW
Evalua- Cut
tion Function
Using Test - - -
Harness
Others - - -
NOTE - - -
T2-2 T2-2 T2-5

Section in T/M)
T5-7-14
Bucket Flow Rate Boom Flow Rate Auxiliary Flow Rate

Control Valve Control Valve Boom Regenerative Valve
Control Valve
• Restricts oil flow raise to • Is shifted by pilot pressure • Is shifted by pilot pressure • Prevents boom cylinder hesi-
bucket during 3-combined from boom lower meter-in cut from auxiliary flow rate con- tation by routing return oil
operation of bucket, arm valve. trol solenoid valve. from boom cylinder bottom
roll-in and boom raise and • Limits flow rate to boom 1 side to rod side.
makes boom raise. spool during combined
operation and improves
combined operation.
• If switch valve is bound with • As below • If spool is bound or spring is • As below
valve activated, bucket circuit broken, orifice does not
is always restricted. change.
• If poppet valve is bound at • If valve is fully opened, boom • If valve is bound at fully • If check valve is kept closed,
fully closed position or if lower speed is fast during closed position, attachment boom is not smoothly low-
switch valve is bound when combined operation. speed becomes slow. ered.
poppet valve is fully closed, • If valve is fully closed, • If valve is bound at fully • If check valve is kept open,
bucket speed becomes slow. machine cannot be raised off opened position, boom does machine cannot be raised off
• If poppet valve is bound at ground. not raise during 3-combined ground.
fully opened position or if operation of swing, arm roll-in
switch valve is bound when and boom raise.
poppet valve is fully opened,
boom does not raise during
3-combined operation of
bucket, arm roll-in and boom
raise.
- - - -
- - - -
- - - -
- - - -
- - - -
T3-3 T3-3 T3-3 T3-3
T5-7-15
Parts Bucket Regenerative

Arm Regenerative Valve Arm Anti-Drift Valve
Item Valve
• Is shifted by pilot pressure • Prevents bucket cylinder • Check valve in arm roll-in re-
from solenoid valve unit (SC). hesitation by routing return oil turn circuit is forcibly opened
• Increases arm speed by from bucket cylinder rod side and arm move only when arm
routing return oil from arm to bottom side. is rolled in. Prevents arm from
Function cylinder rod side to bottom drifting due to oil leaks in
side. control valve.
• Arm regenerative function is • As below • If switch valve is bound,

inoperable. check valve does not open.
Symptoms in control
system when trouble
occurs.
• Arm speed is extremely slow • If check valve is kept closed, • If check valve is kept closed,
during arm level crowding bucket is not smoothly rolled arm roll-in speed becomes
operation while arm regen- in. slow.
erative valve is kept closed. • If check valve is kept open, • If check valve is kept open,
• The lever operated first is bucket power is weak. front attachment drift in-
given priority during com- creases due to oil leaks in
bined operation of arm roll-in control valve.
and swing while arm regen- • Arm moves jerky or arm
erative valve is kept open. speed becomes slow de-
Symptoms in machine pending on valve bound con-
operation when trouble ditions.
occurs.
By Fault
- - -
Code
Evalua- By Monitor - - -
tion Function
Using Test - - -
Harness
Others - - -
NOTE - - -
T3-3 T3-3 T3-3

Section in T/M)
T5-7-16
Auxiliary Flow Pump 1 Flow Rate

Boom Anti-Drift Valve Combiner Valve Bypass Shut-Out Valve Control Valve
• Check valve in boom lower • Is shifted by pilot pressure from • Supplies pressure oil from • Supplies flow rate control
return circuit is forcibly auxiliary flow combiner pump 1 to auxiliary spool pressure Pi to pump 1 regulator
opened and makes boom solenoid valve when and positioning control in response to lever stroke
move only when boom is attachment mode (secondary valve when auxiliary or po- when boom (raise/lower), arm
lowered. Prevents boom pulverizer, hydraulic crusher) of sitioning is operated. (roll-out/in), bucket (roll-out/in),
from drifting due to oil leaks travel speed “ON” is selected. travel, auxiliary or positioning is
in control valve. • Supplies pressure oil from operated.
pump 1 to auxiliary spool.
• If switch valve is bound, • As below • As below • As below
check valve does not open.
• If check valve is kept closed, • If switch valve is kept closed, • If spool is bound at fully • If spool is bound in fully open
boom does not lower. attachment speed does not open position, single at- position, although control lever
• If check valve is kept open, become fast during single tachment operation speed is in neutral, pump 1 swash
front attachment drift in- auxiliary operation. becomes slow. angle is tilted to maximum.
creases due to oil leaks in • If switch valve is kept open, • If spool is bound at fully • If spool is bound in fully open
control valve. attachment speed does not closed position, main relief position, pump 1 control pres-
• Boom moves jerky or arm become slow when attachment valve continues to relieve sure sensor monitors maximum
speed becomes slow de- mode (HSB breaker, NPK with all control levers posi- pressure.
pending on valve bound breaker) of travel speed “OFF” tioned in neutral. • If spool is bound in fully closed
conditions. is selected. • When all control levers are position, although control lever
in neutral, pump 1 pressure is operated, pump 1 swash
is higher than pump 2 pres- angle is held to minimum.
sure according to bound (Bucket speed is very slow.)
spool conditions. • If spool is bound in fully open
position, pump 1 control pres-
sure sensor can not monitor
the pump control pressure.
- - - -
- - - -
- - - -
- - - -
- - - -
T3-3 T3-3 T3-3 T3-9
T5-7-17
Parts Pump 2 Flow Rate Swing Parking Brake Bucket Flow Rate Control
Item Control Valve Release Spool Valve Control Spool
• Supplies flow rate control • Is shifted by boom, arm, • Is shifted by arm roll-in pilot
pressure Pi to pump 2 regula- bucket, swing, auxiliary or pressure. Supplies boom raise
tor in response to lever stroke blade/outrigger pilot pressure. pilot pressure to bucket flow
Function when boom (raise), arm Supplies swing parking brake rate control valve.
(roll-out/in), swing (right/left), release pressure.
auxiliary or blade/outrigger is
operated.
• As below • As below • As below
Symptoms in control sys-
tem when trouble
occurs.
• If spool is bound in fully open • If spool is bound in fully open • If spool is bound in fully open
position, although control lever position, swing parking brake is position, bucket speed
is in neutral, pump 2 swash kept released. (Machine becomes slow when combined
angle is tilted to maximum. vibrates while traveling.) operation of boom raise and
• If spool is bound in fully open • If spool is bound in fully open bucket is made. (Bucket flow
position, pump 2 control position, pressure sensor (front rate control is inoperable.)
pressure sensor monitors attachment) is always ON. • If spool is bound in fully closed
maximum pressure. Thus, engine speed does not position, boom does not raise
• If spool is bound in fully closed decrease when control lever is during 3-combined operation of
Symptoms in machine position, although control lever in neutral during auto-idle bucket, arm roll-in and boom
operation when trouble is operated, pump 2 swash control. raise.
occurs. angle is held to minimum. • If spool is bound in fully closed
(Swing speed is very slow.) position, swing parking brake is
• If spool is bound in fully open kept applied. (Dragging is felt.)
position, pump 2 control pres- • If spool is bound in fully closed
sure sensor can not monitor position, pressure sensor (front
pump control pressure. attachment) is always OFF.
Thus, engine speed does not
increase when control lever is
operated during auto-idle con-
trol.
By Fault
- - -
Code
Evalua- By Monitor - - -
tion Function
By Using Test - - -
Harness
Others - - -
NOTE - - -
T3-9 T3-9 T3-9

Section in T/M)
T5-7-18
Accumulator Transmission Control

Steering Valve Brake Valve
Charging Valve Solenoid Valve
• Supplies pressure oil from • Supplies pressure oil to • Charges pressure oil into • Shifts parking brake and
steering pump to steering front/rear axle brakes in accumulator provided in fast/slow in transmission.
cylinder in proportion to proportion to brake pedal brake circuit. Holds charged
steering wheel rotation. depression. pressure oil for set period of
time.
• Pressure oil is not supplied to • As below • Pressure oil is not charged • As below
steering cylinder in proportion into accumulator.
to steering wheel rotation. • Brake circuit oil pressure
However, steering valve acts stays low.
as a pump, steering cylinder
can be operated.
• Turning force of steering • Although brake pedal is • Service brake is not operable. • If fast/slow speed selection
wheel increases. depressed, brake is not • Service brake does not work solenoid valve is bound in
applied. effectively. neutral, parking brake is kept
• Although brake pedal is not applied although shift switch
operated, brake is applied. is operated.
• If fast/slow speed selection
solenoid valve is bound, Hi/Lo
shifting of transmission is not
achieved although travel
mode switch is operated.
- - - -
- - - -
- - - -
- - - -
- - - -
T3-10 T3-11 T2-4, T3-12 T2-2, T3-13
T5-7-19
Parts Blade/Outrigger Cylinder Travel Forward Pi Cut Travel Reverse Pi Cut

Item Solenoid Valve Solenoid Valve Solenoid Valve
• Releases operate check • Cut travel forward pilot • Cut travel reverse pilot
valve provided in pressure and prevents pressure and prevents
blade/outrigger cylinder. machine from traveling machine from traveling
forward when FNR switch is reverse when FNR switch is
Function in N or R position in order to in N or F position in order to
control forward/reverse control forward/reverse
selection limit and travel selection limit and travel
pilot pressure cut-off pilot pressure cut-off
controls. controls.
• When solenoid valve is • As below • As below
bound, operate check valve
does not open or close.
Symptoms in control system
when trouble occurs.
• Although blade/outrigger • If valve is closed: • If valve is closed:

lever or blade/outrigger Although FNR switch is in N Although FNR switch is in N
switch is operated, position, machine travels position, machine travels
blade/outrigger cylinder is forward. reverse.
not operated. • If valve is open: • If valve is open:
Although FNR switch is in F Although FNR switch is in R
position, machine does not position, machine does not
travel forward. travel reverse.
Symptoms in machine
occurs.
By Fault Code - - -
By Monitor - - -
Function
Evaluation
By Using Test - - -
Harness
Others - - -
NOTE - - -
Descriptions of Control T2-2, T3-12 T2-2 T2-2

Section in T/M)
T5-7-20
Secondary Pilot Relief Pressure

Selector Valve (Optional)
Control Valve (Optional)
• Is shifted by pilotpressure from selector • Is shifted by pilot pressure from
valve control solenoid valve. secondary pilot relief pressure control
solenoid valve.
• If spool is bound or spring is broken, • If spool is bound or spring is broken, relief

pressure oil from breaker does not return circuit in breaker is blocked.
to hydraulic oil tank.
• Breaker stroke becomes few. • Reliefset pressure in auxiliary circuit

does not decrease.
- -
- -
- -
- -
- -
T2-2 T2-2
T5-7-21
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine

troubles and parts contributing to the cause of the
trouble if failed.
Engine System Troubleshooting

Trouble Symptom E-1 E-2 E-3
Starter does not rotate. Although starter rotates, When engine control dial is
Part engine does not start. fully rotated, engine stalls.
When engine control dial is
fully rotated, engine speed is
slow.
MC z z
ECM { z
ICF {
Monitor Unit z {
Pump 1 Delivery Pressure Sensor
Pump 1 Control Pressure Sensor
Pressure Sensor (Front Attachment)
Pressure Sensor (Swing)
Pressure Sensor (Boom Raise)
Pressure Sensor (Arm Roll-In)
Hydraulic Oil Temperature Sensor
Key Switch z
Engine Control Dial
Auto-Idle Switch
Power Mode Switch
Starter Cut Relay z
ECM Main Relay
Battery Relay z
Glow Plug Relay
Engine Electrical Equipment
Engine Unit z z
Pump Regulator
Swing Parking Brake
Release Spool (Signal Control Valve)
Check batteries.
Remark
T5-7-22
NOTE: The trouble symptoms in this table are In case more than one trouble occurs at the
described provided that each trouble same time, find out all faulty components
occurs independently. while checking all suspected components
in each trouble symptom.
E-4 E-5 E-6 E-7

Although engine control dial is Engine speed does not Faulty HP mode. Although key switch is turned
rotated, engine speed does not increase when engine starts. OFF, engine does not stop.
changed.
z z z {
z z { z
z
z
z
z
z {
z
z : Related, required to check

{ : Related. However, in case this component fails, other trouble
symptom will be more noticeable so that this component will not
be the direct cause of the trouble concerned.
T5-7-23
E-8 E-9 E-10

Trouble Symptom
Faulty auto-idle. Faulty E mode. When traveling or operating
front attachment at slow
idle, engine hunts.
Part
MC z z z
ECM { { {
ICF
Monitor Unit
Pump 1 Delivery Pressure Sensor z
Pump 2 Delivery Pressure Sensor z
Pump 1 Control Pressure Sensor z
Pump 2 Control Pressure Sensor z
Pressure Sensor (Travel) {
Pressure Sensor (Front Attachment) {
Key Switch
Engine Control Dial
Auto-Idle Switch z
Power Mode Switch z
Torque Control Solenoid Valve {
Starter Cut Relay
ECM Main Relay
Battery Relay
Glow Plug Relay
Engine Unit z
Pump Regulator
Swing Parking Brake
Release Spool (Signal Control Valve)
z
Remark
T5-7-24
E-11 E-12 E-13 E-14

Although operating attachment When attachment mode is Engine stalls during operation Engine is difficult to start at low
at attachment mode, engine selected, engine speed does not under adverse condition such as temperature.
speed does not increase. decrease. at high altitude.
z z z
{ { z z
{ {
z
{ z
{ z
z
Check batteries.

T5-7-25
E-15 E-16
Trouble Symptom
Although depressing Although depressing
accelerator pedal during accelerator pedal during
travel operation, engine digging operation,
speed does not change. engine speed does not
Part change.
MC (Main Controller) z z
ECM
Pressure Sensor (Travel Forward) { {
Pressure Sensor (Travel Reverse) {
Pressure Sensor (Front Attachment)
Travel N Sensor {
Auto-Idle Switch
Power Mode Switch
Brake Switch z z
FNR Switch z z
Travel Speed Mode Switch {
Engine Speed Control Mode Selection
Switch
z z
Battery Relay
Glow Plug Relay
Engine Unit
Pump Regulator
Remark
T5-7-26
(Blank)
T5-7-27
All Actuator System Troubleshooting

A-1 A-2 A-3
Trouble Symptom
All actuator speeds are slow. All actuators are not Single swing operation
operated. speed becomes slow. Arm
speed is slightly slow during
arm level crowding.
Part
MC z
ECM {
Monitor Unit {
Torque Control Solenoid Valve z
Pilot Shut-Off Solenoid Valve z
Pilot Shut-Off Lever z
Pilot Shut-Off Relay z
Security Relay z
Spool
Main Relief Valve {
Arm 1 Flow Rate Control Valve
Main Pump z z
Regulator { z
Pilot Pump z
Pilot Valve
Pilot Relief Valve z
Pump 1 Flow Rate Control Valve
(Signal Control Valve)
z
Control Spool (Signal Control Valve)
Remark
T5-7-28
A-4 A-5 A-6

Travel is not operated during Although control lever is turned Actuator speed is faster than
single travel operation. Single to neutral, actuator does not normal.
bucket operation speed stop. Precise control cannot be
becomes slow. Boom is not performed.
raised properly during arm level
crowding.
z
z z
z z

T5-7-29
Front Attachment System Troubleshooting

F-1 F-2 F-3 F-4
Trouble Symptom
All front attachment Some cylinder are Arm speed is slow Bucket is slightly
actuator operations not operated or during combined slow during bucket
are weak. speeds are slow. operation. During roll-in single
combined operation operation.
of boom raise and Bucket does not
arm roll-in, boom move smoothly
raise speed is slow. during bucket roll-in
Arm speed is slow single operation.
during arm level
Part crowding.
MC z
Solenoid Valve Unit (SF)
Solenoid Valve Unit (SC) z
Pump 1 Delivery Pressure Sensor {
Pump 2 Delivery Pressure Sensor {
Pressure Sensor (Swing) {
Pressure Sensor (Boom Raise) {
Pressure Sensor (Arm Roll-In) {
Power Digging Switch
Spool z
Main Relief Valve z
Overload Relief Valve z
Load Check Valve
Boom Regenerative Valve
Arm Regenerative Valve z
Bucket Regenerative Valve z
Boom Flow Rate Control Valve
Bucket Flow Rate Control Valve z
Boom Anti-Drift Valve
Arm Anti-Drift Valve
Emergency Valve
Shockless Valve
(Signal Control Valve) z {
Shuttle Valve
(Signal Control Valve) z z
Bucket Flow Rate Control Valve Control
Spool (Signal Control Valve)
Pilot Valve z
Cylinder
Remark
T5-7-30
F-5 F-6 F-7 F-8

When starting to move When starting to move When boom raise or Front attachment drifts
during combined during combined arm roll-out is remarkably.
operation, arm does operation, boom does operated, boom or arm
not smoothly move. not smoothly move. starts to move after
Arm starts to move Boom starts to move slightly moving
slightly slow during arm slightly slow during downward.
roll-in single operation. boom lower single
These troubles often operation.
occur when
temperature is low.
z
z
z
z
z z z
z z z
{

