Technical Manual Hitachi ZX180W-7 Wheeled Excavator | TTLBN50-EN-00

Technical Manual Hitachi ZX180W-7 Wheeled Excavator TTLBN50-EN-00 (Preview)

TTLBN50-EN-00
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Trademark
Safety Alert Symbol and Headline Notations
Units Used
SYMBOL AND ABBREVIATION
Symbol and Abbreviation
CONTRASTING LIST OF PART NAME
Contrasting List of Part Name between Technical Manual and Parts Catalog
SAFETY
Recognize Safety Information
Understand Signal Words
Follow Safety Instructions
Prepare for Emergencies
Wear Protective Clothing
Protect Against Noise
Inspect Machine
General Precautions for the Cab
Use Handrail and Steps
Adjust the Operator’s Seat
Ensure Safety Before Rising from or Leaving Operator’s Seat
Fasten Your Seat Belt
Move and Operate Machine Safely
Start the Engine Only from Operator’s Seat
Jump Starting
Keep Riders off Machine
Precautions for Operations
Perform Job Site Risk Assessment Beforehand
Install OPG Guard
Restriction of Attachment Installation
Provide Signals for Jobs Involving Multiple Machines
Confirm Direction of Machine to Be Driven
Drive Machine Safely

Avoid Injury from Rollaway Accidents
Avoid Accidents from Reversing and Swing Operation
Keep People Clear from Working Area
Never Position the Bucket Over Anyone
Avoid Undercutting
Avoid Tipping
Never Undercut a High Bank
Dig with Caution
Caution with an Overhead Obstacle
Avoid Power Lines
Precautions for Lightning
Object Handling
Protect Against Flying Debris and Falling Object
Park Machine Safely
Handle Fluids Safely−Avoid Fires
Transport Safely
Practice Maintenance Safely
Warn Others of Service Work
Support Machine Properly
Stay Clear of Moving Parts
Prevent Parts from Flying
Avoid Injury from Attachment Falling Accident
Support Maintenance Properly
Prevent Burns
Replace Rubber Hoses Periodically
Avoid High-Pressure Fluids
Prevent Fires
Check for Oil Leaks:
Check for Short circuits:
Clean up Flammable Materials:
Check Key Switch:
Check Heat Shields:
Evacuating in Case of Fire
Beware of Exhaust Fumes
Precautions for Welding and Grinding
Avoid Heating Near Pressurized Fluid Lines
Avoid Applying Heat to Lines Containing Flammable Fluids
Precautions for Handling Accumulator and Gas Damper
Remove Paint Before Welding or Heating
Beware of Asbestos and Silica Dust and Other Contamination
Prevent Battery Explosions
Service Air Conditioning System Safely
Handle Chemical Products Safely
Dispose of Waste Properly
Never Ride Attachment
Notes on Aftertreatment Device
Precautions for Communication Terminal
Precautions for Communication Terminal Equipment
Operation Stop Alarm (ZX135W-7/150W-7/155W-7/175W-7)
Notes on Protection by Operator’s Station when the Machine Rolls Over
Before Returning the Machine to the Customer
SECTION AND GROUP CONTENTS
CONTENTS
OPERATIONAL PERFORMANCE TEST
Introduction
Operational Performance Tests
Preparation for Performance Tests
Standard
Operational Performance Standard Table
Engine System Performance Standards
Travel System Performance Standards
Swing System Performance Standards
Front Attachment System Performance Standards
Blade/Outrigger System Performance Standards
Lever System Performance Standards
Combined Operation System Performance Standards
Hydraulic Components System Performance Standards
Main Pump P-Q Diagram (P1, P2)
Engine Control Dial Activating Range
Pilot Pressure Sensor (4436535) Operation Range
Pump Control Pressure Sensor (4436536) Activating Range
Pilot Pressure Sensor (YA00057050) Operation Range
High Pressure Sensor (4436271) Operation Range
Auxiliary/Positioning Pedal (Electric Lever) Operation Range
Blade/Outrigger Lever (Electric Lever) Operation Range
AFL (Electric Lever) Operation Range
Monitor Indicating Values of ECM
Monitor Indicating Values of MC
Monitor Indicating Values of MC (Pressure Sensor)
Monitor Indicating Values of MC (Solenoid Valve)
Monitor Indicating Values of PLCU
Monitor Indicating Values of Switch Box Controller
Engine Test
Engine Speed
Lubricant Consumption
Machine Performance Test
Travel Speed
Brake Function Check
Parking Brake Function Check
Swing Speed
Swing Function Drift Check
Swing Motor Leakage
Maximum Swingable Slant Angle
Swing Bearing Play
Hydraulic Cylinder Cycle Time
Dig Function Drift Check (Maximum Reach Position)
Dig Function Drift Check (Arm Roll-In Position)
Hydraulic Cylinder Drift Check (Positioning Cylinder)
Control Lever Operating Force
Control Lever Stroke
Combined Operation of Boom Raise and Swing Function Check
Clearance of Front Attachment Connecting Part
Electric Lever Operating Effort (Auxiliary/Positioning Pedal and Blade/Outrigger Lever)
Component Test
Primary Pilot Pressure
Secondary Pilot Pressure (Pilot Valve)
Secondary Pilot Pressure (Electric Lever)
Steering Pump Delivery Pressure
3-Spool Solenoid Valve Unit 1 Set Pressure
3-Spool Solenoid Valve Unit 2 Set Pressure
Axle Lock/Brake Solenoid Valve Unit Set Pressure
Pump 1 and Pump 2 Flow Rate Control Solenoid Valve Unit Set Pressure
Cruise Control Solenoid Valve Set Pressure
Main Pump Delivery Pressure
Main Relief Set Pressure
Main Relief Valve Pressure Adjustment Procedure
High-Pressure Side of Main Relief Pressure Adjustment Procedure
Low-Pressure Side of Main Relief Pressure Adjustment Procedure
Relief Pressure (When Relieving Swing)
Overload Relief Valve Set Pressure
Overload Relief Valve Pressure Adjustment Procedure (Reference)
Main Pump Flow Rate Measurement (P-Q Control (Torque Control))
Main Pump Flow Rate Measurement (Pilot Pressure Characteristics)
Regulator Adjustment
Swing Motor Drainage
Steering Relief Pressure
Brake Pressure (Front Wheel and Rear Wheel)
Brake Accumulator Charging Pressure
Adjustment
Rewrite of Aftertreatment Device Serial No.
