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 ......................... T4-5-4
4-Spool Solenoid Valve Unit Set
Group 2 Standard
Pressure ................................................. T4-5-6
Performance Standards ............................ T4-2-1
Main Pump Delivery Pressure................... T4-5-8
Main Pump P-Q Diagram.......................... T4-2-4
Fan Pump Delivery Pressure .................... T4-5-9
Fan Pump P-Q Diagram ........................... T4-2-5
Main Relief Set Pressure ........................ T4-5-10
Fan Pump I-Q Diagram............................. T4-2-6
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 Fan Pump Flow Rate Measurement........ T4-5-16
Swing Motor Drainage ............................ T4-5-22
Group 4 Excavator Test
Travel Motor Drainage ............................ T4-5-24
Travel Speed ............................................ T4-4-1
Track Revolution Speed............................ T4-4-2
Mistrack .................................................... T4-4-3
Travel Parking Leakage............................ T4-4-4
Swing Speed ............................................ T4-4-5
Swing Function Drift ................................. 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

18JT-4-1
(Blank)

18JT-4-2
 OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS

Use operational performance test procedure to quan-

titatively check all system and functions on the ma-
chine.

Purpose of Performance Tests

1. To comprehensively evaluate each operational
function by comparing the performance test data
with the standard values.
2. According to the evaluation results, repair, adjust,
or replace parts or components as necessary to
restore the machine’s performance to the desired
standard.
3. To economically operate the machine under op-
timal conditions.

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.

The machine performance does not always deterio-

rate as the working hours increase. However, the
machine performance is normally considered to re-
duce in proportion to the increase of the operation
hours. Accordingly, restoring the machine perform-
ance by repair, adjustment, or replacement shall con-
sider the number of the machine’s working hours.

Definition of “Performance Standard”

1. Operation speed values and dimensions of the
new machine.
2. Operational performance of new components
adjusted to specifications. Allowable errors will be
indicated as necessary.

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 20 m (65 ft 7 in), and to
make a full swing with the front attachment ex-
tended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.

PRECAUTIONS
1. Before starting to test, agree upon the signals to T105-06-01-003

be employed for communication among cowork-

ers. Once the test is started, be sure to commu-
nicate with each other using these signals, and to
follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid acci-
dents due to landslides or contact with
high-voltage power lines. Always confirm that
there is sufficient space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil.
Pay special attention to this when removing hy-
draulic pipings.

MAKE PRECISE MEASUREMENT

1. Accurately calibrate test instruments in advance
to obtain correct data. T105-06-01-004
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
 OPERATIONAL PERFORMANCE TEST / Standard
PERFORMANCE STANDARDS

For details including measuring method, refer to T4-3 NOTE: BH: 9.0 m Boom, 3.6 m Arm, 5.2 m3 Bucket
onward. BE: 7.55 m Boom, 3.4 m Arm, 6.7 m3
The value indicated in parentheses is only a Bucket
reference. LD: 6.5 m3 Bucket

* Conditions for measurement: Set the engine control

dial at Fast Idle. Maintain the hydraulic oil
temperature at 50±5 °C (122±9 °F).

EX1200-6
Performance Test Designation Remark
(Performance Standard)
ENGINE SPEED min
-1

Fast Idle Speed (High Idle) 1950±50

Slow Idle Speed 850±50
Auto-Idle Speed 1400±100
TRAVEL SPEED sec/20 m
Fast Speed Mode 21.5±1.6
Slow Speed Mode 30.8±2.0
TRACK REVOLUTION SPEED sec/3 rev
Fast Speed Mode 43.0±4.0
Slow Speed Mode 62.0±4.0
MISTRACK CHECK mm/20 m 200 or less
(Slow and Fast Mode)
TRAVEL MOTOR LEAKAGE mm/5 min 0
SWING SPEED sec/3 rev 34.0±2.0
SWING FUNCTION DRIFT mm/180 1100 or less Front attachment: BH
SWING MOTOR LEAKAGE mm/5 min 0
MAXIMUM SWING ABLE SLANT ANGLE deg. 12 or more Front attachment:
BH (10 or more: LD)
SWING BEARING PLAY mm (in) 2.0 (0.08) or less Allowable limit: 6.3

T4-2-1
 OPERATIONAL PERFORMANCE TEST / Standard

EX1200-6
Performance Test Designation Remark
(Performance Standard)
HYDRAULIC CYLINDER CYCLE TIME sec
Backhoe
Boom Raise 4.9±0.5 BE: 4.6±0.5
Boom Lower 3.3±0.5 BE: 3.5±0.5
Arm Roll-In 4.5±0.5 BE: 4.4±0.5
Arm Roll-Out 4.0±0.5 BE: 4.2±0.5
Bucket Roll-In 3.2±0.5 BE: 3.2±0.5
Bucket Roll-Out 2.8±0.5 BE: 2.7±0.5
Loading Shovel
Boom Raise 5.2±0.5
Boom Lower 4.0±0.5
Arm Roll-Out 2.9±0.5
Arm Roll-In 2.5±0.5
Bucket Roll-In 3.3±0.5
Bucket Roll-Out 2.2±0.5
Bucket Open 1.1±0.5
Bucket Close 1.6±0.5
HYDRAULIC CYLINDER DRIFT CHECK
mm/5 min (in/5 min)
Backhoe
Boom Cylinder 20 (0.8) or less (BE: 30 (1.2) or less)
Arm Cylinder 20 (0.8) or less (BE: 30 (1.2) or less)
Bucket Cylinder 30 (1.2) or less (BE: 30 (1.2) or less)
Front Drift Amount 300 (12) or less (BE: 400 (16) or less)
Loading Shovel
Boom Cylinder 20 (0.8) or less
Arm Cylinder 20 (0.8) or less
Bucket Cylinder 30 (1.2) or less
Front Drift Amount 300 (12) or less
CONTROL LEVER OPERATING FORCE
N (kgf, lbf)
Boom Lever 16.0 (1.6, 3.6) or less
Arm Lever 13.0 (1.3, 2.9) or less
Bucket Lever 13.0 (1.3, 2.9) or less
Swing Lever 16.0 (1.6, 3.6) or less
Travel Lever 24.5 (2.5, 5.5) or less

T4-2-2
 OPERATIONAL PERFORMANCE TEST / Standard

EX1200-6
Performance Test Designation Remark
(Performance Standard)
CONTROL LEVER STROKE mm (in)
Boom Lever 97±10 (3.8±0.4)
Arm Lever 82±10 (3.2±0.4)
Bucket Lever 82±10 (3.2±0.4)
Swing Lever 97±10 (3.8±0.4)
Travel Lever 120±10 (4.7±0.4)
BOOM RAISE/SWING SPEED sec/90°
Backhoe (Standard) 5.5±0.6
Backhoe (BE) 5.4±0.6
Loading Shovel 5.5±0.6
HYDRAULIC SYSTEM
PRIMARY PILOT PRESSURE 2
MPa (kgf/cm , psi)
Fast Idle 4.4±0.5 (45±5, 640±7)
Slow Idle 3.9±0.5 (40±5, 569±7)
SECONDARY PILOT PRESSURE more than 3.6 (37, 526)
2
MPa (kgf/cm , psi)
SOLENOID VALVE SET PRESSURE Value of Dr. ZX×±0.2 Compare with the value of Dr.
2
MPa (kgf/cm , psi) ZX
MAIN RELIEF SET PRESSURE 2
MPa (kgf/cm , psi)
Standard 31.9+2-0
(320+20-0,
4550+285-0)
Pressure Increasing 34.3+2-0
(350 -0, 4980+285-0)
+20

PORT RELIEF PRESSURE 2

MPa (kgf/cm , psi)
Arm, Boom, Bucket 35.3+1-0
(360+10-0,
5120+142-0)
Boom Lower (When Boom Mode Selector is 11.8+1-0
Operated) (120 -0, 1710+142-0)
+10

Bucket Open (LD) 33.3+1-0

(340 -0, 4835+142-0)
+10

Bucket Close (LD) 17.7+1-0

(180 -0, 2560+142-0)
+10

OVERLOAD RELIEF VALVE RELIEF

PRESSURE 2
MPa (kgf/cm , psi)
Travel 36.7+1-0
(375+10-0,
5330+142-0)
Swing 27.4±1
(280±10, 3980±142)
MAIN PUMP FLOW RATE L/min (US gal/min) -
OIL COOLER FAN MOTOR DRIVE PUMP -
FLOW RATE
SWING MOTOR DRAINAGE
0.2 to 0.3 (0.05 to 0.08) Allowable limit: 4 (1)
(WITH CONSTANT SPEED) L/min (US gal/min)
TRAVEL MOTOR DRAINAGE L/min (US gal/min)
5 (1.3) or less Allowable limit: 10 (2.6)
(Slow Speed: With the Track Jacked Up)

T4-2-3
 OPERATIONAL PERFORMANCE TEST / Standard
MAIN PUMP P-Q DIAGRAM
● Pump P-Q control
• Specified engine speed: 1800 min-1 (rpm) Flow Rate
Delivery Pressure
• Power mode switch P mode L/min
MPa (kgf/cm2, psi)
• Hydraulic oil temperature: 50±5°C (122±9 °F) (US gal/min)
A 20.0 (205, 2920) Approx. 340 (90)
NOTE: Refer to T4-5-14. B 25.0 (255, 3630) Approx. 270 (71)
C 30.0 (305, 4340) Approx. 220 (58)

Flow Rate

Delivery Pressure
T18J-04-02-001

T4-2-4
 OPERATIONAL PERFORMANCE TEST / Standard
FAN PUMP P-Q DIAGRAM
● Pump P-Q control
• Specified engine speed: 1800 min-1 (rpm) Flow Rate
Delivery Pressure
• Power mode switch P Mode L/min
MPa (kgf/cm2, psi)
• Hydraulic oil temperature: 50±5°C (122±9 °F) (US gal/min)
A 7.8 (80) 70 (18.5)
NOTE: Refer to T4-5-16. B 23.7 (242) 67 (17.7)
C 26.5 (270) 58 (15.3)

Flow Rate

Delivery Pressure

T18J-04-02-002

T4-2-5
 OPERATIONAL PERFORMANCE TEST / Standard
FAN PUMP I-Q DIAGRAM
● Pump I-Q control
• Specified engine speed: 1800 min-1 (rpm) Fan Pump Control Solenoid Flow Rate
• Power mode switch P mode Valve Command Current L/min
• Hydraulic oil temperature: 50±5°C (122±9 °F) mA (US gal)
71±3
A 370±30
(18.8±0.8)
15±3
B 594±40
(4.0±0.8)

Flow Rate

Fan Pump Control Solenoid Valve

T18J-04-02-003
Command Current

T4-2-6
 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 the monitor unit or Dr.
ZX, which Dr. ZX should be installed 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).

Measurement
1. Measure the engine speeds as shown in the
table.
2. Select the switch positions and the test
conditions as shown in the table below in
response to the engine speed to be measured.

Engine Control Power Mode Auto-Idle

Item Test Conditions for Measurement
Dial Switch Switch
Slow Idle Slow idle P OFF
Fast Idle Measure engine speed with the lever in
Fast idle HP, P, E OFF
(No-Load) neutral.
Fast Idle Measure engine speed while relieving
Fast idle HP, P, E OFF
(Relief Operation) the boom raise circuit.
Auto-Idle Speed Measure engine speed in 4 seconds
Fast idle P ON after returning all control levers to
neutral.

T4-3-1
 OPERATIONAL PERFORMANCE TEST / Engine Test
Evaluation
Refer to Operational Performance Standard in T4-2.

Remedy
Refer to Troubleshooting B in T5-6.

NOTE: Measure the engine speed by using the

engine speed meter as follows.
1. Stop the engine and turn the key switch OFF.
2. Connect the rotation pickup to the injection pipe
of the engine.
3. Start the engine. Read the engine speed at fast
idle and slow idle speed.
Engine speed = Pulse number x 60/138 (min-1)

T4-3-2
 OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED

Summary:
In order to check the performance of travel device
systems (from main pump to travel motor), measure
the time required for the excavator to travel a test
track.

Preparation:
1. Adjust the track sag (530 to 590 mm (21 to 23
in)) on both tracks equally.
2. Prepare a flat and solid test track 20 m (65.6 ft) in
length with extra length of 3 to 5 m (10 to 16 ft)
on both ends for machine acceleration and de-
celeration. Track Sag:
3. Empty the bucket and roll in the arm. 530 to 590 mm
(21 to 23 in)
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T145-05-03-001

Backhoe

Deceleration Zone: Travel Test Distance: Acceleration Zone:

3 to 5 m Finish 20 m Start 3 to 5 m T142-05-03-001
(10 to 16 ft) (65.6 ft) (10 to 16 ft)

Measurement:
1. Measure travel time at both fast and slow travel Loading Shovel
speeds.
2. Select the following switch positions.
Engine Control Dial: Fast Idle
Power Mode Switch: HP Mode
Work Mode Switch: Digging Mode
Auto-Idle Switch: OFF
3. Start traveling the machine in the acceleration
zone with the travel levers to full stroke.
4. Measure the time required to travel 20 m (65.6
ft).
5. After measuring the forward travel speed, swing
T145-05-03-006
the upperstructure 180° and measure the reverse
travel speed.
6. Repeat the measurement three times and calcu-
late the mean values.

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

Solution:
Refer to Troubleshooting B in T5-5.

T4-4-1
 OPERATIONAL PERFORMANCE TEST / Excavator Test
TRACK REVOLUTION SPEED
Summary:
In order to check the performance of travel device
systems (from main pump to travel motor), measure
the track revolution cycle time with the track raised 90 to 110°
off ground.

Preparation:
1. Adjust the track sag (530 to 590 mm (21 to 23 T142-05-03-011
in)) of both side tracks equally.
2. On the track to be measured, put the mark on
one shoe by using a piece of chalk or cloth.
3. Raise the track to be measured as illustrated.

CAUTION: Securely support the raised

machine by using the blocks. 90 to 110°

4. Maintain the hydraulic oil temperature at 50±5 °C

(122±9 °F).
T142-05-03-012

Measurement:
1. Measure the track rotation time at both fast and
slow travel speeds.
2. Select the following switch positions.
Engine Control Dial: Fast Idle
Auto-Idle Switch: OFF
3. Operate the travel control lever of the track to be
measured to full stroke.
4. Measure the time required for 3 revolutions in
both directions after a constant track revolution
speed is obtained.
5. Measure on both tracks in both forward and
Forward
reverse.
6. Repeat the measurement three times and Reverse
calculate the mean value.

Evaluation: Travel Device T145-05-03-001

Refer to Operational Performance Standard in T4-2.

Solution:
Refer to Troubleshooting B in T5-5.

T4-4-2
 OPERATIONAL PERFORMANCE TEST / Excavator Test
MISTRACK
Summary:
1. In oredr to check the performance of travel
device systems (from main pump to travel motor),
allow the machine to travel 20 m (65.6 ft).
Measure the maximum tread deviation from the
tread chord line drawn between the travel start
and end points.
2. If measured on a concrete surface, the tread
deviation has a trend to decrease.
T145-05-03-005

Preparation:
1. Adjust the track sag (530 to 590 mm (21 to 23
in)) of both tracks equally.
2. Prepare a flat and solid test track 20 m (65.6 ft) in
length with extra length of 3 to 5 m (10 to 16 ft)
on both ends for machine acceleration and
deceleration.
3. Set the front attachment in the driving position.
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

T145-05-03-006

Measurement:
1. Measure the amount of mistracking in both fast
and slow travel speeds.
2. Select the following switch positions.
Engine Control Dial: Fast Idle
Auto-Idle Switch: OFF
3. Start traveling the machine in the acceleration
zone with the travel levers at full stroke.
4. Measure the maximum distance between a Deceleration Zone:
3 to 5 m
straight 20 m (65.6 ft) tread chord and the tread (10 to 16 ft)
made by the machine.
5. After measuring the tracking in forward travel,
turn the upperstructure 180° and measure in
Maximum Distance (A)
reverse travel.
6. Repeat the measurement three times and 20 m (65.6 ft)
calculate the mean value.

Evaluation:
Refer to Operational Performance Standard in T4-2.
Acceleration Zone:
3 to 5 m
Remedy: (10 to 16 ft)
Refer to Troubleshooting B in T5-5. T115-07-03-005

T4-4-3
 OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL PARKING LEAKAGE
Summary:
Measure the parking brake function on a specified
0.5 to 1.0 m
slope. (20 to 40 in)

Preparation:
1. The surface of test slope shall be even with a
gradient of 20 % (11.31°).
2. Position the front attachment as follows:
With the arm and bucket cylinders fully extended, T142-05-03-002

hold the bucket 0.5 to 1.0 m (20 to 40 in) above

the ground.
0.5 to 1.0 m
3. Maintain the hydraulic oil temperature at 50±5 °C (20 to 40 in)
(122±9 °C).

Measurement
1. Climb the slope and return the travel lever to
neutral.
2. Stop the engine. T118-04-03-001

3. After the machine stops, put the matching marks

on the track link or the shoe and the track side
frame.
4. After five minutes, measure the distance between
the marks on the track link or the shoe and the
track side frame.

Evaluation Matching
Refer to Operational Performance Standard in T4-2. Marks on Track
Side Frame and Shoe
When Machine Stops.
Displacement measured
after 5 minutes.
T105-06-03-006

T4-4-4
 OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING SPEED
Summary:
1. In order to check the performance of swing
device systems (from main pump to swing motor),
measure the time required to swing three
complete turns.

Preparation:
1. Check lubrication of the swing gear and the
T145-05-03-007
swing bearing.
2. Place the machine on the flat and solid ground
with ample space for swinging. Do not conduct
this test on slopes.
3. Position the front attachment as follows.
Backhoe:
With the arm cylinders fully retracted and the
bucket cylinder fully extended, hold the bucket so
that the height of the arm end pin is the same as
the boom foot pin.
Loading shovel:
With the arm cylinder fully extended and the T145-05-03-008

bucket cylinder fully extended, hold the bucket so

that the height of the arm end pin is the same as
the boom foot pin.
The bucket should be empty.
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

CAUTION: Prevent personal injury. Always

make sure that the area is clear and that
co-workers are out of the swing area before
starting the measurement.
3 Turns
Measurement:
1. Select the following switch positions.
Engine Control Dial: Fast Idle
Auto-Idle Switch: OFF
2. Operate the swing control lever fully.
3. After the swing attains to constant speed,
measure the time required to swing three turns in
one direction.
4. Operate swing control lever fully in the opposite
direction and measure the time required for three
turns.
5. Repeat the measurement three times and T145-05-03-009
calculate the mean value.

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

Solution:
Refer to Troubleshooting B in T5-5.

T4-4-5
 OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING FUNCTION DRIFT
Summary:
1. In oreder to check the performance of swing
brake valve, measure the swing drift on swing
bearing outer circumference when stopping after
a 180° full-speed swing.
2. The mechanical brake for the swing parking
brake is equipped for the swing motor.

Preparation: T145-05-03-007

1. Check lubrication of the swing gear and the

swing bearing.
2. Place the machine on the flat and solid ground
with ample space for swinging. Do not conduct
this test on a slope.
3. Position the front attachment as follows.
Backhoe:
With the arm cylinders fully retracted and the
bucket cylinder fully extended, hold the bucket so
that the height of the arm end pin is the same as
the boom foot pin.
Loading shovel:
With the arm cylinder fully extended and the T145-05-03-008

bucket cylinder fully extended, hold the bucket so

that the height of the arm end pin is the same as
the boom foot pin.
The bucket should be empty.
4. Put the matching marks on the swing bearing
outer circumference (upperstructure side) and
the track frame.
5. Swing the upperstructure 180°.
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

T4-4-6
 OPERATIONAL PERFORMANCE TEST / Excavator Test

CAUTION: Prevent personal injury. Always Return the

make sure that the area is clear and that swing control
co-workers are out of the swing area before lever to the
neutral position.
starting the measurement.
Measurement:
1. Select the following switch positions. Drift
Amount
Engine Control Dial: Fast Idle
Auto-Idle Switch: OFF
2. Operate the swing control lever fully and return it
to the neutral position when the mark on
upperstructure aligns with that on track frame
after swinging 180° .
3. Measure the distance between the two marks.
4. Align the marks again and swing 180°. Then test
in the opposite direction.
5. Repeat the measurement three times and
calculate the mean value. Swing 180 °

Evaluation:
Refer to Operational Performance Standard in T4-2.
Solution:
Refer to Troubleshooting B in T5-5. Operate the swing T142-05-03-003
control lever fully.

T4-4-7
 OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING MOTOR LEAKAGE
Summary:
In order to check the performance of swing parking
brake, measure the upperstructure drift while
suspending a load on a specified slope. (The
mechanical brake for the swing parking brake is
equipped for the swing device.)

Preparation:
1. Check lubrication of the swing gear and the
swing bearing.
2. Load the bucket fully. In lieu of loading the bucket,
weight (W) of the follwing specification can be
used.
W = 7500 kg (16500 lb): Backhoe
9750 kg (21500 lb): Loading shovel T142-05-03-004
3. Position the front attachment as follows.
Backhoe: With the arm cylinder fully retracted
and the bucket cylinder fully extended, hold the
bucket so that the height of the arm end pin is the
same as the boom foot pin.
Loading shovel: With the arm cylinder fully
extended and the bucket cylinder fully extended,
hold the bucket so that the height of the arm end
pin is the same as the boom foot pin.
4. Park the machine on a smooth slope with a
gradient of 26.8 % (15°),
5. Climb a slope and swing the upperstructure to
position it 90° to the slope. Put the matching
marks on the outer circumference of swing
bearing (upperstructure side) and track frame by
using the tape.
6. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measure Distance Between Marks

Measurement:
1. Stop the engine. After five minutes, measure the
distance between the marks along the swing
bearing outer circumference and the track frame.
2. Perform the measurement in both right and left
swing directions.
3. Repeat the measurement three times and Marking on Track Frame
calculate the mean value.
Marking on Swing Bearing
Evaluation:
T105-06-03-010
Refer to Operational Performance Standard in T4-2.

Solution:
Refer to Troubleshooting B in T5-5.

T4-4-8
 OPERATIONAL PERFORMANCE TEST / Excavator Test
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
1. With the upperstructure swung 90° to the slope,
check the maximum slant angle on which the
upperstructure can swing to the uphill side.

Preparation:
1. Check lubrication of the swing gear and the
swing bearing.
2. Load the bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
W = 7500 kg (16500 lb): Backhoe
9750 kg (21500 lb): Loading shovel
3. Position the front attachment as follows.
Backhoe: With the arm cylinder fully retracted
and the bucket cylinder fully extended, hold the
bucket so that the height of the arm end pin is the T142-05-03-004

same as the boom foot pin.

Loading shovel: With the arm cylinder fully
extended and the bucket cylinder fully extended,
hold the bucket so that the height of the arm end
pin is the same as the boom foot pin.
4. Climb a slope and swing the upperstructure 90°
to the slope.
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement:
1. Select the following switch positions.
Engine Control Dial: Fast Idle
Auto-Idle Switch: OFF
2. Operate the swing lever to full stroke to swing the
upperstructure to the uphill side.
3. If the machine can swing, measure the cab floor
slant angle.
4. When the machine can swing, increase the slant
angle. Repeat the test until the maximum swin-
gable angle is obtained. Check in both clockwise
and counterclockwise directions.
5. Repeat the measurement three times and
calculate the mean value.

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

Solution:
Refer to Troubleshooting B in T5-5.

T4-4-9
 OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING BEARING PLAY
Summary:
In order to check the wear of the bearing races and Dial Gauge
the balls, measure the swing bearing play.

Preparation:
1. Check the swing bearing mounting bolts for
looseness.
2. Check lubrication of the swing bearing. Confirm
that bearing rotation is smooth and without noise.
Round Trunk
3. Secure a dial gauge on the round trunk of track
frame by using a magnetic base.
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the front
Magnetic
idlers. Base
5. Position the dial gauge so that its needle point T105-06-03-015

comes into contact with the center bottom sur-

face of the swing bearing outer race.
6. The bucket should be empty.

NOTE: The measured value will vary depending

on where the magnetic base is secured.
Secure the magnetic base onto the round
trunk or in a position as close to the round
trunk as possible.

T4-4-10
 OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Measure the play at positions A, B, C, and D.
2. Position the front attachment as follows.
Backhoe:
With the arm cylinder fully retracted and the A
bucket cylinder fully extended, hold the bucket so D B
that the height of the bucket bottom is the same Measure the plays at
as the boom foot pin. positions A, B, C, and
C D.
Loading shovel:
With the arm cylinder fully extended and the
bucket cylinder fully extended, hold the bucket so
that the height of the bucket bottom is the same
as the boom foot pin.
Record dial gauge reading (h1).
3. Lower the bucket to the ground and raise the
front idler 0.5 m (20 in) by using the front
attachment. Record dial gauge reading (h2).
4. Calculate bearing play (H) from dial gauge
readings (h1 and h2) as follows:
H=h2 - h1
T145-05-03-023
Evaluation:
Refer to Operational Performance Standard in T4-2.

Backhoe
Measurement : (h1) Measurement : (h2)

T142-05-03-006

Loading Shovel
Measurement : (h1) Measurement : (h2)

T142-05-03-005

T4-4-11
 OPERATIONAL PERFORMANCE TEST / Excavator Test
HYDRAULIC CYLINDER CYCLE TIME
Summary:
1. In order to check the performance of front
attachment systems (from main pump to each
cyliner), measure the cycle time of boom, arm,
bucket, and bucket open/close cylinder.
2. The bucket should be empty.

Preparation:
1. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

NOTE: When the bucket weight is increased by

welding wear-resist plates, cylinder cycle
time may become longer. Backhoe

Measurement:
1. Select the following switch positions. Boom Cylinder
Engine Control Dial: Fast Idle
Auto-Idle Switch: OFF
2. Position the front attachment as followings.
Operate the control lever fully and measure the
time to full stroke. (Cylinder full stroke includes
T145-05-03-012
cushioning zone.)
• Backhoe
When measuring the cycle time of the boom
cylinder:
With the bucket cylinder fully extended and the
arm cylinder fully retracted, lower the bucket to
the ground. Arm Cylinder
When measuring the cycle time of the arm
cylinder:
With the bucket cylinder fully extended, adjust the T145-05-03-013

boom height so that the arm oscillation center

faces vertically to the ground while holding the
bucket bottom height at approx. 0.5 m above the
ground.
Set the arm so that the encter of arm operation is
vertical.
When measuring the cycle time of the bucket
cylinder: Bucket Cylinder
T145-05-03-014
Adjust the boom and arm cylinders so that the
bucket oscillation center faces vertically to the
ground.

T4-4-12
 OPERATIONAL PERFORMANCE TEST / Excavator Test
• Loading Shovel Loading Shovel
When measuring the cycle time of the boom
cylinder:
With the bucket cylinder and the arm cylinder
fully extended, lower the bucket to the ground.
When measuring the cycle time of the arm
cylinder: Boom Cylinder
With the arm fully retracted, position the bucket
so that the rear bucket does not come in contact
with the arm stopper. Adjust the boom cylinder
stroke in order to position the bucket bottom 1 m
(39 in) above the ground. T145-05-03-015

When measuring the cycle time of the bucket

cylinder:
With the bucket closed and held in a load dump
position, adjust the boom so that bucket bottom
height is approx. 1 m (39 in) above the ground.
When measuring the cycle time of the bucket
open/close cylinder:
With the bucket cylinder and the arm cylinder Arm Cylinder
T145-05-03-016
fully extended, adjust the boom so that the
bucket bottom height is approx. 1 m (39 in) above
the ground.
3. Repeat the measurement three times and calcu-
late the mean value.
Bucket Cylinder

Evaluation:
T145-05-03-017
Refer to Operational Performance Standard in T4-2

Remedy:
Refer to Troubleshooting B in T5-5.

Bucket Open/Close Cylinder

T145-05-03-018

T4-4-13
 OPERATIONAL PERFORMANCE TEST / Excavator Test
DIG FUNCTION DRIFT CHECK
Summary:
1. Evaluate the internal oil leakage in the control
valve, boom, arm, and bucket cylinders by
measuring cylinder (dig function) drift with the
bucket loaded.

2. When checking soon after cylinder replacement,

T145-05-03-020
slowly operate each cylinder for ten minutes to its
stroke end and bleed air from the cylinder.

Preparation:
1. Load the bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
W = 7500 kg (16500 lb): Backhoe
9750 kg (21500 lb): Loading shovel
2. Position the front attachment as followings. T145-05-03-021

Backhoe:
With the arm cylinder fully retracted, and the
bucket cylinder fully extended, hold the bucket so
that the height of the arm end pin is the same as
the boom foot pin.
Loading shovel:
With the arm cylinder and the bucket cylinder
fully extended, hold the bucket so that the height
of the arm end pin is the same as the boom foot BH: Boom and Bucket Cylinders Retraction
LD: Boom, Arm, and Bucket Cylinders Retraction
pin.
3. Position the arm cylinder with the rod 50 mm (2 Mark Mark
in) extended from the fully retracted position.
Position the bucket cylinder with the rod 50 mm
(2 in) retracted from the fully extended position.
4. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped, T110-06-03-002

measure the change in position of bottom of the

arm tip, as well as the boom, arm and bucket BH: Arm Cylinder Extension
cylinders.
3. Repeat the measurement three times and
calculate the mean value.

NOTE: When the bucket weight is increased by Mark

welding wear-resist plates, cylinder drift
may increase.

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

Solution:
Refer to Troubleshooting B in T5-5. T110-06-03-001

NOTE: BH: Backhoe

LD: Loading Shovel

T4-4-14
 OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER OPERATING FORCE

Summary:
1. Measure a play and operating condition of each
control lever.
2. Measure the maximum operating force of the
front attachment control lever.
3. Measure the operating force at the grip center of
each control lever.

Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
T107-06-03-003

CAUTION: Prevent personal injury. Always

make sure that the area is clear and that
co-workers are out of the swing area before
starting the measurement.

Measurement:
1. Measure each control lever.
2. Select the following switch positions.
Engine Control Dial: Fast Idle
Auto-Idle Switch: OFF
3. In case of boom (raise), arm and bucket lever,
operate each lever to full stroke and measure the
maximum operating force.
4. In case of boom (lower) lever, measure the
maximum operating force with the boom (lower) T107-06-03-004
relieved by raising the machine in a stable area.
5. In case of swing lever, measure the maximum
operating force with swing relieved after securing
the front attachment to prevent turning.
6. In case of travel lever, raise the track to be
measured. Measure the maximum operating
force required.
7. Repeat the measurement three times and calcu-
late the average values.

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

T4-4-15
 OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER STROKE
Summary:
1. Check a play and operating condition and
measure each control lever stroke.
2. Measure the lever stroke at the grip center of
each control lever.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both
side lever strokes.

Preparation:
1. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement: T107-06-03-005

1. Stop the engine.

2. Measure each lever stroke from neutral to the
stroke end of each control lever of boom, arm,
bucket, swing and travel.
3. Measure the chord length from neutral to the
stroke end.
4. Repeat the measuement three times and
calculate the average values.

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

T4-4-16
 OPERATIONAL PERFORMANCE TEST / Excavator Test
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 if the cylinders do not hesitate while oper-
ating the cylinder with the engine running at fast T142-05-03-007
idle.

Preparation:
1. Position the front attachment as followings.
Backhoe:
With the arm cylinder fully retracted and the
bucket cylinder fully extended, lower the bucket
onto the ground.
Loading shovel: T142-05-03-008

With the arm and the bucket cylinders fully ex-

tended, lower the bucket onto the ground.
The bucket should be empty.
2. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

CAUTION: Prevent personal injury. Always

make sure that the area is clear and that
co-workers are out of the swing area before
starting the measurement.

Measurement:
1. Select the following switch positions. T142-05-03-009
Engine Control Dial: Fast Idle
Auto-Idle Switch: OFF
2. Raise the boom and roll the swing in full stroke at
the same time.
Measure the time required to turn the
upperstructure 90° and height (H) of the bucket
teeth. (The bucket should be empty.)
3. Repeat the measurement three times and
calculate the mean value. H

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

Remedy:
Refer to Troubleshooting B in T5-5.
T142-05-03-010

T4-4-17
 OPERATIONAL PERFORMANCE TEST / Excavator Test
(Blank)

T4-4-18
 OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE

Summary:
Measure the primary pilot pressure.

Preparation:
1. Stop the engine.
2. Loosen the filling cap on the hydraulic oil tank
and bleed air.
3. Disconnect the plug from the pilot filter. Install the Plug
adapter (ST 6069) and the pressure gauge (ST
6942) to the pressure check port.
: 14 mm

4. Start the engine. Confirm that no oil leakage is T178-03-07-001

observed at the pressure gauge connection.

5. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement:
1. Select the following switch positions:
Engine Power Mode Auto-Idle
Control Dial Switch Switch
Fast Idle HP Mode OFF
Slow Idle HP Mode OFF

2. Measure pilot pressure in each specified setting

above without load.
3. Repeat the measurement three times and calcu-
late the mean value.

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

T4-5-1
 OPERATIONAL PERFORMANCE TEST / Component Test
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 quantity of shims (2). T178-03-07-001

3. After adjustment, tighten plug (1).

: 25+2 N⋅m (2.5+0.2 kgf⋅m, 18.4+1.5 lbf⋅ft) 1
2
4. After adjustment, check the set pressure.

NOTE: Standard Change in Pressure (Reference)

Shim Thickness Change in Pressure
(mm) kPa (kgf/cm2, psi)
0.25 78 (0.8, 11.3)
0.5 157 (1.6, 22.8)
1.0 304 (3.1, 44.2)

T111-06-04-004

T4-5-2
 OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)

T4-5-3
 OPERATIONAL PERFORMANCE TEST / Component Test
SECONDARY PILOT PRESSURE
Summary:
Measure the secondary pilot pressure at the signal
control valve part.

Preparation:
1. Stop the engine.
2. Loosen the filling cap on the hydraulic oil tank
and bleed air.
3. Measure the secondary pilot pressure at the con-
trol valve connecting side in the signal control
valve. Disconnect the pilot hose from the circuit
to be measured. Connect the hose (9/16-18UNF,
Length: approx. 400 mm (16 in)) to the signal
control valve side. Install the pressure gauge (ST
6315) to the hose.
: 17 mm, 19 mm
NOTE: Use the tool (SNAP-ON GAN850812B:
size 19.05 mm) in order to easily discon-
nect the hose from the signal control valve.

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

observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement:
1. Select the following switch positions:
Engine Power Mode Auto-Idle
Control Dial Switch Switch
Fast Idle HP Mode OFF
Slow Idle HP Mode OFF
2. Measure pilot pressure by using a pressure
gauge with the corresponding control lever oper-
ated to full stroke.
3. Repeat the measurement three times and calcu-
late the mean value.

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

T4-5-4
 OPERATIONAL PERFORMANCE TEST / Component Test

Signal Control Valve (Control Valve Side)

10

2
11
3

4
12

8
13

14

T18J-03-06-002

Port Connecting Location

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-In Pilot Pressure (BH)
Arm Extend (LD)
Port 4 Control Valve Arm Roll-Out Pilot Pressure (BH)
Arm Retract (LD)
Port 7 Control Valve Bucket Roll-In Pilot Pressure (BH)
Bucket Tilt-In Pilot Pressure (LD)
Port 8 Control Valve Bucket Roll-Out Pilot Pressure (BH)
Bucket Tilt-Out Pilot Pressure (LD)
Port 9 Control Valve Left Travel Forward Pilot Pressure
Port 10 Control Valve Left Travel Reverse Pilot Pressure
Port 11 Control Valve Right Travel Forward Pilot Pressure
Port 12 Control Valve Right Travel Reverse Pilot Pressure
Port 13 Control Valve Auxiliary Pilot Pressure (BH)
Bucket Close Pilot Pressure (LD)
Port 14 Control Valve Auxiliary Pilot Pressure (BH)
Bucket Open Pilot Pressure (LD)
NOTE: BH: Backhoe
LD: Loading Shovel

T4-5-5
 OPERATIONAL PERFORMANCE TEST / Component Test
4-SPOOL SOLENOID VALVE UNIT SET
PRESSURE Solenoid Valve Unit
Pressure Gauge
Summary:
Measure the secondary pressure of the 4-spool so-
lenoid valve unit. Compare the result with the data
displayed on the monitor and check for the abnor-
mality.

Preparation:
1. Stop the engine. Hose Tee Adapter T157-05-04-002

2. Loosen the filling cap on the hydraulic oil tank

and bleed air.
3. Connect Dr. ZX and select the monitoring func-
tion. Disconnect the hose from the solenoid
valve to be measured in the 4-spool solenoid
valve unit. Install the tee (ST 6451), the hose
(Parts Number: 4216453), the adapter (ST 6461),
and the pressure gauge (ST 6942).
: 17 mm, 19 mm, 22 mm
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement:
1. Select the following switch positions:
Engine Power Mode Auto-Idle
Control Dial Switch Switch
Fast Idle HP Mode OFF
Slow Idle HP Mode OFF SC SF SI SG

2. Operate the solenoid valve to be measured as

followings.
SG: Turns the heavy lift switch ON.
SI: Turns the travel mode switch ON.
SF: Performs combined operation of boom lower
and arm, or boom lower and bucket.
SC: Turns the boom mode switch ON. Operates
the attachment except for travel.
3. Read the values on both Dr. ZX and the pressure T1V1-03-07-007
gauge.
4. Repeat the measurement three times and calcu-
late the mean value.

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

T4-5-6
 OPERATIONAL PERFORMANCE TEST / Component Test
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 from the most
tightened condition.
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

: 3 N⋅m (0.3 kgf⋅m, 2.2 lbf⋅ft) 2.0 mm (0.079 in) or less

: 3 mm from end of Lock Nut

3. After adjustment, check the set pressure.

NOTE: Standard Change in Pressure (Reference)
Screw Turns 1/4 1/2 3/4 1
kPa 69 137 206 275 7
Change in
(kgf/cm2) (0.7) (1.4) (2.1) (2.8)
Pressure
(psi) (10) (20) (30) (40)

T1V1-04-05-003

7 8

Pressure Pressure
Increase Decrease

W107-02-05-129

T4-5-7
 OPERATIONAL PERFORMANCE TEST / Component Test
MAIN PUMP DELIVERY PRESSURE
Summary:
Measure the delivery pressure of the main pump by
using Dr. ZX or a pressure gauge. Main Pump

Preparation:
1. Stop the engine.
2. Loosen the filling cap on the hydraulic oil tank
and bleed air.
3. Connect Dr. ZX and select the monitoring func-
tion. When Dr. ZX is not available, remove the
plug of the pressure check port from the corre-
sponding main pump delivery port. Install the
adapter (ST 6069), the hose (ST 6943), and the
pressure gauge (ST 6941).
: 6 mm
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement: Pressure Check Port

T18J-04-05-002

1. 1.Select the following switch positions:

Engine Power Mode Auto-Idle
Control Dial Switch Switch
Fast Idle HP Mode OFF

2. Measure pressure with the control levers in neu-

tral without load.
3. Repeat the measurement three times and calcu-
late the mean value.

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

Remedy:
Refer to Troubleshooting B in T5-7.

T4-5-8
 OPERATIONAL PERFORMANCE TEST / Component Test
FAN PUMP DELIVERY PRESSURE
Summary:
Operate the fan pump and measure the delivery
pressure of the fan pump. Fan Pump

Preparation:
1. Stop the engine.
2. Loosen the filling cap on the hydraulic oil tank
and bleed air.
3. Remove the plug of the pressure check port from
the fan pump delivery port. Install the elbow (ST
6287), hose (ST 6943), and the pressure gauge
(ST 6941).
: 6 mm
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement:
1. Select the following switch positions:
T18J-04-05-004
Engine Power Mode Auto-Idle Pressure Check Port
Control Dial Switch Switch
Fast Idle HP Mode OFF

2. Measure pressure with the control levers in neu-

tral without load.
3. Repeat the measurement three times and calcu-
late the mean value.

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

Remedy:
Refer to Troubleshooting B in T5-7.

T4-5-9
 OPERATIONAL PERFORMANCE TEST / Component Test
MAIN RELIEF SET PRESSURE
Summary:
Measure the main relief valve set pressure at the de-
livery port in the main pump. Main Pump

Preparation:
1. Stop the engine.
2. Loosen the filling cap on the hydraulic oil tank
and bleed air.
3. Connect Dr. ZX and select the monitoring func-
tion. When Dr. ZX is not available, disconnect the
plug of the pressure check port from the corre-
sponding main pump delivery port. Install the
adapter (ST 6069), the hose (ST 6943), and the
pressure gauge (ST 6941).
: 6 mm
4. Start the engine. Confirm that no oil leakage is
observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement: Pressure Check Port

T18J-04-05-002

1. Select the following switch positions:

Engine Power Mode Auto-Idle
Control Dial Switch Switch
Fast Idle HP Mode OFF

2. Measure the main relief set pressure at low pres-

sure and the high pressure.
3. When measuring at low pressure, slowly operate
the bucket, arm, and boom control levers. Oper-
ate each cylinder to the stroke end and relieve
each function.
4. When measuring at high pressure, secure the
tracks against an immovable object. Slowly oper-
ate the travel control lever and relieve the travel
function.
NOTE: The swing overload relief pressure is lower
than the main relief set pressure.
Therefore, even if the swing motor is re-
lieved, the main relief set pressure cannot
be measured.

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

T4-5-10
 OPERATIONAL PERFORMANCE TEST / Component Test
NOTE: If the measured pressures for all functions
are lower than the specified range, the Main Relief
Valve
probable cause may be a decrease of
main relief valve set pressure.
If the relief pressure of a particular function
is lower, the probable cause may be other
than the main relief valve.

Main Relief Valve Pressure Adjustment Proce-

dure:
When adjusting the pressure at the high pressure,
adjust the high-pressure main relief pressure.
When adjusting the pressure at the low pressure,
adjust the low-pressure main relief pressure.
If adjusting the high-pressure main relief pressure, T18J-03-03-001
the low-pressure main relief set pressure is changed.
Therefore, adjust the low-pressure main relief pres-
sure after adjusting the high-pressure main relief
1
pressure.
2
•High-Pressure Main Relief Set Pressure Adjust-
3
ment:
1. Loosen lock nut (2). Lightly tighten plug (1) until it 4
comes in contact with the bottom of sleeve (6).
5 A
Tighten lock nut (2) (low-pressure).
: 30 mm
: Lock nut (2):
59 N⋅m (6 kgf⋅m, 43 lbf⋅ft) or less
2. Loosen lock nut (4). While holding the condition
set in step 1, turn plug (3) until the desired pres-
sure is obtained.
: 41 mm
: Lock nut (4)
98 N⋅m (10 kgf⋅m, 72 lbf⋅ft) or less

•Low-Pressure Main Relief Set Pressure Adjust-

ment:
T16J-04-04-003
3. Loosen lock nut (2). Turn plug (1) counterclock-
wise until the specified pressure is obtained.
Tighten lock nut (2).
: 30 mm 1, 3
: Lock nut (2): 59 N⋅m
(6 kgf⋅m, 43 lbf⋅ft) or less
4. After adjustment, check the set pressure.

NOTE: Approx. 4.5 MPa (46 kgf/cm2, 654 psi) Pressure Pressure
Increase Decrease
increase/decreases by a quarter turning.

W107-02-05-127

T4-5-11
 OPERATIONAL PERFORMANCE TEST / Component Test
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary:
1. The set pressures of the overload relief valve and
the port relief valve may be higher than the main
relief set pressure. When measuring these set
pressures, the main relief set pressure should be
increased. This measuring method is hazardous
and the results obtained with this method are un-
reliable.
NOTE: If the set pressures of the overload relief
valve and the port relief valve are lower
than the main relief set pressure, measure
the pressure with the actuator of the circuit
relieved.

2. The oil flow rate used to set the overload relief

pressure is far less than that used to set the main
relief pressure. Therefore, measuring the over-
load pressure in the main circuit by increasing the
main relief set pressure more than the overload
valve set-pressure is not a proper method. In ad-
dition, in case a main relief valve designed to
leak a small quantity of oil before reliving is used,
its pre-leaking start pressure must be increased
more than the overload relief valve set pressure.
However, the pre-leaking start pressure is not
always increased more than the overload relief
valve set-pressure as the adjustable upper limit
of the main relief valve set-pressure is provided.
Accordingly, the overload relief valve assembly
should be removed from the machine and
checked on a specified test stand at a correct oil
flow rate. Some overload relief valves come in
contact with the control valve body to block the oil
passage. When this type of overload relief valve
is checked, the control valve body must be pre-
cisely finished as the test unit. Provide one con-
trol 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.
Operate the actuator of the corresponding circuit
and measure the main pressure. (Refer to MAIN
RELIEF SET PRESSURE.)

T4-5-12
 OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)

T4-5-13
 OPERATIONAL PERFORMANCE TEST / Component Test
MAIN PUMP FLOW RATE MEASUREMENT

• P-Q Control (Torque Control)

Summary: Measurement:
Main pump performance is checked by measuring 1. Maintain the hydraulic oil temperature at 50±5 °C
the pump flow rate by using a hydraulic tester in- (122±9 °F).
stalled at the main pump delivery port (one side) to 2. Measure the maximum flow rate.
be measured. Use Dr. ZX and a hydraulic tester at 3. Select the following switch positions:
the same time. Engine Power Mode Auto-Idle
Control Dial Switch Switch
IMPORTANT: This measurement procedure is a Fast Idle P Mode OFF
simple method. The measured data
will be lower by approx. 5 % than 4. Adjust the relief set pressure of the main relief
the accurately measured value. In valve in the control valve to each pressure point
order to measure accurately, dis- specified along the main pump P-Q curve. (Refer
connect the return circuit from the to T4-2-4). Slowly close the loading valve of hy-
control valve and connect it to the draulic tester (5) while relieving pressure in the
hydraulic oil tank. arm roll-in circuit. Measure the flow rates and en-
gine speeds at each pressure point specified in
the P-Q curve.
Preparation: 5. Repeat the measurement three times and calcu-
1. Stop the engine. Loosen the filling cap on the hy- late the mean value.
draulic oil tank and bleed air. Install a vacuum
pump.
NOTE: Operate the vacuum pump while connect-
ing the pump flow rate test hose.
2. Disconnect the delivery hose from the main pump
to be measured. Connect pipe (1 or 2) to the de-
livery port of the main pump to be measured.
: 41 mm
: 10 mm
3. Connect pipe (1 or 2) to hydraulic tester (5) with
test hose (3) and adapter (4). Install adapter (6),
joint (7), test hose (8), and flange (9) to hydraulic
tester (5).
: 41 mm
: 10 mm
4. Connect the delivery hose to flange (9) with split
flanges (10) and bolt (11).
: 10 mm
5. Connect Dr. ZX and select the monitor function.
When Dr. ZX is not available, a install a pressure
gauge to the main pump to be measured. (Refer
to T4-5-8.)
: 6 mm
6. Remove the vacuum pump. Loosen drain plug
(12) of the pump casing. Bleed air from the cas-
ing until only oil comes out.
7. Fully open the loading valve of hydraulic tester
(5).
8. Start the engine. Check the pressure gauge and
hydraulic tester (5) connection for any oil leaks.

T4-5-14
 OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation:
1. Convert the measured flow rates into those at the 2. Standard Flow Rate
rated pump speed by using the following formu- Refer to Operational Performance Standard in
las: T4-2.
NOTE: When actually measuring, connect pipe (1
Qc = (Np × Q) ⁄ (Ne × i) or 2) to only the pump to be measured.

Qc : Converted Flow Rate

Q: Measured Flow Rate
Np : Rated Pump Speed: 1873 min-1
Ne : Measured Engine Speed:
Values indicated on Dr. ZX
i: Pump Speed Ratio: 1.04 (51/49)

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

Delivery Hose
(To Control Valve)

T173-04-04-002

12
T18J-04-05-007

1- Pipe E (ST 6144) 4 -Adapter PF1 × UNF1-7/8 (ST 7- Joint (ST 6330) 10 - Split Flange (ST 6130)
6146)
2- Pipe B (ST 6143) 5 -Hydraulic Tester (ST 6299) 8- Test Hose (ST 6320) 11 - Bolt (ST 6409) (4 Used)
3- Test Hose (ST 6145) 6 -Adapter PF1 × UNF1-7/8 (ST 9- Flange (ST 6118) 12 - Drain Plug
6146)

T4-5-15
 OPERATIONAL PERFORMANCE TEST / Component Test
FAN PUMP FLOW RATE MEASUREMENT

• P-Q Control (Torque Control)

Summary: Measurement:
Fan pump performance is checked by measuring the 1. Maintain the hydraulic oil temperature at 50±5 °C
pump flow rate by using a hydraulic tester installed (122±9 °F).
at the fan pump delivery port (one side) to be meas- 2. Measure the maximum flow rate.
ured. Use a hydraulic tester. 3. Select the following switch positions:
Engine Power Mode Auto-Idle
IMPORTANT: This measurement procedure is a Control Dial Switch Switch
simple method. The measured data Fast Idle P Mode OFF
will be lower by approx. 5 % than
the accurately measured value. In 4. Adjust the set pressure of the relief valve in the
order to measure accurately, dis- fan valve to each pressure point specified along
connect the return circuit from the the fan pump P-Q curve. (Refer to T4-2-4.)
control valve and connect it to the Slowly close the loading valve of hydraulic tester.
hydraulic oil tank. Measure the flow rates and engine speeds at
each pressure point specified in the P-Q curve.
5. Repeat the measurement three times and calcu-
Preparation: late the mean value.
1. Stop the engine. Loosen the filling cap on the hy-
draulic oil tank and bleed air. Install a vacuum
pump.
NOTE: Operate the vacuum pump while connect-
ing the pump flow rate test hose.

2. Disconnect the delivery hose from the fan pump.

Connect pipe (1 or 2) with the split flange and the
bolt which were used for the disconnected deliv-
ery hose.
: 41 mm
: 10 mm
3. Connect pipe (1 or 2) to hydraulic tester (5) with
test hose (3) and adapter (4). Install adapter (6),
joint (7), test hose (8), and flange (9) to hydraulic
tester (5).
: 41 mm
: 10 mm
4. Connect the delivery hose to flange (9) with split
flange (10) and bolt (11).
: 10 mm
5. Remove the vacuum pump. Loosen drain plug
(12) of the pump casing. Bleed air from the cas-
ing until only oil comes out.
6. Fully open the loading valve of hydraulic tester
(5).
7. Start the engine. Check the pressure gauge and
hydraulic tester (5) connection for any oil leaks.

T4-5-16
 OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation:
1. Convert the measured flow rates into those at the 2. Standard Flow Rate
rated pump speed by using the following formu- Refer to Operational Performance Standard in
las: T4-2.

Qc = (Np × Q) ⁄ (Ne × i)

Qc : Converted Flow Rate

Q: Measured Flow Rate
Np : Rated Pump Speed: 1913 min-1
Ne : Measured Engine Speed:
Values indicated on Dr. ZX
i: Pump Speed Ratio: 1.06 (51/48)

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

Delivery Hose
(To Control Valve)

T173-04-04-002

Fan Pump

12

T18J-04-05-006

1 - Pipe E (ST 6144) 4 -Adapter PF1 × UNF1-7/8 (ST 7 -Joint (ST 6330) 10 -Split Flange (ST 6130)
6146)
2 - Pipe B (ST 6143) 5 -Hydraulic Tester (ST 6299) 8 -Test Hose (ST 6320) 11 -Bolt (ST 6409) (4 Used)
3 - Test Hose (ST 6145) 6 -Adapter PF1 × UNF1-7/8 (ST 9 -Flange (ST 6118) 12 -Drain Plug (G1/2)
6146)

T4-5-17
 OPERATIONAL PERFORMANCE TEST / Component Test
Adjustment of Max. Flow Rate and Min. Flow
Rate
The flow rate is adjusted by changing the servo pis- NOTE: Illustration shows the main pump.
ton max. stroke. When adjusting max flow rate,
loosen nut (2) on the large chamber side of the servo 3 2
piston and turn adjusting screw (1). When adjusting
min. flow rate, loosen nut (3) on the small chamber
side of the servo piston and turn adjusting screw (4). 4 1

NOTE: Change in Flow Rate (Reference)

Main Pumps 1, 2, and 3 Speed: 1873 min-1 T1JB-04-05-002

Fan Pump Seed: 1913 min-1

Adjusting Screw Turn 1/4
Change in Flow Rate
9.55 L/min (2.5 us gal/min)
(Main Pumps 1, 2, and 3)
Change in Flow Rate
3.1 L/min (0.8 us gal/min)
(Fan Pump)
Adjustment of Max. Flow Rate

Flow Rate Flow Rate

Decrease Increase

W107-02-05-129
I

Adjustment of Min. Flow Rate

Flow Rate Flow Rate

Increase Decrease

W107-02-05-129 I

NOTE: I: The signal current of pump control sole-

noid valve.

T4-5-18
 OPERATIONAL PERFORMANCE TEST / Component Test
Adjustment of Main Pump Flow Rate Control
The flow rate control is performed by signal current
(I) of the pump control solenoid valve. The flow rate
control is adjusted by changing the set force of
spring (1).
When adjusting, loosen nut (2) and turn adjusting
screw (3).

1 2 3

T16J-04-04-006

NOTE: Change in Flow Rate (Reference)

Pump Speed: 1873 min-1 Flow Rate Control
Adjusting Screw Turn 1/4 Q
Change in Flow Rate 53.8 L/min (14.2 us gal/min)

Flow Rate Flow Rate I

Decrease Increase

NOTE: I: The signal current of pump control sole-

W107-02-05-129
noid valve.

T4-5-19
 OPERATIONAL PERFORMANCE TEST / Component Test
Adjustment of Fan Pump Flow Rate Control
The flow rate control is performed by signal current
(I) of the pump control solenoid valve. The flow rate
control is adjusted by changing the set force of
spring (1).
When adjusting, loosen nut (2) and turn adjusting
screw (3).