T5-7-31
Front Attachment System Troubleshooting

F-12 F-13 F-14
Trouble Symptom
Attachment speed is Attachment speed is Attachment speed is
fast during combined fast during combined fast during combined
operation of attachment operation of attachment operation of attachment
(optional) and front (optional) and front (optional) and front
attachment (when attachment (when attachment (when
pulverizer or crusher is breaker attached with vibrating hammer is
Part used). auxiliary flow combiner used).
line is used).
MC z z z
Auxiliary Flow Rate Control Solenoid Valve z
Auxiliary Flow Combiner Solenoid Valve z
Maximum Pump 1 Flow Rate Limit Control Solenoid z
Pressure Sensor (Auxiliary) z z z
Pressure Sensor (Travel Forward) z
Pressure Sensor (Travel Reverse) z
Pressure Sensor (Arm Roll-Out) z z
Auxiliary Flow Rate Control Valve z
Auxiliary Flow Combiner Valve z
Remark

NOTE: The trouble symptoms in this table are

described provided that each trouble
occurs independently.
In case more than one trouble occurs at the
same time, find out all faulty components
while checking all suspected components
T5-7-32
Swing System Troubleshooting
S-1
Trouble Symptom
Swing is slow or unmoving.
Part
MC (Main Controller)
Solenoid Valve Unit (SC)
Pump Device
Spool
Load Check Valve
Swing Parking Brake Release Spool
z
z
Arm 1 Flow Rate Control Valve Control
Spool (Signal Control Valve)
Shuttle Valve (Signal Control Valve) {
Swing Device z
Travel Device
Center Joint
Pilot Valve z
Remark

T5-7-33
Travel System Troubleshooting

T-1 T-2 T-3 T-4
Trouble Symptom
Machine does not Machine does not Forward/reverse When releasing
travel. travel forward or travel speeds are accelerator pedal,
reverse. slow. Travel power is hydraulic brake is not
weak. applied.
Part (Macnine runs away.)
MC z z z z
Monitor Unit
Main Pump {
Regulator {
Solenoid Valve Unit (SF) z
z z
Travel Mode Selector Solenoid
Valve
z z
Fast Speed Selection Relay
Slow Speed Selection Relay
FNR Switch { z
Travel Speed Mode Switch {
Brake Switch {
Engine Speed Control Mode
Selection Switch
z
Work Brake Release Switch z
Brake Pressure Sensor
Brake Remaining Pressure Sensor
Travel N Sensor {
Control Valve z z z z
Travel Shockless Valve z z
Accumulator Charging Valve
Brake Valve
Transmission z {
Front Axle z {
Rear Axle z {
Travel Motor z z z z
Center Joint z z
Pilot Valve z
Axle Lock Cylinder
Operate Check Valve (Axle Lock
Cylinder)
Remark
T5-7-34
T-5 T-6 T-7

Travel mode (fast/slow) Axle lock is not Axle lock is not
does not shift. released. operable.
z z z
z z
z
z
z
{
z
z z
{ {
z z

{ : Related. However, in case this component fails, other trouble NOTE: The trouble symptoms in this table are
symptom will be more noticeable so that this component will not described provided that each trouble
be the direct cause of the trouble concerned. occurs independently.
T5-7-35
Brake System Troubleshooting

B-1 B-2 B-3
Trouble Symptom
Parking brake is not operable Service brake is not operable, Work brake is not work
(not applied). or is not applied effectively. operable.
Part
MC z z
ECM {
Monitor Unit
Main Pump
Regulator
Solenoid Valve Unit (SF) z z
Travel Mode Selector Solenoid
Valve
{
FNR Switch {
Travel Speed Mode Switch
Brake Switch z
Engine Speed Control
Mode Selection Switch
Work Brake Release Switch {
Brake Pressure Sensor z
Brake Remaining Pressure Sensor {
Travel N Sensor {
Control Valve
Travel Shockless Valve
Accumulator Charging Valve z
Brake Valve z z
Transmission {
Front Axle z {
Rear Axle z {
Travel Motor
Center Joint
Pilot Valve
Remark

T5-7-36
Steering System / Other System Troubleshooting

H-1 H-2 O-1 O-2
Trouble Symptom
Although steering wheel Although steering wheel Wiper is not operable. Air Conditioner is
is rotated, steering is is rotated, steering is faulty.
heavy. impossible.
Part
Steering Pump z
Steering Valve z z
Center Joint z
Front Axle { {
Other Electrical Equipment z z
Remark

T5-7-37
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter does not rotate.
IMPORTANT: As electric current from the key

switch is not routed to the starter
relay except with the pilot shut-off
lever in the UNLOCK position and
with the brake switch in the P (park-
ing brake) position, the starter does
not rotate. (Refer to the SYSTEM /
Electrical System group.)
YES Faulty starter cut relay.
• This trouble has nothing to do with the electronic
control system such as MC.
• Check the wiring connections first. Switch starter cut relay Disconnect starter cut
YES with other general re- relay.
lay. Check if voltage at
Check if starter rotates. terminals #1 and #3
· Key switch: START NO nector is 24 V.
Check if voltages at · Monitor unit: Primary
YES terminals #5 and #6 in screen · Key switch: START
key switch are 24 V. · Monitor unit: Primary
screen
· Key switch: START
· Monitor unit: Primary Check for continuity YES Faulty key switch.
screen between positive ter-
Check if primary minal in battery and
screen or password NO terminal #1 in key Faulty harness between
input screen is dis- switch. NO battery and key switch.
played on monitor unit.
· Key switch: ON Disconnect connector
YES Faulty monitor unit.
monitor-A in monitor
NOTE: As for the YES unit.
password Check if battery volt- Check if voltage be- Open circuit in harness
setup type age and electrolyte tween terminal #A7 between monitor unit
NO
machine, density are normal, (harness end) of con- and key switch.
NO
and fusible link (45 A) nector and machine is
the pass- is not blown. 24 V or more.
word input
· Voltage: 24 V or more · Key switch: ON
screen is Density: 1.26 or more Faulty battery.
displayed. NO Faulty fusible link.
Key Switch:
Battery Relay:
Terminal A
T105-07-04-002
T178-05-04-001
T5-7-38
Faulty starter, or faulty

YES harness between starter
and battery relay.
YES Check if voltage at
terminal A in battery
relay is 24 V.
Check if voltage at Faulty battery relay.
YES terminal #2 (harness NO
end) of connector in
Disconnect connector starter cut relay is 0
of starter relay 2. V.
Connect terminal S Shorted circuit in harness
(harness end) of con- between starter cut relay
YES nector to machine. NO and emergency stop
Check for continuity switch.
between terminal #4
nector in starter cut
relay and machine. Open circuit in harness
between starter cut relay
NO and starter relay.

between key switch and
NO starter cut relay.

open end side)
Monitor Unit Starter Cut Relay Starter Relay

Connector Monitor-A
#A7
E
S R
T183-05-05-001 T183-05-04-003
T5-7-39
E-2 Although starter rotates, engine does not
start.
YES Faulty ECM main relay.
Connect terminal #1
(harness end) of
connector in ECM
Switch ECM main main relay to ma-
relay with other gen- Connect terminal #5 YES
chine.
eral relay. (harness end) of con- Check for continuity
Check if engine nector in ECM main re- between terminals
starts. lay to machine. #21, #40 (harness
YES Disconnect connector in end) of connector in
ECM. ECM and machine.
Disconnect ECM main Check for continuity
relay from connector. between terminals #2,
Check if voltage be- #5 (harness end) of Open circuit in harness
connector and machine. between ECM main relay
NO tween terminal #3 NO and ECM.
nector and machine is
specification. Open circuit in harness
· Specification: 24V between key switch and
NO
ECM main relay.
· Check if fuse #8 is
blown.

open end side)
ECM Main Relay ECM Connector #21 #24 #5
T183-05-04-003
T1GR-05-04-002
#40 #2
T5-7-40
Disconnect con- YES Open circuit in harness

nector ICF-C in between key switch and
ICF. Check if monitor unit.
YES voltage between
terminal #C7 Check if fuse #18 is blown.
Disconnect
(harness end) of
connector MC-B
connector and Open circuit in harness
in MC.
machine is speci- between key switch and
YES Check if voltage
fication. NO ICF.
between terminal
#B16 (harness · Key switch: ON Check if fuse #18 is blown.
end) of connec- · Specification: 24
tor and machine V
Check if voltage Open circuit in harness
YES between terminal is specification.
between key switch and
#24 (harness · Key switch: ON NO
MC.
Check for conti- end) of connector · Specification: 24
nuity between in ECM and ma- V Check if fuse #18 is blown.
YES terminal #2 (har- chine is specifica-
ness end) of con- tion.
nector in ECM Open circuit in harness
· Key switch: ON
main relay and between key switch and
· Specification: 24 NO
machine. ECM.
V
Check if fuse #18 is blown.
Faulty ground in ECM

NO main relay.

between ECM main relay
NO and ECM.
Connector MC-B Connector ICF-C

#B16
B1 B8
T1V1-05-04-002
#C7
B19 B25
T5-7-41
E-3 When engine control dial is fully rotated, en-
gine stalls.
When engine control dial is fully rotated, en-
gine speed is slow.
Related MC Fault Code: 11003-3, 11004-2
YES Faulty MC, or faulty CAN

between MC and ECM.
Check if fault code is
displayed.
· MC or ECM cannot Refer to Engine Trouble-
be selected on con- NO shooting Manual.
troller diagnosing by
using Dr. ZX.
T5-7-42
E-4 Although engine control dial is rotated, en-
gine speed does not change.
Related MC Fault Code: 11004-2, 11101-3, 11101-4
Faulty engine control dial,

YES or open circuit in harness
between engine control
dial and MC.
Check if fault code 11101-3 or
11101-4 is displayed. Monitor
engine control standard volt-
age (dial angle) by using Dr.
YES Faulty CAN between MC
ZX.
and ECM.
Check if voltage is normal.
· Standard voltage Check if fault code 11004-2 is
Slow idle position: 0.3 to 1 V NO displayed at the same time.
Fast idle position: 4.0 to 4.7 V
· Possible to display by built-in · Possible to display on MC
diagnosing system. monitor by using Dr. ZX.
Faulty MC.
NO
T5-7-43
E-5 Engine speed does not increase when en-
gine starts.
• Refer to the pages for the Auto Warming Up Con-

trol in the SYSTEM / Control System group in the
T/M (Operational Principle).
0 °C or higher
when starting Normal.
NO Monitor oil temperature. Faulty key switch, or

YES open circuit in harness
· Monitor item: Hydraulic between key switch and
Monitor key switch. MC.
oil temperature Check if displayed “ky”
· Possible to display by is highlighted in re-
Check if fault code built-in diagnosing sys- 0 °C or lower sponse to key switch
11901-3 or 11901-4 tem. when starting operation.
is displayed. To A
NO
· Monitor item: Key switch
Faulty hyd. oil tempera-

ture sensor, or open cir-
YES cuit in harness between
hyd. oil temperature
sensor and MC.
NO Faulty MC.
Check if fault code

A 11004-2 is dis-
played at the same
time.
Refer to fault code 11004

YES in Troubleshooting A.
T5-7-44
(Blank)
T5-7-45
E-6 Faulty HP mode
• Even if power mode switch is turned to the HP

mode position, HP mode is not operated. (General
mode normally operates.)
Related MC Fault Codes: 11004-2, 11200-3,

11200-4, 11202-3, 11202-4, 11302-3, 11302-4,
11303-3, 11303-4
• The sensors detect the conditions necessary to • Refer to the pages for HP Mode Control in the
operate HP mode. Therefore, if any of these sen- SYSTEM / Control System group in the T/M (Op-
sors fails, HP mode becomes ineffective. erational Principle).
• Pressure sensors (arm roll-in and boom raise) • Check the wiring connections first.
and pump 1 and 2 delivery pressure sensors are
also engaged in the HP mode control. However, if
these sensors fail, other operating functions will
be also affected.
Faulty power mode

NO switch or open circuit in
harness between power
mode switch and MC.
Monitor power mode

switch.
NO Check if indication is
changed when power
mode switch is turned
to HP mode.
Faulty MC.
· Monitor item: HP mode YES
SW
· Possible to display by
Check if fault code is built-in diagnosing
displayed. system. Faulty corresponding
NO sensor, or open circuit in
harness between MC and
sensor.
Check if fault code

11004-2 is displayed at
YES the same time.

T5-7-46
• Although the power mode switch is not turned to HP
mode, HP mode is operated.
• Boom raise and arm roll-in must be operated

when the average delivery pressures of pump 1
and 2 are high, if HP mode control is performed.
The sensors related to this condition may not be
faulty at the same time.
Shorted circuit in harness

YES between MC and power
mode switch.
Monitor power mode

switch.
Check if “HP” is dis- YES Faulty ECM.
played.
· Monitor item: HP
mode SW Check if fault code
· Possible to display by NO 11004-2 is displayed.
built-in diagnosing
system.
· Power mode switch: Faulty MC.
P mode
NO
T5-7-47
E-7 Although key switch is turned OFF, engine
does not stop. (If the engine does not stop,
stop engine by turning the emergency stop
switch ON located under the seat stand.
Then, begin inspection.)
• Probably the symptoms such as “Engine speed is

slower than specification in all operating ranges”
or “Although engine control dial is rotated, engine
speed does not change” may come up. Perform
troubleshooting for these symptoms.
YES Faulty key switch.
Check if voltage at
terminal #5 in key
switch is 24 V. Shorted circuit in
NO
· Key switch: OFF harness between key
switch and ECM.
in ECM.
tween terminal #24
NO (harness end) of con-
nector and machine is
0 V.
Faulty ECM.
· Key switch: OFF YES
Key Switch
#24
ECM Connector
(Harness end)
T1GR-05-04-002
T105-07-04-002
T5-7-48
(Blank)
T5-7-49
E-8 Faulty auto-idle system
• Although control lever is turned to neutral, auto-idle

is not operated.
Related MC Fault Code: 11004-2, 11304-3, 11304-4,

11307-3, 11307-4
Related ECM Fault Code: 639-2, 639-3
• If trouble symptoms E1 to E8 are recognized, • Refer to the pages for Auto-Idle Control in the
perform the troubleshooting of these troubles SYSTEM / Control System group in the T/M (Op-
first. erational Principle).
• Although failure in pressure sensors (travel for- • Check the wiring connections first.
ward/reverse and front attachment) may have
relevance to malfunction of the auto-idle control.
However, if these sensors fail, other operating
functions will also be affected.
Check if fault code

YES
11004-2 is dis-
played.
Check if fault code
YES for MC or ECM is
displayed.
Monitor auto-idle
switch. Faulty MC.
YES Check if ON/OFF is NO
shifted when
auto-idle switch is
Check if auto-idle is shifted. Open circuit in har-
displayed on monitor ness between
unit. · Monitor item: NO auto-idle switch and
Auto-idle SW MC.
· Auto-idle switch: ON
Disconnect connec-
tor monitor-B in YES Faulty auto-idle
monitor unit. switch.
between terminal
NO #B18 (harness end) Open circuit in har-
of connector and ness between
machine. NO auto-idle switch and
· Auto-idle switch: ON monitor unit.

open end side)
Connector Monitor-B
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
#B18
T5-7-50
Refer to fault code

YES
11004 in Trouble-
shooting A.
Refer to Engine
YES
Troubleshooting
Manual.
Check if fault code
639-2 or 639-3 is
NO displayed. Faulty corresponding
sensor, or open cir-
NO cuit in harness be-
tween MC and sen-
sor.
T5-7-51
• Although auto-idle switch is turned OFF, auto-idle is
operated.
Shorted circuit in
YES harness between MC
MC-B in MC and con- and auto-idle switch.
nector in switch panel.
between terminal #B6 Refer to fault code
(harness end) of con- YES
11004 in Trouble-
nector MC-B and ma- shooting A.
chine. Check if fault code
NO 11004-2 is displayed.
· Auto-idle switch: OFF
Faulty MC.
NO

open end side)
Connector MC-B
#B6
B1 B8
B19 B25
T5-7-52
(Blank)
T5-7-53
E-9 Faulty E mode
• Although power mode switch is turned to the E

mode position, engine speed does not change. (En-
gine speed does not decrease.)

11202-3, 11202-4, 11206-3, 11206-4, 11208-3,
11208-4
• If trouble symptoms E-1 to E-9 are recognized, • Pump 1, 2 control pressure sensors and pump 1,
perform the troubleshooting of these troubles 2 delivery pressure sensors are also engaged in
first. the E mode control. However, if these sensors fail,
• The sensors detect the conditions necessary to other operating functions will be also affected.
operate E mode. Therefore, if any of these sen- • Refer to the pages for E Mode Control in the
sors fails, E mode becomes ineffective. SYSTEM / Control System group in the T/M (Op-
erational Principle).
Faulty power mode

NO switch, or open circuit in
harness between power
mode switch and MC.
Monitor power mode

switch.
When power mode
NO
switch is turned to E
mode, check if indica-
tion is changed.
Faulty MC.
· Monitor item: E/P SW
· Possible to display by YES
built-in diagnosing
Check if fault code is system.
displayed.
Faulty corresponding
NO sensor, or open circuit in
harness between MC and
sensor.
Check if fault code

11004-2 is displayed.
YES

T5-7-54
• Although power mode switch is not turned to E
mode, engine speed decreases.
• Required engine speed from the engine control

-1
dial must be beyond 1800 min when the pump
control pressures of pump 1 and 2 are low or the
average delivery pressures of pump 1 and 2 are
high, if E mode control is performed. The sensors
related to this condition may not be faulty at the
same time.