How to Clear Fault Code
Measuring Method of No-Load-Max Differential Pressure
Differential Pressure Sensor Learning
Filter Maintenance
Procedure after Replacing DCU and ECM
Air Bleeding from the Diesel Exhaust Fluid Defrosting Piping
How to Check Manual Regeneration Switch
Remedy at DEF Pressure Decrease
Clean DEF Tank
Remedy when Mixing Oil in DEF Tank
Calibration of Aerial Angle
Oil Monitoring Sensor Setting
[A] Constant Change (Oil Monitoring Sensor Setting)
[D] Sensor Collective Diagnosis (Oil Monitoring Sensor Functional Check)
[B] Diagnosis of Engine Oil Monitoring Sensor (Oil Monitoring Sensor Functional Check)
[C] Diagnosis of Hydraulic Oil Monitoring Sensor (Oil Monitoring Sensor Functional Check)
TROUBLESHOOTING
Diagnosing Procedure
Introduction
Diagnosis Procedure
Electrical System Inspection
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Instructions for Removing Relays
Fuse Inspection
Fuse Connection Destination
Fusible Link Inspection
Battery Voltage Check
Alternator Check
Continuity Check
Voltage and Current Measurement of 24-Volt Circuit
Voltage and Current Measurement of 5-Volt Circuit
Check by False Signal
Test Wire Harness
Electric Lever (Auxiliary, Positioning) Check
Electric Lever (Blade/Outrigger) Check
AFL Check
Removal of ECM
Installation of ECM
Removal of DCU
Installation of DCU
Removal of VGS Controller
Installation of VGS Controller
Removal of MC (Main Controller)
Installation of MC (Main Controller)
Removal of Monitor Controller
Installation of Monitor Controller
Removal of GSM
Installation of GSM
Removal of PLCU
Installation of PLCU
Removal of Aerial Angle Controller
Installation of Aerial Angle Controller
Mounting Position of Pump Delivery Pressure Sensor
Mounting Position of Pump Control Pressure Sensor
Mounting Position of Boom Lower Pilot Pressure Sensor
Mounting Position of Arm Roll-Out Pilot Pressure Sensor
Mounting Position of Arm 2 Roll-In Pilot Pressure Sensor
Mounting Position of Bucket Roll-Out Pilot Pressure Sensor
Mounting Position of Bucket Roll-In Pilot Pressure Sensor
Mounting Position of Travel Forward Pilot Pressure Sensor and Travel Reverse Pilot Pressure Sensor
Mounting Position of Arm 1 Roll-In Pilot Pressure Sensor
Mounting Position of Swing Pilot Pressure Sensor
Mounting Position of Front Pilot Pressure Sensor
Mounting Position of Auxiliary 1 Pilot Pressure Sensor
Mounting Position of Blade/Outrigger Pilot Pressure Sensor
Mounting Position of Positioning Pilot Pressure Sensor
Mounting Position of Steering Pump Delivery Pressure Sensor
Mounting Position of Brake Remain Pressure Sensor
Mounting Position of Travel N Sensor
Mounting Position of Brake Pressure Sensor
Mounting Position of AFL Pilot Hydraulic Oil Temperature Sensor
Mounting Position of Assist Pilot Pressure Sensor
Mounting Position of Fuel Sensor
Mounting Position of Hydraulic Oil Temperature Sensor
Mounting Position of Differential Pressure Sensor
Mounting Position of Exhaust Temperature Sensor
Mounting Position of NOx Sensor
Mounting Position of Engine Oil Monitoring Sensor
Mounting Position of Hydraulic Oil Monitoring Sensor
Mounting Position of Ambient Temperature Sensor
Mounting Position of Re-Circulated Air Temperature Sensor
Mounting Position of Frost Sensor
Mounting Position of Solar Radiation Sensor
Monitor
Basic Screen of Monitor
Operating Procedures of Service Menu
How to Display Service Menu
How to Display Troubleshooting Screen
How to Display Monitoring
Monitoring Items of Engine Controller (ECM)
Monitoring Items of Main Controller (MC)
Monitoring Items of PLCU
Monitoring Items of Monitor Controller (Information)
Monitoring Items of Switch Box Controller
Monitoring Items of Air Conditioner Unit
How to Display Controller Version
How to Display Operation
How to Display Communication Terminal Status
List of Communication Terminal Status
Operating Procedures of Breaker Alarm
Operating Procedures of Machine Setting (Constant Change)
List of Machine Setting Items
Operating Procedures of Monitor Setting (Operation Permission)
Operating Procedures of Monitor Setting (Maintenance Items)
List of Monitor Setting Items
Operating Procedures of Attachment Setting (Constant Change)
List of Attachment Setting Items
Operating Procedures of Engine Setting
How to Display Aftertreatment Device No.