T1J1-04-05-005

NOTE: Change in Flow Rate (Reference)

Pump Speed: 1913 min-1 Flow Rate Control
Adjusting Screw Turn 1/4 Q

Change in Flow Rate 9.2 L/min

Flow Rate Flow Rate

Increase Decrease NOTE: I: The signal current of pump control sole-
noid valve.
W107-02-05-129

T4-5-20
 OPERATIONAL PERFORMANCE TEST / Component Test
Adjustment of Torque Constant Control (Only
Fan Pump Regulator) NOTE: When adjusting screw (4) is turned, the
The torque control is performed by own pump deliv- inner spring (2) setforce is changed.
ery pressure P. Therefore, the torque constant con- Therefore, when adjusting screw (4) is
trol is adjusted by changing the set force of inner turned, turn adjusting screw (6) 2.24 times
spring (2) and outer spring (1). the turns of adjusting screw (4) in the op-
(Before adjusting screws (4) and (6), put the mark on posite direction in order to keep the inner
the end of the adjusting screw with a white marker spring (2) setforce unchanged.
for the record of the original position.)
When adjusting resetting inner spring (2), loosen nut
(5) and turn adjusting screw (6).
When adjusting resetting outer spring (1), loosen nut
(3) and turn adjusting screw (4).

1 2 3 4

T1J1-04-05-006

NOTE: Change in Pressure When Adjusting

Spring.
Pump Speed: 1750 min-1 Q

Adjusting Screw Turn 1/4

Outer spring
21.5 N⋅m
(2.2 kgf⋅m), 16 lbf⋅ft
Engine Torque
Inner Spring
11.4 N⋅m
(1.2 kgf⋅m), 8 lbf⋅ft
P

4, 6

Increase Decrease

T157-05-04-023

T4-5-21
 OPERATIONAL PERFORMANCE TEST / Component Test
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. Keep oil temperature constant as the drain
amount from the swing motor is much influenced
by oil temperature.

Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F). Rotate the swing motor in order to
warm inside of the motor. A
Drain Hose
2. Stop the engine. Loosen the filling cap on the hy- Swing Motor
draulic oil tank and bleed air.
: 4 mm

3. Disconnect the drain hose of the swing motor to

be measured at part A. Connect a test drain hose
(3/4-16UN) to the motor side and install the plug
(ST 6637) to drain hose (2).
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 70 lbf⋅ft)

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. Also, take care not
to fall off the machine while the
measurement. T18J-04-05-003

Conditions for Measurement:

1. Select the following switch positions:
Engine Power Mode Auto-Idle
Control Dial Switch Switch
Fast Idle HP Mode OFF

T4-5-22
 OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Set the front attachment as illustrated.
NOTE: In case a sufficient space for the
measurement is difficult to find, carry out
the measurement with the boom fully
raised and the arm fully rolled-in
(backhoe)/ extended (loading shovel).
2. Start the engine. Operate and hold the swing
control lever to full stroke. After the swing speed
reaches a constant speed, start the measurement
of the draining oil and the time when drain oil
starts coming out of the drain hose end.
3. Repeat the measurement at least three times in
both clockwise and counterclockwise directions,
The height as boom
and calculate the mean values. foot pin height
4. The measuring time should be for more than 20
seconds. T105-06-03-013

Evaluation:
Refer to Operational Performance Standard in T4-2.
The height as boom
∗ Conversion of amount of drain oil measured into foot pin height
the per-minute value
TBAR-04-04-001
First measure amount of drain oil by using a
calibrated container. Then, convert the measured
drain oil into the per-minute value by using the
formula.

ΔQ = 60 × q / t

ΔQ : Amount of drain oil per minute (L/min)

t : Measured time (seconds)
q : Total amount of drain oil (L)

T107-06-05-008

T4-5-23
 OPERATIONAL PERFORMANCE TEST / Component Test
TRAVEL MOTOR DRAINAGE
Summary:
1. While rotating the travel motor with the track to be
measured raised, measure amount of oil draining
from the travel motor and check travel motor per-
formance.
2. Secure absolute safety for the measuring per-
sons as well as for the surrounding while meas-
uring. Drain Hose
3. Judge travel motor performance from the results
including travel speed, mistrack and so on over-
all.
4. Keep oil temperature constant as the drain
amount from the travel motor is much influenced
by oil temperature.

Preparation:
1. Main hydraulic oil temperature at 50±5 °C (122±9
°F). Rotate the travel motor and warm inside of
the motor.
2. Stop the engine. Turn the filling cap on the hy-
draulic oil tank and bleed air. T18J-04-05-005
3. Disconnect the drain hose in the travel motor at
the travel motor end. Install the plug (ST 6637) to
the disconnected hose. Connect a test drain hose
(3/4-16UN) to the travel motor.
: 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
Test Drain Hose
Conditions for Measurement:
1. Select the following switch positions:
Engine Power Mode Auto-Idle
Control Dial Switch Switch
Fast Idle P Mode OFF

T157-05-04-019

Drain Hose

ST 6637

T183-04-04-011

T4-5-24
 OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
CAUTION: When working around moving
parts is unavoidable, pay special attention to
ensure that hands, feet, and clothing do not
become entangled. Securely support the
raised track by using the blocks.

1. Start the engine. Raise the track to be measured.

2. Rotate the track to be measured. Start the meas-
urement of drain oil and the time when drain oil
starts coming out of the drain hose end.
90° to 110°
3. Repeat the measurement three times in both
clockwise counterclockwise. Calculate the mean
value.
4. The measuring time should be more than 20
seconds. M104-07-067

Evaluation:
Refer to the Operational Performance Standard in
T4-2.
90° to 110°
∗ Conversion of amount of drain oil measured into
the per-minute value

First measure amount of drain oil by using a T1J1-04-04-001

calibrated container. Then, convert the measured

drain oil into the per-minute value by using the
formula:

ΔQ = 60 × q / t

Where:
ΔQ : Amount of drain oil per minute (L/min)
t : Measured time (seconds)
q : Total amount of drain oil (L)

T157-05-04-019

T4-5-25
 OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)

T4-5-26
 SECTION 5
TROUBLESHOOTING

CONTENTS
Group 1 Diagnosing Procedure Group 3 Dr. ZX
Introduction .............................................. T5-1-1 Outline ...................................................... T5-3-1
Diagnosing Procedure .............................. T5-1-2 Self-Diagnostic Results............................. T5-3-4
Select Controller ....................................... T5-3-6
Group 2 Monitor Unit
MCF Main ................................................. T5-3-7
Monitor Unit .............................................. T5-2-1
Monitor Display of MCF (Main) ................. T5-3-8
How to Use Screens ................................. T5-2-9
Setup of MCF (Main)............................... T5-3-14
Screen Display
MCF Sub................................................. T5-3-39
When An Alarm is Issued ...................... T5-2-17
Monitor Display of MC (Sub) ................... T5-3-40
Contents of Alarms ................................. T5-2-19
Special Functions of MCF (Sub) ............. T5-3-44
Troubleshooting...................................... T5-2-21
Setup of MCF (Sub) ................................ T5-3-46
Controller Version ................................... T5-2-23
ICF Controller ......................................... T5-3-57
Monitoring .............................................. T5-2-25
Information C/U: Various Setup............... T5-3-58
Pump 1 Flow Rate Adjustment................ T5-2-28
Monitor Controller ................................... T5-3-64
Attachment Selection.............................. T5-2-29
Monitoring ............................................... T5-3-65
Time Setting ........................................... T5-2-30
Various Settings ...................................... T5-3-69
Back Monitor Setting .............................. T5-2-31
Maintenance Setting ............................... T5-2-33 Group 4 Component Layout
Language Setting ................................... T5-2-38 Main Component Layout ........................... T5-4-1
Pump Device ............................................ T5-4-2
Control Valve ............................................ T5-4-3
Utility Box.................................................. T5-4-5
Inside of Cab ............................................ T5-4-6
Battery Box ............................................. T5-4-12
Engine .................................................... T5-4-14
Radiator .................................................. T5-4-16

18JT-5-1
Group 5 Troubleshooting A MC (Main) Fault Code 11998 .................. T5-5-80
Troubleshooting A Procedure ................... T5-5-1 MC (Main) Fault Code 11999 .................. T5-5-81
MC (Main) Fault Code List........................ T5-5-2 MC (Main) Fault Code 20062 .................. T5-5-82
MC (Sub) Fault Code List ....................... T5-5-18 MC (Sub) Fault Code 15979 ................... T5-5-83
ICF Fault Code List................................. T5-5-22 MC (Sub) Fault Code 15980 ................... T5-5-84
Monitor Unit Fault Code List ................... T5-5-23 MC (Sub) Fault Code 15981 ................... T5-5-85
Dlu2 Fault Code List ............................... T5-5-24 MC (Sub) Fault Code 15982 ................... T5-5-86
MC (Main) Fault Codes MC (Sub) Fault Code 15984, 15987,
11000 to 11002 ..................................... T5-5-25 15988, 15990, 15991 ............................ T5-5-87
MC (Main) Fault Code 11003.................. T5-5-26 MC (Sub) Fault Code 15989 ................... T5-5-88
MC (Main) Fault Code 11004.................. T5-5-27 MC (Sub) Fault Code 15992 ................... T5-5-89
CAN Harness Check .............................. T5-5-28 MC (Sub) Fault Code 15993 ................... T5-5-90
MC (Main) Fault Coce 11100 .................. T5-5-50 MC (Sub) Fault Code 15995 ................... T5-5-91
MC (Main) Fault Code 11101 .................. T5-5-51 MC (Sub) Fault Code 15997 to 15999 .... T5-5-92
MC (Main) Fault Code 11200.................. T5-5-52 ICF Fault Codes 14000 to
MC (Main) Fault Code 11202.................. T5-5-53 14003, 14008 ........................................ T5-5-93
MC (Main) Fault Code 11203.................. T5-5-54 Monitor Unit Fault Code 13303 ............... T5-5-97
MC (Main) Fault Code 11301.................. T5-5-55 Monitor Unit Fault Code 13304 ............... T5-5-98
MC (Main) Fault Code 11302.................. T5-5-56 Monitor Unit Fault Code
MC (Main) Fault Code 11303.................. T5-5-57 13306 and 13308 .................................. T5-5-99
MC (Main) Fault Code 11400.................. T5-5-58 Monitor Unit Fault Code 13310 ............. T5-5-100
MC (Main) Fault Code 11402.................. T5-5-59 Monitor Unit Fault Code 13311 ............. T5-5-101
MC (Main) Fault Code 11404.................. T5-5-60 Pilot Shut-Off Lever Alarm .................... T5-5-102
MC (Main) Fault Code 11405.................. T5-5-61 Dlu2 Fault Code 172 ............................. T5-5-103
MC (Main) Fault Code 11410.................. T5-5-62 When Satellite Communication
MC (Main) Fault Code 11802.................. T5-5-63 Test is NG (Failed) .............................. T5-5-104
MC (Main) Fault Code 11901.................. T5-5-64
MC (Main) Fault Codes 11910, 11911, Group 6 Troubleshooting B
11914, 11918, 11920, 11959, 11961, Troubleshooting B Procedure ................... T5-6-1

11962, 11963, 11964, 11968 ................. T5-5-66 Correlation between Trouble

MC (Main) Fault Code 11960.................. T5-5-68 Symptoms and Part Failures ................... T5-6-2

MC (Main) Fault Code Engine System Troubleshooting ............. T5-6-14

11965 and 11966 .................................. T5-5-70 All Actuator System Troubleshooting ...... T5-6-30

MC (Main) Fault Code 11969.................. T5-5-71 Front Attachment System

MC (Main) Fault Code 11970.................. T5-5-72 Troubleshooting .................................... T5-6-38

MC (Main) Fault Code 11989.................. T5-5-73 Swing System Troubleshooting ............... T5-6-46

MC (Main) Fault Code 11991.................. T5-5-74 Travel System Troubleshooting............... T5-6-49

MC (Main) Fault Code 11992.................. T5-5-75 Other System Troubleshooting................ T5-6-54

MC (Main) Fault Code 11993.................. T5-5-76 Work After Replacing Components ......... T5-6-76
MC (Main) Fault Code 11994.................. T5-5-77 Charge Air Conditioner
MC (Main) Fault Code 11995.................. T5-5-78 with Refrigerant..................................... T5-6-77
MC (Main) Fault Code 11997.................. T5-5-79 Warm-Up Operation ................................ T5-6-84
Inspection ............................................... T5-6-85

18JT-5-2
Group 7 Troubleshooting C
Troubleshooting C Procedure ................... T5-7-1
How to Read Engine Fault Codes............. T5-7-3

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 ............................. T5-8-7
Battery Voltage Check .............................. T5-8-8
How to Check Alternator ........................... T5-8-9
Continuity Check .................................... T5-8-10
Voltage and Current Measurement ......... T5-8-12
Check by False Signal ............................ T5-8-21
Test Harness .......................................... T5-8-22

18JT-5-3
(Blank)

18JT-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

9 groups; Diagnosing Procedure, Circuit Dia-
gram/Component Layout Reference Table, Monitor
Unit, Dr. ZX, Component Layout Troubleshooting A
(base machine diagnosis by using fault codes), Trou-
bleshooting B (base machine diagnosis starting with
inspection of abnormal operational status), Trouble-
shooting C (engine diagnosis by using illumination
status of indicators), and Electrical System Inspection.

• Diagnosing Procedure • Troubleshooting C (engine diagnosis by using il-

lumination status of indicators)
• Circuit Diagram/Component Layout Reference This group contains engine diagnosis by whether
Table the engine maintenance indicator and the engine
warning indicator lights or blinks.
• Monitor Unit
This group contains Layout screen and the oper- • Electrical System Inspection
ating procedures of monitor unit. Refer to this group when required to obtain pre-
cautions and/or information for the electrical sys-
• Dr. ZX tem inspection.
This group contains the operating procedures for
Dr. ZX. Ex.) Fuse Check

• Component Layout IMPORTANT: DLU2 receives and retains a record

of the electrical signal system mal-
• Troubleshooting A (base machine diagnosis by function of each controller in the
using fault codes) form of fault codes by using CAN
Refer to there procedures if any fault codes are communication. In addition, ICF
displayed when each controller (MC (Main, Sub) self-diagnosing function records the
DLU2, ECM, ICF, and monitor unit) is diagnosed electrical signal system malfunction
by using Dr. ZX (or the service menu of the in the form of fault codes.
monitor unit).
Ex.) Fault Code 11004-2: Abnormal can commu-
• Troubleshooting B (base machine diagnosis nication
starting with inspection of abnormal operational
status)
Refer to there procedures when no fault codes
are displayed after diagnosing the machine by
using Dr. ZX (or the service menu of the monitor
unit).

Ex.) Even if the engine control dial is rotated, en-

gine speed dose not change.

T5-1-1
 TROUBLESHOOTING / Diagnosing Procedure
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?

T107-07-01-002

T5-1-2
 TROUBLESHOOTING / Diagnosing Procedure
3. Inspect the machine
Before starting the troubleshooting procedure,
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 circuit tester when checking the
fuses. T107-07-01-003

4. Operate the machine yourself

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

T5-1-3
 TROUBLESHOOTING / Diagnosing Procedure
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 di-
agnosis by using Dr. ZX (the service menu of
monitor unit), write the fault code. Delete the fault T107-07-01-005

code once and retry self-diagnosis again.

If the fault code is displayed again, check the
cause of the trouble by referring to Trouble-
shooting A in this section. After the machine trou-
ble has been corrected, the fault code (displayed
by the service menu of the 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
operating condition of each component by refer-
ring to Troubleshooting B in this section and by
using Dr. ZX (the service menu of the monitor
unit).
If engine stop alarm or engine warning alarm is
indicated on the monitor unit, check the fault T107-07-01-006

code by using Troubleshooting C in this section.

When the fault code is confirmed, repair the fault
referring to the fault code.

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 RETRY button to
erase the accumulated fault codes from
the controller memory and to confirm if any
fault codes are indicated again.

T5-1-4
 TROUBLESHOOTING / Diagnosing Procedure
6. Trace possible causes
Before reaching a conclusion, check the most
suspect causes again.
Try to indentify the actual cause of the trouble.
Based on your conclusion, make a plan for
appropriate repairs to avoid consequent
malfunctions.

T107-07-01-007

T5-1-5
 TROUBLESHOOTING / Diagnosing Procedure
(Blank)

T5-1-6
 TROUBLESHOOTING / Monitor Unit
MONITOR UNIT
Function Outline

Primary Screen

1 2 3 4 5 6 7

8
18
9

10

11

17 16 15 14 13 12
T18J-02-01-007

1 - Work Mode Display 6 - Preheat Display 11 - Rear View Camera 15 - Auxiliary Selection
Selection
2 - Auto-Idle Display 7 - Hour Meter 12 - Menu 16 - Auto-Lubrication Selection
3 - Heavy Lift Display 8 - Auto-Lubrication Display 13 - Auxiliary Selection 17 - Return to Primary Screen
4 - Lubrication Mode Display 9 - Fuel Gauge 14 - Auxiliary Selection 18 - Coolant Temperature
Gauge
5 - Ladder Display 10 - Clock

T5-2-1
 TROUBLESHOOTING / Monitor Unit
● Meter Display
The displayed data for each meter are displayed on Work Mode 2
the monitor unit according to the input signal from
the sensor, the signal received from ICF through the
1
CAN bus line, and the internal data of the monitor 3
unit.

Display Item
1- Coolant temperature gauge (Input signal from
the coolant temperature sensor)
2- Hour meter (Internal data of the monitor unit) 4
3- Fuel gauge (Input signal from the fuel sensor)
4- Clock (Signal received from ICF through the
CAN bus line)

● Work Mode Display (Optional)

The attachments being used are displayed M18J-01-006

according to the signals received from MC through

CAN.

Digging Mode

T1V1-05-01-108

Attachment Mode
(Only the machines equipped with optional parts)

T5-2-2
 TROUBLESHOOTING / Monitor Unit
● Auto-Idle Display (1)
When the auto-idle switch on the switch panel is 1 2 3 4
turned ON, the monitor unit displays the auto-idle.
When the key switch is turned ON with the auto-idle
switch ON, auto-idle display (1) blinks for 10
seconds.

● Heavy Lift Display (2)

When the heavy lift switch is turned ON, the heavy
lift is displayed according to the signal received from
MC through the CAN bus line.

● Lubrication Mode Display (3)

When the lubrication mode selection switch is set to
the AUTO and MANUAL position, the lubrication
mode is displayed according to the signal received
from MC through the CAN bus line. M18J-01-006

● Preheat Display (4)

While ECM supplies current to the air heater, the
data is displayed according to the signal from ECM.
(Refer to SYSTEM / Control System.)

T5-2-3
 TROUBLESHOOTING / Monitor Unit
● Fuel Sensor Error Display Coolant Temperature Fuel Sensor Error
When the fuel sensor is faulty or if the harness Sensor Error Display Display
between the fuel sensor and the monitor unit is open
circuit, the data is displayed on the fuel gauge.

● Coolant Temperature Sensor Error Display

When the coolant temperature sensor is faulty or if
the harness between the coolant temperature
sensor and the monitor unit is open circuit, the data
is displayed on the coolant temperature gauge.

M18J-01-015

● Alarm and Remedy Display against Alarm

The alarm marks are displayed on bottom of the
screen according to the alarm signals received from
each controller through the CAN bus line.
The remedy for each alarm is displayed by key
operation.

Alarm Display M18J-01-013

Remedy Display against Alarm T1V5-05-01-013

T5-2-4
 TROUBLESHOOTING / Monitor Unit
● Troubleshooting
The fault codes are displayed on the screen
according to the signals received from MC (main),
MC (sub), and ICF through the CAN bus line.

Fault Code Display T1V5-05-01-097

● Controller Version
The controller version is displayed.

● Monitoring
Controller Version Display T18J-02-01-016
The temperature and pressure data received from
each controller through the CAN bus line are
displayed on the screen.

Monitoring Screen T18J-02-01-017

T5-2-5
 TROUBLESHOOTING / Monitor Unit
● Pump 1 Flow Rate Adjustment (Only the machines
equipped with the optional parts)
When using the attachments, fine adjust flow rate of
pump 1 by key 1 and key 2 operation.
(Adjusting range: -50 to 50 L/min)
The signals from the monitor unit are sent to MC
(main) through the CAN bus line.
MC (main) drives the pump 1 flow rate control
solenoid valve and adjusts the pump 1 flow rate.
Key 1

Key 2

When Using Breaker 1 M1J5-01-014

● Attachment Selection (Only the machines equipped

with the optional parts)
Digging mode and attachment mode set by Dr. ZX
are selected on this screen.

T5-2-6
 TROUBLESHOOTING / Monitor Unit
● Back Monitor Setting
By key operation, the display types of the ON and
OFF screen for the back monitor auto-control while
traveling can be set.

• Maintenance Setting Back Monitor Setting Screen T1V5-05-01-173

The remaining hours until the next replacement is

displayed.
Replacement items are shown in the item list. The
performed replacement is recorded by selecting
an item.
• Interval ON/OFF Setting
The intervals of replacement items are
individually set.
• Items included in maintenance settings
Engine Oil
Engine Oil Filter
Hydraulic Oil
Hydraulic Oil Pilot Filter
Hydraulic Oil Full-Flow Filter
Pump Transmission Oil Maintenance Setting Screen T1V5-05-01-049
Travel Device Oil
Swing Device Oil
Swing Bearing Grease
Air Cleaner Filter
Engine/Air Conditioner V Belt
Fuel Filter
Air Conditioner Filter

Interval ON/OFF Setting Screen T1V5-05-01-052

T5-2-7
 TROUBLESHOOTING / Monitor Unit
● Language Setting
A language can be selected from the preset
languages according to work environment.

Language Setting Screen T1V1-05-01-137

T5-2-8
 TROUBLESHOOTING / Monitor Unit
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 M18J-01-004

IMPORTANT: Until the alternator starts generating

power after the engine starts, alter-
nator alarm is displayed on the pri-
mary screen.
Pump transmission oil level alarm is
also displayed until the engine
starts.

Alternator Alarm
T18J-05-03-001
Pump Transmission
Oil Level Alarm

T5-2-9
 TROUBLESHOOTING / Monitor Unit
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 password
input screen appears.

T1V5-05-01-093
Password Input Screen
2. 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 delete key.

T1V5-05-01-002
Confirm Key Delete Key

Primary Screen M18J-01-006

T5-2-10
 TROUBLESHOOTING / Monitor Unit
In Case of Inputting an Incorrect Password

1. If inputting an incorrect password, the message

"Password is incorrect." appears by pushing the
confirm key.

T1V5-05-01-093
Password Input Screen

T1V5-05-01-002
Confirm Key Delete Key

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 delete key.

T1V5-05-01-004
Back Key

T1V5-05-01-093

T5-2-11
 TROUBLESHOOTING / Monitor Unit
3. If inputting an incorrect password three times, a
screen appears informing that the security lock
has been applied, and a buzzer sounds for thirty
seconds. During that time, the buzzer does not
stop even if the key switch is turned ON/OFF.

T1V5-05-01-005
Security Lock Screen
4. After thirty seconds, if the key switch is turned to
the ON position, the starting screen appears and
the password input screen appears again. Then a
password can be input again. If inputting an in-
correct password even once this time, the security
lock screen appears again and a buzzer sounds
for thirty seconds. The buzzer does not stop for
thirty seconds even if the key switch is turned
ON/OFF.

5. After the buzzer stops, a password can be input Starting Screen T1V1-05-01-115

again. Turn the key switch to the ON position and

input a password after the password input screen
appears. (Refer to T5-2-10).

6. If inputting an incorrect password again, the secu-

rity lock screen appears again. The buzzer does
not stop for thirty seconds even if the key switch is
turned ON/OFF.

Password Input Screen T1V5-05-01-093

T5-2-12
 TROUBLESHOOTING / Monitor Unit
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 du-

ration 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.
T1V1-05-01-012
Key 1 Key 2 Key 3 Key 4 Key 5

Password Duration Screen (Key Switch: OFF)

2. While the password duration screen is still dis-
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 ex-

plicitly, 0 minute on duration time is as-
sumed.
Key Switch: ON T1V1-05-01-115

3. If the key switch is turned to the ON position within

password duration time, the monitor unit displays
the primary screen after the starting screen.

Primary Screen
M18J-01-004

T5-2-13
 TROUBLESHOOTING / Monitor Unit
Password Change (Optional)

1. After the primary screen is displayed, push the

menu key and display Main Menu.

Menu Key

Primary Screen M18J-01-004

2. Select Password Change from Main Menu by us-

ing keys1 and 2. Push the confirm key. Then, the
password change screen appears.

Key 1 Key 2 Confirm Key M18J-01-016E

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 delete
key.

T1V5-05-01-042
Confirm Key Delete Key

T5-2-14
 TROUBLESHOOTING / Monitor Unit

NOTE: If inputting an incorrect password after

pushing the confirm key, the message
"Password is incorrect." appears.
Push the back key and return to the previ-
ous 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.

T1V5-05-01-130

New Password

6. If inputting the password again, push the delete

key.

T1V5-05-01-131
Confirm Key Delete Key

T5-2-15
 TROUBLESHOOTING / Monitor Unit
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 delete

key in order to erase the entered characters.

T1V5-05-01-132

Confirm Key Delete 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

10. Push key 6, and the primary screen appears.

Primary Screen M18J-01-004

T5-2-16
 TROUBLESHOOTING / Monitor Unit
SCREEN DISPLAY WHEN AN ALARM IS
ISSUED
When any abnormality occurs, the alarm marks are
displayed at the bottom of the screen.

• When the quality of the alarms is two or less

M18J-01-012

• When the quantity of alarms is three or more

M18J-01-013

T5-2-17
 TROUBLESHOOTING / Monitor Unit
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. M18J-01-012

T1V5-05-01-013

T5-2-18
 TROUBLESHOOTING / Monitor Unit
CONTENTS OF ALARMS

Display Contents of Alarms Remedy

Overheat Alarm Engine coolant temperature has abnormally increased.
Stop operation. Run the engine at slow idle speed to lower the
coolant temperature.
M178-01-036

Hydraulic Overheat Alarm Hydraulic oil temperature is above normal.

Stop operation, check hydraulic oil level, check for leaks etc.

T1JB-05-02-001

Engine Warning Alarm Engine or engine related parts are abnormal.

Consult your nearest Hitachi dealer.

M183-01-080

Engine Oil Pressure Alarm Engine oil pressure has decreased. Immediately stop engine.
Check engine oil system and oil level.

M178-01-037

Pump Transmission Oil Level Pump transmission oil level is low. Immediately stop engine.
Alarm Check pump transmission oil system and oil level.
NOTE: When the key switch is turned to the ON position, this
M183-01-073 indicator lights until engine starts. This is normal.
Hydraulic Oil Level Alarm Hydraulic oil level is low. Check hydraulic oil level and refill oil.
NOTE: When operating on a slope, this indicator may light.

M183-01-077

Coolant Level Alarm Coolant level is low. Check coolant level and refill coolant.

M183-01-076

Engine Stop Alarm Indicator lights on if an abnormality in the engine or en-

gine-related parts occurs. (Depending on the severity of the trou-
ble, engine speed may decrease or the engine may automatically
stop.) If this indicator lights on, immediately position the machine
M18J-01-014
in the park position, stop the engine and contact your authorized
dealer.
Engine Oil Level Alarm Engine oil level is low. Check engine oil level and refill oil.

M183-01-075

Alternator Alarm Electrical system is abnormal.

Check the battery and alternator.
NOTE: When the key switch is turned to the ON position, this
M183-01-071
indicator lights until engine starts. This is normal.
Remaining Fuel Alarm Fuel level is low 130 liter (34 US gal) of fuel remains. Refill fuel as
soon as possible.

M178-01-034

T5-2-19
 TROUBLESHOOTING / Monitor Unit

Display Contents of Alarms Remedy

Auto-Lubrication Alarm This indicator will light when any trouble occurs in the
auto-lubrication circuit. Consult your nearest Hitachi dealer.
NOTE: When the MANUAL lubrication mode is selected, this
T1J1-05-01-005 indicator lights.
Air Filter Clogged Alarm Air filter elements are clogged.
Clean or replace air filter elements.

M183-01-067

Work Mode Alarm Work Mode system is abnormal.

Consult your nearest Hitachi dealer.

T1V1-05-01-102

Pilot Control Shut-Off Lever Pilot control shut-off lever system is abnormal.
Alarm Consult your nearest Hitachi dealer.

T1V1-05-01-103

Ladder Position Alarm While the ladder is extended, this indicator lights and when the
gate lock is lowered, alarm buzzer sounds. The machine is not
able to operate in this time. When the ladder is retracted to the
M18M-01-037 locked position, this indicator goes off and the machine is able to
operate.

T5-2-20
 TROUBLESHOOTING / Monitor Unit
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 the key switch ON while pushing the key.

2. After the primary screen appears, push the menu

key and display Main Menu.

Menu Key
Primary Screen M18J-01-004

3. Select Service Menu from Main Menu by using

keys 1 and 2. Push the confirm key. Then, the
service menu screen appears.

NOTE: When pushing the back key, return to the

previous screen.

T1V5-05-01-114
Key 1 Key 2 Confirm Key Back Key

Back Key T1V5-05-01-083

T5-2-21
 TROUBLESHOOTING / Monitor Unit
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

displayed on the screen.

IMPORTANT: Up to twenty failure codes can be

displayed. But, one screen can con-
tain only ten failure codes maximum.
If the screen is fully filled with ten
items, push key 1 and check other
failure codes on the next page.
Key 1 Key 2 Confirm Key Back Key T1V5-05-01-083
When returning to the previous page,
push key 2. A figure enclosed in ( ) indicates the number of failure codes.

6. Select abnormal of a faulty controller by using

keys 1 and 2. Push the confirm key. Then, fault
code is displayed.
As for details of trouble analyses, refer to Trou-
bleshooting A.

NOTE: When pushing the back key, return to the

previous screen.

Key 1 Key 2 Confirm Key Back Key T18J-05-03-003

7. Push key 6, and the primary screen appears.

Key 1 Key 6 Key 2 Back Key T1V5-05-01-097

Primary Screen
M18J-01-004

T5-2-22
 TROUBLESHOOTING / Monitor Unit
CONTROLLER VERSION
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 the key switch ON while pushing the key.

2. After the primary screen appeared, push the

menu key and display Main Menu.

Menu Key
Primary Screen
M18J-01-004

3. Select Service Menu from Main Menu by using

keys 1 and 2. Push the confirm key. Then, the
service menu screen appears.

NOTE: When pushing the back key, return to the

previous screen.

T1V5-05-01-114
Key 1 Key 2 Confirm Key Back Key

Back Key T1V5-05-01-083

T5-2-23
 TROUBLESHOOTING / Monitor Unit
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.

NOTE: When pushing the back key, return to the

previous screen.

T1V5-05-01-083
Key 1 Key 2 Confirm Key Back Key

Key 6 Back Key T18J-02-01-016

5. Push key 6, and the primary screen appears.

Primary Screen M18J-01-004

T5-2-24
 TROUBLESHOOTING / Monitor Unit
MONITORING
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 the key switch ON while pushing the key.

2. After the primary screen appeared, push the

menu key and display Main Menu.

Menu Key
Primary Screen M18J-01-004

3. Select Service Menu from Main Menu by using

keys 1 and 2. Push the confirm key. Then, the
service menu screen appears.

NOTE: When pushing the back key, return to the

previous screen.

T1V5-05-01-114
Key 1 Key 2 Confirm Key Back Key

Back Key T1V5-05-01-083

T5-2-25
 TROUBLESHOOTING / Monitor Unit
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.

T1V5-05-01-083
Key 1 Key 2 Confirm Key
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.

6. Push key 3, and the displayed data are put on

hold.
Push key 3 again, and the records are updated
with the displayed data.

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- Back Key
sage appears, push the confirm key.
Key 1 Key 2 Key 3 Key 4 Confirm Key T18J-02-01-017

NOTE: When pushing the back key, return to the

previous screen.

Back Key

8. Push key 6, and the primary screen appears. Confirm Key T1V5-05-01-088
Key 6

Primary Screen M18J-01-004

T5-2-26
 TROUBLESHOOTING / Monitor Unit
A List of Items to be Monitored

Monitoring
Items Units Remarks
Order
1 Engine Load % Engine Load
2 Coolant Temperature (E) °C Coolant Temperature (E)
3 Fuel Temperature °C Fuel Temperature
4 Engine Oil Pressure kPa Engine Oil Pressure
5 Atmospheric Pressure kPa Atmospheric Pressure
6 Intake Air Temperature °C Intake Air Temperature
7 Boost Pressure kPa Boost Pressure
8 Boost Temperature °C Boost Temperature
9 Coolant Temperature (M) °C Coolant Temperature (M)
10 Target Engine Speed min-1 Target Engine Speed
11 Actual Engine Speed min-1 Actual Engine Speed
12 Pump 1 Delivery Pressure MPa Pump 1 Delivery Pressure
13 Pump 1 Pump Control Pressure MPa Pump 1 Pump Control Pressure
14 Pump 1 Target Flow Rate L/min Pump 1 Target Flow Rate
15 Pump 2 Delivery Pressure MPa Pump 2 Delivery Pressure
16 Pump 2 Pump Control Pressure MPa Pump 2 Pump Control Pressure
17 Pump 2 Target Flow Rate L/min Pump 2 Target Flow Rate
18 Pump 3 Delivery Pressure MPa Pump 3 Delivery Pressure
19 Pump 3 Pump Control Pressure MPa Pump 3 Pump Control Pressure
20 Pump 3 Target Flow Rate L/min Pump 3 Target Flow Rate
21 Pump 4 Target Flow Rate L/min Pump 4 Target Flow Rate
22 Front Pilot Pressure MPa Front Pilot Pressure
23 Swing Pilot Pressure MPa Swing Pilot Pressure
24 Travel Pilot Pressure MPa Travel Pilot Pressure
25 Att. Control Pilot Pressure MPa Att. Control Pilot Pressure
26 EC Dial Angle V Engine Control Dial Angle
27 Hydraulic Oil Temperature °C Hydraulic Oil Temperature
28 Pump 1 Regulator Pressure MPa Pump 1 Regulator Pressure
29 Pump 2 Regulator Pressure MPa Pump 2 Regulator Pressure
30 Pump 3 Regulator Pressure MPa Pump 3 Regulator Pressure
31 Boom Flow Control Pressure MPa Boom Flow Control Pressure
32 Power Boost Control Pressure MPa Power Boost Control Pressure
33 Travel Motor Control Pressure MPa Travel Motor Control Pressure
34 Radio Signal Strength - Radio Signal Strength

T5-2-27
 TROUBLESHOOTING / Monitor Unit
PUMP 1 FLOW RATE ADJUSTMENT
(Only Machines with Optional Parts
Equipped)
IMPORTANT: This operation is available when at-
tachments are used.

1. After the primary screen appears, push the menu

key and display Main Menu.

2. Select Attachment Adjustment from Main Menu by

using keys 1 and 2. Push confirm key. Then, the
Menu Key
attachment adjustment screen appears.
Primary Screen M18J-01-004

NOTE: Attachment Adjustment can be displayed

according to the Dr. ZX setting.

3. Adjust flow rate of pump 1 by using key 2.

When using the currently installed attachments,
pushing key 1 will decrease flow rate of pump 1
and pushing key 2 will increase respectively.

NOTE: When pushing the back key, return to the

previous screen.

4. Push key 6, and the primary screen appears.

T1V5-05-01-019
Key 1 Key 2 Confirm Key

M1J5-01-014
Key 1 Key 2 Back Key

T5-2-28
 TROUBLESHOOTING / Monitor Unit
ATTACHMENT SELECTION
(Only Machines with Optional Parts
Equipped)
1. After the primary screen appears, push the menu
key and display Main Menu.

Menu Key

Primary Screen M18J-01-004

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

Key 1 Key 2 Confirm Key M1J5-05-002

3. Push a relevant key under an attachment mark to

be used in order to select the attachment.
(For example, Breaker 1 is selected.)

NOTE: The attachments can be displayed accord-

ing to the Dr. ZX setting.
NOTE: When selecting Digging, return to Main
Menu.
Digging
4. On the attachment specification screen, confirm if Back Key
specification of the currently installed attachment Select Breaker 1. Work Mode Screen T1J7-02-01-005
matches that displayed on the screen.

NOTE: When pushing the back key, return to the

previous screen.

5. Push the confirm key, return to Main Menu. Back Key

Confirm
Key

Attachment Specification Screen T1JB-05-02-006

T5-2-29
 TROUBLESHOOTING / Monitor Unit
TIME SETTING
1. After the primary screen appears, push the menu
key and display Main Menu.

Menu Key

Primary Screen M18J-01-004

2. Select Time Set from Main Menu by using keys 1

and 2. Push the confirm key. Then, the time set
screen appears.

Back Key
T1V5-05-01-019
Key 1 Key 2 Confirm Key

3. On the time set 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

T5-2-30
 TROUBLESHOOTING / Monitor Unit
BACK MONITOR SETTING
IMPORTANT: The image displayed on the
back-screen is of auxiliary nature at
best. When the machine is operated,
pay thorough attention to surround-
ing situation.

Auto-Control: ON

The image on the monitor unit when traveling is auto-

matically switched to that of the rear view camera.
Menu Key
1. After the primary screen appears, push the menu Primary Screen M18J-01-004

key and display Main Menu.

2. Select Back Monitor Settings from Main Menu by

using keys 1 and 2. Push the confirm key. Then,
the back monitor settings screen appears.

Back Key

Key 1 Key 2 Confirm Key M18J-01-009E

3. Select Auto-Control by using keys 1 and 2. Push

the confirm key. Then, auto-control is set to ON.

NOTE: When pushing the back key, return to the

primary screen.

4. Push key 6, and return to the primary screen.

5. If travel operation is done, the backward image is

displayed on the screen of the monitor unit.

Back Key

M18J-01-017E
Key 1 Key 2 Confirm Key

Back Key
Key 6
M18J-01-018E

T5-2-31
 TROUBLESHOOTING / Monitor Unit
Auto-Control: OFF

Automatic switching function of the images between

the monitor unit and the rear view camera when trav-
eling is set to OFF.

1. After the primary screen appears, push the menu

key and display Main Menu.

Menu Key

Primary Screen M18J-01-004

2. Select Back Monitor Settings from Main Menu by

using keys 1 and 2. Push the confirm key. Then,
the back monitor settings screen appears.

Key 1 Key 2 Confirm Key Back Key M18J-01-009E

3. Select Auto-Control by using keys 1 and 2. Push

the confirm key. Then, auto-control is set to OFF.

NOTE: When pushing the back key, return to the

previous screen.

4. Push key 6, and return to the primary screen.

M18J-01-018E
Key 1 Key 2 Confirm Key Back Key

Back Key

Key 6
M18J-01-017E

T5-2-32
 TROUBLESHOOTING / Monitor Unit
MAINTENANCE SETTING
1. After the primary screen appears, push the menu
key and display Main Menu.

Menu Key

Primary Screen M18J-01-004

2. Select Maintenance Settings from Main Menu by

using keys 1 and 2. Push the confirm key. Then,
the maintenance setup screen appears.

Key 1 Key 2 Confirm Key M18J-01-009E

3. Select an item to be set from among the list of the

maintenance setup screen by using keys 1 and 2.
Push the confirm key. Then, the Interval ON/OFF
setup screen appears.
(For example, Engine Oil is selected.)

T1V5-05-01-049
Key 1 Key 2 Confirm Key
Maintenance Information Display ON/OFF

1. Select ON or OFF for Maintenance Information

Display by using keys 1 and 2. Push the confirm
key.
ON: When time comes to change, an informa-
tion message is displayed on the screen.
OFF: No information message is displayed.
Key 1
Confirm
2. In order to complete setting, push key 6. Then, the Key
primary screen appears. Key 2

Key 6

Interval ON/OFF Setup Screen T1V5-05-01-052

T5-2-33
 TROUBLESHOOTING / Monitor Unit
Change Interval Settings

IMPORTANT: The 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.

Key 1

Key 2 Interval ON/OFF Setup Screen T1V5-05-01-052

2. Set time for change interval by using keys 3 and 4.

3. Select Remaining Hours by using keys 1 and 2.

Push the confirm key.

Key 1

T1V5-05-01-138
Key 2 Key 3 Key 4 Confirm Key

4. The message "Adjust remaining hours to new

change interval. OK?" appears. Then, push the
confirm key.

5. Push key 6, and the primary screen appears.

Key 6 Confirm Key T1V5-05-01-139

Menu Key

Primary Screen M18J-01-004

T5-2-34
 TROUBLESHOOTING / Monitor Unit
Resetting Data

1. If data is reset, push key 5 on the Interval ON/OFF

setup screen.

Key 5

Interval ON/OFF Setup Screen T1V5-05-01-052

2. The message "Reset Data. OK?" appears. Then,

push the confirm key.

3. The value of remaining hours is reset to that of

change interval. Previous change date/hour is
updated with current date and time.

Confirm Key T1V5-05-01-140

T5-2-35
 TROUBLESHOOTING / Monitor Unit
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
starting screen appears. Then, if the maintenance
item exists, the maintenance information display
screen appears for three to ten seconds. Finally
the primary screen appears.
(For example, Hydraulic Oil is displayed.)

NOTE: As for a machine that displays the primary

screen based upon password input, the T1V1-05-01-115
Starting Screen
maintenance information display screen for
the required item appears for three to ten
seconds, after the password is input suc-
cessfully and the confirm key is pushed.
Then, the primary screen appears.

2. When the data is reset, push the reset key while

the maintenance information display screen is
displayed. Back Key
The message "Reset Data. OK?" appears. Then,
push the confirm key.
The value of remaining hours is reset to that of Reset Key
change interval. The previous change date/hour is
updated with current date and time. T1V5-05-01-170
Maintenance Information Display Screen

NOTE: When pushing the back key while the

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.
Back Key

Confirm Key

T1V5-05-01-171
Reset Screen

Menu Key

Primary Screen T1V1-05-03-001

T5-2-36
 TROUBLESHOOTING / Monitor Unit
• When more than two items are displayed
1. If the key switch is turned to the ON position, the
starting screen appears. Then, if the maintenance
item exists, the scheduled maintenance screen
appears for three to ten seconds. Finally the pri-
mary screen appears.

NOTE: As for a machine that displays the primary

screen based upon password input, the
scheduled maintenance screen for the re-
quired items appears for three to ten sec-
onds, after the password is input success-
fully and the confirm key is pushed. Then, T1V1-05-01-115
Starting Screen
the primary screen appears.

2. When the data is reset, while the scheduled

maintenance screen is displayed, select required
item by using keys 1 and 2. Push the confirm key.
Then, the maintenance information display screen
for the selected item appears.
(For example, Hydraulic Oil is selected.)
Key 1 Back Key
NOTE: When pushing the back key while the
scheduled maintenance screen is displayed,
the primary screen appears. Key 2
Confirm
Key
3. Push the reset key while the maintenance infor- T1V5-05-01-169
Scheduled Maintenance Screen
mation display screen is displayed.
The message "Reset Data. OK?" appears. Then,
push the confirm key.
The value of remaining hours is reset to that of
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 T1V5-05-01-170

nance information display screen.

Back Key

T1V5-05-01-171
Reset Screen

T5-2-37
 TROUBLESHOOTING / Monitor Unit
LANGUAGE SETTING
1. After the primary screen appeared, push the
menu key and display Main Menu.

2. Select Language from Main Menu by using keys 1

and 2. Push the confirm key. Then, the language
setup screen appears.

3. Select a desired language by using keys 1 and 2.

Push the confirm key.

NOTE: The languages to be displayed on the Menu Key

screen of the monitor unit have been se- Primary Screen M18J-01-004
lected from twelve languages, namely dis-
play languages 1 or 2, as default.
(Refer to the next page.)

NOTE: When pushing the back key, return to the

previous screen.

Key 1 Key 2 Confirm Key Back Key M18J-01-016E

4. Push key 6, and the primary screen appears.

Back Key

T1V1-05-01-137
Key 1 Key 6 Key 2 Confirm Key

T5-2-38
 TROUBLESHOOTING / Monitor Unit
Lists of Display Languages
Display Languages 1
Language Screen Display
Japanese
T1V1-05-01-141

English
T1V1-05-01-142

Chinese (Simplified)
T1V1-05-01-143

Chinese (Traditional)
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

Dutch
T1V1-05-01-157

Russian
T1V1-05-01-158

Portuguese
T1V1-05-01-159

Finnish
T1V1-05-01-160

Swedish
T1V1-05-01-161

Norwegian
T1V1-05-01-162

Danish
T1V1-05-01-163

T5-2-39
 TROUBLESHOOTING / Monitor Unit
(Blank)

T5-2-40
 TROUBLESHOOTING / Dr. ZX
OUTLINE

Dr. ZX is used for diagnosis of electrical system in-

cluding MC (main), MC (sub), ICF, and the monitor unit.
Dr. ZX is connected to ICF and failure of each control-
ler and each sensor is displayed as a fault code.
(Self-Diagnostic Result)

Dr. ZX displays the input status of sensors and

switches connected to each controller and the output
status to the actuator including the solenoid valve from
the controller with the machine operated in real time.
(Select Controller)

T5-3-1
 TROUBLESHOOTING / Dr. ZX
Operation Dr. ZX Connector
1. Connect Palm (Dr. ZX) to the diagnosing con-
nector in the cab by using the Hot Sync cable and
a connecting harness.
2. Turn the key switch ON or start the engine.
3. When turning Palm ON, the following screen is
displayed on the display of Palm.
• Initial Screen:
Select Dr. ZX icon.
• Password Setup Screen (When the password has
been unset): Set the password.
• Service Software Selection Screen:
+ Select EX1200-6 (ICF-MCF).
• Function Selection Screen:
+ Self-Diagnostic Results
+ Select Controller
T18J-05-04-002

4. Select Self-Diagnostic Result and operate ac-

cording to the instruction under the display
screen.

Palm
（Dr. ZX）

Hot Sync Cable

Connecting
Harness

T1V1-05-07-002

T5-3-2
 TROUBLESHOOTING / Dr. ZX

Start

Initial Screen
Password Setup Screen
• Input Password
Input the former pass-
When the password has been unset
Communication word (6 characters or
Error more).
Next time, input the
• Check Communication Harness same password in order
• Check Fuse to check and push OK.
When the password has been
set

Service Software
Selection Screen

Select EX1200-6 (ICF-MCF) T1V7-05-03-165

Self-Diagnostic
Result Function Select Controller
Select
Function Monitor Unit
MCF Main MCF Sub Information
C/U
Self-Diagnostic
Result of Each Record Main Menu Main Menu Main Menu Main Menu
Controller • Monitor Display • Monitor Display • Information C/U • Monitoring
• Special Function • Special Function Various Setup • Various Setup
• Setup • Setup Password Change Password Change
Select Controller Disp. Record Disp. Record
Password Change Password Change
Op. Manual. Op. Manual.
Retry B

Self-Diagnostic
Result

T5-3-3
 TROUBLESHOOTING / Dr. ZX
SELF-DIAGNOSTIC RESULTS
The self-diagnostic result of each controller is dis-
played.
After starting Dr. ZX, push Self-Diagnostic Results.

T1V7-05-03-001 T1V7-05-03-008 T18J-05-04-003

Function Selection Screen Controller Self- Diagnosis Screen

NOTE: MCF Main: MC (Main)

MCF Sub: MC (Sub)
Monitor Unit: Monitor Unit
Information C/U: ICF

NOTE: Self-diagnosis of controller ICF is done on

the next page.

T5-3-4
 TROUBLESHOOTING / Dr. ZX
Self-Diagnosis
Push Fault of Information C/U. In
After starting Dr. ZX, push case of no faulty, No Fault is dis-
Self-Diagnostic Results. played.

To the
lower

T1V7-05-03-001 T1V7-05-03-008 T18J-05-04-003

Function Selection Screen Controller Self- Diagnosis Screen

By changing the page, the

Push Details, and Details of the forward and backward fault Push Retry B and return to
fault code and Corrective Action code is displayed. Controller Self-Diagnosis Screen
are displayed. after executing Retry B.
Push ESC and Retry B is dis- Push ESC and Retry B Screen is Push ESC and return to Controller
played. displayed. Self-Diagnosis Screen directly.

Details Retry B

ESC ESC

T1V7-05-03-003 T1V7-05-03-005 T1V7-05-03-007

Retry B Screen
If the message of Details is
long, push the arrow and
change the screen.

Retry B

ESC

T18J-05-04-003
Controller Self- Diagnosis Screen

T5-3-5
 TROUBLESHOOTING / Dr. ZX
SELECT CONTROLLER
Select the failure-diagnosis controller.
After starting Dr. ZX, push Select Controller.

T1V7-05-03-001 T18J-05-04-004

Function Selection Screen Controller Selection Screen

NOTE: MCF Main: MC (Main)

MCF Sub: MC (Sub)
Monitor Unit: Monitor Unit
Information C/U: ICF

T5-3-6
 TROUBLESHOOTING / Dr. ZX
MCF MAIN

• Password:
Changes the password input when setting. Title Screen

• Operation Manual:
Refers to the operation manual, but this function is
not available for EX1200-6 MCF (Main) at preset.

• Recorded Data:
Displays data recorded in MC (main) by one day by
using Dr. ZX.

• Start → Main Menu:

• Monitor Display
Displays the control signals of MC (main) and the T1J1-05-03-034

input signals from each switch and sensor.

• Special Function Password
Return to Controller
Change
Makes Special Function disable/enable. Special Selection Screen.
Function is not available for EX1200-6.
• Setup Op. Manual Disp. Record
Adjusts Pump torque, pump delivery flow rate,
solenoid valve output pressure and so on.
Main Menu Screen

T1V7-05-03-012

Monitor Display

Special Function

Setup

T5-3-7
 TROUBLESHOOTING / Dr. ZX
MONITOR DISPLAY OF MCF (Main)
Dr. ZX displays the input signals from switches and
sensors and the control signals from MC(main).