NO between MC and power mode
switch, or faulty power mode
switch.
Monitor power mode switch.
Check if “E” is displayed. YES Refer to fault code 11004 in
Troubleshooting A.
· Monitor item: E/P SW
· Possible to display by built-in Check if fault code
diagnosing system. YES 11004-2 is displayed.
· Power mode switch: P mode Faulty MC.
NO
T5-7-55
E-10 When traveling or operating front attach-
ment at slow idle, engine hunts.

11307-3, 11307-4
• Although the failure in pressure sensors (travel

forward/reverse and front attachment) may have
relevance to malfunction of idle speed-up control.
However, if these sensors fail, other operating
functions will also be affected. (Refer to the rela-
tionship between machine trouble symptom and
related part on page T5-7-2.)
• Refer to the pages for Idle Speed-Up Control in
the SYSTEM / Control System group in the T/M
(Operational Principle).
YES Faulty engine unit or

faulty ECM.
· Set idle speed increasing
Set engine control dial to Min. in MC by using Dr. ZX.
Check if engine speed is
faster than increased idle YES Refer to fault code 11004
speed. in Troubleshooting A.
· Monitor item:
Check if fault code
Requested engine speed
· Possible to display by built-in
diagnosing system.
Faulty MC.
NO
· Set idle speed increasing
in MC by using Dr. ZX.
T5-7-56
E-11 Although operating attachment at attach-
ment mode, engine speed does not in-
crease.

• Refer to the pages for Attachment Operation
• In case trouble symptoms E-1 to E-11 are recog- Speed Increase Control in the SYSTEM / Control
nized, perform the troubleshooting of these trou- System group in the T/M (Operational Principle).
bles first. • Check the wiring connections first.
• Although the failure in pressure sensor (auxiliary)
and power mode switch may have relevance to
the malfunction of attachment operation speed
increase control. However, if these sensor and
switches fail, other operating functions will also be
affected.
NO Normal (Set to “Increase

(+)”.)
Check if attachment
speed adjustment
NO has been set to “In-
crease (+)” on “Pa- YES
rameter Change” in Monitor attachment To A
Dr. ZX. control pilot pressure.
Check if pressure
Check if attachment YES varies in response to
speed adjustment lever stroke. Faulty auxiliary pressure
has been set to “De-
· Monitor item: ATT NO sensor.
crease (-)” on “Pa-
rameter Change” in control pilot pressure
Dr. ZX.
Normal (If P speed is set

to decrease, this control
YES system is deactivated.)
YES Refer to fault code 11004

in Troubleshooting A.
Fault code 11004-2 or

A 11918-2 is displayed.
Faulty MC.
NO
T5-7-57
E-12 When attachment mode is selected, engine
speed does not decrease.
• If trouble symptoms E-1 to E-11 are recognized,

perform the troubleshooting of these troubles be-
forehand.
• Refer to the pages for Attachment Operation
Speed Limit Control in the SYSTEM / Control
System group in the T/M (Operational Principle).
YES Refer to fault code 11004

in Troubleshooting A.
Check if fault code

YES
11004-2 or 11918-2 is
displayed.
Faulty MC.
Check if attachment NO
speed adjustment has
been set to “Decrease
(-)” on “Parameter
Change” in Dr. ZX.
Normal (Set to “Decrease

NO (-)”.)
T5-7-58
(Blank)
T5-7-59
E-13 Engine stalls during operation under ad- Test Harness (ST 7226)
verse condition such as at high altitude. When operating corresponding control lever and
switch: ON
11401-2, 11401-3, 11401-4
• If speed sensing control is not operated, the en-

4
gine will stall under adverse operating conditions.
3
• Check the wiring connections first. 50
150 50 50
1 2 2 1
T107-07-06-015
YES Faulty torque control

solenoid valve.
Disconnect harness of
Check if fault code torque control sole-
NO
11401-2, 11401-3 or noid valve.
11401-4 is displayed. Monitor torque control NO Connect test harness
solenoid valve output. (ST 7226) between
Install pressure gauge solenoid valve and
to output port so that harness.
pressure is measured Check if test harness
by pressure gauge and lamp lights.
Dr. ZX.
NO
Monitor actual engine Check if both meas-
speed. ured pressure values
Check if engine speed by pressure gauge and
is abnormal. Dr. ZX vary identically. Disassemble and
· Monitor item: Pump YES check regulator.
· Monitor item: torque P/S valve output
Actual engine speed · Refer to the Opera-
· Possible to display by tional Performance
built-in diagnosing sys- Test section.
tem.
YES Refer to fault code
11004 in Trouble-
shooting A.
Check if fault code
11004-2 or 11100-2 is
YES displayed. YES Refer to Engine Trou-
bleshooting Manual.
Check if fault code
Faulty MC.
NO
T5-7-60
YES Faulty torque control so-

lenoid valve.

between torque control
NO solenoid valve and MC.
T5-7-61
E-14 Engine is difficult to start at low tempera-
ture. (During cold weather or in cold dis-
tricts, engine is difficult to start or does not
start even if pre-heated.)
Related MC Fault Code: None
• Check if electricity is routed to the glow plugs. • Check the battery.

Check the glow plugs for any abnormality. • Check the wiring connections first.
• The pre-heat system operates only when coolant
temperature is below 20 °C (68 °F).
YES Faulty sensor.
coolant temperature sensor.
Check if voltage at glow plug YES Faulty ECM.
is 20 to 24 V.
· Key switch: ON Disconnect connector in
ECM. Connect terminal #4
(harness end) of connector
NO to machine. Check if prob-
lem is corrected.
· Connect to machine from Measure each glow plug
the back of connector by NO resistance.
using a clip with the con-
nector connected. · Key switch: OFF
· Before measuring, re-
move copper plates
connecting each glow
plug.
• Measurement of Glow Plug Voltage and Resistance

Voltage Check Resistance Check
Remove
the
copper
plate.
Specification: 20 to 24 V Specification: 10 Ω or less
T105-07-04-006 T105-07-04-007
T5-7-62
∞Ω Faulty glow plug.
NO Faulty glow plug relay, or

faulty harness between
Connect connector in glow plug relay and glow
glow plug relay. Connect plug.
YES terminal #4 (harness end)
of connector to machine.
Check if voltage at glow
plug is 20 to 24 V.
· Key switch: ON
between glow plug relay
YES and ECM.
Disconnect connector in
glow plug relay.
Check if voltages at termi-
10 Ω or less nals #1 and #3 (harness
end) of connector in glow
plug relay are 20 to 24 V.
· Key switch: ON If terminal #1 is 0 V, open
circuit in harness be-
tween glow plug relay
and battery. If terminal #3
is 0 V, open circuit in
NO harness between glow
plug relay and terminal M
in key switch.

blown.
T5-7-63
E-15 Although depressing accelerator pedal
during travel operation, engine speed does Connector (Harness end of connector viewed from the
not change. open end side)
• Check that: Switch Panel

Brake Switch: OFF or Axle Lock Position
●
Engine Speed Control Mode Selection Switch:
Pedal Mode Position
FNR Switch: F or R Position
#1
• Faulty pressure sensor (travel forward/reverse)
may be the cause of this problem. In this case,
other functions should become abnormal.
YES Faulty MC.
YES Monitor FNR (R)

switch. Check if ON
is displayed.
Faulty FNR switch.
· FNR switch: R NO
Check if neutral
indicator on steering Faulty brake switch, or
YES shorted circuit in harness
column monitor
lights. between MC and terminal
Monitor parking #3 in brake switch.
· Key switch: ON YES brake switch. Check
· FNR switch: F or R if ON is displayed.
· Brake switch: Faulty MC.
except P (parking NO
Monitor pedal EC brake)
switch. Check if ON
NO is displayed. Disconnect connec-
YES Faulty engine speed con-
tor in switch panel. trol mode selection switch.
· Engine speed control Check if voltage be-
mode selection switch: tween terminal #1
Pedal (harness end) of
NO connector and ma- Open circuit in harness
chine is 5 V. between MC and engine
NO speed control mode selec-
· Key switch: ON tion switch.
T5-7-64
E-16 Although depressing accelerator pedal
during digging operation, engine speed
does not change. Connector (Harness end of connector viewed from the
open end side)
• Check that:
Switch Panel
Work Brake: Operable
FNR Switch: N Position ●
Engine Speed Control Mode Selection Switch:
Pedal Mode Position
• Faulty pressure sensor (travel forward/reverse) #11
may be the cause of this problem. In this case,
other functions should become abnormal.
NO Faulty FNR switch, or

faulty harness between
MC and FNR switch.
Monitor FNR (F) swit-

ch and FNR (R)
switch. Faulty brake switch, or
Check if OFF is dis-
played. Monitor implement between MC and terminal
YES brake state. #3 in brake switch.
FNR switch: N Check if ON is dis-
played.
Faulty MC.
· Brake switch: NO
Monitor pedal EC
Axle lock or Auto axle
switch.
lock
YES Check if ON is dis-
played. Faulty engine speed con-
Disconnect connec- YES
· Engine speed control tor in switch panel. trol mode selection switch.
mode selection switch: Check if voltage be-
Pedal tween terminal #11
NO (harness end) of
connector and ma- Open circuit in harness
chine is 5V. between MC and engine
NO speed control mode
· Key switch: ON switch.
T5-7-65
ALL ACTUATOR SYSTEM TROUBLE-
SHOOTING
A-1 All actuator speeds are slow.

11401-2, 11401-3, 11401-4
• Reduction in pump 1 and 2 flow rate due to some • Although speed is satisfactory, and when power is
reasons or faulty pilot system (A-2) may cause weak, refer to the troubleshooting for faulty main
this trouble. relief valve (F-1).
• Check fuse of the torque control solenoid valve. • Check the wiring connections first.
Faulty torque control so-

lenoid valve, or open
YES circuit in harness be-
tween MC and torque
Check if fault code

YES 11401-2, 11401-3 or
11401-4 is displayed.
YES Faulty CAN between MC
and ECM, or faulty MC.
NO Check if fault code

Check if primary pilot 11004-2, 11100-2 or
11910-2 is displayed. Faulty pump device.
pressure is normal. NO
· Fully boom raised or fully
arm rolled-in
· Monitor item:
Boom raise pilot pres-
sure, Arm roll-in pilot YES Faulty pilot pump, or
pressure clogged pilot filter.
Adjust, disassemble
and clean pilot relief
valve.
NO Check if same symp-
tom appears.
End.
NO
T5-7-66
A-2 All actuator are not operated.
• The pilot shut-off circuit or the electric lever circuit • When the key switch is turned to the START posi-
may be faulty. tion with the engine stop switch in the ON position,
• If the alarm is displayed on the monitor unit, refer the starter rotates.
to Troubleshooting A. Refer to the pages for the Electrical System group
• When the key switch is turned to the START posi- / SYSTEM in the T/M (Operational Principle).
tion with the pilot shut-off lever in the LOCK posi-
tion, the starter does not rotate.
YES Faulty pilot shut-off relay.
Switch pilot shut-off

YES Faulty security relay.
relay with other gen-
eral relay.
Check if actuator can
be operated.
Connect terminal #2
· Pilot shut-off lever: Switch security relay (harness end) of con-
LOCK position with other general nector in pilot shut-off
relay. solenoid valve to ma-
NO Check if actuator can chine.
YES
be operated. Disconnect connector To A
Disconnect connec- in pilot shut-off relay.
· Pilot shut-off lever: tor in pilot shut-off Check for continuity
LOCK position solenoid valve. between terminal #2
Check if voltage be- (harness end) of con-
NO tween terminal #1 nector and machine.
(harness end) of
connector and ma-
chine is 24 V. Open circuit in harness
between pilot shut-off
· Key switch: ON NO solenoid valve and bat-
tery relay.
blown.
· Check if fusible link 65
Connector (Harness end of connector viewed from the A is blown.
open end side)
Pilot Shut-Off Relay Pilot Shut-Off Solenoid Valve

Security Relay
T1V1-05-04-103
#1 #2
T183-05-04-003
T5-7-67

between terminal #2
YES (harness end) of
connector in security
Check for continuity relay and machine.
between terminal #3
YES
Connect terminal #5 (harness end) of
(harness end) of con- connector in security
nector in pilot shut-off relay and machine.
Faulty ground in security
relay to machine.
YES Disconnect security NO relay.
relay.
between terminal #4
nector and machine. Open circuit in harness
Check if voltage between pilot shut-off
YES between terminal NO relay and security relay.
#1 (harness end) of
connector in pilot
A shut-off relay and
machine is 24 V.

NO relay and battery relay.

NO solenoid valve and pilot
shut-off relay.
T5-7-68
Faulty monitor unit, or

between monitor unit and
security relay.
Connect connector YES Faulty pilot shut-off sole-

monitor-B. noid valve.
YES between terminal #2
(harness end) of
connector in pilot
shut-off relay and Faulty monitor unit.
Check for continuity machine. NO
YES between terminals · Pilot shut-off lever:
#B12 and #B19 UNLOCK position
(harness end) of
Connect terminal #2 connector monitor-B.
(harness end) of con- Open circuit in harness
nector in pilot shut-off between terminals #B12
relay to machine. and #B19 (harness end)
Disconnect connector of connector monitor-B,
monitor-B in monitor NO
or faulty pilot shut-off
NO unit. lever.
between terminal #2
nector and machine.
NO relay and monitor unit.

open end side)
Pilot Shut-Off Relay

Connector Monitor-B
#B2
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
T183-05-04-003
#B19 #B12
T5-7-69
A-3 Single swing operation speed becomes slow.
Arm speed is slightly slow during arm level
crowding. (All problems occur at the same
time.)
• The pump 2 flow rate is minimized (approx. 20

L/min) due to some reasons. Accordingly, the
swing motors, which are driven by pressure oil
from pump 2, moves very slow.
• Pressure oil from pump 1 is also routed to the arm
and boom cylinders so that the arm and boom can
move at a slightly slow speed in single operation.
However, during level crowding operation, pres-
sure oil is routed to the boom prior to the arm so
that arm speed becomes very slow.
• Refer to the SYSTEM / Hydraulic System group in
the T/M (Operational Principle).
YES Faulty pump 2 regulator.
Monitor pump 2 flow

control pressure.
Check if pressure in-
creases in proportion to
swing lever stroke.
Bound pump 2 flow rate
· Monitor item: Pump 2 control valve in signal con-
flow control pressure NO trol valve.
built-in diagnosing sys-
tem.
T5-7-70
A-4 Travel is operated during single travel op-
eration. Single bucket operation speed be-
comes slow. Boom is not raised properly
during arm level crowding. (All problems
occur at the same time.)
• The pump 1 flow rate is minimized (approx. 20

L/min) due to some reasons. Accordingly, the
travel motor and bucket cylinder, which are actu-
ated by pressure oil from pump 1, moves very
slow.
• Pressure oil from pump 2 is also routed to the arm
and boom cylinders so that the arm and boom can
move at a slightly slow speed in single operation.
However, in level crowd operation, pressure oil is
routed to the arm prior to the boom so that boom
is scarcely raised.
YES Faulty pump 1 regulator.
Monitor pump 1 flow

control pressure.
creases in proportion to
accelerator pedal stroke.
Bound pump 1 flow rate
· Monitor item: Pump 1 flow control valve in signal control
control pressure NO valve.
tem.
T5-7-71
A-5 Although control lever is turned to neutral,
actuator does not stop.
• Bound spool in the pilot valve or bound main

spool in the control valve is suspected.
YES Faulty pilot valve.
· When control lever is in neu-

tral, pilot pressure is routed to
spool end in control valve.
Check if actuator stops when
pilot shut-off lever is turned to
LOCK position.
Faulty control valve.