Attachment Adjustment
Operating Procedures of Breaker Relief Pressure
Operating Procedures of Auxiliary Overload Relief Valve Set-Pressure
Inspection of Engine Oil Level and Coolant Level
Inspection of Hour Meter and Fuel Gauge
Fuel Gauge
Coolant Temperature Gauge
DEF Gauge
Hydraulic Oil Temperature Gauge
e-Service
Outline of e-Service
List of Operation Data
Communication System
Component Layout
Main Component (Upperstructure)
Main Component (Undercarriage)
Main Component (Front Attachment)
Electrical System (Overview)
Electrical System (Cab)
Electrical System (Switches)
Electrical System (Rear Tray)
Relay Layout
Electrical System (Utility Space)
Electrical System (Relays)
Electrical System (Lights)
Engine Oil Monitoring Sensor
Hydraulic Oil Monitoring Sensor
Engine
Aftertreatment Device
Pump Device
Around Pump Device
Control Valve
Signal Control Valve
Swing Shockless Valve
Swing Device
Accumulator Charging Valve
Travel Shockless Valve
Travel Device
Brake Valve
7-Spool Solenoid Valve Unit
3-Spool Solenoid Valve Unit 1
3-Spool Solenoid Valve Unit 2
2-Spool Solenoid Valve Unit (For Assist) (Option)
2-Spool Solenoid Valve Unit (For Blade/Outrigger Cylinder) (Front) (Option)
2-Spool Solenoid Valve Unit (For Blade/Outrigger Cylinder) (Rear) (Option)
Pump 1 and Pump 2 Flow Rate Control Solenoid Valve Unit
Axle Lock/Brake Solenoid Valve Unit
Transmission Control Solenoid Valve
Cruise Stop Solenoid Valve
Cruise Control Solenoid Valve
Around DEF Tank
Layout of Attachment Spec. Parts
Auxiliary Control Solenoid Valve Unit
Breaker Relief Solenoid Valve
Selector Valve Control Valve
Components in Control Valve
Pilot Valve Side of Pilot Port
Control Valve Side of Pilot Port
Port Layout of Control Valve (Main Circuit)
Port Layout of Control Valve (Pilot Circuit)
Troubleshooting A
Troubleshooting A (Base Machine Diagnosis by Using Fault Codes) Procedure
Contents of Troubleshooting A
MC Fault Code 73000-3
MC Fault Code 73000-4
MC Fault Code 73001-3
MC Fault Code 73001-4
MC Fault Code 73002-3
MC Fault Code 73003-2
MC Fault Code 73005-2
MC Fault Code 73006-2
MC Fault Code 41000-2
MC Fault Code 51000-3
MC Fault Code 51000-4
MC Fault Code 51001-3
MC Fault Code 51001-4
MC Fault Code 51003-3
MC Fault Code 51003-4
MC Fault Code 51005-3
MC Fault Code 51005-4
MC Fault Code 53000-3
MC Fault Code 53000-4
MC Fault Code 53001-3
MC Fault Code 53001-4
MC Fault Code 53003-3
MC Fault Code 53003-4
MC Fault Code 53005-3
MC Fault Code 53005-4
MC Fault Code 53006-3
MC Fault Code 53006-4
MC Fault Code 53015-3
MC Fault Code 53015-4
MC Fault Code 53016-3
MC Fault Code 53016-4
MC Fault Code 51006-2
MC Fault Code 51006-6
MC Fault Code 51006-5
MC Fault Code 51007-2
MC Fault Code 51007-6
MC Fault Code 51007-5
MC Fault Code 51009-2
MC Fault Code 51009-6
MC Fault Code 51009-5
MC Fault Code 51065-2
MC Fault Code 51065-6
MC Fault Code 51065-5
MC Fault Code 51012-2
MC Fault Code 51012-6
MC Fault Code 51012-5
MC Fault Code 51013-2
MC Fault Code 51013-6
MC Fault Code 51013-5
MC Fault Code 51014-2
MC Fault Code 51014-6
MC Fault Code 51014-5
MC Fault Code 51016-2
MC Fault Code 51016-6
MC Fault Code 51016-5
MC Fault Code 51017-2
MC Fault Code 51017-6
MC Fault Code 51017-5
MC Fault Code 51018-2
MC Fault Code 51018-6
MC Fault Code 51018-5
MC Fault Code 51020-2
MC Fault Code 51021-3
MC Fault Code 51021-4
MC Fault Code 51022-3
MC Fault Code 51022-4
MC Fault Code 51025-0
MC Fault Code 51026-14
MC Fault Code 63000-2
MC Fault Code 73007-2
MC Fault Code 73008-2
MC Fault Code 73034-2
MC Fault Code 51030-2
MC Fault Code 51030-6
MC Fault Code 51030-5
MC Fault Code 51054-2
MC Fault Code 51054-6
MC Fault Code 51054-5
MC Fault Code 73028-2
MC Fault Code 41026-0
MC Fault Code 41026-25
MC Fault Code 41027-14
MC Fault Code 41028-14
MC Fault Code 41029-16
MC Fault Code 41029-17
MC Fault Code 41029-18
MC Fault Code 51059-3
MC Fault Code 51059-4
MC Fault Code 51060-2
MC Fault Code 51060-6
MC Fault Code 51060-5