List of Monitor Item

Item
Unit Data
Selecting Monitoring
Requested Engine Speed Req. Eng min-1 Input signal from engine control dial
Accelerator Pedal Position Ac Pedal POS % Input signal from ECM
Engine Load Factor Eng Load Factor % Input signal from ECM
Actual Engine Speed (E) Actual Speed (E) min-1 Input signal from ECM
Actual Engine Speed Actual Speed min-1 Input signal from engine speed sensor
Difference between actual engine speed and re-
Engine Speed Deviation Eng Speed Deviat min-1
quested engine speed
Pump 1 Delivery Pressure P1 Delivery Pres MPa Input signal from pump 1 delivery pressure sensor
Max. pressure when operating pump 1 (for 4-spool
Pump 1 Flow Control Pressure PC1 Pressure MPa
control valve)
Pump 1 Regulator Pressure P1 Reg. Pres. MPa Input signal from pump 1 regulator pressure sensor
Pump 1 Disired Displacement P1 Disired Disp. cm3 Pump 1 flow rate control target rate
Pump 1 Target flow Rate P1 Set Flow Rate L Pump 1 flow rate control target rate
Pump 2 Delivery Pressure P2 Delivery Pres MPa Input signal from pump 2 delivery pressure sensor
Max. pressure when operating pump 2 (for 5-spool
Pump 2 Flow Control Pressure PC2 Pressure MPa
control valve)
Pump 2 Regulator Pressure P2 Reg. Pressure MPa Input signal from pump 2 regulator pressure sensor
Pump 2 Disired Displacement P2 Disired Disp. cm3 Pump 2 flow rate control target rate
Pump 2 Target flow Rate P2 Set Flow Rate L Pump 2 flow rate control target rate
Pump 3 Delivery Pressure P3 Delivery Pres MPa Input signal from pump 3 delivery pressure sensor
Max. pressure when operating pump 3 (for swing con-
Pump 3 Flow Control Pressure PC3 Pressure MPa
trol valve)
Pump 3 Regulator Pressure P3 Reg. Pressure MPa Input signal from pump 3 regulator pressure sensor
Pump 3 Disired Displacement P3 Disired Disp. cm3 Pump 3 flow rate control target rate
Pump 3 Target flow Rate P3 Set Flow Rate L Pump 3 flow rate control target rate
Pump 1 Load Factor P1 Load Factor % Load rate of pump 1
Pump 2 Load Factor P2 Load Factor % Load rate of pump 2
Pump 3 Load Factor P3 Load Factor % Load rate of pump 3
Pump 1 Torque P1 Torque N⋅m Calculation for MC(main)
Pump 2 Torque P2 Torque N⋅m Calculation for MC(main)
Pump 3 Torque P3 Torque N⋅m Calculation for MC(main)
EC Dial Angle Dial Angle V Input signal from engine control dial
Max. hydraulic oil temperature of hydraulic oil tem-
Hydraulic Oil Temperature Hyd Oil Temp. °C
perature sensors 1 and 2
Hydraulic Oil Temperature 1 Hyd Oil Temp. 1 °C Input signal from hydraulic oil temperature sensor 1
Max. pressure when operating boom, arm, bucket,
Front Pilot Pressure Fr Pilot Press MPa
swing, attachment, aux.1 and/or aux.2
Input signal from pressure sensors
Travel Pilot Pressure TR Pilot Press MPa
(travel (left) and (right))
Boom Raise Pilot Pressure Boom Raise MPa Input signal from pressure sensor (boom raise)
Boom Lowering Pilot Pressure Boom Lower MPa Input signal from pressure sensor (boom lower)
Arm Roll-In (BH) Pilot Pressure Arm Roll-In (BH) MPa Input signal from pressure sensor (arm roll-in)
Arm Roll-Out (BH) Pilot Pressure Arm Roll-Out (BH) MPa Input signal from pressure sensor (arm roll-out)
Bucket Roll-In (BH) Pilot Pressure Bucket Roll-In (BH) MPa Input signal from pressure sensor (bucket roll-in)
Bucket Roll-Out (BH) Pilot Pres- Bucket Roll-Out
MPa Input signal from pressure sensor (bucket roll-out)
sure (BH)

T5-3-8
 TROUBLESHOOTING / Dr. ZX

Item
Unit Data
Selecting Monitoring
Swing Pilot Pressure SW Pilot Press MPa Input signal from pressure sensor (swing)
Left Travel Pilot Pressure Left TR Press. MPa Input signal from pressure sensor (travel (left))
Right Travel Pilot Pressure Right TR Press. MPa Input signal from pressure sensor (travel (right))
Att. Control Pilot Pressure Att. Pilot Press. MPa Input signal from pressure sensor (attachment)
Arm Extend (LD) Pilot Pressure Arm Extend (LD) MPa Input signal from pressure sensor (arm extend)
Arm Retract (LD) Pilot Pressure Arm Retract (LD) MPa Input signal from pressure sensor (arm retract)
Bucket Tilt-Out (LD) Pilot Pressure Bucket Tilt-Out (LD) MPa Input signal from pressure sensor (bucket tilt-out)
Bucket Tilt-In (LD) Pilot Pressure Bucket Tilt-In (LD) MPa Input signal from pressure sensor (bucket tilt-in)
Auxiliary Pilot Pressure AUX Pilot Press. MPa Input signal from pressure sensor (auxiliary)
Boom Bottom Pressure Bm Bottom Press MPa Input signal from boom bottom pressure sensor
E/P SW E/P SW P, E Power mode switch selection status
HP Mode SW HP Mode SW OFF, ON Power mode switch selection status
Auto-Idle SW AI SW AI Auto-idle switch ON/OFF status
Travel 2-Speed Chg
Travel Mode SW Lo, Hi Travel mode switch selection status
Ovr SW
Key SW Key SW OFF, ON Key switch ON/OFF status
Not Disp,
Heavy Lift SW (Logo) Heavy Lift SW (Logo) Heavy lift switch selection status
Disp
OFF(main),
Unit Select SW Unit Select SW Unit selection switch ON/OFF status
ON(sub)
HYD Oil Level Check
Hydraulic Oil Level Check SW1 OFF, ON Hydraulic oil level check 1 switch ON/OFF status
SW1
HYD Oil Level Check
Hydraulic Oil Level Check SW2 OFF, ON Hydraulic oil level check 2 switch ON/OFF status
SW2
Engine Oil Level SW EngOil L. SW OFF, ON Engine oil level switch ON/OFF status
Level Check SW Level Check SW OFF, ON Coolant level switch ON/OFF status
Gate Lock SW Gate Lock SW OFF, ON Pilot shut-off switch ON/OFF status
Boom Mode SW Bm Mode SW OFF, ON Boom mode selector switch ON/OFF status
Auto Lubrication Counting SW Lub. Count. SW OFF, ON Auto lubrication limiter switch ON/OFF status
Bk Surveil, Rear watching selector switch ON/OFF status and
Picture Change Signal Picture Change
Trav. Operat traveling
Pump regulator pressure leaning switch ON/OFF
Pump Regulator Leaning SW P Reg. Lean. SW OFF, ON
status, Torque adjustment switch ON/OFF status
Loader Bucket (O/C) Flow Change Loader bucket open/close oil flow rate switch
Loader SW OFF, ON
SW ON/OFF status
Pump Mission Level
Pump Mission Level SW OFF, ON Pump transmission oil level switch ON/OFF status
SW
Power Boost Control Pressure Pw Boost Ctrl Press MPa Control signal to solenoid valve unit (SG)
Travel Motor Control Pressure Tr M Ctrl Pressure MPa Control signal to solenoid valve unit (SI)
Boom Mode Control Pressure Bm Mode Cont. Press MPa Control signal to solenoid valve unit (SC)
Boom Flow Control Pressure Bm Flow Cont. Press MPa Control signal to solenoid valve unit (SF)
Action,
Travel Alarm Travel Alarm Travel alarm Action/No Action status
No Action
Action,
Swing Alarm Swing Alarm Swing alarm Action/No Action status
No Action

T5-3-9
 TROUBLESHOOTING / Dr. ZX

Item
Unit Data
Selecting Monitoring
Auto Idle Speed Con- Engine speed control request signal (1400 min-1)
Auto Idle Speed Control OFF, ON
trol ON/OFF status
Travel/P Speed Engine speed control request signal (1800 min-1)
Travel/P Mode Speed Control OFF, ON
Control ON/OFF status
E Mode Speed Engine speed control request signal (1600 min-1)
E Mode Speed Control OFF, ON
Control ON/OFF status
(P1,P2,P3)
Pump 1,2,3 Reg Learning Cond. P1,2,3 Reg. Pr. L. Cd. L, F1, F2, F3, Pump 1, 2, 3 learning condition
F4
P1(2, 3):
Pump 1,2,3 Reg Learning Status P1,2,3 Reg. Pr. L. St. Pump 1, 2, 3 learning status
-, S, F, L
Pump 1 Regulator Valve Current Pump 1 CUR mA Control signal to pump 1 oil flow control valve
Pump 2 Regulator Valve Current Pump 2 CUR mA Control signal to pump 2 oil flow control valve
Pump 3 Regulator Valve Current Pump 3 CUR mA Control signal to pump 3 oil flow control valve
Boom Flow Control Valve Current Bm Flow C. Val. CUR mA Control signal to solenoid valve unit (SF)
OFF, Auto,
Lubricating Mode Lub. Mode Lubrication mode selection switch status
Manual
Normal,
Auto Lubricate Alarm Auto Lub. Alarm Auto-lubrication status
Abnormal
SUS.,
Lubrication Control Output Lubrication Cont. Out. Grease pump status
Comp.
BR, PU, CR,
Current ATT Type Current ATT Type Communication from monitor unit
VI, Un, Non
Current ATT No. Current ATT No. 1, 2, 3, 4, 5 Communication from monitor unit
BR, PU, CR,
ATT 1 Type ATT 1 Type Communication from monitor unit
VI, Un, Non
ATT 1 No. ATT 1 No. 1, 2, 3, 4, 5 Communication from monitor unit
BR, PU, CR,
ATT 2 Type ATT 2 Type Communication from monitor unit
VI, Un, Non
ATT 2 No. ATT 2 No. 1, 2, 3, 4, 5 Communication from monitor unit
BR, PU, CR,
ATT 3 Type ATT 3 Type Communication from monitor unit
VI, Un, Non
ATT 3 No. ATT 3 No. 1, 2, 3, 4, 5 Communication from monitor unit
BR, PU, CR,
ATT 4 Type ATT 4 Type Communication from monitor unit
VI, Un, Non
ATT 4 No. ATT 4 No. 1, 2, 3, 4, 5 Communication from monitor unit
BR, PU, CR,
ATT 5 Type ATT 5 Type Communication from monitor unit
VI, Un, Non
ATT 5 No. ATT 5 No. 1, 2, 3, 4, 5 Communication from monitor unit

NOTE: ATT: Attachment

BR: Hydraulic Breaker
PU: Pulverizer Crusher
CR: Crusher
VI: Vibrating Hammer
Un: Other (Special Machine)
Non: Non Selection

T5-3-10
 TROUBLESHOOTING / Dr. ZX
(Blank)

T5-3-11
 TROUBLESHOOTING / Dr. ZX
Monitor Display

After starting Dr. ZX, push Select

Controller. Push MCF Main. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T1J1-05-03-010

Function Selection Screen Controller Selection Screen Main Controller Screen

Push Start. Push Monitor Display.

To the
lower

T1J1-05-03-034 T1V7-05-03-012 T1J1-05-03-011

Title Screen Main Menu Screen Enter Model and Serial No.
Screen
Push HOLD and the monitor is
Push the item for Monitor Display stopped temporarily. When the monitor
and push OK. Refer to T5-3-8 as is started again, push HOLD again.
Input the model code and serial for the monitor item. Push ESC
No. and push OK. Push ESC and Push ESC and return to Display Item
and return to Main Menu Screen. Selection Screen.
return to Main Menu Screen.

T1J1-05-03-013 T1J1-05-03-014
T1J1-05-03-012
Enter Model and Serial No. Screen Display Item Selection Screen Monitor Screen

To the next page

T5-3-12
 TROUBLESHOOTING / Dr. ZX

Push Rec. No. and the recording

Push Record. screen for Rec. No. is made.

To the
lower

T1J1-05-03-014 T1V7-05-03-096 T1V7-05-03-097

Monitor Screen Select Write Data-Bank Screen

If Rec. No. has already been re- If Rec. No. has not been recorded
corded and push Over Write, data yet and push Write, data is written Push Comment .
is overwritten. Push ESC and re- to Recording Screen. Push ESC Push ESC and return to Main
turn to Main Menu Screen. and return to Main Menu Screen. Menu Screen.

To the
lower

T1J1-05-03-015 T1V7-05-03-100 T1J1-05-03-016

Recording Screen Recording Screen

Push Re-Input and return to Re-

cording Screen (Comment Input).
Input Weather and Person’s name Push OK and the recording screen Push ESC and return to Main
in change and push OK. (making) is finished. Menu Screen.

T1J1-05-03-017 T1J1-05-03-018 T1J1-05-03-019

Recording Screen (Comment In-

put)

T5-3-13
 TROUBLESHOOTING / Dr. ZX
SETUP OF MCF (Main)
Pump torque, pump delivery flow rate, and solenoid
valve output pressure can be adjusted.

Parameter Change
Item Unit Data
PQ Torque Control N⋅m Adjustment of P-Q curve
Pump P1 Torque Adjustment N⋅m Adjustment of pump 1 P-Q curve
Pump P2 Torque Adjustment N⋅m Adjustment of pump 2 P-Q curve
Pump P3 Torque Adjustment N⋅m Adjustment of pump 3 P-Q curve
Lubrication Interval Adj. min Adjustment of auto-lubrication interval
Pump 1 Min. Displacement Adj. cm3 Adjustment of pump 1 delivery flow rate
3
Pump 2 Min. Displacement Adj. cm Adjustment of pump 2 delivery flow rate
3
Pump 3 Min. Displacement Adj. cm Adjustment of pump 3 delivery flow rate
P1 REG. Offset Adj. MPa Adjustment of pump 1 delivery flow rate
P2 REG. Offset Adj. MPa Adjustment of pump 2 delivery flow rate
P3 REG. Offset Adj. MPa Adjustment of pump 3 delivery flow rate
P1 AUX. Input Function Setting ON, OFF ON/OFF of P1 auxiliary input function
P2 AUX. Input Function Setting ON, OFF ON/OFF of P2 auxiliary input function
P3 AUX. Input Function Setting ON, OFF ON/OFF of P3 auxiliary input function
ATT Mode Storage On/Off ON, OFF ON/OFF of attachment mode memory

IMPORTANT: When turning the key switch to the

OFF position with the ATT mode
memory ON/OFF selection OFF, the
selected work mode becomes inef-
fective and returns to the digging
mode. Next time, the work mode
should be selected. When turning
the key switch to the OFF position
with the ATT mode memory ON/OFF
selection ON, the selected work
mode becomes effective

T5-3-14
 TROUBLESHOOTING / Dr. ZX

Attachment Parameter Change

Item Unit Data
ATT1
ATT1 ATT Type BR PU CR VI Un Non Attachment selection
ATT1 ATT Number 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
ATT1 P2 Swash Angle Adjustment L/min Adjustment of lower limit of maximum pump 2 flow rate
when using attachment
ATT1 Engine Speed Adjustment min-1 Adjustment of engine speed when using attachment
ATT1 Relief Change (OPT) ON, OFF Secondary pilot relief valve ON/OFF selection
ATT1 2nd Relief Change (OPT) ON, OFF Selector valve ON/OFF selection
ATT1 Accumulator Change (OPT) ON, OFF Accumulator ON/OFF selection
ATT1 2-Speed Change (OPT) ON, OFF 2-speed selection ON/OFF selection
ATT2
ATT2 ATT Type BR PU CR VI Un Non Attachment selection
ATT2 ATT Number 12345 Attachment setting number selection
ATT2 P1 Swash Angle Adjustment L/min Adjustment of lower limit of maximum pump 1 flow rate
when using attachment
ATT2 P2 Swash Angle Adjustment L/min Adjustment of lower limit of maximum pump 2 flow rate
when using attachment
ATT2 Engine Speed Adjustment min-1 Adjustment of engine speed when using attachment
ATT2 Relief Change (OPT) ON, OFF Secondary pilot relief valve ON/OFF selection
ATT2 2nd Relief Change (OPT) ON, OFF Selector valve ON/OFF selection
ATT2 Accumulator Change (OPT) ON, OFF Accumulator ON/OFF selection
ATT2 2-Speed Change (OPT) ON, OFF 2-speed selection ON/OFF selection
ATT3
ATT3 ATT Type BR PU CR VI Un Non Attachment selection
ATT3 ATT Number 12345 Attachment setting number selection
ATT3 P1 Swash Angle Adjustment L/min Adjustment of lower limit of maximum pump 1 flow rate
when using attachment
ATT3 P2 Swash Angle Adjustment L/min Adjustment of lower limit of maximum pump 2 flow rate
when using attachment
ATT3 Engine Speed Adjustment min-1 Adjustment of engine speed when using attachment
ATT3 Relief Change (OPT) ON, OFF Secondary pilot relief valve ON/OFF selection
ATT3 2nd Relief Change (OPT) ON, OFF Selector valve ON/OFF selection
ATT3 Accumulator Change (OPT) ON, OFF Accumulator ON/OFF selection
ATT3 2-Speed Change (OPT) ON, OFF 2-speed selection ON/OFF selection

NOTE: ATT: Attachment

BR: Hydraulic Breaker
PU: Pulverizer Crusher
CR: Crusher
VI: Vibrating Hammer
Un: Other (Special Machine)
Non: Non Selection

T5-3-15
 TROUBLESHOOTING / Dr. ZX

Item Unit Data

ATT4
ATT4 ATT Type BR PU CR VI Un Non Attachment selection
ATT4 ATT Number 12345 Attachment setting number selection
ATT4 P1 Swash Angle Adjustment L/min Adjustment of lower limit of maximum pump 1 flow rate
when using attachment
ATT4 P2 Swash Angle Adjustment L/min Adjustment of lower limit of maximum pump 2 flow rate
when using attachment
ATT4 Engine Speed Adjustment min-1 Adjustment of engine speed when using attachment
ATT4 Relief Change (OPT) ON, OFF Secondary pilot relief valve ON/OFF selection
ATT4 2nd Relief Change (OPT) ON, OFF Selector valve ON/OFF selection
ATT4 Accumulator Change (OPT) ON, OFF Accumulator ON/OFF selection
ATT4 2-Speed Change (OPT) ON, OFF 2-speed selection ON/OFF selection
ATT5
ATT5 ATT Type BR PU CR VI Un Non Attachment selection
ATT5 ATT Number 12345 Attachment setting number selection
ATT5 P1 Swash Angle Adjustment L/min Adjustment of lower limit of maximum pump 1 flow rate
when using attachment
ATT5 P2 Swash Angle Adjustment L/min Adjustment of lower limit of maximum pump 2 flow rate
when using attachment
ATT5 Engine Speed Adjustment min-1 Adjustment of engine speed when using attachment
ATT5 Relief Change (OPT) ON, OFF Secondary pilot relief valve ON/OFF selection
ATT5 2nd Relief Change (OPT) ON, OFF Selector valve ON/OFF selection
ATT5 Accumulator Change (OPT) ON, OFF Accumulator ON/OFF selection
ATT5 2-Speed Change (OPT) ON, OFF 2-speed selection ON/OFF selection

NOTE: ATT: Attachment

BR: Hydraulic Breaker
PU: Pulverizer Crusher
CR: Crusher
VI: Vibrating Hammer
Un: Other (Special Machine)
Non: Non Selection

T5-3-16
 TROUBLESHOOTING / Dr. ZX
Adjustment Data List
Min. Adjustment Standard
Adjustment Data Adjustable Range
Value Adjustment
PQ Torque Control 10 N⋅m -1200 to 110 N⋅m 0 N⋅m
Pump P1 Torque Adjustment 10 N⋅m -1000 to 0 N⋅m 0 N⋅m
Pump P2 Torque Adjustment 10 N⋅m -1000 to 0 N⋅m 0 N⋅m
Pump P3 Torque Adjustment 10 N⋅m -1000 to 0 N⋅m 0 N⋅m
Lubrication Interval Adj. 1 min 11 to 253 min 30 min
Pump 1 Min. Displacement Adj. 2.5 cm3 0.0 to 140 cm3 0.0 cm3
Pump 2 Min. Displacement Adj. 2.5 cm3 0.0 to 140 cm3 0.0 cm3
Pump 3 Min. Displacement Adj. 2.5 cm3 0.0 to 140 cm3 0.0 cm3
P1 REG. Offset Adj. 0.006 MPa -0.198 to 0.102 MPa -0.024 Mpa
P2 REG. Offset Adj. 0.006 MPa -0.198 to 0.102 MPa -0.024 Mpa
P3 REG. Offset Adj. 0.006 MPa -0.198 to 0.102 MPa -0.024 Mpa
P1 AUX. Input Function Setting － － OFF
P2 AUX. Input Function Setting － － OFF
P3 AUX. Input Function Setting － － OFF
ATT Mode Storage On/Off － － OFF

T5-3-17
 TROUBLESHOOTING / Dr. ZX
Attachment Adjustment Data List
Min. Adjustment Standard
Adjustment Data Adjustable Range Remarks
Value Adjustment
ATT1
ATT1 ATT Type - BR PU CR VI Un Non BR
ATT1 ATT Number - 1 to 5 1
ATT1 P1 Swash Angle Adjustment 0.5 L/min 100 to 525 L/min 525 L/min
ATT1 P2 Swash Angle Adjustment 0.5 L/min 100 to 525 L/min 525 L/min
-1 -1
ATT1 Engine Speed Adjustment 10 min 0 min 0 min-1
ATT1 Relief Change (OPT) - ON/OFF Unregistration
ATT1 2nd Relief Change (OPT) - C/V or O/T Unregistration
ATT1 Accumulator Change (OPT) - ON/OFF Unregistration
ATT1 2-Speed Change (OPT) - ON/OFF OFF
ATT2
ATT2 ATT Type - BR PU CR VI Un Non BR
ATT2 ATT Number - 1 to 5 2
ATT2 P1 Swash Angle Adjustment 0.5 L/min 100 to 525 L/min 525 L/min
ATT2 P2 Swash Angle Adjustment 0.5 L/min 100 to 525 L/min 525 L/min
-1 -1
ATT2 Engine Speed Adjustment 10 min 0 min 0 min-1
ATT2 Relief Change (OPT) - ON/OFF Unregistration
ATT2 2nd Relief Change (OPT) - C/V or O/T Unregistration
ATT2 Accumulator Change (OPT) - ON/OFF Unregistration
ATT2 2-Speed Change (OPT) - ON/OFF OFF
ATT3
ATT3 ATT Type - BR PU CR VI Un Non BR
ATT3 ATT Number - 1 to 5 3
ATT3 P1 Swash Angle Adjustment 0.5 L/min 100 to 525 L/min 542 L/min
ATT3 P2 Swash Angle Adjustment 0.5 L/min 100 to 525 L/min 525 L/min
-1 -1
ATT3 Engine Speed Adjustment 10 min 0 min 0 min-1
ATT3 Relief Change (OPT) - ON/OFF Unregistration
ATT3 2nd Relief Change (OPT) - C/V or O/T Unregistration
ATT3 Accumulator Change (OPT) - ON/OFF Unregistration
ATT3 2-Speed Change (OPT) - ON/OFF OFF

NOTE: ATT: Attachment

BR: Hydraulic Breaker
PU: Pulverizer Crusher
CR: Crusher
VI: Vibrating Hammer
Un: Other (Special Machine)
Non: Non Selection

T5-3-18
 TROUBLESHOOTING / Dr. ZX

Min. Adjustment Standard

Adjustment Data Adjustable Range Remarks
Value Adjustment
ATT4
ATT4 ATT Type - BR PU CR VI Un Non BR
ATT4 ATT Number - 1 to 5 4
ATT4 P1 Swash Angle Adjustment 0.5 L/min 100 to 525 L/min 525 L/min
ATT4 P2 Swash Angle Adjustment 0.5 L/min 100 to 525 L/min 525 L/min
-1
ATT4 Engine Speed Adjustment 10 min 0 min-1 0 min-1
ATT4 Relief Change (OPT) - ON/OFF Unregistration
ATT4 2nd Relief Change (OPT) - C/V or O/T Unregistration
ATT4 Accumulator Change (OPT) - ON/OFF Unregistration
ATT4 2-Speed Change (OPT) - ON/OFF OFF
ATT5
ATT5 ATT Type - BR PU CR VI Un Non Unregistration
ATT5 ATT Number - 1 to 5 Unregistration
ATT5 P1 Swash Angle Adjustment 0.5 L/min 100 to 525 L/min 525 L/min
ATT5 P2 Swash Angle Adjustment 0.5 L/min 100 to 525 L/min 525 L/min
-1
ATT5 Engine Speed Adjustment 10 min 0 min-1 0 min-1
ATT5 Relief Change (OPT) - ON/OFF Unregistration
ATT5 2nd Relief Change (OPT) - C/V or O/T Unregistration
ATT5 Accumulator Change (OPT) - ON/OFF Unregistration
ATT5 2-Speed Change (OPT) - ON/OFF OFF

NOTE: ATT: Attachment

BR: Hydraulic Breaker
PU: Pulverizer Crusher
CR: Crusher
VI: Vibrating Hammer
Un: Other (Special Machine)
Non: Non Selection

T5-3-19
 TROUBLESHOOTING / Dr. ZX
Parameter Change of MCF (Main)

After starting Dr. ZX, push Select

Controller. Push MCF Main. Push OK.

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T1V7-05-03-001 T18J-05-04-004 T1J1-05-03-010

Function Selection Screen Controller Selection Screen Main Controller Screen

Push Start. Push Setup.

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T1J1-05-03-034 T1V7-05-03-012 T1V7-05-03-016

Title Screen Main Menu Screen

Refer to T5-3-14 as for the item of

Input the password and push OK. Push Parameter Change. Parameter Change. Display the
Push Cancel and return to Main Push ESC and return to Main forward and backward item by
Menu Screen. Menu Screen. pushing these marks.

T1V7-05-03-022 T1J1-05-03-021 T18J-05-04-005

Setup Password Input Screen Setup Item Selection Screen Parameter Change Selection
Screen

T5-3-20
 TROUBLESHOOTING / Dr. ZX
Parameter Input
Example: PQ Torgue Control
Input Value = Normal Value

Input the value and push Execution. Check Adjustment and push Exe-
Push ESC and return to Parameter cute. Push ESC and return to Pa-
Push PQ Torgue Control. Change Selection Screen. rameter Change Selection Screen.

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T18J-05-04-005 T18J-05-04-006 T18J-05-04-007

Parameter Change Selection Parameter Input Screen Adjust Data Confirm Screen
Screen

Push ESC and return to Parameter

Change Selection Screen.

T1V7-05-03-107

T5-3-21
 TROUBLESHOOTING / Dr. ZX
Input Value = Current Value

Input the value and push Execution. Push Execute. Push ESC and re-
Push ESC and return to Parameter turn to Parameter Change Selection
Push PQ Torgue Control. Change Selection Screen. Screen.

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T18J-05-04-005 T18J-05-04-006 T18J-05-04-008

Parameter Change Selection Parameter Input Screen

Screen

Push ESC and return to Parameter

Change Selection Screen.

T1V7-05-03-107

T5-3-22
 TROUBLESHOOTING / Dr. ZX
Input Value > Maximum Value
(Input Value < Minimum Value)
Push Re-Input and return to Pa-
rameter Input Screen. Push Max
Input the value and push Execution. and the maximum value is input.
Push ESC and return to Parameter Push ESC and return to Parameter
Push PQ Torgue Control. Change Selection Screen. Change Selection Screen.

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T18J-05-04-005 T18J-05-04-006 T18J-05-04-009

Parameter Change Selection Parameter Input Screen
Screen

Push ESC and return to Parameter

Change Selection Screen.

T1V7-05-03-107

T5-3-23
 TROUBLESHOOTING / Dr. ZX
When the input value cannot be divided

Push Re-Input and return to Pa-

rameter Input Screen. Push A or B
Input the value and push Execution. and the value of A or B is input.
Push ESC and return to Parameter Push ESC and return to Parameter
Push PQ Torgue Control. Change Selection Screen. Change Selection Screen.

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T18J-05-04-005 T18J-05-04-006 T18J-05-04-010

Parameter Change Selection Parameter Input Screen
Screen

Push ESC and return to Parameter

Change Selection Screen.

T1V7-05-03-107

T5-3-24
 TROUBLESHOOTING / Dr. ZX
Status Selection
Example: P1 AUX. Input Function Setting: Off
Push Exec again on change data
Push OFF and Push Exec. Push screen. Push ESC and return to
Push P1 AUX. Input Function Set- ESC and return to Parameter Parameter Change Selection
ting. Change Selection Screen. Screen.

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T18J-05-04-011 T18J-05-04-012 T18J-05-04-013

Parameter Change Selection Status Selection Screen Adjust Data Confirm Screen
Screen

Push ESC and return to Parameter

Change Selection Screen.

T1V7-05-03-107

T5-3-25
 TROUBLESHOOTING / Dr. ZX
• Attachment Parameter Change

After starting Dr. ZX, push Select

Controller. Push MCF Main. Push OK.

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T1V7-05-03-001 T18J-05-04-004 T1J1-05-03-010

Function Selection Screen Controller Selection Screen Main Controller Screen

Push Start. Push Setup.

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T1J1-05-03-034 T1V7-05-03-012 T1V7-05-03-016

Title Screen Main Menu Screen

Refer to T5-3-15, 16 as for the item

Input the password and push OK. of ATT Parameter Change.
Push ATT Parameter Change.
Push Cancel and return to Main Display the forward and backward
Push ESC and return to Main
Menu Screen. item by pushing these marks.
Menu Screen.

T1V7-05-03-022 T1J1-05-03-021 T1V7-05-03-114

Setup Password Input Screen Setup Item Selection Screen Attachment Selection Screen

T5-3-26
 TROUBLESHOOTING / Dr. ZX
Attachment Parameter Input
Input Value = Normal Value

Input the value and push Execu-

Push ATT1 P1 Swash Angle Ad- tion. Push ESC and return to ATT
Push ATT1. justment. Parameter Change Screen.

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T1V7-05-03-114 T1V7-05-03-115 T18J-05-04-014

Attachment Selection Screen ATT Parameter Change Screen ATT Parameter Input Screen

Adjustment and push Execute.

Push ESC and return to ATT Pa- Push ESC and return to ATT
rameter Change Screen. Parameter Change Screen.

T18J-05-04-015 T1V7-05-03-107

T5-3-27
 TROUBLESHOOTING / Dr. ZX
Input Value = Current Value

Input the value and push Execu-

Push ATT1 P1 Swash Angle Ad- tion. Push ESC and return to ATT
Push ATT1. justment. Parameter Change Screen.

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T1V7-05-03-114 T1V7-05-03-115 T18J-05-04-014

Attachment Selection Screen ATT Parameter Change Screen ATT Parameter Input Screen

Push Execute. Push ESC and return Push ESC and return to ATT Pa-
to ATT Parameter Change Screen. rameter Change Screen.

T18J-05-04-016 T1V7-05-03-107

T5-3-28
 TROUBLESHOOTING / Dr. ZX
Input Value > Maximum Value
(Input Value < Minimum Value)

Input the value and push Execu-

Push ATT1 P1 Swash Angle Ad- tion. Push ESC and return to ATT
Push ATT1. justment. Parameter Change Screen.

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T1V7-05-03-114 T1V7-05-03-115 T18J-05-04-014

Attachment Selection Screen ATT Parameter Change Screen ATT Parameter Input Screen

Push Re-Input and return to ATT

Parameter Input Screen. Push
MAX and the maximum value is
input. Push ESC and return to ATT Push ESC and return to ATT Pa-
Parameter Change Screen. rameter Change Screen.

T18J-05-04-017 T1V7-05-03-107

T5-3-29
 TROUBLESHOOTING / Dr. ZX
When the input value cannot be divided

Input the value and push Execu-

Push ATT1 P1 Swash Angle Ad- tion. Push ESC and return to ATT
Push ATT1. justment. Parameter Change Screen.

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T1V7-05-03-114 T1V7-05-03-115 T18J-05-04-014

Attachment Selection Screen ATT Parameter Change Screen ATT Parameter Input Screen

Push Re-Input and return to ATT

Parameter Input Screen. Push A or
B and the value of A or B is input.
Push ESC and return to ATT Pa- Push ESC and return to ATT Pa-
rameter Change Screen. rameter Change Screen.

T1J1-05-03-032 T1V7-05-03-107

T5-3-30
 TROUBLESHOOTING / Dr. ZX
Status Selection
Example: ATT1, ATT Number

Push “3” and Push Exec. Push

ESC and return to ATT Parameter
Push ATT1. Push ATT1 Number. Change Selection Screen.

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T1V7-05-03-114 T1V7-05-03-115 T1V7-05-03-123

Attachment Selection Screen ATT Parameter Change Screen ATT Status Selection Screen

Check number and push Execute.

Push ESC and return to ATT Pa- Push ESC and return to ATT Pa-
rameter Change Selection Screen. rameter Change Selection Screen.

T1J1-05-03-033 T1V7-05-03-107

T5-3-31
 TROUBLESHOOTING / Dr. ZX
Attachment Setting
Example: Set Crusher 5 to Attachment 1
Push “CR” and Push Exec. Push
ESC and return to ATT Parameter
Push ATT1. Push ATT1 Type. Change Selection Screen.

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T1V7-05-03-114 T1V7-05-03-115 T1V7-05-03-121

Attachment Selection Screen ATT Parameter Change Screen ATT Status Selection Screen

Push “5” and Push Exec. Push

Push ESC and return to ATT Pa- ESC and return to ATT Parameter
rameter Change Selection Screen. Push ATT1 Number.
Change Selection Screen.

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T1V7-05-03-107 T1V7-05-03-115
T1V7-05-03-123
ATT Parameter Change Screen ATT Status Selection Screen

When the work mode screen (Attachment Selection Screen) of the

monitor unit is displayed, Crusher 5 is displayed at Attachment 1.
Push ESC and return to ATT Pa- When pushing key 2, Crusher 5 is selected and the Crusher 5
rameter Change Selection Screen. specification screen is displayed.

Attachment 1

Key 2
T1V7-05-03-107

Attachment Selection Screen

T1J1-05-03-002

T5-3-32
 TROUBLESHOOTING / Dr. ZX
Attachment Non-Setting
IMPORTANT: When the attachment is
“non-setting”, the attachment can-
not be selected on the monitor unit.

Example: Set Attachment to Non-Setting

Push “Non” and Push Exec. Push
ESC and return to ATT Parameter
Push ATT1. Push ATT1 Type. Change Selection Screen.

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T1V7-05-03-114 T1V7-05-03-115 T1V7-05-03-121

Attachment Selection Screen ATT Parameter Change Screen ATT Status Selection Screen

Attachment 4
Push ESC. Attachment 3 Attachment 5

Attachment 2

Attachment 1

T1V7-05-03-107

Attachment Selection Screen

T1J1-05-03-003

T5-3-33
 TROUBLESHOOTING / Dr. ZX
All Parameter Initialize
• If All Parameter Initialize is executed, pump learning
value of MC (main) is erased. The settings of Pa-
rameter Change and Attachment Parameter Change
are initialized so that MC (main) is returned as the
factory setting.

IMPORTANT: Turn the key switch ON with the en-

gine stopped, execute All Parameter
Initialize.

IMPORTANT: Each setting of Parameter Change

and Attachment Parameter Change
may be set for each machine.
Before All Parameter Initialize is
executed, record the current set-
tings. Set the setting again after All
Parameter Initialize is executed if
necessary.

Turn the key switch ON.

After starting Dr. ZX, push Select
Controller. Push MCF Main. Push OK.

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T1V7-05-03-001 T18J-05-04-004 T1J1-05-03-010

Function Selection Screen Controller Selection Screen Main Controller Screen

Push Start. Push Setup.

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next page

T1J1-05-03-034 T1V7-05-03-012 T1V7-05-03-016

Title Screen Main Menu Screen

T5-3-34
 TROUBLESHOOTING / Dr. ZX

Input the password and push OK. Push All Parameter initialize. Push OK.
Push Cancel and return to Main Push ESC and return to Main Push ESC and return to Main
Menu Screen. Menu Screen. Menu Screen.

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T1V7-05-03-022 T1J1-05-03-021 T1J1-05-03-005

Setup Password Input Screen All Parameter Initialize Selection Explanation Screen
Screen

Push OK and execute All Pa-

rameter initialize. Push abort and Push ESC and return to Main Push ESC and return to Main
stop All Parameter initialize. Menu Screen. Menu Screen.

OK

abort

T1J1-05-03-006 T1J1-05-03-007 T1J1-05-03-008

Execution Screen

IMPORTANT: After all parameter initialize opera-

tion is completed, turn the key
switch OFF over 3 seconds.

T5-3-35
 TROUBLESHOOTING / Dr. ZX
Recorded Data Display

After starting Dr. ZX, push Select

Controller. Push MCF Main. Push OK.

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T1V7-05-03-001 T18J-05-04-004 T1J1-05-03-010

Function Selection Screen Controller Selection Screen Main Controller Screen

Push HOLD and the monitor is

Push and select No. Push Execute stopped temporarily. Push HOLD
and the recorded data is regener- again and restart regeneration.
ated. Push DEL and data of Push ESC and Main Menu Screen
Push Disp. Record. selected No. is deleted. is displayed.

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T1J1-05-03-034 T1V7-05-03-124
T1J1-05-03-014
Title Screen Recorded Data Regeneration
Screen

Main Menu Screen T1V7-05-03-012

T5-3-36
 TROUBLESHOOTING / Dr. ZX
Password Change

After starting Dr. ZX, push Select

Controller. Push MCF Main. Push OK.

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T1V7-05-03-001 T18J-05-04-004 T1J1-05-03-010

Function Selection Screen Controller Selection Screen Main Controller Screen

Input the registered password and Input the new password and push
Push Password. push OK. OK.

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T1J1-05-03-034 T1V7-05-03-126 T18J-05-04-064

Title Screen

Input the new password again and Push OK and return to Title
push OK. Screen.

T1V7-05-03-169 T1V7-05-03-128

T5-3-37
 TROUBLESHOOTING / Dr. ZX
(Blank)

T5-3-38
 TROUBLESHOOTING / Dr. ZX
MCF SUB
• Password:
Changes the password input when setting. Title Screen

• Operation Manual:
Refers to the operation manual, but this function
is not available for EX1200-6 MCF (Sub) at pre-
set.

• Recorded Data:
Displays data recorded in MC (sub) by one day by
using Dr. ZX.

• Start → Main Menu:

• Monitor Display T1J1-05-03-034

Displays the control signals of MC (sub) and the

input signals from each switch and sensor. Password
Return to Controller
Change
• Special Function Selection Screen.
Makes Special Function disable/enable.
• Setup Op. Manual Disp. Record
Adjusts step light turning-off time and fan pump
regulator maximum current.
Main Menu Screen

T1V7-05-03-012

Monitor Display

Special Function

Setup

T5-3-39
 TROUBLESHOOTING / Dr. ZX
MONITOR DISPLAY OF MC (Sub)
Dr. ZX displays the input signals from switches and
sensors and the control signals from MC(sub).

List of Monitor Item

Item
Unit Data
Selecting Monitoring
Wiper VR Signal Wiper VR Signal V Input signal from wiper switch
Drain Pressure Drain Pressure MPa Input signal from pump 1 drain pressure sensor
Auxiliary Input 1 AUX Input 1 V Input signal from auxiliary pressure sensor
Auxiliary Input 2 AUX Input 2 V Input signal from auxiliary pressure sensor
Auxiliary Input 3 AUX Input 3 V Input signal from auxiliary pressure sensor
Oil Cooler Inlet Temperature Oil Cooler In T °C Input signal from hydraulic oil temperature sensor
Oil Cooler Outlet Temperature Oil Cooler Out T °C Input signal from hydraulic oil temperature sensor
Hydraulic Oil Temperature 2 Hyd Oil Temp. 2 °C Input signal from hydraulic oil temperature sensor
Auxiliary Pressure (Hight) AUX Pres (Hight) MPa Input signal from AUX. high-pressure sensor
Radiator Outlet Temperature Radiator Out T °C Input signal from coolant temperature sensor
Inter Coolor Outlet Temperature Inter Coolor O T °C Input signal from temperature sensor
Go Up and Down
Go Up and Down Light SW OFF, ON Step light switch ON/OFF status
Light SW
Buzzer Cancel SW Buzzer Cancel SW OFF, ON Buzzer deactivation switch ON/OFF status
Wash SW Wash SW OFF, ON Washer switch ON/OFF status
ON/OFF status of engine maintenance light signal
ECM Mainte. Lamp Monitor Sig O/P Mainte. Lamp OFF, ON
from ECM
ECM Warning Lamp Monitor Sig ON/OFF status of engine warning light signal from
Warning Lamp OFF, ON
O/P ECM
ON/OFF status of engine stop light signal from
ECM Stop Lamp Monitor Sig O/P Stop Lamp OFF, ON
ECM
Swing Reduce HP ON/OFF status of swing/boom priority switch signal
Swing Reduce Horsep. Signal 1 OFF, ON
Signal 1 1
Swing Reduce HP ON/OFF status of swing/boom priority switch signal
Swing Reduce Horsep. Signal 2 OFF, ON
Signal 2 2
Blower Motor Relay Signal Blower MOT Sig. OFF, ON Blower motor relay ON/OFF status
OFF(main),
Unit Select SW Unit Select SW Unit selection switch ON/OFF status
ON(sub)
Key SW Key SW OFF, ON Key switch ON/OFF status
Go U and D Light
Go Up and Down Light Relay OFF, ON Step light relay signal ON/OFF command status
Relay
Wiper Relay Lo Wiper Relay Lo OFF, ON Wiper relay (low) signal ON/OFF command status
Wiper Relay Hi Wiper Relay Hi OFF, ON Wiper relay (high) signal ON/OFF command status
Wash Relay Wash Relay OFF, ON Washer relay signal ON/OFF command status
Buzzer OutPut Sig-
Buzzer OutPut Signal OFF, ON Buzzer ON/OFF command status
nal
Engine Warning Engine warning alarm signal ON/OFF command
Engine Warning Alarm OFF, ON
Alarm status
Eng Oil Pressure Engine oil pressure alarm signal ON/OFF com-
Engine Oil Pressure Alarm OFF, ON
Alarm mand status
Engine Overheat Engine overheat alarm signal ON/OFF command
Engine Overheat Alarm OFF, ON
Alarm status
Fan Pump Valve Current Fan Pump CUR mA Control signal to fan pump control valve
Swing Reduce HP Swing output power decrease level status to MC
Swing Reduce Horsepower Level Level 1, 2, 3
Level (main)
STOP, SLOW,
Wiper Control Status Wiper Control Status STD, Wiper control status
FAST,CONT
Fan Target Flow Rate F Tar Flow Rate L Cooling fan flow rate control target value
Fuel Temperature Fuel Temp. °C Input signal from ECM
Intake Air Temperature Intake Air Temp. °C Input signal from ECM

T5-3-40
 TROUBLESHOOTING / Dr. ZX
(Blank)

T5-3-41
 TROUBLESHOOTING / Dr. ZX
Monitor Display

After starting Dr. ZX, push Select

Controller. Push MCF Sub. Push OK.

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T1V7-05-03-001 T18J-05-04-004 T1J1-05-03-010

Function Selection Screen Controller Selection Screen Main Controller Screen

Push Start. Push Monitor Display.

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T1J1-05-03-034 T1V7-05-03-012 T1J1-05-03-011

Title Screen Main Menu Screen Enter Model and Serial No.
Screen
Push HOLD and the monitor is
Push the item for Monitor Display stopped temporarily. When the monitor
and push OK. Refer to T5-3-40 as is started again, push HOLD again.
Input the model code and serial for the monitor item. Push ESC
No. and push OK. Push ESC and Push ESC and return to Display Item
and return to Main Menu Screen. Selection Screen.
return to Main Menu Screen.

T18J-05-04-018 T18J-05-04-019
T1J1-05-03-012
Enter Model and Serial No. Screen Display Item Selection Screen Monitor Screen

To the next page

T5-3-42
 TROUBLESHOOTING / Dr. ZX

Push Rec. No. and the recording

Push Record. screen for Rec. No. is made.

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T18J-05-04-019 T1V7-05-03-096 T1V7-05-03-097

Monitor Screen Select Write Data-Bank Screen

If Rec. No. has already been re- If Rec. No. has not been recorded
corded and push Over Write, data yet and push Write, data is written Push Comment .
is overwritten. Push ESC and re- to Recording Screen. Push ESC Push ESC and return to Main
turn to Main Menu Screen. and return to Main Menu Screen. Menu Screen.

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T18J-05-04-020 T18J-05-04-021 T18J-05-04-022

Recording Screen Recording Screen

Push Re-Input and return to Re-

cording Screen (Comment Input).
Input Weather and Person’s name Push OK and the recording screen Push ESC and return to Main
in change and push OK. (making) is finished. Menu Screen.

T18J-05-04-023 T18J-05-04-024 T18J-05-04-025

Recording Screen (Comment In-

put)

T5-3-43
 TROUBLESHOOTING / Dr. ZX
SPECIAL FUNCTIONS OF MCF (Sub)
This makes special functions disable/enable.

Special Function Item Table

Item Content
Fan Deactivation Cooling fan control becomes disabled.
Fan Activation Cooling fan control becomes enabled.

NOTE: Fan Deactivation is shown here as an example.

T5-3-44
 TROUBLESHOOTING / Dr. ZX
Example: Fan Deactivation

After starting Dr. ZX, push Select

Controller. Push MCF Sub. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T1J1-05-03-010

Function Selection Screen Controller Selection Screen Main Controller Screen

Push Start. Push Special Function.

To the
lower

T1J1-05-03-034 T1V7-05-03-012 T1V7-05-03-016

Title Screen Main Menu Screen

Push Fan Deactivation. Push Execute.

Push ESC and return to Main Push ESC and return to Control Push ESC and return to Function
Menu Screen. Selection Screen. Selection Screen.

T18J-05-04-026 T18J-05-04-027 T18J-05-04-028

Control Selection Screen

NOTE: If starting again with the key switch OFF,

Fan control becomes enabled.
Even if Fan Activation is selected, cooling
fan control becomes enabled.

T5-3-45
 TROUBLESHOOTING / Dr. ZX
SETUP OF MCF (Sub)
Step light turning-off time, and fan pump minimum flow
can be adjusted.

Parameter Change
Item Unit Data
Delay Tim to Cut of U/D Lgt Adj. sec Adjustment of step light turning-off time
Fan Pump Max. Current Adj. mA Adjustment of fan pump minimum flow rate

Adjustment Data List

Min. Adjustment Standard
Adjustment Data Adjustable Range
Value Adjustment
Delay Tim to Cut of U/D Lgt Adj. 5 sec 15 to 635 sec 60 sec
Fan Pump Max. Current Adj. 5 mA 0 to 650 mA 650 mA

T5-3-46
 TROUBLESHOOTING / Dr. ZX
Parameter Change of MCF (Sub)

After starting Dr. ZX, push Select

Controller. Push MCF Sub. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T1J1-05-03-010

Function Selection Screen Controller Selection Screen Main Controller Screen

Push Start. Push Setup.

To the
lower

T1J1-05-03-034 T1V7-05-03-012 T1V7-05-03-016

Title Screen Main Menu Screen

Input the password and push OK. Push Parameter Change.

Push Cancel and return to Main Push ESC and return to Main Refer to T5-3-46 as for the item of
Menu Screen. Menu Screen. Parameter Change.

T1V7-05-03-022 T18J-05-04-029 T18J-05-04-030

Setup Password Input Screen Setup Item Selection Screen Parameter Change Selection
Screen

T5-3-47
 TROUBLESHOOTING / Dr. ZX
Parameter Input
Example: Delay Tim to Cut of U/D Lgt Adj.
Input Value = Normal Value

Input the value and push Execution. Check Adjustment and push Exe-
Push Delay Tim to Cut of U/D Lgt Push ESC and return to Parameter cute. Push ESC and return to Pa-
Adj. Change Selection Screen. rameter Change Selection Screen.

To the
lower

T18J-05-04-030 T18J-05-04-031 T18J-05-04-032

Parameter Change Selection Parameter Input Screen Change Data Check Screen
Screen

Push ESC and return to Parameter

Change Selection Screen.

T1V7-05-03-107

T5-3-48
 TROUBLESHOOTING / Dr. ZX
Input Value = Current Value

Input the value and push Execution. Push Execute. Push ESC and
Push Delay Tim to Cut of U/D Lgt Push ESC and return to Parameter return to Parameter Change
Adj. Change Selection Screen. Selection Screen.

To the
lower

T18J-05-04-030 T18J-05-04-031 T18J-05-04-033

Parameter Change Selection Parameter Input Screen

Screen

Push ESC and return to Parameter

Change Selection Screen.

T1V7-05-03-107

T5-3-49
 TROUBLESHOOTING / Dr. ZX
Input Value > Maximum Value
(Input Value < Minimum Value)
Push Re-Input and return to
Parameter Input Screen. Push Max
Input the value and push Execution. and the maximum value is input.
Push Delay Tim to Cut of U/D Lgt Push ESC and return to Parameter Push ESC and return to Parameter
Adj. Change Selection Screen. Change Selection Screen.

To the
lower

T18J-05-04-030 T18J-05-04-031 T18J-05-04-034

Parameter Change Selection Parameter Input Screen
Screen

Push ESC and return to Parameter

Change Selection Screen.

T1V7-05-03-107

T5-3-50
 TROUBLESHOOTING / Dr. ZX
When the input value cannot be divided

Push Re-Input and return to

Parameter Input Screen. Push A or
Input the value and push Execution. B and the value of A or B is input.
Push Delay Tim to Cut of U/D Lgt Push ESC and return to Parameter Push ESC and return to Parameter
Adj. Change Selection Screen. Change Selection Screen.

To the
lower

T18J-05-04-030 T18J-05-04-031 T18J-05-04-035

Parameter Change Selection Parameter Input Screen
Screen

Push ESC and return to Parameter

Change Selection Screen.

T1V7-05-03-107

T5-3-51
 TROUBLESHOOTING / Dr. ZX
All Parameter Initialize
• If All Parameter Initialize is executed, the setting of
Parameter Change is initialized so that MC (Sub) is
returned as the factory setting.

IMPORTANT: Turn the key switch ON with the en-

gine stopped, execute All Parameter
Initialize.

IMPORTANT: Each setting of Parameter Change

and Attachment Parameter Change
may be set for each machine.
Before All Parameter Initialize is
executed, record the current set-
tings. Set the setting again after All
Parameter Initialize is executed if
necessary.

Turn the key switch ON.

After starting Dr. ZX, push Select
Controller. Push MCF Sub. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T1J1-05-03-010

Function Selection Screen Controller Selection Screen Main Controller Screen

Push Start. Push Setup.

To the
next page

T1J1-05-03-034 T1V7-05-03-012 T1V7-05-03-016

Title Screen Main Menu Screen

T5-3-52
 TROUBLESHOOTING / Dr. ZX

Input the password and push OK. Push All Parameter initialize. Push OK.
Push Cancel and return to Main Push ESC and return to Main Push ESC and return to Main
Menu Screen. Menu Screen. Menu Screen.

To the
lower

T1V7-05-03-022 T18J-05-04-029 T1J1-05-03-005

Setup Password Input Screen All Parameter Initialize Selection Explanation Screen
Screen

Push OK and execute All Pa-

rameter initialize. Push Abort and Push ESC and return to Main Push ESC and return to Main
stop All Parameter initialize. Menu Screen. Menu Screen.

OK

abort

T1J1-05-03-006 T1J1-05-03-007 T1J1-05-03-008

Execution Screen

IMPORTANT: After all parameter initialize opera-

tion is completed, turn the key
switch OFF over 3 seconds.

T5-3-53
 TROUBLESHOOTING / Dr. ZX
Recorded Data Display

After starting Dr. ZX, push Select

Controller. Push MCF Sub. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T1J1-05-03-010

Function Selection Screen Controller Selection Screen Main Controller Screen

Push HOLD and the monitor is

Push and select No. Push Execute stopped temporarily. Push HOLD
and the recorded data is regener- again and restart regeneration.
ated.Push DEL and data of Push ESC and Main Menu Screen
Push Disp. Record. selected No. is deleted. is displayed.

To the
lower

T1J1-05-03-034 T1V7-05-03-124
T18J-05-04-019
Title Screen Recorded Data Regeneration
Screen

T1V7-05-03-012
Main Menu Screen

T5-3-54
 TROUBLESHOOTING / Dr. ZX
Password Change

After starting Dr. ZX, push Select

Controller. Push MCF Sub. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T1J1-05-03-010

Function Selection Screen Controller Selection Screen Main Controller Screen

Input the registered password and Input the new password and push
Push Password. push OK. OK.

To the
lower

T1J1-05-03-034 T1V7-05-03-126 T18J-05-04-064

Title Screen

Input the new password again and Push OK and return to Title
push OK. Screen.

T1V7-05-03-169 T1V7-05-03-128

T5-3-55
 TROUBLESHOOTING / Dr. ZX
(Blank)

T5-3-56
 TROUBLESHOOTING / Dr. ZX
ICF CONTROLLER

• Password Change
Changes the password.

• Start→Main Menu
• Information C/U Various Setup
Can do initialization of information C/U, setting of
model, serial No. and time, and initialization of
control data.

T18J-05-04-036

T5-3-57
 TROUBLESHOOTING / Dr. ZX
INFORMATION C/U VARIOUS SETUP
List of Controller Data Setting Item

Item Range of Data

Information C/U: Initialize Initialize/ESC
Enter Model and Serial No. Model ASCII (4 characters) 0 to 9, A to Z
Serial No. 000000 to 999999
Enter Date and Time YY 2000 to 2100
Date MM 1 to 12
DD 1 to 31
HH 0 to 23
Time
MM 0 to 59
Control Data: Initialize Initialize/ESC

T5-3-58
 TROUBLESHOOTING / Dr. ZX
Information C/U: Initialize

After starting Dr. ZX, push Select

Controller. Push Information C/U. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-037

Function Selection Screen Controller Selection Screen ICF Controller Screen

Push Information C/U: Various

Push Start. setup. Push Information C/U: Initialize.

To the
lower

T1V7-05-03-025 T18J-05-04-038 T1V7-05-03-027

Title Screen Main Menu Screen Information C/U: Various Setup
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

T5-3-59
 TROUBLESHOOTING / Dr. ZX
Enter Model and Serial No.

After starting Dr. ZX, push Select

Controller. Push Information C/U. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-037

Function Selection Screen Controller Selection Screen ICF Controller Screen

Push Information C/U: Various

Push Start. setup. Push Enter Model and Serial No.

To the
lower

T1V7-05-03-025 T18J-05-04-038 T1V7-05-03-027

Title Screen Main Menu Screen Information C/U: Various Setup
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.

Exec ESC

ESC

OK

T18J-05-04-039 T18J-05-04-040 T1V7-05-03-027

Enter Model and Serial No. Screen Information C/U: Various Setup
Screen

T5-3-60
 TROUBLESHOOTING / Dr. ZX
Enter Time

After starting Dr. ZX, push Select

Controller. Push Information C/U. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-037

Function Selection Screen Controller Selection Screen ICF Controller Screen

Push Information C/U: Various

Push Start. setup. Push Enter Time.

To the
lower

T1V7-05-03-025 T18J-05-04-038 T1V7-05-03-027

Title Screen Main Menu Screen Information C/U: Various Setup
Screen
Push Set and the focused item is
YY. Push ESC and return to
Information C/U: Various Setup
Screen.

YY, MM, DD, HH and MM

The focused item is displayed reversely.
At first, the focused item is YY.

－ ＋
YY, MM, DD, HH and MM YY, MM, DD, HH and MM
Move the focused item. Value of the focused item is increased or
No repeat input. decreased one by one.
In case value is beyond maximum one: Change
T1V7-05-03-032 value into the minimum one
Enter Date and Time Screen In case value is below minimum one: Change
value into the maximum one
No repeat input.

T5-3-61
 TROUBLESHOOTING / Dr. ZX
Control Data: Initialize

After starting Dr. ZX, push Select

Controller. Push Information C/U. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-037

Function Selection Screen Controller Selection Screen ICF Controller Screen

Push Information C/U: Various

Push Start. setup. Push Control Data: Initialize.

To the
lower

T1V7-05-03-025 T18J-05-04-038 T1V7-05-03-027

Title Screen Main Menu Screen Information C/U: Various Setup
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

T5-3-62
 TROUBLESHOOTING / Dr. ZX
Password Change

After starting Dr. ZX, push Select

Controller. Push Information C/U. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-037

Function Selection Screen Controller Selection Screen ICF Controller Screen

Input the registered password and Input the new password and push
Push Password. push OK. OK.

To the
lower

T1V7-05-03-025 T1V7-05-03-126 T18J-05-04-064

Title Screen

Input the new password again and Push OK and return to Title
push OK. Screen.

T1V7-05-03-169 T1V7-05-03-128

T5-3-63
 TROUBLESHOOTING / Dr. ZX
MONITOR CONTROLLER

• Password Change
Changes the password.

• Start→Main Menu
• Monitoring
Displays the control signals of each controller and
the input signals from each sensor on Dr. ZX.
• Various Settings
Can set optional function setting, back monitor
setting, time set function enable / disable, main-
tenance setting, inner hour meter synchronization,
and fuel consumption gauge display ON/OFF
selection.