NO
· Although pilot pressure is not
routed to spool end in control
valve, spool is kept opened
due to binding of spool.
T5-7-72
A-6 Actuator speed is faster than normal
Precise control cannot be performed.
• The pump 1 or 2 flow rate is maximized due to

some reasons.
Therefore, the maximum flow rate is supplied and
actuator speed is faster though the control lever
does not reach the full stroke.
YES Faulty pump regulator.
Monitor pump control pressures

of pump 1 and 2.
Check if pressure changes in
response to lever operation.
Bound pump flow rate control
· Pump 1: Bucket operation valve in signal control valve.
· Pump 2: Swing operation NO
· Monitor item:
Pump 1 flow control pressure
Pump 2 flow control pressure
diagnosing system.
T5-7-73
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
F-1 All front attachment actuator operations are

weak.
• If operating speeds are extremely slow, pump

control may be malfunctioning (A-3, A-4). Faulty
pilot system may also cause this trouble.
34.3 to 36.3 MPa Main relief valve should be nor-

2
(350 to 370 kgf/cm , 4990 to 5280 psi) mal.
Find out cause of trouble by
tracing other trouble symptoms.
Monitor pump 1 and 2 deliv-

ery pressures.
· Monitor item: Pump 1 and 2 de-
livery pressures
· Possible to display by built-in Adjust main relief valve.
diagnosing system.
· Relieve boom, arm and bucket Less than 34.3 MPa
2
circuits. (Less than 350 kgf/cm , 4990 psi)
· Power mode switch: P
· Work mode: Digging
T5-7-74
F-2 Some cylinders are not operated or speeds
are slow.
• When other actuators (travel and swing) operate

normally, the pilot pump (primary pilot pressure) is
considered to be normal.
• If single bucket operation speed is slow, refer to
F-4.
• If single arm roll-in operation speed is slow, refer
to F-5.
• If single boom lower operation speed is slow, refer
to F-6.
YES Bound control valve
spool, or faulty cylinder
(faulty seal kit).
YES Check if overload

relief pressure is nor-
mal.
Monitor pump control Faulty overload relief

pressure. NO valve.
YES Check if pump con-
trol pressure
changes smoothly
while moving control
lever slowly.
· Monitor item: Faulty shuttle valve in
Pump 1 flow pres- NO signal control valve.
Measure or monitor sure, pump 2 flow
secondary pilot pressure
pressure. · Possible to display
Check if secondary by built-in diagnos-
pilot pressure is ing system.
normal.
· Secondary pilot
pressure: YES Bound shockless valve
Refer to the Opera- spool in signal control
tional Performance valve.
Check if secondary
Test section.
pilot pressure at inlet
· Monitor item:
Boom raise pilot NO port to signal control
valve. Faulty pilot valve.
pressure, arm roll-in
pilot pressure. · In case cylinders NO
· Possible to display by other than boom are
built-in diagnosing abnormal, skip this
system. step and go NO.
T5-7-75
F-4 Arm speed is slow during combined opera-
tion. Arm speed is slow during arm level
crowding.
Related MC Fault Code: 11202-3, 11202-4, 11301-3, • Refer to the pages for the SYSTEM / Control
11301-4, 11302-3, 11302-4, 11303-3, 11303-4, System group / Arm Regenerative Control in the
11403-2, 11403-3, 11403-4 T/M (Operational Principle).
Disconnect harness in Faulty solenoid valve

YES
solenoid valve unit (SC). unit (SC).
Connect test harness
NO (ST 7226) between so-
lenoid valve unit (SC)
and harness. Check if Open circuit in harness
Monitor solenoid valve between solenoid valve
unit (SC) output. Install lamp lights. NO
unit (SC) and MC.
pressure gauge to port · Combined operation of
NO SC. boom raise and arm
Check if both measured roll-in.
values by pressure
gauge and Dr. ZX vary YES Faulty arm regenerative
identically. valve.
Check if arm regenera-
· Monitor item: Arm regen- tive valve at 5-spool side
erative P/S valve output YES in control valve is scored
Find out cause of trou-
Check if fault code · Combined operation of or bound.
ble by tracing other
is displayed. boom raise and arm NO trouble symptoms.
roll-in
· Measurement: Refer to
the Operational perform-
ance Test section.
Faulty corresponding
sensor, or faulty MC.
YES between MC and sen-
sor.
T5-7-76
F-4 Bucket is slightly slow during bucket roll-in
single operation. Bucket does not move
smoothly during bucket roll-in single opera-
tion.
• Bucket flow rate control valve or bucket regen-

erative valve may be faulty.
• Refer to the COMPONENT OPERATION / Control
Valve group in the T/M (Operational Principle).
Faulty bucket regenera-

YES tive valve. (Disassemble,
clean or replace.)
Check if bucket re-
YES generative valve in
Install pressure gauge
bucket spool is
to hose SK connecting
bound or scored. Find out cause of trouble
signal control valve to
bucket flow rate control by tracing other trouble
NO symptoms.
valve in control valve.
NO When relieving during
3-combined operation
of boom raise, arm
roll-in and bucket
roll-in, check if pres- Bound bucket flow rate
Check if bucket flow sure is 3.9 MPa (40 control valve control
2
rate control valve in kgfcm ). NO spool in signal control
control valve is valve.
bound or scored.
Faulty bucket flow rate

control valve. (Disassem-
YES ble, clean or replace.)
Signal Control Valve (Control Valve Side)
Hose SK
Bucket Flow Rate

T178-03-06-015 Control Valve T16W-03-03-032
T5-7-77
F-5 When starting to move during combined
operation, arm does not smoothly move.
Arm starts to move slightly slow during arm
roll-in single operation. These troubles often
occur when temperature is low.

YES Faulty arm regenerative

valve. (Disassemble,
clean or replace.)
NO Check if arm regenera-
tive valve is bound or
scored.
Find out cause of trouble
by tracing other trouble
Check if arm anti-drift valve is NO symptoms.
bound or scored.
Faulty arm anti-drift valve.

(Disassemble, clean or
YES replace.)
F-6 When starting to move during combined

operation, boom does not move smoothly.
Boom starts to move slightly slow during
boom lower single operation.

Faulty boom lower me-
NO ter-in cut valve. (Disas-
semble, clean or replace.)
Check if boom lower
NO
meter-in cut valve is Find out cause of trouble
NO
bound or scored. by tracing other trouble
Check if boom re- symptoms.
Check if boom generative valve is
YES bound or scored.
anti-drift valve is
Faulty boom regenerative
bound or scored.
valve. (Disassemble,
YES clean or replace.)
Faulty boom anti-drift

YES valve. (Disassemble,
clean or replace.)
T5-7-78
F-7 When boom raise or arm roll-out is operated,
boom or arm starts to move after moving
slightly downward.
YES Faulty anti-drift valve.

YES Check if anti-drift valves
(arm and boom) are
bound or scored.
Check if load check valve in Oil leaks in cylinder.

control valve is normal. NO
· Disassemble / Visual
Inspection
Faulty load check valve.
NO
NOTE: 1. During the initial stage of operation, oil

pressure and flow rate from the pump is
low. Therefore, if the load check valve is
malfunctioning, the oil in the bottom side
of the boom cylinder flows back into the
circuit through the load check valve so (B)
that the boom cylinder temporarily is re- When Load Check
tracted. Valve is Faulty:
2. As oil pressure and flow rate from the (A)
pump is low, if oil leaks from bottom side
(A) to rod side (B) due to faulty boom
cylinder piston or cylinder barrel, the
boom cylinder is temporarily retracted
during the initial stage of operation. In
addition, cylinder force is reduced. The
cylinder drift increases in this case.
T105-07-04-012
T5-7-79
F-8 Front attachment drifts remarkably.
YES Normal.
Correctly adjust emer-

NO
gency valve and lock it
Check if each front Check if emergency up.
attachment cylin- valve at boom 1 sec-
der drift is within tion in control valve Check if symptom is
NO
specification. 4-spool side is cor- deleted when overload
rectly adjusted. relief valve is tempo-
YES rarily switched with
Check if cylinder drift another overload relief
is reduced when pilot valve.
shut-off lever is
NO turned to LOCK po-
sition.
Faulty pilot valve.

YES
• Boom Cylinder Internal Leakage Check
1. With the bucket cylinder fully retracted and the

arm cylinder slightly extended from the fully re-
tracted position, lower the bucket tooth tips onto
the ground.
2. Remove the hoses from the boom cylinder rod

side. Drain oil from the hoses and cylinders. (Plug
the disconnected hose ends.)
3. Retract the arm cylinder and lift the bucket off the
ground. If oil flows out of the hose removed pipe
ends and the boom cylinders are retracted at this T216-05-04-001
time, oil leaks in the boom cylinders. In case no oil
flows out of the hose removed pipe ends but the
boom cylinders are retracted, oil leaks in the con-
trol valve.
T5-7-80
Emergency Valve
NO Scored control valve

spool, broken spring, or
loose spool end.
NO Check if oil leaks

in cylinders.
Faulty cylinder. (Replace

seal kit.)
YES
Faulty overload relief T16W-03-03-032

YES valve.
TCGB-05-07-001
Adjustment Procedure:
Loosen screw (1) fully and tighten lock nut (2).
: 4 mm
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
T5-7-81
F-9 Attachment speed is fast during combined
operation of attachment (optional) and front
attachment.
When pulverizer or crusher is used.

• Check the wiring connections first. Open circuit in har-
NO ness between MC and
Disconnect connec- pressure sensor (aux-
tor MC-D in MC. iliary).
YES Check for continuity
between terminal
Disconnect connector #D5 (harness end) of Check if voltage be-
in pressure sensor connector and ter- tween terminal #D5
(auxiliary). minal #2 (harness (harness end) of con-
Check if voltage be- end) of connector in nector MC-D and
NO tween terminals #1 pressure sensor YES
machine is 0 V.
and #3 (harness end) (auxiliary).
of connector is 5±0.5 · Key switch: ON
V.
Switch pressure · Key switch: ON
sensor (auxiliary) Check if voltage be-
with other pressure tween terminal #1 Open circuit in har-
YES ness between MC and
sensor. (harness end) of
Check if fault code connector in pres- pressure sensor (aux-
for switched pres- iliary) (terminal #3).
NO sure sensor (auxil-
sure sensor is dis- iary) and machine is
played. between 0.25 and Open circuit in har-
4.75 V. ness between MC and
· Key switch: ON pressure sensor (aux-
NO
iliary) (terminal #1).

YES sor (auxiliary).

open end side)
Pilot Pressure Sensor (Auxiliary)
Pilot Pressure Sensor (Arm Roll-Out)
MC
Connector MC-A
#A7 #A23
T1V1-05-07-102
Auxiliary Flow Rate Control

Solenoid Valve
MC
Connector MC-D T183-05-04-008
#D5
T1V1-05-04-003
T183-05-04-009
#D9
T5-7-82
Disconnect connec- Check if voltage be-
tor MC-D in MC. YES tween terminal #D9
Check for continuity (harness end) of To A
between terminal connector MC-D and
Disconnect connec- YES #D9 (harness end) of machine is 0 V.
tor in pressure sen- connector and ter- · Key switch: ON
sor (arm roll-out). minal #2 (harness
NO Check if voltage be- end) of connector in Open circuit in harness
Switch pressure tween terminals #1 pressure sensor (arm between MC and pressure
sensor (arm roll-out) and #3 (harness end) roll-out). NO
sensor (arm roll-out).
with other pressure of connector is 5±0.5
YES sensor.
V.
Check if fault code
for switched pres- · Key switch: ON Open circuit in harness
Check if voltage be- YES between MC and pressure
sure sensor is dis- tween terminal #1
played. sensor (arm roll-out) (ter-
(harness end) of minal #3).
connector in pressure
NO sensor (arm roll-out)
and machine is be-
tween 0.25 and 4.75 Open circuit in harness
V. between MC and pressure
NO sensor (arm roll-out) (ter-
· Key switch: ON minal #1).
Faulty pressure sensor

(arm roll-out).
YES

between MC and pressure
NO sensor (auxiliary).
Faulty auxiliary flow rate

YES
Check if auxiliary flow
YES rate control solenoid
valve is bound or Faulty auxiliary flow rate
scored. YES
Check if auxiliary control valve in control
Check for continuity in flow rate control valve.
harness between MC valve in control
YES and auxiliary flow rate NO valve is bound or
control solenoid valve. Faulty MC.
scored.
NO
· Between terminal
#A23 of connector Open circuit in harness
A MC-A in MC and ter- between MC and auxiliary
minal #1 of connector flow rate control solenoid
in auxiliary flow rate NO
valve.
connector in auxiliary
flow rate control sole-
noid valve Shorted circuit in harness
between MC and pres-
NO sure sensor (arm
roll-out).
T5-7-83
attachment.
When breaker attached with auxiliary flow com- Shorted circuit in har-
biner line is used. NO ness between MC and
• Check the wiring connections first. pressure sensor (aux-
Disconnect connec- iliary).
tor MC-D in MC.
YES Check if voltage be- Switch pressure sen-
tween terminal #D5 sor (arm roll-out) with
(harness end) of other pressure sen-
Disconnect connector connector and ma- YES sor.
in pressure sensor chine is 0 V. Check if fault code for
(auxiliary). · Key switch: ON switched pressure
NO Check if voltage be- sensor is displayed.
tween terminals #1
Switch pressure of connector is 5±0.5 Open circuit in har-
sensor (auxiliary) V. YES ness between MC and
with other pressure · Key switch: ON pressure sensor (aux-
sensor. Check if voltage be- iliary) (terminal #3).
Check if fault code tween terminals #1
for switched pres- (harness end) of
sure sensor is dis- connector in pres- Open circuit in har-
played. NO sure sensor (auxil- ness between MC and
iary) and machine is pressure sensor (aux-
NO
between 0.25 and iliary) (terminal #1).
4.25 V.
· Key switch: ON

YES sor (auxiliary).
Connector (Harness end of connector viewed from the open

end side)
・ Pilot Pressure Sensor (Auxiliary) MC
・ Pilot Pressure Sensor (Arm Roll-Out) Connector MC-A
#A7 #A23
T1V1-05-07-102
Auxiliary Flow Combiner Solenoid Valve MC T183-05-04-008
Connector MC-D
#D5
T1V1-05-04-003
T183-05-04-009
#D9
T5-7-84

NO between MC and pres-
sure sensor (arm
roll-out).
MC-D in MC. Check if Disconnect connector
YES MC-B in MC and con-
voltage between ter- Check if auxiliary flow
Disconnect connector minal #D9 (harness nector in auxiliary flow NO combiner solenoid
in pressure sensor end) of connector and combiner solenoid valve is bound or To A
(arm roll-out). machine is 0 V. valve. scored.
NO Check if voltage be- Check for continuity
tween terminals #1 YES between terminals #1
and #3 (harness end) and #2 (harness end) Shorted circuit in harness
of connector is 5±0.5 of connector in auxil- between MC and auxil-
V. iary flow combiner
solenoid valve. YES iary flow combiner sole-
· Key switch: ON noid valve.

Check if voltage be- YES between MC and pres-
tween terminal #1 sure sensor (arm roll-out)
(harness end) of con- (terminal #3).
nector in pressure
NO sensor (arm roll-out)
and machine is be-
tween 0.25 and 4.75
V.
NO sure sensor (arm roll-out)
· Key switch: ON (terminal #1).

YES (arm roll-out).
YES Faulty auxiliary flow

combiner solenoid valve.
A Faulty auxiliary flow

YES
Check if auxiliary flow combiner valve.
combiner valve in
NO control valve is bound
or scored. Faulty MC.
NO
T5-7-85
attachment.
When vibrating hammer is used. Disconnect connec-

• Check the wiring connections first. tor MC-D in MC. Open
MC circuit in harness
と圧力センサ(予
NO
Check for continuity between
備)間のハーネス断線MC and pres-
sure sensor (auxiliary).
YES between terminal
#D5 (harness end) of
connector and ter-
minal #2 (harness Checkコネクタのハー
MC-D if voltage be-
end) of connector in tween terminal #D5
ネス側コネクタ#D5端
Disconnect connector (harness
子と本体間の電圧を測 end) of con-
pressure sensor.
in pressure sensor YES 定するMC-D and
nector
(auxiliary). 電圧は 0Visか
machine between 0
NO Check if voltage be- V.
1-
tween terminals #1
and #3 (harness end) · キースイッチ:
Key switch: ONON
Switch pressure of connector is be-
sensor (auxiliary) tween 5±0.5. Open
MC circuit in harness
と圧力センサ(予
with other pressure · Key switch: ON YES between MC and pres-
備)(#3 端子)間のハー
sensor. Check if voltage be- sure
ネス断線 sensor (auxiliary)
Check if fault code tween terminal #1 (terminal #3).
for switched pres- (harness end) of
sure sensor is dis- connector in pres-
played. NO sure sensor (auxil- Open circuit in harness
iary) and machine is MC と圧力センサ(予
between 0.25 and between MC and pres-
NO 備)(#1 端子)間のハー
sure sensor (auxiliary)
4.75 V. ネス断線
(terminal #1).
· Key switch: ON 1

YES (auxiliary).

open end side)
Pilot Pressure Sensor (Auxiliary) MC MC
Pilot Pressure Sensor (Travel Forward) Connector MC-A Connector MC-C
#A5
T1V1-05-07-102
#A31 T183-05-04-008 T1V1-05-07-103

Maximum Pump 1 Flow Rate Limit MC
Control Solenoid Valve Connector MC-D
#D5
T1V1-05-04-003
T183-05-04-009
T5-7-86
YES
To A
Disconnect connector YES tween terminal #C2
in pressure sensor (harness end) of con-
(travel forward). nector MC-C and
NO Check if voltage be- machine is 0 V. Shorted circuit in harness
tween terminals #1 · Key switch: ON between MC and pres-
Switch pressure sen- and #3 (harness end) NO sure sensor (travel for-
sor (travel forward) of connector is 5±0.5 ward).
YES with other pressure V.
sensor. · Key switch: ON
Check if fault code for Open circuit in harness
switched pressure Check if voltage be- YES between MC and pres-
sensor is displayed. tween terminal #1 sure sensor (travel for-
(harness end) of con- ward) (terminal #3).
nector in pressure
NO sensor (travel forward)
and machine is be- Open circuit in harness
tween 0.25 and 4.75 between MC and pres-
V.
NO sure sensor (travel for-
· Key switch: ON ward) (terminal #1).