MC Fault Code 51061-3
MC Fault Code 51061-4
MC Fault Code 51062-2
MC Fault Code 51062-6
MC Fault Code 51062-5
MC Fault Code 50005-17
Monitor Controller (Information) Fault Code 41001-2
Monitor Controller (Information) Fault Code 41002-3
Monitor Controller (Information) Fault Code 41003-3
Monitor Controller (Information) Fault Code 41003-4
Monitor Controller (Information) Fault Code 73033-2
Monitor Controller (Information) Fault Code 41004-14
Monitor Controller (Information) Fault Code 41005-14
Monitor Controller (Information) Fault Code 41006-14
Monitor Controller (Information) Fault Code 41007-14
Monitor Controller (Information) Fault Code 41008-14
Monitor Controller (Information) Fault Code 41004-20
Monitor Controller (Information) Fault Code 73013-2
Monitor Controller (Information) Fault Code 73014-2
Monitor Controller (Information) Fault Code 73015-2
Monitor Controller (Information) Fault Code 73016-2
Monitor Controller (Information) Fault Code 73017-2
Monitor Controller (Information) Fault Code 73018-2
Monitor Controller (Information) Fault Code 73019-2
Monitor Controller (Information) Fault Code 73020-2
Monitor Controller (Information) Fault Code 73021-2
Monitor Controller (Information) Fault Code 68004-12
Monitor Controller (Information) Fault Code 68005-12
Monitor Controller (Information) Fault Code 68006-12
Monitor Controller (Information) Fault Code 68007-12
Monitor Controller (Information) Fault Code 68008-12
Monitor Controller (Information) Fault Code 68009-12
Monitor Controller (Information) Fault Code 41002-4
Monitor Controller (Information) Fault Code 73029-2
Monitor Controller (Information) Fault Code 73069-2
Monitor Controller (Monitor) Fault Code 73010-2
Monitor Controller (Monitor) Fault Code 73011-2
Monitor Controller (Monitor) Fault Code 73012-2
Monitor Controller (Monitor) Fault Code 73030-2
Monitor Controller (Monitor) Fault Code 13911-3
Monitor Controller (Monitor) Fault Code 13912-4
Monitor Controller (Monitor) Fault Code 13913-3
Monitor Controller (Monitor) Fault Code 13914-4
Monitor Controller (Monitor) Fault Code 13917-3
Monitor Controller (Monitor) Fault Code 13918-4
Monitor Controller (Monitor) Fault Code 13921-3
Monitor Controller (Monitor) Fault Code 13922-4
Monitor Controller (Monitor) Fault Code 13943-2
Monitor Controller (Monitor) Fault Code 13944-2
Monitor Controller (Monitor) Fault Code 13951-2
Monitor Controller (Monitor) Fault Code 13991-2
Monitor Controller (Monitor) Fault Code 13992-2
Switch Box Controller Fault Code 14504-3
Switch Box Controller Fault Code 14504-4
Aerial Angle Controller Fault Code 68000-2
Aerial Angle Controller Fault Code 68001-2
Aerial Angle Controller Fault Code 68002-2
Aerial Angle Controller Fault Code 73022-2
Aerial Angle Controller Fault Code 68003-2
PLCU Fault Code 53017-2
PLCU Fault Code 53018-2
PLCU Fault Code 53019-2
PLCU Fault Code 53020-2
PLCU Fault Code 53021-2
PLCU Fault Code 53009-8
PLCU Fault Code 53010-8
PLCU Fault Code 53017-8
PLCU Fault Code 53020-8
PLCU Fault Code 53018-8
PLCU Fault Code 53021-8
PLCU Fault Code 63001-3
PLCU Fault Code 63001-4
PLCU Fault Code 73023-2
PLCU Fault Code 73035-7
PLCU Fault Code 55001-2
PLCU Fault Code 53061-8
PLCU Fault Code 53061-2
PLCU Fault Code 53062-8
PLCU Fault Code 53062-2
PLCU Fault Code 53063-2
PLCU Fault Code 53064-2
PLCU Fault Code 53065-0
PLCU Fault Code 53065-8
PLCU Fault Code 53066-0
PLCU Fault Code 53066-8
PLCU Fault Code 53067-3
PLCU Fault Code 53067-4
PLCU Fault Code 53068-3
PLCU Fault Code 53068-4
PLCU Fault Code 53067-12
PLCU Fault Code 53067-7
PLCU Fault Code 53068-12
PLCU Fault Code 53068-7
PLCU Fault Code 53069-2
PLCU Fault Code 53069-6
PLCU Fault Code 53069-5
PLCU Fault Code 53070-2
PLCU Fault Code 53070-6
PLCU Fault Code 53070-5
PLCU Fault Code 53071-2
PLCU Fault Code 53071-6
PLCU Fault Code 53071-5
PLCU Fault Code 53072-2
PLCU Fault Code 53072-6
PLCU Fault Code 53072-5
PLCU Fault Code 53073-2