T18J-05-04-041

T5-3-64
 TROUBLESHOOTING / Dr. ZX
MONITORING
List of Monitoring Item
Item
Unit Data
Selecting Monitoring
Monitor SW Status ∗ ∗∗ Switch status of monitor unit
Check
Coolant Temperature Coolant Temp. °C Input signal from coolant temperature sensor
Fuel Level Fuel Level % Input signal from fuel sensor
Security Signal Security Signal OFF, ON Communication from monitor unit
Mail SW Mail SW OFF, Operating status of mail
Fuel,
Forward,
Repair,
General

∗ Display when monitoring

T1V7-05-03-044

∗∗ Unit
Switch 1 Switch 7

Switch 8 Switch 14

T5-3-65
 TROUBLESHOOTING / Dr. ZX
Monitor Switch Status Check

IMPORTANT: When selecting Monitor SW Status

Check, other monitoring item cannot
be selected.

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push item for monitoring and push

Start.
Push ESC and return to Main
Push Start. Push Monitoring. Menu Screen.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T1V7-05-03-043

Title Screen Main Menu Screen Monitoring Item Selection Screen

Push ESC and return to Main

Menu Screen.

Switch 1 Switch 7

Switch 8 Switch 14

T1V7-05-03-044
Monitor Switch Condition Check
Screen

T5-3-66
 TROUBLESHOOTING / Dr. ZX
When the key on the monitor unit is pushed, the switch
on Monitor Switch Condition Check Screen related to
the key is turned into black. (Key 3 is pushed here.)
If the switch is not turned into black, check the monitor
unit and the CAN harness.

Monitor Unit Dr.ZX

T1V7-05-03-044
Monitor Switch Condition Check
Screen
M18J-01-004
Push key 3. Switch 3 is turned into black.

T5-3-67
 TROUBLESHOOTING / Dr. ZX
Other Monitoring

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push item for monitoring and push

Start. Refer to T5-3-65 as for the
monitoring item.
Push ESC and return to Main Menu
Push Start. Push Monitoring. Screen.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T1V7-05-03-043

Title Screen Main Menu Screen Monitoring Item Selection Screen

When pushing HOLD, the monitor

is stopped temporarily.
When the monitor is started again,
push HOLD again. Push ESC and
return to Monitoring Item Selection
Screen.

T1V7-05-03-045
Monitoring Screen

T5-3-68
 TROUBLESHOOTING / Dr. ZX
VARIOUS SETTINGS
List of Various Setup Item
Item Unit
Optional Function M1 (Optional Function 1 Allocate)
M2 (Optional Function 2 Allocate) Unset
M3 (Optional Function 3 Allocate) Work Mode Function
M4 (Optional Function 4 Allocate) Auto Lubrication Function
M5 (Optional Function 5 Allocate)
M6 (Optional Function 6 Allocate)
M7 (Optional Function 7 Allocate)
M8 (Optional Function 8 Allocate)
M9 (Optional Function 9 Allocate)
Back Monitor Setup Back Monitor Function Enable/Disable Disable/Enable
Back Monitor Function Image Display Normal/Mirror
Back Monitor Function Image Format PAL/NTSC
Back Monitor Display Normal/Flip Vertical Flip Vertical/Normal
Time Set Function Enable / Disable Disable/Enable
Maintenance Setup Maintenance Function Enable / Disable Disable/Enable
Notification Function Enable / Disable Disable/Enable
Maintenance Display Item ON/OFF
Engine Oil OFF/ON
Engine Oil Filter OFF/ON
Hydraulic Oil OFF/ON
Hydraulic Oil Pilot Filter OFF/ON
Hydraulic Oil Full-Flow Filter OFF/ON
Pump Transmission OFF/ON
Swing Bearing Grease OFF/ON
Travel Device Oil OFF/ON
Swing Device Oil OFF/ON
Air Cleaner Filter OFF/ON
Engine/Air Conditioner V-belt OFF/ON
Air Conditioner Filter OFF/ON
Fuel Filter OFF/ON
Inner Hour Meter Sync. −
Fuel Consumption Gauge Display ON/OFF Selection Disable/Enable

T5-3-69
 TROUBLESHOOTING / Dr. ZX
Option Function Allocate
Example: Allocate Work Mode for Menu 7

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various Setting. Push Option Function Allocate.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-043

Title Screen Main Menu Screen Various Setup Item Screen

Exec: Refer to the next page.

AllClr: Unset all settings of menu 1
Push Next. Push Next. to 9.
Push ESC and return to Main Push Back and return to the former ESC: Return to Various Setting
Menu Screen. screen. Screen.

T1V7-05-03-047 T1V7-05-03-048 T18J-05-04-045

Option Function Allocate Screen

T5-3-70
 TROUBLESHOOTING / Dr. ZX

Move the item by using T and

push Menu 7.

To the
lower

T18J-05-04-045 T1V7-05-03-050 T1V7-05-03-051

Option Function Allocate Execution

Screen is displayed. Push ESC
and return to Various Setup Item
Push Work Mode. Push Exec. Screen.

T18J-05-04-046 T18J-05-04-047 T18J-05-04-048

Option Function Allocate Screen Option Function Allocate Execution
Screen

Function that can be selected: Unset

Work Mode
Auto Lubricate
If the functions that can be selected are too much to be
settled in one page, the next page can be displayed by
using a page change button.

IMPORTANT: The function that has already been

allocated cannot be selected.

T5-3-71
 TROUBLESHOOTING / Dr. ZX
Example: Allocate Work Mode for Menu 3

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various Setting. Push Option Function Allocate.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-043

Title Screen Main Menu Screen Various Setup Item Screen

Push Next. Push Next.

Push ESC and return to Main Push Back and return to the former
Menu Screen. screen.

To the
next page

T1V7-05-03-047 T1V7-05-03-048 T18J-05-04-045

Option Function Allocate Screen

T5-3-72
 TROUBLESHOOTING / Dr. ZX

Push Menu 3. Push Work Mode. Push Exec.

To the
lower

T18J-05-04-045 T18J-05-04-044 T18J-05-04-049

Option Function Allocate Screen

Option Function Allocate Execution

Screen is displayed. Push ESC
and return to Various Setup Item
Screen.

T18J-05-04-050 T18J-05-04-043
Option Function Allocate Execution Various Setup Item Screen
Screen

Work Mode is displayed on the monitor unit screen.

When pushing key F3, Work Mode is displayed.

Work Mode

Work Mode Screen

Key F3 T18J-05-04-001

T1J7-02-01-005

T5-3-73
 TROUBLESHOOTING / Dr. ZX
Example: Make Work Mode for Menu 3 Disable

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various setting. Push Option Function Allocate.

To the
lower

Title Screen T1V7-05-03-025

Main Menu Screen T1V7-05-03-042 Various Setup Item Screen T18J-05-04-043

Push Next. Push Next.

Push ESC and return to Main Push Back and return to the former
Menu Screen. screen.

To the
next page

T1V7-05-03-047 T1V7-05-03-048 T18J-05-04-049

Option Function Allocate Screen

T5-3-74
 TROUBLESHOOTING / Dr. ZX

Push Menu 3. Push Unset. Push Exec.

To the
lower

T18J-05-04-049 T18J-05-04-051 T18J-05-04-045

Option Function Allocate Screen Option Function Allocate Screen

Option Function Allocate Execution

Screen is displayed. Push ESC
and return to Various Setup Item
Screen.

T18J-05-04-052 T18J-05-04-043
Various Setup Item Screen

Work Mode is disappeared on the monitor unit screen.

Work Mode

T18J-05-04-001
M18J-01-004

T5-3-75
 TROUBLESHOOTING / Dr. ZX
Back Monitor Setup
Back Monitor Function: Enable

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various setting. Push Back Monitor Setup.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-043

Title Screen Main Menu Screen Various Setup Item Screen

Push Back Monitor Function Push Enable and push Exec. Push
Enable / Disable. Push ESC and ESC and return to Various Setup Push ESC and return to Various
return to the former screen. Item Screen. Setup Item Screen.

T18J-05-04-053 T1V7-05-03-053 T1V7-05-03-054

NOTE: Push Enable, push ESC, and

return to Various Setup Item
Screen, so that Back Monitor
Function Enable is not set.

T5-3-76
 TROUBLESHOOTING / Dr. ZX
Back Monitor Function: Disable

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various setting. Push Back Monitor Setup.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-043

Title Screen Main Menu Screen Various Setup Item Screen

Push Back Monitor Function Push Disable and push Exec. Push
Enable / Disable. Push ESC and ESC and return to Various Setup Push ESC and return to Various
return to the former screen. Item Screen. Setup Item Screen.

T18J-05-04-053 T1J1-05-03-055 T18J-05-04-063

NOTE: Push Disable, push ESC,

and return to Various Setup
Item Screen, so that Back
Monitor Function Disable is
not set.

T5-3-77
 TROUBLESHOOTING / Dr. ZX
Back Monitor Function Image Display: Normal

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various setting. Push Back Monitor Setup.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-043

Title Screen Main Menu Screen Various Setup Item Screen

Push Back Monitor Function Image Push Normal and push Exec. Push
Display. Push ESC and return to ESC and return to Various Setup Push ESC and return to Various
the former screen. Item Screen. Setup Item Screen.

T18J-05-04-053 T18J-05-04-054 T18J-05-04-055

NOTE: Push Normal, push ESC,

and return to Various Setup
Item Screen, so that Back
Monitor Function Image Dis-
plsy Normal is not set.

T5-3-78
 TROUBLESHOOTING / Dr. ZX
Back Monitor Function Image Display: Mirror

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various setting. Push Back Monitor Setup.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-043

Title Screen Main Menu Screen Various Setup Item Screen

Push Back Monitor Function Image Push Mirror and push Exec. Push
Display. Push ESC and return to ESC and return to Various Setup Push ESC and return to Various
the former screen. Item Screen. Setup Item Screen.

T18J-05-04-053 T18J-05-04-056 T18J-05-04-057

NOTE: Push Mirror, push ESC, and

return to Various Setup Item
Screen, so that Back Monitor
Function Image Display Mir-
ror is not set.

T5-3-79
 TROUBLESHOOTING / Dr. ZX
Back Monitor Function Image Format: PAL

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various setting. Push Back Monitor Setup.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-043

Title Screen Main Menu Screen Various Setup Item Screen

Push Back Monitor Function Image Push PAL and push Exec. Push
Format. Push ESC and return to ESC and return to Various Setup Push ESC and return to Various
the former screen. Item Screen. Setup Item Screen.

T18J-05-04-053 T18J-05-04-058 T18J-05-04-059

NOTE: Push PAL, push ESC, and

return to Various Setup Item
Screen, so that Back Monitor
Function Image Format PAL
is not set.

T5-3-80
 TROUBLESHOOTING / Dr. ZX
Back Monitor Function Image Format: NTSC

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various setting. Push Back Monitor Setup.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-043

Title Screen Main Menu Screen Various Setup Item Screen

Push Back Monitor Function Image Push NTSC and push Exec. Push
Format. Push ESC and return to ESC and return to Various Setup Push ESC and return to Various
the former screen. Item Screen. Setup Item Screen.

T18J-05-04-053 T18J-05-04-060 T18J-05-04-061

NOTE: Push NTSC, push ESC, and

return to Various Setup Item
Screen, so that Back Monitor
Function Image Format
NTSC is not set.

T5-3-81
 TROUBLESHOOTING / Dr. ZX
Back Monitor Display: Normal

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various setting. Push Back Monitor Setup.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-043

Title Screen Main Menu Screen Various Setup Item Screen

Push Back Monitor Display Normal Push Normal and push Exec. Push
/ Filip Vartical. Push ESC and ESC and return to Various Setup Push ESC and return to Various
return to the former screen. Item Screen. Setup Item Screen.

T18J-05-04-053 T1J1-05-03-056 T1V7-05-03-058

NOTE: Push Normal, push ESC,

and return to Various Setup
Item Screen, so that Back
Monitor Display Normal is
not set.

T5-3-82
 TROUBLESHOOTING / Dr. ZX
Back Monitor Display: Flip Vertical

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various setting. Push Back Monitor Setup.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-043

Title Screen Main Menu Screen Various Setup Item Screen

Push Back Monitor Display Push FV and push Exec. Push

Normal/Filip Vartical. Push ESC ESC and return to Various Setup Push ESC and return to Various
and return to the former screen. Item Screen. Setup Item Screen.

T18J-05-04-053 T1V7-05-03-055 T1V7-05-03-056

NOTE: Push FV, push ESC, and

return to Various Setup Item
Screen, so that Back Monitor
Display Flip Vertical is not
set.

T5-3-83
 TROUBLESHOOTING / Dr. ZX
Time Set Function Enable / Disable Selection
Time Set Function: Enable

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various setting. Push Time Set Func Enable/Disable.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-043

Title Screen Main Menu Screen Various Setup Item Screen

Push Enable and push Exec. Push

ESC and return to the former Push ESC and return to Various
screen. Setup Item Screen.

T1V7-05-03-064 T1V7-05-03-066

NOTE: Push Enable, push ESC, and

return to Various Setup Item
Screen, so that Time Set
Function Enable is not set.

T5-3-84
 TROUBLESHOOTING / Dr. ZX
Time Set Function: Disable

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various setting. Push Time Set Func Enable/Disable.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-043

Title Screen Main Menu Screen Various Setup Item Screen

Push Disable and push Exec. Push

ESC and return to the former Push ESC and return to Various
screen. Setup Item Screen.

T1V7-05-03-067 T1V7-05-03-068

NOTE: Push Disable, push ESC,

and return to Various Setup
Item Screen, so that Time
Set Function Disable is not
set

T5-3-85
 TROUBLESHOOTING / Dr. ZX
Maintenance Setup Maintenance Operation Allow
/ Not Allow Selection
Maintenance Operation: Allow
After starting Dr. ZX, push Select
Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various setting. Push Maintenance Setup.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-043

Title Screen Main Menu Screen Various Setup Item Screen

Push Allow and push Exec. Push

Push Maintenance operation ESC and return to the former Push ESC and return to Various
Allow/Not Allow. screen. Maintenance Set Item Screen.

T1V7-05-03-069 T1V7-05-03-070 T1V7-05-03-071

Maintenance Set Item Screen NOTE: Push Allow, push ESC, and
return to Maintenance Set
Item Screen, so that Main-
tenance Operation Allow is
not set.

T5-3-86
 TROUBLESHOOTING / Dr. ZX
Maintenance Operation: Not Allow

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various setting. Push Maintenance Setup.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-043

Title Screen Main Menu Screen Various Setup Item Screen

Push Not Allow and push Exec.

Push Maintenance operation Push ESC and return to the former Push ESC and return to Various
Allow/Not Allow. screen. Maintenance Set Item Screen.

T1V7-05-03-069 T1V7-05-03-072 T1V7-05-03-073

Maintenance Set Item Screen NOTE: Push Not Allow, push ESC,
and return to Maintenance
Set Item Screen, so that
Maintenance Operation Not
Allow is not set.

T5-3-87
 TROUBLESHOOTING / Dr. ZX
Notification Function Enable / Disable Selection
Notification Function: Enable
After starting Dr. ZX, push Select
Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various setting. Push Maintenance Setup.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-043

Title Screen Main Menu Screen Various Setup Item Screen

Push Enable and push Exec. Push

Push Notification function Enable/ ESC and return to the former Push ESC and return to Various
Disable. screen Maintenance Set Item Screen.

T1V7-05-03-069 T1V7-05-03-074 T1V7-05-03-075

Maintenance Set Item Screen NOTE: Push Enable, push ESC, and
return to Maintenance Set
Item Screen, so that Notifica-
tion Function Enable is not
set.

T5-3-88
 TROUBLESHOOTING / Dr. ZX
Notification Function: Disable

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various setting. Push Maintenance Setup.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-043

Title Screen Main Menu Screen Various Setup Item Screen

Push Disable and push Exec. Push

Push Notification function ESC and return to the former Push ESC and return to Various
Enable/Disable. screen. Maintenance Set Item Screen.

T1V7-05-03-069 T1V7-05-03-076 T1V7-05-03-077

Maintenance Set Item Screen NOTE: Push Disable, push ESC,
and return to Maintenance
Set Item Screen, so that No-
tification Function Disable is
not set.

T5-3-89
 TROUBLESHOOTING / Dr. ZX
Maintenance Display Items On/Off Selection
Maintenance Display Items: ON
After starting Dr. ZX, push Select
Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various setting. Push Maintenance Setup.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-043

Title Screen Main Menu Screen Various Setup Item Screen

Push Maintenance Display Items Push ESC and return to the former
On/Off. screen.

To the
next page

By changing the page,

the forward and
T1V7-05-03-069 T1V7-05-03-174 backward items are
Maintenance Set Item Screen displayed.

T5-3-90
 TROUBLESHOOTING / Dr. ZX

Push the displayed item and finally

push OK. Push All Sel and select
all the items.

To the
lower

T1V7-05-03-078 T1J1-05-03-009 T1V7-05-03-081

Display Item Selection Screen

Push ESC and return to

Maintenance Set Item Screen.

T1V7-05-03-082 T1V7-05-03-083 T1V7-05-03-084

T5-3-91
 TROUBLESHOOTING / Dr. ZX
Maintenance Display Items: OFF
After starting Dr. ZX, push Select
Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Push Start. Push Various setting. Push Maintenance Setup.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-043

Title Screen Main Menu Screen Various Setup Item Screen

Push All Clr and all the selected

Push Maintenance Display Items maintenance display items are
On/Off. turned into OFF.

To the
next page

By changing the page,

the forward and
T1V7-05-03-069 T1V7-05-03-174 backward items are
Maintenance Set Item Screen Display Item Selection Screen displayed.

T5-3-92
 TROUBLESHOOTING / Dr. ZX

Push the item which is turned into Push ESC and return to
OFF and finally push OK. Maintenance Set Item Screen.

T1V7-05-03-173 T1V7-05-03-175 T1V7-05-03-172

Display Item Selection Screen

T5-3-93
 TROUBLESHOOTING / Dr. ZX
Internal Hour Meter Synchronization

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Move the item by using T and

Push Start. Push Various setting. push Internal Hour Meter Sync.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-062

Title Screen Main Menu Screen Various Setup Item Screen

Push Sync. Push ESC and return Push ESC and return to Various
to the former screen. Setup Item Screen.

T1V7-05-03-085 T1V7-05-03-086
Maintenance Set Item Screen

T5-3-94
 TROUBLESHOOTING / Dr. ZX
Fuel Cost Meter Display Enable / Disable Selec-
tion
• Fuel Cost Meter Display: Enable
After starting Dr. ZX, push Select
Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Move the item by using T and

push Fuel cost meter display
Push Start. Push Various setting. Enable/Disable.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-062

Various Setup Item Screen
Title Screen Main Menu Screen

Push Enable and push Exec. Push

ESC and return to the former Push ESC and return to Various
screen. Setup Item Screen.

T1V7-05-03-088 T1V7-05-03-089

NOTE: Push Enable, push ESC, and

return to Various Setup Item
Screen, so that Fuel Con-
sumption Gauge Display
Enable is not set.

T5-3-95
 TROUBLESHOOTING / Dr. ZX

• Fuel Cost Meter Display: Disable

After starting Dr. ZX, push Select
Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Move the item by using T and

push Fuel cost meter display
Push Start. Push Various setting. Enable/Disable.

To the
lower

T1V7-05-03-025 T1V7-05-03-042 T18J-05-04-062

Title Screen Main Menu Screen Various Setup Item Screen

Push Disable and push Exec. Push

ESC and return to the former Push ESC and return to Various
screen. Setup Item Screen.

T1V7-05-03-090 T1V7-05-03-091

NOTE: Push Disable, push ESC,

and return to Various Setup
Item Screen, so that Fuel
Consumption Gauge Display
Disable is not set.

T5-3-96
 TROUBLESHOOTING / Dr. ZX
Password Change

After starting Dr. ZX, push Select

Controller. Push Monitor Unit. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-042

Function Selection Screen Controller Selection Screen Monitor Controller Screen

Input the registered password and Input the new password and push
Push Password. push OK. OK.

To the
lower

T1V7-05-03-025 T1V7-05-03-126 T18J-05-04-064

Title Screen

Input the new password again and Push OK and return to Title
push OK. Screen.

T1V7-05-03-169 T1V7-05-03-128

T5-3-97
 TROUBLESHOOTING / Dr. ZX
(Blank)

T5-3-98
 TROUBLESHOOTING / Component Layout
MAIN COMPONENT LAYOUT
Backhoe 2
3

1 4
5

6
7
8 9
10
11
12
13
14
15
16
17
37 18
36

35

34

Loading Shovel
33

4 32
31 19
5 30
39 29 20
3 28
21
2 6 22
23
1 27
26 24
37 25

36
38

41 40
T18J-01-03-010

1 - Bucket Cylinder 12 - Condenser 24 - Swing Control Valve 36 - Travel Pilot Valve

(Air Conditioner)
2- Arm 13 - Fuel Cooler 25 - Travel Device 37 - Bucket
3- Arm Cylinder 14 - Signal Control Valve 26 - Upper Roller 38 - Bucket Open/Close Cylinder
4- Boom 15 - Oil Cooler 27 - Lower Roller (Only Loading Shovel)
5- Boom Cylinder 16 - Oil Cooler Fan Motor 28 - Check Valve 39 - Level Cylinder
6- Front Attachment/Swing 17 - Intercooler 29 - Center Joint (Only Loading Shovel)
Pilot Valve 18 - Radiator 30 - Track Adjuster 40 - Bucket Open/Close Pilot Valve
7 - Hydraulic Oil Tank 19 - Engine 31 - Shuttle Valve (Only Loading Shovel)
8 - Battery 20 - Main Control Valve 32 - Flow Control Valve 41 - Bucket Open/Close Pilot Valve
9 - Fuel Tank 21 - 4-Spool Solenoid Valve 33 - Pilot Shut-Off Solenoid (Only Loading Shovel)
Valve
10 - Lubrication Device 22 - Pump Device 34 - Front Idler
11 - Swing Device 23 - Swing Bearing 35 - Accumulator

T5-4-1
 TROUBLESHOOTING / Component Layout
PUMP DEVICE

1 2 3 4 5

6
18

17

16

15

14 8

13

T18J-01-03-023

12 11 10

1 - Regulator 6 - Main Pump 1 11 - Pilot Pump 15 - Main Pump 2

(Main Pump 3)
2 - Pressure Sensor 7 - Pressure Sensor 12 - Transmission Oil 16 - Pressure Sensor
(Low Pressure) (Low Pressure) Circulation Pump (High Pressure)
3 - Main Pump 3 8 - Oil Cooler Fan Motor Drive 13 - Pressure Sensor 17 - Regulator
Pump (High Pressure) (Main Pump 2)
4 - Transmission Oil Level 9 - Regulator 14 - Pressure Sensor 18 - Pressure Sensor
Switch (Oil Cooler Fan Motor Drive (High Pressure) (Low Pressure)
Pump)
5 - Regulator 10 - Transmission Oil Filter
(Main Pump 1)

T5-4-2
 TROUBLESHOOTING / Component Layout
CONTROL VALVE
Main Control Valve

1
2
3
4
12 5

11

10

T18J-01-03-024

1 - High-Pressure Filter 4 - Bucket 1 7 - High-Pressure Filter 10 - Boom 2

2 - Main Relief Valve 5 - Boom 1 8 - Auxiliary (BH) 11 - Bucket 2
Bucket Open/Close (LD)
3 - Right Travel 6 - Arm 2 9 - Arm 1 12 - Left Travel
NOTE: BH: Backhoe
LD: Loading Shovel

T5-4-3
 TROUBLESHOOTING / Component Layout
Swing Control Valve

2
3
4
T18J-01-03-025
5
6

1 - High-Pressure Filter 3 - Boom 3 5 - Bucket 3 6 - Arm 3

2 - Main Relief Valve 4 - Swing

T5-4-4
 TROUBLESHOOTING / Component Layout
UTILITY BOX
Pilot Filter
Drain Filter

1
3

T18J-01-03-009
1 - Pilot Filter 2 - Utility Box 3 - Pump Drain Filter

Engine Stop Switch

T18J-01-03-020

M18J-03-005
1 - Engine Stop Switch

T5-4-5
 TROUBLESHOOTING / Component Layout
INSIDE OF CAB
Layout

1 2

9 4

5
7
6

M18J-01-002

1 - Horn Switch 4- Key Switch 7- Fuse Box

2 - Multifunction Monitor 5- Air Conditioner Switch 8- Cigarette Lighter
3 - Switch Panel 6- FM/AM Radio 9- Switch Panel (For Option)

T5-4-6
 TROUBLESHOOTING / Component Layout
Multifunction Monitor

2 3 4 5 6 7 8

10

11

T18J-01-03-007

18 17 16 15 14 13 12

1- Coolant Temperature Gauge 7- Preheat Display 13 - Menu

2- Work Mode Display 8- Hour Meter 14 - Auxiliary Selection
3- Auto-Idle Display 9- Auto-Lubrication Display 15 - Auxiliary Selection
4- Heavy Lift Display 10 - Fuel Gauge 16 - Auxiliary Selection
5- Lubrication Mode Display 11 - Clock 17 - Auto Lubrication Selection
6- Ladder Display 12 - Back Monitor Selection 18 - Return to Primary Screen Key

T5-4-7
 TROUBLESHOOTING / Component Layout
Switch Panel

1 2 3 4

M18J-01-019
1 - Heavy Lift Switch 4- Swing/Boom Priority Selection Switch 7- Power Mode Switch
2 - Wiper/Washer Switch 5- Engine Control Dial 8- Travel Mode Switch
3 - Work Light Switch 6- Auto-Idle Selection Switch 9- Key Switch

Switch Panel (For Option)

6
7

T18J-01-03-008
1 - Travel Alarm Deactivation Switch 4- Boom Mode Switch 7- Buzzer Deactivation Switch
(Optional)
2 - Seat Heater Switch (Optional) 5- Level Check Switch 8- Auxiliary
3 - Auxiliary 6- Lubrication Mode Selection Switch 9- Auxiliary

T5-4-8
 TROUBLESHOOTING / Component Layout
Fuse Box

2 3 4

T18J-01-03-011

1 - Pump Learning Switch 3- Fuse Box 2 5- Dr. ZX Connector

2 - Fuse Box 1 4- Power Source Terminal

T5-4-9
 TROUBLESHOOTING / Component Layout
Fuse Box 1

10 20
9 19
8 18
7 17
6 16
5 15
4 14
3 13
2 12
1 11

M1GR-01-003

1- BATT. RELAY (5 A) 6- 12 V UNIT (15 A) 11 - LIGHT 1 (20 A) 16 - PUMP. M. AR (5 A)

2- AIR CONDITIONER (5 A) 7- OPT. 5 (10 A) 12 - LIGHT 2 (20 A) 17 - RADIO (5 A)
3- STOP SOL. (5 A) 8- OPT. 6 (10 A) 13 - WIPER (20 A) 18 - HORN (10 A)
4- TRAVEL AR. (5 A) 9- SAFETY RELAY (5 A) 14 - HEATER (20 A) 19 - LIGHTER (10 A)
5- MCF PWM (20 A) 10 - BACK LIGHT (10 A) 15 - AUTO LUB. (15 A) 20 - ROOM LAMP (5 A)

Fuse Box 2

30 40
29 39
28 38
27 37
26 36
25 35
24 34
23 33
22 32
21 31

M1GR-01-003

21 - ECM MAIN (15 A) 26 - OPT. 4 (10 A) 31 - PREHEAT (5 A) 36 - MMS POW. ON (5 A)

22 - MMS MAIN (5 A) 27 - OPT. 3 (10 A) 32 - ECM POW. ON (5 A) 37 - SAT. POW. ON (5 A)
23 - MCF MAIN (5 A) 28 - OPT. 2 (20 A) 33 - MCF POW. ON (5 A) 38 - ENTRANCE (5 A)
24 - MON. ICF MAIN (5 A) 29 - OPT. 1 (20 A) 34 - MON. ICF POW. ON (5 A) 39 - RADIO BU (5 A)
25 - DLU MAIN (5 A) 30 - DLU/DL. (5 A) 35 - DLU POW. ON (5 A) 40 - SAT. MAIN (5 A)

T5-4-10
 TROUBLESHOOTING / Component Layout
Electrical Equipment Box (Top Rear of Cab)
1 2 3 4 5 6 7 8 9 10

11

12

13

14

15

16

17

29 18

19

20

28 27 26 25 24 23 22 21 T18J-01-03-004

1- MC (Sub) 11 - Fault Code Selection Switch 21 - Connector for DLU

2- ICF Controller 12 - Engine Troubleshooting Switch 22 - Security Relay
3- Starter Cut Relay 13 - Connector for PC (Cummins) 23 - Light Relay 2
4- Pilot Shut-Off Relay 14 - Engine Stop Indicator 24 - Washer Relay
5- Slide Ladder Relay 15 - Light Relay 1 25 - Wiper Relay (High 2)
6- Pump Transmission Oil Level Switch Relay 16 - Engine Warning Indicator 26 - Wiper Relay (High 1)
7- Back Light Relay 17 - Horn Relay 27 - Wiper Relay (Low)
8- Preheat Lamp Relay 18 - Engine Maintenance Indicator 28 - DLU2
9- Auto-Lubrication Relay 19 - Step Light Relay 29 - MC (Main)
10 - Horn Relay 20 - Load Damp Relay

Cab Top Switch Panel

1 - Step Light Switch 3 - Engine Stop Lamp

2 - Cab Light Switch
T18J-01-03-002
1 2 3

T5-4-11
 TROUBLESHOOTING / Component Layout
BATTERY BOX
6 7

4 9

10
3

T18J-01-03-003

1- Fusible Link 4 (45 A) 5- Preheat Signal Relay 8 - Fusible Link 5 (125 A)

2- Fusible Link 3 (75 A) 6- Battery Relay 1 9 - Fusible Link 7 (100 A)
3- Fusible Link 2 (75 A) 7- Battery Relay 2 10 - Fusible Link 8 (100 A)
4- Fusible Link 1 (45 A)

T5-4-12
 TROUBLESHOOTING / Component Layout
The fusible link is used in the circuits and connected to the followings

Item Circuit Connected to

Fusible link 1 ECM power circuit Key switch
MMS/DLU (optional) power circuit Load damp relay
Power circuits of MC (main), MC (sub) Fuse box 2 (#21 to #25)
Power circuits of monitor unit, ICF, and buzzer Fuse box 2 (#38 to #40)
DLU2 power circuit
Step light relay power circuit
Security horn power circuit
Radio backup
Satellite terminal power circuit
Fusible link 2 Back light power circuit Fuse box 1 (#10 to #16)
Power circuits of work light relays 1, 2
Power circuits of switches
Power circuits of washer relay, wiper relays (L,
H1, H2), and wiper motor
Air conditioner power circuit
Auto-lubrication power circuit
Pump transmission level switch power circuit
Fusible link 3 DC-DC converter power circuit Fuse box 1 (#2 to #8)
Power circuits of MC (main), MC (sub), and pilot Fuse box 2 (#26 to #30)
shut-off solenoid valve
Travel alarm power circuit
Air conditioner power circuit
Power circuits of various option
Power circuit of download PC
Fusible link 4 Preheat power circuit Preheat signal relay
Fusible link 5 Alternator Alternator
Fusible link 7 Preheat relay 1 power circuit Preheat relay 1
Fusible link 8 Preheat relay 2 power circuit Preheat relay 2

T5-4-13
 TROUBLESHOOTING / Component Layout
ENGINE
Engine

3
4

T18J-01-03-021

16

15

14

9
10
13 11 T18J-01-03-022

12

T5-4-14
 TROUBLESHOOTING / Component Layout

1 - Coolant Temperature 5 - Engine Speed Sensor 9 - Fuel Filter 13 - Alternator

Sensor (For ECM)
2 - Overheat Switch 6 - Preheat Relay 10 - Engine Oil Pressure Switch 14 - Intake-Air Temperature
Sensor
3 - Starter 7 - Engine Oil Filter 11 - Coolant Filter 15 - Boost Pressure Sensor
4 - Engine Speed Sensor 8 - ECM 12 - Engine Oil Level Switch 16 - Air Heater
(For MC)

Coolant Level Switch

Intercooler Outlet Temperature Sensor
3

T18J-01-03-012
2

1 - Coolant Level 2 - Intercooler Outlet 3 - Radiator

Switch Temperature Sensor

T5-4-15
 TROUBLESHOOTING / Component Layout
RADIATOR

Machine Right Side

T18J-01-03-026

1
10

7
T18J-01-03-027
T18J-01-03-028
8

1 - Intercooler 4 - Reserve Tank 7 - Liquid Tank 9 - Hydraulic Oil Temperature

Sensor
2 - Radiator (3 Lines) 5 - Oil Cooler 8 - Condenser 10 - Atmosphere Temperature
Sensor
3 - Transmission Cooler 6 - Fuel Cooler

T5-4-16
 TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE

Refer to troubleshooting A procedure in case any fault

codes are displayed after diagnosing by using Dr. ZX
or the service menu of the monitor unit.

• How to Read Troubleshooting Flow Charts

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

(3)
NO(NOT OK)

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

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

・ Refer to Electrical System Inspection (Group 8) for descriptions in the dotted-line box.

・ Use Dr. ZX for descriptions in the double-line box.

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

NOTE: Harness end connector viewed from the

open end side by the all connectors image
shown in this section.

Harness End
Connector Harness

Open T6L4-05-03-001
End Side

T5-5-1
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE LIST

Fault Trouble Cause Influenced Control

Code
11000-2 Abnormal EEPROM • Faulty MC (Main) -
11001-2 Abnormal RAM • Faulty MC (Main) -
11002-2 Abnormal A/D conversion • Faulty MC (Main) -
11003-3 Abnormal sensor voltage • Faulty MC (Main) -
• Faulty harness.

11004-2 Abnormal CAN communication • Faulty MC (Main). • Work mode control

• Shorted circuit in CAN • Attachment mode control
bus line. • Swing/boom priority selection
control
• Fan pump flow rate control
• CAN cycle data communication
• Overheat prevention control

11100-2 Abnormal engine speed Engine speed: 3000 min-1 • Speed sensing control
or more • Buzzer control
• Regulator learning control

11101-3 Abnormal engine control dial Voltage: more than 4.75 V • Engine control dial control
high voltage
11101-4 Abnormal engine control dial Voltage: less than 0.25 V • Engine control dial control
low voltage
11200-3 Abnormal pump 1 delivery Voltage: more than 4.75 V • Pump control
pressure sensor high voltage

11200-4 Abnormal pump 1 delivery Voltage: less than 0.25 V • Pump control
pressure sensor low voltage

11202-3 Abnormal pump 2 delivery Voltage: more than 4.75 V • Pump control
pressure sensor high voltage

11202-4 Abnormal pump 2 delivery Voltage: less than 0.25 V • Pump control
pressure sensor low voltage

11203-3 Abnormal pump 3 delivery Voltage: less than 4.75 V • Pump control
pressure sensor high voltage

11203-4 Abnormal pump 3 delivery Voltage: less than 0.25 V • Pump control
pressure sensor low voltage

T5-5-2
 TROUBLESHOOTING / Troubleshooting A

Symptoms in Machine Operation When Trouble Remedy Remedy Reference

Occurs by Dr. ZX Page
- Retrial B • Replace MC (Main). T5-5-25
- Retrial B • Replace MC (Main). T5-5-25
- Retrial B • Replace MC (Main). T5-5-25
- Retrial B • Replace MC (Main). T5-5-26
• Check the harness
(sensor power source).
• Check the connection sensor in MC
(Main).
• Proper pump delivery flow rate to the attachment Retrial B • Replace MC (Main). T5-5-27
cannot be obtained. • Check the CAN harness.
• Swing/boom priority selection cannot be
controlled.
• Cooling fan maximum speed
• All abnormal signals through CAN communication
• Overheat prevention cannot be controlled.

• No speed sensing Retrial B • Check the engine speed sensor. T5-5-50

• No ladder alarm and no pump transmission alarm
buzzer
• Regulator cannot be learned.
• Target engine speed is kept at 1000 min-1. Retrial B • Check the harness. T5-5-51
• Replace the engine control dial.
• Target engine speed is kept at 1000 min-1. Retrial B • Check the harness. T5-5-51
• Replace the engine control dial.
• Flow rate is kept at 19.6 MPa(200 kgf/cm2). Retrial B • Check the harness. T5-5-52
• Replace the pump 1 delivery
pressure sensor.

• Flow rate is kept at 19.6 MPa(200 kgf/cm2). Retrial B • Check the harness. T5-5-52
• Replace the pump 1 delivery
pressure sensor.

• Flow rate is kept at 19.6 MPa(200 kgf/cm2). Retrial B • Check the harness. T5-5-53
• Replace the pump 2 delivery
pressure sensor.

• Flow rate is kept at 19.6 MPa(200 kgf/cm2). Retrial B • Check the harness. T5-5-53
• Replace the pump 2 delivery
pressure sensor.

• Flow rate is kept at 19.6 MPa(200 kgf/cm2). Retrial B • Check the harness. T5-5-54
• Replace the pump 3 delivery
pressure sensor.

• Flow rate is kept at 19.6 MPa(200 kgf/cm2). Retrial B • Check the harness. T5-5-54
• Replace the pump 3 delivery
pressure sensor.

T5-5-3
 TROUBLESHOOTING / Troubleshooting A

Fault Trouble Cause Influenced Control

Code
11301-3 Abnormal swing pilot pressure Voltage: more than 4.75 V • Auto-idle control
sensor high voltage • Swing/Boom priority selection
control
• Boom mode control
• Swing alarm

11301-4 Abnormal swing pilot pressure Voltage: less than 0.25 V • Auto-idle control
sensor low voltage • Swing/Boom priority selection
control
• Boom mode control
• Swing alarm

11302-3 Abnormal boom raise pilot Voltage: more than 4.75 V • Auto-idle control
pressure sensor high voltage • Swing/Boom priority selection
control
• Boom mode control

11302-4 Abnormal boom raise pilot Voltage: less than 0.25 V • Auto-idle control
pressure sensor low voltage • Swing/Boom priority selection
control
• Boom mode control

11303-3 Abnormal arm roll-in pilot pressure Voltage: more than 4.75 V • Auto-idle control
sensor high voltage • Boom mode selector control
• Boom flow rate control valve
control

11303-4 Abnormal arm roll-in pilot pressure Voltage: less than 0.25 V • Auto-idle control
sensor low voltage • Boom mode control
• Boom flow rate control valve
control

11400-3 Abnormal feedback high current of Current: more than 920mA • All pump controls
pump 2 control solenoid valve • Swing cavitation prevention control

11400-4 Abnormal feedback low current of Current: less than 56mA • All pump controls
pump 2 control solenoid valve • Swing cavitation prevention control

T5-5-4
 TROUBLESHOOTING / Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs Remedy Remedy Reference

by Dr. ZX Page
• A/I cannot be released by swing operation. Retrial B • Check the harness. T5-5-55
• Positive control by swing operation is set to the • Replace the swing pilot
maximum flow rate. pressure sensor.
• Swing/boom priority selection cannot be controlled.
• Boom mode control by swing operation cannot be
controlled.
• Swing alarm is outputted.
• A/I cannot be released by swing operation. Retrial B • Check the harness. T5-5-55
• Positive control by swing operation is set to the • Replace the swing pilot
maximum flow rate. pressure sensor.
• Swing/boom priority selection cannot be controlled.
• Boom mode control by swing operation cannot be
controlled.
• Swing alarm is outputted.
• A/I cannot be released by boom raise operation. Retrial B • Check the harness. T5-5-56
• Positive control by boom raise operation is set to the • Replace the boom raise pilot
maximum flow rate. pressure sensor.
• Swing/boom priority selection cannot be controlled.
• Boom mode by boom raise operation cannot be
controlled.
• Boom flow rate control valve control is inoperable.
• A/I cannot be released by boom raise operation. Retrial B • Check the harness. T5-5-56
• Positive control by boom raise operation is set to the • Replace the boom raise pilot
maximum flow rate. pressure sensor.
• Swing/boom priority selection cannot be controlled.
• Boom mode by boom raise operation cannot be
controlled.
• Boom flow rate control valve control is inoperable.
• A/I cannot be released by arm roll-in operation. Retrial B • Check the harness. T5-5-57
• Positive control by arm roll-in operation is set to the • Replace arm roll-in pilot
maximum flow rate. pressure sensor.
• Boom mode by arm roll-in operation cannot be
controlled.
• Boom flow rate control valve control by arm roll-in
operation is inoperable.
• Machine speed of HP mode by arm roll-in operation Retrial B • Check the harness. T5-5-57
does not increase. • Replace arm roll-in pilot
• A/I cannot be released by arm roll-in operation. pressure sensor.
• Positive control by arm roll-in operation is set to the
maximum flow rate.
• Boom mode by arm roll-in operation cannot be
controlled.
• Boom flow rate control valve control by arm roll-in
operation is inoperable.
• Pump 2 cannot be controlled. Retrial B • Check the harness. T5-5-58
• Swing pump flow rate is minimized at swing operation.
• Swing cavitation prevention control is inoperable.
• Pump 2 cannot be controlled. Retrial B • Check the harness. T5-5-58
• Swing pump flow rate is minimized at swing operation.
• Swing cavitation prevention control is inoperable.

T5-5-5
 TROUBLESHOOTING / Troubleshooting A

Fault Trouble Cause Influenced Control

Code
11402-3 Abnormal feedback high current of Current: more than 920mA • Boom flow rate control valve
solenoid valve unit (SF) control
(boom flow rate control)
11402-4 Abnormal feedback low current of Current: less than 56mA • Boom flow rate control valve
solenoid valve unit (SF) control
(boom flow rate control)
11404-3 Abnormal feedback high current of Current: more than 920mA • Pressure rising selection control
solenoid valve unit (SG) when traveling
(main relief pressure selection) • Heavy lift control
11404-4 Abnormal feedback low current of Current: less than 56mA • Pressure rising selection control
solenoid valve unit (SG) when traveling
(main relief pressure selection) • Heavy lift control
11405-3 Abnormal feedback high current of Current: more than 920mA • Travel motor displacement angle
solenoid valve unit (SI) control
(travel mode selection)
11405-4 Abnormal feedback low current of Current: less than 56mA • Travel motor displacement angle
solenoid valve unit (SI) control
(travel mode selection)
11410-3 Abnormal feedback high current of Current: more than 920mA • All pump controls
pump 1 control solenoid valve
11410-4 Abnormal feedback low current of Current: less than 56mA • All pump controls
pump 1 control solenoid valve

T5-5-6
 TROUBLESHOOTING / Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs Remedy Remedy Reference

by Dr. ZX Page
• Boom flow rate control valve control is inoperable. Retrial B • Check the harness. T5-5-59

• Boom flow rate control valve control is inoperable. Retrial B • Check the harness. T5-5-59

• Pressure rising control is impossible. Retrial B • Check the harness. T5-5-60

• Pressure rising control is impossible. Retrial B • Check the harness. T5-5-60

• Travel mode selection is impossible. Retrial B • Check the harness. T5-5-61

• Travel mode selection is impossible. Retrial B • Check the harness. T5-5-61

• Pump 1 control is impossible. Retrial B • Check the harness. T5-5-62

• Pump 1 control is impossible. Retrial B • Check the harness. T5-5-62

T5-5-7
 TROUBLESHOOTING / Troubleshooting A

Fault Trouble Cause Influenced Control

Code
11802-3 Abnormal boom bottom pressure Voltage: more than 4.75 V -
sensor high voltage

11802-4 Abnormal boom bottom pressure Voltage: less than 0.25 V -

sensor low voltage

11901-3 Abnormal hydraulic oil temperature Intake-air temperature: 21 • Overheat prevention control
sensor 1 high voltage °C or more • Fan pump flow rate control
(more than 20°C)

Voltage: more than 4.10V

Continuously 30 seconds
or more
11901-4 Abnormal hydraulic oil temperature Voltage: less than 0.25V • Overheat prevention control
sensor 1 low voltage Continuously 30 seconds • Fan pump flow rate control
or more

11910-2 Actual engine speed reception Faulty harness -

failure
11911-2 Security signal reception failure Faulty harness -

11914-2 Radiator coolant temperature Faulty harness • Overheat prevention control

reception failure
11918-2 Work mode reception failure Faulty harness • Work mode control
• Attachment mode control

11920-2 Fuel flow rate reception failure Faulty harness -

11959-2 Engine ISC information CAN Faulty harness • All pump controls
reception failure
11960-2 Abnormal engine speed control Faulty harness • Power mode control
• All pump controls
11961-2 Cooling fan control status reception Faulty harness -
failure
11962-2 Engine load rate reception failure Faulty harness -

11963-2 Swing power decrease level Faulty harness • Swing/boom priority selection
reception failure control
11964-2 Accelerator pedal position reception Faulty harness -
failure

T5-5-8
 TROUBLESHOOTING / Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs Remedy Remedy Reference

by Dr. ZX Page
- Retrial B • Check the harness. T5-5-63
• Replace the boom bottom
pressure sensor.
- Retrial B • Check the harness. T5-5-63
• Replace the boom bottom
pressure sensor.
• Hydraulic oil overheat prevention cannot be Retrial B • Check the harness. T5-5-64
controlled. • Replace hydraulic oil
• Cooling fan maximum speed temperature sensor 1.
• Reduce pump driving torque.

• Hydraulic oil overheat prevention cannot be Retrial B • Check the harness. T5-5-64
controlled. • Replace hydraulic oil
• Cooling fan maximum speed temperature sensor 1.
• Reduce pump driving torque.
- Retrial B • Check the harness. T5-5-66

• Security is operated when engine control security Retrial B • Check the harness. T5-5-66
and pump control security are turned ON.
• Overheat prevention cannot be controlled. Retrial B • Check the harness. T5-5-66
• Reduce pump driving torque.
• Machine is operated according to the last received Retrial B • Check the harness. T5-5-66
value.

• Fuel flow rate becomes 0 L/min. Retrial B • Check the harness. T5-5-66

• Proper pump driving power cannot be obtained. Retrial B • Check the harness. T5-5-66

• Proper engine speed cannot be obtained. Retrial B • Check the harness. T5-5-68
• Proper pump driving power cannot be obtained.
- Retrial B • Check the harness. T5-5-66

- Retrial B • Check the harness. T5-5-66

Swing/boom priority selection cannot be controlled. Retrial B • Check the harness. T5-5-66

As the accelerator pedal position through CAN from Retrial B • Check the harness. T5-5-66
ECM is not certain, target engine speed is directly
obtained from engine control dial signal.

T5-5-9
 TROUBLESHOOTING / Troubleshooting A

Fault Trouble Cause Influenced Control

Code
11965-2 MCF-Sub unit connection error • MC (Sub) unit • Alarm icon control
connection signal is OFF. • Swing/boom priority selection
• Faulty MC (Sub) control
• Shorted circuit in CAN • Overheat prevention control
bus line • Fan pump flow rate control
11966-2 MCF-Main unit connection error • MC (Main) unit • Pressure rising selection control
connection signal is ON. when traveling
• Heavy lift control
• Travel mode control
• Travel alarm
• Swing alarm
• Boom mode control
• Boom flow rate control
• Engine speed control
(power mode, travel speed control)
• ATT operation hour meter drive
control
• Alarm icon control
• Auto-lubrication control
• All pump controls
• Swing cavitation prevention control
11967-2 Failure of learning pump 3 regulator
pressure
11968-2 Hydraulic oil temperature 2 Faulty harness • Fan pump flow rate control
reception failure
11969-3 Abnormal pump 3 regulator Voltage: more than 4.75 V • Pump 3 flow rate control
pressure sensor high voltage • Learning pump 3 regulator
pressure

11969-4 Abnormal pump 3 regulator Voltage: less than 0.25 V • Pump 3 flow rate control
pressure sensor low voltage • Learning pump 3 regulator
pressure

11970-3 Abnormal feedback high current of Current: more than 920mA • All pump controls
pump 3 control solenoid valve
11970-4 Abnormal feedback low current of Current: less than 56mA • All pump controls
pump 3 control solenoid valve

T5-5-10
 TROUBLESHOOTING / Troubleshooting A

Symptoms in Machine Operation When Trouble Occurs Remedy Remedy Reference

by Dr. ZX Page
• Hydraulic oil overheat alarm lights Retrial B • Check the connection to MC T5-5-70
• Hydraulic oil temperature is kept at 120°C. (Sub).
• Swing/boom priority selection cannot be controlled.
• Reduce pump driving torque.
• Cooling fan maximum speed
• Pressure rising control is impossible. Retrial B • Check the connection to MC T5-5-70
• Travel mode selection is impossible. (Main).
• Even if operating travel, alarm sound stays OFF.
• Even if operating swing, alarm sound stays OFF.
• Boom mode is impossible.
• Boom flow rate cannot be controlled.
• Engine speed does not change according to power
mode (HP/P/E) and A/I.
• Even if operating travel, engine speed does not
change according to travel operation.
• ATT hour meter stops.
• Auto-lubrication control is impossible.
• Pump control is impossible.

• Use characteristics before learning. Retrial B - -

• Cooling fan maximum speed Retrial B • Check the harness. T5-5-66

• No feedback of pump 3 proportional solenoid valve Retrial B • Check the harness. T5-5-71
secondary pilot pressure (slow response) • Pump 3 regulator pressure
• Pump learning is impossible. sensor

• No feedback of pump 3 proportional solenoid valve Retrial B • Check the harness. T5-5-71
secondary pilot pressure (slow response) • Pump 3 regulator pressure
• Pump learning is impossible. sensor

• Pump 3 control is impossible. Retrial B • Check the harness. T5-5-72

• Pump 3 control is impossible. Retrial B • Check the harness. T5-5-72

T5-5-11
 TROUBLESHOOTING / Troubleshooting A

Fault Trouble Cause Influenced Control

Code
11977-3 Abnormal feedback high current of Current: more than 920mA -
proportional valve auxiliary 1
11977-4 Abnormal feedback low current of Current: less than 56mA -
proportional valve auxiliary 1
11980-3 Abnormal feedback high current of Current: more than 920mA -
attachment secondary pilot relief
pressure control proportional
solenoid valve
11980-4 Abnormal feedback low current of Current: less than 56mA -
attachment secondary pilot relief
pressure control proportional
solenoid valve
11985-2 Failure of learning pump 2 - -
regulator pressure
11986-2 Failure of learning pump 1 - -
regulator pressure
11989-3 Abnormal feedback high current of Current: more than 920mA • Boom mode control
solenoid valve unit (SC)
(boom mode selection)
11989-4 Abnormal feedback low current of Current: less than 56mA • Boom mode control
solenoid valve unit (SC)
(boom mode selection)
11991-3 Abnormal travel (right) pilot pressure Voltage: more than 4.75 V • Auto-idle control
sensor high voltage • Travel speed limit control
• Boom mode control
• Pressure rising selection control
when traveling
• Rear monitoring display selection
control
• Travel alarm control

11991-4 Abnormal travel (right) pilot pressure Voltage: less than 0.25 V • Auto idle control
sensor low voltage • Travel speed limit control
• Boom mode control
• Pressure rising selection control
when traveling
• Rear monitoring display selection
control
• Travel alarm control

T5-5-12
 TROUBLESHOOTING / Troubleshooting A

Symptoms in Machine Operation When Trouble Remedy Remedy Reference

Occurs. by Dr. ZX Page
- Retrial B • Check the harness. -

- Retrial B • Check the harness. -

• Attachment relief pressure selection is impossible. Retrial B • Check the harness. -

• Attachment relief pressure selection is impossible. Retrial B • Check the harness. -

• Use characteristics before learning. Retrial B - -

• Use characteristics before learning. Retrial B - -

• Boom mode control is impossible. Retrial B • Check the harness. T5-5-73

• Boom mode control is impossible. Retrial B • Check the harness. T5-5-73

• A/I cannot be released by travel (right) operation. Retrial B • Check the harness T5-5-74
• Engine speed cannot be controlled according to • Replace the travel (right) pilot
travel. pressure sensor.
• Boom mode by travel (right) operation cannot be
controlled.
• Travel pressure rising by travel (right) operation is
impossible.
• Rear monitoring display selection by travel (right)
operation is impossible.
• Travel alarm is outputted.
• A/I cannot be released by travel (right) operation. Retrial B • Check the harness T5-5-74
• Engine speed cannot be controlled according to • Replace the travel (right) pilot
travel. pressure sensor.
• Boom mode by travel (right) operation cannot be
controlled.
• Travel pressure rising by travel (right) operation is
impossible.
• Rear monitoring display selection by travel (right)
operation is impossible.
• Travel alarm is outputted.