(travel forward).
YES

NO sure sensor (auxiliary).
in maximum pump 1 YES Faulty maximum pump 1
flow rate limit control flow rate limit control
solenoid valve. solenoid valve.
YES Check if current be-
tween terminals #1
of connector is be-
tween 56 mA and 920
harness between MC
mA.
A and maximum pump 1
Faulty MC.
flow rate limit control · Key switch: ON
solenoid valve. NO
· Between terminal
#A31 of connector Open circuit in harness
MC-A in MC and ter- between MC and maxi-
NO mum pump 1 flow rate
minal #1 of connector
in maximum pump 1 limit control solenoid
flow rate limit control valve.
solenoid valve
connector in maxi-
mum pump 1 flow rate
limit control solenoid
valve
T5-7-87
SWING SYSTEM TROUBLESHOOTING
S-1 Swing is slow or unmoving.
• Check whether the pilot system is faulty or the • If left travel speed is also slow, refer to A-3.
main circuit is faulty.
• If other functions (front attachment and travel)
operate normally, the pilot pump is considered to
be normal. If the pilot system is displaying a
problem, the cause of trouble may exist in the
circuit after pilot valve.
Check if swing motor

YES parking brake release
valve is scored or
bound.
Check if parking brake
YES release pressure is
approx. 3.9 MPa (40
2
kgf/cm ).
Monitor pump control · Relieve arm circuit. Faulty swing parking

pressure. · Monitor item: brake release spool in
Front pilot pressure NO signal control valve.
YES While slowly operating
swing lever, check if · Possible to display by
pump control pressure built-in diagnosing sys-
varies smoothly. tem.
Monitor secondary · Monitor item:
pilot pressure. Pump 2 flow control
Check if secondary pressure
pilot pressure is nor- · Possible to display by Bound pump 2 flow rate
mal. built-in diagnosing sys- control valve in signal
tem. NO control valve.
· Specification:
Refer to the Opera-
tional Performance
Test section.
· Monitor item: Faulty pilot valve.
Swing pilot pressure NO
tem.
T5-7-88
YES Faulty swing reduction

gear.
YES Check if swing motor drain

oil amount is normal.
· Measurement: Faulty swing motor.
NO Check if swing relief
Refer to the Operational NO
pressure is normal.
Performance Test section.
· Relieve swing circuit.
· Monitor item: Pump 2
delivery pressure
built-in diagnosing sys- Faulty swing relief valve.
tem. NO
· Specification:
Refer to the Opera-
tional Performance
Test section.
Faulty swing motor park-
YES ing brake release valve.
T5-7-89
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Machine does not travel.
• The travel system is inoperable unless the fol- • Air mixing in the transmission hydraulic circuit
lowing conditions are met. may cause the parking brake to drag. Bleed air
FNR Switch: F or R position from the transmission by referring to T5-7-130.
Brake Switch: OFF, Auto Axle Lock or Axle Lock • When other actuators (front attachment and
position swing) operate normally, the pilot pump, pilot filter
• Failure in the transmission and/or axle (front and pilot relief valve are considered to be normal.
and/or rear) may be the cause of the trouble. • Check the wiring connections first.
Check if a noise is emitted from each section.
• Check if parking brake indicator (P), work brake
indicator (S) in the monitor unit and neutral indi-
cator (N) in the steering column monitor are OFF.
Monitor implement
YES brake state.
Check if ON is dis-
played.
Monitor pump 1 deliv-

ery pressure by using
NO Dr. ZX.
creases according to
travel operation.
Faulty control valve
· Monitor item: Pump 1 NO (bound spool).
delivery pressure
the Operational Per-
formance Test section.
Disconnect connectors in
travel forward/reverse Pi cut
solenoid valve.
Check if symptoms disap-
pear.
YES Faulty MC.
Monitor FNR switch.

Check if indication is
YES changed by shifting
switch.
· Monitor item:
FNR (F) SW,
FNR (R) SW
Faulty FNR switch.
NO
T5-7-90
YES Faulty work brake release

switch.
Monitor work brake

release switch.
YES
Check if ON is dis-
played.
· Monitor item:
YES Disconnect connector in Implement brake de- Faulty MC.
solenoid valve unit (SF). active
Check if symptoms dis- NO
appear.
Faulty solenoid valve unit

NO (SF) (bound).
YES Faulty Travel mode selection

solenoid valve (bound).
Monitor fast/slow selec-

tion relays.
Check if OFF is dis- YES Faulty brake switch.
NO
played.
· Monitor item:
T/M change (high speed) Monitor parking brake
T/M change (low speed) switch.
· FNR switch: N NO Check if ON is dis-
played.
· Brake switch: except
P (parking brake) Faulty MC.
NO
T5-7-91
T-2 Machine does not travel forward and re-
verse.
• Failure in the transmission and/or axle (front

and/or rear) may be the cause of the trouble.
Check if a noise is emitted from each section.
• When other actuators (front attachment and
swing) operate normally, the pilot pump, pilot filter
and pilot relief valve are considered to be normal.
NO Check travel spool in

Switch relief valves at control valve for abnor-
mality.
NO forward and reverse
sides in travel motor.
Check if symptoms are
Monitor pump 1 delivery switched.
pressure by using Dr. ZX.
YES
Check if travel for-
ward/reverse relief pres-
sure is normal.
· Refer to the Operational Faulty travel motor relief
Performance Test section.
YES valve.
Monitor FNR switch.

Check if ON is dis- Faulty travel shockless
played when turning valve.
YES
FNR switch to F or R.
· Monitor item:
FNR (F) SW,
FNR (R) SW
Faulty FNR switch, or

open circuit in harness
between MC and FNR
NO
switch.
T5-7-92
YES Faulty counterbalance

valve.
Check counterbalance
NO
valve in travel motor for
abnormality. YES Faulty make-up valve.
Check make-up valve for

abnormality.
NO
Faulty center joint.
NO
Faulty control valve

(bound spool).
YES
T5-7-93
T-3 Forward/reverse travel speeds are slow.
Travel power is weak.
• If the travel motor displacement angle control so- • When other actuators (front attachment and
lenoid valve is faulty, fault code 11422 is dis- swing) operate normally, the pilot pump, pilot filter
played. and pilot relief valve is considered to be normal.
• Failure in the transmission and/or axle (front • Pump 1 flow rate reduction may be the cause of
and/or rear) may be the cause of the trouble. this trouble when bucket single operation speed is
Check if a noise is emitted from each section. slow. Refer to A-3.
• Air mixing in the transmission hydraulic circuit • Check the wiring connections first.
may cause the parking brake to drag. Bleed air
from the transmission by referring to T5-7-130.
NO
Check travel spool in

NO
control valve for ab-
normality.
Faulty control valve.
YES
Monitor slight travel SW
NO by using Dr. ZX.
Check if ON is dis-
played. NO Faulty engine speed control
Disconnect connector mode selection switch.
· Engine speed control
mode selection switch: in switch panel.
Pedal or Dial Monitor slight travel
YES SW by using Dr. ZX.
Check if ON is dis- Faulty MC, or shorted circuit
played. in harness between MC and
YES engine speed control mode
Check if fault code selection switch.
11422 is displayed.
Refer to Troubleshooting A.
YES
T5-7-94
YES Faulty center joint.

Measure drain amount
from travel motor.
Check if drain amount
is normal.
· Refer to the Opera- Faulty travel motor.
tional Performance NO
Test section.
T5-7-95
T-4 When releasing accelerator pedal, hydraulic
brake is not applied. (Machine runs away.)
• If the travel motor displacement angle control so-

lenoid valve is faulty, fault code 11422 is dis-
played.
• Similar symptom may appear when the travel pilot
valve, travel shuttle valve and/or travel spool is
faulty.
NO Faulty control valve.
Check if counterbal-
NO ance valve in travel
motor is abnormal.
Faulty counterbalance valve.

Switch relief valves at
YES
YES forward and reverse
sides in travel motor.
switched.
Faulty travel motor relief

Monitor vehicle speed. YES valve.
Check if speed is
changed according to
accelerator pedal op-
eration.
Faulty travel N sensor, or
faulty harness between MC
NO and travel N sensor.
T5-7-96
(Blank)
T5-7-97
T-5 Travel mode (fast/slow) does not shift.
Travel Mode Selection
• Air mixed in the transmission hydraulic circuit Solenoid Valve
may prevent the transmission from being shifted. Port B Port K
Bleed air from the transmission by referring to
T5-7-130.
• Set the FNR switch in the F or R position. Set the
brake switch in the position other than the parking
position. Perform the troubleshooting.
TCJB-05-07-003
NO
Install pressure gauge to
ports B and K in transmis-
sion changeover solenoid
valve.
YES Check if pressure at each
port varies as shown be-
low when travel speed
mode switch is operated.
Monitor fast speed · Travel speed mode switch: Slow
selection relay and →Pressure at port B: 0 MPa
slow speed selection →Pressure at port K: 3.0 MPa Faulty transmission.
YES relay. · Travel speed mode switch: Fast
When shifting travel →Pressure at port B: 3.0 MPa YES
speed mode switch, →Pressure at port K: 0 MPa
check if ON is dis-
played respectively.
· Monitor item:
T/M selection (Fast)
T/M selection (Slow)
When shifting travel
speed mode switch, Faulty fast/slow speed selec-
check if slow speed tion relay.
indicator in steering NO
column monitor is
ON/OFF normally.
· Travel speed mode

switch: Slow
→Indicator: ON
· Travel speed mode
switch: Fast
→Indicator: OFF
Faulty travel speed mode

switch, or faulty harness be-
NO tween MC and travel speed
mode switch.
T5-7-98
Open circuit in harness between

NO travel mode selection solenoid
valve and fast/slow speed
selection relay.
in travel mode
selection solenoid
valve. Faulty travel mode selection
YES
Check if voltage at solenoid valve (bound spool).
terminal #2 (each
harness end) of With connector in travel
connector is 24 V. mode selection solenoid
valve disconnected, check
· Travel speed mode YES for continuity between
switch: Slow terminal #1 (harness end) of
→Green-yellow line connector and machine. Open ground circuit in harness
· Travel speed mode NO to travel mode selection
switch: Fast solenoid valve.
→Brown-white line
Connector (Harness end of connector viewed from the open

end side)
Travel Mode
Selection Solenoid
Valve Travel Mode Selection Solenoid Valve
Fast Speed Side Slow Speed Side
TCJB-05-07-002
TCJB-05-06-004 TCJB-05-06-004
Brown-White Yellow-Green
First Speed Side Slow Speed Side Line Line
T5-7-99
T-6 Axle lock is not released.
• Check that the brake switch is in the OFF position

first.
YES
Refer to troubleshooting A.
Faulty operate check valve (axle

Check if fault code is YES lock cylinder), or open circuit in
harness between MC and solenoid
11424 is displayed.
value unit (SI).
· Brake switch:
Auto axle lock
or Axle lock
Monitor brake switch.
Check if OFF is
NO displayed.
· Monitor item:
Parking brake SW
Axle lock control state
Faulty brake switch, or shorted
circuit in harness between MC and
NO brake switch.
T5-7-100
T-7 Axle lock is not operable.
• Check that the brake switch is in the auto axle lock

or axle lock position first.
YES
Refer to troubleshooting A.
Faulty operate check valve (axle

YES lock cylinder), or shorted circuit in
Check if fault code is harness between MC and solenoid
11424 is displayed. value unit (SI).
· Brake switch:
Auto axle lock
or Axle lock
Monitor brake switch.
NO Check if OFF is
displayed.
· Monitor item:
Axle lock control state Faulty brake switch, or open circuit
· Brake switch: in harness between MC and brake
NO switch.
Auto axle lock or Axle
lock
T5-7-101
BRAKE SYSTEM TROUBLESHOOTING
B-1 Parking brake is not operable (not applied).
• Bleed air from the transmission by referring to

T5-7-130 before starting troubleshooting.
• If the fast/slow speeds do not change, refer to “T-5
Travel mode (fast/slow) does not shift”.
YES Faulty MC.
Monitor parking brake

switch.
Check if ON is
displayed.
· Brake switch:
P (parking brake) position YES Faulty brake switch.
in brake switch.
NO of connector.
Monitor parking brake
switch.
Check if ON is
displayed. Open circuit in harness
between MC and brake
NO switch.

open end side)
Brake Switch
TCJB-05-07-004
T5-7-102
B-2 Service brake is not operable, or is not
applied effectively.
• The front and rear wheel service brake circuits are

independently designed each other. When either
the front or the rear wheel brake circuit fails,
overall service brake system will not operate
properly.
• Check the brake lining and the accumulator for
any abnormalities, and bleed air from the brake
system by referring to operator’s manual and
T5-7-131 before starting the troubleshooting.
• When other actuators (front attachment, travel
and swing) operate normally, the pilot pump is
NO Faulty accumulator charging

valve.
Monitor brake remain

pressure.
Check if pressure is
12.7 MPa or more. YES Faulty brake system at axle
side.
Monitor brake pressure.

YES Check if pressure is 6 MPa or
more. Faulty brake valve.
NO
· Brake pedal: Fully operated
diagnosing system.
T5-7-103
B-3 Work brake is not operable.
• Check if the brake switch is in the auto axle lock or

axle lock position first.
• When the brake switch is in the auto axle lock or
axle lock position, the work brake is applied.
When the brake switch is in the auto axle lock or
axle lock position and if the work brake is not
applied, the circuit in harness between MC and
brake switch may be open.
• When the speedometer is normal, the travel N
sensor may be normal.
• When other actuators (front attachment, travel
and swing) operate normally, the pilot pump is

11425-3, 11425-4.
YES Faulty solenoid valve
unit (SI).
YES Monitor implement

brake state.
Check if ON is
displayed.
Faulty MC.
YES Monitor brake NO
pressure. Check if
pressure is 6.0 MPa or
more.
· Depress brake pedal
fully. Faulty brake valve.
Monitor axle lock · Possible to display by NO
control state. built-in diagnosing
Check if ON is system.
displayed.
· Brake switch: Auto axle
lock or Axle lock Faulty brake switch.
NO
T5-7-104
STEERING SYSTEM TROUBLESHOOTING
H-1 Although steering wheel is rotated, steering

is heavy.
• Check the steering filter first.
YES Faulty steering pump.
Disconnect hoses from

delivery ports of steering
pump and pilot pump.
Connect hoses each
other to the other side. YES Faulty steering valve.
improved. Monitor steering pump by
using Dr. ZX.
NO Check if pressure is normal.
Faulty relief valve in steering
· Monitor item: Pump 3 delivery NO valve.
pressure
H-2 Although steering wheel is rotated, steering

is impossible.
• Although the steering valve does not have enough

pressure oil from the steering pump, the machine
can turn the left and right.
• If the machine cannot turn the left and right, center
joint maybe faulty.
• If only one side (left or right) can turn, the center
joint or the overload relief valve in the steering
valve maybe faulty.
T5-7-105
OTHER SYSTEM TROUBLESHOOTING
O-1 Wiper is not operated.
Checking Instructions
• The wiper is driven by electric power routed via • When the front window is open, the wiper is not
the relay circuit. The relay circuit is controlled by operated.
the monitor unit. In case the wiper is not operated, Check that the front window is closed securely.
first check if the wiper relay is activated. Next,
check if electric power is routed to the wiper mo-
tor.
YES
Switch wiper relay with Faulty wiper relay.
NO other general relay. Disconnect connector YES
Check if wiper is oper- monitor-A in monitor Faulty monitor unit.
ated. unit.
· Key switch: ON Connect terminal #A2
NO (harness end) of con-
nector to machine. Open circuit in harness
Disconnect wiper relay. between wiper relay and
Check for continuity NO monitor unit.
Check if wiper relay between terminal #A2
is turned ON/OFF (harness end) of con-
according to INT. nector and machine.
position of wiper
switch. YES
Close front window. Faulty wiper motor.
· Key switch: ON Disconnect connector
· Wiper switch: INT YES in wiper motor.
Open front window. Check if voltage be-
tween terminals B and Open circuit in harness
L (harness end) of between window con-
tween terminals B NO
connector is 24 V. tact and wiper motor.
YES and L at window
contact in cab end is · Key switch: ON
24 V. · Wiper switch: ON
· Key switch: ON Open circuit in harness
· Wiper switch: ON NO between wiper relay and
window contact.
T5-7-106
Window Contact (Cab end) Connector

Wiper Motor (Harness end)
INT. Position Setting Time
Slow Speed 8 seconds
Middle Speed 6 seconds B L
Fast Speed 3 seconds

S E
T1V1-05-07-005
Monitor Unit
Connector Monitor-A (Harness end) #A2
T183-05-05-001
Wiper Driving Circuit
Wiper Motor Wiper Relay
Main
Window Contact ↑
T1V1-05-07-004
T5-7-107
O-2 Air Conditioner is faulty
The air conditioner operation system has a

self-diagnosing function. This system performs the
diagnosis by 8-steps as shown in the flow chart be-
low: Check Model Confirmation, Display Function
Confirmation, Present Trouble Diagnosing, Past
Trouble Diagnosing, Sensing Temperature Display,
and Component Operation Check, Correction of the
Set Temperature and Selection of Celsius and Fahr-
enheit Temperature Indication.
Normal Operation
Turn key switch ON while pushing air

conditioner switch and mode switch.
Keep pushing OFF switch

for more than 3 seconds. STEP 0
Check Model Confirmation
Push lower side fan switch. Push upper side fan switch.
Keep pushing OFF switch STEP 1
for more than 3 seconds. Display Function
Confirmation
Keep pushing OFF switch STEP 2
for more than 3 seconds. Present Trouble
Diagnosing
Keep pushing OFF switch STEP 3 Keep pushing air conditioner

for more than 3 seconds. Past Trouble switch for more than 3 seconds.
Diagnosing
Sensing Temperature
Display
Component Operation Check
Push AUTO switch and Push AUTO Push A/C Push A/C switch and
lower side fan switch. Switch and switch and upper side fan switch.
upper side lower side
fan switch. fan switch.
Keep pushing OFF switch STEP 6-1 STEP 6-2
for more than 3 seconds. Correction of the Set Selection of Celsius and Fahrenheit
Temperature Temperature Indication
for more than 3 seconds.
Self-Diagnosis
T5-7-108
Self-Diagnostic System Activation
Fan Switch LCD Air Conditioner Switch
Turn the key switch ON while pushing the air condi-
tioner switch and mode switch on air conditioner con-
trol panel.
STEP 0 Check Model Confirmation

The liquid crystal display (LCD) indicates the ma-
chine model name this system can diagnose. T178-05-08-001
Mode Switch OFF Switch

• The LCD will indicate “Sd” as the check model
name.
• Select next step in order to be performed by oper-
ating the switch as described below.
• Upper side fan switch: To proceed to Step 1
• Keep pressing OFF switch for more than 3 sec-
onds: To return to normal operation
NOTE: The system operation will automatically
proceed to STEP 1 after 5 seconds have
pushed after the check model is displayed.
STEP 1 Display Function Confirmation

Turn all indicators ON in order to check indicator
bulbs.
• The LCD panel and all switch indicators light.