PLCU Fault Code 53074-2
PLCU Fault Code 53075-2
PLCU Fault Code 53076-3
PLCU Fault Code 53076-4
PLCU Fault Code 53077-3
PLCU Fault Code 53077-4
PLCU Fault Code 53076-12
PLCU Fault Code 53076-7
PLCU Fault Code 53077-12
PLCU Fault Code 53077-7
PLCU Fault Code 53078-2
PLCU Fault Code 53078-6
PLCU Fault Code 53078-5
PLCU Fault Code 53079-2
PLCU Fault Code 53079-6
PLCU Fault Code 53079-5
PLCU Fault Code 53080-2
PLCU Fault Code 53080-6
PLCU Fault Code 53080-5
PLCU Fault Code 53081-2
PLCU Fault Code 53081-6
PLCU Fault Code 53081-5
PLCU Fault Code 55002-3
PLCU Fault Code 55002-4
PLCU Fault Code 55003-3
PLCU Fault Code 55003-4
PLCU Fault Code 55004-3
PLCU Fault Code 55004-4
PLCU Fault Code 55005-3
PLCU Fault Code 55005-4
PLCU Fault Code 55006-3
PLCU Fault Code 55006-4
PLCU Fault Code 55007-2
PLCU Fault Code 55014-2
PLCU Fault Code 55008-2
PLCU Fault Code 55009-2
PLCU Fault Code 55010-2
PLCU Fault Code 55010-6
PLCU Fault Code 55010-5
PLCU Fault Code 55011-2
PLCU Fault Code 55011-6
PLCU Fault Code 55011-5
PLCU Fault Code 55012-2
PLCU Fault Code 55012-6
PLCU Fault Code 55012-5
PLCU Fault Code 55013-2
PLCU Fault Code 55013-6
PLCU Fault Code 55013-5
Power-CAN harness Check
Body-CAN Harness Check
ISO-CAN (Engine) Harness Check
IF-CAN Harness Check
OPT-CAN Harness Check
PL-CAN Harness Check
ECM Fault Code List
DCU Fault Code List
Troubleshooting B
Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure
Contents of Troubleshooting B
Relationship between Machine Trouble Symptoms and Related Parts
When a Fault Occurs in MC (Main Controller)
When a Fault Occurs in PLCU
When a Fault Occurs in Switch Box Controller
When a Fault Occurs in Engine Control Dial
When a Fault Occurs in Auto-Idle Switch
When a Fault Occurs in Power Mode Switch
When a Fault Occurs in Travel Mode Switch
When a Fault Occurs in Power Digging Switch
When a Fault Occurs in Pilot Shut-Off Switch (Pilot Shut-Off Lever)
When a Fault Occurs in Manual Regeneration Switch
When a Fault Occurs in Aerial Angle Switch
When a Fault Occurs in FNR Switch
When a Fault Occurs in Engine Speed Control Mode Selection Switch
When a Fault Occurs in Brake Switch
When a Fault Occurs in Working Brake Release Switch
When a Fault Occurs in Blade/Outrigger Main Switch
When a Fault Occurs in Blade/Outrigger Front-Rear Selection Switch
When a Fault Occurs in Blade/Outrigger Left-Right Selection Switch
When a Fault Occurs in Public Road Drive Switch
When a Fault Occurs in Parking Switch
When a Fault Occurs in Automatic Working Brake Switch
When a Fault Occurs in Auto-Lubrication Reset Switch
When a Fault Occurs in Cruise Main Switch
When a Fault Occurs in Cruise Speed Set Switch
When a Fault Occurs in Seat Heater Switch
When a Fault Occurs in Pilot Shut-Off Solenoid Valve
When a Fault Occurs in Hydraulic Oil Temperature Sensor
When a Fault Occurs in Differential Pressure Sensor
When a Fault Occurs in DOC Inlet Exhaust Temperature Sensor
When a Fault Occurs in DOC Outlet Exhaust Temperature Sensor
When a Fault Occurs in SCR Exhaust Temperature Sensor
When a Fault Occurs in Pump 1 Delivery Pressure Sensor
When a Fault Occurs in Pump 2 Delivery Pressure Sensor
When a Fault Occurs in Steering Pump Delivery Pressure Sensor
When a Fault Occurs in Brake Pressure Sensor
When a Fault Occurs in Brake Remain Pressure Sensor
When a Fault Occurs in Pump 1 Control Pressure Sensor
When a Fault Occurs in Pump 2 Control Pressure Sensor
When a Fault Occurs Swing Pilot Pressure Sensor
When a Fault Occurs in Boom Raise Pilot Pressure Sensor
When a Fault Occurs in Arm 2 Roll-In Pilot Pressure Sensor
When a Fault Occurs in Arm 1 Roll-In Pilot Pressure Sensor
When a Fault Occurs in Travel Forward Pilot Pressure Sensor
When a Fault Occurs in Travel Reverse Pilot Pressure Sensor
When a Fault Occurs in Front Pilot Pressure Sensor
When a Fault Occurs in Bucket Roll-In Pilot Pressure Sensor
When a Fault Occurs in Arm Roll-Out Pilot Pressure Sensor