T5-5-13
 TROUBLESHOOTING / Troubleshooting A

Fault Trouble Cause Influenced Control

Code
11992-3 Abnormal pump 2 regulator Voltage: more than 4.75 V • Pump 2 flow rate control
pressure sensor high voltage • Learning pump 2 regulator
pressure
11992-4 Abnormal pump 2 regulator Voltage: less than 0.25 V • Pump 2 flow rate control
pressure sensor low voltage • Learning pump 2 regulator
pressure
11993-3 Abnormal travel (left) pilot pressure Voltage: more than 4.75 V • Auto-idle control
sensor high voltage • Travel speed limit control
• Boom mode control
• Pressure rising selection control
when traveling
• Rear monitoring display selection
control
• Travel alarm control

11993-4 Abnormal travel (left) pilot Voltage: less than 0.25 V • Auto-idle control
pressure sensor low voltage • Travel speed limit control
• Boom mode control
• Pressure rising selection control
when traveling
• Rear monitoring display selection
control
• Travel alarm control

11994-3 Abnormal pump 1 regulator Voltage: more than 4.75 V • Pump 1 flow rate control
pressure sensor high voltage • Learning pump 1 regulator
pressure
11994-4 Abnormal pump 1 regulator Voltage: less than 0.25 V • Pump 1 flow rate control
pressure sensor low voltage • Learning pump 1 regulator
pressure
11995-3 Abnormal arm roll-out pilot Voltage: more than 4.75 V • Auto-idle control
pressure sensor high voltage • Boom mode control
• Boom flow rate control valve
control
• Swing/boom priority selection
control

11995-4 Abnormal arm roll-out pilot Voltage: less than 0.25 V • Auto-idle control
pressure sensor low voltage • Boom mode control
• Boom flow rate control valve
control
• Swing/boom priority selection
control

T5-5-14
 TROUBLESHOOTING / Troubleshooting A

Symptoms in Machine Operation When Trouble Remedy Remedy Reference

Occurs. by Dr. ZX Page
• No feedback of pump 2 proportional solenoid valve Retrial B • Check the harness. T5-5-75
secondary pilot pressure (slow response) • Replace the pump 2 regulator
• Pump learning is impossible. pressure sensor.
• No feedback of pump 2 proportional solenoid valve Retrial B • Check the harness. T5-5-75
secondary pilot pressure (slow response) • Replace the pump 2 regulator
• Pump learning is impossible. pressure sensor.
• A/I cannot be released by travel (left) operation. Retrial B • Check the harness. T5-5-76
• Engine speed cannot be controlled according to • Replace the travel (left) pilot
travel. pressure sensor.
• Boom mode by travel (left) operation cannot be
controlled.
• Travel pressure rising by travel (left) operation is
impossible.
• Rear monitoring display selection by travel (left)
operation is impossible.
• Travel alarm is outputted.
• A/I cannot be released by travel (left) operation. Retrial B • Check the harness. T5-5-76
• Engine speed cannot be controlled according to • Replace the travel (left) pilot
travel. pressure sensor.
• Boom mode by travel (left) operation cannot be
controlled.
• Travel pressure rising by travel (left) operation is
impossible.
• Rear monitoring display selection by travel (left)
operation is impossible.
• Travel alarm is outputted.
• No feedback of pump 1 proportional solenoid valve Retrial B • Check the harness. T5-5-77
secondary pilot pressure (slow response) • Pump 1 regulator pressure
• Pump learning is impossible. sensor
• No feedback of pump 1 proportional solenoid valve Retrial B • Check the harness. T5-5-77
secondary pilot pressure (slow response) • Pump 1 regulator pressure
• Pump learning is impossible. sensor
• A/I cannot be released by arm roll-out operation. Retrial B • Check the harness. T5-5-78
• Positive control by arm roll-out operation is set to the • Replace the arm roll-out pilot
maximum flow rate. pressure sensor.
• Boom mode by arm roll-out operation cannot be
controlled.
• Boom flow rate control valve control is inoperable.
• Swing/boom priority selection cannot be controlled.
• A/I cannot be released by arm roll-out operation. Retrial B • Check the harness. T5-5-78
• Positive control by arm roll-out operation is set to the • Replace the arm roll-out pilot
maximum flow rate. pressure sensor.
• Boom mode by arm roll-out operation cannot be
controlled.
• Boom flow rate control valve control is inoperable.
• Swing/boom priority selection cannot be controlled.

T5-5-15
 TROUBLESHOOTING / Troubleshooting A

Fault Trouble Cause Influenced Control

Code
11997-3 Abnormal bucket roll-out pilot Voltage: more than 4.75 V • Auto-idle control
pressure sensor high voltage • Boom mode control
• Boom flow rate control valve
control

11997-4 Abnormal bucket roll-out pilot Voltage: less than 0.25 V • Auto-idle control
pressure sensor low voltage • Boom mode control
• Boom flow rate control valve
control

11998-3 Abnormal boom lower pilot Voltage: more than 4.75 V • Auto-idle control
pressure sensor high voltage • Boom mode control
• Boom flow rate control valve
control
11998-4 Abnormal boom lower pilot Voltage: less than 0.25 V • Auto-idle control
pressure sensor low voltage • Boom mode control
• Boom flow rate control valve
control
11999-3 Abnormal bucket roll-in pilot Voltage: more than 4.75 V • Auto-idle control
pressure sensor high voltage • Boom mode control
• Boom flow rate control valve
control

11999-4 Abnormal bucket roll-in pilot Voltage: less than 0.25 V • Auto-idle control
pressure sensor low voltage • Boom mode control
• Boom flow rate control valve
control

20001-2 Pump transmission alarm Pump transmission oil -

pressure level is low.
20004-2 Engine stop alarm CAN reception of engine -
stop alarm
20060-2 Pump 1 regulator pressure not learn - -
alarm
20061-2 Pump 2 regulator pressure not learn - -
alarm
20062-0 Hydraulic oil overheat alarm Hydraulic oil temperature: • Overheat prevention control
105°C or more

20070-2 Pump 3 regulator pressure not learn - -

alarm

T5-5-16
 TROUBLESHOOTING / Troubleshooting A

Symptoms in Machine Operation When Trouble Remedy Remedy Reference

Occurs. by Dr. ZX Page
• A/I cannot be released by bucket roll-out operation. Retrial B • Check the harness. T5-5-79
• Positive control by bucket roll-out operation is set to • Replace the bucket roll-out
the maximum flow rate. pilot pressure sensor.
• Boom mode control by bucket roll-out operation
cannot be controlled.
• Boom flow rate control valve control is inoperable.
• A/I cannot be released by bucket roll-out operation. Retrial B • Check the harness. T5-5-79
• Positive control by bucket roll-out operation is set to • Replace the bucket roll-out
the maximum flow rate. pilot pressure sensor.
• Boom mode control by bucket roll-out operation
cannot be controlled.
• Boom flow rate control valve control is inoperable.
• A/I cannot be released by boom lower operation. Retrial B • Check the harness. T5-5-80
• Boom mode by boom lower operation cannot be • Replace the boom lower pilot
controlled. pressure sensor.
• Boom flow rate control valve control is inoperable.
• A/I cannot be released by boom lower operation. Retrial B • Check the harness. T5-5-80
• Boom mode by boom lower operation cannot be • Replace the boom lower pilot
controlled. pressure sensor.
• Boom flow rate control valve control is inoperable.
• A/I cannot be released by bucket roll-in operation. Retrial B • Check the harness. T5-5-81
• Positive control by bucket roll-in operation is set to • Replace the bucket roll-in pilot
the maximum flow rate. pressure sensor.
• Boom mode control by bucket roll-in operation
cannot be controlled.
• Boom flow rate control valve control is inoperable.
• A/I cannot be released by bucket roll-in operation. Retrial B • Check the harness. T5-5-81
• Positive control by bucket roll-in operation is set to • Replace the bucket roll-in pilot
the maximum flow rate. pressure sensor.
• Boom mode control by bucket roll-in operation
cannot be controlled.
• Boom flow rate control valve control is inoperable.
- Retrial B • Check pump transmission oil -
level.
- Retrial B • Engine troubleshooting -

- - - -

- - - -

• Reduce maximum pump flow rate. Retrial B • Check the oil cooler T5-5-82
• Reduce pump driving torque.
• Indicate alarm on monitor unit.
- - - -

T5-5-17
 TROUBLESHOOTING / Troubleshooting A
MC (SUB) FAULT CODE LIST
Fault Trouble Cause Influenced Control
Code
15979-3 Abnormal radiator outlet coolant Voltage: more than 4.10V • Nothing special
temperature sensor high voltage Continuously 30 seconds
or more
15979-4 Abnormal radiator outlet coolant Voltage: less than 0.25V • Nothing special
temperature sensor low voltage Continuously 30 seconds
or more
15980-3 Abnormal oil cooler outlet Voltage: more than 4.10V • Nothing special
temperature sensor high voltage Continuously 30 seconds
or more
15980-4 Abnormal oil cooler outlet Voltage: less than 0.25V • Nothing special
temperature sensor low voltage Continuously 30 seconds
or more
15981-3 Abnormal oil cooler inlet Voltage: more than 4.10V • Nothing special
temperature sensor high voltage Continuously 30 seconds
or more
15981-4 Abnormal oil cooler inlet Voltage: less than 0.25V • Nothing special
temperature sensor low voltage Continuously 30 seconds
or more
15982-3 Abnormal intercooler outlet Voltage: more than 4.10V • Nothing special
temperature sensor high voltage Continuously 30 seconds
or more
15982-4 Abnormal intercooler outlet Voltage: less than 0.25V • Nothing special
temperature sensor low voltage Continuously 30 seconds
or more
15984-2 Pilot shut-off switch reception failure Faulty harness -
15987-2 Fuel temperature reception failure Faulty harness • Fan pump flow rate control
15988-2 Ambient temperature reception failure Faulty harness • Fan pump flow rate control
15989-2 MCF-SUB unit connection failure MC (Sub) unit connection • Wiper/washer control
signal is OFF. • Step light control
• Alarm buzzer control
• Engine alarm icon control
15990-2 Target engine speed reception failure Faulty harness • Fan pump flow rate control
15991-2 Hydraulic oil temperature reception Faulty harness • Fan pump flow rate control
failure
15992-3 Abnormal feedback high current of Current: more than 920mA • Fan pump flow rate control
fan pump control solenoid valve
15992-4 Abnormal feedback low current of Current: less than 56mA • Fan pump flow rate control
fan pump control solenoid valve
15993-3 Abnormal hydraulic oil temperature Voltage: more than 4.10V • Fan pump flow rate control
sensor 2 high voltage Continuously 30 seconds
or more
15993-4 Abnormal hydraulic oil temperature Voltage: less than 0.25V • Fan pump flow rate control
sensor 2 low voltage Continuously 30 seconds
or more
15995-2 Abnormal can communication • Faulty MC (Sub) • Fan pump flow rate control
• Shorted circuit in CAN • CAN cycle data transmission
bus line
15996-3 Abnormal sensor voltage • Faulty MC (Sub) -
• Faulty harness

T5-5-18
 TROUBLESHOOTING / Troubleshooting A

Symptoms in Machine Operation When Trouble Remedy Remedy Reference

Occurs. by Dr. ZX Page
• Nothing special Retrial B • Check the harness. T5-5-83

• Nothing special Retrial B • Check the harness. T5-5-83

• Nothing special Retrial B • Check the harness. T5-5-84

• Nothing special Retrial B • Check the harness. T5-5-84

• Nothing special Retrial B • Check the harness. T5-5-85

• Nothing special Retrial B • Check the harness. T5-5-85

• Nothing special Retrial B • Check the harness. T5-5-86

• Nothing special Retrial B • Check the harness. T5-5-86

- Retrial B • Check the harness. T5-5-87

• Cooling fan maximum speed Retrial B • Check the harness. T5-5-87
• Cooling fan maximum speed Retrial B • Check the harness. T5-5-87
• Wiper/washer cannot be controlled. Retrial B • Check the connection to MC (Sub). T5-5-88
• Step light cannot be controlled.
• Alarm buzzer cannot be controlled.
• Engine alarm icon cannot be controlled.
• Cooling fan maximum speed Retrial B • Check the harness. T5-5-87
• Cooling fan maximum speed Retrial B • Check the harness. T5-5-87

• Cooling fan cannot be controlled. Retrial B • Check the harness. T5-5-89

• Cooling fan cannot be controlled. Retrial B • Check the harness. T5-5-89

• Cooling fan maximum speed Retrial B • Check the harness. T5-5-90

• Cooling fan maximum speed Retrial B • Check the harness. T5-5-90

• Cooling fan maximum speed Retrial B • Replace MC (Sub). T5-5-91

• All abnormal signals through CAN • Check the CAN harness.
communication
- Retrial B • Replace MC (Sub). -
• Check the harness (sensor power
source).
• Check the connection sensor in MC
(Sub).

T5-5-19
 TROUBLESHOOTING / Troubleshooting A

Fault Trouble Cause Influenced Control

Code
15997-2 Abnormal a/d conversion • Faulty MC (Sub) -
15998-2 Abnormal ram • Faulty MC (Sub) -
15999-2 Abnormal eeprom • Faulty MC (Sub) -

T5-5-20
 TROUBLESHOOTING / Troubleshooting A

Symptoms in Machine Operation When Trouble Remedy Remedy Reference

Occurs. by Dr. ZX Page
- Retrial B • Replace MC (Sub). T5-5-92
- Retrial B • Replace MC (Sub). T5-5-92
- Retrial B • Replace MC (Sub). T5-5-92

T5-5-21
 TROUBLESHOOTING / Troubleshooting A
ICF FAULT CODE LIST

Fault Remedy Reference

Trouble Cause
Code Page
14000-2 Abnormal CAN The data cannot be Check the CAN communication bus line. T5-5-93
communication received due to the
noise on the CAN
bus line.
14001-2 Flash memory: The internal memory After initializing the information C/U by using T5-5-93
read / write error is abnormal when the Dr. ZX, retry the troubleshooting.
key 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 After initializing the information C/U by T5-5-93
read / write error is abnormal when the using Dr. ZX, retry the troubleshooting.
key 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.
14003-2 EEPROM: The internal memory Retry the troubleshooting by using Dr. ZX. T5-5-93
sum check error is abnormal when the If the error code is displayed after retry, ICF
key is ON. may be broken.
Replace ICF.
14008-2 Abnormal internal The internal memory Retry the troubleshooting by using Dr. ZX. T5-5-93
RAM is abnormal when the If the error code is displayed after retry, ICF
key is ON. may be broken.
Replace ICF.

T5-5-22
 TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE LIST

Fault Trouble Cause Remedy Reference

Code Page
13303-2 Abnormal thermistor Thermistor temperature: Cool the monitor unit and so T5-5-97
temperature 85C° or more on until the temperature
inside the monitor unit is less
than 85°C.
13304-2 Abnormal REG input H level REG input level is H. Refer to the Troubleshooting T5-5-98
flow chart.
13306-2 Abnormal EEPROM EEPROM reading failure Replace the monitor unit T5-5-99
occurs. when this fault code is
displayed after retrial.
13308-2 Abnormal CAN Bus OFF occurs 5 times or Refer to Check CAN Harness T5-5-99
communication more. on T5-5-26.
13310-3 Shorted circuit in coolant Input 105±30 Ω or less Check the coolant T5-5-100
temperature sensor continues for 60 seconds. temperature sensor and the
harness.
13311-3 Shorted circuit in fuel level Input 3±1 Ω or less continues Check the fuel level sensor T5-5-101
sensor for 60 seconds. and the harness.
13311-4 Open circuit in fuel level Input 135±20 Ω or more Check the fuel level sensor T5-5-101
sensor continues for 60 seconds. and the harness.

T5-5-23
 TROUBLESHOOTING / Troubleshooting A
DLU2 FAULT CODE LIST

Fault Engine Reference

Trouble Cause Remedy
Code Fault Code Page
100-1 143 Engine oil pressure alarm - - -
105-0 155 Abnormal intake manifold - - -
temperature
110-0 151 Coolant overheat alarm - - -
111-1 235 Coolant level alarm - - -
172-3 - Abnormal ambient Voltage: more than 4.10 V • Check T5-5-103
temperature sensor the harness.
high voltage • Replace the
temperature
sensor.
172-4 - Abnormal ambient Voltage: less than 0.25 V • Check T5-5-103
temperature sensor the harness.
low voltage • Replace the
temperature
sensor.
174-0 261 Abnormal fuel temperature - - -
17985-2 - Pump torque adjustment Data cannot be received Check the CAN -
switch reception failure from MC (Main). harness.
17986-2 - Pump 3 delivery pressure Data cannot be received Check the CAN -
reception failure from MC (Main). harness.
17987-2 - Pump 2 delivery pressure Data cannot be received Check the CAN -
reception failure from MC (Main). harness.
17988-2 - Pump 1 delivery pressure Data cannot be received Check the CAN -
reception failure from MC (Main). harness.
17989-2 - Pump 3 regulator pressure Data cannot be received Check the CAN -
reception failure from MC (Main). harness.
17990-2 - Pump 2 regulator pressure Data cannot be received Check the CAN -
reception failure from MC (Main). harness.
17991-2 - Pump 1 regulator pressure Data cannot be received Check the CAN -
reception failure from MC (Main). harness.
17992-2 - Swing operation signal Data cannot be received Check the CAN -
reception failure from MC (Main). harness.
17993-2 - E mode speed limit reception Data cannot be received Check the CAN -
failure from MC (Main). harness.
17994-2 - Travel operation / P mode Data cannot be received Check the CAN -
speed limit reception failure from MC (Main). harness.
17995-2 - Accelerator pedal position Data cannot be received Check the CAN -
reception failure from MC (Main). harness.
17996-2 - ECM actual engine speed Data cannot be received Check the CAN -
reception failure from MC (Main). harness.
17997-2 - MC (Main) actual engine Data cannot be received Check the CAN -
speed reception failure from MC (Main). harness.
17998-2 - Hour meter reception failure Data cannot be received Check the CAN -
from monitor unit harness.
17999-2 - Abnormal communication Data cannot be received Check the CAN -
between ECM and DLU2 from ECM harness.

T5-5-24
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODES 11000 TO 11002

Fault Code Trouble Cause

11000-2 Abnormal EEPROM Faulty MC (Main)
11001-2 Abnormal RAM Faulty MC (Main)
11002-2 Abnormal A/D conversion Faulty MC (Main)

YES * Faulty MC (Main).

Check if operation of engine

and machine is normal.
Faulty MC (Main).
NO

* Even if the engine and the machine are operated

normally with the fault code displayed after retrial,
the machine can be operated as it is.

T5-5-25
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11003

Fault Code Trouble Cause

11003-3 Abnormal sensor voltage Faulty MC (Main)

IMPORTANT: When fault code 11003-3 (Abnormal

Sensor Voltage) is displayed with
other fault code, diagnose on fault
code 11003-3 first.

YES Faulty Sensor.

Disconnect connectors of
all sensors corresponding Disconnect all
to the displayed fault code connectors at MC
(Main) end. Shorted circuit in harness
and retry. YES between MC (Main) and
Check if fault code Check for continuity
between terminals sensor in the harness with
11003-3 disappears. continuity.
#1 and #3 of
NO harness end
connector of each
sensor. Faulty MC.
NO
· Key switch: OFF

Connector (Harness end of connector viewed from the

open end side)
• Pressure Sensor (Boom Raise/Lower, Arm • Pump 1, Pump 2, and Pump 3 Delivery Pressure
Roll-Out/Roll-In, Bucket Roll-Out/Roll-In, Swing, Sensors
Travel (Right/Left), Bucket Open/Close (Loading • Boom Bottom Pressure Sensor
Shovel), Attachment (Optional) • Arm Rod Pressure Sensor
• Pump 1, Pump 2, and Pump 3 Regulator • Arm Bottom Pressure Sensor
Pressure Sensors

T1J1-05-06-002
T1J1-05-06-001

T5-5-26
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11004

Fault Code Trouble Cause

11004-2 Abnormal CAN Faulty MC (Main)
communication

CAN Harness

Monitor Unit

Satellite
communication
Terminal
ICF MC (Main) MC (Sub) DLU2
Dr.ZX

Dr.ZX

CAN Harness

ECM

T18J-02-01-010

• Check the CAN harness between the controllers.

(Refer to CAN HARNESS CHECK on T5-5-28.)

T5-5-27
 TROUBLESHOOTING / Troubleshooting A
CAN HARNESS CHECK

• Check the wiring connections first.

YES
To A
Check for continuity in
YES CAN harness between
MC and ICF.
Open circuit in CAN
harness between
· Key switch: OFF MC and ICF.
NO
Check for continuity in · Check for MC (Main)
YES CAN harness between and MC (Sub)
MC (Main) and MC respectively.
(Sub). · Refer to CAN Harness
Continuity Check on
· Key switch: OFF T5-5-32.
Retry by using Dr.ZX. · Refer to CAN Harness Open circuit in CAN
Check if fault code Continuity Check on harness between
NO MC (Main) and MC
11004-2 is displayed. T5-5-32.
(Sub).

Normal.
NO

Check for continuity

YES
in CAN harness
To B
between DLU and
ECM.
Check for continuity in
YES CAN harness between · Key switch: OFF
· Refer to CAN
MC and DLU2.
Harness Continuity
· Key switch: OFF Check on T5-5-34.
Check for continuity in · Check for MC (Main)
Open circuit in CAN
CAN harness between and MC (Sub)
A NO harness between
MC and monitor unit. respectively.
MC and DLU2.
· Refer to CAN
Harness Continuity
· Key switch: OFF Check on T5-5-33.
· Check for MC (Main) Open circuit in CAN
and MC (Sub) harness between
respectively. NO MC and monitor unit.
· Refer to CAN
Harness Continuity
Check on T5-5-33.

T5-5-28
 TROUBLESHOOTING / Troubleshooting A

Shorted circuit in
CAN harness
YES between ground
Disconnect all circuit and CAN
connectors in MC circuit.
(Main, Sub), ICF,
ECM, DLU2, and Shorted circuit in
YES monitor unit. YES CAN harness
Check for continuity between power
between CAN circuit circuit and CAN
Check for continuity
and ground circuit in circuit.
between CAN circuit
MC (Main, Sub), ICF,
and power circuit in
ECM, DLU2, and NO YES Shorted circuit in
MC (Main, Sub), ICF,
monitor unit. Check for continuity CAN harness
ECM, DLU2, and
· Key switch: OFF monitor unit. between CAN circuit between key signal
· Refer to Discontinuity and key signal circuit circuit and CAN
Check between CAN · Key switch: OFF NO in MC (Main, Sub), circuit.
B Circuit and Ground · Refer to ICF, ECM, DLU2,
Circuit on T5-5-35 to Discontinuity Check and monitor unit. Check for continuity
38. between CAN Circuit between High side To C
· Key switch: OFF NO and Low side in CAN
and Power Circuit on
· Refer to Discontinuity harness.
T5-5-39 to 43.
Check between CAN
Circuit and Key Signal · Key switch: OFF
Circuit on T5-5-44 to · Refer to Discontinuity
47. Check in CAN Harness
on T5-5-48 to 49.
Open circuit in CAN
NO harness between
DLU2 and ECM.

T5-5-29
 TROUBLESHOOTING / Troubleshooting A

YES Shorted circuit in

CAN harness.

Connect connector YES Faulty MC.

YES of MC.
C Check if fault code
11004-2 is Check the
displayed. connection of MC
Connect all NO and connector.
connectors except · Key switch: ON
connector MC-C in · Check for MC
MC. (Main) and MC Connect connector YES Faulty ICF.
Check if resistance (Sub) respectively. of ICF.
NO between terminals YES Check if fault code
#C4 and #C15 of 11004-2 is Check the
Connect connector of displayed.
harness end connection of ICF
MC.
connector MC-C is NO and connector.
Disconnect · Key switch: ON
within 120±10 Ω.
connector IFC-C of
· Key switch: OFF ICF. Connect connector
· Check for MC Check if resistance Connect connector of of monitor unit.
(Main) and MC NO between terminals ICF. YES Check if fault code
(Sub) respectively. #C5 and #C11 of Disconnect 11004-2 is
harness end connector monitor-B displayed.
connector is within of monitor unit.
120±10 Ω. Check if resistance
between terminals · Key switch: ON
· Key switch: OFF
NO #B6 and #B7 of Connect connector of
harness end monitor unit.
Connector (Harness end of connector viewed from connector is within Disconnect
the open end side) 120±10 Ω. connector DLU2-C of
· Key switch: OFF NO DLU2.
MC Check if resistance
Connector MC-C between terminals of
harness end
#C4 #C15 connector is within
C1 C10 120±10 Ω.
· Key switch: OFF
· Between terminals
#45 and #46,
C23 C31 Between terminals
#51 and #52
ICF
Connector ICF-C
#C5

Monitor Unit
Connector Monitor-B
#C11 T1V1-05-04-002

DLU2
#B7 #B6
Connector DLU2-C
#45 #46

43 48
49 54
T183-05-04-013
#51 #52

T5-5-30
 TROUBLESHOOTING / Troubleshooting A

YES Faulty monitor unit.

Check the connection

of monitor unit and
NO connector.

YES Faulty DLU2.

Connect connector of
YES DLU2.
Check if fault code
11004-2 is displayed. Check the connection
of DLU2 and
· Key switch: ON NO connector.

YES Faulty ECM.

YES Connect connector of
Connect connector of ECM.
DLU2. Check if fault code
Disconnect connector 11004-2 is displayed. Check the connection
CAN of ECM. of ECM and
NO connector.
Check if resistance
NO between terminals C
and D of harness end Failure in any
connector is within controller of MC, ICF,
120±10 Ω. NO ECM, DLU2, and
· Key switch: OFF monitor unit.

Connector (Harness end of connector viewed from

the open end side)

ECM
Connector ECM-CAN
#C #D

T18J-05-07-004

T5-5-31
 TROUBLESHOOTING / Troubleshooting A
CAN Harness Continuity Check
IMPORTANT: Before continuity check, turn the key
switch OFF.

• Between MC (Main) and MC (Sub) • Between MC (Main) and ICF, or MC (Sub) and
CAN Harness (High Side): ICF
Check for continuity between terminal #C4 of CAN Harness (High Side):
harness end connector MC (Main)-C in MC (Main) Check for continuity between terminal #C4 of
and terminal #C4 of harness end connector MC harness end connector MC-C in MC and terminal
(Sub)-C in MC (Sub). #C5 of harness end connector ICF-C in ICF.

CAN Harness (Low Side): CAN Harness (Low Side):

Check for continuity between terminal #C15 of Check for continuity between terminal #C15 of
harness end connector MC (Main)-C in MC (Main) harness end connector MC-C in MC and terminal
and terminal #C15 of harness end connector MC #C11 of harness end connector ICF-C in ICF.
(Sub)-C in MC (Sub).

Connector (Harness end of connector viewed from

the open end side)

MC (Main)
Connector MC (Main)-C
MC (Sub)
Connector MC (Sub)-C

#C4 #C15
C1 C10

C23 C31

ICF
Connector ICF-C
#C5

#C11 T1V1-05-04-002

T5-5-32
 TROUBLESHOOTING / Troubleshooting A
• Between MC (Main) and Monitor Unit, or MC • Between MC (Main) and DLU2, or MC (Sub) and
(Sub) and Monitor Unit DLU2
CAN Harness (High Side): CAN Harness (High Side):
Check for continuity between terminal #C4 of Check for continuity between terminal #C4 of
harness end connector MC-C in MC and terminal harness end connector MC-C in MC and terminal
#B7 of harness end connector monitor-B in the #46 of harness end connector DLU2-C in DLU2.
monitor unit.
CAN Harness (Low Side):
CAN Harness (Low Side): Check for continuity between terminal #C15 of
Check for continuity between terminal #C15 of harness end connector MC-C in MC and terminal
harness end connector MC-C in MC and terminal #45 of harness end connector DLU2-C in DLU2.
#B6 of harness end connector monitor-B in the
monitor unit.

Connector (Harness end connector viewed from the

open end side) DLU2
Connector DLU2-C
MC (Main) #45 #46
Connector MC (Main)-C
MC (Sub) 43 48
Connector MC (Sub)-C 49 54

#C4 #C15
C1 C10

C23 C31

Monitor Unit
Connector Monitor-B

#B7 #B6

T183-05-04-013

T5-5-33
 TROUBLESHOOTING / Troubleshooting A
• Between DLU2 and ECM
CAN Harness (High Side):
Check for continuity between terminal #52 of
harness end connector DLU2-C in DLU2 and
terminal #C of harness end connector ECM-CAN
in ECM.

CAN Harness (Low Side):

Check for continuity between terminal #51 of
harness end connector DLU2-C in DLU2 and
terminal #D of harness end connector ECM-CAN
in ECM.

Connector (Harness end of connector viewed from

the open end side)

DLU2
Connector DLU2-C

43 48
49 54

#51 #52

ECM
Connector ECM-CAN
#C #D

T18J-05-07-004

T5-5-34
 TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Ground Circuit Connector (Harness end of connector viewed from
the open end side)
IMPORTANT: Before continuity check, turn the key
switch OFF. Connector MC-A
· In case of continuity, the circuit #A2
between CAN circuit and ground
circuit is shorted.
· In case of discontinuity, the circuit is
normal.
#A13
• MC (Main) and MC (Sub) T183-05-04-008
Between CAN Circuit (High Side) and Ground
Circuit
Check for continuity between terminal #C4 of Connector MC-B
harness end connector MC-C and terminal #A2 of #B8
harness end connector MC-A.

Check for continuity between terminal #C4 of

harness end connector MC-C and terminal #A13
of harness end connector MC-A. #B18
T183-05-04-021

Check for continuity between terminal #C4 of

harness end connector MC-C and terminal #B8 of Connector MC-C
harness end connector MC-B. #C4
C1 C10

Check for continuity between terminal #C4 of

harness end connector MC-C and terminal #B18
of harness end connector MC-B. C23 C31

T5-5-35
 TROUBLESHOOTING / Troubleshooting A
Between CAN Circuit (Low Side) and Ground
Circuit Connector (Harness end of connector viewed from
Check for continuity between terminal #C15 of the open end side)
harness end connector MC-C and terminal #A2 of
harness end connector MC-A. Connector MC-A
#A2
Check for continuity between terminal #C15 of
harness end connector MC-C and terminal #A13
of harness end connector MC-A.

Check for continuity between terminal #C15 of

#A13
harness end connector MC-C and terminal #B8 of T183-05-04-008
harness end connector MC-B.

Check for continuity between terminal #C15 of Connector MC-B

harness end connector MC-C and terminal #B18 #B8
of harness end connector MC-B.

#B18
T183-05-04-021

Connector MC-C
#C15
C1 C10

C23 C31

T5-5-36
 TROUBLESHOOTING / Troubleshooting A
• ICF
Between CAN Circuit (High Side) and Ground Connector (Harness end of connector viewed from
Circuit the open end side)
Check for continuity between terminal #C5 of
harness end connector ICF-C and terminal #A10 ICF
of harness end connector ICF-A. Connector ICF-A

Check for continuity between terminals #C5 and #A10

1 9
#C14 of harness end connector ICF-C. 10 21
22 31
Check for continuity between terminals #C5 and
#C15 of harness end connector ICF-C.

Between CAN Circuit (Low Side) and Ground

Circuit
Check for continuity between terminal #C11 of ICF
harness end connector ICF-C and terminal #A10 Connector ICF-C #C5
of harness end connector ICF-A.

Check for continuity between terminals #C11 and

#C14 of harness end connector ICF-C.
T1V1-05-04-002
Check for continuity between terminals #C11 and #C14 #C15 #C11
#C15 of harness end connector ICF-C.

• Monitor Unit
Between CAN Circuit (High Side) and Ground
Circuit Monitor Unit
Check for continuity between terminals #B7 and Connector Monitor-B
#B11 of harness end connector monitor-B.
#B7 #B6
Check for continuity between terminals #B7 and
#B14 of harness end connector monitor-B.

Between CAN Circuit (Low Side) and Ground

Circuit
Check for continuity between terminals #B6 and #B14 #B11
T183-05-04-013

#B11 of harness end connector monitor-B.

Check for continuity between terminals #B6 and

#B14 of harness end connector monitor-B.

T5-5-37
 TROUBLESHOOTING / Troubleshooting A
• DLU2
Between CAN Circuit (High Side) and Ground Connector (Harness end of connector viewed from
Circuit the open end side)
Check for continuity between terminal #46 of
harness end connector DLU2-C and terminal #12 DLU2
of harness end connector DLU2-A. Connector DLU2-A
#12
Check for continuity between terminal #46 of
harness end connector DLU2-C and terminal #25
of harness end connector DLU2-A.
T18E-05-06-008
#25
Check for continuity between terminal #52 of
harness end connector DLU2-C and terminal #12
of harness end connector DLU2-A.

Check for continuity between terminal #52 of DLU2

harness end connector DLU2-C and terminal #25 Connector DLU2-C
of harness end connector DLU2-A. #45 #46

43 48
Between CAN Circuit (Low Side) and Ground 49 54
Circuit
Check for continuity between terminal #45 of #51 #52
harness end connector DLU2-C and terminal #12
of harness end connector DLU2-A.

Check for continuity between terminal #45 of

harness end connector DLU2-C and terminal #25
of harness end connector DLU2-A.

Check for continuity between terminal #51 of

harness end connector DLU2-C and terminal #12
of harness end connector DLU2-A.

Check for continuity between terminal #51 of

harness end connector DLU2-C and terminal #25
of harness end connector DLU2-A.

T5-5-38
 TROUBLESHOOTING / Troubleshooting A
Discontinuity Check Between CAN Circuit and
Power Circuit Connector (Harness end of connector viewed from
the open end side)
IMPORTANT: Before continuity check, turn the
key switch OFF. Connector MC-A
· In case of continuity, the circuit
between CAN circuit and power #A1
circuit is shorted.
· In case of discontinuity, the circuit is
normal.
#A12
• MC (Main) and MC (Sub) T183-05-04-008
Between CAN Circuit (High Side) and Power
Circuit
Check for continuity between terminal #C4 of Connector MC-B
harness end connector MC-C and terminal #A1 of
harness end connector MC-A. #B7

Check for continuity between terminal #C4 of

harness end connector MC-C and terminal #A12
of harness end connector MC-A.
#B17
Check for continuity between terminal #C4 of T183-05-04-021

harness end connector MC-C and terminal #B7 of

harness end connector MC-B.
Connector MC-C
#C4
Check for continuity between terminal #C4 of
C1 C10
harness end connector MC-C and terminal #B17
of harness end connector MC-B.

C23 C31

T5-5-39
 TROUBLESHOOTING / Troubleshooting A
Between CAN Circuit (Low Side) and Power
Circuit Connector (Harness end of connector viewed from
Check for continuity between terminal #C15 of the open end side)
harness end connector MC-C and terminal #A1 of
harness end connector MC-A. Connector MC-A

Check for continuity between terminal #C15 of #A1

harness end connector MC-C and terminal #A12
of harness end Connector MC-A.

Check for continuity between terminal #C15 of #A12

harness end connector MC-C and terminal #B7 of T183-05-04-008
harness end connector MC-B.

Check for continuity between terminal #C15 of Connector MC-B

harness end connector MC-C and terminal #B17 #B7
of harness end connector MC-B.

#B17
T183-05-04-021

Connector MC-C
#C15
C1 C10

C23 C31

T5-5-40
 TROUBLESHOOTING / Troubleshooting A
• ECM
Between CAN Circuit (High Side) and Power Connector (Harness end of connector viewed from
Circuit the open end side)
Check for continuity between terminal #C of
harness end connector ECM-CAN and terminal ECM
#D of harness end connector ECM-21P. Connector ECM-CAN

Check for continuity between terminal #C of #C #D

harness end connector ECM-CAN and terminal
#G of harness end connector ECM-21P.

Between CAN Circuit (Low Side) and Power

Circuit T18J-05-07-004

Check for continuity between terminal #D of

harness end connector ECM-CAN and terminal
#D of harness end connector ECM-21P. ECM
Connector ECM-21P
Check for continuity between terminal #D of
#G
harness end connector ECM-CAN and terminal
#G of harness end connector ECM-21P.

• ICF
Between CAN Circuit (High Side) and Power #D
Circuit T18J-05-07-001

Check for continuity between terminals #C5 and

#C1 of harness end connector ICF-C.

Check for continuity between terminals #C5 and

#C2 of harness end connector ICF-C. ICF
Connector ICF-C
#C5
#C2
Between CAN Circuit (Low Side) and Power
#C1
Circuit
Check for continuity between terminals #C11 and
#C1 of harness end connector ICF-C.
T1V1-05-04-002
#C11
Check for continuity between terminals #C11 and
#C2 of harness end connector ICF-C.

T5-5-41
 TROUBLESHOOTING / Troubleshooting A
• Monitor Unit
Between CAN Circuit (High Side) and Power Connector (Harness end of connector viewed from
Circuit the open end side)
Check for continuity between terminal #B7 of
harness end connector monitor-B and terminal Monitor Unit
#A16 of harness end connector monitor-A. Connector Monitor-A

T183-05-05-001

#A16

Monitor Unit
Connector Monitor-B
Between CAN Circuit (Low Side) and Power
Circuit
#B7 #B6
Check for continuity between terminal #B6 of
harness end connector monitor-B and terminal
#A16 of harness end connector monitor-A.

T183-05-04-013

T5-5-42
 TROUBLESHOOTING / Troubleshooting A
• DLU2
Between CAN Circuit (High Side) and Ground Connector (Harness end of connector viewed from
Circuit the open end side)
Check for continuity between terminal #46 of
harness end connector DLU2-C and terminal #13 DLU2
of harness end connector DLU2-A. Connector DLU2-A
#13
Check for continuity between terminal #46 of
harness end connector DLU2-C and terminal #26
of harness end connector DLU2-A.
T18E-05-06-008

Check for continuity between terminal #52 of #26

harness end connector DLU2-C and terminal #13
of harness end connector DLU2-A.

Check for continuity between terminal #52 of DLU2

harness end connector DLU2-C and terminal #26 Connector DLU2-C
of harness end connector DLU2-A. #45 #46

43 48
Between CAN Circuit (Low Side) and Ground 49 54
Circuit
Check for continuity between terminal #45 of #51 #52
harness end connector DLU2-C and terminal #13
of harness end connector DLU2-A.

Check for continuity between terminal #45 of

harness end connector DLU2-C and terminal #26
of harness end connector DLU2-A.

Check for continuity between terminal #51 of

harness end connector DLU2-C and terminal #13
of harness end connector DLU2-A.

Check for continuity between terminal #51 of

harness end connector DLU2-C and terminal #26
of harness end connector DLU2-A.

T5-5-43
 TROUBLESHOOTING / Troubleshooting A
Discontinuity Check between CAN Circuit and
Key Signal Circuit Connector (Harness end of connector viewed from
the open end side)
IMPORTANT: Before continuity check, turn the
key switch OFF. Connector MC-B
· In case of continuity, the circuit #B16
between CAN circuit and key signal
circuit is shorted.
· In case of discontinuity, the circuit is
normal.

• MC (Main) and MC (Sub)

T183-05-04-021
Between CAN Circuit (High Side) and Key Signal
Circuit Connector MC-C
Check for continuity between terminal #C4 of
#C4 #C15
harness end connector MC-C and terminal #B16
C1 C10
of harness end connector MC-B.

C23 C31

Between CAN Circuit (Low Side) and Key Signal

Circuit
Check for continuity between terminal #C15 of
harness end connector MC-C and terminal #B16
of harness end connector MC-B.

T5-5-44
 TROUBLESHOOTING / Troubleshooting A
• ECM
Between CAN Circuit (High Side) and Key Signal Connector (Harness end of connector viewed from
Circuit the open end side)
Check for continuity between terminal #C of
harness end connector ECM-CAN and terminal #1 ECM
of harness end connector ECM-31P. Connector ECM-CAN

#C #D

Between CAN Circuit (Low Side) and Key Signal

Circuit
Check for continuity between terminal #D of T18J-05-07-004

harness end connector ECM-CAN and terminal #1

of harness end connector ECM-31P. ECM
Connector ECM-31P
#1

• ICF
Between CAN Circuit (High Side) and Key Signal
Circuit
Check for continuity between terminals #C5 and
#C7 of harness end connector ICF-C. T18J-05-07-002

ICF
Connector ICF-C #C5
Between CAN Circuit (Low Side) and Key Signal
Circuit #C7
Check for continuity between terminals #C11 and
#C7 of harness end connector ICF-C.
T1V1-05-04-002
#C11

T5-5-45
 TROUBLESHOOTING / Troubleshooting A
• Monitor unit
Between CAN Circuit (High Side) and Key Signal Connector (Harness end of connector viewed from
Circuit the open end side)
Check for continuity between terminal #B7 of
harness end connector monitor-B and terminal Monitor Unit
#A7 of harness end connector monitor-A. Connector Monitor-A

#A7

T183-05-05-001

Monitor Unit
Connector Monitor-B

#B7 #B6

Between CAN Circuit (Low Side) and Key Signal

Circuit
Check for continuity between terminal #B6 of
harness end connector monitor-B and terminal
#A7 of harness end connector monitor-A. T183-05-04-013

T5-5-46
 TROUBLESHOOTING / Troubleshooting A
• DLU2
Between CAN Circuit (High Side) and Ground Connector (Harness end of connector viewed from
Circuit the open end side)
Check for continuity between terminal #46 of
harness end connector DLU2-C and terminal #6 DLU2
of harness end connector DLU2-A. Connector DLU2-A
#6
Check for continuity between terminal #46 of
harness end connector DLU2-C and terminal #19
of harness end connector DLU2-A.
Check for continuity between terminal #46 of T18E-05-06-008
#19 #20
harness end connector DLU2-C and terminal #20
of harness end connector DLU2-A.
Check for continuity between terminal #52 of
harness end connector DLU2-C and terminal #6
DLU2
of harness end connector DLU2-A.
Connector DLU2-C
Check for continuity between terminal #52 of #45 #46
harness end connector DLU2-C and terminal #19
of harness end connector DLU2-A. 43 48
Check for continuity between terminal #52 of 49 54
harness end connector DLU2-C and terminal #20
#51 #52
of harness end connector DLU2-A.

Between CAN Circuit (Low Side) and Ground

Circuit
Check for continuity between terminal #45 of
harness end connector DLU2-C and terminal #6
of harness end connector DLU2-A.
Check for continuity between terminal #45 of
harness end connector DLU2-C and terminal #19
of harness end connector DLU2-A.
Check for continuity between terminal #45 of
harness end connector DLU2-C and terminal #20
of harness end connector DLU2-A.
Check for continuity between terminal #51 of
harness end connector DLU2-C and terminal #6
of harness end connector DLU2-A.
Check for continuity between terminal #51 of
harness end connector DLU2-C and terminal #19
of harness end connector DLU2-A.
Check for continuity between terminal #51 of
harness end connector DLU2-C and terminal #20
of harness end connector DLU2-A.

T5-5-47
 TROUBLESHOOTING / Troubleshooting A
Discontinuity Check in CAN Harness

IMPORTANT: Before continuity check, turn the key

switch OFF.
· In case of continuity, the circuit
between CAN (High side) circuit and
CAN (Low side) circuit is shorted.
· In case of discontinuity, the circuit is
normal.
• Connector Monitor-B
• Connector MC (Main)-C and MC (Sub)-C Check for continuity between terminals #B6 and
Check for continuity between terminals #C4 and #B7 of harness end connector monitor-B in the
#C15 of harness end connector MC (Main)-C in monitor unit.
MC (Main).
Check for continuity between terminals #C4 and
#C15 of harness end connector MC (Sub)-C in Monitor Unit
MC (Sub). Connector Monitor-B

#B7 #B6
MC (Main)
Connector MC (Main)-C
MC (Sub)
Connector MC (Sub)-C

#C4 #C15
C1 C10 T183-05-04-013

C23 C31

• Connector ICF-C
Check for continuity between terminals #C5 and
#C11 of harness end connector ICF-C in ICF.

ICF
Connector ICF-C #C5

T1V1-05-04-002
#C11

T5-5-48
 TROUBLESHOOTING / Troubleshooting A
• Connector DLU2-C
Check for continuity between terminals #45 and
#46 of harness end connector DLU2-C in DLU2.

Connector DLU2-C
Check for continuity between terminals #51 and
#52 of harness end connector DLU2-C in DLU2.

DLU2
Connector DLU2-C
#45 #46

43 48
49 54

#51 #52

• Connector ECM-CAN
Check for continuity between terminals #C and #D
of harness end connector ECM-CAN in ECM.

ECM
Connector ECM-CAN

#C #D

T18J-05-07-004

T5-5-49
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11100

Fault Code Trouble Cause Influenced Control

11100-2 Abnormal engine speed Engine speed: 3000 min-1 or more Speed sensing control

• MC (Main) detects by using the engine speed sensor.

The actual engine speed is abnormal.
Diagnose ECM.

T5-5-50
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11101

Fault Code Trouble Cause

11101-3 Abnormal engine control dial Voltage: more than 4.75 V
high voltage
11101-4 Abnormal engine control dial Voltage: less than 0.25 V
low voltage
Faulty harness
Check if harness between MC (Main)
between terminal YES and engine control
#D15 of harness end dial.
YES connector MC
(Main)-D in MC (Main)
Disconnect connector of Disconnect connector and terminal #2 in Faulty MC (Main).
switch panel. Check if of switch panel. switch panel is opened NO
resistance between Check if voltage or shorted.
YES Open circuit in
terminals #1 and #3 of between terminals #1
harness between MC
switch panel end and #3 of harness end YES (Main) or ECM and
connector is 5±0.5 kΩ. connector is 5±0.5 V.
Check if voltage engine control dial
between terminal #1 of (terminal #3).
Insert a test probe into the
back side of connector in · Key switch: ON harness end connector
NO of switch panel and
terminal #2 with switch Open circuit in
panel connector body is specification. harness between
connected. NO ECM and engine
When rotating engine · Key switch: ON control dial (terminal
control dial, check if · Specification: 5±0.5 V #1).
voltage becomes
specification. Faulty engine control
NO dial.
· Specification: Refer to
the table.

Specification of Engine Control Dial

Slow idle 0.3 to 1.0 V
Fast idle 4.0 to 4.7 V

Connector (Harness end of connector viewed from the open end side)
MC (Main)
Connector MC (Main) –D Switch Panel

#3 #2 #1
T183-05-04-009
#D15

T5-5-51
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11200

Fault Code Trouble Cause

11200-3 Abnormal pump 1 delivery Voltage: more than 4.75 V
pressure sensor high voltage
11200-4 Abnormal pump 1 delivery Voltage: less than 0.25 V
pressure sensor low voltage

Check if harness Faulty harness

between terminal #C3 YES between MC (Main)
of harness end and pump 1 delivery
connector MC (Main) pressure sensor.
YES
–C in MC (Main) and
terminal #2 in pump 1
Disconnect connector delivery pressure Faulty MC (Main).
of pump 1 delivery sensor is open or NO
pressure sensor. shorted.
NO Open circuit in
Check if voltage
between terminals #1 harness between MC
and #3 of harness end YES (Main) and pump 1
Check if voltage
connector is 5±0.5 V. delivery pressure
Switch pump 1 delivery between terminal #1 of
sensor (terminal #3).
pressure sensor with harness end connector
pump 2 delivery · Key switch: ON NO in pump 1 delivery Open circuit in
pressure sensor and pressure sensor and harness between MC
retry. body is specification. (Main) and pump 1
NO
Check if fault code is · Key switch: ON delivery pressure
switched. · Specification: 5±0.5V sensor (terminal #1).

Faulty pump 1
YES delivery pressure
sensor.

Connector (Harness end of connector viewed from the open end side)

MC (Main)
Connector MC (Main) –C
Pump 1 Delivery
#C3 Pressure Sensor

C1 C10

C23 C31
T1J1-05-06-002

T5-5-52
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11202

Fault Code Trouble Cause

11202-3 Abnormal pump 2 delivery Voltage: more than 4.75 V
pressure sensor high voltage
11202-4 Abnormal pump 2 delivery Voltage: less than 0.25 V
pressure sensor low voltage

Check if harness Faulty harness

between terminal YES between MC (Main)
#C12 of harness end and pump 2 delivery
connector MC (Main) pressure sensor.
YES –C in MC (Main) and
terminal #2 in pump 2
Disconnect connector delivery pressure
sensor is open or Faulty MC (Main).
of pump 2 delivery
shorted. NO
pressure sensor.
NO Check if voltage Open circuit in
between terminals #1 harness between MC
and #3 of harness end YES (Main) and pump 2
connector is 5±0.5 V. Check if voltage
between terminal #1 of delivery pressure
Switch pump 1 delivery harness end connector sensor (terminal #3).
pressure sensor with · Key switch: ON in pump 2 delivery
pump 2 delivery NO
pressure sensor and Open circuit in
pressure sensor and body is specification. harness between MC
retry. NO (Main) and pump 2
Check if fault code is · Key switch: ON delivery pressure
switched · Specification: 5±0.5V sensor (terminal #1).

Faulty pump 2
YES delivery pressure
sensor.

Connector (Harness end of connector viewed from the open end side)

MC (Main)
Connector MC (Main) –C Pump 2 Delivery
Pressure Sensor
#C12
C1 C10

C23 C31
T1J1-05-06-002

T5-5-53
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11203

Fault Code Trouble Cause

11203-3 Abnormal pump 3 delivery Voltage: more than 4.75 V
pressure sensor high voltage
11203-4 Abnormal pump 3 delivery Voltage: less than 0.25 V
pressure sensor low voltage

Check if harness
between terminal Faulty harness
#C24 of harness end YES between MC (Main)
connector MC (Main) and pump 3 delivery
YES –C in MC (Main) and pressure sensor.
terminal #2 in pump 3
Disconnect connector delivery pressure
of pump 3 delivery sensor is open or Faulty MC (Main).
pressure sensor. shorted. NO
NO Check if voltage Open circuit in
between terminals #1
and #3 of harness end harness between MC
Check if voltage YES (Main) and pump 3
connector is 5±0.5 V.
between terminal #1 of delivery pressure
harness end connector sensor (terminal #3).
Switch pump 1 delivery
pressure sensor with · Key switch: ON in pump 3 delivery
NO
pump 3 delivery pressure sensor and Open circuit in
pressure sensor and body is specification. harness between MC
retry. NO (Main) and pump 3
Check if fault code is delivery pressure
· Key switch: ON sensor (terminal #1).
switched. · Specification: 5±0.5V
Faulty pump 3
YES delivery pressure
sensor.

Connector (Harness end of connector viewed from the open end side)
MC (Main) Pump 3 Delivery
Connector MC (Main) –C Pressure Sensor

C1 C10

C23 C31
#C24 T1J1-05-06-002

T5-5-54
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11301

Fault Code Trouble Cause

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

Check if harness Faulty harness

YES
between terminal #D16 between MC (Main)
of harness end and pressure sensor.
YES connector MC (Main)-D
in MC (Main) and
terminal #2 in pressure
sensor is open or Faulty MC (Main).
Disconnect connector
of pressure sensor. shorted. NO
Check if voltage
NO between terminals #1
and #3 of harness end
connector is 5±0.5 V
Open circuit in
harness between MC
· Key switch: ON Check if voltage YES (Main) and pressure
between terminal #1 sensor (terminal #3).
Switch pressure sensor of harness end
with other pressure NO connector in pressure
sensor and retry. Check sensor and body is Open circuit in
if fault code disappears. specification. harness between MC
NO (Main) and pressure
· Key switch: ON sensor (terminal #1).
· Specification: 5±0.5V

Faulty pressure
YES sensor.

Connector (Harness end of connector viewed from the open end side)

MC (Main)
Connector MC (Main) –D
Pilot Pressure Sensor (Swing)

#D16

T183-05-04-009 T1J1-05-06-001

T5-5-55
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11302

Fault Code Trouble Cause

11302-3 Abnormal boom raise pilot Voltage: more than 4.75 V
pressure sensor high voltage
11302-4 Abnormal boom raise pilot Voltage: less than 0.25 V
pressure sensor low voltage

Check if harness
YES Faulty harness
between terminal #C13 between MC (Main)
of harness end and pressure sensor.
YES connector MC (Main)
–C in MC (Main) and
terminal #2 in pressure
sensor is open or Faulty MC (Main).
Disconnect connector
of pressure sensor. shorted. NO
Check if voltage
NO between terminals #1
and #3 of harness end
connector is 5±0.5 V.
Open circuit in
harness between MC
Check if voltage YES (Main) and pressure
· Key switch: ON between terminal #1 sensor (terminal #3).
of harness end
connector in pressure
Switch pressure sensor NO sensor and body is Open circuit in
with other pressure specification. harness between MC
sensor and retry. Check (Main) and pressure
· Key switch: ON NO sensor (terminal #1).
if fault code disappears.
· Specification: 5±0.5V

Faulty pressure
YES sensor.

Connector (Harness end of connector viewed from the open end side)
MC (Main)
Connector MC (Main) –C Pilot Pressure Sensor (Boom Raise)

#C13
C1 C10

C23 C31 T1J1-05-06-001

T5-5-56
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11303

Fault Code Trouble Cause

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

Check if harness
between terminal #C23 Faulty harness
YES
of harness end between MC (Main)
connector MC (Main) and pressure sensor.
YES –C in MC (Main) and
terminal #2 in pressure
sensor is open or Faulty MC (Main).
Disconnect connector shorted.
NO
of pressure sensor.
Check if voltage
NO between terminals #1
and #3 of harness end
connector is 5±0.5 V.
Open circuit in
harness between MC
Check if voltage YES (Main) and pressure
· Key switch: ON
between terminal #1 sensor (terminal #3).
of harness end
NO connector in pressure
Switch pressure sensor Open circuit in
sensor and body is
with other pressure harness between MC
specification.
sensor and retry. Check (Main) and pressure
· Key switch: ON NO
if fault code disappears. sensor (terminal #1).
· Specification: 5±0.5V

Faulty pressure
YES sensor.

Connector (Harness end of connector viewed from the open end side)

MC (Main)
Connector MC (Main) –C Pilot Pressure Sensor (Arm Roll-In)

C1 C10

#C23
T1J1-05-06-001
C23 C31

T5-5-57
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11400

Fault Code Trouble Cause

11400-3 Abnormal feedback high current of pump 2 control Current: more than 920 mA
solenoid valve
11400-4 Abnormal feedback low current of pump 2 control Current: less than 56 mA
solenoid valve

IMPORTANT: When diagnosing after switching the Specified resistance:

solenoid valve connectors, check Pump control solenoid valve: 17.5 Ω at 20°C
for continuity of the solenoid before 4-spool solenoid valve unit: 18.5 Ω at 20°C
switching.
In case the solenoid is shorted, if the
connectors are switched and the
engine starts, the normal solenoid
valve and MC may be damaged.