• Select the next step in order to be performed by op-
erating the switches as follows:
• Push the upper side of fan switch: To proceed to
“STEP 2.”
• Push the lower side of fan switch: To return to
“STEP 0.”
• Keep pushing the OFF switch for more than 3
seconds: Deactivate the self-diagnostic system.
(Normal function is resumed.)
T5-7-109
STEP 2 Present Trouble Diagnosing
The LCD indicates the fault codes for present ab-
Fan Switch LCD
normalities of the mix door, mode encoder, and/or
sensors.
• In case any abnormalities are present, the LCD in-

dicates the fault codes. If more than one fault code
is detected, the following fault code is displayed af-
ter flashing (0.5 seconds) twice.
Fault Code T178-05-08-001
Open Circuit Shorted Circuit OFF Switch
Mix Door 21 −21
Mode Encoder 22
In-Cab Ambient 23 −23
Temperature
Sensor
Outdoor Ambient 24 −24
Temperature
Sensor
Coolant Tem- 25 −25
perature Sensor
∗
Solar Radiation 26 −26
Sensor
∗
: When solar radiation is shaded, the solar radiation
sensor indicates the fault code of open circuit.
“STEP 3.”
“STEP 1.”
(Normal function is resumed)
T5-7-110
STEP 3 Past Trouble Diagnosing
The LCD indicates the fault codes for past abnor-
malities of the mix door, mode encoder, and/or sen-
sors.
The past stored fault codes are deleted.
• In case any abnormalities occurred in the past, the

LCD indicates the fault codes. If more than one fault
code is detected, the following fault code is dis-
played after flashing (0.5 seconds) twice. T178-05-08-001
Fault Code OFF Switch
Open circuit Shorted Circuit
Mix Door 21 −21
Mode Encoder 22
In-Cab Ambient
Temperature 23 −23
Sensor
Outdoor Ambient
Temperature 24 −24
Sensor
Coolant Tem- 25 −25
perature Sensor
Solar Radiation −26
Sensor
• When the air conditioner switch is kept pushing for
more than 3 seconds, the failure records are de-
leted. After this operation, the air conditioner switch
indicator flashes 5 times. Then, the self-diagnosing
system is deactivated. (Normal functions are re-
sumed.)
“STEP 4.”
“STEP 2.”
T5-7-111
STEP 4 Sensing Temperature Display Fan Mark
The LCD indicates the sensing temperature detected
by each temperature sensor (excluding the insulation
sensor).
• The sensing temperature detected by the in-cab

ambient temperature sensor, outdoor ambient tem-
perature sensor and coolant temperature sensor are
displayed on the LCD in real time. (Figures less
than the decimal point are not displayed.) T178-05-08-001
NOTE: The coolant temperature sensor indicates Fresh Air Vent Switch OFF Switch
“H” when coolant temperature is more than
21 °C (70 °F) and “L” when coolant tem-
perature is less than 21 °C (70 °F).
• Sensing temperature detected by each sensor is
automatically displayed on the LCD and is cycled at
an interval of 3 seconds with the timer. The timer is
turned ON or OFF by operating the fresh air vent
switch.
• Referring to the fan mark can check which sensing
temperature is displayed.
“STEP 5.”
“STEP 3.”
T5-7-112
STEP 5 Component Operation Check Air Conditioner
Fan Switch LCD Switch AUTO Switch
Each component operation is checked by performing
pattern operation.
• Each time the fresh air vent switch is pushed, the

component to be checked is selected in order.
Check which component has been selected by re-
ferring to No. indicated on the LCD. (Refer to table
1.) T178-05-08-001
• Operating pattern of the selected component is
Fresh Air Vent switch OFF Switch
shifted at an interval of 10 seconds. Operating pat-
tern is cycled. (Refer to table 1.)
NOTE: The components other than selected oper-
ate under the standard conditions (shown
by marks* in table 1).
• Push the AUTO switch and upper side of fan
switch: To proceed to “STEP 6-1”.
• Push the A/C switch and upper side of fan switch:
To proceed to “STEP 6-2”.
“STEP 4.”
Table 1
Component Indication Operation Pattern Remarks
on LCD
Air Mix Damper 51 Controls opening extent of air mix 0%, 50%, 100%: “C”, “5” and “H” are in-
damper: 0% (fully closed) → dicated next to the decimal point respec-
50%*→ 100% (fully opened) tively.
Fan 52 Controls air flow volume: Lo → Indicators corresponding to air flow vol-
M(Lo) → M(Hi) → Hi ume light.
Air Vent Location 53 Selects air vent: Front*→ Indicator corresponding to selected air
Front/Rear → Front/Foot → Foot vent lights.
Fresh / Circulation 54 Select Ventilation Mode: Circula- Indicator corresponding to selected
Air Vent Selection tion* → Fresh mode light.
Air Conditioner 55 Turns air conditioner switch: ON* ON: Indicator lights.
→ OFF OFF: Indicator is extinguished.
T5-7-113
STEP 6-1 Correction of the Set Temperature
Fine correction of the set temperature. Temperature
Fan Switch LCD Control Switch AUTO Switch
• Each time when the top or bottom of temperature

control switch is pushed, temperature correction,
displayed on the LCD window, can be changed.
• Actually controlled temperature is the normally set
temperature plus the set temperature correction.
For instance, when the normally set temperature is
25°C (77 °F) and set temperature correction is -1°C T178-05-08-001
(-34 °F), the actually controlled temperature be- OFF Switch

comes 24°C (75 °F).
• Push the AUTO switch and lower side of fan
switch: To return to “STEP 5.”
T5-7-114
STEP 6-2 Selection of Celsius and Fahrenheit
Temperature Indication
Selection of Celsius and Fahrenheit Temperature In-
dication.
• Each time when the fresh air vent switch is pushed,
Celsius or Fahrenheit temperature may be dis-
played alternately.
• Temperature is displayed at the top of LCD window
as follows.
(C: Celsius, F: Fahrenheit) T178-05-08-001
C F Fresh Air Vent Switch OFF Switch

• Push the Air Conditioner Switch and lower side of
fan switch: To return to “STEP 5.”
T5-7-115
ÄPlease fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to the related post / after experiencing a problem with
your machine’s air conditioning system.
< AIR CONDITIONER TROUBLE REPORT > File No.

(1) What Checked by:
Model (Serial No. )
Operation Type Manual Semi-Auto Full-Auto
Delivery Date Year Month
(2) When
Date Year Month Day Operating Hour ( h)
Time Morning Daytime Evening Night
Frequency Every Day Once a Week Once a Month Times per
(3) Where
Job Site Address State County Town
Access Road Condition Paved Not Paved (Gravel Sand Soil)
(4) How (Operating Conditions)
Weather Fine Cloudy Rain Snow
Atmospheric Temperature Very Hot Hot Cold Very Cold
Operating Conditions Parking Traveling Working
Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when
full-auto operation
A/C ON OFF
Control Air Induction Re-Circulation Fresh Air Circulation
Panel AUTO ON OFF Not Available
Fill following items when operated in manual mode or when manual control type unit is used.
Vent Position Front Front / Rear Foot Front / Rear and Foot
Fan First Second Third Fourth Fifth Sixth
(5) How (Problem Symptom)
Abnormal Compressor Operation
Symptom Not turned ON <Check Result>
Not turned OFF (1) Is problem reproducible ?
Others Reproducible
Uncontrollable air temperature Not reproducible
Symptom No cool air (2) Pressure (To be measured at gauge manifold)
No warm air Low Pressure
Others High Pressure
Uncontrollable air volume (3) Which parts have been replaced ?
Symptom Air flows in Hi mode only 1
No air flows
2
Small air volume
Others
Uncontrollable vent hole ∗ Before replacing the control amplifier, be sure to
Symptom Vent hole isn’t selected check that the connectors are correctly connected
while repeatedly disconnecting and reconnecting
Others
connectors.
Abnormal panel indication
Faulty Indica- Vent Hole
tor A/C
AUTO
Fresh Air Circulation
Fan OFF
Fan (Lo • •• Hi)
Temperature Control
Symptom Stays OFF
Stays ON
Blinks
Others
T5-7-116
Refrigerant Quantity....................... 900±50 g
3
Compressor Oil Quantity................ 210 cm
T5-7-117
Cooling Circuit
Refrigerant pressure Bubbles can be seen in sight Piping and/or parts are stained with oil,
in both high and glass. respond to gas detector.
low-pressure sides is
low.
No oil stain is found or gas detector
does not respond. Refrigerant has not
been refilled for longer than one sea-
son.
No bubbles are seen in sight
glass.
After cooling at fast speed continu-

ously, cooling power is reduced. Air
flow volume remains unchanged.
Air flow volume is reduced.
Refrigerant pressure
in low-pressure side Bubbles can be seen in sight Compressor cylinder is extremely hot,
Insuffi- is high. glass. emitting a smell.
cient
Cooling
Power
Refrigerant pressure in Compressor cylinder is extremely hot,
high-pressure side is low. emitting a smell.
Heater unit emits hot air.
Refrigerant pressure
in high-pressure side Bubbles can be seen in sight Refrigerant pressure in low-pressure
is high. glass. side is low.
Condenser is stained and clogged.
Even if condenser is sprayed with water, few bubbles appear. Receiver dryer tem-
perature is low.
After cooling at fast speed continu-

ously, cooling power is reduced. Air Frost forms. Thermistor does not cool.
flow volume is reduced.
Thermistor cools.
T5-7-118
Gas leaks from pipe joints and/or parts. Re-tighten or replace parts.
Normal leakage of refrigerant from hoses. Refill refrigerant.
Improper adjustment (excessive restriction) of expansion valve. Readjust or replace expansion valve.
Clogged expansion valve. Remove clog, or replace receiver and/or expansion

valve.
Clogged low-pressure circuit and/or evaporator. Remove clog, or replace parts.
Frozen expansion valve or water in circuit. After evacuation, refill refrigerant and/or replace re-
ceiver dryer.
Gas leaks from case. Seal gaps by using vinyl tape or packing compound.
Poor contact of expansion valve temperature sensing cylinder. Make good contact. Replace temperature sensing
stay.
Improper adjustment (excessive open) of expansion valve. Readjust or replace.
Insufficient compressor discharge (faulty gasket and/or valve). Replace.
Improper water stop valve wire adjustment and/or faulty stop

valve. Check and readjust or replace.
Poor airtight fitting of outside air damper (outside air induction

Repair.
type).
Clogged high-pressure circuit before receiver dryer. Remove clog, or replace parts.
Clean Condenser.
Excessive refrigerant. Remove excessive refrigerant to proper level.
After evacuation, refill refrigerant and/or replace re-

Air is mixed in system.
ceiver dryer.
Incorrect thermistor location. Correct thermistor location.
Gas leaks from case. Seal gaps by using vinyl tape or packing compound.
Faulty thermistor (stays ON). Disconnected thermistor cord.
Even if function and performance are normal, when Instruct user on correct air-conditioner operation.
air-conditioner is kept operated for a long time with thermistor (Reset thermistor to either minimum or middle cooling
in max. cooling position and air flow in M or L mode, frost may position or increase air flow.)
form.
T5-7-119
Cooling Circuit
Case connection. Louver resonance.
Fan contacts case, or foreign matter enters case.

Blower fan connection.
Brush friction noise, metal and/or thrust washer contact
noise.
Gas blowing sound (roaring). Gas vibration noise (compressor discharge and/or suc-
tion gas noise).
Expansion valve connection, whistle Abnormal noise from expansion valve (Expansion
Noise sound, gas blowing sound. valve is normally functioning.).
Faulty clutch bearing, and/or idle pulley bearing.
Clutch disengaging sound.

Contact of clutch amature due to resonance, or loose
belt and/or screws.
Noisy compressor.
Compressor rotating sound.
Vibration and/or loose screws due to excessive drive
belt looseness.
Broken heater core and/or hose.

Water leak and/or splash.
Clogged case drain port and/or drain hose.
Others
Absorbed cigarette and dust smell on evaporator fins.

Abnormal smell.
T5-7-120
Repair or replace.
Remove foreign matter. Readjust fan motor location.
Slight noise is unavoidable.

Replace if loud.
No functional problem exists.

Provide silencer if intolerable.
Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.
Replace.
Repair or replace clutch. Re-tighten screws.
Repair or replace.
Re-adjust drive belt.
Replace.
Clean.
-1
Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min in L
mode for more than 10 minutes, flush smell out by condensed water.
T5-7-121
Compressor
Compressor does not rotate. Clutch terminal voltage is normal 24 V.
Inoperable
cooling Clutch terminal voltage is low.
system.
Clutch terminal voltage is 0 V.
Bubbles exist even after refrigerant is refilled.
Both high and

low side Check for oil and refrigerant leaks from parts other than
pressures are compressor and pipe joints by using gas detector.
low.
Both com- Check for oil and refrigerant leaks from compressor (no
pressor and leaks from parts other than compressor) by using gas
blower mo- detector.
tor rotate. (Refer to NOTE 1, 2
on page T5-7-125.)
Stain on exterior.
Refrigerant has not been refilled for longer

than one season.
Refrigerant is discharged within 1 to 2

months after being recharged. Check for
refrigerant leaks using gas detector.
Refrigerant is kept charged for longer than

2 years.
Compressor cylinder is not hot. (Refrigerant returns to com-

High pressure side is pressor in liquid form.)
slightly low and low pres-
sure side is high.
No refrigerant returns in liquid form. High pressure side is low.
Bubbles can be seen through Others

sight glass.
High pressure side is high.
Refer to the Cooling Circuit Troubleshooting
Table on page T5-7-118.
Temperature is not cooled when compressor is
operated at fast speed continuously.
Air flow from blower is insufficient.
T5-7-122
Seized clutch. Replace.
Improper gap between amature and rotor (improper air gap).

Replace.
Open or shorted circuit in core cable.
Shaft does not rotate (internally locked). Replace.
Faulty Electrical System.
Faulty Electrical System.
Oil leaks from mechanical seal, gasket, and/or charge valve.

Replace.
Oil leaks from oil plug.
Oil and refrigerant leaks from front housing, and/or cylinder block joint. Replace.
Normal leaks from hoses. Charge

refrigerant.
No leaks (normal).
Refer to the Cooling Circuit Troubleshooting Table on page T5-7-118.
Broken valve (Refer to NOTE 3 on page T5-7-125.)
Replace.
Blown gasket (Refer to NOTE 3 on page T5-7-125.)
Check and adjust

Excessive oil. oil level.
T5-7-123
Compressor
Compressor rotation is abnormally draggy.

Overheating
is susceptible
to occur.
Trouble other than compressor. Refer to the Cooling Circuit Troubleshooting Ta-
ble on page T5-7-118.
Noise is heard when clutch is OFF.
Abnormal
noise
Noise is heard when clutch is ON.
T5-7-124
Broken clutch bearing due to overly tightened belt. Replace.
Shaft does n’o rotate.

Replace.
Shaft rotates draggy.
Broken clutch bearing.

Replace.
Contact or slip due to poor air gap.
Faulty idle pulley bearing.
Refer to the Cooling Circuit

Saggy belt. Troubleshooting Table on
page T5-7-120.
Loose screws.
Broken valve.
Replace.
Blown gasket.
Abnormal internal noise. Replace.
Vibration due to saggy belt.