When a Fault Occurs in Bucket Roll-Out Pilot Pressure Sensor
When a Fault Occurs in Auxiliary 1 Pilot Pressure Sensor (Option)
When a Fault Occurs in Positioning Pilot Pressure Sensor
When a Fault Occurs in Blade/Outrigger Pilot Pressure Sensor
When a Fault Occurs in Assist Pilot Pressure Sensor (Option)
When a Fault Occurs in Travel N Sensor
When a Fault Occurs in Cruise Control Pressure Monitoring Sensor
When a Fault Occurs in AFL Pilot Hydraulic Oil Temperature sensor
When a Fault Occurs in Auto-Lubrication Grease Level Sensor
When a Fault Occurs in Auto-Lubrication Stroke Sensor
When a Fault Occurs in Pump 1 and 2 Torque Control Solenoid Valve
When a Fault Occurs in Maximum Pump 1 Flow Rate Limit Control Solenoid Valve
When a Fault Occurs in Maximum Pump 2 Flow Rate Limit Control Solenoid Valve
When a Fault Occurs in 3-Spool Solenoid Valve Unit 1 (SG)
When a Fault Occurs in 3-Spool Solenoid Valve Unit 1 (SC)
When a Fault Occurs in 3-Spool Solenoid Valve Unit 1 (SF)
When a Fault Occurs in 3-Spool Solenoid Valve Unit 2 (SK1)
When a Fault Occurs in 3-Spool Solenoid Valve Unit 2 (SK2)
When a Fault Occurs in 3-Spool Solenoid Valve Unit 2 (SK3)
When a Fault Occurs in Pump 1 Flow Rate Control Solenoid Valve
When a Fault Occurs in Pump 2 Flow Rate Control Solenoid Valve
When a Fault Occurs in Axle Lock Solenoid Valve
When a Fault Occurs in Brake Solenoid Valve
When a Fault Occurs in Travel Forward Pi Cut Solenoid Valve
When a Fault Occurs in Travel Reverse Pi Cut Solenoid Valve
When a Fault Occurs in Travel Motor Displacement Control Solenoid Valve
When a Fault Occurs in Transmission Control Solenoid Valve
When a Fault Occurs in Blade/Outrigger Solenoid Valve
When a Fault Occurs in Auxiliary Solenoid Valve
When a Fault Occurs in Positioning Solenoid Valve
When a Fault Occurs in Assist Solenoid Valve (Option)
When a Fault Occurs in Pilot Cut-Off Solenoid Valve
When a Fault Occurs in Blade/Outrigger Cylinder Solenoid Valve
When a Fault Occurs in Cruise Control Solenoid Valve
When a Fault Occurs in Cruise Stop Solenoid Valve
When a Fault Occurs in Main Relief Valve
When a Fault Occurs in Overload Relief Valve
When a Fault Occurs in Boom Anti-Drift Valve
When a Fault Occurs in Arm Anti-Drift Valve
When a Fault Occurs in Boom Regenerative Valve
When a Fault Occurs in Arm Regenerative Valve
When a Fault Occurs in Bucket Regenerative Valve
When a Fault Occurs in Bucket Regeneration Cut Valve
When a Fault Occurs in Arm 1 Flow Rate Control Valve
When a Fault Occurs in Boom Flow Rate Control Valve
When a Fault Occurs in Bucket Flow Rate Control Valve
When a Fault Occurs in Auxiliary Flow Rate Control Valve
When a Fault Occurs in Auxiliary Flow Combiner Valve
When a Fault Occurs in Pump 1 Bypass Shut-Out Valve
When a Fault Occurs in Pump 2 Bypass Shut-Out Valve
When a Fault Occurs in Boom Lower Meter-In Cut Valve
When a Fault Occurs in Pump 1 Flow Rate Control Valve
When a Fault Occurs in Pump 2 Flow Rate Control Valve
When a Fault Occurs in Swing Parking Brake Release Spool
When a Fault Occurs in Bucket Flow Rate Control Valve Control Spool
When a Fault Occurs in Steering Valve
When a Fault Occurs in Brake Valve
When a Fault Occurs in Accumulator Charging Valve
When a Fault Occurs in Auxiliary Flow Combiner Control Solenoid Valve (Option)
When a Fault Occurs in Auxiliary Flow Rate Control Solenoid Valve (Option)
When a Fault Occurs in Reducing Valve (For Auxiliary) (Option)
When a Fault Occurs in Selector Valve Control Solenoid Valve (Option)
When a Fault Occurs in Selector Valve (Option)
When a Fault Occurs in Accumulator Control Valve (Option)
When a Fault Occurs in Breaker Relief Solenoid Valve (Option)
When a Fault Occurs in Auxiliary Overload Relief Solenoid Valve (Option)
Identification Symbol of Troubleshooting B
Correlation between Trouble Symptoms and Part Failures
Parts Related with “E-1 Starter does not rotate.”