Switch connectors of
pump 2 control solenoid YES Faulty pump 2 control
valve and pump 1 solenoid valve.
control solenoid valve.
YES
Check if fault code in
pump 1 control solenoid
Check for continuity in valve is displayed. Faulty MC (Main).
harness between MC NO
(Main) and pump 2
control solenoid valve.

· Between terminal
#A30 of connector
MC-A in MC and
terminal #1 of
connector in pump 2 Open circuit in harness.
control solenoid valve NO
· Between terminal
#A19 of connector
MC-A in MC and
terminal #2 of
connector in pump 2
control solenoid valve

Connector (Harness end of connector viewed from the

open end side)
MC (Main)
Connector MC (Main)–A Pump 2 Control Solenoid Valve
#A19

T183-05-04-008 T1J1-05-06-003
#A30

T5-5-58
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11402

Fault Code Trouble Cause

11402-3 Abnormal feedback high current of solenoid valve unit (SF) Current: more than 920 mA
(boom flow rate control valve selection)
11402-4 Abnormal feedback low current of solenoid valve unit (SF) Current: less than 56 mA
(boom flow rate control valve selection)

IMPORTANT: When diagnosing after switching the Specified resistance:

solenoid valve connectors, check Pump control solenoid valve: 17.5 Ω at 20°C
for continuity of the solenoid before 4-spool solenoid valve unit: 18.5 Ω at 20°C
switching.
In case the solenoid is shorted, if the
connectors are switched and the
engine starts, the normal solenoid
valve and MC may be damaged.

Switch connectors of
solenoid valve unit (SF) Faulty solenoid valve
(boom flow rate control unit (SF) (boom flow
YES rate control valve
valve selection) and
other solenoid valve unit selection).
YES (SC, SG, or SI).
Check if fault code of
Check for continuity in switched solenoid valve Faulty MC (Main).
harness between MC unit is displayed.
NO
(Main) and solenoid
valve unit (SF) (boom · After switching the
flow rate control valve connectors, operate
selection). combined operation of
boom and bucket or
· Between terminal arm.
#A20 of connector · Check by using Dr. ZX.
MC-A in MC and
Open circuit in harness.
terminal #1 of
connector in solenoid NO
valve unit (SF) (boom
flow rate control valve
selection).
· Between terminal #A3
of connector MC-A in
MC and terminal #2 of
connector in solenoid
valve unit (SF) (boom
flow rate control valve
selection).

Connector (Harness end of connector viewed from the

open end side)

MC (Main)
Connector MC (Main)–A Solenoid Valve Unit (SF)
(Boom Flow Rate Control Valve Selection)
#A3 #A20

T1V1-05-04-003

T183-05-04-008

T5-5-59
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11404

Fault Code Trouble Cause

11404-3 Abnormal feedback high current of solenoid valve unit (SG) Current: more than 920 mA
(main relief pressure control)
11404-4 Abnormal feedback low current of solenoid valve unit (SG) Current: less than 56 mA
(main relief pressure control)

IMPORTANT: When diagnosing after switching the Specified resistance:

solenoid valve connectors, check Pump control solenoid valve: 17.5 Ω at 20°C
for continuity of the solenoid before 4-spool solenoid valve unit: 18.5 Ω at 20°C
switching.
In case the solenoid is shorted, if the
connectors are switched and the
engine starts, the normal solenoid
valve and MC may be damaged.

Switch connectors of
solenoid valve unit (SG)
(main relief pressure Faulty solenoid valve
control) and other YES
unit (SG) (main relief
solenoid valve unit (SF, pressure control).
YES SC, or SI).
Check if fault code of
switched solenoid valve
unit is displayed. Faulty MC (Main).
Check for continuity in NO
harness between MC
(Main) and solenoid valve · After switching the
unit (SG) (main relief connector, relieve boom
pressure control). raise.
Check by using
· Between terminal #A23 of Dr. ZX.
connector MC-A in MC
and terminal #1 of
Open circuit in harness.
connector in solenoid
valve unit (SG) (main NO
relief pressure control)
· Between terminal #A7 of
connector MC-A in MC
and terminal #2 of
connector in solenoid
valve unit (SG) (main
relief pressure control)
Connector (Harness end of connector viewed from the
open end side)
MC (Main)
Connector MC (Main)–A
Solenoid Valve Unit (SG)
#A7 (Main Relief Pressure Control)

#A23

T1V1-05-04-003

T183-05-04-008

T5-5-60
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11405

Fault Code Trouble Cause

11405-3 Abnormal feedback high current of solenoid valve unit (SI) Current: more than 920 mA
(travel mode selection)
11405-4 Abnormal feedback low current of solenoid valve unit (SI) Current: less than 56 mA
(travel mode selection)

IMPORTANT: When diagnosing after switching the Specified resistance:

solenoid valve connectors, check Pump control solenoid valve: 17.5 Ω at 20°C
for continuity of the solenoid before 4-spool solenoid valve unit: 18.5 Ω at 20°C
switching.
In case the solenoid is shorted, if the
connectors are switched and the
engine starts, the normal solenoid
valve and MC may be damaged.

Switch connectors of
solenoid valve unit (SI) Faulty solenoid valve
(travel mode selection) YES unit (SI) (travel mode
and other solenoid selection).
YES valve unit (SF, SC, or
SG).
Check for continuity in Check if fault code of
harness between MC switched solenoid valve Faulty MC (Main).
(Main) and solenoid unit is displayed. NO
valve unit (SI) (travel
mode selection). · After switching the
· Between terminal connector, set the travel
#A11 of connector mode switch to the fast
MC-A in MC and idle position.
terminal #1 of · Check by using Dr. ZX.
connector in solenoid Open circuit in harness.
valve unit (SI) (travel
NO
mode selection)
· Between terminal
#A17 of connector
MC-A in MC and
terminal #2 of
connector in solenoid
valve unit (SI) (travel
mode selection)

Connector (Harness end of connector viewed from the

open end side)
Solenoid Valve Unit (SI)
MC (Main) (Travel Mode Selection)
Connector MC (Main)–A

#A17

#A11

T1V1-05-04-003

T183-05-04-008

T5-5-61
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11410

Fault Code Trouble Cause

11410-3 Abnormal feedback high current of pump 1 control Current: more than 920 mA
solenoid valve
11410-4 Abnormal feedback low current of pump 1 control Current: less than 56 mA
solenoid valve

IMPORTANT: When diagnosing after switching the Specified resistance:

solenoid valve connectors, check Pump control solenoid valve: 17.5 Ω at 20°C
for continuity of the solenoid before 4-spool solenoid valve unit: 18.5 Ω at 20°C
switching.
In case the solenoid is shorted, if the
connectors are switched and the
engine starts, the normal solenoid
valve and MC may be damaged.

Switch connectors of YES Faulty pump 1 control

pump 1 control solenoid
solenoid valve.
valve and pump 2
YES control solenoid valve.
Check if fault code in
pump 2 control solenoid Faulty MC (Main).
Check for continuity in valve is displayed. NO
harness between MC
(Main) and pump 1
control solenoid valve.

· Between terminal
#A22 of connector
MC-A in MC and
terminal #1 of Open circuit in harness.
connector in pump 1 NO
control solenoid valve
· Between terminal
#A16 of connector
MC-A in MC and
terminal #2 of
connector in pump 1
control solenoid valve

Connector (Harness end of connector viewed from the

open end side)

MC (Main)
Connector MC (Main)–A Pump 1 Control Solenoid
#A16 #A22 Valve

T1J1-05-06-003

T183-05-04-008

T5-5-62
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11802

Fault Code Trouble Cause

11802-3 Abnormal boom bottom Voltage: more than 4.75 V
pressure sensor high voltage
11802-4 Abnormal boom bottom Voltage: less than 0.25 V
pressure sensor low voltage

Check if harness Faulty harness

between terminal #D3 YES between MC (Main)
of harness end and boom bottom
connector MC (Main) pressure sensor.
YES
-D in MC (Main) and
terminal #2 in boom
Disconnect connector bottom pressure sensor Faulty MC (Main).
of boom bottom is open or shorted. NO
pressure sensor.
NO Check if voltage Open circuit in
between terminals #1 harness between MC
and #3 of harness end Check if voltage YES (Main) and boom
connector is 5±0.5 V. between terminal #1 of bottom pressure
Switch boom bottom sensor (terminal #3).
pressure sensor with harness end connector
pump 2 delivery · Key switch: ON in boom bottom
NO Open circuit in
pressure sensor and pressure sensor and
body is specification. harness between MC
retry. (Main) and boom
Check if fault code NO
bottom pressure
(11202) is displayed. · Key switch: ON
sensor (terminal #1).
· Specification: 5±0.5V

Faulty boom bottom

YES pressure sensor.

Connector (Harness end of connector viewed from the open end side)

MC (Main)
Connector MC (Main) –D Boom Bottom Pressure Sensor

#D3

T183-05-04-009 T1J1-05-06-002

T5-5-63
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11901

Fault Code Trouble Cause

11901-3 Abnormal hydraulic oil Intake-air temperature: 21°C or
temperature sensor 1 high more (more than 20°C)
voltage Voltage: more than 4.10 V
The conditions are continued for
30 seconds or more.
11901-4 Abnormal hydraulic oil Voltage: less than 0.23 V
temperature sensor 1 low The condition is continued for 30
voltage seconds or more.

Connect terminals #1
and #2 of harness end YES Faulty MC (Main).
connector in hydraulic
oil temperature sensor
1 by using a clip. Open circuit in
Connect terminal #D6
harness between MC
YES Disconnect connector of harness end
MC (Main) –D from MC connector MC YES (Main) and hydraulic
(Main). oil temperature
(Main)-D in MC (Main)
Check for continuity sensor 1 (terminal
to body.
Disconnect connector of between terminals #D2 #1).
Check for continuity
hydraulic oil temperature and #D6 of harness NO between terminal #2 of Open circuit in
sensor 1. end connector MC harness end connector harness between MC
Check if resistance at (Main)-D. in hydraulic oil NO (Main) and hydraulic
sensor end connector is
temperature sensor 1 oil temperature
specification.
and body. sensor 1 (terminal
#2).
· Specification: Refer to
the table.
Faulty hydraulic oil
NO temperature sensor 1.

Specification of Hydraulic Oil Temperature Sensor 1

Hydraulic Oil Resistance (kΩ)
Temperature
(°C)
-20 16.2±1.6
0 (5.88)
20 2.45±0.24
40 (1.14)
60 (0.534)
80 0.322

Connector (Harness end of connector viewed from the open end side)
MC (Main)
Connector MC (Main) –D
Hydraulic Oil
#D2 Temperature Sensor 1

1 2

#D6 T183-05-04-009

T5-5-64
 TROUBLESHOOTING / Troubleshooting A
(Blank)

T5-5-65
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODES 11910, 11911,
11914, 1198, 11920, 11959, 11961, 11962,
11963, 11964, 11968

Fault Code Trouble Cause

11910-2 Actual engine speed reception Faulty CAN Harness
failure
Sent from: ECM
11911-2 Security signal reception Faulty CAN Harness
failure
Sent from: ECM monitor unit
11914-2 Radiator coolant temperature Faulty CAN Harness
reception failure
Sent from: ECM
11918-2 Work mode reception failure Faulty CAN Harness
Sent from: Monitor Unit
11920-2 Fuel flow rate reception failure Faulty CAN Harness
Sent from: ECM
11959-2 Engine ISC information CAN Faulty CAN Harness
reception failure
Sent from: ECM
11961-2 Cooling fan control status Faulty CAN Harness
reception failure
Sent from: MC (Sub)
11962-2 Engine load rate reception Faulty CAN Harness
failure
Sent from: ECM
11963-2 Swing power decrease level Faulty CAN Harness
reception failure
Sent from: MC (Sub)
11964-2 Accelerator pedal position Faulty CAN Harness
reception failure
Sent from: ECM
11968-2 Hydraulic oil temperature 2 Faulty CAN Harness
reception failure
Sent from: MC (Sub)

T5-5-66
 TROUBLESHOOTING / Troubleshooting A
CAN Harness Check

• When fault code 11910, 11911, 11914, 11918,

11920, 11959, 11961, 11962, 11963, 11964, or
11968 of MC (Main) is displayed, check the CAN
harness on T5-5-28.

CAN Harness

Monitor Unit

Satellite
Communication
Terminal
ICF MC (Main) MC (Sub) DLU2
Dr.ZX

Dr.ZX

CAN Harness

ECM

T18J-02-01-010

T5-5-67
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11960

Fault Code Trouble Cause

11960-2 Abnormal engine speed control The engine speed limit signal
from MC (Main) is not
accordant with ISC information
from ECM.

YES Faulty CAN harness.

Connect all
YES connectors.
Check if fault code
Check for continuity 11960-2 is displayed. Faulty ECM.
between terminal #A27
NO
of harness end
YES connector MC (Main)-A
in MC (Main) and
terminal #19 of harness
end connector 31P in
ECM. Open circuit in
harness between MC
NO (Main) and ECM.
Set power mode switch
to E Mode.
Check if fault code Turn auto-idle switch YES
To A
11960-2 is displayed. ON. Set engine
NO speed in auto-idle
· Auto-idle switch: OFF condition.
Check if fault code
11960-2 is displayed. Normal.
Set power mode NO
switch to P Mode.
NO Fault code 11960-2 is
not displayed. Check for continuity
between terminal #A26 YES Faulty ECM.
· Auto-idle switch: OFF of harness end
connector MC (Main)-A
YES in MC (Main) and
terminal #21 of harness
Open circuit in
end connector 31P in
harness between MC
ECM. NO (Main) and ECM.

T5-5-68
 TROUBLESHOOTING / Troubleshooting A

YES
Faulty ECM.
Check for continuity
between terminal #B23
of harness end
connector MC (Main)-B
A in MC (Main) and
terminal #20 of harness
end connector 31P in
ECM.
Open circuit in
harness between MC
NO (Main) and ECM.

Connector (Harness end of connector viewed from the

open end side)

Connector MC-A

ECM
Connector ECM-31P
T183-05-04-008 #20
#A26 #A27
#19
#21
Connector MC-B

T18J-05-07-002

#B23 T183-05-04-021

T5-5-69
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODES 11965 and 11966

Fault Code Trouble Cause

11965-2 MCF Sub unit connection error MC (Sub) is not connected
normally.
11966-2 MCF Main unit connection error MC (Main) is not connected
normally.

YES Faulty MC (Sub) or part is MC

(Main).
YES Check for continuity between
• Fault Code 11965-2 terminal #B12 of harness end
connector MC (Sub)-B in MC Open circuit in harness
Reconnect connector MC (Sub) and body. between MC (Sub) and
(Sub)-B of MC (Sub). NO ground.
Check if fault code
11965-2 is displayed.
Normal.
NO

YES Faulty MC (Main) or part is

• Fault Code 11966-2 MC (Sub).

Reconnect connector MC
(Main)-B of MC (Main).
Check if fault code
11966-2 is displayed.
Normal.

NO

Connector (Harness end of connector viewed from the

open end side)

Connector MC-B
#B12

T183-05-04-021

T5-5-70
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11969

Fault Code Trouble Cause

11969-3 Abnormal pump 3 regulator Voltage: more than 4.75 V
pressure sensor high voltage
11969-4 Abnormal pump 3 regulator Voltage: less than 0.25 V
pressure sensor low voltage

Faulty harness
Check if harness between MC (Main)
between terminal YES and pump 3 regulator
#D12 of harness end pressure sensor.
YES connector MC
(Main)-D in MC (Main)
Disconnect connector and terminal #2 in
pump 3 regulator Faulty MC (Main).
of pump 3 regulator
pressure sensor. pressure sensor is NO
open or shorted.
NO Check if voltage
between terminals #1 Open circuit in
and #3 of harness end harness between MC
Check if voltage YES (Main) and pump 3
connector is 5±0.5 V. between terminal #1 regulator pressure
Switch pump 1 regulator of harness end sensor (terminal #3).
pressure sensor with · Key switch: ON connector in pump 3
NO regulator pressure
pump 3 regulator Open circuit in
pressure sensor and sensor and body is harness between MC
retry. specification. NO (Main) and pump 3
Check if fault code is regulator pressure
switched. · Key switch: ON
sensor (terminal #1).
· Specification: 5±0.5V
Faulty pump 3
YES regulator pressure
sensor.

Connector (Harness end of connector viewed from the open end side)
MC (Main) Pump 3 Regulator Pressure Sensor
Connector MC (Main)-D

#D12

T1J1-05-06-001

T183-05-04-009

T5-5-71
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11970

Fault Code Trouble Cause

11970-3 Abnormal feedback high current of pump 3 control Current: more than 920mA
solenoid valve
11970-4 Abnormal feedback low current of pump 3 control Current: less than 56mA
solenoid valve

IMPORTANT: When diagnosing after switching the Specified resistance:

solenoid valve connectors, check Pump control solenoid valve: 17.5 Ω at 20°C
for continuity of the solenoid before 4-spool solenoid valve unit: 18.5 Ω at 20°C
switching.
In case the solenoid is shorted, if the
connectors are switched and the
engine starts, the normal solenoid
valve and MC may be damaged.

Switch connectors of YES Faulty pump 3 control

pump 1 control solenoid solenoid valve.
YES valve and pump 3
control solenoid valve.
Check if fault code in
pump 1 control solenoid Faulty MC (Main).
valve is displayed. NO
Check for continuity in
harness between MC
(Main) and pump 3
control solenoid valve.
· Between terminal #A9
of connector MC-A in
MC and terminal #1 of
connector in pump 3 Open circuit in harness.
control solenoid valve NO
· Between terminal
#A15 of connector
MC-A in MC and
terminal #2 of
connector in pump 3
control solenoid valve

Connector (Harness end of connector viewed from the

open end side)

MC (Main)
Connector MC (Main)-A Pump 3 Control Solenoid
#A15 #A9 Valve

T1J1-05-06-003

T183-05-04-008

T5-5-72
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11989

Fault Code Trouble Cause

11989-3 Abnormal feedback high current of solenoid valve unit (SC) Current: more than
(boom mode selection) 920mA
11989-4 Abnormal feedback low current of solenoid valve unit (SC) Current: less than 56mA
(boom mode selection)

IMPORTANT: When diagnosing after switching the Specified resistance:

solenoid valve connectors, check Pump control solenoid valve: 17.5 Ω at 20°C
for continuity of the solenoid before 4-spool solenoid valve unit: 18.5 Ω at 20°C
switching.
In case the solenoid is shorted, if the
connectors are switched and the
engine starts, the normal solenoid
valve and MC may be damaged.

Switch connectors of
solenoid valve unit (SC) YES Faulty solenoid valve
(boom mode selection) unit (SC) (boom mode
and other solenoid valve selection).
YES unit (SF, SG, or SI).
Check if fault code of
switched solenoid valve Faulty MC (Main).
Check for continuity in unit is displayed. NO
harness between MC
(Main) and solenoid valve · After switching the
unit (SC) (boom mode connectors, raise the
selection). boom (except for the
travel operation).
· Between terminal #A10 · Check by using Dr. ZX.
of connector MC-A in MC
and terminal #1 of Open circuit in harness.
connector in solenoid NO
valve unit (SC) (boom
mode selection)
· Between terminal #A6 of
connector MC-A in MC
and terminal #2 of
connector in solenoid
valve unit (SC) (boom
mode selection)

Connector (Harness end of connector viewed from the

open end side)
MC (Main)
Connector MC (Main)-A
Solenoid Valve Unit (SC)
#A6 #A10 (Boom Mode Selection)

T1V1-05-04-003

T183-05-04-008

T5-5-73
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11991

Fault Code Trouble Cause

11991-3 Abnormal travel (right) pilot Voltage: more than 4.75 V
pressure sensor high voltage
11991-4 Abnormal travel (right) pilot Voltage: less than 0.25 V
pressure sensor low voltage

Check if harness
between terminal #D9 YES Faulty harness
between MC (Main)
of harness end
and pressure sensor.
YES connector MC
(Main)-D in MC (Main)
and terminal #2 in
pressure sensor is Faulty MC (Main).
Disconnect connector open or shorted. NO
of pressure sensor.
Check if voltage Open circuit in
NO between terminals #1 harness between MC
YES (Main) and pressure
and #3 of harness end Check if voltage
connector is 5±0.5 V between terminal #1 of sensor (terminal #3).
Switch pressure sensor harness end connector
with other pressure NO in pressure sensor and Open circuit in
· Key switch: ON
sensor and retry. body is specification. harness between MC
Check if fault code (Main) and pressure
· Key switch: ON NO sensor (terminal #1).
disappears.
· Specification: 5±0.5V

Faulty pressure
YES sensor.

Connector (Harness end of connector viewed from the open end side)

MC (Main)
Connector MC (Main)-D Pilot Pressure Sensor (Travel (Right))

#D9

T1J1-05-06-001

T183-05-04-009

T5-5-74
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11992

Fault Code Trouble Cause

11992-3 Abnormal pump 2 regulator Voltage: more than 4.75 V
pressure sensor high voltage
11992-4 Abnormal pump 2 regulator Voltage: less than 0.25 V
pressure sensor low voltage

Check if harness Faulty harness

between terminal #D4
YES between MC (Main)
of harness end and pump 2 regulator
connector MC (Main)-D pressure sensor.
YES in MC (Main) and
terminal #2 in pump 2
Disconnect connector regulator pressure
sensor is open or Faulty MC (Main).
of pump 2 regulator
pressure sensor. shorted. NO
NO Check if voltage Open circuit in
between terminals #1 harness between MC
and #3 of harness end Check if voltage YES (Main) and pump 2
connector is 5±0.5 V. between terminal #1 regulator pressure
Switch pump 1 regulator of harness end sensor (terminal #3).
pressure sensor with connector in pump 2
pump 2 regulator · Key switch: ON
NO regulator pressure
pressure sensor and Open circuit in
sensor and body is
retry. harness between MC
specification.
Check if fault code is NO (Main) and pump 2
switched regulator pressure
· Key switch: ON sensor (terminal #1).
· Specification: 5±0.5V
Faulty pump 2
YES regulator pressure
sensor.

Connector (Harness end of connector viewed from the open end side)

MC (Main) Pump 2 Regulator Pressure Sensor

Connector MC (Main)-D
#D4

T1J1-05-06-001

T183-05-04-009

T5-5-75
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11993

Fault Code Trouble Cause

11993-3 Abnormal travel (left) pilot Voltage: more than 4.75 V
pressure sensor high voltage
11993-4 Abnormal travel (left) pilot Voltage: less than 0.25 V
pressure sensor low voltage

Check if harness Faulty harness

between terminal #D14 YES between MC (Main)
of harness end and pressure sensor.
connector MC (Main)-D
YES
in MC (Main) and
terminal #2 in pressure
sensor is open or Faulty MC (Main).
shorted.
NO
Disconnect connector
of pressure sensor. Open circuit in
NO Check if voltage harness between MC
between terminals #1 Check if voltage YES (Main) and pressure
and #3 of harness end between terminal #1 sensor (terminal #3).
connector is 5±0.5 V of harness end
Switch pressure sensor connector in pressure
with other pressure · Key switch: ON NO sensor and body is Open circuit in
sensor and retry. harness between MC
specification.
Check if fault code (Main) and pressure
disappears. · Key switch: ON NO sensor (terminal #1).
· Specification: 5±0.5V

Faulty pressure
YES sensor.

Connector (Harness end of connector viewed from the open end side)
MC (Main)
Connector MC (Main)-D Pilot Pressure Sensor (Travel (Left))

T1J1-05-06-001

T183-05-04-009
#D14

T5-5-76
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11994

Fault Code Trouble Cause

11994-3 Abnormal pump 1 regulator Voltage: more than 4.75 V
pressure sensor high voltage
11994-4 Abnormal pump 1 Regulator Voltage: less than 0.25 V
pressure sensor low voltage

Check if harness Faulty harness

between terminal between MC (Main)
#D11 of harness end YES and pump 1 regulator
connector MC pressure sensor.
(Main)-D in MC (Main)
YES
Disconnect connector and terminal #2 in
of pump 1 regulator pump 1 regulator
pressure sensor. pressure sensor is Faulty MC (Main).
Check if voltage open or shorted. NO
NO between terminals #1 Open circuit in
and #3 of harness end
connector is 5±0.5 V. harness between MC
YES (Main) and pump 1
Check if voltage regulator pressure
between terminal #1 of sensor (terminal #3).
Switch pump 1 regulator · Key switch: ON harness end connector
pressure sensor with
NO in pump 1 regulator
pump 2 regulator Open circuit in
pressure sensor and
pressure sensor and harness between MC
body is specification.
retry. NO (Main) and pump 1
Check if fault code is regulator pressure
switched. · Key switch: ON
sensor (terminal #1).
· Specification: 5±0.5V
Faulty pump 1
YES regulator pressure
sensor.

Connector (Harness end of connector viewed from the open end side)
MC (Main) Pump 1 Regulator Pressure Sensor
Connector MC (Main)-D

#D11

T1J1-05-06-001

T183-05-04-009

T5-5-77
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11995

Fault Code Trouble Cause

11995-3 Abnormal arm roll-out pilot Voltage: more than 4.75 V
pressure sensor high voltage
11995-4 Abnormal arm roll-out pilot Voltage: less than 0.25 V
pressure sensor low voltage

Check if harness Faulty harness

between terminal #D5 YES between MC (Main)
of harness end and pressure sensor.
YES connector MC (Main)-D
in MC (Main) and
terminal #2 in pressure
Disconnect connector sensor is open or Faulty MC (Main).
of pressure sensor. shorted. NO
Check if voltage
between terminals #1
NO and #3 of harness end
connector is 5±0.5 V.
Open circuit in
· Key switch: ON Check if voltage YES harness between MC
between terminal #1 (Main) and pressure
Switch pressure sensor sensor (terminal #3).
with other pressure of harness end
sensor and retry. connector in pressure
NO sensor and body is Open circuit in
Check if fault code
disappears. specification. harness between MC
NO (Main) and pressure
· Key switch: ON sensor (terminal #1).
· Specification: 5±0.5V

Faulty pressure
YES sensor.

Connector (Harness end of connector viewed from the open end side)
MC (Main)
Pilot Pressure Sensor (Arm Roll-Out)
Connector MC (Main)-D

#D5

T1J1-05-06-001

T183-05-04-009

T5-5-78
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11997

Fault Code Trouble Cause

11997-3 Abnormal bucket roll-out pilot Voltage: more than 4.75 V
pressure sensor high voltage
11997-4 Abnormal bucket roll-out pilot Voltage: less than 0.25 V
pressure sensor low voltage

Check if harness Faulty harness

between terminal #C11 YES between MC (Main)
of harness end and pressure sensor.
YES connector MC (Main)-C
in MC (Main) and
terminal #2 in pressure
sensor is open or Faulty MC (Main).
Disconnect connector
of pressure sensor. shorted. NO
Check if voltage
NO between terminals #1
and #3 of harness end
connector is 5±0.5 V.
Open circuit in
harness between MC
Check if voltage YES (Main) and pressure
· Key switch: ON
between terminal #1 sensor (terminal #3).
of harness end
Switch pressure sensor connector in pressure
with other pressure NO sensor and body is Open circuit in
sensor and retry. specification. harness between MC
Check if fault code (Main) and pressure
disappears. · Key switch: ON NO sensor (terminal #1).
· Specification: 5±0.5V

Faulty pressure
YES sensor.

Connector (Harness end of connector viewed from the open end side)
MC (Main)
Connector MC (Main)-C Pilot Pressure Sensor (Bucket Roll-Out)

C1 C10

#C11

C23 C31 T1J1-05-06-001

T5-5-79
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11998

Fault Code Trouble Cause

11998-3 Abnormal boom lower pilot Voltage: more than 4.75 V
pressure sensor high voltage
11998-4 Abnormal boom lower pilot Voltage: less than 0.25 V
pressure sensor low voltage

Check if harness YES Faulty harness

between terminal #C1
between MC (Main)
of harness end
YES connector MC (Main)-C and pressure sensor.
in MC (Main) and
Disconnect connector terminal #2 in pressure
sensor is open or Faulty MC (Main).
of pressure sensor. NO
Check if voltage shorted.
between terminals #1
NO and #3 of harness end
connector is 5±0.5 V.
Open circuit in
harness between MC
· Key switch: ON Check if voltage YES (Main) and pressure
between terminal #1 sensor (terminal #3).
Switch pressure sensor of harness end
with other pressure connector in pressure
sensor and retry. NO sensor and body is Open circuit in
Check if fault code specification. harness between MC
disappears. (Main) and pressure
· Key switch: ON NO sensor (terminal #1).
· Specification: 5±0.5V

Faulty pressure
YES sensor.

Connector (Harness end of connector viewed from the open end side)
MC (Main)
Connector MC (Main)-C Pilot Pressure Sensor (Boom Lower)

C1 C10
#C1

C23 C31
T1J1-05-06-001

T5-5-80
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 11999

Fault Code Trouble Cause

11999-3 Abnormal bucket roll-in pilot Voltage: more than 4.75 V
pressure sensor high voltage
11999-4 Abnormal bucket roll-in pilot Voltage: less than 0.25 V
pressure sensor low voltage

Check if harness
YES Faulty harness
between terminal #C2
of harness end between MC (Main)
YES connector MC (Main) and pressure sensor.
-C in MC (Main) and
terminal #2 in pressure
sensor is open or Faulty MC (Main).
Disconnect connector
shorted. NO
of pressure sensor.
Check if voltage
NO between terminals #1
and #3 of harness end Open circuit in
connector is 5±0.5 V. harness between MC
Check if Measure (Main) and pressure
· Key switch: ON voltage between YES sensor (terminal #3).
terminal #1 of
harness end
Switch pressure sensor connector in pressure
NO sensor and body is Open circuit in
with other pressure harness between MC
sensor and retry. Check specification.
(Main) and pressure
if fault code disappears. NO sensor (terminal #1).
· Key switch: ON
· Specification: 5±0.5V

Faulty pressure
YES sensor.

Connector (Harness end of connector viewed from the open end side)
MC (Main)
Connector MC (Main)-C Pilot Pressure Sensor (Bucket Roll-In)
#C2
C1 C10

C23 C31
T1J1-05-06-001

T5-5-81
 TROUBLESHOOTING / Troubleshooting A
MC (MAIN) FAULT CODE 20062

Fault Code Trouble Cause

20062-0 Hydraulic oil overheat alarm Hydraulic oil temperature:
105°C or more

• If the sensor related to the overheat prevention

control is abnormal, MC (Main) drives the fan
pump control solenoid valve and maximizes the
fan pump flow rate.
Therefore, when this fault code is displayed
independently, the related sensor is not abnormal.
• When other fault code is displayed at the same
time, diagnose on the former fault code first.
• When the engine starts or hydraulic oil
temperature is low, if this fault code is displayed,
MC (Main) maybe faulty.

YES Faulty oil cooler

bypass check valve.

NO Check if fan speed

is normal.
Faulty fan pump,
YES faulty fan pump
regulator, or faulty
installation of fan.
Check if oil drain
Clean oil cooler. amount of fan
Retry by using Dr.ZX. NO motor is normal.
Check if fault code
disappears. Faulty fan motor.
NO

End (Clogged oil

YES cooler).

T5-5-82
 TROUBLESHOOTING / Troubleshooting A
MC (SUB) FAULT CODE 15979

Fault Code Trouble Cause

15979-3 Abnormal radiator outlet Voltage: more than 4.10 V
coolant temperature sensor The condition is continued for 30
high voltage seconds or more.
15979-4 Abnormal radiator outlet Voltage: less than 0.25 V
coolant temperature sensor The condition is continued for 30
low voltage seconds or more.

Connect terminals #1
and #2 of harness end YES Faulty MC (Sub).
connector in coolant
temperature sensor by
using a clip. Open circuit in
YES Disconnect connector Connect terminal #D6 harness between MC
of harness end YES (Sub) and coolant
MC (Sub)-D from MC
connector MC (Sub)-D temperature sensor
(Sub).
in MC (Sub) to body. (terminal #1).
Check for continuity
Disconnect connector of Check for continuity
between terminals #D9
coolant temperature NO between terminal #2 of
and #D6 of harness Open circuit in
sensor. harness end connector
end connector MC harness between MC
Check if voltage at in coolant temperature
(Sub)-D. NO (Sub) and coolant
sensor end connector is sensor and body.
temperature sensor
specification. (terminal #2).
· Specification: Refer to
the table. Faulty coolant
NO temperature sensor.

Specification of Coolant Temperature Sensor

Coolant Resistance (kΩ)
Temperature
(°C)
-20 16.2±1.6
0 (5.88)
20 2.45±0.24
40 (1.14)
60 (0.534)
80 0.322

Connector (Harness end of connector viewed from the open end side)

MC (Sub)
Connector MC (Sub)–D

#D9
Coolant Temperature Sensor

1 2

#D6 T183-05-04-009

T5-5-83
 TROUBLESHOOTING / Troubleshooting A
MC (SUB) FAULT CODE 15980

Fault Code Trouble Cause

15980-3 Abnormal oil cooler outlet Voltage: more than 4.10 V
temperature sensor high The condition is continued for 30
voltage seconds or more.
15980-4 Abnormal oil cooler outlet Voltage: less than 0.25 V
temperature sensor low The condition is continued for 30
voltage seconds or more.

Connect terminals #1
and #2 of harness end YES Faulty MC (Sub).
connector in oil cooler
outlet temperature
sensor by using a clip. Open circuit in
YES Disconnect connector Connect terminal #D6 harness between MC
of harness end YES (Sub) and oil cooler
MC (Sub)-D from MC
connector MC (Sub)-D outlet temperature
Disconnect connector of (Sub).
in MC (Sub) to body. sensor (terminal #1).
oil cooler outlet Check for continuity
Check for continuity
temperature sensor. between terminals #D4
NO between terminal #2 of
Check if resistance at and #D6 of harness Open circuit in
harness end connector
sensor end connector is end connector MC harness between MC
in oil cooler outlet
specification. (Sub)-D. NO (Sub) and oil cooler
temperature sensor
and body. outlet temperature
sensor (terminal #2).
· Specification: Refer to
the table. Faulty oil cooler outlet
NO temperature sensor.

Specification of Oil Cooler Outlet Temperature Sensor

Hydraulic Oil Resistance (kΩ)
Temperature
(°C)
-20 16.2±1.6
0 (5.88)
20 2.45±0.24
40 (1.14)
60 (0.534)
80 0.322

Connector (Harness end of connector viewed from the open end side)
MC (Sub)
Connector MC (Sub)-D

#D4

Oil Cooler Outlet Temperature Sensor

1 2
#D6 T183-05-04-009

T5-5-84
 TROUBLESHOOTING / Troubleshooting A
MC (SUB) FAULT CODE 15981

Fault Code Trouble Cause

15981-3 Abnormal oil cooler inlet Voltage: more than 4.10 V
temperature sensor high The condition is continued for 30
voltage seconds or more.
15981-4 Abnormal oil cooler inlet Voltage: less than 0.25 V
temperature sensor low The condition is continued for 30
voltage seconds or more.

Connect terminals #1 YES Faulty MC (Sub).

and #2 of harness end
connector in oil cooler
inlet temperature Open circuit in
YES sensor by using a clip. Connect terminal #D6 harness between MC
Disconnect connector of harness end YES (Sub) and oil cooler
MC (Sub)-D from MC connector MC (Sub)-D inlet temperature
(Sub). in MC (Sub) to body. sensor (terminal #1).
Disconnect connector of Check for continuity
oil cooler inlet Check for continuity
between terminals #D4 NO between terminal #2 of
temperature sensor. harness end connector Open circuit in
Check if resistance at and #D6 of harness harness between MC
end connector MC in oil cooler inlet
sensor end connector is temperature sensor NO (Sub) and oil cooler
specification. (Sub)-D. inlet temperature
and body.
sensor (terminal #2).

· Specification: Refer to Faulty oil cooler inlet

the table. NO temperature sensor.

Specification of Oil Cooler Inlet Temperature Sensor

Hydraulic Oil Resistance (kΩ)
Temperature
(°C)
-20 16.2±1.6
0 (5.88)
20 2.45±0.24
40 (1.14)
60 (0.534)
80 0.322

Connector (Harness end of connector viewed from the open end side)
MC (Sub)
Connector MC (Sub)-D

#D10

Oil Cooler Inlet Temperature Sensor

1 2

#D6 T183-05-04-009

T5-5-85
 TROUBLESHOOTING / Troubleshooting A
MC (SUB) FAULT CODE 15982

Fault Code Trouble Cause

15982-3 Abnormal intercooler outlet Voltage: more than 4.10 V
temperature sensor high The condition is continued for 30
voltage seconds or more.
15982-4 Abnormal intercooler outlet Voltage: less than 0.25 V
temperature sensor low The condition is continued for 30
voltage seconds or more.

Connect terminals #1 YES Faulty MC (Sub).

and #2 of harness end
connector in intercooler
outlet temperature Open circuit in
Connect terminal #D6
YES sensor by using a clip. of harness end harness between MC
Disconnect connector YES (Sub) and intercooler
MC (Sub)-D from MC connector MC (Sub)-D
in MC (Sub) to body. outlet temperature
Disconnect connector of (Sub). sensor (terminal #1).
Check for continuity Check for continuity
intercooler outlet between terminal #2 of
temperature sensor. between terminals NO
#D14 and #D6 of harness end connector Open circuit in
Check if resistance at in intercooler outlet harness between MC
sensor end connector is harness end connector
MC (Sub)-D. temperature sensor NO (Sub) and intercooler
specification. and body. outlet temperature
sensor (terminal #2).
· Specification: Refer to
Faulty intercooler
the table.
NO outlet temperature
sensor.

Specification of Intercooler Outlet Temperature Sensor

Hydraulic Oil Resistance (kΩ)
Temperature
(°C)
-20 16.2±1.6
0 (5.88)
20 2.45±0.24
40 (1.14)
60 (0.534)
80 0.322

Connector (Harness end of connector viewed from the open end side)

MC (Sub)
Connector MC (Sub)-D

Intercooler Outlet Temperature Sensor

1 2

#D6 #D14 T183-05-04-009

T5-5-86
 TROUBLESHOOTING / Troubleshooting A
MC (SUB) FAULT CODES 15984, 15987,
15988, 15990, 15991

Fault Code Trouble Cause

15984-2 Pilot shut-off switch reception Faulty CAN harness
failure
Sent from: MC (Main)
15987-2 Fuel temperature reception Faulty CAN harness
failure
Sent from: ECM
15988-2 Ambient temperature Faulty CAN harness
reception failure
Sent from: DLU2
15990-2 Target engine speed reception Faulty CAN harness
failure
Sent from: MC (Main)
15991-2 Hydraulic oil temperature Faulty CAN harness
reception failure
Sent from: MC (Main)

• When fault codes 15984, 15987, 15988, 15990

or 15991 of MC (Sub) is displayed, check the
CAN harness on T5-5-28.

CAN Harness

Monitor Unit

Satellite
Communication
Terminal
ICF MC (Main) MC (Sub) DLU2
Dr.ZX

Dr.ZX

CAN Harness

ECM

T18J-02-01-010

T5-5-87
 TROUBLESHOOTING / Troubleshooting A
MC (SUB) FAULT CODE 15989

Fault Code Trouble Cause

15989-2 MCF Sub unit connection error MC (Sub) is not connected
normally.

Check for continuity between YES Faulty MC (Sub) or part is MC

YES terminal #B12 of harness end (Main).
connector MC (Sub)-B in MC
(Sub) and body.
Open circuit in harness
Reconnect connector MC between MC (Sub) and
(Sub)-B of MC (Sub). NO ground.
Check if fault code
15989-2 is displayed. Normal.
NO

Connector (Harness end of connector viewed from the

open end side)

Connector MC-B

#B12

T183-05-04-021

T5-5-88
 TROUBLESHOOTING / Troubleshooting A
MC (SUB) FAULT CODE 15992

Fault Code Trouble Cause

15992-3 Abnormal feedback high current of fan pump control Current: more than 920mA
solenoid valve
15992-4 Abnormal feedback low current of fan pump control Current: less than 56mA
solenoid valve

IMPORTANT: When diagnosing after switching the Specified resistance:

solenoid valve connectors, check Pump control solenoid valve: 17.5 Ω at 20°C
for continuity of the solenoid before 4-spool solenoid valve unit: 18.5 Ω at 20°C
switching.
In case the solenoid is shorted, if the
connectors are switched and the
engine starts, the normal solenoid
valve and MC may be damaged.

Switch connectors of YES Faulty fan pump control

fan pump control solenoid valve.
solenoid valve and
YES pump 2 control solenoid
valve.
Check if fault code in Faulty MC (Sub).
pump 2 control solenoid NO
Check for continuity in valve is displayed.
harness between MC
(Sub) and fan pump
control solenoid valve.
· Between terminal
#A21 of connector
MC-A in MC and
terminal #1 of Open circuit in harness.
connector in fan pump NO
control solenoid valve
· Between terminal
#A14 of connector
MC-A in MC and
terminal #2 of
connector in fan pump
control solenoid valve

Connector (Harness end of connector viewed from the

open end side)

MC (Sub)
Connector MC (Sub)-A
Fan Pump Control
#A14 #A21
Solenoid Valve

T183-05-04-008 T1J1-05-06-003

T5-5-89
 TROUBLESHOOTING / Troubleshooting A
MC (SUB) FAULT CODE 15993

Fault Code Trouble Cause

15993-3 Abnormal hydraulic oil Voltage: more than 4.10 V
temperature sensor 2 high The condition is continued for 30
voltage seconds or more.
15993-4 Abnormal hydraulic Oil Voltage: less than 0.25 V
temperature sensor 2 low The condition is continued for 30
voltage seconds or more.

Connect terminals #1
and #2 of harness end YES Faulty MC (Sub).
connector in hydraulic
oil temperature sensor Open circuit in
2 by using a clip. harness between MC
YES Disconnect connector Connect terminal #D6
(Sub) and hydraulic
of harness end YES oil temperature
MC (Sub)-D from MC
connector MC (Sub)-D
(Sub). sensor 2 (terminal
in MC (Sub) to body.
Disconnect connector of Check for continuity #1).
Check for continuity
hydraulic oil temperature between terminals #D2
NO between terminal #2 of
sensor 2. and #D6 of harness Open circuit in
harness end connector
Check if resistance at end connector MC harness between MC
in hydraulic oil
sensor end connector is (Sub)-D. NO (Sub) and hydraulic
temperature sensor 2
specification. and body. oil temperature
sensor 2 (terminal
#2).
· Specification: Refer to
the table.
Faulty hydraulic oil
temperature sensor 2.
NO

Specification of Hydraulic Oil Temperature Sensor 2

Hydraulic Oil Resistance (kΩ)
Temperature
(°C)
-20 16.2±1.6
0 (5.88)
20 2.45±0.24
40 (1.14)
60 (0.534)
80 0.322

Connector (Harness end of connector viewed from the open end side)

MC (Sub)
Connector MC (Sub)-D

#D2

Hydraulic Oil Temperature Sensor 2

1 2

#D6 T183-05-04-009

T5-5-90
 TROUBLESHOOTING / Troubleshooting A
MC (SUB) FAULT CODE 15995

Fault Code Trouble Cause

15995-2 Abnormal CAN Faulty MC (Sub)
communication

CAN Harness

Monitor Unit

Satellite
Communication
Terminal
ICF MC (Main) MC (Sub) DLU2
Dr.ZX

Dr.ZX

CAN Harness

ECM

T18J-02-01-010

• Check the CAN harness between the controllers.

(Refer to CAN Harness Check on T5-5-28.)

T5-5-91
 TROUBLESHOOTING / Troubleshooting A
MC (SUB) FAULT CODE 15997 TO 15999

Fault Code Trouble Cause

15997-2 Abnormal A/D conversion Faulty MC (Sub)
15998-2 Abnormal RAM Faulty MC (Sub)
15999-2 Abnormal EEPROM Faulty MC (Sub)

YES * Faulty MC (Sub).

Check if operation of engine

and machine is normal.
Faulty MC (Sub).
NO

* Even if the engine and the machine is operated

normally with the fault code displayed after retrial,
the machine can be operated as it is.

T5-5-92
 TROUBLESHOOTING / Troubleshooting A
ICF FAULT CODES 14000 TO 14003, 14008

Fault Code Trouble Remedy

Execute retrial B in the troubleshooting.
Abnormal CAN
14000-2 If this fault code is displayed after retrial, check the following item.
communication
• Check the CAN communication line (harness).
Flash memory:
14001-2 Execute retrial B in the troubleshooting and execute the following
read / write error
item.
External RAM:
14002-2 • Execute information C/U: Initialize.
read / write error
Execute retrial B in the troubleshooting.
If this fault code is displayed after retrial, check the following item.
EEPROM:
14003-2 • Execute Control Data: Initialize.
sum check error
Execute Enter Model and Serial No.
Then, execute the troubleshooting and execute retrial B.
Execute retrial B in the troubleshooting.
14008-2 Abnormal internal RAM
If this fault code is displayed after retrial, replace the controller.

T5-5-93
 TROUBLESHOOTING / Troubleshooting A
Information C/U: Initialize

After starting Dr. ZX, push Select

Controller. Push Information C/U. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-037

Function Selection Screen Controller Selection Screen ICF Controller Screen

Push Start. Push Information C/U: Various setup. Push Information C/U: Initialize.

To the
lower

T1V7-05-03-025 T18J-05-04-038 T1V7-05-03-027

Main Menu Screen Information C/U: Various Setup

Screen

Push Init and the controller operating

data is initialized.
Push ESC and return to Information Push OK and return to Information Push ESC and return to Main Menu
C/U: Various Setup Screen. C/U: Various Setup Screen. 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

T5-5-94
 TROUBLESHOOTING / Troubleshooting A
Control Data: Initialize

After starting Dr. ZX, push Select Push Information C/U. Push OK.
Controller.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-037

Function Selection Screen Controller Selection Screen ICF Controller Screen

Push Start. Push Information C/U: Various setup. Push Control Data: Initialize.

To the
lower

T1V7-05-03-025 T18J-05-04-038 T1V7-05-03-027

Main Menu Screen Information C/U: Various Setup

Screen

Push Init and the controller control

data is initialized.
Push ESC and return to Information Push OK and return to Information Push ESC and return to Main Menu
C/U: Various Setup Screen. C/U: Various Setup Screen. Screen.

Init

ESC

T1V7-05-03-033 T1V7-05-03-029 T1V7-05-03-027

Control Data: Initialize Screen Information C/U: Various Setup
Screen

T5-5-95
 TROUBLESHOOTING / Troubleshooting A
Enter Model and Serial No.

After starting Dr. ZX, push Select

Controller. Push Information C/U. Push OK.

To the
lower

T1V7-05-03-001 T18J-05-04-004 T18J-05-04-037

Function Selection Screen Controller Selection Screen ICF Controller Screen

Push Start. Push Information C/U: Various setup. Push Enter Model and Serial No.

To the
lower

T1V7-05-03-025 T18J-05-04-038 T1V7-05-03-027

Main Menu Screen Information C/U: Various Setup

Screen

Push OK after inputting model and

Push Exec, and model and serial No. serial No. and return to Enter Model
can be input. and Serial No. Screen.
Push ESC and return to Information Push ESC and return to Information Push ESC and return to Main Menu
C/U: Various Setup Screen. C/U: Various Setup Screen. Screen.

Exec 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

T5-5-96
 TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13303

Fault Code Trouble Remedy

13303-2 Abnormal thermistor temperature Cool the monitor unit and so on until temperature inside the
monitor unit is less than 85°C.

The screen of the monitor unit becomes dark.

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

Faulty monitor unit.

NO

T5-5-97
 TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13304

Fault Code Trouble Remedy

13304-2 Abnormal REG input H level Refer to the following.
• Check the wiring connections first.

Less than 33.5V Faulty monitor unit.

Measure voltage at
Less than 33.5V terminal #C7 of
connector monitor-C.
Open circuit in harness
· Engine: Running between terminal R in
Measure voltage at alternator and monitor unit.
33.5V or more
terminal R in
alternator.

Faulty alternator.
33.5V or more

Connector (Harness end of connector viewed from the open

end side)

Monitor Unit
Connector Monitor-C

6 1
12 7

#C7

T5-5-98
 TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13306 AND 13308

Fault Code Trouble Remedy

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 on T5-5-28.

T5-5-99
 TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13310

Fault Code Trouble Remedy

13310-3 Shorted circuit in coolant Check the coolant temperature sensor and the harness.
temperature sensor

With terminal of coolant

temperature sensor Shorted circuit in harness
disconnected, disconnect YES between monitor unit and
connector monitor-C in sensor.
YES
monitor unit.
Check for continuity between
terminal #C8 of harness end Faulty monitor unit.
Check if resistance of connector in monitor unit and
body. NO
coolant temperature
sensor is specification.
· Specification: Refer to
the table. Faulty coolant temperature
NO sensor.

Coolant Temperature Sensor

Coolant Resistance(kΩ)
Temperature
(°C)
25 7.60
40 4.0±0.13
50 2.7±0.083
80 0.92
95 0.57
104 0.43
110 0.36

Connector (Harness end of connector viewed from

the open end side)

Monitor Unit
Connector Monitor-C

6 1
12 7

#C8

T5-5-100
 TROUBLESHOOTING / Troubleshooting A
MONITOR UNIT FAULT CODE 13311

Fault Code Trouble Remedy

13311-3 Shorted circuit in fuel level sensor Check the fuel level sensor and the harness.
13311-4 Open circuit in fuel level sensor Check the fuel level sensor and the harness.

With connector of fuel Shorted circuit in

level sensor YES harness between
disconnected, disconnect monitor unit and
connector monitor-C in sensor.
monitor unit.
YES Check for continuity
between terminal #C2 of
harness end connector in Connect terminal #1 of
monitor unit and body. harness end connector in
fuel level sensor to body. Faulty monitor unit.
YES
Check for continuity
NO between terminal #C2 of
harness end connector in
Check if resistance of monitor unit and body. Open circuit in
fuel level sensor is harness between
specification. NO monitor unit and
· Specification: Refer to sensor.
the table.
Faulty fuel level
sensor.
NO

Fuel Level Sensor

Float Position Resistance (Ω)
Float Upper Limit
10+0-4
(FULL)
FULL 3/4 19
1/2 32±5
R474.8 1/4 49.3
333 mm 3/4 Alarm Level 67.5±5
Lower Limit
80+12+2
137 mm (EMPTY)
67 mm

204 mm 1/2 Connector (Harness end of connector viewed from

the open end side)

1/4 Monitor Unit

410 mm
Connector Monitor-C Fuel Level Sensor
#C2
EMPTY
T178-05-05-001

6 1 1 2
12 7

T5-5-101
 TROUBLESHOOTING / Troubleshooting A
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

T5-5-102
 TROUBLESHOOTING / Troubleshooting A
DLU2 FAULT CODE 172

Fault Code Trouble Cause

172-3 Abnormal ambient Voltage: more than 4.10 V
temperature sensor high The condition is continued for 30
voltage seconds or more.
172-4 Abnormal ambient Voltage: less than 0.25 V
temperature sensor low The condition is continued for 30
voltage seconds or more.

Connect terminals #1
and #2 of harness end YES Faulty DLU2.
connector in ambient
temperature sensor by
using a clip. Open circuit in
YES Disconnect connector Connect terminal #23 harness between
of harness end YES DLU2 and ambient
DLU2-A from DLU2.
connector DLU2-A in temperature sensor
Disconnect connector of Check for continuity
DLU2 to body. (terminal #1).
ambient temperature between terminals #4
Check for continuity
sensor. and #23 of harness
NO between terminal #2 of Open circuit in
Check if resistance at end connector
harness end connector harness between
sensor end connector is DLU2-A.
in ambient DLU2 and ambient
specification. temperature sensor NO
temperature sensor
and body. (terminal #2).
· Specification: Refer to
the table. Faulty ambient
NO temperature sensor.

Specification of Ambient Temperature Sensor

Ambient Resistance (kΩ)
Temperature
(°C)
-20 16.2±1.6
0 (5.88)
20 2.45±0.24
40 (1.14)
60 (0.534)
80 0.322

Connector (Harness end of connector viewed from the open end side)

DLU2
Connector DLU2-A

#4
Ambient Temperature Sensor

1 2

T18E-05-06-008
#23

T5-5-103
 TROUBLESHOOTING / Troubleshooting A
WHEN SATELLITE COMMUNICATION
TEST IS NG (FAILED)
Connector (Harness end of connector viewed from
the open end side)
• Check the communication line.
1. Check for continuity between terminal #28 of
harness end connector DLU2-B in DLU2 and DLU2
Connector DLU2-B
terminal #10 of harness end connector A in the
satellite communication terminal. #29
2. Check for continuity between terminal #29 of #28
harness end connector DLU2-B in DLU2 and #27
terminal #20 of harness end connector A in the
satellite communication terminal.
T18E-05-04-003
3. Check for continuity between terminal #27 of
harness end connector DLU2-B in DLU2 and Satellite Communication Terminal
terminal #2 of harness end connector B in the Connector A
#2
satellite communication terminal.
#10 #1
10 9 8 7 6 5 4 3 2 1
• Check the power source line of the satellite 20 19 18 17 16 15 14 13 12 11
communication terminal. #11
1. Check the battery power.
Check if voltage between terminal #2 of harness
end connector A in the satellite communication
terminal and body is 24 V.
2. Check the main power. Satellite Communication Terminal
Connector B
With the key switch ON, check if voltage between #2
terminal #1 of harness end connector A in the
satellite communication terminal and body is 24 V. 8 7 6 5 4 3 2 1
3. Check the ground circuit. 16 15 14 13 12 11 10 9
Check for continuity between terminals #11 and
#12 of harness end connector A in the satellite
communication terminal.