Refer to the Cooling Circuit
Troubleshooting Table on
Loose screws. page T5-7-120.
NOTE:
1. Do not quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A
slight oil seepage will appear due to the seal construction. However, this oil seepage will not
cause malfunction. Accurately check whether oil is leaking or seeping only.
2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose sur-
face may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
2
high-pressure side and low-pressure side is 0.5 MPa (5 kgf/cm ) or less. When the clutch is
turned OFF, the pressure difference between high-pressure side and low-pressure side will dis-
appear within about 10 seconds.
T5-7-125
EXCHANGE INSPECTION
Exchange inspection method is a troubleshooting

method to find the trouble location by exchanging the
suspected part/component with another part
/component having identical characteristics.
Pump 2 Pump 1
Many sensors and solenoid valves used on this ma- (5-Spool (4-Spool
chine are identical. Therefore, by using this Section) Section)
switch-check method, faulty part/component, and/or
harness can be easily found.
PP2 PP1
Example: Abnormal pump 1 delivery pressure sensor
high voltage (MC fault code: 11200-3)
Check Method:
1. Switch two delivery pressure sensors located as
Figure A
shown in figure A to figure B.
2. Retry troubleshooting. T157-07-04-006
Result:
In case abnormal pump 2 delivery pressure sensor
high voltage is displayed (MC fault code 11202-3), the
pump 1 delivery pressure sensor is considered to be
faulty.
Pump 2 Pump 1
(5-Spool (4-Spool
In case abnormal pump 1 delivery pressure sensor Section) Section)
high voltage (MC fault code 11200-3) is displayed, the
pump 1 delivery pressure sensor harness is consid-
ered to be faulty. PP1 PP2
Figure B T157-07-04-006
T5-7-126
Applicability of Switch-Check Method
Fault Code Trouble Applicability

11000-2 Abnormal EEPROM Not Applicable
11001-2 Abnormal RAM
11002-2 Abnormal A/D Conversion
11003-3 Abnormal Sensor Voltage Not Applicable
11004-2 CAN Communication Error Not Applicable
11100-2 Abnormal Engine Speed Not Applicable
11101-3 Abnormal Engine Control Dial Sensor High Voltage Not Applicable
11101-4 Abnormal Engine Control Dial Sensor Low Voltage
11200-3 Abnormal Pump 1 Delivery Pressure Sensor High Voltage Applicable
11200-4 Abnormal Pump 1 Delivery Pressure Sensor Low Voltage (Harness/Sensor)
11202-3 Abnormal Pump 2 Delivery Pressure Sensor High Voltage
11202-4 Abnormal Pump 2 Delivery Pressure Sensor Low Voltage
11203-3 Abnormal Pump 3 Delivery Pressure Sensor High Voltage
11203-4 Abnormal Pump 3 Delivery Pressure Sensor Low Voltage
11206-3 Abnormal Pump 1 Control Pressure Sensor High Voltage Applicable
11206-4 Abnormal Pump 1 Control Pressure Sensor Low Voltage (Harness/Sensor)
11208-3 Abnormal Pump 2 Control Pressure Sensor High Voltage
11208-4 Abnormal Pump 2 Control Pressure Sensor Low Voltage
11301-3 Abnormal Swing Pilot Pressure Sensor High Voltage Applicable
11301-4 Abnormal Swing Pilot Pressure Sensor Low Voltage (Harness/Sensor)
11302-3 Abnormal Boom Raise Pilot Pressure Sensor High Voltage
11302-4 Abnormal Boom Raise Pilot Pressure Sensor Low Voltage
11303-3 Abnormal Arm Roll-In Pilot Pressure Sensor High Voltage
11303-4 Abnormal Arm Roll-In Pilot Pressure Sensor Low Voltage
11305-3 Abnormal Travel Forward Pilot Pressure Sensor High Voltage
11305-4 Abnormal Travel Forward Pilot Pressure Sensor Low Voltage
11306-3 Abnormal Travel Reverse Pilot Pressure Sensor High Voltage
11306-4 Abnormal Travel Reverse Pilot Pressure Sensor Low Voltage
11307-3 Abnormal Front Attachment Pilot Pressure Sensor High Voltage
11307-4 Abnormal Front Attachment Pilot Pressure Sensor Low Voltage
11310-3 Abnormal Brake Pressure Sensor High Voltage Applicable
11310-4 Abnormal Brake Pressure Sensor Low Voltage (Harness/Sensor)
11311-3 Abnormal Brake Remaining Pressure Sensor High Voltage
11311-4 Abnormal Brake Remaining Pressure Sensor Low Voltage
T5-7-127

11400-2 Abnormal Feedback Current of Maximum Pump 2 Flow Rate Limit Applicable (Harness)
11400-3 Abnormal Feedback High Voltage of Maximum Pump 2 Flow Rate
11400-4 Abnormal Feedback Low Voltage of Maximum Pump 2 Flow Rate
11401-2 Abnormal Feedback Current of Torque Control Solenoid Valve
11401-3 Abnormal Feedback High Voltage of Torque Control Solenoid Valve
11401-4 Abnormal Feedback Low Voltage of Torque Control Solenoid Valve
11410-2 Abnormal Feedback Current of Maximum Pump 1 Flow Rate Limit
11410-3 Abnormal Feedback High Voltage of Maximum Pump 1 Flow Rate
11410-4 Abnormal Feedback Low Voltage of Maximum Pump 1 Flow Rate
11403-2 Abnormal Feedback Current of Solenoid Valve Unit (SC) Applicable
11403-3 Abnormal Feedback High Voltage of Solenoid Valve Unit (SC) (Harness/Solenoid Valve)
11403-4 Abnormal Feedback Low Voltage of Solenoid Valve Unit (SC)
11424-2 Abnormal Feedback Current of Solenoid Valve Unit (SI)
11424-3 Abnormal Feedback High Voltage of Solenoid Valve Unit (SI)
11424-4 Abnormal Feedback Low Voltage of Solenoid Valve Unit (SI)
11425-2 Abnormal Feedback Current of Solenoid Valve Unit (SF)
11425-3 Abnormal Feedback High Voltage of Solenoid Valve Unit (SF)
11425-4 Abnormal Feedback Low Voltage of Solenoid Valve Unit (SF)
11422-2 Abnormal Feedback Current of Travel Motor Displacement Angle Not Applicable
11422-3 Abnormal Feedback High Voltage of Travel Motor Displacement
Angle Control Solenoid Valve
11422-4 Abnormal Feedback Low Voltage of Travel Motor Displacement
Angle Control Solenoid Valve
11423-2 Abnormal Feedback Current of Travel Make-Up Solenoid Valve Applicable
11423-3 Abnormal Feedback High Voltage of Travel Make-Up Solenoid (Harness/Solenoid Valve)
Valve
11423-4 Abnormal Feedback Low Voltage of Travel Make-Up Solenoid Valve
T5-7-128

11910-2 Actual Engine Speed Not Applicable
11911-2 Security Signal Not Applicable
11914-2 Radiator Coolant Temperature Not Applicable
11915-2 Gate Lock Signal Not Applicable
11918-2 Word Mode Not Applicable
11920-2 Fuel Flow Rate Not Applicable
11502-2 Travel Motor Excessive Rotation Not Applicable
11901-3 Abnormal Hydraulic Oil Temperature Sensor High Voltage Not Applicable
11901-4 Abnormal Hydraulic Oil Temperature Sensor Low Voltage
11921-2 Incorrect Odometer Value Not Applicable
T5-7-129
BLEEDING AIR FROM TRANSMISSION
2 1
IMPORTANT: Release any pressure in the
transmission after removing/installing
the pipe lines or hoses, or changing
the hydraulic oil. If air is mixed in the
transmission gearshift circuit,
malfunction of the transmission may
result.
NOTE: Bleed air by two or more persons. TCJB-01-02-020
1. Start the engine. Park the machine on level firm

ground. Lower the bucket onto the ground.
2. Perform the following steps. Apply the work
brake.
• Set the brake switch to the auto axle lock or axle
lock position. 3
• Depress the brake pedal fully.
NOTE: If the brake switch is the P (parking brake)
position, air bleeding work cannot be
performed.
3. Insert transparent vinyl tube (3) at the end of air

bleed plugs (1, 2) of the transmission. Put the
other one end into transparent container (4) filled
4
with hydraulic oil.
4. Switch travel speed mode switch (5) fast
speed/slow speed 4 to 5 times.
5. Fast speed side: M202-07-023
Set travel speed mode switch (5) to the fast

speed position. Loosen air bleed plug (1).
Slow speed side:
Set travel speed mode switch (5) to the slow
speed position. Loosen air bleed plug (2). Fast Speed 5
6. Discharge air in hydraulic oil. Tighten the air
bleed plug after 15 to 20 seconds. Slow Speed
7. Repeat steps 4 to 5 until air bubbles stop coming
out with the hydraulic oil. (About 4 to 5 times)
8. Tighten the air bleed plug.
TCJB-04-03-001
T5-7-130
BLEEDING AIR FROM BRAKE (AXLE)
IMPORTANT: If air is mixed in the brake system,

the brake function is reduced, 1
possibly resulting in serious hazard.
Be sure to bleed air from the brake
system after disconnecting and
reconnecting the pipe lines, or
changing the hydraulic oil. Bleed air
until hydraulic oil of approx. 500 mL
(0.13 US gal.) is drained from each
wheel (4 places) after air bubbles
disappear.
NOTE: Bleed air by two or more persons.
1. Set the brake switch in the steering column

monitor to the P (parking) position. Start the
engine. Increase the brake pressure.
MCBB-07-044
2. Insert transparent vinyl tube (2) at the end of air
bleed plug (1). Put the other one end into
transparent container (3) filled with hydraulic oil.
3. Depress brake pedal (4) repeatedly several times. 1
Then, depress and hdd brake pedal (4) fully.
4. In step 3, loosen air bleed plug (1) and drain the
hydraulic oil with air for several seconds.
5. Tighten air bleed plug (1).
6. Repeat steps 3 to 5 until air bubbles stop coming
2
out with the hydraulic oil.
NOTE: Although hydraulic oil of 500 mL (0.13 US
gal.) is drained, if air bubbles are still
remaining in the hydraulic oil, continuously
repeat steps 3 to 5.
7. Repeat steps 3 to 5 for the other 3 places. 3
IMPORTANT: After bleeding air from all four

places, bleed air from all four places M202-07-023
once more. After bleeding air by

steps 3 to 5 twice, make sure that air
is completely bled.
MCBB-01-008
T5-7-131
EMERGENCY BOOM LOWERING
PROCEDURE (WITHOUT HOSE RUPTURE
VALVE)
CAUTION: Do not stay under the boom

during operation.
2 1 Boom 1
If the engine stalls and cannot be restarted, lower the

boom to lower the bucket to the ground referring to
the emergency boom lowering procedure stated
below.
1. Remove rubber caps (1, 2) from the boom 1

section at 4-spool side in the control valve.
2. Attach a ring spanner or spanner onto lock nut (8).
Rotate to the left and remove lock nut (8).
: 17 mm
3. Put hexagonal wrench into screw (7). Rotate to
the right until screw (7) stops.
: 4 mm
4. Attach a ring spanner or spanner onto lock nut (5).
Rotate to the left and loosen lock nut (5) slightly.
: 17 mm
5. Put hexagonal wrench into screw (6). Rotate
screw (6) to the right and lower the boom while
adjusting the lowering speed. T16W-03-03-032
: 4 mm
6. Do not remove snap ring (3) and washer (4) at 1
this time. Do not rotate screw (6) too strong, or 3
washer (4) may be deformed. 6
7. After the boom is lowered onto the ground, rotate
4
screws (6, 7) to the left into the position that are
2
pulled completely. Rotate screw (7) to 1/8 turn 5
right. Tighten lock nuts (5, 8). 7
: 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
8
NOTE: If not tightening securely, leakage may
increase. Tighten completely with the
torque specifications.
8. Do not install rubber caps (1, 2) to the different

place.
NOTE: Install screws (7, 6) in this order.
TCGB-05-07-001
T5-7-132
ATTACHMENT CIRCUIT PRESSURE
RELEASE PROCEDURE
As for the machine, attached with the attachment, the

accumulator is equipped between the pilot pump and
the pilot valve.
Set the pilot shut-off lever to the UNLOCK position.

After stopping the engine with the engine stop switch
and when operating the control lever, the accumulator
will perform pressure release procedure in the pilot
circuit.
Travel Pilot Left Pilot Valve Right Pilot Valve

Valve
Pilot Shut-Off
Solenoid Valve
Control Valve
Accumulator
Pilot Pump
Engine TCJB-05-07-005
T5-7-133
(Blank)
T5-7-134
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
1. Disconnect the power source.

Remove the harness from the negative terminal
side in battery first when taking wire harnesses
and connectors off for repair or replacement work.
Failure to do so can result in damage to the wire
harnesses, fuses and fusible links and, in some
cases, cause fire due to short circuiting.
2. Color coding of wire harnesses.
As for the color codes of wire harnesses in the
electrical system, refer to the table below.
In cases on the design sheet where two colors are
indicated for one wire, the left initial stands for
base color, while the right initial stands for marking
color.
Code Color Code Color

R Red W White
L Blue G Green
Or Orange Lg Light
green
Y Yellow B Black
Br Brown P Pink
Gr Gray V Violet
NOTE: • Code BW indicates a black base wire

with white fine-line marking.
• Initials “O” and “Or” both stand for the
color orange.
• Wires with longitudinal stripes printed on
them are not color coded. Do not
confuse them with color coded wires.
T5-8-1
3. Precautions for connecting and disconnecting
terminal connectors.
• When disconnecting the harnesses, grasp
them by their connectors. Do not pull on the Correct Incorrect
wire itself. Release the lock first before
attempting to separate connectors, if a lock is
provided. (Refer to “Instructions for
Disconnecting Connectors on page T5-8-3.)
• The water-resistant connectors keep water out. T107-07-06-001
If water enters them, water will not easily drain

from them. When checking the water-resistant
connectors, take extra care not to allow water
to enter the connectors. In case water should
enter the connectors, reconnect only after the
connectors are thoroughly dried. Correct
• Before connecting terminal connectors, check
Rust
that no terminals are bent or coming off. In
addition, as most connectors are made of brass, Incorrect
(Deformation)
check that no terminals are rusting.
• When connecting terminal connectors provided Incorrect
with a lock, insert them together until the lock (Separation)
“clicks.” T107-07-06-002
• Pull the harness near the connector in order to
check if it is correctly connected.
4. Precaution for using a circuit tester.

• Before using a circuit tester, refer to the
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object to
Wind a Piece of Wire Tester Probe
be measured, voltage range and current
polarity.
• Before starting the connector test, always
check the connector terminal numbers,
referring to the circuit diagram. Sharpen the end of the Wire
When the connector size is very small, and the T107-07-06-003
standard probe size is too large to be used for

testing, wind a fine piece of sharpened wire or a
pin around the probe to make the test easier.
• When checking the connector by using a tester,
insert a tester probe from the harness end of
connector in order not to damage the terminal
inside connector.
T5-8-2
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS
• Push, Unlock and Separate Type
NOTE: 1. Connectors will not be easily separated

even if the lock is pushed while being
pulled. Push the lock first before pulling
the connectors.
2 The lock is located on female side
connector (harness end side).
T107-04-05-002
• Raise Lock, Pull and Separate Type
Locations of This Type Connector

Starter Relay
• Pull and Separate Type

T107-04-05-003
IMPORTANT: Before pulling and separating,

release the lock of connector in the
solenoid valve by using a pair of
pincers.

Dr. ZX
T107-04-05-004
• Push, Unlock, and Switch the Lever Type

Cab Harness to Main Harness
ECM
T1J1-05-08-003
T5-8-3
FUSE INSPECTION
Cracks in a fuse are so fine that it is very difficult or NOTE: All terminals located along the lengthwise
impossible to find by visual inspection. Use a tester in centerline of the fuse box are connected to
order to correctly inspect fuse continuity by following the power source, while terminals located
the instructions described below. away from center of the fuse box are
connected to loads (accessories).
1. Turn the key switch ON. Therefore, test all fuses in the same
When the key switch is turned ON, current from method except for the glow relay circuit
key switch terminal M activates the battery relay fuse. Check the glow relay circuit fuse with
so that electric power is supplied to all circuits the key switch turned to the ON position
except the glow plug relay circuit. (Refer to the and follow the procedure in step 3.
circuit diagram.)
2. Remove the fuse box cover. Set the tester.
(Measurement Range: 0 to 30 V)
3. Ground the negative probe of tester to the vehicle
frame. Touch the terminals located away from
center of the fuse box with the positive probe of
tester one at a time. When normal continuity of a
fuse is intact, the tester will indicate 20 to 25 V
(battery voltage).
30 40
10 20
29 39
9 19
28 38
8 18
27 37
7 17
26 36
6 16
25 35
5 15
24 34
4 14
23 33
3 13
22 32
2 12
21 31
1 11
M178-07-034
M178-07-034
T5-8-4
Fuse No. Capacity Connected to Fuse No. Capacity Connected to

1 20 A Boom Light Relay 21 10 A Clearance Light Relay (Right)
2 10 A Wiper Relay, Washer Relay, 22 10 A Head Light Relay (Right)
Wiper Motor
3 20 A Compressor Relay, Heater 23 10 A High-Beam Relay
Relay
4 10 A Pilot Shut-Off Solenoid Valve, 24 10 A Flasher, Turn Signal Light
Pilot Shut-Off Relay, Security Relay (Left) / (Right), Hazard
Relay, MC Solenoid Valve Switch
Power
5 5A Optional 1, Travel Alarm, 25 15 A Stop Light Relay
Auxiliary Power
6 10 A Optional 2 26 10 A −
7 10 A − 27 10 A Steering Column Monitor
Power
8 30 A ECM Main Relay 28 10 A Slow Speed Selection Relay,
Fast Speed Selection Relay,
Condenser (Pulse Signal
Conversion), Travel N Sensor
9 10 A Security Horn, Security Horn 29 10 A Outrigger Main Relay 1, Travel
Relay, Radio (Backup Power) Forward Pi Cut Solenoid Valve,
Travel Reverse Pi Cut
Solenoid Valve
10 5A MC/ICF Backup Power 30 10 A Assist (Optional), Power
Digging Relay
11 10 A Horn Relay 31 10 A Clearance Light Relay (Left)
12 10 A Cab Light, Radio Power 32 10 A Head Light Relay (Left)
13 10 A Cigarette Lighter 33 10 A Heater Seat (Optional)
14 10 A Fuel Pump 34 10 A Seat Compressor (Optional)
15 10 A Auxiliary 35 15 A Rotary Beacon Light (Optional)
16 5A Glow Plug Relay 36 10 A Rear Cab Light (Optional)
17 5A Air Conditioner Unit Power, 37 10 A Option Controller Power
Compressor Relay, Heater
Relay, Blower Hi Relay
18 5A MC/ECM/ICF/Monitor Unit/ 38 10 A Front Cab Light (Optional)
Option Controller/
Satellite Communication
Terminal Power ON Signal
19 10 A Monitor Unit Backup Power, 39 10 A Option Controller/
Buzzer Power Satellite Communication
Terminal Backup Power
20 5A Optional 3 40 10 A Front Cab Light
T5-8-5
FUSIBLE LINK INSPECTION
Battery Relay
Inspection
1. Visually inspect the fusible link.
Replacement
1. Remove the negative cable from the battery.