Parts Related with “E-2 Even if starter rotates, engine does not start.”
Parts Related with “E-3 Even if power mode switch is operated, power mode is not shifted.”
Parts Related with “E-4 ECO mode is faulty.”
Parts Related with “E-6 Auto-idle system is faulty.”
Parts Related with “E-8 Engine speed does not increase when coolant temperature is low.”
Parts Related with “E-9 Auto shut-down is not activated.”
Parts Related with “E-12 Engine speed does not decrease when audio mute/one-touch idle switch is pushed.”
Parts Related with “E-13 Even if accelerator pedal is operated during travel, engine speed does not change.”
Parts Related with “A-1 All actuators do not work.”
Parts Related with “A-2 All actuator speeds are slow.”
Parts Related with “A-3 Actuator does not stop even if control lever is set to neutral.”
Parts Related with “A-4 Manual regeneration of aftertreatment device cannot be performed.”
Parts Related with “A-5 Travel operation speed is slow when performing travel single operation.” Bucket single operation speed is slow. Boom can hardly be raised in level crowding operation. (All problems occur at the same time.)”
Parts Related with “A-7 Swing single operation speed is slow. Arm speed is slightly slow when performing arm level crowding operation. (All problems occur at the same time.)”
Parts Related with “A-8 Swing speed is slow or arm roll-in speed is slow when performing combined operation of swing and arm roll-in.”
Parts Related with “A-10 Actuator speed is faster than normal.Precise control cannot be performed.”
Parts Related with “F-1 All front attachment actuator powers are weak.”
Parts Related with “F-2 Front attachment drifts remarkably.”
Parts Related with “F-3 When boom raise or arm roll-out is operated, boom or arm starts to move after moving slightly down.”
Parts Related with “F-4 Even if power digging switch is pushed, power does not increase. Boom raise power is weak when performing digging operation.”
Parts Related with “F-5 Boom, arm, or bucket single operation is not operated. Boom, arm, or bucket single operation speed is slow.”
Parts Related with “F-6 Bucket roll-in operating speed is slow or power is weak when performing digging operation.”
Parts Related with “F-7 When performing combined operation, arm does not start to move smoothly. Arm starts to move slightly slow when performing arm single operation. These troubles often occur when temperature is low.”
Parts Related with “F-8 When performing combined operation, boom does not start to move smoothly. Boom starts to move slightly slow when performing boom lower single operation.”
Parts Related with “F-9 Boom lower speed above ground is faster than other actuators when performing combined operation. Machine cannot be raised off the ground.”
Parts Related with “F-11 Arm roll-in speed is slow when performing combined operation. Arm roll-in speed is slow when performing arm level crowding operation.”
Parts Related with “F-12 Arm roll-out speed is slow when performing combined operation of boom raise, arm roll-out, and attachment.”
Parts Related with “F-13 Difficult to raise the machine off the ground.”
Parts Related with “F-14 Attachment speed is slow when performing combined operation of attachment and arm.”
Parts Related with “F-17 Bucket roll-in single operation speed is slightly slow. Bucket does not move smoothly in bucket roll-in single operation.”
Parts Related with “S-1 Swing speed is slow or is not operated.”
Parts Related with “S-3 Swing speed is slow when performing combined operation of swing and arm. Swing does not start to move smoothly. Swing power is weak.”
Parts Related with “T-1 Machine does not travel.”
Parts Related with “T-2 Machine does not travel forward or in reverse.”
Parts Related with “T-3 Travel speed is slow or power is weak in both forward and reverse travel.”
Parts Related with “T-4 Hydraulic brake does not work (machine rolls away) even when foot is released from the accelerator pedal.
Parts Related with “T-5 Transmission (high speed/slow speed) does not switch.”
Parts Related with “T-6 Axle lock is not released.”
Parts Related with “T-7 Axle lock is not activated.”
Parts Related with “B-1 Parking brake control does not operate.”
Parts Related with “B-2 Service brake does not work or does not work well.”
Parts Related with “B-3 Working brake control does not operate.”
Parts Related with “B-4 Working brake is not released.”
Parts Related with “ST-1 Steering wheel rotates but rotates heavily.”
Parts Related with “ST-2 Machine cannot be turned even if steering wheel is turned.”
Parts Related with “O-1 Work light (boom) does not light.”
Parts Related with “O-2 Cab light does not light.”
Parts Related with “O-3 Wiper is not operated.”
Parts Related with “Washer is not activated.”
Parts Related with “O-5 Work light (cab front 1) does not light.”
Parts Related with “O-6 Camera image does not change when aerial angle switch is pressed.”
E-1 Starter does not rotate.
E-2 Even if starter rotates, engine does not start.
E-3 Even if power mode switch is operated, power mode is not shifted.
E-4 ECO mode is faulty.
E-6 Auto-idle system is faulty.
E-8 Engine speed does not increase when coolant temperature is low.
E-9 Auto shut-down is not activated.