T5-5-104
 TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
(Machine Diagnosis by Using Trouble
Symptom)

Refer to troubleshooting B for diagnosis by using On the front section pages of this group are the tables
trouble symptom. Apply troubleshooting B procedure indicating the relationship between machine trouble
when no fault code is displayed on the service menu symptoms and related parts which may cause such
(built-in diagnosing system) in monitor unit and the trouble if failed.
diagnosing by Dr. ZX although the machine operation Start the troubleshooting with more probable causes
is abnormal. When the fault code is displayed, refer to selected by referring to these tables.
the troubleshooting A group and diagnose.

z How to Read the Troubleshoting Flow Charts

YES(OK)
(2)

・ (1) After checking or measuring item (1), select either YES (OK) 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 10) in this section.

・ Use the service menu in monitor unit (Built-in diagnosing system) or 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: Harness end connector viewed from the

open end side by the all connectors image
shown in this section.

Harness End
Connector Harness

Open End T6L4-05-03-001

Side

T5-6-1
 TROUBLESHOOTING / Troubleshooting B
CORRELATION BETWEEN TROUBLE
SYMPTOMS AND PART FAILURES
This table indicates the relationship between machine
troubles and parts contributing to the cause of the
trouble if failed.
Engine System Troubleshooting
E-1 E-2 E-3 E-4
Trouble Symptom Starter does not rotate. Even if starter rotates, Even if engine control HP mode is faulty.
engine does not start. dial is rotated, engine
speed does not change.
Engine speed fluctuates.

Parts

MC(Main) { z
ECM z z {
Starter Cut Relay z
Pilot Shut-Off Switch z
Engine Stop Switch z
Key Switch z
Engine Control Dial z
Auto-Idle Switch
Power Mode Switch z
Battery Relay 1 z
Battery Relay 2 z
Starter Relay 2-1 z
Starter Relay 2-2 z
Engine Electrical Equipment z {
Engine Unit z z z
Check batteries. Check fuel system. (filter Open circuit in harness. Faulty harness.
and piping) (Loose and
disconnection of
Remark
connector)

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.

T5-6-2
 TROUBLESHOOTING / Troubleshooting B

E-5 E-6 E-7 E-8

P mode is faulty. E mode is faulty. Auto-idle system is faulty. Even if key switch is
turned OFF, engine does
not stop.

z z z
{ { { z

z
z
z
z z {

Faulty harness. Faulty harness. Check pilot pressure

sensor.

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 in each trouble symptom.

T5-6-3
 TROUBLESHOOTING / Troubleshooting B

E-9 E-10
Trouble Symptom Engine stalls during Engine is difficult to start
operation under at low temperature.
adverse condition
such as at high
Parts altitude.

MC (Main) z
ECM { z
Pump 1 Delivery Pressure Sensor {
Pump 2 Delivery Pressure Sensor {
Pump 3 Delivery Pressure Sensor {
Pump 1 Regulator Pressure Sensor {
Pump 2 Regulator Pressure Sensor {
Pump 3 Regulator Pressure Sensor {
Pump 1 Control Solenoid Valve {
Pump 2 Control Solenoid Valve {
Pump 3 Control Solenoid Valve {
Pump Regulator z
Preheat Signal Relay z
Preheat Relay 1 z
Preheat Relay 2 z
Air Heater 1 z
Air Heater 2 z
Check fuel system for
clogging.

Remark

z: Related, required to check NOTE: The trouble symptoms in this table are
{: Related. However, in case this component fails, described provided that each trouble
other trouble symptom will be more noticeable so occurs independently.
that this component will not be the direct cause of In case more than one trouble occurs at
the trouble concerned. the same time, find out all faulty
components while checking all suspected
components in each trouble symptom.

T5-6-4
 TROUBLESHOOTING / Troubleshooting B

All Actuator System Troubleshooting

A-1 A-2 A-3 A-4
Trouble Symptom All actuators are not All actuator speeds are Actuator does not stop Actuator speed is faster
operated. slow. even if control lever is than normal.
turned to neutral. Machine mistracks when
travel lever is operated
Parts at half stroke.
Precise control cannot
be performed.

MC (Main) z z
ECM {
Monitor Unit {
Pilot Shut-Off Relay z
Security Relay {
Main Relief Valve z
Main Pump {
Main Pump Regulator {
Pilot Pump z
Pilot Relief Valve z
Pilot Shut-Off Switch {
Pilot Shut-Off Solenoid Valve z
Pump 1 Control Solenoid Valve { z
Pump 2 Control Solenoid Valve { z
Pump 3 Control Solenoid Valve { z
Pump 1 Regulator Pressure
{ z
Sensor
Pump 2 Regulator Pressure
{ z
Sensor
Pump 3 Regulator Pressure
{ z
Sensor
Pump 1 Delivery Pressure Sensor { z
Pump 2 Delivery Pressure Sensor {
Pump 3 Delivery Pressure Sensor { z
Control Valve z
Pilot Valve z
Refer to F-1.

Remark

z: Related, required to check NOTE: The trouble symptoms in this table are
{: Related. However, in case this component fails, described provided that each trouble
other trouble symptom will be more noticeable so occurs independently.
that this component will not be the direct cause of In case more than one trouble occurs at
the trouble concerned. the same time, find out all faulty
components while checking all suspected
components in each trouble symptom.

T5-6-5
 TROUBLESHOOTING / Troubleshooting B

A-5 A-6 A-7 A-8

Trouble Symptom Fan rotation speed is Overheating occurs. When operating Attachment operating
remains unchanged at Fan rotation speed is attachment, specified speed is too slow.
maximum. slow. pump 1 flow rate is not
obtained.
Parts

MC (Main) { { z z
MC (Sub) z z
ECM {
Monitor Unit z z
Fan Pump z z
Fan Pump Regulator z z
Pump 1 Regulator Pressure
z
Sensor
Pump 2 Regulator Pressure
Sensor
Pump 1 Control Solenoid Valve z
Pump 2 Control Solenoid Valve
Fan Pump Control Solenoid
z z
Valve
Pilot Pump {
Pressure Sensor (Auxiliary) z
Engine Control Dial {
Hydraulic Oil Temperature
{
Sensor
Intake-Air Temperature Sensor {
Boost Temperature Sensor {
Coolant Temperature Sensor {
Control Valve z
Fan Motor z
Fan Relief Valve z
Pilot Valve z
Oil Cooler Bypass Check Valve z
Refer to A-2. Refer to A-2.
Remark

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.

T5-6-6
 TROUBLESHOOTING / Troubleshooting B

A-9
Overheating occurs
easily when operating
breaker.

Refer to A-4 and A-8.

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 in each trouble symptom.

T5-6-7
 TROUBLESHOOTING / Troubleshooting B
Front Attachment System Troubleshooting

F-1 F-2 F-3 F-4

Trouble Symptom
All front attachment Even if heavy lift is Some cylinders are not Arm or bucket is slow
actuator power are turned ON, power does operated or speeds during combined
weak. not increase. Boom are slow. operation of boom
raise power is weak lower and arm, or
during digging boom lower and
Parts
operation. bucket.

MC (Main) z
Pressure Sensor (Boom Lower) z
Pressure Sensor (Arm Roll-Out) {
Pressure Sensor (Arm Roll-In) {
Pressure Sensor (Bucket Roll-Out) {
Pressure Sensor (Bucket Roll-In) {
Solenoid Valve Unit (SG) z
Solenoid Valve Unit (SF) z
Solenoid Valve Unit (SC)
Heavy Lift Switch z
Boom Mode Switch
Control Valve z
Main Relief Valve z z
Overload Relief Valve { z
Boom Overload Relief Selection Valve
Load Check Valve
Anti-Drift Valve
Boom Flow Rate Control Valve z
Arm Flow Rate Control Valve
Boom Regenerative Valve {
Arm Regenerative Valve
Shockless Valve (Signal Control Valve) {
Arm Flow Rate Control Valve Control
Spool
Shuttle Valve z
Pilot Valve z {
Shockless Valve {
Cylinder
Refer to A-1 and A-2. Refer to F-6.
Remark

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.

T5-6-8
 TROUBLESHOOTING / Troubleshooting B

F-5 F-6 F-7 F-8

Boom raise speed is slow, Even if boom mode switch When boom raise or arm Front attachment drifts
during arm level crowding is pushed, machine is roll-out is operated, boom remarkably.
operation (combined raised. or arm starts to move after
operation of boom raise moving slightly downward.
and arm roll-in). Arm does
not move smoothly.

z
z z z

z
z

z
{

{
{
{
z z

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 in each trouble symptom.

T5-6-9
 TROUBLESHOOTING / Troubleshooting B

Swing/Travel System Troubleshooting

S-1 S-2 T-1 T-2
Trouble Symptom Swing is slow Swing is fast. Both right and left One side track does
or unmoving. When swing is tracks do not rotate or not rotate or rotates
operated fully, swing is rotate slowly. slowly. Machine
Parts slow. mistracks.

MC (Main) z { {
Pressure Sensor (Swing) z
Pressure Sensor (Travel (Right)) { {
Pressure Sensor (Travel (Left)) { {
Solenoid Valve Unit (SI) { {
Pump 1 Delivery Pressure Sensor {
Pump 2 Delivery Pressure Sensor {
Pump 3 Delivery Pressure Sensor {
Pump 1 Regulator Pressure Sensor { {
Pump 2 Regulator Pressure Sensor { {
Pump 3 Regulator Pressure Sensor {
Pump 1 Control Solenoid Valve {
Pump 2 Control Solenoid Valve {
Pump 3 Control Solenoid Valve {
Main Pump {
Pilot Pump z
Pilot Relief Valve z {
Control Valve z { {
Main Relief Valve z {
Load Check Valve {
Flow Combiner Valve
Pilot Valve z { z
Swing Device z
Travel Device { z
Center Joint z
Flow Combiner Valve Control Spool
Swing Parking Brake Release Spool z
Shuttle Valve z {
Travel Mode Switch
Refer to A-1 and A-2. Refer to A-1, F-2, and
Remark T-4.

T5-6-10
 TROUBLESHOOTING / Troubleshooting B

T-3 T-4
Machine mistracks during Fast travel is not selected.
combined operation of Travel mode does not
travel and front change from slow mode
attachment. to fast mode.

z
{
{
{
{
{
{
{
{
{

z
z

z
z
z

z: Related, required to check NOTE: The trouble symptoms in this table are
{: Related. However, in case this component fails, described provided that each trouble
other trouble symptom will be more noticeable so occurs independently
that this component will not be the direct cause In case more than one trouble occurs at
of the trouble concerned. the same time, find out all faulty
components while checking all suspected
components in each trouble symptom.

T5-6-11
 TROUBLESHOOTING / Troubleshooting B

Other System Troubleshooting

O-1 O-2 O-3 O-4
Trouble Symptom Wiper is not operated. Washer is not Auto-lubrication is Level check is faulty.
operated. faulty.

Parts

MC (Main) z z
MC (Sub) z z
Monitor Unit { z
Wiper Relay z
Washer Relay z
Auto-Lubrication Relay z
Fan Pump Control Solenoid Valve
Auto-Lubrication Device z
Engine Oil Level Switch {
Coolant Level Switch {
Wiper/Washer Switch z z
Level Check Switch z
Lubrication Selection Switch z
Wiper Motor z
Washer Motor z
Air Conditioner
Fan Pump
Step Light Switch
Step Light Relay
Step Light
Distribution Valve z

Remark

T5-6-12
 TROUBLESHOOTING / Troubleshooting B

O-5 O-6 z: Related, required to check

{: Related. However, in case this component fails,
Step light does not light. Air Conditioner is faulty.
other trouble symptom will be more noticeable so
that this component will not be the direct cause
of the trouble concerned.

NOTE: The trouble symptoms in this table are

described provided that each trouble
{
occurs independently
In case more than one trouble occurs at
z
the same time, find out all faulty
components while checking all suspected
components in each trouble symptom.

z
z
z
z
z

T5-6-13
 TROUBLESHOOTING / Troubleshooting B
ENGINE SYSTEM TROUBLESHOOTING
E-1 Starter does not rotate.

IMPORTANT: As electric current from the key

switch is not routed to starter relay
with the pilot shut-off lever in the
UNLOCK position, the starter does
not rotate. (Refer to Electrical
System.)

• This trouble has nothing to do with the

electronic control system such as MC.
YES Faulty starter cut
• Check the wiring connections first.
relay.
Switch starter cut
relay with other Disconnect starter
YES general relay. cut relay.
Check if starter Check if voltage at
rotates. terminal #3 of
NO harness end
Check if voltage at · Key switch: START connector is 24 V.
terminals #5 and #6 in
YES · Key switch: START.
key switch are 24 V.
YES
· Key switch: START Faulty key switch.

Check if battery Check for continuity

voltage and between battery
NO positive terminal and Faulty harness
electrolyte density is
normal, and fusible terminal #1 in key NO between battery
link is not blown. switch. and key switch.
· Voltage: 24 V or more
Density: 1.26 or more
Faulty battery or
faulty fusible link.
NO

Battery Relay: Terminal B

Key Switch:

T178-05-04-001

T105-07-04-002

T5-6-14
 TROUBLESHOOTING / Troubleshooting B

Faulty starter, or
YES faulty harness
between starter and
Check if voltage at battery relay.
NO terminal B in battery
relay is 24 V.
Check if voltage at
terminal #2 of · Key switch: ON Faulty battery relay.
YES harness end NO
connector in starter
Disconnect connector cut relay is 0 V.
Shorted circuit in
of starter relay 2.
· Key switch: START harness between
Connect terminal #1 of
starter cut relay and
YES harness end connector YES pilot shut-off switch,
to body. Check for
or faulty pilot
continuity between
shut-off switch.
terminal #4 of harness
end connector in
starter cut relay and Open circuit in
body. harness between
NO starter cut relay and
starter relay 2.

Open circuit in
harness between
NO key switch and
starter cut relay.

Connector (Harness end of connector viewed from the

open end side)

Starter Cut Relay

Starter Relay 2

T18E-05-05-002

T18J-05-08-001

T5-6-15
 TROUBLESHOOTING / Troubleshooting B
E-2 Even if starter rotates, engine does not start.

Faulty engine (Refer

NO to Engine Manual.)
YES Check if fuel line is
Disconnect filled with air.
connector
ECM-31P. Bleed air from fuel
YES Check if voltage at injection pump.
terminal #1 of YES
harness end
connector is 24 V.
· Key switch: ON Faulty harness
Disconnect YES between fuse box
connector and ECM or faulty
ECM-21P. engine stop switch.
Check if voltage at Check if voltage at
terminals #G and NO fuse #32 is 24V.
#D of harness end · Key switch: ON
connector are 24 Faulty harness
V. between fuse box
NO and key switch.

· Key switch: OFF

Faulty harness
YES between fuse box
and ECM.

Check if voltage at
fuse #21 is 24V.
NO
Faulty harness
between fuse box
NO and battery.

Connector (Harness end of connector viewed from the

open end side)
Connector ECM-21P Connector ECM-31P
#G
#1

#D
T18E-05-05-005 T18E-05-04-004

T5-6-16
 TROUBLESHOOTING / Troubleshooting B
E-3 Even if engine control dial is rotated,
engine speed does not change.
Engine speed fluctuates.

Reference
Related Fault Code Trouble
Page
11101 Abnormal engine control dial T5-5-51
MC
Accelerator pedal position reception
(Main) 11964 T5-5-66
failure

• When the harness is likely to open the circuit between the engine control dial and ECM, the symptom that
engine speed increases and decreases occurs.
• Check the wiring connections first.
Faulty engine control
dial, or open circuit in
YES 5V power source
harness between
engine control dial and
ECM.

Check if fault code 11101-3 or

11101-4 is displayed. YES Faulty harness
Monitor standard voltage (Dial Check if harness between ECM and
angle) of engine control dial by between terminal #5 engine control dial.
using Dr. ZX. of harness end
Check if voltage is abnormal. YES
connector ECM-31P
in ECM and terminal
· Standard voltage
Check if fault code #2 in switch panel is Faulty ECM.
Slow idle position: 0.3 to 1.0 V
11964-2 is displayed at open or shorted.
Fast idle position: 4.0 to 4.7 V NO
· Possible to display by using NO the same time.
built-in diagnosing system.
· Possible to display by
using built-in Faulty engine.
diagnosing system.
NO

Connector (Harness end of connector viewed from the

open end side)
ECM Connector ECM-31P Switch Panel

#5 ●

#2

T18J-05-07-002

T5-6-17
 TROUBLESHOOTING / Troubleshooting B
E-4 HP mode is faulty.
When the engine control dial is fully rotated in the
HP mode, engine speed is slow.

• Check the wiring connections first.

YES Faulty MC (Main).

Monitor by using Dr. ZX.

Monitor HP mode YES Check if either one of travel/P
switch. speed control or E mode
Check if HP mode speed control is turned ON.
switch indication is Faulty ECM or faulty
ON (outline · Monitor item:
Travel/P speed control, NO engine.
character) when
power mode switch E mode speed control
is turned to HP · Power mode switch:
mode. HP mode

Faulty power mode

· Monitor item: switch or open circuit
HP mode SW in harness between
· Power mode switch: NO power mode switch
HP mode and MC (Main).

T5-6-18
 TROUBLESHOOTING / Troubleshooting B
Even if the power mode switch is not turned to HP
mode, HP mode is selected.

Shorted circuit in
YES harness between
MC (Main) and
power mode switch.

Monitor power mode

switch.
Check if HP mode Monitor by using Dr.
switch indication is ON ZX.
(outline character). Check if travel / P YES Faulty ECM.
speed control is ON
· Monitor item:
indication when
HP mode SW
power mode switch is
· Power mode switch:
turned to P mode.
P mode NO Check if E speed
control is ON
indication when
Faulty MC (Main).
power mode switch is
turned to E mode. NO

· Monitor item:
Travel/P speed control,
E mode speed control
· Power mode switch:
P mode or
E mode

T5-6-19
 TROUBLESHOOTING / Troubleshooting B
E-5 P mode is faulty.

When the engine control dial is at the maximum

position, even if the power mode switch is turned to
P mode, engine speed does not change. (Engine
speed does not decrease.)

Check for YES Faulty ECM.

continuity between
terminal #A26 of
harness end
connector MC
YES (Main)-A in MC
(Main) and
Monitor travel/P terminal #21 of
mode speed control. harness end
Check if travel/P Open circuit in
connector harness between
speed control is ON ECM-31P in ECM. NO MC (Main) and ECM.
YES indication (outline
character).
Monitor E/P mode
switch. · Monitor item:
Turn power mode Travel/P speed control
switch to P mode. · Power mode switch: Faulty MC (Main).
Check if E/P mode P mode NO
switch indication is
P.

· Monitor item:
E/P mode SW
· Power mode switch: Faulty power mode
P mode switch, or shorted
circuit in harness
between MC (Main)
NO and power mode
switch.

Connector (Harness end of connector viewed from the

open end side)

Connector MC-A ECM

Connector ECM-31P

#21

#A26 T183-05-04-008

T18J-05-07-002

T5-6-20
 TROUBLESHOOTING / Troubleshooting B
E-6 E mode is faulty.

When the engine control dial is at the maximum

position, even if the power mode switch is turned to
E mode, engine speed does not change. (Engine
speed does not decrease.)

Check for YES Faulty ECM.

continuity between
terminal #A27 of
harness end
connector MC
YES (Main)-A in MC
(Main) and
terminal #19 of
harness end Open circuit in
Monitor E mode
connector harness between
speed control.
Check if E mode ECM-31P in ECM. NO MC (Main) and ECM.
YES
speed control is ON
indication (outline
character).

· Monitor item:
Monitor E/P mode Faulty MC (Main).
E mode speed control
switch. · Power mode switch: NO
Turn power mode E mode
switch to E mode.
Check if E/P mode
switch indication is
E.
· Monitor item:
Faulty power mode
E/P mode SW
switch, or open circuit
· Power mode switch:
in harness between
E mode NO MC (Main) and power
mode switch.

Connector (Harness end of connector viewed from the

open end side)

Connector MC-A ECM

Connector ECM-31P

#19

#A27 T183-05-04-008

T18J-05-07-002

T5-6-21
 TROUBLESHOOTING / Troubleshooting B
Even if the power mode switch is not turned to E
mode, E mode is selected.

Shorted circuit in harness

between MC (Main) and
YES
power mode switch, or
faulty power mode switch.

Monitor power mode

switch.
Check if E/P mode
switch indication is E. YES Faulty MC (Main).
Monitor E mode
· Monitor item: speed control.
E/P mode SW Check if E mode
· Power mode switch: speed control is
P mode NO displayed ON
indication.
· Monitor item: Faulty ECM.
E mode speed control NO
· Power mode switch:
P mode

T5-6-22
 TROUBLESHOOTING / Troubleshooting B
E-7 Auto-idle system is faulty.
Even if the control lever is turned to neutral,
auto-idle system is not operated.

• In case trouble symptoms such as E1 to E6 occur, • Refer to SYSTEM / Control System / Auto-Idle
perform troubleshooting of these troubles first. Control in T/M (Operational Principle).
• Even if failure in each pilot pressure sensor may • Check the wiring connections first.
have relevance to malfunction of the auto-idle
control, if these sensors fail, other operating
functions will also be affected. Check for continuity
between terminal YES Faulty ECM.
#B23 of harness end
YES connector MC
(Main)-B in MC
(Main) and terminal
#20 of harness end
connector ECM-31P Open circuit in
Monitor by using Dr. in ECM. harness between
NO MC (Main) and ECM.
YES ZX.
Check if auto-idle
speed control is ON.
· Monitor item:
Monitor by using Dr. Auto-idle speed
ZX. Faulty MC (Main).
control
Check if ON/OFF in · Auto-idle switch: ON NO
auto-idle SW is · Do not operate the
shifted when control lever for three
auto-idle switch is seconds or more.
shifted.
Open circuit in
· Monitor item: YES harness between
Auto-idle SW
auto-idle switch and
MC (Main).
Check if auto-idle
indication is
NO displayed on monitor
unit.
Faulty auto-idle
· Auto-idle switch: ON switch.
NO

Connector (Harness end of connector viewed from the

open end side)
ECM
Connector MC-B Connector ECM-31P

#20

#B23 T183-05-04-021

T18J-05-07-002

T5-6-23
 TROUBLESHOOTING / Troubleshooting B
Even if the auto-idle switch is in the OFF position,
auto-idle system is operated.

Shorted circuit in
harness between MC
YES (Main) and auto-idle
Disconnect connector MC-B in
MC (Main) and connector of switch.
switch panel.
Check for continuity between
terminal #B13 of harness end
connector MC-B and body.

Faulty MC (Main).
· Auto-idle switch: OFF NO

Connector (Harness end of connector viewed from the

open end side)

Connector MC-B

B1 B8

B19 B25
#B13

T5-6-24
 TROUBLESHOOTING / Troubleshooting B
E-8 Even if the key switch is turned OFF, engine
does not stop.
(If the engine does not stop, stop the engine
by turning the engine stop switch to the
STOP position located in the utility cover.
Then, start inspection.)

• The symptoms such as “Engine speed is slower

than specification in all operating ranges” or
“Even if engine control dial is rotated, engine
speed remains unchanged” may occur. Perform
troubleshooting for these symptoms.

YES Faulty key switch.

Check if voltage at
terminal #5 in key
switch is 24 V.
NO Shorted circuit in
Key switch: OFF harness between key
Disconnect switch and ECM.
connector ECM -31P.
Check if voltage
NO between terminal #1
of harness end
connector and body
Faulty ECM.
is 0 V.
YES
Key switch: OFF

Key Switch: Connector (Harness end of connector viewed from the

open end side)

Connector ECM-31P #1

T18J-05-07-002

T105-07-04-002

T5-6-25
 TROUBLESHOOTING / Troubleshooting B
E-9 Engine stalls during operation under
adverse condition such as at high altitude.

Reference
Related Fault Code Trouble
Page
11004 Abnormal CAN communication T5-5-27
Abnormal pump 1 delivery pressure
11200 T5-5-52
sensor
Abnormal pump 2 delivery pressure
11202 T5-5-53
sensor
Abnormal pump 3 delivery pressure
11203 T5-5-54
sensor
Abnormal pump 2 control solenoid
11400 T5-5-58
valve circuit
MC
Abnormal pump 1 control solenoid
(Main) 11410 T5-5-62
valve circuit
Abnormal pump 3 regulator pressure
11969 T5-5-71
sensor
Abnormal pump 3 control solenoid
11970 T5-5-72
valve circuit
Abnormal pump 2 regulator pressure
11992 T5-5-75
sensor
Abnormal pump 1 regulator pressure
11994 T5-5-77
sensor

• If speed sensing control is not operated, the

engine will stall under adverse operating
condition.
• As the pump control solenoid valve, the pump
regulator pressure sensor, and the regulator are 3
used for each, all may not become faulty at the
same time.
Or, if one is faulty, the machine mistracks.
• Check the wiring connections first.

Faulty MC (Main) or faulty

NO adjustment of regulator.

Measure pump flow rate. · Refer to OPERATIONAL

Check if pump P-Q curve is PERFORMANCE TEST.
normal.

· Refer to OPERATIONAL
PERFORMANCE TEST.
Faulty engine unit.
YES
· Refer to Engine
Troubleshooting Manual.

T5-6-26
 TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-6-27
 TROUBLESHOOTING / Troubleshooting B
E-10 Engine is difficult to start at low
temperature.

• The troubleshooting when the air heater cannot • When preheating once and operating again, turn
be operated in the engine is explained here. the key switch OFF and preheat again in five
• The preheating function is operated only when minutes. (Even if preheating within five minutes,
temperature in the engine intake line is 0°C or the preheating function is not operated.)
less. • The preheating function is automatically
completed in 30 seconds.

YES Faulty preheat signal

Check if voltage relay.
YES at terminal #5 in
preheat signal
Check if voltage
relay is 24 V.
at terminal #3 of
YES harness end · Key switch: ON
(A)
connector in NO
preheat signal
relay is 24V. Faulty harness
Check for between battery and
continuity · Key switch: ON
preheat signal relay,
between terminal NO or faulty fusible link 4.
YES #2 of harness
end connector in
preheat signal
relay and body.
Disconnect
preheat signal Faulty ground of
relay connector. terminal #2 in preheat
Check if voltage signal relay.
NO
at terminal #1 of
harness end
connector is 24
V. Faulty harness
YES
between ECM and
· Key switch: ON Disconnect preheat signal relay.
connector
ECM-2P.
NO Check if voltage
at terminal #1 is
24 V. Faulty ECM.
NO
· Key switch: ON

Connector (Harness end of connector viewed from the

open end side)
Preheat Signal Relay Connector ECM-2P
Connector

3 5
T146-05-04-009 T18E-05-05-002

T5-6-28
 TROUBLESHOOTING / Troubleshooting B

YES
(B)
Check if voltage
YES at terminal M10
(air heater end) in
Check if voltage preheat relay is
at terminal M10 Faulty preheat
YES (black line) of 24V. relay.
NO
harness end in · Key switch: ON
preheat relay is Faulty harness
Check for
24V. between preheat
continuity
YES relay and battery,
between ground
circuit in preheat NO or faulty fusible link
relay and body. 7 or 8.
Check if voltage
at terminal M5
(A) (white line) of Faulty ground in
harness end in preheat relay.
preheat relay is NO
24V.
· Key switch: ON

Faulty harness
between preheat
NO signal relay and
preheat relay.

YES Faulty air heater.

Check for
continuity
(B) between preheat
relay and air
heater. Faulty harness
between preheat
· Key switch: ON NO relay and air
heater.

T5-6-29
 TROUBLESHOOTING / Troubleshooting B
ALL ACTUATOR SYSTEM
TROUBLESHOOTING
A-1 All actuators are not operated.

• Check the wiring connections first.

YES Faulty pilot shut-off

relay.

Switch pilot shut-off

YES relay with other
general relay.
Check if fault code YES
is improved. Faulty security relay.
Switch security
relay with other
general relay. Disconnect
NO Check if fault code connector of pilot
is improved. shut-off solenoid
valve. A
Monitor pilot shut-off NO
Check if voltage at
switch. terminal #1 of
Check if ON is harness end
changed. connector is 24 V.

· Monitor item (MC): · Key switch: ON

Gate lock SW
· Pilot shut-off lever:
Faulty pilot shut-off
UNLOCK NO switch.

YES Faulty monitor unit.

Disconnect connector
YES of pilot shut-off
solenoid valve.
Check for continuity
between terminals #1 Faulty pilot shut-off
and #2 of solenoid NO solenoid valve.
valve end connector.
A
Faulty fuse #5, or
open circuit in harness
between fusible link #3
NO and pilot shut-off
solenoid valve.

Connector (Harness end of connector viewed from the

open end side)
Pilot Shut-Off Solenoid Pilot Shut-Off Solenoid
Valve Valve (Solenoid Valve End)

T183-05-04-010 T1J1-05-07-006

T5-6-30
 TROUBLESHOOTING / Troubleshooting B
A-2 All actuator speeds are slow.

• Reduction in pump 1, 2, and 3 flow rate due to

some reasons or faulty pilot system may cause
this trouble.
• Even if speed is satisfactory, in case power is
weak, refer to all front attachment actuator power
are weak (F-1).
• Check the wiring connections first.

YES Faulty pilot pump or

Check if same clogged pilot filter.
symptom still
appears after
NO
disassembling,
cleaning, and
adjusting pilot relief End.
valve.
NO

Check if primary
pilot pressure is
normal. Refer to Engine
YES Troubleshooting
· Specification: Manual.
Refer to OPERATIONAL
PERFORMANCE TEST.
Fully boom raised or arm Monitor actual
roll-in engine speed.
· Monitor item: Check if abnormal NO Faulty main relief
Boom raise pilot YES
speed is indicated. valve.
pressure, arm roll-in pilot
pressure
· Monitor item: Check if main relief
Actual engine speed NO pressure is normal.
· Possible to display by
· Refer to
using built-in
OPERATIONAL
diagnosing system Faulty pump
PERFORMANCE
TEST for pressure YES device.
measurement
procedure.

T5-6-31
 TROUBLESHOOTING / Troubleshooting B
A-3 Actuator does not stop even if control
lever is returned to neutral.

• Stuck spool in the pilot valve or stuck main spool

in the control valve is suspected.

YES Faulty pilot valve.

· When control lever is in

Check if actuator stops when neutral, pilot pressure is
raising the pilot shut-off lever. routed to spool end in control
valve.
Faulty control valve.
NO
· Even if pilot pressure is not
routed to spool end in control
valve, spool is kept opened
due to binding of spool.

A-4 Actuator speed is faster than normal.

Machine mistracks when travel lever is
operated at half stroke.
Precise control cannot be performed.

• The pump 1, pump 2, or pump 3 flow rate is

maximized due to some reasons.
• If the fault code is not displayed, the pump device
may be faulty.
If the fault code is displayed, refer to
Troubleshooting A.

T5-6-32
 TROUBLESHOOTING / Troubleshooting B
A-5 Fan rotation speed remains unchanged
at maximum.

• Check if the fault code is not displayed first.

• If the sensor corresponding to fan pump flow rate
control is abnormal, fan rotation speed becomes
maximum.
• If all actuator speeds are slow, refer to A-2.

YES Faulty fan pump or faulty

Install a pressure fan pump regulator.
gauge to port Pr in
fan pump
regulator.
When following
conditions exist,
check if pressure is Faulty fan pump control
changed. NO solenoid valve (stuck).

· Air conditioner switch:

ON
· Engine control dial:
Slow→Fast

T5-6-33
 TROUBLESHOOTING / Troubleshooting B
A-6 Overheating occurs.
Fan rotation speed is slow.

Related Fault Code Trouble Reference

Page
Abnormal CAN
11004 T5-5-27
communication
MC (Main)
Abnormal hydraulic oil
11901 T5-5-64
temperature sensor 1
Abnormal fan pump control
15992 T5-5-89
solenoid valve
MC (Sub)
Abnormal hydraulic oil
15993 T5-5-90
temperature sensor 2

• Check the wiring connections first.

YES Faulty oil cooler

bypass check valve or
faulty MC (Sub).

Disconnect
connector of fan
control solenoid
valve.
YES Faulty fan pump
Check if fan
rotation speed control solenoid valve
becomes fast. (stuck).

Install a pressure
gauge to port Pr in
YES Faulty fan pump or
NO fan pump regulator.
faulty fan pump
Check if pressure at
regulator.
port Pr is 3.9 MPa
(40 kgf/cm2, 570 psi). Measure drain
amount of fan
· Engine control dial: motor.
Fast NO
Check if drain
amount is normal.
Faulty fan motor.
NO

T5-6-34
 TROUBLESHOOTING / Troubleshooting B
A-7 When operating attachment, specified
pump 1 flow rate is not obtained.

Reference
Related Fault Code Trouble
Page
11004 Abnormal can communication T5-5-27
Abnormal pump 1 control
11410 T5-5-62
MC solenoid valve
(Main) 11918 Work mode reception failure T5-5-66
Abnormal pump 1 regulator
11994 T5-5-77
pressure sensor

• Even if the front attachment is operated with the

work mode in digging, pump 1 flow rate is remains
minimum.
• Check the wiring connections first.

YES Refer to
Troubleshooting A.

Check if fault code

is displayed. YES
Faulty monitor unit.

Check if track
revolution
NO speed of travel
(left) is within
specification. Faulty MC (Main).
NO
· Refer to
OPERATIONAL
PERFORMANCE
TEST.

T5-6-35
 TROUBLESHOOTING / Troubleshooting B
A-8 Attachment operating speed is too slow.

• If all actuator speed are slow, refer to A-2.

• Even if the front attachment is operated with the
work mode in digging, pump 1 flow rate is remains
minimum.
• Check the wiring connections first.

YES Faulty control valve

spool.
Check if auxiliary
YES spool in control
valve is stuck or
seized.
Monitor ATT pilot Faulty MC (Main) or
pressure. NO faulty monitor unit.
Check if pressure is
within specification.

· Possible to display by
using built-in Faulty pilot valve.
diagnosing system. NO
· Engine control dial:
Fast
· Control pedal:
Full stroke

T5-6-36
 TROUBLESHOOTING / Troubleshooting B
A-9 Overheating occurs easily when operating
breaker.

Reference
Related Fault Code Trouble
Page
Abnormal pump 2 control solenoid
11400 T5-5-58
valve
MC
11918 Work mode reception failure T5-5-66
(Main)
Abnormal pump 2 regulator
11992 T5-5-75
pressure sensor

• If overheating occurs when operating except the

breaker, refer to A-6.
• Check the wiring connections first.

YES Faulty pump 2 or faulty

pump 2 regulator.
Monitor target pump 2
flow rate.
Select attachment
mode (breaker) in work
mode.
Check if flow rate
increases.
· Monitor item: Pump 2 Faulty MC (Main).
NO
target flow rate
· Attachment operation

T5-6-37
 TROUBLESHOOTING / Troubleshooting B
FRONT ATTACHMENT SYSTEM
TROUBLESHOOTING
F-1 All front attachment actuator power are
weak.

• If operating speeds are extremely slow, pump

control may be faulty (A-1, A-2). Faulty pilot
system may also cause this trouble.

31.9 to 34.3 MPa Main relief valve is normal.

(325 to 350 kgf/cm2, 4640 to 4990 psi) Find out cause of trouble by
tracing other trouble
symptoms.
Monitor pump 1, 2, and 3
delivery pressure.
Adjust main relief valve.
· Monitor item:
Pump 1, 2, and 3 delivery pressure 31.9 MPa
· Possible to display by using built-in (325 kgf/cm2, 4640 psi)
diagnosing system
· Relieve boom, arm, and bucket
circuits.
· Power mode switch: HP
· Work mode: Digging

T5-6-38
 TROUBLESHOOTING / Troubleshooting B
F-2 Even if heavy lift is turned ON, power does
not increase.
Boom raise power is weak during digging
operation.

Reference
Related Fault Code Trouble
Page
MC
11404 Abnormal solenoid valve unit (SG) T5-5-60
(Main)

• Refer to SYSTEM / Control System / Heavy Lift

Control in T/M (Operational Principle).

YES Refer to
Troubleshooting A.

Faulty heavy lift

Check if fault code
switch, or open
is displayed.
Monitor heavy lift NO circuit in harness
switch. between heavy lift
Check if Disp (outline switch and MC
character) is (Main).
displayed when
NO pushing heavy lift
switch. Monitor main relief YES Faulty main relief
control pressure. valve.
· Monitor item: Check if pressure is
Heavy lift SW approx. 3.9 MPa.
YES
· Monitor item: Faulty MC (Main).
Power Boost Control NO
Pressure
· Possible to display by
using built-in diagnosing
system

T5-6-39
 TROUBLESHOOTING / Troubleshooting B
F-3 Some cylinders are not operated or speeds
are slow.

• When other actuators (travel and swing motors)

are operated normally, the pilot pump (primary
pilot pressure) is considered to be normal.
• Refer to F-6 if boom lower is abnormal.

Stuck control valve

YES spool or faulty cylinder
(faulty seal kit).
Check if overload
YES relief pressure is
Monitor pump control normal.
pressure.
Check if pump control Faulty overload relief
YES pressure changes NO valve.
smoothly while moving
control lever slowly.
Monitor or measure
Faulty shuttle valve in
secondary pilot
· Monitor item: NO signal control valve.
pressure.
Check if secondary Pump 1 flow control
pilot pressure is pressure, pump 2 flow
normal. control pressure, pump 3
flow control pressure
· Possible to display by
· Secondary pilot using built-in diagnosing
pressure: Faulty pilot valve or
system stuck shockless valve
Refer to
OPERATIONAL NO spool (during
PERFORMANCE abnormal boom
TEST. operation).
· Monitor item:
Boom raise pilot
pressure, boom lower
pilot pressure, arm
roll-in pilot pressure,
arm roll-out pilot
pressure, bucket roll-out
pilot pressure, bucket
roll-in pilot pressure

T5-6-40
 TROUBLESHOOTING / Troubleshooting B
F-4 Arm or bucket is slow during combined
operation of boom lower and arm, or
boom lower and bucket.

Reference
Related Fault Code Trouble
Page
Abnormal arm roll-in pilot pressure
11303 T5-5-57
sensor
11402 Abnormal solenoid valve unit (SF) T5-5-59
Abnormal arm roll-out pilot pressure
11995 T5-5-78
sensor
MC
Abnormal bucket roll-out pilot pressure
(Main) 11997 T5-5-79
sensor
Abnormal boom lower pilot pressure
11998 T5-5-80
sensor
Abnormal bucket roll-in pilot pressure
11999 T5-5-81
sensor

• Refer to SYSTEM / Control System / Boom Flow

Rate Control Valve Control in T/M (Operational
Principle).

YES Refer to
Troubleshooting A.

Check if fault code

is displayed. Monitor solenoid valve
unit (SF). YES Faulty boom flow
Check if pressure is rate control valve.
approx. 3.9 MPa
NO
· Monitor item: Faulty MC (Main).
Boom flow control pressure NO
(Possible to display by
using built-in diagnosing
system)
· Combined operation of
boom lower and arm or
bucket.

T5-6-41
 TROUBLESHOOTING / Troubleshooting B
F-5 Boom raise speed is slow during arm
crowding operation (During combined
operation of boom raise and arm roll-in)
Arm does not move smoothly.

• Refer to SYSTEM / Hydraulic System in T/M

(Operational Principle).

YES Faulty arm

regenerative valve
Check if arm (switch valve).
YES regenerative valve
Install a pressure
gauge to port SK in (switch valve) is stuck
signal control valve. or seized.
Faulty arm flow rate
YES Check if pressure is NO control valve.
approx. 3.9 MPa (40
kgf/cm2, 570 psi).
· Engine control dial:
Fast Stuck arm flow rate
Measure and monitor control valve control
secondary pilot · Relieve boom raise NO
and arm roll-in. spool in signal
pressure. control valve.
· Secondary pilot
pressure: Refer to
OPERATIONAL Faulty pilot valve.
PERFORMANCE
TEST. NO
· Monitor item:
Boom raise pilot
pressure, arm roll-in
pilot pressure

Signal Control Valve

(Control Valve Side)

Port SK

T18J-05-08-002

T5-6-42
 TROUBLESHOOTING / Troubleshooting B
F-6 Even if boom mode switch is pushed,
machine is raised.

Reference
Related Fault Code Trouble
Page
MC
11989 Abnormal solenoid valve unit (SC) T5-5-73
(Main)

• Refer to SYSTEM / Control System / Boom Mode

Control in T/M (Operational Principle).
• Check the wiring connections first.

Disconnect boom mode

switch and connector MC
(Main)-B in MC (Main). YES Faulty MC (Main).
Check for continuity
NO between terminal #9 of
harness end connector in Open circuit in
Switch the boom mode boom mode switch and harness between MC
switch with level check terminal #B2 of harness (Main) and boom
NO NO
switch. end connector in MC mode switch.
Check if symptom is (Main).
Monitor boom mode improved.
switch. Faulty boom mode
Check if indication is YES switch.
ON (outline
character).

· Monitor item: NO Faulty MC (Main).

Boom mode SW Monitor solenoid valve
unit (SC).
YES Check if pressure is
approx. 3.9 MPa. Faulty boom overload
relief valve in control
· Monitor item: valve or faulty boom
YES
Boom mode control overload control valve.
pressure
· Boom mode switch:
ON
· Boom lower operation

Connector (Harness end of connector viewed from the

open end side)

Boom Mode Switch Connector MC-B

#B2
B1 B8

T1J1-05-07-003
B19 B25
#9

T5-6-43
 TROUBLESHOOTING / Troubleshooting B
F-7 When boom raise or arm roll-out is
operated, boom or arm starts to move after
moving slightly downward.

Damaged control valve spool,

NO broken spring, or loose spool
end.
YES Check if excessive
cylinder internal
leakage is found.
Faulty cylinder seal.
Check if load check YES
valve in control valve
is normal.
· Disassemble / Faulty Load check valve.
visual inspection
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 faulty,
the oil in the bottom side of the boom
cylinder flows back into the circuit through (B)
the load check valve. Therefore, the boom
cylinder is temporarily retracted. When the load check
valve is faulty: (A)
2. As oil pressure and flow rate from the
pump is low, if oil leaks from bottom side
(A) to rod side (B) due to faulty boom
cylinder piston or cylinder barrel, the boom
cylinder is temporarily retracted during the
initial stage of operation. In addition, when
cylinder force is reduced, the cylinder drift
increases in this case.
T105-07-04-012

T5-6-44
 TROUBLESHOOTING / Troubleshooting B
F-8 Front attachment drifts remarkably.

YES Faulty pilot valve.

YES Faulty corresponding

Check if cylinder drift cylinder.
is reduced when pilot
shut-off valve is YES Check if cylinder
closed. internal leakage is
found. Faulty corresponding
control valve
Check if
NO (damaged spring or
corresponding
loose spool end).
overload relief
NO pressure is normal.

· Refer to Faulty corresponding

OPERATIONAL overload relief valve.
PERFORMANCE NO
TEST for pressure
measurement
procedure.

Boom Cylinder Internal Leakage Check

1. With the bucket cylinder fully retracted and the
arm cylinder slightly extended from the fully
retracted position, lower the bucket tooth tips onto
the ground.
2. Disconnect 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 disconnected T105-07-04-009

piping ends and the boom cylinders are retracted

at this time, oil leaks in the boom cylinders. If no
oil flows out of the hose disconnected piping ends
but the boom cylinders are retracted, oil leaks in
the control valve.

T5-6-45
 TROUBLESHOOTING / Troubleshooting B
SWING SYSTEM TROUBLESHOOTING
S-1 Swing is slow or unmoving.

• Check whether the pilot system is faulty or the

main circuit is faulty.
• If other functions (front attachment and travel) are
operated normally, the pilot pump is considered to
be normal. If the pilot system is faulty, the cause
of trouble may exist in the circuit after the pilot
valve.

Install a pressure gauge to Check if swing motor

port SH. Measure parking YES parking brake release
brake release pressure. valve is stuck or seized.
Check if pressure is
YES
between 3.4 to 4.9 MPa (35
to 50 kgf/cm2, 495 to 710 Faulty swing parking
brake release valve
psi).
Monitor secondary spool in signal control
pilot pressure. · Arm relief operation NO valve.
Check if secondary
pilot pressure is
normal.
· Specification: NO Faulty pilot valve.
Refer to
OPERATIONAL Disassemble and clean
PERFORMANCE pilot valve.
TEST. NO Check if trouble occurs.
· Monitor item: Faulty swing shuttle
Swing pilot pressure YES valve.
· Possible to display by
using built-in
diagnosing system

Signal Control Valve

(Pilot Valve Side)

Port SH

T1J1-05-07-005

T5-6-46
 TROUBLESHOOTING / Troubleshooting B

YES Faulty swing reduction

gear.
Check if swing motor
YES drain oil amount is
normal.
· Measurement:
Refer to Faulty swing motor.
NO Check if swing relief OPERATIONAL NO
pressure is normal. PERFORMANCE
TEST.
· Swing relief operation
· Monitor item:
Pump 3 delivery pressure Faulty swing relief
· Possible to display by valve.
NO
using built-in diagnosing
system
· Specification:
Refer to OPERATIONAL
PERFORMANCE TEST.

Faulty swing motor

YES parking brake release
valve.

T5-6-47
 TROUBLESHOOTING / Troubleshooting B
S-2 Swing is fast.
When swing is operated fully, swing is slow.

Reference
Related Fault Code Trouble
Page
MC
11301 Abnormal swing pilot pressure sensor T5-5-55
(Main)

YES Refer to Trouble-

shooting A.
Check if fault code
is displayed.
Faulty MC (Main).
NO

T5-6-48
 TROUBLESHOOTING / Troubleshooting B
TRAVEL SYSTEM TROUBLESHOOTING
T-1 Both right and left tracks do not rotate or
rotate slowly.

• Both right and left pilot valves, travel motors,

and/or control valve spools are unlikely to be
faulty at the same time.
• If both travel systems are not operated, the pilot
system, which is applied to both side travel
motors, may be faulty. If the primary pilot pressure
is lower than specification, the front attachment
operating speed becomes slow as well. Refer to
A-1.
• If the fast travel mode cannot be selected, refer to
T-4.
• If the power is insufficient, it seems that pressure
is not built up, check the pressure sensor (travel)
circuit, and refer to F-2.

T5-6-49
 TROUBLESHOOTING / Troubleshooting B
T-2 One side track does not rotate or rotates
slowly. Machine mistracks.

• Check that both side track sags are equally

adjusted.
• Faulty pump control will cause the machine to Check if travel motor
mistrack. In this case, other trouble symptoms NO drain oil amount is
such as slow bucket or swing single operation normal.
speed, or slow arm roll-in and boom raise speed · Specification: Refer
in level crowding operation will occur at the same to OPERATIONAL
time. PERFORMANCE
TEST.
• In only one side track does not rotate, the pilot
valve, the control valve, the travel motor, or the Check if symptom is
center joint may be faulty. YES switched when right and
left travel line hoses are
switched each other at
the top of center joint.
Check if travel relief
YES pressure in slow speed Stuck control valve
side is normal. YES spool.
· Travel relief operation
· Monitor item: Pump 1 Switch forward travel
Check if secondary and 2 delivery pressure relief valve with reverse
travel pilot pressure · Possible to display by NO travel one, or right travel
is normal. using built-in diagnosing relief valve with left one.
system Check if symptom is
· Monitor item: · Specification: switched.
Travel pilot pressure Refer to OPERATIONAL
· Possible to display by PERFORMANCE TEST.
using built-in Faulty pilot valve.
diagnosing system NO

Relationship between Faulty Seal Location and Mistrack

Direction

Seal When pivot turn is

When traveling straight
NO. performed Seal Location
1 External Oil Leakage ←

2 1

3
2

Travel (Right
4 Forward)
3
Travel (Left
Forward) 4
5 Travel (Right
Reverse)

Travel (Left
6 Reverse) 5

6
7 External Oil Leakage ←
7 W183-03-08-001

T5-6-50
 TROUBLESHOOTING / Troubleshooting B

NO Faulty travel motor.

Disassemble and clean NO Faulty travel reduction

travel motor gear.
YES displacement angle
control mechanism.
Check if any Faulty travel motor
Disassemble and abnormality is found. displacement angle
clean travel motor YES control mechanism.
YES counterbalance valve.
Check if same
symptom occurs. Faulty counterbalance
NO valve.

NO Faulty center joint.

Faulty travel relief

YES valve.

Arrangement of Piping

2
1

1 - Travel (Right Reverse) 4 - Travel (Right Forward)

3 2 - Travel (Left Reverse) 5 - Drain Hose
6 3 - Travel (Left Forward) 6 - Pilot Hose
4 (Travel Mode Selection)

5 W142-03-03-002

Machine Front

T5-6-51
 TROUBLESHOOTING / Troubleshooting B
T-3 Machine mistracks during combined
operation of travel and front attachment.

Faulty flow combiner

Disconnect hose (SL) valve control spool in
YES
connecting to flow signal control valve.
combiner valve from
signal control valve.
NO Install a pressure gauge
to signal control valve. YES Faulty load check
Check if signal pressure Check load check valve.
is approx. 3.9 MPa (40 valve for any
Check flow kgf/cm2, 570 psi). NO abnormality. Find out cause of
combiner valve in trouble by tracing
control valve for any NO other trouble
abnormality. symptoms.

Faulty flow combiner

YES valve.

Signal Control Valve

(Control Valve Side)

Port SL

T18J-05-08-002

T5-6-52
 TROUBLESHOOTING / Troubleshooting B
T-4 Fast travel is not selected.
Travel mode does not change from slow
mode to fast mode.

Reference
Related Fault Code Trouble
Page
11405 Abnormal solenoid valve unit (SI) T5-5-61
Abnormal travel (right) pilot pressure
MC 11991 T5-5-74
sensor
(Main)
Abnormal travel (left) pilot pressure
11993 T5-5-76
sensor

• Refer to SYSTEM / Control system / Travel Motor

Displacement Angle Control in T/M (Operational
Principle).
• Check the wiring connections first.

Faulty travel mode

NO switch or open circuit
in harness between
travel mode switch
Monitor travel mode and MC (Main).
switch.
Check if indication is Faulty travel motor
switched in response YES displacement angle
to travel mode switch Check if travel motor
control mechanism.
operation. Monitor travel motor YES displacement angle
displacement angle control mechanism is
abnormal. Faulty travel motor or
control pressure.
faulty travel reduction
· Monitor item: Check if pressure is NO
gear.
Travel mode SW YES approx. 3.9 MPa

Faulty MC (Main).
· Monitor item: NO
Travel motor control
pressure
· Possible to display by
using built-in diagnosing
system
· Travel mode: Fast

T5-6-53
 TROUBLESHOOTING / Troubleshooting B
OTHER SYSTEM TROUBLESHOOTING

O-1 Wiper is not operated.

• The wiper is not operated at any wiper switch

position.
Monitor wiper
operating condition. YES Faulty wiper motor.
Shift wiper switch.
YES Check if STOP,
SLOW, STD, FAST,
Monitor wiper VR and CONT are
shifted in this order. Faulty MC (Sub).
signal.
Shift wiper switch. NO
Check if wiper VR
signal value is · Monitor item:
changed. Wiper control
status
· Monitor item:
Wiper VR signal Faulty wiper switch, or
open circuit in harness
NO between wiper switch
and MC (Sub).

• When the wiper switch is in the INT position, the

wiper is not operated, or when the wiper switch is
ON, the wiper is not operated.

Switch wiper relay YES Faulty wiper relay.

Low with wiper relay
YES High.
Check if wiper is
operated. Open circuit in harness
between wiper relay and
Monitor wiper relay · Key switch: ON MC (Sub).
Lo or wiper relay Hi. NO
Set wiper switch in
each position. Check
if wiper relay Lo or Hi
is turned ON.

· Monitor item:
Wiper relay Lo or wiper Faulty MC (Sub).
relay Hi NO
· Wiper switch:
INT or ON

T5-6-54
 TROUBLESHOOTING / Troubleshooting B
O-2 Washer is not operated.

YES Faulty washer relay.

Switch washer
relay with other
YES
general relay.
Check if washer
is operated. To A
Monitor washer relay. NO
Push washer switch.
YES Check if wash relay is
turned ON.

Monitor washer · Monitor item:

switch. Wash relay
Push washer
switch. Check if
wash SW is turned
ON. Faulty MC (Sub).
· Monitor item: NO
Wash SW

Faulty washer switch,

or open circuit in
harness between
NO washer switch and MC
(Sub).

Faulty washer motor,

Disconnect connector or open circuit in
MC (Sub)-B of MC YES
harness between
(Sub). washer motor and
Check for continuity washer relay.
between terminal #B24
A
of harness end
connector and terminal Open circuit in harness
#2 of harness end between washer relay
connector in washer NO and MC (Sub).
relay.

Connector (Harness end of connector viewed from the

open end side)
Washer Relay
Connector MC (Sub)-B

#2

T18J-05-08-001

#B24 T183-05-04-021

T5-6-55
 TROUBLESHOOTING / Troubleshooting B
O-3 Auto-lubrication is faulty.

• The grease pump is not operated. (Both of auto and manual)

• Check the wiring connections first.
• Damage of the lubrication piping and clogged distribution valve may occur.
• In case of manual-lubrication, the auto-lubrication alarm is always indicated.

YES Faulty grease pump.

Disconnect connector
of grease pump.
YES Check if voltage at
terminal #1 of harness
Monitor lubrication end connector is 24V.
mode selection YES Faulty auto-lubrication
switch. Check if Connect the relay.
AUTO is displayed. · Key switch: ON disconnected
Or, check if · In grease pump connector.
auto-lubrication on operation timing Switch auto-lubrication
monitor unit is relay with other
NO Disconnect connector
displayed AUTO. general relay.
of auto-lubrication
Check if grease pump
relay.
is operated.
Check if voltage at
· Monitor item: terminals #1 and #3
Lubricating mode NO
of harness end
· Lubrication mode connector is 24 V.
selection switch:
AUTO Disconnect lubrication
mode selection switch
and connector MC
(Main)-B in MC (Main). YES
Faulty lubrication
Check for continuity mode selection switch.
between terminal #6 of
harness end connector
NO in lubrication mode Open circuit in
selection switch and harness between
terminal #B3 of lubrication mode
NO selection switch and
harness end connector
in MC (Main). MC (Main).