2. Pull out the fusible link. Replace the fusible link.
3. Install the negative cable to the battery.
Fusible Link M178-07-049
Fusible Link
T111-04-05-015
T5-8-6
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between

the battery positive terminal and the vehicle frame.
Normal Voltage: 24 V
NOTE: If voltage is abnormal, recharge or replace To Battery Relay

the battery.
2. Start the engine. Check voltage between the

battery positive terminal and the vehicle frame.
Normal Voltage: 26 to 28 V
NOTE: If voltage is abnormal, check the charging

system.
T162-05-06-005
T5-8-7
HOW TO CHECK ALTERNATOR Monitor Unit
Generally, if the alternator has generated electricity,

alternator alarm will disappear.
If the alternator alarm displays while the engine is
running, the alternator might be defective.
How to Check Alternator

1. Turn the key switch to the ON position. Confirm
that the alternator alarm is displayed.
2. Measure voltage between terminals B and E of

the alternator.
If the measured voltage is around 24 V, the
Alternator Alarm
alternator circuit can be considered normal. TCJB-05-02-050
If the measured voltage is low, a shortage in

battery capacity or looseness of the wire
connectors of alternator circuit might be the cause
of the malfunction.
When voltage is 0 V, the wiring between fuse box
and alternator might be loose or disconnected.
Also, the alternator cannot generate electricity if
the ground line is disconnected.
B
3. Next, start the engine and measure voltage
generated while as the alternator rotates. As
described above, measure voltage between
terminals B and E on the side of alternator.
If voltage is around 28 V, the alternator is
operating normally.
If the rated voltage is not being generated (around E
24V), there is some trouble with the alternator or
the regulator.
T157-07-06-003
T5-8-8
CONTINUITY CHECK Harness
Single-line continuity check A a

Disconnect both end connectors of the harness and
check continuity between both ends:
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity Ω
NOTE: When the one end connector is far apart

from the other, connect one end of
connector (A) to the machine chassis using Connect to the A a
machine.
a clip. Then, check continuity of the
harness through the vehicle frame as
illustrated.
Ω
To machine
If the ohm-meter reading is: 0 Ω = Continuity
∞ Ω = Discontinuity
A a
Single-line short-circuit check x Short-circuit
Disconnect both end connectors of the harness and between the
harness and
check continuity between one end connector of the the machine.
harness and the vehicle frame: Ω
If the ohm-meter reading is:
0 Ω = Short circuit is present.
∞ Ω = No short circuit is present.
T107-07-05-003
Multi-line continuity check First short-circuit (Clip)

Disconnect both end connectors of the harness, and
short-circuit two terminals, (A) and (B), at one end a
A
connector, as illustrated. Then, check continuity B b
between terminals (a) and (b) at the other connector. C c
If the ohm-meter reading is ∞ Ω, either line (A) - (a),
Second
or (B) - (b) is in discontinuity. To find out which line is short-circuit
discontinued, conduct the single line continuity
check on both lines individually, or, after changing
Ω
the short-circuit terminals from (A) - (B) to (A) - (C),
check continuity once more between terminals (a)
and (c).
T107-07-05-004
Short-circuit between
NOTE: By conducting the multi-line continuity harnesses
check twice, it is possible to find out which
line is discontinued. With terminals (A) and A a
(C) short-circuited, check continuity B X
b
between terminals (a) and (c). C c
0 Ω = Line (B) - (b) has discontinuity.
∞ Ω = Line (A) - (a) has discontinuity.
Multi-line short-circuit check Ω

Disconnect both end connectors of the harness, and
check continuity between terminals (A) and (B) or
(C). T107-07-05-005

0 Ω = Short-circuit exists between the lines.
∞ Ω = No short-circuit exists between the lines.
T5-8-9
VOLTAGE AND CURRENT
MEASUREMENT
Turn key switch ON so that the specified voltage

(current) is supplied to the location to be measured.
Judge if the circuit is normal by evaluating whether the
measured voltage (current) matches the specification.
24-Volt Circuit
Start checking the circuit in order up to the
location to be measured from either power
source or actuator side. Thereby, the faulty
location in the circuit will be found.
Black Probe (Negative) of Tester:
To ground to the vehicle frame
Red Probe (Positive) of Tester:
To touch the location to be measured
Engine Key Switch Location to be Measured Specification

Power Circuit
Stopped OFF Between (2) and (1): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (2): One Battery 10 to 12.5 V
Stopped OFF Between (3) and (1): Two Batteries 20 to 25 V
Stopped OFF Between (4) and (E): Battery Power 20 to 25 V
Stopped OFF Between (5) and (E): Fusible Link 20 to 25 V
Stopped OFF Between (1) and (E): Backup Current* 6 mA
Preheating Circuit
Stopped ON or START Between (6) and (E): Key Switch 20 to 25 V
Stopped ON or START Between (7) and (E): Glow Plug 20 to 25 V
Charging Circuit
Fast Speed ON Between (8) and (E): Alternator (B) / Generating 26 to 30 V
Voltage
Fast Speed ON Between (9) and (E): Battery Relay / Generating 26 to 30 V
Voltage
Fast Speed ON Between (10) and (E): Fuse Box / Starter Relay (R) 26 to 30 V
/ Generating Voltage
Fast Speed ON Between (11) and (E): Generating Voltage 13 to 30 V
Fast Speed ON Between (12) and (E): Monitor Unit (C7) 13 to 30 V
Surge Voltage
Prevention Circuit
Idle Speed ON Between (8) and (E): Alternator (B) 26 to 30 V
Idle Speed ON Between (11) and (E): Starter Relay (R) 13 to 30 V
Idle Speed ON Between (13) and (E): Load Damp Relay 26 to 30 V
Idle Speed ON Between (9) and (E): Battery Relay 26 to 30 V
Accessory Circuit
Stopped ON Between (14) and (E): Auxiliary 20 to 25 V
Stopped ON Between (15) and (E): Cigarette Lighter 20 to 25 V
Stopped ON Between (16) and (E): Radio, Cab Light 20 to 25 V
Stopped ON Between (17) and (E): Battery Relay 20 to 25 V
*Before measurement, disconnect the negative cable from the battery.
T5-8-10
Key Switch
Fuse
Box
5
1 2 3 4 6
17
Load
Damp
Relay
Battery Relay
Battery
13 10 14 15 16
9
Starter
Relay
11
8 7
Glow Plug Relay
Alternator
Glow
Plug
12
C7
Monitor
Unit
TCJB-05-08-001
T5-8-11
Engine Key Switch Location to be Measured Specification

Starting Circuit
Started START Between (18) and (E): Key Switch 20 to 25 V
Started START Between (19) and (E): Battery Relay (Coil) 20 to 25 V
Started START Between (20) and (E): Battery Relay (Switch) 20 to 25 V
Started START Between (21) and (E): Starter (B) 20 to 25 V
Started START Between (22) and (E): Starter (C) 20 to 25 V
Started START Between (23) and (E): Starter Relay (S) 20 to 25 V
Started START Between (24) and (E): Starter Cut Relay 20 to 25 V
Started START Between (25) and (E): Fuse Box 20 to 25 V
Started START Between (26) and (E): Fuse Box 20 to 25 V
Started START Between (27) and (E): ICF(C7) 20 to 25 V
Started START Between (28) and (E): Monitor Unit (A7) 20 to 25 V
Started START Between (29) and (E): MC(B16) 20 to 25 V
Started START Between (30) and (E): ECM(24) 20 to 25 V
Started START Between (31) and (E): Option Controller (B16) 20 to 25 V
Started START Between (32) and (E): ECM Main Relay 5V
Started START Between (33) and (E): ECM Main Relay 20 to 25 V
T5-8-12
25 26 18
Starter
Cut Relay
19
Battery
20 24 Fuse
Starter Box
21
Starter
Relay 22
23
32
ECM
Main
Relay
33
Option
ECM MC Monitor Unit ICF Controller
24 B16 A7 C7 B16
TCJB-05-08-001
30 29 28 27 31
T5-8-13
Key
Engine Location to be Measured Specification
Switch
Pilot Shut-Off Circuit
Stopped ON Between (34) and (E): Fuse Box 20 to 25 V
Stopped ON Between (35) and (E): Pilot Shut-Off Relay 20 to 25 V
Stopped ON Between (36) and (E): Pilot Shut-Off Solenoid Valve 20 to 25 V
Stopped ON Between (37) and Ground: Pilot Shut-Off Relay 20 to 25 V
Stopped ON Between (38) and (E): Security Relay 20 to 25 V
T5-8-14
34
Battery
Battery Relay
Fuse Box
36
Pilot
Shut-Off
Solenoid
Security Pilot
Relay Shut-Off
Relay
38 37 35
TCJB-05-08-001
T5-8-15
Fuse
5 Voltage Circuit
Power Signal or
• Voltage between terminal #1 and the vehicle Two Polarities Source Ground
frame 1 2
Disconnect the connector with the key switch OFF.
Measure voltage between terminal #1 on the
machine harness end connector and the vehicle
frame (ground).
• Key switch: ON V
• Tester black terminal (negative):
Connected to the vehicle frame (ground)
• Tester red terminal (positive):
Connected to terminal #1
T107-07-05-006
Power
Evaluation: Three Polarities
Source Signal Ground
If the measuring voltage is within 5±0.5 volts, the 1 2 3
circuit up to terminal #1 is normal.
• Voltage between terminal #1 and the ground

terminal T107-07-05-007
Disconnect the sensor connector with the key switch

OFF. Two Polarities
1 2
Measure voltage between terminal #1 on the
machine harness end connector and the ground
terminal (terminal #2 for two polarities, or terminal
#3 for three polarities).
V
• Key switch: ON
• Tester black terminal (negative):
Connected to the ground terminal
(terminal #2 or #3)
• Tester red terminal (positive):
Connected to terminal #1 T107-07-05-008
Evaluation: Three Polarities

If the measured voltage is within 5±0.5 volt, the 1 2 3
circuit up to terminal #1 or the ground terminal
(terminal #2 or #3) is normal.
T107-07-05-009
T5-8-16
CHECK BY FALSE SIGNAL

Two Polarities
Turn the key switch OFF. Disconnect the sensor (Hydraulic Oil Temperature Sensor)
connector. Turn the key switch ON. Connect terminal (Fuel Sensor)
1 2
#1 (power source) of machine harness end connector
to terminal #2 (signal). (Power voltage is used as a
false signal.) Check this state by using the monitor
function of Dr. ZX. When the maximum value is
displayed, MC and the circuit up to the machine
harness end connector are normal. If “ON” is displayed,
the pressure switch circuits are normal. Connect
IMPORTANT: Do not connect terminal #1 or #2 to

terminal #3 or to the vehicle frame
(ground) when checking a T107-07-05-010
three-polarity connector. Three Polarities

(Pressure Sensor)
(Pump Delivery Pressure Sensor)
NOTE: Some kinds of sensors can be monitored (Pump Control Pressure Sensor) 1 2 3
by the service menu of monitor (the built-in (Brake Pressure Sensor)
diagnosing system). (Brake Remaining Pressure Sensor)
(Boom Bottom Pressure Sensor)
Connect
T107-07-05-011
T5-8-17
TEST HARNESS
Install a test harness between connectors. Check the

circuit condition depending on whether the test
harness lamp lights or extinguishes during operation.
Parts Number 4283594 (ST 7126)

Use in order to check a single-line (discontinuity
and/or voltage).
During Operation: Lamp is ON. To Measuring Point.

To Ground
T107-07-05-012
Parts Number 4283594 (ST 7126)
Parts Number (ST 7226)

Use in order to check the solenoid valve unit circuits.
4
When the corresponding control lever or switch is 3
50
operated: Lamp is ON. 50
150 50
1 2 2 1
Parts Number (ST 7226) T107-07-06-015
T5-8-18
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162
SERVICE MANUAL REVISION REQUEST FORM
NAME OF COMPANY: MODEL:

PUBLICATION NO.:
YOUR NAME: (Located at the right top corner in the cover page)
DATE: PAGE NO.:

(Located at the bottom center in the page. If two or more re-
FAX: visions are requested, use the comment column)
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.
REPLY:
(Copy this form for usage)

THE ATTACHED DIAGRAM LIST
(The following diagrams are attached to this manual.)
1. ELECTRICAL CIRCUIT DIAGRAM (STANDARD)

(ZX140W-3: Up to serial No.002747/ ZX140W-3-AMS: Up to serial No.021417)
ELECTRICAL CIRCUIT DIAGRAM (STANDARD)
(ZX140W-3: Serial No.002748 and up/ ZX140W-3-AMS: Serial No.021418 and up)
2. ELECTRICAL CIRCUIT DIAGRAM (OPTIONAL)

ELECTRICAL CIRCUIT DIAGRAM (OPTIONAL)
3. CONNECTORS
CAB HARNESS
4. CAB HARNESS (PRODUCTION APRIL 2010 AND UP)

CAB HARNESS
5. ENGINE HARNESS
FLOOR HARNESS
6. MONITOR HARNESS
CHASSIS HARNESS
7. LEFT CONSOLE HARNESS

LEFT CONSOLE HARNESS
8. AUXILIARY / POSITIONING SELECT HARNESS

THE ATTACHED DIAGRAM LIST
9. BLADE / OUTRIGGER HARNESS

LICENSE PLATE HARNESS
10. POSITIONING HARNESS

PRESSURE SENSOR (POSITIONING) HARNESS
11. SWING PARKING BRAKE RELEASE HARNESS
12. ENGINE SUB HARNESS (1)

ENGINE SUB HARNESS (2)
13. BACK LAMP RELAY HARNESS

BACK LAMP RELAY HARNESS
14. HYDRAULIC CIRCUIT DIAGRAM (2-PIECE BOOM, FULLY OPTIONAL)

HYDRAULIC CIRCUIT DIAGRAM (MONOBLOCK BOOM, FULLY OPTIONAL)
NOTE: As for the optional harness diagram, refer

to “e-Cabinet”.

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INTRODUCTION

• Please refer to the other materials (operator’s

• Each page has a number, located on the center

Consecutive Page Number for Each Group

In this manual, the following safety alert symbol and • CAUTION:

RECOGNIZE SAFETY INFORMATION

UNDERSTAND SIGNAL WORDS

• To avoid confusing machine protection with personal safety

• NOTE indicates an additional explanation for an element

FOLLOW SAFETY INSTRUCTIONS

PREPARE FOR EMERGENCIES

WEAR PROTECTIVE CLOTHING

You may need:

• Avoid wearing loose clothing, jewelry, or other items that

PROTECT AGAINST NOISE

GENERAL PRECAUTIONS FOR CAB

USE HANDHOLDS AND STEPS

ADJUST THE OPERATOR'S SEAT

ENSURE SAFETY BEFORE RISING FROM OR LEAV-

FASTEN YOUR SEAT BELT

• We recommend that the seat belt be replaced every three

MOVE AND OPERATE MACHINE SAFELY

HANDLE STARTING AIDS SAFELY

• Starting fluid is highly flammable.

OPERATE ONLY FROM OPERATOR'S SEAT

KEEP RIDERS OFF MACHINE

PRECAUTIONS FOR OPERATIONS

INVESTIGATE JOB SITE BEFOREHAND

EQUIPMENT OF HEAD GUARD, ROPS, FOPS

ROPS: Roll-Over Protective Structure

PROVIDE SIGNALS FOR JOBS INVOLVING MUL-

CONFIRM DIRECTION OF MACHINE TO BE DRIVEN

DRIVE MACHINE SAFELY

• Driving on a slope may cause the machine to slip or over-

AVOID INJURY FROM ROLLAWAY ACCIDENTS

AVOID INJURY FROM BACK-OVER AND SWING

decreases, reduce speed and use proper lighting.

NEVER POSITION BUCKET OVER ANYONE

• Be careful when working on frozen ground.

NEVER UNDERCUT A HIGH BANK

DIG WITH CAUTION

OPERATE WITH CAUTION

AVOID POWER LINES

PRECAUTIONS FOR LIGHTENING

PROTECT AGAINST FLYING DEBRIS

PARK MACHINE SAFELY

• Close windows, roof vent, and cab door.

HANDLE FLUIDS SAFELY−AVOID FIRES

• All fuels, most lubricants, and some coolants are flammable.

Be sure to further follow the details described in the TRANS-

PRACTICE SAFE MAINTENANCE

Before servicing the machine:

• If a maintenance procedure must be performed with the

WARN OTHERS OF SERVICE WORK

SUPPORT MACHINE PROPERLY

STAY CLEAR OF MOVING PARTS

PREVENT PARTS FROM FLYING

STORE ATTACHMENTS SAFELY

SUPPORT MAINTENANCE PROPERLY

• After operation, engine coolant is hot and under pressure.

Hot fluids and surfaces:

REPLACE RUBBER HOSES PERIODICALLY

• Failure to periodically replace rubber hoses may cause a fire,