E-12 Engine speed does not decrease when audio mute/one-touch idle switch is pushed.
E-13 Even if accelerator pedal is operated during travel, engine speed does not change.
A-1 All actuators do not work.
A-2 All actuator speeds are slow.
A-3 Actuator does not stop even if control lever is set to neutral.
A-4 Manual regeneration of aftertreatment device cannot be performed.
A-5 Travel operation speed is slow when performing travel single operation. Bucket single operation speed is slow. Boom can hardly be raised in level crowding operation. (All problems occur at the same time.)
A-7 Swing single operation speed is slow. Arm speed is slightly slow when performing arm level crowding operation. (All problems occur at the same time.)
A-8 Swing speed is slow or arm roll-in speed is slow when performing combined operation of swing and arm roll-in.
A-10 Actuator speed is faster than normal. Precise control cannot be performed.
F-1 All front attachment actuator powers are weak.
F-2 Front attachment drifts remarkably.
F-3 When boom raise or arm roll-out is operated, boom or arm starts to move after moving slightly down.
F-4 Even if power digging switch is pushed, power does not increase. Boom raise power is weak when performing digging operation.
F-5 Boom, arm, or bucket single operation is not operated. Boom, arm, or bucket single operation speed is slow.
F-6 Bucket roll-in speed is slow or power is weak when performing digging operation.
F-7 When performing combined operation, arm does not start to move smoothly. Arm starts to move slightly slow when performing arm single operation. These troubles often occur when temperature is low.
F-8 When performing combined operation, boom does not start to move smoothly. Boom starts to move slightly slow when performing boom lower single operation.
F-9 Boom lower speed above ground is faster than other actuators when performing combined operation. Machine cannot be raised off the ground.
F-11 Arm roll-in speed is slow when performing combined operation. Arm roll-in speed is slow when performing arm level crowding operation.
F-12 Arm roll-out speed is slow when performing combined operation of boom raise, arm roll-out, and attachment.
F-13 Difficult to raise the machine off the ground.
F-14 Attachment speed is slow when performing combined operation of attachment and arm.
F-17 Bucket roll-in single operation speed is slightly slow. Bucket does not move smoothly in bucket roll-in single operation.
S-1 Swing speed is slow or is not operated.
S-3 Swing speed is slow when performing combined operation of swing and arm. Swing does not start to move smoothly. Swing power is weak.
T-1 Machine does not travel.
T-2 Machine does not travel forward or in reverse.
T-3 Travel speed is slow or power is weak in both forward and reverse travel.
T-4 Hydraulic brake does not work (machine rolls away) even when foot is released from the accelerator pedal.
T-5 Transmission (high speed/slow speed) does not switch.
T-6 Axle lock is not released.
T-7 Axle lock is not activated.
B-1 Parking brake control does not operate.
B-2 Service brake does not work or does not work well.
B-3 Working brake control does not operate.
B-4 Working brake is not released.
ST-1 Steering wheel rotates but rotates heavily.
ST-2 Machine cannot be turned even if steering wheel is turned.
O-1 Work light (boom) does not light.
O-2 Cab light does not light.
O-3 Wiper is not operated.
O-4 Washer is not operated.
O-5 Work light (cab front 1) does not light.
O-6 Camera image does not change when aerial angle switch is pressed.
Exchange Inspection
How to Lowering Boom When Emergency and When Engine Stops without Hose Rupture Valve
How to Lowering Boom When Emergency and When Engine Stops with Hose Rupture Valve
Air Bleeding Procedures for Transmission
Air Bleeding Procedures for Brake (Axle)
How to Release Parking Brake in Case of Emergency and When Engine Stops
Recovery After Parking Brake Release
Air Conditioner
Outline of Air Conditioner
Component Layout of Air Conditioner
Functions of Main Electrical Parts
Troubleshooting of Air Conditioner
Monitor Controller (Monitor) Fault Code 13911-3
Monitor Controller (Monitor) Fault Code 13912-4
Monitor Controller (Monitor) Fault Code 13913-3
Monitor Controller (Monitor) Fault Code 13914-4
Monitor Controller (Monitor) Fault Code 13917-3
Monitor Controller (Monitor) Fault Code 13918-4
Monitor Controller (Monitor) Fault Code 13921-3
Monitor Controller (Monitor) Fault Code 13922-4
Monitor Controller (Monitor) Fault Code 13943-2
Monitor Controller (Monitor) Fault Code 13944-2
Monitor Controller (Monitor) Fault Code 13951-2
Monitor Controller (Monitor) Fault Code 13991-2
Monitor Controller (Monitor) Fault Code 13992-2
Faulty Cooling (1)
Faulty Cooling (2)
Faulty Cooling (3)
Faulty Cooling (4)
Faulty Cooling (5)
Faulty Heating (1)
Faulty Heating (2)
Others
Blower motor does not operate.
Compressor clutch does not operate.
Cooling Circuit Check by Using Manifold Gauge
Work after Replacing Components
Refill Compressor Oil
Necessity of Purging
Procedures for Charging Air Conditioner with Refrigerant
Warm-Up Operation
Hose and Pipe Tightening Torque
Cleaning Method of Evaporator
SERVICE MANUAL REVISION REQUEST FORM
The Attached Diagram List