Connector (Harness end of connector viewed from the open end side)

Lubrication Mode Selection Switch Grease Pump Connector MC (Main)-B

#B3
B1 B8
1
2
T1J1-05-07-003

#6 B19 B25

T5-6-56
 TROUBLESHOOTING / Troubleshooting B

Faulty MC (Main), or
Disconnect auto-lubrication open circuit in harness
relay and connector MC YES between
(Main)-B. auto-lubrication relay
Check for continuity between and grease pump.
YES terminal #2 of harness end
connector in auto-lubrication
relay and terminal #B24 of
harness end connector in Open circuit in harness
MC (Main)-B. between
NO
auto-lubrication relay
and MC (Main).

Faulty fuse #15, or open

circuit in harness
NO between fuse #15 and
auto-lubrication relay.
Connector (Harness end of connector viewed from the open end side)

Auto-Lubrication Relay Connector MC (Main)-B

B1 B8

B19 #B24 B25

T18J-05-08-001

T5-6-57
 TROUBLESHOOTING / Troubleshooting B
• The grease pump does not stop.
Even if the lubrication mode selection switch is
turned OFF, the auto-lubrication does not stop.

YES Faulty auto-lubrication

relay.
Switch auto-lubrication
relay with other general
relay.
Check if auto-lubrication YES Faulty MC (Main).
stops. Disconnect connector MC
(Main)-B in MC (Main).
Check if auto-lubrication
NO stops. Shorted circuit in harness
between auto-lubrication
NO relay and MC (Main).

• When the auto-lubrication device is stopped, the

auto-lubrication alarm is indicated at the same time.

• Grease may be run out or the proximity switch may

be broken as a cause.
Check the following.
1. Grease level in cartridge
2. Air get mixed in circuit
3. Inside plug is provided in cartridge
4. Faulty proximity switch

T5-6-58
 TROUBLESHOOTING / Troubleshooting B
Adjustment of Proximity Switch

1. Loosen the nut.

: 17 mm

2. Slowly tighten the proximity switch until the end of Indicator

the proximity switch comes in contact with the Proximity Switch
protrusion part. Nut

3. Loosen the proximity switch from half turn to one

turn. Set the indicator position as illustrated.

IMPORTANT: As the proximity switch may be

damaged, do not tighten the nut T142-06-04-024
excessively.
Proximity
Switch
4. Tighten the nut and secure the proximity switch.
Nut
: 17 mm
: 0.78 N⋅m (0.08 kgf⋅m, 0.57 lbf⋅ft)
Protrusion
Part

Pin

T142-06-04-025

T5-6-59
 TROUBLESHOOTING / Troubleshooting B
O-4 Level check is faulty.

• Even if the level check switch is turned ON, the

alarm (Green or red) is not displayed on the monitor
unit.

Reference
Related Fault Code Trouble
Page
MC (Main) 11004 Abnormal CAN communication T5-5-27
Monitor Unit 13308 Abnormal CAN communication T5-5-99
MC (Sub) 15995 Abnormal CAN communication T5-5-91

YES Faulty MC (Main) or

faulty monitor unit.

Monitor level check

switch.
Check if ON
(outline character)
is displayed.
· Monitor item:
Switch connector of level YES
Level check SW Faulty level check
check switch with that of
· Level check switch: ON switch.
boom mode switch.
· Key switch: ON
Check if symptom is
NO improved.
Faulty MC (Main), or
open circuit in harness
NO between level check
· Boom mode switch:
switch and MC (Main).
ON
· Key switch: ON

T5-6-60
 TROUBLESHOOTING / Troubleshooting B
• Even if the level check switch is turned OFF, the
alarm (Green or red) is displayed on the monitor unit.

Reference
Related Fault Code Trouble
Page
MC (Main) 11004 Abnormal CAN communication T5-5-27
Monitor Unit 13308 Abnormal CAN communication T5-5-99
MC (Sub) 15995 Abnormal CAN communication T5-5-91

YES Faulty level check

switch.

Connect the disconnect

connector.
YES
Disconnect connector of
level check switch.
Check if alarm
disappears.
Faulty MC (Main).
NO
Disconnect
connector B in
monitor unit.
Check if alarm
disappears.

Faulty monitor unit.

NO

T5-6-61
 TROUBLESHOOTING / Troubleshooting B
O-5 Step light does not light.

• Check the wiring connections first.

YES Faulty step light relay.

Open circuit in harness

NO between MC (Sub) and
Disconnect connector MC
Switch step light relay (Sub)-B. step light switch.
with other general Check for continuity
relay. between terminal #B6 of
Check if step light NO harness end connector in
lights. MC (Sub) and terminal #9
of harness end connector
in step light switch. Monitor step light relay.
Check if go up and down
Disconnect connector in light relay is ON (outline
step light switch. YES character).
Short terminals #8 and
NO
#9 of harness end.
Check if step light lights. · Monitor item:
Go up and down light relay
· Step light switch: ON
Step Light
Faulty step light switch.
YES

M183-01-036

Connector (Harness end of connector viewed from the open end side)

Step Light Relay

#B6
Connector MC (Sub)-A Connector MC (Sub)-B

T18J-05-08-001

Step Light Switch

T183-05-04-005
#A28

#8 #9 T1J1-05-07-003

T5-6-62
 TROUBLESHOOTING / Troubleshooting B

NO Faulty MC (Sub).

NO Open circuit in harness

between fuse #38 and
MC (Sub).

Disconnect connector MC
(Sub)-A.
Open circuit in harness
Check if voltage at NO
YES between step light and
terminal #28 of harness
step light relay.
end connector in MC Connect all
(Sub) is 24 V. connectors.
Disconnect connector
of step light.
YES Check if voltage at
terminal #1 of harness
end connector is 24V.

Faulty step light.

YES

T5-6-63
 TROUBLESHOOTING / Troubleshooting B
O-6 Air Conditioner is faulty.

The air conditioner has a self-diagnosis function.

The self-diagnosis functions to:
• Display Fault Codes
• Change Displayed Fault Codes
• Delete Fault Code
• End Fault Code Display

• Display Fault Code Temperature

Fan OFF Switch Control Switch
1. Push the fan OFF switch and turn the fan OFF.
2. Push and hold both the upper and lower sides of
the temperature control switch on the air
conditioner control panel at the same time for
more than 3 seconds with the key switch ON.
NOTE: After operation has been performed, the
buzzer will sound. M178-01-017
3. If any fault codes are found, the LCD displays the LCD
fault codes as "E ”.
NOTE: If more than one fault code is found, the
lower number fault code will be displayed
first.

Fault Code List

Location in
Fault Code Cause Symptom
Trouble
Abnormal Open circuit in air circulation Y value (air flow-in temperature) cannot
E11
circulation air sensor be adjusted in response to the
sensor Shorted circuit in circulation air set-temperature.
E12
sensor
Abnormal fresh air E13 Open circuit in fresh air sensor Operation is controlled under such
sensor Shorted circuit in fresh air circumstance as no fresh air sensor is
E14
sensor provided.
Abnormal solar Shorted circuit in solar Operation is controlled under such
radiation sensor E18 radiation sensor circumstance as no solar radiation
sensor is provided.
Abnormal Open circuit in evaporator Operation is controlled under such
E21
evaporator sensor sensor circumstance as the evaporator
Shorted circuit in evaporator temperature is set to 10°C (50°F).
E22
sensor
Abnormal damper E43 Abnormal air vent damper Corresponding damper servo becomes
E44 Abnormal air mix damper inoperable.
Abnormal circulation/fresh air
E45
damper
Coolant Open circuit in coolant Operation is controlled under such
E15
temperature temperature sensor circumstance as the water temperature is
sensor Shorted circuit in coolant set to 60°C (140°F). (Warm-up control is
E16
temperature sensor not performed.)
Abnormal Abnormal high/low refrigerant The compressor clutch is disengaged.
E51
refrigerant pressure (The compressor stops.)

T5-6-64
 TROUBLESHOOTING / Troubleshooting B
• Change Displayed Fault Code Temperature
Control Switch
1. When displaying more than one fault code, press
either the upper or bottom side of the temperature
control switch key. The following fault code is
displayed.
NOTE: Each time the displayed fault code is
changed, the buzzer sounds. In case only
one fault code exists, the displayed fault M178-01-017
code remains unchanged. LCD

• Delete Fault Code LCD

1. Push and hold both the circulation air switch and

the fresh air switch for more than 3 seconds at the
same time and delete the fault code.
NOTE: After the fault code is deleted, the buzzer
will sound.
2. After the fault code has been deleted, the LCD M178-01-017
displays “E – – “. Circulation Fresh Air
Air Switch Switch

• End Fault Code Display Fan OFF Switch

1. Push the fan OFF switch, or push the upper side

of the fan switch key. The self-diagnostic mode is
completed.

M178-01-017
Fan Switch

T5-6-65
 TROUBLESHOOTING / Troubleshooting B
※ Please 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
Model (Serial No. ) Checked by:
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 position ∗ Before replacing the control amplifier, be sure to check
Symptom Vent position isn’t selected that the connectors are correctly connected while
repeatedly disconnecting and reconnecting connectors.
Others
Abnormal panel indication
Faulty Indicator Vent Position
A/C
AUTO
Fresh Air Circulation
Fan OFF
Fan (Lo • •• Hi)
Temperature Control
Symptom Stays OFF
Stays ON
Blinks
Others

T5-6-66
 TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-6-67
 TROUBLESHOOTING / Troubleshooting B
Cooling Circuit

Refrigerant pressure Bubbles can be seen in sight Piping and/or parts are stained with oil,
in both high and glass. respond to gas detector.
low-pressure sides is
low.
No oil stain is found or gas detector
does not respond.
Refrigerant has not been refilled for
longer than one season.

No bubbles are seen in sight glass.

After cooling at fast speed

continuously, 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- glass. emitting a smell.
is high.
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 Bubbles can be seen in sight Refrigerant pressure in low-pressure

in high-pressure side glass. side is low.
is high.
Condenser is stained and clogged.

Even if condenser is sprayed with water, few bubbles appear.

Receiver dryer temperature is low.

After cooling at fast speed

continuously, cooling power is Frost forms. Thermistor does not cool.
reduced.
Air flow volume is reduced.
Thermistor cools.

T5-6-68
 TROUBLESHOOTING / Troubleshooting B

Gas leaks from pipe joints and/or parts. Re-tighten or replace parts.

Normal leakage of refrigerant from hoses. Refill refrigerant.

Improper adjustment (Excessive restriction) of expansion Readjust or replace expansion valve.

valve.

Clogged expansion valve. Remove clog, or replace receiver and/or expansion

valve.

Clogged low-pressure circuit and/or evaporator. Remove clog, or replace parts.

Frozen expansion valve or water in circuit. After evacuation, refill refrigerant and/or replace
receiver 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

Air is mixed in system.
receiver 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.

T5-6-69
 TROUBLESHOOTING / Troubleshooting B
Cooling Circuit

Case connection. Louver resonance.

Fan contacts case, or foreign matter enters case.

Blower fan connection.
Brush friction noise, metal and/or thrust washer contact
noise.

Gas blowing sound (Roaring). Gas vibration noise (Compressor discharge and/or
suction gas noise).

Expansion valve connection, whistle Abnormal noise from expansion valve (Expansion
Noise sound, gas blowing sound. valve is normally functioning.).

Faulty clutch bearing, and/or idle pulley bearing.

Clutch disengaging sound.

Contact of clutch amature due to resonance, or loose
belt and/or screws.

Noisy compressor.
Compressor rotating sound.
Vibration and/or loose screws due to excessive drive
belt looseness.

Broken heater core and/or hose.

Water leak and/or splash.
Clogged case drain port and/or drain hose.
Others

Absorbed cigarette and dust smell on evaporator fins.

Abnormal smell.

T5-6-70
TROUBLESHOOTING / Troubleshooting B

Repair or replace.

Remove foreign matter. Readjust fan motor location.

Slight noise is unavoidable.

Replace if loud.

No functional problem exists.

Provide silencer if intolerable.

Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.

Replace.

Repair or replace clutch. Re-tighten screws.

Repair or replace.

Re-adjust drive belt.

Replace.

Clean.

Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in L
mode for more than 10 minutes, flush smell out by condensed water.

T5-6-71
 TROUBLESHOOTING / Troubleshooting B
Compressor

Compressor does not rotate. Clutch terminal voltage is normal 24 V.

Clutch terminal voltage is low.

Clutch terminal voltage is 0 V.

Inoperable
Cooling Bubbles exist even after refrigerant is refilled.
System.
Check for oil and refrigerant leaks from parts other than
Both high and low side
compressor and pipe joints by using gas detector.
pressures are low.
than compressor) by using gas detector.
Both
Check for oil and refrigerant leaks from
compressor (no leaks from parts other

compres-
sor and
blower
motor (Refer to NOTE 1, 2 on page T5-6-75.)
Dirt on Exterior

rotate.
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

High-pressure side is compressor in liquid form.)
slightly low and
low-pressure side is high. No refrigerant returns in liquid form. High-pressure side is low.
(Bubbles can be seen through
sight glass.) Others

High-pressure side is high.

Refer to the Cooling Circuit
Troubleshooting Table on T5-6-68.
Temperature is not cooled when compressor is
operated at fast speed continuously.

Air flow from blower is insufficient.

Compressor rotation is abnormally draggy.

Overheating is
susceptible to
occur.

Refer to the Cooling Circuit

Trouble other than compressor. Troubleshooting Table on T5-6-68.

T5-6-72
 TROUBLESHOOTING / Troubleshooting B

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 T5-6-68.

Broken valve (Refer to NOTE 3 on T5-6-75.)

Replace.
Blown gasket (Refer to NOTE 3 on T5-6-75.)

Oil check
Oil level
Excessive oil
adjustment

Broken clutch bearing due to overly tightened belt. Replace.

Shaft does not rotate.

Replace.
Shaft rotates draggy.

T5-6-73
 TROUBLESHOOTING / Troubleshooting B
Compressor

Noise is heard when clutch is OFF.

Abnormal
Noise

Noise is heard when clutch is ON.

T5-6-74
 TROUBLESHOOTING / Troubleshooting B

Broken clutch bearing.

Replace.
Contact or slip due to poor air gap.

Faulty idle pulley bearing.

Refer to the Cooling Circuit
Troubleshooting Table on
Saggy belt.
T5-6-70.

Loose screws.

Broken valve.
Replace.
Blown gasket.

Abnormal internal noise. Replace.

Vibration due to saggy belt. Refer to the Cooling Circuit

Troubleshooting Table on
T5-6-70.
Loose screws.

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
surface may be detected. As long as the specified rubber hoses are used, the problem should not
occur. (In case a large leaks is detected, the hose may be broken.)
3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between
high-pressure side and low-pressure side is 0.5 MPa (5 kgf/cm2, 72.5 psi) or less. When the
clutch is turned OFF, the pressure difference between high-pressure side and low-pressure side
will disappear within about 10 seconds.

T5-6-75
 TROUBLESHOOTING / Troubleshooting B
WORK AFTER REPLACING
COMPONENTS
The following work is required after replacing
compressor, high pressure hose, low pressure hose,
condenser, receiver tank, liquid hose, and air
conditioner unit.
The same work is required when gas leakage is found.

1. Add compressor oil

Oil amount: 220 cm3 (0.23 US qt)

2. Charge air conditioner with refrigerant

• Purging
• Charge air conditioner with refrigerant
• Warm-up operation
• Inspection

T5-6-76
 TROUBLESHOOTING / Troubleshooting B
CHARGE AIR CONDITIONER WITH
REFRIGERANT
Necessity of Purging
Make sure to purge the air conditioner circuit with a
vacuum before charging with refrigerant (R134a)
because the following problems can arise if air or
other gases remain in the A/C circuit.
Air
1. Pressure Rise in the High Pressure Side:
If air remains in the air conditioner circuit, this
disturbs the heat exchange between refrigerant
and air in the condenser, causing pressure to rise
in the high pressure side (Compressor side).
Usually, refrigerant gas is easily liquefied,
however, air cannot be liquefied and remains as a
gas in the condenser because the temperature at
which air liquefies is extremely low. That is,
liquidation of the refrigerant gas in the condenser Pressure increases if air
W115-02-10-001
decreases by the amount of air in the circuit, and remains in the air
conditioner circuit.
the gas pressure in the high pressure side
increases accordingly.

2. Metal Corrosion:
If air remains in the air conditioner circuit, a
chemical reaction between refrigerant and
moisture in the air takes place, and as a result,
hydrochloric acid, that corrodes metals such as
aluminum, copper and iron, is produced.

3. Plugging of the Expansion Valve by Moisture: Hydrochloric

When high pressure refrigerant gas passes Hydrochloric acid Acid W115-02-10-002

through the expansion valve, gas pressure corrodes metals if

moisture exists.
decreases and temperature drops. Moisture
included in high pressure refrigerant gas in the air
Metal
conditioner circuit freezes at the expansion valve Corrosion
orifice, plugging refrigerant flow. Operation of the
air conditioner becomes unstable and cooling
efficiency lowers.

Plugged
Refrigerant
Ice produced at the Flow
expansion valve
disturbs refrigerant W115-02-10-003
flow, lowering cooling
efficiency.

Low Cooling
Efficiency

T5-6-77
 TROUBLESHOOTING / Troubleshooting B
Purging Procedure Gauge Manifold

Low Pressure
IMPORTANT: Never mistake the charge hose Valve
connections.
1. Close the high and low pressure valves on the Low Pressure
Charge Hose
gauge manifold (Parts Number 4360564). High Pressure
Valve
Connect the high-pressure-side charge hose and
the low-pressure-side charge hoses to the
High Pressure
high-pressure-side charge valve (“D” marked) and Charge Hose
to the low-pressure-side charge valve (“S” Center
marked) located on the compressor, respectively. Pressure
Charge Hose
Connect the charge hose located on the center of Vacuum Pump
the manifold bottom to the vacuum pump (Parts
Number 4360565).
NOTE: Vacuum Pump Joint Adapter (Parts
Number 4360566).

W115-02-10-005

Low
Pressure Side
Compressor S

D
IMPORTANT: Remove refrigerant remained in the High
air conditioner circuit and operate Pressure Side
the vacumu pump. T142-02-05-018

Fully Open
2. Open the high pressure and low pressure valves
in the gauge manifold. Perform purging for 10
minutes or more by operating the vacuum pump. Fully Open

In Operation

W115-02-10-005

T5-6-78
 TROUBLESHOOTING / Troubleshooting B
IMPORTANT: If the pointer returns to 0, retighten
the line connections and perform
purging again. Close
3. When the low pressure gauge reading falls below
-100 kPa (-755 mmHg), stop the vacuum pump Close
and close the high and low pressure valves. Wait
for approximately five minutes and confirm that
the pointer does not return to 0.

In Operation

W115-02-10-005

4. With the high pressure and low pressure valves of

the gauge manifold closed, connect the charge
hose to the refrigerant container (Parts Number
4347644).

Refrigerant
Container

W115-02-10-007

5. Loosen the charge hose connection to the gauge

manifold and open the refrigerant container valve
to purge air in the charge hose with the refrigerant
pressure.
Loosen

Open

W115-02-10-007

T5-6-79
 TROUBLESHOOTING / Troubleshooting B
IMPORTANT: Always stop the engine when
charging the air conditioner with
refrigerant. Do not position the
High
refrigerant container upside down Tighten
Pressure
during charging operation. When Gauge
changing the refrigerant container
Open
during charging operation, purge air
from the charge hose, as shown in
step 10. Charge the low pressure
side hose first.
6. Fully tighten the charge hose connection to the
Open
gauge manifold. Open the high pressure valve
and refrigerant container valve to charge with
refrigerant (R134a).
Close the high pressure valve and refrigerant
container valve when the high pressure gauge
reading reaches 98 kPa (1 kgf/cm2, 14 psi).

NOTE: Use warm water of 40 °C (104 °F) or less to W115-02-10-007

warm the refrigerant container to aid in

charging operation.

W115-02-10-008

IMPORTANT: Use the leak tester for R134a.

7. After charging, check the line connections for gas
leaks by using leak tester (Parts Number
4360567).

T5-6-80
 TROUBLESHOOTING / Troubleshooting B
8. Confirm that the high pressure and low pressure
valves in the gauge manifold and the refrigerant
container valve are closed.
Start the engine and operate the air conditioner.
Operating Conditions of the Air Conditioner:
Engine Speed : Slow Idle
Cab Window : Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum

IMPORTANT: Do not open the high pressure valve

in the gauge manifold.
9. Open the low pressure valve in the gauge
manifold and the refrigerant container valve to
charge with refrigerant until the bubbles seen in
the receiver tank sight glass disappear. Open

NOTE: The required refrigerant quantity is

1250±50 g. (2.76±0.11 lb)

10. If the refrigerant container becomes empty during

the charging work, replace it with a new
refrigerant container as follows:
• Close the high pressure and low pressure valves Open
on the manifold gauge.
• Replace the empty container with a new one.
• Tighten, then slightly loosen the refrigerant
container joint.
• Slightly open the low pressure valve on the
manifold gauge.
• When the refrigerant container joint starts to leak,
immediately tighten the refrigerant container joint
and close the low pressure valve on the manifold W115-02-10-007

gauge.
Close
11. After charging, close the low pressure valve in the
gauge manifold and the refrigerant container
valve. Stop the engine.

Close

W115-02-10-007

T5-6-81
 TROUBLESHOOTING / Troubleshooting B
IMPORTANT: If the air conditioner is operated with
very low refrigerant, cause a
negative effect on the compressor.
If the air conditioner is overcharged
with refrigerant, cooling efficiency
will lower and abnormal high Sight Glass
pressure will arise in the air
conditioner circuit, causing danger.
12. Start the engine and operate the air-conditioner
again.
Observe the sight glass of the receiver tank and
check refrigerant quantity.
Operating Conditions of the Air Conditioner:
Engine Speed : Slow Idle Receiver Tank
Cab Window : Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum
W115-02-10-009

NOTE: As the bubbles in the sight glass vary

depending on the ambient temperature,
check refrigerant quantity confirming the
changes in pressure .
Checking procedures: Stop the air
conditioner and wait until refrigerant returns
to the balanced pressure. Then, start the
air conditioner again.

Refrigerant Refrigerant Flow in Sight Glass Explanation for Refrigerant Flow in Sight Glass
Quantity (Approx. 1 min. after air conditioner
switch is turned ON)
Adequate Immediately after the air conditioner is turned ON, few
bubbles are seen. Then the flow becomes transparent
W115-02-10-016
and shows thin milk white color.
Overcharged No bubbles are seen after the air conditioner is turned
ON.
W115-02-10-017

Not Enough Bubbles are seen continuously after the air

conditioner is turned ON.
W115-02-10-018

Bubbles exist: Bubbles are seen in Milk white: Refrigerant flow shows thin milk
refrigerant flow as both liquid white as oil and refrigerant are
refrigerant and refrigerant separated.
gas exist, being mixed. W115-02-10-021

W115-02-10-019

Transparent: Refrigerant flow is

transparent as only liquid
refrigerant exists.
W115-02-10-020

T5-6-82
 TROUBLESHOOTING / Troubleshooting B

CAUTION: Wait until the high-pressure-side

pressure drops to less than 980 kPa (10
kgf/cm2, 142 psi) before attempting to
disconnect the high-pressure-side charge
Hose. Otherwise, refrigerant and compressor
oil may spout.

13. After checking refrigerant quantity, disconnect the

low-pressure-side charge hose first. After the
high-pressure-side pressure drops, disconnect
the high-pressure-side charge hose.

NOTE: Do not discharge refrigerant in the charge

hose in order not to discharge refrigerant
into the atmosphere for the environmental
protection.

T5-6-83
 TROUBLESHOOTING / Troubleshooting B
WARM-UP OPERATION
After charting the air conditioner, carry out warm-up
operation five minute to lubricate system with
compressor oil.

Operating Conditions of the Air Conditioner:

Engine Speed : Slow Idle
Cab Window : Fully Open
Cooler Switch : ON
Airflow Volume : Maximum
Thermo Switch : Maximum

T5-6-84
 TROUBLESHOOTING / Troubleshooting B
INSPECTION
After warm-up operation, carry out gas leak check and
performance check.
Leak Tester

CAUTION: Refrigerant will produce

poisonous material if exposed to heat of
1000°C or more. Never bring refrigerant close
to a fire.

1. Check the air conditioner for gas leaks by using a

leak tester.
• Perform checking under well-ventilated conditions.
• Thoroughly wipe off dust from the charge hose
connections of the compressor.
W115-02-10-013
• Pay special attention to check the line
connections.
• If any gas leaks are found, retighten the line
connections.

2. Performance Check
Carry out performance check of the air
conditioner after checking each air conditioner Retighten Line
component. Connection
• Check foreign matter is not present in each
component.
• Carry out ON-OFF check of the compressor
clutch.
• Check compressor fan belt tension. W115-02-10-014
• Check coolant level in the radiator.
• Operate the air conditioner and check the
performance.

3. The checklist before the summer season is as

follows:
• Check each air conditioner component for
abnormalities.
• Check the line connections for oil leaks.
• Check refrigerant quantity.
• Check the engine cooling circuit.
• Check belts for wear. Replace if necessary.

4. Off-Season Maintenance
• During off-season, operate the idler pulley and
compressor at least once a month for a short time
in order to check for any abnormal sounds.
• Do not remove the compressor belts during
off-season. Operate the compressor occasionally
at slow speed for 5 to 10 minutes with the belt
slightly loosened in order to lubricate the machine
parts.

T5-6-85
 TROUBLESHOOTING / Troubleshooting B
(Blank)

T5-6-86
 TROUBLESHOOTING / Troubleshooting C
TROUBLESHOOTING C PROCEDURE

Troubleshooting C indicates a fault code with a

blinking indicator on the engine troubleshooting
device and diagnoses the failure details when an
engine-stop warning or an engine warning alarm is
displayed on the monitor unit.

T5-7-1
 TROUBLESHOOTING / Troubleshooting C
Inspection Method

When any trouble occurs in the engine or components Monitor Unit

regarding the engine, one of the following indicators
comes ON on the monitor unit:
• Engine Stop Indicator (1)
• Engine Warning Indicator (2)
The engine troubleshooting device is also provided to
check more detailed failure conditions.

You can find the engine troubleshooting device in

electrical component box (3) in the cab. Turn the key
switch to ON. If there is any fault code, one of the
following indictors that corresponds to the failure level
lights.
• Engine Stop Indicator (red) (5)
• Engine Warning Indicator (amber) (6) 2 1
• Engine Maintenance Indicator (yellow) (7) M18J-11-001

In addition, you can let a failure code displayed (with a

blinking warning indicator that indicates details of the
engine) by using Engine Troubleshooting Switch (4).
When a fault code is displayed, record the fault code
(3 digits) and consult to CUMMINS.

M18J-01-025
3
Engine Troubleshooting Device

M18J-01-026

T5-7-2
 TROUBLESHOOTING / Troubleshooting C
HOW TO READ ENGINE FAULT CODES

1. Stop the engine and turn the key switch to ON 8

position.
2. When there is a fault code, a fault indicator that 4
corresponds to the fault level lights. When there
is no fault code, all indicators go off.
5
3. Turn Engine Troubleshooting Switch (4) to ON
6
position.
4. Engine Stop Indicator (red) (5) lights. Engine
7
Maintenance Indicator (yellow) (7) blinks for once.
After one second, Engine Warning Indicator
(amber) (6) indicates the fault code for two times
consecutively. The fault code is indicated
repeatedly in the above sequence. M18J-01-026

5. A number is indicated by a blinking count of

Engine Warning Indicator (amber) (6). The
indicator goes off for one second between each Example: Blinking condition of Engine Warning
digit. Indicator (amber) of Fault Code 132.
6. When Engine Troubleshooting Switch (4) is
th th st
turned to OFF, an indicated troubleshooting code 100 digit 10 digit 1 digit
goes off.
Turn
ON
NOTE: When several fault codes are occurring,
Engine Maintenance Indicator (yellow) (7) (Amber) ×2
blinks for once between indications of each
fault code. After one second, Engine Light off
Warning Indicator (amber) (6) indicates the
1 sec.
next failure code for two times 1 sec.
1 sec.
consecutively. The fault code is indicated Turn
repeatedly in the above sequence ON

(Yellow)
NOTE: After completing indication of all fault
codes, Engine Maintenance Indicator
Light off
(yellow) (7) blinks for once. After one
second, Engine Warning Indicator (amber) T18J-05-09-001

(6) repeats indicating from the first fault

code.

NOTE: When Engine Fault Code Selector Switch

(8) is moved to INC side for once, the next
fault code from a current fault code is
displayed. When Engine Fault Code
Selector Switch (8) is moved to DEC side
for once, the previous fault code from a
current fault code is displayed.

T5-7-3
 TROUBLESHOOTING / Troubleshooting C

FAULT SPN
CODE/ FMI
LAMP TROUBLE REMARK

111 629 Engine Control Module – Critical internal failure

Yellow 12
112 635 Engine Timing Actuator is not responding to ECM
Amber 7 commands
113 635 Engine Timing Actuator Circuit - shorted high
Amber 3
115 190 Engine Speed/Position Sensor Circuit - lost both of two
Amber 2 signals from the magnetic pickup sensor
116 156 Fuel Timing Pressure Sensor Circuit - shorted high
Amber 3
117 156 Fuel Timing Pressure Sensor Circuit - shorted low
Amber 4
118 135 Fuel Pump Delivery Pressure Sensor Circuit - shorted
Yellow 3 high
119 135 Fuel Pump Delivery Pressure Sensor Circuit - shorted low
Yellow 4
121 190 Engine Speed/Position Sensor Circuit - lost one of two
Amber 10 signals from the magnetic pickup sensor
122 102 Intake Manifold Pressure Sensor #1 Circuit - shorted high
Amber 3
123 102 Intake Manifold Pressure Sensor #1 Circuit – shorted low
Amber 4
131 091 Accelerator Pedal Position Sensor Circuit - shorted high
Amber 3
132 091 Accelerator Pedal Position Sensor Circuit - shorted low
Amber 4
133 29 Remote Accelerator Pedal Position Sensor Circuit -
Amber 3 shorted high
134 29 Remote Accelerator Pedal Position Sensor Circuit -
Amber 4 shorted low
135 100 Engine Oil Pressure Sensor Circuit - shorted high
Amber 3
141 100 Engine Oil Pressure Sensor Circuit - shorted low
Amber 4
143 100 Engine Oil Pressure Low - Warning Engine Oil Pressure Alarm
Red 1

T5-7-4
 TROUBLESHOOTING / Troubleshooting C

FAULT SPN
CODE/ FMI
LAMP TROUBLE REMARK

144 110 Engine Coolant Temperature Sensor Circuit - shorted high

Amber 3
145 110 Engine Coolant Temperature Sensor Circuit - shorted low
Amber 4
147 091 Accelerator Pedal Position Sensor Circuit - low frequency
Amber 8
148 091 Accelerator Pedal Position Sensor Circuit - high frequency
Amber 8
151 110 Engine Coolant Temperature High – Critical Coolant Overheat Warning
Red 0
153 105 Intake Manifold Temperature Sensor #1 Circuit - shorted
Amber 3 high
154 105 Intake Manifold Temperature Sensor #1 Circuit – shorted
Amber 4 low
155 105 Intake Manifold Temperature #1 High - Critical Intake Manifold Temperature
Red 0 Abnormal
219 1380 Low Oil Level in the Centinel makeup oil tank
Amber 1
221 108 Ambient Air Pressure Sensor Circuit - shorted high
Amber 3
222 108 Ambient Air Pressure Sensor Circuit - shorted low
Amber 4
223 1265 Engine Oil Burn Valve Solenoid Circuit - shorted low
Amber 4
225 1266 Engine Oil Replacement Valve Solenoid Circuit - shorted
Amber 4 low
231 109 Engine Coolant Pressure Sensor Circuit - shorted high
Amber 3
232 109 Engine Coolant Pressure Sensor Circuit - shorted low
Amber 4
233 109 Engine Coolant Pressure Low - Warning
Red 1
234 190 Engine Speed High – Critical
Yellow 0
235 111 Engine Coolant Level Low - Critical Coolant Level Warning
Red 1

T5-7-5
 TROUBLESHOOTING / Troubleshooting C

FAULT SPN
CODE/ FMI
LAMP TROUBLE REMARK

237 644 External Speed Input (Multiple Unit Synchronization) -

Amber 2 data incorrect
254 632 Fuel Shutoff Valve Circuit - shorted low
Amber 4
259 632 Fuel Shutoff Valve - stuck open
Amber 7
261 174 Fuel Temperature High - Warning Fuel Temperature Abnormal
Red 0
263 174 Fuel Temperature Sensor Circuit - shorted high
Amber 3
265 174 Fuel Temperature Sensor Circuit - shorted low
Amber 4
292 1083 Auxiliary Temperature Sensor Input # 1 Engine Protection
Yellow 14 - Critical
293 1083 Auxiliary Temperature Sensor Input # 1 Circuit – shorted
Yellow 3 high
294 1083 Auxiliary Temperature Sensor Input # 1 Circuit – shorted
Yellow 4 low
296 1084 Auxiliary Pressure Sensor Input # 2 Engine Protection -
Yellow 14 Critical
297 1084 Auxiliary Pressure Sensor Input # 2 Circuit – shorted high
Yellow 3
298 1084 Auxiliary Pressure Sensor Input # 2 Circuit – shorted low
Yellow 4
299 1384 Engine Shutdown Commanded by J1939
Yellow 31
316 931 Fuel Supply Pump Actuator Circuit - shorted high
Yellow 3
318 931 Fuel Supply Pump Actuator – mechanically stuck
Amber 7
343 629 Engine Control Module – Warning internal hardware
Nothin 12 failure
g
346 630 Engine Control Module – Warning Software error
Nothin 12
g
349 191 Transmission Output Shaft (Tailshaft) Speed High –
Amber 0 Warning

T5-7-6
 TROUBLESHOOTING / Troubleshooting C

FAULT SPN
CODE/ FMI
LAMP TROUBLE REMARK

384 626 Start Assist Device Control Circuit Error (Ether Injection)
Yellow 11
415 100 Engine Oil Pressure Low - Critical
Red 1
422 111 Engine Coolant Level Sensor Circuit - data incorrect
Amber 2
423 156 Fuel Timing Pressure or Timing Actuator Stuck
Amber 2
426 639 SAE J1939 datalink - cannot transmit
Yellow 2
427 639 SAE J1939 not fast enough
Nothin 9
g
431 91 Accelerator Pedal Idle Validation Circuit - data incorrect
Yellow 2
432 91 Accelerator Pedal Idle Validation Circuit - out of calibration
Yellow 13
441 168 Battery #1 Voltage Low - Warning
Yellow 1
442 168 Battery #1 Voltage High - Warning
Amber 0
451 157 Injector Metering Rail #1 Pressure Sensor Circuit - shorted
Amber 3 high
452 157 Injector Metering Rail #1 Pressure Sensor Circuit - shorted
Amber 4 low
455 633 Fuel Control Valve Circuit – shorted high
Amber 3
467 635 Timing Rail Actuator Circuit – data incorrect
Amber 2
468 633 Fuel Rail Actuator Circuit – data incorrect
Amber 2
487 626 Start Assist Device - Canister Empty (Ether Injection)
Yellow 1
489 191 Transmission Output Shaft (Aux Gov) Speed Low –
Amber 1 Warning

T5-7-7
 TROUBLESHOOTING / Troubleshooting C

FAULT SPN
CODE/ FMI
LAMP TROUBLE REMARK

497 1377 Multiple Unit Synchronization Switch Circuit - data

Amber 2 incorrect
514 633 Fuel Control Valve – mechanically stuck
Amber 7
527 702 Auxiliary Input/Output #2 Circuit - shorted high
Amber 3
529 703 Auxiliary Input/Output #3 Circuit - shorted high
Amber 3
551 091 Accelerator Pedal Idle Validation Circuit - shorted low
Amber 4
553 157 Injector Metering Rail #1 Pressure High - Warning level
Amber 0
554 157 Fuel Pressure Sensor Error
Amber 2
555 1264 Engine Blowby - Warning level
Red 0
611 1383 Engine Hot Shutdown
Yellow 31
649 1378 Change Lubricating Oil and Filter
Yellow 0
719 1264 Crankcase Blowby Pressure Sensor Circuit - shorted high
Amber 3
729 1264 Crankcase Blowby Pressure Sensor Circuit - shorted low
Amber 4
753 723 Engine Speed/Position #2 - Cam sync error
Yellow 2

T5-7-8
 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.
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
 TROUBLESHOOTING / Electrical System Inspection
3. Precautions for connecting and disconnecting
terminal connectors.
• When disconnecting the harnesses, grasp them
Correct Incorrect
by their connectors. Do not pull on the wire itself.
Release the lock first before attempting to
separate connectors, if a lock is provided. (Refer
to “Instructions for Disconnecting Connector” on
page T5-8-3.)
• The water-resistant connectors keep water out. If T107-07-06-001

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
that no terminals are bent or coming off. In Rust
addition, as most connectors are made of brass, Incorrect
check that no terminals are rusting. (Deformation)
• 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.
When the connector size is very small, and the Sharpen the end of the wire
standard probe size is too large to be used for T107-07-06-003

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
 TROUBLESHOOTING / Electrical System Inspection
INSTRUCTIONS FOR DISCONNECTING
CONNECTORS

• Push, Unlock, and Separate Type

(Most of connectors are “Push, Unlock, and Sepa-
rate 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 con
nector (harness end side).
T107-04-05-002
Connector
1A, 1B, 1C, 2A, 2B, 2C, 3A, 3B, 3C, 4A, 4B, 4C, 8,
10,11, 16, 17, 18, 19, 20, 21, 22, 23, 25, 26, 30, 31,
32, 33, 34, 36, 38, 39, 40, 41, 42, 43, 44, 45, 45, 47,
48, 50, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64,
67, 68, 70, 71, 73, 74, 75, 76, 77, 78, 81, 82, 83, 84,
85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98,
99
A, B, C, D, E, F, J, K, L, M, N, O, P, Q, R, T, U, and X

• Pull and Separate Type

IMPORTANT: Before pulling and separating, re-

lease the wire lock in the hydraulic
oil temperature sensor by using a
pair of pincers.

Connector
5, 6, 7, 9, 12, 13, 14, 15, 24, 27, 29, 35, 37, 49, 51, 52,
65, 66, 69, 72, 79, 80,
G, H, I, V, W, Y
a, b, c, and d T107-04-05-004

T5-8-3
 TROUBLESHOOTING / Electrical System Inspection
FUSE INSPECTION
Cracks in a fuse are so fine that it is very difficult or NOTE: All terminals located along the lengthwise
impossible to find by visual inspection. Use a tester 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 con-
nected to loads (accessories). Therefore,
1. Turn the key switch ON. test all fuses in the same way except for
When the key switch is turned ON, current from the fuses #9 and #31 fuse. Check fuse #9
key switch terminal M activates the battery relay and follow the procedure in step 3 after the
so that electric power is supplied to all circuits key switch is turned to the START position.
except the fuses #9 and #31 circuit. (Refer to the As current flows to fuse #31 only when the
circuit diagram.) air heater is operated, remove the fuse
2. Remove the fuse box cover. Set the tester. and check for continuity.
(Measurement Range: 0 to 30 V)
3. Ground the negative probe of the tester to the
body. Touch the terminals located away from cen-
ter of the fuse box with the positive probe of the
tester one at a time. When normal continuity of a
fuse is intact, the tester will indicate 20 to 25 V
(battery voltage).

Load Side (Outside)

＋
·
T142-06-06-004

Battery Side (Inside)

T5-8-4
 TROUBLESHOOTING / Electrical System Inspection
Fuse Box 1

10 20
9
19
8
7 18
17

16
6 15
5
14
4
3 13
2 12
1 11

·
M1GR-01-003

Fuse
Capacity Connected to
No.
1 5A Battery Relays 1 and 2
2 5A Air Conditioner
3 5A Ladder Relay
4 5A Travel Alarm (Optional)
5 20 A MC (Main, Sub), Pilot Shut-Off Relay, Pilot Shut-Off Solenoid Valve
6 15 A DC-DC Converter
7 10 A Seat Heater (Optional)
8 10 A Seat Heater (Optional)
9 5A Starter Cut Relay
10 10 A Back Light Relay
Light Relay 1, Travel Alarm Deactivation Switch, Lubrication Mode Selection Switch,
11 20 A Boom Mode Switch, Buzzer Deactivation Switch, Step Light Switch, Cab Light
Switch, Level Check Switch
12 20 A Light Relay 2
13 20 A Washer Relay, Wiper Motor, Wiper Relay (Low, High 1, High 2)
14 20 A Compressor Clutch Relay, Blower Main Relay
15 15 A Auto-Lubrication Relay
16 5A Pump Transmission Alarm Switch
17 5A Radio
18 10 A Horn Relay
19 10 A Cigar Lighter
20 5A Cab Light

T5-8-5
 TROUBLESHOOTING / Electrical System Inspection
Fuse Box 2

29 39
38
28
27 37
26
36
25 35
24
34
23
33
22
32
21
31

·
M1GR-01-003

Fuse
Capacity Connected to
No.
21 15 A ECM
22 5A MMS/DLU (Optional)
23 5A MC (Main, Sub)
24 5A Buzzer, Monitor Unit, ICF
25 5A DLU2
26 10 A Option
27 10 A Option
28 20 A Option
29 20 A Option
30 5A Download PC
31 5A Preheat Lamp Relay
Engine Stop Indicator, Engine Warning Indicator, Engine Maintenance Indicator, En-
32 5A
gine Stop Switch
33 5A MC (Main, Sub)
34 5A Monitor Unit, ICF
35 5A DLU2
36 5A MMS/DLU (Optional)
37 5A Satellite Communication Terminal
38 5A Step Light Relay
39 5A Security Horn, Radio
40 5A Satellite Communication Terminal

T5-8-6
 TROUBLESHOOTING / Electrical System Inspection
FUSIBLE LINK INSPECTION

• Fusible Links 1 to 4 Fusible Links 1 to 4 Fusible Links 5, 7, 8

Pull out and visually inspect the fusible links.

• Fusible Links 5, 7 and 8

Check for continuity between both ends of the
fusible link.

T18F-01-02-002

T5-8-7
 TROUBLESHOOTING / Electrical System Inspection
BATTERY VOLTAGE CHECK
1. Turn the key switch OFF. Check voltage between
the battery positive terminal and the body
(ground).

Normal Voltage: 24 V To Battery Relay

NOTE: If voltage is abnormal, recharge or replace

the battery.

2. Start the engine. Check voltage between the

battery positive terminal and the body (ground).

Normal Voltage: 26 to 28 V V

NOTE: If voltage is abnormal, check the charging

system.

T162-05-06-005

T5-8-8
 TROUBLESHOOTING / Electrical System Inspection
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 run-
ning, 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 the

body.
If the measured voltage is around 24 V, the al-
ternator circuit can be considered normal. Alternator Alarm M18J-01-005
If the measured voltage is low, a shortage in bat-
tery capacity or looseness of the wire connectors
of alternator circuit might be the cause of the
malfunction. Terminal R Terminal B
When voltage is 0 V, the wiring between fusible
link 5 and alternator might be disconnected. Also,
the alternator cannot generate electricity if the
ground line is disconnected.

3. Next, start the engine and measure voltage gen-

erated while the alternator rotates. As described
above, measure voltage between terminals B and
the body.
If voltage is around 28 V, the alternator is operat-
ing normally.
If the rated voltage is not being generated
(around 24 V), there is some trouble with the al-
ternator or the regulator.

T18E-05-08-004

T5-8-9
 TROUBLESHOOTING / Electrical System Inspection
CONTINUITY CHECK
Harness
Single-line continuity check
Disconnect both end connectors of the harness and A a
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 con-
nector (A) to the body by using a clip. Then,
check continuity of the harness through the Connect to the A a
body.
body as illustrated.

If the ohm-meter reading is: 0 Ω = Continuity

Ω
∞ Ω = Discontinuity To body

Single-line short-circuit check

Disconnect both end connectors of the harness and
A a
check continuity between one end connector of the x
Short-circuit
harness and the body: between the
harness and
If the ohm-meter reading is: the body.
0 Ω = Short-circuit is present. Ω
∞ Ω = No short-circuit is present.

T107-07-05-003

T5-8-10
 TROUBLESHOOTING / Electrical System Inspection
Multi-line continuity check
Disconnect both end connectors of the harness, and
short-circuit two terminals, (A) and (B), at one end First short-circuit (clip)
connector, as illustrated. Then, check continuity be-
tween terminals (a) and (b) at the other connector. If A a
the ohm-meter reading is ∞ Ω, either line (A) - (a), or B b
(B) - (b) is in discontinuity. To find out which line is C c
discontinued, conduct the single line continuity check Second
on both lines individually, or, after changing the short-circuit
short-circuit terminals from (A) - (B) to (A) - (C),
check continuity once more between terminals (a)
Ω
and (c).

NOTE: By conducting the multi-line continuity T107-07-05-004

check twice, it is possible to find out which Short-circuit between

line is discontinued. With terminals (A) and harnesses
(C) short-circuited, check continuity be-
tween terminals (a) and (c). A a
X
If the ohm-meter reading is: B b
C c
0 Ω = Line (B) - (b) has discontinuity.
∞ Ω = Line (A) - (a) has discontinuity.

Multi-line short-circuit check

Disconnect both end connectors of the harness, and Ω
check continuity between terminals (A) and (B) or
(C).
If the ohm-meter reading is:
0 Ω = Short-circuit exists between the lines. T107-07-05-005

∞ Ω = No short-circuit exists between the lines.

T5-8-11
 TROUBLESHOOTING / Electrical System Inspection
VOLTAGE AND CURRENT MEASURE-
MENT
Turn key switch ON so that the specified voltage (cur-
rent) is supplied to the location to be measured.
Judge if the circuit is normal by evaluating whether
the measured voltage (current) matches the specifica-
tion.

24-Volt Circuit
Start checking the circuit in order up to the loca-
tion to be measured from either power source or
actuator side. Thereby, the faulty location in the
circuit will be found.
Black Probe (Negative) of Tester:
To ground to the body (ground)
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 Ground: Fusible Link 1 20 to 25 V
Stopped OFF Between (5) and Ground: Fusible Link 7 20 to 25 V
Stopped OFF Between (6) and Ground: Fusible Link 8 20 to 25 V
Starting Circuit
Stopped ON or START Between (8) and Ground:Preheat Relay 1 20 to 25 V
Stopped ON or START Between (9) and Ground:Preheat Relay 2 20 to 25 V
Stopped ON or START Between (10) and Ground: Air Heater 1 20 to 25 V
Stopped ON or START Between (11) and Ground: Air Heater 2 20 to25 V
Surge Voltage
Prevention Circuit ON Between (7) and Ground: Load Damp 26 to 30 V
Idle Speed Relay

NOTE: *: Before measurement, disconnect the negative cable from the battery.

T5-8-12
 TROUBLESHOOTING / Electrical System Inspection

Power Circuit
Key Switch
Fusible Link 1

4
Fusible Link 7 3 2 1

7 5 Fusible
Link 8 Battery

2 1 6
5 3 Battery
Relay 2
Load Damp Relay
Fuse Box 2
Battery
Relay 1

2524 2322 2140 3938

Preheat Relay 1

Step Light Relay

Air Heater 1
8
Radio, Security Horn,
Security horn Relay
10
Satellite Communication Terminal Preheat Relay 2
ECM
Air Heater 2
MMS (Optional)/DLU (Optional) Connector

MC (Main, Sub) 9 11
Buzzer, Monitor Unit, ICF

DLU2
T18J-02-05-001

T5-8-13
 TROUBLESHOOTING / Electrical System Inspection

Engine Key Switch Location to be Measured Specification

Starting Circuit
Started START Between (12) and Ground: Key Switch 20 to 25 V
Started START Between (13) and Ground: Key Switch 20 to 25 V
Started START Between (14) and Ground: Fuse Box 20 to 25 V
Started START Between (15) and Ground: Fuse Box 20 to 25 V
Started START Between (16) and Ground: Battery Relay 2 (Coil) 20 to 25 V
Started START Between (17) and Ground: Battery Relay 1 (Coil) 20 to 25 V
Started START Between (18) and Ground: Battery Relay 2 (Switch) 20 to 25 V
Started START Between (19) and Ground: Battery Relay 1 (Switch) 20 to 25 V
Started START Between (20) and Ground: Starter 2 (B) 20 to 25 V
Started START Between (21) and Ground: Starter 1 (B) 20 to 25 V
Started START Between (22) and Ground: Starter Cut Relay 20 to 25 V
Started START Between (23) and Ground: Starter Relay 2-2 (S) 20 to 25 V
Started START Between (24) and Ground: Starter Relay 2-1 (S) 20 to 25 V

T5-8-14
 TROUBLESHOOTING / Electrical System Inspection
Starting Circuit

Key Switch
Fusible Link 1

Battery Relay 2
B A
18 S E
Battery Relay 1 16
Fuse Box 1 Fuse Box 2 B A
19 S E Battery

12 13

9 1 37 36 3534 33 32 17
14 Starter Cut Relay
1 2
MMS/DLU 15 3
(Optional) 4
Starter Relay 2-2
Starter 2 B S
C
DLU2 22
M
B 20
C 23
Satellite
communication
Terminal Starter Relay 2-1
Starter 1 B S
Engine Stop C
Switch M 21
Monitor Unit 1 8 B
4 5
C 24

ICF

MC (Main)
MC (Sub) ECM

T18J-02-05-003

T5-8-15
 TROUBLESHOOTING / Electrical System Inspection

Engine Key Switch Location to be Measured Specification

Accessory Circuit
Stopped ON Between (25) and Ground: Key Switch 20 to 25 V
Stopped ON or ACC Between (26) and Ground: Fuse Box 20 to 25 V
Stopped ON or ACC Between (27) and Ground: Fuse Box 20 to 25 V
Stopped ON or ACC Between (28) and Ground: Fuse Box 20 to 25 V
Stopped ON or ACC Between (29) and Ground: Fuse Box 20 to 25 V

T5-8-16
 TROUBLESHOOTING / Electrical System Inspection
Accessory Circuit

Key Switch
Fuseble Link 1

Battery
25

26 27 28
Fuse Box 1

17 18 19 20

29

Cab Light

Ciger Lighter

Horn Relay

Radio

T18J-02-05-002

T5-8-17
 TROUBLESHOOTING / Electrical System Inspection

Engine Key Switch Location to be Measured Specification

Charging Circuit
Running ON Between (30) and Ground: Alternator (B) 26 to 30 V
Running ON Between (31) and Ground: Fusible Link 26 to 30 V
Running ON Between (32) and Ground: Alternator (R) 20 to 25 V
Running ON Between (33) and Ground: Monitor Unit 20 to 25 V
Running ON Between (34) and Ground: ICF 20 to 25 V

T5-8-18
 TROUBLESHOOTING / Electrical System Inspection

Charging Circuit
Key Switch
Fusible Link 1
Battery Relay 2
Fusible Link 2 B A
S E
Fusible Link 3
Battery Relay 1
Fuse Box 1 B A
Fusible Link 4 S E Battery

Fusible Link 5

Fusible Link 7

31
Fusible Link 8

34

ICF Alternator
B

Monitor Unit R
30

33 32

T18J-02-05-004

T5-8-19
 TROUBLESHOOTING / Electrical System Inspection
5-Vol Circuit
Power Signal or
• Voltage between terminal #1 and the body Two Polarities Source Ground
Disconnect the connector with the key switch OFF. 1 2
Measure voltage between terminal #1 on the body
harness end connector and the body (ground).

• Key switch: ON
• Tester black terminal (negative):
Connected to the body (ground) V
• Tester red terminal (positive):
Connected to terminal #1

Evaluation:
T107-07-05-006
If the measuring voltage is within 5±0.5 volts, the
Power
circuit up to terminal #1 is normal. Three Polarities
Source Signal Ground
1 2 3

T107-07-05-007

• Voltage between terminal #1 and the ground Two Polarities

1 2
terminal
Disconnect the sensor connector with the key
switch OFF.
Measure voltage between terminal #1 on the body
harness end connector and the ground terminal V
(terminal #2 for two polarities, or terminal #3 for
three polarities).

• Key switch: ON
• Tester black terminal (negative):
Connected to the ground terminal T107-07-05-008
(terminal #2 or #3)
• Tester red terminal (positive): Three Polarities
Connected to terminal #1 1 2 3

Evaluation:
If the measured voltage is within 5±0.5 volts, the
circuit up to terminal #1 or the ground terminal
V
(terminal #2 or #3) is normal.

T107-07-05-009

T5-8-20
 TROUBLESHOOTING / Electrical System Inspection
CHECK BY FALSE SIGNAL
Two Polarities
Turn the key switch OFF. Disconnect the sensor con- (Hydraulic Oil Temperature Sensor)
nector. Turn the key switch ON. Connect terminal #1 (Fuel Sensor)
1 2
(power source) of the body 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 body 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 body (ground)
when checking a three-polarity Three Polarities
T107-07-05-010

connector.
(Pressure Sensor)
(Pump Delivery Pressure Sensor)
NOTE: Some kinds of sensors can be monitored (Pump Regulator Pressure Sensor) 1 2 3
by the service menu of the monitor (the
built-in diagnosing system).

Connect

T107-07-05-011

T5-8-21
 TROUBLESHOOTING / Electrical System Inspection
TEST HARNESS
Install a test harness between connectors. Check the
circuit condition depending on whether the test har-
ness 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 Location to Be Measured
To Ground

Parts Number 4283594 (ST 7126) T107-07-05-012

T5-8-22